Extrusion Research Articles

PSIX-3 Dental stick extrusion utilizing spray dried plasma

Abstract Dental stick extrusion utilizes various ingredients to form the ideal texture and quality product. Alternative ingredients to enhance or impact texture, palatability and/or plaque removal can be useful to improve dental stick manufacturing. Spray dried plasma (SDP) is a consistent high protein ingredient commonly utilized in pet food for functional texture properties, enhancing palatability, and supporting overall health. Thus, the study objective was to evaluate how SDP inclusion with other ingredients impacts texture of extruded dental formulas. Three formulas were developed utilizing SDP to replace wheat starch (WS) or Arabic gum in the control formula. The formulas were: Control: WS and gum; SDP1: SDP and WS replacing gum; and SDP2: SDP replacing WS and gum. Dental sticks were made at the Extru-Tech technology testing center using a 525 single screw extruder with the product densification unit (PDU) removed and replaced with a mid-barrel valve and 3 cooling heads to cause densification. The sticks were manufactured as solid square sticks. Generally, a single screw with a PDU, or a traditional parallel-shaft twin screw is used to manufacture dental sticks. However, the equipment alterations used worked like a single screw with a PDU; thus, it would be expected that the results would translate to a traditional single screw configuration. Glycerin at 12% (% to dry feed rate) and chicken fat were added to the pre-conditioner at set rates to optimize expansion and product quality. Processing conditions were monitored and adjusted on the various formulations during production to optimize extrusion. Texture was measured on a TA.XT Plus utilizing an adjustable bridge with a rounded-end knife probe for a 3-point bend. Dental sticks of 8 cm in length were placed over the two bridge spans spaced 5 cm apart to measure maximum force (hardness) and work to peak force (work to break) to determine texture parameters. Ten dental sticks per treatment were analyzed. All formulas utilizing SDP were successful in producing dental sticks. No differences (P > 0.05) were noted in force with SDP formulas compared with control. Work to peak was greater (P < 0.05) in SDP formulas compared with control formula. Formulation matrix impacts results. In the current formulas, both Arabic gum and WS were altered in the formulas and depending on amount of SDP used similar texture was noted. In conclusion, SDP can be incorporated into dental stick formulas and utilized as a processing aide. Overall, depending on target hardness and ingredient matrix, SDP can be an alternative to various ingredients to maintain or improve product quality.

In Situ Enzymatic Polymerization of Ethylene Brassylate Mediated by Artificial Plant Cell Walls in Reactive Extrusion.

Herein, we describe a solvent-free bioinspired approach for the polymerization of ethylene brassylate. Artificial plant cell walls (APCWs) with an integrated enzyme were fabricated by self-assembly, using microcrystalline cellulose as the main structural component. The resulting APCW catalysts were tested in bulk reactions and reactive extrusion, leading to high monomer conversion and a molar mass of around 4 kDa. In addition, we discovered that APCW catalyzes the formation of large ethylene brassylate macrocycles. The enzymatic stability and efficiency of the APCW were investigated by recycling the catalyst both in bulk and reactive extrusion. The obtained poly(ethylene brassylate) was applied as a biobased and biodegradable hydrophobic paper coating.

Dosage by design – 3D printing individualized cabozantinib tablets with immediate release

Production of patient-specific dosage forms is important to improve patient adherence and effectiveness while reducing the prevalence and severity of adverse effects. Due to its possibility of rapid prototyping 3D printing can be used to produce individual dosages while utilizing techniques such as hot melt extrusion to increase the bioavailability of poorly soluble drugs. In this work, Parteck MXP and Kollicoat IR were used as water-soluble polymer bases for formulation development for 3D printing of various dosages incorporating cabozantinib while enabling immediate release. The effect of tablet design and the excipients sorbitol, croscarmellose sodium, and sodium starch glycolate was investigated for this goal. A way to calculate the size of tablets for predetermined dosages is proposed to enable the printing of individual strengths from one formulation. Rheological data were collected to deepen the understanding of the role of melt viscosity in 3D printing and hot melt extrusion processes. The production of immediate-release cabozantinib tablets containing every therapeutically relevant dosage in a single unit produced by two-step 3D printing was realized.

Fabrication and performance of short glass fiber reinforced polyamide composites

This article deals with the impact of short glass fiber (GF) on the performance of 60/40 wt% of polyamide 6/polyamide 12 (PA6/PA12) blend. The short fiber-reinforced composites were fabricated by using melt compounding via twin screw extruder and injection molding. The morphological, water uptake, rheological, thermo-mechanical, and mechanical properties of the composites were discussed. The morphological observations show that the PA6/PA12 blend exhibited compatible morphology and also adhesion between the fiber and matrix was quite strong. The tensile strength/modulus and storage modulus of the blend were substantially improved with GF reinforcement as a result of these morphological findings. While the water uptake of neat PA6 decreased significantly after blending with PA12, the incorporation of GF further reduced the water uptake of the PA6/PA12 blend. The thermomechanical analysis showed the enhancement of the stiffness of the composites and also glass transition temperature increment.

Investigation of the Influence of Copovidone Properties and Hot-Melt Extrusion Process on Level of Impurities, In Vitro Release, and Stability of an Amorphous Solid Dispersion Product.

Hot-melt extrusion (HME) is a widely used method for creating amorphous solid dispersions (ASDs) of poorly soluble drug substances, where the drug is molecularly dispersed in a solid polymer matrix. This study examines the impact of three different copovidone excipients, their reactive impurity levels, HME barrel temperature, and the distribution of colloidal silicon dioxide (SiO2) on impurity levels, stability, and drug release of ASDs and their tablets. Initial peroxide levels were higher in Kollidon VA 64 (KVA64) and Plasdone S630 (PS630) compared to Plasdone S630 Ultra (PS630U), leading to greater oxidative degradation of the drug in fresh ASD tablets. However, stability testing (50 °C, closed container, 50 °C/30% RH, open conditions) showed lower oxidative degradation impurities in ASD tablets prepared at higher barrel temperatures, likely due to greater peroxide degradation. Plasdone S630 is suitable for ASDs with drugs prone to oxidative degradation, while standard purity grades may benefit drugs susceptible to free radical degradation, as they generate fewer free radicals post-HME. ASD tablets exhibited greater physical stability than milled extrudate samples, likely due to reduced exposure to stability conditions within the tablet matrix. Including SiO2 in the extrudate composition resulted in greater physical stability of the ASD system in the tablet; however, it negatively affected chemical stability, promoting greater oxidative degradation and hydroxylation of the drug substance. No impact of the distribution of SiO2 on drug release was observed. The study also confirmed the congruent release of copovidone, the drug substance, and Tween 80 using flow NMR coupled with in-line UV/vis. This research highlights the critical roles of peroxide levels and SiO2 in influencing the dissolution and physical and chemical stability of ASDs. The findings provide valuable insights for developing stable and effective pharmaceutical formulations, emphasizing the importance of controlling reactive impurities and excipient characteristics in ASD products prepared by using HME.

3D printing food flow in different extruders based on crazy and adaptive salp swarm algorithm-deep extreme learning machine improved-lattice Boltzmann method

Extrusion is significant in achieving 3D printing emulsion. The piston and screw extruders are the common structures to achieve the extrusion. The chocolate emulsion is taken for example, two extruders are numerically investigated and compared based on the fluid dynamic analysis. To conduct the simulations, the crazy and adaptive salp swarm algorithm-deep extreme learning machine (CASSA-DELM) is proposed to predict the viscosity of the chocolate emulsion, which is used to replace the traditional fitted model. The built model can avoid non-consistency in the whole shearing rate range. Then, an improved lattice Boltzmann method (I-LBM) is introduced to process the non-Newtonian behavior of the emulsion. In the simulation, the CASSA-DELM model provides the viscosities for each iteration in I-LBM based on the obtained shearing rates. Because the attachment(s) may be generated on the walls, the no-attachment and with-attachment(s) cases are explored, and the necessary results are obtained, which indicate that the piston extruder is more suitable for extruding the single component of food fluid. The screw extruder is recommended for the multiple components of food fluid because the vortex in the X-Y cross-section contributes to further mixing action for the emulsion containing different materials, such as the investigated chocolate emulsion. The indirect experiments are conducted to validate the above conclusions. The current work can contribute to improving the extruding theory of material extrusion technologies.

Closed-loop circular economy in ‘upcycled’ acrylonitrile–butadiene–styrene vitrimer

Today, the issue of plastic waste pollution has reached unprecedented levels. The increasing production of plastics, combined with a decreasing rate of recycling, has significantly worsened this problem in recent years. While a wide range of plastics are manufactured, thermoplastics are a type that can be recycled relatively easily. However, recycled thermoplastics often have lower mechanical properties compared to new ones. Considering this challenge, making thermoplastics recyclable could revolutionize the recycling process and represent a major advancement towards establishing a circular economy for plastics. In this study, virgin acrylonitrile–butadiene–styrene (ABS) was transformed into a vitrimer through reactive melt extrusion using a bio-derived crosslinker containing dynamic imine linkages. This crosslinker results in a dynamic network, in the melt, as observed from the higher gel fraction and imparts recyclability to the resulting ABS vitrimer, which exhibits higher yield strength (by 15 %) and Young’s modulus (by 19 %). Remarkably, the mechanical and thermal properties of the vitrimer remain largely unchanged even after undergoing five cycles of reprocessing. In addition, the resulting vitrimer is dimensionally stable as inferred from creep studies and shows rapid stress relaxation at higher temperature following Arrhenius behaviour. The electron paramagnetic resonance (EPR) spectra were captured at room temperature for both ABS and its vitrimer. The difference in singlet band intensities in the spectra begins to suggest that the vitrimer is more stable post multiple recycling. While this research focused on virgin ABS, the approach outlined in the study has the potential to be applied to post-consumer recycled (PCR) ABS. This could introduce recyclability to PCR ABS and pave the way for a closed-loop circular economy for ABS plastics.

Solvent Minimized Synthesis of Amides by Reactive Extrusion

AbstractHerein, we report on the translation of a small scale ball‐milled amidation protocol into a large scale continuous reactive extrusion process. Critical components to the successful translation were: a) understanding how the different operating parameters of a twin‐screw extruder should be harnessed to control prolonged continuous operation, and b) consideration of the physical form of the input materials. The amidation reaction is applied to 36 amides spanning a variety of physical form combinations (liquid‐liquid, solid–liquid and solid‐solid). Following this learning process, we have developed an understanding for the translation of each physical form combination and demonstrated a 7‐hour reactive extrusion process for the synthesis of an amide on 500 gram scale (1.3 mols of product).

Solvent Minimized Synthesis of Amides by Reactive Extrusion.

Herein, we report on the translation of a small scale ball-milled amidation protocol into a large scale continuous reactive extrusion process. Critical components to the successful translation were: a) understanding how the different operating parameters of a twin-screw extruder should be harnessed to control prolonged continuous operation, and b) consideration of the physical form of the input materials. The amidation reaction is applied to 36 amides spanning a variety of physical form combinations (liquid-liquid, solid-liquid and solid-solid). Following this learning process, we have developed an understanding for the translation of each physical form combination and demonstrated a 7-hour reactive extrusion process for the synthesis of an amide on 500 gram scale (1.3 mols of product).

Hot Melt Extruded High-Dose Amorphous Solid Dispersions Containing Lumefantrine and Soluplus

Over the last 15 years, a small number of paediatric artemisinin-based combination therapy products have been marketed. These included Riamet® and Coartem® dispersible tablets, a combination of artemether and lumefantrine, co-developed by the Medicines for Malaria Venture and Novartis. Disappointingly, patient compliance, requirement for high-fat meal, and sporadic drug dissolution behaviours following administration still result in considerable challenges for these products. The first and foremost barrier that needs addressed for successful delivery of the artemether/lumefantrine combination is the poor solubility of lumefantrine within the gastrointestinal fluids. In this work, amorphous solid dispersions of lumefantrine within Soluplus®-based matrices have been manufactured using hot melt extrusion as a potential formulation strategy to achieve enhanced dissolution and apparent solubility. The drug loading capacity of Soluplus® to accommodate amorphous lumefantrine, whilst ensuring improved in-vitro dissolution performance, was investigated. The extrusion process employed a variety of processing parameters, including various temperature profiles and different production scales. The influence of variation in extrusion conditions upon the physical stability of manufactured amorphous solid dispersions was also examined. This allowed for a greater understanding of the role of extrusion processing conditions on the performance of supersaturated amorphous solid dispersions during dissolution and storage. This may allow for the design and manufacture of drug enabled formulations with lower drug dosing and thus a lower risk of adverse effects.

The Designs and Testing of Biodegradable Energy-Absorbing Inserts for Enhanced Crashworthiness in Sports Helmets.

This article addresses manufacturing structures made via injection molding from biodegradable materials. The mentioned structures can be successfully used as energy-absorbing liners of all kinds of sports helmets, replacing the previously used expanded polystyrene. This paper is focused on injection technological tests and tensile tests (in quasi-static and dynamic conditions) of several composites based on a PLA matrix with the addition of other biodegradable softening agents, such as PBAT and TPS (the blends were prepared via melt blending using a screw extruder with mass compositions of 50:50, 30:70, and 15:85). Tensile tests showed a positive strain rate sensitivity of the mixtures and a dependence of the increase in the ratio of the dynamic to static yield stress on the increase in the share of the plastic component in the mixture. Technological tests showed that increasing the amount of the plasticizing additive by 35% (from 50% to 85%) results in a decrease in the minimal thickness of the thin-walled element that can be successfully injection molded by about 32% in the case of PLA/PBAT blends (from 0.22 mm to 0.15 mm) and by about 26% in the case of PLA/TPS blends (from 0.23 mm to 0.17 mm). Next, the thin-walled elements (dimensions of 55 × 55 × 20 mm) were manufactured and evaluated using a spring-loaded drop hammer. The 60 J impact energy was tested in accordance with the EN 1078 standard. The dynamic crushing test included checking the influence of the materials' temperature (-20, 0, 20, and 40 °C) and the impact velocity. It was proven that the maximum deflection increases with increasing material temperature and an increase in the share of the plastic component in the mixture. The PLA15PBAT85 blend was selected as the most effective material in terms of its use as an energy-absorbing liner for sport helmets. Johnson-Cook and Cowper-Symonds material plasticizing models were constructed. Their use during dynamic FE simulation provided results that were in good agreement with those of the conducted experiment.

Modelling of Bond Formation during Overprinting of PEEK Laminates.

The rapid technological progress of large-scale CNC (computer numerical control) systems for Screw Extrusion Additive Manufacturing (SEAM) has made the overprinting of composite laminates a much-discussed topic. It offers the potential to efficiently produce functionalised high-performance structures. However, bonding the 3D-printed structure to the laminate has proven to be a critical point. In particular, the bonding mechanisms must be precisely understood and controlled to ensure in situ bonding. This work investigates the applicability of healing models from 3D printing to the overprinting of thermoplastic laminates using semi-crystalline, high-performance material like PEEK (polyether ether ketone). For this purpose, a simulation methodology for predicting the bonding behaviour is developed and tested using experimental data from a previous study. The simulation consists of a transient heat analysis and a diffusion healing model. Using this model, a qualitative prediction of the bond strength could be made by considering the influence of wetting. It was shown that the thermal history of the interface and, in particular, the tolerance of the deposition of the first layer are decisive for in situ bonding. The results show basic requirements for future process and component developments and should further advance the maturation of overprinting.

Manufacturing processes, additional nutritional value and versatile food applications of fresh microalgae Spirulina.

Spirulina is capable of using light energy and fixing carbon dioxide to synthesize a spectrum of organic substances, including proteins, polysaccharides, and unsaturated fatty acids, making it one of the most coveted food resources for humanity. Conventionally, Spirulina products are formulated into algal powder tablets or capsules. However, the processing and preparation of these products, involving screw pump feeding, extrusion, high-speed automation, and high-temperature dewatering, often result in the rupture of cell filaments, cell fragmentation, and the unfortunate loss of vital nutrients. In contrast, fresh Spirulina, cultivated within a closed photobioreactor and transformed into an edible delight through harvesting, washing, filtering, and sterilizing, presents a refreshing taste and odor. It is gradually earning acceptance as a novel health food among the general public. This review delves into the manufacturing processes of fresh Spirulina, analyzes its nutritional advantages over conventional algal powder, and ultimately prospects the avenues for fresh Spirulina's application in modern food processing. The aim is to provide valuable references for the research and development of new microalgal products and to propel the food applications of microalgae forward.

Continuously producible aztreonam-loaded inhalable lipid nanoparticles for cystic fibrosis-associated Pseudomonas aeruginosa infections – Development and in-vitro characterization

Cystic fibrosis (CF) is a genetic disorder affecting nearly 105,000 patients worldwide and is characterized by poor respiratory function due to accumulation of thick mucus in the lungs, which not just acts as a physical barrier, but also provides a breeding ground for bacterial infections. These infections can be controlled with the help of antibiotics which can be delivered directly into the lungs for amplifying the local anti-bacterial effect. More than 50 % of CF patients are associated with Pseudomonas aeruginosa infection in their lungs which requires antibiotics such as Aztreonam (AZT). In this study, we prepared inhalable AZT-loaded lipid nanoparticles using Hot-melt extrusion (HME) coupled with probe sonication to target Pseudomonas aeruginosa infection in the lungs. The optimized nanoparticles were tested for physicochemical properties, stability profile, in-vitro aerosolization, and antimicrobial activity against Pseudomonas aeruginosa. The optimized nanoparticles with a PEI concentration of 0.1 % demonstrated a uniform particle size of <50 nm, a spherical shape observed under a transmission electron microscope, and >70 % drug entrapment. Incorporating cationic polymer, PEI, resulted in sustained drug release from the lipid nanoparticles. The in-vitro aerosolization studies exhibited a mass median aerodynamic diameter (MMAD) of <4.3 μm, suggesting deposition of the nanoparticles in the respirable airway. The antimicrobial activity against Pseudomonas aeruginosa showed the minimum inhibitory concentration of the formulation is 2-fold lower than plain AZT. Stability profile showed the formulations are stable after exposure to accelerated conditions. In conclusion, hot-melt extrusion in combination with probe sonication can be used as a potential method for the continuous production of AZT-loaded lipid nanoparticles with enhanced anti-bacterial activity.

Scope and Application of Hot Melt Extrusion in the Development of Controlled and Sustained Release Drug Delivery Systems.

Controlled-release drug delivery systems (CRDDS) are more beneficial than conventional immediate release (IRDDS) for reduced intake, prolonged duration of action, lesser adverse effects, higher bioavailability, etc. The preparation of CRDDS is more complex than IRDDS. The hot melt extrusion (HME) technique is used for developing amorphous solid dispersion of poorly water soluble drugs to improve their dissolution rate and oral bioavailability. HME can be employed to develop CRDDS. Sustained release delivery systems (SRDDS), usually given orally, can also be developed using HME. This technique has the advantages of using no organic solvent, converting crystalline drugs to amorphous, improving bioavailability, etc. However, the heat sensitivity of drugs, miscibility between drug-polymer, and the availability of a few polymers are some of the challenges HME faces in developing CRDDS and SRDDS. The selection of a suitable polymer and the optimization of the process with the help of the QbD principle are two important aspects of the successful application of HME. In this review, strategies to prepare SRDDS and CRDDS using HME are discussed with its applications in research.

Current Perspectives on Development and Applications of Cocrystals in the Pharmaceutical and Medical Domain.

In recent years, the design of pharmaceutical cocrystals has garnered significant attention. The process of cocrystallization offers a remarkable opportunity to develop drug products with enhanced properties such as improved stability, solubility, hygroscopicity, dissolution rate, and bioavailability. This detailed review delves into this evolving area, thereby exploring its relevance in pharmaceutical formulation by defining cocrystals and their practical applications and also by discussing methods for their preparation as well as characterization. It also contrasts traditional and innovative techniques for cocrystal formation. Historically, cocrystals have been synthesized using methods like solvent evaporation, grinding, and slurry techniques; however, each has its own set of limitations under specific conditions. The latest trends in cocrystal formation lean toward more advanced approaches such as spray-drying, hot melt extrusion, and supercritical fluid technology, as well as the cutting-edge technique of laser irradiation. The aim behind developing new methods is not just to address the limitations of traditional cocrystallization techniques but also to streamline the process by introducing simpler steps and enabling a continuous production workflow for cocrystal products. In general, this full-length review article offers a report on various techniques available for the creation of pharmaceutical cocrystals, along with the methods for their evaluation. Moreover, it includes reporting developments and diverse applications of cocrystals along with the commercially available cocrystals in the pharmaceutical as well as medical domains.

Influence of reinforcement phase content on mechanical properties of hydroxyapatite/carbon fiber/polyether-ether-ketone composites 3D printed by screw extrusion

Hydroxyapatite/polyether-ether-ketone (HA/PEEK) composites are promising prosthesis materials due to their biological activity, but they often have mechanical properties that fall short of clinical requirements, typically with HA content below 40 wt%. This study utilized a customized screw extrusion-based 3D printhead, incorporating carbon fiber (CF) to produce HA/CF/PEEK composites with enhanced mechanical properties and HA content up to 60 wt%. The investigation focused on the effects of HA and CF content on the crystallization process and mechanical properties. Results showed that HA and CF affect crystallization differently due to varying densities; a phase volume ratio above 20 % inhibits crystallization. The elongation at break for composites with 10 wt% HA was 27.9 %, a record for 3D-printed HA/PEEK composites. The tensile strength for composites with 10 wt% HA and 40 wt% CF reached 115.7 MPa, the highest among the tested three-phase composites. Data fitting indicated that the effects of HA and CF on strength are independent. The toughness decreases exponentially with increased reinforcing phase content. This study explored a new method for preparing HA/PEEK and HA/CF/PEEK composites, expanding the performance boundaries of PEEK composites, enhancing their potential applications in bone implants.

Study on distribution of hydroxyapatite (HA) in twin screw extruded cum injection moulded polylactic acid (PLA) composites and their effect on mechanical property

Hydroxyapatite (HA) reinforced polylactic acid (PLA) composite is the most investigated material for biodegradable implant applications such as screws and plates. The objective of this work is to test hypothesis of distribution of HA in PLA composite influence on the variations in the properties of the composites. Investigation was done for the distribution of HA in PLA injection mould (IM) composites for the various concentrations (2 to 8 wt.%) and their effect on mechanical properties such as flexural and tensile test. Proportionate quantity of HA was introduced at fixed intervals in a twin screw extruder for the preparation of PLA composites pellets containing in various wt.% of HA. The distribution of HA in IM PLA composite specimens was analysed by elemental mapping using scanning electron microscope (SEM) and also by estimation of residue (HA) after burn out test of sampling of specimens. Differential scanning calorimetry (DSC) was used for the study of effect of HA in PLA composites. The value of standard deviations of mechanical properties, taken as a rudimentary measure of reliability of IM PLA-HA composites, was found to have influence from the distributions of HA. Among the composites studied, PLA-HA composite with 4 and 5 HA wt.% found exhibiting reliable mechanical property due to crystallinity of 31.83% and a comparatively better homogenous dispersion of HA in PLA. A case study of distribution of HA in a product, namely, bone screw, promulgated the issues of IM PLA-HA composites for biomedical applications.

Compatibility study of recycled Polypropylene (PP)/Poly(ethylene terephthalate) (PET) blends nanocomposites with PP‐g‐MAH: Modeling of twin screw extrusion

AbstractAlthough the utilization of recycled polymers is essential to sustain the environment, conventional recycled polymers face limitations in application due to the degradation of their properties caused by impurities. To solve the problem the performance deterioration of these recycled polymers, this study aimed to enhance their compatibility by chemically adding polypropylene‐graft‐maleic anhydride (PP‐g‐MAH) and physically manipulate a screw profile by using an extrusion simulation program. As a result of applying the optimized extrusion process set by the simulation program, significant improvements in the compatibility and dispersion of fillers within the polymer were observed through scanning electron microscopy image analysis. In addition, through detailed analysis of rheological data, the positive impact of adding compatibilizer and changing screw profile on rheological properties was demonstrated. As the compatibility of recycled polymer blends improved, tensile strength increased by approximately two‐fold and thermal conductivity was significantly improved, which were decisive factors in dramatically enhancing the performance of recycled polymers. These improved polymer properties provide an opportunity for recycled polymers to be applied more broadly and will expand the potential for new applications in various industrial fields.

Structural, physicochemical and technofunctional properties of corn gluten meal modified by extrusion

This study aimed to evaluate the influence of sample moisture, extrusion temperature, and extruder screw speed on the hydration properties of corn gluten meal (CG), optimize process condition for the highest protein solubility at pH 7 (PS7) and WAC, and assess the effect of the optimized extrusion process on the structural, chemical, physical, and technofunctional properties of CG proteins. Extrusion was carried out at different sample moisture (20%–40%), temperatures (120–160 °C), and screw speeds (33–117 rpm) using a complete factorial design with two central points. All extrusion conditions resulted in reduced hydration properties. Extrusion with 20% sample moisture, 120 °C and 117 rpm resulted in the lowest loss of water absorption capacity and protein solubility at pH 7 (optimized condition). After optimized extrusion, the GC became darker and showed greater activity and protein emulsifying capacity and lower foaming capacity. Furthermore, CG proteins had reduced solubility at different pHs. Changes in technofunctional properties resulted from changes in protein structure after extrusion. The new protein structure is stabilized by non-covalent bonds (hydrogen bonds and hydrophobic interactions) and disulfide bonds. Extruded corn gluten has the potential to be used as an ingredient in bakery, emulsified meat products, salad dressings, vegetable pates, and desserts.