Spray Engineering Devices Ltd. (SEDL), a clean-tech engineering firm specialising in thermal heat recovery and biomass utilisation, has unveiled a comprehensive roadmap aimed at transforming India’s sugar and ethanol sectors sustainably. The company showcased how dry biomass, including sugarcane bagasse and other agricultural residues, can be efficiently converted into ethanol using electricity-based gasification and circular processing technologies, achieving production at globally competitive prices.
With India reaching its 20% ethanol blending target five years ahead of the 2030 deadline and gearing up to implement E27 blending norms by August, SEDL’s roadmap aligns seamlessly with national objectives focused on energy security, sustainability, and carbon neutrality. Government data indicates that ethanol blending has saved over ₹1.36 lakh crore in foreign exchange over the past nine years and has resulted in payouts exceeding ₹3.1 lakh crore to farmers and distilleries, setting the stage for a ₹1 lakh crore ethanol-driven economy by 2027.
SEDL Managing Director Vivek Verma highlighted the vast potential of agricultural waste, noting, “India produces millions of tonnes of agricultural residue annually, much of which goes unused or is burnt. We’re creating pathways to convert this waste, whether sugarcane biomass, spent wash, or paddy husk—into clean energy sources like ethanol and SAF, while also generating benefits in water conservation, energy efficiency, and rural livelihoods. Producing ethanol from biomass at global benchmark costs can redefine rural bio-economics and contribute significantly to energy independence and climate goals.”
One of SEDL’s standout innovations is its electricity-powered gasification system that produces ethanol and Sustainable Aviation Fuel (SAF) from diverse feedstocks such as bagasse, farm residue, and municipal waste. The process achieves high energy output, between 4,000 and 5,000 kWh per tonne, with minimal tar generation, offering a cleaner, cost-effective alternative to conventional crude oil-based fuels.
The company also showcased its Smart Village Model, which includes decentralised jaggery processing through boilerless, MVR-driven systems. These units eliminate fossil fuel use, generate clean water, and support village-scale enterprises. The model integrates rooftop solar, clean cooking solutions, and zero liquid discharge (ZLD) water recycling, offering a scalable blueprint for net-zero rural development.
In the field of industrial water treatment, SEDL introduced its LTE® system powered by Mechanical Vapor Recompression (MVR), achieving near-total water recovery without steam or chemical usage. This technology, already in use at distilleries like Dalmia Bharat and Kenya’s Kibos Sugar, turns difficult distillery waste into reusable water for agriculture and other uses.
For the sugar industry, SEDL spotlighted two efficiency-boosting technologies: the honeycomb calandria batch pan, implemented at KM Sugar Mills, which enhances crystallisation and reduces steam usage by up to 15%; and a condensate-based juice heating system trialled at facilities including Uttam Sugar, RBNS, and Daurala, which offers 7–10% steam savings by replacing fresh steam with recycled condensate.
Recognising these innovations, Vivek Verma received the Excellence Award at the STAI Convention, while Dr. A.K. Nanda, SEDL President, was honoured with the Dr. P. J. Manohar Rao Gold Medal for co-product innovation. Additionally, SEDL was named Best Machinery Manufacturer (Sugar) at the Bharatiya Sugar national symposium in Kolhapur earlier this month.
With over 100 global patents, three advanced manufacturing facilities in India, and exports to more than 40 countries, SEDL serves diverse sectors including sugar, ethanol, jaggery, food and beverage, pharmaceuticals, green chemicals, and automotive. The recent presentation of five technical papers to sugar industry professionals underscores the company’s commitment to research and its role in driving India’s clean energy and bioeconomy ambitions forward.
