Sugar refinery plant

Types of sugar refinery plants

A sugar refinery plant is a manufacturing facility that processes raw sugar into refined sugar for sale in domestic and international markets. Several types of sugar refinery plants exist to produce different kinds of sugar and supply various markets worldwide. They can be classified based on their production capacities, the types of sugar they refine, the technology used, and the plant's scale.

• By production capacity: The small-scale sugar refinery has a capacity of about 100 to 200 metric tonnes per year. It operates mainly to fulfill the local market demand. Intermediate sugar refineries have a production capacity of about 30, 000 to 50, 000 metric tonnes per year. It is well-equipped to satisfy the demand of an entire country or a vast geographical area. A large-scale sugar refinery has an annual production capacity of about 300, 000 metric tonnes per year. It is capable of processing large quantities of raw sugar to produce enormous volumes of refined sugar to cater to international markets.
• By the kind of sugar refined: A sugar beet refinery plant processes sugar extracted from sugar beets, removing impurities and converting the juice into crystallized sugar. A cane sugar refinery plant does the same for cane sugar. A cane-sugar refinery plant can also refine decolorized sugar (semi-refined sugar) for direct consumption.
• By technology used: A sugar refinery using a liquid ion exchange technique is an integrated sugar processing plant that can produce high-quality sugar. Liquid ion exchange refers to the solution-based extraction and separation of certain chemical ions using polymeric materials. Alternatively, some sugar refinery plants use other chemical processes to purify refined sugar.
• By scale: An industrial-scale sugar refinery operates in an area of over 10, 000 square meters and uses extensive commercial sugar production technologies. Industrial-scale sugar refineries produce sugar to be commercialized and sold in supermarkets, retail stores, and wholesale distributors. An artisanal sugar refinery is a small processing facility that produces specialty sugars for niche markets, gourmet foods, or local consumption. These refineries often prioritize traditional methods and may focus on organic or sustainable practices.

Specifications and Maintenance

Specifications

• Plant Capacity:

  The amount of raw sugar that the refinery plant can process in a given time period, usually expressed in tons per day or per hour.

• Degree of Refining:

  Sugar refinery plants can refine sugar to different levels of purity and whiteness. Some plants may aim for sugar with maximum purity and minimal coloration, while others may produce sugar with a lower degree of refinement.

• Product Range:

  The types of refined sugar produced by a refinery plant, such as granulated sugar, powdered sugar, crystalline sugar, etc.

• Processing Technology:

  The methods used to refine sugar, such as physical processes like crystallization and centrifugation, or chemical methods like carbonatation or phosphatation.

• Equipment and Machinery:

  The types of equipment used for sugar refining, such as dissolvers, filters, evaporators, crystallizers, centrifuges, dryers, etc.

• Quality Standards:

  The sugar refinery plants must meet specific quality standards, such as ISO certification, food safety regulations, and sugar quality criteria.

Maintenance

To keep a sugar refinery plant running smoothly, timely and effective maintenance is crucial. Below are some general maintenance suggestions for sugar refinery plants, which should be adapted to the specific models and conditions of the plants based on their manufacturers' instructions.

• Regular Inspection and Monitoring:

  Inspect the key parts, equipment, and pipelines of the sugar refinery plant regularly to check for issues like wear, leakage, or loose connections. Monitor the operating status, temperatures, pressures, flow rates, etc. of critical components to ensure they are within the normal range. Timely address any abnormalities that arise.

• Cleaning and Degreasing:

  Periodically clean and degrease the whole sugar refinery plant, especially its key parts and air and water pipelines. This helps to remove dirt, grease, and other contaminants to maintain the hygiene and operational efficiency of the equipment.

• Lubrication Maintenance:

  Perform lubrication maintenance on the movable parts of the sugar refinery plant, such as bearings, gears, and chains. Apply the appropriate lubricating grease or oil according to the equipment manual to reduce friction and wear between components and enable smooth operation.

• Maintenance and Replacement of Wearing Parts:

  Wearing parts, such as screens, filters, and pumps, sustain constant friction and may experience gradual wear over time. Periodically check these parts to replace them when they show signs of damage or wear to ensure the stable operation of the entire equipment.

• Equipment Calibration:

  Regularly calibrate and adjust the key control instruments of the sugar refinery plant, such as pressure gauges, temperature controllers, and flowmeters, to ensure their accurate measurement and control.

• Pay Attention to Safety:

  Ensure compliance with safety standards and regulations during maintenance operations. Wear appropriate safety equipment and tools and properly handle and store materials and waste. Maintain a clean and safe work environment.

Scenarios of a sugar refinery plant

• Production of refined sugar for food and beverage industry:

  Sugar refinery plants are primarily used to produce refined sugar, which is an essential ingredient in the food and beverage industry. The process involves the use of a sugar refinery factory from raw sugar to white sugar that is free of impurities and has a consistent quality. Refined sugar is widely used in the production of soft drinks, baked goods, jams, sauces, and other food products.

• Export of refined sugar:

  The global demand for refined sugar continues to grow, leading to opportunities for exporting sugar refinery plants. Countries with a high production capacity of sugar cane and sugar beets often invest in sugar refinery plants to process raw sugar into refined sugar for export to international markets. Refined sugar is highly sought after in countries that have limited production capabilities of sugar crops. The sugar refinery plants are used to produce sugar for export, generating significant revenue for the country.

• Production of by-products:

  In addition to producing refined sugar, sugar refinery plants also have the potential to generate several by-products from the sugar refining process. These by-products include molasses, refined sugar, treacle, and ethanol, among others. Molasses is a viscous by-product of sugar extraction, and it is used in the production of animal feed, distilleries, and other industrial applications. Sugar refinery plants also produce treacle, which is used in the production of confectionery, baked goods, and other food products. Furthermore, sugar can be fermented to produce ethanol, which is then utilized in the manufacturing of alcoholic beverages, solvents, and biofuels. As a result, sugar refinery facilities are a reliable supply of raw materials for numerous sectors.

• Production of high fructose corn syrup:

  Fructose corn syrup, which is created from sugars in maize, is one of the significant items that sugar refinery facilities can manufacture. Refined sugars like glucose and fructose are present in high quantities in high fructose corn syrup, making it an appealing sugar substitute. With its similar sweetness profile to sucrose, high fructose corn syrup is primarily utilized as a sugar substitute in the production of soft drinks, fruit juices, and other processed food products.

How to choose sugar refinery plants

• Understand the market demand:

  First, it's essential to analyze the local and regional market demands. Consider the capacity required, the types of sugar that consumers demand, and the potential for future market expansion.

• Selecting the right type:

  Several models of sugar refinery plants are available. Here are some of the most popular ones:

  Bulk sugar refinery plant: It processes large amounts of sugar and is ideal for producing granulated sugar in massive quantities. The plant typically has a significant production capacity and is designed to handle large volumes of raw materials efficiently.

  Mini sugar refinery plant: It is suitable for producing specialty refined sugars such as white sugar, golden sugar, and brown sugar. The production capacity is relatively lower than that of bulk sugar refineries. However, it can offer more flexibility in processing various sugar types.

  Integrated sugar refinery and distillery plants: It can produce refined sugar and alcoholic beverages such as ethanol or industrial alcohol. These plants typically have distillation units that can process sugarcane molasses into ethanol, providing an additional source of revenue for the refinery.

• Adequate supply of raw materials:

  Ensure a stable and sufficient supply of raw materials, like raw sugar or sugarcane, for the refinery's operations. Establish strong relationships with suppliers to maintain consistency and quality in the sourcing of raw materials.

• Considering the technology:

  Focus on advanced refining techniques, such as decolorization and deodorization, to produce high-quality refined sugar. Moreover, select plants that utilize energy-efficient processes and sustainable practices, such as using waste heat recovery and integrated bioenergy systems, to minimize environmental impact and reduce operating costs.

• Cost:

  When choosing a sugar refinery plant, it's essential to consider its purchase cost, installation and commissioning expenses, operating and maintenance costs, and energy consumption and utility expenses. Striking a balance between the cost and quality of the plant is crucial.

Q&A

Q: What material is used to manufacture sugar refinery equipment?

A: Various materials like stainless steel, carbon steel, cast iron, alloy steel, and plastic are used to make different pieces of sugar refinery machinery. Stainless steel is frequently utilized in food-grade sugar refinery equipment because it is strong, will not rust, and is easy to clean. Parts that are not rustable, like machine bases, are made of cast iron.

Q: What is the trend in the sugar refinery equipment market?

A: The global sugar refinery equipment market size was valued at $5.8 billion in 2021 and is projected to reach $10.4 billion by 2031, registering a CAGR of 6.1% during the forecast period.

Q: What is the difference between a sugar refinery and a sugar mill?

A: A sugar mill produces raw sugar from sugar beets or sugarcane, while a sugar refinery processes the raw sugar into refined white sugar.

Q: Do buyers need a license to purchase sugar refinery plant equipment?

A: Usually, individuals or businesses do not need a license to purchase sugar refinery equipment. However, they may need to comply with certain regulatory standards and obtain licenses for refinery operations.