Process of sugar production from sugarcane - sugar factory

• Content outline Introduction

Sugar

Sugarcane and its cultivation

Process of manufacturing of sugar

By product of sugar factory

summary

• Introduction

Sugar • General term indicating sweet carbohydrates

• Mono-, di- and poly-saccharides

• Obtained from plants, largely sugarcane & sugar beet plant

• Sugar is a vital ingredient in most of out daily consumption For example: Soft drinks, juices, tea, biscuits, sweet meats, bakery items, deserts, etc.

• Introduction• have two main source/raw material for sugar

Manufacturing these are:

• sugar cane and sugar beet.

• For now we see how to extract from sugar cane.

• Many physic-chemical process are take place during

sugar production.

• In addition to sugar production sugar factory produce by

product.

• PROCESS OF SUGAR PRODUCTION

•Raw material for sugar production• Sugar cane and sugar beet

SUGAR CANE AND ITS CULITIVATION• Sugarcane plants are a genus of tall tropically growing

perennial grasses from the family Poaceae.

• Sugar cane is in the same family as grass, and grows in the form of tall, narrow stalks, or canes.

• Sugar cane is rich in sucrose there used for sugar production.

PROCESS OF SUGAR PRODUCTION SUGAR CANE AND ITS CULITIVATION Planting Sugar Cane

• Select healthy sugar cane plants• Split the sugar cane stems into foot-long pieces• Dig furrows in a sunny planting spot • Moisten the furrows• Plant the sugar cane• Wait for the sugar cane to grow

Growing and Harvesting Sugar Cane • Fertilize the sugar cane with nitrogen • Weed the planting bed often • Wait until fall to harvest• Harvesting of sugarcane at a proper time

Statement or caption here

PROCESS OF SUGAR PRODUCTION SUGAR CANE AND ITS CULITIVATIONSugar Harvesting of cane is generally two types:• MANNUAL: in manual type harvesting, canes are harvested by the

help of manpower or labour.• MECHANICAL: in this type of harvesting, canes are harvested by

the machine (harvester or combine machine).

Mannual mechanical


• MANUFACTURING PROCESS

• TRANSPORTING• sugar cane are transported to the sugar industries by the help

of :

track Tractor Animals

• PROCESS OF SUGAR PRODUCTION• MANUFACTURING PROCESS

• Washing, Cutting of Canes, Shredding • Washing the sugarcane before processing i.e. removing dirty.

• Cutting operation is the first operation in industry.

• Cutters are mechanical equipment which is used to cut the canes into

desired size.

• Shredder is used to remove leaves and undesired solid particles from cane.

Cane knifes washer shredder



• Milling Milling is process of crushing the sticks of sugar cane to extract the juice. The shredded cane is fed through a series of crushing mills to extract the sugar rich

juice. Consists of three roller mills connected in series:o Top rollero Feed rollero Discharge roller

These used to extract the juice from crushing sticks. To make the mill process more efficient, the poor juices of the subsequent millings

are reprocessed (mashing process) and hot water is applied in the lastmilling to increase the extraction.

Bagasse is produce as a by product.



• Clarification• In clarification process sludge, mud, suspended & colloidal particles are

removes by some chemical compounds.• Raw cane juice are filled in clarifier (conical shape vessel), where

phosphoric acid, lime & sulphur dioxide are mixed with the help ofagitator.

• When these chemicals are mixed, suspended and colloidal particles arecollect in flock and resulting settled down.

• Neat and clean juice comes out from the upper section of clarifier, sludgeand mud are collect in bottom and drainage to rotary filter.• Calcium phosphate : as flocculent• Lime & SO2 : acts as bleaching agent• CO2 : acts as acidifying agent

•



• FILTRATION• Clarified mud from the clarifier further filtered in rotary filter.

Mud & sludge are stick on the periphery of rotating drum by theaction of suction. Solid cake removes from the drum by doctor blade.



• Evaporation• Evaporators are used in process industry to concentrate liquids.• The operation is performed normally by use of low pressure, dry &

saturated steam.• The evaporator consist a heat exchanger in inner section .• In the evaporator feed interred at upper section and concentrated

thick liquor exit at bottom section.• Multiple effect evaporator increase quality

Multiple effect evaporator



• Crystallization• In the field of engineering crystallization process

considered as mass transfer operation.• Purest form of substance is obtained.• The object of the process is usually the recovery of the

solute (crystals) from the solvent.• Process consist 3 major events:

• Clustering• Nucleation• growth



• Separation /centrifugation• Separate sugar from molasses /mother liquor• Centrifuge operates at 100-1800 rpm• Molasses pass through perforations• Sugar crystals are washed with 85ᴼC water• Raw sugar and molasses produced

centrifuge



• Refining• A sugar refinery is a refinery which processes raw sugar into white

refined sugar.• Refining process consist of 4 step ;

• Affination - dissolving off some surface impurities• Carbonatation - removing further impurities that precipitate

from solution with calcium carbonate• char filtration - removing further impurities with activated

carbon• Recovery - using a vacuum process (see salt recovery). The

liquor left over from the preparation of white sugar and thewashings from the affination stage both contain sugar which itis economic to recover.

• PROCESS OF SUGAR PRODUCTION• MANUFACTURING PROCESS

• Refining process


• Drying• Drying is very essential mass transfer operation in processing sugar

cane into sugar.

• The wet raw sugar from centrifuges goes to rotary drier to remove the

water from the wet sugar to reduce moisture content to 0.5-2%; using

hot air at 110ºC which flow counter currently with sugar.


• Storage/packaging• packing is final process of sugar manufacturing process.

• Containers opaque, airtight, moisture/odor proof

• Glass canning jars or cans for liquid sugars

• Factors affecting sugar storage

• Temperature

• Moisture

• Quality of sugar

• Light

• Grain size and distribution

• Compression


• Raw & Refined Sugar • 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

• MANUFACTURING

PROCESS

• By product of sugar factory• Cane tops

• Cane tops have no real market value.

• When fresh, of about 2.8 MJ of metabolizable energy per kilo of dry matter.

• However cane tops should be collected and transported from

• the cane fields to the feedlot

• Bagasse

• It is the fibrous residue of the cane stalk left after

• Crushing and extraction of the juice

• It consists of fibres, water and relatively small

• Quantities of soluble solids-mostly sugar

• It is a color less, in flammable, volatile, aromatic liquid

• Use as bioful

Statement or caption here• By product of sugar factory Filter mud / press mud and Spent Wash

The precipitated impurities contained in the cane juice, after removal byfiltration, form a cake of varying moisture content called filter mud.

This cake contains much of the colloidal organic matter, anions thatprecipitate during clarification, as well as certain non-sugars.

Molasses Molasses is the final effluent obtained in the preparation of sugar by

repeated crystallization It is the residual syrup from which no crystalline sucrose can be obtained

by simple means

The yield of molasses is approximately 3.0 percent per tonne of cane.

Engineering

Process of sugar production from sugarcane - sugar factory