Dr. A. D.

Shinde college of Engineering, Bhadgaon Environmental Studies

Visit Report on

VSANTRAO DESAI AAJARA SAKHAR KARKHAN,LI.

AMRUTNGAR – GAWASE.

Submitted in partial fulfillment of the requirements for the award of degree of Bachelor in Technology

Academic Year 2023-24

Submitted by

Mr. Amte Vishal Bharat PRN- 2023078218

Under the guidance of

Miss. S.T. Dundge

Teaching Faculty, Computer Science and Engineering DepartmentDADSCOE, Bhadgaon.

Dinkarrao K. Shinde Smarak Trusts

DR. A. D. SHINDE COLLEGE OF ENGINEERING.

Bhadgaon, Gadhinglaj. Dist: Kolhapur Pin: 416502
Department of Computer Science and Engineering

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Dinkarrao K. Shinde Smarak Trust’s

DR. A. D. SHINDE COLLEGE OF ENGINEERING, BHADGAON

Site- Bhadgaon, Tal – Gadhinglaj, Dist – Kolhapur 416502

This is to certify that, following students have satisfactorily completed the report on
work entitled, “Sugar Factory” . This mini project is being submitted for the partial fulfilment
of the award of degree of Bachelor of Technology in Computer Science and Engineering
under Shivaji University, Kolhapur, for year 2023-2024.

Student Name PRN No. Sign

Mr.Amte Vishal Bharat 2023078218

Miss.S.T.Dundge Prof. M.K.Hasabe Dr.D.V.Ghewade

Guide Head of Department Principal

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

INDUSTRIAL VISIT
AJARA SUGAR FACTORY

DATE : 02nd March 2024

SECTION : II YEAR

EVENT : Industrial Visit

Faculty Co-ordinators:
1) Miss.S.T.Dundge

EVENT DESCRIPTION:
An industrial visit has been organized by department of computer science
engineering for II- year IV semester students on 02nd march 2024. The main
objective of the visit was to provide a technical exposure to the students about the
manufacturing process and technology.
Totally 70 students of II- year CSE

SESSION ACTIVITIES:
The students were accompanied by 2 faculty members. The buses with students
have started from our college at 11:00 AM on 02nd march 2024 and reached the
AJARA Sugar Factory, by 12:30 PM.

EFFTRONICS VISIT:
Students visited AJARA Sugar factory and learnt about

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Cane Carrier

This is used to transport cane to the milling tandem and consists of chains and slats.
Its width is normally equal to the mill size. Mill cane-crushing unit having
normally consisting of threrollers in a heavy steel housing. Cane first passes
between the top and front rollers, then between the top and back rollers, to extract
the juice. Cane Crushing unit, preceding the first mill to crush the cane prior to
extraction of juice, for the purpose of improving the quantity of juice extracted.
Normally consists of two rollers. Shredder has the same purpose as the crusher, but
a different principle. Consists of a drum, with a concentric shaft, on which hammers
are mounted on arms

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Mill Tandem

A complete mill is complex, consisting of crusher (or shredder) and all mills,
together with drives and reducing gears.

Cane Knives

These are mounted on cane carriers prior to entrance to mills, for preventing entire
cane stalks from entering the mills, straightening and precutting the cane, for the
purpose of improving juice extraction and saving driving power at the same time.

Intermediate Carriers

These transport the milled cane (bagasse) from one mill to the next. Baggage Carrier,
this carries the bagasse from the last mill to the boilers, and its excess to storage.

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Power Plant

This produces electricity by means of non-condensing steam turbines, which drive

generators. For the off-season diesel-driven generators are mainly used, to produce a
limited quantity of electricity.
Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Juice Heater

A heat exchanger in which juice is heated by using steam as a medium, normally a

multi-pass system. Juice flows through tubes, while steam passes along the outside
of the tubes, in the cylindrical body. They can be used horizontally as well as
vertically.

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Clarifier
It is a large vertical cylindrical tank, where juice is given time for decantation, to
separate the clear juice from the turbid, which still contains the mud. Juice flow is
continuous.

Filter
A device to separate the mud from the turbid juice; normally of the rotary vacuum
type. Can also be any kind of pressure filter, provided with filter cloth, to let the
juice pass and retain the mud on its surface.

Evaporator
A series of vessels, in which excess water from the juice is evaporated to form a more
concentrated liquid, now called syrup. The vessels work in series under increasing
vacuum conditions, to reduce the boiling temperature gradually as the concentration
increases step-wise. This prevents overheating of juice and loss of sucrose. The
vessels together form a triple-, quadruple- or quintuple-effect evaporator.

Vacuum Pan

Like an evaporator vessel, a continuation of the evaporating process, but carried so

far that crystallization occurs. Also boils under vacuum for reduced boiling
temperature. The syrup is now transformed into massecuite (fill mass-strike-
skipping), which is a mixture of grain (crystals) and mother liquor (molasses).

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

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Crystallizer
A strike receiver in which the charge from the vacuum pan is stored before
going to the centrifugals. Its purpose is cooling, to increase grain size and
reduce sucrose left in molasses.

Centrifugal
A machine with a fast spinning drum and a screen, inside, through which the
molasses can pass while the crystals are retained. Separation is based on the
difference in specific gravity, amplified by centrifugal force.

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Dryer
A long drum-like rotating cylinder, where sugar is brought in contact with heated
air, to reduce its moisture content.

Cooler
Same as a dryer, but air is dry and cooled to reduce temperature of sugar, heated by
the dryer. This is to prevent caking during storage. The combination of dryer and
cooler into one body is often called a Granulator.

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ABOUT AJARA SUGAR FACTORY:

AJARA Sugar and Industries Corporation Ltd is one among the leading sugar
manufacturing companies in India . Its allied business consists of manufacturing and
marketing of Rectified Spirit, Extra Neutral Alcohol, Ethanol, Incidental
Cogeneration of Power, Organic Manure, Mycorrhiza Vam, Calcium Lactate and
CO2 Late Shri. Vasantrao Desai ICS, a top bureaucrat and civil servant had
conceived the idea of promoting agro based industries, when he was director of
industries, Maharashtra state. By virtue of his position as director of industries, he
had exposure to the industrial sector which prompted him to take over the sugar
industry in 1997 at Ajara which was not doing well. The sugar factory was of 600
TCD and it was christened as The AJARA Limited.
He was a source of inspiration to many entrepreneurs to setup sugar industries in
Maharashtra Some of them are Ajara Sugars. The Ajara Ltd never looked back from
the year 1997 and gradually by stages it had expanded to 7500 TCD which is the
present capacity. The Ajara Ltd., consequent to diversified operations had, over the
years became a conglomerate with multi locational and multi product units, each the
size of an independent company. The company has also envisaged plans to setup
different projects which required focused attention and substantial resources.
Therefore, it had been decided to reorganize The Ajara Ltd

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

PROCESS FLOW CHART

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 Sugar Processing

Harvesting.
Sugar cane and sugar beets are typically harvested from fields mechanically. The
harvested plant materials are frequently sieved to remove dirt and rocks before being
loaded onto trucks and taken to the factory for processing.

Washing and Initial Preparation.

As soon as the sugar cane or sugar beets arrive at the factory, they are washed extensively.
Washing can occur on belts that are sprayed with water or in flues that are full of water.
Rotating drums are often used as washing stations. Water is sprayed into the drum and product
rotates within the drum, rubbing against itself to remove dirt. After washing, the sugar cane or
sugar beets are conveyed into the factory using screws or belts. The sugar cane is crushed using
swing-hammer shredders or heavily grooved crusher rollers. Sugar beets are cut using slicing
machines, which tear them into strips smaller than French fries, called cossettes. The cossettes
are soaked in hot water tanks, while the crushed sugar cane is sprayed with hot water. Both
processes serve to swell the plant cells in preparation for extraction.
Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Juice Extraction.

The sugar cossettes are pumped into the bottom of 10- to 20-meter-tall tanks. A rotating
shaft in the center transports the sugar beet strips upwards against the downward flow of
water as the sugar is extracted. For sugar cane, milling is used to extract the juice. A series
of five mills compresses the sugar cane fibers and separates the juice from the bagasse,
which can be used later as a fuel source. The initial juice is dark green in color and is acidic
and turbid. The juice is collected in large vats and the sugar concentration is measured.

Purification of Juice.

Tall towers, 10 to 20 meters high, are used to purify and lighten the color of the cane juice.
The juice is introduced at the top of the tower and sulfur dioxide vapor is introduced at the
bottom. The sulfur dioxide rises up through the tower in a process called sulfitation. Gas is
added at 120 to 200 pounds per million pounds of juice. Carbonation or alkalization is used
to further separate the soluble non-sugar materials from the sugar juice. Carbonation
employs calcium carbonate or calcium sulfite to aid in precipitation. The juice is heated to
denature the protein content and is then mixed with a slurry of calcium hydroxide, called
milk of lime. Carbon dioxide gas bubbles can also be introduced in this step to lower the
alkalinity and precipitate the carbonation sludge, which is filtered to purify the juice.

The clarification process typically takes several hours. At the end, the sludge is removed
from the bottom of the tank and the juice is removed from the top. Secondary filtration is
used to extract any remaining sugar from the sludge. This produces a material called mud,
which can be used later to fertilize fields.

The clarified juice is then boiled in a series of vacuum evaporators until it reaches a
concentration of 50%–65% sugar. Each subsequent evaporator in the series has a higher
vacuum pressure than the previous evaporator, resulting in the sugar syrup boiling at
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progressively lower temperatures as it moves through the process. Sediment is skimmed off
the top of the evaporators using paddle skimmers, producing a thick, nearly colorless sugar
syrup.

Crystallization.

During the next step in the manufacturing process, a single-stage vacuum pan is used to
evaporate the syrup until it is saturated with sugar crystals, which are formed through a
process called seeding. A milky solution of pure sucrose suspended in alcohol and glycerin
is the seed that is slowly added to the syrup. The small grains of sugar present in the
solution serve as nuclei, helping to draw out the sugar in solution and convert it into
crystals. As the mixture is boiled in a vacuum pan, water evaporates and sugar crystals
continue to grow into a paste called massecuite, a dense mixture of syrup and sugar
crystals. This mixture is then transferred into a large container called a crystallizer, where
the massecuite is slowly stirred and cooled, continuing the crystallization process.

Centrifugation.

To separate the massecuite into sugar crystals and molasses, the massecuite is added to a
high-speed centrifuge. The centrifuge, which rotates at 1,000 to 2,800 revolutions per
minute, contains a perforated metal cylindrical basket. During centrifugation, the molasses
passes out of the lined centrifuge basket and is drawn to the outside of the centrifuge where
it is removed and sent to storage tanks. The sugar is retained in the lined centrifuge basket.
Spring water is used to wash the crystals as they are centrifuged.

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Dr. A. D. Shinde college of Engineering, Bhadgaon Environmental Studies

Drying and Packaging.

The damp sugar crystals are dried in large, hot air dryers, reaching a moisture content of as
low as 0.02%. Next, the sugar is gently tumbled through heated air in a granulator. The
dried crystals are then separated into different sizes through vibrating screens and placed
into storage bins. Finally, the sugar is packaged for the consumer.

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Group Photo Visit

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