The working process of the sugar industry is described. The process is described for sugar-cane. Sugar bit isn't included here.

1. WELCOME

2. A PRESENTATION
ON
SUGAR INDUSTRY

3. CONTENT
Introduction
Raw Materials
Composition
Manufacture Process
Instrumentation
Estimation
By Products

4. SUGAR
 A generic name for sweet
tasting
 Can be mono, di and poly
saccharide
 Soluble carbohydrate
 Found in tissues of most plants
but sucrose in especially
concentrated in sugar cane and
sugar beet

5. COMPOSITION OF SUGAR
Composition Amount Analysed
Moisture 82.91%
Ascorbic acid 3.39 mg/100ml
Reducing sugar 0.50%
Total Sugar 16.32%
Total Carbohydrate 9.23 gm/100ml
Viable bacterial count 4.56 x 106 cfu/ml
Viable yeast and mold count 2.6 x 105 cfu/ml

6. RAW MATERIALS
There are mainly two types of raw
materials occurs in nature from which
sugar is made of.These are sugar cane
and sugar beet.They have slight
difference in chemical component.The
raw materials of cane sugar is the
whole stem of the cane, which grows
above the ground. On the other hand
the raw materials of beet sugar is the
entire root of the plant and so, grows
under ground.

7. SUGAR CANE
Is a grass of the genus Saccharum, tribe
Andropogoneae that looks like bamboo and can reach
10 to 13 feet in height.
Is cultivated in warm, moist, tropical or semitropical
climates.
Contains 75-82% water, 10-15% crystalline sugar, 0.5-
1.0% reducing sugar, 10-16% fiber 1.0% ash and 1.0%
organic acid specially ascorbic acid.
The prime sugar cane growing regions, such as
Mauritius, Dominican Republic, Puerto Rico, Peru,
Brazil, Bolivia, Colombia, Guyana, Ecuador, Cuba, El
Salvador, Jamaica, Bangladesh, India, Pakistan,
Indonesia, Philippines, Malaysia, Australia, Hawaii and
a great portion of United State.
In Bangladesh sugar cane is grown in about 0.38 million
acres of land.

8. COMPOSITION OF SUGAR CANE

9. SUGAR BEET
Is a plant whose root contains a high
concentration of sucrose.
Is cultivated in temperate climates, adapts well
to very cold and warmer climates.
In the beginning only 6% sucrose was found in
sugar beet but now it is increased by 28%.
Also contains 5% fiber and 72-75% water.
Is grown in eleven states, Europe is by far the top
world producer.

10. MANUFACTURING PROCESS
OF SUGAR

11. STEPS OF MANUFACTURING PROCESS OF SUGAR
Extraction of juice
Purification of juice
Clarification of juice
Concentration or evaporation
Crystallization
Separation of crystals
Refining of crystals
Recovery of sucrose from molasses

12. FLOW CHART: MANUFACTURE OF SUGAR FROM
SUGAR CANE

14. EXTRACTION OF JUICE
Washed to remove mud and trash.
Cut into small lengths by sharp rapidly
moving knives(500-1200 r.p.m.).
Dropped over a moving belt to be carried to
extractor.
Converted the cane into chips.
Passed the crushed cane through a series of
mills which consists of three grooved rolls.
About 90-96% juice extracted.

15. PURIFICATION OF JUICE
Brownish green opaque liquid which contains pectic substance, water,
organic matter, coloring matter, mineral salts, reducing sugar, gums, fine
particle of bagasse that hampers crystallization.
Cane juice is acidic and having pH 5.1-5.7
Should be made alkaline to neutralize the presence of pectic substance as
it is fermented to pectic acid which catalyze cane sugar into non-
crystallizable sugar.This process is called defection (it is the process of
preparation of raw liquor for filtration by removing solid impurities).

16. CLARIFICATION OF JUICE
The clarification process is designed to remove both soluble and insoluble
impurities (such as sand, soil, waxes, gums etc.)
Clarification of juice or conversion of raw sugar into white crystalline sugar
carried out by Sulphitation and carbonation process.

17. SULPHITATION
• Juice Sulphitation is the process of purification of cane juice by
employing lime and sulphur dioxide gas which generally used for
clarification of sugar cane juice in planitation white sugar manufacturing
industry.
• This juice is subjected for continuous liming & sulphitation process to get
sufficient removal of non- sugars and finally maintained neutral pH of 7.0 to 7.1.

18. REACTION OF SULPHITATION
The solution of Ca(OH)2 will dissociate completely as.
 Ca(OH)2 ↔ Ca++ + 2OH– ( Dissociation Of Ca(OH)2 )
Ca++ + 2OH– – → Ca(OH)2
The pH of the lime solution is above 12.6 at 30 o C , when SO2 gas is passed liquid
H2SO3 (Sulphurous acid) is formed.
 SO2 + H2O ↔ H2SO3
The sulphurous acid get dissociated at high initial pH into H+ & SO3
— ions.
 H2SO3 ↔ 2H+ + SO3
—
Immediately the product of (Ca++) and (SO3
—) which exceed the solubility product
of CaSO3 & more CaSO3 precipitate will result.
 Ca++ + SO3
— ↔ CaSO3
Mean while the OH– ion from Ca(OH)2 molecule will react with H+ ions & with
H2SO3 to form undissociated water molecule.

19.  2H+ + 2OH– ↔ 2H2O
With continues sulphitation further more & more CaSO3 will be precipitated. Resulting
gradual decrease in the Ca++ ions the stage will come when the solubility product of Ca++ and
so3
2- → solubility product of (CaSO3) with minimum Ca++ ions remain in the solution.
 Ca(OH)2 + H2SO3 ↔ CaSO3 + 2H2O
Calcium bi sulphite formation :
If we pass more SO2 gas than the pH will be on the acidic side, with decrease in pH
dissociation of more & more HSO3 ions are possible. Then stage will come where system is
try to maintain the balance of SO3
— ion concentration as it is reduced by dissolving
CaSO3 precipitated.
 H2SO3 ↔ H+ + HSO3
–
Dissolved CaSO3,
 CaSO3 ↔ Ca++ + SO3
—
 SO3
— + H+ ↔ HSO3
–
 precipitated CaSO3 = Dissolved CaSO3

20. CONCENTRATION OR
EVAPORATION
Clarified juice is concentrated into thick syrup under reduced pressure in a multi
effect vacuum evaporator , usually quadruple effect or triple effect evaporators
are used by steam heat.
Pressure is the evaporators are maintained.

21. CRYSTALLIZATION
The crystallization process the syrup is boiled at low temperatures under partial
vacuum and some seeds are added which causes the development and growth
of sugar crystals and the outcome is called massecuite (raw sugar crystals
mixed with molasses).
Most of the water heating by a evaporator and form concentrated sugar syrup
and cool slowly till crystal of sugar are separated out.

22. SEPARATION OF CRYSTAL
Crystals are separated from molasses by whirling in centrifugal machine.
High speed centrifugal machine is used that the crystal easily separated from
liquid portion.

23. REFINING OF CRYSTALS
Dissolved in hot water and boiled with animal charcoal or norit (coconut
charcoal) for decolourisation in the solution and then filtered.
Concentrated under reduced pressure in multi- effect evaporators and
crystallized again.

24. RECOVERY OF SUCROSE FROM
MOLASSES
The molasses contain considerable sucrose after separation of crystals.
The mother liquor is boiled then cool slowly and some freash crystal
separated out .
Molasses still contains sucrose which recovered by chemical method.
The liquid obtained from the separation of crystal is diluted with water then
treated with strontium hydroxide in a treating tank.
Distrontium is precipitated out and then it suspended in water. It
decomposed into sucrose and strontium carbonate.
 C12H22O11.2SrO+ 2CO2 C12H22O11+ 2SrCO3

25. INSTRUMENTATION
OF

26. FLOW CHART: INSTRUMENTATION

27. TESTING OR ESTIMATION OF SUGAR
Sugar contain non sugar or invert sugar (glucose, fructose) as impurity.
For testing Fehling solution added into the sample, a yellow or red ppt indicates
the presence of invert sugar or reducing sugar.
If no ppt form, concentrated HCl added in another sample and boil for few
minutes.
Then cooling and neutralize by adding 10% NaOH.a yellow ppt form by adding
fehling solution.This indicates the presence of sucrose and polyose which gets
hydrolysed with dilute HCl to invert sugar.
The presence of large ppt after after hydrolyzed than before indicates the
presences of sucrose as well as invert sugar.
By specific rotation sugar can also be tested.

28. BY PRODUCTS
OF
SUGAR INDUSTRY

29. DEFINITION:
The by product is an incidental or secondary product, which made in
the manufacture or synthesis of a main product.
The relationship between the by product and the main product
changes in economic or industrial conditions or with advancement of
science.

30. In sugar manufacturing process three important byproducts are obtained.
I. Bagasse
II. Molasses
III. Press Mud
IV. Fly Ash

31. BAGASSE
• The dry pulpy residue left after the extraction of juice from the sugar cane or other
processed plants.
• Can replace the environmentally-friendly product that we use everyday and reduce our
reliance on harvesting wood.
• The quantity of bagasse produce in any sugar factory mainly depends upon the fiber
content of the sugarcane

32. UTILIZATION OF BAGASSE
About 70% of bagasse is used as a fuel for generating steam for power heat to run
the sugar mill.
remaining 30% is used in other daily and industrial purpose, such as
Manufacturing paper
Fiber board
Particle board
Food of boilers
Nano cellulose
Furfural and Acetic acid
Alcohol
Activated carbon
Bagasse ash
Co-generation

33. MOLASSES
• Thick, dark brown juice obtained from raw sugar during the refining process.
• Obtained as a mother liquor which also called green syrup.
• Contain about 15-20% water, 50-55% of total sugars and the rest non sugar.

34. UTILIZATION OF MOLASSES
Contain vital vitamin and minerals such as calcium, magnesium, vitamin-
B6,selenium and different types of carbohydrate.
Acid like citric acid, lactic acid, oxalic acid, maleic acid, butyric acid .
Solvent and chemicals like ethanol, butanol, acetone, glycerol etc.
Inhibit the growth of microorganism.
Edible syrup
Vinegar
Cattle feed
Road surfacing

35. PRESS MUD
The residue of the filtration of
sugar juice.
Also called ‘de-sugarised’ mud
or ‘filter cake’.
Mainly contain calcium
sulphite, calcium phosphate
and some organic impurities of
the of the juice is on the weight
basis about 3% of the weight of
cane crushed.

36. UTILIZATION OF PRESS MUD
Use as a fertilizer
Unfavorable for microbial action
Raw materials for wax
Saline soils
Industrial applications like cement and paint manufacturing, brick making,
foaming agent etc

37. FLY ASH
Is a multi process by
product of bagasse
produced from the mining
of sugarcane

38. UTILIZATION OF FLY ASH
Used in removal of zinc from waste water.
Used in removal of copper from waste water.
Used in removal of lead from waste water.
Used with Portland cement to increase strength.
Used as replacement of fly ash brick.
Used in removal of Cr6+ and Ni2+ from solution

39. THANK
YOU