Growing interest in protein snacks
Extruded snacks such as high-protein crisps, puffs and crackers are a fast-growing category driven by healthy snacking. Pea protein and rice protein are the most preferred protein sources in these products thanks to their allergen-friendly nature and neutral taste. However, as protein content rises, extrusion behaviour changes and it becomes harder to keep the light, crunchy structure.
Balancing protein and starch
Starch is the key ingredient that provides expansion in extruded products. Starch gelatinises inside the extruder, and as the product leaves the die, the pressure drop causes water to flash off and puff the product. As protein content rises, starch content falls and expansion decreases; the product becomes denser and harder. A balance must therefore be struck between protein content and expansion.
Pea protein and rice protein
Pea protein shows good flow and structure-forming behaviour in extrusion. Rice protein gives a more neutral taste and completes the amino acid profile when blended with pea protein. Protein levels in protein crisps can range from 30% to 60%; at high levels, starch sources such as rice flour, pea starch or potato starch should be kept in the formula to support expansion.
Process parameters
Moisture, screw speed, temperature profile and die design directly affect expansion. With high-protein blends, keeping moisture low and optimising die temperature can improve expansion. Process parameters should be readjusted with every formula change.
Hardness and mouthfeel
The most common complaints about high-protein extruded products are excessive hardness and a dry mouthfeel. Protein grade, starch level, added fat and fibre affect these properties. Fine proteins give a more homogeneous structure.
Seasoning application
Extruded products are coated with oil spray and seasoning after drying. Spices such as onion powder, garlic powder, red chili powder and thyme also help mask the legume notes of plant proteins. Seasoning particle size is important for adhesion and distribution.
Labelling and nutrition claims
A "source of protein" claim requires at least 12% of the product's energy to come from protein, and a "high protein" claim at least 20%. Claimed values should be verified by analysis.
Sourcing notes
PERDIST supplies pea protein, rice protein, potato and rice starch and seasoning spices to extruded snack manufacturers with their documents.
Frequently asked questions
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