Blog

Commercial Herb Drying

January 26, 2026

Food brands are increasingly choosing EnWave’s REV™ technology for herb drying because it delivers significantly higher retention of flavor and aroma compounds compared to freeze drying, while reducing drying time from days to under an hour. Data from recent basil studies confirm that REV™ preserves volatile oils (e.g., camphor, pinene, limonene, eucalyptol) at nearly double the levels of freeze drying, with additional advantages in energy savings, color, and nutrient retention.

Main Methods for Commercial Herb Drying

Air drying: Inexpensive but slow, resulting in high losses of aroma and nutrients due to extended exposure to heat and air (volatile oils can be reduced by 50–70%).
Freeze drying (FD): Preserves herb structure, but is energy intensive, slow (24-48 hours/cycle), and less effective at protecting specific high-value aroma compounds.
REV™ microwave vacuum drying: Rapid (<60 minutes), gentle, and proven through data to best preserve both flavor and color.

Why Herbs Need Careful Drying

Herbs lose value rapidly without proper drying: volatile oils define their taste and aroma, and too much heat/oxygen destroys these or leads to rapid quality loss. Drying stabilizes potency and shelf life for uses in tea, spice, and extracts. Poor-quality drying reduces usability and marketability.

Data: How Do The Methods Compare?

Basil Oil Compounds After Drying (μg/g):

Method	Camphor	Pinene	Limonene	Eucalyptol
REV™	44.53	4.74	33.58	158.32
Freeze Dry	22.34	1.00	14.90	55.64
AD-REV	23.24	3.11	22.54	86.66
Air Dry	21.55	2.12	21.53	49.32

Source: McGill University, 2024, Basil Leaf Flavor Analysis (EnWave project)

Key Insights:

REV™ dried basil retained almost twice the camphor, limonene, and eucalyptol compared to freeze and air drying.
Air drying and freeze drying both lost significant amounts of crucial aroma compounds.
REV™ at 50°C provided the highest retention overall.

Why Choose REV™?

Superior Flavor & Aroma: Quantified results show >90% retention of essential oils, compared to 55–65% for freeze drying.
Faster Processing: Drying is completed in 10–60 minutes (vs. 24–48 hours for freeze drying).
Energy Efficient: Uses up to 80% less energy (latest industrial data).
Color and Nutrient Retention: Better antioxidant and vitamin retention compared to conventional methods.
Consistent Uniformity: Suitable for both leafy and root herbs (basil, mint, ginseng, etc.).

Texture and Shelf Life

REV™ dried herbs maintain whole leaves and a crisp, grindable texture, no case hardening. Shelf life exceeds 2 years at room temperature, owing to high retention of oils and low water activity.

Commercial Practicalities

Scalability: REV™ lines are modular, running small (pilot) to industrial scales (10–120kW systems).
Cost: Lower energy use and higher yields deliver a faster payback period.
Food Safety: Uniform vacuum microwave process inactivates more microbes than freeze drying for a safe, food-grade product.

Validated by McGill University, 2024

“REV 50°C treatment produced the highest retention of all measured flavor and aroma compounds in basil leaves, nearly double the performance of freeze and air drying.” – Basil Leaf Flavor Analysis, Prof. Xiaonan Lu, PhD

Clean Label & Innovation Ready

No carrier or processing additives needed. REV™ delivers pure, potent product ready for “just herbs” labeling, key for consumer trust and premium pricing.

Get Started

Pilot with REVworx toll drying service.
Send samples and evaluate full spectrum results.
Review shelf life, yield, and cost data.
Scale up as needed, risk-free.

In summary: REV™ is scientifically validated as the most effective method for preserving the full value of commercial herbs (flavor, nutrition, and color) at a scale and cost fit for today’s food brands.

FAQ

What is the best method for commercial herb drying?

REV™ microwave dehydration for speed, quality, cost. Tops freeze drying.

Does freeze drying preserve herb oils?

Yes but slower process loses some to oxidation. REV™ retains more.

Is microwave drying safe for herbs?

Yes. Low temp vacuum. FDA approved.