A Project Report

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

BACHELOR OF TECHNOLOGYMECHANICAL 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
9in 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

FILIBHIT) for providing us with the opportun i ty 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)

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

We hereby declare that this submission is our own work which is being
p r e s e n t e d i n t h e p r o j e c t w o r k e n t i t l e d " S T U D Y O F S U G AR
MANUFACTURING" in partial fulfillment of requirement for the award of the
degree INDUSTRIAL TRAINING at LALIT HARI SUGAR FACTORY
PILIBHIT (U. F. is an authentic record of the work carried out by us during
the period of 16/06/2011 to 15107/2011 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 hi g h e r

learn41g except where the acknowledgement has been made in the text.
 MOH1T SAXENA

CONTENTS OF THE REPORT:

Abstract
L.H.sugar factory's profile
Sugar manufacturing
Process chart
The Energy Aspects
Hillhouse
Boilerhouse
Powerhouse
Clarification and boiling house:
Boiling and curing house
:\;w 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 Hon's share in accelerating
indusVgzation process and bringing socio -economic changes in under
developed rural areas. Sugar industry covers around 7.5% of total rural
population and provides emp[oyment to 5 lakh rural people. About 4.5 crore
farmers are engaged in sugarcane cultivation in IncIa. 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 &L el leader provided it comes out of the
vicious cycle of shortage and surplus of sugarcane, lower sugarcane yield,
lower sugar recovery, ever 4icreasing 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 FACTORY'S PROFILE

L.H. Sugar Factories Ltd. is located near Tanakpur Road ire

(UP.). 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

: Process Used
Steam Generation
Total Power Generation(installed) Plant
Normal Power Generation Consumption
Avg. Exported Power
: 10.000 TPD
: Double Sulphitation : 245 Tonne
/Hour :4 MWH
: 4 M W H : 25 MWH :1
MWH
 Avg. Sugar Production : 9000 Quintals/Day
:* Avg. Mo[asses production : 4000 Quintals/Day
Avg. Press Mud Prodution : 3500 Quintals/Day

SUGAR MANUFACTURING
The History
It is thought that can 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 can
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 E326,000, a figure that had grown by 1815 to 3,000,000. This situation was to
stay urthl 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
Brtain'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 an 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 EUis 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
Nice are 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 1 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
Cril-12 nO n. The simplest of the sugars is glucose, C61- 11206,
although its physical chemistry is not that simple
because it occurs in two distinct forms which affect some of its properties. Sucrose,
12H2211, 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' [eaves their green colour.
The reaction of photosynthesis can be written as the following chemical equation
when sucrose is being made:

12 CO2 + 11 H2 0 = C12 H22 Oil 12 02

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 can sugar is made in two stages. Raw sugar i 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

AWE
PP[ PAPatv.iii

.k
L we. SIR Ale P f m
0/40111011 frf RAG Ilf

Mill 111114 - 4

WH A M 4 1 1 1 . 0

i ma l l i q s op
j ULM PTA MN

0144 AC IAA

w-
ell TRATION

4
F IL 17 R <ACE FA MR AI F

11a P uus

E#

Si OP
Ca Akif it AIWA I SLOPPY SO EP
91:UPPVSIED

11111 0'
IPLPAM A 11101111
111411%* Eliot C 01.4%$11C

r
clE=L inoir
4
'A' A I A Ws'
IlAss coup
MA L N OL ASI M

I V MAGMA 11.9 Igo LAsVE 1

61 ____________ I
T
C A MA G N A
lir SEI GAR [ T
IPIRLIFIP

SAG.USI.4

1
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 harum officinarum, S. spontaneum, S. barber/ 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 1 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 can 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 can
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 Sue ar Production Mid 1990's

Lde
7irK
AUSTRALIA
1-.7 million tons
Exports:
5 .5 million tons
[Production:
[Population: 1 million
[Per Capita Consumption: 45 kg

BRAZIL

Exports: 6 million tons

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

w r

E.U.
4

rExports: 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 possble if sugar losses are to be
avoided yet needs to have a suffic ient supply in storage for times when cutting and
transport are stopped, whether deliberately or not. Typically, can is processed within
24 hours of cutting;
Cane preparation is critica! to good sugar extraction, particularly with diffusion
extraction. This is achieved with rotating knives and sometimes hammer res
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 ;e quickly so that the cane an d its sugar
:-44P14'