SUGAR MILL AUTOMATION SYSTEM

Continuous, Un-interrupted and Constant Rate of Feeding maintains Donnelly Chute Levels and increases Mill Performance as well as Throughput
Elimination of Choking at Preparatory Devices, Mills, Chutes, or Carriers reduces downtime
Maintained Juice to Maceration Water Ratio increases Evaporation Efficiency
Optimum Mill Speeds with respect to Loads and Levels ensure good Milling Results at all times
Effective water saving and cutting off water flow when crushing is stopped.
Constant Juice Flow for the Process ensures even loading in the Boiling House and Stabilizes and Reduces the Steam Consumption which means higher Boiling House efficiency and Bagasse Saving
Stable Juice Flow also helps in better Juice pH Control which in turn ensures better Juice and Sugar Colour which means better Sugar Price
Constant Dry Bagasse Feed to Boilers ensures better Steam Generation Efficiency
All the above is only possible when Donnelly Chute Levels are accurately sensed in a well tuned and synchronous Mill Automation System.

Constant Load on Preparatory Devices ensures Better Cane Preparation resulting in a better Preparatory Index
Constant Load on Mills and Level in all Donnelly Chutes results in Power and Steam Savings as well as improves Mill Performance in terms of:
- Increased Extraction
- Better Reduced Mill Extraction or RME
- Reduced Bagasse Pol and Moisture
- Constant Power Demand in Mill House which comprises about 40% or more of the overall Factory Power Consumption results in Overall Stable Power throughout the Factory
Constant Load on Mills also results in Lesser Mechanical Wear & Tear
- Lesser Maintenance Cost

Infra Red Type Donnelly Chute Level Sensing of all Donnelly Chutes
Hall's Effect Type Cane Blanket Level Sensing
Hall's Effect Type Top Roller Lift Sensing
All Preparatory Devices and Mill (Pressure Feeders if driven by separate Drives) Drive Load Current Sensing by High Precision Non-Invasive CT Protectors and Isolating Converters to sense
Preparatory Devices and Mill Turbine Chest Pressure Sensing, by Pressure Transmitters
Live Steam Pressure Sensing, by Pressure Transmitters
Hydraulic Drives Pressure Sensing, by Pressure Transmitters
Maceration Water Flow Sensing
Juice Tank Level Sensing
Juice Flow Sensing by Mass or Magnetic Flowmeter
Mill Hydraulic Pressure Sensing, by Pressure Transmitters
Mill and Preparatory Devices Bearing Temperature Sensing and Monitoring
Motor Winding / Motor Cage Temperature Sensing and Monitoring
All Inter-Carriers, Cane Carriers, Bagasse Carriers, Mills, Pumps, On / Off / Run Condition Sensing and Inter-Lock Protection

Automatic Cane Feed Control: Speed Control of all Cane Carrier, Rake Carriers, Belt Carriers etc., which Feed Cane to the Mills
Automatic Mill Speed Control: All Mill Speed Controls and Variation with respect to individual Mill’s Load and its Donnelly Chute Level
Maintain Mill and Pressure Feeder Speed Ratio if driven by separate Drives
Next Mill Donnelly Chute Level and Speed Feedback for Mill Speed Control
Maintained Mill Speed Safe Operating Band
Auto Maceration or Imbibition Control: Controlled Maceration Water Flow as per Dynamic Process Conditions
Juice Flow Stabilization: Controlled and Constant Juice Flow to Process / Boiling House as per Dynamic Process Conditions

All following conditions will Raise Alarm and Implement Safety Controls as per Factory Conditions and Customization to User Needs:

Donnelly Chute Levels for Cane Carrier Speeds
Tripping of any Carrier / Pump / Mill will Trip all preceding Carriers
Tripping of any Mill will Trip all preceding Mills (By User’s Choice)
Cane Juice Tank Level increase beyond Preset High Level to Reduce Cane Carrier Speeds
Cane Juice Tank Level increase below Preset Low Level to increase Cane Carrier Speeds (After Checking other Process Dynamics) and Juice Pump Speed Reduction (By User’s Choice)