Biodegradable materials are used in the manufacture of packaging and compostable films and various types of medical products. These have demonstrated high potential in medical applications: cardiac, vascular and orthopaedic conditions in adults as well in children. In our research, the extrusion-cooking technique was used to obtain environmentally friendly loose-fill foams as packaging. Potato starch was the basic raw material. Polyvinyl alcohol was used as an additive in the amount of 1%, 2% and 3% to replace starch. The components were mixed and moistened with water to various initial moisture contents of the blend (17%, 18% and 19%). The processing of starch foams employed the TS-45 single screw extruder-cooker (Gliwice, Poland) with the L/D ratio of 12. The foams were processed with various screw speeds (100 and 130 rpm) and with two types of forming dies (circular and ring die). The extrusion-cooking process efficiency (kg h−1) and the energy consumption (kWh kg−1) during the processing were also measured. The results showed that the processing efficiency of potato starch foams varied depending on the level of polyvinyl alcohol, the shape of the forming die and the screw speed applied. The analysis of energy consumption, mechanical properties and FTIR analyses demonstrated that the type of the forming die and the initial moisture level had the most significant impact on specific energy demands during the processing of potato starch-based foams.