Turnkey Sugar Complexes: Engineered for Your Business Model
From High-Efficiency Cogeneration to Boiler-Less Operations: We Build Plants That Match Your Energy Vision.
Building a sugar plant requires more than just assembling machinery; it requires a thermodynamic master plan. At Spray Engineering Devices Limited (SED), we don’t force a standard template. We analyze your regional energy costs, power export potential, and by-product goals to deliver a custom turnkey solution.
Whether you need a power-exporting cogeneration hub with high-pressure boilers, an energy-efficient plant with maximum bagasse saving, or a complete “boiler-less” plant, SED takes full responsibility from concept to commissioning.
Choose Your Plant Configuration
The High-Efficiency Cogeneration Plant
We deliver complete turnkey plants integrated with boilers and turbines, engineered to surpass industry benchmarks with minimum steam consumption to maximize power export. While standard plants consume 30–40% steam on cane, SED’s integrated design achieves steam-on-cane ratios as low as 20%, without any sugar diversion to the distillery.
The Advantage
Steam is directed to high-efficiency turbines with minimal extraction of low-pressure exhaust steam, allowing you to export substantial power to the grid while running the process house.
Key Inclusions
High-pressure boilers, turbo alternators, and process house equipment such as FFEs and honeycomb calandria design pans, compatible with operation at lower steam pressure and temperature.
The Boiler-Less Sugar Plant
For producers who view bagasse as a cash crop (for paper, tableware, 2G ethanol, green chemicals), we offer our revolutionary boiler-less configuration. By utilizing Mechanical Vapour Recompression (MVR) with our energy-efficient equipment, we eliminate the need for a conventional process boiler and turbine.
The Advantage
100% bagasse saving. Instead of burning your raw material for fuel, you save every kilogram of bagasse to create a new, high-value revenue stream.
Key Inclusions
MVR-integrated process house equipment, condensate heating systems, 100% clean water recovery, and Zero Liquid Discharge (ZLD) technology.
The Technology Inside Your Turnkey Plant
Evaporation
Our FFTE and plate-type evaporators operate as some of the industry’s most efficient heat exchangers, ensuring gentle juice treatment and preventing sugar inversion and colour formation
Juice Heating and Clarification
Condensate tubular heaters, advanced juice treatment processes, SRT clarifiers, and correction heating using direct contact heaters (DCH) remove impurities with minimal residence time, ensuring clear juice enters the evaporators.
Crystallization
Our Spray Continuous Pan (SCP®) and honeycomb calandria batch pans utilize low-temperature vapours to produce uniform, high-quality crystals while maximizing steam economy.
Heat Recovery
The Flash Cigar® system recovers heat from condensate and feeds it back into the process so no energy is wasted. Condensate heat is recovered, and cooled condensate is reused.
Evaporation
Our FFTE and plate-type evaporators operate as some of the industry’s most efficient heat exchangers, ensuring gentle juice treatment and preventing sugar inversion and colour formation
Crystallization
Our Spray Continuous Pan (SCP®) and honeycomb calandria batch pans utilize low-temperature vapours to produce uniform, high-quality crystals while maximizing steam economy.
Juice Heating and Clarification
Condensate tubular heaters, advanced juice treatment processes, SRT clarifiers, and correction heating using direct contact heaters (DCH) remove impurities with minimal residence time, ensuring clear juice enters the evaporators.
Heat Recovery
The Flash Cigar® system recovers heat from condensate and feeds it back into the process so no energy is wasted. Condensate heat is recovered, and cooled condensate is reused.
Why Choose SED?
Custom Steam Economy
We don’t just “reduce” steam; we design for a specific target, delivering steam-on-cane performance of up to 20% for turbine-integrated plants, without any sugar diversion to distilleries.
Zero-Surprise Execution
We bridge the gap between manufacturing and installation to eliminate third-party delays.
Proven Track Record
With projects across 40+ countries, including major installations such as Onkar Sugar (formerly known as Gokul Mauli Sugar) and Dewan Sugar expansions, we consistently deliver on efficiency and execution.
Global Logistics
Whether domestic or international—such as Al Khaleej Sugar Co. LLC, Dubai, or Gledhow Sugar, South Africa—our logistics team ensures export-ready dispatch and on-time delivery.
Ready to Design Your Plant?
Consult with our EPC experts to decide between a high-efficiency cogeneration setup or a boiler-less configuration.
Request a Technical Feasibility Study