Physical, morphological and techno-functional properties of extruded corn snacks fortified with brown seaweed

Extrusion is common in snack production, but many products are nutritionally limited. Brown seaweeds are sustainable fortifying ingredients rich protein, fibre, and minerals. This study aimed to assess the effects of brown seaweed fortification in corn-based snack on the quality-related properties of extruded products. Corn-based extrudates were enriched with Saccharina latissima (5%) and Alaria esculenta (5–15%) and analysed for physical, textural, morphological, and techno-functional properties, along with compositional characterization. Seaweed fortification increased dietary fibre (insoluble dietary fibre 1.42–4.86 g/100 g; soluble dietary fibre 0.49–2.03 g/100 g), and mineral content, but reduced expansion (4.37–2.97) and porosity (88.12–69.15%), resulting in denser (bulk density 53.52–77.38 kg/m³), harder (33.22–60.95 N) and less crispy products (7.43–5.43 N). Techno-functional properties remained stable across formulation (water solubility index 26.44–31.36%; water absorption index 5.59–6.66 g/g; oil absorption capacity 2.06–2.14 g/g). These findings highlight brown seaweeds as promising sustainable ingredients for extruded snacks, where moderate inclusion levels can combine compositional enhancement with acceptable texture.