Effect of extrusion parameters and feed composition on physical characteristics, aroma profile and acrylamide content in pea protein-enriched corn extrudates

Low-moisture extrusion is gaining relevance for high-protein snacks, yet its effect on product quality and safety remain insufficiently understood. In this study, the effects of pea protein isolate content (0–70%), moisture (15–17%), and extrusion parameters, including screw speed (400–500 rpm) and barrel temperature (up to 145–160 °C) were studied using a twin-screw extruder. Product characteristics were evaluated in terms of bulk density, dimensions, texture, colour, and aroma profile while acrylamide levels were quantified to assess safety. Feed composition had a greater influence than extrusion parameters. Among the investigated processing conditions, formulations containing up to 50% pea protein represented a practical optimum, providing relatively better physical properties and enhanced aroma formation while maintaining low acrylamide levels, whereas higher protein incorporation (70%) led to pronounced and less desirable changes. Overall, low-moisture extrusion is promising for high-protein snacks with low acrylamide risk.