Innovative Retrofit Solutions to Reduce Energy Use and Improve Drying Performance in Conventional Hot-Air Herb Dryers

Hot-air drying is widely adopted for herbs because it is robust and easy to control, yet it is often energy-intensive and may operate far from optimal conditions when industrial dryers rely on fixed airflow paths and large air recirculation rates. This work investigates a conventional basket-type, adiabatic hot-air dryer through an instrumented 30 h drying campaign and a psychrometric energy analysis. The hot-air drier is designed to reduce the relative humidity of herbs from the environmental value (highly variable as a function of the species, the weather conditions, and, mostly, the seasonality) to 20%. Temperature and relative humidity were measured at four positions to characterize the shelf-by-shelf drying sequence and to identify process phases. A mass balance indicated that approximately 3.8 t of water was removed during the trial. Based on the measured thermodynamic states of the moist air and estimated airflow rates (35,000–53,000 m3/h), the baseline configuration was analyzed and an upgrade strategy was proposed to improve dehumidification and overall efficiency while preserving the conventional hot-air-drying concept. The alternative solution integrates a refrigeration-based dehumidification loop (heat pump) to decouple moisture removal from sensible heating; three plant layouts and seasonal boundary conditions (summer/winter) were simulated. For the most favorable configurations, the specific final–primary energy demand and the associated CO2-equivalent emissions were reduced by about 70–85% compared with the baseline, depending on the airflow rate and recirculation strategy. The results highlight practical retrofit options for existing herb dryers and provide a transparent framework for translating measured psychrometric states into energy and emission indicators. The results, achieved and discussed in this study, were used to optimize the utilization of an already existing and operative hot-air dryer. Based on the proposed working configuration, the dryer now allows achieving the fixed target for herb mixtures of the previous configuration and, at the same time, reducing the energy consumption and associated equivalent CO2 emitted, as well as achieving process completion in less time.