The overall objective of this work was to design, develop, and evaluate a novel process to create orally self-disintegrating puffs from milk protein with enhanced nutritional, flavor, and textural qualities. The market for such puffs is dominated by carbohydrate-based puffs that are lacking protein and high in sugar, catering primarily to infants and failing to address the nutritional needs of the elderly, many of whom require high-protein foods and may also suffer from swallowing difficulties and lactose intolerance. The first aim of this work was to understand the rheological behaviors of lactose-hydrolyzed and unhydrolyzed skim milk concentrates and reconstituted powder samples prior to supercritical fluid extrusion (SCFX) processing. Formulations containing lactose-hydrolyzed (LHSMP) or unhydrolyzed regular skim milk powder (SMP) in combination with 80% protein-containing milk protein concentrate (MPC80) powder and a calcium chelator, were processed using low-temperature, low- shear SCFX with dense carbon dioxide (CO2) to produce protein-rich puffs that disintegrate in the mouth within 30 seconds. Results indicated that the SCFX puffs were nutritionally enhanced through CO2-induced temporary acidity within the SCFX system, in combination with the galactose within LHSMP, which acted as a precursor to the formation of short-chain galacto- oligosaccharides during extrusion. To ensure the mechanical collapse under realistic oral conditions, the compressive strength properties of these puffs were modeled using variable contact area. To further enhance the consumer appeal, a novel flavor, pigment, and bioactive compound depositing technique was developed that utilizes the solvent properties of SC-CO2 to encapsulate solutes within the internal cell surfaces of the orally self-disintegrating puffs. Both methyl anthranilate and spinach-extracted chlorophyll were successfully deposited within the CO2 filled cellular architecture of the puffs. Additionally, the natural calcium chelators casein phosphopeptide (CPP) and citric acid (CA) were investigated as a possible alternative for phosphate-based calcium chelators. The MPC80-CPP puffs showed calcium chelation efficiency equivalent to the phosphate-based chelators. This research leveraged the multifunctionality of SCFX processing to produce nutritionally superior, clean label, functional snack products for infants and elderly with swallowing difficulty.