Water, vapor, and heat transport mechanisms and thermomechanical changes occurring inside the expanding extrudate were described using hybrid mixture theory-based unsaturated transport equations. Transport equations were transformed from the Eulerian coordinates to the Lagrangian coordinates. Good agreements between the predicted and experimental values of surface temperature, moisture content, and expansion ratio of the extrudates were obtained. The model was also used to calculate temperature, moisture content, pore-pressure, and viscoelastic-stress distribution in the extrudate. Matrix collapse and glassy crust formation under the surface was calculated as a function of extrusion conditions. Expansion behavior of the extrudate was described using the difference between stress due to pore pressure and viscoelastic stress. The modeling results can serve as a guide for predictably modifying the extrusion parameters for obtaining specific textural attributes of expanded starch for various food, feed, and biomedical applications. (c) 2015 American Institute of Chemical Engineers AIChE J, 61: 4517-4532, 2015