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)
