SED drives Parag Agro’s 7000 TCD expansion

Spray Engineering Devices (SED), a Indian clean-tech process engineering company, has announced the successful delivery and commissioning of critical modernization and expansion technologies for Parag Agro Foods & Allied Products at its sugar facility in Ravadewadi, Pune, Maharashtra. This upgrade has enabled the plant to expand its capacity to 7000 tons of cane crushed per day (TCD) while substantially strengthening its overall energy efficiency.

The project integrates SED’s advanced steam-saving technologies and high-efficiency process equipment, marking a significant milestone for both companies. With this expansion, Parag Agro reinforces its position as a strong player in the sugar industry, now operating a factory designed for superior thermal performance and a reduced carbon footprint through smarter energy utilization.

Vivek Verma, managing director, SED, said, “At SED, our mission is to help sugar manufacturers expand capacity while reducing their environmental footprint. The Parag Agro project demonstrates how falling film evaporators and honeycomb calandria pan designs, compatible with low-temperature crystallization, can deliver significant efficiency gains while supporting sustainable growth.”

Yashwardhan Dahake, chairman, Parag Agro Foods & Allied Products, added “This modernization has enabled us to expand production while lowering operating costs and energy use. With SED’s technologies, we are confident of achieving stronger performance benchmarks and contributing to broader industry sustainability goals.”

Following the upgrade, Parag Agro has already achieved a crushing capacity of 7000 TCD, with steam consumption reduced to just 21–22% on cane with B-Molasses diversion — a significant improvement from the previous 32%. These results demonstrate the effectiveness of SED’s modernization strategy in delivering real-time energy savings and production gains.

At the core of the modernization are two falling film evaporators (FFEs) commissioned in Phase 1, with two additional FFEs added as part of the Phase 2 expansion. Each unit features a heating surface of 5,000 m² and operates at steam pressures of 170–180 kPa. Together, these units significantly enhance steam economy and ensure superior thermal efficiency across the plant.

The expansion also includes three new Spray Continuous Pan (SCP) chambers installed alongside the existing SCP chambers commissioned in Phase 1. Designed to operate on low-grade vapours instead of prime steam, the system enables precise boiling at 85–90°C, reduces operational costs, and delivers substantial energy savings.

The modernization forms part of a phased upgrade, with Phase-I and Phase-II collectively adding two FFEs, three SCP crystallization chambers, and specialized condensate heaters for raw and sulphited juice. These additions optimize heat recovery and crystallization efficiency across the plant.

All newly installed systems — including the FFEs, SCP chambers, and condensate juice heaters — have been seamlessly integrated with the plant’s distributed control system (DCS), enabling real-time monitoring and automated control of flow, temperature, and level parameters. This strengthens operational stability and ensures consistent performance throughout the crushing season.

The project also involved precise engineering to synchronize the plant’s existing evaporation bodies with the newly added units, enabling smooth, balanced, and reliable operation under varying loads. With commissioning aligned to the start of the crushing season, Parag Agro is now fully equipped to meet its expanded production targets while delivering stronger energy and cost-efficiency benchmarks.

Established in 1992, Spray Engineering Devices is a technology-driven companies, providing integrated energy-saving equipment and solutions for water, biofuel, jaggery, and sugar industries across 40+ countries.