Development and Shelf-Life Study of Twin-Screw Extruded Fish Snacks Using Mackerel and Rohu Powder

Fish has a lot of promise for creating novel, nutrient-dense food products since it is a rich source of high-quality protein, vital amino acids, Omega-3 fatty acids, and other minerals. In order to improve the texture, nutritional profile, and shelf life of a fish-based extruded snack supplemented with corn and millet flour, this study used extrusion technology. Five formulations were made with different amounts of millet flour (20–40%), maize flour (50%), and fish powder (10–30%). To guarantee constant product quality, optimized extrusion parameters were used, such as a barrel temperature of 112°C, screw speed of 320 rpm, and feed rate of 210 g/min. Seasoning, tapioca starch (3–5%), and natural preservatives (tocopherols) were added to enhance the product's functionality and sensory qualities. Considering a protein level of 25% per 100 g and a well-balanced amino acid profile, Treatment 5 (30% fish powder, 50% maize flour, 20% millet flour) stood out as the best formulation among the others. Treatment 5 received a taste and texture rating of 8.5 on a 9-point hedonic scale, suggesting strong customer approval. The product demonstrated exceptional stability and sharpness, retaining its quality for three months in ambient circumstances. This study emphasizes how fish-based extruded snacks can offer a nutrient-dense, shelf-stable substitute for traditional snacks, encouraging the exploitation of underutilized fish resources and boosting both food security and economic expansion.