Protein Snack Product Development: Complete R&D Guide

The demand for protein snack foods all over the world is currently higher than just for those who attend gyms. Modern-day consumers are looking for quick, easy-to-carry, high-protein snack foods that they can incorporate into their daily lives, whether it’s at work, on the go travelling or as a snack between meals. As a result, protein snack product development, compared with other types of snack product development, requires a much more technical and research and development (R&D) driven approach rather than just focusing primarily on flavour. Companies that develop successful protein snacks are typically those that begin investing in R&D early, gaining an understanding of how protein products behave in a different way than traditional snack foods.

This blog will provide readers with the entire R&D development process for successful protein snack products from start to finish, and will provide readers with a hands-on, industry-specific approach to prototyping and launching a new protein snack.

Want to optimise your Food Business? Request a free consultation!

Explore Our Exclusive Food Product Development

Understanding the Market Before Development Begins

When developing a protein snack, it is important to know the target audience. For example, a snack targeting endurance athletes will be developed differently than one designed for children, office workers, and senior citizens. All aspects of the development such as the amount of protein contained, texture preferences, sweetness, and serving sizes will vary depending on who the product is designed for.

Conducting market research will provide the answers to three main questions at this point in the development:

• What is the consumer’s expectation for the amount of protein contained in each serving?
• What is the appropriate delivery format based on their lifestyle (bar, chip, bite, puff, cookie)?
• Which claims would be most appealing to the consumer: high protein, clean label, plant-based, or low sugar?

The answers to the above questions will help in avoiding changes in future development process and provide an accurate blueprint for the R&D department as they begin designing the snack.

Explore Now: Trending and Market Leading Food Business Ideas

Selecting the Right Protein Source

Selecting the correct protein is among the most critical technical steps in the creation of snack products; the interactions between different protein sources are also the most greatly affected by the processing and storage of the product. Many companies have begun to use protein blends in lieu of the single protein source to help mitigate the challenges presented by using one source of protein alone. By utilizing mixtures of proteins, manufacturers have been able to achieve a more balanced approach to nutrition, flavour, texture, and cost savings. During the research process, a variety of protein products are tested for their solubility, swelling capacity when hydrated, particle sizes, and their ability to work with both fats and carbohydrates in a formulation.

Managing Particle Size and Texture

The way of  protein snack product development textures feel in the mouth (i.e. “mouthfeel”) and the structure/integrity of protein, are directly affected by the size of the protein particles used in the products. Larger particles may give the product a gritty texture, while ultra fine powders may attract too much water, causing hard, dry products to form.

In the research and development of protein snacks, particle size analysis is key to establishing how:

• Texture is influenced when chewing a bar or baked product
• Extruded products expand
• The amount of energy required to press them together when compressed

Early particle size optimization allows developers to create products with consistent, even mouthfeels without the use of artificial textures.

Balancing Fat, Protein, and Carbohydrates

Protein-rich products such as protein snack product development differ from traditional snack formulations as they rely on very narrow margins for formulation. To maintain stability in protein rich products both carbohydrate(s) and fat compete for moisture and structure to create the desired nutritional attributes; therefore, the ratio of protein to carbohydrate and fat(s) must be properly balanced.

Fats improve a product’s softness, enhance the flavours of the ingredients and increase shelf stability. Carbohydrates provide bulk and sweetness and help to hold the ingredients together. While protein has nutritional value, it has the tendency to cause the product to become hard or dry out during storage.

Product Development and Research are focused on identifying the optimal protein/carb/fat ratio to maintain the desired textural properties of the product from its initial production through the final date of its intended shelf life, depending on processing and storage methods and packaging formats.

Moisture Binding and Shelf Stability

Controlling moisture is the main obstacle in making healthy snacks. Proteins are hygroscopic substances, so proteins attract and absorb moisture. Unmonitored moisture during processing and storage will bring changes in texture, a risk of microbial contamination, or the product may collapse due to moisture loss.

A proper moisture binding system may incorporate natural binds (fibres, polyols) or a combination of binds that maintain moisture activity without being detrimental to product labelling claims. Product Development and Research conduct both water activity testing and textural analysis to determine moisture levels throughout the product’s intended shelf life and shelf stability.

Processing Conditions and Equipment Selection

Protein snack quality depends heavily on processing conditions, as extreme temperatures, shear force and/or long cooking times may cause proteins to denature. This results in low textural quality, off-flavours and nutritional loss. Examples of protein snack processing include but are not limited to the following methods:

• baking for bars and cookies
• Extrusion for puffs and crisps 
• Cold pressing for nutrition bars 
• Roasting for clusters and bites

During pilot trials, R&D adjust parameters including temperature, shear force, mixing speed and residence time to maintain protein functionality while optimising for commercial efficiency.

Flavour Development and Masking Strategies

Many protein ingredients have inherent bitter or beany flavours, particularly plant-based protein formulations. Through proper flavour development, these off-flavours can be effectively managed rather than being completely shadowed by other flavours. Research and Development teams utilise various combinations of natural flavours, acids, fats and sweeteners to form flavour-balanced profiles. Sensory panels provide important feedback regarding aftertaste, aroma and overall experience. Therefore, the ultimate goal in producing protein snacks is to ensure that consumers perceive the flavour as enjoyable and do not associate it with the fact that it is a functional product.

Learn More: Art and Science of Food Formulation

Nutritional Validation and Label Accuracy

Food product developers create new protein snacks through a process that includes research and development (R&D), market analysis, and testing before the final product is ready. Once the product formulation has been established, nutritional analysis and validation of the protein content will be required through laboratory testing to support claims made on the packaging of the snack. An incorrect label may create regulatory problems and result in a lack of confidence in the company by the consumers. Developers will review allergen declarations, ingredient lists, and other claims that support the product at this point. Clean-label positioning requires concentration on all excipients and processing aids that are used throughout the development process.

Shelf-Life Testing and Stability Trials

Shelf-life testing is not a formality; it is a core part of protein snack R&D. Products are stored under controlled conditions to simulate real-world environments, including temperature fluctuations and humidity exposure.

Testing focuses on:

• Texture changes over time
• Flavour stability
• Moisture migration
• Microbial safety

These trials help define realistic best-before dates and identify packaging requirements such as barrier films or modified atmosphere systems.

Scaling from Pilot to Commercial Production

Protein snack product development in the laboratory does not necessarily equal product performance at commercial scale. The way ingredients disperse, transfer heat, and mix in commercial-sized processing equipment will vary greatly from how they would in the lab. While producing prototype protein snack products at a pilot production scale, research and development staff will fine-tune production parameters to ensure that product quality remains unchanged while maximising product yield and minimising production costs. By doing so, the final commercialised protein snack product will meet both quality and commercialisation standards. 

Conclusion

To create a protein snack product from protein snack product development, it takes cooperation between disciplines such as food science and nutrition, processing technologies, and the market place. Companies will be much more successful in launching protein snack products that drive sales and create long-term brand loyalty when they consider research and development as an investment, a strategic one for the long term rather than an expense. A company will create protein snacks that taste good and feel good, providing trust to the consumer through the creation of the product based on functional ingredients and effective control of processing and shelf-life stability from the start.