Solutions to boost sustainability, reliability and safety in sugar production

Sugar farmers and processors face tough commercial realities as soaring costs of energy, raw materials and transportation bite into profit margins. Outdated and unreliable machinery reduces yields while putting workers at risk. And with food manufacturers and consumers demanding ever lower prices, there’s pressure on the sugar industry to make more efficient use of energy, water and raw materials.

ABB sugar industry solutions enable farmers and processors to optimize the profitability, safety and sustainability of their operations. From beet and cane farming to processing and logistics, our energy efficient motors and drives, Programmable Logic Controllers (PLCs) and digital services can improve energy efficiency and production uptime for sugar producers while enhancing safety to personnel and overall product quality.

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Find out how your applications could be operating more efficiently, reliably and safely

Growing success for sugar farmers

Making sure crops have the correct amount of nutrients, sunlight and water is crucial to healthy growth for high yielding plants. Sugar cane in particular is typically grown in locations experiencing high levels of evaporation. As such, its thirst for water requires the use of irrigation in regions where water is a precious commodity.

Sugar cane is often grown in areas where access to infrastructure may be limited and aging equipment unsafe. With energy prices rising to record levels in recent years, farmers must maximize production efficiency without endangering workers’ safety.

ABB can deliver significant benefits to sugar farmers as well as the equipment manufacturers and system integrators that supply them. Our drive, motor and PLC solutions supported by our service solutions help farmers and raw ingredient producers ensure quality and consistency across their operations, while tackling today’s sustainability challenges and keeping personnel safe.

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Energy efficient sugar processing

Many sugar processing plants and refineries are decades old, with aging machinery that’s less efficient and reliable than modern equivalents. Assets are rarely optimized for the digital extraction of process data, making it difficult to get an accurate picture of how equipment is performing. 

Plants frequently run 24/7 during harvest time, followed by quiet periods. These intense operating cycles lead to machinery aging faster and putting production at risk. Environmental conditions in tropical and subtropical regions can be tough on mechanical and electrical equipment, while accumulated dust can create explosion risks. Sugar plants are often located close to farming areas where the electricity network can be weak, heightening the risk of equipment performing inefficiently or malfunctioning.

ABB products are designed to meet the demanding needs of sugar production processes. From ATEX motors and energy saving drives to advanced PLCs, ABB can help sugar producers improve the sustainability, reliability and safety of their operations.

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Logistics and storage

Large quantities of sugar pose a serious explosion risk to workers, with dust build-ups caused by outdated equipment and production methods exacerbated by poor ventilation. Running ventilation systems and conveyors 24/7 during production cycles uses large amounts of electrical energy. Failure of these systems can lead to expensive plant downtime and lost production. 

Energy-efficient motors by ABB can deliver significant cost savings. Reliable, high- performance drives and PLCs ensure seamless operation of conveyors and air handling units, reducing wear and tear on components. Our digital remote monitoring services can also help detect potential faults before they turn into failures, ensuring assets stay in good health and keeping unwanted downtime to a minimum. 

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Materials

White paper: How to make sugar production more productive and sustainable using variable speed drives

ABB drives and motors to ensure energy efficiency at the world’s biggest beet sugar factory

Energy-saving variable-speed drives and efficient permanent magnet motors will help Canal Sugar to reduce energy consumption at its world-class factory in Egypt.

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A sugar-sweet start

The Nordzucker AG factory in Uelzen has been the first site in Germany where ACS880-17 regenerative drives control batch centrifuges. The braking energy of the motors is fed through these regenerative devices back into the grid. The FSO-12 safety-function module ensures high safety.

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