Vacuum freeze-drying of biological materials is one of the best methods of water removal, with final products of highest quality. The solid state of water during freeze-drying protects the primary structure and the shape of the products with minimal volume reduction. In addition, the lower temperatures in the process allow maximal nutrient and bioactive compound retention. This technique has been successfully applied to diverse biological materials, such as meats, coffee, juices, dairy products, cells, and bacteria, and is standard practice for penicillin, hormones, blood plasma, vitamin preparations, etc. Despite its many advantages, having four to ten times more energy requirements than regular hot air drying, freeze-drying has always been recognized as the most expensive process for manufacturing a dehydrated product. The application of the freeze-drying process to plant-based foods has been traditionally dedicated to the production of space shuttle goods, military or extreme-sport foodstuffs, and specialty foods such as coffee or spices. Recently, the market for ‘natural’ and ‘organic’ products is, however, strongly growing as well as the consumer’s demand for foods with minimal processing and high quality. From this perspective, the market for freeze-dried plant-based foods is not only increasing but also diversifying. Freeze-dried fruits and vegetables chunks, pieces, or slices are nowadays majorly used in a wide range of food products such as confectionaries, morning cereals, soups, bakeries, meal boxes, etc. Instant drinks are prepared out of freeze-dried tea, coffee, or even from maple syrup enriched with polyphenol concentrated extracts from trees. The possibilities are endless. In this review, the application of freeze-drying to transform plant-based foods was analyzed, based on the recent research publications on the subject and personal unpublished data. The review is structured around the following related topics: latest applications of freeze-drying to plant-based foods, specific technological problems that could be found when freeze-drying such products (i.e., presence of cuticle; high sugar or lipid concentration), pretreatments and intensification technologies employed in freeze-drying of plant-based foods, and quality issues of these freeze-dried products.

Plants need to be protected against pests and diseases, so as to assure an adequate production, and therefore to contribute to food security. However, some of the used pesticides are harmful compounds, and thus the right balance between the need to increase food production with the need to ensure the safety of people, food and the environment must be struck. In particular, when dealing with fruit and vegetable wastes, their content in agrochemicals should be monitored, especially in peel and skins, and eventually minimized before or during further processing to separate or concentrate bioactive compounds from it. The general objective of this review is to investigate initial levels of pesticide residues and their potential reduction through further processing for some of the most contaminated fruit and vegetable wastes. Focus will be placed on extraction and drying processes being amid the main processing steps used in the recuperation of bioactive compounds from fruit and vegetable wastes.

Convective hot air drying and freeze drying were investigated as potential dehydration processes to obtain powders of seabuckthorn fruit pulp. Halved seabuckthorn fruits were placed in a hot air dryer and dried at 1 m/s and at 50 or 60°C or freeze dried at less than 30 mTorr and at 20 or 50°C shelf plate temperature. An initial characterization of the seabuckthorn pulp (moisture, pH, soluble solid content, vitamins C and E, total phenolics, and carotenoids) was performed. Water loss, total phenolic compounds, total carotenoids, and vitamin C were determined at different processing times. Vitamin E was determined before and at the end of drying. Freeze-drying kinetics were faster than air drying, probably due to lower moisture diffusion in the compact, sugary, and oily structure of the air-dried tissue. The temperature had an important impact on hot air–drying and freeze-drying kinetics. Drying method and processing times affected the remaining phenolic, carotenoid, and vitamin contents of seabuckthorn berries. Freeze drying was revealed as a superior method to obtain seabuckthorn powders because of the lower residual moisture content, the ease of grinding, as well as the better nutritional retention.

Osmotic dehydration of whole seabuckthorn berries, followed by convective or vacuum drying, was investigated. First, different pretreatments were applied to the fruits in order to accelerate the rate of osmotic dehydration: immersion in liquid nitrogen, steam blanching, or freeze cycles. Immersion in liquid nitrogen was found to be the best pretreatment to maximize dehydration rate and to increase sugar gain during osmotic dehydration. An evaluation of moisture loss and sugar gain kinetics during osmotic dehydration of seabuckthorn fruits pretreated with liquid nitrogen, followed by vacuum or hot-air drying, was then performed. Loss of nutritional compounds due to processing was also measured. Sugar intake and partial dehydration of seabuckthorn samples increased with osmosis time and reached an equilibrium value after 4 h treatment. The finish drying methods (vacuum or convective) applied after OD showed a marked impact on the remaining moisture content of seabuckthorn samples. Concentration of some nutritional compounds was, however, dramatically reduced after the combined osmotic dehydration/drying processes.

Orange byproduct (flavedo and albedo) from juice extraction, was used as raw material for this study. Kinetics of total phenolic and total flavonoid contents and antioxidant activity was experimentally determined during both conventional (agitation at 80 rpm) and ultrasound assisted (at 520 and 790 W/L) aqueous extraction from orange byproduct at 5, 15, and 25 °C. An extraction mathematical model was also developed. Significant increase of biocompounds extraction yields was observed as temperature and acoustic power density increased. Ultrasound assistance allowed higher yields at lower temperatures and shorter times. Yields of total phenolic and total flavonoid contents and antioxidant activity obtained with ultrasound extraction (790 W/L, 25 °C, 3 min) were 29%, 39%, and 197% higher, respectively, than those obtained by conventional extraction. The extraction kinetics curves were properly represented by the Weibull model for both conventional and acoustic extraction (mean relative error lower than 5%). Naringin, neohesperidin, and hesperidin were the main phenolic compounds found in the extracts, followed by ferulic, sinapic, and cuomaric acids. Neohesperidin, hesperidin, coumaric acid, and sinapic acid presented the highest yields, especially when extraction was assisted by ultrasound. Meanwhile, naringin and ferulic acid were extracted in a lesser extent, most likely due to their lipophilic character.

Several freeze-drying and spray-drying methods were investigated in relation to the retention of immunoglobulins (Ig) A, IgG, and IgM. Spray drying produced human milk powders with 2% humidity and a good retention of IgG (>88%) and IgM (∼70%). However, only 38% of IgA remained after spray drying. For freeze drying, only the highest heating plate temperature used in this study (40°C) brought IgA content down to 55% in powder with 1.75% residual humidity, whereas milk samples undergoing lower temperatures had higher preservation rates (75% for IgA and 80% for IgG and IgM) and higher residual moisture contents. From these results, it can be concluded that IgA is the most sensitive Ig lost during drying processing of human milk. The best method to generate human milk powders without a significant loss of Ig was thus freeze drying at 30°C heating plate temperature, which accelerated the process compared to lower processing temperatures, but still had good overall Ig retention.