Reliable Inline Concentration Measurement in Challenging Sugar & Molasses Applications

Overview

A major sugar and molasses producer struggled to accurately measure concentration in high-viscosity, high-temperature molasses streams. Traditional methods, including optical refractometers and lab sampling, proved unreliable and introduced variability between process and measured values. Forberg Smith worked with the manufacturer to implement an inline approach capable of generating repeatable concentration data directly in-process, eliminating the need to remove and test samples externally.

The Challenge

Small changes in temperature and aeration significally impacted Brix readings, making it difficult to correlate lab results to actual process conditions.

Exisiting approaches created significant challenges:

Inline refractometers fouled quickly due to coating on lenses

Lab sampling introduced variability as temperature, pressure and entrained air changed between the process and testing environment

Even short delays between sampling testing altered readings

The customer needed a reliable way to measure concentration (percent sucrose to water) in high viscous, high-temperature, and high-pressure sugar and molasses streams.

Implementation Highlights

Worked closely with plant technicians, engineers, and plant managers

Collaborated across operations and instrumentation teams

Partnered with manufacturer experts for validation and performance tuning

Stood behind the solution through extended runtime and verification

The Solution

Forberg Smith implemented a Coriolis-based inline measurement approach to overcome the limitations of optical and lab based methods in molasses service. This enabled direct, in-process concentration readings without variability from sampling.

A proven Coriolis platform

1

An Endress+Hauser Promass F500 Coriolis meter was selected for its ability to capture density, flow, and temperature directly inprocess, enabling concentration calculation without sample extraction. Unlike optical refractometers, it is not affected by coating or optical interference, allowing it to operate reliably in viscous molasses streams.

Hands-on validation and support

2

Beyond supplying the meter, the Forberg Smith team installed and commissioned the instrument onsite and ran the meter continuously under normal operating conditions. Calibration was adjusted incrementally until inline results aligned with the expected process behavior.

A multi-stage delivery approach

3

The project evolved through continuous collaboration. Adjustments were made based on collected operating data to ensure results remained accurate and repeatable over time, with ongoing onsite support sustaining performance under changing conditions.

Impact

The implementation delivered measurable improvements in data reliability and process consistency. By enabling accurate, inline concentration readings, the solution reduced dependence on lab sampling, eliminated discrepancies between lab and process data, and improved downstream control. As a result, the customer was able to operate more consistently while expanding the use of inline monitoring across additional process areas.

Reliable inline concentration visibility in previously unmeasured areas

Reduced reliance on lab sampling and manual verification

Strengthened alignment between lab and process data

Improved downstream processs control

Your Possibility. Our Purpose.

Forberg Smith brings application expertise that delivers in the most challenging process environments. By combining proven technologies with hands-on validation and real-world testing, the team enables reliable, in-process data and consistent control—turning complex measurement challenges into repeatable, high-confidence outcomes.

Connecting power with possibility is not just our vision. It’s what we do every day.