AUTOMATIC JAGGERY PLANT

[EIRI/EDPR/3955] J.C.: 2079

INTRODUCTION

Sugar industry in India is a well-developed industry and one of the largest sectors
after Textile. It provides rural employment opportunities and plays an important
role in the economy. Jiggery is also manufactured from sugarcane juice and is
widely consumed in households, eateries, restaurants, sweetmeat shops etc. In
crude form it has industrial applications also. In rural areas it is also a substitute
for sugar. Sugar is a costly product as compared to jaggery; manufacture of sugar
involves many technicalities and is capital intensive. Production of jaggery is
simple and does not call for large investment.

Jaggery is a typical Indian product and finds wide application in day to day life
food preparations. It is a rural industry and can be produced in sugar cane
growing regions such as Maharashtra, U.P, Gujarat, Bihar etc. Know how has been
developed by CFTRI and is available. Compliance under PFA Act is mandatory.

Jaggery is an unrefined sugar product made in Asia and Africa.It’s sometimes

referred to as a “non-centrifugal sugar,” because it’s not spun during processing to
remove the nutritious molasses.Similar non-centrifugal sugar products exist all
over Asia, Latin America and the Caribbean, although they all have different
names.

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Jaggery or “Gur” or Whole Sugar Is a Pure, Wholesome, Traditional, unrefined,
whole sugar. It contains the natural goodness of minerals and vitamins inherently
present in sugarcane juice & this crowns it as one of the most wholesome and
healthy sugars in the world. Jaggery industry in India is a well-developed industry
and one of the largest after textiles. It provides rural employment opportunities and
plays an important role in Indian economy. Jaggery is also manufacture from
sugarcane juice and is very widely used not only in individual households but also
in many eateries, restaurants, clubs and hostels and it has certain industrial
applications as well.

Manufacture of sugar involves many technical aspects and the capital investment
is also on the higher side. Compared to this, production of jaggery is very simple
and the capital cost is also very limited. Due to its wide applications, the market
for jaggery is continuously growing. Jaggery is made of the products of both
sugarcane and the palm tree. The sugar made from the sap of the date palm is
both more prized and less commonly available outside of the regions where it is
made. The sago palm and coconut palm are also now tapped for producing jaggery
in West Bengal, South India, Pakistan, and Sri Lanka. In Sri Lanka, syrup extracts
from Caryotaurens trees are widely used for jaggery production. This is considered
the best quality jaggery available in local market and is given a higher value than
jaggery coming from other sources.

Maharashtra state is Pioneering State of Sugar industry in India, Where the farmer
grouped forming Co-Operative movement and the technology and thereby the
industry is well established. This resulted in the cane grower getting due price for
his agriculture produce. Review of last few years however depicts a different picture
whereby the grower farmer has to undergo considerable hardships due to
adequate/ improper planning of cane harvesting inefficient process control and
management. This has resulted into uncertainty of the price accrued for the crop.

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 CONTENTS

INTRODUCTION
THESE PRODUCTS INCLUDE:
PROJECT LOCATION
CLIMATE
TRANSPORTATION
AIR
RAIL
ROAD
RAW MATERIAL DETAILS
VARIETIES OF SUGARCANE
TABLE
TABLE -SUGARCANE VARIETIES IN CULTIVATION OR RECOMMENDED
FOR CULTIVATION
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:
ADVANTAGE & BENEFIT
SOME OF THE FOLLOWING ARE HEALTH BENEFIT OF JAGGERY.
LIVER DETOXIFICATION
IMPROVED IMMUNE FUNCTION
VALUE ADDITION IN JIGGERY
COMPOSITION & SPECIFICATION
COMPOSITION OF CANE `GUR' & PALM `GUR'
STORAGE OF JAGGERY:
PROPERTIES AND CHARACTERISTICS OF JAGGERY POWDER
JAGGERY IS BEST ALTERNATIVE OF SUGAR AS IT DIFFERS IN VARIOUS
AREAS SUCH AS
COMPARISON CHART OF NUTRITIVE VALUE OF JAGGERY, KHANDSARI
AND SUGAR
USES & APPLICATION
OTHER USES
B.I.S. SPECIFICATIONS
MARKET SURVEY
UTTAR PRADESH SUGARCANE ACREAGE DOWN BY 1 PERCENT
MAHARASHTRA’S NET CANE AREA HAS GONE UP BY ABOUT 43 PERCENT
TIMELY, ADEQUATE RAINFALL LEADS TO INCREASED SUGARCANE AREA
IN KARNATAKA

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TAMIL NADU SUGARCANE AREA TO REMAIN AT SAME LEVEL
SUGARCANE AREA IN GUJARAT TO INCREASE BY 7 PERCENT
GLOBAL CONSUMPTION OF JAGGERY ON RISE IN 2020
PRICES
PRESENT MANUFACTURERS/SUPPLIERS OF JAGGERY
DIFFERENT FORM OF JIGGERY AND THEIR PRODUCTION METHOD
SOLID JAGGERY (CUBE SHAPE)
LIQUID JAGGERY
GRANULAR OR POWDER JAGGERY
MANUFACTURING PROCESS OF SOLID JIGGERY
MAIN STEPS IN JAGGERY MAKING PROCESS:
EXTRACTION OF JUICE:
CLARIFICATION OF JUICE:
CONCENTRATION OF JUICE:
PROCESS FLOWSHEET OF GUR/JAGGERY MANUFACTURING
PROCESS FLOWCHART FROM CLIENT
MECHANICAL LAYOUT 1
MECHANICAL LAYOUT-2
MECHANICAL LAYOUT-3
MECHANICAL LAYOUT-04
LAYOUT-05
MANUFACTURING PROCESS OF JAGGERY POWDER
EXTRACTION OF JUICE FROM SUGARCANE:-
BOILING OF JUICE:-
PURIFICATION OF JUICE:-
CONCENTRATION OF JUICE:-
CRYSTALLIZATION:-
PACKAGING:-
PROCESS FLOW DIAGRAM OF JAGGERY POWDER
MACHINERY SUPPLIERS
RAW MATERIAL SUPPLIERS
MACHINERY PHOTOGRAPHS
RAW MATERIAL PHOTOGRAPHS
PRODUCT PHOTOGRAPHS

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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

Plant Capacity 10 Ton/Day

Land & Building (3000 sq.mt.) Rs. 2.20 Cr
Plant & Machinery Rs. 2.84 Cr
Working Capital for 1 Month Rs. 50 Lac
Total Capital Investment Rs. 5.96 Cr
Rate of Return 27%
Break Even Point 58%

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