Extraction of sugar from sugar beets is a process optimized over decades based on experience gathered during production. This process improvement is achieved without any systematic approach for optimization which raised the question whether such a mature process can be further optimized effectively, applying methods developed in the last decade like statistical experiment design or physicochemical modeling. Viable areas of operation for the respective approaches will be assessed and discussed using the example of sucrose extraction from sugar beet. Operating conditions are optimized regarding extraction kinetics and equilibrium behavior. Physicochemical modeling, however, requires detailed information on phase equilibria, fluid dynamics, and mass transfer effects. Here, the phase ratio can be identified as a sensitive parameter and process performance like the HETP (high equivalent of a theoretical plate) value can be enhanced. Therefore, the volumetric productivity serves as indicator. Potentials of process design and process optimization by a combination of statistical design of experiments and physicochemical modeling approaches are assessed, and respective possibilities and limitations are discussed.

The deduction of a kinetic model of colour formation, especially by the Maillard reaction, in heated concentrated carbohydrate solutions is described on the basis of systematic experimental studies. The main parameters of the colour formation are included such as reaction time, temperature, pH, amounts of sucrose, glucose, fructose, amino‐nitrogen and dry matter. The model is based on a three step first order consecutive reaction beginning with sucrose via glucose/fructose and dicarbonyl compounds to the colourants. The suitability of the model was tested on model experiments as well as on experiments with technical solutions in an evaporation station. It resulted in a good correspondence between measured and calculated colour values. The potentials of the model are discussed and the range of applications is pointed out.

Tower extraction has become the state-of-the-art technology for extracting sugar from cossettes. Sugar yield and plant economy are factors that have made this technology prevail over other extraction methods. In particular for high throughput rates per extraction line, tower extraction plants are unrivalled. The possibilities to reduce the energy consumption during extraction are shown using the example of a technologically leading European sugar producer. Thanks to the installation of large extraction plants in the sugar factories of Schweizer Zucker AG at Frauenfeld and Aarberg, the extraction losses and also the raw juice draft could be reduced significantly. Based on the records of the campaigns from 2000 to 2014, the paper reports on results of the operation of a modern tower extraction plant. In the more recent past, there has been a trend towards longer beet campaigns, and sugar factories are increasing their capacities due to economic reasons. Depending on the project conditions, various extension concepts are coming into effect. Special emphasis has to be placed on future-oriented material selection.

With the liberalization of the European sugar sector, the industry is free to export sugar to the world market, competing with other sugarcane producing countries. To understand competitiveness, it is imperative to compare total production costs, including both raw material (farm) and processing costs (mill). Therefore, farmlevel production costs from agri benchmark combined with an engineering approach to calculate processing costs were merged to calculate sugar production costs in Germany and Brazil. The necessary data related to investment costs and technical coefficients was obtained in collaboration with BMA. Results show that processing one ton of white sugar (excluding raw material costs) from sugarcane in Brazil is more than USD30/t cheaper than processing sugar beet in Germany. Including raw material costs and the sales of byproducts, white sugar production in Brazil has a total cost advantage of USD112/t over German factories. Key differences in production costs are associated with labor (20%), depreciation (20%) and energy costs (40%). The findings indicate that even with equivalent raw material costs, the lower net processing costs are a major competitive advantage for Brazilian sugar producers. The combination of the typical farm approach and the dynamic engineering model can be applied to other regions, allowing for the estimation of regional production and shifts in global sugar supply.

The drying of pressed sugar beet pulp in a pressurised fluidised bed with superheated steam is widely used in the sugar industry and can be considered to be state of the art for energy-efficient drying concepts in combined plant systems. The process has been used on a large scale in the sugar industry for more than 20 years. In the past campaign, BMA subjected existing drying systems at various locations to a number of refinements. These systematic, process engineering modifications allow the driers to work more efficiently and reliably. Feeding pressed pulp into a fluidised-bed drier is a critical phase in the drying process and can lead to malfunctions. The ability to determine the fluidisation conditions in the first drier cells provides more detailed insights into the process so that critical situations can be detected at an early stage and therefore malfunctions can be avoided. Further investigations have shown that the height of the fluidised bed has a considerable effect on adequate product transport and on the degree to which the heat from the circulated steam is utilised and, consequently, on water evaporation.