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International Journal of Applied Agricultural Research

ISSN 0973-2683 Volume 4 Number 3 (2009) pp. 203–214


© Research India Publications
http://www.ripublication.com/ijaar.htm

Prospects of Jaggery Industry in Karnataka


- A Case Study

G.B. Jayamala, M. Chowde Gowda, H.N. Ramya, M. Shankar


and P.N. Krishnamma

Dept. of Agril. Engineering, University of Agricultural Sciences,


Bangalore 560 065

Karnataka has been playing a key role in sugar industry since 1950s with rapid
expansion during 1990s and onwards. Sugar cane cultivation on 0.16 million hectares
during 1980-81 has increased to 0.48 million hectares during 2006-07 i.e., over three
fold increase in two and a half decades. Cane yield per hectare was 66 tones during
1979-80 has increased to 105 tones during 2006-07 i.e., 59 per cent increase. During
1980-81 number of sugar factories were only 23 has increased to 63 i.e., nearly three
fold increase. Similarly in respect of sugar recovery percent there is a spectacular
increase by 0.42 per cent from 1980-81[1]. Karnataka is one of the major sugarcane
growing states in the country producing 48.96 million tones of cane and ranking fifth
in area as well in production and stands second in the productivity. The recovery
percentage is about 10.79 per cent. The major sugarcane growing districts in
Karnataka are Belgaum (43 %), Bagalkot (16 %), Bijapur (10 %), Mandya (5 %) and
Mysore (4 %). There are 63 sugar industries in Karnataka, out of which two industries
are under government sector, 21 are managed by co-operatives and the remaining 40
are owned by private management. Out of 63 sugar industries, 33 sugar industries are
located in northern three districts of Karnataka viz. 19 in Belgaum, 11 in Bagalkot and
3 in Bijapur. The data in Table 1 indicates that up to the year 2000 there were only 34
sugar mills in Karnataka crushing cane and from 2000 onwards 15 new mills have
commissioned and other 14 are in the pipeline. It is also clear that no sugar mills exist
before 1930 in Karnataka. The entire cane grown prior to 1930 was used for making
jiggery. During last two decades (Table 2), the scenario of sugarcane cultivation and
processing in Karnataka has changed prominently as compared to the India as a
whole. Some of the prize winning farmers in Bagalkot and Belgaum districts of
Karnataka have harvested up to 360 tones/ha. The state has large potential to increase
the productivity of cane as well as sugar recovery level. The above facts show that
technology and do-how exist in Karnataka to achieve a much higher level of
productivity and quality production.
204 G.B. Jayamala et al

Table 1: Sugar mills established during different periods in Karnataka.

Sl.No. Year of establishment No. of sugar mills


1 1930-40 2
2 1941-50 1
3 1951-60 1
4 1961-70 3
5 4971-80 13
6 1981-90 6
7 1991-2000 8
8 2000-2007 15+14*
Total number of sugar factories 63
*14 Sugar factories are likely to commence crushing soon

Table 2: Progress of sugarcane industries in India and Karnataka over last two and a
half decades [1].

SL. Particulars 1980-81 2006-07 % increase


No over 1980-81
1 No. of sugar mills - India 314 553 76
2 No. of sugar mills - Karnataka 23 63 174
3 Area under sugarcane in ha-India 26,48,000 43,61,000 65
4 Area under sugarcane in ha- Karnataka 1,56,000 4,80,000 208
5 Cane yield tone/ha - India 48.0 64.6 35
6 Cane yield tone/ha - Karnataka 66.0 105.0 59
7 Sugar recovery percent -India 9.98 10.36 0.38
8 Sugar recovery percent - Karnataka 10.37 10.79 0.42

Need for establishment of jaggery industry in Karnataka


Jaggery, which is still dominating in the preparation of food items in the rural area, is
of ancient origin. Jaggery making is a rural based agro-industry located at the
convenient place of the farmers and helping them to avoid the harassment that the
farmers has to undergo in transporting cane to the sugar mills, cost of transportation
involved and delay in payments made by the sugar mills [2] . According to the
estimates made two third of the sweeteners required in the food habits of rural
populace is met by jaggery because of the facts that it is not only a chief sources of
sweetening in the food habits of rural mass but has considerable linkage in the rural
economy. By 2020 the Indian population would be around 1360 million. Considering
an average of 40 kg of sweeteners consumption per head per year, the country would
produce 54 million tones of sweetener to meet the demand, of which over 40 per cent
is met by jaggery alone. This industry requires very less capital investment for
establishment and operation and does not require any sophisticated machinery and
Prospects of Jaggery Industry in Karnataka 205

equipment as compared to sugar industry and hence, production of jaggery is within


the reach of sugarcane farmers or a small entrepreneur [3]. Further, it is estimated that
crushing sugarcane for jaggery, fetches three times more profitable than supplying to
sugar mills [4]. Over 55-60 per cent of the sugarcane produced in Karnataka is crushed
for jaggery production. Apart from creating an employment opportunity to the rural
people the jaggery industry provides highly nutritious product at lower cost to the
rural poor [5 & 6]. It is therefore, imperative to establish this industry in the state by
introducing modern equipment and technology; (i) to strengthen the economic status
of the rural community, (ii) to encourage decentralized production of jaggery with
available locally made equipment and machinery, (iii) to encourage the farmer to
harvest the cane with his convenient avoiding transportation cost of cane to the sugar
mill and (iv) to create ready market in the neighborhood. Apart from this there will be
flexibility in shifting jaggery production into value added sweeteners like, khandsari
(brown sugar), rab (massecuite), liquid jaggery, powdered jaggery etc. which might
be more advantages to the jaggery producers.

Choice of Jaggery
Production and consumption of sugar has increased enormously in the world. The
average consumption of sugar per capita differs from country to country. The
wealthiest countries like U.K., U.S.A., Canada, Sweden and Australia consume an
average of about 50 kg per capita of sugar a year, while the under developed countries
like India, Pakistan and China consume an average of 15 kg or less per capita. Much
of the sugar in the diets of the high-consuming countries is from manufactured foods
like confectionery, soft drinks and bakery products. Dietary sugar is a mixed blessing
because it makes the food more attractive and appetizing, but excess consumption
leads to sever health problems of human beings. Because of this, more attention is
paying towards the development of alternate sweeteners from sugarcane. Jaggery is
considered to be the best alternative sweetener as we could see from Table 3 that it
has a good source of minerals like calcium, iron and phosphorus and other medicinal
properties as compared to sugar which serves the purpose of only sweetening agent.
Production of jaggery is cheap and simple as compared to sugar. It can be produced at
farm level with semiskilled workers without any complicated machineries and
equipment. The phenomenal expansion of sugar industry in Karnataka had little
impact on the jaggery industry. The jaggery industry in Karnataka continues to be an
industry of grate importance and relevance. There is a considerable demand for
jaggery in the market for local consumption and also for export, hence option for
producing good quality jaggery with advanced practices is imminent which enhances
the consumption rate, fetch higher market and improve the economy of the
cultivators, jaggery makers and traders [7] .
206 G.B. Jayamala et al

Table 3: Composition in sugar and jaggery made from sugarcane [8].

Item Moisture Sucrose Reducing Protein Fat Calcium Phosphorus Iron Total Energy
(g) (g) Sugar (g) (g) (g) (mg) (mg) (mg) minerals kcl
(g)
Sugar 0.40 99.50 --- --- --- --- --- --- 0.05 398
Jagger 3-10 60-85 5-15 0.40 0.10 8.00 4.00 11.4 0.6-1.0 383
y 0

Option of processing sugarcane for jaggery


Comparative analysis made on processing of cane for sugar and jaggery (Table 4)
shows that crushing of sugarcane for jaggery is more advantageous than production of
crystal sugar. It is clear from the data that more sucrose is recovered in sugar industry
due to higher juice extraction but certain minerals which are considered to be
important for health and nutrition point of view are lost. In case of jaggery making
sucrose recovery relatively low due to lower juice extraction but it is supplemented by
recovery of reducing sugars and minerals which make it more nutritious and health
friendly.

Table 4: Loss of cane constituents during processing of jaggery and sugar [8].

Constituents Approximate % Percent loss during processing


of cane of cane weight Jaggery Sugar
Sucrose 8 -13 3-4 0.7 - 1.9
Reducing sugar 0.3 - 2.5 0.1 - 1.0 0.3 - 2.5
Minerals (Ca, Mg, Fe, Mn, P) 0.1 - 0.2 0.0 0.1 - 0.2
Proteins and Fats 0.1 - 0.15 0.2 - 0.3 0.1- 0.15

Over view of sugarcane processing industries in Karnataka


Jaggery making is a vast cottage industry under the decentralized sector in Karnataka.
Most of the jaggery units in state are operated by the farmers for crushing their own
crop. Some of the jaggery units operate purely on commercial basis by purchasing
cane from the farmers. Jaggery units in Karnataka supply over 40 per cent demand of
the sweetener in the state besides providing employment to the rural people. Despite
its vast magnitude, the jaggery industry has serious drawbacks in terms of poor
quality production, lack of standardization in quality production, wasteful utilization
of heat energy, excessive loss of product due to improper processing and poor
hygienic conditions of the units, improper packing and storage.

Jaggery Processing
The jaggery units operates for 5-6 months in a year engaging skilled /semiskilled man
power available in the locality on contract basis with some experience on jaggery
Prospects of Jaggery Industry in Karnataka 207

processing. The major advantage of establishing jaggery unit by the farmer is timely
harvesting and crushing of matured sugarcane with a limited haulage is under his
control, there by he can get quality product with higher yield. Figure 1 depicts the unit
operations of typical jaggery processing industry.

Figure 1: Flow chart showing typical jaggery processing operation in Karnataka.


208 G.B. Jayamala et al

(i) Juice extraction


The extraction of juice should be taken as far as possible from fresh cane and in any
case not later than 24 hours after harvest to prevent inversion of sucrose into glucose
and fructose and formation of other harmful substances. The juice should be collected
after straining through a fine sieve or muslin cloth to remove suspended impurities
and should be boiled as quickly as possible (within 8-10 hrs) to avoid bio-
deterioration losses. Jaggery manufacturing in Karnataka is done by farmers
themselves for their own consumption as well as for marketing using three roller
horizontal type power crushers and 2 or 3 open pan juice boiling furnace systems. It is
observed that in the existing cane crushing system about 50-55 per cent juice is
extracted and the remaining 25-30 per cent is remain with bagasse due to poor
extraction and will be burnt with bagasse as fuel. Juice extraction in jaggery industries
is done by dry crushing process where whole cane is fed in to crusher without
saturation. The crusher should be capable of giving at least 65 to 70 per cent juice
extraction otherwise there will be loss of sugar in the bagasse [9&10]. The studies made
at various institutions suggested that addition of fourth roller to the existing crusher
may improve juice extraction efficiency. As a result four roller horizontal type power
driven crusher has been developed [11&12] it gave up to 64 per cent juice extraction at
3.7 mm roller gap and at 3.3 m / min. roller speed [13] . On the contrary, the study of
Yadav [14] indicated reduction in 3-4 per cent crushing efficiency by introducing
power operated four rollers horizontal crusher due to higher operating speed of
rollers.

(ii) Juice boiling


In jaggery industries, boiling of cane juice is the second important operation.
Conventionally jaggery is made by boiling sugarcane juice in the underground
furnace constructed using locally available materials. Most of the jaggery industries in
Karnataka continued to use the conventional furnace system with an expansion of two
or three open pans fitted over it. The thermal efficiency of conventional furnaces is
very poor. Single pan furnaces for jaggery making were familiar in 1940’s and later in
1960’s double pan furnaces which were superior over single pan furnaces in
consuming less fuel energy and higher production were introduced. Later in the year
2000 the triple pan furnaces which were improved version of double pan furnace were
introduced in the state [15]. During last two decades considerable work has been done
by various institutions to improve the thermal efficiency of existing juice boiling
furnaces [16,8 &17]. These improved designs drastically reduced fuel combustion
(bagasse), human labour, drudgery and inconvenience otherwise involved in the
traditional furnaces including loading and unloading of cane juice at different stages
of boiling and concentration process. Further, it was observed that the new designs of
furnaces resulted in saving up to 11 per cent fuel (bagasse) and about 20 per cent
increase in jaggery production with reduced chimney smoke [3].
Despite the development of improved furnaces, the whole bagasse available in the
jaggery industry is consumed to concentrate juice and overall heat utilization
efficiency of these improved furnaces is merely 20 per cent which is too low. To
achieve maximum heat utilization efficiency, Mohan Naidu [9] made the following
Prospects of Jaggery Industry in Karnataka 209

suggestions; (i) provide chimney with good draft to escape burnt gases, (ii) provide a
baffle wall in the furnace to prevent escape of heat through the chimney passage, (iii)
use galvanized iron open pans to prevent reaction of iron with the juice constituents
forming dark coloured substances, (iv) construct furnace in such a way that the heat
should spread uniformly throughout the bottom of the open pan and (v) make
provision to remove ash in the furnace periodically to provide proper air flow with
better combustion.

(iii) Juice clarification


The main objective of clarification is to make juice clear and light in colour. It also
helps in preventing charring or overheating during concentration. Jaggery prepared
from clarified juice is light in colour, crystalline in structure, hard, less hygroscopic
and hygienic. Freshly extracted juice is acidic in nature with pH of around 5.2.
Boiling of this juice under acidic condition will invert the sucrose leading to problems
in solidification and development of dark coloured jaggery. Hence before boiling the
juice pH is to be adjusted to 6.8 with the addition of a clear solution of lime (CaOH).
The clarification of juice depends on the composition of juice that affects the quality
of jaggery. Besides sugar, it contains suspended impurities in the form of coarse
particles and colloids, soil particles, wax, fat, protein, gum and other colouring
matters which are extracted from the cane during juice extraction and they remain in
colloidal form [23]. On vigorous boiling, the non-sugars float on the surface of the
boiling juice in the form of scum which is to be removed as and when formed
periodically. When the clear juice starts boiling, any one of the available organic
clarificants such as Deola, Bhendi, Castor, Groundnut, Soybean, Phalsa may be added
to further clarify the syrup and improve the colour of jaggery, storability and
marketability. Chemical clarificants are generally used as a supplement to the
vegetable clarificants to give more luster and brilliance to the jaggery. Most of these
chemical clarificants are polyacrylamide based compounds, while some are ion
exchange resins. These chemical clarificants adversely affect the health of human
beings since traces of chemicals remain in the final product [18]. All these chemicals
(except lime) brighten jaggery initially, but become dull during storage.

(iv) Evaporation and concentration of juice


After the scum is removed, the juice is boiled briskly by gradually raising temperature
of 100 to 105 ºC for an hour or little more for evaporating most of the water content in
it. When the temperature reaches 105 ºC the juice starts frothing. At this time onwards
the fire will be regulated to prevent caramelization and spilling over the sides of the
pan. The temperature of boiling starts raising fast from 105 ºC; during this period the
syrup will be constantly stirred to prevent charring and spilling over the sides of the
pan. At this stage ground nut/ castor/ mustard oil of 20-25 ml is added to prevent
frothing to certain extent and to facilitate easy flow of jaggery from the pan to the
cooling platform. The optimum temperature to reach striking of syrup is between 118
-120 ºC.
210 G.B. Jayamala et al

(v) Cooling and molding of syrup


Cooling and molding process after removal from the evaporation pan influence the
mechanical strength of jaggery [19]. Once the striking point is achieved the pan is
removed from the furnace and the syrup is poured on the cooling platform. Then, this
hot syrup constantly stirred with the help of ladle for aerating and cooling the liquid
syrup which helps in producing a crystalline material. Then this cooled syrup in the
form of semi-solid liquid is poured into wooden / metal molds of required shape and
sizes which are kept moist. This syrup solidifies in the molds and on cooling they are
removed and dried in an open air. In case of making round balls by hand manually,
the semi-solid syrup is cooled well and balls will be prepared with the help hand
gloves.

(vi) Standardization of shape and size of jaggery molds


The size, shape and weight of jaggery moulds vary according to the needs of the
consumers and market demand. In Karnataka pellets, round balls, cubes, cakes and
buckets type of molds weighing between 50 g (pellets) to 30 kg (buckets) are
commonly made. Shape and size of the jaggery molds play an important role in
effective drying and storage, easy handling and packing, minimizing losses during
transportation and distribution, and attracting the consumers. Over sized molds create
problems in handling storage and transportation, while, smaller size molds crumble
resulting into coarse powder. Because of this diversity in the shape and size of jaggery
does not attract for development of standard size molds, however, a standard molding
frame has been developed [20] to produce brick shaped jaggery weighing 125, 250 and
500 g. Patel et al. [21] reported that the smaller size bucket shaped jaggery molds of 1
kg and 2 kg were superior in respect of keeping quality. The brick shaped jaggery has
highest bulk density and less porosity. Both the factors are desirable for better storage
space utilization. Compressive stress of brick shaped jaggery is higher which can
withstand greater stack height during storage and transport. In addition the brick
shaped jaggery can be easily packed, stored and distributed without any loss during
handling and meets the consumer’s acceptance

(vi) Jaggery storage


Production of jaggery is a seasonal and is stored over a fairly long period of 6-8
months. During storage jaggery undergoes various physical, chemical, biological and
microbiological changes depending upon the type of storage and conditions under
which it is stored. Physical changes include colour impairment such as darkening, loss
of texture and change in taste caused by biochemical disintegration of some of the
jaggery constituents and weight loss due to desiccation. Chemical deterioration
includes biochemical changes in the jaggery composition, particularly those
responsible for inversion of sucrose and discolourisation. Damage from insects and
ants in particular, is the most and important form of biological spoilage. Fermentation
and biochemical degradation caused by yeasts and moulds are the usual forms of
microbial deterioration. All these changes in stored jaggery can be minimized through
well designed storage structures and controlling storage conditions provided the
jaggery meets the quality requirements before being stored.
Prospects of Jaggery Industry in Karnataka 211

Over 3 million tones of jaggery are stored annually for consumption during and
after the monsoon in the country. Out of this about 2 million tones is stored at the
domestic level and one million tones on a large scale by traders [8]. It has been
estimated that about 10 per cent loss takes place in quality and quantity during
monsoon which will amount to a loss of over 3,00,000 lakh tones of jaggery in
storage alone. At normal ambient temperature, good quality jaggery can withstand
atmospheric relative humidity up to 65 per cent and poor quality jaggery up to 50 per
cent. Thus, every kind of jaggery can be safely stored up to 50 per cent R.H. Locally
available materials like cane trash, furnace ash, palm leaves mat, rice husk and
groundnut husk have been used as storage blankets for storing of jaggery in jaggery
making units, trade centers and retailers in Karnataka. Though most of these blankets
impart partial protection to jaggery against moisture during storage but are not
hygienic. Baboo and Solomon [8] suggested improved practices for safe storage of
jaggery: (i) Moisture content of jaggery should be less than 6 per cent before storage,
(ii) Fresh jaggery should not be covered with polythene sheet or air tight material and
sufficient ventilation should be provided, (iii) Storage of jaggery in polythene lined
gunny bags found to be safe and (iv) Use of chemical clarificants, inferior, premature
or over mature cane makes the jaggery unfit for storage particularly during monsoon.
Under the prevailing temperature conditions in the country, loss of jaggery colour
and flavor is natural and cannot be prevented even under proper storage conditions.
Experiments conducted at various institutions in the country indicate that cold storage
is most suited as compared to ordinary storage of jaggery. However, for minimizing
deterioration in quality during cold storage, wrapping of jaggery (palm leaves mat or
alkathene + hessian cloth) is necessary. . In cold storage jaggery can be stored as fresh
for a year or so. Considering the amount of jaggery production and its ever-increasing
demand within the country and export market, there is a need to develop and expand
cold storage technology and warehouse network for long term storage of jaggery

(vii) Grading of jaggery


The problem of grading jaggery is indeed difficult because of the wide variation in its
quality, its complex chemical composition and the marked deterioration it undergoes
during storage. Presently there is no recommended grading criterion in force, which
could be used to classify quality of jaggery in the trade centers of Karnataka.
Sometimes liquefied jaggery of obnoxious and unpleasant odor / smell is consumed
by economically poor people, as there are no standards to classify good and poor
quality jaggery. Quality parameters of jaggery in terms of its colour, texture and taste
varies from place to place and its end use as to whether to be used for table or for
cooking purpose. Some people prefer to have jaggery with light golden yellow colour
and medium soft texture and sweet in taste, while others prefer to have brown or
brownish yellow colour with crystalline structure Baboo and Solomon [22] reported
grading of jaggery based on NR values (Table 5). According BIS specifications
jaggery should be prepared in the form of solid molds which shell be of firm
consistency. It shall be golden yellow to light brown in colour, free from dirt and
other extraneous matter and substances deleterious to health. Shell be sweet to taste
212 G.B. Jayamala et al

and shall not possess sour, salty or any other objectionable taste. The jaggery shall
also comply with requirements given in Table 6.

Table 5: NR Values for grading of jaggery [22].

NR Values Grade Quality


> 65 A1 Excellent
60-65 A2 Good
45-60 B Medium
< 45 C Poor

Table 6: Standard requirement for sugarcane jaggery.

Sl No Characteristic Requirements Methods of test


Grade-1 Grade-2
1 Sucrose (db) % by mass, Min. 80 70 IS 1152:1976
2 Reducing sugars (db) % by 10 20 IS 5982:1970
mass, Max.
3 Moisture % by mass, Max. 5 7 IS 5982:1970
4 Water soluble matter (db) % by 1.5 2.0 IS 5982:1970
mass, Max.
5 Sulphated ash (db) % by mass, 3.5 5.0 IS 1679:1970
Max.
6 Sulphur dioxide (db) ppm, Max. 50 50 IS 5982:1970
7 Ash insoluble in dilute HCI (db) 0.3 0.3 IS 12923:1990
% by mass, Max.

(viii) Diversification of jaggery production


Shifting of jaggery production into value added product by inclusion of nutritive
substances like puffed rice, gram, various kinds of nuts, popped grain amaranth, etc.,
as source of micro-nutrients and energy will not only increase demand for this kind of
jaggery but also will be a cheap source of nutrition to the poor and malnourished
children. In Karnataka as well as in several parts of the country, the farmers prepare
jaggery spiced with ginger, elachi and such other desirable spices, especially for their
home consumption, since some of these spices and condiments have nutritional
values; such product will be a value added food and have very high market. Jaggery is
also made in the forms other than solid molds such as rab, kakavi (liquid jaggery) and
khandsari (powdered jaggery).
Technology has been developed for making kakavi on commercial scale. An
advantage of this technology is that jaggery storage problem is alleviated. Kakavi is
liked for table purposes in western India. Rab is a semi-solid liquid form of jaggery.
The crystals are gradually developed upon storage. The rab crystals are more
Prospects of Jaggery Industry in Karnataka 213

nutritious than mill sugar as it contains, iron, phosphorus and calcium. The biggest
advantageous of making rab is that it can be made in any type of sugarcane
particularly when jaggery does not set well. Khandsari made from jaggery in the form
of coarse powder is brownish in colour. It is highly nutritious and facilitates easy
drying, handling, storage, transport and distribution.

(ix) Organic jaggery


Increasing consciousness about the health hazard caused by the excessive use of agro-
chemicals in modern agriculture has brought about a major shift in consumer
preference towards safe and quality food. As a result, the demand for organic food is
growing at an increased rate, especially in the developed countries. In Karnataka,
there is a shift towards organic food by higher income group of consumers. Therefore,
the health conscious consumers prefer the organic jaggery traditionally manufactured
in the villages since time immemorial. The processing techniques of organic jaggery
are as old as our culture. An account of its nutritive content, keeping quality and
assured market growing of sugarcane only with organics and preparation of jaggery
with organic clarificants assumes importance in order to produce quality jaggery as
there is a growing demand for organic jaggery with in the state and in the export
market.

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