Techno-Economic Feasibility of Functional Snacks from Brewer’s Spent Grain and Sweet Potato: A Simulation Study

This study evaluates the techno-economic feasibility of producing a functional baked snack formulated with sweet potato flour, cereals, and upcycled brewer’s spent grain (BSG). The analysis, developed in SuperPro Designer®, integrates experimentally derived parameters from literature, justifying the transition from laboratory-scale data to an industrial production model. The analysis identified refrigerated storage (48 h) and tray drying as the primary bottlenecks limiting throughput. By synchronizing equipment cycles and increasing the number of units, the production capacity was adjusted from 154.32 to 1077.21 metric tons per year, capturing approximately 0.8% of the estimated annual demand for sweet potato snacks in Mexico. Economic evaluation for this scale demonstrated a capital investment of USD 24.6 million and annual operating costs of USD 8.49 million. The inclusion of a sedimentation-based water treatment, while increasing costs, enables a significant reduction in freshwater intake. The project yielded a payback period of 3.62 years and a Net Present Value (NPV) of USD 23.908 million. Sensitivity analysis revealed that profitability is strongly influenced by production volume and sweet potato costs. These findings provide a realistic framework for assessing the commercial viability of functional food formulations when scaled for industrial production.