Spray Engineering Devices Limited (SED) successfully completed a steam-efficiency upgrade at Tirupati Sugars Limited’s Bagaha facility in Bihar. The modernisation programme has reduced steam consumption to below 34% on cane, meeting the performance parameters set for the project. The upgrade marks an important step in improving energy efficiency at the plant while maintaining compatibility with its existing infrastructure.
Improving Efficiency Without Major Utility Replacement
The project formed part of Tirupati Sugars’ strategic initiative to enhance operational efficiency without undertaking costly large-scale utility replacements. Instead, the company focused on process optimisation and the integration of energy-efficient equipment. Importantly, the upgrade was seamlessly retrofitted into the plant’s existing boiler and turbine systems. As a result, the facility achieved a significant reduction in steam demand while continuing to operate within its established steam and power network. The approach not only ensured technical compatibility but also made the modernisation economically viable for an operating sugar factory.
Engineering Precision Key to Steam Efficiency
Vivek Verma, Managing Director of Spray Engineering Devices Limited, highlighted, “Improving steam efficiency in an operating sugar plant requires precise engineering, proper heat-recovery integration, and careful execution without disturbing existing utilities,” Verma said. “This project clearly demonstrates that efficiency improvements can be achieved through engineered upgrades and optimised process configuration.”
Tirupati Sugars Targets Improved Steam Economy
From the plant operator’s perspective, the upgrade aligns with Tirupati Sugars’ broader objective of improving the steam economy of its existing facility. Deepak Yadav, Managing Director of Tirupati Sugars Limited, Bagaha, noted that the project has delivered the expected performance results. “The objective of this upgrade was to improve steam economy of our existing plant through process optimisation and energy-efficient equipment. The project has been implemented as planned, and the plant is now operating at improved efficiency levels in line with the expected performance parameters,” Yadav said.
Key Technology Upgrades in the Boiling House
As part of the project, SED carried out the engineering, supply, and commissioning of several high-efficiency process systems. These included, High-efficiency condensate juice heaters, falling film evaporators, flash cigar systems, honeycomb calandria batch pans and receiving crystallisers.
Advanced automation and process control integration
Together, these upgrades have significantly improved boiling house operations and optimised the plant’s overall heat balance. Consequently, the facility now operates with lower energy consumption and improved resource efficiency.
A Model for Modernising Existing Sugar Plants
Across India, sugar mills are increasingly prioritising modernisation of existing facilities instead of investing in expensive greenfield projects. In this context, the Bagaha upgrade demonstrates how targeted technology improvements can enhance plant performance and profitability. As per the press release, by proving that legacy plants can achieve modern efficiency standards through strategic upgrades, SED and Tirupati Sugars are providing a practical roadmap for energy conservation and sustainable sugar manufacturing in India.
