Consumers are hungry for more protein—but not just in shakes and bars. Today’s shopper is looking for protein in everyday formats: crunchy snacks, breakfast cereals, and even baked inclusions. That shift is creating a huge opportunity for brands to innovate using extruded protein systems. 

With the right formulation and processing strategy, extrusion offers an ideal way to deliver protein-enriched, shelf-stable, and scalable products across multiple categories. Here’s how formulators can take full advantage. 

Why Protein is No Longer a Niche 

Protein has become a baseline expectation in food and beverage—spanning health-conscious shoppers, fitness enthusiasts, and families alike. Consumers associate protein with benefits like: 

• Sustained energy

• Satiety and appetite control

• Muscle maintenance

• Balanced nutrition throughout the day
   

More than ever, they’re seeking protein in familiar, convenient formats—from cereals and crisps to better-for-you pretzels and portable puffs. 

Extrusion: A Flexible Platform for Protein Innovation 

Extrusion offers unmatched versatility when it comes to developing high-protein foods in snackable and ready-to-eat forms. Whether you’re creating a light puff, a dense high-protein crisp, or a custom inclusion for baked goods or clusters, extrusion allows for fine-tuned control over: 

• Texture – airy, crunchy,  or crispy. 

• Shape and size – from classic curls to flakes, balls, or novel inclusions  

• Protein content – customizable based on desired nutritional profile

• Flavor and appearance – through heat control, coating systems, and post-extrusion treatments
   

The result: a broad product toolbox for brands looking to differentiate with protein while staying on-trend. 

Formulating for Protein and Performance 

Protein is a powerful nutritional tool—but it comes with formulation challenges. Different protein sources behave differently during extrusion: 

• Dairy proteins (like caseinates or whey isolates) provide high-quality nutrition but may reduce expansion.
   

• Plant proteins (pea, fava, rice) offer label appeal and sustainability points, but often require blends or binders to achieve optimal texture.

• Blends of plant and dairy proteins can strike a balance between nutrition, function, and texture.
   

Other key considerations: 

• Target protein content per serving

• Impact on expansion and structure

• Sensory optimization (flavor masking, crunch, mouthfeel)
   

Collaborating with protein and extrusion specialists can help streamline development and avoid costly trial-and-error. 

Beyond Snacks: Expanding Protein into Every Eating Occasion 

Extruded protein systems are not limited to salty snacks. Here’s where brands are pushing boundaries: 

✅ High-Protein Breakfast Cereals 

Fortified flakes, clusters, or crispies with 8–12g protein per serving—ideal for morning convenience and energy. 

✅ Bite-Sized Savory Snacks & Puffs 

Airy, crunchy snacks that deliver flavor and protein—perfect for portion packs or post-workout formats. 

✅ Inclusions for Bars, Granola & Bakery 

Crispy extruded pieces that add protein plus texture—great in clusters, bars, or as mix-ins & toppers. 

Bringing It All Together: Protein with Purpose, Powered by Process 

Protein is no longer a “specialty” ingredient—it’s a foundational component of modern food design. Brands that harness the customizability and efficiency of extrusion are better positioned to deliver on evolving consumer demands: 

• More protein in familiar formats

• More variety across day parts

• More texture and flavor innovation

• And more ways to stand out in crowded categories

Want to explore how our protein ingredients perform in extrusion? Our technical team can help you develop the right blend for your format, texture, and protein target. 

Let’s make your next protein product smarter—and snackable. 

Talk to one of our experts today to learn more about PROtext® and how it could fuel your next innovation.