Optimization of the extrusion parameters for the production of lentil–quinoa extrudates enriched with pumpkin.

This article focuses on optimizing the extrusion process parameters to develop a protein- and fiber-rich snack product based on yellow lentil, quinoa, and pumpkin flours. Using a Box–Behnken experimental design and stepwise response surface methodology (RSM), the study investigated the effects of pumpkin-flour ratio (25–75%), feed moisture content (14–22%), and barrel screw speed (120–180 rpm) on physical properties such as water activity, water absorption and solubility indices, expansion ratio, bulk density, porosity, oil absorption, and hardness. The optimized conditions—44.2% pumpkin flour, 22% feed moisture, and 172.1 rpm screw speed—produced an extrudate with balanced texture and nutritional qualities, including approximately 15% fiber, 17.3% protein, antioxidant activity, and 362.6 kcal/100 g caloric value. The study suggests this formulation as a functional, gluten-free snack and a potential plant-based meat alternative for vegetarian and vegan consumers.