Case Study: Efficient Sieving of Melt Sugar Using SIVTEK Vibro Separator
Introduction: Why Filtration Matters in Melt Sugar Processing
In sugar manufacturing, one of the most critical processing steps occurs right after extraction—filtration of melt sugar. This viscous sugar juice, produced from crushed cane or beet, carries fibrous particles and residual impurities that must be removed before refining. If these are not routinely filtered out, they can compromise product quality, cause downstream equipment damage, and create inefficiencies in processing.
The traditional filtering methods usually do not sustain throughput against their ability to produce consistent clarity. Galaxy Sivtek addressed this challenge by deploying its Sivtek Vibro Separator, specifically developed for accurate and hygienic high-capacity sieving of melt sugar. At a leading sugar production facility, this separator proved its value by eliminating bottlenecks and ensuring a consistent supply of impurity-free melt sugar.
Challenges: Poor Filtration and Process Downtime
The client—a well-known sugar manufacturing company—was struggling with ongoing issues in processing melt sugar. Their previous filtration solution was not able to keep pace with their increased production demand nor reliably remove all the fibrous material.
The primary challenges included:
- Ineffective impurity removal: Fibrous particles and coarse residues were sneaking into the later stages of the process, resulting in unclear sugar.
- Clogged filtration units: Frequent blockages led to unexpected shutdowns, which hampered production efficiency.
- Manual cleaning downtime: Maintenance took longer than necessary due to the design flaws of the existing setup.
- Non-hygienic process conditions: The inadequate sealing allowed for external contamination, thus complicating the meeting of industry hygiene standards.
As a result, the team was in search of a more robust, hygienic, and high-performance sieving system that could sieve melt sugar effectively while sustaining continuous operation.
Solution: Sivtek Vibro Separator
Galaxy Sivtek proposed the implementation of the Sivtek Vibro Separator—a powerful circular vibrating sieve known for its high throughput and efficiency in wet applications like melt sugar processing.
The Sivtek Vibro Separator uses controlled vibratory motion to achieve fine filtration. The sieve is able to separate out fibrous impurities from the sugar juice without obstructing flow or otherwise damaging the product, making it a particularly effective sieve for melt sugar applications and hygienic operation.
Key Features of the Implemented Solution:
- It is built on the configuration of multiple Vibro Separators that can work in parallel to meet even the stringent requirements of high throughput operations.
- Very careful selection of mesh size to separate fibrous impurities from product without obstruction of juice flow.
- Hygienic design for food-grade processing and sanitary applications.
- Clean-in-Place (CIP), very quick cleaning and decreased downtime.
- Completely enclosed, dust-tight design for cleanliness and plant hygiene.
Results Achieved: Enhanced Hygiene, Higher Throughput & Product Quality
After the install of the Sivtek Vibro Separator, a significant improvement was seen for the melt sugar filtration process. Key results were:
- Superior Filtration Quality: Unwanted fibers and coarse particles were effectively removed, improving the purity of the sugar juice.
- Uninterrupted Operation: The plant reported a significant reduction in clogging issues and cleaning-related downtimes.
- Higher Equipment Life: By having cleaner melt sugar flow to the downstream equipment, there was a decrease to wear & tear.
- Enhanced Productivity: The continuous, high-throughput operation helped the plant meet rising production targets without performance loss.
- Hygienic Compliance: The sealed, food-safe design of the separator met all hygiene and operational standards with ease.
Conclusion:
In sugar processing, clarity and consistency are non-negotiable. With traditional filtration methods unable to match growing production needs, advanced sieving technology becomes essential. The Sivtek Vibro Separator delivered a game-changing solution by enabling precise, high-throughput filtration of melt sugar—helping this client unlock better quality, higher productivity, and reduced downtime.
Its ability to sieve melt sugar efficiently while operating under stringent hygiene conditions makes it a reliable choice for modern sugar plants.
At Galaxy Sivtek, we have partnered with many renowned organizations in the sugar processing industry and beyond to put forth long-term solutions.
Looking to enhance your melt sugar filtration process? Connect with our experts today and discover how our sieving solutions can transform your production line.
