GANAPATHI SUGAR INDUSTRY LTD

DATE: 27 Feb 2023. BATCH-2

VISIT TO - Sugar factory

ADDRESS:- Ganapathi sugar industries kulbgoor,
Fasalwadi,sangareddy -502294, Telangana state

OBSERVATIONS

The department of Community medicine has organized a visit to the Sugar factory Kulbgoor.
Fasalwadi, Sangareddy.

1) purpose: The purpose of the visit is Study the process of manufacturing Sugar from Sugar
Cane.

2) Schedule : Schedule for the visit as follows

Venue : Ganapati Sugar Industries Ltd kulbgoor, Fasalwadi. Sangareddy

Date: 27/02/2023

Duration: 1:00pm to 3PM

3 ) DETAILS OF THE VISIT: on 27th February 2023 at 1:00pm Students reached at the Sugar
factory at fasalwadi. After reaching. we were Introduced to the working staff
of the Sugary factory, they Explained us about the process of manufacturing Sugar from Sugar
Cane, and then we were taken around to see the process of making sugar from Sugarcane by
Incharges, The Incharge Explained how the Sugarcane is used to make Sugar and Begasse is
used as a biofuel for production of heat, Energy and
Electricity. This plant has a Capacity of 6,000 TCD (tons of
Cane per day) and daily crush about 600 tonnes.

The Complete process of making sugar from Sugarcane takes around 3 to 4hrs (crush sugar
cane ,make sugar& packaging it).
1.Crushing sugarcane and Extract as much juice as possible
3. after making sugar syrup, make mastic 4.Then ,with the help of machines, Convert these
Crystals into Sugar- granules
5.Then,packaging them as per the grading.

This plant has a Capacity of 6,000 TCD and daily crush about 6,000 tonnes, need 16 mega
watts power& two turbines to run this type of plant, one quintal Sugarcane yeild around 11-12
kilos of sugar and apart from Sugar, Sugar mills also can produce many other things like :This
sugar factory have started generatingpower. molasses are used to make Ethanol and Spirit.
sugar cane residue is used in making fuel and paper.
The fresh mud is used in a different ways:
1. organic Compost (or) pesticides 2.Another one is Coal fuel for brick kilns.

Require of machinery 1. Weight Cave machine

2. Cane Carriers
3. Cave kicker 4. Cane leveler
5. Fibrizor
6. milling :Juice heater, juice sulphiter, Treated juice heater ,clacifier, Evaporation
7. Turbine. 8. Boilers
9. pan supply tank 10. Centrifugal machine

process of making sugar from Sugarcane: Sugar Cane from the fields which is Weighted on
weight bridge is unloaded into the feeder table, It is dropped into Cane Carrier and Cane Carrier
Carries the Sugar Cane for further preparation. Firstly, cane is cutting with the help of Cane
kicker and then Cane move on for Levelling next Cane leveler is leveling all the passed Cane
and fibrizor.
prepared Cane passes through the four Conservative mill, which Consist of 3 cylindrical roller
and 5 mills are driven by Powerful 1200DC motors.
1)Juice extraction process:
The Sugar Cane Juice Extracted from the 1st mill and 2nd mill is collected together at one
place and dropped into bottom tank which is uplifted to store tank later. Hot water is added at
the discharge of 4th mill for Extracting maximum sugar Juice from the Bagasse.
Final discharge of Bagasse from 5th mill is Carried to boiler through rack Elevator then,
Bagasse is stored to the backyard of mill and using boiler to steam generate and Excess
bagasse is used later during mill stoppage. Steam generated from the Boiler is sent Set after
while and generated power distributed to the mills through pannel, Surplus power is Exported.
2)Juice heating process:
Extracted juice mixed with water is Sent to Boiling house and juice is heated in juice heater at
70°℃ in order to bleach and maintain pH of the juice, it is treated with the milk of lime and
Sulphur dioxide.
The treated juice is further heated 105°C. Then, the Juice goes into the clarifier tank. It takes
around 2hrs to settle Impurities to the bottom of the tank. The Settled mud is pumped to mud
filter where, the mud is filtered from juice and filtered juice is returned to process further while
the fresh mud remains outside.
3)Crystallization process:
The clarifier juice Collected from the Clarifier tank is now Boiled and this brings the
Concentration of sugar Juice from 15 % to 60% .The Juice is Evaporated to syrup stage .The
Syrup is treated with Sulphur dioxide gas Sulphur dioxide is pumped to vaccume tank for
further Concentration and formation of sugar and leads to formation of sugar crystals inside the
vaccume tank, workers regularly check how the sugar is crystalizing.
when the crystals reached its desired Size It will dropped down to the Centrifugal machine.
4)Molasses separation process: The machine is
operated between 1000 to 1200 rpm which draws the molasse to outer shell. Hot water is
Sprayed inside the basket to wash crystals and separate molasse from the basket. It takes to
the Section for reprocess.
Crystals separation process:
The Sugar crystals inside the basket is dropped and then goes to the dryer.
5) Moisture removing process : Hot air is blown into the
dryer to remove moister Content from the sugar crystal. The sugar with the standard size are
carried to storage bin .
6)Sugar bagging process: Finally the sugar is
baged in bags of 50kg. Bagged sugar are carried by belt Conveyors and stocked in godown and
delivered to customers.

Conclusion :Through this visit, we learn about the manufacturing process of refined sugar from
Sugar cane through machinery and Chemicals involved in it. Each & Every byproduct in factory
is recycled and used further. Finally, we Express our
gratitude to the principal, Dr. Venkateshwarlu sir, and the department faculty of Community
medicine, Dr. Surekha madam and Dr. Rambabu sir , for arranging for the visit.