ANNUAL PLANT PROCESS CONFERENCE (2011) Draft Final

ANNUAL PLANT & PROCESS
CONFERENCE (2018/19)
FACTORY OPERATION
JULY 2019
PRESENTATION OUTLINES
1. Brief history on the development sugar industry

in Ethiopia
2. Objective of the Plant & Process Conference
3. Factory Past 10 years Performance & 2019/12
Plan Review
4. Milling Season 2018/19 – performance
5. The way forward (Strategic & Debottlenecking
Plan)
Historical Development of Ethiopian Sugar Industry
• History of Ethiopian Sugar Industry stars some 65

Years back, when the two oldest & pioneer sugar
factories (Wonji & W/Shoa) were established by
Holland Company, HVA by the year 1954/55, with
initial design capacities of 1,420 TCD & 1,650 TCD,
respectively.
• The 3rd oldest sugar factory, Metahara sugar factory,
was installed by the same Company & come into
operation in year 1968/69 with initial capacity of
1,700 TCD, which later on expanded to 5,000 TCD in
the year 1981/82.
• The other 4th sugar factory, Finchaa sugar factory,

was installed with initial design capacity 4,400
TCD & started operation by the year 1998/1999
and later expanded to the design capacity of
12,000 TCD and operating since 2013/14 (2005
E.C.)
• With these four sugar factories that had initially
different design capacities have attained a total
annual production capacity of 302, 517.2 tons in
2009/10 (2003 E.C.)
• During 2018/19 milling season eight factories were in

operation. These are Wonji (6,250 TCD), Metahara
(5,372 TCD), Finchaa (12,000 TCD), Kesem (6,000 TCD,
Arjo-Didessa (8,000 TCD), Tendaho (13,000 TCD), Omo
Kuraz 2 (12,000 TCD) & Omo Kuraz 3 (12,000 TCD).
• Kesem, Arjo Didessa & Tendaho sugar factories started
operating with some technical problems associated
with initial factory design & cane supply problems.
• Omo kuraz 2 & Omo Kuraz 3 sugar factories are under
commissioning and performance guarantee test trials
since 2017/18 (Omo Kuraz 2) & 2018/19 (Omo Kuraz 3).
• In the course of its development the industry has faced
so many challenges & opportunities at different time as
result of reforms conducted.
• The cane quality, the tonnage of cane harvested &
recoveries are affected by various factors in spite of all
efforts exerted during the periods under review.
• An increase in the length of milling season in the
existing factories was also observed when compared to
the industry norms that had contributed to the increase
in production cost. Capacity utilizations are also on the
low side due higher stoppages for both factory and non-
factory reasons.
• In addition, decline in factories Key Performance
Indicators like, Mill Extraction & Boiling House
Efficiencies caused due to various technical problems
result in a lower Overall Sucrose Recovery
• Besides, some problems associated with skill of man
power, technical issues and working standards/culture,
the effect of cane quality was also affects the factors
adversly.
• Although the number of factories under operation,
including the new sugar factories/projects (Omo 2 &
Omo 3) which are under performance test trails has
increased in to three folds, the annual production
increase is still insignificant.
• Thus, this Plant & Process Conference is aimed to
review the past 10 years Production & Key
Performance Indicators trend of the four factories
(Wonji, Metahara, Finchaa & Kesem),
• Performance of 2018/19 (2011 E.C.), Plan for
2019/20 (2012) and a Strategic Plan prepared as
a way forward to fill the gaps identified that
enables to build the technical, human, material,
organizational, restoring previous industry
cultures, systems & norms as well as operational
capabilities of the factories are included
6,000,000
4,836,090
5,000,000 Plan
Cane Crushed in MT, Sugar Production in Qts
4,000,000
3,609,736
3,500,257
3,000,000 3,025,172
Establishment - FSF Expansion of FSF - 2,469,925
2,513,350
(2,347,609)
2,000,000 2nd Phase MSF - 1,777,452

1,713,025 Energy Audit MSF 1,714,736
1,454,693
Effect of Cane Cycle (1,212,341)
1,044,696
Establishment of MSF
1,000,000
W/Shoa -358,730 631,036
PRODUCTION SEASON
Challenges & Opportunities during the Industry
Development
• The structural reforms conducted in the industry had both opportunities &
challenges
• Decentralization of the factories had created a good opportunity for former
factories, namely Wonji , Metahara & Finchaa to be autonomous & manage
their own budget and directed by their own Board of Directors; Problem of
fund availability for modernization & debottlenecking the factories to boost
their production and achieve their annual production plan.
• Decline in cane yield due to disturbance in cane cycle – as a result of
enforced high production order & lack of fertilizer (imposed by government).
• To reverse the problem incentive system & Productivity Improvement
strategy (Pilot Project) was implemented at MSF
• The Reform conducted in 2011 (2003 E.C.)
Development the Ethiopian Sugar Industry
(WSSF)
Cane Rehabilitation
Establishment of Cycle
Shoa Sugar disturb
Factory ance
Development the Ethiopian Sugar Industry
(MSF)
2nd
2nd Expansion 3rd
3rd Expansion Energy Audit
ከ2450 - 3000 ከ3000 - 5000
1stst Expansion
ከ1700 - 2450
Decline
in cane
yield
Factory Past 10 years Performance &
2019/20 Plan Review
PODUCTION TREND SUMMARY
Capacity 2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17 2017/ 18 2018/ 19 Plan
2019/20
Wonji Sugar Factory

Season Days 222 239 256 256 274 275 246 243 206 154
Tons sugar cane
crushed 534,163 640,791 628,582 362,951 681,671 906,090 812,768 766,037 606,730 506,798 674,656
Qts. sugar
production 75,220 70,113 42,091 80,666 111,015 93,430 82,931 59,805 49,584 78,177
60,339
Factory Yield, % 11.21 11.58 11.11 11.60 11.83 12.25 11.50 10.80 9.82 9.78 11.59
Sucrose % cane 13.84 14.21 14.05 14.7 14.06 13.99 13.30 12.52 12.22 13.96
Metahara Sugar Factory
Season Days 280 248 265 263 263 251 248 210 237 243
Tons sugar cane
crushed 1,203,249 1,001,400 982,966 901,931 1,155,550 1,101,161 787,066 874,385 741,048 751,649 988,817
Tons sugar 101,962 69,866 82,448

production 120,035 93,140 93,170 114,900 111,052 68,228 63,390 100,296
Factory Yield, % 9.98 10.18 9.48 10.33 9.94 10.08 8.88 9.43 9.21 8.43 10.14
Sucrose % cane 11.86 12.12 11.65 12.5 12.5 11.12 11.60 11.53 11.05 12.30
PODUCTION TREND SUMMARY
Plan
Capacity 2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17 2017/ 18 2018/ 19 2019/20
Finchaa Sugar

Factory
Season Days 240 250 230 235 242 237 244 236 205 226 180
Tons sugar cane 957,933 77,941 867,014 950,221 1,145,272 1,324,488 1,096,218 1,237,053 18,632 877,484 1,400,446
crushed
Tons. sugar
110,560 98,723 101,604 111,732 128,837 138,907 110,090 131,502 86,438 86,438 157,517
production
Sucrose % cane 11.54 11.24 11.72 11.76 11.25 10.49 10.04 10.63 9.41 9.24 11.25
Kessem Sugar Factory
Season Days 261 258 245 220 189
Tons sugar cane

399,629 567,706 400,775 294,376 679,427
crushed
Tons. sugar 30,954 31,398 24,045 67,945

production 41,333
Factory Yield, % 7.74 7.28 7.83 8.17 8.70
Sucrose % cane 8.55 7.70 9.08 9.13 11.25

PODUCTION TREND SUMMARY (WSF)
1,200,000
Cane Crushed in tons, Sugar Production Qts.
1,000,000
Sugar Production
1,110,150 Plan- 781,770
800,000
600,000
400,000
200,000
-
Plan 2019/20 2009/10 2010/11 2011/12 2013/14 2014/15 2015/16 2016/17 2017/ 18 2018/ 19 2019/ 20
Production Seson
Specification of Downtimes & Time Efficiencies (WSF)
80
TRIAL TEST OF NEW FACTORY

72.87 Overall Time Efficiency
70
68.34
Factory Oveall Time Plan- 70

60 Efficiency
50
Total Down Time
Plan 30
40
Factory Causes
31.66
30 (27.46%)
20
Non- factory cause
10
0
2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/ 17 2017/18 2018/192019/20 (Plan)
Factory Key Performance Trend (WSF)
SUCROSE BALANCE
16.00
Sucrose % Cane - 14.70
Plan 13.96
14.00
Factory Yield - 12.25

12.00 12.07 12.22
11.50
Final Molasses
10.00 9.79 9.80
Value , %
8.00
6.00
Sucrose Lost in Bagasse
4.78
4.00
Undetermined Loss -2.43

2.00 2.23
Sucrose Lost in F.cake
-
2009/10 2010/11 2011/12 2013/14 2014/15 2015/16 2016/17 2017/18 2018/ 19 2019/20 (Plan)
Production season
PODUCTION TREND SUMMARY (MSF)
1,400,000
1,200,349
1,200,000
1,149,000
Plan 1,002,960
1,000,000
800,000
698,661
633,902
600,000
400,000
200,000
)
1
7
0
lan
/1
/1
/1
/1
/1
/1
/1
/1
/1
/1
09
10
11
12
13
14
15
16
(P
17
18
Production Seson
20
20
20
20
20
20
20
20
0
20
20
/2
19
20
Specification of Downtimes & Time efficiencies (MSF)
Time 90Efficiency
Down Time & Time Efficiency, %
82
80 80.58
70
60
50
40
30
20
10
0
2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/ 17 2017/18 2018/19 Plan (2019/20)
Production Season
Factory Key Performance Indicators Trend (MSF)
SUCROSE BALANCE
14 Sucrose % cane -13.3
12.3
12 Plan
Loss in bagasse 10.09

10
VALUE, %
0
2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17 2017/18 2018/ 19 2019/20 (Plan)
PRODUCTION SEASON
PODUCTION TREND SUMMARY (FSF)
1,800,000
Plan
1,575,170
1,600,000
Sugar Production -
1,389,070 1,400,446
1,400,000
1,200,000
1,000,000
Cane Crushed 810,560
(2018/19)
800,000
600,000
400,000
200,000
0
0 1 2 3 4 5 6 7 8 9 0
9 /1 0 /1 1 /1 2 /1 3/1 4 /1 5/1 6 /1 /1 8/1 9 /2
0 1 1 1 1 1 1 1 1 7 1 1
20 20 20 20 20 20
Production 20
Season 20 20 20 20
a n
Pl
Specification of Downtimes & Time Efficiencies (FSF)
Overall Time
Efficiency
90
(79.52)
80
70 65
Down Time & Time Efficiency (%)
60
50 50.96
Factory Down Causes
40 (41.45)
Total Factory Downtimes 35.66
30
Non-factory Causes - 23.13
20 (21.19%)
10
0
/10 /11 /12 /13 /14 /15 /16 1 7
/18 /19 /20
0 9 1 0 1 1 1 2 1 3 1 4 1 5
1 6/ 1 7 1 8 1 9
20 20 20 20 20 20 20 20 20 20 20
an
Pl
Production Season
Factory Key Performance Trend (FSF)
SUCROSE BALANCE
16
14
Value, %
12
10
PRODUCTION SEASON
PRODUCTION TREND - KSF
800000
700000 Plan (679,450)
567,706. (cane)
Cane Crushed in tons, Sugar Production Qts
600000
500000
413,330 (Sugar)
400000
300000
240450
200000
100000
Production Season
D o w n T im e & T im e E ffi c i e n c y ( %
Specification of Downtimes & Time Efficiencies (KSF)
70
Time Efficiency (61.28)
60 60
50
40
30
20
10
PRODUCTION SEASON
Factory Key Performance Trend (KSF)
40
SUCROSE BALANCE
Total Loss (35.8)
35
30
25 Loss in Final Molasses

Value, %
23.04
20
15
11.8
10 Undetermined Loss
(4.8)
5
Loss in F.Cake1.24
0
2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17 2017/18 2018/19Plan 2019/20
Production Season
Production Summary (2018/19)
Season Days Tons sugar cane crushed Sucrose % cane Tons Sugar Production Factory Yield, %
Factory
Plan Actual +/- Plan Actual % Plan Actual % Plan Actual % Plan Actual %
Wonji 152 200.5 48 665,000 506,798 76.2 13.96 12.20 87.4 78,596 49,584 63.09 11.82 9.78 82.7
Metehara 242 236.3 (5.70) 1,002,560 751,649 75.0 11.90 11.03 92.7 95,000 63,390 66.73 9.48 8.43 89.0
Finchaa 178 226.0 49 1,384,500 877,484 63.4 13.39 12.91 96.4 135,000 81,056 60.04 9.75 9.24 94.8
Kesem 128 220 92 498,830 294,376 59.0 12.11 11.61 95.9

50,000
24,045 48.09 10.02 8.17 81.5
Sub Total 699 883 183 3,550,890 2,430,307 68.4 12.84 11.94 93.0 358,596 218,074 60.81 10.27 8.97 87.4
A)
Arjo 26 110,500 75,179 68.0 12.00 11.01 91.8 10,819 5,853.3 54.10 9.79 7.79 79.5
Didessa
Tendaho 128 116,144 130,923 112.7 10.50 10,000 4,751.7 47.52 8.61 3.63 42.2
Omo 50 239,973 126,186 52.6 10.25 20,000 6,934.3 34.67 8.33 5.50 66.0
Kuraz 2
Omo 67 239,973 251,641 104.9 10.25 20,000 15,721.1 78.61 8.33 6.25 75.0
Kuraz 3
Sub Total 270 0 706,590 583,930 82.6 10.75 60,819 33,260 54.69 8.77 5.70 65.0
(B)
Total 970 883 4,257,480 3,014,237 70.8 419,415 251,335 59.93 8.61 8.34 96.9
(A+B)
Percent share of Sugar Production
Omo Kuraz-2, 2.76 Omo Kuraz-3; 6.26

Tendaho; 1.89
Arjo Didessa; 2.33 Wonji; 19.73
Kesem; 9.57
Metehara, 25.22
Finchaa; 32.25
Major Causes for 2018/19 Performance Decline
I. WSF
1. Input Cane Quality
Parameters Target Actual
Sucrose % Cane 13.98 12.22
Field Yield 11.83 10.73
Trash % Cane <3 11
Primary juice purity 85 81.35
 Sucrose % cane & field yield/recoverable sugar were very

low, which affects factory yield and overall recovery of the
factory
 Trash content of cane was very high, as a result it affects the
entire factory performance adversely
 Purity of cane was very low, which affects sugar recovery
adversely
I. WSF . . .
2. Extraction plant performance
Preparation Index 90 84.65
Mill Extraction 95 95.26
Reduced Mill Extraction 96 95.93
Primary juice extraction 67 57.91
Imbibition % fiber 250 227.96
Pol % bagasse 2.0 2.13
Sucrose los in bagasse % sucrose in cane 5.35 5.02
 Preparation index was low, as a result primary juice extraction

was very low and pol % bagasse was a bit high
SUCROSE BALANCE (WSF)
Loss in bagasse
5.02% Loss in filter cake
2.23%
Loss in final
molasses
10.88%
Undetermined
losses
1.84%
Overall sucrose
recovery
80.14%
I. WSF . . .
3. Boiling house performance
BHR 90 84.26
Overall Recovery 84.0 80.44
Sucrose los in filter cake % sucrose in cane 0.65 2.23
Sucrose los in final molasses % sucrose in cane 9.31 10.88
Undetermined Sucrose los % sucrose in cane 1.0 1.84
 BHR of this year was the lowest in the past 10 years
 87 to 89 % was achieved in the old factories
 Overall recovery was very low, more than 3% lower than the
target, due to high sucrose loss through F/Cake, F/molasses
and undetermined losses
I. WSF . . .
3. Boiling house performance . . .
 High loss through F/cake was due to mud pumping from Dorr to
OCF causing mud chain breakage and poor filterability. The other
cause was due to operational problem (unable to regulate high
and low vacuum to the standard at the first quarter of the
operation season)
 High loss through molasses was due to centrifugal plant technical
problem (project defect and spare shortage), as a result
continuous pan was out of line to overcome low grade cuite load.
Moreover, high purity molasses was feed to low grade cuite and
cause to increase loss through molasses
 High undetermined loss was due to:
– Mechanical :- over flow & leakage of liquors
– Chemical:- high purity drop b/n PJ % MJ (-4.94) due to poor mill sanitation
I. WSF . . .
4. Down time analysis
4.1 Factory cause
 Plan =18 %
 Actual=20.25%
 Cane unloading =2.54 %
 Clarification & Evaporation =2.38%
 Vacuum plant =0.79%
 From Crystallizers to sugar dryers =0.7%
 Boiler plant =3.84%
 PM = 0.44%
 Repair=6.31 %
 Excess = 1.21%
 Shortage = 0.29%
 Boiler water shortage =1.76%
I. WSF . . .
4. Down time analysis . . .
4.2 Non Factory cause
Plan =7 %
Actual=21.15%
• LOC due to rain = 7.82%  Total Down time
• LOC due to organization = 5.02%  Plan = 25%
• To take out stone = 0.11%  Actual = 41.4%
• EEPCO/Power turbine interruption=3.9%  Overall time
• Shunting tractor accident =0.39% efficiency
• Before and after season = 2.26%  Plan = 75%
 Actual = 44.48%
II. MSF
Trash % Cane < 3.0 4.6
 Sucrose % cane & field yield/recoverable sugar

were very low, which affects factory yield and
overall recovery of the factory
II. MSF . . .
Primary juice extraction 65 60(only TB)
 Mill Extraction results were the lowest as compared with the

recent 10 years result. As a result sugar loss through bagasse
was very high
 Very low imbibition % fiber was used. As a result high loss of
sucrose in bagasse and low Mill Extraction
SUCROSE BALANCE (MSF)
Loss in bagasse
10.09%
Loss in filter cake
0,75%
Loss in final molasses

9.30%
Undetermined losses
5.60%
Overall sucrose recovery

76.24%
II. MSF . . .
BHR 90 84.80
 BHR of this year was the lowest in the past 10 years
 Overall recovery was very low, more than 6% lower
than the target, due to high sucrose through bagasse
and in undetermined losses
II. MSF . . .
 High loss in bagasse was due to oldness of the diffuser
plant and operational and maintenance problem on both
mills
Mechanical :-TB vibrating screen sieve torn out and lack
of replacement sieve during first quarter of the
operation period. As a result juice lost during mixed juice
and sulphited mixed juice thanks and pumps cleaning
Chemical:- high purity drop b/n MJ % CJ (-2.77) due to
on off and under capacity operation of extraction plant
and long retention time of juice in juice clarifiers
II. MSF . . .
4.1 Factory cause
 Plan =15.85 %
 Actual=30.66%
 Repair=15.79%
 Excess of juice, syrup & molasses = 0.14%
 Excess of bagasse = 0.21%
 Shortage of seam = 0.07%
 Boiler plant =11.43%
 PM =2.60%
 Various including electrical & Instrumental =0.41%
II. MSF . . .
4.2 Non Factory cause
Plan =4.15 %
Actual=5.44%,  Total Down time
the highest in 10yrs  Plan = 20%
• LOC due to rain = 3.3%;  Actual = 36.1%;
the highest in 10yrs
the highest in 10yrs Overall time
• LOC due to organization = 1.88%; efficiency
 Plan = 80%
the highest in 10yrs
 Actual = 63.9%
• Before and after season = 0.26%
III. FSF
Trash % Cane 3 2.5
 Sucrose % cane & field yield/recoverable sugar

were very low, which affects factory yield and
III. FSF . . .
Pol extraction 95 94.79
 Preparation index was low, as a result primary juice extraction

was very low and pol % bagasse was a high
 Primary juice extraction and Imbibition % fiber was very low;
as a result Mill Extraction was low and sucrose loss in bagasse
was high
SUCROSE BALANCE (FSF)
Loss in Bagasse
5.58% Loss in Filter
Cake
1.15%
Loss in Final
Molasses
8.98%
Undetermined
Loss
6.44%
Overall Sucrose
Recovery
77.85%
III. FSF . . .
BHR 90 82.26

than the target, due to high sucrose loss through
F/Cake, F/molasses and undetermined
III. FSF . . .
 High loss through F/cake was due to operational
problem & technical problems on OC Filters
 High loss through molasses was due to
operational and technical problem (at vertical
crystallizers cuite conditioning not done due to
leaky tubes)
– Mechanical :- leakage + over flow of liquors
– Chemical:- fermentation at diffuser plant
III. FSF . . .
4.1 Factory cause
 Plan =27 %
 Actual=35.66%
 Mechanical Repair=14.81%
 Boiler plant PD =5.39%
 PM = 3.35%
 Electrical & Instrumentation = 3.27%
 Excess = 0.96%
 Shortage = 7.56%
 Miscellaneous = 5.72%
III. FSF . . .
4.2 Non Factory cause  Total Down time
 Plan = 35%
Plan =8 %  Actual = 58.8%
Actual=23.13%,  Overall time
 LOC = 3.72% efficiency
 Plan = 65%
 Other non factory cause =19.41%  Actual = 41.2%
IV. KSF
Trash % Cane 7.0 Not done
 Sucrose % cane & field yield/recoverable sugar were very

low, which affects factory yield and overall recovery of the
factory
 Trash content of cane was very high, as a result it affects
the entire factory performance adversely
adversely
IV. KSF . . .
Preparation Index 90 -
Pol % bagasse <2.0 2.26
 Primary juice extraction and Imbibition % fiber was very low;

as a result Mill Extraction was low and sucrose loss through
bagasse was high
 Preparation index was not done
SUCROSE BALANCE (KSF)
Loss in Bagasse
6.41% Loss in Filter Cake
0.43%
Loss in Final Molasses

23.04%
Overall Sucrose
Recovery
Undetermined Loss
69..69%
0.43%
IV. KSF . . .
BHR 90 75.20
F/molasses
IV. KSF . . .
 High loss through molasses was due to:
• centrifugal plant technical problem (project defect
and spare shortage), as well as
• continuous pan was not in lined due to steam
shortage related with back pressure turbine problem.
• Moreover, high purity molasses was feed to low grade
cuite and sometimes sent to final molasses whenever
sudden power turbine stoppage has occurred and
cause to increase loss through molasses
IV. KSF . . .
4.1 Factory cause
 Plan =25 %
 Actual=54.35%
• Boiler plant and accessories = 29.03%
• Cane preparation plant = 1.59 %
• Milling plant = 2.21%
• Clarification & Evaporation plant = 0.94%
• Vacuum plant = 0.03%
• From Crystallizers to sugar dryers = 0.38%
• Mechanical Repair at different plants = 17.68%
• Power plant = 0.88%
• PM = 0.44%
• Various including electrical & Instrument = 0.48%
• Excess (juice, mud, syrup) = 0.64%
IV KSF . . .
4.2 Non Factory cause  Total Down time
Plan =10 %  Plan = 35%
 Actual = 60.79%
Actual=6.44%,
 Overall time
• LOC due to rain = 4.28% efficiency
• LOC due to organization = 0.09 %  Plan = 65%
• Labor trouble = 0.16%  Actual = 39.21%
• Others = 1.9%
• Shortage of raw water = 0.04%
• Before and after season = 0.17%
V. ADSF
Field Yield -
Trash % Cane -
Primary juice purity -
 Sucrose % cane was very low, which affects factory yield and
adversely
V. ADSF . . .
 Sucrose loss through bagasse was very high due to:

• Oldness of cane preparation equipments (cane cutter #1
and shredder bypassed )
• Overhead crane problem mill bearings not serviced, as a
result low hydraulic pressure & imbibition were used to
extract the juice
• Mill #2,3 & 5 was bypassed different times due to coupling
bearing problem
SUCROSE BALANCE (ADSF)
Loss in Bagasse;
9.49
Loss in Filter Cake;
0.67
Loss in Final
Molasses; 13.98
Overall Sucrose Undetermined

Recovery; 70.65 Loss; 5.21
V. ADSF . . .
BHR - -

F/molasses & undetermined loss
V. ADSF . . .
 High loss through molasses was due to:
 long waiting of the cane after cutting without crushing. As a result
inversion of sugar has occurred which affects sucrose crystallization by
increasing viscosity of the syrup.
 Material handled for long hours in the process house (waiting cane
supply) cause inversion and increase molasses quantity, so that loss
through molasses has increased.
 Vertical crystallizer not in lined. Operational problem (skill gap to keep
up SOPs)
– Mechanical :- sugarcane damage at cane yard; spillage and leakage
– Chemical:- inversion of sucrose at different plants starting from cane up
to syrup including thermal distraction during power interruption
has happened
V. ADSF . . .
 Total Down time
4.1 Factory cause  Plan = 35%
Plan =20 %  Actual = 60.79%
Actual=20.89  Overall time
4.2 Non Factory cause efficiency
Plan =10 %  Plan = 70%
 Actual = 33.85%
Actual=45.26%,
The way forward (Strategic & Debottlenecking Plan)
• Thus, to over come the problems we faced in
the past years, a strategic document is prepared
to fill the gaps identified that enables to build
the technical, human, material, organizational
as well as operational capabilities of the
factories in this off season & next three years.
• A rehabilitation and debottlenecking plans have
also prepared, to be implemented in priority
based on criticality and financial capability.

ANNUAL PLANT PROCESS CONFERENCE (2011) Draft Final

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ANNUAL PLANT PROCESS CONFERENCE (2011) Draft Final

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ANNUAL PLANT & PROCESS

1. Brief history on the development sugar industry

• History of Ethiopian Sugar Industry stars some 65

• The other 4th sugar factory, Finchaa sugar factory,

• During 2018/19 milling season eight factories were in

2,000,000 2nd Phase MSF - 1,777,452

W/Shoa -358,730 631,036

Wonji Sugar Factory

Tons sugar 101,962 69,866 82,448

Kessem Sugar Factory

Season Days 261 258 245 220 189

Tons sugar cane

Tons. sugar 30,954 31,398 24,045 67,945

Factory Yield, % 7.74 7.28 7.83 8.17 8.70

Sucrose % cane 8.55 7.70 9.08 9.13 11.25

TRIAL TEST OF NEW FACTORY

Factory Oveall Time Plan- 70

Factory Yield - 12.25

Undetermined Loss -2.43

Loss in bagasse 10.09

700000 Plan (679,450)

25 Loss in Final Molasses

Kesem 128 220 92 498,830 294,376 59.0 12.11 11.61 95.9

Omo Kuraz-2, 2.76 Omo Kuraz-3; 6.26

 Sucrose % cane & field yield/recoverable sugar were very

 Preparation index was low, as a result primary juice extraction

 Sucrose % cane & field yield/recoverable sugar

 Mill Extraction results were the lowest as compared with the

Loss in final molasses

Overall sucrose recovery

 Sucrose % cane & field yield/recoverable sugar

 Preparation index was low, as a result primary juice extraction

 Overall recovery was very low, more than 6% lower

 Sucrose % cane & field yield/recoverable sugar were very

 Primary juice extraction and Imbibition % fiber was very low;

Loss in Final Molasses

 Sucrose loss through bagasse was very high due to:

Overall Sucrose Undetermined

 Overall recovery was very low, more than 10% lower

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