Reliable sugar solution preparation starts with the right process
Producing sugar solutions from crystal sugar gives manufacturers greater control over their production process and reduces dependence on purchased liquid sugar.
At the same time, maintaining a consistent sugar concentration can be challenging. Variations in crystal sugar properties, changing production requirements and fluctuating operating conditions can all influence the dissolving process.
Reliable food and beverage production depends on a sugar solution that consistently meets process requirements. This requires more than simply measuring the final Brix value.
GEA DISUGAR combines automated process control, concentration monitoring and efficient dissolving technology to support stable operation and reproducible product quality. In addition to concentration, the system monitors relevant process conditions to help maintain consistent process performance under changing production conditions.
Benefits
- Consistent sugar concentration
- Reliable downstream production
- Reduced operator intervention
- High Brix accuracy
- Flexible production concepts
- Integrated pasteurization available
- Efficient dissolving through high-turbulence mixing
The DISUGAR product family
The overview below highlights the GEA DISUGAR product family portfolio and the specific features of each solution for different productions requirements.
GEA DISUGAR-T
For flexible batch production of standardized sugar solutions
Suitable for applications where sugar solutions are prepared in batches and production volumes, recipes or operating schedules may vary.
The system supports reproducible sugar solution preparation through precise process control and automated monitoring.
Key features
• Controlled heating
• Brix and temperature monitoring
• Automatic push-out function
• Automated CIP
GEA DISUGAR-C
For continuous production of standardized sugar solutions
Suitable for production environments requiring a continuous supply of sugar solution with controlled concentration and stable quality.
The system continuously controls sugar dosing, water addition and concentration adjustment to support reliable operation and consistent process conditions.
Key features
• Automated sugar and water dosing
• In-line Brix measurement
• Start-up without product losses
GEA DISUGAR-H
For continuous production of standardized sugar solutions
Suitable for applications requiring sugar solution preparation and thermal treatment within a single integrated process.
The system combines sugar dissolving, deaeration, pasteurization and cooling while continuously monitoring critical process parameters to support product quality and process reliability.
Key features
• Integrated pasteurization
• Integrated deaeration
• Monitoring of Brix, flow rate and temperature
• Regenerative heat recovery
• Positive pressure gradient across the plate heat exchanger
Technical overview
| Selection criterion | DISUGAR-T | DISUGAR-C | DISUGAR-H | |
| Production concept | Batch | Continuous | Continuous | |
| Maximum concentration | 67 °Brix | 65 °Brix | 67 °Brix | |
| Integrated pasteurization | No | No | No | |
| Integrated deaeration | No | No | Yes | |
| Heat recovery | No | No | > 90 % | |
Brix accuracy: up to ± 0.1 °Brix across the DISUGAR product family. Operating temperature: 29 - 50 °C, depending on system type.
Applications
GEA DISUGAR systems are suitable for a wide range of beverage, food and ingredient applications, including:
- Soft drinks
- Nectars
- Syrups and beverage bases
- Ketchup
- Jam
- Ingredient processing
System configuration
DISUGAR systems can be configured according to application, capacity and process requirements.
Depending on the selected system, a range of process, utility and sugar handling options is available.
Available options
- Water fine dosing
- Mass flow measurement
- Utility consumption measurement
- Sugar supply systems
- Sugar storage and handling equipment
- UV treatment
System scope is configured according to application and production requirements.
For continuous sugar dissolving, CoreDISUGAR provides the essential GEA control logic and process interdependencies within a standardized automation module. It allows the overall control system to be built around proven GEA process functionality instead of developing the sugar dissolving logic separately for each project.
The standardized control approach can simplify system integration and troubleshooting, support efficient commissioning and reduce the effort required to implement the sugar dissolving process within the overall automation concept. The surrounding automation can still be adapted to the specific production environment.
Contact our experts
Whether you are planning a new production line or optimizing an existing sugar dissolving process, GEA can support the definition of the appropriate production concept, control strategy and system configuration.
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