Inline Measurement Technology for Foreign Object Detection and Moisture Monitoring in the Sugar Industry

Process‑critical parameters often change unnoticed during seasonal operation

In the sugar industry, seasonal production cycles, varying raw‑material qualities and high throughput volumes directly affect process stability. Deposits can detach and appear as foreign objects. During the processing of pressed sugar beet pulp, moisture content significantly influences energy efficiency and material quality. Without continuous inline data, uncertainties arise in process control and quality assurance.

Early detection of foreign objects and moisture values makes it possible to keep processes stable and compensate for deviations during ongoing operation.GreCon Engineering

Lack of Transparency in the Process – Solid Facts from the Industry

In sugar production, many quality‑ and cost‑relevant parameters are still monitored discontinuously or only by sampling. Without consistent inline measurement technology, the basis for reliably assessing processes and intervening in time is missing.

25 %

Material usage – typical overdosing without inline measurement

> 70 %

most quality deviations occur before final inspection

> 72 h

Time delay between process deviation and laboratory result

Solutions and concepts

Sugar production relies on two central measurement tasks: foreign object detection and moisture measurement. These can be technically covered by the following GreCon systems:

MATCONTROL HF model full-surface measurement installed above a production line

Inline foreign object detection

GreCon MATCONTROL HF provides high‑resolution, full‑surface monitoring of the material flow to detect density deviations, structural irregularities and foreign objects in real time. The measurement data support the stabilisation of upstream cleaning and conveying steps by identifying anomalies before they affect downstream processing.

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Inline moisture measurement

GreCon MOISTURECONTROL measures the moisture content of beet pulp, pressed material or intermediate products continuously and without sampling delays. The real‑time data enable more precise control of drying, pressing and pelletising, supporting energy‑efficient operation and consistent material conditions.

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The future of industrial measurement technology

“With increasing process dynamics, rising energy intensity and tighter tolerances, inline measurement technology is gaining importance. Modern plants no longer rely solely on final inspections but integrate measurement values directly into their control loops. Measurement technology is therefore becoming a decisive tool for stability, reproducibility and resource efficiency.”GreCon Engineering

Workers display holographic data in factory hall

Consequences of Missing or Insufficient Measurement – More Than Just Scrap

Production deviations develop gradually. Without continuous measurement data, foreign objects, moisture fluctuations or structural changes in beet pulp or intermediate sugar products remain undetected for long periods – until scrap, complaints or unplanned downtime occur.

Economic consequences
Increased material consumption, unplanned downtime, rising unit costs.

Operational consequences
Unstable processes, frequent readjustments, overload of quality control.

Strategic consequences
Production performance becomes harder to predict, reduced competitiveness.

The cost of doing nothing is high. Reliable measurement technology is not a convenience option – it is a strategic prerequisite for stable processes.

finger in front of laptop points to holographic statistics

Sugar Production Presents Specific Measurement‑Technology Requirements

Sugar production involves demanding process conditions in which reliable inline measurement is essential:

Typical challenges

Highly fluctuating moisture levels in raw materials such as beet pulp
Seasonal deposits and contaminations carried through the process
High speeds during transport, cleaning and processing
Limited accessibility to measurement points in closed or insulated plant sections
Delayed laboratory analyses for moisture and product quality

The result? Processes with high variation and error potential.

These risks are not theoretical – they occur daily, often go unnoticed and lead to significant costs.
That is why industrial measurement technology is not optional, but essential.
And this is exactly where Fagus‑GreCon comes into play.

GreCon Product overview

Everything at a glance: our measurement technology solutions

The data obtained from GreCon measurement systems forms the basis for efficient, stable and reproducible sugar production. Measurement takes place inline, continuously and fully process‑integrated – precisely where deviations occur.

Supported measurement and optimisation tasks

Foreign object detection
Moisture measurement

The systems are modular, long‑term stable and can be integrated into both existing and new plants. The goal is a reliable data foundation for well‑founded decisions and efficient processes.

We look forward to hearing from you.

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Process fluctuations and contaminations impair quality in sugar production

Inline measurement technology for the early detection of foreign objects and moisture deviations