Sugar manufacturing process

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2. SUGAR MANUFACTURING PROCESS Sugar Introduction, R aw and R efined Sugar, Factors Affecting Sugar Storage 4/19/2014 2

3. INTRODUCTION Sugar General term indicating sweet carbohydrates Mono-, di- and poly-saccharides Obtained from plants, largely sugarcane & sugar beet plant Pakistan 12 th largest producer of sugar Per capita consumption of sugar is 25kg More than 81 sugar mills in Pakistan 4/19/2014 3

4. MANUFACTURING PROCESS 4/19/2014 4

5. Harvesting Of Sugarcane Fully mature Two types Manual Mechanical 4/19/2014 5

6. FLOW DIAGRAM transportation 4/19/2014 6

7. Transport and Handling Animal driven carts Trolleys Trucks 4/19/2014 7

8. FLOW DIAGRAM 4/19/2014 8

9. Material Handling and Storage Stored in cane yards Carried from cane yard to feeding area by hook/chain Cranes Reelings Conveyer belt Carry Huge suction truck 4/19/2014 9

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11. Washing 4/19/2014 11

12. Cutting of Canes To aid the cane crushing Cane knives to cut cane into smal l pieces 4/19/2014 12

13. FLOW DIAGRAM 4/19/2014 13

14. Shredding To remove leaves and nodes Hammer mill shredder 4/19/2014 14

15. Extraction of juice 4/19/2014 15

16. Crushing Cane crushed to break hard structure Cells containing juice are ruptured No juice extracted Increase efficiency of juice extraction Subjected to crusher with corrugated blades 4/19/2014 16

17. FLOW DIAGRAM 4/19/2014 17

18. Milling Tandems 3 roller mills connected in series Top roller Feed roller Discharge roller 5-7 in number Extract the juice from crushed cane 4/19/2014 18

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20. Products of Mills 4/19/2014 20

21. FLOW DIAGRAM 4/19/2014 21

22. Use of Bagasse Stored in bagasse storage Used as fuel to generate steam Steam used for Generating electricity Evaporation of juice before crystallization 4/19/2014 22

23. FLOW DIAGRAM 4/19/2014 23

24. Clarification/Defecation To remove non-sugars and impurities Liming Sulphitation Phosphatation Carbonation 4/19/2014 24

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26. FLOW DIAGRAM 4/19/2014 26

27. Filtration Mud from clarifier still contain some residual juice Filtered to extract residual juice in Rotary Vacuum Filters 4/19/2014 27

28. FLOW DIAGRAM 4/19/2014 28

29. Evaporation Juice evaporated to obtain super saturated solution Increase concentration of juice from 15ᴼ brix to 65ᴼ brix Juice preheated to around 107-110ᴼC Two types of evaporators Single effect evaporators Multiple effect evaporators 4/19/2014 29

30. Multi-Effect Evaporator 4/19/2014 30

31. Cont… Steam used to evaporate juice 1 liter steam to evaporate 4 liter juice Steam temperature 113-130ᴼC at 1 st pan and 55ᴼC at last pan Each subsequent vessel with decreasing pressure Last pan being under almost a total vacuum 4/19/2014 31

32. FLOW DIAGRAM 4/19/2014 32

33. Crystallization Carried out in single effect high-vacuum boiling pans Brix are increased from 65ᴼ to 75ᴼ by boiling at 60ᴼC Three stages of crystallization Nucleation Initiation elongation 4/19/2014 33

34. Cont… Massecuite mixture of crystals and mother liquor (molasses) resulting from the crystallization Transferred to crystallizer at low temprature 4/19/2014 34

35. FLOW DIAGRAM 4/19/2014 35

36. Centrifugation Separate sugar from molasses Centrifuge operates at 100-1800 rpm Molasses pass through perforations Sugar crystals are washed with 85ᴼC water Raw sugar and molasses 4/19/2014 36

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38. FLOW DIAGRAM 4/19/2014 38

39. Drying and Packaging Sugar tumbled through large cylindrical dryers Sorting Packaging 4/19/2014 39

40. REFINING 4/19/2014 40

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42. Receiving and storage 4/19/2014 42

43. Affination Mixture of raw sugar with high purity syrup (85%) called magma Melts outermost layer of the raw sugar crystal at 50ᴼC Centrifugation to remove resulting syrup from melting of the outer layer 4/19/2014 43

44. Melting Affinated sugar dissolved with hot condensate to conc. of 72ᴼ brix Melted at 85ᴼC in Batch or continuous melter 4/19/2014 44

45. Purification Remelt may contain some impurities and colorants Liming 1. Partial 2. Complete Carbonization Colorants remover by decolorization 4/19/2014 45

46. Decolorization Two methods Granular activated carbon (GAC) Ion exchange resine 4/19/2014 46

47. Evaporation & Crystallization Sugar syrup evaporated up to super saturation Crystallization Centrifugation to obtain refined sugar crystals 4/19/2014 47

48. Drying and Storage Bucket elevator on conveyer Hot air for drying Sieving Fine, medium and bold grains Storage in godowns Cool, dry, moisture and odor free 4/19/2014 48

49. Packaging Containers opaque, airtight, moisture/odor proof Glass canning jars or cans for liquid sugars 4/19/2014 49

50. Raw & Refined Sugar Raw sugar Obtained directly from sugarcane juice without refining Most natural sugar Brown in color due to molasses Refined sugar Have white luster and transparent Bleached to remove color and other impurities 4/19/2014 50

51. Factors affecting sugar storage Temperature Moisture Quality of sugar Light Grain size and distribution Compression 4/19/2014 51

52. Thanks For Your Attention 4/19/2014 52