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Sugar plant automation and optimization

Worldwide, sugar mills are being modernized and automated in response to the vital need of more efficient production, to be able to compete globally.

Sugar processing is an energy intensive industry that requires precise control and continuous reliability, especially during seasonal production cycles. We help connect independent production processes and suppliers with a distributed control system that provides a single interface to control production. And, we help you do more with less energy, from reusing centrifuge braking energy to replacing cane mill steam turbines with variable speed drives and induction motors. Along with energy savings, these solutions reduce maintenance costs, improve availability and provide precise speed control.

Many known sugar brands around the globe turn to ABB with their requirements for distributed control systems (DCS), measurement & analytics, HMI, energy-efficient motors, drives and PLC, manufacturing execution systems (MES), process and production intelligence software, robots and more. They get access to the state-of-the-art, proven tools, process knowledge and partner network that help them reduce operating costs, get started on their digital journey and unlock new business value.

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For example, steam consumption can be calculated, monitored and controlled to match the actual demand of individual parts of the plant, which have direct impact on overall power consumption, resulting in a reduction of up to 20%. Or switching to a modern ABB rib cooled motor and drive package can reduce cane crusher energy consumption by 40% while improving reliability in harsh conditions.

After automation system modernization by ABB partner in India, throughput of Baramati Agro sugar plant increased by 25%, plant availability improved by 15%, power consumption decreased by 10%, manpower costs reduced by 50%. Complete plant information, history and diagnostics help further improve sugar and cogeneration processes.

Got challenges with sugar manufacturing processes?

We design process & batch control, electrical control, safety, logistics, information and asset management solutions. We can integrate them with existing systems of different types, ages and brands.

Contact us to get started

When sugar companies like Baramati Agro, Südzucker, Thai Roong Ruang (TTR) Group, Glinojeck need help with modernization, digitalization and more advanced automation to optimize their sugar cane and sugar beet mills or sugar refineries, here is what they do.

Control

Every. Thing. Controlled.

  • Varying raw materials, unpredictable orders and the demand for new product varieties require flexibility in production planning.
  • Rising costs of energy consumption and pollution control, complying with environmental standards call for energy and emissions monitoring and simplified reporting.
  • Ever-changing food safety standards emphasize the need for better raw material traceability, laboratory sampling, and product control.

Visualize

End-to-end visibility

  • Consistent, easy, user-friendly, logical interface improves operator intuitive actions and productivity
  • Pre-determination of the required KPIs and relative measurements improve the efficiency of the cycle
  • Loops performance and quality measurements reported to management to easily rectify faults and errors in the field or in the process, to achieve savings in loop time, fuel consumption, vapor generation, etc.
  • Less time to troubleshoot problems through accurate and easy diagnosis about where, who and when problems happen

Optimize

Data-driven manufacturing

  • Increase sugar / sweeteners production output and safety through more efficient utilization of company assets and capacities, and thus reduce the Total Cost of Ownership (TCO)
  • Introduce new sugar product varieties that are economically viable, consistent in quality, traceable and available just-in-time for the customers
  • Reduce energy costs, utilize sugar manufacturing by-products as renewable energy sources, protect water security and meet local environmental regulations

You can also benefit from our 20+ years of experience in sugar processes. ABB is different.

ABB's pre-engineered sugar control library is able to deliver precise handling of all steps of the process and ensure consistent and high quality sugar products. We offer pre-studies, function specifications, system layouts, process applications, batch / S88, MES / S95, horizontal / vertical system integration, reporting, training and validation. We know the scientific, engineering and business reasons that underpin decisions. We incorporate this understanding into our end-to-end solutions
Sugar library

The sugar application library is a complete, consistent and comprehensive software databank of all sugar process applications, including vacuum pan, extending from beet and cane to refined sugar.

We can make you more competitive

We can help you digitalize your assets, satisfy mandatory requirements, refine designs for a variety of scenarios and unlock new business models to transform your sugar production.

How can we best co-develop and collaborate?

Schedule a meeting with our consultant

Awards and recognition

According to ARC Advisory Group, ABB has got the world's most popular distributed control systems (DCS). - System 800xA, Freelance DCS and other heritage brands. We are No.1 over a decade and delivered automation solutions  to more than 100 countries, in a variety of industries.

ABB's extended automation system ABB Ability System 800xA and its ergonomic control room design have won multiple awards. Control engineers and operators love this user-friendly system for its ability to meet their needs and its outstanding integration capabilities. It comes with the unique batch and recipe management solutions and pre-engineered sugar control library for automating sugar production process. They have been created according to demands and descriptions from major industry consultants like BMA, Ibro, Fcb and provide tools to achieve compliance.

The capacity and efficiency of a sugar mill depend on the number of cycle times achieved by the system. This can also be influenced by adjusting acceleration and deceleration times for the rotation centrifuges. ABB's solution that helps select the right motors and drives for sugar refineries was recognized by The Emirates Energy Awards committee.

Some of ABB sugar references

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