During last couple of years, mills in India are seen moving towards modern process automation to improve the plant performance and process efficiency. Better process control and higher operational consistency can be achieved by minimizing the human interference with good process automation resulting in better performance of the plant. A modern batch pan automation system along with online optical crystal monitoring system installed on one pan at DCM Shriram Limited, Unit-Loni during the crushing year 2021-2022. After commissioning of the pan automation, the results of the pans operated manually, and the pan operated automatically were compared. The automatic pan took approx. 20% less time than the manually operated pan to complete one strike. The water consumption in the automatic pan was approximately. 60% less in comparison to the manual operation. In fact, several pan strikes carried out without water addition. Due to the consistent operation and better brix development, the massecuite exhaustion was also improved by approx. 0.70 units. The online optical crystal monitoring system provides additional insight monitoring of the crystallization as well as making the pan boiling process it truly man-less. The paper presents a case study of the pan automation system installed at DCM Shriram Limited, Loni and its results and future plans.
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