In the crystallization stage, the operator supervises the process, taking decisions of the operation according to their observation of the crystals during their growth. Although the results are achieved through experience, these processes vary from one operator to another and the success in taking decisions depends on the experience and skill of each of them. This situation makes it very difficult to maintain a uniform quality of the sugar produced since it is not very common that there is a unit of criteria for decision making as well as homogeneity among factors such as the experience, skill and knowledge of the process of each worker.
To obtain sugar crystals of a uniform size it is very important to adequately control the process from the same emulsion with seed crystals. The operator must adequately control the flow, decide on the right moment for the sowing of seeds, decide if it is necessary to add water in the crystallization process among many other decisions. If something goes wrong in the process it is necessary to recirculate the crystals to the previous process with the consequent loss of production time, Energy Costs, lost in terms of opportunity cost of the unprocessed sugar. What is proposed is a tool that facilitates decision making during this process.
Here are the 6 main reasons why all sugar factories should have a crystallography laboratory.
1. Optimization in the depletion of honey.
The process of manufacturing sugar is summarized in the depletion of sucrose in honey that ends up moving to the crystals in the different bins, as these processes are controlled in terms of CV and size of the glass, the process will be more efficient. With the crystallography system you can measure the crystals and determine the CV to have control of the process ..
2.Opportunity cost in steam consumption.
The experience of our clients has shown that using the crystallography system it is possible to achieve reductions in energy consumption due to the lower use of water in the process.
3. Standardization of processes to obtain uniform crystals.
With the crystallography system it is possible to determine the best operating conditions of each tank and once established it is possible to standardize the process taking into account the variability of the raw material
4. Excellence in seed crystals.
Through the measurement of seed crystals (slury) with the crystallography system, it is possible to determine the best operating conditions for the ball mill that produces it, this is of vital importance because during the sugar manufacturing process the crystals coming from of the emulsion only grow and do not reproduce unless it is a false templa.
Here we present a document that supports this point:
5. Avoid the spontaneous reproduction of crystals with a controlled handling of the templa.
The fact of being able to measure the crystals with the crystallography system in a precise way, makes the monitoring process more efficient in the different temples, giving the opportunity to minimize the spontaneous generation of crystals from operating errors in the buckets.
6. Improvement of the coefficient of variation
According to the experience of our clients we have found that once the crystallography system was applied in an efficient way, it was possible to reduce the CV levels from the emulsion of seed crystals to mass A, obtaining as a result the improvement in the quality of the sugar, seeking to reach the optimal results proposed in the studies of engineer Jaime Peñaranda.
7. Managerial vision of the crystallography laboratory.
One of the main stages in the sugar process is crystallization and in this the greatest difficulty is presented in the treatment of by-products of different qualities to obtain homogeneous quality sugar. For every manager, it is well known that a process that is not measurable and can not be measured can not be controlled. It is precisely the main objective of this document to indicate how a process as important as the crystallization process that does not have measurement tools can be controlled correctly in order to achieve its greatest effectiveness. The crystallography laboratory is a technology that has increasingly entered the sugar industry as a tool with which it is possible to measure and control all the operating parameters of the crystallization process in order to maximize its effectiveness.
Here we present a document where you can expand the information provided: