Sugarcane Plantation and Sugar Mill with by Product (Cap: 500 TCD)

SUGARCANE PLANTATION AND SUGAR MILL WITH BY PRODUCT (CAP: 500 TCD) 

 [EIRI/EDPR/4702] J.C.: 2921XL

INTRODUCTION

In general sugarcane grows well in well drained, medium loam soil which is neither too acidic nor too alkaline, though cane is grown in the pH range 4.5 to 8.5. In sandy loam soil, incorporation of organic matter is necessary as also additional irrigation. If the soil is clayey, more care is necessary in cultivation. The soil should preferably be deep. Sugarcane can grow in low lands, provided water logging does not persist for a long period and the variety grown is tolerant to the situation.

It is best to grow sugarcane on a 3-year rotation - plant crop, first ratoon, second ratoon and cereal, leguminous/green manure crop. It is important that the organic matter and the nitrogen content of the soil is maintained properly. The practice of green manuring, as followed in Australia, is important. If possible the green manure crop should be grown separately and ploughed in at the appropriate time. If this is not feasible, the green manure crop should be taken as an inter crop by sowing along with the planting of sugarcane or a little earlier.

Characteristics of Sugar Cane:

Sugar Canes types selected for Commercial Cultivation should have certain general. Characteristics such as good germinability to ensure good stands, a deep root system, moderate but not too heavy tailoring for a fair measure of uniformity in development and maturity of Canes and moderate height to prevent loss by lodging some of the objective of sugarcane breeding in India are high yielding high sucrose varieties suited to various agro climatic regions of the Country; early, mid season and late maturing types to extend the crushing season; varieties responsive to high Nitrogen fertilization with determent to quality.

Area and Production of Sugar Cane:

Sugar Cane is the main sources of Sugar in the world, the Sugarcane Crop accounting for 56 per cent of the total world production of Sugar. Sugar Cane cultivation being confined to tropical and Sub tropical Zones Brazil and Cuba are the three largest Cane growing Countries from the point of area under the crop, with each of them growing the Cane Crop annually oner a million hectares or more and accounting among themselves for almost half of the world area under this crop.

Climate & Season:

Sugarcane cultivation is restricted to a belt lying between 35o N and S of equator. It is essentially a tropical crop that requires a long summer growing season with adequate rainfall and a fairly dry, sunny and cool but frost free ripening and harvesting season.

Sugar Cane is generally planted in the spring and harvested at the age of 10 - 12 months in most of the Countries. In India most of the Sugar Cane is planted early in the spring i.e. January to March.

Soil: Sugar Cane is grown under varied soil Condition in India. The Cane growing soils in India are classified into three major group viz alluvial, black and mud soil.

Sugar is a universal sweetening agent and sugar - cane is the primary age - old source of it. Sugar cane is a very important industrial crop, accounting for about 60% of sugar production in the world.

From the times immemorial the word "sugar" is being used variously  to express delight as well as distrust  sarcastically. Sugar has  been used in human diet  through the functions of pancreas, depending  on the quantity of sugar consumed. It is must for human diet when taken directly or indirectly through various carbohydrate containing food stuffs.

Sugar as sucrose is important for energy and metabolic activities.

COST ESTIMATION

Plant Capacity            40,000 Kg./Day

Land & Building (4500 Acres)    Rs. 25.01 Cr

Plant & Machinery                    Rs. 31.30 Cr

Working Capital for 2 Months    Rs. 8.07 Cr

Total Capital Investment          Rs. 68.14 Cr

Rate of Return                          33%

Break Even Point                      56%

CONTENTS

INTRODUCTION

CHARACTERISTICS OF SUGAR CANE:

AREA AND PRODUCTION OF SUGAR CANE:

CLIMATE & SEASON:

PROPERTIES OF SUGAR

RAW SUGAR:-

CUBE SUGAR:-

ICING SUGAR:-

LIQUID SUGAR:-

UTILISATION OF BY-PRODUCTS:-

BAGASSE AS RAW MATERIAL FOR PAPER AND BOARDS:

USES & APPLICATION

GUIDELINES FOR SUGARCANE PLANTATION

LAND PREPARATION

PLOUGHING

HARROWING

LEVELLING

LAY OUT OF FIELD

BASAL APPLICATION OF ORGANIC MANURE AND FERTILIZER

MAIN FIELD PREPARATION AND TRANSPLANTING

INTERCULTURAL OPERATIONS

TRASH MULCHING

CROP ROTATION

GAP FILLING

EARTHING UP

CONTROL/REGULATION OF FLOWERING IN SUGARCANE

DETRASHING

PROPPING

REMOVAL OF WATER SHOOTS

COVERING THE FIELD WITH GREEN LEAF MANURE PLANTS

PIT METHOD OF SUGARCANE UNDER DRIP FERTIGATION SYSTEM

WEED MANAGEMENT IN PURE CROP OF SUGARCANE

RAW MATERIALS

SUGARCANE:-

LIME STONE:-

COKE:-

SULPHUR:-

SUPERPHOSPHATE:-

SODIUM HYDROSULPHITE:-

FLOCUULENTS:-

FILTER CLOTH:-

GUNNY BAGS:-

QUALITY CONTROL AND SPECIFICATIONS

SEQUENCES IN SUGAR MANUFACTURE

SUGAR

EXTRACTION OF JUICE

CLARIFICATION

EVAPORATION

CENTRIFUGATION

GRADATION & PACKING

SUGAR MANUFACTURING PROCESS

FLOWCHART SUGAR MANUFACTURING PROCESS

CO-GENERATION

SCHEMATIC OF COGENERATION PROCESS

MARKET OVERVIEW OF SUGAR IN TANZANIA

TANZANIA CAN BECOME AFRICA’S HUB FOR SUGAR

BEGIN WITH RECENT DEVELOPMENT

FOCUS ON INDUSTRIAL SUGAR

SUPPORTIVE POLICIES

SUGAR PRODUCERS

ONGOING DEVELOPMENTS

CURRENT PLAYERS

DETAILS OF SUGAR CANE PLANTATION

PREPARATORY CULTIVATION:

SEED RATE, TIME OF PLANTING AND SPACING:

HOEING AND WEED CONTROL:

IRRIGATION:

LODGING:

PROCESS FLOW SHEET

MANUFACTURING PROCESS FOLLOWED IN SUGAR INDUSTRY

STEPS IN SUGAR MANUFACTURE

MILLING:

CLARIFICATION:

EVAPORATION:

CRYSTALLIZATION:

SEPARATION:

REFINEMENT:

DRYING:

PACKING:

PROCESS OF MANUFACTURE

JUICE EXTRACTION

CLARIFICATION:-

EVAPORATION:-

CRYSTALLIZATION:-

CENTRIFUGATION:-

DRYING:-

DRYING OF SUGAR:-

DRYING OF SUGARS AND THEIR IMPORTANCE ON KEEPING QUALITY:-

DETAILED PROCESS DESCRIPTION IS SUGAR MANUFACTURE

PROCESS DESCRIPTION

CANE SUGAR PRODUCTION -

FIGURE SIMPLIFIED PROCESS FLOW DIAGRAM FOR CANE SUGAR PRODUCTION.

REFINED SUGAR PRODUCTION -

FIGURE SIMPLIFIED PROCESS FLOW DIAGRAM FOR REFINED SUGAR PRODUCTION.

BY-PRODUCTS OF SUGAR INDUSTRY

THE BY-PRODUCTS OF SUGAR INDUSTRY ARE:

BAGASSE:-

MOLASSES:-

FILTER CAKE:-

SUGARCANE WAX:-

BYE PRODUCTS OF THE SUGAR INDUSTRY

BAGASSE:-

CHEMICALS:-

MOLASSES:-

ALCOHOL BY PRODUCTS AND DERIVATIVES:

FILTER MUD:

SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

SUPPLIERS OF RAW MATERIALS

QUICK LIME

SODA ASH

HYDROCHLORIC ACID

SULPHURIC ACID

SODIUM HYDROSULPHITE

SUPER PHOSPHATE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)