Preliminary Step of the Digital Twin Model Design for High Moisture Extrusion of Proteins from Alternative Sources

The objective of this study is to develop a deeper understanding of the high-moisture extrusion (HME) process for producing meat-like products from alternative proteins and to establish a foundation for the implementation of a Digital Twin (DT) framework. Since twin screw extruder (TSE) is largely a black-box system with limited temperature sampling and no direct velocity measurements, a mechanistic modelling framework was developed as an initial step toward DT implementation. To achieve this, numerical simulations were conducted to analyse key transport phenomena and axial velocity distribution, pumping efficiency, and dispersive mixing behaviour, within a co-rotating twin screw extruder. A steady-state approximation with frozen rotor analysis was employed to model TSE behaviour. The numerical simulations provided insights into the axial velocity distribution along the screws, the effect of screw speed on pumping efficiency, and the role of dispersive mixing in the process. These findings contribute to a better understanding of the extrusion process and lay the groundwork for future advancements in DT applications, aiming at process optimization, improved material structuring, and enhanced production efficiency for alternative protein-based meat analogues.