Manufacturing process

(a) Cutter

• The cutter consists of knives on a cylindrical shaft

which rotate at a velocity of 400 to 500 rpm.

• The knives cut the canes into small pieces.

(b) Crusher

• Canes are shredded here.

• It consists of two rollers rotating in opposite direction
(c) Series of Pressure mills

• Crushed canes are passed through four pressure

mills to extract juice.

• About 85-90% of juice present in cane is extracted.

• Bagasses are produced as byproduct.

 (d) Clarifier

• In general two methods of clarification are available for the

manufacture of white sugar, namely, Sulfitation process and
Carbonation process.
• Sugar cane juice has a pH of about 4.0 to 4.5 which is quite acidic.
• Milk of lime is added to the cane juice to adjust its pH to 7.
• The juice is then heated to a temperature above its boiling point.
The superheated juice is then allowed to flash to its saturation
temperature: this process precipitates impurities which get held
up in the calcium carbonate crystals.
• The flashed juice is then transferred to a clarification tank which
allows the suspended solids to settle.
• The supernatant, known as clear juice is drawn off of the clarifier
and sent to the evaporators.
(e) Rotary filter
• The underflow mud from the bottom of thickener is passed to a
continuous rotary filter press to recover sugar solution.
• This sugar solution if it is clear, is passed to multi effect
evaporator or otherwise recycled back to clarifier.

(f) Multi effect evaporator

• Here juice is concentrated from 80-85% H2O to 40% H2O to make
juice ready for crystallization.

(g)Crystallizer
• The clarified concentrated sugar solution comes to crystallizer.
• The sugar solution is further boiled in vacuum pans at vapour
temperature of 57˚C until fine cloud of crystals is seen.
• Crystallization is completed in vacuum pan unit.
(h) Centrifuge
• The mixture of crystals and syrup is called masscuite.
• The masscuite from crystallizer is centrifuged in basket type
centrifuge to remove mother liquor (molasses) which is a byproduct.
• The high grade sugar crystals are obtained here.
• The centrifuge speed is maintained at 800 to 1000 rpm.
Process flow sheet
CHARACTERISTICS OF WASTE.
TREATMENT PROCESS
 Anaerobic treatment using both digesters and
lagoons have found to be more economical and
efficient than conventional activated sludge
process.
 Where sufficient land is available, a two stage
biological treatment , with anaerobic lagoons
followed by aerobic waste stabilization ponds is
recommended.
 The mill effluent is pretreated primarily in bar
screens and grease trap.
 The effluent is then sent to the equalizing cum
first digestion pond having a detention period of
one day.
 It is then taken to the aerobic lagoons where
B.O.D loading of 0.23 to 0.32 kg/m3/day and
detention period of 7 days is provided.
 It is then sent to the waste stabilization pond
having detention period of 12 days and finally the
treated effluent is discharged into the stream.
 Sugarcane processing also creates effluents that flow
into water and damage important ecological area
 The massive quantities of plant matter and sludge
washed from mills decompose in freshwater bodies,
absorbing all the available oxygen and leading to
massive fish kills.
 It also gives offensive odours and turns the stream
water to black.
BY PRODUCT RECOVERY
The byproducts of cane industry are as follows.
 Molasses

 Bagasse

 Filter mud.
1. MOLASSES
 It is a dark, sweet syrupy byproduct made during
the extraction of sugars from sugarcane.
 molasses are usually of three types –light
molasses ,dark molasses and black strap
molasses.
 Black strap molasses has high concentrations of
minerals and vitamins and are used in
distilleries.
 The main products of molasses fermentation are
rum, ethyl alcohol, acetic acid , citric acid, yeast .
2) BAGASSE
 It is the fibrous residue of the cane stalk left after
crushing and extraction of the juice.
 The generation of electricity from bagasse is the
easiest and best utilization of this byproduct.
 Good quality wrapping and magazine paper can
be produced with high percentage of bagasse
3.FILTER MUDS
 The precipitated impurities contained in the cane
sugar, after removal by filtration ,form a cake of
varying moisture content called filter muds.
 These contains phosphate and nitrogen and as a
result they can be used as fertilizer
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