Reduced microbial sucrose losses in clarification and filtration: improving mud filtration with an innovative cleaning system

Microbial activity causes significant sucrose losses during clarification and filtration in sugar factories, impacting product quality and production costs. This study aimed to reduce these losses by implementing an innovative cleaning system in rotary vacuum filters. Two cleaning approaches were evaluated: a conventional manual cleaning system and a clean-in-place (CIP) system. In the conventional setup, periodic manual cleanings were performed, whereas the CIP system used continuous cross-flow cleaning with hot water through internal filter pipes. Microbial metabolites, such as volatile acidity (titration), D-lactic acid (enzymatic kit) and mannitol contents (HPLC), were measured for each scenario. We statistically analyzed the collected data to determine each cleaning system’s effectiveness in reducing microbial activity and to estimate mannitol balance and sucrose losses across scenarios. The CIP cleaning system reduced microbial metabolite levels, with median reductions of 46% in D-lactic acid and 19% in volatile acidity compared with the conventional system. Additionally, sucrose losses were reduced from 1800 kg to 600 kg per day with the CIP system. Undetermined sucrose losses also decreased from 14–35% under the conventional system to 2–9% with the CIP system. This approach improved filter juice quality and generated annual economic benefits of approximately USD230,000 for the mill. Implementing a CIP cleaning system in rotary vacuum filters reduces microbial activity, improves product quality and significantly lowers sucrose losses in sugar factories. The economic advantages underscore this system’s potential for industrial application.