Steam Economy


Installation of our unique VIJAY-CONDENSATE heaters along with well engineered flash heat recovery system can bring down the steam demand to 33-34 % for sugar process compared to 41-42% on cane in standard sugar plant without any Compromise & complications in process parameters & system.

This proven simple system has improved final sugar quality, extraction efficiency and overall capacity of plant at low investment with unimaginable viability.


The principle adopted is the primary heating of raw juice using conventional juice heater by low temperature vapors is carried out by vapor condensate after flashing to gain potential and further intensive bleeding to result maximum steam economy.

Our liquid to liquid counter current tubular condensate heater uses vapor condensates only after flashing to heat the raw juice to 70 -72 deg C with a stand by provision of one segment for cleaning .

Identical type feed heater recovers exhaust condensate heat by preheating of clear juice to gain steam economy & avoids loss of pure condensate due to flashing with proper sealing at high pressure end in simple way.

Our well designed flashing system operates & handles entire condensates by 3 numbers of identical pump sets with elimination of more number of smaller size pumps to gain electrical power and maintence cost end. The system can be incorporated even for evaporator section installed at 6000mm.Addition of our direct contact heaters for further improves economy of plant by recovery of waste heat from clarifier, filter vapors, Juice & evaporator ammonia vapors.


  • Lowest steam consumption of 33 -34 % for entire sugar process.
  • Complete elimination of medium pressure steam for sugar operations.
  • 99 – 99.5 % pure exhaust condensate back to boiler at 100 – 102 deg C.
  • Simpler system identical to operation of conventional juice heaters with easy supervision, highly reliable and repeatable.
  • The separate second effect vapor condensates circuit enables for use of cooling tower make up after conditioning and reduces pollution load for CO-generation plant.
  • The low temperature of excess vapor condensate at 45 -48 deg C is directly and easily handled as dilution water for treated sugar factory effluent (or) directly used at distillery.
  • Low investment with assured shortest pay back of below one normal sugar season.


The system reduces steam & power demand in boiling house and increases plant operating capacity with best quality sugar out put with higher extraction efficiency.


We have already installed this system successfully at Shri Khedut Sahakari Khand Udyog Mandli Ltd., Kosamba, Tal.-Hansot, Dist.-Bharuch (Gujrat) – India.

During Season 2009-10

1. Shree Khedut S.K.U.M. Ltd., Pandvai, Kosamba, GUJRAT STATE –
Achieved 33-34% on cane on days average from 1st day

During Season 2010-11

1.Shri Vitthalrao Shinde S.S.K. Ltd., Madha, Dist.-Solapur (350 TCH)
Achieved 32-33% Steam on Cane
2. Nira Bhima S.S.K. Ltd., Indapur, Dist. – Pune (150 TCH)
Achieved 33-34% on Steam Cane
3. Ryatar S.S.K. Niyamit, Timmapur, Mudhol, Dist.- Bagalkot (190 TCH)
Achieved 33-34% steam on Cane

During Season 2011-12

1.M/s. Bhimashankar S.S.K.Ltd, Tal.Manchar, Dist.Pune. (Maharashtra) (170TCH)
Achieved 35-36% Steam on Cane
2. M/s. Tridhara Sugars Ltd, Amadapur Dist.Parbhani. (Maharashtra) (140TCH)
Achieved 35-36% Steam on Cane

During Season 2012-13

1.M/s. Shree Ganesh Khand SKUM Ltd.A/p.Vataria, Tal.Hansot, Dist.Bharuch, (Gujarat) (170TCH)
Achieved 34-35% Steam on Cane
2. M/s. Shree Shivsagar Sugars Ltd., Udapudi, (Karnataka) (130TCH)
Achieved 35-36% Steam on Cane

During Season 2013-14 
1. Ashok SSK Ltd., Shrirampur, Ahmednagar (Maharashtra)
2. Tikaula Sugar Ltd., Tikaula, Muzaffarnagar (U.P.)
3. Gayatri Sugar Complex, Sadashiv Mandal, Nizamabad (A.P.)
4. Naraingarh Sugar Mills Ltd., Village-Banondi, Naraingarh, Ambala (Haryana)

During Season 2014-15 
1. Shahabad Co.Op. Sugar Mills Ltd., Kurukshetra (Haryana)
2. Vitthalrao Shinde SSK Ltd., Madha, Solapur (Maharashtra)
(Repeat Order- for Diffused cane juice plant)

During Season 2015-16 
1. Shree Dudhganga Vedganga SSK Ltd., Bidri, Kagal, Kolhapur (Maharashtra)
2. Piccadilly Agro Ind. Ltd., Piccadilly (Haryana)

During Season 2016-17 
1. Vishwasrao Naik SSk Ltd., Shirala, Sangli, Maharashtra
2. Shree Ganesh Khand, Vataria, Bharuch (Gujrat)
(Repeat Order- Second generation of our steam economy & achieved 32% steam on cane)
3. Mylar Sugars Ltd., Billary (Karnataka)
(Complete process plant commissioned at 34% on cane with zero intake water/service water conservation)
4. Vikas SSK Ltd., Latur (Maharashtra)


1. M/s. Ashok SSK Ltd., Shrirampur, Ahmednagar. (Maharashtra)
2. M/s. Tikaula Sugars Ltd., Tikaula, Muzaffarnagar. (U.P.)
3. M/s. Gayatri Sugar Complex, Sadasiva Mandal,Nizamabad (A.P.)
4. M/s. Nairangarh Sugar Mills Ltd,Village: Banondi, Naraingarh, (Ambala).