Carbonatation control that lowers energy use

Purification is often considered the heart of the sugar manufacturing process. It defines the quality of the thin juice and directly influences the efficiency of crystallisation. Yet it is also one of the largest consumers of energy and raw materials, including lime and coke.

With fluctuating raw juice quality, manual control of carbonatation becomes challenging. Operators commonly overdose milk of lime or overheat juice to maintain flocculation, which leads to avoidable energy loss and higher operating costs.

Sensing the Invisible

Reducing energy consumption starts with visibility. You cannot control what you cannot measure in real time.
Sucrosphere is currently deploying a suite of sensors built specifically for the purification stage.

NIR Sensors

Continuous monitoring of raw juice, thin juice, and thick juice parameters enables operators to maintain process stability and consistency.

Flocculation Quality Sensors

Currently in development, these sensors assess flocculation quality directly rather than relying on operator estimation. This allows precise dosing of flocculation aids and significantly reduces overconsumption.

These tools provide the immediate data required to stabilise quality and minimise energy waste.

The Road to MPC (2026)

While enhanced sensing already supports better control, it also forms the foundation for full automation.

Sucrosphere’s Purification MPC is scheduled for release in 2026. It will use real-time KPIs from the sensor suite to autonomously manage:

• Temperature profiles

• Lime dosage

• Flocculation stability

By continuously optimising the carbonatation process, the MPC ensures the lowest possible energy consumption while consistently delivering high-quality juice to the evaporators.

Preparing for the Automated Sugar House

Stabilising your carbonatation process today with high-quality data is the most effective way to prepare for the fully automated sugar house of tomorrow.
With the right sensors, the right KPIs, and the right control strategy, purification shifts from a judgment-based operation to a predictable, energy-efficient, data-driven process.