Assessing the impact of plasma-activated water-assisted heat-moisture treatment on the extrusion-recrystallization process of hausa potato starch.

The study explored the plasma-activated water (PAW)-assisted heat-moisture treatment (HMT) on the structural, physico-chemical properties, and in vitro digestibility of extrusion-recrystallized starch. Native starch of hausa potatoes underwent modification through a dual process involving PAW-assisted HMT (PHMT) followed by extrusion-recrystallization (PERH) using a twin-screw extruder. The PHMT sample showed surface roughness and etching with a significantly greater (p ≤ 0.05) RC (20.12 %) and ΔH (5.86 J/g) compared to DHMT. In contrast, PERH-induced structural damage, resulting in an irregular block structure, and altered the crystalline pattern from A to B + V-type characterized by peaks at 17.04°, 19.74°, 22°, and 23.94°. DSC analysis showed two endothermic peaks in all the extrusion-recrystallized samples, having the initial peak attributed to the melting of structured amylopectin chains and the second one linked to the melting of complexes formed during retrogradation. Dual-modified samples displayed notably increased transition temperatures (To1 74.54 and 74.17 °C, To2 122.65 and 121.49 °C), along with increased RS content (43.76 %-45.30 %). This study envisages a novel approach for RS preparation and broadens the utilization of PAW in starch modification synergistically with environmentally friendly techniques.

HME-assisted formulation of taste-masked dispersible tablets of cefpodoxime proxetil and roxithromycin.

Objectives: Antibiotics are the most commonly administered medications among pediatric patients. However most of the time, accurate dose administration to children becomes a problem due to the extremely bitter taste. Cefpodoxime proxetil (CP) and roxithromycin (ROX) are antibiotics often prescribed to the pediatric population and have a bitter taste. Marketed formulations of these drugs are dry suspension and/or tablets. The lyophilization method involves various steps and thus is time consuming and expensive. The objective of this study was to mask the bitter taste of CP and ROX without compromising the solubility and drug release profile compared to marketed formulations, as well as to overcome the disadvantages associated with the currently used lyophilization technique. Methods: Hot melt extrusion (HME) technology was used to process CP and ROX individually with Eudragit E PO polymer. The extrudates obtained were characterized by Fourier transform infrared spectroscopy, powder X-ray diffraction, and differential scanning calorimetry. The powdered extrudates were formulated as dispersible tablets and evaluated for in vitro and in vivo taste-masking efficiency. Results: The tablets prepared in this study showed comparable dissolution profiles but the taste-masking efficiency was significantly enhanced compared to the marketed tablets of CP and ROX. The results of in vivo human taste-masking evaluation were also in agreement with the in vitro taste-masking studies. Conclusion: The current work presents solvent-free, scalable, and continuous HME technology for addressing the bitter taste issues of CP and ROX. The disadvantages associated with the currently used lyophilization technique were overcome by developing the formulations using HME technology.

Effect of inside-out meniscal repair on meniscal dimension in meniscal tear patients.

Background: It remains controversial whether meniscal repair causes meniscal extrusion. This study aimed to investigate the effect of inside-out meniscal repair on meniscal dimensions in patients with meniscal tear of the mid-body-posterior horn. Methods: This retrospective study included 75 patients who underwent meniscal repair followed by MRI within 2 weeks after surgery between 2020 and 2022. Patients with a discoid lateral meniscus, pull-out repair, concomitant osteotomy, all-inside repair only, and revision surgery were excluded. Thirty-three meniscal tear treated using an inside-out arthroscopic repair technique were included in the lateral meniscus (LM, n = 19) and medial meniscus (MM, n = 14) tear groups. Thirty-six participants with intact meniscus were included as controls. Meniscal extrusion and posterior shift were measured on coronal and sagittal MRI pre-operatively and within 2 weeks postoperatively. Results: Preoperative coronal extrusion was significantly greater in the LM tear group than in the control group (P = 0.001). Coronal extrusion and posterior shift were significantly smaller postoperatively than preoperatively in the LM tear group (P < 0.001 and, P = 0.008, respectively). Pre- and postoperative coronal extrusion in the MM tear group were not significantly different (P = 0.291). Postoperative coronal extrusion in both LM and MM tear groups were not significantly correlated with the number of sutures required for repair (LM: P = 0.765, R = -0.076, MM: P = 0.1, R = 0.497). Conclusions: The torn meniscus of the mid-body - posterior horn before surgery was extruded and shifted posteriorly in both LM and MM tears, and repair using an inside-out arthroscopic technique was effective in reducing meniscal extrusion and posteriors shift in the LM tear immediately after surgery.

Mechanism of l-cysteine-induced fibrous structural changes of soybean protein at different high-moisture extrusion zones.

In this study, the fibrous structure formation mechanism of soybean protein during high moisture extrusion processing was investigated using a dead-stop operation, and based on the interaction between soybean protein concentrate (SPC) and L-cysteine (CYS). The thermal properties, SDS-PAGE and particle size distribution of the samples from different extrusion zones were investigated. It was revealed that the addition of a moderate amount of CYS (0.1 %) promoted the fibrous structure formation in the SPC extrudates and optimised the textural properties of the SPC extrudates. In the extruder barrel, addition of CYS (0.1 %) promoted protein depolymerisation and unfolding in the mixing and cooking zones, and facilitated protein aggregation in the die and cooling zones. Protein solubility and raman spectroscopy revealed that disulfide bonds were principally responsible for fibrous structure formation; favoured when the intermolecular disulfide bonds (t-g-t mode) was increased. Finally, the transformation of protein conformation was revealed by secondary structure and surface hydrophobicity, which confirmed that the effect of CYS on protein conformation mainly occurred in the cooling zone. This study provides a theoretical basis for the application of CYS to regulate the fibrous structure of meat analogues.

A multihole nozzle controls recrystallization of high-moisture extruded maize starches: Effect of cooling die temperature.

Hot extrusion is utilized for starch modification due to its high mechanical input and product output. Amylose recrystallization commences and primarily depends on intermolecular interactions after conventional extrusion. Hence, the design of a new component based on the existed extrusion system was aimed at facilitating molecular aggregation, potentially accelerating starch recrystallization. In this study, a nozzle sheet comprising 89 holes was integrated into the cooling die. The impact of the multihole nozzle on the structure and in vitro digestibility of extruded maize starches after retrogradation was examined at varying cooling die temperatures. The results showed that the nozzle-assembled extrusion system operated effectively without additional mechanical or yield losses. At 50 °C, the crystallinity of nozzle-produced starch was approximately 70 % higher than that of conventionally extruded starch, predominantly owing to the B-type allomorph of the amylose double helix. Recrystallized amylopectin was also found in these nozzle-produced starches, indicating that multihole nozzle-induced uniaxial elongational flow resulted in the rapid starch crystallization. The increased formation of recrystallized amylose led to improved molecular order in starch structures while reducing their digestibility. These findings revealed a new approach to improve starch crystallinity by incorporating a nozzle sheet in the extrusion process.

An Enhanced Temperature Control Approach to Simulate Profile Extrusion.

Thermoplastic extrusion, a widely used method for processing thermoplastic materials, requires precise temperature control to ensure product quality. However, existing computer-aided engineering tools often oversimplify the temperature distribution calculations, leading to additional discrepancies between simulations and the actual processes. This study introduces a novel multi-region modeling approach to address this issue. By employing realistic temperature control conditions, the methodology overcomes the limitations of current numerical modeling tools. The key contributions include the development of a transient, incompressible, non-isothermal solver integrated into the OpenFOAM computational library and the implementation of a specialized boundary condition that emulates Proportional-Integral-Derivative (PID) control using real-time thermocouple measurements. The findings highlight temperature deviations at the flow channel walls and total pressure drop while demonstrating a smaller impact on velocity and flow uniformity at the outlet under steady-state conditions. This research substantially advances the understanding of thermal dynamics in extrusion processes, offering crucial insights for enhancing temperature control and laying the groundwork for more effective and precise operational strategies.

Study on the Melt Rheological Characterization of Micro-Tube Gas-Assisted Extrusion Based on the Cross-Scale Viscoelastic Model.

In the micro-tube gas-assisted extrusion process, flow theories ignoring cross-scale viscoelastic variations fail to effectively characterize the rheological state of the melt. To investigate the impact of cross-scale viscoelastic variation on the quality of the micro-tube gas-assisted extrusion, a 3D multiphase flow extrusion model incorporating a double gas-assisted layer was developed. Subsequently, we modified the DCPP constitutive equations based on the cross-scale factor model. Both the traditional and gas-assisted extrusions were simulated under macroscale and cross-scale models using the Ansys Polyflow. Finally, using the established gas-assisted extrusion platform, extrusion experiments were conducted. The results indicate that, owing to the reduced melt viscosity under the cross-scale model, the deformation behavior of the melt is more pronounced than in the macroscale model. The cross-scale model's numerical results more closely match the experimental outcomes under the same parameters, thereby confirming the feasibility of the theoretical analysis and numerical simulation. Moreover, the predictive capability of the cross-scale model for the micro-tube gas-assisted extrusion is further validated through numerical and experimental analyses with varying parameters. It is demonstrated that the cross-scale viscoelastic variation is a critical factor that cannot be overlooked in the gas-assisted extrusion.

Evaluation of Various Types of Alginate Inks for Light-Mediated Extrusion 3D Printing.

Naturally derived biopolymers modifying or combining with other components are excellent candidates to promote the full potential of additive manufacturing in biomedicine, cosmetics, and the food industry. This work aims to develop new photo-cross-linkable alginate-based inks for extrusion 3D printing. Specifically, this work is focused on the effect of the addition of cross-linkers with different chemical structures (polyethylene glycol diacrylate (PEGDA), N,N'-methylenebisacrylamide (NMBA), and acrylic acid (AA)) in the potential printability and physical properties of methacrylated alginate (AlgMe) hydrogels. Although all inks showed maximum photo-curing conversions and gelation times less than 2 min, only those structures printed with the inks incorporating cross-linking agents with flexible and long chain structure (PEGDA and AA) displayed acceptable size accuracy (~0.4-0.5) and printing index (Pr ~1.00). The addition of these cross-linking agents leads to higher Young's moduli (from 1.6 to 2.0-2.6 KPa) in the hydrogels, and their different chemical structures results in variations in their mechanical and rheological properties. However, similar swelling ability (~15 swelling factor), degradability (~45 days 100% weight loss), and cytocompatibility (~100%) were assessed in all the systems, which is of great importance for the final applicability of these hydrogels.

Physical models of bacterial chromosomes.

The interplay between bacterial chromosome organization and functions such as transcription and replication can be studied in increasing detail using novel experimental techniques. Interpreting the resulting quantitative data, however, can be theoretically challenging. In this minireview, we discuss how connecting experimental observations to biophysical theory and modeling can give rise to new insights on bacterial chromosome organization. We consider three flavors of models of increasing complexity: simple polymer models that explore how physical constraints, such as confinement or plectoneme branching, can affect bacterial chromosome organization; bottom-up mechanistic models that connect these constraints to their underlying causes, for instance, chromosome compaction to macromolecular crowding, or supercoiling to transcription; and finally, data-driven methods for inferring interpretable and quantitative models directly from complex experimental data. Using recent examples, we discuss how biophysical models can both deepen our understanding of how bacterial chromosomes are structured and give rise to novel predictions about bacterial chromosome organization.

A Descriptive Study on Imperiled Cochlear Implant Salvage Using Double Flap Cover-What We Learned in 6 Years.

Cochlear implant surgery is the standard of care for severe sensorineural hearing loss. Infection followed by implant extrusion is an infrequent complication of this surgery. The ideal treatment is explantation of the implant. However, implant removal and reimplantation is a challenging surgery and may have poor speech reception outcomes. The cost of a new implant especially in developing countries is also a deterrent. Our study dwells on the feasibility of salvaging exposed cochlear implants by a combination of pericranial flaps followed by a scalp flap cover. The study was done in a tertiary care hospital over a period of six years. Out of 303 cochlear implant surgeries, 12 patients had implant exposure and extrusion. Patients having meningitis and sepsis were excluded from the study. All patients underwent debridement and cover with double flap (Pericranial flaps and scalp rotation flap). The average operating time was 2.17 h. The surgery is technically simple with a short learning curve. It brings in rich blood supply and there is fair amount of tissue mobility. In 11 patients we were able to salvage the implant. Patients were followed for a period of 01 year post operatively. Our study suggests that salvage of infected implant should be attempted as it is feasible, durable and effective in appropriate patients.

Cell division-dependent dissemination following E-cadherin loss underlies initiation of diffuse-type gastric cancer.

Loss of the cell-cell adhesion protein E-cadherin underlies the development of diffuse-type gastric cancer (DGC), which is characterized by the gradual accumulation of tumor cells originating from the gastric epithelium in the surrounding stroma. How E-cadherin deficiency drives DGC formation remains elusive. Therefore, we investigated the consequences of E-cadherin loss on gastric epithelial organization utilizing a human gastric organoid model and histological analyses of early-stage DGC lesions. E-cadherin depletion from gastric organoids recapitulates DGC initiation, with progressive loss of a single-layered architecture and detachment of individual cells. We found that E-cadherin deficiency in gastric epithelia does not lead to a general loss of epithelial cohesion but disrupts the spindle orientation machinery. This leads to a loss of planar cell division orientation and, consequently, daughter cells are positioned outside of the gastric epithelial layer. Although basally delaminated cells fail to detach and instead reintegrate into the epithelium, apically mispositioned daughter cells can trigger the gradual loss of the single-layered epithelial architecture. This impaired architecture hampers reintegration of mispositioned daughter cells and enables basally delaminated cells to disseminate into the surrounding matrix. Taken together, our findings describe how E-cadherin deficiency disrupts gastric epithelial architecture through displacement of dividing cells and provide new insights in the onset of DGC. © 2024 The Authors. The Journal of Pathology published by John Wiley & Sons Ltd on behalf of The Pathological Society of Great Britain and Ireland.

Optimization of the extrusion parameters for the production of lentil-quinoa extrudates enriched with pumpkin.

This study aimed to develop a protein-fiber-rich extruded product based on yellow lentil, quinoa, and pumpkin flours. The final product quality is affected by formulation and extrusion parameters. Therefore, the effect of the pumpkin-flour ratio (A: 25-75%) and feed moisture content (C: 14-22%) besides barrel screw speed (B: 120-180 rpm) on the physical attributes of extrudates was investigated. Box-Behnken experimental design and stepwise-response surface method were used to analyze the effects of various process variables and ingredients on extrudates. The pumpkin-flour ratio had a significant positive correlation with bulk density (BD), water solubility index (WSI), and oil absorption index. Whereas the correlation between pumpkin-flour ratio with hardness, porosity, expansion ratio (ER), and water absorption index (WAI) was negative (P < 0.05). The feed moisture content positively affected the water activity (aw) and WAI and negatively affected the harness of samples (P < 0.05). The screw speed had a positive effect on ER, porosity, and WSI, whereas it negatively influenced the hardness, BD, and aw. By increasing the pumpkin-flour ratio, air cell size and wall thickness of samples had been decreased. The results showed that 44.2% pumpkin flour, 22% feed moisture, and 172.1 rpm screw speed gave an optimized product. There was no significant difference between predicted and experimental values (except for ER). The optimized snack was a good source of fiber (around 15%), protein (17.3%), and antioxidants (TPC = 15.28 mg GAE.g-1 and antiradical scavenging activity (DPPH) = 33.66%). The caloric value of the optimized snack was 362.6 cal.100g-1. The current formulation can be considered as the base of snack food or plant-based meat alternatives.

Meniscal extrusion consensus statement: A collaborative survey within the Meniscus International Network (MenIN) Study Group.

PURPOSE: The purpose of the present study was to perform a survey administered to members of the Meniscus International Network (MenIN) Study Group, seeking to delineate the most contentious aspects of meniscal extrusion classification and provide a foundation for new, more comprehensive definitions and treatments for these pathologies. METHODS: MenIN Study Group is a group of international experts treating and performing research on meniscus pathology and treatment. All MenIN Study Group members were asked to complete a survey aimed at establishing criteria for the optimal classification system for meniscal extrusion. Data obtained from the completed questionnaires were transferred into a spreadsheet and then analysed. All responses are presented as counts, percentages or means. RESULTS: Forty-seven (85.5%) MenIN Study Group members completed the survey and were included in this analysis. Key aspects recommended for inclusion in a comprehensive classification system for meniscal extrusion included laterality (93.6%), anatomical location (76.6%), patient age (76.6%), body mass index (BMI) (68.1%) and aetiology (68.1%). For classifying meniscal extrusion, 53.2% considered the distance in millimetres from the tibial plateau's outer margin as the most reliable measurement technique on imaging. Preferences for imaging modalities varied, with 44.7% favouring weight-bearing magnetic resonance imaging (MRI) and 36.2% opting for weight-bearing ultrasound due to its greater availability. Respondents advocated for a classification system addressing stability or progression of meniscal extrusion (66%), reducibility (53.2%), potential progression of knee osteoarthritis (OA) (83%), influencing treatment approaches (83%), a gradation system (83%), consideration of dynamic factors (66%), association with clinical outcomes and prognosis (76.6%) and investigation around centralization procedures (57.4%). CONCLUSIONS: In conclusion, the findings of this survey shed light on the global perspectives regarding meniscal extrusion classification. It was generally felt that a new classification of extrusion measured on MRI scans at the mid-tibial plateau should be developed, which considers factors such as laterality, anatomical location, age, BMI and aetiology. Additionally, the results support the integration of dynamic factors and clinical outcomes in MRI-based classifications to inform treatment approaches. LEVEL OF EVIDENCE: Level IV.

Immunostimulatory potential of extruded plant-based meat: effect of extrusion moisture level on macrophage activation.

In this study, the effect of different moisture levels in extruded plant-based meat on macrophage immunostimulation, and the potential of this meat as a protein source and a solution to environmental and economic challenges associated with conventional meat was investigated. To determine the effects of the extruded plant-based meat, cell viability assay, enzyme-linked immunosorbent assay, flow cytometry, and western blotting were performed. Low-moisture (LMME) and high-moisture meat extracts (HMME) showed higher potential to activate macrophages and regulate cytokine production than raw material extract. Treatment with LMME and HMME resulted in increased expression of CD80, CD86, and MHC class I/II proteins, indicating their potential to activate macrophages. Western blotting suggested that the immune activation observed in a previous study of macrophages was because of the phosphorylation of MAPKs and NF-κB. These findings suggest that extruded plant-based meat can potentially be used as an immunostimulatory food ingredient.

Pre-silking water deficit in maize induced kernel loss through impaired silk growth and ovary carbohydrate dynamics.

Both carbon limitation and developmentally driven kernel failure occur in the apical region of maize (Zea mays L.) ears. Failed kernel development in the basal and middle regions of the ear often is neglected because their spaces usually are occupied by adjacent ovaries at harvest. We tested the spatial distribution of kernel losses and potential underlying reasons, from perspectives of silk elongation and carbohydrate dynamics, when maize experienced water deficit during silk elongation. Kernel loss was distributed along the length of the ear regardless of water availability, with the highest kernel set in the middle region and a gradual reduction toward the apical and basal ends. Water deficit limited silk elongation in a manner inverse to the temporal pattern of silk initiation, more strongly in the apical and basal regions of the ear than in the middle region. The limited recovery of silk elongation, especially at the apical and basal regions following rescue irrigation was probably due to water potentials below the threshold for elongation and lower growth rates of the associated ovaries. While sugar concentrations increased or did not respond to water deficit in ovaries and silks, the calculated sugar flux into the developing ovaries was impaired and diverged among ovaries at different positions under water deficit. Water deficit resulted in 58% kernel loss, 68% of which was attributable to arrested silks within husks caused by lower water potentials and 32% to ovaries with emerged silks possibly due to impaired carbohydrate metabolism.

Computational modelling of extrusion process temperatures on the interactions between black soldier fly larvae protein and corn flour starch.

Insects such as the black soldier fly (BSF) are recently being studied as food sources to address concerns about how to meet the food demand of the growing world population, as conventional production lines for meat proteins are currently unsustainable sources. Studies have been conducted evaluating the use of insect proteins to produce extruded foods such as expanded snacks and meat analogues. However, this field of study is still quite new and not much has been studied beyond digestibility and growth performance. The purpose of this work was to evaluate the compatibility of protein extracted from BSF flour with corn flour starch within an extruded balanced shrimp feed model through molecular dynamics simulations, for which cohesive energy density and solubility parameter (δ) of both components were determined. The calculations' results for the protein molecule systems yielded an average δ of 14.961 MPa0.5, while the δ for starch was calculated to be 23.166 MPa0.5. The range of difference between both δ (10 > Î´ > 7) suggests that the interaction of the BSF protein with corn starch is of a semi-miscible nature. These results suggest that it is possible to obtain a stable starch-protein mixture through the extrusion process.

Eucalypt Extracts Prepared by a No-Waste Method and Their 3D-Printed Dosage Forms Show Antimicrobial and Anti-Inflammatory Activity.

The pharmaceutical industry usually utilizes either hydrophobic or hydrophilic substances extracted from raw plant materials to prepare a final product. However, the waste products from the plant material still contain biologically active components with the opposite solubility. The aim of this study was to enhance the comprehensive usability of plant materials by developing a new no-waste extraction method for eucalypt leaves and by investigating the phytochemical and pharmacological properties of eucalypt extracts and their 3D-printed dosage forms. The present extraction method enabled us to prepare both hydrophobic soft extracts and hydrophilic (aqueous) dry extracts. We identified a total of 28 terpenes in the hydrophobic soft extract. In the hydrophilic dry extract, a total of 57 substances were identified, and 26 of them were successfully isolated. The eucalypt extracts studied showed significant antimicrobial activity against Staphylococcus aureus, Pseudomonas aeruginosa, Bacillus subtilis, Candida albicans, Corynebacterium diphtheriae gravis, and Corynebacterium diphtheriae mitis. The anti-inflammatory activity of the dry extract was studied using a formalin-induced-edema model in mice. The maximum anti-exudative effect of the dry extract was 61.5% at a dose of 20 mg/kg. Composite gels of polyethylene oxide (PEO) and eucalypt extract were developed, and the key process parameters for semi-solid extrusion (SSE) 3D printing of such gels were verified. The SSE 3D-printed preparations of novel synergistically acting eucalypt extracts could have uses in antimicrobial and anti-inflammatory medicinal applications.

Orthodontic Extrusion of Subgingivally Fractured Lateral Incisor and Canine Using Gold Post: A Case Report: 1 Year Follow-Up.

The case report describes a multidisciplinary approach using orthodontic forced eruption to facilitate prosthetic restoration of a maxillary permanent lateral incisor and canine with poor restorability for a young patient. Restoration after orthodontic eruption presents a more conservative treatment choice in young patients compared with prosthetic restoration after extraction. On examination, the patient had root stumps in the region of 22 and 23. We decided to treat the patient by orthodontic extrusion followed by endodontic post and core. The case was treated with the help of 19 gauge wire and gold posts.

Optimizing metal part distortion in the material extrusion-thermal debinding-sintering process: An experimental and numerical study.

The thermal debinding-sintering process plays an essential role in the context of material extrusion-based additive manufacturing (AM) for producing parts using metal injection molding (MIM). During thermal debinding, metal parts often experience material distortion and porosity, which negatively impacts their mechanical properties. Slowing down the debinding speed is a common approach to mitigate material distortion and porosity. However, this leads to a significant increase in the debinding time. In this study, we carried out debinding-sintering experiments to optimize the distortion and porosity in metal parts. These metal parts were manufactured utilizing bronze/polylactide (PLA) blend filaments and placed in crucibles of different sizes (small, medium, and large), with different heating rates and holding times. The results revealed that the small crucible yielded higher porosity levels in the metal parts, which could be reduced from 23% to 12% by extending both the heating and holding times. In contrast, the medium crucible managed to reduce porosity to approximately 15% without requiring an extension of the processing time. The large crucible, on the other hand, couldn't achieve further porosity reduction due to challenges in reaching the desired temperature. To gain a deeper insight into temperature distribution during the debinding process, we performed numerical simulations using the computational fluid dynamics (CFD) technique and obtained temperature profiles within the kiln using the three crucibles. Ultimately, we carried out standard mechanical tests on the resulting metal parts and evaluated the thermal debinding procedure under various conditions. The approach we employed, combining experiments and numerical simulations, demonstrated significant promise for enhancing the quality of metal parts in the thermal debinding-sintering process.

Understanding the Dynamics of Polymer Extrusion: Simulation of Thermoplastics Processing with Planetary Roller Extruders.

Resource efficient processing of polymers is of paramount importance to minimize energy consumption, processing time, and material losses in the polymer industry. This study is concerned with polymer processing in planetary roller extruders. A three-dimensional numerical flow simulation was tailored to understand the polymer flow through the extruder in detail. Using the simulation software ANSYS Polyflow, we quantified both directly measurable process parameters, such as pressure build-up, and more intangible parameters, such as material shear. By varying operational and material parameters in a sensitivity analysis, we showed that the dynamics, material stress and pressure build-up are controlled primarily by the number of spindles and their rotational speed. Notably, this work provides the first successful validation of a 3D simulation of a polymer flow in a planetary roller extruder against actual experimental data. The simulation showed robust agreement between the simulated and experimental values, provided that a critical backpressure length is reached. This computational approach minimizes labor-intensive experimental testing in polymer processing.