Clean Energy Science and Technology 2024, 2(4), 218.

https://doi.org/10.18686/cest218

Article

Solar energy utilization and conservation in an industrial solar drying

process
Cortés Rodríguez Elizabeth1,*, Ruiz Mercado Claudia Araceli2

1 Crear,
Innovar, Desarrollar S.A. de C.V., Merida 97204, Mexico
2 Universidad
Autónoma de Yucatán, Merida 97000, Mexico
* Corresponding author: Cortés Rodríguez Elizabeth, [email protected], [email protected]

CITATION Abstract: Decarbonization in food production systems is one of the greatest challenges today.
Elizabeth CR, Araceli RMC. Solar Solar drying is one of the processes that can help this energy transition and improve food
energy utilization and conservation in production systems. This research presents the results of the development of a new solar drying
an industrial solar drying process. technology with applicability in the food production system. A technoeconomic assessment
Clean Energy Science and
Technology. 2024; 2(4): 218.
was carried out. The best configuration for an integral drying system for various applications
https://doi.org/10.18686/cest218 was obtained. The developed solar drying technology is portable, efficient, modular, versatile,
continuous processing, with minimal degradation in the dehydrated product. According to the
ARTICLE INFO annualized cost method calculations, the cost of drying products with this technology is much
Received: 1 August 2024 lower than when using conventional energies and has a short payback period of 1–2 years. This
Accepted: 4 December 2024 research is the first part of the ongoing project. Improved equipment and various applications
Available online: 17 December 2024
are in progress.
COPYRIGHT Keywords: modular; decarbonization; portable; versatile; efficient; drying equipment

1. Introduction
Copyright © 2024 by author(s).
Clean Energy Science and Today, decarbonization, the process of reducing carbon emissions, produced by
Technology is published by Universe
human activity, especially carbon dioxide (CO2), into the atmosphere is an important
Scientific Publishing. This work is
licensed under the Creative issue globally. To achieve decarbonization, an energy transition is necessary to
Commons Attribution (CC BY) eliminate carbon in energy production and reduce the consumption of conventional
license.
https://creativecommons.org/licenses/
energy in production systems based on clean alternative energies [1].
by/4.0/ This research is focusing on utilization of solar energy in an industrial process
with great demand for thermal energy such as the drying and the conservation of solar
energy and usage in a new solar drying technology. These allows for improvement in
the food production system, specifically to avoid food waste on farms. These
developments contribute to achieving a net zero goal by 2050.
One of the most utilized post-harvest processes in food conservation is the drying.
The heat energy consumed during the drying process is about 12%–40% of total
industrial energy consumption in the developed countries. This employs 20%–70% of
the total cost of production depending on the type of industries. The utilization of solar
energy in drying processes minimizes the consumption of non-renewable sources by
27%–80% [2].
Solar drying concept is an emerging technology for drying industries such as
food, automobiles, paper, and allied products, including rubber, sugarcane, sewage
and industrial waste. The solar dryers equipped with Thermal Energy Storage (TES)
systems have helped to decrease the total time required for drying. Solar-based drying
technology is a promising area of research. The commercialization of solar dryers is

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increasing day by day for different drying applications in industries [2]. One example
of these applications is the industrial processes involved in food production systems.
For the last 3 years the United Nations (UN) has designated September 29 as the
day to highlight the problem of food waste and loss in the world [3]. This year the
focus is carried out by “Taking action to transform food systems”, proposing to make
food systems more resilient and sustainable from the field to the consumer.
According to data from the report by the UN Food and Agriculture Organization
[4], it indicates that the food production systems are responsible for 21%–37% of
Greenhouse Gas (GHG) emissions globally. Also, if food loss were a country, it would
be the third emitter of GHG emissions on the planet. This consumes 30% of the land
used for cultivation and consumes 20% of water. If all the food wasted in the world
could be used, malnutrition in the world could be ended and 2 billion people fed [5].
Currently 828 million people suffer from hunger, that is, 1 in every 10 inhabitants on
the planet [6].
In Mexico, more than 30% of the food produced is wasted, which is equivalent
to 12 million tons that could feed 7 million people [7]. The main causes of waste in
the crop field are the lack of post-harvest technology, high transportation and cold
chain costs, lack of adequate transportation, infrastructure, logistics and consumer
market requirements.
There is a high potential of solar energy usage for different industrial drying
applications. One of the application areas in this research is the food production
system. We developed a portable, efficient, profitable solar drying technology for
different uses. In this paper the summary results obtained for the development of a
healthy and sustainable food production system are presented.

2. Materials and methods

The technoeconomic assessment was used as a methodology (Figure 1).
Technoeconomic assessment (TEA), is a widely practiced approach used in both
academia and industry for simultaneously evaluating the technical feasibility and the
economic viability of a process technology, a product, or a project. A TEA is useful
for making a variety of high-level decisions including whether a project should be
pursued or terminated, which option best meets a business objective, and where
priority should be placed to reduce risk and cost [8].

Figure 1. Generic stage-gate process for commercialization of a new idea [8].

A common discipline of successful companies is the use of a formalized Stage-

Gate process for assessing technoeconomic factors to help with decision making. A
simplified staged process for converting an idea into a commercial success which
appears in Figure 1. Gate reviews are conducted periodically to determine if a project
should advance to the next stage, be redirected to resolve outstanding issues, or be

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terminated [8].
A commercial technological solution for avoiding food waste on farms using
solar energy was the initial idea. This was requested by Mexican farmers. A Proof of
Concept (POC) was developed to demonstrate the viability of a product in the market.
A Proof of Value (POV) was developed to identify the value of a particular offering
to customers. This helps the companies to decide whether the product is worth
investing in.
Process and product were developed with a technology assessment and economic
evaluation in parallel and iteratively. In this gate, technical feasibility was carried out
analyzing and establishing the bases for the implementation and execution of the
project establishing recommendations for scale up approaches. Then the final
technical, economic and market evaluations were carried out as the final stage.

3. Results and discussion

3.1. Idea
Initially, this project was developed according to the requirements and needs of
Mexican farmers. The rest of the main actors of the food supply chain, manufacturer
and marketer also were considered as the value proposition and goal of the research is
to develop a technological solution to improve the food supply chain. Through a field
and market research the main problems and solutions in the food supply chain in
México were identified (Figure 2).

Figure 2. Results of the analysis of the food supply chain, problems and solutions.

For the farmers the main problem is overcompensation due to the expected losses
because of the market requirements for size, color, appearance in general, the high cost
of transport and cold chain and the lack of technology for storage and packaging on
the farm. Actually, 30% of the food production on the farm is wasted. Accordingly,
there is need to design a portable system, modular and scalable, ready to operate on
the farm, lowering the cost of transportation by reducing the weight of the fresh
product by 90%. For the manufacturer, the main problems are pollution and loss of
nutrients (indicated by the loss of color, flavor and appearance). These problems will
be solved by a solar continuous processing and improved control system. For the
marketer, the product needs to meet the standards of market regulations. Current

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products have low nutritional value. Therefore, a technology with flexibility and
versatility in operation is needed and the products obtained need to be differentiated
and standardized with capacity for rehydration for various uses.
According to the results obtained, there is a need to develop an improved drying
process. This increases the profitability of the entire value chain farmer, manufacturer
and marketer will be increased. In general, the economic and operational efficiency of
the drying process will be maximized.
In this gate, the main characteristics required for the technological solution to be
developed were established.

3.2. Proof of Concept (POC)

Effective process and product development require timely and well-informed
decisions. A robust, early-stage TEA which addresses the uncertainty of an evolving
technology is invaluable in decision making in any technology organization. Use of
ranking tools and approaches organizes the consideration of multiple factors and
provides a good way of presenting the rationale for the decision to stakeholders [8].
The Political, Economic, Social, Technological, Environmental, Legal (PESTEL)
analysis was the tool to decision making process in this gate. This tool allows us to
consider the PESTEL factors. The POC was carried out considering the external
factors that affect the project in a direct way. A PESTEL analysis was developed for
each factor. The results obtained are summarized in Tables 1–6. This type of chart
was constructed through consensus by an assessment team. This analysis allows to
compare a number of options against specific criteria where a plus (+), minus (−), or
even (0). where VN = Very negative (–2), N = Negative (–1), Z = Zero (0), P = Positive
(1), VP = Very positive (2) score is used to differentiate each option. The sum of scores
(T = Total) is tallied in a final row to illuminate the favored option. This result clearly
shows how the options ranked relative to each other is a simple tool that clarifies why
a specific decision was made.

Table 1. Political factor.

Variable VN (–2) N (–1) Z (0) P(1) VP(2) T References
Governments can provide great interest and X 2 Suresh et al. [9]
motivation in using solar technologies, which
include solar drying systems by applying
policies such as renewable portfolio standards
(RPS), feed-in-tariff (FIT), and incentives.
Governments of any size can lessen the X 2 Suresh et al. [9]
environmental impact of their regions through
a reduction in GHG emissions from carbon
usage by increasing their reliance on
distributed sources of renewable energy
Most policy goals seek to encourage the X 2 Suresh et al. [9]
diversity of power-generating sources, lessen
reliance on fossil fuels by the state, boost the
use of renewable energy, cut carbon
emissions, or other combinations of these
goals

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Table 2. Economic factor.

Variable VN (–2) N (–1) Z (0) P(1) VP(2) T References
Each year, an estimated one-third of all food X –1 United Nations [10]
produced, equivalent to 1.3 billion tons worth
about $1 billion, ends up rotting in consumer
and retail bins, or spoiling due to poor
transport and harvest practices.
Globally, researchers estimate that, in food X –1 Xue et al. [11]
supply chains, the percentages of food loss in
production, postharvest and consumption
stages are 24%, 24% and 35%, respectively.
The waste of agricultural crops on farms is X –1 FAO [12]
mainly related to economic losses due to over
production and the rejection of valuable
products considered not suitable for
consumption or commercialization because of
their appearance or size.
Solar drying is an economical, accessible and X 2 Salvo and Franco [13]
widely used alternative in various post-harvest
processes.
The global solar dryer market has reached a X 2 FACTMR [14]
valuation of US$2.64 billion in 2022. Sales of
solar dryers accounted for nearly 8% share of
the global dryer market at the end of 2021.
The Dehydrated Food Market size is estimated X 2 Mordor 24 [15]
at USD 245.39 billion in 2024, and is expected
to reach USD 337.18 billion by 2029, growing
at a CAGR of 6.56% during the forecast period
(2024-2029).

Table 3. Social factor.

Variable VN (–2) N (–1) Z (0) P(1) VP(2) T References
If we could use all the food waste in the world, we X 2 WFP USA [5]
could feed more than 2 billion people and solve
undernourishment..
828 million people suffer from hunger, e.i. 1 in X –2 FAO et al. [6]
every 10 people on the planet.
The agriculture sector is the world’s largest X 2 United Nations [16]
employer and provides livelihoods for 40% of
today’s world population. It is the largest source of
income and employment for poor rural households.

Table 4. Technological factor.

Variable VN (–2) N (–1) Z (0) P(1) VP(2) T References
The food production stage has been considered X –1 United Nations [17]
one of the “critical points” in value chains.
However, access to adequate technology in
developing countries allows only 30% of
agricultural production to undergo industrial
processing.
The development and application of hybrid X 2 Chayan et al. [18]
energy systems is currently one of the emerging
technologies with the greatest prospects for the
development of solar drying systems.

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Table 4. (Continued).
Variable VN (–2) N (–1) Z (0) P(1) VP(2) T References
The investment cost in solar technology is X –1 Kong et al. [19]
higher than in technology that uses energy from
fossil fuels.
There are industrial applications in Mexico and X –1 Chayan et al. [18]
it is one of the technologies in which research
and application development are still ongoing.
Ensuring the continuity of the process operation X 2 Chanda et al. [20]
due to the intermittency that occurs in the case of
renewable energies is one of the greatest
challenges in these processes.
Greenhouse effect (GHE) technology X 2 Patil and Gawande [21]
appreciably improves the quality of produce and
reduces the drying time as compared to the
traditional open sun drying method.
In the case of the solar tunnel dryer, it can be X 2 Lingayat and Balijepalli [22]
applied in addition to the food industry in sugar
production and in the marine industry.
For solar tunnels and greenhouse drying the X 2 Deng et al. [23]
equipment is cheap; the drying temperature is
higher than that of sun drying or shade drying. In
the drying of some materials, the color can be
better guaranteed.
The drying efficiency is increased and drying X 2 Vishnuvardhan et al. [24]
time is decreased due to the storage system in
the solar tunnel dryer.
A tunnel dryer is the most widely used method X 2 Ortiz-Rodriguez et al. [25]
for industrial dehydration of fruits and
vegetables. The drying time depends on the
moisture content of the product, the exposure
area, the initial product load, and the
meteorological conditions. The tunnel
greenhouse drier works continuously, obtaining
a daily production.
Solar tunnel dryers are mostly used for large X 2 Lingayat et al. [26]
scale drying of agricultural goods.
High costs of materials, installation and control X 2 Patil and Gawande [21]
systems used are a disadvantage in its
implementation, since it requires a significant
initial investment compared to common devices
that run on conventional fuels.

Table 5. Environmental factor.

Variable VN (-2) N (-1) Z (0) P(1) VP(2) T References
If food waste were a country, it would be the X –2 FAO [2]
third largest emitter of greenhouse gas
emissions on the planet at 8%. It would
consume 30% of the land used for cultivation. It
would also consume 20% of the fresh water.
One of the main emitters of GHG are food X 2 Crippa et al. [27]
systems. Food systems are globally responsible
for 21–37% of total greenhouse gas emissions.
They cause deforestation for use of crop areas;
the loss of associated biodiversity; use of
resources like water, and pollution from the use
of pesticides. Food loss and waste is a global
problem with important implications.
Food loss and waste is an important topic due to X 2 Chauhan et al. [28]
its high socioeconomic costs and its relationship
to waste management and climate change
challenges.

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Table 6. Legal factor.

Variable VN (–2) N (–1) Z (0) P(1) VP(2) T References

In Mexico there is a law that favors the use X 2 CRE [29]

of renewable energies and the financing of
the energy transition.
There are laws that protect technological X 2 GOB [30]
developments in the area of solar drying,
such as patent protection..
There are laws and regulations that govern X 2 NOM-044-FITO-1995 [31]
the operation of drying processes and
ensure the quality of dried products.

Political factor (Table 1). Considering the political factors favor the use of
renewable energies and the development of technologies that employ this type of
energy were analyzed.
Political factor: Total = 6. This is good opportunity for the energy transition and
the promotion of more sustainable alternatives.
Economic factor (Table 2). From an economic perspective, negative impacts of
food waste and the post-harvest alternative of a solar dryer usage to avoid food loss
were analyzed.
Economic factor: Total = 3. The results indicated that this alternative would
benefit the economy of farmers, by being able to market products considered outside
the standards; adding value to agricultural products that, when processed, can enter a
higher market niche than fresh products.
Social factor (Table 3). From a social standpoint, supporting small-scale food
producers is critical to improving food security, reducing poverty and hunger, the
waste of natural resources and deforestation due to agricultural expansion.
Social factor: Total = 2. This result indicates the implementation of technology
such as a solar dryer can help produce high-value foods and preserve the nutritional
properties of farm products.
Technological factor (Table 4). The main variables analyzed were the type of
dryer, auxiliary energy system, operational factors, applications, investment cost. The
results obtained indicated that tunnel-type dryers are the most commonly used for food
processing; the greenhouse effect improves the quality of the products and reduces
drying time; hybrid energy systems avoid the inconveniences of intermittent solar
energy. tunnel and greenhouse dryers are easier to scale up to an industrial level.
Although the investment cost is higher, operating costs are considerably reduced.
Technological factor: Total = 15. It is a high value. Therefore it is highly
technologically favorable to develop a tunnel type dryer with a greenhouse effect and
a hybrid energy system to ensure continuity in the drying process and optimize its
operation, ensuring the quality of the products.
Environmental factor (Table 5). From an environmental perspective, the main
factor to be analyzed was the negative impact of food waste, as the resources invested
in production are lost.
Environmental factor: Total = 2. The proposed dryer could reduce these impacts
by taking advantage of products that would not even be marketed by market standards.

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In addition, the use of a dryer reduces the use of fossil fuels contributing to the
decarbonization process.
Legal factor (Table 6). In a new technology to be commercialize the legal
perspective is important. Therefore, the main laws and intellectual protection were
considered.
Legal factor: Total = 6. This indicates that there are laws that favor the use of
renewable energy and the development of innovative solar technology with its
respective intellectual protection in the form of patents, in addition to the rules and
regulations for the production of dehydrated foods helping to ensure the quality of the
processes and products.
The conclusions of this analysis indicated that there is a large area of opportunity
for a feasible scientific and technological (Total score 15) development with a great
implication in the economic, social and environmental sectors, great favored by the
political (Total score 6) and legal sphere (Total score 6) for the development and use
of a solar dryer with a hybrid energy system at an industrial level. With the main
challenge and risk in the economic factor (Total score 3), like a new technology.

3.3. Proof of value (POV): Evaluation of the conventional dryers and solar
dryers
POV was developed considering the offering of solar dryers in the Mexican
market. Basic conventional electric dryers, industrial dryers and solar available dryers
were evaluated. The main parameters analyzed were operating conditions, and price.
It was assumed that the capacity and cost of labor are identical in both equipment
(Figure 3).

Figure 3. Analysis of solar dryers available on the market in Mexico 2024.

The results obtained for operation parameters indicated the time of process with
electric equipment is almost 6–8 times faster than the solar equipment.
For price parameters, the electrical equipment price is 15%–200% higher than
the solar one. Conventional equipment has a higher operating cost, due to the higher
cost of fossil energy.
This is important when scaling up the technology towards an industrial
implementation. It is noted that the cost per initial investment increases considerably
depending on the scale.
Solar dryers on small scales can be considerably cheaper. However, they have
the disadvantage of the time of process being longer, since only solar energy is use.

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It is worthwhile to point out that in the last years the approaches to sustainable
food drying have been focused on improving the efficiency of the dryer, which may
be achieved through insulation, heat recovery, recirculation and altering operating
constraints of the systems. Also, the focus has been on reduction of drying time,
improving or substituting the system’s energy supply by using combined heat and
power (CHP), biomass derived fuels and other renewable energy sources, mainly
hybrid systems [32]. The recent trends that are reshaping the domain of solar drying
venture into the dynamic evolution of materials, innovative designs, and the seamless
amalgamation of these advancements with state-of-the-art energy storage solutions. In
doing so, also navigation of the complex confluence of technology, innovation, and
sustainability, cast light on how solar drying has transcended its conventional practices
to become an advanced, eco-conscious discipline [33].
According to the market forecasting analysis, the global solar dryer market was
valued at USD 3.5 billion in 2023 and is predicted to increase at a compound annual
growth rate of 10.6 % from 2023 to 2031 [34].
Considering the results obtained of the idea assessment, POC and the above
information the development, design and operation of a solar dryer with a solar-
assisted energy type (hybrid system) for energy source was considered as the best
option to respond to the solutions required by the consumer.
With this equipment a more uniform and continuous operation can be obtained
by combining various energy sources. The drying process needs to be carried out
efficiently, so solar energy must be used as the primary source, taking advantage of
the greatest amount of time possible. It is necessary to consider the usage of materials
and development of a control system that allow this to be done. They are expensive.
However, currently there are adequate tools and materials for solar concentration and
microprocessors for the development of interfaces necessary for the control of
industrial processes with a focus on efficient use of energy at low cost. In the case of
drying of vegetable raw materials, if it is not done under controlled conditions the
product is contaminated. Its characteristics are not standardized nor does it comply
with food safety regulations. It is therefore lacking real added value for export or high-
value markets. For this reason it is necessary to establish scalable parameters for a
technological innovation of our own creation with an optimal cost-benefit ratio, with
an improvement in product quality and safety, high energy, operational and economic
performance, with a versatility of use and load in the process, but with continuous
energy availability, using an electronically controlled system for data acquisition and
monitoring through self-created software.
This entire system will be used for the drying process of different raw materials,
according to the requirements of the process and the product, with an efficient use of
energy, reducing the costs of the process and the final product. Since, as it is a self-
created technology, the costs of the equipment and consequently of the transformation
process would be reduced, ensuring an adequate rate of return. This would grant an
important competitive advantage in operation due to the operation and design of the
system components.
The POV analysis indicated that the proposed process and equipment are
innovative for the food industry carrying out a sustainable modernization in

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accordance with current sustainability-technological innovation requirements.

Therefore, this proposal meant value to the customer and the company, and the
development of the next gate for this process was possible.

3.4. Process and product development

The technology assessment and economic evaluation should be done in parallel
and iteratively. Assessment of the technology is the first part of a TEA. The concept
needs to be rock solid in terms of technical feasibility and the economic target. As a
developing technology, it will mean that some significant portion of the process has
not been practiced at a commercial scale. The technology will have a higher degree of
technical risk which should be managed appropriately [8].
The first question to ask when assessing a new technology is does it violate any
laws of thermodynamics or nature. So, the assessment analysis started with the
evaluation of the solar drying process in the Yucatan Peninsula as the first step. Then,
the operational requirements for solar drying was established with the relationship
between solar radiation and temperature. Finally, it was possible to develop a feasible
solar dryer design and evaluate the operation.
3.4.1. Evaluation of the solar drying process in the Yucatan Peninsula
In order to determine whether the solar drying process (regardless of its
configuration, method and/or technology) was feasible in the Yucatan Peninsula, the
solar area potential needs to be known. The following data are documented [35]:
 Average monthly number of hours of sunshine per day: between 6 and 8.5 h.
 Average daily ambient temperature greater than 30 ℃ from March to October,
with a critical period in the months of April, May and June with average
maximum temperatures of 37 ℃ and extreme maximum of 40 ℃.
 Availability of solar radiation per hour. With maximum daily integrated solar
radiation of 1016 W/m2; and with a minimum integrated solar radiation of 560
W/m2.
 As can be seen, there is excellent solar potential in the area, since throughout the
year (months such as June and July) up to 8.5 h of sunshine can be used; likewise,
having an ambient temperature greater than 30 ℃ is appropriate, since it will
allow maintaining the heat gained by using radiation, which can be said to have
adequate levels, ranging between 1.106 and 560 W/m2. In other words, in the
Yucatan Peninsula, there is between 79% and 40% of radiation with respect to
the solar constant.
The data above indicated that the solar drying process in the Yucatan Peninsula
was viable, since if implemented, this would mean a relatively lower economic cost
with respect to conventional dryers and zero operating costs with respect to energy
usage.
Although the technical feasibility is positive, it is necessary to know the
performance and parameters for the drying process within equipment such as the
proposed.
3.4.2. Operacional requirements for solar drying
One of the first parameters to design a drying process is to determine the
appropriate drying temperature. The radiation levels in the Yucatan Peninsula were

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measured to assure that it is a feasible place for the implementation of solar dryers,
also if the desired temperatures in a solar dryer will be reached. It is considered that to
carry out a good drying process, the air, which serves as a workflow, must have a
temperature between 40 ℃ and 70 ℃; likewise, it must contain minimum amounts of
humidity (which it has gained outside, prior to entering the system); in addition, its
movement must be constant.
For this case, an indirect radiation dryer which is one of the simplest solar dryers
was used. If the temperatures are the minimum required for drying agro-food products
(and sustained for a suitable period of time) and for drying habanero chili, the
feasibility would be proven. For this case, radiation and temperature measurements
were taken inside the experimental prototype, this for a period of 800 min, that is, 12.5
h. The habanero chili has been chosen as the base product to be dried, because it has a
large amount of water content, on average 90%. The samples were stipulated in sizes
of 0.3 and 1.3 cm. A Kipp Zonen pyranometer model CMP10 for radiation measures
and LM35 temperature sensors were utilized.
From the readings taken, as it can be seen in Figure 4, the radiation levels were
variable throughout the day; this may be due to different factors such as cloudiness
and time of day. However, the temperatures obtained inside the dryer and their
variations did not greatly affect the desired temperatures, since most of the time above
50 ℃ was obtained (desired temperature for drying habanero peppers) or, failing that,
at the limit of 40 ℃. An effective range of between 50 ℃ and 70 ℃ has practically
been stipulated; where it is possible to dry the product and preserve both its color and
its own characteristics (Hernández et al. [36]). These results indicated the Yucatan
Peninsula had adequate conditions for the solar drying process and a feasible place for
the implementation of the solar dryer to be developed.

Figure 4. Laboratory-scale radiation temperature measurements in an indirect solar

dryer.

3.4.3. Feasible solar dryer design

According to an analysis developed through 100 of the 1675 articles It was found
that the energy efficiency of greenhouse-type solar dryers is 11–73 %, and the energy
efficiency of solar air collectors and biomass furnaces integrated into them is in the
range of 45–81 % and 47–87 %. The lifetime of various greenhouse type solar dryers
is between 4–35 years, their price is between $220–$10,659 USD and the payback
period is between 0.3–11 years, embodied energy is 136–18,302 kWh, and EPBT is in
the range of 1.1–3.63 years [37].
Due to the above information the feasible design selected to be developed was a

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greenhouse-type solar dryer.

According to the initial requirements of the supply chain identified, the main
characteristics of the technology to be developed were:
Portable system: The dehydration process could be located on the farm or in the
city, eliminating losing nutrients due to transportation and storage. This was done with
a modular and portable greenhouse structure and the usage of affordable and efficient
and new materials like recyclable plastic covering and rigid materials. This new
system is described in our patent: MX_W_2022_084942.
Processing continuous form. The system operates during the day and night,
eliminating the loss of product which would result with intermittent solar energy.
There are different alternative auxiliary systems for heating due to the intermittency
of solar energy. These systems allow conservation of the solar heat energy for further
usage. The results of an art review indicated that the combined power and drying,
application of phase change materials and hybrid drying systems with regard to
agricultural products are the most auxiliary energy systems utilized [38].Indeed, a new
auxiliary system considering phase change materials was developed. This is described
in our patent: MX_E_2018_092688.
Improved control system. Minimisation of the thermal degradation is indicated
in the colour, flavour, aroma and appearance that remain similar to the fresh product.
It is pointed out that this kind of system is expensive [38]. However, we developed an
affordable system that allows for controlling the drying system according to the raw
material. Python was one of the platforms used. We are improving our wifi system for
the control system of the entire drying system.
Differentiated products. The dehydrated foods obtained retain their organoleptic
and nutritional properties, without additives and they can be rehydrated. This was
obtained due to the improved control system developed.
Modular and scalable system. The processing capacity could be adapted
according to the required production. This is done due to the portable structure and the
possibility to scale up it according to the needs of the capacity of production required.
Several and different types of equipment could be operated at the same time.
Flexibility and versatility in operation. Processing several kinds of food at the
same time. This is done due to the modular structure.
Therefore, most of the goals initially proposed at the beginning of the project
were achieved. The results of the first stage of this project have been presented.
It is worthwhile to point out that different forms could be obtained with the
technology, preserving the colour, taste and aroma of the food’s fresh products. Also,
we are developing new applications in other areas like, recycling food waste of
industries like beer factories, batteries recycling process among others. Also, we have
2 trademarks CREID BIA and CREIDBI used to promote Mexican regional cuisine
especially ethnic products of Mayan origin.
3.4.4. Operation the feasible design of solar dryer
We designed and built a new greenhouse dryer and a new conservation energy
system. The goal for these systems is to operate in a continuous form for drying. The
operation of these systems is described as follows.
The system is made up of three integrated subsystems: (1) a solar air heating

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system, (2) an indirect solar dryer or drying chamber, and (3) an auxiliary air heating-
dehumidification system to obtain a continuous drying process. During daylight hours,
the sun’s radiant energy is used for the drying process, and during the absence of solar
radiation, a thermal storage system or thermal reservoir or a hybrid energy system is
used according to the needs of the process to be carried out, the operating facilities,
and the geographic location. To achieve continuous operation, air heating is
performed, this allows the drying process to continue at night and when there is a
decrease in solar intensity due to intermittence. The equipment used in the system are:
filters, axial fans, control equipment developed by our work team, photovoltaic cells,
inverters, batteries, temperature sensors, relative humidity sensors, air flow sensors,
and radiation measurement sensors. The system operates using solar energy to heat the
initial drying air, which upon leaving the drying process is sent to the thermal tank for
the purpose of dehumidifying and recirculating it, as there is a negative gradient of
approximately 5–10 ℃, during solar hours, as indicated in Figure 5.

Figure 5. Operation of the drying system with coupled thermal reservoir.

In conditions of intermittent solar energy and absence of solar energy, access to

ambient air is closed, so the cover of the drying chamber, i.e., the air heating system
is used as an insulator to avoid nocturnal heat losses, thus, only air from the thermal
tank is recirculated to the drying tunnel or plenum. In this mode, the temperature inside
the thermal tank tunnel is kept constant and with a positive gradient of approximately
10–30 ℃ with respect to the environment. Likewise, a thermal equilibrium is achieved
between both equipment (thermal tank and drying tunnel), with positive gradients of
the system of approximately 10–20 ℃ with respect to the environment during night
hours, allowing the drying process to be carried out, obtaining a temperature of
approximately 30–45 ℃ maximum, allowing slow but continuous drying, avoiding
rehydration of the product in process during night hours or intermittent solar energy,
since the same mode is applied when there are decreases in radiation during solar
hours. The above mentioned allows continuity of the drying process, since the system
operates in batches with loads from 250 to 500 kg, in a total drying time range from 8
h to 30 h considering the presentations of the cut and whole product according to the
characteristics of the material to be dried.

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3.5. Scale up demonstration

According to the test developed before. The main equipment was built and the
auxiliary equipment fitted. Then operational tests were carried out on habanero chili
as a base product and subsequently on various products simultaneously, from aromatic
herbs, fruits, vegetables and a variety of chili peppers. Four points were monitored:
the air temperature sensor at the thermal reservoir inlet (Dr), air temperature sensor at
the thermal reservoir exit (Tr), air environmental temperature sensor (Am) and air
temperature sensor at the drying chamber (Tu). DHT Humidity and temperature sensor
model 22 and LM35 temperature sensor were utilized in the test. In the Figure 6, the
location of these sensors is indicated.

Figure 6. Location of sensors inside the drying tunnel and thermal storage.

Drying tests with Habanero Chili

Initially, the processing time was 90 h without thermal storage. With the coupling
tests, the time was reduced to 27 h, that is, 70% less. The tests were carried out in
environmental conditions with excellent solar radiation for certain periods and with
intermittent periods and therefore a decrease in temperature.
The results showed that there was a thermal equilibrium in the system that allows
obtaining storage temperatures (Dr. Tr, Tu) and a decrease in humidity in periods of
high humidity in the environment (Am = 100%), as observed in Figures 7 and 8
respectively.

Figure 7. Temperature variation vs. time in the drying kinetics of habanero chili
with the reservoir thermal-drying chamber system.

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 Clean Energy Science and Technology 2024, 2(4), 218.

Figure 8. Humidity variation vs. time in the drying kinetics of habanero chili with
the reservoir thermal-drying chamber system.

Therefore, the use of the thermal storage tunnel system allowed obtaining
reductions in drying time of chopped habanero chili of the order of 30 to 50% of the
initial tests according to the current environmental conditions. For whole habanero
chili, drying times of 36 to 48 h were obtained in periods of low and high solar
intermittence. It is worth pointing out that the normal time for a sky open solar drying
is on average 72 and 120 h for chopped and whole habanero chilli.
It is noted that the green, yellow, orange and red colors were obtained and
maintained as close to the fresh product as shown in Figure 9, it is indicated in circles.
It should be noted that the different colors of habanero chili are associated with the
degree of maturity of the fresh product, in an increasing manner, that is, green at the
lowest degree of maturity and red at the highest degree of maturity.

Figure 9. (a) habanero chili dried orange; (b) habanero chili dried red; (c) habanero
chili and chopped green; (d) habanero chili and chopped yellow.

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 Clean Energy Science and Technology 2024, 2(4), 218.

The results of the humidity and volume reduction of the dried products of whole
habanero chili indicate that on average the whole chilies shrink in the drying process
by 50 to 30% of their initial volume (Table 7). The official procedures described by
Horwitz and Latimer [39] were used for the analyses shown in Table 7.

Table 7. Humidity and shrinkage results of drying whole habanero chili.

Maturity level Humidity (%) Shrinkage (%)
Red 9.64 49.44
Orange 10.56 32.39
Yellow 11.54 39.17

3.6. Commercialize: Tests in the drying plant

Field tests were carried out coupling other drying equipment and thermal storage
(Figure 10) with various products. The goal was to analyze and test various air flow
arrangements, by operating the system in parallel and with counterflow of the
humidified air. This air was dehumidified as it passed through the thermal storage
tunnels and heated in turn to be sent back to the drying tunnels. Also, the controls were
tested and monitoring points along the system.

Figure 10. CREID BI SAFE® Drying system with a coupled reservoir thermal.

The energy consumption of the developed process was analyzed considering

conventional technologies based on electricity and natural gas as energy sources
(Table 8). The financial results obtained have been promising not only with respect to
the annual energy use, but also in the annual investment, which places the developed
continuous solar process as the best option over the processes and equipment that use
conventional energies.

Table 8. Comparison of energy–cost of the developed process vs. conventional

drying processes for a fixed annual production.
Energy source Anual energy (USD) Annual investment (USD)
Natural gas 15,255.16 21,129.40
Electricity 11,258.40 32,119.100
Developed process 521.30 1490.90

The financial projection was carried out from the perspective of the producer who
acquired the technology. The preliminary results show the viability of acquiring the
technology and a payback time of approximately 2 years and 2 months. These

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indicators may vary depending on the crop to be processed, on which the yield and
processing time depend. Without the project, the raw material would not be processed,
which would mean an economic loss for the producer and under the scheme that said
raw material is the loss of the crop, the differential is high. From a total loss of 10%
to 20% of production to a total use of it.
Likewise, if the financial projection is carried out considering the perspective of
the manufacturer who acquires the technology, the break-even point will be reached
with 35.34% of sales and a payback time of 1 year and 11 months.
According to these indicators, the drying plant project is viable and economically
profitable.
In Figure 11, it can be observed that the colors and appearance of the dry products
are similar to the fresh products.

Figure 11. Some dried products (a) epazote; (b) sweet chili, Xcatic, habanero; (c)
orange; (d) chaya; (e) poblano chili, jalapeño, bell pepper; (f) tomato; (g) pineapple;
(h) red onion; (i) white onion; (j) lemon.

At this stage, the initial characteristics proposed for the equipment referring to
portable system, modular and scalable system, solar continuous processing, improved
control system, flexibility and versatility in operation and the production of
differentiated and standardized food products are obtained.
Therefore, a new solar drying technology has been developed. CREID BI SAFE®
will be an intelligent solution advancing food processing efficiency.

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 Clean Energy Science and Technology 2024, 2(4), 218.

4. Discussion
At this point in the development, the monitoring and control system has shown
various failures in the sensors when the scale is up. The development of an improved
monitoring system and a wireless system with more robust monitoring are being
worked on.
Likewise, the possibility of creating a more robust air heating system is being
considered. The use of technologies such as parabolic solar collectors or heliostats,
among others, are under development.
The use of biodiversity and carbon footprint indicators specifically coupled to the
production system and the crop field are developing.
With this technology and process new applications are being developed like
waste recovery from a beer factory, a battery recycling production among others.
Sinergy and alliance with small farms and new food products are developing.
A line of healthy and sustainable products have been developed according to the
needs of the market to articulate the food supply chain in a sustainable way, avoiding
food waste in the crop field.

5. Conclusion
The results of the development of a new solar drying technology with
applicability in the food production system were presented. The best configuration for
an integral drying system for various applications was obtained. Therefore, the solar
drying technology developed was portable, efficient, modular, versatile, continuous
processing, with minimal degradation in the dehydrated product. According to the
annualized cost method calculations, the cost of drying products with this technology
was much lower than when using conventional energies and had a short payback
period of 1–2 years. This research is the first part of the ongoing project. Improved
equipment and various applications are in progress.
Today for the technology, we have 2 patents MX_W_2022_084942 and
MX_E_2018_092688 in Mexico and 1 trademark CREID BI SAFE. We have 2
trademarks CREID BIA and CREIDBI used to promote Mexican regional cuisine
especially ethnic products of Mayan origin.

Author contributions: Conceptualization, CRE and RMCA; methodology, CRE and

RMCA; design of equipment and software, CRE and RMCA; validation, CRE and
RMCA; formal analysis, CRE and RMCA; investigation, CRE and RMCA; resources,
CRE and RMCA; data curation, CRE and RMCA; writing—original draft preparation,
CRE and RMCA; writing—review and editing, CRE and RMCA; visualization, CRE
and RMCA; supervision, CRE and RMCA; project administration, CRE and RMCA;
funding acquisition, CRE and RMCA. All authors have read and agreed to the
published version of the manuscript.
Conflict of interest: The authors declare no conflict of interest.

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 Clean Energy Science and Technology 2024, 2(4), 218.

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