Project overview Compost produced from biological wastes does not contain any chemicals unfavorable to living soil. This organic fertilizer is also one of them which contain phosphate, nitrogen solubilizing bacteria and decomposing fungi, which is co-friendly and protect the plants from various soil borne diseases. Production of composed fertilizer from Sugar press mud, residues by-products of sugar industries is found to be worthy for maintaining health of plant and soil properties and protects the plant from various soil borne diseases. In this feasibility paper, composting of SPM on commercial basis is discussed. Availability in Pakistan: In Pakistan there are almost 81 sugar mills of crushing capacity of 6.1 Million tons. Sugarcane is planted on approximately 1.1 M Hectors producing 5.5 Million tones sugar with an average yield of 51 tones per Hector. In which almost 82-84 % cane is utilized in sugar industries. According to an estimate Pakistan sugar industry is producing about 1.2 - 1.8 million tones of SPM every year.

1. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.

2. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.
PRE-FEASIBILITY: Sugar Press mud compost fertilizer
Project overview
Compost produced from biological wastes does not contain any chemicals unfavorable to
living soil. This organic fertilizer is also one of them which contain phosphate, nitrogen
solubilizing bacteria and decomposing fungi, which is co-friendly and protect the plants from
various soil borne diseases.
Production of composed fertilizer from Sugar press mud, residues by-products of sugar
industries is found to be worthy for maintaining health of plant and soil properties and protects
the plant from various soil borne diseases. In this feasibility paper, composting of SPM on
commercial basis is discussed.
Availability in Pakistan:
In Pakistan there are almost 81 sugar mills of crushing capacity of 6.1 Million tons. Sugarcane is
planted on approximately 1.1 M Hectors producing 5.5 Million tones sugar with an average
yield of 51 tones per Hector. In which almost 82-84 % cane is utilized in sugar industries.
According to an estimate Pakistan sugar industry is producing about 1.2 - 1.8 million tones of
SPM every year.
Process details:
Production of compost fertilizer is very simple process as described in block diagram in figure 1.
Following processing stages are required

3. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.
Raw Materials Recipe and formulation:
Composting/Digestion:
Compost Yard :
2 acres of compost yard is concreted using
HDPE sheet of 250 micron thick over which
RCC of 1:2:4 mixture of 150 mm is used.
Curb wall (optional) is provided to prevent
the seepage of water from the compost
yard. A garland canal is constructed to
collect seepages during the composting
operations. The seepages are collected in a
tank which is made seepage proof as per
the specifications mentioned for water
storage pond. The efluent from the sump
well is pumped back either on to the
compost yard/ water storage pond.
Composting procedure:
SPM, local rock phosphate, SSP and sulfur mud with the specifications given in Table 1, were
mixed thoroughly and piled of appropriate length, 1-4 in width and 0.5 metre high in
semicircle shape. These piles were given time to be composited and to complete digestion
process for about 14-21 days. During piling, the mixture was mixed, turned and watered to
maintain moisture content of 50-60 %. A turner was used for turning process to maintain
uniformity and thoroughly mixing as shown in Figure 2.

4. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.
Granulation Unit:
The compost mixture from the digestion unit. is then sent to granulation unit.
Screening Unit:
After granulation of compost, it is sent to screening unit. Average size of the bio-fertilizer
should be of 5mm diameter for the ease of farmer and good quality granule. Oversize and
undersize granules are recycled again to dryer unit. This screening unit is same as the screening
process used for SSP screening. Product of required size is sent to Packaging unit where it is
packed in the bags through auto-filling. And then finally product is sent to distribution unit.
Testing of final product:
After the production of bio-fertilizer it is tested For
Organic matter (25% )
Product specification:
Bio-fertilizer produced is high in phosphorous contents due to the addition of SSP and local rock
phosphate as both contain 18.5% and 30-32% P2O5 respectively. Granules of bio-fertilizer
produced are of good quality and spherical in shape due to the addition of Rock phosphate.
Area requirements:
Sufficient Area is required to compost Sugar press mud (SPM) such as:
Area for composting: concrete area of 2 Acres is proposed for composting.
Area of 300-500 yards is recommended for granulation, screening and filling packing and
storage /distribution.
Construction specification:
Composting area is concreted (1:2:4) mixture (2 acre).
HDPE 250 micron may also be employed below concrete to further minimize seepage.
Curb wall may be employed 2 ft high 4” block (to Avoid spillage of water )
A garland canal is created to collect seepage.
Manufacturing area hight is 13 ft
Storage area height 15 ft

5. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.
Godown, Packing and Weighing Facilities:
1 200 kg capacity scale for weighing 50 kg bags.
2 Weigh bridge 30MT capacity for weighing Trucks & Tractors.[ optional]
3 Stitching machine 2 No. for Stitching HDPE bags.
4 Conveyer 1 NO. for loading of Bags.
5 Sealing machine for sealing of 2 kg plastic pouch.
6 Godown for storing of Packed Material & packing. Size 15 x 12 m.
Application and results:
Application of compost fertilizer in connection with chemical fertilizer increased the yield of
all tried crops for about 20 % to 40 % in comparison to chemical fertilizer alone.
The application of bio compost to soil improved the physiochemical properties of soil due to
its high humus content.
The need of chemical fertilizer was decreased upto 25%-30%.
The efficiency of applied chemical fertilizer improved when it is applied in combination of
composted SPM bio fertilizer.

6. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.
Machinery:
A) Aerotiller /
OR
B) turner:
C) Water Sprayer

7. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.
D) Inoculator Tank: For Microbes
E) L/T FRONT END LOADER CUM EXCAVATOR

8. Head Office: Plot No 3 Main Jail Road PIB Colony 74800, Karachi . PABX: (+9221)
34943440 , Fax: (+9221) 34930930 Cell: (+92) 332-2466440 , (+92) 314-2172647
Factory : Quarter No. F , 91 /A Jail Road Jahangir East Karachi. Phone : 0213-4910410
Email : ahl_rd@yahoo.com , ahlabspk@gmail.com.
F) Sieving and
transport tractors
with trolleys
G) Underground
filling system