An Investigation of the Use of Microwaves and Airborne Ultrasound in the Convective Drying of Kale: Process Efficiency and Product Characteristics

This study evaluated different hybrid drying modes, combining traditional convective drying with microwave radiation and airborne ultrasound for the dehydration of green leafy vegetables. The central composite design method was used to analyze the impact of microwave and ultrasonic waves on kinetics, energy consumption, and various quality parameters, like color, ascorbic acid, polyphenol, carotenoid, and chlorophyll content in Brassica oleracea , var. acephala . The results of the applied experimental design, i.e., the surface response methodology, showed that the application of microwaves and ultrasound decreased the drying time considerably and enhanced the moisture evaporation from the kale leaves, significantly improving the drying rate and energy efficiency. The drying rate increase demonstrated varying results with changes in air temperature. Specifically, ultrasound resulted in a 69–100% increase, microwaves in a 430–698% increase, and a combination of ultrasound and microwaves in a 463–950% increase at 70 and 50 °C, respectively. Specific energy consumption decreased by 42–51% for ultrasound, 80–87% for microwaves, and 82–90% for ultrasound and microwaves at 70 and 50 °C, respectively. The drying parameters were also found to be better at a higher temperature, but the increase in the drying rate caused by microwaves and ultrasound was notably lower. Moreover, the analysis of the key kinetic parameters and material qualities led to the conclusion that the synergistic action of microwave- and ultrasound-assisted convection contributes to better drying effectiveness and product quality, demonstrating greater retention of vitamin C, phenolics, and natural dyes of up to 90%.