Reliable valve technology in sugar production: handling abrasive and sticky media

Sugar production is a complex process in which reliability and precise process control are essential. From the moment sugarcane or sugar beets are processed to the refining of crystal sugar, valves are exposed to varying pressures, temperatures, and product characteristics. In virtually every stage, from extraction and evaporation to filtration and crystallization, valves must handle viscous or abrasive substances that are tough on seals and moving parts.

To keep production efficient and stable, valves must not only be durable but also ensure consistent flow and low maintenance. In this blog, we’ll show how Bray Controls develops valve solutions specifically designed for these challenges. With advanced materials, robust construction, and intelligent automation, our valves continue to perform reliably even under the harshest conditions in the sugar and ethanol industries.

The challenge: sticky and abrasive media in sugar-rich processes

During sugar refining and processing, valves are constantly exposed to viscous juices, sugar crystals, and slurries. These substances can accumulate inside the valve body, leading to blockages, wear, or leakage. Such conditions put stress on the seals and can reduce control accuracy, resulting in unplanned downtime. That’s why it’s crucial that the valve design matches the medium and the process in which it operates.

Additionally, valves must withstand high temperatures, pressure fluctuations, and chemical exposure during stages such as evaporation, filtration, and crystallization. This combination of thermal and mechanical stress places high demands on material selection, sealing, and actuation. Only valves with a robust design and intelligent engineering can remain reliably operational under such conditions for extended periods.

Bray Controls develops valves specifically engineered for these demanding processes. By combining durable, wear-resistant materials with advanced sealing technology and customized automation, our systems operate smoothly and maintain performance even under the toughest conditions.

Sustainable solutions for demanding environments

Bray’s product range for the sugar industry includes butterfly valves, knife gate valves, and control valves designed for long-lasting, reliable performance in harsh process environments.

Butterfly valves: leak-free and resistant to high temperatures

Our high-quality butterfly valves deliver completely leak-free performance in applications involving steam, condensate, and abrasive media. They are resistant to high temperatures and chemical exposure and feature a maintenance-friendly design that minimizes downtime, crucial for continuously operating plants. Thanks to their compact build and modular configuration, they are easy to integrate into existing piping systems, simplifying installation and servicing. In this way, Bray Controls butterfly valves contribute to reliable and cost-effective operation throughout the entire refining chain.

Knife gate valves: trouble-free handling of solids

In processes involving sugar crystals and viscous slurries, Bray Controls knife gate valves prevent product buildup or sticking. Smart features such as flush ports and deflection cones keep the seat clean, ensuring smooth operation and reduced maintenance needs. With their rugged construction and high wear resistance, these valves are particularly suited for pipelines in which solids frequently pass through. This ensures consistent flow and a longer service life, even under demanding process conditions.

Control valves: precise flow control for abrasive media

The Series S19/S19L control valves provide extremely precise flow regulation, even with abrasive slurries. Their self-cleaning segment design and wear-resistant components maintain accuracy and longevity, even under intensive use. Thanks to their advanced control characteristics, the process remains stable and repeatable, an important factor for consistent product quality. Moreover, the valves are designed for quick and easy inspection and maintenance, minimizing downtime and costs.

Smart automation for maximum efficiency

A reliable valve becomes truly valuable when it is intelligently controlled. That’s why Bray Controls offers not only mechanical solutions but also advanced automation technology. With electric and hydraulic actuators, smart positioners, and IIoT-compatible sensors, operators can monitor and optimize processes in real time. These systems enable fast response, energy efficiency, and improved control over product quality.

The result? Less manual intervention, shorter downtime, and a stable production process, exactly what a modern sugar plant needs to stay competitive.

Certified quality and global reliability

At Bray Controls, quality and safety always come first. Our valves and actuators comply with internationally recognized certifications such as Lloyd’s Register, UL, and ABS. This ensures reliable performance even in the most demanding environments.

Thanks to this quality assurance, Bray Controls valves perform excellently across various applications, from abrasive sugar slurries and viscous molasses to steam systems. With their robust design and low-maintenance components, they provide maximum uptime, reduced costs, and improved process safety.

Bray Controls: your partner in reliable process control

Bray Controls combines technical expertise, sustainable products, and global service to make production processes in the sugar and ethanol industries more stable and efficient. As a trusted partner, we support our customers in optimizing their facilities with valve solutions that guarantee long-term performance and maximum uptime.

Contact our specialists for personal advice or download our brochure for more information about our solutions for sugar refining and ethanol production.