Detailed project report on jaggery automatic plant

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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