Impact of enrichment and feed rate on the techno-functional properties of extruded fava bean protein

Despite growing interest in plant-based meat analogues, replicating the texture and nutritional profile of meat remains a challenge. Fibre addition in high moisture extrudates enhances both fibrous structure and nutritional value. With increasing consumer demand for non-soy protein sources, and the lack of research evaluating fibre-enriched extrusion, this study evaluated the effect of enriching fava bean protein isolate (FBPI) with 15 % fava bean flour and 10 % bean pod extract (FBEP), and the impact of two feed rates (25 and 35 rpm) during high-moisture extrusion (twin-screw speed: 150 rpm; nozzle diameter: 3 mm; water feed: 23.5 g/min; barrel temperatures: 65–120–150 °C) on the techno-functional properties of the product. FBEP exhibited higher moisture, water activity, hygroscopicity, fat absorption, and water absorption index than FBPI. The resulting extrudates (EPT1 at 25 rpm and EPT2 at 35 rpm) showed lower water solubility, fat and water absorption indices, and swelling factor, suggesting favourable liquid absorption. Lower feed rates (EPT1) led to reduced diameter, swelling index, and energy consumption—desirable features in high-moisture extrudates. This study provides a formulation and processing strategy that aligns functional and sustainability goals, and shows potential for nutritional requirements in the development of clean-label, legume-based meat analogues.