High-moisture extrusion modifies texture and improves nutritional value of sunflower meal-pea protein meat analogues

• Meat analogues were produced from sunflower meal (SFM) and pea protein isolate (PPI). • SFM-PPI meat analogues were harder and darker than cooked chicken. • SFM-PPI meat analogues had similar protein quality to cooked chicken and beef. • Tryptophan was the first limiting amino acid in SFM-PPI meat analogues. • Chlorogenic acid and phytic acid were significantly reduced by extrusion. Incorporating protein-rich food industry by-products, such as sunflower meal (SFM), into foods aligns with the United Nations Sustainable Development Goals by promoting environmentally less resource-intensive food alternatives for a more secure food future. In this study, SFM and pea protein isolate (PPI) were selected for high-moisture meat analogue (HMMA) production due to their complementary amino acid profiles, low-cost, and relatively low allergenicity compared to common plant proteins like soy and wheat. HMMAs made from two blends of expeller-pressed SFM and PPI (40:60 and 50:50, w/w) were extrusion cooked at two different feed moisture contents (FMC) (48 % and 58 %, w.b.) and three different extruder barrel temperature profiles (60–80–115–125 °C, 80–100–125–135 °C, and 100–120–135–145 °C). The physical (texture and color) and nutritional (protein quality and anti-nutritional factors) quality of the resulting HMMAs were examined. While all HMMAs studied were harder and darker than cooked chicken, they became softer and lighter in color as FMC increased, and extrusion temperature decreased. Overall, all HMMAs studied had comparable protein quality to cooked chicken and beef, with 70–74 % (d.b.) protein content and 86–89 % in-vitro protein digestibility, with tryptophan being the first limiting amino acid. Moreover, extrusion processing significantly ( p < 0.05) reduced the levels of anti-nutritional compounds including phytic acid, trypsin inhibitors, and chlorogenic acid. These findings highlight SFM’s potential as a novel protein source in meat analogue formulations, demonstrating a sustainable way to add value to an underutilized by-product in the food industry.