Terms and explanations

Introduction to the main types of technologies Conventional technology This technology of sugar production is most common on continents, in countries and regions where climatic conditions allow growing and processing sugar beets. First stage - removing stones and metal things, removing leaf residues, washing and slicing of the sugar-beets into slices are the initial operations. The second stage - in this process, the juice is extracted from the sliced sugar beet. This happens in a diffusion plant, where beet chips are washed with hot water to extract sugar. The resulting juice is fed for further processing for produce sugar, and the pulp enters the presses, where the remaining juice is removed, and then to the drying plant, where the pulp is dried. Later, feed pellets are produced from the dried pulp. The third stage - is the purification of beet juice. Lime milk and CO² are used to purify the juice. Limestone is used to produce CaO and CO². The use of lime in the usual process is about 2% of the mass of beets. Sometimes, depending on the quality of lime, this value can be about 3%. It is a direct dependence on the amount of sugar beet. The classical purification of beet juice consists of liming, carbonation, sediment separation and sulfidization. However, this process does not remove all non-sugars (proteins, pectins, inorganic salts and coloring substances) from sugar juice. Fourth stage - is evaporation in multistage evaporators. At this stage, the juice partially thickens, but it is not yet suitable for sugar crystallization. Also, during evaporation, steam of lower pressure and temperature is obtained, which in the future will be used to control the crystallization process. The fifth stage - thickening and crystallization. Further evaporation of water leads to crystallize and growth of crystals. Stage six - the final sugar production process. As soon as crystals begin to appear, the concentrated syrup containing sugar crystals is centrifuged in several stages in centrifuges. The separated sugar crystals are dried with hot air in drum dryers and sieved. The resulting granulated sugar enters the warehouse or packaging workshop. Since it is impossible to extract all the sugar, when the crystals are separated from the concentrated syrup, a viscous liquid is obtained - beet molasses (molasses). Molasses is subject to desaccharification, and this requires additional equipment that allows you to extract 20-45% of sugar from it. Main by-products: In addition to the main product, most high-performance sugar factories also produce a wide range of other products from by-products such as beet pulp and molasses. Sugar beet pulp in combination with a biologically based polymer, polylactic acid, forms polymer composites that have tensile properties similar to those of commercial plastics and have a very wide range of applications. The pulp can be plasticized and used as a copolymer. From beet pulp, it is also possible to produce pectin, which is widely used in pharmaceuticals, cooking and confectionery. Molasses is used to produce betaine, which is also known as trimethylglycine or glycine betaine. The yield of betaine is 3-8% of the weight of the produced by-product - molasses and is one of the most valuable sub-products in the production of sugar. Betaine is a good humidifier and osmoprotector, which is why it is used for the production of perfumes, and because of some unique properties as a medicinal product in medicine. Ion exchange technology Ion exchange processes have provided significant assistance in the production of sugar from sugarcane and raw sugar to reduce scale formation in evaporators and other heat exchange equipment. Similarly, ion-exchange bleachers are useful for the production of high-quality consumer sugar. IER (Ion Exchange Resin) bleaching plants are quite compact, fully automated and very flexible in use. The spread of this technology largely depends on the local situation and the prices of ion exchange resins. The best effect can be achieved in combination with active granular coal (GAC) filters. Since IER and GAC differ in adsorption characteristics, they are used together for maximum bleaching efficiency. Some sugar mills use both technologies based on an updated cost/efficiency estimate on a case-by-case basis. This technology also has disadvantages. One of them is the price of resins and the necessary equipment for the recovery (purification) of ion-exchange resins. Filtration by ceramic membrane filters The membrane filtration technology in sugar production is attractive because it allows eliminating the use of chemicals as lime, carbon dioxide and sulphur, producing high-quality sugar and obtaining various sub-products with high added value and also allows for a 25-40% reduction in the size of service personnel and save up to 35% of energy resources. Membrane filtration has attracted due to its high impurity and color pigments removal efficiency, energy-efficiency, ease of operation, and small square of workshop. In the process of the purification, clarification and discoloration operations removing non-sugars impurities, including suspended solids, colloids, salts, and pigments, to ultimately obtain a brilliant, light coloured and transparent sugar. Thanks to the use of multi-stage cascade filtration, the degree of sucrose extraction from sugar beet reaches 99-99.8%. In this way, depleted molasses is obtained, in which the proportion of sugar reaches only 0.2-0.7%. Steps such as microfiltration of sugar juice using microfiltration membrane filters, discoloration of sugar juice using ultrafiltration membrane filters and concentration of sugar juice based on water extraction using nanofiltration or reverse osmosis membrane filters also make it possible to reduce or eliminate part of the some conventional equipment, which significantly reduces investment.

Features Exceptional properties - Organic sugar is sugar in the production of which chemical substances harmful to the environment and to humans and their compounds present in traditional sugar production are not used. Compared to regular sugar, organic sugar has a rich taste and the absence of chemicals, containing a lot of nutrients, vitamins and minerals. Interpretation errors - In fact, all sugar, except artificial, is organic, but it can only be called that because it is of natural origin. Pure organic sugar differs from ordinary sugar in that its production does not use fossil and industrial chemicals such as lime, carbon dioxide, sulfur dioxide or sulfur itself. Thus, the resulting sugar does not contain additional chemicals that are not removed during the production process. As a result - organic sugar is sugar that is produced without the use of chemicals.

Features Exceptional properties - Ecological sugar is a particularly pure sugar that is produced only from raw materials grown in farms that adhere to strict standards of ecological agriculture and in the processing of which chemical substances and their compounds present in traditional sugar production that are harmful to the environment and humans are not used. Compared to ordinary sugar, ecological sugar has a rich taste and no traces of pesticides, as well as chemicals, while containing a lot of nutrients, vitamins and minerals. Interpretation errors - Ecological sugar is often confused with organic sugar. Ecological sugar can be produced only from ecological raw materials, in the cultivation of which pesticides and mineral fertilizers were not used and the farms themselves are located away from industry and other sources of pollution. It is impossible to produce ecological sugar from raw materials grown in non-ecological farms, since pesticides and traces of fertilizers are not removed. As a result, ecological sugar is produced exclusively from environmentally friendly raw materials.

The main stages of production Overview There are several different technologies for the production of sugar. With what different technological solutions they just did not exist and for the processing of what raw materials they were not intended, the structure of the plant does not change. Different technological units, i.e. equipment and its characteristics, may change or be absent. There are many technological stages involved in the production of sugar, but basically they can be divided into eight parts: 1. Acceptance of raw materials and its primary processing 2. Production of intermediate raw materials (sugar solution) 3. Processing of intermediate raw materials (purification and thickening) 4. Crystallization 5. Separation (centrifugation) 6. Drying of sugar crystals 7. Sifting 8. Warehousing and packing Production expansion - The processing of by-products and the production of sub-products is an additional expansion of production, since it practically does not affect the main sugar production. When processing different raw materials, different by-products are also formed. When processing cane, bagasse (cane pulp) is obtained as a by-product, and molasses is obtained when processing sugar beet. These different by-products are processed in different ways, and sometimes they are not processed at all, but are sold as they are. Processing of any raw materials using conventional technology has one thing in common, the by-product is molasses, which is subject to further processing, but whether it will be processed depends on the sales market and the decisions of the owner of the sugar factory. In the production of sugar using SUSEP technology, depleted molasses is obtained, i.e. without sugar in the composition and which is sold as an additive to feed or as fertilizers.

Difficulties and their elimination Sugar beet processing - Sugar production is special, as it directly depends not only on the processed type of raw materials, but also on its quality. The production itself is seasonal, since it is impossible to provide the plant with raw materials all year round, and it is technically difficult and even very expensive to store it. Moreover, with long storage, the raw material deteriorates, i.e. it loses its main property - sugar content. Moreover, for example, sugar beet is attacked by various insects and mold appears. Because of these reasons, sugar factories are designed for the sugar beet processing season, which lasts on average 90-120 days a year, after which it switches to the processing of secondary (additional) raw materials. In this way, the plant's operating season is extended to 10-11 months per year, minus planned and emergency stops for repairs, as well as preventive maintenance. Decisions - The provision of raw materials is the main concern of all sugar factories. There are two simple solutions - to close the plant before the next sugar beet harvest or to process secondary (additional) raw materials. The first option is unprofitable, since workers need to be released on vacation and it is questionable whether they will wait for the next season or since they will find a new job during that time. Moreover, due to the shutdown of production, the temperature regime changes and the equipment deteriorates. The second option is the processing of secondary (additional) raw materials. This option is the most acceptable for most sugar factories. As the main additional raw material is raw cane sugar. By processing raw sugar, the plant's operating season is extended and jobs are saved. Processing of this raw material has its advantages and disadvantages. As an advantage, we can highlight the simplicity of transposting and storing raw materials, as well as the convenience of processing. The main disadvantages are the high market price of the raw materials themselves and high cost of sugar produced. Another solution is the processing of molasses. Such production can ensure the duration of production at a sugar factory up to 10-11 months a year and save jobs. The disadvantages of such a technological model are the need for a separate workshop, expensive operation and an average efficiency result. Most sugar factories processing molasses operate on the basis of ion exchange technology, which is able to extract 15-25% of sugar from molasses. Due to such a low economic effect, many sugar producers refuse to process molasses using ion exchange technology, and molasses is sold for the production of yeast or alcohol. Modernization of the sugar factory is one of the solutions that allows to increase productivity and efficiency. In the fact that many entrepreneurs do not want to invest in updating the equipment that is still working, most sugar factories have been operating non-stop for 3-5 years until the planned overhaul, which is extended from the completion of sugar beet processing until the autumn of next year, i.e. until the next sugar beet harvest. The disadvantages of modernizing old-type plants are incompatibility with the latest technologies, the complexity and even the inability to modernize individual old equipment, as well as the complexity of dismantling old and installing new equipment. In most cases, it is easier to design and build a new modern sugar factory than to modernize the old one.

Models of sugar factories by production duration Short production cycle - This model of sugar production is most common among sugarcane processors in warm and tropical regions. The leaders in the cultivation and processing of this raw material are Brazil, India, China, Thailand, Pakistan, Mexico, Australia, Argentina, the Philippines and a number of countries in Africa. This season lasts 5-6 months. Most sugar producers in Central and South America do not produce the final product, but a semi-finished product. Thus, they optimize their production by processing huge amounts of raw materials, and the produced product - raw sugar is exported for further processing. The main buyers of raw sugar are sugar beet processing plants, which, after processing the main raw materials, process raw sugar. Extended production cycle - his model of sugar production is the main one among sugar beet processors. Since the sugar beet processing season is quite short and lasts only 3-4 months a year, almost all sugar factories compensate for the time interval between harvests by processing raw sugar, producing cane (brown) sugar, which by its nutritional properties is more valuable than beet sugar.

Raw materials Sugar beet - This is a biennial plant with large lush leaves and sweet roots. Contains 14-21% sucrose, 5% fiber, 1.5% nitrogenous substances. It is an important raw material for sugar production. Leaves, pulp and molasses are used as feed. During the processing of beet pulp, pectin is obtained, and during the processing of molasses, sugar and betaine are additionally extracted. About 165 kg of sugar is obtained from 1 ton of sugar beets. The yield of sugar depends on the sugar content of the roots, i.e. on the amount of sugar as a percentage of the mass of beets, which can range from 14% to 21%, depending on the growing region, soil and sugar beet variety. Cane raw sugar - This is cane sugar that has undergone minimal processing. In all cases, raw sugar is a product of the first stage of the cane sugar producing process, and as a result it has some very characteristic characteristics like specific color and impurities. In principle, raw sugar is dried sugar cane juice containing sucrose crystals mixed with molasses and many additional components of cane juice, such as inverted sugars (glucose and fructose), minerals, vitamins, organic acids and trace elements. This sugar is also known as ICUMSA 600-1500. It is very important that in all countries the price of raw cane sugar is calculated based on the average sucrose content of 96% (PS - polarimetric sucrose). CLASSIFICATION: VHP - Brown raw sugar (very high polarity) with sucrose content of at least 99.3-99.4%. VVHP - Brown raw sugar (very-very high polarity) with sucrose content of more than 99.5% and lightness. HP - Brown raw sugar (high polarity). The sucrose content ranges from 98% to 99.3%. Contains few impurities) LP - Brown raw sugar (low polarity). Raw sugar with a sucrose content of less than 98%. Molasses - In the process of sugar production, the juice extracted from sugar beet is boiled until the sugar crystallizes and precipitates. The syrup remaining after crystallization is called molasses. As a rule, sugar sugar beet juice goes through three cycles of boiling and crystallization to extract as much sugar as possible. With each subsequent cycle, the remaining molasses contains less and less sugar. Molasses can vary in color, sweetness and nutritional value depending on the variety or amount of extracted sugar. Although sugar beet juice goes through three cycles of boiling and crystallization, conventional sugar production technology is not able to extract all the sugar from it. Such sugar is called direct polarization sugar. The sugar content in molasses averages from 36% to 52%, and sometimes reaches even 60% of the total weight of molasses. More modern technologies are used to extract the remaining sugar. To extract such sugar, ion exchange technology or membrane filtration technology is most often used. CHARACTERISTICS OF BEET MOLASSES: 1. Dry substances: min. 75% 2. Sucrose (by direct polarization): 36-52% 3. Invert sugar (fructose and glucose): no more than 2.5% 4. Conductometric ash: min. 9% 5. Sulfites and sulfur dioxide: not more than 0.1% 6. Calcium and magnesium salts: not more than 1.0%. 7. Volatile acids, such as acetic acid: not more than 0.8% We draw attention to the fact that sugar-containing molasses is obtained only in the production of sugar using classical technology, and the characteristics of beet molasses depend on the quality and condition of the equipment and even the actions of the plant's technologists. When sugar is produced by processing sugar beets using SUSEP technology, only depleted molasses is obtained, i.e. without sugar in the composition. Corn syrup - Syrup is obtained by hydrolysis of corn starch solution. It is also called high fructose corn syrup (HFCS). Various forms of corn syrup contain from 42 to 55 percent fructose. In terms of taste, HFCS is similar to sugar, although HFCS is slightly sweeter. Scientists measured the relative sweetness of natural and artificial sweeteners and found that HFCS is 1.5 times sweeter than table sugar, and also increases the tendency to obesity, as a result of which sugar obtained from corn is not widely distributed, except in Asian countries. The production of sugar from HFCS is also unattractive, since corn must first be processed into syrup, which requires a separate plant and appropriate investments.

White sugar White beet sugar - The main product is white beet sugar. Since no chemicals are used in the production of SUSEP technology, such sugar meets all the standards of organic sugar. Thanks to the membrane purification of beet juice, in fact all impurities is removed even before the crystallization process, and the refining stage plays only a symbolic role. The centrifugation process performs the function of "purification of the purified", since beet juice is purified from pigments, salts, odors, etc. by passing bi-ceramic membrane filters. High quality meets the requirements of the European food legislation (EU Grade II) and ICUMSA 45. SPECIFICATION: Color: the interval between ICUMSA-25 and ICUMSA-45 Polarization: min. 99.9% degree polarization Size of crystals: 0.40 - 0.80 mm Moisture: max. 0.04% by weight Invert sugar: max. 0.03% by weight Ash content: max. 0% by weight Solubility: 100% SO²: 0% Sediments: 0% Smell: free of any smell White cane sugar - This sugar is produced by processing raw cane sugar or cane molasses. Thanks to SUSEP technology, specific pigments are removed, but all the useful and characteristic properties of cane sugar remain. The sugar quality meets the requirements of the European food legislation (EU Grade II) and ICUMSA 45. SPECIFICATION: Color: the interval between ICUMSA-45 and ICUMSA-100 Polarization: min. 99.8% degree polarization Size of crystals: 0.40 - 0.80 mm Moisture: max. 0.04% by weight Invert sugar: max. 0.03% by weight Ash content: max. 0% by weight Solubility: 100% SO²: 0% Sediments: 0% Smell: free of any smell None: Sugar beet has a lower molecular weight of dyes, a lower content of polysaccharides and has dyes mainly consisting of products of alkaline decomposition of invert sugar, which distinguish the coloring matter of beet from the coloring matter of sugar cane. Because of these properties, the sugar class is also different. However, both types of sugar produced by SUSEP technology comply with the ICUMSA 25-45 standard, but according to internationally recognized standards it is classified as ICUMSA 45. Although ICUMSA is a fairly reliable means of determining the quality of sugar, it should be noted that the above classification system is based on the so-called Brazilian standard SGS ICUMSA. In this system, ICUMSA 45 is considered the purest form of sugar, and the higher the numbers, the less refined the sugar. However, the European system is different, and in some cases sugar can be described as ICUMSA 42 rather than ICUMSA 45. The same applies to other sugar classes according to the ICUMSA classification.

The main by-products of sugar beet processing Sugar beet pulp - (SPB) is a wet slices of sugar beet. Since its yield during sugar beet processing is very high, it is considered the main by-product of sugar production. In terms of cost, although it is not the most expensive by-product, it has a very wide range of applications, both fresh and dry. The yield of wet SPB coming out of the diffusion apparatus is 70... 83% by weight of processed beets. The humidity of fresh SPB is in the range of 92...95%. SPB is rich in carbohydrate polymers and other minor components. Wet SPB can be used directly after pressing (40-55% dry matter) or dried to a content of 81-85% dry matter. As a feed, can be used fresh and dry too. With large volumes of sugar beet processing, it is advisable to produce pectin and other products from SPB. Dry SPB with a humidity of 15-20% chemically consists of cellulose (22-30%), hemicellulose (24-32%) and pectin (15-32%) with a small amount of protein (10-11%), as well as lignin (3-6%), ash (about 3.7%) and fat (about 1.4%). The composition of SPB strongly depends on the variety and quality of sugar beet, as well as on the technological equipment. Molasses - is a syrupy by-product obtained after sugar crystallization from concentrated sugar juice extracted from sugar beet roots. The yield of molasses from 1 ton of processed sugar beet by conventional technology reaches 4.3-4.8% (43-48 kg). Molasses (molasses) is the most valuable by-product of sugar production and has a very wide range of applications. Molasses is the main cheese for the production of confectionery yeast, as well as for the production of high-quality alcohol. In addition to direct use, it is suitable for further processing. Basically, there are two types of molasses - beetroot and cane. The first is obtained by processing sugar beet, and the second by processing of sugar cane or raw cane sugar. The value of molasses is also attached to the fact that most sugar factories are not able to extract all the sugar from the utfel during the refining process, which enters the by-product - molasses. The sugar in the molasses is called sugar by direct polarization, and its share of the total weight of molasses is in the range of 36% to 52%, and in some cases, depending on the condition of the equipment of the sugar factory and the production process, this figure can reach even 60%. To reduce the proportion of such sugar in molasses, ion exchange technology or membrane filtration is used. In addition to sugar, molasses contains many other valuable substances, such as various minerals, vitamins, amino acids and more. Molasses is also one of the most valuable sources for the production of organic betaine, which is widely used as a drug and food additive. SPECIFICATION: Dry matter content: 73-85% The mass fraction of sugar by direct polarization: 36-52% (average 48%) Reducing substances: 0.2-2.5% Raffinose: 0.6-1.4% Nitrogenous substances: 1.5-2% Betaine: 4-8% Lactic acid: 4-6% Acetic and formic acids: 0.2-0.5% Conductometric ash: 6-11% Purity: 56-62% Viscosity: 4-8 Pa at 40°C pH: 6-8 Density: 1400-1475 kg/m³ None: SUSEP membrane filtration allows you to isolate all sugar from beet juice (99.5-99.8%), resulting in the formation of a by-product - depleted molasses. Since SUSEP filtration is used to purify beet juice even before evaporation, only sucrose crystals and desaccharified intercrystalline solution are formed during the crystallization process, which also lacks non-sugars. Thus, SUSEP technology is able to reduce the proportion of sugar in depleted molasses to 0.2-0.7% of its total weight.

Most popular sub-products Cellulose - is a polydisperse polymer with a high molecular weight. Since the lignocellulose fraction of dried sugar beet pulp contains 22-30% cellulose, sugar beet pulp is known as one of the sources of cellulose. The production of pulp from beet pulp does not have a huge distribution, since it is economically advantageous to process only very large volumes of raw materials, and the production of pulp complicates the separation of other sub-products from beet pulp. At the price of the sub-product itself, its extraction is often not even profitable, since it prevent the opportunity to reducing more valuable sub-products. Pectin - is one of the most popular by-products of sugar production from sugar beet. It is used in dessert fillings, sweets, medicines, as a stabilizer of fruit juices and milk drinks, as a source of dietary fiber, as well as as a stabilizer in parfumeria. According to economic calculations, the production of sub-product like pectin in factories with a capacity of less than 7.000-10.000 tons per day for raw materials is not advisable, as it requires large investments, and the price of the products produced is quite low.. Many sugar factories are limited only to the production of feed pellets. Betaine - is a valuable compound that is used in animal feed, as well as for pharmaceutical and cosmetic purposes. It is a natural amino acid compound, also known as trimethylglycine. There is enough of it in molasses, a byproduct of sugar production. Beet molasses can contain 3-12% betaine by volume of sugar beet molasses (usually 4-8%), and sometimes even more. According to economic calculations, the production of sub-products like betaine in factories with a capacity of less than 7.000-10.000 tons per day for raw materials is not advisable, as it requires large investments, and the price of the products produced is quite low. Many sugar factories are limited only to the sale of molasses to factories producing confectionery yeast, alcohol or same betaine.

Waste from sugar production Primary processing of sugar beets - In this technological process, sugar beets are washed with a large amount of water, which then enters a drum-rotor filter, where remnants of roots and leaves are separated. The remains of leaves and roots are suitable for use as fertilizers. The washing water after the drum-rotor filter enters the settling tank, from which the sediment deposited in the precipitator enters the belt filter press to remove water. The drained mass is suitable for returning to the fields, as it does not contain any foreign impurities, with the exception of soil residues (peat, sand, clay) removed from beets. The water itself, after purification and filtration, is fed back to the production for further washing of sugar beet. Thus, the water for washing sugar beet circulates in a closed circle, and the excess leaves, roots and soil are returned back to the fields. This technological process is absolutely waste-free. Raw sugar for the production of sugar is dissolved in hot water, and low-pressure and low-temperature steam is also used to accelerate this process. The approximate total consumption of water and steam is about five times the weight of the raw material (ratio 5:1). The amount of water used may vary, since the concentration of solids dissolved in the solution must comply with established technological standards. Since all the water and steam used in the process are components of the sugar solution being prepared, the process itself does not contain industrial waste. Molasses, like raw sugar, is dissolved in hot water for the production of sugar, and low-pressure and low-temperature steam is also used to accelerate this process. The approximate total consumption of water and steam is about five times more than the weight of the raw material (ratio 5:1). The amount of water and steam used may vary, since the concentration of molasses solids dissolved in the solution must comply with established technological standards. Since all the water and steam used in the process are components of the sugar solution being prepared, this process does not contain industrial waste. Filtration and sugar separation of beet juice or sugar-containing solution on SUSEP membrane filters takes place using water. High-pressure water is used only for flushing filter elements. During filtration, the released non-sugars in the form of a solution, as well as the water used for washing the filter elements, enter the buffer tank, from which they subsequently enter the evaporator for partial condensation and at the final stage are mixed with beet pulp or enter the technological equipment for the production of betaine. In the process, only two intermediate solutions are obtained - a solution with sugars and a solution with non-sugars. This process is waste-free. Evaporation of beet juice or sugar-containing solution consists of evaporation in evaporators and crystallizers. In evaporators, with the help of vacuum, which accelerates this process, helping to evaporate water from the sugar-containing solution, as well as steam, which is used for boiling it, the sugar-containing solution partially thickens. The thickened sugar-containing solution, also called syrup, enters the crystallizers. In crystallizers, sugar-containing syrup, when heated, passes into the crystallization stage, at which intact sugar molecules are arranged in a certain repeating order and an intercrystalline solution appears. The resulting viscous mass consisting of sugar crystals and an intercrystalline solution is called utfel. At the final stage, the wafer enters centrifuges to separate sugar crystals from an intercrystalline solution, the so-called molasses. Only steam is used in the evaporation and crystallization processes. The used steam (secondary steam) is later sent to condensers for cooling, cleaning and return to the steam boiler. Water in the processes of evaporation and crystallization is used in a closed circle in the form of steam. This process is waste-free. Summarizing - the entire production process of sugar production using SUSEP technology, regardless of the processed raw materials, is completely waste-free, since the main resource is water circulating in a closed circle, chemicals are not used in production, and all by-products are completely processed.

The main costs of sugar production Direct costs consist of the cost of raw materials, prices and consumption of energy resources, taxes, as well as a component of employees' wages. Such expenses are directly affected by the economic situation in the country, the productivity of the sugar factory, as well as the market for products. Each option should be considered individually. Additional expenses consist of expenses that do not directly affect the production itself and its quality. Such expenses include the costs of packaging, the type of packaging and the transportation of products. Also, such expenses include the transportation of by-products and sub-products. All these production costs for the cost of production have no effect, since the buyer pays for the packaging and the type of packaging, and transportation. Regarding logistics, both the manufacturer and the buyer the cost of transportation can agree.

What does the profitability of a sugar factory really mean? The profitability of a sugar factory depends on many factors. The key factors are the cost of raw materials, energy consumption and installed capacity of the sugar factory. Direct costs, such as wages and energy, can still be adjusted by optimizing the functions of the workforce and automating more production processes. As for the prices of purchased raw materials and products sold, everything is much more complicated here, since local and foreign markets mainly influence here. The installed capacity of the sugar factory affects the volume of products produced per day. Theoretically, the higher the productivity of a sugar factory, the higher its profitability, but again, there should also be a very clear assessment and balance, since any productivity is limited by the market. Increase profitability can in few ways. One of them is that it is necessary to clearly defined the direction of marketing, i.e. choose a model that best matches the ability to sell products. It is necessary to clearly determine which type of packaging is most suitable. Here we mean the type of packaging of product, which can be either wholesale packaging as big bags or bags of 50 kg, or small retail packaging in weighing 1-2 kg or even "sticks" of 3 or 5 grams. In fact also affects which shares of the total volume of products will be packaged on different types of packaging. It is also very important to optimally distribute the processing time of various types of raw materials. Profitability will be low if the secondary raw materials are processed for only 2-4 months. The optimal solution is to processing additional raw materials as long as possible.

Market analysis and opportunity assessment First steps are to analyze the market, technical capabilities, i.e. energy resources, communications, and conduct a general economic assessment. The main step at the moment is market analysis, since in the absence of a market for products, further actions lose all meaning. It makes sense to choose the location of a sugar factory that is planned to be built, with suitable communications and road communication, only knowing the possibilities of selling products and having technical characteristics, i.e. the needs of energy and other resources of technological equipment. The project requires clear and impeccable economic calculations, as they can give not only a general, but also an accurate idea of the planned business. During the technical and economic assessment, energy consumption, volumes of the main and by-products produced, costs and other parameters, as well as characteristics are clarified. With all this information, you can assess the feasibility of investments and the implementation of the project as a whole, and after receiving positive indicators, start developing a business plan. Feasibility study - (FS) is an analysis of any project, and in simple words, it is a package of calculations and analytical documents and conclusions containing both primary and initial data, as well as basic technical and organizational solutions, evaluation and other indicators that allow considering the feasibility and effectiveness of an investment project as a whole. It is also the main document for preparing any business plan. To prepare a business plan, you must first have a reasoned justification. Business plan - is a document that allows you to calculate the volume of investments and describes the prospects for the development of a sugar factory and includes a description of the current situation, market analysis, individual stages, production, profitability forecast, as well as expected opportunities and risks during the implementation of the project. The business plan should be justified by clear production characteristics of the planned production line and calculations. Financing can be different. The implementation of different projects requires different amounts of investment. If own funds are not enough, and in most cases it happens, since the construction of a sugar factory requires large investments, then investments will be required. To attract investments, it is necessary to prepare an impeccable business plan, because any investor wants to make sure of the expediency of their investments and see the profitability of future investments. Since sugar production belongs to the food industry and is closely related to agriculture, it is always necessary to analyze and verify the situation, as this may be a priority public sector that receives subsidies or benefits.

The main directions of production Agricultural direction of production includes the processing of sugar beet, which in most cases in many countries is priority, since it covers many sectors and is often supported by the state. Despite these advantages, this direction also has some disadvantages, such as dependence on crop quality, climatic conditions and even logistics. Direction of processing direction includes the processing of by-products and imported raw materials. The processing of local or imported raw materials ensures a longer and more stable production with the least influence of extraneous factors, covering both the processing of molasses and the processing of raw sugar. This direction also requires specific solutions, as well as additional investments in equipment, storage facilities or storage tanks for storing raw materials. Summarizing - each direction of production has its own advantages and needs to be evaluated separately, especially since the choice must correspond to the available technical and other capabilities. If we compare them both, they are partially similar in profitability. From an economic point of view, the best option is a universal direction, i.e. covering both directions, since it reduces various risks arising from the supply of raw materials, and also prolongs the production cycle of the plant as much as possible.

Turnkey services and solutions We offer a set of solutions covering both preparatory and executive work. Absolutely all work is carried out strictly in order, which saves time and thereby reduces the likelihood of any errors. The package of our services consists of successive stages, which are checked and agreed separately. This procedure of management, organization and quality control of the offered goods and services complies with the international standard ISO 9001. The order of work, including preparatory and executive work: 1. Drawing up a task 2. Market analysis 3. Specification of technical conditions 4. Ordering an offer 5. Additional specification of technical conditions 6. Development of a feasibility study 7. Preparation of a commercial offer 8. Clarification of tasks 9. Primary technical project 10. Carrying out initial estimate works 11. Conclusion of a design contract 12. Detailed technical design 13. Clarification of the estimate 14. Confirmation of project documentation 15. Conclusion of the General Agreement 16. Phased production, supply and installation of equipment 17. Commissioning and staff training 18. Commissioning 19. Training of personnel during production 20. Technical support and maintenance Stagedness of work performance covers each step of the project implementation. Production, delivery and installation of technological equipment can consist of 6-12 separate stages, depending on the selected production model, equipment configuration and design capacity of the sugar factory under construction. This order of work reduces the complexity and inconvenience in the supply of equipment, its storage on the construction site and installation. It is also a kind of insurance for the equipment supplies and the work performed, as paid for each stage separately. The principle of operation reduces financial risks for both the customer or investor, and for the contractor.

General information about the service life of technological equipment Equipment service life is designed for a service life of 15-25 years before major repairs, but depends on the type of processed raw materials, the duration of its processing, as well as on the production load. The main equipment has a service life of at least 15 years, as it is made exclusively of AISI 304 stainless steel, and some even of AISI 316. Such equipment includes various containers, evaporators, etc. Moving components and assemblies, such as mixers, gear motors, electric valves, belts and chains, have a service life in the range from 5 to 10 years, but it must be borne in mind that such a service life of these units and individual parts can only be achieved with proper operation and proper care for them. As for automation and control, these nodes and components can serve from 3 to 10 years, but it should be borne in mind that this does not apply to switching components with electromechanical contacts. In order to extend the service life of the equipment and individual components, it is always necessary to follow the rules and procedures of operation. Please note that the service life of the product should not be confused with the warranty period. The warranty period of service is different for each type of equipment and depends on the guarantees provided by the suppliers of individual components. In accordance with the rules of warranty service and guarantees, WESTTEX Group provides the following warranty periods: Not hidden jobs: 12 months Hidden jobs: 60 months Capacitive equipment (internal): 24 months Capacitive equipment (external): 60 months Installation materials and equipment: 12 months Automation and control systems: 12 months Moving and rotating components and assemblies: 12 months SUSEP filter elements: 24 months Different filter elements: 12 months Steam boilers: 24 months Generators and turbines: 12 months Packaging equipment: 12 months Other equipment and accessories: 12 months Note: The warranty period for each project and individual equipment is determined depending on the components. To extend the warranty period, we can offer equipment with components from other manufacturers, without changing the quality and functionality of the equipment itself, or insure products with an insurance company for a longer period.

Main types of maintenance Automatic maintenance is carried out using software and PLC. This type of maintenance is controlled by a computer in the central control center, which, using a given algorithm and remote PLCs, checks various signal sources, measuring instruments, protection and control circuits, etc. Information about the condition of the equipment in real time is displayed to the operator on the monitor, and the results of the work performed are stored in the database. The algorithm of automatic maintenance is determined by the manufacturer. Preventive maintenance, like automatic maintenance, can be performed using software and PLC, but also manually. Mechanical components and equipment are checked visually and with the help of measuring instruments, and automation and control units are checked with the help of special software and measuring instruments. Before prevention, the equipment is put into service mode, and the results of the work performed will be saved in the database. The service schedule is at the discretion of the technical staff. Periodic maintenance is carried out either in accordance with the procedure established by the manufacturer, or in accordance with the established internal procedure of the sugar factory itself. Periodic maintenance can be carried out with or without a production shutdown. During maintenance work, structural and mechanical parts of technological equipment are mainly checked, as well as detected malfunctions are eliminated. As a rule, such work covers only that part of the technological equipment that cannot be checked automatically, much less remotely. The frequency of such works is once every 2-3 months, the duration is from several hours to a day. Planned maintenance is carried out every 3-5 years and is intended for a full-scale inspection of all technological equipment, not excluding repair work. During this maintenance, the condition of the equipment is checked, and individual components are replaced or repaired. The duration of such works often requires from 1 to 3 months and is always planned in advance. The schedule and procedure for carrying out such work are established in accordance with the condition and service life of the equipment, as well as in accordance with the manufacturer's recommendations. It is very common to upgrade equipment during such work. Remote maintenance covers any remote diagnostics of technological equipment and its individual components. This type of service literally represents only remote monitoring and diagnostics, as it is carried out using the Internet. Diagnostic work consists of checking equipment without interfering with production, which means that when they are performed, production or its individual processes do not stop. For diagnostics, the Internet and the corresponding automation components are required, as well as a PLC, which plays the role of a diagnostic tool. Remote maintenance is carried out by the decision of the manufacturer or at the request of the client. Factory maintenance is designed to check and repair individual equipment and its components at the factory. In order to avoid interruptions and production stoppages, the customer must take care of the availability of appropriate components or components in the warehouse, which are removed from the equipment and sent to the manufacturer, and in exchange for the sent components are replaced with those available in stock. Such work is always initiated only by the client.

How long does it take to build a sugar factory? Terms of construction depends on the capacity of the sugar factory that is planned to be built, the production model, available communications, road communication, climatic conditions and even the time of year when construction is planned to begin. Since the construction of any sugar factory is a complex solution, it certainly requires complex preparatory work. Each sugar factory is designed individually, and thus the technological scheme is created only for a specific project. It is almost impossible to use a technical project from another object, since there are always more differences than coincidences due to different technical conditions. The construction period is set individually, but in total it is 20-24 months, and sometimes more. The general construction period covers the preparation of project documentation, production and supply of equipment, installation and even commissioning. Reduction of construction time before the start of production. One of them is to carry out all preparatory work until spring, or rather, until suitable conditions for performing land works appear. Another way is to choose a suitable model of a sugar factory. If a model is selected with the possibility of processing both sugar beet and additional raw materials, then you can focus on starting the processing of secondary raw materials in the first place, and leave the processing of sugar beet in the background. For example, the processing of molasses or raw sugar can be started in 14-16 months, and the rest of the equipment can be installed in the production process, i.e. for the reception and primary processing of sugar beet. The bottom line is that the amount of work on installing equipment for processing additional raw materials is less than for installing equipment for processing sugar beet. These solutions, in principle, do not reduce the total time required for construction, but allow you to start sugar production 8-10 months earlier, which, in turn, affects the payback period.

The cost of a sugar factory How much investment will be required to implement a sugar production project depends on a lot. Basically, it depends on the capacity of the planned sugar factory, as well as on the chosen model. Each option is unique due to the technical conditions and production requirements. Moreover, there are no fixed prices for such projects, since these are not general consumer goods. It is much easier to clarify the initial tasks, as well as the existing conditions for the implementation of such a project and contact us to get an approximate price. Knowing the approximate price will make it easier for you to make decisions, choosing the best option and planning a budget. Whether there will be discounts depends on the market prices for raw materials. The price of a sugar factory depends not only on technological solutions, but also on the quantity and configuration of equipment. The sugar factory is made of metal and metal structures, which make up 90-95% of the total volume of all equipment. Considering also the fact that most of the equipment is made of stainless steel, it is easy to understand that binding to world prices is inevitable. We always try to offer our customers only the best solutions and always recommend not to debug the decisions made, as metals are getting more expensive every year. The best discount is the timely start of construction, without waiting for the price to rise.

Is the sugar factory environmentally friendly? Eco-friendly production - Any sugar factory based on SUSEP technology is friendly to nature. Chemicals and their compounds are not used in production, and the only energy resources are electricity and natural or liquefied gas, which do not pollute the environment. By-products are processed without leaving waste, and water is used in a closed circle. By all indicators, sugar factories built on the basis of SUSEP technology are ecological and comply with the international standard ISO 14001. Certification - To certify a sugar factory, you will need to contact a government agency or a private certification company and apply for certification. This will also require existing production, as a complex of different measurements is carried out. Please note that the environmental certificate of production and the certificate of environmental products are different things.

Mistakes in business planning

Planning and documentation - The main mistake in planning the construction of a sugar factory is to deny the advantages of market analysis and economic calculations. Often, the decision on the implementation of a project is made only on the basis that the products will be produced and, as it were, automatically occupy a niche in the market. Not true. It should be taken into account that large competitors in the market always have the opportunity to reduce the prices of their products and thereby exclude you from the market. To avoid this, market analysis and full-scale economic calculations are required. After completing this preparatory work, you will be able to assess the flexibility and stability of your future business. Wrong choice of performance - Some entrepreneurs are looking for sugar factories "mini", "nano" or even container, that is, mobile execution. We are very sorry, but sugar factories of this type and especially of this design do not exist. This is a commercial deception or just a way to attract an interested businessman and lure money out of him. It is technically impossible to reduce a sugar factory to such size, and even more so to build it on the basis of modern advanced technologies. There are three main types of sugar factories by performance: Low performance: 50-500 tons per day for beet Medium performance: 1000-3000 tons per day for beet High performance: 5000-12000 tons per day for beet Attention: Plants with a capacity of less than 50 tons per day (by sugar beet) are designed for their own needs and are not subject to commercial sugar production. Choosing from the wrong end this is the choice of the productivity of a sugar factory with a fixed annual capacity of product. Such a choice is wrong, since the output of products depends on the sugar content in the raw material and it is never stable. Then it is simpler to focus on productivity with an average sugar content in the main raw material and try to produce the missing quantity of sugar, increasing the total processing time of additional raw materials. The plot is too small - The land area for a sugar factory depends on the planned production capacity and the selected model. The minimum land area for a sugar factory of "low" performance can be 3.5 - 5 hectares. For "medium" and "high" performance, 5-7 hectares or even more may be required. To build a factory in the courtyard of a private house certainly will not work. Lack of energy resources - The sugar factory needs continuous power supply, gas supply and water supply. This requires two separate power supply lines and two water sources, as well as a gas pipeline with an appropriate flow rate. One of the electrical lines is used as the main one, while the other remains a backup. Exceptions are possible at medium- or high-capacity plants when they are equipped with their own thermal power plants. The same applies to water supply. It is impossible to think that for such production there will be enough power of household electricity supply, gas and water flow rate. Poor road communication - Road communication is particularly important and affects not only the provision of raw materials, but also to realization of products. Poorly developed road infrastructure is the cause of huge traffic queues to the reception point at the sugar factory, but also complicates road communication near it. When choosing a site for a sugar factory, it is always necessary to evaluate the road infrastructure or agree that you will have to invest extra and build roads yourself. Misconception about construction deadlines - There are cases when entrepreneurs tell that they are offered to build a sugar factory in 6-8 months. If you are one of them and believe in it, then such a "manufacturer" or "supplier" has simply deceived you. It is impossible to build a sugar factory in such a short time, since it is not a consumer product, but a complex individual project consisting of many stages. Only one preparation of various technical and other documentation takes 2-4 months, and much more time is required for the production, delivery and installation of equipment! No manufacturer keeps "ready-made" sugar factories in stock, but only produces equipment to order. Only units of various equipment are stored in the warehouse, which are actually small stocks. In fact, a sugar factory can be built in 20-24 months. Manufacturer and Supplier - Alas, you are unlikely to implement a project by choosing and spending time on communication and correspondence with a "manufacturer" or "supplier" who is simultaneously engaged in the sale of mobile phones, canned fish and sugar factories. This is called "selling air". This completely misleads the buyer, deprives him of full-fledged information and in most cases is only a cover for fraud. The client wants to get the correct information about the sugar factory from the manufacturer or technologist, but what information can a "firm" offer that also sells buttons, bulldozers or nails at the same time? Be careful and ask for information only to those who themselves understand what he produce and what he offer. Self-search of equipment - The most common mistake, since most entrepreneurs lack even basic knowledge and experience for sugar production. The bottom line is that entrepreneurs are looking for equipment on the Internet and choose one that is absolutely not suitable for sugar production. For example, he chooses a beet cutter for fodder beets and thinks that it is suitable for cutting sugar beets into cossettes. Alas, such equipment has different purpose and characteristics. Moreover, the shape of the resulting chips on a beet cutter intended for fodder beets is not suitable for use in a diffusion plant for the isolation of sucrose. This choice is also influenced by unscrupulous manufacturers, as well as resellers, who, thinking that if the equipment is suitable for something, then it will also be suitable for sugar production, and thereby offer such equipment as "equipment for sugar factories". Turnkey solutions - It sounds very attractive, but in most cases it's just marketing tricks. In reality, the manufacturer of equipment and technological lines cannot provide all materials and components, and even more so construction materials for the construction of a turnkey plant, since he himself produces only technological equipment, but not construction and installation materials. The same applies to the workforce that is required to implement the project. The equipment manufacturer is physically unable to staff and send the necessary number of specialists and workers on a business trip for almost 2 years. It's even financially unprofitable. In practice, turnkey projects are implemented only with the help of a general contractor, which is often a local company that supplies construction materials, enters into contracts with contractors and acts as an intermediary between the customer and the manufacturer of the main equipment. Before you start enjoying a "cheap" offer, we suggest clarifying what the supplier offers and what is included in the project package. Otherwise, the equipment you purchased will lose any meaning, and the completion of the project will cost many times more than the equipment itself cost. The best choice is a comprehensive solution. Financing errors - The main mistake are thinking that any project can be implemented with personal funds and investments are not needed. Alas, but it certainly won't work to build a sugar factory for a monthly salary. Is not an argument and the fact that there is land, land or experience in growing sugar beet. Without investment, such projects are not implemented, and it costs a lot of money, since this is not a household equipment, but a whole factory. It is also necessary to take into account the fact that you will need not only funds for the construction itself, but also a corresponding working capital budget for the purchase of raw materials, payment for energy resources and taxes, as well as the payroll and operational materials.

WESTTEX team