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<p>Alternative proteins are gaining attention as sustainable ingredients, driving research into advanced processing to optimize their structure and function. Hot-melt extrusion (HME) has emerged as a solvent-free, continuous technology capable of texturizing protein matrices while embedding bioactive compounds. This review critically evaluates recent advances in applying HME to design alternative protein carriers for controlled antioxidant release. Particular attention is given to how extrusion-induced transformations influence antioxidant encapsulation, stability, and release behavior across diverse protein sources, including plant, insect, and microbial proteins, and antioxidant classes such as polyphenols, carotenoids, and vitamins. Comparative studies reveal that extrusion parameters (temperature, moisture, screw speed) and formulation choices (additives, blends) are key to retention and release kinetics. Antioxidant-loaded protein matrices may also inform functional-food and active packaging applications, particularly where controlled antioxidant availability is needed to delay oxidative deterioration or support targeted release. However, results remain inconsistent: high thermal loads may degrade sensitive antioxidants, whereas optimized conditions can enhance their extractability or stabilize them through entrapment. Knowledge gaps persist regarding molecular-level protein–antioxidant interactions and the long-term stability of extruded systems. Variability also arises from differing analytical methods across studies. Despite these challenges, HME offers a promising, scalable route to integrate clean-label antioxidants into sustainable protein systems. By tailoring both texture and delivery, protein-based extrudates could reduce reliance on synthetic additives while valorizing underutilized protein resources. In summary, HME provides a versatile platform to couple structural design with functional delivery, warranting further exploration for next-generation food and nutraceutical applications.</p> Graphical Abstract <p></p>

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From Structure to Function: Hot-Melt Extruded Alternative Proteins for Antioxidant Delivery

  • 期刊论文

  • 发表日期：

    2026年6月26日

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  • Tan Hoang Le

摘要

Alternative proteins are gaining attention as sustainable ingredients, driving research into advanced processing to optimize their structure and function. Hot-melt extrusion (HME) has emerged as a solvent-free, continuous technology capable of texturizing protein matrices while embedding bioactive compounds. This review critically evaluates recent advances in applying HME to design alternative protein carriers for controlled antioxidant release. Particular attention is given to how extrusion-induced transformations influence antioxidant encapsulation, stability, and release behavior across diverse protein sources, including plant, insect, and microbial proteins, and antioxidant classes such as polyphenols, carotenoids, and vitamins. Comparative studies reveal that extrusion parameters (temperature, moisture, screw speed) and formulation choices (additives, blends) are key to retention and release kinetics. Antioxidant-loaded protein matrices may also inform functional-food and active packaging applications, particularly where controlled antioxidant availability is needed to delay oxidative deterioration or support targeted release. However, results remain inconsistent: high thermal loads may degrade sensitive antioxidants, whereas optimized conditions can enhance their extractability or stabilize them through entrapment. Knowledge gaps persist regarding molecular-level protein–antioxidant interactions and the long-term stability of extruded systems. Variability also arises from differing analytical methods across studies. Despite these challenges, HME offers a promising, scalable route to integrate clean-label antioxidants into sustainable protein systems. By tailoring both texture and delivery, protein-based extrudates could reduce reliance on synthetic additives while valorizing underutilized protein resources. In summary, HME provides a versatile platform to couple structural design with functional delivery, warranting further exploration for next-generation food and nutraceutical applications.

Graphical Abstract