Under the ever changing scenario of sugar and distillery industry in India, there have been number of requirements emerging with an aim to minimize the operating cost of boilers. One of such factors in molasses-based distilleries operating on syrup as their feed stock is to consume very low amount of Spent Wash produced in conventional low pressure incineration boilers. In such cases, the ratio of spent wash and bagasse would be 10:90 by heat value. In such cases, bagasse becomes the main fuel and total energy potential of bagasse is not utilized while firing in these low pressure boiler. Isgec took an initiative to design a high pressure boiler which can fire spent wash up to 10 per cent (on heat basis) in combination of bagasse, thus utilizing the potential of higher power generation with the same quantity of bagasse. Boiler operation with bagasse has been working satisfactory and all the parameters are as per design prediction and providing high cycle efficiency as desired. All the parameter for achieving the required thermal environment for effective combustion of spent wash has been achieved effectively in the boiler. This hybrid design boiler is producing steam to run sugar plant and distillery thereby reducing the overall capex.