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This study aims to develop sweet chestnut incorporated corn-based extrudates by the optimization of process conditions.

The independent process variables for extrusion (blend ratio, barrel temperature, screw speed and feed moisture) were investigated to govern their impact on reliant variables, namely, bulk density, specific mechanical energy, water absorption index, water solubility index, color and hardness. Product and system responses were significantly (p < 0.05) affected by the independent variables. Experimental design with quadratic models experienced a high coefficient of determination (R² = 0.99).

Numerical optimization for the development of extrudates resulted in optimum conditions having corn flour: sweet chestnut flour (80:20), barrel temperature (120°C), screw speed (340 rpm) and feed moisture (12%). Fat, moisture and protein contents of the developed extrudates using optimum conditions were significantly (p < 0.05) lower compared to raw materials – corn and sweet chestnut. The packaging of extrudates in aluminum laminates revealed shelf stability of three months at room temperature without deterioration of quality.

Nutritionally rich sweet chestnut extruded products would be an exclusive option to already existing snacks in the market and can facilitate a new sphere in extruded product sector.