Revolutionize your sugar

production with innovative

process control

Bernd Langhans, Siemens DI PA S

Ralf Neckermann, Siemens DI PA S

Unrestricted | © Siemens 2024 | Digital Industries | Process Automation | SIMATIC PCS neo
Industry requirements for Distributed Control Systems
in the context of digitalization

Global Lifecycle
PROCESS Collaboration compatibility
INDUSTRIES
Scalability Intuitive Modular
from small units
user guidance Automation
to large plants

Combining Cyber Security

the real and the threats and
virtual world regulations

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Highlights of SIMATIC PCS neo

neo System Access

Direct and secure connection to the
system via web – anywhere, anytime
neo Collaboration
and device independent Multi-user web engineering;
global collaboration on a new level;
highly efficient

Support of the
Object- open MTP
oriented Data standard
Management Modularization and

Always up-to-date and neo Usability

SIMATIC PCS neo package unit integration
made easy
consistent information neo Scalability
Easy and intuitive GUI; all tasks in one New system software,
From smallest applications
workbench (Administration, Engineering, completely web-based (HTML5) to world-scale plants
Monitoring & Control)

Common Application Architecture

with SIMATIC PCS 7
APL, CMT, Technological Products, COMOS, PAA, Recipes …

Investment Protection Know-how Protection

Common Hardware and Network Platform
with SIMATIC PCS 7

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Key challenges and business drivers in the sugar industry

1 Transparency Operational targets

• Trustworthy origin from the plantation to the packaged product
• Monitor product quality
~15%
Energy
2 Engineering Efficiency cost reduction

• Increase automation level and remote-control capabilities

• Optimize plant engineering time ~20%
Operational
3 Sustainability cost reduction
• Decrease energy consumption
• Optimize Input/Output ratio
>30%
4 Operation Efficiency Engineering
cost reduction
• Ensure continuous analysis of plant performance
in remote locations
• Optimize operation and logistics

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Sugar industry sets ambitious targets for greater efficiency and sustainability

Situation today Goal for tomorrow

Sustainability • E.g., 1.4T – 2.5T Steam/T-Sugar • 1 to 1.2 T-Steam/T-Sugar = 15 – 50% savings

Operation Efficiency
• High number of operators/process operation • 3 – 5 operators per plant/~300 operations per day

• Downtime due to equipment failures • Longterm plant availability

• Less downtimes through active asset management

Transparency • No online real-time KPI for quality, energy and materials • Online decision making based on KPI

Engineering Efficiency • Low level of automation and fragmented

engineering landscape • Standardization of engineering with DCS system
• No overview and central control • Higher performance & fast reactions to downtimes
• Outdated package unite control

SIMATIC PCS neo & NAHMAT meet the challenges of the sugar industry
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SIMATIC PCS neo and NAHMAT can be a major lever to reach the ambitious
targets of the sugar industry

Goal for tomorrow SIMATIC PCS neo concept NAHMAT concept

Siemens assures application availability for long plant
Long-term plant availability SIMATIC PCS neo long-term support concept
lifecycles

Web technology allows usage of mobile devices for

SIMATIC PCS neo &flexibility
High flexibility for operators
complete NAHMAT meet the challenges
of operators ofcompletely
Faceplates the sugar industry
adapted to mobile devices

Online decision-making
based on KPIs
Advanced Process Graphics Live data monitoring of production KPIs

Standardization of Innovative engineering concept and Dedicated sugar production library (NAHMAT), APL,
Engineering with DCS system industry libraries as in SIMATIC PCS 7 CMT, PAA, Recipe Management*

Higher performance & fast Advanced Alarm Control, well arranged faceplates
reactions to downtimes
Diagnostic and maintenance concept
and analysis functions

* APL = Advanced Process Library, CMT = Control Module Type,

PAA = Process Automation Accelerator
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SIMATIC PCS neo System Overview
Zero Installation Client, Plant Central Software Licenses Management, Web-based, but data ownership stays at the customer

Uses web-technologies Remote access (only if desired)

based on HTML5 for via a Terminal Server in the
communication between DMZ (demilitarized zone)
Servers and Web Clients with corresponding
security standards

SIMATIC PCS neo works No pre-installation on devices

in a local network which necessary to run SIMATIC PCS
is usually not connected neo due to Zero Installation
to the internet Client approach

Web-based means
1 Your data is safe because you can host it in your local network
Online and offline set-ups in any aspect from
2 Reduced effort for stations due to no installation effort engineering to license management up to
3 Using web-technologies with HTML5 give maximum flexibility
operations and diagnostics
for distributed collaboration in engineering and operation
as well as remote access

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SIMATIC PCS neo Usability
Engineering and Monitoring & Control in one workbench

Engineering Monitoring & Control

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SIMATIC PCS neo NAHMAT Library
Dedicated Sugar Library increases efficiency in engineering and operation

NAHMAT Solutions for Sugar NAHMAT Solutions for General Use

NAHMAT NAHMAT NAHMAT NAHMAT NAHMAT NAHMAT

Crystal Common Centrifuge Centrifuge Sequence Motor
Control Vapor Rail Master Automation Control Sequence
(NCC) (NCVR) (NCM) (NCA) Control
Optimized Optimized Master Automation Solution Advanced
crystal growth vapor control and drives for a simple motor
for sugar distribution for batch for a sugar sequence sequence
production in a sugar centrifuge batch control via control
factory stations centrifuge Faceplate strategies

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Use Case: Smart Boiling Control
Improve the Sugar Crystallization and Energy Consumption

Full control of the process The "boiling trends" as basis for

success
Customer Value:
• Reduced Steam
Consumption
per ton of sugar (~15%)
• Reduced average
boiling time (~10 - 20%)
• Estimated ROI
around 150 days

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Use Case: Smart Boiling Control
SIMATIC PCS neo & NAHMAT optimizes your operations significantly (real example)

Boiling curve of a manual strike Boiling curve of an automated strike

26%
Reduction
of batch time
2:20 h 1:43 h

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SIMATIC PCS neo with NAHMAT library fits perfectly to the sugar industry
Customer References

Ing La Cabana KSL Sugar Saharuang Sugar KTIS Sugar TRR Sugar
El Salvadore Thailand Thailand Thailand Thailand

Sugar House Complete Factory Sugar House Sugar House Sugar House
4 pans 4 pans 9 pans 5 pans

10,000 TCD 20,000 TCD 20.000 TCD 25,000 TCD 20,000 TCD

Brownfield Greenfield Brownfield Brownfield Brownfield

Full automation Full automation Full automation Full automation Full automation

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NAHMAT Crystal Control Vacuum Pan Sugar Crystallization

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NAHMAT Crystal Control Vacuum Pan Sugar Crystallization

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NAHMAT Crystal Control Vacuum Pan Sugar Crystallization

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NAHMAT Crystal Control Vacuum Pan Sugar Crystallization

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NAHMAT Crystal Control Vacuum Pan Sugar Crystallization

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NAHMAT Crystal Control Vacuum Pan Sugar Crystallization

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SIMATIC PCS neo with NAHMAT library
Ready for Gen AI integration

First Gen AI
support
solutions in
NAHMAT

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Summary:
SIMATIC PCS neo system functions lead to tangible customer values

Customer Values Cost savings

• Reduced steam consumption per ton of sugar: ~ 15 %

• Reduced average boiling time: ~ 10 - 20 %

• Optimized plant operation: ~ 10 - 20 %

Estimated ROI with SIMATIC PCS neo after around 150 days

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 SIMATIC PCS neo
Thank you for your attention!
© Siemens 2024
Subject to changes and errors. The information given in this document only contains general descriptions
and/or performance features which may not always specifically reflect those described, or which may undergo
modification in the course of further development of the products. The requested performance features are binding
only when they are expressly agreed upon in the concluded contract.
All product designations may be trademarks or other rights of Siemens AG, its affiliated companies or other companies
whose use by third parties for their own purposes could violate the rights of the respective owner.

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