A new kind of extrusion food using brewer’s spent grain (BSG) was developed with corn and BSG as the main materials.The extrusion conditions and snack formula was studied.The physicochemical properties of sectional expansion index (SEI),hardness and organoleptic feature of the snack are the verifiable objectives in this research.The optimal value of BSG addition (A),material moisture content (B),screw speed (C),and cooking temperature (D) was obtained by singe factor experiment.Based on this result,an orthogonal experimental design was adopted to optimize the extrusion craft.It was found that the best extruding conditions were:feeding speed 25 kg/h,BSG addition 10%,material moisture content 17%,screw speed 300 r/min,and cooking temperature 130℃.Comparing with corn snack without BSG,the content of protein and dietary fiber in BSG-corn snack was increased significantly.