The kcp sugars vuyyuru was first started in 1936.

The process of manufacturing sugar from sugarcane involves many unit operations such as crushing
of cane, concentration of thin juice to syrup, boiling of syrup to produce crystals, and separation of
crystals from centrifuging and also grading of sugar.

Cane from the Fields is brought to Factory through Lorries and Bullock Carts. Sugar cane of
5-6 ft long is unloaded in to the Cane Trolleys and weighed on the Electronic Weigh Bridges
and conveyed to the Tilting Table by Pushers and Hailers. Sugar cane is unloaded into the
Cane Carrier by Truck Tilting system. Then the cane is carried to the Cane Preparatory
Devices such as Cane Knives, Cutters, Shredders, etc., where it is prepared to 80 to 85%
broken cells. The Prepared Cane is then fed to milling tandem, which consists of 6 nos. of 3-
Roller Mills (usually). The Juice is extracted by exerting pressure on the Top Rollers of each
of these Mills. Fresh water known as imbibition water is sprayed on the blanket of the
bagasse to dilute the juice contained in it for complete extraction. The juice obtained at
different mills is mixed known as mixed raw juice. The bagasse obtained from the last mill is
used as a fuel in the Boiler for steam generation. It consists of 50% moisture and 2% sugar.
Bagasse can also be used for paper manufacture, furfural, cattle feed, briquettes etc.

The Mixed Juice consists of Sugar, Glucose, Fructose, and many other salts. It also contains
colouring matters. It has a pH of 5.8 and total Dissolved Solids or Brix may vary from 15 to
18%. It is necessary to remove all the impurities and to rise the pH and brix of the raw juice.
In order to this, first, the juice is weighed and preheated to 70oC.
Then it is sent to the Sulphiter where SO2 and lime are added. This Sulphited juice is further
heated to 105oC in Juice Heaters.
Then it is fed to the Clarifier, before that Magnafloc is added which helps in quick settling of
muds in the Clarifier and Clear Juice is fed to the Evaporators.
The Muddy Juice along with Bagacillo is fed to the Vacuum Filters. The mud will be
separated from the juice in the Vacuum Filters. Filtered juice will send back to process and
filter cake will be sent out. Filter cake is a byproduct, from which we can make waxes and it
can be used as Manure to the cane fields.
The Clear Juice is Fed to the Multiple Effect Evaporators where the thin juice of 15o Bx is
concentrated to Syrup of 60o Bx. After evaporation, the syrup is fed to a Sulphiter. Here
again SO2 is added, hence this process is known as Double Sulphitation Process. The Syrup is
further concentrated in Vacuum Pans to form Crystals. A mixture of Mother Liquor and
Crystals is called Masseccuite. The boiling is stopped after achieving the required size of
crystals and it is dropped into a Crystallizer. The stirrers keep the Masseccuite in motion in
the Crystallizer till the Masseccuite is cooled to optimum temperature for further growth of
Crystals.
This Masseccuite to fed to the Centrifugal Machine through the Pug Mills where the Sugar
and Molasses are separated. The final molasses will send to the distillery for the
manufacture of Rectified Spirit. The sugar from the Centrifugal is Dried and Cooled while
passing through hoppers and fed to Bucket Elevators. The Sugar is graded according to its
crystal sizes and stored in bins. The Sugar will be bagged through automatic weighers,
stitched and stored in the godowns through belt conveyors and stackers.