Sugar Qulity

Module 12: Sugar – Quality and Storage
Module 12
Sugar- Quality and Storage
Sugar Engineering and Manufacturing Training Team 1

Sugar Quality Control
Introduction
Today, quality control has become a natural requirement of industrial production, and
encompasses further requirements for food safety and quality management for any organization
in the food chain. In the sugar industry, we are aware that the final products, raw sugar and white
sugar must conform strictly to the requirements dictated by buyers and customers.
Three main requirements for any organization producing sugar are as follows:
 To supply its customers with sugar that is SAFE and FIT FOR PURPOSE.
 To validate compliance with specification agreed with customers.
 To ensure that sugar supplied meet the provisions of all relevant food laws and Codes of
Practice applicable through the supply chain.
Unless in agreement with all practice involved, it is desirable to have standard methods of
analysis available to both buyers and sellers. The International Commission for Uniform
Methods of Sugar Analyses, generally known as ICUMSA, is the international organization
concerned solely with methods of analysis for the sugar industry.
The factories have a laboratory where all sugar are sampled according to a defined sampling plan
and thereafter analyzed. After storage in sugar silos, this sugar is sampled once more when
loaded in marine vessels at the tine of export to the European Union, United Sates and other
destinations. Moreover, sugar packed in polypropylene bags and container polyethylene liners
are also sampled and analyzed before storage for export to various destination.
A Definition of Quality Control

A pertinent definition of “QULITY” would be “that combination of engineering and

manufactured characteristics in a product that determine the degree to which it will meet the
expectation of the customer”.
In short “Quality” means “fitness for use and purpose”.
The process of delegating responsibility and authority for management activity is generally
called “CONTROL”.
In the sugar industry, the personal who mange, perform and verify work affecting quality will
have the organizational freedom and authority to:
(1) Initiate action to prevent the occurrence of product nonconformity.
(2) Identify and record any product quality problems.
(3) Initiate, recommend or provide solutions through designated channels.
(4) Verify the implementation of solutions.
(5) Control further processing, delivery or installation of nonconforming product until the
deficiency or unsatisfactory condition has been corrected.
What is Sugar Quality?
Sugar quality refers to the following major fields of interest:
(a) The physical quality characteristics.

(b) The chemical and microbial compositional quality characteristics.
(c) The properties of the sugar in solution from.
(d) The level of customer.
The physical quality characteristics are the following:
(a) Crystals shape

(b) False farinas and conglomerates

(c) Size and distribution

(d) Reflectance, visual appearance
(e) Gloss
The chemical and microbial compositional quality characteristics are the following:
(a) Sucrose Content

(b) Moisture Content
(c) Invert Sugars Content
(d) Ash Content
(e) Heavy Metals: – Pb, As, Cu, Hg, Cd
(f) Other Metals: – Al, Fe
(g) Microbiological Flora –Yeasts, Moulds, Bacteria and Pathogens
(h) Minerals Slats: – Mg, K, Na, Ca, P
(i) Nutritional Values: – Carbohydrates, Proteins, Fats, Fibers
(j) Sulphurdioxide (SO2) Level
(k) Odour
(l) Taste
The following are the properties of sugar solutions:
(a) Colour
(b) Turbidity
(c) Filtration Rate
The levels of contaminates under control are:
(a) Insoluble Matter

(b) Black Specks
(c) Glass
(d) Metallic Particles

(e) Non-Metallic Particles – Pan Scales

(f) Conglomerates – Discolored or Colored
Criteria Required By Buyers
The refiners require a good quality raw sugar with a polarization greater than 96 0Z, which will
filter well (a filterability index not less than 45, following the Nicholson and Horsley-Australian
method) and an optimum keeping quality, measured by a dilution indicator around 35.0
Moreover, ash content, colour and grain size are also accounted for premium or penalty
evaluation to sellers.
Basically, buyers of direct consumption sugar are strict on the following characteristics:
 A Clean Sugar
 A Dry Sugar
 A Sugar of a Consistent Colour
 A Uniform Grain Size
The sugar must comply with all the requirements of the European or international regulations
regarding traceability, hygiene and food safety.
Control Systems Established By the Sugar Syndicate
The sugar Syndicate establishes certain hard and fat rules to be observed by all the sugar
factories over the island so that we have the respect of our buyers.
The sugars received daily at the warehouses and at the Port Terminal are sampled according to a
sampling plan along the production line. The systems also ensures that the quality of the sugars
meet with the required criteria imposed by the Syndicate for good keeping and refining qualities

at storage and during exportation. The sugars must be compliant with food laws in the country if
importation and must correspond to the buyers’ requirements.
Moreover, statistical techniques help in placing the producer in a strong competitive position
through the ability to provide statistical proof of quality and uniformity.
The Price of Raw Sugar
The basic price of raw sugar is made on the basis of 96 0Z polarization. All factories are thus
geared to produce a raw sugar having a polarisation value not less than 98 0Z.
The Mauritius Sugar Syndicate stresses on this requirement for at least two reasons:
 The keeping quality of the sugar is better at 98 0Z than at 96 0Z.
 A premium of 1.4 % of the basic price is paid to every extra degree of polarisation above
96 0Z. This is the method of payment according to the rules of the sugar Association of
London.
Refiners agree to pay on a 96 0Z polarization basis plus a premium even if they are to receive a
sugar not less than 98 0Z, because they can show that the refining costs are less for a new sugar
having higher polarisation. Moreover, they have less affination water to handle and a pure crystal
to melt.
Sugars for direct consumption are based on the agreed European Union sic price and additional
quality ands market premium that can be negotiated with buyers.
Sampling of Sugar
Sugar in Bulk
 In order to control the quality of sugar received at the terminal, a fixed weight of sugars is
sampled systematical and consistently from each box of sugar weighted at the receiving
station of the Terminal (See Fig, 1, 2 and 3).

 At the time of shipment of the stored sugar in the sugar soils, a sample sugar is
systematically and consistently taken for each 20 tonnes dump delivered on board of the
ship.

Figure 1: Sampling at Receiving Station

Figure 2: Sugar Boxes (Traceability)

Figure 3: Symbols per Sugar Factory (Traceability)

Sampling Frequency
At the Receiving Station: 54 grammes per tonne of sugar
At the Loading Station: 20 grammes per tonne of sugar
Sample Preparation
 At the receiving station: at the end of the sampling time, the content of each sample storage
container is tumbled mechanically in a larger container to achieve a homogenous mix of
sugar of this particular factory.
For each factory, about 450 g is taken and placed into air tight sampling bottles and then sent
to the MSS for analysis.
 At the loading station: for every 1,000 tonnes of out-loaded sugar, the sugar is tumbled
mechanically in a larger container to achieve as quickly a possible a homogenous mix.
About 450 g is taken and placed into two air tight sampling bottles and then sent to the MSS
for analysis.
Sugar for Direct Consumption
 Sampling of sugar in bags follows a sampling plan. This operation is carried out at the
factory.
 The sugar bags are not sampled at the warehouse so as to prevent any risk of external
contamination after bagging and sewing at the factory.

Sampling Frequency
At the bagging station of the factory: 5 – 10 grammes per 50 Kg bag
Sample Preparation
Samples taken from the bags are homogeneously mixed at the factory’s own laboratory; then a
1- Kg sample is sent in a hermetically sealed plastic container to the MSS for analysis.
Sampling plan for raw and white sugar (See Figs. 4 and 5).

Manufacture of a ‘Quality’ Sugar
Raw Sugar
Polarisation
The polarization of a sugar depends both on its moisture and on its impurities content. These
factors must be controlled throughout processing:
(A) Clarification [For Turbidity],

(B) Evaporation [For 0Brix],
(C) Boiling [For Purity and Crystallization],
(D) Centrifugals [For % Moisture; Washings, Molasses Film],
(E) Dryers [For % Moisture + Temperature 0C],
(F) Storage [For Environmental Conditions (Ambient Air)]
% Moisture
Three types of moisture are associated with the sugar crystals:
 “Inherent” Moisture: This is water occluded within the crystals structure. This moisture
does not migrate to the surface, and is not affected by the drying process.
 “Bond” Moisture: This moisture remains on the surface of the crystals, but trapped in the
form of a saturated film of syrup.
 “Free” Moisture: This moisture is available for evaporation on top of the crystals.
For optimum moisture of a given type of sugar, centrifugal operations are important to ensure a
good separation of the molasses from the sugar crystals.

At the centrifugals, a sugar is “purged”, i.e. the molasses are removed from the crystals molasses
mixture (massecuits). Moreover, the sugar is often washed with water at varying temperatures
(80 – 85 0C), but superheated steam at 110 0C may be used. As a result of such operations, more
or less water or “impurities” are left round the sugar crystals.
Generally, sugar discharged from the centrifugals has 1 % to 2 % moisture when followed by the
drying process, but it is possible to lower the % moisture at the centrifugal between 0.50 – 0.30
%.
At drying stage, pre-set operating conditions for air temperature and its relative air humidity are
set up for a given production flow through the dryer.
A corresponding sampling plan will establish spot sampling practices before and after the dryer
to evaluate sugar moisture to the silos.
During the “conditioning phase” air at a given temperature and humidity is blown into the silo in
order to allow sugar to be equilibrium with ambient air so that the crystalline sugar does take or
give off moisture.
Therefore, there is merit in drying sugar in a co-current air flow, but cooling in a counter-current
air flow. Note that a lower temperature is required at dryer outlet. In a counter current air flow,
the temperature gradient between the cooling air and the ‘cooled’ sugar is low. This prevents
rapid cooling of the sugar crystals.
An over-dried sugar will enhance crystal breakage at change-over points on conveyor belts and
during free-falling in the silos.
When hot sugars ( > 32.0 0C) are strode, the sugar will stay hot for more than 24 hours. During
this period, moisture migration will take place due to the temperature gradient created when
pilling up of sugars at various temperatures. The risk of a rise in moisture in the first instances
are high; this will be followed by a drying off stage of the super saturated syrupy layer, owing to
interstitial hot air circulation leading to hardening of the sugar mass.

Dilution Indicator
Sugar must be adequately dried but within certain % moisture limits. This is determined through
the dilution indicator of the sugar.
% Moisture
Dilution Indicator ( D.I )   100
100  ( Pol O
Z  % Moisture)
Note the relationship between the % moisture and the non-sugars content (See Fig. 6).
 When D I. is less than 33.3 :The sugar is in the safety zone
 When D.I. is between 33.3 and 50.0 :The sugar is in the doubtful zone
 When D.I. is greater than 50.0 :The sugar is in the deterioration zone
White Sugar: Moisture % < 0.06 % (Total Moisture)

(Schematically: 0.02 % Water of Crystallization: 0.02 % Bond Moisture; 0.02 % Surface
Moisture)
Figure 6: Dilution Indicator for Raw Sugar

Grain Size and Regularity

As grain size affects affination and consequently the early refining stage, such criteria are
included in the quality evaluation of the raws. For direct consumption sugars grain size is related
to the consistent visual appearance of the sugar and to its bulk density characteristics for packing
and its remelting efficiency for industrial use.
At Boiling Stage in Vaccum Pans
A uniform, well-formed crystal of fair size will purge more freely in the centrifugals, making it
easier to reach the correct moisture – Pol ratio essential for good keeping quality. In fact large
grains ( 0.80 mm) have fewer surfaces and, therefore, absorb less moisture during adverse
storage conditions. Rolled grains, conglomerates or clusters can hold dilute molasses in their
interstices and lead to incubation of microbial growth.
The crystal size of a raw sugar is usually between 0.60 and 1.0 mm. Crystals of uniform size
from a low turbidity (  200 m.a.u @900 nm) massecuites, free from bagaccillo and any other
extraneous matter, are highly desirable. a coefficient of variation between 25 and 30 % and a
grain between 0.85 and 0.90 mm for raws and between 0.40 and 0.60 mm for white sugar are
recommended.
At Centrifugals
Too high and prolonged spinning will break or abrade crystals, thus increasing small grains and
breakages in the final product.
At the Dryer
Too high spinning at the centrifugals increases breakage, fines and dust when sugar falls from
lifters in the rotary type dryer. These lifters are the radial pates specially designed to cascade the
sugar evenly through the process air.
At Handling for Storage

An over –dried sugar will enhance crystals breakage at change-over points on conveyor belts and
during free –falling in the silos.
Ash, Reducing Sugars and SO2
In quality evaluation of raws, numerous ratios are often used for judging particular refining
performance. These included invert/ash, organic and many other ratios.
The main source of mineral elements (ash forming constituents) is the clarified juice. At the
clarification stage, elements are selectively removed. At pH 8.0, Fe 3+ and Al3+ are precipitated,
while 20 % of CaSO4 is removed at pH 7.0.
K+, Cl-, Na+, SO42- are partially removed at clarification; they are traceable at evaporators,
vacuum pans and crystallizers.
Since the refining operation is essentially a laundry process to remove the maximum amount of
non-sugars, the efficiency is affected quantitatively and qualitatively by the different non-sugar
content, hence the importance of the analysis of ash and reducing sugars.
Some of the effects of high ash content % raw sugars on the refining process:
 Loss of decolourisation in char house

 High yield and high purities in final molasses
 Short-ion – exchange cycles
 More water to wash chart
 Scaling problems in evaporators and pans
 High ash content in refined sugar
 Low pan yields due to excessive washing in centrifugals
 Increased steam consumption]
 Impaired refined sugar quality for chocolate, candy and sweet production

A high SO2 Content in raw sugar is highly dependent on the use of sodium hydrosulphite
(Na2S2O4) commonly called Blankite in pan boiling to improve colour and to reduce viscosity of
mother liquor.
Note that a maximum level of 10 ppm in the finished product is the legal requirement.
Odour and Taste
Sugar is noted to have the ability to absorb odours from the atmosphere surrounding it.
During the finishing operations of sugar manufacture, it is important to prevent the storage of
strong–odour products in the vicinity of sugar crystals. Petroleum products, biocides and
detergents should not be present in the bagging /storage area of sugar.
Colour and Tubidity
The two main sources of colour in sugar are colour pigments in the sugar plant and colour
formed during processing itself.
The increase in colour depends on the nature of the colour bodies in the sugar so0lution. For
example, it is generally known that the plant pigment colorants in the raw cane sugar (flavones)
are pH-sensitive. The contribution to raw sugar colour increases rapidly between pH and pH 9.
On the other hand, factory –produced colorants are pH-insensitive. The melanoidins and caramel
type products as a result of the heat and temperature levels during processing.
Sugar colour is, therefore, highly dependent on pH control at the clarification stage and on the
temperature profile during subsequent evaporation, boiling and crystallization, cooling, drying
and storage.
Colloidal matter present in the sugar solution causes light scattering, thus increasing the “colour”
that is measured. These colloidal particles are the cause for turbidity of sugar solution. Colloid
removal is highly dependent on the efficiency of the clarification process for an optimum setting
rate of colloidal particles (size 10-4 – 10-6mm) and that of the boiling stages in preventing fewer
cutting and recycling of impurities during each finishing stage.

Filterability (See Fig. 7)
Filterability is a very important refining quality parameter to the refiner. The melted sugar must
filter well at the refiner.
Figure 7: Bulk Raw Sugar – Penalty Chart. Filterability and Starch Content
Influences of Bad Filterability in Refinery
Poor filterability reduces the Brix of the remelt or the rate of remelt, or both at the same time.
This is a costly operation in terms of steam consumption. It is, therefore, accounted as a
production loss.
A reduced Brix decrease the viscosity of the remelt and leads to a better filtration, but an increase
in energy is needed at the evaporation and boiling stages.

Reasons for Bad Filterability
Suspended solids of particle size less than 5 microns and generally less than 1 micron.
Substance which have filtration –impeding properties such as:
 Starch
 Dextran
 Soluble phosphates
 Wax
 Gums
 Sillica and other polysaccharides
Measures adopted during processing of a raw sugar to improve filterability.
 An enzymatic process to reduce starch level
 A better liming process (e.g saccharate liming), a better pH control, especially for
juice preservation during week-ends and long hours of stoppage.
 An optimum dosage of flocculants established by the factory control laboratory
 Production of less “B” massecuites or remelt of “B” and “C” massecuites
 Production of grains with M.A. not greater than 0.90 mm
 Sieving of sugar after centrifugals
 Quality control of intermediate products for turbidity, filterability and starch
content.
Extraneous Matter in Raws

Identification of “Production Sensitive Areas” which can be described as “an area where the
sugar is now beyond processing stage and any contamination at this point will not be removed by
normal manufactured procedures.’
Such areas referred to above are the following:
 All run-offs, screw conveyors and receiving thoughts carrying massecuites from
vacuum pans to crystallizers and centrifugals.
 All conveyor systems (screen, bucket or belt) carrying sugar to the dryer and to
sugar bins.
 The Dryer
 The Conditioning Bin.
 The Storage Bin.
 The Bagging Station or The Loading Station.
 Sugar Transport System (Lorries, Boxes, etc)
The Following Safety Measures Are Recommended:
 To fix covers on sugar product where practical and necessary.
 On the run-offs
 On top of crystallizers
 On top of conveyor systems
 On top of sugar bins
 Care should betaken to allow for air circulation under coves where necessary
 To fix plated walkways with stand up curb edges on top of any product receiver.
 To fix screens or services at the following points:
 Under the centrifugals (a vibrating screen)

 At the end of any conveyor belt discharging sugar into another conveyor leading
to the dryer or sugar bin
 At the dryer outlet
 To place a magnetic separator at one or more of the following points
 After the centrifugals outlet

 Along the vibrating screen
 At any change over point of conveyor belts
 After the dryer
 Before the inlet of the sugar bin
 A the outlet of the sugar bin
 To enforce strict rules and regulations for personnel behavior:
 Signs for “NO SMOKING AREAS”

“EATING IS STRICTLY FFORBIDDEN”
“NO JEWELLERY IS ALLOWED”
“NO GLASS BOTTLES IN THIS AREA”
 To Prohibit:
 The use of red lead based paints on surface and covers in contact with sugar
 ‘Write engineering ‘ in the vicinity of ‘exposed product’
 Cotton waste left over after maintenance
 To ban the use of any form of glass material:
 Protect all electric lights with plastic covers

 No glass bottles
 Ban the use of glass thermometers
 To establish an INSPECTION, MEASUREMENT and RECORD programme for
the following:
 Cleaning frequency of magnetic separation

 Weighing and identification of ferrous (metallic ) material

 Build –ups and lump formation on screens , buckets and bottom covers
 Pan scales
 Black specks (carbon particles , fly –ash , dust)
 Rubber pieces from fraying belts
 Sugar lumps and conglomerates
 Bagaccilo
 Wooden splinters
 Plastic fibers from brushes
 Micro –organisms
To establish a sanitation progreamms for the establishment of proper hygienic standard for:
 The Personnel:
Uniforms and head covers in the bagging area

Hand washing and toilet facilities
 The product during the finishing operations:
Prevention of any risk of prockets of microbial growth

Monitoring of sugar moisture and temperature
Preventing the storage of hot and humid sugar in bins
Time for condition of sugar before bagging
 Provision of pest control:
 Provide a rodent control systems

 Insectocutors for flying insects
 Any system for keeping birds away from the bagging area

REFINED SUGAR EEC. NO 2
Analyses
The following analyses should be done on refined sugar:
1. Polarization  Same as for raws and the dilution indicator
2. Moisture  Calculated
3. Visual Appearance - BRUNSWICK Colour Method]
4. Colour in Solution - ICUMSA method no 4
5. Ash - CONDUCTIVITY method
6. Reducing Sugars - KINGHT and ALLEN method
There is an allocation of points given the last three analyses, i.e. 3,4 and 5 and the total number
of points must not exceed 22 as described below in your handout “white sugar quality definition
and specification”.
Note:
Total number of points allocated for Brunswick colour, ICUMSA colour and conductivity ash
should not exceed 22.
Example:
 Pol 99.834 %
 H2O 0.045 %
 Ash 0.020 %
 Reducing Sugars 0.030 %
 ICUMSA colour 42 ICUMSA units
 BRUNSWICK Colour 4 on Scale Reading
Number of Points Allocated
a) Brunswick colour 4 x 2poionts = 8.00 Points

b) ICUMSA colour 4  7.5 points = 5.60 Points

c) Conductivity ash 0.02  0.0018 = 11.11 Points
Total Number of Points = 24.71 Points
Conclusion
The individual results meet the required standard for category No.2, but since the overall results
is greater than 22 points, the white sugar taken here as an example falls onto category No.3.
QULITY COCNTROL TECHNIQUES
Process Validation
Definition
Any planned actions which can be carried on to be confident that a new process/equipment is
completely under control and able to deliver products or services within the specifications.
 Validation has to be based on the Risk analysis

 Actions have to be planned during the different projects phases
 Actions have to be followed and documented
 Workforce-operators and supervisors have to be identified and trained
Risk Analysis - Main Risks
 Food Safety
 Microbiological
 Physical (Foreign Particles)
 Chemical
 Product Specification conformity
 Cost of the process/equipment itself
Risk analysis-Product specification conformity
 Process or Equipments specification

 Ensure an adequate Process identifier (PID) –a specific code, a numerical value

attributed and which specifies which process is on going or starting. It also allows
identification of most commands related to a process which is simultaneously
running on a multiple function processor.
 Process Deviation
 Sensors Deviation
 Control Loops Deviation
 Laboratory Analysis Deviation
 Equipment Deviation
 Utilities Parameters Flow Rate, Pressure, Temperature)
 Raw Material Deviation
 Processing Aids
 Procedures
 Human Resources (Recruitment, Training, Procedure, Management)
 Environment
Example: Equipment - Dryer

Quality Control Plan
A. Distribution
 The quality control plan is meant for the technical management and
administrative team of the organization:
i) Production Manager
ii) Site Manager
iii) Process Engineer
iv) Quality Manager
B. Objective
 To lay out all activities and specific measures taken to perform and record the
controls of product under consideration.

C. Scope
 All quality controls performed and completed by the operator, the laboratory or
any automation equipment in view of compliance with specifications.
D. Definitions in the Plan
 Product On which control will be performed
 Aim Defines the interest, the reason and the need for the control
 Control
- Who The person/operator responsible for performing or any service provider

from the refinery/factory central lab or any sub contractor for the control.
 How Documented procedure/instruction sheet describing the means to

perform the control task or the instruction manual.
 Frequency Number of data capture, controls to be done under normal process.
 Classification: As a result of the interest, the reason and the need for the
control
 Class 1 Specification parameter (regulatory or customer’s) where any

deviation from specified value indicates a nonconformity.
 Class 2 Specific control parameter which deviation triggers rules

established by management team.
 Class 3 Guiding parameter not related to quality
 Method

 What Characteristic, criteria or specification which is to be measured.
 How Mean used to perform the control (analysis, visual, weighing or

automation).
 Who Person (operator, analyst or equipment) performing the control.
 Records Document number min which related control results are grouped
 Target Values Class 1, value targeted as specification
Class 2 and 3, value as indicator for guidance
Limits are inclusive of targets values

Document Valid only with the ‘Organization ‘ Letterhead

QUALITY CONTROL PLAN-FACTORY/REFINERY
Department : Quality Document No………… QULATIY PROCEDURE
Date ……… Page x/xx
Control Method
Product Aim Who How Frequency Class What How Who Record Target
Value
Sugar Follow up Quality No…
Specification Control
Parameters Dept
Melt
Clarified
Juice
Lime
Molasses
Dryer
ORGANISATION FOPR QULITY ASSURANCE

Quality Assurance involves the integration of the following related techniques and activities in
order to provide confidence that a product satisfies buyer’s needs.
QULATIY ASSURANCE
Administration &
Communication
Producer/Buyer
Support
Product Reliability SUGAR
Manufacturing –handling
Storage-Quality control
Laboratory Inspection & Performance Reports

Analyses Control Records & Data Statistical /others
collection
   
Lab, control Tech. At clarification Station Records per sugar Establishment of
  Factory specification
Standard analytical At Boiling Station  
methods (ICUMSA)  Records per type of Collaborative Tests
 At Crystallisers sugar 
Keeping Qualities   Weekly Bulleting
 At Centrifugals Records per shipment 
Refining Qualities   Annual report
 At screens Annual production 
Analyses of non-sugars  records Guidelines &
At Belt Conveyors Instruction

At Bucket Elevators

At Conditioning Bins


Number of Data = n
Value of Data; X1, X2, X3 to Xn
Mean value of Data: X
(X1  X )2
Variance ( S 2 ) :   n  1
( X1  X )2
S tan dard Devation ( S .D) : 
n  1
 ( S .D ) 
99 % Confidence Limits : X  2.576 Or 3.00  
 n 

Prerequisite Programmes – PRP (s)
The organization shall establish, implement and maintain PRP (s) to assist in controlling
a) the like hood of introducing food safety hazards to the product though the work
environmental.
b) Biological , chemical and physical contamination of the products 9s), including cross
contamination between products, and
c) Food safety hazard levels in the product and product processing environment.
When selecting and/or establishing PRP(s) , the organization shall consider and utilize
appropriate information [e.g statutory requirements, customer requirements, recognized
guidelines, Codex, Alimentarius Commision (codex) Principles and codes of practices, national ,
international or sector standards].
Organizing for such programmes PRP (s) in sugar factories implies the consideration of the
following:

1. Construction and lay –out of buildings and associated utilities

2. Lay-out of premises, including workspace and employee facilities
3. Supplies of air, water , energy and other utilities
4. Supporting services, including waste and sewage disposal
5. The suitability of equipment and its accessibility for cleaning , maintenance and
preventative maintenance
6. Management of purchased materials (e.g. raw materials, ingredients , chemical and
packaging), supplies 9e.g. water , air, steam and ice), disposals (e.g waste and
sewerage ) and handling of products ( e.g. storage and transportation)
7. Measures for the prevention of cross contamination
8. Cleaning and sanitizing
9. Pest control
10. Personal hygiene
11. Other aspects as appropriate
Verification of the PRP(s) shall be planned and PRP(s) shall be modified as necessary. Records
of verifications and modifications shall be maintained. Documents should specify how activities
included in the PRP(s) are managed.
Defining A Procedures For A Quality System
 Procedures control process or activities
 A well defined procedure controls a logically distinct process or activity, including the
associated inputs and outputs.
 Such a Procedure Defines
1. The work that should be done

2. Explains how it should be done
3. Who should do it
4. and under what circumstances

 In Addition, it Explains
1. What authority and what responsibility has been allocated

2. Which supplies and materials should be used
3. And which documents and records must be used to carry out the work.
While procedures may be documented, ISO usually expects them to be documents
Notes on Hazard Analysis of Critical Control Points (HACCP)
In view of new legislation in EU and in the US regarding food safety and to prevent any food
contamination, the application of HACCP to any sector of the food chain has been recommended
The Hazard Analysis of Critical Points (HACCP) is a system, which identifies specific hazards
(i.e. biological, chemical or physical properties) that adversely affect the safety of the food and
specifies measures for their control.
The system is based on the principle that food safety issues can be eliminated or minimized by
PREVENTION during production rather than detection in the finished product.
The concept of HACCP is to assure food safety through development, implementation and
effective management of a functional process hazard control programme. In conjunction with the
Good manufacturing practices (GMP) HACCP should extend the control options by identifying.
What may go wrong, How, Where and When?
HACCP is the precursor of an effective quality system in that it (a) identifies what needs to be
included in the quality system and as importantly (b) it will identify what controls are not
needed.
12 Steps of the HACCP

1. Set up the HACCP team

2. Describes the product under manufacture
3. Determine the scope of the HACCP study
4. Work out a flow diagram of the process
5. Confirm flow diagram on site
6. List potential risk associated with each of the process flow diagram, perform a risk
analysis and define measures to be enforced in order to control these risks
7. Determine the CCP (Critical Control Points)
8. Establish the critical target for each CCP
9. Establish a monitoring system for each CCP
10. Take corrective measures
11. Apply validation procedures
12. Establish records and register them in a record file
Setting up a HACCP Study
Such study comprises the following stages:
1. Make up your TEAM

 Process Manager
 Chemist
 Factory Assistant
 Factory Supervisor
2. Define the SCOPE
Type of hazard to be identified
 Chemical
 Physical
 Microbiological
3. Define the AREA TO BE STUDIED
From mills to sugar bins?

 From mills to vacuum filter?

 From clarifier to vacuum pan?
 From vacuum pan centrifugal? Product Sensitive Areas?
 From centrifugal to dryer?
 From dryer to conditioning bin?
 From conditioning bin to bagging?
 From sugar bin to lorry?
4. Make a FLOW DIAGEM for the Product/Process including
 Floor plants and equipment layout

 Sequences of all process steps
 Time /temperature profile of raw, intermediate or final product
 Potential time delay
 Flow conditions of the sugar product
 Any product recycle loop
 Equipment design feature (void space present)
 Cleaning and disinfecting procedures
 Environmental hygiene
 Pathway /route of personnel
 Route for potential cross-contamination
 Personnel hygiene practices
 Storage conditions
 ANY OTHER DATA NEEDED
5. Go for an ON-SITE VERTICATION of flow diagram and confirm
 Accurate representation of the operation

 The following nights shifts /weekend running of operation
 Amendments for any deviation from original diagram

6. Identify and list ALL HAZARDS associated with every processing steps.
 Biological (e.g. microbial due to pH, % H2O, Temperature OC, % R.H, Oxy/Red,
potential, insects, rodents, birds, etc)
 Chemical (e.g. heavy metals (Pb, As, Cu, Hg) from factory origin, biocides,
processing chemicals –flocculants, pan aids, surfactants, viscosity reducers,
grease, gear oil, etc.)
 Physical (e.g. metallic filings. glass, wood, cigarettes, belts, wires, nuts bolts,
etc).
7. List the MONITORING PROCEDURES/CONTROL MEASURES/DEVICES for

each hazard identified.
 Screens
 Magnets
 Covers
 Insectocutors
 Baits
 Curtains (Rubber or Plastic)
 Doors
 By-passes
 Thermometers
 pH controllers
 Detailed cleaning procedures and records of the frequency of cleaning
 pH control records
 Temperature measurements and records
 Inspection check-list for contamination
 Pest control records
 Personnel hygiene policy and records
 Identification of contamination level an records
8. Apply HACCP DECISION TREE to each process step in order to identify CCPs
(Critical Control Points).

 Q.1. Are the control measures in place for the hazard?

 Q.2. Does the step eliminate or reduces the hazard to an acceptable level?
 Q.3 could contamination occur at unacceptable levels (s) or increase to un
acceptable level (s) after this particular process step?
 Q.4. Will a subsequent step eliminates or reduces the hazard to acceptable
level?
9. Establish TAREGET (S) and TOLERANCE at each CCP, e.g.:
 Assessing temperature limit at bagging

 Weighing of metallic (ferrous) fillings present
 Weighing of non-metallic (non-ferrous) fillings present
 Rapid moisture analysis of the sugar
 Osmophilic levels in intermediate products
10. Establish a MOINTORING SYSESTEM for each CCP for e.g.:
 Metallic
1. inspect hourly and keep records of tailings present on magnets

2. Randomly inspect and keep records of presence of metallic particles on
screen
3. Randomly observe and keep record of the flow rate and thickness of sugar
blanket through the magnets.
4. Test the bagged product on a code basis (five bags take at random examine
and record for metallic particles)
 Non Metallic
1. Monitor heat transfer coefficient of evaporators, vacuum pans and dryers

2. Randomly inspect and keep record of presence of non metallic particles on
screen

3. Randomly observer and keep record of the flow rate and thickness of sugar
blanket on screen.
4. Test the bagged product on a code basis (five bags taken at random examine
and keep record none).
 Presence of Glass
1. Inspect and eliminate any movable sources of glass in the product sensitive
areas; discard.
2. Inspect and record presence of protection of high level strip lights with
diffuser
3. Inspect and record that no window panes are broken near/in the bagging
area.
 Rodents
1. Inspects daily and keep record of rodent faces.

2. Examine and keep record of baits and traps
3. Inspect and record presence of gnawing
4. Call independent contractor when necessary
 Flying Insects
1. Inspect daily and record observations on insectocutors.
 Cockroaches and Lizards
1. Examine and keep record of bails

2. Inspect for the presence of debris around bagging areas.
 Birds

1. Inspect for presence of droppings on conveyor and bin covers and record if
any
2. Inspection for presences of feathers on conveyor and bin covers and record
if any.
 Microbial
1. ensure and keep records of cleaning frequency of equipment and sanitaioin

2. Ensure and keep records of employee hygiene and laundry services for
clothing
3. Measure and record temperature of intermediate product at regular intervals
4. Measure and record temperature at bagging
5. Test microbial profile (including osmophis) regularly and record
11. Establish a COREECTIVE ACTION plan for any observed deviation from targets and
tolerances.
 Provide for a return belt conveyor from sugar bins to remelet

 Provide for by-pass at exit of crystallizers, on vibrating screens.
12. Establish RECORD KEEPING and DOCUMENTATION
13. VERIFICATION
14. REVIEW of the HACCP plan
Personnel Hygiene and Health Requirements

1. Hygiene Training
 Factory management should arrange fore adequate and continuing training

of all workers specifically those in the ‘product sensitive areas’ of the factory.
They should be trained in hygienic handling of the sugars as well as in personal
hygiene in order to understand all the precautions necessary to prevent
contamination of the sugar.
2. Medical Examination
 The employees who are in contact with the sugar during their work should
have a medical examination prior to employment. This examination should also
be carried out regularly so as to ensure personnel to be free from any epidemic
disease. a record of such information should be made readily available to all
authorities concerned.
3. Communicable Diseases
 Factory management should ensure that no worker known or suspected to be

suffering from or to be a carrier of a diseases likely to be transmitted through the
‘exposed sugar’ or infected with wounds, skin infections, sores or with diarrhoea,
is allowed to handle sugar within the ‘product sensitive areas’. Any person so
affected should immediately report to the management that he is ill as he may
directly or indirectly contaminate sugar with pathogenic micro-organisms.
4. Injuries
 Any worker who has a cut or wound should not continue sugar or sugar
contact surface until the injury is completely protected by a conspicuous
waterproof covering firmly secured, adequate first-aid facilities should be
provided for this purpose.
5. Changing Facilities and Toilets

 Adequate and conveniently located changing facilities and toilets should be

provided. These areas should be hygienic, well lit, ventilated and should not open
on to ‘exposed sugar’ areas.
6. Washing of Hands
 Each worker wile on the processing line in those areas known, as product
sensitive Areas should wash their hands frequently and thoroughly with a suitable
unscented soap and warm water. Disposal towels should be available for drying
hands.
 Hands should always be washed:

(a) Before starting work,
(b) Immediately after using the toilet,
(c) After handling contaminated material.
 Hands should be washed and disinfected immediately after handling any

material capable of transmitting diseases.
 Hand washing facilities should be provided at each access point to those

“Product Sensitive Areas”
 Notices requiring hand washing should be displayed
 Factory management should supervise to ensure compliances with this

requirements
7. Personal Cleanliness

 Every worker engaged in the sugar handling areas namely the identified
‘product Sensitive Areas” should maintain a high degree of personal cleanliness.
Clean protective clothing will be provided .In order to ensure cleanliness of
cloths, a contract laundry service will be appropriate.
8. Visitors
 Factory management should take all the necessary precautions for visitors in
‘Product Sensitive Areas’ to prevent sugar contamination. The use of protective
clothes should be enforced and no jewelry should be worn.
9. Supervision
 Responsibility for ensuring compliance by all personnel with all the above
requirements should be specifically allocated to the supervisory personnel.
Bulk Handling
Introduction
The bulk sugar terminal in Mauritius was built in 1980. Its main economic advantage over
loading as practiced previously have proved to be:
 A reduction in handling costs of export sugars
 A decrease in sugar losses. Previously, with the semi – bulk system, some
10,000 tonnes of sugar (i.e. 1.0 - 1.5 % of total export) were lost during
handling. With bulk handling, the losses have been reduced to some 800 tonnes,
i.e 0.2 % of bulk sugar export.
 Relief of ship congestion in the larbour.

 Rapid reclaiming of sugar for export at short notice
 Uniformity and improvement in quality
 More efficient use of storage areas.
A shipment of 12,000 tonnes takes only 2  eight – hour days to be loaded, compared with 12
days previously.
Function of a Bulk Sugar Terminal
The most important element of a bulk handling system is the setting up and operation terminal
facilities for receiving, storage and shipping the sugar. Thus, the main function of the terminal is
to provide buffer storage to cope with the inflow from the factories, while meeting the required
shipping programme.
The terminal must be equipped with adequate facilities, including accurate weighing and must
have large uninterrupted storage, be secure against cyclonic conditions, protected against tide
and storm surges, and easily filled and emptied. It must be adjacent to proper wharf and berthing
facilities to suit the size of shipping to be used, and it must be equipped with rapid unloading
facilities, including accurate weighing. The whole sequence of handling must be achieved in an
expeditious and clean manner.
Bulk Sugar Headlining Methods (See Fig.8)
All over the world, the operation of a bulk sugar terminal follows more or less the same pattern.
 Sugar arrives at the bulk sugar terminal in trailers with prime movers, or rigid type
Lorries or other means of transport.

 The sugar is weighted, and the vehicles are unloaded. From the intake hopper, the sugar
falls onto conveyor belts which carry it to the top of the silos, where it falls from the roof
level to the floor of the silo.
 Sugar is extracted from the silo through a tunnel under the floor. Usually, there are square
openings in the silo floor, each fitted with a steel hopper and louvered control gates. To
extract sugar, a control gate is opened, allowing the sugar to flow on to a conveyor belt
underneath the silo floor.
 In modern sugar silos, approximately two thirds of the sugar in the silo can be extracted
by gravity in this manner, but the remainder has to be moved mechanically from the sides
of the silo to the tunnel hoppers. The reclaimed sugar is transported to the wharf edge by
belt conveyors.
 Finally, the sugar is conveyed up the ship loader boom and drops down a telescopic chute
to a rotating thrower which sprays the sugar into the ship’s hold.
Type of Terminal at Port Louis
The choice of a particular type of silo for Mauritius was conditioned by a number of factors, the
main ones being:
 Total Storage Capacity

 Ground Available
 Condition of Sub-Soil
 Required Rate of Discharge
 Insulation
 Structure

It is usual to provide for a storage capacity equivalent to 40 % of the total annual sugar
production. The storage capacity of the Mauritian silos has been fixed by the sugar industry
at 350,000 tonnes, bearing min id that the aim of Mauritius was to produce 800,000 tonnes of
sugar annually.
Due to the high relative humidity of the air in Mauritius, a high rate of discharge is needed,
as well as adequate insulation of the silo.
A silo structure must be designed to resist gusts of up to 240 Km/h in the event of a cyclone
hitting the island during the summer months.
Various types of silos are built nowadays with special characteristics for storing and handling
raw sugar under different climatic and site conditions.
A board division can be drawn between “vertical silos” in which the floor area is small in
relation to the total volume, and “horizontal silos” in which the reverse is the case. The main
difference in the choice of design of structure lies in the extent to which the lateral
“horizontal silos” of the A-shaped type have been found to be more suitable for our local
conditions’.
Structures of the Bulk Sugar Terminal
The essential structures of the terminal in Port Lois are:
 Receiving stations for sugar
 Conveyors feeding sugar into the bulk storage shed
 The bulk storage shed (i.e. the silo)
 Out loading conveyors feeding the sugar from the bulk storage shed to the weighing
tower, shipping gallery and the (mobile) ship loader
 The weight tower

 The wharf structure
 The (mobile) ship loader which distributes the sugar in the ship’s holds
Essential Notes on Structures of the Storage Shed
 Two A-shaped silos, each having a storage capacity of 175,000 tonnes. Each silo is 364.6
metres long by 45.7 metres wide and 25 metres high.
 The silo floors are above the level of maximum storm surges. The sides are reinforced by
concrete retaining walls up to a height of 25 meters.
 The slope of the roof steel trusses approximates the angle of repose of the sugar heap,
thereby enclosing the minimum volume necessary to accommodate the stored sugar.
 Access for cleaning inspection and maintenance of the roof is provided in the form of
walkways with handrails. Safety platforms and fences against accidental falls from the
sleepy sloping roofs are also provided.
 Another feature of the storage sheds are the fire fighting access walkways. They are
external to the sheds and run along both sides of each silo.
 Large openings with steel roller shutters or sliding doors are provided at each end of the
silo to provide access for front-end-loaders and also for controlled ventilation A 2 ½
meters square opening is provided in each end wall at apex gangway level to provide
further controlled ventilation.
 Floor openings are provided for the flow of sugar to the out loading system. The surface
of the floors and walls are treated to withstand attack by acids in sugar solutions and,
throughout their length, the floors slope outwards 0.5 meters from the centre line to the
side walls. The floors are provided with scuppers at the side walls to drain water used for
washing.

Storage Requirements and Control
Bulk Handling Characteristics
There are three characteristics which the sugar should have in order to be handled in bulk.
They are:
1. The Free-Flowing Properties of the Sugar

2. Its Bulk Density
3. Its Angle of Repose
Free Flowing Properties
The behavior of bulk sugar is strongly influenced by the film of molasses which enrobes each
crystal of raw sugar.
This film is saturated with sucrose and contains nearly all the moisture and practically all the
non-sucrose, namely the reducing sugars, the mineral and organic salts and various micro-
organisms. Some moisture is included within the crystal and migrates slowly outwards. The
behavior of the sugar in relation to the surrounding air and with the adjacent crystals is
determined by this film of molasses. Deterioration reactions also occur in this film of molasses.
If on one side, over dried sugars have a low percentage of molasses, a high polarization and are
free-flowing, dust problems can happen due to the dryness of the sugar. A high percentage of
molasses, a high percentage of moisture and a low polarization will render the sugar sticky and
hence no free-flowing characteristics. So, it is important to have all sugars adequately dried
though not over dried before entering storage.
Other factors affecting the free-flowing properties of the sugar are:
 The particle size distribution of the sugar

 The atmospheric humidity
 The packing of the sugar due to traveling shocks
 The surface texture of the sugar container

 The material used as thermal insulation

 The difference of temperature outside and inside the container
 The time the sugar stays in the container
Bulk Density
Bulk density varies with the degree of packing of the sugar. It may be accepted that the combined
effects of time and compression will reduce the sugar to practically its minimum bulk volume,
i.e. maximum bulk density.
Experiments have proved that maximum bulk density varies only slightly with crystal size and
percentage moisture of the sugar. Hence, irrespective of the conditions of the sugar as it enters
bulk silo, the sugar can be packed to its minimum volume. 881 Kg per m3 is the usual bulk
density accepted as a satisfactory figure.
Angle of Repose
The angle of repose of sugar is the angle which the sugar pile (formed by allowing sugar to fall
freely by gravity) makes with the horizontal. The angle of repose of sugar changes with moisture
content. In moist conditions, the highest angle recorded was bout 400 in Queensland. Under
conditions of storage for a certain time, angle of 30 0 have been recorded in other countries. In
Reunion Island, values ranging from 330 to360 are noted. The assumed angle of repose is snow
taken as being 350.
Deterioration of Sugar
In assessing the chance of raw sugar deterioration under any given set of circumstances, it should
be remembered that even with a relatively ”healthy sugar”, infection is all too easy from contact
with other sources of infection, particularly if several different raw sugars are mixed in a sugar
silo. Nevertheless, even in a badly infected raw sugar, the organisms are relatively inactive
unless the syrup layer surrounding the crystal of sugar is in a suitable condition to permit their
activity.

The following changes are noted duet to ad storage:
a) Physical Changes:
 Absorption of moisture by the sugar

 Caking of the sugar
b) Chemical and Bacteriological Changes:
 Increase in the number of micro-organisms with simultaneously an increases in

acidity of the medium
 Increase in reducing sugars
 Alteration in color of the raw sugars
To understand the mechanism of these phenomena and to establish conditions required to prevent
them, it is important to study to equilibrium between the sugar and the humid air.
Sugar always contains a certain amount of water in the form of a syrup layer (film of molasses)
which surrounds the crystals. This film contains the major non-sugars.
When such sugar is placed in an atmosphere more or less humid, two equilibriums are produced
simultaneously among the three existing phases, i.e. sugar, and film of molasses and air.
a) An equilibrium between the crystals and the film of molasses which enrobes it. This film
remains saturated while dissolving the crystal or it becomes more soluble while forming a
layer of sugar crust on the crystal. This layer of sugar crust is derived from this molasses
film.
b) An equilibrium between the water content of the film of molasses which enrobes the crystal
and the water content of the air around the crystal. This is by far the most important
equilibrium, because it finally controls the first equilibrium. This important equilibrium is
reached when the vapour pressure of the film of molasses (also called vapour pressure of the
sugar) is equal to that of the air surroundings.

In the study of this equilibrium, one usually uses relative humidity (i.e. the ratio between the
moisture in the air and the moisture at saturation point for a given temperature) Thus, the value
of the equilibrium is called the equilibrium relative humidity (ERH). If the humidity of air is
greater than the ERH of the sugar, the later will absorb moisture from the air and in the reserve
condition, the sugar dries out.
Factors which influence the equilibrium are:

a) Purity of Sugar, hence that of the film of molasses .Impurities decreases ERH. So
the purer is the sugar, the higher is its ERH. Not only the quantity of impurities,
but also the quality of these impurities affects the ERH. So, two sugars of the
same purity may have different ERH.
b) Grain Size: Fine and false grains increase the surface of contact to help the sugar
crystals to “grow together”. Hence, this effect decreases ERH.
c) Temperature: An increase in temperature reduces the relative humidity of the air

and a decrease in temperature produces the reserve situation.
d) Moisture of Sugar: Equilibrium curves have been established between ERH of

sugar and its moisture content, but a better estimation of the relationship is by the
establishment of the equilibrium curve of the sugar under study itself.
Physical Changes
If the film of molasses which enrobes the crystal gives off its water content, the film becomes
supersaturated: the sugar crystallizes to attain equilibrium, thus binding together adjacent
crystals. This is the process occurring during caking of sugar.
If on the other hand the film of molasses absorbs moisture, liquefaction of the sugar crystals
occurs.

Studying equilibrium (b), it is noted that the film of molasses will give off it’s a water content
every time the ERH is greater than that of the air surroundings.
Hence, it is important to have a sugar which is in equilibrium with the ambient air and to have a
sugar at a suitable temperature.
Chemical and Bacteriological Changes
1. If sugar has high moisture content the development of micro-organism is accelerated.

Below a certain ERH, the activity of these micro-organisms (mainly yeasts and fungi) is
reduced to a minimum and it’s thus harmless. As soon as fermentation starts, there is
inversion taking place and an increase in reducing sugars is noted. These reducing
sugars beings hygroscopic, moisture content of the sugar is increased. As a result of
fermentation, the acidity of sugar increase, thus lowering pH and causing further
deterioration of the sugar. Microbial activity is also related to temperature and it seems
that as the temperature is increased up to a maximum of approximately 40 0C, activity
is also increased.
So, it is important to store sugar as dry as possible to prevent moisture migration and moisture
concentration at a certain point, and to maintain a low temperature.
2. Increase in reducing sugars is a result of fermentation. In raw sugars, this can also occur
if sugar has been stored previously at a low pH.
3. Changes in colour of raw sugar usually take place at pH values below 7.0. “Maillard
Reaction” occurs and the increase in temperature produced by the reaction increases
colour through caramelisation. Colour changes can also happen as a consequently of
reducing sugars produced and a lowering of pH values through fermentation. It is
highly influenced by a high temperature and amino acids of the stored sugar.

Control
Dilution Indicator
For many years, the potential microbiological activity in the syrup layer enrobing the crystals of
raw sugar has been assessed by calculating the dilution indicator (D.I)
% Moisture
Dilution Indicator ( D.I )   100
100  ( Pol OZ  % Moisture)
However, the formula has serious limitations and should only be regarded as an indication based
on the usual standard raw sugar analysis.
Raw sugars should have a polarization within the following range on reception at the bulk
terminal.
Minimum = 98.5 0S
Maximum = 99.0 0S
It is generally considered that a raw sugar with a D.I. of 50 or more will deteriorate on storage,
but will not deteriorate if its D.I. is 33.3 or less. Between 33.3 and 50, it is in a so- called
doubtful zone.
In practice, however , penalties are generally jot inflected non raws when the D.I lies in the
doubtful zone, but the more the D.I gets close to 50, the greater the danger of deterioration.
Referring to chart of penalties, (See Fig. 9) it is noted that raws polarizing bless than 98.5 and
above are penalized. It is observed from this table that the penalties are more severe when the
D.I is 50 or more, and very severe for D.I values of 60 or more. Provision is also made for sugars
with a D.I of less than 25.0 because of the dangers of moisture migration, hence caking, and of
explosion due to sugar dust.

Should the polarization be lower than 98.5, colour formation during storage will be more
important and the danger of deterioration will be greater at D.I values falling within the doubtful
zone. Hence, sugars of Pol lower than 98.5 suffer more severe penalties on D.I than those above
98.5 and are also penalized for colour, the lower the Po, the larger the colour penalty.
D.I. Penalty on sugar polarizing less than 98.5 starts at 40.0 D.I, instead of 45 for sugars
polarizing 98.5 or more
The Tolerable Ranges for:
 Polarisation less than 98.50 = D.I 25.0 up to D.I. 39.9

 Polarisation more than 98.50 = D.I 25.0 up to D.I 44.9
Since colour of Maurtiuis raws has so for not been a problem to refiners, a penalty is inflected on
sugars polarizing less than 98.5.
Temperature and Relative Humidity Control
Silo Insulation and Structure
As silo insulation is one of the conditions which will check the caking of sugars, it is very
important to be up to the standard. The insulation of the horizontal sugar silo is provided by
using a synthetic cladding material which has physical strength and a long life even in corrosive
conditions. The insulating material minimizes condensation within the silo, while the outer
surfacing is resistant to abrasion.
Doors and windows are as airtight as possible.
It is also recommended that sugars should no leave factories at a temperature above 32 0C.
Ventilation of the silo is eased by the installed at intervals along the ridge of the loading roof and
in the end walls. Ventilation is required:

 To remove exhaust fumes produced by front-end loaders when ship loading

operations are in progress.
 To introduce dry air when suitable conditions exist outside the sheds
 To dry the interior after washing down the sheds following removal of sugars.
Dust Formation and Explosion
The major cause of dust formation is the rapid drying of the film of syrup left in sugar crystals
after spinning. This rapid drying deposits fine sugar particles on the crystals faces. Unfavorable
phenomena, such as caking and dust formation, may be caused by condition existing during the
drying process. A high degree of Pol, a low percentage of moisture and a fine grain will favour
dust formation. As a result of this, sugar handling, sugar loading and shipment may also increase
the dust level 3 to 5 times the level in the original product.
Danger of explosion can happen at any instant. Dust explosions occur in two stages. Firstly,
ignition of a dust cloud takes place, producing a primary explosion. The disturbance produced by
the primary explosion rises into the air dust which may have been lying on the floor, shelves,
sills, beams and machinery. The explosion is then propagated through this secondary coluld,
producing a secondary explosion which can spread through the whole of the silo. A dust
explosion of 7-8 bar can easily damage a sugar silo and lead to death of many people.
Necessary precautions to reduce dust hazards are:
 Prevention of excessive dust by making sure that sugars is at a relatively high

degree of polarisaion and not excessively dry.
 A good house- keeping system so that dust can be cleaned up as often as necessary.
Fire
Pure sugars melts at 160 0C and decomposes at 170 to 180 0C. Its ignition temperature is about
460 0C. Stored in bulk, pure sugar is not easily ignited. Generally, sugar chars and caramelises
before it reaches the temperature at which it will burn in air. A skin forms over the surface of the

bulk of sugar, restricting air access and reducing the rate of burning. Even so, serious fires have
occurred where the flow of the molten sugar encourage fire spread.
Most fires start small and in their early stages grow comparatively slowly so providing over an
appreciable tie the opportunity of discovery and treatment. This is not the case, however, with
explosions which are the result of extremely rapid burning in a confined space and which are
more difficult to suppress once started. Fires sometimes produce explosions, and explosions start
from fires.
Fire Protection Measures
To enable action to be taken as rapidly as possible to control any fire which may break out within
the terminal installation, fire warning and fighting equipment are installed.
A fire detector system would perform the following functions:
 Automatically detect both visible and invisible products of combustion

 Sound a fire alarm bell located near to the fire control panel
 Sound a siren mounted externally to the building
 Transmit a coded signal to the district fire station
 Provide a district audible alarm at the indicator at the indicator board in the event of
loss of power to the detector circuits.
 Provide a visual indication that the man supply is switched on to the equipment.
 Provide a warning light and audible alarm in the Terminal manager’s office.
These detectors are located in the sugar silos, switch rooms, weight tower and reclaiming
tunnels.
Fresh Water Storage Tank and Pump Houses
Two sources of water supply are available: a fresh water storage tank with a capacity of 450,000
liters and slat water from the harbour in unlimited quantities.

An electrically driven fresh water pump is installed adjacent to the fresh water tank and a diesel
driven salt water pump nearby. These pumps have a minimum capacity of 11,500 liters peer
minutes at 90 meters head.
Hydrant services are provided throughout the terminal station and are charged with fresh water
all the time. On opening any hydrant, the drop in pressure starts up the fresh water pump.
External fire walkways are provided along the top of the sides walls of the silos. These enable
fire hoses to be brought to bear upon a fire within a silo and ready access to the silo interior is
obtained from walkways by means of doors and kick-in panels in this side wall sheeting.
A total of approximately 66 portable manually operated fire extinguishers are located at readily
accessible places throughout the bulk terminal.
Safety Equipment
Emergency stop switches and pull wire operated stop with indicator lights are provided for each
conveyor, together with belt tracking and motor isolating switches, where necessary.
Automatically operated safety warming hoots furnish pre-warning of conveyor belts starting, to
ensure safety of personnel.

REFERENCES
1. ICUMSA, Report of the proceedings 17th Session (1478): Subj.3, Appendix 4.
2. SCHEIDER, F (1979) – Sugar Analysis. ICUMSA Methods
3. OFFICIAL METHODS OF CONTROL AND ANALYSIS FOR MAURITUS SUGAR

FACTORIES (1970)
4. MEADE, G.P. & CHEN, J.C.P. (1977). Cane Sugar Handbook. A manual for Cane Sugar
Manufacturers and their Chemists, 10th edition
5. ICUMSA, Report of the proceedings 15th Session (1970): Subj. 27, Appendix I.
6. ICUMSA, Report of the proceedings 14th Session (1966): Subj. 27 Appendix.

Sample Examination Questions
Module: Sugar Quality
Date: 14 November 2011
Time Allowed: 60 Minutes
Mark Allocated: 100 Marks
Question 1.
(a) What do you understand by a “Productivity Sensitive Area”?
(b) Identify the area considered as a “Product Sensitive” in a sugar factory.
(c) List briefly the safety measures you would recommend in the vicinity of the “Sensitive
Area” of your factory so as to eliminate or reduce the risk of contamination which will
not be removed by normal manufacturing processes.
Question 2.
(a) List the physical and chemical changes noted due to bad storage of sugar.
(b) What are the objectives and the scope of a quality control plan?
(c) As a result of the interest, the reason and the need for control, how would you define and
classify the control parameters in the quality Control Plan?
(d) How would you set up the definition of “Control” in your Quality Control Plan?
Question 3.

(a) When establishing a pre-requisite programme for the HACCP study, the organization
needs to refer to the appropriate source information available. What is the kind of
standard source information required? List six examples of such information sources.
(b) What are the various areas of interest that the management of a sugar factory should
consider when organizing the pre-requisite programmes. List them.
(c) How would you define a “Procedure” for a quality system?
Question 4.
A Quality Assurance department ensures that all the activities related to quality provide
Confidence that the sugar delivered satisfies the buyers’ needs.
(a) Where in your factory would you suggest to establish an inspection measurement and
record programmme?
(b) Suggest how you would use a known “Quality Tool” to examine (1) a contamination
problem (2) the setting up of control limits of a given parameter.
Question 5.
Even in a badly “infected” raw sugar, the micro-organisms are relatively inactive unless the
syrup layer surrounding the crystal of sugar is in a suitable condition to allow their activity.
(a) Describe the changes that occur when hot (40 OC) sugar at 0.02 – 0.04 % moisture in
polypropylene bags with liners in stored at a relative humidity levels of 50 – 55 %.
(b) List the bacteriological changes noted due to bad storage of the sugar in bags and
describe the causes of such changes.
Date: 17 September 2010

Question 1.
(a) What do you understand by the term “Quality”?
(b) “Quality of Sugar” refers to four major fields of interest Name them.
(c) List physical, chemical and microbial quality characteristics of sugar which are of interest
of buyers.
Question 2.
(a) List the physical and chemical changes noted due to bad storage of sugar.
(b) What are the objectives and the scope of a quality control plan?
(c) As a result of the interest, the reason and the need for control, how would you define
and classify the control parameters in the quality Control Plan?
(d) The “Cause to effect diagram” is a quality tool. List other examples of quality tool.
Question 3.
(a) When establishing a pre-requisite programme for the HACCP study, the organization
needs to refer to the appropriate source information available. What is the kind of
standard source information required? List six examples of such information sources.

(b) What are the various areas of interest that the management of a sugar factory should
consider when organizing the pre-requisite programmes. List them.
(c) How would you define a “Procedure” for a quality system?
Question 4.
Food safety is today an obligation in any sugar manufacturing plant.
(a) List three biological, three physical and three chemical hazards linked to the
manufacture of sugar.
(b) What does a CCP mean? List the four important questions in the decision tree you
would apply to each process in order to identify a CCP.
Question 5.
(a) Three types of moisture are associated with the sugar crystal. Describe each of them.
(b) What are the various “Processes” in the sugar manufacture that are linked to the
determination of sugar moisture? Describe briefly each of them?
(c) What do you understand by “Dilution Indicator”? To what does the Safety, Doubtful and
Deterioration zone refer to.
Date: 10 November 2009

Question 1. Three types of moisture are associated with the sugar crystal.
(a) Name them and briefly explain which form of moisture is critical to the storage of the
sugar.
(b) Explain briefly the stages of your process in sugar manufacture which would determine
the final % moisture of the sugar produced.
(c) Describe briefly the formula used to evaluate the risk of deterioration of the sugar high
moisture content?
Question 2. Describe the changes that occur to white sugar if bagged hot ( ~ 40 OC) in
polypropylene lined bags and stored in a dry and hot condition relative humidity of air is 50 % –
65 % and air temperature is 35 OC – 40 OC).
Question 3.
(a) What does HACCP stands for?
(b) Why is HACCP important to any sector of the food chain?
(c) Describe briefly the HACCP concept?

(d) Prior to a HACCP study along your manufacturing process, you are required to organize
for good manufacturing practice (GMPs) which are also called Pre-requisite Programmes
(PRPs). Two of such programmes are:
(1) To consider the lay out of the promises including the work places and employee
facilities.
(2) To organize and manage the purchase of the chemicals and packaging.
List six other programmes or practices you have to organize prior to your HACCP study.

Question 4.
(a) Name the analyses involved and explain why points are allocated to only those three
analyses of refined sugar EEC Grade II?
(b) What are the effects of high ash content of raw sugar on the refining process?
(c) List the precautions taken when performing the analyses of conductivity ash content of
raw sugar.
Question 5.
(a) List the physical, chemical and microbiological changes that are noted due to bad storage
of sugar.
(b) Describe one chemical, one physical and one microbiological change.
(c) What do you understand by ERH?

Sugar Qulity

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Module 12: Sugar – Quality and Storage

Sugar- Quality and Storage

Sugar Engineering and Manufacturing Training Team 1

Sugar Quality Control

 To validate compliance with specification agreed with customers.

A Definition of Quality Control

Sugar Engineering and Manufacturing Training Team 2

A pertinent definition of “QULITY” would be “that combination of engineering and

(1) Initiate action to prevent the occurrence of product nonconformity.

(2) Identify and record any product quality problems.

(3) Initiate, recommend or provide solutions through designated channels.

(4) Verify the implementation of solutions.

What is Sugar Quality?

Sugar quality refers to the following major fields of interest:

(a) The physical quality characteristics.

The physical quality characteristics are the following:

(a) Crystals shape

Sugar Engineering and Manufacturing Training Team 3

(c) Size and distribution

(a) Sucrose Content

The following are the properties of sugar solutions:

The levels of contaminates under control are:

(a) Insoluble Matter

Sugar Engineering and Manufacturing Training Team 4

(e) Non-Metallic Particles – Pan Scales

Criteria Required By Buyers

Control Systems Established By the Sugar Syndicate

Sugar Engineering and Manufacturing Training Team 5

 The keeping quality of the sugar is better at 98 0Z than at 96 0Z.

Sugar Engineering and Manufacturing Training Team 6

Sugar Engineering and Manufacturing Training Team 7

Figure 1: Sampling at Receiving Station

Sugar Engineering and Manufacturing Training Team 8

Figure 2: Sugar Boxes (Traceability)

Sugar Engineering and Manufacturing Training Team 9

Figure 3: Symbols per Sugar Factory (Traceability)

Sugar Engineering and Manufacturing Training Team 10

At the Receiving Station: 54 grammes per tonne of sugar

At the Loading Station: 20 grammes per tonne of sugar

Sugar for Direct Consumption

Sugar Engineering and Manufacturing Training Team 11

At the bagging station of the factory: 5 – 10 grammes per 50 Kg bag

Sugar Engineering and Manufacturing Training Team 12

Manufacture of a ‘Quality’ Sugar

(A) Clarification [For Turbidity],

Three types of moisture are associated with the sugar crystals:

Sugar Engineering and Manufacturing Training Team 13

Sugar Engineering and Manufacturing Training Team 14

 When D I. is less than 33.3 :The sugar is in the safety zone

White Sugar: Moisture % < 0.06 % (Total Moisture)

Figure 6: Dilution Indicator for Raw Sugar

Sugar Engineering and Manufacturing Training Team 15

At Boiling Stage in Vaccum Pans

Sugar Engineering and Manufacturing Training Team 16

Ash, Reducing Sugars and SO2

 Loss of decolourisation in char house

Sugar Engineering and Manufacturing Training Team 17

Odour and Taste

Colour and Tubidity

Sugar Engineering and Manufacturing Training Team 18

Filterability (See Fig. 7)

Influences of Bad Filterability in Refinery