This research aims to develop shelf-stable, ready-to-cook vegan patties through hybrid processing strategies that enhance structural architecture, rehydration behaviour, microbial safety, and sustainability, while addressing the economic and environmental limitations of cold-chain-dependent refrigerated patties. Low moisture extrusion based texturization was used to investigate protein&ndashstarch composite systems, thus examining the effect of partially substituting pea protein with soy or brown rice protein. Formulations were prepared with pea protein as the primary base, partially replaced (25% or 50%) by soy or rice protein, with wheat gluten and potato starch fixed at 15% and 30% (w/w), respectively. Results showed that the soy-substituted blends formed a fine, uniformly porous network with enhanced rehydration capacity and a softer texture, along with greater thermal stability, increased disulphide bond formation, and protein aggregation, thereby improving cohesiveness, springiness, and resilience. In contrast, rice protein blends restricted radial expansion, producing dense, irregular matrices with reduced rehydration potential and lower shear resistance, reflecting weaker protein&ndashstarch interactions. Among all blends, 50% soy substitution (BL3) demonstrated the highest thermal stability (T_denaturation = 93.48°C), while spectroscopic analysis confirmed conformational rearrangements, &beta-sheet predominance, and improved hydrophilicity in soy-containing systems. Collectively, these findings highlight the pivotal role of protein composition in governing matrix architecture and rehydration, offering mechanistic insights for designing functional extrudates as bases for shelf-stable patties. A blanching study was conducted to optimize and understand the enzymatic inactivation in pea&ndashpotato matrices using steam&ndashmicrowave treatment with rapid vacuum cooling. Process at the optimized conditions (2 W/g microwave power density, 2.5 s steam exposure, 142.5 s total MW duration) effectively inactivated peroxidase and polyphenol oxidase, enhanced moisture diffusivity, and reduced effluent generation compared to conventional hot-water blanching. These results help in the development of an effective process flow for the production of a vegan patty with structural integrity, rapid rehydration, safety, and consumer-acceptable quality.