Several ecological advantages could result if electricity co-generation in sugar factories could be extended to cane residues that are otherwise unutilized. A major constraint is managing the excessive fire-side deposits in biomass combustors. Unlike bagasse and most woody biomass, the firing of cane tops and leaves and cane trash could lead to excessive fouling problems. The sugarcane bio-fuels' propensity to foul and slag has been investigated. Based on their fouling and slagging tendencies, bagasse has been classified as a "wood-like" fuel, CT&L a "straw like" fuel and trash lies in between the two. The paper discusses the possibility of recuperating the cane tops and leaves in view of producing extended bagasse for enhancing bio-electricity output. Pre-combustion bio-fuel processing includes shredding, milling for moisture reduction and leaching of the minerals contained in the CT&L. The results of a full fuel cycle analysis reveal the energy and environmental benefits that could result from the improved system.