Mapping the most effective measures to optimize carrot slice tray drying using physics-based and Monte Carlo simulations

Optimizing convective tray drying for carrot slices requires addressing various process variables and objectives. Balancing quality, throughput, and energy consumption requires understanding mechanisms and considering the effort and effect of individual practical use cases. This study uses Monte Carlo simulations of a physics-based model to assess dehydration and identify ideal optimization measures from a base case. Reducing slice thickness from 5 mm to 2 mm cuts drying time by 62 % while preserving 220 % more β-carotene, making it the most effective optimization strategy. The effects on the throughput of fresh produce (+6 %) and energy consumption (+6 %) are negligible. To reduce energy consumption, it proves beneficial to reduce the airspeed from 1.8 m/s to 0.6 m/s - a 35 % reduction. However, this adjustment results in a 77 % drop in carotene retention and a 48 % reduction in throughput. Increased carotene retention (+39 %) and throughput (+28 %) can be achieved by increasing the airspeed from 1.8 m/s to 3 m/s. However, this improvement requires 30 % more energy. Given these trade-offs, it is essential to consider the constraints imposed by the production environment and situation. The results of this study support the identification of the ideal case-specific optimization strategies and thus help to avoid costly trial-and-error approaches in the future.