Stabilizing Sugar Crystallization for Quality & Efficiency

Consistency Is Key in Multi-Vessel Cooking

In the first crystallization step, six vessels process syrup into sugar. Each vessel must complete its batch in sync — delays force water addition, which increases syrup content, energy use, and risk of sieve clogging. Uniform behavior across vessels is crucial to maintain quality and efficiency.

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The Approach

• Batch Quality Counts: counted good vs bad batches per vessel using Value-Based searches (bad = duration > 1h 45m), capturing true production performance.

• Power Drop Detection: monitored for drops below 20 kW once reaching the target volume (800 L) — a critical sign of potential crystallization risk.

• Cross-Vessel Comparison: compared batch profiles across vessels, overlapping reference layers and combining multiple charts into one graph to expose the root of inconsistencies.

• Integrated Dashboards: built dashboards with monitors, filters, and historical ideal-batch overlays for clear, actionable visibility.

Insight: With these capabilities, you gain a contextualized, real-time view of batch behavior, enabling early detection of risks and driving consistent product quality.

Results

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Takeaway

By aligning batch durations and detecting early deviations, the team improved sugar quality, reduced steam use, and avoided sieve clogging — achieving up to 12% faster batch times.

Ready to bring consistency and savings to your batch processes? Let’s talk.

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