M.Sc. Felix Ellwanger

  • Postanschrift: Kaiserstr. 12
    Liefer- und Besucheranschrift: Gotthard-Franz-Straße 3
    Geb. 50.31, 4. OG
    D-76131 Karlsruhe

About myself

I completed both my bachelor's and master's degree in chemical engineering at the Karlsruhe Institute of Technology. My first contact with food process engineering was during my bachelor's degree course in "food technology". During my master internship at Capol GmbH in Elmshorn I was able to consolidate my interest in the food sector. There I was working in R&D on the further development of anti-sticking agents for fruit gums. During the master's course I deepened my knowledge in food process engineering and in the field of gas particle systems. In my master thesis at the Institute of Food Process Engineering I simulated the two-phase flow through an ACLR atomizer, which can be used in the field of spray drying. During my studies I enjoyed working scientifically, especially in the field of LVT, so I am looking forward to work as a research assistant at the institute of LVT.

Research focus

The extrusion process is a continuous, thermomechanical process in which various steps, such as mixing, melting and forming, take place simultaneously. In recent years, extruders have been increasingly used to produce meat analogues. For this purpose, proteins of various origins are functionalized and textured with the help of the extruder. Process conditions such as temperature, shear stress, pressure and residence time have a major influence on the reactions of the proteins. Since the process conditions always occur simultaneously during extrusion, the influence of individual process conditions on the reaction behaviour of the proteins is still unclear. In my work I therefore deal with the influence of process conditions on the reaction behaviour of proteins.


In order to further characterize the extrusion process, both experimental and numerical flow simulations are used. In the experiment, image recordings, sensors and the operating parameters of the extruder can be used to gain information about residence time distribution, temperature profiles and other important parameters. With the help of a closed cavity rheometer, it is also possible to observe individual process conditions such as the shear rate under extrusion-like conditions. This allows the pure influence of the shear rate on the reaction behavior of proteins to be investigated.
Furthermore, numerical flow simulation offers the possibility to gain insights into process variables that are not accessible in experiments. For example, the exact temperature distribution in the extruder can be determined, as well as the resulting thermal stress that affects the proteins used.


Current offers for Bachelor and Master theses
title date type advisor


Influence of Lowering the pH Value on the Generation of Fibrous Structures of Protein Gels with Different Network Types
Ellwanger, F.; Fuhrmann, M.; Karbstein, H. P.; Saavedra Isusi, G. I.
2024. Gels, 10 (3), Art.-Nr.: 173. doi:10.3390/gels10030173
Application of the ramp test from a closed cavity rheometer to obtain the steady-state shear viscosity η ( γ̇ )
Ellwanger, F.; Georgantopoulos, C. K.; Karbstein, H. P.; Wilhelm, M.; Azad Emin, M.
2023. Applied Rheology, 33 (1), Art.-Nr.: 20220149. doi:10.1515/arh-2022-0149
Highly protein-loaded melt extrudates produced by small-scale ram and twin-screw extrusion - evaluation of extrusion process design on protein stability by experimental and numerical approaches
Dauer, K.; Kayser, K.; Ellwanger, F.; Overbeck, A.; Kwade, A.; Karbstein, H. P.; Wagner, K. G.
2023. International Journal of Pharmaceutics: X, 6, Art.-Nr.: 100196. doi:10.1016/j.ijpx.2023.100196
Morphology Development and Flow Characteristics during High Moisture Extrusion of a Plant-Based Meat Analogue
Wittek, P.; Ellwanger, F.; Karbstein, H. P.; Emin, M. A.
2021. Foods, 10 (8), Art.-Nr.: 1753. doi:10.3390/foods10081753


Challenges in obtaining the steady-state shear viscosity of protein-water mixtures under extrusion-like conditions
Ellwanger, F.; Karbstein, H.; Emin, M. A.
2024, April. Annual European Rheology Conference (AERC 2024), Leeds, United Kingdom, April 9–12, 2024
The pH Modulation during Plant Protein Extrusion: Impact on Meat-Like Structures
Ellwanger, F.; Fuhrmann, M.; Karbstein, H.; Saavedra Isusi, G.
2024, March. Plant Protein Extrusion Conference (2024), Chatham, United Kingdom, March 14–15, 2024
Local process conditions in the twin-screw extruder during the functionalization of highly concentrated protein systems
Ellwanger, F.; Karbstein, H.; Emin, M. A.
2023, September. 14th European Congress of Chemical Engineering and 7th European Congress of Applied Biotechnology (ECCE & ECAB 2023), Berlin, Germany, September 17–21, 2023
Ernährung von Morgen – Insekten und Pflanzen als Proteinlieferanten
Ellwanger, F.
2023, August. Gamescom (2023), Cologne, Germany, August 23–27, 2023
Numerische Ermittlung lokaler Prozessbedingungen während der Doppelschneckenextrusion pflanzlicher Proteine
Ellwanger, F.; Pernice, L.; Karbstein, H. P.; Azad Emin, M.
2023. Jahrestreffen der DECHEMA-Fachgruppen Hochdruckverfahrenstechnik (2023), Bochum, Germany, March 13–15, 2023
Extrudierte Insektenmehle für die Brotherstellung
Ellwanger, F.; Schmid, V.; Marel, A.-K.; Wiedenmann, V.; Müller, A.; Meinhardt, A.-K.; Mayer-Miebach, E.; Hetzer, B.; Sciurba, E.; Huch, M.; Karbstein, H.; Emin, A.
2022, April 28. Anuga Foodtec (2022), Cologne, Germany, April 26–29, 2022
Analyse der Prozessbedingungen während der Doppelschneckenextrusion pflanzlicher Proteine mit numerischen und rheologischen Methoden
Ellwanger, F.; Husfeldt, A.; Karbstein, H. P.; Emin, A.
2022, March 11. Jahrestreffen der ProcessNet-Fachgruppen Lebensmittelverfahrenstechnik und Trocknungstechnik (2022), Frankfurt am Main, Germany, March 10–11, 2022
Functionalizing insects via twin-screw extrusion
Ellwanger, F.; Schmid, V.; Karbstein, H. P.; Azad Emin, M.
2022. Food Extrusion : Alternative Proteins and Plant-Based Meat (2022), Freising, Germany, June 1–2, 2022


Modulation of the fibrous structures of high moisture meat substitutes by altering the pH
Ellwanger, F.; Fuhrmann, M.; Schaaf, U. van der; Karbstein, H.; Saavedra Isusi, G.
2024, April. Annual European Rheology Conference (AERC 2024), Leeds, United Kingdom, April 9–12, 2024
Modulierung der faserartigen Strukturen von nassextrudierten Fleischersatzprodukten durch Veränderung des pH-Wertes
Ellwanger, F.; Fuhrmann, M.; Karbstein, H.; Saavedra Isusi, G.
2024, February. Jahrestreffen der DECHEMA/VDI-Fachgruppe Lebensmittelverfahrenstechnik (2024), Quakenbrück, Germany, February 27–28, 2024
Meat Substitutes as a Source of Protein in the Diet – Influence of Altering the pH on the Formation of Fibrous Structures
Ellwanger, F.; Fuhrmann, M.; Karbstein, H.; Saavedra Isusi, G.
2023, November. DECHEMA Infoday "Food Proteins from Biotechnology" (2023), Frankfurt am Main, Germany, November 30, 2023
Numerical and rheological analysis of the twin-screw extrusion process for the production of meat substitutes
Ellwanger, F.; Karbstein, H.; Emin, M. A.
2023, November. 37th EFFoST International Conference (2023), Valencia, Spain, November 6–8, 2023
Highly Protein-Loaded Melt Extrudates Produced by Small-Scale Ram and Twin-Screw Extrusion - Evaluation of Extrusion Process Design on Protein Integrity by Experimental and Numerical Approaches
Dauer, K.; Ellwanger, F.; Emin, M. A.; Karbstein, H.; Wagner, K. G.
2023, October. AAPS PharmSci 360 (2023), Orlando, FL, USA, October 22–25, 2023
Using Moving Particle Simulation Approach to Investigate Mechanical and Thermal Stress Profile in a Twin-Screw Extruder
Ellwanger, F.; Pernice, L.; Karbstein, H.; Emin, A.
2023, June 20. 14th International Congress on Engineering and Food (ICEF 2023), Nantes, France, June 20–23, 2023
Modelling and Analysis of the Effect of Process and Geometry Parameters on Multiphase Flow Formation in ACLR Atomizers
Ballesteros Martinez, M.; Ellwanger, F.; Wittner, M.; Gaukel, V.
2021, March 10. Jahrestreffen der ProcessNet Fachgruppen Mehrphasenströmung (MPH) und Computational Fluid Dynamics (CFD 2021), Paderborn, Germany, March 9–10, 2021