Consumers are hungry for more protein and 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 casein or whey proteins) provide high-quality nutrition but may reduce expansion
• Plant proteins (pea, fava, soy) 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 while giving brands a proprietary option.

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 is ideal for morning convenience and energy. 
• Bite-Sized Savory Snacks & Puffs – Airy, crunchy snacks that deliver flavor and protein is perfect for portion packs or post-workout formats. 
• Inclusions for Bars, Granola & Bakery – Crispy extruded pieces that add protein plus texture is 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

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