In a landmark achievement for sustainable industrial engineering, Spray Engineering Devices Ltd. (SED) has successfully commissioned a major sugar refinery capacity expansion and energy optimisation project for Shri Dutt India Private Limited (SDIPL) at its Kandla facility in Gujarat.
Completed in under twelve months, the project increased the refinery’s capacity from 1,000 tonnes per day (TPD) to 2,500 TPD, while retaining the existing boiler infrastructure. Notably, SED achieved the expansion without any additional boiler investment, setting a new benchmark for rapid and energy-efficient industrial scale-up in India’s sugar sector.
Setting New Benchmarks in Rapid, Sustainable Scale-Up
Among the fastest large-scale expansions in the Indian sugar industry, the project highlights how modernisation of existing assets can unlock significant capacity gains. Instead of deploying capital-intensive new utilities, SED optimised the refinery’s core process systems, proving that sustainable growth and accelerated execution can go hand in hand. As a result, the project establishes a compelling model for refineries seeking higher throughput under tight timelines and energy constraints.
Leadership Perspectives on Engineering Innovation
Commenting on the milestone, Vivek Verma, Managing Director, Spray Engineering Devices Ltd., said the project underscores the role of process innovation in sustainable manufacturing. “This project demonstrates the capability of our latest Batch Crystallisation Pans to operate at extremely low Delta T levels. By optimising heat transfer, we enabled Shri Dutt India to more than double its output while retaining its existing steam generation infrastructure. It reinforces that engineering innovation is central to sustainable industrial growth.”
Echoing this view, Jeetendra Dharu, Director, Shri Dutt India Private Limited, emphasised the execution excellence behind the project. “The entire project—from concept to commissioning—was completed in less than twelve months. This reflects seamless coordination between teams and SED’s strong commitment to meeting aggressive execution timelines.”
Key Project Highlights
*2.5x Capacity Expansion: Scale-up from 1,000 TPD to 2,500 TPD
*Infrastructure Optimisation: MVR-based system eliminated the need for new boiler investments
*Proprietary Technology: Honeycomb Calandria Batch Pans operating at an industry-leading 20–25°C Delta T
*Fast-Track Execution: Concept-to-commissioning achieved in under 12 months
Advanced Process Integration Drives Energy Efficiency
At the core of the project is SED’s proprietary integration of Mechanical Vapour Recompression (MVR) with Batch Crystallisation Pans. These pans feature Honeycomb Calandria technology. Operating at an ultra-low temperature differential of just 20–25°C, the system significantly enhances heat transfer efficiency while sharply reducing steam consumption. This advanced configuration allowed SDIPL to unlock higher capacity without increasing energy demand. It demonstrates a practical pathway to low-carbon industrial expansion.
Delivering World-Class Outcomes with Lower Carbon Impact
Reflecting on the project’s complexity, Priti Ruparel, representing the leadership at SDIPL, noted the technological and execution challenges involved. “This was a significant challenge in terms of both time and technology. We placed our trust in SED’s technical expertise, and they delivered a truly world-class sugar refinery.” As per the press release, by eliminating the need for additional boiler infrastructure, the refinery achieved a 2.5x capacity increase with a significantly reduced carbon footprint. Ultimately, the project sends a clear message to the industry. Technological innovation—rather than added utilities—is the key to sustainable, high-impact industrial growth.
