Jaggery is a sweetener extracted from sugarcane juice and is used widely in India for centuries. Conventional jaggery making process utilizes bagasse for boiling of sugar cane juice which releases pollutants into the atmosphere, and high particulate matter from these emissions causes air pollution. Also, these processes operate under low thermal efficiency and use artificial clarificants, which are harmful to human health. There have been several studies reported on enhancing the thermal efficiency of these process. However, there is not much focus on integrating these process with renewable energy technologies to overcome the environmental impacts. Therefore, the present study is aimed at developing a solar-powered jaggery industry with freeze pre-concentration integrated into conventional and modified heating pans. The system performance, environmental impacts and economic feasibility were assessed by carrying out 4E (Energy-Exergy-Environment-Economic) analyses by developing a mathematical model. The proposed system is designed to produce 300 kg of jaggery per day when operated for 7.5 h in 3 batches with average solar direct normal irradiation of 662 W/m2 and 343 °C. The system is also integrated with auxiliary heating for uninterrupted production, even in the absence of sunlight. The environmental analysis shows mitigation of nearly 2015.95 to 3062.15 tons of CO2 emission during its 25 years of lifespan under 300 clear days of operation each year. Jaggery produced by this technique is rich in its colour and entirely safe for human consumption as no artificial clarificants are used. The economic analysis shows that the amount invested can be recovered in a span of 12.03 to 13.45 years for the jaggery selling price of USD.0.514/kg or INR.36/kg.