Mysore Sugar Company Limited, Mandya

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CHAPTER-2
INDUSTRY PROFILE AND
COMPANY PROFILE















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2.1 INDUSTRY PROFILE


2.1.1 INTRODUCTION
India has been known as the original home of sugar and sugarcane. Indian mythology
supports the above fact as it contains legends showing the origin of sugarcane. India is the
second largest producer of sugarcane next to Brazil. Presently, about 4 million hectares of land is
under sugarcane with an average yield of 70 tons per hectare.
India is the largest single producer of sugar including traditional cane sugar sweeteners,
khandsari and Gur equivalent to 26 million tons raw value followed by Brazil in the second place
at 18.5 million tones. Even in respect of white crystal sugar, India has ranked No.1 position in 7
out of last 10 years.

Traditional sweeteners Gur & Khandsari are consumed mostly by the rural population in
India. In the early 1930s nearly 2/3rd of sugarcane production was utilized for production of
alternate sweeteners, Gur & Khandsari. With better standard of living and higher incomes, the
sweetener demand has shifted to white sugar. Currently, about 1/3rd sugarcane production is
utilized by the Gur & Khandsari sectors. Being in the small scale sector, these two sectors are
completely free from controls and taxes which are applicable to the sugar sector.
The advent of modern sugar processing industry in India began in 1930 with grant of tariff
protection to the Indian sugar industry. The number of sugar mills increased from 30 in the year
1930 - 31 to 135 in the year 1935-36 and the production during the same period increased from
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1.20 lakh tones to 9.34 lakh tones under the dynamic leadership of the private sector.
The era of planning for industrial development began in 1950-51 and Government laid down
targets of sugar production and consumption, licensed and installed capacity, sugarcane
production during each of the Five Year Plan periods.

2.1.2 HISTORY

The discovery of sugarcane, from which sugar as it is known
today, is derived dates back unknown thousands of years. It is
thought to have originated in New Guinea, and was spread
along routes to Southeast Asia and India. The process known
for creating sugar, by pressing out the juice and then boiling it into crystals, was developed in
India around 500 BC.
Its cultivation was not introduced into Europe until the middle-ages, when it was brought to
Spain by Arabs. Columbus took the plant, dearly held, to the West Indies, where it began to
thrive in a most favorable climate.
It was not until the eighteenth century that sugarcane
cultivation was began in the United States, where it was planted in
the southern climate of New Orleans. The very first refinery was
built in New York City around 1690; the industry was established
by the 1830s. Earlier attempts to create a successful industry in the
U.S. did not fare well; from the late 1830s, when the first factory was built. Until 1872, sugar
factories closed down almost as quickly as they had opened. It was 1872 before a factory, built in
California, was finally able to successfully produce sugar in a profitable manner. At the end of
that century, more than thirty factories were in operation in the U.S.

2.1.3 MANUFACTURING PROCESS
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Sugar (sucrose) is a carbohydrate that occurs naturally in every fruit and vegetable. It is a
major product of photosynthesis, the process by which plants transform the sun's energy into
food. Sugar occurs in greatest quantities in sugarcane and sugar beets from which it is separated
for commercial use. The natural sugar stored in the cane stalk or beet root is separated from rest
of the plant material through a process known as refining.

2.1.4 FOR SUGARCANE, THE PROCESS OF REFINING IS CARRIED
OUT IN FOLLOWING STEPS
Pressing of sugarcane to extract the juice.
Boiling the juice until it begins to thicken and sugar begins to crystallize.
Spinning the crystals in a centrifuge to remove the syrup, producing raw sugar.
Shipping the raw sugar to a refinery where it is washed and filtered to remove
remaining non-sugar ingredienats and color.
Crystallizing, Drying and Packing the refined sugar.
Beet sugar processing is similar, but it is done in one continuous process without the raw sugar
stage. The sugar beets are washed, sliced and soaked in hot water to separate the sugar -
containing juice from the beet fiber. The sugar-laden juice is then purified, filtered, concentrated
and dried in a series of steps similar to cane sugar processing. For the sugar industry, capacity
utilization is conceptually different from that applicable to industries in general. It depends on
three crucial factors the actual number of ton of sugarcane crushed in a day, the recovery rate
which generally depends on the quality of the cane and actual length of the crushing season.
Since cane is not transported to any great extent, the quality of the cane that a factory receives
depends on its location and is outside its control. The length of the crushing season also depends
upon location with the maximum being in south India. Sugarcane in India is used to make sugar,
khandsari or Gur. However, sugar products produced worldwide are divided into four basic
categories: granulated, brown, liquid sugar and invert sugar. Granulated: Granulated sugar is
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the pure crystalline sucrose. It can be classified into seven types of sugar based on the crystal
size. Most of these are used only by food processors and professional bakers. Each crystal size
provides unique functional characteristics that make the sugar appropriate for the food
processor's special need.

2.1.5 TYPES OF SUGAR
Granulated Sugar: Most of these are used only by food processors and professional bakers and
are not available in the supermarket. The types of granulated sugars differ in crystal size. Each
crystal size provides unique functional characteristics that make the sugar appropriate for the
food processor's special need
Regular Sugar, Extra Fine or Fine Sugar: "Regular" sugar, as it is known to consumers, is
the sugar found in every home's sugar bowl and most commonly used in home food preparation.
The food processing industry describes "regular" sugar as extra fine or fine sugar.
Fruit Sugar: Fruit sugar is slightly finer than "regular" sugar and is used in dry mixes such as
gelatin desserts, pudding mixes and drink mixes. The uniformity of crystal size prevents
separation or settling of smaller crystals to the bottom of the box, an important quality in dry
mixes and drink mixes.
Bakers Special: Bakers Specials crystal size is even finer than that of fruit sugar. As its name
suggests, it was developed specially for the baking industry. Bakers Special is used for sugaring
doughnuts and cookies as well as in some commercial cakes to produce fine crumb texture.
Superfine, Ultrafine, or Bar Sugar: This sugar's crystal size is the finest of all the types of
granulated sugar. It is ideal for extra fine textured cakes and meringues, as well as for sweetening
fruits and iced-drinks since it dissolves easily.
Confectioners (Powdered) Sugar: This sugar is granulated sugar ground to a smooth powder
and then sifted. It contains about 3% corn starch to prevent caking. Confectioners sugar is
available in three grades ground to different degrees of fineness.
Coarse Sugar: The crystal size of coarse sugar is larger than that of "regular" sugar. Coarse
sugar is normally processed from the purest sugar liquor. This processing method makes coarse
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sugar highly resistant to colour change or Inversion (natural breakdown to fructose and glucose)
at high temperatures.
All nations across the world are concerned about the rate of increase in the global warming. India
through its large sugarcane industry can play a significant role in mitigating the same. The recent
awareness of the advantages of using green fuel for generation of power and use of gasohol to
reduce automobile emissions have led to setting up of a number of co-generation plants in
various sugar mills and the Government of India is taking steps to encourage manufacture of
Ethanol for the purpose of doping motor fuel to reduce air pollution. The Indian sugar industry
can therefore, make an intelligent use of this opportunity for its sustainable growth. It is observed
that this can be possible through change in its present product mix. The various likely options are
the setting up of:
Manufacture of sugar, alcohol and power from sugarcane.
Sugar, power and alcohol chemical complexes.-
Gasohol power complexes from sugarcane.
As on date there is no Ethanol - Power complexes existing in the country or probably elsewhere
and setting up of these will require large initial investments. Similarly, there are very few sugar
mills in the country at present, which are co-generating, power and producing downstream
chemicals from alcohol due to poor economy of scales. With steps being taken to rapidly
modernize the Indian sugar industry, it is now possible to save large quantities of Bagasse for use
as fuel to produce power. Similarly, with the decision to encourage mixing gasoline with ethanol
as an oxygenate the demand for ethanol is expected to rise rapidly. In view of poor capacity
utilization of the existing distilleries mostly annexed to the sugar mills, availability of
necessary feedstock will facilitate meeting the increase in demand for gasohol. The process in
the existing sugar mills, therefore, can be modified through nominal investments such that if
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required, the production of sugar can be suitably curtailed without affecting the economy of
sugar mill or reducing any off take of sugarcane.
India is the original home of sugarcane and it had a flourishing sugar industry in the ancient time.
But the modern sugar manufacturing industry dates back from 1903 when some modern sugar
mills were established in Bihar. But the real development of the industry took place only after
1932.
India is currently the largest sugarcane producer in the world accounting for 10% of world
production. Sugar is a growing industry with the cane area, yield and recovery of sugar
increasing, over the decades though there are cyclic variations from year to year. The most of
sugar mills until now incinerates sugar cane waste instead of maximizing electricity generation.
The factory or the sugar industry occupies the important place in the country. Sugar factories are
located in the rural areas and the focal point so economical activities in their surroundings. This
is one industry where the contact between industry and agriculture increase. Direct and intimate
which is contributing to the rural Development Program of our country.
Sugarcane is a tropical grass belonging to; the some genus as sorghum and maize. The trash free
mill able sugarcane stalk contains about 73% solids. The solids in turn comprise of soluble
solids, mainly sucrose and fiber, the woody fiber of the cane is known as Bagasse and is about
30% of the weight of sugarcane. Thin Bagasse is being used as the fuel for the boilers in the
sugar mills. With the emergency of the new techniques for the manufacture of sugar generation
of power. Bagasse based co-generation of electricity has assumed new and significant relevance.
It is an important source of energy, which needs to be fully, utilized the national in the context of
ever increasing demand for energy.
The fuel value of Bagasse is approximately equivalent to; that of two barrels of fuel 0il. Storage
of large volume of combustible Bagasse has been difficult in sugar company premises, and also
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the disposal of the large quantities otherwise in cumbersome, most of the sugar plant boilers has
been designed to use almost all Bagasse generated by the factory. Despite being use of the
largest producers of cane in the world and hailing over 400 sugar mills working in the country.
And sugar industries in India are facing lot of problems. Those are,
Inadequate supply of sugarcane.
High cost of production.
Short crushing season.
Inefficient management.
Unfavorable government policy.
Some companies using Old and outdated technology.
Less sugar price in the sugar market.
With numerous advantages like reduction in transportation of fuel and reduction in transmission
losses, cogeneration in sugar industry also raises a futuristic source in the way of India self-
reliance in the power sector particularly in the rural areas. Rural Electrification Corporation
limited is a government of India enterprise funding the electricity boards for rural electrification
project. REC encourages the co-generation of surplus electricity from sugar industries with the
objectives of developing rural power centers. Indian is the second largest producer of sugarcane
next to Brazil. Presently, about 4 million hectares of land is under sugarcane with an average
yield of 70 tons per hectare.
More over Indian sugar industry have spread over mainly in rural areas; as such major share of
benefits should flow to words rural population. Besides present position of the industries shake
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less the policy of supporting farming economy by increasing sugar cane prices will ultimately
raise the sugar crop. So emphasis has to be to words cane development both by yield and quality.
So at this junction it would be appropriate to consider, if no full liberalization at least partial by
eliminating some of the undesirable constraints, by which would help industry in the closing
environment when India needs to increase its foreign earnings, n the world market.
Sugar is the most important agro based industry of India has its marked place in the countrys
economy. The reforms under the liberalization policies of government of India are fast taking
place and changing the industrial sense in the country. However it appears that the winds of
liberalization and deregulation which are blowing presently through other industrial sectors have
by passed the sugar industry, moreover Indian sugar industry had spread over mainly in rural
areas; as such major share of benefit should flow to words rural population. Besides, present
position of the industry is Shaklees. The policy of supporting farming economy by only
increasing sugarcane prices will ultimately raise the sugar cost so emphasis has to be to words
cane development both by yield and quality. So at this juncture it would be appropriate for
government to consider.
The Indian sugar industry has always been highly regulated by the requirements of a license foe
setting up or the expanding of a sugar factory restriction and control on the sale and dispatches of
sugar, fixation of statutory minimum cane price payable, fixation of levy sugar price, restriction
on import and export, on restriction on stock holding and so forth. With the government decision
to liberalize of restriction has adversely affected the industry.

Nearly 29 sugar factories producing 0.12 million tons sugar in 1930-31 the sugar sector has
grown to 423 factories and is expected to produce around a million tons of Sugar during 1999-
2000. The impressive growth in the number of sugar factories and sugar production could be
attributed so the growth of the cooperative sector in the sugar industry. The cooperative sector of
the sugar industry had hardly any presence as late 1955-56. When the cooperative sector was
comprised of three sugar factories and could produce only 0.02 million ton sugar. This was
merely 1.2% of the total. However, the scenario is entirely different during 1999-2000, when 250
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cooperative sugar factories are expected to produce around 10.3 million tons of sugar out 18.2
million tons which is around 57% of the total.
In 1989-90, the country produced 222,628,000 tons of sugar from 3, 40,500 hectares under
cultivation or 65.383 kg/hectare. The northern state of utter Pradesh is the leading producer of
cane, accounting for over 97 million tons or 44.6% of the total. Maharashtra and Tamilnadu are
the second and third ranking sugarcane producers, with 34,008,000 tons or 13.5% of total
21,918,000 tons or 11.2% of total, respectively, Bagasse, the fibrous residue of the sugar cane
used for raising steam in boilers, accounts for approximately 30% of the weight.
Sugar mills are privately owned, publicly owned and owned by cooperatives of the 491 licensed
sugar factories, 288 are in the cooperative sector, accounting for 59% of the factories installed
and 62.4% of the national output of sugar most of the remaining mills are in private hands.
Asia produced 40.4 million tons sugars. Out of this, India has produced 18.2 million tons. The
sugar producers of an Asia are a major reckoned with and India is a major player in this. In India
reforms are going on at a very fast place and during the coming years -Indian sugar production
will reach new heights.


2.2 COMPANY PROFILE

The Mysore Sugar Company Limited is a government of Karnataka enterprise. The companys
principal business activity is the manufacture sugar and Alcohol. The company is also engaged
in the processing of by products from sugar manufacturer and marketing sugar and other
products. The government of Karnataka owns about 51% of the equity capital of Mysore Sugar
Company Limited. The remaining shares are held by the financial institution and about 14,000
farmers.
The Maharaja of Mysore and his Diwan, Sir Mirza Ismail, established the Mysore
Sugar Company in January 1933. This is the first sugar factory in MYSORE state was built in
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Mandya town, which is about 100km from Bangalore, on the way to Mysore. It was designed
by BharathaRatna Sir M. Vishveswaraiah.
This famous engineer was also responsible for K.R.S Dam and a reservoir, which turned
the dry, arid district of Mandya into prosperous sugar cultivation belt within a year of its
founding. The plants were imported from Scotland and installed. Operations were begun soon
after, in its very first year the company earned a net profit of Rs 300 lakhs. This is one of oldest
plant is located in a good cane area and has a potential of crushing about 1.4 million tons of cane
per annum.
The Company beginning with 400 tones of milling plant, the factorys capacity was
periodically expanded to the present 5000 tons per day. In the near future capacity will be further
expanded to 8000 tons.
The district of Mandya produces about 4 million tons of sugarcane every year. Unlike
other part of India, Sugarcane here available up to 9 months in a year.
2.2.1 NATURE OF THE BUSINESS
Agriculture Industry: Sugar Industry is mainly depends upon the Agriculture sugar cane is the
main raw material for the manufacturing of sugar. Therefore, these sugar factory activities are
depended on agriculture.
Some time sugar industry may face the non-availability of raw sugar cane due to some reasons
like, failure of the crops, Low Production; failure of monsoon etc., Due to this reason sugar
Industry production is vary from year to year.
Seasonal Crop: Basically sugar industry highly depends on sugar cane. Mandya district is
situated in southern dry zone with moderate temperature and humidity; Rainfall varies from
760mm to 880mm, Due to this reason sugar cultivation starts between the months June to August
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of every year. Basically sugar cane harvesting starts after 9-10 months. Therefore the cane
availability is very high in the month of April and May.
2.2.2 VISION, MISSION AND QUQLITY POLICY
Vision:In concern to the vision of Mysore Sugar Ltd., this company has a great vision to
moderate the plants and implementing new plants like co-generation plants, which costs are
around 90 cores to increase the production capacity and utilize the high availability of sugar
cane. And it also has a long cherished tradition of curing for the people who work in its various
units by implementing welfare measures.
Mission: The Mysore Sugar Co. Ltd. highly concentrates the increase the production capacity
of the factory by establishing co-generation plant. Mysore Sugar Co. Ltd., employed number of
field officers to educate the farmer to cultivate sugarcane scientifically.
Quality policy: The Mysore Sugar company assures if its products by ensuring strict compliance
with the approval standards and documents systems, use of quality raw materials and
components, as also proper keep of machinery.
Companys quality policy includes
Selecting the right kind of raw material and accessories.
Adopting stringent quality control at various process of manufacturing.
Strict adherence to specification with emphasis on consistent quality in all areas of
operations.
Planning Program for acquiring samples in order to ensure standard quality.
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Product design to fully meet customer requirements including quality, design,
economy etc.
The Quality management system is designed to meet the requirement of the international
standard for each and every order it is been into consideration.
2.2.3 PRODUCT PROFILE
The factory obtains the sugarcane, which is procured from more than 14000 farmers. And other
raw materials that are required for the operation taken from the vendors & these vendors will be
evaluated on the basis of price and quality and then the required raw material will be taken from
the efficient vendors. The transport of sugarcane from farmers to the factory will be engaged
through Lorries, who will be taken through bidding and also farmers themselves supply by their
own bullock carts or by tractors.



For the purchase of other raw materials manager will receive the material requisition slip from
the usage department, which should be signed by all the department heads and by the general
manager. Then the purchase department will evaluate the list of vendors and the tabulated
comparative statement will be sent to the usage department. Then on the basis of the opinion of
the usage department the purchase department will send a file to the management, than on the
basis of this file the purchase department will place the purchase order.
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The company main product is sugar, it produces Two types of sugars are as follows.

Brown Sugars
It also called Golden Yellow Sugar White moist granulated sugar blended with small quantities
of pure sugars syrups selected for color and taste can also be produced boiling refinery cane
syrups until brown sugar crystals form used in baked goods, meat glazes, and condiments.

Raw sugar
In the form of dry, brown sugar crystals (the color being due to presence of impurities) obtained
from the evaporation of clarified sugar cane juices imported for processing into refined sugar.
This product is not sold to consumers because it does not meet Canadian standards for health and
hygiene.
Different Types of By-Products in Mysore Sugar Co Ltd:
BAGASSE MOLASSES

PRESS MUD DISTILLERY




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LIQUOR ARRACK



HIGH EFFICIENCY CO-GENERATION OF ELECTRICITY



Bagasse:It is the by-product left behind after crushing of Sugar cane. It is used as fuel in the
sugar factory boilers. Excess Bagasse finds use as a raw material in paper manufacture.
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Press MUD: It is the by-product generated by Cane juice filtration during sugar manufacture
press mud is used as a fertilizer in sugar cane cultivation, because of its rich manure properties.
Molasses: It is a by-product of sugar refining chiefly used for alcohol production. The entire
Molasses output is routed to the distillery unit.
Arrack: The Company is a major supplier of Arrack. In earlier years, the company catered to
the arrack demand of 13 districts in Karnataka.
Distillery Unit:The Company produces industrial and potable spirits totalling around 100 lakhs
litre per annum. The Company production of industrial spiritmainly sold to chemical industries,
hospitals, educational institutions and research centre.
Acetic Acid Plant: The acetic acid plant was established to supply acetic acid to the Mysore
acetate & Chemicals, as their raw material.
2.2.4 AREA OF OPERATION
The Mysore Sugar Company Ltd. has a wide regional operation. As a public ltd., industry its
marketing operation its decision is taken by the Government of Karnataka. It has to conduct
operation within 40km around the Mandya district. But its marketing operation is conducted
Regional, National as well as global wide as per the Government instruction.
2.2.5 OWNERSHIP PATTERN
The Mysore Sugar Ltd. is a Government Undertaking Company. The Government of Karnataka
owns about 51% in the equity share capital of the Mysore Sugar Ltd., The remaining 49% of the
equity shares are held by other financial institutions and about 14,000 farmers.
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2.2.6 COMPETITORS INFORMATION
The Mysore Sugar Co. Ltd., is a Government Undertaking Company, So, all the strategies are
done by government itself. For some extent it is facing competition from private Sugar factories
like Sri Chamundeshwari Sugar Co. PVT Ltd., S C Mallaiah sugar Co. PVT LTD, Bannari
Amman Sugar Co PVT LTD. and other Khandasari Mills and the local Jaggery Mills . While
there are competitions, the Mysore Sugars Co. Ltd., carrying its activities without threats because
farmers of this region has believed about company.
2.2.7 FUTURE GROWTH AND PROSPECTS
The management has a future plan for expansion. Due to increase in the supply of sugar cane it
has decided to increase the cane crushing capacity from 5000 to 7000 metric tons per year
Planning for the further automation.
Planning to expand plant capacity from 5000 TCD to 7000 TCD.
Promoting lift irrigation projects.
Planning for the expansion of Co-generation of power.
Planning to improvise the infrastructure facility and construct quarters and buildings.

2.2.8 SWOT ANALYSIS OF THE COMPANY
SWOT is an acronym used to describe the particular Strength, weakness, opportunities
and Threats that are strategic factors for a specific company. SWOT analysis not only results in
the identification of corporations distinctive competencies, the particular capabilities and
resources that a firm possesses and the superior way in which they are used.

STRENGTHS
A strong goodwill and reputation.
ISI certificate confirmed by the bureau leades to quality product and service.
A strong quality control department.
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Adoption of new technology and machineries.
Financial Assistance by State Government.
Location in the heart of the city.
It has a wide distribution network.
The company very talented and skilled employees at all the level.

WEAKNESS
Sales promotional are not very effective.
Weak in financial strategy as well as financial department.
Political interference.
Crisis between management and employees.
The efficiency of the commitment of the workers are not checked effectively because
of which the workers can take undue advantage.

OPPORTUNITIES
Rapid growth of agriculture Sector.
Awareness among the farmer for quality Sugar Cane.
Increase export share in the market.
Increase the divers product line. Implement change in technology.

THREATS
Gambling of Monsoon.
Crisis between management and farmer for regarding price fixation.
High competition from private companies.
Decrease in sugar cane growth.

2.2.9 FINANCIAL STATEMENT

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Profit & Loss Account For The year Ended 31
st
march 2012

PARTICULARS 2012
Sales and other income 363409741
Other income 24261033

Increase /(decrease) in stock of finished goods & WIP (70168825)
TOTAL INCOME 317501949
Manufacturing and other expenses 477423243
Administrative expenses 8212467
financial expenses 299971877
Depreciation 12434314
Amortisation of intangible expenses 10348729
TOTAL EXPENSES 808390630
PROFIT/(LOSS) for the year (490888681)
Extraordinary items 9369169
Prior period adjustment (269115193)
Less: provision for taxation
Net profit (loss) for the year
Opening balance B/D
(12917)
(702106940)
(2691151811)
PROFIT AFTER TAX (3393258751)




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Balance sheet for the year Ended 31
st
march 2012

PARTICULARS 2012
I.SOURCE OF FUND
1.SHARE HOLDERS FUND
a)capital 87343000
b)Reserve and surplus 47956000
2.LOAN FUNDS
a)secured loans 1324319995
b)Un secured loan 1842202489
TOTAL 3301821484
2.APPLICATION OF FUND
1.FIXED ASSET
a)Gross block 477362208
b)less depreciation 311403636
c)Net block 165958573
2.INVESTMENT 1702000
3.CURRENT ASSETS,LOANS&ADVANCES
a)inventories 222175729
b)sundry debtors 22480128
C)cash and bank balance 121580773
d)loans and advance 88582620
CURRENT LIABILITIES&PROVITIONS
a) current liabilities & provision 1706531370
NET CURRENT ASSETS (1251712120)
4.a)Miscellaneous expenditure
P&L A/C _G/R

3369392991

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