Ultrasound-assisted vacuum drying in foods: mechanisms, quality attributes, and industrial potential

Ultrasound-assisted vacuum drying (USVD) has emerged as an increasingly studied food drying approach to overcome mass and energy transfer limitations associated with conventional vacuum drying. This study aims to clarify the behavior of the USVD process by synthesizing findings from product- and condition-specific studies. This review critically examines 38 core USVD studies published between 2014 and 2025, complemented by related comparative research, to assess the effects of USVD on drying efficiency, product quality, and key process parameters across diverse food matrices. The reviewed literature consistently demonstrates that USVD enhances drying kinetics, with increases in drying rate reaching approximately 94%, depending on product characteristics and operating conditions. Due to shorter drying times, USVD also provides potential economic advantages through reduced energy costs, equipment utilization and overall process costs. Furthermore, research has found that USVD retains quality attributes including color and bioactivity of a wide range of foods. USVD-dried products commonly exhibit improved microstructural integrity and enhanced porosity, which imparts superior rehydration. In conclusion, this study highlights the strong potential of USVD to enhance drying efficiency while preserving product quality.