Tomato drying implies high energy consumption due to the high moisture content, and limiting drying temperatures is necessary to avoid carotenoid degradation. To explain the mechanism of moisture transport through the material and to scale up the drying process, drying experiments are needed and supported by mathematical modeling. For the Rila tomato peel drying process, ten thin-layer mathematical models were formulated based on experimental data for six temperatures (50–75 °C) and validated by statistical analysis. Considering the slab geometry of the peels sample and Fick’s second law of diffusion model, the calculated effective moisture diffusivity coefficient values D_eff varied between 1.01 × 10⁻⁹–1.53 × 10⁻⁹ m²/s with R² higher than 0.9432. From the semi-theoretical models, Two-term presents the best prediction of moisture ratio with the highest R² and lowest χ² and RMSE values. Using the experimental data on extract quality (carotenoid content), two degradation models were formulated. Increasing the drying temperature from 50 °C to 110 °C, a degradation of 94% for lycopene and 83% for β-carotene were predicted. From the energy analysis, a specific energy consumption of 56.60 ± 0.51 kWh is necessary for hot-air drying of 1 kg of Rila tomato peel at 50 °C to avoid carotenoid degradation.

Lycopene, β-carotene and ω-fatty acids are major compounds in tomatoes with known antioxidant activity, capable of preventing health disorders. The identification of potential natural sources of antioxidants, extraction efficiencies and antioxidant activity assessments are essential to promote such products to be used in the food, pharmaceutical or cosmetic industries. This work presents four added-value products recovered from tomatoes: pigmented solid oleoresin, pigmented oil and two raw extracts from supercritical and Soxhlet extraction. Different parameters including the matrices of tomatoes, extraction methods, green solvents and operating parameters were varied to obtain extracts with different qualities. Extract analysis was performed using UV–VIS, FT–IR, GC–MS, Folin–Ciocalteu and DPPH methods. The highest-quality extract was the solid oleoresin obtained from pomace using supercritical CO₂ extraction at 450 bar, 70 °C and 11 kg/h: 1016.94 ± 23.95 mg lycopene/100 g extract, 154.87 ± 16.12 mg β-carotene/100 g extract, 35.25 ± 0.14 mg GAE/g extract and 67.02 ± 5.11% inhibition DPPH. The economic feasibility of the three extraction processes (1:10:100 kg dried pomace/batch as scalability criterion) was evaluated. The most profitable was the supercritical extraction process at the highest capacity, which produces pigmented solid oleoresin and oil with high content of lycopene valorized with a high market price, using natural food waste (pomace).

The food, cosmetic and pharmaceutical industries have strong demands for lycopene, the carotenoid with the highest antioxidant activity. Usually, this carotenoid is extracted from tomatoes using various extraction methods. This work aims to improve the quantity and quality of extracts from tomato slices by enhancing the recovery of the carotenoids from the solid matrix to the solvent using 20 w/w% seeds as modifiers and supercritical CO₂ extraction with optimal parameters as the method. Tomato (TSM), camelina (CSM) and hemp (HSM) seeds were used as modifiers due to their quality (polyunsaturated fatty acids content of 53–72%). A solubility of ~10 mg carotenoids/100 g of oil was obtained for CSM and HSM, while, for TSM, the solubility was 28% higher (due to different compositions of long carbon chains). An increase in the extraction yield from 66.00 to 108.65 g extract/kg dried sample was obtained in the following order: TSM < HSM < CSM. Two products, an oil rich in carotenoids (203.59 mg/100 g extract) and ω3-linolenic acid and a solid oleoresin rich in lycopene (1172.32 mg/100 g extract), were obtained using SFE under optimal conditions (450 bar, 70 °C, 13 kg/h and CSM modifier), as assessed by response surface methodology. A recommendation is proposed for the use of these products in the food industry based on their quality.

Recovery and reuse of high-acidity vegetable oil waste (higher content of free fatty acids) is a major concern for reducing their effect on the environment. Moreover, the conventional deacidification processes are known to show drawbacks, such as oil losses or higher costs of wastewater treatment, for which it requires great attention, especially at the industrial scale. This work presents the design of a highly efficient and sustainable process for Camelina sativa oil deacidification by using an ecofriendly method, namely molecular distillation. Experimental studies were performed to identify operating conditions for removing of free fatty acids (FFA) by molecular distillation which involves the oil evaporation in high vacuum conditions. The experimental studies were supported by statistical analysis and technical-economic analysis. Response surface methodology (RSM) was employed to formulate and validate second-order models to predict deacidification efficiency, FFA concentration, and triacylglyceride (TAG) concentration in deodorized oil based on three parameters effects, validated by statistical p-value < 0.05. For a desirability function value of 0.9826, the optimal parameters of evaporator temperature at 173.5 °C, wiper speed at 350 rpm, and feed flowrate at 2 mL/min were selected. The results for process design at optimal conditions (using conventional and molecular distillation methods) showed an efficiency over 92%, a significant reduction in FFA (up to 1%), and an increase in TAG (up to 93%) in refined oil for both methods. From an economical point of view, the deacidification by molecular distillation of Camelina sativa oil is a sustainable process: no wastewater generation, no solvents and water consumption, and lower production costs, obtaining a valuable by-product (FFA).