Sugar & Bioethanol Production

Unlocking Hidden Efficiency & Sustainability

Redefining the optimization & efficiencies in the manufacturing process of Sugar Mill and Bioethanol Plant.

Maximize Sugar Recovery

Improve sucrose extraction efficiency with real-time process intelligence that minimizes losses across milling, clarification, and crystallization.

Higher Cane throughput, Improved Yields

Focusing on KPIs, minimizing Pol Percent in Bagasse, Moisture percent in Bagasse and maximizing Mixed Juice Brix.

Stabilize Fermentation & Boost Ethanol Yield

Predict inhibitors, control critical parameters, and prevent batch variability with AI models tuned for continuous, high-yield ethanol production.

Lower Energy Use Across the Plant

Optimize steam, power, and heat balance dynamically to reduce fuel costs and improve turbine, boiler, and evaporator performance.

Seal the Losses. Unlock More Ethanol Every Single Day.

🧺
Raw Material
Operational Loss: Starch inconsistency & moisture
Business Impact: Lower fermentable solids
Visionaize Intelligence: Smart storage insights & spoilage detection
🏭
Liquefaction
Operational Loss: Poor gelatinization
Business Impact: Unused starch → efficiency loss
Visionaize Intelligence: Real-time liquefaction optimization
🧫
Fermentation
Operational Loss: Contamination or stuck batches
Business Impact: Sugars diverted to acids & glycerol
Visionaize Intelligence: Predictive contamination control
🍬
Saccharification
Operational Loss: Incomplete starch conversion
Business Impact: Reduced ethanol yield
Visionaize Intelligence: AI-optimized saccharification
⚗️
Distillation
Operational Loss: High steam load
Business Impact: Higher cost & downtime
Visionaize Intelligence: Steam balancing & purity optimizer
🌾
DDGS
Operational Loss: Over-drying & inconsistency
Business Impact: Reduced co-product value
Visionaize Intelligence: Drying automation & quality monitoring

A 2-3% yield improvement translates directly to multi-crore savings per year.

CASE STUDY

AI-Driven Yield & Energy Optimization in Sugar Mills

Sugar mills operate in highly variable conditions due to seasonal cane quality, geographic sourcing, and siloed process data. Operators struggle to consistently maximize extraction, reduce Pol and moisture in bagasse, manage steam usage, and maintain plant stability. These inefficiencies impact yield, energy cost, and overall mill profitability.

slide3
CASE STUDY

AI-Based Fermentation Optimization for Ethanol Plants

Fermentation relies heavily on manual dosing, offline lab measurements, and long 50–60 hour batch cycles. Lack of real-time visibility into pH, gravity, and sugar levels leads to inconsistent yield, delayed corrective action, and difficulty planning distillation schedules. Variability in process conditions impacts ethanol purity and overall batch efficiency.

slide3
CASE STUDY

Revenue Growth Through KPI & Process Optimization

Sugar mills struggle with fragmented data, manual KPI tracking and inconsistent process control across milling, juice clarification, crystallization and recovery units. Variability in key parameters leads to avoidable losses, off-spec production and missed revenue opportunities, with no real-time insight into where performance is slipping.

slide3

Connect with a Digital Twin specialist

Connect with us

Where Artificial Intelligence Steps In

Smarter data. Smarter operations. Smarter sugar & ethanol plants.

  • Stabilize critical processes by predicting variations in cane preparation, milling, extraction, evaporation, and crystallization before they impact output.
  • Optimize energy-intensive areas like boilers, turbo-generators, and steam networks with real-time load balancing and fuel-efficiency insights.
  • Maximize sugar recovery through continuous setpoint adjustments maintaining ideal purity, brix, temperature, and flow.
  • Accelerate production cycles by optimizing fermentation duration, enabling more batches per month with consistent quality.
  • Ensure yield consistency with AI-driven prediction of variability in cycle time, ethanol purity, and final output.
  • Improve operational planning with accurate scheduling for distillation and downstream units.
  • Lower production costs through enzyme and yeast dosing optimization and higher throughput.
  • Reduce downtime using predictive maintenance for mills, boilers, and critical rotating equipment.
  • Enable centralized, remote monitoring for anomaly detection, advisory systems, and real-time optimization.
  • Digitize process intelligence with automated tracking of key parameters—pH, gravity, temperature, sugar levels, fermentation time, purity, and cost—eliminating manual logbooks and scattered data sources.

Ready to Transform?

If your sugar mill or bioethanol plant is under pressure to reach higher yield, lower energy usage, extend campaign length, or improve co-gen economics – let’s talk.
Connect with Visionaize and explore how our AI-driven optimisation platform can be configured for your unique operation.

Let’s talk digital twins

Unique Visionaize Value-Proposition

  • Real-time AI models that continuously learn mill behavior and predict process deviations in advance.
  • Smart setpoint recommendations to stabilize operations and improve yield and recovery.
  • Simultaneous optimization of key KPIs including throughput, energy efficiency, and product quality.
  • Advanced AI/ML modelsto enhance fermentation performance with accurate predictions of batch completion, ethanol purity, production cost, and maintenance needs.
  • Operator-focused advisory dashboards with real-time insights and remote monitoring capability.
  • Clear profitability impact by reducing process losses, maximizing output, and optimizing resource and energy usage.

Talk to an expert



    We generally respond within 24 hours