Maximize Extraction, Minimize Power Consumption
What Is It?
A Milling System, also known as a Milling Tandem, is a critical unit in sugar manufacturing designed to extract juice from prepared sugarcane through mechanical crushing. It typically comprises a series of Three-Roller Mills, each equipped with independently driven rollers for enhanced control and energy efficiency. These rollers apply high compressive force to the chopped cane, gradually extracting the juice as it passes through each stage. Modern milling systems use VFD-controlled motors, precision-engineered grooved rollers, and integrated feeding mechanisms like the Toothed Underfeed Roller (TUFR) to ensure optimal throughput, maximum juice recovery, and uniform load distribution. The system also includes supporting conveyors, cutters, and juice collection setups to form a continuous and efficient extraction line.
HowIt Works
Cane Preparation
Harvested sugarcane is fed onto a Cane Carrier, which transports it to the Chopper and Cutter (1). Here, the cane is chopped into smaller pieces to improve juice extraction efficiency.
Cane Distribution
The chopped cane is then conveyed to the Main rack area, where it is evenly distributed and directed toward the first mill for crushing.
Milling Process
The milling tandem typically consists of a series of Three-Roller Mills, each equipped with individually VFD-controlled motors on each roller. This allows precise speed control and ensures uniform load distribution for optimized juice extraction.
- Top Roller : Initiates compression and feeds cane to the lower rollers.
- Toothed Underfeed Roller (TUFR) : Provides efficient grip on prepared cane and increases feed consistency to the feed roller.
- Feed Roller (Chevron Grooved) : Ensures uniform cane feeding, reduces slippage, and enhances juice extraction efficiency with VFD-controlled operation.
- Discharge Roller: Enables smooth bagasse discharge with individual drive control to optimize juice extraction.
(Note: Independent roller drives eliminate reliance on large, energy-intensive main drives.)
Sequential Milling
After passing through the first mill, bagasse is further chopped in Cutter (2) for finer preparation. It then moves via the Inter-Rack Carrier to the next mill in the sequence. The number of mills depends on plant scale and desired extraction efficiency.
Juice Collection
The extracted juice from each mill is collected and transferred to a Mixed Juice Tank for subsequent processing.
Bagasse Handling
The final dry fiber (bagasse) is conveyed to storage yards using belt conveyors for further use.
Challenges Faced with Conventional Mills
Consume excessive power
Require complex mechanical alignment
Involve frequent downtime and skilled maintenance
Need of Bulky civil foundation
Consume excessive power
Involve frequent downtime and skilled maintenance
Require complex mechanical alignment
Need of Bulky civil foundation
Spray’s MillDrive System Solution
Compact inline planetary drives
Elimination of heavy foundations and civil structures
Fewer components, spares, and lubrication points
Full automation with low-speed operation (1–4 RPM)
Improve ROIHow It Helps
| Efficiency | Direct Benefit |
|---|---|
| >90% Gearbox Efficiency | Reduced power bills to 10kw/Ton of cane |
| Variable Frequency Drives | Precision milling = Maximum juice extraction |
| Low-Speed Operation (1–4 RPM) | Higher Primary & Reduced Mill Extraction (PME/RME) |
| Fewer Components & Maintenance Points | Lower downtime & OPEX |
| No extra Foundation Required for gearbox and motor | Saved civil costs & faster erection |
| Semi-skilled Operation Feasible | Reduced manpower costs |
| Fully Auto Mode | Consistent performance with minimal supervision |
Streamlined DesignOptimized Savings
Join hundreds of global sugar factories already maximizing their yield while minimizing costs. Contact us today to discuss how Spray’s mill systems can upgrade your operations for the future.
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