20 years of innovation in sugar-processing technology: a review

Since 2004, Bosch Projects’ innovation initiatives have led to the successful development of various equipment designs, improvements and technologies in the sugar industry. These developments have always been in response to a need to improve factory efficiencies, performance and operability, whilst reducing costs. The invaluable contributions of seasoned engineers, stemming from diverse regions, factories and positions within the sugar industry have been instrumental in advancing this initiative. This paper serves as a comprehensive review of some of the Bosch Projects’ select equipment developed, the development process and the benefits and performance of the technologies in practice. In addition, new information is presented on some of the innovations. The paper highlights several “industry firsts” due to these developments, originating in the South African sugar industry, which have now been adopted in several other sugar industries, globally, including Australia. The equipment discussed is: diffusion extraction to increase recoveries, avoid the use of potentially exportable power, and save costs (diffuser chains and gearboxes) and enable clarifier mud recycling; direct and indirect juice heating; dimple tubes; a novel rotary screen for both juice and ash applications; lamella clarification applied in the sugar industry; massecuite reheating; long-tube climbing-film evaporators for high capacity, low-cost first and second effects that minimise sucrose losses and avoid pumping; and a novel and highly effective horizontally configured vertical-tube continuous-vacuum pan. Where appropriate, results are quoted to demonstrate that the use of these techniques and plant has enabled factories to achieve desired objectives.