What is happening in the sugar-energy sector?

Artificial intelligence combined with advanced sensors is transforming the industrial routine of Brazilian sugarcane mills. A world-first technology, developed by a research and automation consulting firm based in Piracicaba, São Paulo, is proving that it is possible to increase efficiency, reduce waste, and boost profitability without expanding infrastructure, teams, or grinding volumes.

According to simulations and projects already underway, gains reach 0.5% in extraction and 0.5% in fermentation, and can be higher depending on each mill.

Real results: $18 million increase in EBITDA

In a typical mill grinding 3.8 million tons per season, the results are impressive. The increase in EBITDA reaches $18 million per year, with a gain of $0.62 per ton of processed cane. Water savings reach 2 million cubic meters per season, and the investment pays back in the first year of operation. Extra revenue ranges between $5 and $6 million per season, and sugar recovery increases by 0.25%.

How the technology works?

The system monitors more than 40 parameters in real time, anticipating losses and improving production routes. NIR on-line sensors based on near-infrared spectroscopy monitor fiber, brix, pol, and cane maturity in real time. Artificial intelligence combined with Machine Learning makes algorithms adjust industrial variables automatically every second. Automation occurs without human intervention, adjusting the process according to the quality of the cane entering. Predictive analytics anticipates failures and shutdowns for preventive maintenance.

The return on investment comes not only from the direct increase in efficiency, but also from avoided losses. AI anticipates deviations and reduces waste, highlights Jaime Finguerut, chemical engineer and technical director of the consulting firm responsible for the project.

Benefits that go beyond finance

Process stability is ensured with less variation in production. Predictability of failures enables preventive maintenance before breakdowns. Precise control of raw materials monitors freshness, cleanliness, and maturity. Energy optimization results in better cogeneration of energy from biomass. The same team produces more, with reduced operating costs.

Connection with Vottax solutions

This case from the sugar-energy sector demonstrates in practice the same value that Vottax Technology offers its clients. The predictive technology used in the sector converges with Vottax's MES with AI algorithms trained on IoT data, which detects anomalies up to 48 hours in advance. The real-time IoT sensors in the project correspond to the IoT solutions for factories, engineering, and logistics offered by Vottax.

The Machine Learning applied in the sugar-energy sector is the same Machine Learning available on the Vottax platform for predictive analytics. Big Data and cloud computing for business intelligence are among the solutions offered by Vottax. The company is a certified SAP, Salesforce, and Thomson Reuters partner, and offers fiscal and tributary software integrated with ERP.

Vottax is your SAP, Thomson Reuters, and Salesforce partner, offering innovative solutions that apply artificial intelligence to accelerate digital transformation across sectors, from IT to fiscal, tributary, compliance, legal, and CRM.