Solution

FLEXHYON Solutions: The Future of Electrified Industrial Heating

Recognizing the significance of energy efficiency in industry and carbon emissions reduction, FLEXHYON is proposing a clever combination of alternative fully electrified heating systems (microwave, heat pumps, ultrasound) to tackle three specific industrial processes: ultrafast drying of compact material, drying of granular materials and distillation/extraction of ground material to address their urgent need to transition from fossil energy to renewable and low-carbon energy sources. Three optimized prototypes will be built and demonstrated in 3 industrial environments: ceramics, feed production, biomass. The quality and economic impact of the developments will be evaluated using LCA and LCC; environmental and technical performances, health protection, safety will be demonstrated and validated. Sound market strategies will be developed, giving clear indications on scalability, transferability and replicability across different industrial sectors, commercialization and deployment will be achieved through development and validation of set of business models for the 3 business cases.


The FLEXHYON solutions will exhibit significantly higher energy efficiency in comparison to traditional fossil fuel-based heating technologies, therefore leading to a reduction in GHG emissions, maximizing primary energy savings, and enabling higher production flexibility (e.g. production on-demand, production on-site). Their scalability (upscaling, downscaling) will allow to better follow market demand and enable leaner production paradigms.


To achieve the project goals, FLEXHYON combines 9 partners covering the whole technical value chain required for the development and validation of alternative fully electrified heating systems. The Consortium will also implement different dissemination and communication activities to raise awareness about the benefits of alternative heating systems in industry and exploitation opportunities from know-how generated and exploitable results developed.

Microwave-Based Drying System

This microwave-powered heating system is designed for high-efficiency drying processes, particularly in ceramic manufacturing and granular material production. Unlike conventional heating, microwave drying delivers faster, uniform heating, reducing energy waste and processing time. This solution optimises:

  • Precise moisture control to enhance product quality.
  • Lower energy consumption compared to fossil fuel-based drying.
  • Scalability for integration in other material processing industries.

Heat Pump-Assisted Processing for Feed Production

FLEXHYON is introducing heat pump technology to replace steam-based heating in animal feed production. This solution:

  • Reduces energy consumption by using heat recovery mechanisms.
  • Ensures a stable heating environment for better nutrient preservation.
  • Improves efficiency and cost-effectiveness, making it suitable for large-scale adoption.

Ultrasound-Based Extraction for Biomass Processing

This innovative ultrasound-based system enhances extraction processes in biomass industries, including biofuel and pharmaceutical applications. Ultrasound waves disrupt plant cell structures, improving extraction yields while reducing solvent use and processing time. The technology is designed to:

  • Enhance efficiency and resource use in biomass conversion.
  • Reduce environmental impact by minimising energy demand and waste.
  • Support the transition to sustainable bio-based products.