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Sugar manufacturing process
This document provides an overview of the sugarcane processing and sugar production process. It details each step from harvesting sugarcane to processing it in sugar mills to extract the juice, and then refining the juice to produce raw and refined sugar. The key steps involve crushing the sugarcane, extracting and clarifying the juice, evaporating and crystallizing it to produce raw sugar, and then further processing the raw sugar through affination, melting, purification and recrystallization to produce refined white sugar. Factors like temperature, moisture, light and compression are important for proper storage of sugar.
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Sugar manufacturing process
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- 2. Sugar Introduction, Rawand Refined Sugar, Factors Affecting Sugar Storage 4/19/2014 2
- 3. INTRODUCTION Sugar • General termindicating sweet carbohydrates • Mono-, di- and poly-saccharides • Obtained from plants, largely sugarcane & sugar beet plant • Pakistan 12th largest producer of sugar • Per capita consumption of sugar is 25kg • More than 81 sugar mills in Pakistan 4/19/2014 3
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- 5. Harvesting Of Sugarcane •Fully mature • Two types – Manual – Mechanical 4/19/2014 5
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- 7. Transport and Handling •Animal driven carts • Trolleys • Trucks 4/19/2014 7
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- 9. Material Handling andStorage • 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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- 12. Cutting of Canes •To aid the cane crushing • Cane knives to cut cane into small pieces 4/19/2014 12
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- 14. Shredding • To removeleaves and nodes • Hammer mill shredder 4/19/2014 14
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- 16. CRUSHING • Cane crushedto 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
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- 18. MILLING TANDEMS • 3roller 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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- 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
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- 24. CLARIFICATION/DEFECATION • To removenon-sugars and impurities – Liming – Sulphitation – Phosphatation – Carbonation 4/19/2014 24
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- 27. FILTRATION • Mud from clarifierstill contain some residual juice • Filtered to extract residual juice in Rotary Vacuum Filters 4/19/2014 27
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- 29. EVAPORATION • Juice evaporatedto 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
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- 31. CONT… • Steam usedto evaporate juice • 1 liter steam to evaporate 4 liter juice • Steam temperature 113- 130ᴼC at 1st pan and 55ᴼC at last pan • Each subsequent vessel with decreasing pressure • Last pan being under almost a total vacuum 4/19/2014 31
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- 33. CRYSTALLIZATION • Carried outin 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 – mixtureof crystals and mother liquor (molasses) resulting from the crystallization • Transferred to crystallizer at low temprature 4/19/2014 34
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- 36. CENTRIFUGATION • Separate sugarfrom 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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- 39. DRYING AND PACKAGING •Sugar tumbled through large cylindrical dryers • Sorting • Packaging 4/19/2014 39
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- 43. AFFINATION • Mixture ofraw 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 sugardissolved with hot condensate to conc. of 72ᴼ brix • Melted at 85ᴼC in Batch or continuous melter 4/19/2014 44
- 45. PURIFICATION • Remelt maycontain some impurities and colorants • Liming 1. Partial 2. Complete • Carbonization • Colorants remover by decolorization 4/19/2014 45
- 46. DECOLORIZATION • Two methods 1.Granular activated carbon (GAC) 2. Ion exchange resine 4/19/2014 46
- 47. EVAPORATION & CRYSTALLIZATION • Sugarsyrup 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 & REFINEDSUGAR • 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
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