The document discusses the importance of automating sugar mill operations. It outlines the inefficiencies of manual mill house and cane feeding systems, including irregular crushing, juice extraction, and bagasse quality. Automation provides regular cane feeding, increased crushing capacity by 5%, and real-time monitoring to improve decision making. The key benefits are reduced errors, higher sugar production through uniform extraction, and improved boiler and power plant efficiency from regular supply of bagasse and juice. Automation pays for itself through increased crushing capacity and reduced product losses.

1. The Digital Sugar Mill
Seminar on Sugar & Ethanol Automation

2. The Importance of Mill House
Automation
Khalid Hayat Khan
Chief Operating Officer
Faran Sugar Mills

3. The Importance of
Mill House
Automation
Agenda
Introduction to Mill House Operation
Efficiency of Mill House
Drawbacks of a Manually Operated Mill House
Drawbacks of a Manually Operated Cane Feeding System
Consequences of Manual Cane Feeding System
Automated Cane Feeding System & Mill House Operations
System Architecture
Advantages of Automation
Real-Time Monitoring
Conclusion
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4. Introduction to Mill House Operation
 The initiation point for all sugar processes is the Mill House
Efficiency of Mill House directly affects:
Increase in crushing capacity
 Juice extraction efficiency
 Reduction of moisture percentage in bagasse
 Bagasse Pol loss
Low wear and tear
Low energy consumption and low torque

5. Efficiency of Mill House
1. Increase in sugar production
As an industry average, assuming 6000 TCD capacity, automation is able to save 1.8 tons
of sugar per day. (Assuming 95.51% extraction efficiency)
2. Efficiency of Boiler operations 3. Reduce Load on Motors and Power House
Reduced bagasse
Pol & moisture
results in
improved quality of
combustion
Reduce energy
consumption &
improves steam
regularity
Regular cane
feeding results in
improved crushing
capacity
Reduce
degenerative effect
on expensive
electrical
equipment

6. Drawbacks of a Manually Operated Mill House
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7.  Unmonitored Parameters
Lots of guess work increases chances of error
 Inability to save records or study trends
 Leads to poor decision making
More stoppages
More energy consumption
Human Error
 Human Response Time leads to Irregularity in Cane Feeding
Drawbacks of Manual Cane Feeding System

8. Consequences of Manual Cane Feeding System
Non-uniform juice
extraction
Average Bagasse Pol
value increases, causing
losses
Irregular moisture
content reduces Boiler
efficiency
Leads to Irregularity in
Power Consumption
Causes undesirable
Torque occurred on
Electrical equipment
Irregular Feeding

9. Automated Mill House Operations
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10. Automated Mill House and Cane Carrier
Reduces Human Error and Response Time
Integrated Mill House Operation
Cane Carrier Speed, & Mill Chute Level
Automation Control Philosophy

11. System Architecture

12. Advantages of Automation
Regularity in Cane
Feeding
Increase in
Crushing Capacity
“On average, an
automated
millhouse will
increase
crushing
capacity by 5%.”
Increases Process
House Efficiency
Due to
regulated and
uniform supply
of juice and
steam pressure
Allows real-time
monitoring of
entire operation
Quicker response
time
Empowering end-
user to make
better decisions
based on reliable
data
Reduced margin of
error due to guess
work

13. Real-Time Monitoring

14. Advantages of Automation
Reduced Fluctuation
Steam and Power
Fluctuation
Regulated feeding of all
tandem mills
Increases overall
equipment efficiency
and utilization
Reduced need of
personnel monitoring
Man power can be
allocated for other
important functions

15. Conclusions
Regularity in cane feeding is the key to operational efficiency.
Global practice of automated systems is the surest way to achieve uniformity and
control over all critical parameters.
Reduction in product losses and Increase in crushing capacity are worth the
justifiable investment, resulting in a smooth payback over a short period of time.
Continued aftermarket support is critical in ensuring sustainable return on investment
in automation.

16. Question & Answers
Thank You for Your Valuable Time