BATCH VACUUM PAN AUTOMATION WITH BRIX ANALYZER AND DENSITY BRIX

Technical Benefits:

• Accurate Brix Sensing And Control Aids In Controlled Super-Saturation Of Massecuite
• Excellent Control Throughout The Concentration, Graining, Build-Up And Tightening, And The Last Stages Of Each Pan Strike
• The Automation System Creates Near Ideal Boiling Conditions In The Pan Body In Terms Of Brix, Vacuum, Temperature And Level, And This Helps To Regulate The Pan Boiling Process As Below:
  • Vacuum And Temperature Synchronization Is Achieved As Per The Vacuum Table Throughout The Strike Time (In Full Pan Automation)
  • Highly Accurate Brix Sensing By Fluid-Density-Brix Analyzer And Sensor
  • Super-Saturation Is Accurately Controlled By Regulating Intake Of Material To Maintain The Brix At Preset Values In All Stages Of The Strike
  • Mechanical Circulator Is Automatically Started With Speed Control Corresponding To Level And Temperature To Forcefully Facilitate Massecuite Movement And Ensure Original Grain Protection From Dissolution Especially During The Final Stage
  • Automatic / Semi-Automatic Slurry Charge System At The Preset Brix Value, After Level Reduces Due To Evaporation To Start Graining Stage With Prompting Mechanism To Alert The Pan-Man
  • Automatically Controlled Intake Of Movement Water To Maintain Brix Till The Grain Is Stabilized With Prompting Mechanism To Alert The Pan-Man
  • Automatic Intake Of Material After Grain Is Stabilized To Start The Build-Up And Tightening Stage With Progressive Preset Brix Set Points For Each Level Till Full Pan Level
  • Accurate Control During The Last Stage Of The Strike Allows Movement Water Intake Only, If Necessary, With A Prompting Mechanism To Alert The Pan-Man
    • Thus, No Excessive Super Saturation
      • Hence No Second Or False Grain Formation
      • Thus, Excess Water Addition To Dissolve False Grain Or For Massecuite Movement Is Avoided
        • Increased Sugar Production
        • Water Saving
        • Steam / Vapour Saving
        • Higher Production And Recovery
        • Uniform Original Grain Size Without Second Grain
        • Lesser Strike Time

Commercial Benefits Of Yutech Batch Pan Automation:

• Get Increased Production In Same Time With Better Recovery And No Rework Wastage
• Or Get Reduction In Strike Time By 10 To 15%, Thus Increase In Number Of Pan Strikes
• Huge Steam And Water Saving In Regular Production
• Excellent Sugar Colour And Quality With Uniform Grain Size
• Reduced Costs In Terms Of Time And Resources Wasted In Re-Melting And Re-Boiling
• Maximized Capacity Utilization In Pans And Centrifugal Machines
• Better Purging And Lower Loads On Centrifugal Machines
• Increased Profitability

Advantages Of Yutech Sensing And Controls:

• Pan Boiling accounts for roughly 30-40% of the Sugar Manufacturing Process / Boiling House Energy needs.
• YUTECH Batch Pan Automation saves a huge amount of Energy in terms of Steam / Vapour. This can be Quantified by Steam and Vapour Condensate Flow Measurement.
• Conventional Pan Boiling is too dependent on Pan-man, over the years Pan Boiling has come to be known more as an Art than Science and this very Art is being lost.
• Correct Brix Sensing, Co-ordinated Level, Temperature, and Vacuum Controls assist in Creating Excellent Pan Boiling Conditions.
• The Brix Reading is always a very big point of contention between the Pan-man and the Chemist. YUTECH Fluid-Density-Brix Analyzers solve this problem by giving true Brix Readings in all Massecuites / Syrups at all given times, thus YUTECH Batch Pan Control Algorithm creates Excellent Pan Boiling Conditions.
• Human Attention Span has its limitations, and the Pan Operator cannot always be fully attentive, this sometimes results in Over-Thickening of the Massecuite leading to Water Addition for Dilution. Water Addition when done other than in the Grain Stabilization Stage and the Final Stage (if required) is an UNACCOUNTED AND PURE WASTAGE OF WATER AND HEATING STEAM.
• YUTECH Fluid-Density-Brix Analyzers and YUTECH Batch Pan Control Algorithm together address this issue AND EFFECT HUGE TIME, WATER, STEAM, AND ELECTRICITY SAVINGS with INCREASED AS WELL AS BETTER QUALITY SUGAR PRODUCTION.
• YUTECH Fluid-Density-Brix Sensing does not involve any Complicated and Unnecessarily Expensive Technologies like Microwave, or, Torque sensing, or earlier techniques OF RF, or HF Conductivity.
• YUTECH Motorized Fluid-Density Sensor and Analyzer Set measures the Power required by the Motor to agitate and stir the Massecuite / Syrup. This Sensed Power is converted first into Density (Kg/m 3) and then into Brix using YUTECH Fluid-Density-Brix Equation which is a set of Complex Mathematical Formulae which linearizes the Power and Converts it into Brix. It further Compensates for Pan Level and Temperature.
• YUTECH Batch Pan Control Algorithm is based on years of experience and interactions with numerous Pan Operators, Chemists, Process Managers, and Engineers in a vast number of Sugar Factories.
• Steam Economy norms have reduced the Pan Boiling Temperatures to about 90oC or lower, which has substantially reduced Steam Consumption. However, the Flip Side of this is Lower Natural Circulation within the Pans, which leads to many problems like False Graining, and Pocket Formation. YUTECH insists on Mechanical Circulators to restore the Circulation and Circulator Speed Variation as per Process Conditions and Temperature to ensure that Material is forced to Circulate. Thus, Ensuring NO FALSE GRAIN OR POCKET FORMATION.