Steam consumption reduced below 34 per cent on cane, delivering efficiency improvements through economically viable modernization for a running plant

Spray Engineering Devices Limited (SED) has announced the successful completion of a steam-efficiency upgrade at Tirupati Sugars Limited’s Bagaha facility in Bihar. The modernisation has brought down steam consumption to below 34 per cent on cane, in line with the performance parameters defined for the project.

The project was part of a targeted effort by Tirupati Sugars to enhance operational efficiency without the need for large-scale utility replacements. By focusing on process optimisation and the integration of energy-efficient equipment, the upgrade was seamlessly retrofitted into the plant’s existing boiler and turbine systems. This approach has delivered a reduction in steam demand while ensuring compatibility with the existing steam and power system, making the modernisation economically viable for a running factory.

Vivek Verma, Managing Director of Spray Engineering Devices Limited, said: “Improving steam efficiency in an operating sugar plant requires precise engineering, proper heat-recovery integration, and careful execution without disturbing existing utilities. This project demonstrates that efficiency improvement can be achieved through engineered upgrades and optimised process configuration.”

Deepak Yadav, Managing Director of Tirupati Sugars Limited, Bagaha, added: “The objective of this upgrade was to improve steam economy of our existing plant through process optimisation and energy-efficient equipment. The project has been implemented as planned, and the plant is now operating at improved efficiency levels in line with the expected performance parameters.”

The scope of work included the engineering, supply, and commissioning of high-efficiency condensate juice heaters, falling film evaporators, flash cigar, honeycomb calandria batch pans, receiving crystallizer, automation, and process control integration. These upgrades have optimised boiling house operations and overall heat balance, resulting in a leaner, more resource-efficient facility.

As sugar mills across India increasingly prioritise modernising existing infrastructure over expensive greenfield expansions, this project serves as a practical roadmap for improving margins through energy conservation. By proving that legacy plants can achieve modern efficiency standards, SED and Tirupati Sugars are contributing to more sustainable and cost-effective sugar manufacturing in the region.