Optimization of extruded snacks enriched with sprouted Andean grains and freeze-dried meat using mixture design: nutritional, physical and bioactive evaluation

The combination of sprouted Andean grains and animal protein in extruded snacks represents a promising, though still largely unexplored, strategy for developing foods with greater nutritional and functional value. In this study, extruded snacks were developed using sprouted quinoa flour (SQF), sprouted amaranth flour (SAF), and freeze-dried Cavia porcellus meat (FCMP). A mixed design with extreme vertices was applied to evaluate the effect of the proportions of SQF (10–88%), FCMP (2–8%), and SAF (10–88%) on protein content, total phenolic content (TPC), expansion index (EI), bulk density (BD), and sensory acceptability. In addition, the desirability function was used to maximize protein content, TPC, and EI and to minimize BD. The results showed that increasing the FCMP content raised protein content and BD but reduced EI, while higher proportions of SQF improved TPC and extrudate expansion. The fitted models showed an adequate statistical fit (R² > 0.80; p < 0.05). With a desirability of 0.88, the optimized formulation consisted of 68.77% SQF, 5.58% FCMP, and 25.66% SAF. This formulation contained 15.59 g/100 g of protein, 148.77 mg GAE/100 g of TPC, an EI of 2.26, a BD of 0.26 g/cm³, and a sensory acceptability score of 4.4/5 points. In addition, it exhibited a protein digestibility of 92.1% and an essential amino acid profile consistent with the FAO reference standard. These results demonstrate the potential of sprouted Andean grains and FCMP for the development of extruded snacks with higher nutritional and bioactive value, although further studies are needed to validate their market acceptance.