Sant Tukaram Sugar Factory — Energy Assessment & Co-Generation Optimisation

We conducted a comprehensive energy assessment of a leading sugar manufacturing facility with an integrated 15 MW co-generation plant. The engagement evaluated electrical systems, utility operations, process equipment, and energy consumption across the entire production cycle — from sugarcane handling and juice extraction to crystallisation, drying, and power generation.

The study identified multiple opportunities to improve operational efficiency, reduce electrical consumption, and enhance process reliability through engineering upgrades and automation. Key recommendations included installation of Variable Frequency Drives (VFDs) on motors, conveyors, pumps, and feeding systems; optimisation of compressor, injection water, and hot water systems through intelligent control and automation; and upgrading legacy slip-ring motors to high-efficiency induction motors.

Further recommendations covered electrical infrastructure — earthing, power factor correction, and capacitor bank modernisation — alongside cooling tower water management, HVAC efficiency for electrical rooms, and corrective safety actions on panels, motor terminals, and rotating equipment. Performance monitoring metrics were developed for the co-generation plant to maximise steam utilisation and power generation efficiency.

The assessment concluded with a detailed roadmap for data-driven energy conservation projects, supported by equipment performance monitoring, operational benchmarking, maintenance analysis, and energy consumption tracking. The project demonstrates our capability to deliver practical, high-impact energy optimisation for large industrial process plants — reducing operating costs, improving reliability, and maximising the efficiency of both process and utility systems.