How Siena Can Help You Formulate Puffed Snacks That Stand Out

Puffed snacks have taken over grocery aisles — from protein-packed chickpea curls to clean-label veggie puffs, consumers are craving crunchy, airy, better-for-you bites. But behind every bag of craveable snacks is a complex process of R&D, formulation, and scaling.

At Siena, we specialize in helping food and beverage startups turn bold ideas into market-ready products — and puffed snacks are one of our favorite categories to develop.

Why Puffed Snacks Are in Demand

The appeal of puffed snacks is no mystery:

• They offer fun texture and crunch without deep-frying
• They’re ideal for clean-label or allergen-friendly positioning
• They serve as a canvas for unique flavors and functional ingredients
• They scale well with the right extrusion and co-manufacturing support

But getting a puff just right — in terms of taste, structure, and scalability — is no easy task.

Where Siena Comes In

We help you formulate, optimize, and scale puffed snacks from concept to production. Here’s how:

1. Ingredient Selection & Formulation

Puffed snacks start with the right starch and protein blend. Whether you’re using lentils, quinoa, chickpeas, or emerging grains, our food scientists work with you to develop a base formula that delivers on both texture and nutrition.

We also consider:

• Functional ingredients like protein isolates, fibers, or adaptogens
• Clean-label binding systems
• Allergen-free or gluten-free positioning
• Extrusion compatibility

2. Flavor Development & Optimization

Puffed snacks need to pop with flavor — and we help make that happen. We work with savory, sweet, or global spice profiles, and fine-tune flavor systems for heat stability and even distribution.

Whether you’re after a fiery sriracha puff, truffle salt crunch, or a dairy-free nacho cheese, we make sure the flavor hits every time.

3. Extrusion Readiness & Scale-Up

Formulating is only half the battle — your puff also needs to run well through extrusion equipment.

We’ll help:

• Adjust hydration and ingredient ratios for optimal expansion
• Select compatible equipment or work with your chosen co-manufacturer
• Test and troubleshoot with real-world extrusion partners

We collaborate directly with pilot plants and co-manufacturers to ensure your product is scalable from day one.

4. Shelf-Life, Nutrition, and Compliance

Siena can run:

• Shelf-life testing to evaluate texture, oil migration, and flavor over time
• Nutritional panels based on your final formula
• Clean-label claims and allergen statements

We help ensure your puffed snack is ready for retailers, e-commerce, and investors.

5. Investor-Ready Samples & Go-To-Market Support

Need samples for a pitch, trade show, or retailer meeting? We produce small-batch, high-quality samples that mirror your production version.

Plus, our team can support your pitch deck, logo design, and packaging so you can hit the market with confidence.

Why Partner With Siena?

We’re not just formulators — we’re startup collaborators. We act as your R&D department, helping you avoid costly mistakes and accelerate your path to market.

Whether you’re launching your first puffed snack or extending your brand into a new format, we’ll guide you from idea to shelf.

Ready to Create the Next Great Crunch?

Let’s chat. Whether you’re working with a novel ingredient or need help scaling your existing prototype, Siena is ready to help bring your puffed snack to life.

Reach out today to schedule a call with our formulation team.