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    Detailed Project Report on jaggery automatic plant

    Detailed Project Report on jaggery automatic plant
    Detailed Project Report on jaggery automatic plant
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      JAGGERY AUTOMATIC PLANT
      [CODE NO.3304]

       

      BRIEF INTRODUCTORY OVERVIEW
       
      Jaggery is one of the natural sweeteners used in most parts of India. The jaggery industry is one of the well known small scale cottage industry in India. It needs to be noted that the production of jaggery ranges between 5 million tons to 7 million tons. In the traditional method adopted in this industry, feeding of sugarcane is done manually by the labor. Furthermore, crushing is done by the ‘Three roller pan system’. 
      It is understood that the current efficiency of jaggery plant is around 50-60%. Cost of feeding operations is high and many a times, juice extraction from crushing is not efficient. The various problems associated with having a jaggery plant are: skilled labor, low profit, high raw material cost, transportation, and few more. Thus, to overcome the associated problems, automation in jaggery plant is necessary. 
       
      STAGES OF JAGGERY MAKING
       
      Before extracting juice from sugarcane, the two stages of jaggery making involve sugarcane cutting and transportation.  The various steps in jaggery making involve: 
      - Harvesting of sugarcane
      - Extraction of juice (crushing)
      - Settling
      - Clarification
      - Boiling of juice (Open Furnace)
      - Cooling of juice
      - Moulding
      - Purification of juice
      - Concentration of juice
      - Packaging of juice
      - Storage
       
      CONVENTIONAL SYSTEM AND AUTOMATION SYSTEM
       
      The conventional jaggery system consists of three rollers as depicted in the figure. To start with, sugarcane is inserted into inclined and parallel roller which is then followed by crushing. Labor is needed to feed and place sugarcane in front of this system. To save labor and increase efficiency, automated feeding system is adopted which refers to the use of hydraulic systems. 
       
      In the automated system, sugarcane is placed between the fixed plate and the moving plate. Much pressure is applied on sugarcane so that it gets squashed and its volume gets reduced. The juice, thus extracted is then filtered and collected with the help of a tray which is fitted at the bottom of the system. 
       
      Depending on the Sugarcane Compression Test, Side Plate, Pushing Plate and Base of Machine are selected. The cylinder and the tank are also appropriately selected. The automated machine consists of designed hydraulic unit, selection of pump, direction of control valve as well as relief valve. The electric components selected are related to power supply, sequential timer, relay, contactor as well as final set up of machine and testing. 
       
      The fully automated jaggery unit has industry wide application in sugar industry for conversion of sugarcane juice into sugar. Superior quality of raw material is used for production and manufacturing of this plant. These automated jaggery plants are high in demand in the market and are priced economically. These automated plants are known for characteristics such as heat resistance, sturdy construction, optimum efficiency, corrosion resistance, error-free operation and excellent performance. The jaggery that is obtained at the end of the automated process is excellent in taste and color. 
      COST ESTIMATION


      Plant  Capacity                                             :       (300 TCD)
      land & Building (12000 Sq.Mtrs)              :        Rs. 6.02 Cr
      Plant & Machinery                                        :       Rs. 8.85 Cr
      Working Capital for 2 Months                    :        Rs. 2.45 Cr
      Total Capital Investment                             :       Rs. 17.60 Cr
      Rate of Return                                              :      18%
      Break Even Point                                         :       61%

      INTRODUCTION    
      ADVANCES IN JAGGERY INDUSTRY    
      TABLE COMPOSITION OF CANE `GUR' & PALM `GUR'    
      SPECIFICATION OF JAGGERY POWDER    
      PROPERTIES AND CHARACTERISTICS OF JAGGERY POWDER    
      COMPARISON CHART OF NUTRITIVE VALUE OF JAGGERY,
      KHANDSARI AND SUGAR    
      PROPERTIES    
      TABLE-JUICE CONSTITUENTS OF SOME VARIETIES OF SUGARCANE    
      ANALYSIS OF JUICE OF MATURE (GOOD) SUGARCANE    
      COMPOSITION OF SUGAR CANE JUICE    
      USES & APPLICATION    
      USES AND APPLICATION OF JAGGERY POWDER    
      B.I.S. SPECIFICATIONS    
      MARKET SURVEY    
      PRODUCTION OF GUR/JAGGERY
      APPARENT CONSUMPTION OF JAGGERY (LACS MT.)    
      ESTIMATED DEMAND IN LACS MT.    
      DEMAND SUPPLY GAP    
      JAGGERY PRICES SHOOT UP, IN LINE WITH THOSE OF SUGAR    
      CURRENT DEMAND    
      DEMAND GROWING    
      GOOD RESPONSE    
      JAGGERY EXPORT DATA    
      PRESENT MANUFACTURERS/SUPPLIERS OF JAGGERY    
      VARIETIES OF SUGARCANE    
      TABLE 1-SUGARCANE VARIETIES IN CULTIVATION OR RECOMMENDED
      FOR CULTIVATION    
      DIFFERENT FORM OF JIGGERY AND THEIR PRODUCTION METHOD    
      MANUFACTURING PROCESS OF SOLID JAGGERY    
      PROCESS FLOWSHEET OF GUR/JAGGERY MANUFACTURING    
      MANUFACTURING PROCESS OF JAGGERY POWDER    
      PROCESS FLOW DIAGRAM OF JAGGERY POWDER    
      BLOCK DIAGRAM OF JIGGERY POWDER PLANT    
      METHOD OF MANUFACTURING DIFFERENT TYPE OF JIGGERY    
      UNIT OPERATION OF JIGGERY MANUFACTURE
      PLANT LAYOUT    
      TURNKEY CONSULTANTS    
      SUPPLIERS OF PLANT AND MACHINERIES FOR JAGGERY    
      SUPPLIERS OF RAW MATERIALS    
                  
              
      APPENDIX – A:

       1.      COST OF PLANT ECONOMICS      
       2.      LAND & BUILDING                                      
       3.      PLANT AND MACHINERY                                  
       4.      FIXED CAPITAL INVESTMENT                             
       5.      RAW MATERIAL                                         
       6.      SALARY AND WAGES                                     
       7.      UTILITIES AND OVERHEADS                              
       8.      TOTAL WORKING CAPITAL                                
       9.      COST OF PRODUCTION                                   
      10.      PROFITABILITY ANALYSIS                               
      11.      BREAK EVEN POINT                                     
      12.      RESOURCES OF FINANCE                           
      13.      INTEREST CHART                                       
      14.      DEPRECIATION CHART                                   
      15.      CASH FLOW STATEMENT                                   
      16.      PROJECTED BALANCE SHEET      

       

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