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311311 - Sugarcane Mills
311312 - Cane Sugar Refining
311313 - Beet Sugar Manufacturing
311320 - Chocolate & Confectionery Manufacturing from Cacao Beans
311330 - Confectionery Manufacturing from Purchased Chocolate
311340 - Nonchocolate Confectionery Manufacturing |
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
Industry Facts
• This sub-sector generates $1.5 billion in revenue each year from the processing of sugarcane (U.S. Census Bureau)
• Sugarcane processing is a seasonal industry - most plants operate from 20-32 weeks each year. (Int'l Finance Corp)
• 60% of the world's sugar is produced from sugarcane (Int'l Finance Corp)
CHP Market Saturation
Data not available
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Industry Drivers
• Large thermal energy loads
• Increase process efficiency
• Energy Intensive Industry
• Reliable Power – unplanned power outages can lead to sucrose deterioration before processing can occur
Thermal Opportunities
Reciprocating engines, with a power size range of 30kW–8MW, generate engine jacket heat from 180-200°F, and exhaust heat at around 1200 °F. Industrial turbines, with a power range from 1-20+ MW, generates heat from 900-1100°F. This heat can be recovered and used to heat or cool products in a variety of food processing steps such as:
• Large amounts of warmed water required for sucrose extraction and sugar crystal washing
• Constant, reliable heat source is necessary for heat clarification
• Large amounts of heat required for evaporation and drying
• Cool air is needed for cooling sugar crystals
• 20 cubic meters of water is used for each ton of sugarcane processed (Int'l Finance Corp.)
Process Description
Sugarcane may be harvested mechanically or by hand, but must be transported to a processing plant immediately because sucrose decays very quickly. The sugarcane is cleaned and then is milled in two steps.
The canes are first broken using a combination of knives, shredders, crushers, and rollers. The canes are then ground using a series of roller mills. After each roller, water is run over the crushed sugarcane. The water run in the opposite direction that the sugarcane travels, beginning at the last mill, and ending at the first. This process, called imbibition, maximizes the amount of sucrose extracted from the sugarcane. The juice (water with the dissolve sucrose) is strained, and then clarified by heating it with a small amount of lime. The lime neutralizes the acids that are created as the juice is heated to around 200º F (95º C). Impurities precipitate out, and the remaining sucrose and water solution moves to the evaporator.
The juice first passes through a heat exchanger, and then through multiple effect evaporators. Pressure decreases at each evaporator, allowing the juice to boil at successively lower temperatures. The remaining syrup is approximately 65% sucrose and 35% water. The syrup is aerated, filtered, and clarified again before being sent to vacuum pans for crystallization.
The syrup is boiled to a level of super saturation and then seeded to catalyze crystal formation. When the volume of sugar crystals and liquor reach the maximum level, the mixture is sent to a centrifugal separator. The centrifuge separates the sugar crystals from the liquor left over. The liquor is returned to the vacuum pans and the process is repeated twice more. All of the crystals are washed, dried, cooled and sold as cane sugar. The liquor left over after the third centrifuging is sold as black strap molasses. Some of the black strap molasses is used as the seeding solution for crystal formation. (EPA)
Associations
The Sugar Association
American Sugar Alliance
Sugar Industry Technologists, Inc.
Events
International Sweetener Syposium - August 7-11, 2004
Sugar Industrial Technologists Annual Technical Meeting - April 3-6, 2005
Industry Leaders/Case Studies
M.A. Patout & Sons Ltd. - LA
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
Industry Facts
• Over $3 billion in revenue is generated each year from the refining of raw cane sugar (U.S. Census Bureau).
• Sugarcane processing is a seasonal industry - most plants operate from 20-32 weeks each year. (Int'l Finance Corp)
• 60% of the world's sugar is produced from sugarcane (Int'l Finance Corp)
CHP Market Saturation
Data not available
Geographic Location
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Industry Drivers
• Increase process efficiency
• Energy intensive industry
• Reliable power can eliminate unplanned downtime that leads to loss of revenue
Thermal Opportunities
• Hot water is needed for washing sugar crystals
• Steam is used to melt the sugar crystals
• Reliable heat source is needed for correct operation of evaporators and dryers – temperatures over 200º F are reached (EPA)
• Cool air is used to lower the temperature of the sugar before packaging
Process Description
In some cases, cane sugar is refined at the facility where it is milled, or raw cane sugar is shipped to facilities dedicated to cane sugar refining. Integrated mills are included in sub-sector 311311. The sugar is first washed with nearly saturated syrup to loosen molasses film in a process called affination. The crystals are separated from the syrup with a centrifuge, and then washed with hot water.
The crystals are sent to a melter where they are combined with sweetwater and steam heated. The sugar solution is filtered and chemically clarified by phosphatation or carbonation. The sugar is decolorized through an absorption process, and sent through a series heaters, multiple effect evaporators, and vacuum pans which form a crystal-liquor mixture, similar to the process used in sugarcane processing. This mixture is centrifuged and the liquor completes the cycle 2-3 more times.
White sugar is usually obtained from the first two batches. Brown sugar is obtained the rest of the time. The sugar crystals are washed one last time, and dried at a temperature of approximately 230º F (110 º C). The crystals are cooled and packaged for retail sale. Other processed sugar products that may result are powdered sugar, liquid sugar, and molasses. (EPA)
Associations
The Sugar Association
American Sugar Alliance
Sugar Industry Technologists, Inc.
Events
International Sweetener Syposium - August 7-11, 2004
Sugar Industrial Technologists Annual Technical Meeting - April 3-6, 2005
Industry Leaders/Case Studies
N/A
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• Over $2 billion is generated each year by facilities that manufacture refined beet sugar from sugar beets (U.S. Census Bureau)
• Highly seasonal industry - production plants run only 6-18 weeks each year (Int'l Finance Corp.)
• 40% of the world's sugar is produced from sugar beets (Int'l Finance Corp.)
• 15 cubic meters of water are used per metric ton of beets processed (Int'l Finance Corp.)
Data not available
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• High thermal energy use throughout the entire process
• Escalating energy costs – beet sugar processing plants consume 7% of all energy used by the food processing industry (ACEEE)
• Single most energy intensive industry – 8.3 kWh/$ of shipments (USDA)
• Increases process efficiency
• Hot water is used for washing sugar crystals at many stages in the manufacturing process
• Large amounts of heat are used in evaporators and dryers – temperatures over 200º F (93º C) are reached (EPA)
• Steam may be used to melt the sugar crystals at different points in the process
Beets are first washed and cut into long thin strips called cossettes. The cossettes are fed into a diffuser which extracts the juice and discards the pulp to a dryer. The extracted juice travels to a purification station where it is treated with milk of lime, carbonated, and filtered. If increased purity is desired, this process is repeated.
Multiple effect evaporators boil the juice in a vacuum to create a thick syrup. The syrup is heated until crystallization occurs. This mixture of syrup and crystals is called massecuite. The massecuite is piped to a centrifugal separator which separates the crystals from the liquor. The liquor is reheated and sent through the evaporators again, or it is reboiled to form molasses. The sugar crystals are washed with hot water before being refined (Michigan History, Arts, & Libraries Website).
Raw beet sugar is refined in the same was that raw cane sugar is refined. The sugar is first washed with nearly saturated syrup to loosen molasses film in a process called affination. The crystals are separated from the syrup with a centrifuge, and then washed with hot water. The crystals are sent to a melter where they are combined with sweetwater and steam heated. The sugar solution is filtered and chemically clarified by phosphatation or carbonation. The sugar is decolorized through an absorption process, and sent through a series heaters, multiple effect evaporators, and vacuum pans which form a crystal-liquor mixture, similar to the process used in sugarcane processing. This mixture is centrifuged and the liquor completes the cycle 2-3 more times.
White sugar is usually obtained from the first two batches. Brown sugar is obtained the rest of the time. The sugar crystals are washed one last time, and dried at a temperature of approximately 230º F (110 º C). The crystals are cooled and packaged for retail sale. Other processed sugar products that may result are powdered sugar, liquid sugar, and molasses (EPA).
Beet Sugar Development Foundation
The Sugar Association
American Society of Sugar Beet Technologists
American Sugar Alliance
Sugar Industry Technologists, Inc.
International Sweetener Syposium - August 7-11, 2004
American Society of Sugar Beet Tech. Biennial Meeting - March 2-5, 2005
Sugar Industrial Technologists Annual Technical Meeting - April 3-6, 2005
Amalgamated Sugar Company
American Crystal Sugar Company
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• Nearly $4 billion in revenue is generated from the sale of chocolate cacao products and chocolate confectioneries (U.S. Census Bureau)
No data available
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• High Cost of Energy – over $26 million spent on electricity purchased for heat and power annually by the industry (U.S. Census Bureau)
• Power Reliability – loss of heat sources can result in entire batches of melted chocolate hardening, leading to a financial loss attributed to downtime and lost product
• High thermal loads throughout the process
• Hot air is used to dry the cacao beans
• Cacao beans are roasted at temperatures exceeding 200º F (148.3º C)
• The conching process takes place at a temperature of 180º F (82.2º C) for an extended period of time
• The melted chocolate must be cooled after the conching process
• All piping in the plant must be heated so that the chocolate remains in the liquid phase and can flow from one section of the processing facility to another
Cacao beans must be harvested by hand. The two main cacao bean seasons are November-January and May-July. The fruit is broken open, and the beans and pulp are removed. The beans and pulp are placed in boxes and allowed to ferment for 5-6 days. At this point, the pulp has drained and the sugar in the beans has become an alcohol.
The cacao beans are dried with hot air dryers, and then the beans are roasted at 210º F (99º C) for anywhere from 10-115 minutes depending on the desired flavor. The cacao shells are removed by a process called winnowing, and the beans are ground. The resulting liquid is called cacao liquor. Liquor made from low quality beans is used to produce cacao butter or powder, and liquor made from high quality beans is used to produce chocolate.
To produce chocolate, sugar is added to liquor and the mixture is ground further. This liquid chocolate is continuously stirred and mixed at a temperature of 180º F (82.2º C). This process is called conching. The longer a chocolate is conched, the higher the quality of the resulting product. Cacao butter, milk, vanilla, or a soy stabilizer may be added during conching, along with any other ingredients. (NVogue) Most conching takes anywhere from 24-72 hours. The chocolate is then poured into molds, allowed to cool, packaged and sold either to retail establishments or wholesale for further processing. (Hershey's)
World Cocoa Foundation
American Association of Candy Technologists
National Confectioners Association
National AACT Technical Seminar - September 20-22, 2004
World Cocoa Foundation Partnership Meeting - October 13-15, 2004
All Candy Marketplace - February 8-10, 2005
International Cocoa Conference - May 31- June 3, 2005
Hershey - http://www.intpower.com/applications/hershey_plant.htm
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
Nearly $8 billion in revenue is generated from the sale of chocolate confectioneries made from purchased chocolate. (U.S. Census Bureau
Data not available
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High cost of energy in states with a large number of plants – New York, California, Texas
Power Reliability – loss of process heating results in the hardening of melted chocolate and financial loss due to downtime and discarded batches
Large, stable industry – at least one purchased chocolate confectionery manufacturing plant in each state (U.S. Census Bureau)
Heat is needed to re-melt the chocolate and for re-conching if desired
A controlled, reliable source of heat is required for tempering
The chocolate must be cooled once it has been poured into the molds
All pipes used to moves the chocolate from one section of the plant to another need to be heated to prevent the chocolate from hardening in the lines
When the purchased whole-sale chocolate arrives at the confectionery plant, it is melted and may be conched if a greater quality is desired or other ingredients are to be added. The chocolate is tempered, or cooled at a slow, very controlled rate to achieve the desired texture and consistency. Nuts, or other similar ingredients are added during this step. The chocolate is poured into molds and cooled before being packaged for retail sale. (Hershey’s)
World Cocoa Foundation
American Association of Candy Technologists
National Confectioners Association
National AACT Technical Seminar - September 20-22, 2004
World Cocoa Foundation Partnership Meeting - October 13-15, 2004
All Candy Marketplace - February 8-10, 2005
International Cocoa Conference - May 31- June 3, 2005
M&M Mars Inc.
Hershey’s - http://www.intpower.com/applications/hershey_plant.htm
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
Over $5 billion in revenue is generated each year from the sale of non-chocolate confectioneries. (U.S. Census Bureau)
Data not available
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High thermal loads in most processes
Power Reliability
Rising cost of energy in high-production states
Most processes involve some kind of steam-jacketed kettle or boiler
All processes involve the use of cool air streams to quickly lower the temperature of the product
In the chewing/bubble gum manufacturing process, a constant, reliable heat source is needed to prevent the gum base from hardening prematurely
A large variety of non-chocolate confectionery products are produced, each with a very different production process. Three products produced in this sub-sector are jellybeans, marshmallows, and chewing/bubble gum. General processes for the manufacture of these confectioneries are detailed below:
Jellybeans:
The gel-center of the jellybean is the first part to be manufactured. The two main ingredients are sugar and corn syrup. The ingredients are cooked in a large boiler. The gel is pumped to a molding tray covered in corn starch, and allowed to dry for around 12 hours. The gelled centers are conveyed through a steam bath and sprayed with sugar, before being placed in a rotating drum called an engrossing pan. This drum is rotated and sugar is gradually added. The sugar slowly forms a shell around the gelled-center. Color and flavor are added to the jellybean, and they are polished with confectionery glaze. (CandyUSA).
Marshmallows:
Gelatin, starch, corn syrup, sugar and water are combined in a large kettle, heated, and mixed. The resulting mixture is called slurry, and travels through a whipper that gives it a lighter, fluffier texture. If a color other than white is desired, it is added at this step. The marshmallow is deposited onto a conveyor where they are coated with sugar and cooled. (Marshmallow Peeps Website)
Chewing/Bubble Gum:
The gum base (in most cases chicle) is heated in a large steam-jacketed kettle to temperatures around 240º F (116º C). The resulting syrup is filtered, centrifuged, and filtered a second time using vacuum strainers. The melted chicle must be kept hot during the clarification and filtration process or it will begin to harden. The syrup is poured into a large mixer where other ingredients, such as color, flavoring, powdered sugar, or corn syrup are added. The gum mixture is poured onto a conveyor belt and cooled with cool air jets. The gum passes through an extruder, causing it to be smoother and have a finer texture. Finally, the gum passes through a series of rollers that flatten it to the desired thickness before being cut and packaged. (Ford Gum)
American Association of Candy Technologists
National Confectioners Association
National AACT Technical Seminar - September 20-22, 2004
All Candy Marketplace - February 8-10, 2005
Cadbury Adams - http://www.chpcentermw.org/pdfs/020709ChicagoIL/020709_Brown-4-8MW.pdf
NECCO - http://www.foodprocessing-technology.com/projects/necco/
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