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Screw Profile Design in Food Extrusion: What We Know, What We Don’t, and How to Make Smart Choices

Screw profile design is a critical but still non‑standardized aspect of food extrusion. While the basic functions of conveying, mixing, and kneading elements are well established, there is no universal method for combining these elements to suit different ingredient systems or product goals. Variations in moisture, rheology, thermal transitions, and material flow behavior require process‑specific decisions rather than fixed design rules. 

This webinar provides a concise overview of screw geometry, element selection, and how these choices affect shear, residence time, pressure buildup, and energy input during extrusion. Participants will learn how to use measurable process indicators, such as torque, SME, and viscosity to guide rational adjustments and reduce trial‑and‑error. By linking fundamental principles with practical decision‑making tools, the session offers a clearer framework for evaluating and optimizing screw configurations across a range of food extrusion applications.

Key Learning Objectives:

  • Understand how to select appropriate screw types for single‑screw extrusion across various pet food and aquafeed products.
  • Identify key twin‑screw elements and clearly recognize the function each element performs in the extrusion process.
  • Learn the essential steps for designing a twin‑screw profile tailored to snack foods and meat analogue production.
  • Develop the ability to predict which screw elements and their placement, will accelerate product development and improve process outcomes.
     
Dr. Debomitra Dey (Language: English)
Debomitra Dey

Debomitra Dey is an Advanced Application Scientist at Anton Paar USA, specializing in extrusion processing for snacks, meat analogues, and pet food. She leads application‑lab trials, optimizes ingredient and process interactions, and supports rapid prototype development across industry projects. Before joining Anton Paar, she worked as a Food Extrusion Specialist at CW Brabender Instruments in New Jersey.

Debomitra earned her Ph.D. in Food Science from Washington State University and has published multiple research papers in food science and technology. She collaborates actively with universities and academic partners, advancing work in rheology, thermal analysis, structure-function relationships, and the extrusion behavior of emerging and plant‑based ingredients. Her work emphasizes practical problem‑solving, cross‑functional collaboration, and developing clear, science‑driven guidance for the extrusion community.