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Sugar

SWEET SUCCESS

Considering the variations in the price of sugar worldwide and production volumes sugar production process that exceed local consumption, sugar companies are constantly seeking to improve their overall performance of the operation while lowering their costs. We have worked with several sugar mills that seek to reduce their costs while ensuring the highest quality of their products, increasing the efficiency of their processes both in the field and in the factory.

One of the challenges in this industry is to achieve the involvement of all levels of the organization, as well as unionized collaborators and sugarcane associations. It is of the utmost importance that improvements are reflected in the main efficiency indicators of the harvest and in the cost of sugar production.

01.

Field

Solutions

  • • Planning and supervision process of fieldwork to improve cane quality and yields (from land preparation to cane harvest).

  • • Planning and logistics model to reduce harvest losses by improving cane freshness.

  • • Harvest supervision system to increase the quantity and quality of cane (cane left in the field, impurities, reducers, etc.).

Benefits

  • • Increase in field performance.

  • • Improved cane freshness hours from cutting to milling, resulting in reduced harvesting losses.

02.

Factory and Maintenance

Solutions

  • • Definition of operating parameters and control model through factory dashboards.

  • • Design of supervision routines to ensure hour-by-hour management of parameters.

  • • Equipment preventive maintenance model and work order control.

  • • Design and implementation of key management indicators in all areas.

Benefits

  • • Reduction of production costs.

  • • Reduction of factory losses (use of bagasse, cachaca and final honey).

  • • Improved factory efficiency.

  • • Reduction in the combined biomass and fuel oil consumption cost.

  • • Increased milling rate.

  • • Reduction in mill downtime.

03.

Inter-harvest Repairs

Solutions

  • • Redesign of repair processes to improve the use of human and material resources within the inter-harvest cycle.

Benefits

  • • Reduction of lost time in the factory.

  • • Reduction in fuel oil and biomass consumption.

  • • Reduction in repair time (days).

04.

Structure and Training

Solutions

  • • Training for the development of management skills.

  • • Design of the structure for greater fluidity and effectiveness in operations.

Benefits

  • • Results-oriented organizational culture.

“The newly implemented methodology has contributed to us achieving the highest levels of production of sugar and sugar cane grinding in the history of the factory during this harvest as well as the best levels of efficiency…”

President Ingenios Santos

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