This document provides information about the sugar industry in Pakistan. It discusses the history of sugar mills in Pakistan, the importance of the sugar industry, the manufacturing process of sugar including cane preparation, juice extraction, purification and crystallization. It also discusses factors affecting sugar production such as fertilizers and burning cane, and ways to improve sugar production such as utilizing byproducts, using organic fertilizers, paying farmers higher prices, and adopting green technologies.

2. SUGAR INDUSTRY

3. NAME : FARAZ KHAN
ROLL NO : 21CH110
SECTION : 2
SUBJECT : (CPT)
SUBMITTED TO : MA'AM AISHA KOUSAR
TOPIC : SUGAR INDUSTRY

4.  CONTENTS
 INTRODUCTION
 HISTORY OF SUGAR MILLS
 WHY THE SUGAR INDUSTRY IS IMPORTANT TO US ?
 MANUFACTORING OF THE SUGAR
 PROCESS FLOW DIAGRAM
 USAGE OF GREEN TECHNOLOGY IN SUGAR INDUSTRY
 FACTORS AFFECTING SUGAR PRODUCTION
 HOW CAN WE IMPROVE OUR SUGAR PRODUCTION

5. Introduction
SUGAR
Sugar is commonly used as a sweetener. It is the worlds valuable
nutritious foods and is the main source of carbohydrates and
provides inexpensive calories for human body. Sugar comes in a
wide variety of forms. The most common is granulated sugar, also
called table sugar, which is the most refined form. Granulated
sugar with larger crystals is called coarse sugar; with smaller
crystals, it is called superfine sugar. Brown sugars in various color
ranges are defined by the amount of molasses present within
them; they range from bright yellow to dark brown.

6. Sugars of various crystal sizes provide unique functional
characteristics that make the sugar suitable for different
food and beverages. Sucrose is the chemical name of
sugar formula of sucrose is (C12H22O11) melting point
of sucrose is 186°C.Two main sources of sugar are
sugarcanes and beet. Normally industries are based on
sugarcane. Sugarcane is a large perennial tropical
grass. It grows to a height varying from 10-15 feet. It is
bamboo like stalk whose diameter varies from 2” to 3”.

7. SUGARCANE
Sugarcane today is considered as one of the best converters
of solar energy into biomass and sugar. It is a rich source of
food (sucrose, jiggery and syrup), fiber (cellulose), fodder
(green leaves and tops of cane plant, bagasse, and
molasses and to some extent press mud), fuel and chemical.
The main by-products are bagasse, molasses and press
mud. The other products and their by-products of less
commercial value are green leaves and tops, trash, boiler
ash and effluent generated by sugar industry and distillery.

8. History Of Sugar Mills
At the time of independence in 1947, there were only two sugar mills in
Pakistan.
The output of these factories was not sufficient for meeting the domestic
requirements. The country started to import sugar from other countries and
huge
foreign exchange was spent on this item. the first sugar mill was established at
Tando Muhammad Khan in Sindh in the year 1961.During the year 1997-
1998 there were 75 sugar mills. In the country and it produces 2.4 million metric
Tons. In 2009 /10 Sugar cane is grown on over a million hectares and provides
the
raw material for Pakistan's 81 sugar mills. Sugarcane is an important industrial
and
cash crop in Pakistan & it produces numerous valuable by products like, alcohol
used by pharmaceutical industry, ethanol used as a fuel, bagasse used for
paper
and fuel.

9. Sugar industry is an agro based industry which provides
employment to the landless rural population and has a great
impact on the economy of the country. In Pakistan normally
season starts in November and ends in April. The three principal
bye-products of a sugar industry are bagasse's, molasses and
press cake which along constitute about 40 per cent of the weight
of the total cane crushed.
 Pakistan Sugar Mills Association (PSMA) has listed the names
of sugar mills of Pakistan province. There are 87 names of
Sugar Mills listed on their website among which 45 are located
in Punjab,33 in Sindh and 9 in KPK.

10. Sugar mils of Pakistan are listed below :
 Crescent Sugar Mills.
 Najma Sugar Mills Ltd..
 Fauji Sugar Mills.
 Khairpur Sugar Mills.
 Shakarganj Mills Ltd..
 Jauharabad Sugar Mills Ltd..
 Tandlianwala Sugar Mills Ltd.
 Ranipur Sugar Mills (PVT.) Ltd
 D.W Sugar Mills Limited.
 Haseeb Waqas Sugar Mills Limited.

11.  Why is sugar industry important for Pakistan?
In Pakistan after textile , sugar industry is the 2nd biggest industry. It is
one of the worlds valuable nutritious foods and is the main source of
carbohydrates and provides inexpensive calories for human body.
Sugarcane is the fourth largest cash crop grown in Pakistan which
contributes to the agriculture economy of the crop value of Rs. 48,292
million. The industry is a catalyst to development and creates
employment in rural and deep rural areas. It provides direct employment
to over 5 lakh not only for skilled laborers but also to semi-skilled
laborers in sugar mills
 Why should the sugar mills be ideally located?
 Sugar cane contain sucrose and starts losing its sucrose content as soon
as it is harvested.it needs to be crushed immediately.
 Sugar cane is bulk and heavy. Therefore its transportation cost is high.
 Rural areas are usually densely populated and provides cheap laborer
and huge market. Therefore, the ideal location for sugar mills is in close
proximity of sugarcane producing areas.

12. Manufacturing of Sugar
Raw Materials
 Sugarcane
 Lime
 Phosphoric acid
 Carbon dioxide, sulphur dioxide
 Hot water
Sugar preparation is divided into four steps :
 Cane preparation
 Juice extraction
 Juice purification
 Concentration and crystallization
 Separation of crystals

13. CANE PREPRATION
The preparation of the cane is accomplished in several ways:
1) Harvesting
Sugarcane is harvested from fields mechanically. The harvested plant materials
are frequently sieved to remove dirt and rocks before being loaded onto trucks
and taken to the factory.
2) Washing of Cane
Sugar cane is cleaned by flooding with
warm water.
Purpose
To remove rocks ,trash ,dust and leaves.

14. 2) Cutting
Cutting is done by revolving the knifes that
cut the sugarcane into chips but extracted
no juice.
3) Shredding
Shredder cut the cane into finest particles.
By shredders that tear the cane into shreds
but extract no juice.

17. JUICE EXTRACTION
 Freshly cutting and shredded cane is transported towards a
series of roller mills to extract juice.
 A series of three roller mills compresses the sugar cane fibers
and separates the juice from the bagasse. The initial juice is
dark greenish in color and is acidic and turbid. The juice is
collected in large tanks and the sugar concentration is
measured, Hot water is sprayed to get the maximum amount of
juice from the cane ,about 85-95% of juice present in cane is
extracted.
 Remaining cellulosic material discharged from the diffuser is
called as bagasse, which can be used later as a fuel source.

19. JUICE PURIFICATION/ CLARIFICATION
Extracted juice is in dark green color containing about 15% sucrose and
small amount of glucose ,fructose , vegetable proteins etc .so it requires
clarification.
• The juice is screened and clarified to remove floating impurities.
• After screening the fresh juice which is greenish in color and which
has around 15% of sucrose is being sent to deflection unit in which
The juice is heated to denature the protein content and is then mixed
with a slurry of calcium hydroxide, called milk of lime to remove
organic acids and phosphates. By Adding lime and agitation causes
coagulation of colored and nitrogenous compounds and come on
surface, Then further the defecated juice is treated with sulphur
dioxide to maintain pH of solution.

20. • After that slurry is being sent to carbonation tank in which we
treated the solution with CO2 for the carbonation purpose. To
remove excess lime and to recover sucrose from calcium
sucrate.
• Later the carbonated mass is decolorized with bone char and
light greenish color solution is produced.
• The clarification process typically takes several hours. At the
end, the sludge is removed from the bottom of the tank and the
juice is removed from the top.

22. Conclusion
In this particular section we can remove the dark green color and further
impurities of the juice that is being extracted. The material which was came on
surface of deflection unit known as mud. Mud from clarifier still contain some
residual juice so it is send to the rotary filter then this filter extract residual juice
from mud and we get the residue known as Press cake.
Press Mud or Cake
Press mud is the residue of
the filtration of sugarcane juice.
It is used as manure and
that of carbonation
factories are usually burnt.

23. Concentration and Crystallization
• Sugar solution is passed through multiple effect evaporators , here
juice is concentrated from 80-85% H2O to 40-45% H2O to make juice
ready for crystallization.
• Concentrated thick liquor is further boiled in vacuum pan crystallizer
at vapored temperature of 57°C until white cloud is forms, As the
mixture is boiled in a vacuum pan, water evaporates and sugar
crystals continue to grow into a paste called massecuite, a dense
mixture of syrup and sugar crystal. Sugar syrup is evaporated up to
super saturation.
• . This mixture is then transferred into a large container called a
crystallizer, where the massecuite is slowly stirred and cooled,
continuing the crystallization process
• The small grains of sugar present in the massecuite serve as a
nuclei, helping to draw out the sugar in solution and convert it into
crystals.

25. Separation of crystals
• To separate the massecuite into sugar crystals and molasses, the
massecuite is added to a high-speed centrifuge, which rotates at
1,000 to 1200 rpm contains a perforated metal cylindrical basket.
During centrifugation, the molasses passes out of the centrifuge
basket and is drawn to the outside of the centrifuge where it is
removed and sent to storage tanks. The sugar is retained in the
centrifuge basket.
• Then the raw sugar is boiled and washed to remove the further
impurities.
• The raw sugar crystals are dried in large hot air dryers , reaching a
moisture content of as low as 0.02%. Next, the sugar is gently
tumbled through heated air in a granulator. The dried crystals are
then separated into different sizes through vibrating screens, then
the sugar crystals are ready to go the markets.

27. Molasses :
Molasses is the final mother liquor leftover after the
crystallization of sugar. Molasses is not as sweet as
table sugar. It s a thick dark brown liquid.it is a liquid
sugar that primarily contains sucrose and smaller
amounts of the monosaccharide's fructose and glucose.
It is used to produce ethanol, candies , chocolates and
cookies.
Bagasse :
Bagasse is a fibrous residue left over after the
sugarcane is crushed. The fiber content of bagasse
(cellulose) is used in cellulose industries like the
pulp, paper, particle boards, cattle-feed etcI.it is used
as animal feed and as boiler fuel.

28. HOW ELECTRICITY IS PRODUCED IN SUGAR
INDUSTRY?
In sugar industries electricity is generated with steam
turbines using fossil fuels, nuclear, biomass, biogas,
geothermal, and solar thermal energy. Other major electricity
generation technologies include gas turbines, hydro turbines,
wind turbines The by-product from the crushing of
sugarcane, bagasse is also used as boiler fuel in the sugar
mills, which is used to drive turbines that generate electricity.
The flue gases produced in the boilers have to be treated by
an elaborate air pollution control system.

29.  What is Bio mass include?
Biomass is organic, meaning it is made of material that
comes from living organisms, such as plants and animals.
The most common biomass materials used for energy are
plants, wood, and waste. Bio mass include any agricultural
residues, forest residues and industrial waste. Biomass
energy can also be a non-renewable energy source.
 What is Bio gas?
Biogas is produced when bacteria digest organic matter(bio
mass) in the absence of oxygen. This process is called
anaerobic reaction.

30.  USAGE OF GREEN TECHNOLOGY IN SUGAR
INDUSTRY :
o Green Technology : (given information is from Google)
Green technology is a term that describes the use of technology and science to
reduce human impacts on the natural environment. Green technology helps
manage and recycle waste material. A lot of recyclable material has allowed
individuals to create plant fertilizer, sculptures, fuel, and even furniture
• In particular green technologies helps to reduce waste , conserves water
and consume less energy as compared to traditional technologies.

32. • Sugar cane production often pollutes fresh water and during the production of sugar,
large volume of water is used by sugar mills for processing which absorbs all the
available oxygen in water and leading to massive fish kills, and this water also cannot
used for irrigation. Therefore it is necessary to treat waste water before their disposal.
• Processing of sugarcane in industries using green technologies can develop effective and
affordable sugar in developing countries.
• ONE OF THE pathways to a sustainable future for the sugar industry is to adopt bio-
refinery models which have the capacity to generate higher value products from sugar
crops and its processed residues.
• The vast majority of ethanol is produced from sugar cane molasses, a by-product of
sugar. Ethanol blended fuel can help in reducing crude oil imports.
• The mill generates its own electricity of 33,408 megawatt per hour (MWH) from bagasse;
however, it would be more feasible if they used biogas produced rom spent wash which
was a by-product of ethanol generation from molasses .In this way, the mill would also be
able to sell excess electricity to the government.
• Boiler ash can be used as a soil conditioner.
• Vinasse can potentially be used as a potassium rich fertilizer.
• To reduce the fly ash that sugar mill generates, you can dry it before using it so it burns
more efficiently and generates less emissions

33.  IMPORTANCE OF GREEN TECHNOLOGIES FOR SUSTAINABLE
DEVELOPMENT :
Green Technologies expands the range of available options and potential
strategies for achieving sustainable development goals such as clean water
and sanitation, affordable and clean energy, climate action, and life below
water and on land while reducing the costs of their implementation over time
.
 BENEFITS :
There are many advantages of green technologies include : It is
environmentally friendly that means no harmful emission to the air , does not
require a lot of money for it’s operation , never run out because of it’s
renewable technology . It helps to reduce carbon dioxide emission in the air
and it reduces global warming pollution and it is tax friendly also .
 DRAWBACKS :
The initial investment or implementation cost is very high . People are still
not familiar with the technology . People have very lack of information about
the green technologies and it is very costly when it comes to business .

34. FACTORS AFFECTING SUGAR PRODUCTION :
• Fertilizers are a great help to sugar cane farmers But some fertilizers need to be
used mindfully. Examples of such fertilizers are inorganic nitrogen fertilizers, which
are chemical-based fertilizers that contain high levels of nitrogen. Nitrogen is one of
the nutrients that crops need the most to grow but too much nitrogen can lead to soil
acidification, or the soil becoming excessively acidic which will lead to a significant
decline in crop production.
• Burning sugar cane to remove the outer leaves from their stalks before they’re
harvested used to be common practice. It made harvesting them easier and quicker,
but it degraded the soil’s quality by causing it to lose moisture and organic matter.
• High cost of production.
• Alcohol production from can e or beet results in the by-product ; vinasse which is
routinely dumped into the rivers.

35.  How can we improve our sugar product
 In Pakistan utilization of sugar bye-products has not received much attention as
compared to other countries of the world. Proper and economic utilization of
these byproducts can reduce the cost of production of sugar to some extent.
 Instead of inorganic fertilizer, organic options like compost and cow manure
based fertilizers need to be used more widely.
 sugar industries owners should have to pay good amount to the cane
farmers so they can plant sugarcane because low yield of cane is a big
issue for sugar industry.
 The more invested in maintaining soil health, the better the crop yield will be
without negatively impacting the environment.
 Vinasse can potentially be used as a potassium rich fertilizer.
 Zero pollution milling which involves totally recycling treated effluents for use
in cooling towers and spray ponds is also becoming more common.
 Excess electricity generated from steam can be sold to local power
companies.