Upcycled plant protein ingredients for extruded snack fortification
Research-driven solution leveraging food industry waste streams (okara, brewers' spent grain) combined with mushrooms to create high-protein, extruded plant-based snacks. Uses dry fractionation, enzymatic, and alkali methods to isolate protein and fiber, enhancing nutritional profiles while delivering insights into food matrix structure-function relationships.
Overview
This research program focuses on transforming food industry waste streams—such as okara and brewers' spent grain—into high-value, protein-enriched ingredients for extruded plant-based snacks. By combining these upcycled materials with mushrooms, the team creates nutritious snack products that address two pressing industry needs: reducing food waste and meeting growing consumer demand for plant-based protein options. The work provides new insight into how molecular interactions within the food matrix influence texture, structure, and overall product quality, enabling manufacturers to formulate better-performing extruded products.
Technical specifications
Core capabilities and methods:
- Twin-screw extrusion processing for plant-based snack production
- Dry fractionation, enzymatic treatment, and alkali-based isolation of protein and fiber from waste streams
- Characterization using DSC (differential scanning calorimetry), TGA (thermogravimetric analysis), particle size analysis, and FTIR (Fourier-transform infrared spectroscopy)
- Analysis of glass transition temperature and its role in governing extruded product structure
- Development of predictive mathematical models linking ingredient properties to final product characteristics
- Assessment of structural, functional, and physicochemical properties of enriching powders and finished snacks
Key features:
- Converts underutilized waste streams into functional food ingredients
- Enhances protein content in extruded snacks without compromising texture
- Enables formulation of upcycled products with improved nutritional profiles
- Supports integration of nanofibrils for enhanced snack functionality (planned)
Technology readiness level
The underlying extrusion and characterization capabilities are established, with a twin-screw extruder and supporting analytical equipment operational since 2020. The team has already validated the approach through industry collaborations, including extruded mushroom products with brewers' spent grain developed with BC Craft Breweries, plant-based beef formulations with Protein Industries Canada and Wamame Foods Inc., and plant-based sushi with Konscious Foods Inc. The next phase focuses specifically on fortifying extruded snacks with protein- and fiber-rich powders isolated from okara, including pre-treatment optimization, ingredient impact assessment, and predictive modeling. The technology is positioned for continued collaborative development with industry partners seeking sustainable, protein-enriched snack formulations.
About Sustainable Bioproduct Innovations
Sustainable Bioproduct Innovations Inc. (SBI) is a company dedicated to the commercialization of sustainable, plant-based ingredients for the agri-food and natural health sectors. The company serves as an innovation bridge, licensing advanced research—notably fat mimetic technology from the University of British Columbia—and transforming it into market-ready, functional food solutions. Their flagship product, 0Fat, is a plant-derived fat substitute formulated from chia seed mucilage and plant fibers. Engineered as micro-particles, these ingredients effectively replicate the mouthfeel, texture, and stability of traditional fats while significantly reducing calories and saturated fat content in various food applications.
This technology addresses critical industry challenges, including rising consumer demand for healthier options, the need for clean-label ingredients, and evolving government mandates regarding saturated fat labeling. By offering a versatile, cost-effective, and environmentally sustainable alternative to animal-derived fats or palm oil, SBI enables food manufacturers to reformulate products like spreads, cheeses, and meat alternatives without compromising on quality. The company actively collaborates with industry partners, such as the PEQISH Group, to integrate these innovations into commercial product lines and improve the health profile of packaged foods.
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