Starches in Extruded and Processed Foods

Abstract Purpose of Review This review aims to provide a comprehensive and critical analysis of extrusion as a sustainable technology for starch modification. Specifically, it addresses how extrusion processing alters the structural, physicochemical, and functional properties of starch from different botanical sources, and how processing parameters influence these modifications. Recent findings Recent studies have demonstrated that extrusion significantly affects starch structure through mechanisms such as gelatinization, disruption of crystalline regions, and molecular depolymerization. Processing conditions, including barrel temperature, moisture content, and screw speed, play a decisive role in determining the extent of these transformations. In addition, emerging approaches—such as enzymatic-assisted extrusion, extrusion coupled with 3D printing, and advanced extrusion cooking systems—have shown promising potential for tailoring starch functionality with greater precision. Notably, extrusion has also been associated with increased formation of resistant starch, contributing to improved nutritional properties. Summary Extrusion promotes substantial molecular rearrangements in starch, leading to enhanced technological performance and expanded industrial applicability. The ability to control structural modifications through processing parameters makes extrusion a versatile tool for designing starch-based ingredients with targeted functionalities. Furthermore, the generation of resistant starch highlights its potential in the development of healthier food products. Overall, extrusion represents a powerful and adaptable strategy, with significant implications for future research and innovation in starch-based food systems.