Farm to Fork strategies focus on making value chains fair, healthy and sustainable. The sugar production industries are facing difficult challenges. Energy, raw material and transportation costs are increasing amid global and regional instability, while food producers and consumers are demanding ever lower prices. Meanwhile, the need to improve safety and sustainability while ensuring profitability is putting increasing pressure on producers to improve productivity while reducing both energy usage and waste. As such, the industry requires solutions that can help to make vital improvements within the areas of:
- Sustainability – where improvement comes in the form of energy savings, optimized use of water and raw materials and ventilation, protection of the local environment, and reduction of waste
- Reliability – where the need to reduce wear and tear on assets in use, prolong equipment life, and eliminate the risks of unplanned stoppages are all critical to profitable operation
- Safety – where keeping personnel safe from harm is non-negotiable, and ensuring that food safety is maintained throughout the value chain
ABB offers application-based solutions for raw material production, processing, and logistics sectors across the entire value chain for both sugar cane and sugar beet. Leveraging our domain expertise, efficient motors, and drives, we can help reach reliability and performance goals while also substantially reducing energy costs. Our programmable logic controllers (PLC) can deliver integrated control systems that help to provide enhanced digital visibility and control over processes in sugar farming, processing, and onwards to logistics - providing solutions from Farm to Fork.
Farming
Challenges in the sugar farming industry
Almost 80 percent of the sugar grown throughout the world is cane sugar, which is mostly farmed in the southern hemisphere in tropical and subtropical regions. The remaining 20 percent is beet sugar, which is typically farmed in the northern hemisphere. Both beet and cane sugar are relatively slow crops, with beet taking up to seven months from sowing to harvesting, while cane sugar typically takes 12-18 months
Keeping crops healthy in difficult conditions
Ensuring that crops receive the right amount of nutrients, sunlight and water is crucial to stimulate healthy growth that provides high yielding plants. Sugar cane in particular is grown in warmer locations, which can result in high levels of evaporation. As such, it typically needs far more water than other crops, requiring the use of irrigation. In warmer climates, water is often scarce, so sugar farmers cannot afford to waste it. Climate change is likely to make this even more of a challenge in the future.
The need for modern machinery
Furthermore, under-investment in infrastructure can be an issue in some countries where cane sugar is grown. As such, machinery can be outdated, inefficient and unreliable, leading to low productivity and high production costs. At the same time, efficiency needs to be maximized to reduce resource and energy costs, and ensure that harvests are as profitable as possible.
Solutions across the value chain
ABB offers a suite of solutions for equipment that can deliver vast benefits for sugar farmers, as well as the equipment manufacturers and system integrators that supply them. Across the sugar industry, ABB understands the applications and issues that matter, and can help the industry to tackle the array of sustainability, reliability and safety challenges faced within the sector.
Farming
Challenge
SUSTAINABILITY
Water and energy are precious commodities, and I need to reduce consumption of both wherever possible
RELIABILITY
Pumps are often situated outdoors, exposing them to weather and dirt
SAFETY
I need to ensure that crops are kept healthy to ensure that end products are of the highest quality
Irrigation/pumps
ABB solar pump drive makes water available in locations with no grid access, while ensuring efficient water usage
Drives and motors (using smart sensors) and remote monitoring provide early warning of any equipment wear that may require attention
Drive and motor can provide continuous monitoring and adjust watering cycles according to ambient conditions
Processing
Moving sugar processing into the future
Sugar is a well-established industry, and many sugar processing plants and refineries are already several decades old. As a result, machinery is often aging, and less efficient and reliable compared to modern equivalents. Many motor-driven assets are not optimized for the extraction of process data digitally, and so it can be difficult to get a full and accurate picture of how processes are running and the condition of powertrain equipment. This can make it difficult to optimize processes and reduce the energy usage of high power machinery.
Downtime must be avoided at all cost
Unplanned interruptions in the process cost a lot of money. Plants in many parts of the world generally operate on a highly seasonal basis, typically running 24/7 at peak times, followed by periods when production is stopped, and when equipment is maintained and prepared for the next harvest. These intense operating cycles result in considerable strain on equipment. Machinery must nevertheless provide excellent reliability, and available maintenance time must be efficiently utilized to ensure that downtime is avoided during production periods.
Mitigating explosion risks
Ambient conditions in the tropical and subtropical regions where sugar cane grows can be tough for both mechanical and electrical equipment. Dust is another challenge in some production stages. Accumulations of dust in concentrated amounts can potentially create an explosion risk.
Management of byproducts
Byproducts such as bagasse and molasses are used as fuel to generate steam, which can be used to directly power machinery, or be converted to electrical energy in a turbine. These processes must be carefully managed to ensure good power quality, and avoid introducing or exacerbating the effects of harmonics.
ABB solutions for the sugar processing industry
ABB products are designed to meet the needs of sugar production processes. From Explosion-proof motors across a wide power range, to advanced industrial PLCs and energy saving drives, ABB is equipped to help sugar producers to improve the sustainability, reliability and safety of their operations.
Processing
SUSTAINABILITY
Rollers, shredders and cutters are energy-intensive applications
RELIABILITY
High intensity processes cause mechanical stress on machinery, and any stoppage can be costly
SAFETY
I need to protect personnel from moving machinery
Preparation
Accurate speed and torque control improves process flow and energy efficiency
Drive reduces strain on mechanical components for increased longevity and lower maintenance requirements
Functional safety in drives reduces risks for operators
— Processing
SUSTAINABILITY
I need to maximize the efficiency of juice extraction processes to enhance productivity and reduce costs
RELIABILITY
Shredders are in continuous use during production seasons
SAFETY
I need to protect personnel from moving machinery
Shredding
Drive and motor ensures optimal shredding control and efficiency
Robust ABB motors are designed to withstand the toughest environments
Functional safety in drives reduces risks for operators
SUSTAINABILITY
Milling is the most energyintensive stage of the process
RELIABILITY
Mills are often run at speeds other than nominal speed, and may be oversized
SAFETY
Dusty and explosive environments pose a potential health risk
Drive and high efficiency motors can reduce energy consumption by up to 30%
Drive ensures that application avoids tripping in the event of sudden loads
Explosion-proof motors provide safe operation in hazardous areas
SUSTAINABILITY
Control of juice flow and temperature is important to enhance operational efficiency
Clarification — Processing
RELIABILITY
Motors without speed control are run constantly at full throttle, causing potential reliability issues
SAFETY
Separators can cause injury to personnel
Drive and PLC provides precision control over process to respond instantly to variations
Drive provides easy pump and mixer speed control for smooth management of process
Safe torque off function in drives improves operational safety
— Processing
SUSTAINABILITY
Motors must run at different speeds to cope with variable liquid thickness
RELIABILITY
Frequent speed changes can cause premature wear to pipes and valves
SAFETY
I need to make sure that all operations across my plant are safe
Soft start function in drives minimizes stresses in pipes
Fieldbus connectivity allows streamlined integration with plant DCS and safety systems
Drive and PLC provide precision process control for greater efficiency Evaporating
— Processing
SUSTAINABILITY
I need to reduce my energy costs, and make the most of onsite generation
RELIABILITY
My centrifuges require high starting torque, and resistance to strong mechanical forces
SAFETY
Dusty environment creates an explosion risk
Centrifuging
Regenerative braking in drives achieves significant energy savings with low harmonic emission
Precise motor control provides extremely accurate speed control over the entire speed range, reducing stress on components
Explosion-proof motors ensure safe operation in hazardous areas
Processing
Challenge Solution
SUSTAINABILITY
High intensity processes can generate a lot of heat, so I need my cooling towers to be as efficient and effective as possible RELIABILITY
Conventional belt and gear drive systems typically have high maintenance requirements
SAFETY
Rotating equipment can create a safety risk
Cooling towers
Baldor-Reliance® RPM AC cooling tower motor and drive package reduces energy consumption
Cooling tower motor replaces shaft and gearbox arrangement, reducing maintenance needs
Motor and drive package for cooling towers has fewer moving mechanical parts compared to conventional systems
Challenge Solution
SUSTAINABILITY
Old sugar mills often have inefficient boilers and steam turbines
RELIABILITY
Any downtime to my power generation capabilities will mean additional electricity costs
SAFETY
I need to maintain the correct pressure in my boilers to ensure safe operation
Co-generation
Electrically-driven machinery using motors and drives is much more energy efficient than steam-driven
Drive ensures smoother motor operation for boiler pumps and fans for increased reliability
Drive’s fast response time ensures correct boiler pressure is maintained at all times
Logistics and storage
Preventing dust build-ups
Large quantities of sugar in concentrated amounts are a serious explosion risk. Proper ventilation to prevent dust and particle build-ups is vital to ensure safety of personnel.
Ensuring
end product quality
Processed sugar products do not need to be kept refrigerated, but they do need to be kept dry and at room temperature. Running ventilation systems and conveyors 24/7 during production cycles uses large amounts of energy. Failure of these systems can lead to expensive plant downtime and lost production, and so logistics and storage operators need to be able to trust that their equipment is both energy efficient and highly reliable.
Proven solutions for the sugar industry
ABB offers a wide range of motion solutions designed to address the needs of companies involved in logistics and storage of sugar. High energy efficiency motors can deliver considerable energy and cost savings while drive and PLCs ensure seamless operation of conveyors and air handling units to reduce wear and tear on components. Digital remote monitoring services can also help to detect potential faults before they turn into failures, keeping downtime to a minimum.
Logistics and storage
Challenge
SUSTAINABILITY
I need to reduce the energy usage on my conveyors
RELIABILITY
Sugar facilities are mechanically challenging and dusty environments
SAFETY
I must keep personnel safe from dangerous moving machinery
Conveyors
Solution
Drives’ built-in brake provides precise control of conveyor without external hardware
PLC combined with drives and motors ensures perfect synchronization of multiple conveyors for less wear on equipment
Integrated functional safety in drives reduces risk to personnel
Logistics and storage
SUSTAINABILITY
Fans are energy-intensive applications, and I need to reduce my energy costs
RELIABILITY
Blowers/pneumatic transport are the easiest way of moving materials from one point to another, and so any downtime will affect production
SAFETY
Sugar particles in high concentrations are an explosive substance
Drive can reduce a fan’s energy usage by up to 30%
Remote monitoring equipment ensures that potential faults can be identified long before they cause failures
Drives ensure optimal airflow, while Ex-certified motors reduce explosion risk in combustible atmospheres
ABB Motion solutions for sugar production
— High efficiency motors
Variable speed drives/variable frequency drives
Programmable Logic Controllers (PLCs) and Human Machine Interfaces (HMIs)
• ABB offers a comprehensive range of reliable and high efficiency motors for all sugar production processes from farm-to-fork
• Super premium efficiency IE4 induction and permanent magnet motors can significantly reduce energy usage, while meeting and exceeding Minimum Energy Performance Standards (MEPS) around the world
• Explosion-proof motors ensure safe operation in hazardous and dust-affected environments
• Ultra-premium efficiency IE5 SynRM motors including SynRM IE5 Increased Safety and VSD packages can achieve unprecedented energy savings for sugar production applications
• Integrated motor packages provide easy installation and high efficiency
• ABB drives are made with efficiency and performance in mind to empower productivity for producers of sugar. They provide flexibility to optimize processes and control across the value chain, while achieving high reliability for less downtime.
• Achieves substantial energy savings by delivering precision control to ensure that a motor only uses the energy it needs for a given output.
• Built-in features and functionality tailored to industrial processes.
• EnergySave Calculator tool allows you to predict energy performance and savings prior to investing
• Functional safety built-in
• Regenerative braking for improved process energy efficiency
• ABB automation devices deliver solutions with high performance and flexibility to be effectively deployed in applications across the sugar value chain
• ABB range of PLCs can provide solutions for small, medium and high-end applications
• Maximize energy recovery and on-site generation output.
• Ideal choice for high availability, extreme environments, condition monitoring, motion control and safety solutions
• Constantly monitors process variables and can instruct motor and drive equipment to adjust operations instantaneously to match requirements in real-time
• Safety PLC specifically designed for safety applications involved in machinery and process automation —
ABB Motion success stories in sugar production
ABB drives and motors to ensure energy efficiency at the world’s biggest beet sugar factory.
Canal Sugar is a major new agro-industrial complex located west of the city of Minya, around 240 km south of Cairo. ABB delivered energy-efficient variablespeed drives (VSDs) and motors to run the factory’s 15 batch and ten continuous centrifuges, which play a central role in the sugar process. ABB also provided commissioning services to ensure effective and trouble-free startup.
For the batch centrifuges, Canal Sugar used a package consisting of an ACS880 multidrive, 15 air-cooled permanent magnet (PM) motors, a 3000 kVA dry transformer and cabling. The multidrive system is customized for regenerative operation, which saves energy by transferring energy generated by centrifuges in the braking stage of the cycle to those that are accelerating.
The selected PM motors feature IE4 efficiency. The IE4 PM motors used have a wide speed range, and can deliver high torque even at very low speeds. This makes them an ideal match for driving the batch centrifuges. In addition, their high power factor of 0.97 not only reduces losses but also helps to maintain network quality, thereby ensuring stable operation of applications in the factory.
The ten continuous centrifuges are powered by ACS880 single drives and process performance induction motors. Canal Sugar opted for ultra-low harmonic drives in order to avoid disturbances in the network, and ensure high reliability.
Belgian sugar producer improves uptime and realizes a 12% energy saving with ABB digital solutions.
A sugar processing plant in Belgium is enjoying improved process uptime, optimized maintenance cycles, and a 12 percent increase in energy efficiency thanks to ABB digital solutions provided by Duvivier Dexis, an ABB channel partner.
When the plant was facing critical production downtime, it turned to their trusted partner, Duvivier Dexis for help. ABB Ability™ Monitoring Service was used to track the condition and performance of the most critical electrically-powered assets: four drying drums and three fans.
The monitoring data showed that one of the three fans driven by 30 kW electric motors responsible for transporting sugar was operating with high vibration levels. An on-site investigation revealed that sugar particles had built up on the fan blades, causing an imbalance. A quick clean-up of the fan blades and replacement of the radial fan filters resulted in increased uptime and also achieved a surprising 12 percent energy saving, with EUR 4,000 yearly savings per fan. With this simple cleaning operation, the customer was able to make a big impact in reducing unnecessary costs by acting on the data insights coming from the condition monitoring system.
Our service expertise, your advantage
Keep your operations running profitably, safely and reliably
• Maximize uptime, extend product life cycle, and enhance the performance and energy efficiency of your assets.
• Enable innovation and success through digitalization by securely connecting and monitoring your motors and drives, increasing reliability and improving efficiency.
• Our domain expertise is strengthened by a service offering tailored to your needs, enabling you to unlock new possibilities and achieve more sustainable outputs.
The
expertise and capabilities together to enhance your business performance Partnered solutions
Delivering digital for
Smart. Secure. Connected.
ABB Ability™ digital solutions
ABB offers a range of advanced services and digital solutions based around the ABB Ability™ platform, which can help to maximize the potential of your motor-driven applications across the entire powertrain.
ABB Ability™ Mobile Connect
ABB Ability™ Mobile Connect for drives allows equipment manufacturers to communicate with drive users or service personnel on-site, helping them easily commission and troubleshoot drives remotely. Chats and sharing of images and backups via smartphone makes the technical support process quick and efficient.
This increases opportunities to provide online technical support for end customers – without complex connectivity infrastructure. This is ideal for facilities in remote locations lacking in modern communications provision.
ABB Ability™ Condition Monitoring for drives
ABB Ability™ Condition Monitoring for drives keeps you one step ahead of process issues. The service provides fact-based insight into the performance and efficiency of VSDs, via KPIs and signal data, to keep processes running smoothly.
Irregularities in operations can be identified and solved long before they result in equipment failure, reducing downtime while enabling a shift towards predictive maintenance, while allowing additional opportunities to optimize performance based on the data.
ABB Access and local support
ABB Ability™ Condition Monitoring for powertrains
ABB Ability™ Condition Monitoring for powertrains optimizes the performance and efficiency of rotating equipment. It enables full transparency on all parameters for drives, motors and pumps, and can also be applied to applications such as centrifuges, mixers, shredders and boilers.
ABB Ability™ Smart Sensors
ABB’s Condition Monitoring solutions are underpinned by Smart Sensors: small devices which can be fitted directly to the chassis of a motor with minimal installation and no wiring required. The device gathers near real-time data measuring parameters such as temperature, vibration, magnetic flux and noise, which can then be aggregated, stored and analyzed by the cloud to gain unprecedented insight into equipment condition and performance. Potential equipment issues can therefore be detected before they turn into faults, without having to manually inspect the motor.
Engage ABB support locally
As well as serving the market directly, ABB continuously develops a network of valueadding channel partners that enhance ABB’s market reach and proximity around the world. Local expertise, combined with a world-leading product and service offering, can help to provide support at every stage of the sugar value chain.
ABB’s carefully selected channel partners are regularly trained in the latest products, techniques and best practices, as well as being periodically assessed on their core competencies to ensure that customer expectations can always be fulfilled, 24 hours a day, anywhere in the world.
The ABB Value Provider program ensures that approved third parties deliver authorized sales, support, service and engineering in cooperation with ABB, bringing ABB’s products and services straight to the customer’s front door.
Summary
Across the sugar production value chain, from farming through to logistics, key stakeholders face an array of challenges in ensuring maximum efficiency with minimum waste, while attempting to reduce costs wherever possible. Meanwhile, the industry is also working hard to improve its environmental footprint.
ABB’s Motion portfolio delivers solutions with tangible benefits for improving the sustainability of operations, and the reliability and safety of sugar production processes, from Farm to Fork.
