Bangabandhu Sheikh Mujibur Rahman Science and

Technology University, Gopalganj-8100

An Industrial Tour (Field Work)

REPORT On
Sugar Preparation and Fermentation Technology
[Upon Visiting Carew & Company Bangladesh Limited, Darshana, Chuadanga]

Course Code: ACCE-263

Course Title: Field Work

Jahid Bin Haider

(Assistant Professor)
Department of Applied Chemistry and Chemical Engineering, BSMRSTU

Shariful Islam
Student ID: 19ACE021; Session: 2019-202; 2nd year 2nd Semester
Department of Applied Chemistry and Chemical Engineering, BSMRSTU

Date of submission: 20/07/2023

 A Report on
INDUSTRIAL TOUR (FIELD WORK)
TO
Carew and Co. (Bangladesh)
Darshana, Chuadanga.

PRESENTED BY

8th BATCH
DEPARTMENT OF APPLIED CHEMISTRY AND CHEMICAL ENGINEERING

BANGABANDHU SHEIKH MUJIBUR RAHMAN SCIENCE AND TECHNOLOGY

UNIVERSITY, GOPALGANJ-8100, BANGLADES
 ACKNOWLEDGEMENT
At the outset, we would want to express our sincere gratitude and praise to Almighty Allah,
the most benevolent and gracious Creator, who has made it possible for us to complete the
course.
We received a fantastic chance to study and advance my career throughout the training and
tour. We underwent with the ACCE 8th batch. As a result, we view ourselves as a really
fortunate person who was given the chance to participate in it. Additionally, we are grateful
that we got to meet so many fantastic people and experts who helped me get through this
time.

In light of the foregoing, we would like to take this opportunity to express our sincere
gratitude and appreciation to our supervisor, Md. Lawshan Habib (Assistant Professor &
Chairman, Department of Applied Chemistry & Chemical Engineering, BSMRSTU,
Gopalganj), who, despite being incredibly busy with his duties, took the time to listen to
me, guide me, and keep me on the right path while allowing me to complete my training at
their prestigious industry. A better advisor for this training could not have been envisioned
by us.

We would like to extend our sincere gratitude to Dr. Md. Kamruzzaman (Associate
Professor, Department of Applied Chemistry & Chemical Engineering, BSMRSTU,
Gopalganj) for making a wise decision, providing the necessary counsel and direction, and
setting up all of the necessary facilities to facilitate the session. We'd like to express my
gratitude for his contribution right now.

We would like to express our sincere appreciation to Md. Mehedi Hasan Babu (Assistant
Professor, Department of Applied Chemistry & Chemical Engineering, BSMRSTU,
Gopalganj), Jahid Bin Haider (Assistant Professor, Department of Applied Chemistry &
Chemical Engineering, BSMRSTU, Gopalganj), and all other teachers in my department for
their thoughtful and priceless guidance that was very helpful for the improvement of our
training and tour of duty.

We also want to express our sincere gratitude to all of my friends for their continual support,
helpful advice, and engaging and entertaining company. This chance, in our opinion, marks
a significant turning point in our professional life. To achieve our chosen career goals, we
will attempt to utilize our newly acquired skills and information as effectively as possible
and to continually develop them. We hope to be able to aid all of you in the future.

18th June 2023 Shariful Islam

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 ABSTRACT
Industrial visits represent important activities in any engineering undergraduate program
that contribute to the achievement of various essential learning outcomes and program
objectives. This is achieved through identifying learning outcomes and a suitable industrial
site to achieve them. It is an important phase of a student life.
A well planned, properly executed and evaluated industrial training helps a lot in
developing a professional attitude. It develops an awareness of industrial approach to
problem solving, based on a broad understanding of process and mode of operation of
organization. During a period of a day training in Carew and Co Ltd is they only licensed
distillery producing alcohol made from sugar molasses in Bangladesh and located is
Darshana, Chuadanga, Khulna Division, Bangladesh. The great effort behind the production
of industrial product have been understood during this training.

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 OBJECTIVE
In the highly complex and technical field of Chemistry where technology is evolving with
lightning speed, it is very necessary to remain updated with the latest advancements. Hence,
interaction of the students of the technical institutions with the plants and industry is of
prime importance. The main objective of industrial Tour was to bridge the gap between
classroom teaching and practical working environment and to bring in some positive
intangible changes to the personalities of students which results from long distance group
travel and industrial visit. With this objective an industrial trip was organized by Department
of Chemistry BSMRSTU, on June 18, 2023 to in Carew and Co Ltd is they have only
licensed distillery producing alcohol made from sugar molasses in Bangladesh and located
is Darshana, Chuadanga, Khulna Division, Bangladesh.

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 TOUR DETAILS
Here are the tour details of Visiting the Carew & Co (Bangladesh) Ltd:

Serial NO Item Time

1 Reporting Time 11.00 AM

2 Introductory talk about industry visit 11.15 AM

Visit Industry
3 11.15 AM - 12.30 PM
(Sugar Plant Production)
Visit Industry
4 12.30 PM – 01.30 PM
(Distillery Unit)
5 Group Photo 01.45 PM

DETAILS OF JOURNEY
On 18th June 2023, 41 students of Second Year of Department of Applied Chemistry and
Chemical Engineering along with the Teacher of the Department of Applied Chemistry and
Chemical Engineering, Bangabandhu Sheikh Mujibur Rahman Science and Technology
University, Gopalganj-8100 visited Carew & Co (Bangladesh) Ltd which is located
at Darshana, Chuadanga, Khulna Division, Bangladesh. We left our Campus at 6.30am and
reached Carew & Co (Bangladesh) Ltd by 11.00 AM. We travelled in our university buses.
The Security Officer Welcome the busses and guided for the entry in formulation plant and
seminar rooms. The 41 students were divided into two group and visited the plant. After
visiting the plant, the officer told us the important processes of the manufacturing of sugar
were explained. They cover each and every small aspect of the sugar by giving day todays
life examples. Many students have asked the queries and the instructor has solved them very
cleverly and politely.

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 TABLE OF CONTENTS

SERIAL CONTENTS PAGE NO

1 Acknowledgment i

2 Abstract ii

3 Objective iii

4 Tour Derails iv

5 Details of journey iv

6 SUGAR INDUSTRY 1-22

7 Chapter 1 2-7

8 introduction 2

9 History of carew and company Ltd 3

10 Industry Profile 4

11 Power Source 4

12 Raw Material 5

13 Chapter 2 8-17

14 Instrument 8-12

15 Process of sugar production 13

16 Cane sugar production 13

17 Beet Sugar production 14

18 Products of sugar industry 14

19 Disposal Unit of Sugar Industry 16

20 Chapter 3 18-22

21 Quality Control 18

22 Packaging 19

23 Marketing and Distribution of Sugar 21

24 DISTILLERY UNIT 23-48

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25 Chapter 4 24-28

26 Introduction 24

27 Short history of The Plant 24

28 Company Profile 25

29 Power Source 26

30 Useful Info (Definition) 27

31 Chapter 5 29-36

32 Raw Material 29

33 Instrumentation 30-35

34 Chapter 6 36-43

35 Process of Alcohol Production 36

36 Yeast Culture 37

37 Distillation 39

38 Product 40

39 Grading of spirit 41

40 Foreign Liquor Product 42

41 Chapter 7 44-48

42 Quality Control 44

43 Packaging 46

44 Distribution 48

45 TOUR & ENTERTAINMENT 49-52

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SUGAR
INDUSTRY
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CHAPTER 1
1.1 INTRODUCTION

Carew & Co (Bangladesh) Ltd. is the only licensed distillery producing alcohol made from
sugar molasses in Bangladesh and It is the only distillery in Bangladesh owned by the
Government of Bangladesh. It is located inside Darshana Sugar Mills compound and is
under the authority of Bangladesh Sugar and Food Industries Corporation. It is one of the
15 sugar mills owned by Bangladesh Sugar and Food Industries Corporation that makes a
profit.

Figure 1 : main gate of sugar carew and company (Bangladesh)

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Figure 2: Front of sugar mill

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1.2 HISTORY OF CAREW AND COMPANY LTD.

The journey of Carew & Company began in the early nineteenth century. According to
the Dhaka Tribune, in 1805 a British industrialist named John Maxwell set up the first
distillery of the subcontinent in Kanpur, British India. As the British presence in the region
increased, so did the business of Maxwell’s distilleries. To assist in meeting this additional
demand, he hired a Sugarcane and Spirit Specialist, Robert Russell Carew. Later, seeing the
profits of this business in India, Robert Carew bought the distillery along with two partners.

Robert’s distillery was attacked during the Sepoy Mutiny of 1857. Carew’s younger brother,
who was working as a manager, was killed by the sepoys. Later, when the British
government took control of everything, Robert returned to the distillery business. With the
help of the British Army, Robert re-established his distillery. A joint stock company was
established in 1897, first in Asansol, then in Katni, and later in 1938, a branch of Robert’s
Carew Distillery was established in Darshana.

The purpose of this Darshana Carew & Company (East Bengal) was to produce sugar and
LPG spirit by threshing sugarcane. The Sugar Mill’s machinery and equipment were
brought from M / S Blairs Ltd.

After the partition of the country in 1947, when the British left the region, the government
of Pakistan took control of the organization. From 1947-1971 it was called Carew &
Company (Pakistan) Limited. After 1971, the name of the company was changed to Carew
& Company (Bangladesh) Limited. After the independence of the country, the government
of Bangladesh nationalized it along with other institutions. In 1973 Carew & Co.
(Bangladesh) Ltd covering an area of about 3,562 acres, including a playing field,
processing factory, labor office, school, residential area, a mosque, and medical facilities,
was nationalized.

Carew has the largest area among the sugar industries of the country. Built on more than
3,000 acres, the company cultivates sugarcane in about 2,340 acres. Carew also earns by
producing other crops on the rest of the land. Other than the sugarcane season it cultivates
other crops during the off season. The country’s sugar industry employs more than 11,000
(11,462) employees in 15 mills, of which more than 1,100 (1,102) work in Carew.

Since after a few years of nationalization, most of the factories in the sugar industry have
been continuously operating at loss. As a result, the government has to subsidize these
companies by hundreds of crores of taka every year. According to TBS sources, since 1938-
2021, this government owned company made a profit only 4 times in these 83 years. Which
means, Carew & Company has been running at a loss for 79 years. Although it made a profit
from other units, Carew had an overall loss due to the sugar unit.
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1.3 INDUSTRY PROFILE:

• Name of the industry : Carew & Co (Bangladesh) Ltd

• Date of visit :18-06-2023
• Build up area : 3572 acres
• Established year : Established in 1938
• Plant location : Darshana, Chuadanga, Khulna
• Major products : Sugar
• By products : Bagasse’s, Molasses, Mud
• Raw materials required : Sugarcane
• Laboratory facilities : High quality research lab

1.4 POWER SOURCE:

1.4.1 COGENERATION POWER:

Cogeneration involves the use of high-pressure boilers for producing steam and Turbo
generators for generating power. The by-product from the crushing of sugarcane, bagasse is
recycled and used as boiler fuel in the sugar mills. It is burned at temperatures of up to 400-
800 ºC to produce steam, which is either used as heat for the milling process or to drive
turbines that generate electricity. This process is called cogeneration. The high-pressure
steam passes through the turbine and generates power. The low-pressure steam from the
turbine is used in the processing of sugar.
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Figure 3: Cogeneration power supply in sugar industry

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This coordination plant is fast plant in India install air cooled condensers Instead of water-
cooled condenser for its turbine. Event for the air cold condenser incur a much higher
investment cost than the water cold condensers.
Traditional sugar mills with no export of electrical power to the grid generally generate 10-
20 kWh electrical energy/tc and consume 480-550 kg steam/tc. Modern sugar mills with
efficient cogeneration system installations generate electrical energy in the range of 115-
120 kWh/tc.

1.5 RAW MATERIAL:

1.5.1 TYPE OF RAW MATERIAL:

The following raw material are used in sugar manufacturing process:

• Cane Sugar
• Beet Sugar, and
• High Fructose Corn Syrup.

1.5.1.1 CANE SUGAR:

Cane sugar is processed into raw sugar by a sequence of operations: harvesting, cutting,
crushing, extraction of juice, clarification, evaporation, crystallization, centrifugation, and
refining.

1.5.1.2. BEET SUGAR:

Beet sugar processing involves harvesting, slicing, extraction of juice, carbonization,

evaporation, crystallization, and refining.
The heating process used for these processes and the resulting low water activity of the end
products greatly decreases the initial micro flora with the remaining organisms consisting
primarily of heat resistant spores (Owen, 1977), such as those
from Bacillus and Clostridium species. While spores of Clostridium botulinum have been
detected in sugar, they are of little relevance due to the low water activity of the
confectionery products. For High Fructose Corn Syrup, which utilizes.

1.5.1.3 HIGH FRUCTOSE CORN SYRUP:

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For High Fructose Corn Syrup, which utilizes enzymatic processing, the primary organisms
of concerns are spoilage organisms such as osmophilic yeast like Zygosaccharomyces
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rouxii and Saccharomyces cerevisiae, which are not relevant to hard candy confectionery
processing.

1.5.2 RAW MATERIAL SOURCE:

Sugarcane is a tropical plant that looks something like bamboo. Sugarcane is grown in
tropical climates in states like Louisiana, Texas, Florida and Hawaii. Sugar is made in the
leaves of the sugarcane plant through photosynthesis and stored as a sweet juice in sugarcane
stalks. Sugarcane is cut down and harvested then sent to a factory.

Figure 4: Sugarcane Field

1.5.3 RAW MATERIAL AVAILABILITY:

It is widely produced in Bangladesh. In 2021, sugar cane production for Bangladesh was
3.33 million tone’s. Between 1991 and 2021, sugar cane production in Bangladesh was
decreasing on average by 2.32% each year, although before that, it grew from 5.4 million
tons in 1973 to 7.68 million tons in 1991.

1.5.4 RAW MATERIAL STORAGE:

The packed sugarcane pieces sold in supermarkets are precooled at 0 to 4oC (32 to 39oF)
overnight. The packed cane is then shipped to supermarket on the second day and displayed
on the shelf at 7 to 10oC (44 to 50oF). Stalks can be stored under cool, moist conditions for
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about two weeks, though they may dry slightly.

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1.5.5 RAW MATERIAL QUALITY:

Sugarcane soils become less fertile and fail to provide larger yields due to the considerable
depletion of soil nutrients. Hence, soil management through nutrient replenishment by
adding fertilizers and manures to the soil can maximize sugarcane yield and is indispensable
for a good harvest.
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CHAPTER 2

2.1 INSTRUMENT
In sugar refining and manufacture, machinery such as evaporators, steam boilers, vacuum
pans, and centrifuges are used to make granulated sugar. The process begins with the
harvesting of sugar cane. Next, the cane is cut and crushed to release the juices. The juice is
boiled to create a syrup which is then clarified and crystallized. Finally, the sugar is sorted
and packaged.
In this part of our report, we focus on the equipment that is used.

2.1.1 BELT CONVEYORS

Belt conveyors are the most widely used and versatile mode of mechanical conveying
systems employed to transport materials horizontally or on an inclined either up or down.
The working principle of the belt conveyor is simple: it uses a motor to power an idler
pulley, which in turn because the pulley to move the length of the belt. The force that drives
the conveyor is produced by friction between the idler pulley and the underside of the
conveyor's moving surface.

Figure 5: Belt Conveyer

2.1.2 ROLLER CRUSHER

The roller crusher has wide application in the industries of mining, building materials,
chemical industry, metallurgy, sugar industry, etc. The roller crusher can do secondary and
fine crushing of materials with middle hardness or middle minus hardness, such as mineral,
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rocks, coke, coal, slag, sugar cane, scoria, and fire-proof material, etc. In a roll crusher
comminution primarily involves individual particles nipped between converging roller
surfaces. The forces of compression and friction between the rolls and particles are
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responsible for size reduction, provided the combined forces exceed the compressive
strength of the particle.

Figure 6: Roller Crusher

2.1.3 MIXING COLUMN

It is the column that is used to mix components. Almost all the industries use the column
for mixing operations. One or more than one agitator is used inside the column to mix the
solids or liquids.
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Figure 7: Mixier
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2.1.4 CUTTER
A cutting tool or cutter is typically a hardened metal tool that is used to cut, shape, and
remove material from a workpiece by means of machining tools as well as abrasive tools by
way of shear deformation. The majority of these tools are designed exclusively for metals.

There are several different types of single-edge cutting tools that are made from a variety of
hardened metal alloys that are ground to a specific shape in order to perform a specific part
of the turning process resulting in a finished machined part. Single-edge cutting tools are
used mainly in the turning operations performed by a lathe in which they vary in size as well
as alloy composition depending on the size and the type of material being turned. These
cutting tools are held stationary by what is known as a tool post, which is what manipulates
the tools to cut the material into the desired shape. Single-edge cutting tools are also the
means of cutting material performed by shaping machines and planning machines, which
remove material by means of one cutting edge.

Figure 8: Sugarcane Cutter.

2.1.5 VACUUM EVAPORATOR

Vacuum evaporation is used to increase concentration of substances dissolved in water.

Process is based on the dependency of boiling temperature of water on air pressure. As
opposed to classical distillation, the air pressure in boiling chambers is decreased. This
means that the boiling temperature of water is lower. Lower boiling temperature requires a
less intensive energy source for heating. That’s why operating costs are very low.
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Vacuum evaporation has two outputs. The first one is a distillate, clean water, which can be
either discharged or recycled back into the production process. The distillate has very low
conductivity. The second output is a concentrated, concentrated solution. The concentrate
can be further used if it is a product or it contains valuable substances. If the concentrate is
further unusable, it must be professionally disposed of.

Figure 9: Vacuum Evaporator

2.1.6 BOILER
Boiler is the equipment that generates heat. The heat is then used to produce energy.
Steam boilers are used in sugar mills to generate electricity and for heat in various stages of
production, such as the crystallization process. This process converts the sugar syrup into
sugar crystals. Optimizing the performance of the boilers improves energy efficiency and
reliability for this required heat and electricity.

In the sugar factory, steam is mainly used to generate electricity, concentrate sugar juice and
dry sugar. Most sugar mills use bagasse and coal as fuel. The economic viability of sugar
cane mills depends largely on the use of bagasse as fuel to generate power and steam for
processing. In addition, other biomass fuels (wood, straw, etc.) can also be used to reduce
the cost of boiler fuel. Petroleum and natural gas fuels can also be used in sugar refineries,
which have the advantages of no pretreatment, continuous combustion and high combustion
efficiency.
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Figure 10: Boiler

2.1.7 CRYSTALLIZER
In Crystallizers, it is a process which consists of mixing the massecuite for a certain time
after dropping from the pans, and before passing to the centrifugal. Which aims at
completing the formation of crystals and forcing further exhaustion of the mother liquor.
Crystallization in motion is a process in which the masseuses are slowly stirred while they
cool from pan dropping temperature to one nearer to surrounding atmosphere temperature.
Progressive cooling reduces the solubility of sugar and forced crystallization to continue.
Continuous stirring minimizes the internal differences in temperature and supersaturation
and this reduces the danger of false grain formation. The above process is carried out in
special equipment called crystallizer.

Figure 11: Crystallizer

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2.2 PROCESS OF SUGAR PRODUCTION

Sugar production involves several processes, depending on the type of sugar being
produced. The two primary types of sugar are cane sugar and beet sugar. Here are the general
processes involved in the production of each type:

2.2.1 CANE SUGAR PRODUCTION:

1. Harvesting: Mature sugarcane plants are harvested by cutting them close to the
ground.

2. Milling: The harvested sugarcane is taken to a sugar mill, where it undergoes milling
to extract the juice. This is done by crushing the cane to extract the sweet juice.

3. Juice purification: The extracted juice contains impurities such as plant material
and soil. It is purified by filtration and often treated with lime to remove any acidic
impurities.

4. Evaporation: The purified juice is then heated to evaporate excess water, resulting
in a thick syrup called cane juice or cane syrup.

5. Crystallization: The cane juice is further concentrated and boiled to promote sugar
crystallization. As the syrup cools, sugar crystals form and are separated from the
liquid.

6. Centrifugation: The sugar crystals are separated from the remaining liquid by
centrifugation, a process that involves spinning the mixture to separate the denser
crystals from the lighter molasses or syrup.

7. Drying and Packaging: The separated sugar crystals are dried to remove any
remaining moisture and then packaged for distribution.
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Figure 12: Preparation of sugar

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2.2.2 BEET SUGAR PRODUCTION:

Figure13: Beet sugar preparation Diagram

1. Harvesting: Sugar beets are harvested by uprooting the entire plant.

2. Washing and Slicing: The harvested sugar beets are thoroughly washed to remove
dirt and debris. They are then sliced into thin strips called cassettes.

3. Extraction: The cassettes are soaked in hot water, which helps to extract the sugar
from the beets. The resulting liquid is known as beet juice.

4. Juice purification: Similar to cane sugar production, the beet juice is purified
through filtration and treatment with lime to remove impurities.

5. Evaporation: The purified beet juice undergoes a series of evaporations to remove

excess water and concentrate the sugar content.

6. Crystallization: The concentrated beet juice is boiled, and sugar crystals begin to
form. The mixture is further cooled to allow more crystals to develop.

7. Separation and Drying: The sugar crystals are separated from the remaining liquid
through centrifugation, and the separated crystals are dried to remove moisture.

8. Packaging: Once dried, the sugar crystals are packaged for distribution.

2.3 PRODUCT OF SUGAR INDUSTRY

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We obtain product from sugar industry. This product are generally two types

1. Main product
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2. Byproduct
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2.3.1 MAIN PRODUCT:

The main product of sugar industries is sugar. Sugar industries are primarily involved in the
production of various types of sugar, such as granulated sugar, powdered sugar, brown
sugar, and liquid sugars like syrup and molasses. These sugars are derived from sugar cane
or sugar beets through the process of extraction, purification, and refining.

Sugar is a widely used sweetener in food and beverage products, and it serves as a crucial
ingredient in baking, confectionery, soft drinks, and other food processing industries. It is
also used in the production of various food products like jams, jellies, candies, chocolates,
desserts, and pastries. Additionally, sugar is utilized in the production of alcoholic beverages
and as a sweetener in hot and cold beverages, including tea, coffee, and soft drinks.

2.3.2 BYPRODUCT:
The sugar industry produces various byproducts during the process of extracting sugar from
sugarcane or sugar beets. Some common byproducts of the sugar industry include:

1. BAGASSE: It is the fibrous residue left after crushing and extracting juice from
sugarcane. Bagasse is commonly used as a biofuel to generate steam and electricity
in sugar mills. It can also be utilized in the production of paper, pulp, and compost.

2. MOLASSES: This is a dark, syrupy byproduct obtained during the sugar refining
process. Molasses contains residual sugars, minerals, and other nutrients. It is often
used in the production of rum, as a flavoring agent in food products, and as an
ingredient in animal feed.

3. PRESS MUD: It refers to the solid residue obtained after the filtration of
sugarcane juice. Press mud is rich in organic matter, nitrogen, and phosphorous. It
is commonly used as a soil conditioner or organic fertilizer in agriculture.

4. VINASSE: This is a liquid residue generated during the fermentation and distillation
processes in the production of ethanol from sugarcane. Vinasse contains organic
matter and nutrients, and it can be used as a fertilizer or in biogas production.

5. FILTER CAKE: It is a solid residue obtained from the filtration of sugar syrup.
Filter cake is often rich in sucrose and can be further processed to extract additional
sugar or used as an ingredient in animal feed.
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2.4 PRODUCT SPECEFICATION:

1. REFINED SUGAR: Refined sugar is the most commonly produced and consumed
product of the sugar industry. It is typically obtained from sugarcane or sugar beet.
The percentage of refined sugar can vary, but it usually represents a significant
portion of the overall production, often around 70% or higher.

2. MOLASSES: Molasses is a byproduct of sugar production, rich in minerals and

vitamins. It is a thick, dark syrup that can be further processed into various types
such as blackstrap molasses, light molasses, and others. The percentage of molasses
produced is generally lower than refined sugar, often ranging from 10% to 20%.

3. RAW SUGAR: Raw sugar refers to the less refined form of sugar that contains more
impurities. It is an intermediate product that can be further processed into refined
sugar. The percentage of raw sugar can vary, but it is typically around 10% to 20%
of the total sugar production.

4. OTHER BYPRODUCTS: The sugar industry also produces various byproducts,

including bagasse (fibrous residue from sugarcane), beet pulp (from sugar beet
processing), and ethanol (obtained from fermentation of molasses or sugarcane
juice). These byproducts contribute to a smaller percentage of the overall production,
usually less than 10%. It's important to note that these percentages are approximate
and can vary depending on the specific sugar industry, region, and market
conditions.

2.5 DISPOSAL UNIT OF SUGAR INDUSTRY

In sugar industries, the disposal unit refers to the system or process used to manage and
handle waste generated during the sugar production process. Sugar production generates
various types of waste, including bagasse (sugar cane fiber), filter cake (residue from juice
filtration), molasses, and wastewater.
Here are some common disposal units or methods used in sugar industries for different
types of waste:

1. BAGASSE: Bagasse is often used as a renewable fuel source in sugar mills. It is

burned in boilers to produce steam and generate electricity for the sugar production
process. Excess bagasse can be stored and used as biomass fuel or sold to other
industries for energy generation.
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2. FILTER CAKE: Filter cake, which is the residue left after filtering the sugar juice,
can be reused or disposed of in several ways. It is commonly used as fertilizer or
animal feed due to its high organic content. Filter cake can also be converted into
biogas through anaerobic digestion or composted for agricultural applications.
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3. MOLASSES: Molasses, a byproduct of sugar refining, is a viscous, dark liquid. It

has various applications in the food, animal feed, and alcohol industries. Excess
molasses can be sold to other businesses or further processed to produce ethanol,
rum, or other alcoholic beverages.
4. WASTEWATER: Sugar production generates significant volumes of wastewater
that require treatment before disposal. Wastewater treatment plants are employed to
remove suspended solids, organic matter, and other contaminants from the water.
The treated water can then be reused within the sugar mill or discharged in
compliance with environmental regulations.

It's important for sugar industries to adhere to proper waste management practices to
minimize environmental impact and optimize resource utilization. Regulations and best
practices may vary depending on the region and local environmental laws.
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CHAPTER 3
3.1 QUALITY CONTROL

Quality control is a process that is used to ensure a certain level of quality in a product or
service. It might include whatever actions a business deems necessary to provide for the
control and verification of certain characteristics of a product or service. Most often, it
involves thoroughly examining and testing the quality of products or the results of services.
The basic goal of this process is to ensure that the products or services that are provided
meet specific requirements and characteristics, such as being dependable, satisfactory, safe
and fiscally sound.

Quality control in the sugar industry refers to the processes and procedures implemented to
ensure that sugar products meet specific standards and requirements. These standards may
include factors such as purity, moisture content, color, granulation, and overall quality. The
primary goal of quality control is to ensure that the sugar produced is safe, consistent, and
meets the expectations of consumers and regulatory bodies.

Here are some key elements of quality control in the sugar industry:

1. Raw Material Inspection: Quality control begins with the inspection of the raw
materials, primarily sugarcane or sugar beets. This involves assessing the quality,
maturity, and cleanliness of the raw material before processing.

2. Laboratory Testing: Samples from different stages of the production process are
collected and analyzed in the laboratory. Various tests are conducted to determine
parameters such as sucrose content, moisture content, impurities, color, and grain
size distribution.

3. Process Monitoring: Quality control involves closely monitoring the various stages
of the sugar production process, including milling, extraction, clarification,
evaporation, crystallization, and drying. Continuous monitoring helps identify and
rectify any deviations from the desired standards.

4. Equipment Calibration: Instruments and equipment used in the production

process, such as pH meters, refractometers, colorimeters, and scales, need to be
regularly calibrated to ensure accurate measurements.

5. Packaging and Labeling: Quality control extends to the packaging and labeling of
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sugar products. Packaging materials should be suitable for sugar storage and
transportation, and labels must provide accurate information about the product,
including nutritional values, expiry dates, and any relevant certifications.
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6. Hygiene and Sanitation: Maintaining a clean and sanitary production environment

is crucial for quality control. Regular cleaning and disinfection of equipment, storage
areas, and processing facilities help prevent contamination and ensure the integrity
of the sugar products.

7. Compliance with Standards and Regulations: Quality control in the sugar

industry involves adhering to local and international standards and regulations.
These may include food safety regulations, quality management systems, and
certifications such as ISO 9001.

8. Quality Assurance Programs: Implementing comprehensive quality assurance

programs is essential. These programs include training employees, establishing
standard operating procedures, conducting internal audits, and engaging in
corrective and preventive actions to maintain and improve quality standards.

By implementing these quality control measures, the sugar industry can produce consistent,
safe, and high-quality sugar products that meet consumer expectations and comply with
industry regulations.

Figure 14: Quality Control

3.2 PACKAGING
Packaging in the sugar industry plays a crucial role in preserving the quality and integrity
of the sugar products, ensuring their safe transportation, and providing information to
consumers. Here's a brief discussion about packaging in the sugar industry:

1. Material Selection: Sugar is commonly packaged in bags or sacks made from

materials such as paper, woven polypropylene, or plastic. The choice of packaging
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material depends on factors like product type, shelf life, storage conditions, and
transportation requirements. The selected material should be durable, resistant to
moisture and pests, and capable of maintaining the sugar's quality.
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2. Packaging Formats: Sugar packaging comes in various formats, including bulk

packaging for industrial use and consumer-oriented packaging for retail sale. Bulk
packaging options may include large bags, containers, or bulk trucks for delivery to
industrial customers, while consumer packaging typically involves smaller packages
like retail bags, cartons, or sachets.

3. Protection from Contamination: Packaging should provide adequate protection to

prevent contamination of the sugar. This involves using materials with barrier
properties that guard against moisture, insects, rodents, and other external factors
that could compromise the sugar's quality and safety.

4. Labeling and Information: Sugar packaging must include appropriate labeling and
information for consumer awareness. Labels typically contain important details such
as product name, brand, nutritional information, ingredients, allergen warnings,
manufacturing date, expiration date, and batch/lot numbers. Compliance with
labeling regulations and accurate information is essential.

5. Sealing and Closure: Packaging should be properly sealed and closed to maintain
the freshness and quality of the sugar. This can be achieved through techniques such
as heat sealing, adhesive sealing, closures. Effective sealing prevents moisture
absorption, contamination, and loss of product quality.

6. Product Identification: Packaging may include specific features to identify the

product type or differentiate various sugar varieties, such as brown sugar, white
sugar, powdered sugar, or specialty sugars. This helps consumers easily identify and
choose the desired product.

7. Packaging Efficiency: In industrial-scale sugar production, packaging processes

should be efficient and optimized for productivity. This may involve the use of
automated packaging machinery, bulk filling systems, and conveyor systems to
streamline packaging operations and minimize human error.

8. Sustainability Considerations: Increasingly, the sugar industry is focusing on

sustainable packaging solutions. This includes using eco-friendly materials,
reducing packaging waste, promoting recyclability and exploring innovative
packaging designs to minimize environmental impact.

Packaging in the sugar industry not only ensures product integrity and safety but also serves
as a means of communication between producers and consumers. By employing suitable
packaging practices, sugar manufacturers can meet consumer expectations, comply with
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regulatory requirements, and protect the quality of their products throughout the supply
chain.
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3.4 MARKETING AND DISTRIBUTION OF SUGAR

Marketing and distribution of sugar involve various activities aimed at promoting and
delivering sugar products to consumers. Here is a brief overview of the process:

1. Production: Sugar is primarily derived from sugar cane or sugar beets through a
process of extraction, refining, and purification. This step takes place in sugar mills
or refineries.

2. Packaging: After the refining process, sugar is packaged into different forms such
as granulated sugar, powdered sugar, or sugar cubes. Packaging may vary depending
on the target market and consumer preferences.

3. Branding and Labeling: Sugar producers typically establish brands to differentiate

their products in the market. They create labels and packaging designs that convey
product information, such as the brand name, type of sugar, nutritional facts, and
sometimes marketing messages.

4. Market Segmentation: Sugar is a widely consumed product, catering to various

segments of the population, including households, food manufacturers, and the
hospitality industry. Marketers identify and target specific consumer segments based
on their needs, preferences, and purchasing power.

5. Advertising and Promotion: Sugar producers engage in advertising and

promotional activities to create awareness, build brand recognition, and encourage
consumption. This can involve television and radio advertisements, print media,
online marketing, social media campaigns, and sponsorships.

6. Distribution Channels: Sugar is distributed through a network of channels,

including wholesalers, retailers, and food service providers. Wholesalers purchase
large quantities from producers and distribute them to retailers who sell to end
consumers. Food service providers such as restaurants and hotels may also procure
sugar directly from wholesalers or manufacturers.

7. Logistics and Transportation: Sugar is transported from the production facilities

to distribution centers or directly to retailers using various means of transportation,
including trucks, trains, ships, or air freight. Efficient logistics management ensures
timely delivery and minimizes product damage or spoilage.

8. Retail Placement: Sugar products are displayed and sold in retail outlets such as
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supermarkets, grocery stores, convenience stores, and online marketplaces. The

placement of sugar on store shelves, end-cap displays, or online platforms plays a
crucial role in attracting consumer attention and influencing purchasing decisions.
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9. Pricing and Promotions: Pricing strategies vary depending on factors like

competition, production costs, and market demand. Manufacturers may offer
discounts, special promotions, or bulk pricing to stimulate sales and gain a
competitive edge.

10. Consumer Support and Feedback: Companies often provide customer support
channels for inquiries, complaints, or feedback. This allows them to address
consumer concerns promptly and maintain customer satisfaction.

Overall, the marketing and distribution of sugar involve understanding consumer

preferences, building brand recognition, establishing distribution channels, and
implementing effective promotional strategies to meet consumer demand and achieve sales
objectives.
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DISTILLAR
Y UNIT
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CHAPTER 4
4.1 INTRDCUTION

Figure 15: Carew & company Distillery Unit

• Name Of the Industry Limited: Carew & Co (Bangladesh) Ltd, Darshana

Distillery.

• Location: Darshana, Chuadanga, Khulna Division, Bangladesh.

• Date of Industry Visit: 18 June 2023

4.2 SHORT HISTORY OF THE PLANT

The journey of Carew & Company began in the early nineteenth century. According to the
Dhaka Tribune, in 1805 a British industrialist named John Maxwell set up the first distillery
of the subcontinent in Kanpur, British India. As the British presence in the region increased,
so did the business of Maxwell’s distilleries. To assist in meeting this additional demand,

He hired a Sugarcane and Spirit Specialist, Robert Russell Carew. Later, seeing the profits
of this business in India, Robert Carew bought the distillery along with two partners.

Robert’s distillery was attacked during the Sepoy Mutiny of 1857. Carew’s younger brother,
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who was working as a manager, was killed by the sepoys. Later, when the British
government took control of everything, Robert returned to the distillery business. With the
help of the British Army, Robert re-established his distillery. A joint stock company was
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established in 1897, The purpose of this Darshana Carew & Company (East Bengal) was to
produce sugar and LPG spirit by threshing sugarcane.

The Sugar Mill’s machinery and equipment were brought from Glasgow’s M / S Blairs Ltd.
first in Asansol, then in Katni, and later in 1938, a branch of Robert’s Carew Distillery was
established in Darshana.

After the partition of the country in 1947, when the British left the region, the government
of Pakistan took control of the organization. From 1947-1971 it was called Carew &
Company (Pakistan) Limited. After 1971, the name of the company was changed to Carew
& Company (Bangladesh) Limited. After the independence of the country, the government
of Bangladesh nationalized it along with other institutions. In 1973 Carew & Co.
(Bangladesh) Ltd covering an area of about 3,562 acres, including a playing field,
processing factory, labor office, school, residential area, a mosque, and medical facilities,
was nationalized.

Carew has the largest area among the sugar industries of the country. Built on more than
3,000 acres, the company cultivates sugarcane in about 2,340 acres. Carew also earns by
producing other crops on the rest of the land. Other than the sugarcane season it cultivates
other crops during the off season.

The country’s sugar industry employs more than 11,000 (11,462) employees in 15 mills, of
which more than 1,100 (1,102) work in Carew.

4.3 COMPANY PROFILE:

4.3.1 OWNERSHIP OF THE INDUSTRY:
Carew & Co (Bangladesh) Ltd. is the only licensed distillery producing alcohol made from
sugar molasses in Bangladesh. It is the only distillery in Bangladesh owned by the
Government of Bangladesh. Carew & Company is the only government distillery in the
country under Bangladesh Sugar and Food Industries Corporation (BSFIC).

4.3.2 PRODUCTS OF THE DISTILLERY PLANT

• Fine Brandy
• Cherry Brandy
• Yellow Label Malted Whiskey
•
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Imperial Whiskey
• Old Rum
• Rosa Rum
• Gold Riband Gin
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• Orange Curaçao
• Tsarina Vodka (AKA Jorina Vodka)

4.3.3 PRODUCTION CAPACITY:

The company manufactures country spirit (CS), rectified spirit (RS), and denatured spirit
(DS), and two types of vinegar named malted vinegar and white vinegar. The overall
production capacity of the company's two distillery plants of CS, RS and DS is 1.35 crore
proof liters.

4.3.4 COMPANY PROFIT YEAR:

Carew and Co have made profits only four times so far in its 83-year timespan. It profited
for the first time in FY2017-18. It also profited in the next three consecutive years.

In FY2020-21, it made a profit of Tk29.18 crore from distilleries, hand sanitizer, vinegar
and organic fertilizer factories. However, in this period it counted a loss of about Tk76 crore
in sugar.

That year, the company's income from organic fertilizer factory was Tk25 lakh, Tk1.5 crore
from hand sanitizer and Tk32.88 lakh from vinegar. In 2019-20 FY, Carew and Co made a
profit of Tk9.33 crore, up from Tk8.21 crore in FY2018-19.

4.4 POWER SOURCE:

Boiler is a distillery power source of Carew, Boilers are used in distilleries to heat the kettle,
for sanitation and sterilization, for pasteurized heating, to maintain precise temperatures and
to meet production demands efficiently. Boilers are essential in the distilling process
because making spirits requires hot water to be at specific temperatures, and a boiler helps
the distiller control temperatures. The ability to control this heat improves the quality of the
spirit and ensures the distiller’s safety.

Boilers create high-quality steam that impacts a spirit’s taste and are commonly used to
sanitize and sterilize distilling equipment. In some instances, boilers can even help control
a distillery’s air temperature where tastings and tours take place.
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Figure 16: water tube boiler.

2.4 USEFULL INFORMATION (DEFINITION)

1. MOLASSES: Molasses is the mother liquor left after the crystallization of
sugarcane juice. It is a dark colored viscous liquid. Molasses contains about 60%
fermentable sugar.

2. BAGASSE: Bagasse is the dry pulpy residue left after the extraction of juice from
sugar cane.

3. PRESS MUD: Press mud is the compressed sugar industry waste produced during
filtration of cane juice.

4. ETHANOL: Ethanol is a volatile, flammable, clear, colorless liquid. Ethanol is a

good solvent. It is also used as a germicide, beverage, antifreeze, fuel, depressant
and chemical intermediate. It can be made by the fermentation process of material
that contains sugar or from the compound which can be converted to sugar. Yeast
enzyme readily ferment sucrose to ethanol.

5. YEAST: Yeast are the microorganisms that are used for fermentation of sugar.
Saccharomyces cerevisiae are the yeast used in molasses fermentation

6. RECTIFIER SPIRIT: a mixture of ethanol (95.6 percent) and water produced as

an azeotrope by distillation.

7. ABSOLUTE ALCOHOL: Ethanol containing less than one per cent of water by
weight is known as absolute alcohol.
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8. EXTRA NEUTRAL ALCOHOL: Extra Neutral alcohol (ENA) is the most-pure

version of any alcohol. ENA alcohols are made from different (raw) materials such
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as sugarcane molasses or grains (Grain Neutral Spirit).

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9. COUNTRY SPIRIT: Plain country spirit shall be the alcoholic distillate obtained
from fermented mash of molasses.
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CHAPTER 5
5.1 RAW MATERIALS

• Molasses
• Yeast
• water

5.1.1 RAW MATERIALS SOURCE

Carew produces 3 by-products that are found after extracting sugar from sugarcane. Carew
collects by-products from other units in the sugar industry and uses them as the raw material
for its diverse product portfolio. Molasses is the main ingredient in Carew’s liquor
production. This molasses is sent to the carew distillation unit. For example, in the 2019-
2020 fiscal year, more than 4,000 metric tons (4,139) tons of molasses were produced, all
of which were used in the Carew factory.

5.1.2 RAW MATERIALS STORAGE

Molasses must be stored in steel tanks to prevent it from contamination and loss of
fermentable sugars. The preferments need to steam sterilized, cleaned and washed before
inoculation of yeast cells so that the yeast grows healthy to produce maximum ethyl alcohol
in fermenters. Large volume storage tanks of molasses provide continuous supply of
molasses and store the fresh molasses from sugar processing section during the fermentation
process. The molasses from the tanks are diluted with water to obtain the sugar
concentration around 10-15%. Sugars stored at a relative humidity much below this will
tend to cake because of sucrose crystallization caused by molasses concentration and
cementing together of crystals. Yeast should be collected no more than 24 hours after being
crashed in the fermenter.

5.1.3 RAW MATERIALS QUALITY

Molasses is defective, healthy, and of good quality. Molasses is the final mother liquor or
runoff obtained when separating sucrose crystals in centrifuges. Molasses contains sugars!
that are not economically viable to separate through crystallization methods. Molasses is a
concentrated solution of various mineral and organic substances, some of which are in a
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colloidal state. The density of molasses ranges from 1.35 to 1.40. Based on qualitative and
physicochemical indicators, molasses can be classified as normal or defective. The
technological quality of beet molasses primarily depends on the duration and storage
conditions of sugar beets. Molasses obtained from long-stored sugar beets has reduced
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quality indicators and results in decreased yields of alcohol and baker’s yeast during
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processing at distilleries, making it defective molasses, unlike normal molasses, ferments

poorly and leaves a significant percentage of unfermented sugar, resulting in reduced
alcohol and yeast production. The poor fermentability of defective molasses is attributed to
the unfavorable chemical composition of molasses, which contains harmful impurities that
suppress yeast activity, as well as the influence of bacterial infection. Terbo yeast is use to
produce alcohol because turbo yeast is best suited if you are in a hurry or if maximum
alcohol yield is your goal. You will achieve the best results if you add sugar to the mash.
Turbo yeast is also the best for the production of alcohol from sugar water, or for
fermentation at higher temperatures. The optimum temperature for carrying out
fermentation of molasses is 30°c The yeast produces and quality of molasses check in
quality control room in this industry.

5.1.4 RAW MATERIAL AVAILABLITY

Molasses is the main ingredient in liquor of alcohol production. Molasses was produced
4,139 metric tons in 2019-2020 session in carew industry. This year produced 10,80,000
proof liters of liquor, 26,00,000 liters of country spirit, 8,00,000 liters of denatured spirit.
Day by day increasing demand of alcohol in Bangladesh, as a result increase demand of
molasses.

But day by day decrease produced in sugarcane in Bangladesh. The sugarcane producing
area is drastically reduced in Bangladesh due to shortage of arable land, and more areas are
being used for growing cereals and other short-duration crops like maize and vegetables for
higher profit. So it can be said that the quantity of molasses in stock is less than the demand.

5.1.5 TRANSPORYATION
The entire transportation system is comparatively better than other districts. To reach to
Dhaka you need to spend 4 to 5 hours. Trucks are mainly used for transporting goods. The
products are sent to Dhaka and Chittagong by trucks.

5.2 INSTRUMENTATION
The instruments used in alcohol production can vary depending on the scale of production
and specific processes employed. However, instruments and equipment used in this type of
production may include:
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5.2.1 YEAST PLANT

Yeast a tiny single celled microorganism, a type of fungus, is an example of a biological
raising agent. Yeast feeds on the sugar contained materials, producing carbon dioxide and
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alcohol, in a process called fermentation.

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Figure 17: Yeast Plant

5.2.2 PITCHING VAT

The next task after yeast culture is to fill the pitching vat. When the media brix is 6-6.5 in
one Pitching vat, half of the total amount of yeast is transferred to another pitching vat. In
the same way, another more pitching vat is filled.

Figure 18: Yeast Pitching vat

5.2.3. FERMENTATION TANK

These are large containers that hold the alcoholic mixture during fermentation process. The
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tanks are typically made of stainless steel to ensure hygiene and prevent contamination.
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Figure 19: Large fermentation vat

5.2.4 EVAPORATOR
Its main role is to concentrate the alcohol solution by removing water through the process
of evaporation. The evaporator helps to increase the concentration of alcohol in the solution
by evaporating water. The evaporator utilizes heat energy to evaporate water from the
alcohol solution. By recycling or reusing the steam generated during the evaporation
process, it helps to minimize energy consumption and improve the overall efficiency of
alcohol production. During evaporation, certain impurities may also be removed along with
the water

Figure 20: Evaporator

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5.2.4 DISTILLATION COLUMNS

These tall, vertical towers are used to separate alcohol from the fermented mixture. The
distillation process utilizes the different boiling points of alcohol and other components to
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separate them through evaporation and condensation

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5.2.5 CONDENSERS
These devices condense the alcohol vapor back into liquid form after it evaporates in the
distillation column. Condensers typically consist of a series of tubes or coils that are cooled
by water or air.

5.2.6 HEAT EXCHANGERS

These devices help in controlling the temperature during various stages of alcohol
production. They can transfer heat from one fluid to another, ensuring efficient use of energy
and maintaining optimal conditions for fermentation and distillation.

Figure 21: Heat Exchangers

5.2.7. STORAGE TANKS

Once the alcohol has been distilled and purified, it is stored in large tanks before further
processing or packaging. These tanks are typically made of stainless steel and have
temperature and pressure control systems.
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Figure 22: storage tank

5.2.8 FILTRATION EQUIPMENT

Filtration is used to remove impurities and particles from the final alcohol product. Filtration
equipment, such as filter presses or membrane filters, are used to achieve this.

5.2.9 PUMPS AND PIPES

Pumps and pipes are used to transport the molasses, yeast, fermented mixture, and alcohol
between different stages of the production process. They ensure the efficient flow of
materials and maintain the required pressure and flow rate.

5.2.10 ANALYTICAL INSTRUMENTS

Various analytical instruments, such as pH meters, refractometers, and hydrometers, are
used to monitor and control the fermentation process, alcohol content, and other parameters
to ensure the quality and consistency of the final product.
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Figure 23: Refractometer

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Figure 24: pH meter

Figure 25: Hydrometer

Overall, the apparatus used in alcohol production involves a combination of fermentation

tanks, distillation columns, condensers, heat exchangers, storage tanks, filtration equipment,
centrifuges, pumps, pipes, and analytical instruments. These devices work together to
Produce alcohol while maintaining quality and efficiency throughout the production process
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CHAPTER 6

6.1 PROCESS OF ALCOHOL PRODUCTION

Carew & Company (Bangladesh) Ltd., produces alcoholic beverage only from the distilled
liquors (spirit) based on the yeast fermentation process of molasses. Molasses is received
from the sugar factory, which contain 48% to 52% of total sugar. Black strap molasses is
concentrated cane juice from which no cane sugar has been extracted.

Ethyl alcohol is produced from such organic materials that contain sugar or its precursor as
fundamental units. Sugarcane molasses, a by-product of sugar mill contains high % of
sucrose & Fructose. Molasses is a dark color viscous liquid also known as mother liquor left
after the crystallization of cane sugar from cane juice still contains considerable amount of
s sucrose. Black strap molasses is concentrated cane juice from which no cane sugar has
been extracted. Molasses is converted in to ethyl alcohol by means of yeast, which contains
enzyme invertase and zymase responsible for fermentation.

Figure 26: Distillery Laboratory

When these Molasses are incubated with suitable microorganisms and allowed to ferment,
the end-product is a liquid containing anything from a few percent up to 16% or more of
alcohol, with an acid pH and depleted in nutrients for most contaminating microorganisms.
Further distillation will increase the alcohol strength and produce spirits of many types, e.g.,
whisky, brandy, vodka, gin, rum, etc., which can contain between 40 and 50% ethanol.
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However, the yeast species used in this context is Saccharomyces cerevisiae. The detailed
procedure from molasses to spirit is very long and step by step process and all the steps are
briefly described below.
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6.1.1 DILUTION OF MOLASES

Molasses is received from the sugar factory; The undiluted blackstrap molasses is usually
between 79- and 85-degrees brix. Brix is a measure of the number of dissolved solids in a
liquid via its specific gravity, and is used specially to measure dissolved sugar. One degree
Brix is 1 gram of sucrose in 100 grams of solution. Molasses is received from the sugar
factory, which contain 48% to 52% of total sugar. Then the molasses is diluted to 10-15%
total sugar. High degrees brix of molasses is diluted to Low degree brix. This process is
called brix down or dilution of molasses. This process is applied to decrease the
concentration of sugar content because high concentrated molasses does not support direct
yeast fermentation. High concentration of wort may kill the activity of Yeast.

6.1.2 STERILIZATION OF WORT

For sterilization, 14-14.5 brix of wort poured into the plant till the one third portion of plant
(approximately, 500 liters). Then 500 grams of T.S.P and 1 liter of H2SO4 are added to the
wort and heated it until it reaches at the temperature of 110-115⁰C. This way sterilization of
wort was completed. Finally, sterilized wort allowed to cool down so that it can be used in
Yeast Plant. It is to be mentioned that H2SO4 is used for the hydration of ethylene thereby
help producing ethyl alcohol. The pH of solution also brought down to 4.5-5.0 which is
favourable for yeast culture.

6.1.2YEAST CULTURE
within Yeast Plant Yeast grown in laboratory condition cannot be used instantly. Before
using, yeast must be cultured in yeast plant through the series of plants, First the yeast is
cultured in laboratory then cultured yeast is transfer to Yeast Plant I, Yeast Plant II and
Yeast Plant III. Detailed process of serial culture is given below:

1. LABORATORY STEP: In laboratory the small amount of preserved yeast is

mixed with 10 ml of sterilized wort then the solution kept in controlled temperature
around 30 degrees. Then the inoculation of yeast is mixed with 250 ml wort then
500 ml then mixed with 1 liter of worth sequentially and given proper time in each
step of mixing to propagate the yeast cell. Finally, the inoculation of yeast solution
is mixed with 10 liter of wort in laboratory. Then the solution is ready for yeast
plant 1. This total laboratory process takes around 8 hours.

2. YEAST PLANT I: Firstly, 10 liters of cultured yeasts from laboratory is mixed

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with 100 liters of sterilized diluted molasses media. At this stage, there are 160-220
million yeasts per milliliter of culture. Then 500-gram urea and 1-2 penicillin is
added to the media and allowed for the propagation of yeasts for 12 hours
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3. YEAST PLANT II: After 12 hours, yeast from 1st Plant is transferred into Yeast
Plant II. The amount of media in plant II is 500 liter. Like Plant I, 500 gram of urea
and 2 penicillins are added to the media and allowed propagation for 8-10 hours.

4. YEAST PLANT III: In the very same manner, after 8-10 hours, yeasts from plant
II are transferred to the Yeast Plant III and 1 kg of urea and 3 penicillin is added to
the media. The amount of media in plant III is about 2500 liters. This process
continues until 25 to 30 crore yeast cells are present in one ml of solution

Figure 27: yeast culture

6.1.3 FILLING THE PITCHING VAT

The next task after yeast culture is to fill the pitching vat. There are three successive steps
through which pitch vat is filling up. They are provided below:

1. STEP I: If the media brix is 6-6.5 of yeast solution from plant III, then it is ready
to pour into pitch vat. Meanwhile, it was upgraded to the 9.0 brix by the addition of
appropriate amount of wort. Now, 2 liters of H2SO4, 2 kg of urea and 1 kg of T.S.P
is added to the pitch vat

2. STEP II: Again, if the brix of the media is down to 6-6.5, it is to be upgraded to
9.0 brix with appropriate amount of wort. At this stage, 2 liters of H2SO4, 2 kg of
urea and 1 kg of T.S.P is added again.

3. STEP III: In this step, when the media brix is get lower to 6-6.5, then pitch vat is
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make full with appropriate amount of wort. Then, 4 kg of H2SO4, 4 kg of urea, and
2 kg of T.S.P is added to the wort.

When the media brix is again 6-6.5, half of the total amount of yeast is transferred to another
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pitching vat. In the same way, another more pitching vat is filled.
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6.1.4 FILLING THE FERMANTATION VAT

To carry out the fermentation process, The yeast media from pitching vat is taken into one
fermentation vat. Meanwhile, fermentation vat of 75000 Liter in capacity is filled up
stepwise with wort. For one single fermentation vat, total 10-12 kg of urea is added by three
times and total 8-10 liters of H2SO4 added by two times.

Figure 28: 3 pitching vats for yeast culture

6.1.5 FERMENTATION PROCESS AND REACTION

After adding the yeast medium and molasses in fermentation vat the final fermentation
process starts. Time needed for fermentation is about to 24- 30 hours. The Alcohol or spirit
is produced by the fermentation process by the following biochemical reaction:

𝐶12𝐻22𝑂11 + H2O (Invertase) → 𝐶6𝐻12𝑂6 (Glucose) + 𝐶6𝐻12𝑂6 (Fructose)

𝐶6𝐻12𝑂6 (𝑍𝑦𝑚𝑎𝑠𝑒) → 2𝐶2𝐻5𝑂𝐻 + 2𝐶𝑂2

As soon as the fermentation in a fermentation vat is completed, it is subjected to fractional

distillation by which spirit is isolated.

6.1.6 DISTILLATION
After the fermentation process complete the final solution is subjected to fractional
distillation. For the process the wash is taken in a storage tank by pumping. Then the wash
is passed through beer steel and the wash is heated in beer steel. Then the wash is transferred
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to the boiling column. At this column the wash is heated to 78-80 C which is the boiling
point of alcohol. in this column the alcohol evaporates along with some azeotropic mixer.
Then the vapor alcohol is condensed in the condenser and then the condensed liquid alcohol
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around 75-95% alcohol are collected from the condenser. The whole process is very long
and it takes about 110-120 hours.

Figure29: Alcohol preparation Diagram

6.2 PRODUCT
The main product of Carew & Co is sugar. But after extracting sugar from sugarcane,
various products are produced as by-products, which include local liquor, foreign liquor,
spreat. The company manufactures country spirit (CS), rectified spirit (RS), and denatured
spirit (DS),. The overall production capacity of the company's two distillery plants of CS,
RS and DS is 1.35 crore proof litres. The highest production so far was 52.76 lakh proof
litres – half of the capacity remaining unused as market demand was low.

6.2.1 SPREAT
There are five types of spirit produced by the distillation at Darshana distilleries. They are:
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Rectified Spirit (RS), Denatured Spirit (DS), Country Spirit (CS), and Extra Neutral Alcohol
(ENA), and Absolute alcohol.
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GRADING OF SPIRIT
In carew and company The molasses are processed into five different types of spirits:
denatured spirit, rectified spirit, country liquor spirit and extra neutral alcohol. The rectified
spirit is used to distil whiskey. The denatured spirit acts as solvent and fuel. The country
liquor spirit is, as its name suggests, a local brew. The extra neutral alcohol is used in the
production of cosmetics, perfumes and white alcohol

6.2.1.1 RECTIFIED SPIRIT

Rectified spirit, also known as neutral spirits, rectified alcohol, or ethyl alcohol of
agricultural origin is highly concentrated ethanol which has been purified by means of
repeated distillation, a process that is called rectification. It typically contains 95% alcohol
by volume (ABV) (190 US proof). The purity of rectified spirit has a practical limit of 95.6%
ABV when produced using conventional distillation processes, because a mixture of ethanol
and water becomes an azeotrope at this concentration. Neutral spirits are used in the
production of blended whiskey.

6.2.1.2 DENATURED SPIRIT

Denatured alcohol, also called methylated spirits or spiritus, is ethanol that has additives to
make it poisonous, extremely bad tasting, foul smelling or nauseating, to discourage
recreational consumption. In some cases, it is also dyed. Denatured alcohol is used as a
solvent and as fuel for alcohol burners and camping stoves.Denatured alcohol is a form of
ethanol containing a high amount of additives and denaturants that makes it poisonous.
Denatured ethanol has bad taste and foul smell that makes it unsafe for drinking. Sometimes
it is also added with some dyes to distinguish denatured ethanol from absolute ethanol

6.2.1.3 EXTRA NEUTRAL ALCOHOL

Extra neutral alcohol is colorless and has a neutral smell and taste. It is generally distilled
from sugarcane molasses. It is used as a base for manufacturing Indian made foreign liquor.
It has a strength of 75 proof when bottled. The Potable alcohol is a triple distillated alcohol
with negligible impurities to be used in the high cosmetic industry, perfumeries as well as
for the production of white alcohol brands such as vodkas, liquors and aperitifs.

6.2.1.4 COUNTRY SPIRIT

The country liquor spirit is, as its name suggests, a local brew. Country sprit means plain
spirit of a strength lower than forty degrees over proof, manufactured from molasses, gur,
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mahua, rice or any other materials which is issued for consumption as potable alcoholic
liquor and is not deemed to be foreign liquor,
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6.2.1.5 ABSOLUTE ALCOHOL:

Absolute/Undenatured alcohol is the pure form of ethanol that contains no or fewer additives
and denaturants. Absolute alcohol is a common name for the chemical compound ethanol.
To qualify as "absolute," the ethyl alcohol must contain no more than one percent water. In
other words, absolute alcohol is liquid alcohol that is at least 99 percent pure alcohol by
weight. Absolute ethanol has a variety of applications and is commonly used as a reagent,
solvent, disinfectant, antiseptic, feedstock, fuel, and low-temperature liquid.

6.2.2 FOREIGN LIQUOR PRODUCTS

At present, Carew and Company produces nine brand of foreign liquor products which are
all distilled alcoholic beverages with 42.76% alcohol contents or 75 proof. Following seven
brands are well-known and rest two, Orange Crackaloo and Cherry Brandy, are just recent
up upcoming, hence they are not provided in the following list.

Carew has nine brands of "foreign liqueur"

1. Fine Brandy
2. Cherry Brandy
3. Yellow Label Malted Whiskey
4. Imperial Whiskey
5. Old Rum
6. Rosa Rum
7. Gold Riband Gin
8. Orange Curaçao
9. Tsarina Vodka (AKA Jorina Vodka)
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Figure 30: All nine foreign liquor brand in one shot

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The different composition of different foreign are given below

Brand Name Composition Alcohol content

Gold Riband Gene ENA + Distilled Water + Gin Flavor (from IFF) 42.76%
Yellow Label Malted ENA + Distilled Water + Malt + Yellow Label
42.76%
Whisky Malted Whisky Flavor + Caramel
Tsarina Vodka RS + Distilled Water 42.76%
RS + Distilled Water + Brandy Flavor +
Fine Brandy 42.76%
Caramel
RS + Distilled Water + Whisky Flavor + 42.76%
Imperial Whisky
Caramel
CS + Distilled Water + Matured in Wooden Vat 42.76%
Old Rum
+ Caramel
CS + Distilled Water + Matured in Wooden Vat 42.76%
Rosa Rum
+ Caramel
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CHAPTER 7
7.1 QUALITY CONTROL:
The organization has quality control department like other elite company. They have
program for improving product quality. Research and development department works for
improving quality’s standard are the basis of quality measurement and between these they
follow BSTI standard in case of product quality control. Moreover, they have inspection
team for quality control. Quality control in the alcohol industry is of utmost importance to
ensure the safety, consistency, and overall quality of alcoholic beverages. Various measures
and processes are implemented to maintain high standards and meet regulatory
requirements. Here are some key aspects of quality control in the alcohol industry:

1. RAW MATERIAL EVALUATION: Quality control starts with evaluating the

quality of raw materials used in alcohol production, such as molasses, grains,
grapes, or other ingredients. Suppliers are typically vetted to ensure they meet
quality standards, and samples may be analyzed for chemical composition and
potential contaminants.

2. PRODUCTION PROCESS MONITORING: Throughout the production

process, specific parameters are monitored to maintain consistency and quality.
This includes monitoring fermentation conditions, distillation temperatures,
filtration processes, and aging or maturation processes. Automated systems and
manual checks are employed to detect any deviations from the desired
specifications.

3. LABORATORY TESTING: Regular laboratory testing is performed to analyze

alcohol samples for various parameters. This includes alcohol content, acidity, pH
level, residual sugars, volatile compounds, and potential contaminants such as
pesticides, heavy metals, or mycotoxins. Testing ensures compliance with legal
requirements and helps identify any issues that may affect the final product.

4. QUALITY ASSURANCE SYSTEMS: Establishing robust quality assurance

systems is crucial. This involves implementing standard operating procedures
(SOPs) that outline specific quality control measures at each stage of production. It
includes protocols for cleaning and sanitization, equipment calibration,
maintenance schedules, and documentation of all processes.

5. PACKAGING AND LABELING COMPLIANCE: Quality control extends to

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the packaging and labeling of alcoholic beverages. Packaging materials are

evaluated for safety and integrity, while labeling is reviewed for accuracy and
compliance with local regulations. This includes verifying alcohol content, allergen
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declarations, health warnings, and appropriate labeling for restricted or regulated

ingredients.

6. QUALITY ASSURANCE AND HACCP: Quality assurance protocols, including

Hazard Analysis and Critical Control Points (HACCP), are implemented to identify
potential hazards and establish control measures to mitigate them. This systematic
approach helps prevent contamination and ensures product safety.

7. AGING AND MATURATION: For products like wine and brandy, aging and
maturation processes are essential in developing complex flavors. Quality control
involves monitoring the aging conditions and storage to achieve desired
characteristics.

8. COMPLIANCE WITH REGULATORY STANDARDS: The alcohol industry

is subject to various regulations and standards set by local, regional, and
international authorities. Quality control processes should ensure compliance with
these standards, which can include aspects such as product composition, labeling
requirements, safety regulations, and adherence to specific production methods
(e.g., for certain types of wines or spirits).

9. SENSORY EVALUATION: In addition to laboratory testing, sensory evaluation

plays a vital role in quality control. Trained personnel conduct sensory analysis to
assess the appearance, aroma, taste, and overall sensory characteristics of alcoholic
beverages. This helps identify any deviations from expected profiles and ensures
consistency and quality across batches.

10. RECALL PROCEDURES AND TRACEABILITY: In the event of a quality

issue or safety concern, having well-defined recall procedures and robust
traceability systems is crucial. These systems allow for swift identification,
isolation, and removal of affected products from the market, thereby minimizing
potential risks and protecting consumers.

11. PACKAGING INSPECTION: Packaging plays a vital role in preserving the

quality of the product. Quality control includes inspections of bottles, corks, labels,
and other packaging materials to avoid any potential issues.

12. CONTINUOUS IMPROVEMENT: Quality control in the alcohol industry is an

ongoing process. Companies regularly review their procedures, incorporate
customer feedback, and update their quality control measures to strive for
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continuous improvement.
It's important to note that quality control practices may vary across different types of
alcoholic beverages (e.g., beer, wine, spirits) and local regulations. Each producer should
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tailor their quality control processes to their specific operations and adhere to the applicable
regulatory requirements to ensure consumer safety and satisfaction.

7.2 PACKAGING:
In recent years, the alcoholic beverages packaging industry has witnessed significant growth
and innovation. With the rising popularity of alcoholic beverages across the globe,
manufacturers are increasingly focusing on creating packaging solutions that not only
preserve the quality of the product but also enhance its appeal to consumers. In this article,
we will explore the various aspects of the alcoholic beverages packaging industry, including
its trends, challenges, and future prospects.

The alcoholic beverages packaging industry plays a crucial role in ensuring the integrity and
attractiveness of alcoholic products. Packaging not only serves as a means of product
protection but also acts as a marketing tool, influencing consumer perceptions and purchase
decisions. From glass bottles to cans and pouches, there are various packaging options
available in the market catering to different types of alcoholic beverages.

Figure 31: Different type of packaging

7.2.1 IMPORTANCE OF PACKAGING IN THE ALCOHOLIC BEVERAGES

INDUSTRY:
Packaging holds immense importance in the alcoholic beverages industry. It not only
protects the product from external factors such as light, air, and moisture but also preserves
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its taste and quality. Moreover, packaging serves as a medium for branding and
differentiation, helping alcoholic beverage companies create a unique identity in the market.
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7.2.2 TYPES OF ALCOHOLIC BEVERAGES PACKAGING:

• GLASS BOTTLES: Glass bottles are widely used for packaging alcoholic
beverages, especially premium spirits and wines. They offer a classic and elegant
look and are highly customizable in terms of shape, size, and design.

• RIGID METAL (ALUMINUM CANS/BOTTLES): Aluminum cans are popular

for packaging beer and ready-to-drink cocktails. Cans are lightweight, portable, and
offer convenience to consumers. They also provide better protection against light
and oxygen, preserving the freshness of the product.

• TETRA PAK AND CARTONS: Tetra Pak and carton packaging are commonly
used for wine, spirits, and mixers. These packaging formats are lightweight, easy to
carry, and provide good barrier properties, ensuring the product remains
uncontaminated.

• POUCHES AND BAG-IN-BOX: Pouches and bag-in-box packaging are gaining

popularity in the alcoholic beverages industry. They are suitable for packaging wine,
spirits, and premixed cocktails. These formats offer convenience, portability, and
sustainability benefits.

• PLASTICS (RIGID, FLEXIBLE)

• PAPER AND BOARD (cartons, cases, backing cards, wrapping, etc.)

7.3 MARKETING IN THE ALCOHOL INDUSTRY:

Bangladesh is a predominantly Muslim country, and Islam prohibits the consumption of
alcohol. As a result, the sale and consumption of alcohol are severely restricted in the
country. The government strictly controls the alcohol industry and imposes stringent
regulations on its distribution and sale.
1. TARGET AUDIENCE: Alcohol companies tailor their marketing strategies
to appeal to specific target audiences. This can include demographic factors like
age, gender, and lifestyle preferences.

2. BRANDING AND PACKAGING: The branding and packaging of alcohol

products play a crucial role in marketing. Unique and eye-catching labels, logos,
and designs help products stand out on store shelves and attract consumer
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attention.

3. LIMITED AVAILABILITY: Alcohol is not readily available in public places,

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The government only permits a few designated areas, such as some hotels,bars
and international clubs, to serve alcohol to foreign tourists,non-Muslim
foreigners and over 21 ages people with special permits.

4. STATE MONOPOLY: Historically, the Bangladesh government has

maintained a monopoly on the importation, distribution, and sale of alcoholic
beverages. It allowed a state-run entity, the Bangladesh Distillery Limited
(BDL), to produce and distribute a limited range of alcoholic beverages.

5. ADVERTISING RESTRICTIONS: Advertising of alcoholic beverages is

restricted in Bangladesh. You won't find alcohol advertisements on television,
radio, or billboards.

6. SOCIAL STIGMA: Due to religious and cultural norms, alcohol consumption

is associated with social stigma in Bangladesh. This further restricts the growth
and marketing of the alcohol industry.

7.4 DISTRIBUTION:
1. RETAILERS: Alcohol products are typically distributed through a network of
retailers, including government permitted hotels, bars, night club and international
clubs.

2. BARS AND RESTAURANTS: The on-premise sector, including bars, pubs,

restaurants, and clubs, represents a significant distribution channel for alcoholic
beverages.

3. WHOLESALE AND DISTRIBUTION COMPANIES: alcohol manufacturers

often work with wholesalers and distributors to get their products to retailers and
other establishments. These companies handle the logistics and supply chain
aspects of the distribution process.
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TOUR &
ENTERTAINMENT
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3.1 MUJIBNAGAR VISIT

After visiting Carew & co Bangladesh Ltd. Plant we also visited Mujibnagar Complex,
Meherpur. Mujibnagar is a significant historical place in Bangladesh. It holds great
importance in the country's struggle for independence.On April 17, 1971, the Provisional
Government of Bangladesh was formed at Mujibnagar, which served as the capital during
the Bangladesh Liberation War.
After the declaration of independence, the leaders of the newly formed government, who
were in hiding due to the crackdown by Pakistani authorities, assembled in Baidyanathtala,
a small town near Meherpur district in present-day Bangladesh. The place was later named
Mujibnagar in honor of Sheikh Mujibur Rahman, the founding leader of Bangladesh and a
prominent figure in the independence movement.
On April 17, 1971, the provisional government was formed at Mujibnagar with the
following key figures:
1. Sheikh Mujibur Rahman - President
2. Syed Nazrul Islam - Vice President
3. Tajuddin Ahmad - Prime Minister
4. Muhammad Mansur Ali - Minister of Finance and Planning
5. Khondaker Mostaq Ahmad - Minister of Foreign Affairs

Figure 32: Bangladesh Map on Historical Mujibnagar, Meherpur

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Figure 33: Mujibnagar Memorial Monument,Meherpur

3.2 GROUP PHOTO:

Here we took some photos and some of these are-
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Figure 34: Group Photo with Honorable Teachers at BSMRSTU Campus

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Figure35: Entering to the plant

3.3 CONCLUSION:
Industrial tour on Carew & Co Bangladesh Ltd really opened an arena of knowledge of real
situation. I think Carew & co Bangladesh Ltd has a deep concern about its better-quality
assurance, modern production technology, meeting customer demand, effective marketing
strategies etc. It meets a large portion of demand of alcoholic product in Bangladesh. Only
better-quality product and strategic marketing helped Carew & co Bangladesh Ltd.
This trip was immensely useful to us and the concepts we learnt will be forever embedded
in our minds.
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