The aim of the current research project was to explore the possibilities of combining pressurized carbon dioxide with hot melt extrusion of polyvinylpyr-rolidone-co-vinyl acetate 64, Eudragit (R) E100 and ethylcellulose 20cps, to evaluate the ability of the pressurized gas to act as a temporary plasticizer as well as to produce a foamed polymeric material. Pressurized carbon dioxide was injected into a Leistritz Micro 18 intermeshing co-rotating twin-screw melt extruder using an ISCO 260D syringe pump. The physicochemical characteristics of the polymers before and after injection of carbon dioxide were evaluated using MDSC, dissolution measurements, specific surface area measurements, porosity, dynamic vapour sorption and microscopy. An extruder set up and screw configuration were configured and optimized for injection of pressurized CO2. Carbon dioxide acted as plasticizer for all three polymers, reducing the processing temperature during the hot melt extrusion process. The specific surface area and the porosity of the polymers was increased after treatment with carbon dioxide, resulting in enhanced dissolution. The macroscopic morphology was changed to a foam-like structure due to expansion of the carbon dioxide at the extrusion die. This resulted in improved milling efficiency. (c) 2005 Elsevier B.V. All rights reserved.