Chiang Mai Journal of Science

     Puffed snacks have gained attention due to their light texture and appealing taste. However, refined grain flour-based products generally provide little nutritional content, especially protein and dietary fiber. In an effort to improve their nutritional quality, extruded snacks were developed by blending corn flour with cowpea, chickpea, and mung bean flours at substitution levels of 25–50%. Extrusion was carried out using a twin-screw extruder at a barrel temperature of 150 °C, screw speed of 85 rpm, and die diameter ratios ranging from 2 to 2.50. The products were then dried at 60 ± 0.5 °C. Five formulations were developed: E0 (100% corn flour); E1 (50% corn and 50% cowpea); E2 (50% corn and 50% chickpea); E3 (50% corn and 50% mung bean); and E4 (25% each of corn, cowpea, chickpea, and mung bean flours). The snacks developed from E4 showed the highest protein (23.34 ± 1.27%), dietary fiber (2.32 ± 0.22%), FRAP activity on a dry weight basis (48.70 ± 0.30 µmol Fe²⁺/g), and DPPH radical scavenging activity (12.50 ± 0.23%). SEM analysis revealed an enhanced protein matrix continuity along with improved cellular structure. Overall, incorporating pulses into extruded snacks significantly enhanced their nutritional and functional properties, offering a healthier alternative to conventional refined-grain snacks.