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Pulse flours are an excellent source of nutrients and when incorporated as ingredients in processed food products can improve the nutritional profile. Interest from food processors to use these ingredients in food products is high, however undesirable off flavours found in pulses are a major obstacle to the wide spread adoption of these ingredients by food processors. Pre-treating pulses using various thermal technologies can effectively de-activate or minimize their off flavours, however the effects of these treatments on the end product quality of foods formulated with pulse flours is unknown. In this study whole yellow peas, red and green lentils, chickpeas and navy beans were treated using infrared thermal technology, pin milled into flour and incorporated into various processed food product formulations. Expansion ratio, bulk density and texture (crispness) of directly expanded extruded snacks made with flour milled from thermally treated pulses was assessed and compared to untreated samples. Expansion ratio and bulk density values for thermally treated samples ranged from 3.52 -3.75 and 0.050 – 0.135 g/mL respectively. Significant differences in expansion ratios were detected for extruded snacks made with thermally treated yellow pea, green lentil and navy bean flours. Crispness of extruded snacks was assessed by measuring the number of force peaks determined by instrumental compression and ranged from 213 – 328 peaks. Significant differences in crispness were detected for snacks made with thermally treated green and red lentil flours. Thermal treatments of pulses prior to milling result in moderate effects on end product end quality of extruded snacks. Similar trends are expected in other processed foods including baked products.