Use of computational fluid dynamics to improve the energy efficiency of thermal processes in the food industry.
A recent study, carried out by a group of Polish researchers (Szpicer et al., 2025), evaluates the application of computational fluid dynamics (CFD) simulations in the analysis of thermal processes used in the food industry. The focus is on understanding heat transfer, fluid flows and temperature distribution during various processing methods, such as baking, frying, pasteurisation and cooling.
The analysis highlights that CFD simulations provide detailed information, which is often difficult to obtain through experimental methods alone, enabling the optimisation of process parameters to improve product quality and safety. According to the authors, CFD is capable of effectively modelling complex thermal phenomena, providing valuable data on temperature gradients and flow configurations.
These simulations contribute to the design of more efficient equipment, improving energy consumption and ensuring uniform heat treatment – a crucial aspect for preserving the nutritional and organoleptic characteristics of food products. The use of CFD also leads to significant advances in process development, reducing lead times, energy consumption and associated costs. In conclusion, future research should focus on refining these models and their application in emerging food processing technologies.
Innovative solutions for improving the energy efficiency of freeze-drying processes.
Freeze-drying (FD) is one of the main methods for preserving food quality, particularly for heat-sensitive foods. However, high operating costs and low productivity limit its use. The aim of a recent study, carried out by a group of international researchers (Al Faruq et al., 2025), was to illustrate the progress made to date in improving the energy efficiency of freezing and FD processes, thereby reducing processing times and energy consumption.
These improvements involve a combination of innovative technologies such as: radio frequency (RF), high pressure (HP), magnetic field (MF), high-voltage electric field (HVEF), microwave (MW), infrared radiation (IR), ultrasound (US) and controlled instantaneous pressure drop (DIC). In particular, hybrid systems that integrate these technologies with FD demonstrate synergistic benefits in improving drying kinetics and reducing operating costs. Recent trends also include the application of artificial intelligence (AI) and machine learning to model, monitor and optimise FD processes, enabling better control.
These tools, in particular, allow for more accurate modulation of the nucleation rate and, consequently, the size of ice crystals, thereby reducing production costs and improving the overall quality of finished products. However, to achieve true sustainability, progress is essential not only in the hardware and software of the drying plant, but also in closely related areas such as energy sources, energy conversion, energy recovery from low-temperature heat sources (including exhaust gases from dryers) and the control of environmental pollution.
References: Szpicer et al., Applied Sciences, 15, 2025, 1–33; Al Faruq et al., Food Engineering Reviews, 17, 2025, 859–883.
