From Sugar to Renewable Biomass – The Re-Engineering of Mauritius' Sugar Industry

Source Omnicane Website

This lecture was delivered by Jean Claude Autrey, General Secretary of the International Society of Sugar Cane Technologists, delves into how Mauritius is redefining its sugar sector, shifting from traditional sugar production to a renewable biomass industry that embraces sustainability and cutting-edge technology. 

 

 Key Points and Takeaways from the Presentation on Sugarcane Production in Mauritius

• Sugarcane originated in New Guinea and spread through Asia, the Mediterranean, and then to the Americas and Africa. The two main types are Saccharum officinarum (noble cane with high sugar content) and Saccharum spontaneum (wild cane, known for its vigor and adaptability). Crossbreeding between these two types led to hybrid varieties, with the "POJ 2878" cane from Java being particularly influential on most cultivated varieties today.
• The Dutch brought sugarcane from Java in 1639, initially for producing arrack but large-scale cultivation began under French rule (1715–1810) and expanded by the British (1810–1968).
• In 1921, Dutch researchers in Java created a new type of sugarcane by combining two species: one with high sugar content (Saccharum officinarum ) and another with strong disease resistance (Saccharum spontaneum ). The hybrid POJ 2878, increased sugarcane yields by 30–50% worldwide. In Mauritius, it raised production from 3.6 tons per hectare to 6.6 tons per hectare in the 1920s. Developed from early research in 1886, POJ 2878 changed how sugarcane was grown globally. A wonder ans Gane Changer Cane.
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• Sugar cane is a high-yield crop due to its large biomass, often producing over 40 tons per hectare.
• Sugar cane is grown in 115 countries, covering 27 million hectares, and accounts for 79.1% of global sugar production.
• Globally, sugar production in 2023/24 totalled 187 million tonnes, with sugarcane contributing 148 million tonnes (79.1%) and sugar beet accounting for 39 million tonnes. Brazil dominates the industry, producing 45 million tonnes annually on 10 million hectares, with 50% of its sugarcane area dedicated to bioethanol production. In contrast, Mauritius ranks 21st globally for sugarcane production, contributing only 238,854 tonnes in 2023 from 35863 ha, highlighting the country's relatively small scale and limited market share compared to leading producers.
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Historical Context: From Dutch Introduction to British Industrialization

The story of sugarcane in Mauritius begins in 1639 when Dutch settlers introduced it for arack production. However, large-scale cultivation only began under French rule (1715–1810), transforming the island into a major exporter of both sugar and rum. By 1810, annual sugar production reached 2,750 tons, with arack production at 300,000 liters . Under British colonial rule (1810–1968), mechanized mills revolutionized productivity, increasing output dramatically.

• Sugar production in the region saw significant growth over the centuries, starting with an output of 457 tons in 1812. Following the abolition of slavery in 1834 and the introduction of indentured labour in 1835, production soared to 150,480 tons by 1861. This upward trend continued, reaching its peak during the colonial era in 1953 with a record output of 456,681 tons.
• Key milestones during this period included the establishment of research institutions like the Sugar Research Station in the 1920s and the Chamber of Agriculture in 1953, which drove innovation and productivity. By independence in 1968, sugarcane had become central to Mauritius' economy, contributing 30% of GDP and accounting for 90% of export value.

Post-Independence Peak: The Era of "King Sugar"

In the decades following independence, the sugar industry continued its dominance, peaking in 1973 with record production of 719,000 tons. This period saw significant institutional reforms and technological advancements.

At its peak, the industry employed 280,000 workers , representing 25% of the population , and cultivated 79,000 hectares of land. Sugarcane earned its nickname "King Sugar" due to its overwhelming economic importance.

Challenges Post-Independence: Decline and Adaptation

Despite its early successes, the industry faced mounting challenges in the late 20th and early 21st centuries:

• Global Competition : Rising production costs made Mauritian sugar uncompetitive compared to global leaders like Brazil and India.
• Trade Agreements : The loss of preferential pricing under the Lome Convention for the EU Sugar Protocol in 2005 resulted in a 36% reduction in revenue. By 2023 , the industry's contribution to GDP dropped to 0.23% , with only 35,000 hectares under cultivation compared to 79,000 hectares previously. This led to reforms aimed at reducing costs, increasing productivity, and diversifying outputs. The number of sugarcane farmers declined significantly, with only 3,000 workers remaining today compared to 8,200 previously.
• Climate Change : Warming temperatures reduced yields by 5–10% , while increased cyclone frequency destroyed crops (e.g., Cyclone Belal in 2024 destroyed 20% of crops ).

These pressures contributed to a sharp decline in production and employment: Land Use : Reduced from 79,000 hectares in the 1970s to 35,000 hectares in 2023.

·       The sugar production industry is divided into three categories, individual planters. growing companies and the millers. Individual planters number around 28,000. They cultivate 45% of the total area and produce 40% of the total sugar. On the other hand, the other group cultivate 55% of the area and produce 60% of the sugar.

·       Production : Fell to 238,000 tons annually by 2023. Employment : Shrunk from 8,200 workers in the past to 3,000 workers today. Economic Contribution : GDP contribution dropped from 30% in the 1970s to 0.67% in 2023 

·       The price has increased by more than 11 times from 1979 (Rs 2,296) to the 2024 projection (Rs 26,000+), showing significant inflation in the sugar market over this period.

Diversification and Innovation: Beyond Traditional Sugar

To adapt to changing circumstances, the industry diversified into high-value products and renewable energy:

• Specialty Sugars: Specialty sugars now account for 54% of total production, reaching 128,000 tons annually.
• Bagasse-Based Electricity: Bagasse provides 12–19% of Mauritius' electricity, by utilizing bagasse, Mauritius avoids burning coal and prevents the emission of 500,000 tonnes of CO2, a testament to the power of sustainable resource management. This transition began with intermittent generation in the 1950s, evolved to seasonal generation in the 1980s, and achieved year-round firm power production through plants like FUEL, DRBC, CTBV, and CTSAV.
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  Source News Moris, 2022

  
  
• Ethanol Production: One tonne of sugarcane yields 85 liters of ethanol , with Mauritius targeting 50 million liters annually by 2030 
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  Source Bioethanol Distillery, Omnicane Website, 2024

  
   Research institutions like the Mauritius Sugar Industry Research Institute (MSIRI) have played a critical role in driving innovation, focusing on drought-resistant hybrids, biofertilisers, and carbon-capture techniques. Today, MSIRI operates across four key areas: sugarcane improvement through breeding and biotechnology, field management optimization, environmental sustainability research, and value-addition studies. This comprehensive approach has helped transform Mauritius's sugar industry from traditional farming to a modern biorefinery concept, adapting to contemporary challenges while maintaining research excellence. Through varietal development, agricultural optimization, environmental protection, and product diversification, MSIRI continues to drive innovation in the sugar sector, ensuring its relevance in an evolving global market.

Environmental Contributions: A Carbon-Negative Industry

Mauritius' sugar industry stands out for its environmental benefits:

• Sugarcane absorbs 20 tonnes of CO₂ per hectare annually, making it a significant carbon sink.
• Studies confirm that sugarcane does not pollute rivers or groundwater, preserving water quality and soil health.
• Carbon footprint analysis shows that after accounting for bagasse-based electricity, the net carbon footprint becomes -0.17 kg CO₂e per kg of sugar, positioning Mauritius as a leader in sustainable agriculture, and making the industry carbon-negative. This means the sugar industry in Mauritius is actually removing more carbon from the atmosphere than it emits, effectively serving as a carbon sink.

Current Challenges: Competitiveness and Climate Resilience

Despite its achievements, the industry faces several hurdles:

• High Production Costs : Mauritius has the highest production costs among major producers, making it unprofitable at prevailing international prices.
• Ageing Plantations: Over 43% of crops are over eight years old , reducing yields.
• Labor Shortages: Mechanization remains essential to offset rising labor costs, which historically accounted for over 50% of production expenses.
• Climate Threats: Temperature increases since 1950 have reduced yields by 5–10% , exacerbating vulnerabilities.
  

 

Source Le Defi Media, 2024

Future Prospects: Embracing Biomass and Technology

Looking ahead, the industry aims to reinvent itself as a renewable biomass sector:

• Government Initiatives: A revolving fund of 500 million rupees was established in 2023 to replant 2,800 hectares, though 17,000 hectares remain underutilized .
• Advanced Techniques: Technologies like CRISPR and precision agriculture are being explored to develop high-yield, disease-resistant varieties.
• Circular Economy: Pilot projects focus on converting sugarcane waste into bioplastics, packaging materials, and biofuels, aligning with global trends toward sustainability.

Notably, sugarcane processing facilities now function as bio-refineries, producing multiple outputs:

• Raw, White, Organic, and Specialty Sugars : For food manufacturing.
• Steam/Electricity: Through cogeneration using bagasse.
• Ethanol, Solvents, and Biochemical : Via distillery operations.
• Biofertilizers and Bioplastics: Repurposing cane trash and other residues.

·       A common misconception is that ethanol or electricity production can replace sugar entirely. Sugar remains the primary revenue source (75%), alongside electricity (18%) and ethanol (7%) from co-products.Politicians often advocate for ethanol production over sugar, but this is economically unviable without proper planning.

·       Despite attempts to diversify agricultural production by growing various food crops like maize, rice, groundnut, sunflower, lupin, and soyabean, these efforts were unsuccessful. The failures stemmed from multiple challenges: the local agro-climatic conditions were not suitable, production costs were too high, the operations lacked economies of scale, the crops weren't competitive in the market, and market opportunities were limited. This suggests sugar cane remained the preferred crop choice for this region, likely due to its better adaptation to local conditions and stronger economic viability.

Broader Economic Impact: Beyond Agriculture

The sugar industry's influence extends beyond traditional agricultural boundaries:

• Profits have diversified into sectors like tourism, textiles, banking, education, and urban development, supporting broader economic growth.
• Modern mills, such as Terra, Omnicane, and Alteo, specialize in different product lines, ensuring efficient resource utilization.
• These three mills process sugarcane from 8,200 planters. In 2023, these mills produced 240,000 tons of sugar between July and December. The mills are specialized: Terra produces 80,000-85,000 tons of special sugars, Omnicane operates the sole refinery producing 250,000 tons of white refined sugar, and Alteo contributes 65,000-85,000 tons of special sugars.

Global Benchmarks and Lessons Learned

Comparisons with global competitors highlight areas for improvement:

• Brazil Produces 750 million tons/year, allocating 60% of sugarcane for ethanol and achieving yields of 80 tons/ha .
• India Subsidizes small farmers with $1.3 billion/year, maintaining competitiveness despite lower yields.
• Ethanol Production: 1 ton of sugarcane = 85 liters of ethanol (Brazil produces 30 billion liters/year; Mauritius targets 50 million liters by 2030).
• Bioplastics: Global market worth $10 billion (2023); Mauritius explores partnerships with EU firms.
• Mauritius can learn from these models to enhance scale, subsidies, and innovation.

Key Numerical Highlights

• Global Production : Cultivated in 115 countries , covering 27 million hectares , contributing 79.1% of global sugar production .
• Mauritius' Peak Production : 719,000 tons in 1973 .
• Current Production : 238,000 tons annually on 35,000 hectares .
• GDP Contribution : Dropped from 30% to 0.67% .
• Export Value : Decreased from 90% to 12.5% .
• Carbon Absorption : Sugarcane absorbs 20 tonnes of CO₂ per hectare annually .
• Bagasse Contribution : Provides 12–19% of electricity , preventing 500,000 tonnes of CO₂ emissions annually .
• Labor Force Reduction : From 8,200 workers to 3,000 workers .
• Sugar Prices : Increased from Rs 2,296 per tonne in 1979 to over Rs 26,000 in 2024

Conclusions

Despite challenges, the sugar industry remains culturally significant, symbolizing Mauritius' identity as "King Sugar." It supports rural livelihoods, conserves soil, and mitigates climate change. As the industry evolves, it embraces sustainability, technology, and circular economy principles, proving that even traditional sectors can thrive in a modern world.