<p>This paper presents the development and successful industrial application of an innovative Mechanical Vapour Recompression (MVR)-based thermal waste heat recovery system for sugarcane processing. The technology enables high heat economy by recompressing and reusing vapour, thereby eliminating the need for conventional utilities such as boilers, turbines, condensers, and cooling towers. The system integrates low-temperature evaporation with falling-film plate evaporators, achieving enhanced energy efficiency, complete elimination of biomass combustion, and 100% bagasse saving. This approach transforms the sugar industry landscape by enabling carbon-negative and water-positive operations through zero biomass burning and full water recovery. A 250 tonnes cane crushed per day (TCD) sugar plant was successfully engineered, erected, and commissioned during the sugarcane crushing season 2022–23 operating entirely without a boiler. At an 8300 TCD facility, MVR-assisted melt concentration increased raw melt from 61 to 74% at 80 t/h, delivering 7 t/h steam savings using two multi-effect falling-film plate evaporators (4000&#xa0;m²). In Phase II in the cane crushing season 2023–24, three additional evaporator units (7500&#xa0;m²; 165 t/h) were installed for juice concentration from 10–12% to 30–32%, reducing total steam usage from 39 to 30% on cane while increasing plant capacity to 10,800 TCD. Overall, the adoption of MVR demonstrates a viable pathway towards boiler-free, energy-efficient, low-carbon sugar and ethanol production.</p>