Sugar mill operations management and optimization: a case study

Best practice examples of how an Indian sugar and ethanol producer is scaling digitalization to become the most cost-effective and sustainable sugar company in the region.

In a rapidly evolving global market, a multi-site sugar manufacturing company recognized the need to modernize its operations. Faced with rising energy costs, volatile commodity prices, and increasing regulatory scrutiny, the company set out to transform its traditional mills into smart, data-driven production hubs.

The goal was ambitious: to become the most cost-effective and sustainable sugar producer in the region. This meant rethinking how data, people, and processes could work together to unlock untapped potential.

Scaling-digital-to-unlock-full-potential-in-sugar-mills
Scaling digital to unlock full potential in sugar mills

Laying the digital foundation

The transformation began with a fundamental shift in how data was managed. The company implemented a scalable industrial DataOps platform on premises capable of collecting high-frequency signals from a wide array of sources—legacy DCS systems, PLCs, energy meters, and even older archives. This data, transmitted efficiently using lightweight protocols like MQTT, was consolidated across multiple sites, creating a unified, real-time view of operations.

This created a foundation that could continue to grow with the business, adapt to future needs, and support advanced applications like AI and machine learning in the future.

Scaleable industrial DataOps on premises
Creating a best practice for a cost-effective data management and consolidation with a scalable Industrial DataOps on premises

Empowering decision-makers with insight

With the data infrastructure in place, the next step was to make that information actionable. Using a PIMS (Production and Process Information Management System) solution based on ABB Ability™ Knowledge Manager, the company deployed a suite of self-service dashboards and reports. These tools gave production managers, engineers, and maintenance teams the ability to monitor everything from steam distribution and juice extraction to bagging efficiency and operator performance.

For the first time, teams could see in real time whether they were on track to meet their targets—and if not, they got the tools to quickly identify deviations and take corrective action.

PIMS for sugar and ethanol production
Self-service analytics dashboards, reports and notifications with data aggregation across multiple sites

Optimizing the distillery and bagasse boiler

The company didn’t stop at visibility. It moved decisively into optimization. In the distillery section, involving precise control of temperature, flow, and chemical reactions, PID loop performance became another area of focus. Through real-time monitoring and tuning, the company achieved a 10–30% reduction in process variability, leading to more consistent product quality and smoother operations.

One of the most impactful changes came from applying advanced process control (APC) to the bagasse boilers. ABB Ability™ Expert Optimizer provides predictive values to simultaneously improve combustion efficiency, reduce emissions, control and minimize oxygen in boilers, which increases plant energy production, improving the economic profit of the plant. By fine-tuning combustion, the company reduced fuel consumption by up to 4%, cut power usage by 5%, and lowered excess air levels—all while improving steam generation efficiency by 1%.
Bagasse boiler optimization
Advanced process control for bagasse boiler optimization

Looking ahead: a culture of continuous improvement

data-integration sugar

This high-scale digitalization initiative wasn't a one-time project—it was the beginning of a new way of working. The company is now considering further APC opportunities in areas like evaporator and crystallization optimization, lime kiln control, and even autonomous boiler operations. Workshops and training sessions have helped bring employees along on the journey, fostering a culture of innovation and continuous improvement.

As part of the next steps and goals currently in progress, the company is implementing power export forecasting to reduce penalty costs by up to 50%. This initiative is expected to further enhance the economic performance of the co-generation process, ensuring that energy production aligns more closely with grid requirements and contractual obligations—ultimately contributing to both sustainability and profitability.

Get in touch with our experts today by filling out the contact form and start your journey toward smarter and more sustainable sugar production.

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