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Usman Report

Usman Report

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Published by usman0553
an internship report on shakarganj mills limited prepared by usman farooq
an internship report on shakarganj mills limited prepared by usman farooq

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Published by: usman0553 on Jul 15, 2009
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05/01/2013

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Shakarganj Historical Background
 
Shakarganj’s history dates back to 1967. The company was incorporated on 20 September 1967 with the object of setting up a sugar mill in district Jhang in the central Punjab.Commencement of business certificates was issued on 23 February 1970.A mill with a design capacity of 1500 TCD extendable to 2000 TCD was planed and ordered for supply of equipment was placed with Messrs. Stork-Werkspoor sugar B.V., of Netherlands.Letter of credit was opened on 31 December 1969 and 10 January 1970. Construction of building started in March 1971.The implementation of the project got delayed due to war in 1971 resulting in breakupof the country. Some shipment of machinery was delayed. Insulation of equipment stated on 1
st
January 1972 and project commenced trial operation on 7 January 1974. Public offer of shareswas made on 21 may, 1979.Even since the team at shakarganj has never looked back. The sugar factory has beenexpanded to a capacity of 10000 TCD extendable to 14000 TCD and has become the largestsugar factory in the country. Shakarganj realized the need for research and setup shakarganjsugar research institute in 1983. This was to strengthen research activities in sugar caneagriculture, sugar manufacturing and engineering.Shakarganj has diversified into utilization of co-products, with the addition of a distillery in 1986and particleboard plant in 1991.shakarganj took a major step in co-generation of electricity for sale to the national grid in 1983.Balancing and modernization of sugar plant was carried out between 1976 and 1980and plant capacity was upgraded to 2000 TCD. By 1986 the capacity was increased to 5000TCD(total cane / day). The team at shakarganj recognized technological advancements andkept constantly in step with the latest innovation and development in sugar industry.A modern distillery based on Biostill technology was addedin 1986. The distillery unit went intoproduction on 20 september,1986 with an installed capacity of 45000 liters of industrial alcoholper day.In 1990 a particle board plant with a daily production capacity of 30 cubic meter wasadded to convert surplus bagasse into value added products.In 1991 work initiated on doubling the capacity of the plant with the provision to further extendthe capacity to 14000 TCD. Entire designing and engineering work was done in house by theshakarganj team. The program was completed in 1992. It pushed the mill capacity to 10000TCD extendable to 14000 TCD. This made shakarganj, Pakistan’s largest sugar mill.Shakarganj took a major step in co-generation of electricity for sale to national grid.Agreement with Water and Power Development Authority (WAPDA) was signed on 25 July1993 at Lahore making shakarganj the first private sector power supplier in Pakistan.Shakarganj took care of 12.86 percent of Jhang City’s power requirement during crushingseason. Since 1995, 2 MW electricity is being supplied to a neighboring textile company
.
Shakarganj Research Institute:
:
Shakarganj research institute (SSRI) was set up in 1983to strengthen researchactivities in sugarcane Agriculture, sugar manufacturing and engineering. In first phase,
 
Internship Report
activities in sugarcane agriculture were stared, which resolved around selecting new sugarcanevarieties and providing guidance to sugarcane growers about agronomic, pathological andentomological problems of crop. This is the only institute of its kind in Pakistan. Facilities at theinstitute include laborites for Breeding, Agronomy, Soil Science, Plant Pathology and Biologicalcontrol of Borers. In 1983 experiments were started on 10 hectors of land in vicinity of institute.The institute has 600 hectares of land at its disposal. Sugarcane is planted on 500 hectares for research experiments.By the year 1988 two verities, SPSG-26 and SPSG-394 were selected. Both wereearly maturing and sugar contents was higher than BL-4 (present commercial variety). Oncompletion of agronomic and pathological tests these verities were released to farmers. Areaunder these varieties is gradually increasing. Two new varieties, SPSG-224 andSPSG-79 havebeen added to the list recently.Biological control of Pyrilla was stated in 1991. Control of borer complex was statedfrom 1995. During 1996, 4500 hectares of sugar cane crop was covered through biologicalcontrol.The institute also organizes workshops and invites world-renowned sugar experts for interaction with Pakistani experts. Shakarganj Sugar Research Institute was selected byinternational society of sugarcane technologists to host the first ISSCT workshop in Pakistan onEngineering and Energy workshop on factory design from 23 February to 28 February, 1997.
Environmental Awareness:
Shakarganj is clear about its responsibilities to the environment and is very active inconservation. We are constantly making efforts to reduce waste and recycle processchemicals. Our environmental policy evolves around three basic principles:
Shakarganj assumes responsibility for environment
Decision shall favor environment
Information shell be open and free.
Shakarganj takes active part in tree plantation with the community. To set anexample 40000 trees have been planted around the sugar factory. The same piece of land had only one tree in 1974. Recycling of sugarcane nutrient to the field is done bymixing filter cake with distillery stillage
.
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Internship Report
Cane is Brought from cane yard to Sugar Factories on the Trucks and Tralers .Cane weighingis take place with the help of Three Weigh Bridges. These Weigh Bridges are Avery EnglandDesign .02 Weigh Bridges are for Gross Weight and 01 Weigh Bridges is for TareWeight..Capacity of the Weigh Bridges is 50 Tons..
Cane Unloading:
Cane Unloading is done with the help of Electric Hoists. Three Electric Hoist areattached to Mill Tandem .The Function of these Electric Hoists is to Lift the Caneloaded Truck and throw it to Dumping Carrier.
 Electric Hoist:
Motor Brake TypeSteel wire ropeRope Diameter 7/8 inchGear Reduction gear Lifting Speed 13-20 ft/ minLifting Height 20 m
Dumping Carrier:
There are three dumping carrier in each mill tandom. In Which sliding plates areattached which carry the cane to the Main Carrier. Idler Pulleys are used to support the chainon which sliding plates move. These idler pulleys are coated with some material so that to stopwear and friction. V-Belt drive used to transmit power from motor driven shaft to gear systemand from there with the chain sprocket mechanism it drives the Dumping.Dumping Carrier Length 42 ftDumping Carrier Width 17 ftDumping Carrier Angle 18degLinear Speed 24 ft/ minGear Ratio 1/80
Sliding Plates:
Length 6.5 feetWidth 8-9 inchesRoller Chain pitch 9 inches
Chain Sprocket Mechanism:
When high torque load is to be transmitted. We use chain sprocket mechanism.By the Formula of power as torque is very high and speed is low then slippage takes place. Sobelt could not be used there and chain sprocket mechanism is the better choice.
Mill Tandem NO. 02:
Mill Size 38*78 inchesDia of Mill Roller Shell 38 inchesLength of Mill Roller Shell 78 inches
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