The present study explores the process optimization for production of chemical-free and iron-fortified jaggery with focus to improve its quality and nutritional value. Traditional jaggery production has limitations in terms of quality, yield, high moisture and harmful chemical usage. The present study emphasized on development of scientific process for chemical-free jaggery production using optimal sugarcane variety, maturity harvesting index, better juice recovery with horizontal cane crushers, natural clarificants for removing impurities and tools for accurate striking temperature measurement. Further, the research also involved optimal production process for development of iron-fortified jaggery. For this, food-grade iron compounds, i.e. Ferrous Fumarate (C4H2FeO4), Ferrous Ascorbate (C12H14FeO12) and Ferric Ammonium Citrate (C6H8FeNO7) were used for fortification. Jaggery fortified with Ferric Ammonium Citrate showed highest acceptability with maximum score in terms of stability, taste, colour and texture. Bio-accessibility studies indicated that jaggery fortified with 2 mg of iron showed optimal absorption, while increased iron levels diminished absorption due to saturation and solubility issues. This study established an optimized process for manufacturing of chemical-free and fortified jaggery with enhanced nutritional benefits contributing to food safety and public health.