Integrated design and optimization of a conceptual double drum dryer for drying of wheat flour slurry: Experimental validation and computational analysis

Abstract This study presents a novel conceptual laboratory‐scale double drum dryer (LDD) optimized for the efficient drying of wheat flour slurry into flakes. The research stems from the need to address the complexities of previous methodologies, lack of studies on industrial‐sized dryers, and high cost. The methodology involved designing dryer components, transmission system, creating engineering drawings, and simulating LDD with varied operating parameters. Verification was done using industrial double drum dryer (IGD) data and MATLAB simulations. Parameters were explored including temperature (120–140°C), drum dimension (0.1–0.7 m), and film thickness (0.3–0.6 mm). The design closely matched real‐world performance metrics with mean relative deviations of 2.67%, 3.30%, 10.12% for drum speed, water content, and throughput respectively. The predictive model outperformed the IGD, achieving a 9.13% increase in throughput. Optimal LDD parameters were identified 0.7 m length, 0.2 m diameter, 0.3 mm film thickness, 40% slurry TSS, 120°C temperature, and 4.47 rpm rotational speed, resulting in 3.00% water content and 132.78 kgh −1 throughput offering valuable insights for similar applications in the food industries. Practical applications The research on the novel laboratory‐scale double drum dryer for drying wheat flour‐based slurry holds significant practical implications in the food industry. Firstly, the optimized design and simulation‐based approach offer a cost‐effective and efficient solution for small‐scale food processing businesses aiming to produce wheat flour flakes. By identifying optimal drying parameters, including temperature, drum dimensions, and film thickness, the research enables precise control over the drying process, leading to enhanced product quality and throughput. Moreover, the close agreement between simulation results and industrial observations validates the effectiveness of the proposed methodology, instilling confidence in its practical applicability. The development of a prototype based on these findings facilitates the adoption of this technology by small‐scale enterprises, empowering them to improve their production processes and competitiveness. Overall, this research contributes to advancing drying technology in the food industry, offering tangible benefits in terms of product quality, efficiency, and operational cost reduction.