Innovations in food extrusion technologies: Applications, advances, and future prospects-a review

• Extrusion enables functional food development via thermal treatment. • 3D printing creates customized food structures with novel ingredients. • Novel extrusion techniques improve food texture and product value. Innovations in food extrusion technologies have significantly expanded their applications beyond traditional processing, encompassing personalized nutrition, targeted bioactive delivery, and sustainable packaging solutions. This review highlights cutting-edge advancements such as hot melt extrusion (HME), supercritical fluid-assisted extrusion, and extrusion-based food printing, with particular emphasis on their impact on food formulation, functional food development, personalized nutrition, sustainable packaging, and overall innovation. It focuses on state-of-the-art techniques, including HME, supercritical fluid-assisted extrusion, and extrusion-based 3D/4D/5D/6D printing, showcasing their ability to deliver bioactive compounds, create customized food structures, and develop eco-friendly packaging solutions for next-generation food products. HME offers superior taste masking, improved product uniformity, and efficient delivery of bioactive compounds. Supercritical fluid-assisted extrusion enables the preservation of heat-sensitive nutrients while enhancing the nutritional quality of food products. Similarly, extrusion-based 3D food printing allows the creation of intricate, customized food structures tailored to individual dietary needs, supporting the development of personalized and digitalized food systems. Moreover, extrusion is increasingly being used to produce biodegradable packaging materials as sustainable alternatives to conventional plastics, contributing to environmental conservation. Collectively, these advancements underscore the transformative potential of extrusion technologies in shaping next-generation food products and eco-friendly packaging, positioning extrusion as a key driver of innovation and sustainability in the future food industry.