Double Sulphitation Technology		Journey from raw sugar to refined sugar
	Processing sugar from sugar-beet

Manufacturing Process

Most of us remain unclear of the manufacturing of sugar. Let us delve into
the intricacies involved in the manufacturing process.

a) MANUFACTURING PROCESS

• The manufacturing of sugar begins when harvested cane is received at the mill gate, after which cane is weighed on the platform type weighbridges. This has the weight recording arrangement linked to a computer that records the gross and net weights as well as the price payable to the farmers. Cart cane gets unloaded directly into the cane carrier and tractor trolleys whereas truck cane is unloaded with the help of overhead traveling cranes.
  
  

• The sugarcane is uniformly fed to the fibrizor to prepare the same for efficient milling. The prepared cane will then pass through the four milling tandem for the initial grinding. The juice extracted is strained and kush-kush separated from the juice is returned to the mill tandem. Bagasse from the last mill is conveyed to the boilers as fuel by means of a carrier system.

• The mixed juice from the milling plant is mechanically screened, followed by double sulphitation process. The juice is then heated to about 70 degree centigrade in rapid flow vertical juice heater to maintain good co-efficient of heat transfer. The heated juice is limed and sulphsited in a continuous juice sulphiter, and then heated to 105 degree centigrade and passed through a flash tank for the removal of gas and air before letting it into continuous 36" dia clarifier, where the settling of the mud floc takes place. Accumulated mud from the mud boot is separately withdrawn by gravity flow. Clear juice is withdrawn from the upper regions through the overflow box for further treatment.

• Clarified juice from the clarifier is further heated to around 15 degree centigrade in a plate heat exchanger, before being pumped for thickening. Vapour from the 2nd effect is used to heat the pans. A quintuple effect evaporator is used for the final thickening of the juice into syrup. The syrup at 60-65 degree centigrade is further bleached by passing it through a continuous syrup sulphitation vessel and pumped to pan supply tanks at the pan floor.

• Intensive exhaustion takes place in the pans before crystallization. Air-cooled crystallizers are used for proper crystallizations. After the mother liquor in the massecuite is exhausted to the optimum limit i.e. the maximum sugar from the mother liquor has been transferred to sugar crystals, the two constituents are separated in the centrifugals. The sugar is washed thoroughly with super heated wash in stages within the centrifugal baskets.

• The sugar discharged from centrifugals is conveyed, dried and cooled by multi-tray hoppers. The sugar is then screened in a grader so as to separate fine and lumps. Sugar is thereafter sack filled, stitched and conveyed to the sugar warehouse.

b) STEAM GENERATION

Two bagasse fired water tube boilers are provided to meet the requirements of the factory process. The boiler is equipped with oil burners designed for 50% of steam capacity. The boiler is rated for an output of 70 tonnes of steam per hour operating pressure.

c) POWER GENERATION

Three 3MW Turbo Alternators are provided for the power requirement of the factory. In addition, one 250 KW diesel powered generation and one transformer 500 KW to trap grid power is also provided to supplement the availability of power.

MEASURES TAKEN BY DSIL FOR CANE DEVELOPMENT

DSIL follows an extensive cane development process, assisted by the Cane Development Councils. The main objectives of cane development measures are listed below:

• Production of improved and early varieties of Sugarcane.
  
  

• Increase in per acre yield so that farmers can maximize their earnings and DSIL is assured of an increased supply.
  
  

• Providing seeds, fertilizers and pesticides to farmers through the six Kisan Seva Kendras at different locations, covering the command area of DSIL, so that their crop is not vulnerable to diseases etc.
  
  

• Procurement of cane seeds from Sugarcane Research Station, and distribution of seeds to growers for raising foundations and primary nurseries.
  
  

• Financial assistance for raising and maintenance of nurseries.
  
  

• Conducting training seminars for farmers at the Research Station, at DSIL's expenses.
  
  

• Road development in the respective council areas as well as repair and maintenance of different link roads.
  
  

• Conducting trial demonstrations on plots and cane seed treatment programs through M.H.A.T.