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Estandardização e Automatização do Controlo das Cores nos Cristalizadores
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Resumo(s)
A variabilidade da cor nos açúcares brancos produzidos na Sidul, em particular nos tipos G e GB, tem-se revelado um desafio crítico para a operação, com impacto direto na estabilidade da qualidade e nos custos de produção. Este problema está associado à etapa de cristalização, onde a decisão sobre a quantidade de xarope granulado a reaproveitar (backboiling) influencia simultaneamente o recycle do processo e a cor final do açúcar. Atualmente, esta decisão é reativa e dependente da experiência dos chefes de turno, resultando em variações significativas e em maiores custos.
O presente estudo, realizado entre fevereiro e setembro de 2025, teve como objetivo desenvolver uma ferramenta de tomada de decisão para apoiar a definição da quantidade de licor concentrado a alimentar à cristalização. A ferramenta foi construída com base em regressão múltipla, relacionando a cor do xarope granulado, a cor do licor branco e a cor objetivo do açúcar final, resultando numa equação que permite calcular diretamente a tonelagem de licor concentrado a introduzir em cada cozedura.
A ferramenta, implementada em Excel e já aplicada em ambiente industrial, demonstrou resultados positivos nas métricas de equilíbrio. Com a sua utilização, observaram-se melhorias significativas: a purga de xarope granulado desceu 0,73 m³/cozedura/semana, o reciclo reduziu 2,31% e os açúcares enviados para dissolução diminuíram de 11,99 ton/semana. Já a métrica de toneladas de G e GB produzidas por cozedura manteve-se estável (diferença de - 0,15 ton), confirmando que o aumento do backboiling não comprometeu o rendimento produtivo.
Quanto à cor, o G manteve-se estável (35,80 UI vs. objetivo de 42 UI) e o GB desceu para 28,67 UI (objetivo de 31 UI), afastando-se dos valores definidos. Ainda assim, verificou-se redução da variabilidade, aumentando a estabilidade do processo. Parte desta limitação resulta do desalinhamento entre NIR e ICUMSA (métodos de medição de cor), cuja recalibração em curso deverá trazer ganhos mais fiáveis nos açúcares finais.
Em suma, a ferramenta desenvolvida permitiu reduzir ineficiências, melhorar métricas de equilíbrio críticas sem impacto negativo no rendimento produtivo e tornar o processo de cristalização mais estável e previsível, constituindo um passo relevante para o controlo da variabilidade da cor do açúcar granulado e granulado branco produzidos na Sidul.
The variability of color in white sugars produced at Sidul, particularly in types G and GB, has proven to be a critical challenge for operations, with direct impact on quality stability and production costs. This issue is linked to the crystallization stage, where the decision on the amount of jet syrup to be recycled (backboiling) simultaneously affects both process recycle and the final sugar color. Currently, this decision is reactive and dependent on the experience of shift supervisors, resulting in significant variations and increased costs. The present study, conducted between february and september 2025, aimed to develop a decision-making tool to support the definition of the quantity of evaporated fine liquor to be fed into crystallization. The tool was built using multiple regression, relating the color of jet syrup, the color of evaporated fine liquor, and the target color of the final sugar, resulting in an equation that directly calculates the tonnage of evaporated fine liquor to be introduced in each batch. The tool, implemented in Excel and already applied in an industrial environment, demonstrated positive results in the balance metrics. With its use, significant improvements were observed: the purge of jet syrup decreased 0,73 m³/crystallization/week, recycle was reduced 2,31%, and remelted sugars decreased 11,99 tons/week. Meanwhile, the metric of G and GB tons produced per crystallization remained stable (difference of -0,15 ton), confirming that the increase in backboiling did not compromise production yield. Regarding color, G remained stable (35.80 IU vs. a target of 42 IU), and GB decreased to 28.67 IU (target of 31 IU), moving further from the defined objectives. Even so, variability was reduced, leading to greater process stability. Part of this limitation results from the misalignment between NIR and ICUMSA (color measurements methods), whose ongoing recalibration is expected to bring more reliable improvements in final sugar color. In summary, the developed tool reduced inefficiencies, improved critical balance metrics without negatively affecting production yield, and made the crystallization process more stable and predictable, representing a relevant step toward controlling color variability in granulated and granulated white sugars produced at Sidul.
The variability of color in white sugars produced at Sidul, particularly in types G and GB, has proven to be a critical challenge for operations, with direct impact on quality stability and production costs. This issue is linked to the crystallization stage, where the decision on the amount of jet syrup to be recycled (backboiling) simultaneously affects both process recycle and the final sugar color. Currently, this decision is reactive and dependent on the experience of shift supervisors, resulting in significant variations and increased costs. The present study, conducted between february and september 2025, aimed to develop a decision-making tool to support the definition of the quantity of evaporated fine liquor to be fed into crystallization. The tool was built using multiple regression, relating the color of jet syrup, the color of evaporated fine liquor, and the target color of the final sugar, resulting in an equation that directly calculates the tonnage of evaporated fine liquor to be introduced in each batch. The tool, implemented in Excel and already applied in an industrial environment, demonstrated positive results in the balance metrics. With its use, significant improvements were observed: the purge of jet syrup decreased 0,73 m³/crystallization/week, recycle was reduced 2,31%, and remelted sugars decreased 11,99 tons/week. Meanwhile, the metric of G and GB tons produced per crystallization remained stable (difference of -0,15 ton), confirming that the increase in backboiling did not compromise production yield. Regarding color, G remained stable (35.80 IU vs. a target of 42 IU), and GB decreased to 28.67 IU (target of 31 IU), moving further from the defined objectives. Even so, variability was reduced, leading to greater process stability. Part of this limitation results from the misalignment between NIR and ICUMSA (color measurements methods), whose ongoing recalibration is expected to bring more reliable improvements in final sugar color. In summary, the developed tool reduced inefficiencies, improved critical balance metrics without negatively affecting production yield, and made the crystallization process more stable and predictable, representing a relevant step toward controlling color variability in granulated and granulated white sugars produced at Sidul.
Descrição
Palavras-chave
Cristalização Cor Backboiling Xarope Granulado Açúcar Granulado Açúcar Granulado Branco