Introduction:
Screens for Bagasse Water Reuse are no longer optional in sugar production. Water is one of the most expensive and limited resources in a mill. For every tonne of cane crushed, a mill uses 1,500 to 2,000 liters of water. Most of this water does not disappear – it ends up as wastewater.
Walk through any sugar mill after crushing starts, and you will see the floors wet from washing and cooling pits overflowing near the bagasse section. That water is mixed with fibers, mud, and fine particles. Mills often let it flow to the drains. But that water has value. With the right screen, you can capture it, clean it, and use it again.
Government rules are also clear. MoEFCC and CPCB guidelines now push mills to reuse 80–90% of water internally. That means the days of letting water flow out unchecked are over. And this is where wedge wire technology comes in.
At Multitech Engineers, we have worked with sugar mills for years. We have seen how simple design choices like putting the right screen in the right place can be. That saves thousands of liters every day. This is not a theory. It’s what mills like yours are doing now to cut water costs and meet compliance.
What is Bagasse Water and Where Does It Come From?
Let’s understand Bagasse and the water around it.
Bagasse is the dry, fibrous residue left after crushing sugarcane. But it is never fully dry. It carries moisture, and during handling, some of that water flows out. Mills use water in different steps around bagasse:
- Washing the bagasse storage floors
- Cooling water in bagasse pits
- Handling mud and juice spillages
This water does not look clean. It carries tiny fibers, mud, and even sugar traces. But do not let that fool you. It is not a waste – it is reusable. The problem is, if you reuse it without filtering, the fibers clog pumps, block pipelines, and overload the Effluent Treatment Plant (ETP).
That is why mills install Screens for Bagasse Water Reuse at critical points. A good screen traps fibers but keeps water flowing freely. And that is what wedge wire screens do best.
Think of it like a simple kitchen sieve – but designed for industrial scale. Instead of straining tea leaves, you are straining fibers from thousands of liters of water every hour. The principle is the same, but the design is engineered for heavy-duty work in hot, wet, and corrosive environments.
Wedge Wire Screens for Bagasse Water Reuse
When you look at a sugar mill’s water system, floor wash pits and cooling drains are the big trouble spots. Water flows in fast, mixed with fibers, mud, and sometimes oil from machines. If you let that go straight to the pump or ETP, it is a nightmare. That blocked suction, choking pipelines, and rising maintenance costs.
That is where wedge wire screens come in. They sit right in these pits and act like the first guard. The V-shaped wires allow water to pass easily while holding back fibers and solids. Unlike mesh or perforated plates, wedge wire does not clog as quickly because of its trapezoidal profile.
Here is what happens when you use them:
- Pumps stop choking on fibers.
- 70% of wash water gets recovered for reuse.
- The load on the Effluent Treatment Plant drops.
You get cleaner pits and less downtime. And the best part? No complicated machinery. Just a well-designed screen doing its job every hour of the day.
Designing the Right Screen: What Sugar Mills Need to Know
Not all screens work the same. The difference between a good design and a bad one shows up in one crushing season. At Multitech Engineers, we design wedge wire screens for sugar mills based on flow conditions and pit layout.
Here are the critical specs you should check:
| Feature | Recommended Range | Why It Matters |
|---|---|---|
| Slot Size | 0.25–1 mm | Stops fibers but keeps flow smooth |
| Material | SS 304 or SS 316L | Handles hot water and prevents corrosion |
| Wire Profile | Trapezoidal | Less clogging, easy cleaning |
| Support Rod | Horizontal/Vertical | Handles heavy water load |
Shape matters too:
- Flat panels work best in open channels or small drains.
- Semi-cylindrical screens fit well in deep pits where water enters at high velocity.
Every mill layout is different, so custom fabrication is key. You do not just pick a screen from a catalog and hope it fits. That is why we build them to your flow conditions and space.
Water Savings Per Tonne: What is the Real Impact?
Numbers tell the story better than words. When mills start reusing bagasse water from floor wash and cooling pits, the savings add up fast:
- 200–400 liters of water per tonne of cane can be reused.
- A 5,000 TCD mill can save 1–2 million liters every day.
Think of that in real terms. That is the same as filling 400 tankers of water daily. For mills in regions where water costs are high or supply is tight, this is a big difference.
And it is not just about cost. Compliance is getting stricter. The 2024 MoEF guidelines want 80–90% reuse within the mill. If you start with simple steps like wedge wire screens, you are already ahead.
Big players are doing it:
| Sugar Mill | What They Did | Impact Achieved |
|---|---|---|
| Balrampur Chini | Installed wedge wire screens in wash pits | 25% less freshwater used in daily operations |
| Dalmia Bharat Sugar | Launched floor wash water reuse project | 20% reduction in utility costs |
| EID Parry | Used screens for condensate water reuse | 30% lower load on the Effluent Treatment Plant (ETP) |
These are not small wins. They show that designing for reuse works – not in theory, but on the ground.
Compliance and Sustainability: Why This Step Counts
Regulations are no longer a distant threat. The MoEFCC and CPCB have made it clear: sugar mills must aim for 80–90% water reuse inside the plant. The 2024 draft guidelines for Zero Liquid Discharge (ZLD) do not just apply to big mills; they will soon cover everyone.
And the truth is, you cannot hit those targets by relying only on Effluent Treatment Plants. Treatment is the last step. Filtration at the source – before the water becomes too dirty is cheaper and more effective.
Installing wedge wire screens in bagasse water pits is one of the easiest steps toward compliance. It cuts the load on your ETP, saves energy, and reduces freshwater dependency. That also adds value to your CSR and ESG scores. Customers, investors, and auditors all look for sustainability actions that are real and measurable. Screens give you that proof.
Multitech Engineers: Designing Solutions That Work in Sugar Mills
We have worked with sugar mills long enough to know that no two layouts are the same. That is why we do not sell off-the-shelf screens. We design them for your pits, your flow, and your operating conditions.
Our wedge wire products for sugar industries include:
- Flat wedge wire panels for drainage channels and floor wash areas.
- Semi-cylindrical screens for bagasse cooling pits and high-flow zones.
- Screen baskets and assemblies for handling heavy solid loads.
We build them from SS 304 or SS 316L for durability in hot, corrosive environments. Our screens are easy to clean, long-lasting, and custom-fabricated to your mill’s needs.
Working with Multitech means you get a partner who understands bagasse water challenges inside out. Not just a supplier sending standard parts.
Conclusion:
Every mill dreams of ZLD, but it does not start with big plants or costly systems. It starts with a simple screen sitting in a pit, stopping fibers from going where they do not belong. That is the first filter. And that is the smartest move you can make today.
Install Screens for Bagasse Water Reuse, and you are not just saving water – you are saving time, energy, and compliance headaches. It is like fixing a leak before the tank runs dry. Simple, effective, and proven.
At Multitech Engineers, we design screens that work like silent workers in your mill – doing their job 24/7, without drama, without breakdowns. If you are serious about sustainable sugar production, start with the screens. Because the cleaner the start, the easier the finish.
