Vol. 9, Issue 12, Part J (2025)

Fish and fishery resources represent an invaluable source of high quality proteins, essential amino acids, long-chain omega-3 fatty acids, minerals and bioactive compounds; however, a substantial proportion of low value species and processing by-products remain underutilized in many regions. Extrusion technology has emerged as an efficient, high temperature short time (HTST) process capable of transforming fish raw materials including mince, surimi, protein isolates and by-products into shelf-stable, nutritious and consumer-acceptable value-added products. This review integrates current scientific knowledge on the principles, mechanisms and technological advances in extrusion as applied to fish-based product development. Key aspects such as raw material selection, physicochemical transformations, nutritional retention, techno-functional properties, sensory attributes, product diversification and the influence of processing parameters are comprehensively discussed. Special emphasis is placed on modern innovations such as twin-screw extrusion, co-extrusion, microencapsulation, high-moisture texturization and 3D food printing that enable the incorporation of heat-sensitive bioactive and the creation of texturized seafood analogues. Economic and environmental perspectives highlight the role of extrusion in resource utilization, reduction of post-harvest losses and support for circular economy models. Although issues such as lipid oxidation, flavour masking and reduced expansion at higher fish inclusion levels pose challenges, continuous improvements in formulation science and process optimization offer viable solutions. Overall, extrusion remains a transformative and sustainable platform for producing nutrient-dense, versatile and high value fish products that align with global health, nutrition and sustainability goals.