NF Alarcon, R Larrahondo, R Hernandez, AP Quiceno and R Rojas
Ingenio Mayagüez, Candelaria-Pradera Highway Km 2, Valle del Cauca, Colombia
This study was conducted due to the increase in the deviation of undetermined sucrose losses in a dual sugar and ethanol factory. This deviation was related to factors such as inadequate assurance of sucrose input and imprecise quantification of the factory stock, which affected the calculations of the factory’s sucrose balance and, consequently, the decision-making process. To resolve this deviation, strategies based on Industry 4.0 were implemented. These included the installation of continuous automated samplers for raw juice and molasses, as well as the use of a system that allowed the historical tracking and automatic transfer of factory information using the SCADA system. This facilitated real-time calculation and monitoring of the factory’s sucrose stock balance. These technologies provided real-time access to key production process data, improving the precision of sucrose balance oversight. Improvements implemented resulted in a notable reduction in the deviation of undetermined losses % cane, from 3.13% in 2022 to 1.063% in 2023. Furthermore, a 98% correlation between real sucrose and apparent sucrose was achieved, establishing this value as a key indicator for determining increased accuracy when to conduct preventive interventions in sampling equipment. This improved control allowed for timely identification of deviations and optimization of preventive maintenance decisions. The implementation of Industry 4.0-based strategies not only improved the precision and reliability of sucrose balance calculations but also enabled continuous monitoring of critical process parameters. In summary, the adoption of these advanced technologies represents a fundamental step towards enhancing the competitiveness and efficiency of sugar and ethanol factories, ensuring better operational control and more efficient resource utilization.