In this work, we synthesized and economically analyzed a sustainable process of industrial production of microencapsulated anthocyanins powder (MAP) from Hibiscus sabdafiffa L. calyx (HSC) with the assistance of SuperPro Designer software. Open literature data were used in the synthesis of flowsheet and minimum selling price (MSP) of MAP was the only economic parameter used to assess the profitability of MAP production plant. Scale-up studies in the range of 0.127–130.393 × 103 kg/y MAP were conducted to identify the most economically feasible production capacity of MAP. Sensitivity and uncertainty analyses were further conducted on the most economically feasible capacity to determine technical and cost variables of significance. Material and energy demands and cost parameters increased with pant capacity. A power law relationship (R2 = 0.9081) was obtained between the MSP and selected range of plant capacities. The plant capacity of 108.551 × 103 kg/y MAP had the least MSP of 4013 US$/kg MAP and was selected as the most economically feasible capacity. Regarding the economics of plant capacity of 108.551 × 103 kg/y MAP, Packed Bed Adsorption (PBA) chromatography column was required in multiples and its cost contributed approximately 59% to the total equipment purchased cost (EPC). Consumables cost was the highest contributor to total operating cost (TOpC) and MSP showed a linear dependence (R2 = 0.9935) on the discount rate. Sensitivity and uncertainty analyses showed that resin binding capacity, PBA resins purchase cost and Hibiscus sabdafiffa L. calyx anthocyanins (HSCAs) recovery had most contributions to uncertainties in MSP.
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