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This work presents a model-based approach to systematically derive optimal operating policies for an existing industrial-scale tunnel dryer. The primary focus of the study is to control the shrinkage stage, during which product fracture risk is highest, with the minimum energy cost possible. First, the steady-state dryer operation is optimized with the attained operating policy resulting in 1.5% fuel economy, while assuring product quality. The dryer operation is then optimized at transient state, investigating two case studies, with the derived optimization results being thoroughly compared with those attained when no control actions are taken. The first case considers a 9.57% increase in dryer productivity. It is demonstrated that the derived operating policy guarantees a well-controlled drying process, with the minimum extra fuel consumption being about 7.7%. The second case study considers the coexistence of two different raw clay-based ceramics in the dryer. Once again, the optimal operating scheme assures the final product quality, but with a minimum thermal energy consumption increase of 3.4%.

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