Extrusion is a versatile process capable of producing a variety of new and novel foods and ingredients, thus increasing manufacturing opportunities. Further, it could provide nutritious, safe, sustainable, and affordable foods, especially directed at individualized consumer needs. In addition to past research efforts, more investigations should be conducted in order to refine, redesign, or develop new extrusion processing technologies. The present review highlights the current advances made in new and novel food product development by considering the extrusion process, the influencing parameters, and product characteristics and properties; the most promising extrusion processes that can be used in novel food product and ingredient development, such as extrusion cooking, hot-melt extrusion, reactive extrusion, and extrusion-based 3D printing; the possibilities of using various raw materials in relation to process and product development; and the needs for product development modeling along with extrusion process design and modeling. In correlation with extruded product development, topics that merit further investigation may include structure formation, plant and animal biopolymers functionalization, biopolymer reactions, process simulation, modeling and control, engineering and mechanical aspects of extruders, analysis of pre-processing treatments, as well as prototyping, risk analysis, safety, sensory and consumer acceptance.

The osmotic dehydration (OD) of tomatoes in solutions of alternative sweeteners was investigated using Response Surface Methodology (RSM), while selected desirability functions were implemented in order to define the optimum process parameters (temperature/duration of osmotic treatment, osmotic solution composition and concentration). Mass exchange, color and texture were measured during the process. Changes in color occurred rapidly at the beginning of the process, while firmness was significantly increased, indicating that OD processing led to tomato texture improvement. Color and firmness changes were adequately modeled using a polynomial model. RSM coupled with desirability functions was applied to optimize OD procedure in terms of color retention and maximum solid gain, a requirement for candied products. A maximum desirability was obtained by incorporating oligofructose into the osmotic solution, at relatively short treatment times. Results were validated and sensory analysis was conducted at the optimized conditions to assess samples’ organoleptic acceptance.

The effects of legume incorporation and sweetener substitution on the quality characteristics of innovative biscuits were investigated. The wheat flour was substituted with chickpea and lentil flour at ratios ranging from 0 to 30% legume to whole-meal dicoccum wheat flour. The sugar was substituted by oligofructose at 50 and 100% levels. The quality characteristics, including physicochemical properties (moisture content, water activity, and color), sorption characteristics, structural and textural properties, and sensory properties, were significantly affected by the substitutions. Sorption phenomena were excellently described by the Guggenheim, Anderson, and de Boer (GAB) model, while its parameters were affected by substitutions. Scanning electron microscopy revealed a porous structure with starch granules embedded within the protein matrix, showing restricted gelatinization and keeping largely their form. The incorporation of legume flour increased the biscuit density, hardness, and spread ratio and decreased the color of the products. Furthermore, principal component analysis (PCA) analysis of instrumental and sensory characteristics showed that texture and sweetness were the key quality characteristics for product acceptance. It was found that highly acceptable legume-based biscuits with alternative sweeteners can be produced, with 50% oligofructose substitution and legume flour incorporation (chickpea or lentil) up to 30%.

In order to obtain nutritious, low calorie candied pumpkins, of superior quality, air drying kinetics of pretreated pumpkin slices were investigated using three different drying temperatures (40, 60 & 80 °C). Before drying, pumpkins were osmotically treated using different osmotic agents, namely sucrose, oligofructose and their mixture (1:1) in a solution of a constant concentration (70°Brix), at three temperature (75, 85 & 95 °C) for 150 min. Changes in texture (hardness and compression work) were determined during drying and sensory characteristics of the final products were evaluated by trained panelists. A first-order reaction kinetic model was used to predict the drying rate and hardness, in which the rate constant was a function of the process temperature. The results showed that as the drying temperature is increased, the drying constant also increases whereas the equilibrium moisture content of the dehydrated products decreases. The hardness of candied pumpkins was mostly affected by the air drying temperature regardless the osmotic dehydration conditions. Sensory evaluation of the final candied pumpkins, showed a preference for the products osmotically treated by oligofructose.