Rapid, flexible pilot extrusion with 3D-printed tooling

The Danish Technological Institute provides a flexible, food-approved pilot facility designed for the rapid development and testing of food products, including plant-based meat alternatives, snacks, and breakfast items. The facility features a twin-screw extruder that supports both wet and dry extrusion processes. A key capability of this service is the use of 3D-printed tooling, which allows for the customization of extruder parts, such as screw configurations and die designs, to meet specific product requirements. This flexibility enables developers to test 5-8 different recipes in a single day, with production batches as small as 20 kg. By conducting trials in these controlled, hygienic conditions, food producers can efficiently refine recipes, evaluate ingredient functionality, and adjust process parameters to optimize texture, taste, and structure. The service includes professional support from specialized technicians, comprehensive documentation of test results, and access to additional analytical and sensory facilities to help accelerate the path to market. The institute also offers small-scale contract manufacturing for intermediate products, such as textured vegetable protein (TVP) or high-moisture meat analogues (HMMA), for use in customer samples or further production.