Abstract: A gluten-free pasta system is disclosed comprising nano-refined almond-based flour, a psyllium husk serum binder, improved dough preparation methods, and a specialized extrusion die for high-oil doughs. Almond flour, almond protein powder, and tapioca starch are mechanically refined to micron- or sub-micron-scale particle sizes to improve hydration, cohesion, and dough elasticity. A psyllium husk serum is prepared by hydrating and mechanically processing psyllium to form a smooth, uniform gel that enhances binding and structural integrity. The refined flour and serum are combined with water to form a cohesive dough exhibiting reduced oil separation and improved extrusion stability. An improved extrusion die having tapered flow channels, polished or non-stick surfaces, and pressure-modulating features enables stable formation of pasta shapes from high-oil doughs. Methods of manufacturing pasta and related extruded food products using the disclosed compositions and systems are also provided.