The objective of this study was to investigate the screw configuration allowing oil extraction from sunflower seeds with a twin-screw extruder. Experiments were conducted using a co-rotating twin-screw extruder. Five screw profiles were examined to define the best performance (oil extraction yield, specific mechanical energy and oil quality) by studying the influence of operating conditions, barrel temperature, screw speed and feed rate. Generally, the position and spacing between two reversed screw elements affected oil extraction yield. An increase of oil extraction yield was observed as the reversed screw elements were moved with increased spacing between two elements and with smaller pitch elements. In addition, oil extraction yield increased as barrel temperature, screw speed and feed rate were decreased. Highest oil extraction yield (85%) with best cake meal quality (residual oil content lower than 13%) was obtained under operating conditions of 120 degrees C, 75 rpm and 19 kg/h. Furthermore, the operating parameters influenced energy input. A decrease in barrel temperature and feed rate followed by an increase in screw speed increased energy input, particularly specific mechanical energy input. Effect of the operating parameters on oil quality was less important. In all experiments tested, the oil quality was very good. The acid value was below 2 mg of KOH/g of oil and total phosphorus content was low, below 100 mg/kg. (c) 2005 Elsevier Ltd. All rights reserved.