A mathematical model was developed to simulate fluid flow, heat transfer, and melting kinetics of starch in a co-rotating intermeshing twin-screw extruder (TSE). The partial differential equations governing the transport phenomena of the biomaterial in the extruder were solved by a finite element scheme. For validating the model, the predicted product pressure, bulk temperature at the entrance of the die, and minimum residence time of the biomaterial in the extruder were compared with experimental data. Standard errors of product pressure, bulk temperature at the die entrance, and minimum residence time were about 8.8, 2.8, and 17.3%. Simulations were carried out to investigate profiles of product pressure, bulk temperature, and melt fraction within the extruder during extrusion. (C) 2006 Wiley Periodicals, Inc.