Industrial Infrastructure
& Engineering Capacity
Operating a heavy industrial manufacturing complex, we engineer and fabricate turnkey sugar processing machinery strictly adhering to ASME, CE, and ISO 9001:2015 standards. Our infrastructure encompasses advanced 5-axis CNC machining, submerged arc welding (SAW) stations, and full-scale NDT (Non-Destructive Testing) laboratories, ensuring precision manufacturing for high-capacity milling, clarification, and crystallization stages.
1990
Year Established
150,000 ft²
ISO-Certified Production Facility
45+
Senior Mechanical & Process Engineers
15,000 T
Annual Steel Fabrication Capacity
60+
Registered Technical Patents
100%
NDT & X-Ray Weld Inspection
0.01 mm
CNC Machining Tolerance
50+
Global Export Countries
Heavy Equipment
Fabrication Specifications
Heavy Plate Cold Forming
Equipped with 4-roll CNC hydraulic plate bending machines. Processing capacity covers Carbon Steel SA-516 Grade 70 up to 4" (100mm) thickness and Duplex Stainless Steel up to 2.5" (65mm). Maximum plate width handling of 13 ft (4,000mm) with pre-bending precision maintained within 1.5x plate thickness. Fully compliant with ASME Section VIII Div 1 for vacuum pans, crystallizers, and evaporator calandrias.
Large-Scale CNC Machining
Operating heavy-duty 5-Axis CNC horizontal boring and vertical milling centers capable of supporting a maximum payload of 80 Metric Tons. Machining envelope extends to 40 ft (12m) in length and 15 ft (4.5m) in swing diameter. Dimensional tolerances are strictly controlled to ±0.0004" (0.01mm) with surface finish accuracy down to Ra 0.8, crucial for mill roller shafts, trunnions, and high-torque gearboxes.
Certified Welding & NDT
Utilizing automated tandem SAW, GTAW, SMAW, and FCAW processes. 100% of operators are certified under AWS D1.1 and ASME Section IX. In-house Level III NDT laboratory performs 100% Radiographic Testing (RT), Ultrasonic Testing (UT), Magnetic Particle Inspection (MPI), and Liquid Penetrant Inspection (LPI). Maintaining a First Time Quality (FTQ) weld pass rate exceeding 99.2% for critical pressure-retaining components.
FEA & Mechanical Engineering
Engineering phase executed via SolidWorks Professional and ANSYS. Conducting rigorous Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to simulate thermal gradients, pressure thresholds (up to 300 psi), and metal fatigue life cycles exceeding 100,000 operational hours. Generating precise 3D digital twins, automated BOMs, and ISO-compliant manufacturing drawings prior to material processing.
Process Equipment Engineering
Heavy Duty Milling Tandems
Crushing Capacity 2,500 to 15,000 TCD with Mill Extraction Efficiency > 96.5%.
Metallurgy En8/40C8 UT-tested forged alloy steel shafts; high-porosity coarse-grain cast iron rollers (IS 11201).
Mechanical Integration Donnelly chuting, TRF feeding systems, centralized PLC lubrication, hydraulic loading (up to 300 kg/cm²).
Falling Film Evaporators
Heating Surface Area 2,000 m² to 12,000 m² per vessel. Configurable for quintuple effect.
Thermal Efficiency Vapour bleeding configuration achieves steam % cane < 38%.
Fabrication Specs SA-249 TP304/316L ERW tubes, precision poly-baffle juice distributors, entrainment catchers (carry-over < 100 ppm).
Continuous Vacuum Pans
Throughput Volume 40 T/hr to 150 T/hr continuous boiling for A, B, and C Massecuite.
Calandria Design Floating/Honeycomb calandria architectures maintaining Surface/Volume ratio > 10 m²/m³.
Process Control Top-mounted planetary gear mechanical circulators, DCS automated super-saturation control, nominal boiling temp 65°C.
Industrial Centrifugals
Batch Machines 1,200 to 2,250 kg/charge capacity, operating at up to 24 cycles per hour.
Continuous Machines 1100mm to 1500mm basket diameter, processing capacity 10 - 30 T/hr.
Drive & Dynamics SAF 2205 Duplex SS stress-relieved baskets, regenerative VFDs, active vibration monitoring (ISO 10816 compliant).
Recent Turnkey Projects
Florida, USA - Boiling House EPC Upgrade
Technical Scope Turnkey fabrication and installation of a Quintuple Effect Evaporator Station. Includes four 5,000 m² Falling Film Evaporators constructed with SA-240 Type 304L SS shells and SA-249 TP304L tubing. 100% ASME Section VIII Div. 1 compliant.
Performance Metrics Reduced process steam consumption from 45% to 36% on cane. Achieved a steady-state syrup Brix of 68°Bx. Entrainment losses maintained below 50 ppm. Documented ROI achieved in 2.4 harvest seasons.
São Paulo, Brazil - 12,000 TCD Milling Tandem
Technical Scope Engineering and commissioning of five 45" x 90" heavy-duty mills. Features UT-tested En8 forged alloy steel shafts, planetary gearboxes (service factor 2.5), 1000 kW VFD AC motors, and automated hydraulic loading systems operating at 280 kg/cm².
Performance Metrics Surpassed guaranteed performance parameters by achieving a 97.8% Reduced Mill Extraction (RME). Final bagasse moisture content stabilized at 48.5%. Unplanned mechanical downtime reduced by 22% compared to legacy steam-turbine configurations.
Global Engineering Certifications
ASME 'U' Stamp
Section VIII Div. 1
Certified fabrication of pressure vessels, including evaporators and vacuum pans. Authorized for designs up to 3,000 PSI (200 bar) and capacities exceeding 150 m³.
ASME 'S' Stamp
Section I Boilers
Compliant assembly of high-pressure bagasse-fired power boilers. Engineering ratings cover capacities up to 140 TPH, 110 bar working pressure, and 540°C superheated steam.
ISO 9001:2015
TÜV NORD Audited
QMS enforcing 100% material traceability (MTRs), stringent dimensional tolerances for heavy mechanical components, and mandatory non-destructive testing (NDT) documentation.
CE Marking
PED & MD Compliant
Harmonized compliance with the EU Pressure Equipment Directive (2014/68/EU) and Machinery Directive (2006/42/EC). Includes ATEX conformity for sugar dust environments.
Lifecycle Lifecycle
& Field Engineering
OEM Spares Inventory
Stocking over 15,000 critical wear components. Inventory includes IS 11201 cast iron mill rollers, duplex stainless steel centrifugal screens (0.06mm slot width), and SAE 660 bronze bearings. Guaranteed 48-hour global dispatch for emergency AOG requirements.
Site Commissioning
Deployment of OSHA/BOSIET-certified mechanical engineers for turnkey site erection. Services encompass precision laser alignment (tolerance <0.05mm), foundational grouting, DCS loop testing, and dynamic load balancing prior to cold/hot commissioning phases.
Equipment Retrofits
Comprehensive refurbishment extending legacy equipment lifecycle by 10-15 years. Specialized in mill roller re-shelling utilizing 58-60 HRC complex carbide hardfacing. Upgrading existing evaporator configurations to achieve a 15-20% increase in operational heating surface area.
Performance SLA
Backed by an 18-month mechanical defect warranty from B/L issuance or 12 months post-commissioning. Service Level Agreement (SLA) incorporates 24/7 remote diagnostic support via IIoT sensors, guaranteeing 98.5% mechanical availability during peak crushing seasons.
Frequently
Asked Questions
Find expert answers regarding our heavy fabrication capabilities, international logistics, and sugar mill turnkey engineering processes.
12 to 16 weeks for standard evaporators and crystallizers. Turnkey milling tandems and highly customized heavy equipment require 24 to 32 weeks depending on scale and material availability.
Yes. We provide flexible incoterms including FOB, CIF, or DDP. Our logistics team handles Break Bulk (BBK), Flat Rack (FR) securing, and Out of Gauge (OOG) transport, ensuring safe delivery to your plant site.
Yes. We execute build-to-print manufacturing with strict IP protection. We require your CAD/PDF files to verify tolerances, and we will provide a precise, itemized fabrication quote within 72 hours.
Our facility operates under ISO 9001:2015. Pressure vessels are designed and stamped per ASME Section VIII Div 1. All structural welding complies with AWS D1.1, and materials are backed by EN 10204 3.1 Mill Test Certificates.
We implement rigorous Non-Destructive Testing (NDT) protocols. This includes 100% Ultrasonic Testing (UT) on heavy forgings to eliminate internal voids, Radiographic Testing (RT) on critical pressure seams, and Magnetic Particle Inspection (MPI) for surface integrity.
Absolutely. Alongside standard mechanical warranties against defects, we offer contractual performance guarantees tied to specific KPIs (e.g., sucrose extraction rates, final moisture content, or steam economy), which are jointly verified during on-site commissioning.
Yes, brownfield integrations are our specialty. Our engineering team can conduct 3D laser scanning of your existing facility to ensure millimeter-perfect piping tie-ins and structural fits for new falling film evaporators, minimizing downtime.
We deliver a comprehensive Turnkey Manufacturer's Data Report (MDR). This package includes As-Built CAD drawings, detailed Operation & Maintenance (O&M) manuals, Welding Procedure Specifications (WPS/PQR), NDT reports, and full material traceability records.
