Internship report

Name: Muhammad Ali

Registration No: 2014-GCUF-013171
Submission Date:
 TABLE OF CONTENTS

Sr No Particulars Page No
 Preface I
 Executive Summery II
 Dedication III
 Table of Content IV

1 History 5
2 Objective 8
3 Vision 9
4 Production Process 9
5 Production 10
6 Process of Boiler 11
7 Lab Testing 12
8 Massecuite and molasses analysis: 13
9 Purpose: Results: Variation: 15
10 Beggas pole analysis: 18
11 Syrup and liquor analysis: Results: Purpose 19
12 Special analysis checking: 20
13 Vacuums filter cake analysis: Results: Purpose 21
14 Juice sample analysis: Results: Purpose: 24
15 Juice sample analysis: Variation: 25
16 Baggass sample analysis: Results: Purpose: 26
17 Boiler water analysis: Results: Purpose: 27
18 Baggass moisture analysis: Results: Purpose: 32
19 Baggass moisture analysis: Variation: 33
20 Buying Products 34
21 Quality Control 34
22 Conclusion 41
23 Suggestion 42
 PREFACE
This Project Report has been prepared in partial fulfilment of the
requirement for the Subject: Practical Studies of the program
B.S Food Science in Principals of Production (Sem. VII) in
the academic year 2014-2018.

For the preparing of Project Report, I have work In Darya Khan

Shugar Mills and its roles in development of technology in the
world, Industry & Vision, contribution of Darya Khan Shugar
Mills in the growth of Shugar and its departments like
Production department, services, marketing mix, Customer
relationship .

The Project Report starts with the basic concepts of Shugar

Mills, history of Darya Khan Shugar Mills and also covers the
general information of the Darya Khan Shugar Mills and its
functional departments like Production department, analysis
department, marketing department, human resource department
and financial department.
 The information presented in this Project Report is obtained
from sources like Practical work have perform in Darya Khan

ShugarMills. EXECUTIVE SUMMERY

It is necessary to have practical knowledge before doing any

work because of today’s competitive world. Any organization’s
success depends upon availability of their products and their
services to the customer. So for that the distribution channel is
necessary so it is important to study the distribution channel in
Production department.

To know about the position of the Industry and about the

industry’s structure. The Production department is necessary to
be studied and in it I has added different concepts of Production
and analysis .

I am over whelmed with pleasure while presenting this report

on Darya khan sugar mill. I am presenting here different Process
Objective vision and Results , Variation ,Purposes. In this I am
also presenting the basic information about the Production and
their results and also present different variation. This Industry
has made its progressive curve due to exemplary teamwork in all
departments and it provides the policies to the customers with
many characteristics.

Acknowledgement:
All praises be to Allah who guides us in darkness and help in
difficulties. If ocean turn into ink and all of woods become pens,
even then the praises of Allah almighty cannot be expressed. He,
who created the universe and everything in the universe, nothing
can happen without Allah permission and every one in universe
is answerable to him. Numerous blessing for Holy Prophet
(PBUH), who’s preaching are right pathway for our success in
the both lives.
I am heartily thankful to Mr. Akbar, Mr.Medhi, Mr. Hammad,
and Mr. Shabaz from Quality Department and Mr. Nawaz from
Production Department whose encouragement, guidance and
support from the initial to the final level enabled me to develop
an understanding of my projects at every step during this period.
They gave me full assistance regarding my area of
responsibility. They were very cooperative and willing to help
when I faced any problem & asked for help. There was a very
good learning environment. I will always remember their
Cooperation and support.
Muhammad Ali
551
B.S Food Science & Nutrition
Department of Food Science & Nutrition
G.C.U.F, Layyah Campus
History of Darya Khan Shugar Mill:
Fecto Sugar Mills Limited was the Group’s first Sugar Mill: It was incorporated
as a Public Limited Company and is listed at Karachi, Lahore and Islamabad Stock
Exchanges. The Group and the dedicated efforts of the management along with the
personal interest of the Chairman, Chief Executive, acquired the Project in 1975
and Directors has resulted in tremendous improvement in the results over a very
short period of time.
The Company achieved a turnaround by not only posting profits but also started
declaring dividends consistently. It received Award of Top Companies of 1982 by
The Karachi Stock ExchangeLtd.
The Mill is located in Darya Khan, Distt Bhakkar. It is spread over an area of 200
acres. Initially the production capacity was 20728 tonnes which was later enhanced
through BMR in 1996 to 40800 tonnes.

Objectives:
1. To produce and sell good quality sugar at competitive price
2. To strive for the welfare of farmers, buyers, sellers and staff
3. To conduct all business affairs in an ethical way conforming to laid
down rules
4. To reach higher position in sugar industry and sustain that position.
Vision:
Presently, SSL is implementing several projects aimed at social reform
and providing impetus to cultural and sports activities in the Gokak
region. It has set the goal of achieving a turnover of Rs. 1,000 crore by
2020 and joining the league of prestigious and role model companies.
SSL also has an ingrained objective of spending a part of its net profit
for social welfare, education, health, culture, sports and other socially-
oriented activities

Production process:
There are following step which are include in the production of sugar
mill.

1 Jack system (unloading 8 Scrapper 15 Evaporator body

trolley)
2 Main carrier 9 Screener 16 Pan section
3 Elevator 10 Boiling House 17 Centrifugal machine
4 Feeder 11 Vapor Heate 18 Taloflask
5 Top rolla 12 Juice Tank 19 Refine pan
6 Hydraulic cap 13 Clarified point 20 Refine centrifugal
7 Discharge rolla 14 Clear juice tank 21 Filling

Production:
1. Unloading trolley:
First of all sugar cane trolley enters into the mill and weight it. Then trolley
is unload on the jack system.

2. Main carrier:
In main carrier uni greater are present which cut the sugar cane into small
pieces.
3. Elevator:
These elevators are receiving the sugar cane and send to mill house to no.1
and no.2 mill.
No.1 mill is also called D1 mill and no.2 mill is called D2 mill.
4. Feeder:
In mill house feeder are present which are pushed the sugar cane to extract
the juice.
5. Top rolla:
At this stage water is add to squeeze the further juice.

6. Discharge rolla:
At this stage juice is transferred to tank where scrapers are present which
clean the juice.
7. Screening:
In this section juice is clean from all impurities and transferred to
large tank.
8. Boiling house:
After mill house juice is come into boiling house.

9. Vapors heaters:
In vapors heaters juice is hot and steam is formed. Steam is
transferred to boiler and juice is transferred to primary and secondary heater.
Temperature of primary heater is 55-60kp.
Temperature of secondary heater is 105kp.
Led is also added in juice to clear it and its ph should be 7.4.
10. Vacuum filter:
At this stage juice is clarified by adding the lime. At this
stage mud conveyors are present which remove the mud. Now juice is clear
from all waste materials.

11. Clear juice tank:

After vacuum filter juice is transferred to clear juice tank
and store in it.Two clarification tanks are used in it. Juice lines are separate
and mud lines are separate.
12. Evaporator body:
4-6 evaporator bodies are present in which boiling of
juice or syrup is done. In it circulation flow is 835m3/hours. Temperature
of falling film evaporator (FFE) or evaporator body is 116-125c.
An almost line of juice is 12 inch. Maximum FFE brix is 30-35.In last body
juice is fully ripen.
13. Pan section:
In this section there are seven batch pan are present whish are
named as B1, B2, B3, B4, B5, B6 and B7 batch pan. These seven batch pan
are present at D1 station. D1 batch pan are different from D2 batch pan.
Their pan capacity, condenser capacity, dryers, hoppers are totally different
from D2.
B1 batch pan:
Dia meter of tube= 4
Length of tube = 4ft
Capacity = 35ton
Capacity of condenser = 8ton
Temperature of calendria = 100-105c
Pressure of calendria =0-0.1
Temperature of shell = 65-60c
Heating surface = 350-400
Brix outlet of massecuite = 97-99
Brix inlet syrup = 60-70
To clean the pan adds caustic soda during brushing.
14. Centrifugal machine:
Three centrifugal machines are present in
mill which is named as A1, A2and A3 machine.
A1:Capacity = 10-12ton/hours
Power = 90kw
Rotation = anti-clockwise
A pug mill is used for making the A sugar, a liquor, it contain 8 centrifugal
machine. Liquor passé to taloflask then passes to refine pan and then dryers
and hoppers and then making the bags.
B2:
Capacity = 12-15ton/hours
Power = 75kw
It contain 6 centrifugal machine.AB pug mill contain 2 centrifugal machine.
B3:
 Capacity = 20ton/hours

15. Taloflask:
At this stage liquor comes from centrifugal machine A, B,
and C. At taloflask four chemical are used to clear the liquid and remove the
waste material. The name and function of chemical are;
Lime and phosphoric acid:
They form the layer of mud which is present in
liquor and form raw leakers.
Talo floc:
It provides a shine to raw leakers and forms the fine leakers.
Talo float:
It separates the mud from fine leakers .Mud is float over the leakers.
At this stage flow of liquid is 50m3/hours.
16. Refine pan:
Tis pan is also called D2 pan.
In these pan fine leaker is cook and form crystal of sugar.
There are three types of pan.
One for A sugar.
Second for B sugar.
Third for C sugar.
R1 pan:
Dia of tube is = 4
Length of tube = 1m
Capacity = 60tons
No. of tubes = 800-900
Capacity of condenser = 18tons
Temperature of calendria = 100-110c
Pressure of calendria = 0.5-1kp
R2 pan:
Dia of tube is = 4
Length of tube is = 1cm
No. of tube = 800-900
Capacity = 60tons
Pressure of shell vapors = 700- 760mm/hg
Temperature of calendria = 100-110c
R3 pan:
No. of tubes = 800-900
 Capacity = 60tons
Pressure of vapors steam = 700-760mm/hg

17. Refine centrifugal machine:

When the sugar is formed in crystal or in
grain form in refine pan then sugar is transferred to refine centrifugal
machine and this machine separate the correct size of crystal of sugars and
incorrect size of crystal are then transferred to refine pan and further cooked.
18. Sugar dryer:
Damp sugar crystals are dried by being tumbled through
heated air in a granulator. The dry sugar crystals are then sorted by size
through vibrating screens and placed into storage bins. Sugar is then sent to
be packed in the familiar packaging.

19. Packing:
Sugar is pack in gunny bags and bins.
The amount of sugar which is filled in bags is fixed which is 50kg.

Boiler:
There are two types of boiler which are work together at a
time which are named as D1 and D2 boiler.
D1 boiler:
In this four boiler are present and each boiler has a capacity of
20ton.
There are following specification of D1 boiler:
Capacity = 20TPH
Working pressure = 20 ATU
Temperature = 350C
Heating surface area= 862m2
Furnace grate area = 6.38m2
Furnace volume = 28.72m3
Super heater heating surface = 319m2
Super heater no. of coils = 72
Super heater coil dia = 38.3mm
Economizer heating surface area = 57.5m2
Economizer no. of coils = 7
Air heater heating surface area = 424m2
Air heater no. of tube = 800
Air heater tube length = 2840mm
Mud drum to steam drum distance = 8750mm
Id fan capacity = 97500m3/hr., 970 rpm
Fd fan capacity = 41500m3
Furnace temperature = 945-965C
After air heater = 235-245C
Air temperature after air heater = 200C
Feed water temperature = 95C
D2 boiler:
D2 boiler is a one boiler which has capacity of 80ton.
There are following specification of D2 boiler:
Capacity = 80TPH
Working pressure = 25.5bar
Working temperature = 360C
Heating surface area = 1860m2
Furnace grate area = 520m2
Furnace volume = 420m3
Super heater heating surface = 190m2
Super heater no. of coils = 48
Super heater coil dia = 50.8 x 3.6mm
Super heater coil length = 24800mm
Air heater heating surface area = 1930m2
Air heater no. of tube = 1768original +1000 extension
Distance mud drum to steam drum = 10600mm
ID fan capacity = 5100m3/min, 980rpm
FD fan capacity = 1920m2/min, 1480rpm
Secondary air fan capacity = 1320m3/1450rpm
Furnace temperature = 1320-1450C
Feed water temperature = 105C
The capacity of D1and D2 boiler is 160ton.
Ph of boiler is 10.
Ph of feed is 8.
Fuel of boiler is begass.
At boiler steam is converting into energy.

Process of boiler:
There are following steps in of boiler;

1 Begass carrier 7 Mud drum

2 Feeder 8 Steam drum
3 Furnace 9 Super heater
4 FD motor 10 Gage glass
5 ID motor 11 Watch
6 Header

Begass carrier:
In begass carrier begass come from mill house to boiler over
the conveyor belt.
Feeder:
Feeder receives the begass and spread it into the boiler by shoot
begass. Four feeders are present.
Furnace:
Begass scorch in the furnace and make a steam.
Furnace temperature is 365-370C.
FD motor:
FDmotor presents inside the boiler and provide the air to
boiler.
ID motor:
It presents outside the boiler and remove the smoke from boiler.
Mud drum:
It provides water to the boiler.
Steam drum:
Steam store in steam drum.
Super heater:
They are present at back side. Steam removes from steam drum
and come in super heater. In super heater tube are present in upward
position.
Gauge glass:
Gauge glass tells the level of water.
 Watch:
It tell the pressure at which boiler is work.
Red light tells temperature of boiler and green light tells the load of boiler.

Header:
At this stage steam is divided into different parts and then transferred to
different parts of mill.

Lab testing:
There are following test are perform in the lab to check out
the brix,pol,purity and quality of sugar sample,

Massecuite and molasses analysis:

Mix the sample well.
Done the ten time dilution of massecuite and molasses.
Fill the cylinder with 10% solution and check out the brix with hydrometer.
Then done the pole by adding the led acetate.
Check out the pole from Polari meter and evaluate the purity.
Results:
Purity formula:
Pol% /Brix% x 100=Purity
Variation:
If variation occurs in sample of sugar then try again to perform the
test.
Purpose:
The purpose is that to perform the test to check out the quality, brix
and purity of sugar sample.
Beggas pole analysis:
Procedure:
Initially we take the weight of empty container.
Then take 100g sample in container and make the solution 1000g.
Then heat it for half an hours and then cool it.
Then know the pole.
Then put the value in formula and evaluate the value of pole.
Results:
Formula:
Final weight-initial weightx48x0.26x1.3
Purpose:
Its purpose is to check out the sugar that how much sugar presents in
baggas.
Variation:
If variation occurs in sample of sugar then try again to perform the
test.
Syrup and liquor analysis:
Mix the syrup and liquor sample well.
Make the 20% solution of syrup and liquor.
Take 200g sample and make the 1000g volume.
Fill the cylinder with sample and check the brix by hydrometer.
Done the pole by polarimeter.
After brix and pole evaluate the purity.
Results:
 Purity formula:
Pol%63.10/brix64.05x100=98.52 purity

Purpose:
This test is perform to check out the quality and how much sugar% is
present in it.

Special analysis checking:

Clean the burette, funnel, beaker, pipette, cylinder and volume flask well.
Done the calibration of balance before the weight.
The sample which is analysis should take care the weight.
Mix the sample well.
Solution which is used in analysis calibration should be done.
After analysis results should be sending to section.

Vacuums filter cake analysis:

Take the mix sample of all vacuum filters and mix well.
Take 50g sample and add the 2g led acetate.
Mix well with pistol martyr and make the volume of 200g.
Done the pole of mix sample and check the pole with polarimeter.
Results:
Formula:
Pole reading x2 vacuum filter 1.2x2= v.f pol%
Purpose:
Its purpose is to check out the pole of the sample of sugar.
Juice sample analysis:
Clean the basket, glass and trails of juice with hot water.
Collect the sample after every five minutes and done the sampling for one
hours.
 Clean the funnel, beaker and cylinder well.
Fill the cylinder with juice and put the hydrometer in it.
Put the led acetate in the sample and done the pole for ten minutes.
Then check out the brix and pole.
After brix and pole evaluate the purity.
Results:
Purity formula:
Pol%/brix x 100=purity 15/18x100=83.33
Purpose:
The purpose of juice sample analysis is to determine the purity.
Variation:
If variation occurs then try to again to perform the test.

Baggass sample analysis:

Collect the sample for 30minutes from the last mill of mill house.
Mix the all sample well and make 100g sample.
Add 1000ml water and soda ash.
Boil for 30-35 minutes.
After cooling pole is done and check out the pole with Polari meter
Results:
Formula:
Wt-wt2-48x.26xpolreading/100=Baggas pol%.
1700-1170-48x.26x1.5/100=1.88
Purpose:
Its purpose is to determine the baggass pole %.

Boiler water analysis:

Collect the boiler water sample for 10 minutes.
 Check out the ph by PH meter and TDS by TDS meter.
If the hardness is occur in boiler water then take 100ml sample and add
buffer solution and EDT indicator.
Done the titration by EDTA solution.
After titration apply the formula for hardness.
Results:
Burette reading x 1000/100=hardness
Purpose:
Its purpose is to determine the hardness of boiler water.

Baggass moisture analysis:

To check out the moisture take 100g baggass.
Baggass layer should be 120-125C.
Keep in oven approximately 3 hours and check out the weight
continuous.
When weight stop at one place and wait till the room temperature
achieve which is 20C.
Results:
Wt1-Wt2=-100
100g-49.30gm-100=50.70%
Purpose:
Its purpose is to check out the
moisture % in baggass sample.
Variation:
If the variation occurs in baggass moisture analysis test then try to
again to perform the test.

Byproducts:
The bagasse produced after extracting the juice from sugar cane is
used as fuel to generate steam in factories. Increasingly large amounts of bagasse
are being made into paper, insulating board, and hardboard, as well as furfural, a
chemical intermediate for the synthesis of furan and tetrahydrofuran.

The beet tops and extracted slices as well the molasses are used as feed for cattle. It
has been shown that more feed for cattle and other such animals can be produced
per acre-year from beets than from any other crop widely grown in the United
States. The beet strips are also treated chemically to facilitate the extraction of
commercial pectin.

The end product derived from sugar refining is blackstrap molasses. It is used in
cattle feed as well as in the production of industrial alcohol, yeast, organic
chemicals, and rum.

Quality Control:
Mill sanitation is an important factor in quality control measures. Bacteriologists
have shown that a small amount of sour bagasse can infect the whole stream of
warm juice flowing over it. Modern mills have self-cleaning troughs with a slope
designed in such a way that bagasse does not hold up but flows out with the juice
stream. Strict measures are taken for insect and pest controls.

Because cane spoils relatively quickly, great steps have been taken to automate the
methods of transportation and get the cane to the mills as quickly as possible.
Maintaining the high quality of the end-product means storing brown and yellow
refined sugars in a cool and relatively moist atmosphere, so that they continue to
retain their moisture and do not become hard.
 Conclusion:

The measurement of sucrose inversion across unit processes in the sugar industry
is notoriously difficult and has meant that very limited diagnosis of process
problems contributing to sucrose losses has occurred. Sucrose concentrations are
traditionally measured at the factory using polarization or optical rotation purity
measurements. Results from this study showed that sucrose inversion in various
sugar cane juice samples strongly depended on pH, temperature and also solid
content. Increasing solid content, pH and temperature during both heating and
storage at room temperature, increased the rate of sucrose inversion. The tendency
of changes of the amounts of reducing sugar and sucrose in sugar cane samples by
varying temperature and pH were found to resemble to those for the sample model.
To minimize the total reducing sugar, we recommended that temperature was a
critical factor controlling sucrose inversion whereas the anion at the higher pH had
a slightly influence on physical and chemical properties of the juice compared to
the high stability and purity of pure cane sugar.