Proposal of stages by controlling the efficiency analysis in sugar and ethanol mills

DUARTE, Alexandre; LEMOS, Stella Vannucci; SALGADO JUNIOR, Alexandre; SOUZA JUNIOR, Marco Antonio; DONEGÁ, Ricardo

doi:10.1590/fst.11617

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Research Paper • Food Sci. Technol 38 (Suppl. 1) • Dec 2018 • https://doi.org/10.1590/fst.11617 copy

Proposal of stages by controlling the efficiency analysis in sugar and ethanol mills

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract

This study aimed to identify the main points of control in the efficiency of the productive process in sugarcane mills. Thus, a two-stage DEA approach applied for a sample of 121 mills, distributed among the seasons of 2010/2011 until 2014/2015. The first stage separated the efficient mills in transforming the total recovered sugar (TRS) of the processed sugarcane into sugar and ethanol, and the second stage identified significant production process variables in the efficiency with truncated regression. Besides, with the help of industry experts and statistical analysis, established 13 variables, which could control and increase the efficiency of the sugar and ethanol production processes, contributing to the overall efficiency of sugar and ethanol units.

Keywords:
Data Envelopment Analysis (DEA); energy; sugar and ethanol mills

	*TRS (ton)*	*Sugar production (ton)*	*Ethanol Production (m³)*
Minimum	126,030.72	63,881.04	31,819.24
Maximum	958,749.79	703,150.99	246,365.36
Mean	416,347.68	276,746.03	106,080.25
Median	361,585.69	263,242.14	90,134.08
Standard Deviation	209,855.55	160,574.93	54,526.08

*Final product*	*Processes*	*Indicators*
Common processes in the production of sugar and ethanol	Raw material	Chopped sugarcane delivered (%)
		Delivery time of the cane (h)
		Purity at the press (%)
		Dextran (mg/L Brix)
		Diatraea saccharalis (%)
	Juice extraction	Overall improvement (%)
		Fiber (ton/h)
		Soaking of the fiber (%)
		Total TRS extraction (%)
		TRS of the bagged sugar cane (%)
	Filter cake	Filter cake (kg/T of sugarcane)
	Filter cake	TRS lost (%)
Ethanol production	Mud	Impurities (%)
		Temperature (°C)
		Brix ethanol (%)
		Rods x 10⁵/mL
		Yeast (%)
		Vinasse loss (%)
		Flegmass loss (%)
Common processes in the production of sugar and ethanol	Yield	Total Corrected Recovered (%)
		TRS balance – ethanol (L/T)
		TRS balance – sugar (kg/T)
		TRS balance – water loss in vacuum multijets
		TRS balance – losses at multijet filters (%)
		TRS balance – residual water losses (%)
		TRS balance – indeterminable losses (%)
Ethanol production	Yield	Antibiotics (mg/L)
Sugar production	Analysis of the sugar	Purity of A-molasses (%)
Sugar production	Analysis of the sugar	Purity of B-molasses (%)

	*2010/2011*	*2011/2012*	*2012/2013*	*2013/2014*	*2014/2015*
*Minimum*	0.8801	0.8491	0.8308	0.8482	0.8722
*Mean score*	0.9617	0.9415	0.9404	0.9420	0.9577
*Bias*	0.0066	0.0057	0.0055	0.0063	0.0052
*Corrected score*	0.9550	0.9358	0.9349	0.9358	0.9524
*Maximum*	1.0000	1.0000	1.0000	1.0000	1.0000

Variable	Coef.	Sig.	Variable	Coef.	Sig.	Variable	Coef.	Sig.
V2	-0.0529	0.004 ^a a Significant at the 5 % level. Source: The authors (2018).	V26	0.0665	0.136	V52	0.1014	0.101
V3	-0.0444	0.000^a	V27	0.0125	0.994	V53	0.0127	0.859
V10	-0.5121	0.004^a	V28	-2.9010	0.302	V57	-0.8207	0.331
V14	0.0028	0.001^a	V29	0.4826	0.000^a	V58	-3.7086	0.000^a
V15	0.5315	0.000^a	V32	-3.7707	0.072	V59	-1.2378	0.126
V17	-0.0651	0.092	V33	-0.0001	0.950	V60	0.1745	0.480
V21	0.0018	0.791	V43	0.1530	0.000^a	V61	0.0225	0.257
V23	-0.0015	0.809	V44	-6.1263	0.002^a	V70	-0.1903	0.001^a
V24	0.1579	0.684	V45	-9.4405	0.058	V71	0.1866	0.089
V25	0.0283	0.148	V49	0.2410	0.169	Constant	80.8582	0.040^a
Wald statistic		242.52	Log likelihood		-25,880,465	Prob>chi²		0.000

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[1] * Corresponding author: svlemos@usp.br