DON’T WAIT, ELIMINATE: TACKLING MICROBIAL CHALLENGES IN SUGARCANE PROCESSING

Sugarcane processing is a race against time. Once cane is cut, its juice becomes a nutrient-rich medium where microbial growth takes off rapidly. If left uncontrolled, bacteria such as Leuconostoc mesenteroides and Lactobacillus spp. quickly multiply, producing dextran, lactic acid, and other unwanted byproducts. These not only increase viscosity but also lower juice clarity, reduce sugar recovery, and even disrupt ethanol yields in distilleries.

This is why antimicrobials and biocides are no longer optional — they are essential safeguards in every modern sugar mill and distillery. By acting early and strategically, they protect process efficiency, preserve sugar recovery, and secure long-term profitability.

Microbial contamination is not a localized issue — it is a global challenge, particularly in tropical countries like India, Brazil, and Thailand where high humidity and warm climates accelerate cane deterioration. Even small delays in crushing can turn fresh cane juice into a hotspot of microbial activity, making early intervention critical.

Below, we break down how three specialized solutions — Bactosafe DF, Bactoshield, and Bactoferm — tackle microbial challenges at different stages of sugarcane processing.

Antimicrobials V/S Biocides

Before diving into the products, let's clarify the difference:

• Antimicrobials are agents that target and control microbial activity, primarily in the cane juice or fermentation medium. Their role is to stop bacteria from consuming sugars and producing harmful acids or dextran.
• Biocides, on the other hand, provide a broader protective action on the equipment and environment. They prevent microbial colonies from forming on surfaces, pipelines, evaporators, and storage tanks — reducing slime, scaling, and energy losses.

Together, they work as the first and last line of defense — protecting juice quality, equipment performance, and fermentation efficiency.

In practical terms, antimicrobials act inside the juice — like guards protecting sucrose molecules from being stolen by bacteria — while biocides act on the environment, keeping pipelines, evaporators, and tanks clean. Together, they not only safeguard product quality but also cut operational expenses such as excess steam usage, frequent chemical dosing, and unplanned cleaning stoppages.

Understanding the Science: Why Microbial Control Matters

Microbial contamination in sugar processing is often underestimated because it is not immediately detectable. However, the biochemical reactions triggered by microbial growth can drastically impact both sugar and ethanol industries:

• Dextran Formation: Leuconostoc mesenteroides converts sucrose into dextran, a gummy polysaccharide that raises juice viscosity, blocks filters, and reduces clarification efficiency.
• Acid Production: Lactobacillus spp. and related microbes consume fermentable sugars, producing lactic acid and acetic acid (primarily from the action of Acetobacter species). These acids lower pH, disturb crystallization, and hurt fermentation yields.
• Slime & Scaling: When microbes colonize pipelines, evaporators, or storage tanks, they form biofilms and slime layers that reduce heat transfer, cause scaling, and force frequent shutdowns.
• Fermentation Competition: In distilleries, bacteria compete with yeast for sugar, reducing ethanol conversion efficiency and forcing distillers to use broad varities of antibiotics.

In numbers, the problem becomes even clearer:

• Every 1000 ppm of dextran can cause a 3–4 kg sugar loss per ton of cane.
• A 1% rise in bacterial contamination can reduce ethanol yield by 5–7%.
• Microbial scaling in evaporators can increase steam consumption by 10% or more, directly raising energy costs.

BACTOSAFE DF – CONTROLLING BACTERIAL LOAD AT THE SOURCE

Freshly harvested cane begins deteriorating almost immediately. Within 30–40 minutes, bacterial load doubles if left unchecked. Leuconostoc mesenteroides, in particular, is notorious for converting sucrose into dextran, increasing viscosity and complicating processing. Even a 1000 ppm increase in dextran can reduce sugar recovery by 3–4 kg/ton of cane. Mills without effective bacterial control often face 10–15% higher chemical consumption during clarification.

How Bactosafe DF addresses this:

• Rapidly suppresses Leuconostoc mesenteroides and related microbes.
• Maintains low juice viscosity for smooth pumping.
• Reduces sucrose losses in molasses.
• Cuts down on lime and flocculant usage.
• Improves throughput and mill efficiency.

Mechanism of Action

Bactosafe DF works by penetrating bacterial cell walls and disrupting essential metabolic processes such as carbohydrate fermentation and polysaccharide production. By halting dextran formation at the microbial level, it preserves sucrose integrity and ensures stable juice quality right from the start.

Why It Stands Out

Plant trials show Bactosafe DF can reduce bacterial counts by 80–90% in the first stage of processing — directly translating into higher sugar recovery and lower operational costs.

BACTOSHIELD – LONG-LASTING BIOCIDE FOR PROCESS PROTECTION

Bactoshield is a specialized biocide formulated to protect equipment surfaces, evaporators, pipelines, and storage tanks from microbial scaling, fouling, and slime formation. Unlike antimicrobials that act mainly on juice, Bactoshield defends the processing environment itself.

How Bactoshield addresses this:

• Prevents slime buildup in pipelines and evaporators.
• Inhibits biofilm formation, protecting equipment life.
• Enhances heat transfer efficiency, lowering steam demand.
• Reduces unplanned shutdowns and cleaning needs.

Mechanism of Action

Bactoshield acts by creating a controlled-release biocidal environment on equipment surfaces. Its active molecules penetrate microbial biofilms, disrupting cell membranes and halting colony formation. Unlike short-lived treatments, it provides sustained protection that minimizes recurring contamination.

Why It Stands Out

Bactoshield provides long-lasting protection with controlled-release action. Mills using Bactoshield report up to 15% lower energy consumption and 25–30% fewer stoppages for cleaning.

BACTOFERM – SAFEGUARDING FERMENTATION EFFICIENCY

Bactoferm is a specialized antimicrobial solution designed for distilleries and ethanol plants. It ensures that yeast fermentation proceeds smoothly by controlling competing bacterial growth.

How Bactoferm addresses this:

• Selectively inhibits bacterial contaminants without harming yeast.
• Stabilizes fermenter pH by lowering acidity.
• Reduces sugar wastage to acids, channeling more into ethanol.
• Supports yeast health, ensuring consistent ethanol yields.

Mechanism of Action

Bactoferm works through selective inhibition. Its antimicrobial agents target bacterial metabolic pathways — specifically lactate and acetate production — while leaving yeast's ethanol pathway unaffected. This ensures that sugars are preserved for ethanol generation, not wasted on acid production.

Why It Stands Out

Trials show that Bactoferm improves ethanol yield by 3–5%, reduces chemical load, and ensures a cleaner, more sustainable fermentation process compared to conventional antimicrobials.

Conclusion

Microbial contamination is invisible but extremely costly in sugarcane processing and ethanol production. From juice deterioration to scaling, from molasses losses to reduced ethanol yield — the financial impact can run into millions per season.

With targeted solutions like:

• Bactosafe DF – Protects juice quality and preserves sucrose.
• Bactoshield – Guards equipment and improves energy efficiency.
• Bactoferm – Secures fermentation and boosts ethanol yield.

Together, they form a comprehensive antimicrobial and biocide strategy — ensuring cleaner processes, higher recoveries, and stronger profitability.

Backed by The Catalysts Group's expertise in sugar and ethanol processing, these solutions are built to meet real industry challenges and deliver measurable value season after season.