SUGARCANE PLANTATION AND ORGANIC

JAGGERY PLANT (100 TCD)

[EIRI/EDPR/3739] J.C.: 1831INR,1832US$

INTRODUCTION

Sugarcane (Saccharum officinarum) is the principal source of sugar production

and contributes to nearly 95% of the global sugar pool. The plant is native to
India. Besides India, which is the major producer of sugarcane and sugar in the
world, sugarcane is also grown also in Brazil, Cuba, Pakistan, Thailand,
Philippines, Argentina, Colombia, Indonesia and South Africa.

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 are 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.

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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
soil in India are classified into three major group viz alluvial, black and mud soil.

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Jaggery or gur is a specific type of sugar popular in India. It is normally
manufactured from either sugar cane or date palms, but recent trends in its
manufacture have resulted in jaggery made from the sap of coconut and sago
palms. While jaggery is useful in cooking, it is also an ancient part of Ayurvedic
medicine and has spiritual significance in India too.

This type of sugar is considered unrefined and is produced by boiling raw sugar
cane or palm juice in iron pans. It is then formed into blocks. Because it does not
go through additional processing, it does retain some of the natural vitamins and
minerals of the ingredients used, though boiling the juice does deplete some of
these. Many people do consider jaggery healthier than more refined sugar since it
is less stripped of natural nutrients.

In traditional Indian medicine, called Ayurveda, this sugar has several purposes.
It may be prescribed for use for people with sore throats. It has some use in the
treatment of bronchial or lung infections, and in fact in research has shown to
possibly offset some of the lung damage caused by silicosis, a disease of the lungs
that occurs when people are exposed for a long time to silica powder.

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When sugar from sugarcane was introduced cannot be definitely stated, but
brown sugar or gur (Jaggery) was the first known form of sugar manufactured
from sugarcane as well as from wild date palm (phonnix sulvestris), palmyra palm
(Borassus flapellifar), toddy palm (Caryota urens) and other palms that contain
12-14% sugar in their sap tapped for the purpose. Fermented toddy sap yields a
beverage commonly used in India. An about one lakh tonne of brown sugar or gur
is still produced from palm sap in India. Gur has always been and is still being
recommended in Ayurvedic Medicinal system for nutritive quality and as a much
safer form of sugar than pure white (centrifugal) sugar for regular consumption. In
the Indian sub-continent the gur is commonly used in preference to molasses free
white sugar for many sweet prepartions because of its specific taste. In fact, the
findings of a British scientist, John Yadkin, have shown that heavy consumption
of highly clarified white sugar or pure sucrose obtained from the modern sugar
mills is largely responsible for hyperinsinulism and coronary heat diseases in
human beings. Gur is safe from this aspect.

Gur (Jaggery) production in India is more than 1.5 times of that of white sugar
production (a decade back it was double). Nearly half of the total cane production
is utilised for gur produced by open pan method; its production by vacuum
process has not been yet successful. Gur production is 10-12% from cane in open
pan and about 15% in vacuum process. Even at higher price than white sugar the
gur (that contains 70-75% sucrose, 14-16% invert sugars, 5% moisture, and 5%
other ash creating material) is still preferred for many special dishes and also in
daily use. Besides Indian many countries of Central Americal (Costa Rica, Mexico),
sough Americal (Brazil, Columbia) and Asia (including Pakistan, Indonesia, Japan)
use this kind of non-crystalline sugar called variously (Repodura, Chancaca,
Pancoa, Mascasvado, Popiton, Jaggery, etc.) Asian countries are the largest
consumers (80-) of these forms of sugar.

Gur (Gul, gud, vellum, bella), is the product obtained on concentrating sugarcane
juice with or without prior purification, into a solid or semi-solid state. It is
produced almost throughout India and forms an important item of the Indian diet.
The manufacture of gur holds a very important place in the rural economy of the
country. Uttar Pradesh accounts for c. 45 percent of the total production of gur
while Punjab and Haryana account for some 10 percent. The States of
Maharashtra, Andhra Pradesh, Mysore and Tamil Nadu together account for some
30 percent of the total production of gur in the country.

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 CONTENTS

INTRODUCTION
CHARACTERISTICS OF SUGAR CANE:
AREA AND PRODUCTION OF SUGAR CANE:
CLIMATE & SEASON:
IMPORTANCE OF JAGGERY
NUTRITIONAL VALUE AND USES OF JAGGERY
COMPOSITION OF GUR:-
TABLE COMPOSITION OF CANE `GUR' & PALM `GUR'
PROPERTIES
THE REQUIREMENT OF FRESH CRUSHER JUICE
TABLE-JUICE CONSTITUENTS OF SOME VARIETIES OF SUGARCANE
ANALYSIS OF JUICE OF MATURE (GOOD) SUGARCANE
COMPOSITION OF SUGAR CANE JUICE
SOLUBLE SOLIDS OF SUGAR CANE JUICE IS CLASSIFIED AS FOLLOW:
USES & APPLICATION
STORAGE OF GUR:-
GRADING OF GUR :-
USES AND APPLICATION OF JAGGERY POWDER
JAGGERY POWDER MEDICINAL BENEFITS
B.I.S. SPECIFICATIONS
COMPOSITION & SPECIFICATION OF JAGGERY POWDER
JAGGERY IS BEST ALTERNATIVE OF SUGAR AS IT DIFFERS IN
VARIOUS AREAS SUCH AS
SPECIFICATIONS OF JAGGERY
MARKET SURVEY
MAJOR IMPORTING COUNTRIES OF JAGGERY & CONFECTIONERY
JAGGERY & CONFECTIONERY EXPORTS FROM INDIA
EXPORT DATA OF JAGGERY
TABLE: SUGARCANE VARIETIES IN CULTIVATION OR RECOMMENDED
FOR CULTIVATION
MEDICINAL BENEFITS OF JAGGERY
ORGANIC SUGARCANE PLANTATION
CLIMATE AND SOIL REQUIREMENT
CROPPING SEASON AND DURATION
PRE-CULTIVATION PRACTICES
IMPORTANT VARIETIES
SEED-SETT/BUD SELECTION FOR PLANTING
SEED-SETT TREATMENT
PREPARATION OF NURSERY

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A) EMPTY BAG
B) SOIL-FILLED BAG WITH CUTTING
PLANTING PATTERN
PATTI (TWIN ROW) METHOD: 8 FT PATTA METHOD
10 FT PATTA METHOD
MIXED CROPPING METHOD AS PER SOWING SEASON: ADSALI
PRE-SEASONAL
SURU
TRANSPLANTATION OF NURSERY GROWN SEEDLINGS
RATOONING
WEEDS
MANAGING SOIL FERTILITY
WATER REQUIREMENTS
WATER CONSERVATION
PLANT PROTECTION
PROBLEM INSECTS
YIELD
MANUFACTURING PROCESS OF JAGGERY FROM SUGARCANE (ORGANIC)
FLOW CHART FOR JAGGERY MAKING PROCESS:
MAIN STEPS IN JAGGERY MAKING PROCESS:
EXTRACTION OF JUICE:
CLARIFICATION OF JUICE:
CONCENTRATION OF JUICE:
STORAGE OF JAGGERY:
DETAILS OF SUGARCANE PLANTATION
PREPARATORY CULTIVATION:
SEED RATE, TIME OF PLANTING AND SPACING:
HOEING AND WEED CONTROL:
IRRIGATION:
LODGING:
PROCESS FLOW SHEET
MANUFACTURING PROCESS OF SOLID JAGGERY
PROCUREMENT AND SORTING:-
WASHING AND CLEANING:-
JUICE EXTRACTION:-
CLARIFICATION :-
CONCENTRATION:-
COOLING AND PACKAGING:-
MANUFACTURING PROCESS OF JAGGERY POWDER
EXTRACTION OF JUICE FROM SUGARCANE:-
BOILING OF JUICE:-
PURIFICATION OF JUICE:-
CONCENTRATION OF JUICE:-
CRYSTALLIZATION:-

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PACKAGING:-
PROCESS FLOW DIAGRAM OF JAGGERY POWDER
BLOCK DIAGRAM OF JAGGERY POWDER PLANT
METHOD OF MANUFACTURING DIFFERENT TYPE OF JAGGERY
SOLID JAGGERY (CUBE SHAPE)
LIQUID JAGGERY
GRANULAR JAGGERY
VALUE ADDITION IN JAGGERY
UNIT OPERATION OF JAGGERY MANUFACTURE
SOLID JAGGERY
LIQUID JAGGERY
GRANULAR JAGGERY
VERTICAL THREE ROLLER CRUSHER
HORIZONTAL THREE ROLLER CRUSHER
JUICE BOILING IN OPEN PAN
LIME ADDITION FOR JUICE CLARIFICATION
TRANSFERRING HOT THICK SYRUP INTO WOODEN MOULDS
SHAPES & SIZES OF JAGGERY
STIRRING OF HOT THICK SYRUP FOR UNIFORM COOLING
HOT THICK SYRUP TRANSFERRED TO TRAY FOR SCRAPPING
SCRAPPING INTO GRANULES WITH WOODEN SCRAPPER
DRYING OF GRANULAR JAGGERY
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
SUPPLIERS OF PLANT AND MACHINERIES

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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)

COST ESTIMATION

Land & Building (15000 sq.mt.) Rs. 2.71 Cr

Plant & Machinery Rs. 4.56 Cr
Working Capital for 3 Months Rs. 1.81 Cr
Total Capital Investment Rs. 9.53 Cr
Rate of Return 23%
Break Even Point 70%

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