Innovative Gluten-Free Fusilli Noodle Formulation: Leveraging Extruded Japanese Rice and Chickpea Flours

Background: The growing demand for nutritionally balanced, gluten-free products has encouraged the development of innovative formulations that deliver both sensory quality and functional benefits. Combining rice and legume flours offers promising alternatives to mimic gluten-like properties while improving nutritional value. This study aimed to develop a gluten-free fusilli noodle using extruded flours based on mixtures of Japanese rice (JR) and chickpea (CP) particles. Methods: A 23 factorial design with augmented central points was applied to evaluate the effects of flour ratio (X1, CP/JR, 20–40%), feed moisture (X2, 24–30%), and extrusion temperature (X3, 80–120 °C) on responses from process properties (PPs), extruded flours (EFs), and noodle properties (NPs). Results: Interaction effects of X3 with X1 or X2 were observed on responses. On PP, X1 at 120 °C reduced the mechanical energy input (181.0 to 136.2 kJ/kg) and increased moisture retention (12.0 to 19.8%). On EF, X1 increased water-soluble solids (2.3 to 4.2 g/100 g, db) and decreased water absorption (8.6 to 5.7 g/g insoluble solids). On NP, X1 also affected their cooking properties. The mass increase was greater at 80°C (140 to 174%), and the soluble-solids loss was greater at 120 °C (9.3 to 4.5%). The optimal formulation (X1–X2–X3: 40–30%–80 °C) yielded noodles with improved elasticity, augmented protein, and enhanced textural integrity. Conclusions: Extruded flours derived from 40% chickpea flour addition and processed under mild conditions proved to be an effective strategy for enhancing both the nutritional and technological properties of rice-based noodles and supporting clean-label alternative products for gluten-intolerant and health-conscious consumers.