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Fundamental, physics-based modeling of complex food processes is still in the developmental stages. This lack of development can be attributed to complexities in both the material and transport processes. Society has a critical need for automating food processes (both in industry and at home) while improving quality and making food safe. Product, process, and equipment designs in food manufacturing require a more detailed understanding of food processes that is possible only through physics-based modeling. The objectives of this paper are (1) to develop a general multicomponent and multiphase modeling framework that can be used for different thermal food processes and can be implemented in commercially available software (for wider use) and (2) to apply the model to the simulation of deep-fat frying and hamburger cooking processes and validate the results. Treating food material as a porous medium, heat and mass transfer inside such material during its thermal processing is described using equations for mass and energy conservation that include binary diffusion, capillary and convective modes of transport, and physicochemical changes in the solid matrix that include phase changes such as melting of fat and water and evaporation/condensation of water. Evaporation/condensation is considered to be distributed throughout the domain and is described by a novel nonequilibrium formulation whose parameters have been discussed in detail. Two complex food processes, deep-fat frying and contact heating of a hamburger patty, representing a large group of common food thermal processes with similar physics have been implemented using the modeling framework. The predictions are validated with experimental results from the literature. As the food (a porous hygroscopic material) is heated from the surface, a zone of evaporation moves from the surface to the interior. Mass transfer due to the pressure gradient (from evaporation) is significant. As temperature rises, the properties of the solid matrix change and the phases of frozen water and fat become transportable, thus affecting the transport processes significantly. Because the modeling framework is general and formulated in a manner that makes it implementable in commercial software, it can be very useful in computer-aided food manufacturing. Beyond its immediate applicability in food processing, such a comprehensive model can be useful in medicine (for thermal therapies such as laser surgery), soil remediation, nuclear waste treatment, and other fields where heat and mass transfer takes place in porous media with significant evaporation and other phase changes.

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