Renewable and Sustainable Energy Reviews 96 (2018) 167–180

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Renewable and Sustainable Energy Reviews

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Upgradation of jaggery production and preservation technologies T

⁎
Rakesh Kumar , Mahesh Kumar
Mechanical Engineering Department, Guru Jambheshwar University of Science & Technology, Hisar 125001, India

A R T I C LE I N FO A B S T R A C T

Keywords: Jaggery is a traditional concentrated product of sugarcane juice which is easily and cheaply available to the
Jaggery Indian rural population. Several value added jaggery based products are also very popular in large section of
Bagasse population throughout the country. Jaggery is a good source of minerals and nutritiants and also has various
Jaggery manufacturing plant medicinal values. With the increasing demand of this nutritive sweetener, efforts are being made to develop a
Jaggery preservation
standard manufacturing package that will increase its productivity besides quality improvement in terms of
Jaggery storage
Jaggery packaging
hygiene, standardization of shape, size, and storability. The thermal and overall efficiencies of jaggery making
plants are very low due to loss of thermal energy through flue gasses and un-designed constructional parameters
of plant. The storage of jaggery is also a major problem. Since, it is much influenced by the contents of invert
sugars and mineral salts that are hygroscopic in nature. This intends us to study the technological upgradations
used for the production and preservation of jaggery in order to prioritise the required advancements. This paper
gives an overview of the technological upgradation of jaggery manufacturing plants and the preservation of
jaggery by using different storage and packaging methods.

1. Introduction
Jaggery is the most popular traditional Indian sweetener produced
by concentration of sugarcane juice without the separation of molasses.
It is an unrefined, non-centrifugal whole cane sugar consumed all over
the world. Organic jaggery is prepared without the use of any chemical/
synthetic additives [1]. The color of jaggery varies from golden brown
to dark brown but from market point of view light golden colored
jaggery is very popular. Jaggery is produced all over the world under
different names [2]. It is regularly consumed as a sweetener. It is also
used as a main ingredient in number of traditional Indian dishes. Jag-
gery is a rich mixture of minerals and vitamins, thus it is the healthiest
sugar from the group of sweeteners. The mineral contents in jaggery are
approximately 50 times greater than refined sugar and 5 times more
than brown sugar [3]. Jaggery is a good source of energy (383 kcal/
100 g) and has various medicinal values [4,5]. In Ayurveda (5th Veda)
it is considered as the best base material for the preparation of medi-
cines [6,7]. In India, jaggery has been prepared since from Vedic-period
as its reference is found in mythological texts and Rig-Veda [8].
Depending upon the end use mainly three types of commercial
jaggery is available in the market, namely, solid jaggery, liquid jaggery,
and granular jaggery [9]. To prepare solid jaggery the clarified sugar
cane juice is boiled at its striking point temperature varying from 116 to
120 °C and then filled in to the molds of different shapes and sizes. The
moisture contents of solid jaggery lies in between 5% and 7% as per the
Bureau of India Standard [10]. The liquid jaggery is semi liquid syrup
made by boiling of sugarcane juice below striking point temperature
varying from 105 to 108 °C [11]. It contains 30–36% water, 40–46%
sucrose, 15–25% invert sugar and 0.30% calcium [12]. The granular
jaggery is prepared by rubbing the concentrated product of sugarcane
juice with wooden scrappers to form grains instead of molding [13].
The striking point temperature for granular jaggery ranges from 120 to
122 °C and it contains about 1.65% water and 88.6% sucrose [14].
About 80% of the total jaggery produced in India is prepared in solid
form and remaining 20% is prepared in liquid as well as in granular
form [15,16].
Among the major agro processing industries of India Jaggery/
Khandsari is one of the oldest, largest, and most important industry.
Jaggery making plants are placed in decentralized sectors in India. This
industry is meeting about 40% of the total requirement of sweeteners
and giving employment to 2.5 millions of people in rural areas with
minimum capital investment [17]. It was estimated that about 50% of
total sugarcane produced in India is used to manufacture 8–10 million
tons of jaggery [18]. India is the largest producer and consumer of
jaggery in the world. Out of total production in the world more than
70% of jaggery is produced in India [19]. The main cost of jaggery
production is around 50% of total cost, which is followed by labor cost,
material cost, marketing cost and interest [20]. The profitability of

⁎
Corresponding author.
E-mail addresses: rakeshkumar.bisla@gmail.com (R. Kumar), mkshandilya1@gmail.com (M. Kumar).

https://doi.org/10.1016/j.rser.2018.07.053
Received 29 September 2017; Received in revised form 27 July 2018; Accepted 29 July 2018
1364-0321/ © 2018 Elsevier Ltd. All rights reserved.
R. Kumar, M. Kumar Renewable and Sustainable Energy Reviews 96 (2018) 167–180

jaggery producer depends upon the efficient marketing. The marketing

SNK 07337, SNK 0680 and Co 92005 are the excellent varieties of sugarcane for the color and

Sugarcane is one of the best available natural converters of solar energy into biomass (bagasse)
of jaggery through Cooperative Sangh is reported to be more profitable

Bagasse used as a fuel in all jaggery-manufacturing plants plays an important role in the
to the producers than the others [21]. The market value of jaggery is
much affected by appearance parameters like color, texture, and smell

Bagasse can also be used to generate secondary biofuels like ethanol and n-butanol.
of jaggery [22]. The jaggery marketing based on ID3 decision tree al-

Vegetable based clarificants are more efficient to clarify raw sugarcane juice.
gorithm can provide a good marketing response on the basis of avail-
ability, price and season to the end-users [23]. Jaggery is exported from
India to different countries like USA and UK. It is the best exportable
sweetener produced at lowest cost which can be very helpful to earn
valuable foreign money. The lack of infrastructural facilities and in-
sufficient price distributions are the major factors, which affects the
production and marketing of jaggery [24]. The jaggery has a good
demand in domestic and foreign market. The values of nominal pro-
tection coefficient and domestic resource cost of jaggery were observed
less than unity, which shows that it is a good exportable product and
has high export competitiveness [25].
economic development of rural areas.

In India, all jaggery manufacturers use traditional methods to

manufacture organic jaggery. The traditional jaggery making process
quality parameters of jaggery.

has very low thermal efficiency. Since these units are generally de-
signed by local artesian and large part of energy is wasted to the at-
mosphere in the form of flue gasses. It requires high skill and more
manual labor due to lengthy heating operation. Due to batch produc-
tion, the traditional jaggery manufacturing process cannot be used for
mass production. In India, jaggery is manufactured during the winter
and sugar.
Remarks

and spring seasons and it is stored for rest of the year. The storage of
jaggery is a major problem as it absorbs moisture from the air, which
changes its properties. The traditional storage methods are not very
Conducted an experiment on highly productive sugarcane hybrid clones for can yield, jaggery

Compared the efficiency of some organic clarificants used in jaggery manufacturing process.

efficient in all environmental conditions mainly in the rainy season. It

Studied the by-products of sugarcane which can be used for the generation of secondary

has been estimated that more than 10% of jaggery produced in India
Conducted a survey on techno-economic analysis of bagasse opportunities in jaggery

worth US $ 0.6 million is lost every year due to deterioration under

normal storage process [26].
In order to overcome these problems and drawbacks many attempts
have been made by various researchers to improve the efficiency of
jaggery making plants and to enhance the shelf life of jaggery to store
under different environmental conditions. The present paper is initiated
to discuss the progress made towards the technological advancements
in jaggery making process and preservation methods.
Overviewed the second generation biofuel technologies.

2. Elements and operations of jaggery manufacturing process

Jaggery manufacturing is a continuous heat and mass transfer

process in which fresh sugarcane juice and bagasse are used as raw
material and fuel respectively. The progressive heating and stirring of
sugarcane juice in an open pan changes the sugarcane juice from liquid
yield and quality parameters.

to semi-solid, which further becomes solid after cooling in an open

earthen pan. The traditional jaggery manufacturing process involves a
number of operations that are performed by skilled and semi-skilled
Main findings on the elements of jaggery manufacturing plant.

persons.
Description

2.1. Elements of traditional jaggery manufacturing process

industry.
biofuels.

The basic elements used in traditional jaggery manufacturing pro-

cess are sugarcane juice, bagasse, and clarificants. Sugarcane juice is an
2013

2011

2010
2012

1954
Year

opaque liquid available in different colors from gray dark green to light
yellow depending upon the variety of canes used [15]. The different
Patel and Suryavanshi [30]

varieties of sugarcane hybrid clones cultivated in India are used to

Guddadamath et al. [27]

produce jaggery of good color and quality. Number of researches has

Singh and Singh [33].

been conducted in this area and it was found that sugarcane SNK
Ralph et al. [29]

07337, SNK 0680 and Co 92005 are excellent on color and quality
Soloman [28]

parameters of jaggery [27].

Researchers

In all jaggery manufacturing plants fibrous part of sugarcane stalk

remains after crushing named as bagasse is directly used as a fuel. In
addition to this molasses is also a valuable byproduct of the jaggery
manufacturing process that also serves as fuel. Thus this industry does
Sr. No.
Table 1

not depend on additional fossil fuel for its production. Sugarcane is one
1.

2.

3.
4.

5.

of the best available natural converters of solar energy into biomass

168
R. Kumar, M. Kumar
(bagasse) and sugar [28]. Bagasse can also be used to generate sec-
ondary biofuels like ethanol and n-butanol [29]. The cost of bagasse as
a fuel is one third of the other available fuels [30]. Thus it plays an
important role in the economic development of rural areas in which
jaggery making units and sugar plants are established [31].
Clarificants are the organic and inorganic elements that are used to
clarify the raw sugarcane juice in jaggery making process [32]. In
jaggery making plants generally vegetable based clarificants (organic
elements) like stem and root of green plants of deola and bhendi, green
bank of phalsa and semul trees, dry bank of sukhlai plant, seeds of
castor, ground nut and soybean, etc., and chemical based clarificants
(inorganic elements) like sodium hydrogen sulfite (hydros), calcium
oxide (lime), sodium carbonate, sodium bicarbonate, and super phos-
phate are used [33]. The various effects of vegetable and chemical
clarificants on the quality of jaggery are reviewed time by time by the
researchers [34–38].
The important findings related with the elements of jaggery man-
ufacturing processes are summarized in Table 1.
From the above discussion it is observed that sugarcane juice, ba-
gasse, and clarificants are the major elements of a jaggery manu-
facturing plant. The juice obtained from sugarcane SNK 07337, SNK
0680, and Co 92005 among the other varieties are found to give good
quality jaggery. The bagasse as a fuel plays an important role in the
economic development of rural areas in which jaggery plants are es-
tablished. Vegetable and chemical based clarificants are being used in
jaggery making plants to clarify the raw sugarcane juice.
2.2. Operations of traditional jaggery manufacturing process
The traditional Jaggery manufacturing process involves a number of
operations which are shown in Fig. 1.
The first step of jaggery manufacturing operation is the weighing of
cane and then transferred for the extraction of sugarcane juice by
crushing it in a crusher (Kelhua). Traditionally vertical or horizontal
crushers with three rollers are used to crush canes. Conventionally,
crusher is operated by a pair of bullocks. Now a day's bullocks are re-
placed by a diesel engine. The juice recovery efficiency of vertical and
horizontal crusher varies from 50% to 55% and 55–60% respectively.
The crushing efficiency can be increased from 77% to 80% by using
multiple crusher and hot water during crushing but it is not feasible in
the case of traditional tiny jaggery making plants [15]. The schematic
views of different sugarcane crushers are shown in Fig. 2.
The crushed sugarcane juice is then stored in a masonry settling
tank and left for some time to separate the heavier impurities under the
process of plain sedimentation. The clean sugarcane juice taken from
the settling tank is transferred to the boiling pan where it is heated
along with continuous stirring operation.
Fig. 1. Flow chart of Jaggery manufacturing operations.
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Renewable and Sustainable Energy Reviews 96 (2018) 167–180
In all jaggery manufacturing plants bagasse is used as a fuel. It
contains fibers and sugar having high calorific values 19259 kJ/kg and
16747 kJ/kg respectively [39]. The efficient combustion of bagasse
depends upon the percentage of moisture content. The calorific value of
bagasse can be increased up to 10% by decreasing the moisture content
half of its initial level [40]. The percentage of bagasse in sugarcane
varies from 23% to 37% depending upon the variety of sugarcane used
[41]. It is reported that by crushing 1000 kg of sugarcane 650 kg of
juice and 350 kg of bagasse can be obtained [42]. The fresh bagasse
coming from crusher contains 50% moisture, 47% fibers, 2.5% sugar
and 0.5% minerals [43]. Open sun drying of bagasse is a traditional
method used in all jaggery making plants which can decrease the
moisture content from 50% to 20% [42]. Number of methods (like hot
air oven method and microwave oven, etc.) has been suggested by the
researchers to determine the level of moisture content of a bagasse
sample. The use of microwave oven to determine the value of moisture
content is more efficient and less time consuming as compared to the
hot air oven method [44]. Time required for heating of juice depends
upon the experience of the worker, since over heating can burn the
product and thus changes the taste of finished product. Both the op-
erations of boiling and clarification of juice take place simultaneously.
Clarification is the process in which impurities are removed from
sugarcane juice. The quality of jaggery depends on the type of clar-
ificants used and the clarification efficiency of sugarcane juice [45].
The use of bhendi powder, bhendi mucilage and groundnut milk as
herbal clarificants [46] was found to be more efficient for maintaining
the quality of jaggery than the other herbal and synthetic clarificants
[47,48]. The cost of organic jaggery is estimated to be 25% higher than
the jaggery prepared by using inorganic clarificants [49]. The effec-
tiveness of juice clarification plays an important role in maintaining the
quality and storage life of jaggery [50]. Sulfur dioxide is most popular
clarificants agent that may produce sulphates and organo-sulfur which
are hazardous for human beings [51]. The addition of lime in sugarcane
juice improves the consistency of jaggery by increasing crystallization
of sucrose, but the excess addition of lime can darken the color of final
product [52]. The use of copolymers as a clarificants after liming de-
creases the clarification time which results in reduction of sucrose in-
version, organic acid, reducing sugars, and helps in the formation of
colored elements [53]. The quality of jaggery depends on the type of
clarificants used and the clarification efficiency of sugarcane juice [54].
The effects of vegetable and chemical clarificants on the quality of
jaggery are reviewed time by time by many researchers [33–38]. Re-
sponse surface method suggested that 77.55 °C temperature, 1.5 mm
thickness of charcoal and 0.48 g/lit deola were very efficient to opti-
mize the clarification process of sugarcane juice [55].
After heating and clarification the concentrated product is trans-
ferred to the wooden/ aluminum molds mesh or to a wide open earthen
pan for cooling. At the end of jaggery manufacturing process the fin-
ished product molded in different shapes and sizes like in rectangular
shape (0.250–1 kg), cubic shape (2.5 cm3 and weight 20 g) bucket shape
(10–20 kg) and trapezoidal shape (5 kg) [56].
The important findings related with the operation of traditional
jaggery manufacturing processes are summarized in Table 2.
From the above discussions it is observed that the complete jaggery
manufacturing process is a continuous and systematic process starting
from the crushing of sugarcane in a crusher, settling of juice in a tank,
preheating of juice in a gutter pan, clarification of juice, and boiling of
juice by using bagasse as a fuel. The use of multiple crusher and hot
water can increase the crushing efficiency of crusher from 50% to 80%.
The combustion efficiency of bagasse can be increased up to 10% by
decreasing the moisture content half of its initial level. Chemical and
herbal clarificants are being used to remove the impurities from the
sugarcane juice. Herbal clarificants are found more efficient but in-
crease the preparation cost of jaggery by 25%.
R. Kumar, M. Kumar
Fig. 2. Schematic views of different sugarcane crushers.
3. Up-gradation in jaggery manufacturing plants
This section is intended to discuss the progress made towards the
technological advancement in jaggery manufacturing plants. The tra-
ditional jaggery manufacturing plants are placed in decentralized sec-
tors of India. These plants are made tiny in size by the local artisans
[18]. In India, traditionally three types of jaggery manufacturing plants
are used, namely, single-pan, two-pan, and multi-pan (three or four-
pan) jaggery manufacturing plant. In single-pan plant, a pit type fur-
nace is made into the ground with ordinary small bricks or building
blocks wall of 100–150 mm high placed around the top to ensure a level
for flat surface to support the pan. The furnace can be either round or
rectangular according to the type of pan used. A round or circular
furnace is the most efficient design but the ease of manufacture and cost
of the pans often dictates type of furnace. Two holes positioned oppo-
site each other are required, one to feed bagasse into the furnace and
the other to exhaust smoke and other products of combustion. Pans
used in traditional jaggery manufacturing plants are usually rectangular
with flat surface or hemispherical or cone shaped. Rectangular shape
does not allow even heating as burning of the product may occur. Pans
for the round furnace should be hemispherical or cones shaped which
allow more even heating but are more expensive and difficult to man-
ufacture. Cones shaped pans are often used in parts of Asia for syrup
production but less often for jaggery production as the thick viscous
massecuite are difficult to remove from them. The schematic view of
temporary single pan jaggery making plant is shown in Fig. 3a.
In two-pan jaggery-making plants, two pans are used in series at the
top of furnace. The two-pan plant was manufactured at the Indian in-
stitute of sugarcane research Lucknow (IISR) to overcome the problem
of single pan unit. The second pan placed in the way of hot flue gasses
after boiling pan is known as gutter pan. The sugarcane juice was
preheated in the gutter pan and then transferred to the boiling pan for
heating up to the striking temperature. The schematic view of two-pan
jaggery making furnace is shown in Fig. 3b.
170
Renewable and Sustainable Energy Reviews 96 (2018) 167–180
In multi-pan jaggery making plants, in addition to boiling and gutter
pans one or two more pans are placed in series in the way of waste flue
gases to extract more heat. The first and the second pans are used only
to pre-heat the sugarcane juice by utilizing thermal energy of hot flue
gases. The pre-heated sugarcane juice is finally transferred to the
boiling pan placed exactly over the flames having highest temperature
than the others. The direction of transformation of juice is opposite to
the direction of motion of hot flue gases for the better utilization of
thermal energy of hot flue gases. Moreover, such an arrangement can be
used for continuous jaggery production. The other constructional fea-
tures of three or four-pan units are similar to that of two-pan jaggery
making plant. The schematic view of four-pan jaggery making plant is
illustrated in Fig. 3c.
Rao et al. (2003) observed that traditional single pan jaggery
manufacturing plant has very low value of thermal efficiency (14.75%)
and high value of bagasse consumption (3.85 kg per kg of jaggery
produced) [42]. Sharon et al. (2013) found that the low efficiency of
traditional jaggery making plant is due to partial crushing of sugarcane
in a crusher (about 60% efficiency) and the use of open pan for the
concentration process of jaggery [52]. Manjare and Hole (2013) ob-
served that the thermal efficiency of the traditional jaggery making
plant can be increased and bagasse consumption can be decreased by
the implementation of a pre-heater and economizer for preheating of
sugarcane juice [57]. Anwar (2014) fabricated an efficiency booster at
the bottom of single pan jaggery manufacturing plant, which was stated
to improve thermal efficiency up to 35%, saving of fuel up to 26%, and
decreases time required per batch up to 30% for the production of
jaggery [58]. The schematic view of efficiency booster used in jaggery
manufacturing plant is shown in Fig. 4.
Agalave (2015) found that the use of fins and baffle at the bottom of
single pan plant improve the thermal efficiency of plant by 9.44% along
with the saving of fuel and energy by 31.34% as compared to tradi-
tional plant [59]. Madanrao (2017) found that the use of fins at the
bottom of boiling pan of a prototype model of traditional single pan
R. Kumar, M. Kumar Renewable and Sustainable Energy Reviews 96 (2018) 167–180

jaggery making plant can increase the thermal efficiency of the plant

The fresh bagasse coming from crusher contains 50% moisture, 47% fibers, 2.5% sugar and 0.5% minerals.
Calorific value of bagasse can be increased up to 10% by decreasing the moisture content half of its initial

Bhendi powder, bhendi mucilage and groundnut milk (herbal clarificants) were found to be more efficient
The percentage of bagasse in sugarcane varies from 23% to 37% depending upon the variety of sugarcane

By crushing 1000 kg of sugarcane 650 kg of juice and 350 kg of bagasse can be obtained. OSD of bagasse
from 15.35% to 24.50% and decrease the bagasse consumption from

Optimized the clarification parameters of sugarcane juice for 77.55 °C temperature, 1.5 mm thickness of
3.83 kg to 2.75 kg per kg of jaggery produced [60].

Cost of organic jaggery was reported to be 25% higher than the jaggery prepared by using inorganic
Baboo and Anwar (1995) placed a second pan (gutter pan) in the
way of hot flue gasses after boiling pan of a traditional jaggery making
High calorific values of bagasse consisting of fibers (19259 kJ/kg) and sugar (16747 kJ/kg).
plant to improve its thermal efficiency [61]. Singh et al. (2008) found
that the performance of two-pan jaggery making plant under forced
draft conditions was higher than natural draft conditions, which re-
sulted in saving of 8% of bagasse and increase in efficiency by 2.6%

Produced sulphates and organo-sulfur, which are hazardous for human beings.
[62]. Singh et al. (2009) observed that the overall efficiency of im-
proved two-pan furnace was 29.3% and saving in operating cost of
34.82% as compared to traditional single pan furnace [63]. Anwar
(2010) increased the heat utilization efficiency of two-pan jaggery
making plant (about 9.44%) by using fins at the bottom of boiling and
Increased the crushing efficiency to the extent of 77–80%.

gutter pans along with the saving of bagasse and energy by 31.34%
[64]. The schematic views of fins at the bottom of boiling and gutter
pans used in jaggery manufacturing plant is shown in Fig. 5.
decreases the moisture content from 50% to 20%.

than the other herbal and synthetic clarificants.

Manjare and Hole (2016) improved the thermal efficiency of tra-

ditional two-pan jaggery making plant from 16.16% to 24.36% by
implementing an economizer and pre-heater, which utilizes the exhaust
heat and thus reduced the bagasse consumption by 1.2 kg per kg of
charcoal and 0.48 g/lit of deola.

jaggery produced [65].

Madan et al. (2004) carried out a comparative performance trial on
existing and improved three-pan jaggery making plants. It was observed
that the specific bagasse consumption of traditional three-pan jaggery
making plants can be improved from 2.24 kg to 1.96 kg per kg of jag-
gery produced by using fire-bricks with refractory cement, circular
clarificants.

cross-section and optimum height of chimney, sliding dampers, firing

Remarks

platform and fire grate [18]. Singh (2009) fabricated a three-pan jag-
level.

used.

gery manufacturing plant for the better utilization of thermal energy of

hot flue gases at IISR Lucknow which resulted in good heat utilization
Studied the efficiency of traditional jaggery making furnace and open sun drying

Studied the applications of response surface method to optimize the clarification

Analyzed the chemical reactions of sulfur dioxide as a clarificant after absorption
Multiple crusher along with hot water results in increase in sugarcane crushing

efficiency of about 34.3% [66]. Shankar et al. (2009) evaluated the

performance of multi-pan plant over traditional jaggery making plant
Studied the effect of different clarifying agents on the quality of jaggery.

and observed that it was better option for the utilization of fuel and
Quality parameters of sugarcane bagasse for the industrial utilization.
Studied the effect of moisture content on calorific value of bagasse.

quickness in boiling of sugarcane juice as compared to traditional single

Analyzed the availability of bagasse and power produced by it.

pan plant [67]. Sardeshpande et al. (2010) evaluated the thermal per-
formance of a four-pan jaggery making plant and observed that the
controlled fuel feeding of bagasse reduced the specific fuel consumption
Studied the calorific values of by products of bagasse.

from 2.39 kg to 1.73 kg per kg of jaggery prepared [68]. Arya et al.

Conducted a case study on organic jaggery in India.

(2013) improved the performance of a three-pan jaggery manufacturing

plant by using some constructional changes [69]. The changes resulted
in reduction in bagasse consumption and increase in jaggery production
capacity of about 12% and 23% respectively along with lesser emission
and lower exhaust gas temperature. Shiralkar et al. (2014) found that
parameters of sugarcane juice.

the thermal efficiency and bagasse consumption of multi-pan jaggery

by alfallfa and sugar beets.

making plant were 46% and 1.44 kg/kg of jaggery produced with
Main findings on the operations of jaggery manufacturing plant.

0.13 m3/s flow rate of air through the furnace [70]. Santhy and Baburaj
(2015) carried out a study on the socio-economic impact of multiple-
(OSD) of bagasse

pan furnace over single-pan furnace jaggery manufacturing plant and

stated that the three-pan furnace plant was more fuel efficient, eco-
Description

efficiency.

nomic and profitable for the higher volume operations [71].

Rane and Jabade (2005) proposed a new concept of heat pump
based freeze concentration system (FCS) for the concentration of su-
garcane juice in a jaggery making process [72]. Sugarcane juice flows
2007

2005

1982
2013

2003

1977
2012

2007

1944

2015
Year

over the refrigerated surface which performs the function of condenser

and evaporator alternatively and then transferred to the boiling pan for
Ramanagowda et al. [49]
Agarwal and Maroo [41]

Kumar and Chand [55].

further concentration. This process improved the concentration of su-

garcane juice from 20 to 40 brix resulted with the saving of bagasse
Kumar et al. [48]

consumption of about 1338 kg per day for the production of 1000 kg of

Rao et al. [15]

Rao et al. [42]

Thomas [51]
Paturao [39]

jaggery. The schematic view of freeze concentration system used in

Researchers

Anwar [40]

Rao [43]

jaggery manufacturing plant is shown in Fig. 6.

Sahasrabudhe et al. (2011) developed a mathematical model for
analyzing the freeze concentration system of sugarcane juice in a jag-
gery making process and concluded that an optimum freeze con-
Sr. No.
Table 2

centration system can be designed by estimating the various input

10.
1.

2.

3.
4.

5.

6.
7.

8.

9.

parameters [73]. Kumar and Chand (2015) found the optimum process

171
R. Kumar, M. Kumar Renewable and Sustainable Energy Reviews 96 (2018) 167–180

Fig. 3. Schematic views of different jaggery making plants.

parameters of clarification of sugarcane juice by using response surface

Fig. 4. Schematics of efficiency booster.
method [55]. Rane and Uphade (2016) stated that the freeze pre-con-
centration of sugarcane juice has better prospects for efficient way of
jaggery making but it increases the sugar lost in inclusion and the cost
of system [74].
Kavatkar et al. (2015) fabricated an automatic fuel feeding system
for automatic feeding of the bagasse in a crusher to save the labor cost
and to increase overall efficiency of jaggery plant [75]. Nikam et al.
(2015) compared the performance parameters of a conventional and
improved jaggery manufacturing plants and stated that it is very es-
sential to improve the overall performance of the plant by modifying
the constructional parameters of furnace and chimney [76]. Madrid

Fig. 5. Schematic views of fins at the bottom of boiling and gutter pan.

172
R. Kumar, M. Kumar
Fig. 6. Schematic view of freeze concentration system.
(2017) numerically evaluated and analyzed the process of heat transfer
from hot flue gasses to sugarcane juice in an open heat exchanger by
using CFD simulations tools [77]. Jakkamputi and Mandapati (2016)
observed that the utilization of solar energy for the preheating of su-
garcane juice and inlet air improves the performance of jaggery making
plant along with the saving of bagasse per kg of jaggery produced [78].
Madrid et al. (2016) developed a CFD simulation module to analyze the
heat transfer process through the pans of jaggery making plant at the
“Santa Rosa de Chonta” located at the northern highlands of Peru [79].
The qualitative results are reported to be in good accordance with field
measurements. However, the simulation of complete sugarcane pro-
duction would have given a better representation of the heat transfer
processes. Nikam and Nelge (2017) numerically analyzed the cooling of
jaggery by using heat exchanger for which the velocity and temperature
distributions were reported to be in accordance with experimental re-
sults [80]. Magade et al. (2017) manufactured a prototype of jaggery
manufacturing plant that was stated to be more productive and fuel
efficient [81].
It is observed from the literature that jaggery is being manufactured
allover India in small scale plants following tradditional methods. The
energy efficiency and productivity of these plants is found to vary from
15% to 51% and 10–12% respectively that is very low and needs suf-
ficient attention for its improvements and optimizations as well. This
can be increased by following some viable methods like better utiliza-
tion of thermal energy and automation of jaggery manufacturing op-
erations. These kinds of improvements may lead to the establishment of
large scale plants, which could be economical and profitable for the
farmers, entrepreneurs and customers.
The above discussion given on technological advancement in jag-
gery manufacturing plants have also been summarized in Table 3.
From the above discussion it is observed that the efficiency of jag-
gery making plant depends upon the complete combustion of bagasse,
better utilization of heat, draft generated, material used in plant con-
struction, and the height of chimney. The efficiency of traditional jag-
gery making plants is very low because they are fabricated by local
artisans. To improve the efficiency of traditional jaggery making plant a
second pan called gutter pan is being used to preheat the sugarcane
juice before boiling pan. The rate of heat transfer from hot flue gases to
sugarcane juice has been attempted to increase by using fins at the
bottom of boiling and gutter pans. Three and four-pans were also uti-
lized to improve the overall efficiency of the plant by extracting more
heat from the waste flue gases. However, the use of three or four pans
does not show significant improvement in the thermal efficiency and
reduction in bagasse consumption of the plant.
4. Studies on shelf life of jaggery
The shelf life of jaggery is the time for which it maintains its
properties. The storage life of jaggery is mainly depends upon the at-
mospheric humidity and temperature. Jaggery contains invert sugar,
173
Renewable and Sustainable Energy Reviews 96 (2018) 167–180
reducing sugar, glucose, fructose, proteins, iron and mineral salts [82].
The invert sugar and mineral salts are hygroscopic in nature. The pre-
sence of moisture in jaggery changes its biological properties (like
color, taste and state) and thus spoils the jaggery [83,84]. For good
keeping quality of jaggery, the moisture content should not exceed 6%
[85]. It was estimated that during monsoon season more than 10% of
total jaggery produced in India of value 0.6 million US $ is lost annually
[26]. In order to improve the shelf life of jaggery, the researchers adopt
different traditional and improved methods. In this section, studies on
storage, packaging and solar drying of jaggery are discussed which
claims improvement in the shelf life of jaggery under different en-
vironmental conditions. In India, manufacturing of jaggery starts in the
month of September/October and continues till March/April and stored
for the rest of the year. It has been estimated that one third to one-half
of the total production of jaggery is stored every year [86]. The pre-
treatment of sugarcane juice with nitric oxide gives better color and
level of sucrose which helps to increase the shelf life of jaggery [87].
The storage of jaggery is an important aspect to preserve it in un-
favorable environmental conditions. Traditionally earthen pot, wooden
box, and metal drums are used for jaggery storage that varies from
region to region. In some areas, jaggery is stored in the form of a heap
and covered with cane trash, bagasse, wheat straw, cottonseed, furnace
ash, Palmyra leaf mat, rice husk, etc. to protect it from the direct
contact of moist air [19]. Number of researches has been conducted on
storage behavior of jaggery. The jaggery stored in tin containers absorbs
much less moisture as compared to earthen pots [88]. A study on the
design of a godown for the storage of jaggery during the rainy period
has been carried out [89]. The jaggery can be stored for longer duration
under controlled environmental conditions of about 40–45% relative
humidity [90]. The effects of orthophosphoric acid on physical [91] and
chemical [92] properties of jaggery were reported by the researchers.
The first national seminar on jaggery manufacture, its quality, and
storage was organized in 1985 at IISR, Lucknow [93]. The jaggery
stored in painted earthen pitchers or plastic containers [94] had less
increase in reducing sugars than unpainted ordinary earthen pots and
could be kept for a longer time [95]. The jaggery can be stored for a
longer time up to eight months at low temperature [96]. Jaggery can be
stored without any physical changes for a period of 20 months at a
temperature range of 7–9 °C [97]. The techno-economic analysis of cold
storage of jaggery revealed that establishment of new cold storage ex-
clusively for jaggery was not feasible economically. The excessive use of
sulfite as a clarificant can affect the color of jaggery during storage
[98].
The excessive growths of microbial during storage of jaggery are
very harmful to human body [83]. The storage life of jaggery powder is
also affected by the shape and sizes of jaggery particles. It was observed
that jaggery powder of coarse grade (0.5–0.708 mm) was more accep-
table in terms of its chemical properties and organoleptic characteristics
than medium (0.351–0.420 mm) and fine (0.211–0.296 mm) in 100
gauge polyethylene bag for the period of six months [99]. IISR
 Table 3
Researches on technological advancements on operational conditions of jaggery manufacturing plants.
Sr. No. Researchers Year Description Remarks

1. Rao et al. [42] 2003 Evaluated the thermal efficiency and bagasse consumption of traditional real jaggery making Low thermal efficiency (14.75%) and high bagasse consumption (3.85 kg/kg of jaggery).
R. Kumar, M. Kumar

plant.
2. Sharon et al. [52] 2013 Conducted a study on various energy losses in a real traditional jaggery making plant. Crushing efficiency (60%) and concentration efficiency (14.75%) were observed low.
3. Manjare and Hole [57] 2013 Implemented a sugarcane juice pre-heater and economizer to utilize the exhaust heat in a Small increase in thermal efficiency from 16.16% to 24.36% and reduction in bagasse
traditional single pan jaggery making plant. consumption by 1.2 kg/kg of jaggery produced.
4. Anwar [58] 2014 Designed and fabricated an efficiency booster in single pan jaggery making plant by increasing Improved thermal efficiency (35%), saving of fuel (26%) and time consumed (30%) during
the turbulence inside the furnace. the process.
5. Agalave [59] 2015 Improved the thermal efficiency of traditional single pan jaggery making plant by using fins and Increased the thermal efficiency by 9.44% and saving of fuel/energy by 31.34%.
baffles at the bottom of the pan.
6. Madanrao [60] 2017 The heat utilization efficiency of traditional single pan jaggery making plant was increased by Increased by 9.15% and decreased the bagasse consumption by 28.19%.
using modified pan having fins at the bottom and decreases the bagasse consumption.
7. Baboo and Anwar [61] 1995 Developed a two-pan jaggery manufacturing plant to improve the heat utilization efficiency of Better utilization of thermal energy of hot flue gasses was stated good and it is being adopted
jaggery making plants. in all newly constructed jaggery making plants.
8. Singh et al. [62] 2008 Compared the performance of two-pan jaggery making plant under forced and natural drafts. The combustion efficiency of the two pan jaggery making plant under forced draft was
observed 2.6% higher as compared to natural draft.
9. Singh et al. [63] 2009 Compared the overall efficiency and operating cost of two-pan jaggery making furnace with High overall efficiency (29.3%) and low operating cost (2.27 Rs per kg of jaggery) was
traditional single pan jaggery making furnace. observed.
10. Anwar [64] 2010 Implemented the concept of fins at the bottom of boiling and gutter pans in a two-pan jaggery Increase in heat utilization efficiency of about 9.44% and saving of bagasse/energy by
making furnace to increase the efficiency of heat utilization. 31.34% was observed.
11. Manjare and Hole [65] 2016 Employed a juice pre-heater and economizer for the utilization of exhaust heat in a traditional Increase in thermal efficiency (50.74%) and decrease in the bagasse consumption by 1.2 kg/
two-pan jaggery making plant. kg of jaggery produced was observed.
12. Madan et al. [18] 2004 Conducted a comparative performance trial on existing and improved three-pan jaggery making Decrease in specific bagasse consumption from 2.24 kg to 1.96 kg per kg of jaggery produced
plants. was observed.
13. Singh [66] 2009 Developed a three-pan jaggery making plant at IISR Lucknow. Moderate percentage of heat utilization efficiency of the flue gases about 34.3% was found.
14. Shankar et al. [67] 2009 Studied the performance of multi-pan and traditional single pan furnaces for the better Could be optimized by the selection of a proper gauge material and design parameters of a

174
utilization of fuel and quickness in boiling of sugarcane juice. jaggery making plant.
15. Sardeshpande [68] 2010 Studied the performance of a four-pan jaggery making plant under controlled fuel feeding of Reduce the specific fuel consumption from 2.39 kg to 1.73 kg per kg of jaggery prepared.
bagasse.
16. Arya et al. [69] 2013 Improved the performance of three-pan jaggery making plant by using some constructional The bagasse consumption was observed to decrease (12%) and the jaggery production
changes. capacity was increased (23%).
17. Shiralkar et al. [70] 2014 Conducted an experimental study for the calculation of thermal efficiency, bagasse No any appreciable difference between the thermal efficiency and bagasse consumption of
consumption and the flow of air through traditional single-pan and multi-pan jaggery making traditional single-pan and multi-pan jaggery making furnaces. The multi-pan jaggery furnace
furnaces. was more productive than single pan furnace due to their semi-continuous nature.
18. Santhy and Baburaj [71] 2015 Studied the socio-economic impact of multiple pan furnace over single-pan furnace in jaggery Three-pan furnace plant was stated more economic and profitable for the higher volume of
preparation. jaggery production then single-pan furnace.
19. Rane and Jabade [72] 2005 Proposed the concept of heat pump based freeze concentration system to increase the Heat pump based freeze concentration system leads to decrease in the mass of bagasse
concentration of sugarcane juice in a jaggery making system. consumption.
20. Sahasrabudhe et al. [73] 2011 Developed a mathematical model for analyzing the freeze concentration system of sugarcane A mathematical model is always very helpful in studying the benefits and drawbacks of a
juice in a jaggery making process. process without carrying out any actual operation.
21. Kumar and Chand [55] 2015 Studied the optimization parameters for the clarification of sugarcane juice by using response The response surface method is very efficient statistical tool to obtain optimal response
surface method. parameters of a process by following a sequence of designed experiments.
22. Rane and Uphade [74] 2016 Improved the thermal efficiency and clarification of juice in a traditional jaggery making plant Freeze pre-concentration could be an efficient jaggery making process but it increases the
by using freeze pre-concentration process. sugar lost in inclusion and the cost of the system.
23. Kavatkar et al. [75] 2015 Developed an automatic sugarcane feeding system to increase the overall efficiency of the The proposed automatic fuel feeding system could eliminate the human effort, but it could
jaggery making plant. not maintain the continuity of the fuel feeding process.
24. Nikam et al. [76] 2015 Studied the improvement of overall performance of a jaggery making plant by improving the Jaggery production, bagasse consumption, emissions and temperature of exhaust were stated
constructional parameters of furnace and chimney. as important parameters for the improvement of plant performance.
25. Madrid et al. [77] 2015 Numerically analyzed the process of heat transfer in open heat exchanger used for jaggery CFD could be a good simulation tool for the numerical analysis of heat transfer process for
production. jaggery production in open heat exchanger.
26. Jakkamputi and Mandapati 2016 Studied the utilization of solar energy to pre-heat the sugarcane juice and inlet air of jaggery Utilization of solar energy in pre-heating the sugarcane juice and inlet air would increase the
[78] making plant. efficiency of jaggery making plant.
27. Madrid et al. [79] 2016 Developed a CFD simulation module to analyze the heat transfer process through the pans of CFD could be a good simulation tool to simulate the various operating parameters of jaggery
jaggery making plant without actual experimentation. making process by using various boundary conditions.
(continued on next page)
Renewable and Sustainable Energy Reviews 96 (2018) 167–180
 Table 3 (continued)

Sr. No. Researchers Year Description Remarks

28. Nikam and Nelge [80] 2017 Analyzed the pre-heating of sugarcane juice experimentally and analytically by using thermal The utilization of thermal energy of freshly made jaggery during its solidification process
energy of freshly made jaggery during its solidification process. could be very efficient for pre heating of sugarcane juice.
R. Kumar, M. Kumar

29. Magade et al. [81] 2017 Simulated a prototype design of jaggery making plant by using a boiler, net separator and PLC A water tube boiler and PLC controller could be used to make the process continuous and
controller for the automation of jaggery packaging. automatic.

175
Table 4
Studies on the affects of storage materials on the shelf life of jaggery.
Sr. No. Researchers Year Storage material / conditions Description Pros/cons

1. Gunjal and Galakatu [90] 1986 Godown storage with controlled relative Studied the shelf life of jaggery under controlled environmental conditions. Longer jaggery storage time in 40–45% relative humidity.
humidity
2. Baboo and Shukla [94] 1987 Painted and unpainted earthen pot Improved the domestic storage techniques of jaggery. Jaggery could be stored for a longer period in painted earthen pot.
3. Singh [95] 1998 Painted and unpainted earthen pot Studied the effect of jaggery storage on reducing sugars. Painted earthen pot had less increase in reducing sugars.
4. Uppal and Sharma [106] 1999 Airtight container Evaluated the shelf life of jaggery prepared from new varieties of sugarcane in Physico-chemical properties of jaggery (like color and sweetness)
during rainy season. were not affected.
5. Uppal and Sharma [96] 2002 Low temperature Studied the storage life of jaggery at low temperature. Could be stored for a period of eight months.
6. Uppal [97] 2002 Low temperature Calculated the storage time of jaggery at 7–9 °C temperature. Could be stored for a period of 20 months.
7. Chand et al. [100] 2011 Jaggery cum storage bin Compared the storage life of jaggery in jaggery cum storage bin with open and Jaggery could be stored for a period of six months in jaggery cum
polyethene bags. storage bin.
Renewable and Sustainable Energy Reviews 96 (2018) 167–180
 R. Kumar, M. Kumar

Table 5
Studies on the affects of packaging materials on the shelf life of jaggery.
Sr. No. Researchers Year Storage material Description / Remarks Pros/cons

1. Shinde et al. [105] 1983 Polyethene film Studied the effect of form and color of polyethene as a wrapping No inversion of non-reducing sugar and no change in reducing sugar during storage was
material on keeping quality of jaggery during storage. reported.
2. Gupta et al. [107] 2002 Nitrogen packaging Investigated the packaging behavior of jaggery with vacuum The nitrogen packaging of solid jaggery maintained its freshness for a longer period.
and nitrogen environments.
3. Mandal et al. [26] 2006 Painted earthen pot, heat sealed packet Compared commonly used packaging materials for keeping Painted earthen pot, heat sealed packet of LDPE and PET jar with airtight lid were the best
of LDPE and PET jar quality of jaggery during monsoon season. jaggery packaging method in monsoon season.
4. Rai and Paul [19] 2007 Earthen pot, wooden box and metal Reviewed the packaging requirements of highly respiring Avoid anaerobic respiration of the packaged produce.
drum products.
5. Singh and Singh 2008 Three ply packaging materials Studied the processing, handling and storage of jaggery in three For solid jaggery the three ply packaging materials were stated more suitable as quality
[108] ply packaging material. packaging material.
6. Singh [109] 2008 LLDPE, PP, LD/HD/LLD, BOPP and PET Conducted a study to compare the effects of different packaging Three ply packaging material was observed as the best packaging material due to high
materials on keeping quality of jaggery. strength, low water vapour transmission rate and least oxygen transmission rate.
7. Unde et al. [99] 2011 100 gauge polyethylene bag at room Studied the effecct of different particle sizes on storability of Particle size of coarse grade (0.5–0.708 mm) can be stored for a period of six months.
temperature jaggery powder.
8. Sankhla et al. [110] 2011 Low density polyethene pouch and Studied the effect of packaging material and irradiation (3 kGy, Low-density polyethene pouch and paper bags subjected to medium dose irradiation at
paper bags 5 kGy and 7 kGy) on storage stability of jaggery. 7 kGy were found best.
9. Kumar et al. [86] 2012 PET film with 100% Nitrogen Observed the effect of modified atmosphere packaging on PET film with 100% Nitrogen could be used for longer duration.
keeping quality of jaggery.

176
10. Shukla [111] 2012 Whey Evaluated the effect of edible coating and packaging materials Use of whey as a coating and packaging material was very effective to preserve jaggery
on microbiological characteristics of jaggery. for longer time.
11. Singh et al. [112] 2012 Nitrogen Studied the shelf life of jaggery under modified environmental Packaging of jaggery with nitrogen was found very effective to maintain all the physico-
conditions. chemical, microbial and overall parameters than vacuum, polythene bags and airtight
containers at room temperature.
12. Kumar et al. [113] 2013 PET film Analyzed the effect on color of jaggery cube under modified PET film was the best jaggery packaging method than LDPE, PP and laminated aluminum
atmospheric conditions packed in a plastic film. film under modified atmospheric packaging conditions.
13. Kumar et al. [114] 2013 Triple layered vacuum packaging Investigated the processing, packaging and storage of jaggery in Packaging of jaggery in a triple layered vacuum packaging material for the change in
different layered and vacuum packaging materials. color, sucrose content, hardness, reducing sugar, moisture content, porosity and microbial
load was found very effective.
14. Kumar et al. [86] 2013 PET film under 100% nitrogen Studied the effect of modified atmospheric packaging conditions Packaging of jaggery in PET film under 100% nitrogen showed less reduction in quality
on keeping quality of jaggery. parameters during storage than LDPE and PP films.
15. Chand et al. [101] 2014 Edible coating Studied the effecct of edible coating on quality parameters of Drying cum bin with edible coating of whey protein could be used to store for longer
jaggery. duration.
16. Patil and Anekar 2014 Presterilized PET bottle Studied the effect of parameters and storage conditions on More efficient storage in presterilized PET bottle and 7 °C temperature.
[102] quality of jaggery.
17. Anwar et al. [103] 2015 Vitamin C enriched Compared the storage life of jaggery with vitamin C enriched Observed same storage life under same environmental conditions.
jaggery.
18. Mishra et al. [104] 2016 Carboxy methylcellulose (CMC) and Studied the effect of CMC and WP on quality of jaggery during Could be used to maintain the quality of jaggery for some time.
whey protein (WP) storage.
19. Kumar et al. [115] 2017 CMC & hydroxyl propyl methyl cellulose Evaluated the storage life of jaggery under different edible Reported that use of CMC and HPMC as an edible coating material may improve the
(HPMC) coating materials. storage life of jaggery up to 225 days.
Renewable and Sustainable Energy Reviews 96 (2018) 167–180
R. Kumar, M. Kumar Renewable and Sustainable Energy Reviews 96 (2018) 167–180

developed an improved drying cum-storage bin (100 kg capacity) and a

It was observed that for a given size of greenhouse CMTC is a strong function of mass of jaggery,

It was observed that the shape and size of jaggery samples play an important role in the variation

The present model was stated very effective to design a greenhouse dryer for a thin layer and

drying under natural convection mode by detecting the patterns from the experimental data.
ANN model is a computer program designed to predict the hourly mass of jaggery during its
The number of air charges per hour, relative humidity and the surface area of jaggery were
godown of six tones capacity which was found suitable for almost all

ANFIS model is also known as universal estimator, which can be used to learn nonlinear
the regions in India [9]. The change in quality characteristics during
storage such as moisture content, color, sucrose, and reducing sugar
were found more efficient in jaggery cum storage bin than open pan and
polyethylene bag for a period of six months [100]. The storage of jag-

stated to be the most effective parameters in greenhouse drying of jaggery.

gery in IISR bin was also found most efficient than the polythene bag
and open storage under hilly climatic conditions. The PET film with
100% Nitrogen can be used to store jaggery for a longer period than jute
bags [86]. The storage of jaggery in drying cum storage bin with edible
coating of whey protein was found to be good as compared to uncoated
jaggery [101]. The storage of jaggery in a presterilized PET bottle at
refrigeration temperature (7 °C) was found more efficient than at room
temperature (27 °C) and high temperature (37 °C) [102]. A study was
conducted on storage life of value-added jaggery using vitamin C and
plain jaggery for a period of 10 months and observed that the storage
behavior of both jaggery are same under same environmental condi-
temperature and relative humidity.

tions [103]. Mishra et al. (2016) utilized the carboxy methyl cellulose
and whey protein to maintain the moisture content of jaggery or storage
of jaggery for some time [104]. The various studies carried out on
of the values of CMTC.

given mass of jaggery.

storage and packaging of jaggery is summarized in Table 4 & Table 5

respectively.
The various studies carried out on solar drying of jaggery are
summarized in Table 6.
Pros/cons

functions.

The schematic views of natural and forced convection greenhouse

jaggery dryers are shown in Fig. 7a & b.
From the discussion given in Table 4 and Table 5 it is observed that
Developed a thermal model for the greenhouse drying of jaggery under forced convection mode

Developed an adaptive-network-based fuzzy inference system (ANFIS) model by using MATLAB

(Fig. 7b) for predicting the value of jaggery temperature, greenhouse temperature and moisture
Calculated the convective mass transfer coefficient (CMTC) for the greenhouse drying of jaggery

Developed a thermal model for the greenhouse drying of jaggery with thin layer under natural

during its drying under natural convection mode (Fig. 7a). The predicted results of ANN model

software for the natural convection greenhouse drying of jaggery (Fig. 7a) to forecast the values

jaggery is being stored in tin, painted earthen pot, low temperature

Evaluated the convective mass transfer coefficient (CMTC) for greenhouse drying of jaggery

storage, drying cum storage bin, PET film with nitrogen and whey
Developed an artificial neural network (ANN) model to predict the hourly mass of jaggery
convection mode (Fig. 7a) for predicting the value of jaggery temperature, greenhouse

coatings. The storage of jaggery in drying cum storage bin with whey
coating is found to be most effective for keeping the quality of jaggery.
The greenhouse drying of jaggery is an efficient approach to remove the
were validated with experimental results on the basis of statistical parameters.

moisture content of jaggery and to store it for longer duration. The

ANFIS and ANN models could be used to forecast the experimental
of temperature of jaggery, greenhouse air and the moisture evaporated.

parameters and to predict drying rate for greenhouse drying of jaggery.

5. Summary
under forced and natural convection modes (Fig. 7a&b).

The traditional jaggery manufacturing plants requires a very little

investment and provides employment to the rural peoples. These plants
are designed by local artisans without any proper design considera-
tions, as a result of which large portion of energy is wasted with flue
under natural convection mode (Fig. 7a).

gases and thermal efficiency of plants becomes very low. To overcome

temperature and moisture evaporated.

this problem two-pan, three and four-pan plants are used to consume
maximum thermal energy of hot flue gasses. Numbers of researches
have been conducted in this direction to increase the performance of
jaggery making plant. These researches include utilization of fins, baf-
Description / Remarks

fles, energy booster, economizer, and juice pre-heater, heat pump based
freeze concentration system of sugarcane juice, optimum height of
chimney, draft generated through the furnace, and the material used for
evaporated.

the construction of furnace, etc. From the available literature on up-

gradations for the production of jaggery manufacturing plants the use
of multi-pan plant with heat pump based freeze concentration system is
found to be a good approach for efficient production of jaggery from
2006b
2006a

2006c
2004

2014

2014
Year

sugarcane juice.
The storage of jaggery is also a big problem. The traditional storage
Studies on solar drying jaggery.

methods namely earthen pot, wooden box and metal drum, etc. are not
very effective for keeping quality of jaggery. PET film, edible coating,
Parkash and Kumar

Parkash and Kumar

Kumar and Tiwari

Kumar and Tiwari

Kumar and Tiwari

Tiwari et al. [56]

drying cum storage bin, low temperature storage, PET film with 100%
nitrogen are used as packaging materials for keeping quality of jaggery.
Researchers

The storage of jaggery in drying cum storage bin with whey coating is
[116]

[117]

[118]

[119]

[120]

most effective for keeping the quality of jaggery for longer duration.
The greenhouse drying of jaggery before storage is also an efficient
approach to increase the storage life of jaggery at lower cost without
Sr. No.
Table 6

consuming any other source of energy. The future scopes of jaggery

1.

2.

3.

4.

5.

6.

manufacturing process may be approached towards increase in plant

177
R. Kumar, M. Kumar
Fig. 7. (a&b) Schematic view of greenhouse jaggery dryers.
efficiency by its proper design considerations and mathematical mod-
elling, decrease in moisture content and rate of bagasse consumption,
rate of heat transfer enhancement from hot flue gases to sugarcane
juice, and automation of jaggery making processes.
6. Unsolved problems, difficulties, and suggestions for future
works
The thermal and overall efficiencies of jaggery manufacturing plants
are very low that depend upon number of factors. Some of the major
factors which needs due attention are design and constructional para-
meters of plant, combustion of bagasse, utilization of thermal energy of
hot flue gasses and the draft generated through the furnace. All these
parameters are directly linked to the efficiencies of jaggery making
plant. Hence efforts can be made towards the improvement of these
parameters along with the automation of different operations involved
178
Renewable and Sustainable Energy Reviews 96 (2018) 167–180
in jaggery manufacturing process. Low juice recovery efficiency, low
productivity and high operational time of traditional jaggery making
plants are also major challenges for the researchers. The storage and
preservation of jaggery for a longer period is very difficult. Since the
storage life of jaggery is much affected by the contents of invert sugars
and mineral salts which are hygroscopic in nature. Jaggery can be
preserved for a longer duration either by controlling different en-
vironmental conditions or by minimizing hygroscopic property of jag-
gery. Improvement in heat utilization efficiency, pre heating of juice,
use of freeze concentration process, automation of different processes
and maintaining the keeping quality of jaggery for a longer duration
under all the environmental conditions are some of the current research
activities being performed by the researchers. In nutshell, optimization
of jaggery manufacturing processes, upgradation in traditional jaggery
manufacturing plants and preservation of jaggery are the major chal-
lenge before the researchers. These challenges could be fulfilled by
R. Kumar, M. Kumar
scientists/researchers working efficiently in the field of jaggery pro-
duction and its storage. The government and researchers should en-
courage farmers to utilize solar energy in heating of sugarcane juice to
make the jaggery manufacturing process eco-friendly.
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