Sugar and Confectionery Product Manufacturing Business Guide
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We documented 3 challenges in Sugar and Confectionery Product Manufacturing. Now get the actionable solutions — vendor recommendations, process fixes, and cost-saving strategies that actually work.
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All 3 Documented Cases
Idle Vacuum Pans and Delays from Manual Crystallization Monitoring
Reduced strikes per day due to labor-intensive monitoringOperators spend excessive time on manual sampling and adjustments during crystallization, causing equipment idle time and production bottlenecks. Without automated vision or Brix sensors, pans cannot discharge promptly upon reaching desired crystal size. This leads to lost capacity in continuous sugar manufacturing lines.
Reprocessing of False Crystals Due to Inconsistent Size Distribution
1% yield loss per strike before control implementationCrystals exiting the optimal supersaturation range stop growing, melt, or form fines, necessitating reprocessing which increases production costs and reduces yield. Inconsistent crystal size distribution (CV) and mean aperture (MA) fail quality specs, leading to rework. This directly ties to cost of poor quality in tempering control.
Excessive Steam and Water Consumption in Crystallization Strikes
25% increase in steam consumption per strike; 7 m³ water per 85 m³ pan strike before optimizationPoor control of supersaturation during sugar tempering and crystallization leads to formation of unwanted fine crystals (fines) and conglomerates, requiring additional steam for reprocessing and water to eliminate false crystals. This wastes energy and resources in every batch strike. Inadequate real-time monitoring results in suboptimal crystal growth outside the ideal supersaturation range.