A Review of Recent Advances in Micro Heat Exchangers in the Food and Pharmaceutical Industries

Micro heat exchangers (MHXs) have emerged as a critical technology for advanced thermal management in the food and pharmaceutical industries due to their high surface area-to-volume ratios, compact design, and precise temperature control. This review provides a systematic and integrated analysis of MHX technology, covering their fundamental principles, classification, design methodologies, performance enhancement techniques, and industrial applications. Unlike existing reviews, the present work establishes a unified framework that links microscale heat transfer mechanisms, such as Brownian motion, surface corrugation effects, and non-dimensional parameters, with practical design choices, manufacturing routes, and the process requirements specific to food and pharmaceutical systems. The subsequent sections explore the key performance-influencing factors, including channel geometry, surface enhancement strategies, nanofluid utilization, and governing non-dimensional numbers (e.g., Nusselt, Reynolds, and Knudsen numbers), which are systematically compared across different operating regimes. Recent advances in materials and fabrication techniques, such as laser ablation, lithography, micro-milling, embossing, and additive manufacturing, are analyzed with respect to their scalability, thermal–hydraulic performance, and industrial feasibility. Furthermore, the review highlights the emerging trends in micro heat exchanger (MHX) optimization, including computational fluid dynamics (CFD)-driven design, smart monitoring systems, and energy-efficient integration within processing lines. Finally, the paper also identifies the key challenges and limitations of micro heat exchangers, including pressure drop, fouling, scaling, manufacturing complexity, and cost constraints. These are critically discussed along with future research directions aimed at improving reliability and sustainability. By consolidating the dispersed research outcomes into a coherent, design-oriented perspective, this review offers new insights and practical guidance for researchers, engineers, and industry practitioners seeking to advance the deployment of MHXs in food and pharmaceutical processing.