A Project Report

ON
PROCESS OF SUGAR
MANUFACTURING
(Industrial Training Report)
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR

COMPLETION OF DEGREE

BACHELOR OF TECHNOLOGY(MECHANICAL ENGINEERING)

BATCH -2008-2012

SHRI RAM MURTI SMARAK COLLEGE OF ENGINEERING

AND TECHNOLOGY (BAREILLY)

SUBMITTED BY: SUBMITTED TO :

MOHIT SAXENA Er. SHAILENDRA DEVA

Roll No-0801440030 (Head of Department-ME)
Batch-2008-2012 Branch-Mechanical Engg.
 CERTIFICATE

This is hereby declare that the project work entitled PROCESS OF

SUGAR MANUFACTURING submitted by Mohit Saxena to LALIT
HARI SUGAR FACTORY PILIBHIT (U.P.) for the award of the INDUSTRIAL
TRAINING is a genuine record of the work carried out by them during the
period of 15 JUNE, 2011 to 15 JULY, 2011.

It is further certified that this project has been developed by Mohit

Saxena , in original and has been the result of their personal efforts with
little assistance wherever required.

Mr
Project Incharge
LALIT HARI SUGAR
FACTORY
PILIBHIT (U.P.)
ACKNOWLEDGEMENT

A very special thanks to Mr. ..Training incharge (LHSF

PILIBHIT) for providing us with the opportunity to avail the excellent
facilities and infrastructure in terms of the faculty, the computer lab, the
library, and last but not the least, the ambience which served as the turning
point of my career.

We are also grateful to the college for providing us with the opportunity to
work with them and undertake a project of such importance.

MOHIT SAXENA

B.Tech. (VII SEMESTER)

S.R.M.S.C.E.T., Bareilly
DECLARATION

We hereby declare that this submission is our own work which is being
presented in the project work entitled STUDY OF SUGAR
MANUFACTURING in partial fulfillment of requirement for the award of the
degree INDUSTRIAL TRAINING at LALIT HARI SUGAR FACTORY
PILIBHIT (U.P.) is an authentic record of the work carried out by us during
the period of 16/06/2011 to 15/07/2011 and that, to the best of our
knowledge and belief.
It contains no material previously published or written by another person nor
material which to a substantial extent has been accepted for the aware of
any other degree or diploma of the university or other institute of higher
learning except where the acknowledgement has been made in the text.
 MOHIT SAXENA

CONTENTS OF THE REPORT:

Abstract
L.H.sugar factorys profile
Sugar manufacturing
Process chart
The Energy Aspects
Millhouse

Boilerhouse

Powerhouse

Clarification and boiling house:

Boiling and curing house

Cogeneration power
Molasses
Challenges for sugar industry
 Conclusions and suggestions

INDIAN SUGAR INDUSTRY - A STRONG

INDUSTRIAL BASE FOR RURAL INDIA

ABSTRACT

Indian sugar industry, second largest agro-based processing industry afte

the cotton textiles industry in country, has a lion's share in accelerating
industrialization process and bringing socio-economic changes in under
developed rural areas. Sugar industry covers around 7.5% of total rural
population and provides employment to 5 lakh rural people. About 4.5 crore
farmers are engaged in sugarcane cultivation in Inda. Sugar mills
(cooperative, private, and public) have been instrumental in initiating a
number of entrepreneurial activities in rural India. Present paper is an
attempt as to review progress of sugar industry in India, understand it's
problems and challenges in context of ongoing liberalization process.
Indian sugar industry can be a global leader provided it comes out of the
vicious cycle of shortage and surplus of sugarcane, lower sugarcane yield,
lower sugar recovery, ever increasing production costs and mounting
losses. It needs quality management at all levels of activity to enhance
productivity and production. Attention is required on cost minimization and
undertaking by product processing activities.
 MOHIT SAXENA

L.H.SUGAR FACTORYS PROFILE

L.H. Sugar Factories Ltd. is located near Tanakpur Road in Pilibhit

(U.P.). Nearest Railway Station is Pilibhit at the distance of 0.5 km. The
factory started its crushing operation in the year 1910. The licensed
crushing capacity of the plant was 300 TPD, 650 TPD. In 1928 1300
TPD in 1932-33, 3500 TPD in 1986-87, 5500 TPD in 2001-02, 6000 TPD
in 2002-03, 7200 TPD in 2004-05, 8000 TPD in 2005-06, 10000 TPD in
2006-07 and now the capacity of the plant is 11000 TPD 49522
Some important data related to L.H.S.F. is:

Cane Crushing Capacity : 10,000 TPD

Process Used : Double Sulphitation
Steam Generation : 245 Tonnes/Hour
Total Power Generation(installed) : 46 MWH
Normal Power Generation : 40 MWH
Avg. Exported Power : 25 MWH
Plant Consumption : 15 MWH
 Avg. Sugar Production : 9000 Quintals/Day
Avg. Molasses production : 4000 Quintals/Day
Avg. Press Mud Prodution : 3500 Quintals/Day

SUGAR MANUFACTURING
The History
It is thought that cane sugar was first used by man in Polynesia from where
it spread to India. In 510 BC the Emperor Darius of what was then Persia
invaded India where he found "the reed which gives honey without bees".
The secret of cane sugar, as with many other of man's discoveries, was
kept a closely guarded secret whilst the
finished product was exported for a rich
profit.

It was the major expansion of the Arab

peoples in the seventh century AD that
led to a breaking of the secret. When
they invaded Persia in 642 AD they
found sugar cane being grown and
learnt how sugar was made. As their
expansion continued they established sugar production in other lands that
they conquered including North Africa and Spain.

Sugar was only discovered by western Europeans as a result of the

Crusades in the 11th Century AD. Crusaders returning home talked of this
"new spice" and how pleasant it was. The first sugar was recorded in
England in 1099. The subsequent centuries saw a major expansion of
western European trade with the East, including the importation of sugar. It
is recorded, for instance, that sugar was available in London at "two
shillings a pound" in 1319 AD. This equates to about US$100 per kilo at
today's prices so it was very much a luxury.

In the 15th century AD, European sugar was refined in Venice, confirmation
that even then when quantities were small, it was difficult to transport sugar
as a food grade product. In the same century, Columbus sailed to the
Americas, the "New World". It is recorded that in 1493 he took sugar cane
plants to grow in the Caribbean. The climate there was so advantageous
for the growth of the cane that an industry was quickly established.
By 1750 there were 120 sugar refineries operating in Britain. Their
combined output was only 30,000 tons per annum. At this stage sugar was
still a luxury and vast profits were made to the extent that sugar was called
"white gold". Governments recognised the vast profits to be made from
sugar and taxed it highly. In Britain for instance, sugar tax in 1781 totalled
326,000, a figure that had grown by 1815 to 3,000,000. This situation
was to stay until 1874 when the British government, under Prime Minister
Gladstone, abolished the tax and brought sugar prices within the means of
the ordinary citizen.

Sugar beet was first identified as a source of sugar in 1747. No doubt the
vested interests in the cane sugar plantations made sure that it stayed as
no more than a curiosity, a situation that prevailed until the Napoleonic
wars at the start of the 19th century when Britain blockaded sugar imports to
continental Europe. By 1880 sugar beet had replaced sugar cane as the
main source of sugar on continental Europe. Those same vested interests
probably delayed the introduction of beet sugar to England until the First
World War when Britain's sugar imports were threatened.

One of the most important examples of governmental actions is within the

European Union where sugar prices are so heavily subsidised that over 5
million tons of white beet sugar have to be exported annually and yet a
million tons of raw cane sugar are imported from former colonies. This
latter activity is a form of overseas aid which is also practised by the USA.
The EU's over-production and subsequent dumping has now been
subjected to GATT requirements which should see a substantial cut-back in
production over the next few years.

An interactive World Map of Sugar production

Introduction
Sugar is made by some plants to store energy that they don't need straight
away, rather like animals make fat. People like sugar for its sweetness and
its energy so some of these plants are grown commercially to extract the
sugar:
Sugar is produced in 121 Countries and global
production now exceeds 120 Million tons a year.
Approximately 70% is produced from sugar
cane, a very tall grass with big stems which is
largely grown in the tropical countries. The
remaining 30% is produced from sugar beet, a
root crop resembling a large parsnip grown mostly in the temperate zones
of the north.

What we call sugar, the chemist knows as 'sucrose', one of the family of
sugars otherwise known as saccharides in the grouping called
carbohydrates. Carbohydrates, as the name implies, contain carbon and
hydrogen plus oxygen in the same ratio as in water. The saccharides is a
large family with the general formula C nH2nOn. The simplest of the sugars is
glucose, C6H12O6, although its physical chemistry is not that simple
because it occurs in two distinct forms which affect some of its properties.
Sucrose, C12H22O11, is a disaccharide, a condensation molecule made up of
two glucose molecules [less a water molecule to make the chemistry work].

The process whereby plants make sugars is photosynthesis. The plant

takes in carbon dioxide from the air though pores in its leaves and absorbs
water through its roots. These are combined to make sugar using energy
from the sun and with the help of a substance called chlorophyll.
Chlorophyll is green which allows it to absorb the sun's energy more readily
and which, of course, gives the plants' leaves their green colour. The
reaction of photosynthesis can be written as the following chemical
equation when sucrose is being made:

12 CO2 + 11 H2 O = C12 H22 O11 + 12 O2

carbon dioxide + water = sucrose + oxygen

This shows that oxygen is given off during the process of photosynthesis.

Historically, sugar was only produced from sugar cane and then only in
relatively small quantities. This resulted in it being considered a great
luxury, particularly in Europe where cane could not be grown. The history of
man and sugar is a subject in its own right but suffice to say that, even
today, it isn't easy to ship food quality sugar across the world so a high
proportion of cane sugar is made in two stages. Raw sugar is made where
the sugar cane grows and white sugar is made from the raw sugar in the
country where it is needed. Beet sugar is easier to purify and most is grown
where it is needed so white sugar is made in only one stage.

PROCESS CHART

SugarCane
Sugar cane is a genus of tropical grasses which requires strong sunlight
and abundant water for satisfactory growth. The Latin names of the species
include Saccharum officinarum, S. spontaneum, S. barberi and S. sinense.
As with most commercial crops, there are many cultivars available to the
cane farmer, usually hybrids of several species. Some varieties grow up to
5 metres tall.

The cane itself looks rather like bamboo cane and it is here that the
sucrose is stored. In the right climate the cane will grow in 12 months and,
when cut, will re-grow in another 12 months provided the roots are
undisturbed.

A typical sugar content for mature cane would be 10% by weight but the
figure depends on the variety and varies from season to season and
location to location. Equally, the yield of cane from the field varies
considerably but a rough and ready overall value to use in estimating sugar
production is 100 tons of cane per hectare or 10 tons of sugar per hectare.

SugarBeet
Sugar beet is a temperate climate biennial root crop. It produces sugar
during the first year of growth in order to see it over the winter and then
flowers and seeds in the second year. It is therefore sown in spring and
harvested in the first autumn/early winter. As for sugar cane, there are
many cultivars available to the beet farmer. The beet stores the sucrose in
the bulbous root which bears a strong
resemblance to a fat parsnip.

A typical sugar content for mature beets is 17%

by weight but the value depends on the variety
and it does vary from year to year and location to
location. This is substantially more than the
sucrose content of mature cane but the yields of
beet per hectare are much lower than for cane so
that the expected sugar production is only about
7 tons per hectare.

The World of Sugar Production : Mid 1990's

AUSTRALIA

Exports: 4.7 million tons

Production: 5.5 million tons
Population: 19 million
Per Capita Consumption: 45 kg

BRAZIL

Exports: 6 million tons

Production: 14.5 million tons
Population: 167 million
Per Capita Consumption: 48 kg

E.U.

Exports: 5.5 million tons

Extraction
There are several important aspects to extraction which involve the energy
balance of the factory, the efficiency of extraction and therefore ultimately
the profitability of operations:

The manager needs to process the cane as soon as possible if sugar

losses are to be avoided yet needs to have a sufficient supply in
storage for times when cutting and transport are stopped, whether
deliberately or not. Typically, cane is processed within 24 hours of
cutting;

Cane preparation is critical to good sugar extraction, particularly with

diffusion extraction. This is achieved with rotating knives and
sometimes hammer mills called "shredders". However shredding
requires extra energy and more equipment;

The extraction is actually conducted as a counter-current process

using fresh hot water at one end being pumped in the opposite
direction to the cane. The more water that is used, the more sugar is
extracted but the more dilute the mixed juice is and hence the more
energy that is required to evaporate the juice;

The more accurately that the mills are set [adjusted], the drier is the
residual fibre and hence the less sugar remaining in the fibre;

A typical mixed juice from extraction will contain perhaps 15% sugar and
the residual fibre, called bagasse, will contain 1 to 2% sugar, about 50%
moisture and some of the sand and grit from the field as "ash". A typical
cane might contain 12 to 14% fibre which, at 50% moisture content gives
about 25 to 30 tons of bagasse per 100 tons of cane or 10 tons of sugar.

Harvesting
Cane grows very tall in good growing regions - certainly up to 3 metres/10
feet tall - and still has some green leaves when ripe although most leaves
have dried off by then. Where possible the cane is fired before harvesting
to remove the dead leaf material and
some of the waxy coating. The fire
burns at quite high temperatures but
is over very quickly so that the cane
and its sugar content are not
harmed.

In some areas burning is not

permitted because of the nuisance
value to local communities of the
smoke and carbon specs that are
released. However there is no environmental impact, the CO 2 released
being a very small proportion of the CO 2 fixed with photosynthesis during
growth and the improved sugar extraction meaning that less cane needs to
be grown on fewer acres to satisfy the world's sugar demand.

Harvesting is done either by hand or by machine. Hand cut cane -- cane

cutting is a hard and dirty job but can employ lots of people in areas where
jobs are scarce -- is cut at about ground level, the top green leaves are
cropped off and then the stalk is bundled whole. Once a complete bundle
has been assembled it is removed from the field with a light cart and may
then be transferred to a larger vehicle for transport to the mill.

Most machine-cut cane is chopped into short lengths but is otherwise

handled in a similar way as hand cut cane. Machines can only be used
where land conditions are suitable and the topography is relatively flat. In
addition the capital cost of machines and the loss of jobs caused makes
this solution unsuitable for many sugar estates.
Evaporation

The mixed juice from extraction is preheated prior to liming so that the
clarification is optimal. The milk of lime, calcium hydroxide or Ca(OH) 2, is
metered into the juice to hold the required ratio and the limed juice enters a
gravitational settling tank: a clarifier. The juice travels through the clarifier at
a very low superficial velocity so that the solids settle out and clear juice
exits.

The mud from the clarifier still contains valuable sugar so it is filtered on
rotary vacuum filters where the residual juice is extracted and the mud can
be washed before discharge, producing a sweet water . The juice and the
sweet water are returned to process.

The clear juice has probably only 15% sugar content but saturated sugar
liquor, required before crystallisation can occur, is close to 80% sugar
content. Evaporation in a steam heated multiple effect evaporator is the
best way of approaching the saturated condition because low pressure
water vapours can be produced for heating duties elsewhere in the factory.
The evaporator sets the steam consumption of the factory and is designed
to match the energy balance of the entire site: the manager wants to avoid
burning auxiliary fuel and equally wants to avoid paying to dispose of
surplus bagasse. The greater the number of effects, the less steam is
required to drive the first effect. Each subsequent effect is heated by the
vapour from the previous effect so has to be operated at a lower
temperature and therefore lower pressure.

Boiling
Physical chemistry assists
with sugar purification
during the crystallisation
process because there is
a natural tendency for the
sugar crystals to form as
pure sucrose, rejecting
the non-sugars. Thus,
when the sugar crystals
are grown in the mother
liquor they tend to be pure
and the mother liquor
becomes more impure.
Most remaining non-sugar
in the product is
contained in the coating
of mother liquor left on the
crystals

The mother liquor still

contains valuable sugar of
course so the
crystallisation is repeated
several times. However
non-sugars inhibit the
crystallisation. This is
particularly true of other sugars such as glucose and fructose which are the
breakdown products of sucrose. Each subsequent step therefore becomes
more difficult until one reaches a point where it is no longer viable to
continue.

The crystallisation step itself - a "boiling" - takes place in a vacuum pan: a

large closed kettle with steam heated pipes. [In practice the heating is done
with a low pressure water vapour from the evaporator.] Some modern pans
are continuous flow devices but most are batch devices which go through a
discrete cycle and are then emptied for a new boiling. A typical cycle might
be 4 hours long. The mixture of crystals and mother liquor from a boiling,
called the "massecuite", is dropped into a receiving tank called a
crystalliser where it is cooled down and the crystals continue to grow. This
also releases the pan for a new boiling. From the crystalliser the
massecuite is fed to the centrifuges.

In a raw sugar factory it is normal to conduct three boilings. The first or "A"
boiling produces the best sugar which is sent to store. The "B" boiling takes
longer and the retention time in the crystalliser is also longer if a
reasonable crystal size is to be achieved. Some factories re-melt the B
sugar to provide part of the A boiling feedstock, others use the crystals as
seed for the A boilings and others mix the B sugar with the A sugar for sale.
The "C" boiling takes proportionally longer than the B boiling and
considerably longer to crystallise. The sugar is usually used as seed for B
boilings and the rest is re-melted.

Various boilers which are used here in L.H.S.F. are:

THERMAX BOILER
CAPACITY : 45 TPH
WORK PRESSURE : 21 Kg/cm square
STEAM TEMRERATURE : 340 deg C
HEATING SURFACE : 2204 m square
INSTALLATION YEAR : 1991
LIPI BOILER
CAPACITY : 20 TPH
WORK PRESSURE : 21 Kg/cm square
STEAM TEMRERATURE : 345 deg C
HEATING SURFACE : 1026 m square
INSTALLATION YEAR : 1998
WIL BOILER
CAPACITY : 45 TPH
WORK PRESSURE : 45 Kg/cm square
STEAM TEMRERATURE : 445 deg C
HEATING SURFACE : 2106 m square
INSTALLATION YEAR : 2001
SISTON BOILER
CAPACITY : 120 TPH
WORK PRESSURE : 67 Kg/cm square
STEAM TEMRERATURE : 525 deg C
 HEATING SURFACE : 5359 m square
INSTALLATION YEAR : 2007
The Energy Aspects
The steam is raised in bagasse fired boilers which usually have a
secondary fuel to accommodate imbalances in bagasse supply
and steam or power demand. The factory designer attempts to
balance the site such that bagasse is neither left over nor
insufficient: any secondary fuel costs money and a large surplus
of bagasse may cost money to dispose. Balancing is done by
selecting the right mix of turbine and electric drives for major
equipment and selecting the pressure of the steam to give the
efficiency required. In many cases this does not recognise the full
energy value of the bagasse and is therefore wasteful in an
overall sense. Today, more and more factories are considering
power export as another by-product of sugar production. To do
this they are improving the efficiency of their thermodynamic
cycles and converting equipment drives to optimise power output.

Factories are frequently in very undeveloped places and have no

connection to an external power supply. This requires special
techniques to start the factory and means that any breakdown in
the power house impacts on the entire neighbourhood. Wives
soon tell their husbands what happened to dinner when their
spouses lost power!

Sucrose extraction from beets is easier than with cane for several
reasons of which keeping quality and diffusion characteristics are
the two most important.

Stored correctly, beet will keep for several weeks after harvesting
without substantial loss of sucrose content. It is generally
harvested or stored on the farm and delivered to the factory up to
48 hours before harvesting. In countries with very cold winters,
however, this can be a much longer time with large ventilated
piles kept at the factory to avoid process disruptions caused by an
inability to harvest or transport the crop. The beets need
protection from frost and from overheating in the piles but as a
biennial plant it expects to survive over winter in order to come to
life in spring and grow to seed.

Unlike cane extraction, it is important to avoid rupturing the cells

of the beet because the sucrose is readily diffused out of whole
cells and extraction can therefore be achieved preferentially. This
results in a high purity juice without a lot of the cell material and
other non-sugars found in cane juice. The slicing is therefore
done with sharp knives which cut a V section slice of 4 to 5 mm
thickness. The slices, known as cossets in some parts of the
world, look somewhat like "potato sticks".

A typical raw juice from diffusion will contain perhaps 14% sugar
and the residual pulp will contain 1 to 2% and a total of 8 to 12%
solids.

Pressing
The spent slices are de-sweetened in large screw presses where
a variable pitch screw pushes the pulp at ever increasing
pressure through a perforated, usually conical tube. The juice
flows away and the pressed pulp, at around 70% moisture
content, discharges from the end of the tube. Molasses is often
added to the pressed pulp before drying in order to provide a
higher sugar content animal feed. Typically 2 tons of pressed pulp
and 0.4 tons of molasses are dried to make 1 ton of dried pulp at
10% moisture content. The dried pulp is then extruded into pellets
to increase the density of the product and make it easier to store
and handle.

The drying process is energy intensive, using about 1/3 of the

total factory fuel consumption. Generally driers are large rotating
drums with air at 600 to 900 C used to drive the water out of the
pulp. Some new driers use steam so that the water driven off can
be used as heat in the sugar manufacturing process.
Carbonatation
Carbonatation is achieved by adding milk of lime [calcium
hydroxide, Ca(OH)2] to the liquor and bubbling carbon dioxide
through the mixture. The gas, which is obtained from the
manufacture of the lime in the first place, reacts with the lime to
form fine crystalline particles of calcium carbonate which occlude
the solids. To obtain a stable floc, the pH and temperature of the
reaction are carefully controlled. Beet factories use much more
lime than cane factories, some 1 to 3% of CaO on beet is used.

The filtration is undertaken with rotary leaf filters where the liquor
is pumped from the outside of the leaf to the middle where the
clear liquor is collected or in a clarifier where settling occurs. As
the layer of floc builds up in a leaf filter it increase the pressure
drop across the system until the filter is effectively choked and
taken off line for cleaning. The clarifier is run continuously
however. The lime mud that is collected from either method is still
wet with sugar liquor so it is de-sweetened by slurrying with water
- the resultant sweet water is used elsewhere in the process - and
re-filtering it to a mud with 50% or less moisture. The mud is then
dumped or used as lime on fields.

The efficiency of the factory depends substantially on the use of

multiple effect evaporation, as with the raw cane sugar factory. It
is even more important for the beet factory because there is no
surplus fibre available to porvide fuel for the power house. The
greater the number of effects, the less steam is required to drive
the first effect. Each subsequent effect is heated by the vapour
from the previous effect so has to be operated at a lower
temperature and therefore lower pressure. In is not unusual to
see 6 and sometimes 7 effects in a beet factory although many
cane factories only have 3 or 4 effects.

Decolourisation
Granular activated carbon is the modern equivalent of "bone
char", a carbon granule made from animal bones. Today's carbon
is made by specially processing mineral carbon to give a granule
which is highly active but also very robust: it can withstand the
mechanical abrasion that results from transporting it around the
plant.

The carbon is used in the process in very large columns, perhaps

10 or more metres high. The sugar liquor, at about 65% dry
solids, is pumped through 2 columns in series. Because of
limitations in distributing the liquor across the width of large
columns it is quite normal to split the total liquor flow into three or
more parallel streams, each of which passes through a pair of
columns. The first column of the pair has been in use for some
time while the second column is fresher. When the carbon in the
first column reaches is practical limit of absorption, that column is
switched out of line, the second column becomes the first column
and a column with fresh carbon becomes the second column. In a
typical refinery with say 3 streams of liquor, a column will come off
line every three days so any one column has a life of 18 days of
which 9 are hard working in the first column position.

Decolourisation with granular activated carbon typically achieves

90% effectiveness: a 1200 colour liquor entering the system will
depart at about 120 colour.

MILLHOUSE:
Mill house is the cane crushing unit which consists of cane carrier,
cane cutter having cutting knives, milling tandem, bagasse carrier
and conveyor. Cane feeding to the cane carrier is done by
unloaders and feeder table. As the cane carrier moves, the cane
kicker evens out cane load in the cane carrier and then two sets
of cane knives cut the cane into small pieces. This process of
cane cutting is called 'cane preparation. These cane pieces then,
pass through different mills and the juice is extracted. The mills
are driven by D.C.motors. The residue which comes out of the mill
after extraction of juice is called bagasse.

Various milling units used in LHSF are :-

Mill GRPF 500kwatt d.c., 1000kw d.c.

Mill GRPF 522kwatt dc.

o 900kwatt variable frequency drive

Mill GRPF hydraulic drive 900kwatt v.f.d.

Mill GRPF 400h.p hydraulic drive

o 900kwatt v.f.d

Mill GRPF 500kwatt v.f.d

o 900kwatt v.

BOILERHOUSE:
Boiler generates steam by burning the bagasse. The steam is
used in powerhouse, boiling house, curing house. The steam
required by the Sulphitation process varies from 42 - 45 % on
cane crushed per hour.

POWERHOUSE:
The high pressure steam generated by the boiler is utilized for
production of power by the turbo-alternators. The power produced
is used for captive needs and the surplus power is exported to the
government grid. The low pressure steam that comes out from the
turbo alternator is utilized for boiling the extracted juice.
CLARIFICATION AND BOILING HOUSE:

The juice extracted by the mills is measured by juice flow system. The
measured juice is heated in juice heater in two stages. First the juice is
heated by the vapours from fourth and third bodies of evaporator in
different heaters. This heating is called primary heating. The heated juice is
treated with milk of lime and sulphur-di-oxide to coagulate maximum
impurities and sent for secondary heating. The secondary heating is done
with vapours from second body of evaporator and vapours from the first
body or exhaust steam. The treated juice is passed to clarifier, where in
clear juice is removed from the top and settled mud at the bottom is
separated. To extract sugar from the mud, it is taken to vacuum filter in
which juice and filter cake are separated. Juice is taken back to process
and the mud is disposed as solid waste. Clear juice from clarifier is taken to
evaporator for evaporating its water content. First body is heated by
exhaust steam, and other bodies by the vapours of the previous body. The
total water evaporated in the evaporator is 75-80 % percent. The juice after
evaporation is called as syrup. This syrup is normally of 60 % solids of its
total weight. The syrup is then sulphited in syrup Sulphitation tower.
BOILING AND CURING HOUSE
Sulphited syrup is taken to pan floor for making sugar crystal. Three
massecuites boiling systems is normally adopted, in which, A, B and C
Massecuites are boiled. A-massecuites is formed by boiling syrup, sugar
melt ,A light molasses and on B-single cured sugar as seed. This A-
Massecuite is boiled till it attains the required size of sugar crystal and it is
dropped into crystallizers and cooled. After exhaustion of sugar in solution,
the A massecuite is passed on to the centrifugals for separating sugar
crystals from the massecuite. The separated 'A' sugar is bagged after
drying.A-Light and A-Heavy molasses are pumped to pan floor and are
used for making A- and B-Massecuite respectively

B-Massecuite boiled in B pans is dropped into B- Crystallizers and then it

is cured in B-Centrifugal machines. B-heavy molasses and B-single
cured sugar are obtained separately. B-single cured sugar is used as seed
for A massecuite. B-heavy molasses is used for making C-Massecuite in
C-pans. C-Massecuite is dropped into C-Crystallizers where it is cooled.
C-Massecuite is then taken to C-fore worker centrifugal machines for
curing. Final molasses and C-single cured sugar are obtained. 'C' Single
cured sugar is again cured in another centrifugal machine in which C-
double cured sugar and C-light molasses are obtained. C-light molasses
are taken to pan floor and is used in making C-Massecuite. C-double
cured sugar is melted and is used in making 'A' Massecuite.

Sugar discharged from 'A' Machine is dropped on to grass hopper

conveyors. By passing hot air in hoppers the sugar is dried and taken to
grader in which powder and roris are separated. The required grade sugar
is bagged.

COGENERATION POWER
Cogeneration involves the use of high pressure Boilers for producing
steam and Turbo generators for generating power. The high pressure
steam passes through the turbine and generates power. The low pressure
steam from the turbine is used in the processing of sugar. This process of
utilization of steam for generating power and for processing of sugar is
called cogeneration.

This cogeneration plant is the first plant in India to install Air cooled
condensers instead of water cooled condensers for its turbines. Even
though the Air cooled condensers incur a much higher investment cost
than the water cooled condensers, it is environment friendly and they
totally eliminate the use of water. This is an important environment feature
given the scarcity of water in the region and a positive step towards water
conservation.

MOLASSES
The history of the Word molasses ( Melasse in German and Dutch) is not
mentioned in Etymological dictionaries since it is quite definitely and clearly
derived from the Romanic languages.
The term molasses is applied to the final effluent obtained in the
preparation of sugar by repeated crystallization.The amount of molasses
obtained and its quality (composition) provide information about the nature
of the beets (local conditions of growth and effects of the weather) and the
processing in the sugar factory, such as the efficiency of the juice
clarification, the method of crystallization during boiling, and the separation
of the sugar crystals from the low-grade massecuite.
If the concept molasses is to be strictly defined it is necessary to
distinguish between theoretical and practical molasses. The theoretically
final molasses is a mixture of sugar, nonsugars and water, from which no
saccharose crystallizes under any conceivable physical and technically
optimum conditions, with no regard to time. If relatively more favourable
conditions for crystallization are maintained (low water content, low
temperature, long crystallization time, thin layers of the syrup film) the
crystallization might be so extended that with intensive centrifugation of the
molasses a quotient (Q) of 49 would be attainable. Q represents the
percentage of sugar in the total solid content of the molasses.

The lower the purity or purity coefficient, the more closely a syrup
approaches theoretical molasses. Unusual specimens of molasses,
produced in experimental studies, have quotients from 45 to 50. The
practically obtainable molasses is the end syrup from which, with
maintenance of the technical conditions promoting crystallization, no
significant additional amounts of saccharose can be recovered by further
concentration. In this sense molasses with purity quotients above 64 are no
longer true molasses they are crystallisable syrups.

The objective of the sugar industry is to produce molasses whose purity is

as low as possible. Commercial molasses ordinarily have a quotient
around 60, i.e. approximately 48 % sugar is present in molasses whose
solids content is 80%. (Q denotes purity quotient of molasses; S is sugar
content; T represents dry substance.) Efforts to understand and master the
conditions leading to exhausted molasses are as old as the sugar industry
itself. Since the formation of molasses and the problems of crystallization
of sugar are closely related, a clear understanding of the influences of the
nonsugar substances on the crystallization of the saccharose from
aqueous solutions simplifies the study of the formation of molasses. The
many studies along these lines can be divided fundamentally into two
categories.

(i) Mechanical theory of molasses formation

This old theory is based on the decrease in the rate of crystallization which
depends on the speed with which the dissolved sugar molecules are
transported out of the liquid on to the crystal surface as well as on the rate
at which they are built into the crystal lattice.

(ii) Chemical theory of molasses formation

This theory is based on the mutual solubility influences in the system:
water sugar, salts or non sugar components. In many studies of the
influence of the non sugar components on the solubility of sucrose, pure
substances or mixtures of pure substances have been employed, but they
did not always correspond to the complicated relationships prevailing in
molasses. The use of ion exchangers made it possible to start these
investigations directly on molasses. It has been found that nitrogenous
materials have practically no effect with respect to the sucrose solubility;
potassium and sodium have considerably stronger molasses-producing
properties than calcium and lithium. Because of the economic significance
of the composition of final molasses there is great permanent interest in the
sugar industry in being able to calculate beforehand the amount of
molasses that may be expected, i.e. at the time of delivery and processing
of the beets.
Molasses is a viscous by-product of the processing of sugar cane, grapes
or sugar beets into sugar. The word molasses comes from the Portuguese
word melao, which ultimately comes from mel, the Latin word for "honey".
[1]
The quality of molasses depends on the maturity of the sugar cane or
sugar beet, the amount of sugar extracted, and the method of extraction.
Sweet sorghum syrup is known in some parts of the United States as
molasses, though it is not true molasses.
CHALLENGES FOR SUGAR INDUSTRY
India ranks first in sugar consumption and second in sugar production in
world but it's share in global sugar trade is below 3%. Indian sugar industry
has been facing raw material, and resource as well as infrastructural
problems. Globalization has brought a number of opportunities but at the
same time posed certain challenges before sugar industry. Most of sugar
units in India utilize production capacity below 50%. Low capacity utilization
and inadequacy of raw material led to closer of 100 sugar factories in India.
Mounting losses and decreasing networth of sugar factories have been
responsible for sickness of sugar industry. Sickness in sugar industry has
reached to an alarming proportion. Indian sugar industry has been cash
striven for decades. Low cash inflow due to piling stocks leads to serious
financial crisis and finally to closing sugar factories.

Sugar prices have been a political issue rather than economical issue.
Many a times it worsens economy of sugar factories. The main concern of
sugar industry in India is fluctuations in sugarcane production due to
inadquate irrigation facilities, lower sugarcane yield, and frequent droughts
in tropical and sub-tropical areas where sugarcane is grown ona large
scale. In addition, sugarcane yield has been lower (59 Mts per hectare).
Sugar recovery is also lower in comparison with other sugar manufacturing
countries. This leads to escalation of production costs and weakness
competitive edge of the industry. Most of sugar mills in India are having
daily sugarcane crushing capacity of 1250 tonnes. These mills cannot have
economies of scale so they have to incur high production costs. Indian
sugar industry is characterized by high production costs. Therefore, daily
crushing capacity should be extended to 2500 tonnes. Obviously, industry
has a great challenge of existence in global market. In recent years,
sugarcane production in India has decelerated to a great extent due to
water and power shortage. Special attention is needed to be given on
water resource management. All the area under sugar cultivation should be
brought under drip irrigation to conserve water as well as fertilizers.
Adequate and regular power supply to sugarcane growers and sugar
factories would increase production andproductivity. To enhance share of
Indian sugar industry in global trade, quality and quantity of sugar needs to
be enhanced.
CONCLUSION & SUGGESTIONS

Sugar industry is the second largest agro-based industry in India. Sugar

factories, particularly cooperative sugar factories in Maharastra and other
states have been instrumental in building confidence among rural people
and strengthening industrial base in rural India. In the era of globalization,
sugra industry needs more competitive edge which can be given by way of
modernization, enhancing productivity, and manufacturing excellent quality
sugar at competitive prices. It needs quality management at every level of
activity to enhance its performance. The need of the hour is to liberalize
industry from clutches of unprofessional people. Most of the sugar units do
not have byproduct utilization plants. Projects based on bagasses and
molasses should be initiated. Ethanol, alochol, and paper projects have
tremendous scope for development in India. In future, 10-15% ethanol may
be allowed to be blended with petrol. Bagasses based power generation
projects installed adjacent to each sugar factory would fulfill need of power.
Research programme should be undertaken in area of sugarcane
cultivation, enhancing sugarcane productivity, and sugar recovery.
Sugarcane prices should be fixed on basis of sugar recovery. Attention is to
be given on manufacturing quality sugar as per international standards at
competitive prices.