Search Results (17)

Parboiling improves rice-milling performance and consumer acceptance; however, drying parboiled rice can be energy intensive and highly sensitive to drying conditions, making it costly for processors. High head rice yield (HRY) and whiteness index (WI) are essential for commercial value because they reduce breakage and improve visual quality. In the United States, parboiled rice is typically dried in a two-stage process using rotary drum and crossflow dryers, but the high temperature condition of rotary drums can increase energy demand and compromise rice quality. This study evaluated the drying kinetics, effective moisture diffusivity (D_eff), energy consumption, and quality for three common cultivars (CLL 18, RT 7521, and Titan) using four methods: natural air drying (NAD), two-pass hot air oven drying (OO), two-pass fluidized bed drying (FBD), and a hybrid of oven and fluidized bed method (OFBD). Moisture content (MC) was monitored during drying until 12.5% (w.b.) to understand the drying kinetics. FBD achieved the fastest drying, reducing Titan MC from 38.24% to 13.79% (w.b.) in 60 min (two passes). It also produced highest D_eff across cultivars and consumed less energy (1.6599 kWh) as compared to OFBD (1.6733 kWh) and OO (1.68 kWh). Among nine thin-layer models explored, the logarithmic model provided the best fit, and Midilli–Küçük and Verma et al. models performed better in specific cases. NAD produced a higher quality of HRY (Titan: 65.33 ± 2.07%) and WI (RT 7521: 63.99 ± 0.25) than FBD but required 7–10 days to reach the target moisture content, limiting industrial applicability. Results from this study show that drying method and rice cultivars significantly influenced parboiled rice quality, and FBD offered efficient drying without compromising parboiled rice quality. Full article

The food processing industry is undergoing a profound transformation with the integration of Artificial Intelligence (AI), evolving from traditional automation to intelligent, adaptive systems aligned with Industry 5.0 principles. This review examines AI’s role across the food value chain, including supply chain management, quality control, process optimization in key unit operations, and emerging areas. Recent advancements in machine learning (ML), computer vision, and predictive analytics have significantly improved detection in food processing, achieving accuracy exceeding 98%. These technologies have also contributed to energy savings of 15–20% and reduced waste through real-time process optimization and predictive maintenance. The integration of blockchain and Internet of Things (IoT) technologies further strengthens traceability and sustainability across the supply chain, while generative AI accelerates the development of novel food products. Despite these benefits, several challenges persist, including substantial implementation costs, heterogeneous data sources, ethical considerations related to workforce displacement, and the opaque, “black box” nature of many AI models. Moreover, the effectiveness of AI solutions remains context-dependent; some studies report only marginal improvements in dynamic or data-poor environments. Looking ahead, the sector is expected to embrace autonomous manufacturing, edge computing, and bio-computing, with projections indicating that the AI market in food processing could approach $90 billion by 2030. Full article

While traditional disposal of solid waste from the global wine industry causes significant environmental burden and hazards, a range of value-added by-products can be produced from the grape marc. This review focuses therefore on crucial sustainability-enhancing technologies for pomace dewatering and separation, which constitute a mandatory stage in obtaining storage-stable by-products and final value-added commodities. A number of dryers and separators were considered for pre-treatment of wet grape marc and analysed in terms of their design characteristics, functionality, feasibility, throughput and efficiency. A multi-criteria decision analysis was carried out to compare, rank and select the equipment which is most suitable for the purpose. It was found out that the rotary drum dryer and the drum screen separator with internal blade rotor are the best candidates to fulfil the technology requirements, while the flowsheet that includes an initial separation followed by drying of the resulting fractions is a rather attractive option. Valorising grape waste worldwide contributes substantially to achieving the United Nations Sustainable Development Goals for responsible consumption and production, mitigating climate change, caring for health and well-being, preserving land life and combating hunger. Full article

The drying process is widely used in the food industry for its ability to remove water, provide microbial stability, and reduce spoilage reactions, as well as storage and transportation costs. In particular, rotary drum drying becomes important when it is applied to liquid and pasty foods because of the desire to maintain defined characteristics in terms of product moisture. This drying process is characterized by the existence of many linearities; therefore, different strategies for controlling this process have been proposed. This work focuses on the design of a hybrid PI–fuzzy control scheme for the rotary drum drying process; the idea is to use the advantages of fuzzy logic to obtain a robust monitoring and control system. A pilot plant rotary drum dryer was used to tune the PI control part. Then, the proposed scheme was programmed and tested at the simulation level, comparing it with a classical PI control algorithm. Full article

The coffee fruit is preferably harvested at the cherry stage, with high moisture and metabolic activity, and must then undergo a drying process for better preservation of the bean and its sensory attributes. In this context, this study aimed to characterize the final quality of the Arara cultivar Arabica coffee processed using the wet method and subjected to six drying methods: three conducted at the agro-industrial establishment (fixed-bed dryer, rotary drum dryer, and combined drying) and three laboratory-scale methods (convective oven, cast-tape drying, and suspended terrace). Drying was carried out to reduce the coffee’s moisture content from an initial value of 46.2% on a wet basis (w.b.) to a final average value of 11.35% (w.b.). The fruits of in natura demucilaged coffee and the processed dry coffee beans were characterized for moisture, ash content, nitrogen compounds, lipids, total titratable acidity, organic acids, sugars, and the instrumental color of the beans. The sensory profile of the Arabica coffee was evaluated by five coffee specialists using the methodology proposed by the Specialty Coffee Association (SCA), and all the coffees were classified as a specialty. Full article

An experimental study and dimensional analysis of the effective heat transfer coefficient in a continuous-indirect rotatube dryer using forest biomass as the granular material isare developed in the present work. The study employed a factorial design $3^3$ to investigate the effects of feed flow frequency (20–35–50 (Hz)), drum rotational velocity (6–8–10 (rpm)), and saturated vapor pressure (4–5–6 (bar)) on the heat transfer coefficient. During steady state conditions, the moisture content profiles and inlet and outlet temperatures were measured within the experimental region, and parameters, such as the effective heat transfer coefficient, solid retention change, and moisture content ratio were studied. The results showed that heat transfer was optimized with high solid feeding rates, low pressure, and low rotation, with solid feeding being the predominant factor. The moisture content profiles revealed a change in the hydrodynamic behavior, with the center point of the experimental region being the least optimal. The dimensional analysis yielded a Nu number as a function of Pe, Fr, and the feeding dimensionless number. A new dimensionless energy efficiency number improved the coefficient correlation from 85.88 (%) to 94.46 (%), indicating the developed model potential to predict dimensionless variables and scale continuous-indirect rotatube dryers. Full article

Conventional flighted rotary drums usually have flights parallel to the rotating axis, which cannot facilitate the axial motion of the materials in the drum. Here, a new type of horizontal rotary drum with inclined flights and beads was designed. Inclined flights are used to facilitate the axial movement of beads and material, while beads are used as fillers to increase the gas-liquid contact area and to crush the solid materials. We simulated the drum and studied the axial motion of fillers using the discrete element method (DEM). To improve the mass and heat transfer performance, we optimized the distribution of beads in the active phase. The effects of the rotational speed, joint angle, and inlet flow rate in the drum were investigated systematically. The individual effects were evaluated in terms of the mass of particles in the active phase (MAP) and passive phase (MPP), the percentage of the active phase occupied by the particles (OAR), and the axial speed (AS). The response surface methodology (RSM) was used to investigate the significant effects of the interaction between the parameters. The maximum MAP value can be obtained by the following parameters: a rotational speed of 37 rpm, joint angle of 139°, and inlet flow rate of 7.83 kg/s. The interaction between rotational speed and inlet flow rate is the most significant for MAP. The joint angle and inlet flow rate have a significant interactive effect on AS. Besides, the rotational speed, joint angle and inlet flow rate show an interactive effect on OAR and AS. Based on the optimization results, the effect of the inclined angle on the axial motion of beads was also evaluated. The axial motion of the beads occurs mainly in the active phase. Compared to the drum without inclined flights, the drum with inclined flights has an enhanced axial speed increased by 26%. This study will be helpful for the design and optimization of drums with inclined flights. Full article

Rotary drum dryers operating in co-current mode are commonly used for drying food and feed in leaf form, reducing the damage caused by the high air temperatures typical of these dryers, as well as providing advantages including reduced drying times and increased energy efficiency. However, drying control to ensure a desirable product exit moisture content is strongly based on empirical practices, which are usually jealously guarded by producers and users, grounded in simplified mathematical modelling. To overcome these uncertainties, in this work, a more complete mathematical modelling approach, based on the solution of ordinary differential equations (ODEs), is developed. The ODEs describe the drying process in the drum dryer, where the air is continuously cooled and humidified as the product dries. The mathematical model developed was experimentally verified in a drum dryer by drying alfalfa, and the maximum relative error was found to be only 2.4%. Finally, a comparison between the complete model proposed here and a simplified model was conducted, using both for drying control to keep the product exit moisture content constant (i.e., at 0.111). The results indicated that the simplified model provided values of air inlet temperatures erroneously higher, up to +8.2%, with a consequent higher energy consumption, lower dried alfalfa quality, and a greater risk of fire, given that the product exit temperature was dangerously increased. Full article

As the human population grows and the demand for food grows with it, the recycling, or containment of materials is important for resource consumption. Nitrogen is one of the main plant nutrients, most commonly used as the chemical substance urea. Because urea is very soluble and at a relatively low temperature (50–60 °C) it hydrolyses easily (releases N₂ and CO₂) in soil solutions; this is why very large amounts of nitrogen are lost and greenhouse gases are released and this causes serious environmental problems. Therefore, the aim of this study was to create microalgae-enriched nitrogen fertilizers with different binders that inhibit nitrogen leaching from the soil. Binders such as water (W), polyvinyl acetate dispersion (PVAD), molasses (M), potato starch (S), and carboxymethyl cellulose (CMC) were used in this study and their influence on leaching was analysed. Granular fertilizers were produced in a drum granulator and dryer under equal conditions: granulation time was 7 min, granulation took place at a temperature of 50–60 °C, at a drum rotation speed of 26 rpm, with a 5° inclination angle of the drum. The results show that the highest quantity of the marketable fraction was 43.01 (±3.068%) and it was obtained using urea, with 10% (w/w) microalgae additive, and 11.4% (w/w) of 5% concentration molasses solution. The granules of the fertilizer marketable fraction are similar in size because the size guide number (SGN) of the granules vary in a narrow range and fall within the interval of 287 to 304; this means that the average particle size is ~3 mm. When different binders were used, the average static crushing strength of the granulated fertilizers was lower (approximately 6–12 MPa) than using water alone (approximately 12–16 MPa), but the lower values still fell into the required range. Additives of PVAD solutions and molasses solutions have been found to retain nitrogen in sand. The method of one-way analysis of variance (ANOVA) was used to evaluate the results. Full article

Thedistribution of aggregates in the cross-section of the drum, in the case of equipment used for the production of asphalt mixtures, essentially influences the performance of rotary dryers. In the research carried out in this article, the optimization of the distribution of particles in the active region of the drum was pursued by modifying the geometric shape of the flights, taking into account at the same time the influence of the technological parameters of operation such as drum rotation speed and drum filling degree. The studies were performed using the discrete element method (DEM), and the obtained results revealedthat flight geometry strongly influences drying efficiency. The efficiency of rectangular double-angled type flights is strongly influenced by the drum rotation speed, especially at high levels of filling degree (20%), with the mass of aggregates exposed to drying increasing by 41.11% when drum rotation speed increases from 10 rpm to 15 rpm. Similarly, hook-type flights show a minimum efficiency at 15% filling degree and 15 rpm. The comparative analysis of the flight shape is not only carried out in order to establish the variant that ensures maximum drying efficiency but also from the point of view of execution technology. (Original flights can be obtained by deep drawing, but they have a complex geometric configuration; cup flights can be obtained very easily from tubular material cut on the generators; hook flights by deep drawing or welding the cut tubular material on a straight plate, and the L type by deep drawing). Taking into account that semi-finished products can be very thick, it is possible that, in some cases, hot embossing is necessary, so making them out of tubular material eliminates these inconveniences. All the presented results highlight that the rectangular, double-angled and hook-type flights are the most appropriate shapes that can be used regardless of the drum filling degree and rotation speed. Full article

This study was designed to examine broken riceberry (BR) powder production through the use of a double drum dryer. There were two stages involved: (1) to study the optimized drum drying conditions for BR powder using response surface methodology (RSM), and (2) to utilize BR powder for the development of instant beverages. According to the results, the optimum drum drying condition was a drum temperature of 125 °C and drum speed of 1.0 rpm. Under these conditions, BR powder contained moisture = 5.81%, water activity = 0.494, total color difference 15.45, DPPH scavenging activity = 73.93%, water solubility index (WSI) = 52.33%, and water absorption index (WAI) = 10.52. For the utilization of BR powder for developing instant beverages, the product quality was light purple in color, water activity = 0.354, DPPH scavenging activity = 45%, WSI = 65.75%, and WAI = 12.25. The developed instant beverage contained 4.28% moisture, 13.89% protein, 12.42% fat, 4.23% fiber, and 2.23% ash. The microbial properties were <10 CFU/g for aerobic plate count and yeast and mold. The overall liking score was ‘like moderately’. This study indicated that the BR powder is of good quality and has potential in the beverage industry. Full article

In this study, a new type of rotary dryer filled with inert alumina ceramic bead (ACB) fillers was introduced to treat the industrial wastewater, e.g., the high-salt wastewater and landfill leachate. Numerical simulations based on the Discrete Element Method (DEM) on the motion trajectory of ACB fillers in the rotary dryer were conducted, and the parameters of flight structure, rotational speed, and filling degree on the dynamic behavior of ACB fillers were optimized. Under various rotational speeds and filling degrees, the experimental results fit the numerical-simulated results very well. The optimized flight configuration was the straight flights with a length of 65 mm, and the optimized rotational speed and filling degree were 35 rpm and 15%, respectively. Under the optimized condition, both the response variables, the mass of particles in the airborne phase (MAP) and the percentage of occupied area in the airborne region (OAR), have the optimal values, in which the dryer will have a better drying performance. Besides, the lower-right area of the drum is empty which is convenient for the installation of the inlet pipe. The drying experiments of industrial wastewaters were also studied using this ACB filled rotary drum dryer under the optimized conditions. Under the optimal operational conditions, the evaporation capacities of the high-salt wastewater and landfill leachate could reach as high as 49.7 kg/h and 90 kg/h, respectively. This study highlights the integration of evaporation and drying processes of this novel ACB filled rotary dryer and provides an efficient and zero-liquid-emission strategy for the thermal treatment of industrial wastewater. Full article

Most agricultural products are harvested with a moisture content that is not suitable for storage. Therefore, the products are subjected to a drying process to prevent spoilage. This study evaluates an infrared rotary dryer (IRRD) with three levels of infrared power (250, 500, and 750 W) and three levels of rotation speed (5, 10, and 15 rpm) to dry terebinth. Response surface methodology (RSM) was used to illustrate and optimize the interaction between the independent variables (infrared power and rotation speed) and the response variables (drying time, moisture diffusivity, shrinkage, color change, rehydration rate, total phenolic content, and antioxidant activity). As infrared power and rotation speed increased, drying time, rehydration rate, antioxidant activity, and total phenolic content decreased, while the other parameters were increased. According to the results, the optimum drying conditions of terebinth were determined in the IRRD at an infrared power of 250 W and drum rotation speed of 5 rpm. The optimum values of the response variables were 49.5 min for drying time, 8.27 × 10⁻⁹ m²/s for effective moisture diffusivity, 2.26 for lightness, 21.60 for total color changes, 34.75% for shrinkage, 2.4 for rehydration rate, 124.76 mg GAE/g d.m. for total phenolic content and 81% for antioxidant activity. Full article

This work studied the effect of drum-rotation frequency, drum temperature, and water-to-pulp ratio in a double-drum drier on the content of sulforaphane, glucoraphanin, total phenolic compounds, ascorbic acid, and antioxidant activity of broccoli pulp through a multilevel factorial design with one replicate. Drum-drying conditions did not significantly affect sulforaphane content, unlike glucoraphanin, however the poor adherence of broccoli pulp resulted in a final product with undefined shape and heterogeneous color. On the other hand, antioxidant activity was unevenly affected by drying conditions; however, drum-rotation frequency affected it in the same way that phenolic compounds and ascorbic acid, showing a concordant behavior. The ascorbic acid content decreased significantly after drying, and it was highly dependent on the experimental factors, resulting in a regression model that explained 90% of its variability. Drum-rotation frequency of 5 Hz, drum temperature of 125 °C, and water-to-pulp ratio of 0.25 resulted in an apparent increase of sulforaphane and phenolic compounds content of 13.7% and 47.6%, respectively. Drum drying has great potential to fabricate dehydrated broccoli-based foods with functional properties. Besides, since drum drying has low investment and operation costs, it represents a very attractive option for the industrialization of broccoli derivatives. Full article

This paper focuses on indirect biomass drying. It compares the operating characteristics of a laboratory-scale drum dryer and a pilot-scale rotary dryer. Before the design of an industrial dryer for a specific material, it is important to experimentally prove the process and to determine the drying characteristics of the material. To verify the portability of experimental results for indirect dryers, a drum dryer with indirect electric heating in a laboratory scale was designed and built to test and study the process of indirect drying. Based on the results obtained on a small-scale device, a prototype of a pilot steam-heated rotary dryer was designed and manufactured. A broad range of experiments with green wood chips and wet bark from open-air storage with moisture contents of 50 to 65 wt % were carried out on both dryers. The drying curves indicating the process, the square and volumetric evaporation capacities, and the drying energy consumption were obtained and compared, and the feasibility of indirect drying for these tested types of biomass was confirmed. Full article