Industrial Training Report

2010-2011

INTRODUCTION
The Sugar industry is described as industry, which is involved in the production of edible sugar from raw sugar cane and sugar beet. Sugar is extracted from two raw materials, sugar cane and beet and is produced in over 100 countries. Nearly 60 per cent of the world sugar is produced from sugar cane and the balance is from sugar beet. Cane sugar is grown mainly in warm, southern hemisphere regions while beet is generally grown in cooler areas in the northern hemisphere. Both taste the same and produce white sugar although beet sugar, typically, smaller and more uniform crystal shapes. The sugar industry is a seasonal industry where the season for beet based sugar is 6 to 18 weeks and cane based lasting for 12 to 22 weeks.

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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 Mandya town, which is about 100km from Bangalore, on the way to Mysore. It was designed by Bharatha Ratna 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.

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HISTORY OF SUGAR
India has been known as the original home of sugar and sugar cane. Indian mythology supports the above fact as it contains some legends showing the origin of sugar cane. The growth the sugar industry is full of tales of adventure and conquest. It received attention of the builders of different Empires from time to time. About 800 B.C. sugar cane was perhaps taken eastward, i.e. China, where it found suitable soil for development. About 327 B.C. when Alexander the great, invaded India he and his soldiers were the First Europeans to see sugar cane in India. On their return westward they took sugar cane to Europe, but it was about 700 A.D. that it is was actually cultivated there. It was between the fourth and sixth centuries that the art of making sugar was discovered in India. The cane was cut into pieces and crushed by a heavy weight and the juice thus obtained was boiled and stirred until solids formed. These solids being of uneven shapes and sizes were called Sarkara, the Sanskrit term for gravel. The modern word Sugar is a derivative of the word Sarkara. The larger solids were called Khand from which the word Candy has been derived. The Chinese Emperor, Tsai-Hang sent a mission to Bihar in about 600 A.D. to ascertain and study the art of sugar manufacture. From India the knowledge of sugar making went over to Persia. It would thus be seen that India has been the original home of sugar cane as also sugar manufacture.

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RAW MATERIALS PROCESSED

1. Carbohydrates present in many plants having more or less sweet taste are called as Sugar. The primary sugar, glucose, is a product of photosynthesis and occurs in all green plants. In most plants, the sugars occur as a mixture that cannot readily be separated into the components. In the sap of some plants, the sugar mixtures are condensed into syrup. Juices of sugar cane and sugar beet are rich in pure sucrose, although beet sugar is generally much less sweet than cane sugar. These two sugar crops are the main sources of the commercial sucrose. 2. Sugar cane: Sugar cane is a thick, tall, perennial grass that flourishes in the tropical or subtropical regions. Sugar synthesized in the leaves is used as a source of energy for growth or is sent to the stalks for storage. It is the sweet sap in the stalks that is the source of sugar. The reed accumulates sugar to about 15 percent of its weight. Sugar cane yields about 2,600,000 tons of sugar per year. Sugar cane takes about seven months to mature in a tropical area and about 12-22 months in a subtropical area. At this time, fields of sugar cane are tested for sucrose, and the most mature fields are harvested first. 3. Sugar Beet: Sugar beet is a beetroot variety with the highest sugar content, for which it is specially cultivated. While typically white both inside and out, some beet varieties have black or yellow skins. About 3,700,000 tons of sugar is extracted from sugar beet. 4. Other sugar crops include sweet sorghum, sugar maple, honey, and corn sugar. The types of sugar used today are white sugar (fully refined sugar), composed of clear, colorless or crystal fragments; or brown sugar; which is less fully refined and contains a greater amount of treacle residue, from which it obtains its colour.

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THE MANUFACTURING PROCESS

Fig -1 Manufacturing Process

Planting and harvesting

Sugar cane requires an average temperature of 75 degrees Fahrenheit (23.9 degrees) .Many developed countries do harvesting of both cane and sugar beet by machine; although in many developing countries it is also done by hand. The harvested cane stalks and beets are loaded mechanically or physically into trucks or tractors and taken to mills for processing into raw sugar. Once there, they are cleaned, washed, milled to extract juice, filtered, and purified. The result is a clear, sugar-filled juice.

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Preparation and Processing

Fig-2 Unloading Of Cane

After the cane arrives at the sugar mills, it is mechanically or physically unloaded and excessive soil and rocks are removed. At this point, the cane is clean and ready to be milled

3) Juice extraction process

Two or three heavily grooved crusher rollers break the cane and extract a large part of the juice, or swing-hammer type shredders (1,200 RPM) shred the cane without extracting the juice. Revolving knives cutting the stalks into chips are supplementary to the crushers. (In most countries, the shredder precedes the crusher.) A combination of two, or even all three, methods may be used. The pressing process involves crushing the stalks between the heavy and grooved metal rollers to separate the fiber (bagasse) from the juice that contains the sugar.

As the cane is crushed, hot water (or a combination of hot water and recovered impure juice) is sprayed onto the crushed cane counter currently as it leaves each mill for diluting. The extracted juice contains 95 percent or more of the sucrose present. The mass is then diffused, a process that involves finely cutting or shredding the stalks. Next, the sugar is separated from the cut stalks by dissolving it in hot water or hot juice.

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Fig-3 Tandem mill

Fig-4 Milling of Cane

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Purification of juice:clarification and evaporation

The juice from the mills, a dark green color, is acid and turbid. The clarification (or defecation) process is designed to remove both soluble and insoluble impurities (such as sand, soil, and ground rock) that have not been removed by preliminary screening. The process employs lime and heat as the clarifying agents. Milk of lime (about one pound per ton of cane) neutralizes the natural acidity of the juice, forming insoluble lime salts. Heating the lime juice to boiling coagulates the albumin and some of the fats, waxes, and gums, and the precipitate formed entraps suspended solids as well as the minute particles.

The muds separate from the clear juice through sedimentation. The non-sugar impurities are removed by continuous filtration. The final clarified juice contains about 85 percent water and has the same composition as the raw extracted juice except for the removed impurities.

Fig-5 Removal of Press Mud

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To concentrate this clarified juice, about two-thirds of the water is removed through vacuum evaporation. Generally, four vacuum-boiling cells or bodies are arranged in series so that each succeeding body has a higher vacuum (and therefore boils at a lower temperature). The vapors from one body can thus boil the juice in the next onethe steam introduced into the first cell does what is called multiple-effect evaporation. The vapor from the last cell goes to a condenser. The syrup leaves the last body continuously with about 65 percent solids and 35 percent water.

5) Crystallization

Crystallization is the next step in the manufacture of sugar. Crystallization takes place in a single-stage vacuum pan. The syrup is evaporated until saturated with sugar. As soon as the saturation point has been exceeded, small grains of sugar are added to the pan, or "strike." These small grains, called seed, serve as nuclei for the formation of sugar crystals. (Seed grain is formed by adding 56 ounces [1,600 grams] of white sugar into the bowl of a slurry machine and mixing with 3.3 parts of a liquid mixture: 70 percent ethylated spirit and 30 percent glycerin. The machine runs at 200 RPM for 15 hours.) Additional syrup is added to the strike and evaporated so that the original crystals that were formed are allowed to grow in size.

Fig-6 Sugar Crystal Formation in Pan

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The growth of the crystals continues until the pan is full. When sucrose concentration reaches the desired level, the dense mixture of syrup and sugar crystals, is discharged into large containers known as crystallizers. Crystallization continues in the crystallizers as the syrup and sugar crystals are slowly stirred and cooled.

syrup and sugar crystals from the mixers is allowed to flow into centrifugals, where the thick syrup, or molasses, is separated from the raw sugar by centrifugal force.

6) Centrifuging

The high-speed centrifugal action used to separate the syrup and sugar crystals into raw sugar crystals and molasses is done in revolving machines called centrifugals. A centrifugal machine has a cylindrical basket suspended on a spindle, with perforated sides lined with wire cloth, inside which are metal sheets containing 400 to 600 perforations per square inch. The basket revolves at speeds from 1,000 to 1,800 RPM. The raw sugar is retained in the centrifuge basket because the perforated lining retains the sugar crystals. The mother liquor, or molasses, passes through the lining (due to the centrifugal force exerted). The final molasses (blackstrap molasses) containing sucrose, reducing sugars, organic non-sugars, ash, and water, is sent to large storage tanks. Once the sugar is centrifuged, it is "cut down" and sent to a granulator for drying. In some countries, sugar cane is processed in small factories without the use of centrifuges, and a dark-brown product (non-centrifugal sugar) is produced. Centrifugal sugar is produced in more than 60 countries while non-centrifugal sugar in about twenty countries.

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7) Drying and Packaging

Damp sugar crystals are dried by being tumbled through heated air in a granulator. The dry sugar crystals are then sorted by size through vibrating screens and placed into storage bins. Sugar is then sent to be packed in the familiar packaging we see in grocery stores, in bulk packaging, or in liquid form for industrial use.

Fig-7 Packing Facility

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BY PRODUCTS OF SUGAR INDUSTRY

In the process of sugar manufacturing the major by-products, which are derived are molasses, bagasse and press mud, and these by-products account for about 40 percent by weight, of total sugar cane crushed. India has achieved considerable progress in the utilization of by-products bagasse and molasses. Today sugar mills are adopting an integrated business model that revolves around effective utilization of by-products including ethanol and bagasse. Molasses Molasses is used primarily in the production of alcohol (rectified spirit). It accounts for 4.3% - 4.7% per ton of sugar cane crushed. Bagasse The fibre (30% - 33% per ton of sugar cane crushed) formed from crushing sugar cane is called bagasse, which is used as a combustible in furnaces to produce steam, which, in turn, is used to generate power. Sugar mills use bagasse to generate power needed for processing sugar cane. It is also used as raw material in the production of paper and as feedstock. Press Mud Press mud accounts for around 3%-5% per ton of the sugar cane crushed. Sulphination press mud is mainly used as manure.

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Fig-8 By-Products of Sugar Industry

SUGAR GLOSSARY Brix: A unit used to express the concentration of solids in aqueous sugar solutions. Clarification: The process of separating insoluble suspended matter and some soluble substances from cane juice, to produce a clear juice. Fiber: Fiber is the cane plants vegetable skeleton in which juice is stored and through which plant food, dissolved in water, is distributed throughout the plant. In the milling process, the fiber cells are ruptusred, thus freeing the juice. The fiber content of sugar cane varies according to variety. The normal range is 10% to 16%. A medium and consistent fiber content is desirable in commercial varieties. Filter Mud: In clarifying cane juice, the insoluble matter extracted from the juice forms a mud, which is removed from the clarifiers, filtered and washed to recover the sugar it contains. Filter mud consists of 25% solids and 75% water. The solids consist of mainly field soil, fiber, calcium phosphate, denatured protein and a small amount of sugar.

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Molasses: The black syrup, commonly known as molasses or C syrup, remaining after the sugar syrup has been boiled and passed through the centrifugal for the last item in a mill or refinery. The sugar it contains cannot be removed economically. A typical analysis of final molasses includes sucrose (34.1%), reducing sugars (16.5%), ash (11.3%), water (21.8%) and various sugar, gums and acids (16.3%). The ash includes calcium, magnesium, potassium, silicon, iron, and phosphorous and other elements in the form of inorganic salts. Fructose: A sugar, which occurs in, fruit, the nectar of flowers, honey, and in cane juice and sugar products. It is formed in equal quantity with glucose when sucrose is inverted. In solution, it rotates polarized light to the left. It has the chemical composition C6H12O6. Glucose: A sugar, which occurs naturally in grapes, honey, sweet fruits, and in cane juice and sugar products. It can also be made from wheat. In the human body, sucrose is converted into glucose and fructose before being used to provide energy. It has the chemical composition C6H12O6 and may also be called dextrose. HFCS: High Fructose Corn Syrup. This is the most common name for starch-based fructose/glucose syrups. Corn is the starch base of these syrups. Other suitable but not as widely used starch sources include rice, wheat and tapioca. In Europe HFCS is referred to as iso-glucose. Inversion: The conversion of sucrose, with the addition of water, into a mixture of equal amounts of glucose and fructose. The action is one of hydrolysis and may be carried out by the action of the enzyme invertase, or by heating with dilute acids. The liquid product from this process is called invert sugar. Juice: Cane juice consists of water with sugar and other substances dissolved in it and a proportion of insoluble particles suspended in it.

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Non-Centrifugal Sugar: In some areas of the world sugar cane juice is merely evaporated to produce a crude raw sugar; the sugar crystals are not removed from the mother syrup in centrifugals. The sugar is generally consumed where it is produced. Some of these sugars are known as Jaggery, Gur, Piloncilo and Muscovado. Jaggery and Gur are made in India by evaporating cane juice in an open pan. The juice is evaporated to almost dryness and is then cast in open moulds or loaves. A large amount of sugar consumed in India is in this form. Refined Sugar: Sugar, which has passed through the refining process (involving removal of impurities) making it more suitable for direct human consumption or use in the manufacture of other foods. Also known as white sugar Sucrose: Commonly referred to as sugar. A carbohydrate having the chemical composition C12H22O11. It comprises two simple sugars - glucose and fructose. Syrup: In refineries, syrup refers to the less pure solution, which is spun off crystals in centrifugals. In the milling process syrup is the name of the product stream after it leaves the evaporators and before it enters the pans. Vaccum Pan: Cylindrical steel vessel in which a steam heated surface is used to boil sugar syrups under partial vacuum at relatively low temperatures.

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10. REFERENCES
Food Industry Report ICRA Research Analysis (www.icra.com) Directorate of Sugar (www.directorateofsugar.com) (www.indiancommodity.com) Sugar Industry HDFC Securities Limited (www.site.securities.com) Sugar manufacturing World Bank Group FICCI Food and Beverages Survey Global Competitiveness Analysis of India Sugar Report December 2001. Indian Sugar Mills Association (www.isma.com) Little Sweet: Indian Sugar Sector Fitch Rating, Food/India Special Report (www.site.securities.com) Sugar Industry Sector Report B&K Research Report 19th April, 2006 (www.site.securitie.com) Sugar Sector Report Karvy Stock Broking Limited (www.site.securities.com) CIER Industry Statistics (www.site.securites.com) Dhampur Sugar (www.sugarindia.com) Sugar Sector (www.mcxindia.com) Industry Monitor Budget Issue ICRA Information, Grading and Research Service, March 2005. (www.icraindia.com) (www.wikipedia.com) Source: www.sugarindia.com

Capitaline Database

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BIBLIOGRAPHYS 1. DIMAT LIBRARY. 2. ARTICLES IN NEWSPAPER(ET)

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