Hazardous chemicals in extruded food: A comprehensive review of their occurrence, detection, toxicity, and mitigation strategies

The extrusion process is a widely utilized food processing technique that involves forcing a mixture of ingredients through a perforated plate or die under high pressure and temperature. This method not only shapes the food but also induces significant structural changes in its components, leading to various nutritional benefits. Despite the nutritional attributes of extruded food products, the extrusion process is known to produce hazardous chemicals such as polycyclic aromatic hydrocarbons (PAHs), acrylamide, furan, and heterocyclic aromatic amines (HCAs). These compounds, formed due to high temperatures and complex chemical reactions, pose significant health risks due to their carcinogenic and toxic properties. This review paper comprehensively examines the nutritional benefits of extruded food samples. It also highlights the occurrence and mechanism of the formation of certain chemicals in extruded samples during the extrusion process. Advanced analytical techniques, including gas chromatography-mass spectrometry (GC-MS), high-performance liquid chromatography (HPLC), and liquid chromatography-tandem mass spectrometry (LC-MS/MS), are discussed for their efficacy in identifying and quantifying these compounds in extruded food. Furthermore, the paper explores the toxicity profiles of PAHs, acrylamide, furan, and HCAs, emphasizing their health impacts. Mitigation strategies are critically reviewed, highlighting approaches such as optimizing extrusion parameters, improving material selection, and employing post-extrusion treatments. Additionally, the importance of real-time monitoring systems and the potential of innovative non-thermal processing techniques are evaluated. This review underscores the necessity of integrated strategies to minimize the formation of hazardous chemicals during extrusion, ensuring extruded product safety and consumer health. Through continued research and technological advancements, the extrusion industry can enhance its practices to mitigate these risks effectively.