Hot air frying as a healthier alternative to deep fat frying for shrimp: comparative analysis of physicochemical and sensory properties

• Hot air frying (HAF) is introduced as a scientifically supported, health-oriented, and innovative alternative to deep fat frying (DFF) for shrimp, significantly reducing oil absorption without compromising overall product quality. • Textural and structural attributes of air-fried shrimp are notably enhanced, including increased elasticity, cohesiveness, and reduced shrinkage, contributing to improved sensory appeal and preservation of the natural product structure. • Color stability and visual quality are better maintained in HAF-processed shrimp, demonstrated by lower browning and chroma indices, supporting enhanced consumer appeal and marketability. • Detailed modeling of heat and mass transfer in shrimp provides actionable insights, facilitating the development of optimized, healthier, and more efficient frying processes for seafood manufacturing. • The outcomes align with public health and environmental sustainability objectives, showing that HAF-processed shrimp can be produced with lower fat content, greater energy efficiency , and reduced environmental impact. The growing global consumption of shrimp has increased the demand for healthier and more efficient cooking technologies. This study explores hot air frying (HAF) as an alternative to deep fat frying (DFF) in shrimp processing. A comparative analysis was conducted to assess physicochemical and sensory qualities, along with heat transfer and mass transfer phenomena, and their influence on key quality attributes. The results showed that HAF improved texture parameters such as springiness, cohesiveness, and elasticity, while reducing shrinkage and preserving product structure. Color measurements indicated lower browning index and chroma values, suggesting enhanced visual appeal. Sensory evaluation confirmed that air-fried shrimp achieved comparable acceptance to deep-fried samples, while also reducing oil uptake, with 160°C for 12 minutes identified as optimal. Modeling outcomes revealed effective moisture diffusivity ranging from 2.13 to 5.30 × 10⁻⁹ m²/s, with Biot numbers and transfer coefficients increasing at elevated temperatures, highlighting the improved thermal performance of HAF. These findings position HAF as a health-oriented and technically sound method for producing high-quality shrimp in modern food processing systems.