PRODUCTION PROCESS IN SUGAR

INDUSTRY
Presented by:
M.Mustafeez ur Rehman
&
Wasif Naeem.
SUGAR
Sugar is a vital ingredient in most of out daily
consumption articles. For example: Soft
drinks,juices, tea, biscuits, sweetmeats, bakery
items ,deserts, etc.
It is a vital need more than a want to our
society.
INTRODUCTION

The Second Largest agro based industry

after Textiles.
Pakistan is an important cane producing
country and is ranked fifth in world cane
acreage and 15th in sugar production.
Its share in value added of agriculture and
GDP are 3.4 percent and 0.7 percent,
respectively
HISTORY

During the year 1997-1998 there were 75 sugar

mills in the country and it produces.
Sugarcane is grown on over a million hectares
and provides the raw material for Pakistans 75
sugar mills.
Dewan Sugar Mills Limited established as a
public limited company in 1982 is one of the
largest sugar mills ofPakistan having a cane
crushing capacity of over 9,000tons per day.
Cont....
MANUFACTURING
PROCESS

Cleaning
Slicing
Juice extraction pressing
Purification
Evaporation
Crystallization
REFINERY
SEPARATION AND PACKAGING
CLEANING

After the cane arrives at the mill yards, it is

mechanically unloaded, and excessive soil and
rocks are removed.

The cane is cleaned by flooding the carrier with

warm or by spreading the cane on agitating
conveyors that pass through strong jets of water
and combing drums.

At this point, the cane is clean and ready to be

milled.
GRINDING/ SLICING

After the cleaning process, a machine led by a

series of rotating knives, shreds the cane into
pieces. This is known as "grinding.

During grinding, hot water is sprayed on to the

sugarcane to dissolve any remaining hard sugar.
The smaller pieces of cane are then spread out on
a conveyer belt.
JUICE EXTRACTION

The shredded pieces of sugarcane travel on

the conveyer belt through a series of heavy-
duty rollers, which extract juice from the
pulp.

The pulp that remains or "bagasse" is dried

and used as fuel. The raw juice moves on
through the mill to be clarified.
PURIFICATION OF JUICE

The juice from the mills, a dark green color, is acid

and turbid. The clarification (or defecation)
process is designed to remove both soluble and
insoluble impurities (such as sand, soil, and
ground rock) that have not been removed by
preliminary screening.

The process employs lime and heat as the

clarifying agents.
Cont
Carbon dioxide and the milk of a lime are added
to the liquid sugar mixture and it is heated to the
boiling point, as the process of clarifying begins.

As the carbon dioxide travels through the liquid it

forms calcium carbonate, which attracts non-
sugar debris (fats, gums, and wax) from the juice,
and pulls them away from the sugar juice. The
juice is then pushed through a series of filters to
remove any remaining impurities.
 Cont

The muds separate from the clear juice through

sedimentation. The non-sugar impurities are
removed by continuous filtration.

The final clarified juice contains about 85 percent

water and has the same composition as the raw
extracted juice except for the removed impurities.
EVAPORATION

To concentrate this clarified juice, about two-thirds

of the water is removed through vacuum
evaporation.

Generally, four vacuum-boiling cells or bodies are

arranged in series so that each succeeding body
has a higher vacuum (and therefore boils at a
lower temperature).

The syrup leaves the last body continuously with

CRYSTALLIZATION

The crystallization process takes place in vacuum

pans which boil thejuice at lower temperatures
under vacuum.

When the juice concentrates it is 'seeded' with

tiny sugar crystals which provide the nucleus for
larger crystals to form and grow. When the
crystals reach the desired size the process is
stopped.

The remaining mixture is a thick mass of large

REFINERY

Raw sugar is transported to a Cane Sugar Refinery

for the removal of molasses, minerals and other
non-sugars, which still contaminate the sugar.
This is known as the purification process.

Raw sugar is mixed with a solution of sugar and

water to loosen the molasses from the outside of
the raw sugar crystals, producing a thick matter
known as "magma."
Cont

Large machines then spin the magma, which

separate the molasses from the crystals. Crystals
are promptly washed, dissolved and filtered to
remove impurities.

The golden syrup which is produced is then sent

through filters to remove the color and water.
What's left is a concentrated, clear syrup, which is
again fed into a vacuum pan.
SEPARATION AND PACKAGING

Once the final evaporation and drying

process is done, screens separate the
different sized sugar crystals. Large and
small crystals are packaged and shipped,
labeled as white, refined, sugar.
CONCLUSIONS

Sugar industry has a potential to achieve heights in

Pakistan if major steps are taken into consideration in this
regard.
Sugar industry being the second largest agro based
industry faces a lot of problems and if steps for its
betterment are not taken this industry can collapse which
will result in importing sugar from foreign countries and
would eventually result in an increase in the trade deficit.
Other than sugar we can diversify and produce Ethanol
which has been proved to be very helpful in developing
economies and ease our import bill.