{"id":242374,"date":"2026-10-19T09:54:11","date_gmt":"2026-10-19T07:54:11","guid":{"rendered":"https:\/\/www.alimentibevande.it\/uncategorized\/3d-food-printing-la-personalizzazione-diventa-processo\/"},"modified":"2026-10-19T10:06:57","modified_gmt":"2026-10-19T08:06:57","slug":"3d-food-printing-personalization-becomes-a-process","status":"publish","type":"post","link":"https:\/\/www.alimentibevande.it\/en\/macchine-alimentari-en\/technology\/3d-food-printing-personalization-becomes-a-process\/","title":{"rendered":"3D Food Printing: Personalization Becomes a Process"},"content":{"rendered":"\n

12:30 p.m. Lunchtime. In a home kitchen of a future that may not be so far off, software prepares personalized recipes based on nutritional needs, sensory preferences, desired texture, and portion size. A food cartridge deposits layers of dough, gel, or plant-based proteins; a few minutes later, a custom-designed food appears on the plate. This is the most evocative image of 3D food printing<\/strong>: science fiction, perhaps, but not entirely out of step with current research trends. While this scenario may still seem distant in a domestic setting, the food industry and researchers are already working to implement the technology in more concrete applications\u2014not as an alternative to traditional high-throughput production lines, but as a potential process module for specialized production. This is where 3D food printing can find its niche: where shape, texture, portion control, and nutritional customization matter more than speed\u2014from senior nutrition to dysphagia, from structured plant-based foods to functional snacks and gourmet applications.<\/p>\n\n\n\n

Where 3D food printing is already feasible<\/strong><\/h2>\n\n\n\n
\"\"<\/a><\/figure>\n\n\n\n

Research is underway, the food industry is taking its first steps, and 3D food printing<\/strong>\u2014the construction of food through the controlled, layer-by-layer deposition of edible matrices designed from a digital model\u2014is beginning to move beyond the realm of technological demonstration to carve out its own place in production. Not everywhere, not for every food product, and not with the same level of maturity. The point is not to envision production lines capable of replacing conventional processes, but to understand in which areas controlled deposition can generate real value. The most convincing answer comes from products where shape, texture, composition, and portion size are not merely commercial variations, but integral to their function. This is the case with texture-modified foods for the elderly and patients with dysphagia<\/strong>, where purees and soft matrices can be restructured into more recognizable forms and enriched in a controlled manner. The same principle, with different objectives, applies to high-end pasta and chocolate, functional snacks, and structured plant-based products, where gels, emulsions, and protein-based mixtures allow for manipulation of internal geometries, ingredient distribution, and sensory perception. These applications differ in maturity and scale but are united by the same logic: not to produce faster, but to produce in a more targeted manner [Derossi A et al. npj Sci Food<\/em> 2024; IUFoST Sci Inf Bull<\/em> 2021; Ma Y et al. Curr Opin Food Sci<\/em> 2019].<\/p>\n\n\n\n

From the printer to the food machine<\/strong><\/h2>\n\n\n\n

For this process to become industrialized, however, the printer must cease to be viewed as a laboratory device and instead be regarded as a food-grade machine<\/strong>. At the heart of the process, in most of today\u2019s most realistic applications, is extrusion<\/strong>: a deposition system capable of processing pastes, purees, doughs, gels, chocolate, cheeses, emulsions, and protein matrices with widely varying viscosities and behaviors [Xiao S et al. Foods<\/em> 2025; Paolillo M. PhD Thesis, University of Foggia, 2022]. Alternatives do exist\u2014inkjet, binder jetting, powder-based systems, or hybrid solutions\u2014but they remain more limited, often tied to specific materials or functions [Paolillo M. PhD Thesis, University of Foggia, 2022; Zhu W et al. Foods<\/em> 2023]. Extrusion, on the other hand, taps into the most promising aspect of 3D food printing: transforming a semi-solid food matrix into a controlled three-dimensional structure. This gives rise to the distinction between syringe-based systems, suitable for small batches and more viscous materials, pneumatic systems, which are more sensitive to pressure regulation, and screw-based solutions, which operate on a continuous-feed principle because they allow material to be fed during deposition\u2014though they are not without challenges when the matrix exhibits high viscosity or mechanical resistance, potentially leading to control issues, thermomechanical stress, and localized overheating [Paolillo M. PhD Thesis, University of Foggia, 2022]. The industrial challenge lies precisely here: it is not enough to deposit food in a new form; it is necessary to control flow rate, temperature, pressure, nozzle geometry, cleanability, and repeatability as process variables [Xiao S et al. Foods<\/em> 2025; Derossi A et al. npj Sci Food<\/em> 2024].<\/p>\n\n\n\n

Food ink: when the recipe becomes the process material<\/strong><\/h2>\n\n\n\n
\"\"<\/a><\/figure>\n\n\n\n

It is in food ink <\/strong>that the machine encounters its true critical material. In 3D food printing, a recipe is no longer merely a sensory or nutritional formulation; it becomes a process material, required to behave predictably inside the nozzle, during deposition, and after layer formation. A dough, pur\u00e9e, or gel must flow when subjected to stress, quickly regain its structure once deposited, and support the weight of subsequent layers without collapsing. It is within this rheological window that much of the printability is determined: viscosity, shear-thinning behavior, yield stress, thixotropy, and post-extrusion stability are not mere laboratory details, but parameters that determine geometric accuracy, process continuity, and the quality of the finished product. The literature indicates, as a guideline, a yield stress range of approximately 500\u20131,500 Pa as a useful range for combining extrudability and structural integrity, although this depends heavily on the matrix and machine parameters [Derossi A et al. npj Sci Food<\/em> 2024; Paolillo M. PhD Thesis, University of Foggia 2022]. The complexity increases because food matrices are biologically variable and sensitive to temperature, resting time, hydration, particle size, and interactions between ingredients. For this reason, hydrocolloids, protein gels, emulsions, oleogels, and multi-material systems serve not only to \u201cmake a food printable,\u201d but also to construct a raw material designed to be dispensed, deposited, stabilized, and consumed with repeatable characteristics [Ma Y et al. Curr Opin Food Sci<\/em> 2019; Yang M et al. Gels<\/em> 2026].<\/p>\n\n\n\n

Senior Nutrition and Dysphagia: the Most Established Application<\/strong><\/h2>\n\n\n\n

Among the most well-established applications today, senior nutrition and foods for dysphagia likely represent the area where 3D food printing most clearly demonstrates its practical value. The underlying problem is well known: in texture-modified diets, safe swallowing is often achieved at the expense of a significant loss of recognizability, palatability, and nutritional density. Purees, blended foods, and homogenized preparations meet a functional need, but they can reduce the enjoyment of a meal and contribute to lower energy and protein intake in frail individuals [Lorenz T et al. Foods 2022; Shao J et al. Foods 2025]. In this context, 3D food printing adds value not because it \u201cshapes\u201d food in an aesthetic sense, but because it allows for the reconstruction of soft, safe matrices in controlled portions that are more recognizable and potentially enriched<\/strong> with protein, vitamins, or other nutrients. The decisive step is anchoring the process to objective texture criteria: printed foods for patients with dysphagia can be evaluated based on IDDSI levels and practical tests\u2014such as fork pressure tests\u2014to assess cohesion, softness, and suitability for swallowing [Lorenz T et al. Foods 2022; Shao J et al. Foods 2025; Yang M et al. Gels 2026]. The European PERFORMANCE project has clearly demonstrated this direction: bringing pureed foods back to forms closer to the original food, integrating nutritional customization, meal management software, and production methods better suited to nursing homes and care- d food services [CORDIS, 3D printing to the rescue of gastronomy for frail seniors 2023]. This application still needs to be scaled up, but it is industrially promising because it addresses clinical needs while ensuring texture standardization, portion control, and process repeatability.<\/p>\n\n\n\n

Structured plant-based foods: building fiber, fat, and texture<\/strong><\/h2>\n\n\n\n

A second area\u2014less developed but closely watched by the industry\u2014is that of structured plant-based foods<\/strong>. Here, 3D food printing ventures into territory distinct from clinical nutrition: it must not only make food more customizable but also help shape the product\u2019s textural experience. In plant-based meat substitutes, one of the main challenges remains the reproduction of fiber, juiciness, fat distribution, and chew resistance\u2014that is, the internal architecture that, in animal-based products, arises from a complex biological structure. The multi-material deposition of protein batters, gels, emulsions, and oleogels can offer a way to spatially organize components with different behaviors: the protein phases influence texture and chew resistance, while oleogels and emulsions can help simulate the lipid component, juiciness, and sensory release during consumption [Xiao S et al. Foods 2025; Derossi A et al. npj Sci Food 2024; Ma Y et al. Curr Opin Food Sci 2019]. This is a field in which startups and applied research have already produced interesting examples, but the gap to industrial-scale production remains significant: costs, deposition speed, formulation stability, and integration with cooking or post-processing are still unresolved issues [Eswaran H et al. Ann 3D Print Med 2023; Ma Y et al. Curr Opin Food Sci 2019]. The value of 3D food printing, in this case, lies not in imitating meat visually, but in using geometry to influence structure, texture, and sensory perception.<\/p>\n\n\n\n

<\/p>\n\n\n\n

Article from the October issue of the magazine \u201cMacchine Alimentari\u201d<\/strong> <\/span><\/a><\/div>\n\n\n\n

<\/p>\n\n\n\n

To continue reading, click here and subscribe<\/strong><\/span><\/a><\/div>\n","protected":false},"excerpt":{"rendered":"

3D food printing will not replace traditional production lines, but it can become a process module for highly complex niche markets: senior nutrition, dysphagia, plant-based foods, functional snacks, and gourmet foods, where shape, texture, and composition become valuable, controllable industrial variables<\/p>\n","protected":false},"author":3836,"featured_media":242368,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[20657,20572],"tags":[23120],"tipologia":[],"coauthors":[16393],"class_list":["post-242374","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-macchine-alimentari-en","category-technology","tag-3d-food-printing"],"acf":[],"yoast_head":"\n3D Food Printing: Personalization Becomes a Process - Alimentibevande.it<\/title>\n<meta name=\"description\" content=\"3D food printing will not replace traditional production lines, but it 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