Post-harvest losses of horticultural products in tropical highland regions can exceed 30% due to insufficient drying infrastructure. Although solar drying offers a low-carbon preservation alternative, its performance is strongly constrained by climatic variability. In regions such as Mosquera, Cundinamarca (Colombian Andes), characterized by fluctuating solar radiation (4.2–4.8 kWh/m²·day), high relative humidity, and frequent cloud cover, conventional passive solar dryers exhibit limited efficiency and operational reliability. This study presents the design and assessment of a hybrid solar dryer integrating solar thermal energy with photovoltaic-powered auxiliary heating to ensure stable operation under variable conditions.
The system was dimensioned for 10 kg of fresh tomatoes using a coupled heat and mass transfer model under local climatic inputs. The configuration combines direct solar heat gain with photovoltaic-driven electric heating, maintaining target drying temperatures (45–60 °C) under low irradiance conditions (<300 W/m²). Environmental performance was evaluated through a cradle-to-grave life cycle assessment (LCA), comparing industrial (stainless steel–polycarbonate), traditional (wood–glass), and circular (recycled polymers–natural fibers) designs in terms of embodied energy, carbon footprint, and durability.
The hybrid configuration reduces drying time by 25–30% relative to passive systems while ensuring thermal stability. The circular design exhibits the lowest initial carbon footprint (≈30 kg CO₂-eq), whereas the industrial configuration achieves superior eco-efficiency over a 10-year lifespan due to enhanced durability and thermal performance. Photovoltaic integration offsets approximately 134 kg CO₂-eq annually and results in an economic payback period of 7–9 years under local electricity tariffs.
These results demonstrate a robust, energy-efficient, and low-carbon drying solution adaptable to diverse tropical highland contexts, highlighting the potential of hybrid solar systems coupled with circular materials to enhance climate resilience in agro-industrial applications.