Turning Excellence into Tangible Outcomes
Real Results Delivered
From achieving 25% steam on cane in brownfield projects (2015–16) to delivering fully boiler-less plants (2019–20).
Repeat Business & Trust
More than 60% of our order book comes from repeat customers who have seen the tangible benefits of our technology firsthand.
Holistic Engineering
We look at the entire factory ecosystem. From sugarcane preparation to sugar bagging, we analyse energy balance, water balance, and equipment performance to ensure high efficiency across the system.
A History of "Firsts"
SED has consistently led the global sugar industry with groundbreaking innovations, introducing technologies that were implemented for the first time ever and reshaping what factories can achieve.
First Boiler-Less Sugarcane Processing Plant (Global)
First MVR Based Distillery (India)
First to Achieve 25% Steam on Cane in Greenfield Plants (Global)
First Low-Temperature Evaporator Module (LTEM®)
First Spray Continuous Pan (SCP®) in the Indian Market
First Brownfield Capacity Doubling Without New Boilers
Case Studies: Real Projects. Real Impact.
The Turnaround Story
Challenge: A financially distressed 2500 TCD plant with outdated infrastructure and high energy costs due to external fuel purchase.
Solution: Comprehensive technical audit and phased modernization plan focusing on energy reduction and process debottlenecking.
Result: Plant revived, stabilized, and became profitable on a sustainable basis.
Phases:
- Phase 1: Capacity expanded from 2500 TCD to 3600 TCD.
- Phase 2: Capacity further increased from 3600 TCD to 5000 TCD (achieving up to 5500 TCD).
- Achievement: Won the prestigious National Efficiency Award.
Key Takeaway: Achieved massive capacity jump without any investment in new steam generation section. Massive reduction in steam demand from 54% to 28% on cane.
The Zero-Emission Revolution: Eco Tech Agro
Project: World's First Boiler-less Sugarcane Processing Plant
SED implemented its pioneering Boiler-Free Technology using Mechanical Vapour Recompression (MVR) based Low-Temperature Evaporation (LTE®). This 750 TCD sugarcane processing plant operates entirely without a boiler, utilizing electrical energy instead of thermal combustion.
Key Achievements:
- Zero Emissions: Complete elimination of smoke and ash; no CO2 emissions.
- 100% Bagasse Saved: Saved biomass is being directed to their existing paper plant.
- 100% Water Recovery: The plant requires no external water source and using 100% high-quality cooled condensate for irrigation.
- Energy Efficiency: Lower power consumption in its class through MVR closed-loop technology.
- Higher Yield: Improved reduced mill extraction more than 98% and bagasse moisture less than 45% ensures higher yield.
Powering the Giant: Al-Khaleej Sugar Refinery Dubai, UAE
Project: Falling Film Plate Evaporator Integrated with MVR for the World's Largest Standalone Sugar Refinery
Challenge: Processing massive volumes requires immense thermal energy, making efficiency a critical operational priority.
Solution: SED deployed its advanced Low Temperature Evaporator (LTE®) technology to operate in conjunction with Mechanical Vapor Recompressors (MVR).
Key Achievements:
- Massive Scale: Successful installation of world largest Falling Film Plate Evaporators (FFPE) with a total heating surface area of 34,000 m².
- Energy Optimization: Significant reduction in steam and power demand by recycling thermal energy through recompression, setting a benchmark for energy efficiency in mega-refineries.
Capacity Enhancement: Shri Dutt India, Kandla, Gujarat
Project: 2.5x Capacity Expansion via MVR based Crystalization
Challenge: The client required a massive expansion in refining capacity without a proportional increase in steam generation infrastructure or energy costs.
Solution: A strategic upgrade using Mechanical Vapour Recompressors (MVR) integrated with Honeycomb Calandria Batch Pans and Falling Film Plate Evaporators.
Key Achievements:
- 2.4x Capacity Jump: Production capacity increased from 1,000 TPD to 2,400 TPD (Refined Sugar Output).
- Steam Efficiency: Achieved a groundbreaking steam consumption rate of <0.40 Ton per ton of sugar (reduced from 1.0 Ton/ton).
- Technology Deployed: Installation of Direct Contact Heaters, Condensate Flashing Systems, melt concentration and sophisticated MVR based Batch Pan.
Our Equipment for Sugar Refineries
Awards &Recognition
S. Nijalingappa Sugar Institute Sweet Memories
2025, Honored for valued association and contribution to knowledge sharing and institutional excellence in the sugar industry.
Platinum Sponsor at UPDA International Summit
2025, Recognized as a leading platinum sponsor supporting global collaboration, innovation, and growth in the sugar sector.
Excellence Award STAI
2025, Presented for outstanding performance, innovation, and sustained excellence in sugar industry operations and solutions.
Dr. Bansidhar Gold Medal – STAI Convention
2023, Awarded at the 80th STAI Annual Convention for technical excellence in sugar process innovation.
Distinguished Speaker – National Sugar Institute
2023, Mr. Vivek Verma recognized as a Distinguished Speaker at the Executive Development Programme organized by the National Sugar Institute, Kanpur.
SISSTA 51st Convention – Sponsorship Appreciation
2022, Recognized for Gold Sponsorship at the 51st Annual Convention of SISSTA held in Tirupati, showcasing continued contribution to sugar sector events.
Mangal Singh Gold Medal Award
July 2017, Mr. Vivek Verma was awarded the Mangal Singh Gold Medal by DSTA, Pune, for his original technical paper on advanced sugar process engineering.
SISSTA Silver Medal
2013, Awarded to Mr. Vivek Verma for the best technical paper on enhancing power generation, recognizing his impactful research in the sugar sector.
Industrial Excellence Award
August 2010, The Sugar Technologists' Association of India (STAI) conferred Mr. Vivek Verma with the 'Industry Excellence Award' for his outstanding contribution in developing equipment design for the sugar and allied industry.
Life Time Achievement Award
August 2008, STAI conferred the Lifetime Achievement Award to SED founder Mr. N.K. Varma for his visionary foresight and dedication to the advancement of the cane sugar industry.
Dr. Bansi Dhar Gold Award
2006, STAI presented Mr. Vivek Verma with this award for the best original paper titled 'Conservation of Steam in Sugar Industry' based on GMR Industries Ltd.'s experience.
NOEL DEERR Gold Medal
2006, Awarded by STAI to Mr. Vivek Verma for his original paper on innovations in energy and conservation within the sugar industry.
NOEL DEERR Gold Medal
2005, STAI awarded Mr. Vivek Verma the NOEL DEERR Gold Medal for his original paper on steam conservation in the sugar industry, based on GMR Industries Ltd.’s experience.
SISSTA 52nd Convention – Gold Sponsorship
2005, Received appreciation as a Gold Sponsor at SISSTA's 52nd Annual Convention, reinforcing support for sugar industry innovation.
Exhibitor – 81st Annual Sugar Expo (STAI)
2000, Honored as Valued Sponsor and Exhibitor at the 81st Annual Convention and International Sugar Expo organized by STAI.
STAI Silver Medal
2001, Awarded to Mr. Prateek Verma for the second-best paper titled 'Automation of Cooling & Condensing System' in the sugar industry.
Engineering Excellence for India’s Leading Companies
Partnering with Global Leaders Across Continents
Why Choose SED?
Expertise
Our team brings years of industry experience, ensuring high-quality solutions tailored to your needs.
Innovation
We remain at the forefront of innovation, continuously adopting advanced technologies to enhance efficiency and sustainability across sectors.
24 x 7 Support
From project inception to post-commissioning support, we are committed to our clients every step of the way.
Reach out to us
You can reach us at:
+91-172-3508200
info@sprayengineering.com
Spray House Plot No C-82 Industrial Area Phase-7 SAS Nagar Mohali-160055 Punjab India
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