The Laboratory of Process Design and Analysis (ESAD) — formerly known as the Laboratory of Physical Processes Engineering — is essentially the evolution (through a series of renamings accompanied by modernization of its scope) of the Laboratory of Inorganic Chemical Technology (AHT), which was established in 1908, well before the foundation of the School of Chemical Engineering in 1917.

According to the Government Gazette (Government Gazette 307B/22.04.1994), the purpose of the Laboratory is:

• The experimental and applied study of the physical processes of industry (e.g., distillation, drying, extraction, filtration, evaporation, reverse osmosis), aiming at the analysis of the fundamental phenomena.
• The development of mathematical models describing physical processes and the thermophysical properties of materials.
• The design of physical processes with the goal of determining their operation, sizing of equipment/machinery, and optimization.

Within this framework, ESAD covers the educational needs and provides laboratory support for the following undergraduate courses:

• Physical Processes Engineering I (5^th semester)
• Physical Processes Engineering II (6^th semester)

Students receive both theoretical and practical training through laboratory exercises designed to familiarize them with the study of Physical Processes. Examples include: Heat Exchange, Drying, Distillation, Extraction, Fluidization, Crystallization, Evaporation, and Reverse Osmosis.

From a research perspective, ESAD has been active since the 1990s in process and system design and optimization, ranging from simple processes to large-scale systems. Among others, extensive studies have been conducted on: drying, reverse osmosis, extraction, gas purification processes, food processing in oily environments, integrated complex systems in metallurgy and refineries, energy integration, and utility management. Today, the Laboratory’s research activity remains dynamic (with participation in Greek and European research projects and strong publication output) and is aligned with modern technological developments related to Physical Processes. In this context, two main research areas can be identified:

1. Food Engineering and Technology

As a consistent philosophical approach, ESAD combines food engineering with technological development, treating these areas as an integrated whole. Taking into account modern consumer demands and European guidelines for foods of high nutritional value and improved organoleptic characteristics — while reducing the use of ingredients such as sugar, salt, and synthetic additives, as well as lowering CO₂, energy, water, and raw material footprints — and leveraging the rich Greek flora, abundant in herbs with unique bioactive properties, ESAD has oriented its Food Engineering and Technology research towards the following areas:

• Modeling and simulation of processes
• Process design and optimization
• Investigation of the effect of process conditions on the quality of final products
• Design and development of innovative products with predefined thermophysical properties and advanced nutritional and organoleptic characteristics using modern food-processing technologies
• Development of structured foods with low sugar and salt content
• Innovative extruded products enriched with legume proteins, plant fibers, probiotics, and natural additives
• Development of extracts using “green” extraction methods (microwave, ultrasound, PLE) from food industry by-products
• Development of natural food additives from plants and microalgae
• Development of bakery products with added soluble and insoluble dietary fibers
• Life-cycle analysis (LCA) of food processes

2. Process Design and Energy Integration

Aligned with modern energy-sector requirements, ESAD focuses on systems that utilize renewable energy sources — thermal, wind, photovoltaic, and cogeneration. In this framework, it is engaged in the following areas:

• Design of new industrial applications
• Optimization of existing industrial applications
• Development of computational tools for process design and optimization (Simulators)

To achieve these objectives, the Laboratory currently possesses more than 50 (small and large) laboratory instruments and continuously upgrades its equipment according to modern trends in its research fields.

Indicative equipment includes:

• Spray dryer
• Dynamic Mechanical Analyzer (DMA)
• Differential Scanning Calorimeter (DSC)
• High-Performance Liquid Chromatograph (HPLC)
• Mechanical testing device (tensile, compression)
• Food extruder
• Aerosol sampling and recording systems
• Integrated 3D printing system
• Microbiological measurement system
• Ultrasound and microwave extraction system (US/MW)
• High-pressure liquid extraction system
• Particle size and emulsion distribution analysis system
• Electrohydrodynamic encapsulation device (Electrospinning)
• Laboratory bioreactor
• Stomach and intestine process simulator