Final

Year
PRESENTATION
Project

DESIGN AND DEVELOPMENT OF

SMART JAGGERY
PRODUCTION REACTOR
 Dr. M. Tayyeb
Javed
Project Supervisor

Mr. Abid Ilyas

Co-Supervisor

Abdul Hanan
Awais Abid
Zafar
Roll#02 Roll#15
PROJECT SUPERVISOR (MENTOR)

Prof. Dr. M. Tayyeb Javed

PhD Process Engineering| MSc Nuclear Engineering
|BSc Chemical Engineering

Advisor
Society for the Promotion of Entrepreneurship and
Leadership (SPEL), PIEAS

Coordinator
ORIC

Manager
Business Incubation Centre, PIEAS
ADVISOR

Dr. Shahid Afghan is working as

Acting CEO at Sugarcane Research
and Development Board. He has
30-year experience of sugarcane
plant improvement, teaching and
administration. Dr. Afghan is HEC
approved PhD supervisor, Editor-in
-Chief of Pakistan Sugar Journal, also
he has completed national and
international research projects on
sugarcane with WWF-Pakistan
ADVISOR

DIRECTOR SUGARCANE RESEARCH

INSTITUTE, AARI (MEMBER SRDB).
CONTRIBUTION IN MORE THAN 6
VARIETIES OF SUGARCANE .
HEADING MULTIPLE PROJECTS RELATED TO
SUGARCANE RESEARCH AND
DEVELOPMENT.
ADVISOR

Dr Azhar ul haq (LATE)

Director Post Harvest Research Centre,
AARI,
Faisalabad, Pakistan
WHAT IS JAGGERY ?

Nutritional Aspect per 100gm

BENEFITS OF JAGGERY OVER SUGAR

High risk of Diabetes

Very low chance of Diabetes
JAGGERY

Causes Obesity
Helps weight loss (Potassium)

Contains Vitamins & Nutrients Simply Sucrose

(60 times)

Almost No minerals

SUGAR
Prevents Anemia, Asthma, cough
and cold

Cleanses lungs, stomach, -----

respiratory tract

Natural Sweetener Chemically Processed

 PROBLEMS

Sub- Policies supporting

Standard Inefficient SUGAR production
Technique Method and discouraging
Jaggery in the past

Due to less demand

most of the people Hardcore Doesn’t
preferred adopting Labor Meet Food
other professions Standards

Jaggery
No is Not common
anymore and
R&D getting demand is also dying
Rare
 OUR GOAL

MODERNIZATION of old technique

Production up to FOOD STANDARDS

Equipping with MODERN APPARATUS

Improving EFFICIENCY

CHANGING PEOPLE’s LIFE

 EXECUTION PLAN

•Acquiring Recipe

•Innovating the old Technique

•Employing modern and efficient

machinery
 LITERATURE REVIEW

• Monograph of Gur Industry by S.C.ROY

• Sugar Cane Cultivation and Management

Authors: Bakker, H

• Development of sugarcane Plant by Bakkar

• Jaggery Plant Project Report

 SURVEY
• Jaggery Manufacturing Technique (Recipe)
 PROCESS FLOW CHAR

1st Stage 2nd Stage 3rd Stage

•Juice Extraction •Initial Heating •Heating
•Add additives
•Remove slag

6th Stage 5th Stage 4th Stage

•Shaping jiggery •Slow cooling at •High heating
room temperature •Add additives
•Remove slag
DIAGRAM
JUICE EXTRACTION
• Juice extraction is the first step of this
whole process and the quantity of end
product depends directly on the
percentage juice extraction.

• The producers usually 3-miller Juice extractor is used.

• The machine is powered by a 15HP gasoline engine.

• A pre-weighed sample of sugarcane was crushed and juice was

obtained. 175Kg of sugarcane was crushed to get 95Kg of cane juice i.e.
54.5% extraction by weight.

• This juice had a volume of 88liters since its density was calculated to be
1.08Kg/dm3. This was the exact volume being used for producing a single
batch. The temperature of this juice was 38o.
INITIAL HEATING

• The freshly extracted juice was left

standing until all of the bagasse particles settle down.
Later on the juice was filtered using a fine piece of
cloth as filter and poured directly into a container for
initial heating. This container was placed right before
the exhaust pipe of the fire Killen. The temperature of
this pan was measured to be 80o. Juice is heated
there for about 35 minutes. There the maximum
temperature of juice is about 75o after 35 minutes of
heating
SLAG REMOVAL

• In the next stage the juice is poured into the

adjacent pan which is slightly closer to the fire and
hence on a higher temperature. After pouring the
juice, impurities start accumulating on the top in the
form of slag within first 10min of the heating. After
skimming the slag, a very minute quantity of
GaoZaban, 0.064Kg is added. Within 5 minutes more
slags starts appearing on the surface which is
skimmed off and about 0.013Kg of Caustic is added
to the syrup. After cooking for 20 straight minutes at
94o the juice is shifted into the next pan. Juice
spends about 35 minutes in this pan
BOILING

• In this last stage of heating, the juice is

boiled on the main flame and is heated on the highest
temperature. After shifting 0.013Kg of Caustic is added to
it. After 5min bubbles starts appearing on the surface and
the level starts rising and reaches a maximum level in
2min. At that stage the temperature of juice is about
101oC. After 7-8min the bubbles start settling down until
the juice becomes clear once again at about 104oC. After
waiting for 2min about 10gm of Mustard Oil is added to it.
Mustard oil helps the entrapped air in the molecules in
escaping. The juice transforms into a thick paste with the
passage of time. The temperature of paste keeps rising for
next 7-8min then at 115oC the paste is considered fully
boiled and is hence transferred into the coolingblocks.
 COOLING

• After the paste is formed, it is transferred into a wooden

container where 0.013Kg of Caustic is added to it. The
paste is then left for some time to cool down by itself at
room temperature. After some time it is being mixed by
using a scraper tool in order to assist cooling. By that
time temperature of the paste gets down to about 86oC.
It is mixed for next 10min and then again left for some
more time to cool down naturally. It keeps solidifying
every passing moment until it turns into a semi-solid after
20min. At this point paste cools down to 72oC. This
cooled paste is turned into a typically common shape
called PAISI using a scraper tool. The final product of this
process, PAISIs weighs about 16.7Kg which means that
78.3Kg of water was evaporated during this boiling
process.
 INNOVATION

• Efficient Extraction
•Juice
1st stage Extraction

• More heating 2nd stage •Initial Heating

•Heating • 2 stages combined

3rd stage •Add additives
•Remove slag • Automatic slag removal
• More efficient heating
•High heating
4th stage •Add additives
•Remove slag
• No heat loss
• Fast cooking
• Automatic cooling •Slow cooling

• Fast cooling 5th stage at room

temperature

6th stage
•Shaping
jiggery
• Standard shape
• Easy to handle
 IMPROVED CRUSHER DESIGN

• As currently the juice extraction is very low due to

poor roller extractor design. We have decided to
invent a new design to gain maximum efficiency
thus leading to higher production. We are willing to
take juice extraction to 65-70 % which is part of our
next semester.
INITIAL FILTRATION
INITIAL HEATING TANK
SLAG REMOVING
BOILING
ASSEMBLY MODEL
EFFICIENCY DIFFERENCES
 SUMMARY

Components Current Future

• Sugarcane • 175 kg • 175 kg

crushed

• Juice extracted • 95 kg (54.5%) • 117 Kg (67 %)

• Jaggery • 16.7 kg • 20.5 kg

produced

• Avg. Time • 123 min • 60 min

Consumed
(per batch)

• 188º C • ---
• Exhaust gas temp
 PATENTS AND DESIGNS

• Crushers pair(Custom)
• Slag Filtration Mechanism(PATENT)
• Mini Boiler(Custom)
• Steam Jacketed Cooking Pots(Custom)
• AI Controlled Cooking Analyzer(PATENT)
• Paisi-Making and Cooling Machine(PATENT)
 PROJECT TIMELINE

• We are aiming to capture 5% of the overall

sugarcane production of Punjab next year which
will produce 11000 ton (Meteric) generating
Rs 840 million.
SUGARCANE MAIN CULTIVATION
AREA

KPK
MAJOR CITIES
ACQUIRING DATA FROM CROP SURVEY
DEPT.
CREATE WINNERS
 PAY BACK PERIOD

ONE
Season
We are aiming to capture 5% of the overall sugarcane production of Punjab
next year which will produce 11000 ton (Meteric) generating Rs 840
million.