Methods of Dehydration

A number of drying methods are available – some are suited for solid foods,
others for liquid foods or mixtures containing food pieces.

Types of Driers

The common driers used for liquid and solid foods may be categorized as

i) Air convection driers- Hot air supplies the heat needed for moisture removal
and evaporation. If the food is a liquid, it is sprayed or poured into pans or on
belts.

ii) Drum driers or roller driers- Food is spread on the surface of a heated drum,
and moisture is removed as the drum rotates (ideal for liquid foods, purees and
mashes which are applied as thin films on the drier)

iii) Vacuum driers- Vacuum driers are employed to lower the temperature of
drying. Food is dried in a vacuum chamber at low pressure, which lowers the
boiling point of water, aiding in moisture removal.

iv) Freeze driers- Freeze driers are vacuum driers where an extremely low
temperature is used – water vapour directly forms ice without going through the
liquid state.

The above classification of driers is not rigid since many driers are used in
combinations, e.g., a drum drier can be operated in vacuum or by blowing high-
velocity healed air.
 1. Air-convection driers

Air-convection driers: There are some common aspects of the different types of
air-convection driers.

They all have

a) an insulated enclosure,

b) a means of circulating air through the enclosure, and

c) a means of heating this air.

They also have means of supporting foods to be dried, and devices to collect dried
food.

Air may be heated directly or indirectly. In direct heating, air is in direct contact
with combustion gases. In indirect heating, the air is heated in contact with a hot
surface, which is heated by a convenient method.

A direct heating method may contaminate the food product, which is not the case
with indirect heating.

Kiln drier: The simplest type of air-convection drier is the kiln drier. In this case,
there is direct heating of air.
Cabinet drier A step more advanced than the Kiln drier is the cabinet drier.
Food loaded in trays or pans in thin layers are placed in the cabinet, and air heated
by an indirect method is blown across food trays. This method is used for small-
scale operations. Foods commonly dried by this method are fruits and vegetables.
The drying time is of the order of 10-20 hours.

Tunnel drier- (Conveyor belts move food through a tunnel with hot air
circulating) For larger operations, a tunnel drier is used. Wet food carts are
moved through the tunnel on a continuous belt. Heated air is blown in a direction
opposite to the movement of food carts (counter-current principle). The belt is
usually a metal mesh and heated air is blown through the mesh.

Fluidized bed drier

Another type of air-convection drier is the fluidized bed drier. A fluidized bed
dryer consists of a chamber or container where the material to be dried is placed.

Heated air or gas is blown into the chamber from beneath the material.

The force of the incoming air or gas causes the material to become suspended or
"fluidized," resembling a boiling or bubbling fluid.
The continuous agitation of the material ensures even and rapid drying.

Spray drier: The most important kind of air-convection drier is the spray drier.
More food is dehydrated by using this drier than all other kinds of driers put
together.

Spray drying is limited to liquids, low-viscosity pastes, or purees. Food in the

form of a fine spray or mist is introduced into a tower or chamber along with
heated air. The small droplets make intimate contact with hot air, blast off their
moisture, become small particles, and drop to the bottom of the tower, from where
they are removed. Drying takes place in a matter of seconds. The air temperature
will be 204°C, but the food particles, never reach a temperature above 82°C as
evaporation cools the food. This method of dehydration can produce a high-
quality product even with heat-sensitive materials like milk, eggs and coffee.

[Link] or roller drier

Drum or roller drier: Liquid foods, purees, and mashes, are dried by this
method. The food to be dried is applied, as a continuous thin layer, on to the
surface of a revolving drum or between a pair of drums moving in opposite
directions, generally heated by steam. The dried thin layer of food on the drum is
scraped by a scraper blade positioned at a point on the drum. Some foods when
dry are sticky and cannot be scraped off from the drum when hot. Such a sticky
food becomes brittle when cold, which facilitates scraping. Providing a cold zone
on a drum thus helps the drying of such foods.

The drum temperature is usually kept above 100°C. The drum is kept at 150°C
when a film of food 1.6 mm in thickness gets dried in one minute or less. For heat
resistant food products, drum drying is one of the least expensive dehydration
methods. Drum-dried foods generally will have a somewhat more "cooked"
character than the same material spray-dried.

[Link] driers

Vacuum driers: This method of drying of foods is expensive but gives high-
quality foods. The drying system consists of a vacuum chamber that can
withstand external air pressure, and contains shelves or other supports to hold
food. This kind of vacuum drier is for batch-type operation. For continuous
operation a belt drier is used. The shelves are heated electrically or by circulating
a heated fluid. The food gets heated by conduction and also by radiated heat from
shelves above and below. The drying chamber is evacuated by a suitable device
maintained outside the vacuum chamber. The water that evaporates from the food
is condensed.

Liquid foods dehydrated by vacuum drying have a puffed structure and are easily
dissolved in water. Because of the low temperature used, there is minimal flavour
change and other kinds of heat damage in this method of drying.

[Link]-drying

Freeze-drying is used to dehydrate sensitive high-quality liquid foods, such as

coffee and juices, and also solids of high value, like strawberries, shrimps, etc.,
having delicate flavour, colour and textural attributes, which cannot be preserved
by any other drying method. In freeze-drying, water evaporates from ice without
passing through the liquid stage, i.e., water from ice directly becomes water
vapour. This happens at a temperature of 0°C or below, and at a low pressure of
4.7 mm of mercury or less.

Frozen food is dried by keeping it in a vacuum chamber maintained at a pressure

of 0.1 to 2 mm of mercury and maintaining the temperature of the chamber just
below the melting point of ice. Under such conditions, water from the frozen food
evaporates at the maximum rate. Since the frozen food remains rigid, the
evaporation of water leaves voids behind it, resulting in a porous sponge-like
dried material. After the food is dried, it is packed under nitrogen.
 Foam drying

Foam-drying (puff dry) at atmospheric pressure can be employed to dehydrate

foods and obtain products with qualities like vacuum-dried ones. This method of
drying is very economical compared to the vacuum drying method, and can be
applied to liquid foods and purees which can be pre-foamed (whipped) before
drying. As foaming creates an enormous surface area for quick moisture removal,
drying of foams can be rapid at atmospheric pressure at a reduced temperature.
For foods that do not whip readily, some whipping agents (vegetable proteins,
gums, monoglycerides) are added prior to being whipped. Stable foams are cast
in thin layers into trays or belts and dried by various heating schemes.

Solar drying

Solar food drying is an ideal application for solar energy. Solar radiation passes
through the clear glass top of a wooden dehydrator box, then the heat trapped by
the box dries the food. The dehydrator also may have an absorber plate inside,
which indirectly heats food and creates a convection current of air. The easiest
solar food dryer to build is a "hot box." One type of solar food dryer integrates
the solar collector and food drying cabinet into a compact configuration, which
uses both direct heating (like the solar hot-box dryer) and indirect heating from
the absorber plate. In a solar food dehydrator, foods are dried quicker on par with
an electric food drier. It is relatively compact and lightweight for portability. A
simple solar dehydrator can be used at the household level as it is easy to load,
unload, and clean.
Applications of Dehydration

Dehydration is a widely used food preservation method in the food industry. It involves
removing moisture from food, which inhibits the growth of microorganisms and slows down
enzymatic reactions, thereby extending the shelf life of the food.

Preservation of Fruits and Vegetables:

• Dehydration preserves the natural sugars, vitamins, and flavours of fruits and
vegetables, allowing them to be stored for long periods. These dried products can be
consumed as snacks, used in cooking, or rehydrated for various culinary uses.
• Examples: Dried fruits like raisins, apricots, apples, and vegetables like dried
tomatoes, onions, and garlic.

Production of dehydrated food Powders:

• Dehydration is used to create concentrated, easy-to-store powders from fruits,
vegetables, and spices. These powders are used as flavourings, in baking, or as
ingredients in processed foods.
• Examples: Fruit powders (like strawberry, mango), vegetable powders (like tomato,
spinach), and spice powders (like garlic, onion).

Meat and Fish Products:

• Dehydrating meat and fish products extend their shelf life without refrigeration. These
products are popular as protein-rich snacks or as components of meals in regions
where fresh meat preservation is challenging.
• Examples: Beef jerky, dried fish, and biltong.

Dairy Products:
• Dehydration is used to remove water from dairy products, making them easier to store
and transport. Milk powder, for example, is used in various food products and can be
reconstituted by adding water.
• Examples: Milk powder, whey powder, and dried cheese.

Herbs and Spices:

• Dehydration is crucial for preserving herbs and spices, ensuring they retain their
flavor and aroma over extended periods. Dried herbs and spices are essential
ingredients in cooking and food processing.
• Examples: Dried herbs like basil, oregano, thyme, and spices like chili powder,
cinnamon, and turmeric.

Instant and Convenience Foods:

• Dehydration is used to create instant foods that can be quickly rehydrated by adding
hot water. These products are convenient for consumers and have a long shelf life,
making them popular for quick meals.
 • Examples: Instant noodles, soup mixes, and dehydrated meals (like instant mashed
potatoes).

Snack Foods:
• Dehydration is used to create crunchy, shelf-stable snacks from fruits, vegetables, and
other ingredients. These snacks are popular for their convenience and long shelf life.
• Examples: Potato chips, banana chips, dried fruit chips, and dehydrated vegetable
crisps.

Cereal and Grain Products:

• Dehydration helps in producing lightweight, shelf-stable cereal products that retain
their crunchiness and are easy to prepare.
• Examples: Breakfast cereals, puffed rice, and instant oatmeal.

Coffee and Tea:

• Dehydration is essential for producing instant coffee and drying tea leaves. This
process preserves the flavor and aroma, making it easy to store and prepare these
beverages.
• Examples: Instant coffee, tea leaves, and herbal tea blends.

Bakery Products:
• Dehydration is used to produce dry mixes that can be easily stored and quickly
prepared by adding liquid ingredients.
• Examples: Biscuit mixes, pancake mixes, and cake mixes.

Fermented Products:
• Dehydration is used to preserve fermented foods, retaining their flavor and probiotic
benefits for longer storage.
• Examples: Dried sauerkraut, kimchi, and miso powder.
 Difference between Drying and Dehydration

Aspect Drying Dehydration

Drying is the process of removing Dehydration is a specific form of drying that

moisture from a substance to reduce its involves the removal of water content from food
moisture content and prevent spoilage or products to extend their shelf life and preserve
Definition degradation. their nutritional value.

Can refer to any material or substance, Primarily used in the context of preserving food
Scope not limited to food. products.

Various drying methods, including

natural air drying, sun drying, Specific dehydration methods such as air drying,
Methods convection drying, freeze drying, etc. sun drying, freeze drying, or food dehydrators.

General objective may be to reduce Main objective is to preserve food by reducing

moisture content, preserve, or change moisture content while maintaining its flavor and
Objective the physical properties of the substance. nutritional quality.

Applied to a wide range of materials,

such as textiles, ceramics, and Primarily used for preserving fruits, vegetables,
Application chemicals. meat, herbs, and other food products.

Typically yields a food product that is shelf-stable

May not necessarily result in a product and can be consumed in its dehydrated state or
End Product suitable for consumption. rehydrated for use.

May extend the shelf life of some Specifically focused on extending the shelf life of
Shelf Life materials but not necessarily food. food products.

Nutritional May not prioritize retaining the Emphasizes maintaining the nutritional content of
Value nutritional value of the material. food, especially vitamins and minerals.

Common Drying wood, fabrics, paints, and Dehydrating fruits, vegetables, meat, herbs, or
Examples chemicals. making fruit leather and beef jerky.
 Difference Between Freeze drying and Dehydration

Aspect Freeze Drying Dehydration

Involves freezing the product and then

removing moisture through sublimation Involves removing moisture from the product
(direct conversion of ice to vapor) in a using methods like hot air, sun drying, or
Method vacuum. specialized dehydrators.

Preserves the product's original texture,

Preservation flavour, colour, and nutritional value to May cause some loss of flavour, colour, and
Objective a high degree. nutrients due to exposure to heat.

Involves freezing the product at very Generally, uses higher temperatures, ranging
low temperatures, often below -40°F (- from 90°F (32°C) to 200°F (93°C), depending
Temperature 40°C) or even lower. on the method.

Requires specialized equipment,

including a freeze dryer with vacuum Utilizes various equipment such as ovens,
Equipment chambers and condensers. dehydrators, and simple air-drying methods.

Typically, a slower process due to

Processing sublimation; it may take hours to days to Usually faster, with drying times ranging from
Time complete. several hours to a few days.

Achieves complete removal of moisture

Moisture from the product, resulting in a very low Reduces moisture content, but not necessarily
Removal moisture content (less than 5%). to the same extent as freeze drying.

Effective in preventing microbial Slows down microbial growth but doesn't

Microbial growth due to the extremely low always prevent it entirely. Additional
Control moisture content. preservation methods may be needed.
Offers an extended shelf life, often
several years to even decades, Provides a moderate shelf-life extension,
depending on the product and typically ranging from a few months to a couple
Shelf Life packaging. of years.

Commonly used for preserving high-

value products, including
Common pharmaceuticals, gourmet foods, and Used for a wide range of food products such as
Examples sensitive biological samples. fruits, vegetables, herbs, and meat.

Requires a significant initial investment

in equipment and energy costs, making More affordable, as it doesn't require
Cost it relatively expensive. specialized equipment like freeze dryers.

Freeze-dried products can be easily

rehydrated to their original state when Rehydration is possible for dehydrated products
Rehydration needed. but may not fully restore the original texture.