No question about it, sugar plants consume vast amounts of electricity, and with a lot of aging equipment, there’s no doubt that several motors and the mechanical systems they drive are probably consuming more power than they should—due to worn bearings and a general lack of maintenance. In many instances, motors are probably not using variable speed drives, and large inrush currents place a big demand on electrical utilities.
Unfortunately, in many facilities, managers have grown accustomed to high energy usage and carbon emission levels. But today, it’s becoming easier to install sensors to monitor motor currents and vibration due to worn bearings. With digitalization, it’s easier to “pick the low-hanging fruit” and get some big returns.