Blends of whey protein concentrate (WPC) and corn meal, which were separated into four particle fractions (residual on a #30 screen, #40 screen, #60 screen and through a #60 screen), were extruded at two moisture conditions (23 and 28%) to determine the effects of particle size on the extrudate properties. Smaller particle size fractions exhibited increased solubility and significantly higher viscosity both with and without added protein. When WPC was added to the corn meal, a large reduction in paste viscosity was observed regardless of the particle size. The blend with similar particle size distributions of corn meal and WPC had a significantly higher viscosity than the other blends. The expansion ratio, porosity and breaking strength of this blend, when extruded at the lower moisture content, were improved to the extent that they behaved similarly to extrudate made from corn meal alone.