Hybrid mechanistic modeling of integrated enzymatic and vacuum processing for sustainable banana syrup production

ABSTRACT A novel integrated enzymatic–vacuum evaporation process was developed to enhance the sustainability and quality of banana syrup production. A hybrid mechanistic–empirical modeling framework was established by integrating response surface methodology (RSM) with mechanistic enzyme kinetics, where RSM-derived parameter domains and interaction effects were used to calibrate and constrain Michaelis–Menten formulations, quantitatively described enzyme synergy (β = 24.6 % h⁻¹ %⁻²) and achieved superior predictive accuracy ( R 2 = 0.987), providing physically interpretable kinetic parameters for rational process design. Vacuum evaporation at 50°C and 100 kPa reduced processing time by 40% while producing syrup with 89.2% antioxidant retention and desirable sensory attributes ( L* = 79.8, clarity = 0.86). The proposed Energy–Quality Coupling Model introduced a Specific Energy–Quality Index ( SEQI = 0.842), demonstrating a 37% reduction in specific energy consumption (2.69 vs. 4.28 kWh kg⁻¹ water) without compromising product quality ( Q quality = 0.88). Multi-objective Pareto optimization identified a balanced condition with 0.3% pectinase and 0.3% cellulase at 50°C for both enzymatic and evaporation stages as the optimal strategy, supported by sensitivity analysis that highlighted cellulase concentration and evaporation temperature as key control parameters. By explicitly coupling empirical optimization with mechanistic thermodynamic and kinetic modeling, the proposed framework provides a unified understanding of the interactions among enzymatic kinetics, energy transfer, and product quality evolution, a transferable and recalibratable modeling framework for sustainable process intensification applicable to other tropical fruit syrups with similar structural characteristics.