A Project Report

ON
PROCESS OF SUGAR
MANUFACTURING
(SUMMER INTERNSHIP REPORT)
Submitted in partial fulfillment of the requirement for the award of the degree of

DIPLOMA IN ENGINEERING (Mechanical Engineering)

Submitted by: Pratik kumar Submitted to: Er. Ajay kumar

Roll no-511362520015 (Head of Department-ME)

Batch-2020-2023 Branch-Mechanical Engg.

Semester-5th

Year-3rd

10 Feburary 2023 to 10 March2023

CERTIFICATE
This is hereby declare that the project work entitled
“PROCESS OF SUGAR MANUFACTURING” submitted by Pratik
kumar to BHARAT SUGAR MILL SIDHWALIA(BIHAR) for the
award of SUMMER INTERNSHIP is a genuine record of the
work carried out by them during the period of 10th FEB to
10th MARCH 2023.
It is further certified that this project has been developed by
PRATIK KUMAR, in original and has been the result of their
personal efforts with little assistance wherever required.

Sri Umesh Kumar Singh

CHIEF ENGINEER

BHARAT SUGAR MILLS, SIDHWALIA

GOPALGANJ (BIHAR)
ACKNOWLEDGEMENT
A very thanks to Sri Umesh kumar singh CHIEF ENGINEER (BHARAT
SUGAR MILL) for providing us with the opportunity to avail the
excellent facilties and infrastructure in terms of the faculty,the
ambience which served as the turning point of my career.

We are also grateful to college for providing us with the opportunity

to work with hem and undertake a project of such importance.

PRATIK KUMAR
Diploma in mechanical engg.(5th semester)
B.K.N.S.G.P GOPALGANJ,BIHAR
DECLARATION
We hereby declare that this submission is our own work which is
being presented in the project work entitled “STUDY OF SUGAR
MANUFACTURING” in partial fulfilment of requirement of the
certificate of the SUMMER INTERNSHIP at BHARAT SUGAR MILL,
SIDHWALIA , GOPALGANJ(BIHAR) is an authentic record of the work
carried out by us during the period of 10/02/2023 to 10/03/2023 and
that, to the best of our knowledge and belief.
It contains no material previously published or written by another
person nor material which to a substantial extent has been accepted
for the aware of any other degree or diploma of the university or
other institute of higher learning except where the
acknowledgement has been made in the text.
CONTENT OF THE REPORT :
Abstract
BHARAT SUGAR MILL,SIDHWALIA Profile
Sugar manufacturing
Process chart
The Energy Aspects
 Mill house
 Boiler house
 Power house
 Clarification and boiling house
 Boiling and curing house
 Cogeneration power
Molasses
Challenge for sugar industry
 Conclusions and suggestions
Abstract
Indian sugar industry, second largest agro-based processing industry
after the cotton textiles industry in country, has a lion’s share in
accelerating industrialization process and bringing socio-economic
changes in under developed rural areas. Sugar industry overs around
7.5% of total rural population and provides employment to 5 lakh
rural people. About 4.5 crore farmer are engaged in sugarcane
cultivation in India . sugar mills (cooperative , private ,and public)
have been instrumental in initiating a number of entrepreneurial
activities in rural India. Present paper is an attempt as to review
progress of sugar industry in India, understand its problems and
challenges in context of ongoing liberalization process . Indian sugar
industry can be a global leader provided it comes out of the vicious
cycle of shortage and sugarcane,lower sugarcane yield,lower sugar
recovery, ever increasing production costs and mounting losses. It
needs quality management at all levels of activity to enhance
productivity and production. Attention is required on cost
minimization and undertaking by product processing activities.
BHARAT SUGAR MILL’S PROFILE
BHARAT SUGAR MILL LTD. Is located in Sidhwalia in Gopalganj(Bihar). Nearest Railway Station is
Sidhwalia is at the distance of 700m. The factory started its crushing operation in the 1st January
2000. The licensed crushing capacity of the plant is 5000 TPD. It is the unit of MAGADH SUGAR AND
ENERGY LTD.BHARAT sugar mill plant make Texmaco. It is the most important sugar mill in bihar.
In this plant the sugar is make by the process of double sulphitation.

Some important data related to B.S.M is:

 Cane crushing capacity :5,000 TDP(TONNES
PER DAY)
 Process Used : Double Sulphitation
 Steam generation : 50tonnes/hour
 Total power generation (installed) :18MW
 Plant consumption :8MW
 Milling plants :
Leveller,Cutter,Shredder,4 nos. mills,3Rollers,Roller Size
39”*78”
 FIG. CANE YARD

2. Cane Yard
After weighing, the cane tractors come to the cane yard and there
are two cranes for unloading. They lift the cane to the feeder
table. These cranes can lift maximum 10 MT. Once cane is put on
the feeder table, it goes through the leveler first. Then the
sugarcane is chopped by two sets of rotating cutters. After that
chopped cane come to the shredder where it is shredded. Those
are the cane preparation steps undergoing in the cane yard
section.
Figure 02 - Rotating cutters

2.1. Mill House

There are four mills in the factory. Each mill is powered by a steam turbine. Duty of this section is
juice extraction from the cell opened canes effectively. Cane is shredded by the shredder. Shredder
is powered by a steam turbine and it consists of 18 hammers in one line and 8 such lines around the
axis. After that cane falls on to a belt conveyor and comes to the 1st mill. Cane enters to the mill from
the top roller and feeder roller and comes out through the top roller and discharge roller. 180
kg/cm2 pressure is applied to the top roller. Extracted juice falls to a sump at the bottom. 1st mill
bagasse is sent to the 2nd mill via inter carrier. Likewise, 2nd mill bagasse is sent to the 3rd mill.
Extracted juice from 1st and 2nd mill is sent to the production section directly. But, 3rd mill juice is
added back to the 1st mill bagasse at the inter carrier while 4th mill juice is added to the 2nd mill
bagasse. Hot imbibition water at 60 0c is added to the bagasse coming out from the 3rd mill. Final
bagasse which comes out from the 4th mill is sent to the boiler house. Moisture content of the final
bagasse should be between 48% and 52% and the POL value (Polarization angle which describes the
sugar level of bagasse) is lower than 2%.
 Figure 03 - The shredder

2.2. Boiler house and the steam flow of the factory

This is the place where all the steam required for the factory is produced. Boiler house consists of
two water tube boilers and the capacity of each boiler is 25 MT per hour. Superheated steam at
3600C and 21.1 kg/cm2 is produced by these boilers. Final bagasse of the mill section is used as the
fuel for these boilers. There are two furnaces in this section. Before the bagasse is fed into the
furnaces, chemical are added to reduce its moisture content. Flue gas of the furnaces are used to
preheat ambient air and that air is blown to the combustion chamber by a blower. This mechanism
helps to burn bagasse effectively.

Firstly, steam produced by the boilers are used to power two turbines in the power house, four
turbines in the mill house and the turbine coupled to the shredder. Then the turbine exhausts are
used to provide the thermal energy for the juice pre-heaters, evaporators and vacuum pan boilers in
the process house. Condensate of each equipment is collected to a tank near the boiler house and is
reused to produce steam.
 Figure 04 – Boiler House

2.3. Process House

2.4.1. Juice Clarification

Extracted raw juice comes to the raw juice tanks after screening. Lime is added at a rate of 2 kg per
ton of cane to maintain its pH value. This method is called cold liming. Then juice goes through two
heaters called juice primary heaters. Mixed juice is heated up to 550C to 650C by these two heaters.
Again, lime is added and the pH value of the mixed juice is raised to 6.9 to 7.1. Maintaining pH value
at this level helps sediment mud properly in the clarifier. This liming method is called hot liming.
Limed juice then goes through another two heaters and heated up to 1050C. This is the temperature
at which the juice solution has the lowest viscosity and it helps a proper sedimentation of mud. This
is called juice secondary heating.

Secondary heated juice is then pumped to a flash tank. Gases are removed from this tank and is
called flashing. Then the juice enters to the juice clarifier. It is also called as subsider. Just before
entering to the subsider, 1g per ton of cane flocculent solution is added to the juice. This helps to
settle floating impurities.

The clarifier consists of five compartments. Each compartment is sloped towards the center of the
clarifier and settled impurities collected from the bottom center of the vessel. Overflow of each
compartment is collected as clarified juice. Retention time of the clarifier is 6 hours.

2.4.2. Rotary Vacuum Filter

Separated mud in the subsider is mixed with baggacillo (fine bagasse separated from final bagasse of
the mill section by a cyclone separator) in a mixing tank. Then the mixture is brought to the mud
filter. Mud filter consist of rotating drum with screened stainless steel surface. Suction pipes are
there inside the drum and connected to the screen to create the vacuum necessary. Drum is rotating
approximately at a rate of 1/3 RPM. The drum is divided to three specific sections; no vacuum, low
vacuum (200 mm Hg) and high vacuum (250 mm Hg). Hot water is sprayed from the top of the filter
to get the maximum sucrose from the mud. Filter cake is carried out to the outside by a conveyer
and the filtrate is returned to the juice liming tank. In this way, 99% of the sucrose is recovered.

2.4.3. Evaporators
Clarified juice contains about 85% of water and 15% of dissolved solids. This water is removed by an
evaporation process. This process removes about 75% of water and the end product is called syrup.
There are 4 evaporators in series and the process is called multiple effect evaporation. First three
evaporators work under normal pressure conditions while the 4th one works under a vacuum
pressure. Purpose of applying a vacuum is to boil juice at a lower temperature. This method avoids
caramelization of sucrose. The syrup formed in evaporators is pumped to the storage tanks.

2.4.4. Pan Boiling

Vacuum pans form sugar seeds from the syrups. This is called pan boiling. There are four vacuum
pans, each one with a capacity of 42 MT. Three types of sugar is formed in this process; Type A, B
and C. They are categorized by the grain size.

• C massecuite grain size - 0.3 mm

• B sugar grain size - 0.5 to 0.8 mm

• A sugar grain size - 0.8 to 1.1 mm

There are two pans for C boiling and C graining. Other two are for A boiling and B boiling. Operating
temperature of each pan is 600C. This temperature should be properly maintained. Otherwise,
sucrose can be caramelized.

In the pan boiling process sugar crystals are developed by adding sugar powder (slurry), which is
prepared at the laboratory. In this method, no crystals are formed. Only executing growth of small
crystal in massaecuite. It is done by adsorbing sucrose in mother liquor onto the crystals. But to
develop crystal in sugar liquid, there should be a considerable super saturation, with the crystal
growth, the super saturation of mother liquid drops. It is maintained using vacuum in pan. There are
three zones of super saturation in sugar process.

• The labile zone: in this zone, existing crystal growth and new crystals form even in the
absence of existing crystals.
• The Intermediate zone: new crystals can form in this zone, but only in the presence of
existing crystals
• The Meta stable zone: being the nearest to saturation, existing crystals increase in size, but
new crystals cannot form. Pan boilers should be kept in this zone at boiling process. Below
this zone sugar crystal will dissolve and above this zone false grain will immediately appear.

2.4.5. Slurry preparation

Crystal size is larger than 185µm, 1000 g raw sugar is mixed 500 ml Butanol in mixing chamber for
about 6 hours. Then 950 ml prepared slurry and 1050 ml Butanol is again mixed. This mixture is used
to prepare C-seed.

Figure 05 - Inside a pan boiler

2.4.6. Centrifuging
There are five continuous centrifuges (2000 rpm) to separate C sugar from molasses. They are
automated and have 0.2 MT per hour capacity. Similarly, there are 4 number of fully manually
operated centrifuges (1000 rpm) for separate A and B sugar.

Figure 06 - Centrifugal separators

2.4.7. Drying
The commercial sugar (Type A) leaving the centrifugal machine contains 1-1.5 % moisture. Because
of that, it cannot be filled in bags for sale. This moisture content may be reduced to about 0.2%.
Therefore, drying of sugar is done in a rotary dryer with a rate of 12 MT per hour where the excess
moisture is removed from the sugar crystals. Hot air at 60-650C is introduced to the drum of this
dryer. Finally, dried sugar crystals are sent to two bins of capacity 60 MT for storage. Stored sugar is
bagged and sent to the stores.

Figure 07 - Rotary dryer

3. VISIT INSIGHTS
FLOW CHART OF SUGAR PROCESS:
 SWOT ANALYSIS OF BHARAT SUGAR MILLS LIMITED
STRENGTH
 Bharat Sugar Mills has hard working, cooperative and trained staff.As well as very
friendly environment.
 The turnover ratio is very low because it is offering best packages to its emloyees.
 ISO certified
 The HR department is working for the increasing communication and computer skills of
lower staff.
 Ease of access to the top management.

WEAKNESS
 No integrated control system to controlthe plant .
 The packaging is manually controlled causing more men power.
 Operations of plant below its capacity due to low demand.

OPPORTUNITY
 The demand of sugar is increasing with the passage of time
therefore the importance of this sugar plant has much
increased.
THREATS
 Availability of raw material as large amount only in three monts in
year.