ISSCT Pre-Congress Tours

ISSCT

PRE-CONGRESS TOURS

SUGAR FACTORIES

RESEARCH INSTITUTES

18-21 FEBRUARY 1999

Tour No 1 - Daurala

Daurala

Tour No 2 - Pune

VSI, Ajinkyatara, Bhima Patas

Tour No 3 - Coimbatore

SBI, TNPL, Sakthi Sugars

TOUR NO 1.

DAURALA SUGAR WORKS

Management

Vice Chairman : Tilak Dhar

Executive Director : N.N. Joshi

Advisor (Technical) : V.K. Rohtagi

DCM Shriram Industries Ltd. ( DCMSIL), of which DAURALA SUGAR WORKS, DAURALA (DSW) is the flagship unit, is a highly diversified group with operations in Sugar, Alcohol, Organic and inorganic chemicals, drug intermediates, and rayon tyre cord. It is situated at village Daurala about 100 Km from New Delhi, on the Delhi - Dehradun national highway.

SUGAR UNIT : DSW was set up in 1932 by Late Sir Shriram to capitalise on the sugar cane rich resources of this area, at an incipient capacity of 500 TCD. Today DSW is one of the most efficient and modern sugar factories of the country having a capacity of 6500 TCD and following the standard Double sulphitation process. DSW has further obtained a license for expansion to 8000 TCD on which the work is already in progress.

SUGAR REFINERY: In 1940, the first sugar refinery plant of India was set up to manufacture refined sugar conforming to international standards. The product range includes double refined sugar cubes, breakfast sugar, pharmaceutical grade sugar and sugar sachets for use by airlines, hospitals, hotels and the pharmaceutical Industry.

DISTILLERY : The plant today is among the largest distillation plants in India with installed capacity of 45 Million Litres of alcohol and 600,000 cases of Indianj Made Foreign Liquor (IMFL) per annum.

CHEMICAL PLANT: This plant is a leading exporter of fine aromatic chemicals and manufactures Benzyl Cyanide, Benzyldehyde, Phenyl Acetic Acid and other allied chemicals.

CO-GENERATION OF POWER : DSW has a large power house with a generating capacity of 20 MW. Nearly 3 MW power is co-generated after meeting the sugar factory requirement and is supplied to various allied units at Daurala. The boilers have been designed for multi-fuel firing arrangement and are equipped with very effective wet scrubbing system to meet the stringent requirement of pollution control.

EFFLUENT TREATMENT PLANT (ETP) : There are separate ETP plants, for both Distillery and Sugar Factory effluents, developed with in-house R&D, simultaneously producing bio-gas as by-product which is used as fuel at the boilers.

TISSUE CULTURE : A tissue culture lab has been set up as an R&D unit with a view to produce healthy seed material of various sugar-cane varieties through micro-propagation.

SUGARCANE RESEARCH FARMS :

DSW has its own sugarcane Research Farm at village Palhera, about 8 Kms from Daurala, for developing betterhigh yield varieties of cane.

IS0-9000 CERTIFICATION - The greatest achievement of DSW in recent times has been the accreditation of the prestigious ISO-9002 Certificate

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TOUR NO 2.

VSI, AJINKYATARA, BHIMA PATAS

VASANTDADA SUGAR INSTITUTE (VSI)

Management

President : Sharad Pawar

Vice President : Shivajirao G. Patil

Director General : V.P. Rane

Vasantdada Sugar Institute (VSI) formerly known as Deccan Sugar Institute, is an autonomous body. Established by the sugar cane grower members of co-operative sugar factories with the active and generous support of the Government of Maharashtra state, it is the only organization of its kind in the world.

AIMS & OBJECTIVES : VSI endeavours to improve productivity on farms and in factories through training, extension and research.

LOCATION : VSI is located in a typical rural setup at Manjari village near Pune city on the banks of the river Mula-Mutha. It is 22 km /25 km from Pune railway station/airport respectively.

ORGANIZATIONAL STRUCTURE : The institute performs its multifarious functions through interdisciplinary groups within a divisional structure that is dsicipline-based. For administrative convenience, the following divisions and sections have been created :

Technical Divisions :

Agricultural Science & Technology
Sugar Technology
Sugar Engineering
Alcohol & Fermentation Technology
Sugar Chemistry & By-products
Electronics & Computer
Instrumentation
Chemical Engineering

Other divisions include Academic and other supporting divisions

STAFF : VSI has over 200 permanent employees. Of these, about 90 are scientists and technologists and the rest are supporting staff. Moreover, about 60 employees normally work on various sponsored R&D schemes.

RECOGNITION : VSI is recognised by the GOvernment of India as a centre of advanced research. It is also recognised as a centre for undertaking research leading to Ph.D. degrees of various universities. VSI laboratories have been recognised by the Central and State pollution contriol boards. VSI is also one of the few centres for analysing sugar samples according to ICUMSA norms.

ACTIVITIES :

Research & Development : VSI's current interests include, interalaia, development of promising sugarcane varieties through bio-technology, water conserving irrigation system, eco friendly methods of crop production & protection, reduction in sugar losses in factories, cogeneration, energy audit, pollution abatement, application of modern and sophisticated techniques in farms and factories, and development of by-products.
Extension Servies & Consultancy
Human Resources Development
Testing Services
Dissemination of Information through Mass Communication

MAJOR ACHIEVEMENTS : In the two decades of its existence, VSI has published a large number of research papers, completed several projects, developed diagnostic and control systems, brought about process optimisiation and obtained patents. Notable among its achievements are automatic drip irrigation system for cane, vermicompost from farm waste, biofertilisers, biological control ofpests and diseases, development of cane varieties through tissue culture, microprocessor based pH control, on-line estimation of brix using nucleonic density meter, automatic estimation of moisture in bagasse, development of by-products like oxalic acid and sugar esters, reduction in sugar losses, and improvement in the quality of sugar during processing.

AJINKYATARA SAHAKARI SAKHAR KARKHANA LTD.

Located in Satara district, Maharashtra, 120 km from Pune on Pune -Bangalore National Highway No 4.

Management

Chief Executive - Shri Vikramsinh H. Apradh

Chief Engineer - Shri M.S. Shinde

Cane Development Officer - Shri P.T. Khot

Technical Specifications

Clarification process : Double sulphitation.

Crushing capacity : 2500 TCD.

Preparatory devices :

a) Cane Chopper - 36 knives Swing dia. 1200 mm

b) Cane leveller - 48 knives, dia. of tip 1400 mm - driven by 250 HP electrical motor.

c) Cane cutter - 52 knives, dia. of tip 1400 mm- driven by 400 HP electrical motor.

d) Shredder swing type - 102 Hammers, Swing dia. 1524 mm, R.P.M. 1000 driven by steam turbine of 750/1000 BHP

Mill details - Five mills driven by steam turbines.

i)One zero mill - five roller mill with GRPF arrangement. Texmaco Walker make size 915 x 1700 mm

ii) Four mills - 12 rollers tandem with TRPF arrangement. Bauckwolf Make size 810 x 1525 mm.

Boilers - Three boilers

i) Two Nos. bent water tube boilers, MakeBauckwolf, Capacity 24MT/Hr. Working pressure 21 kg/cm.2 340 deg. C. temp. with economiser and air heater and fly ash collector.

ii) One No, bent water tube boiler , Make Texmaco, Capacity 32 Mt/Hr. Working pressure 45 kg/cm2, 420 deg.C. temp. With economiser air heater and fly ash collector.

Duration of season : Approximately 180 days.

Total cane crushed in 1997-98 : 464034 MT.

Recovery % cane : 11.00 %

Distillery : Continuous bio-still fermentation distillery having capacity 30 KLPD

Factory Farm :

i) Total area : 10.00 hectares.

ii) Major Varieties : Co-86032, Co-7219, Co8014, Co-7527, Co-8021

iii) Average yield : 65 M.T./hectare.

BHIMA PATAS

Management

Chairman : Sri Subhash Baburao Kool, M.L.A.

Managing Director: Mr. B.N. Hande

LOCATION : In Pune district, Maharashtra, 50 km from Pune on Pune-Sholapur National Highway No.9

Technical Specifications

Clarification Process : Double Sulphitation

Crushing Capacity : 5000 TCD

Milling Plant

i) 4 sets of knives

ii) 1 fiberizor

iii) 5 mills each having 4 rollers and i underfeed roller

iv) 15 rollers 1000 mm x 2000 mm

Duration of Season : 179 days

Total Cane Crushes (1997-98) : 828,972 M.T.

Recovery % Cane : 10.90

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TOUR NO 3.

SBI, TNPL, SAKTHI SUGARS

SUGARCANE BREEDING INSTITUTE (SBI)

COIMBATORE (INDIA)

Background

The Sugarcane Breeding Institute since its inception in 1912 has maintained a commendable performance in evolving improved sugarcane varieties. The Institute had so far evolved about 2500 'Co' releases for evaluation at different Sugarcane Research Stations covering various agro-climatic regions of the country. Varieties bred at Coimbatore and selected from the fluff occupy more than 95% of the area under sugarcane in most of the sugarcane growing states in the country and forms the mainstay of the Indian Sugar Industry. Coimbatore bred varieties popularly known as "Co canes" found their way into commercial cultivation in nearly 21 countries. Sugarcane Breeding Institute is one of the two repositories of the world collection of sugarcane germplasm.

Location

The Institute is located at Coimbatore, 8km from Coimbatore Railway Junction and about 13 km from Coimbatore airport.

Research Centres

The Institute has one Regional Station and five Research Centres. The Research centre at Kannur houses one of the two repositories of world collection of germplasm.

Organisational set up

The Institute has a sanctioned strength of over 350 personnel including 90 Scientists. There are three major Divisions viz. Crop Improvement (Plant Breeding, Genetics and Cytogenetics), Crop Production (Plant Physiology, Soil Chemistry, Fertility and Microbiology, Agricultural Chemistry and Agronomy) and Crop Protection (Plant Pathology, Agricultural Entomology and Nematology) besides Extension and Statistics Sections.

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TAMIL NADU NEWSPRINT AND PAPERS LIMITED (TNPL)

BACKGROUND

The Tamil Nadu Newsprint and Papers Limited was established with a capital outlay of Rs 2400 million by the Government of Tamil Nadu specifically to meet the twin objectives of

(a) increasing the National production of both Newsprint and Writing and Printing Paper

(b) utilisation of Bagasse, a renewable non-conventional raw material.

The Mill is situated at Pugalur in Karur District. The Mill is designed to produce 50,000 tpa of Newsprint and 40,000 tpa of Writing and Printing Paper with flexibility to meet market demand and operational exigencies. Bagasse Pulp account for over 70% in the Newsprint furnish and 75% in Writing and Printing furnish.

TIE-UP FOR BAGASSE:

The annual Bagasse requirement of the Mill, after Expansion, is around 800,000 tonnes (Mill wet). TNPL will procure the raw material requirement from 6 tied-up Sugar Mills located within a range of 5-160 Km from the Factory, in exchange of Steam for the supply of bagasse which TNPL has installed 12 Coal-fired Boilers at these Sugar Mills.

PROCESS DESCRIPTION

ZONE A

Zone A consists of the Bagasse Handling Plant, Woodyard, Water Treatment Plant And Effluent Treatment Plant

ZONE B

Zone B consists of the Pulp Mill which comprises three streets, namely, Hardwood Pulping, Chemical bagasse Pulping and Mechanical bagasse Pulping.

ZONE C

Zone C consists of the Paper Machine and Finishing House

ZONE D

Zone D comprises the Chemical Recovery Plant and Power Boilers. The mill has four Service Boilers, each of 60 T/hr steam generation capacity at 44 Kg/cm². The boilers are specially designed for the high ash content Indian Coal, to get maximum efficiency. The Mill has facilities for captive power generation of 26 MW.

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SAKTHI SUGARS

SAKTHI SUGARS LIMITED is one of the largest producers of sugar in the country. The products are Crystal White sugar, Industrial Alcohol, Molasses, Ductile Cast Iron etc.

Management

Managing Director : Sri M. Manickam

General Manager : Sri P Natarajan

Dy Genl Manager - Operations : Sri N N Prithiviraj

Dy Genl Manager - Process : Sri C M Nallasamy

Asst General Manager - Cane : Sri R Palanisamy

1. Sakthinagar Unit

The Sakthinagar Sugar Unit was set up in 1984 with an installed capacity of 1250 TCD on the banks of the River Bhavani in Periyar district. Its present capacity is 5000 TCD. This giant among the sugar units in the South achieved a crushing of over 1,250,000 tonnes in 1994-95 crushing season which is a record in itself. Sakthinagar Sugar Unit provides a ready market for the cane produced by the cane growers of the area.

Refined Sugar of ICUMSA 35 and below is manufactured here and this unit has been consistently winning the efficiency award by the Govt. of India for the years since the award was established in 1988.

The Research & Development Wing

The R & D wing of the unit has constant interaction with the Sugar cane Breeding Institute and has been introducing high performance cane varieties ahead of the Industry.

The Distillery

Commissioned in 1972, the capacity of the Distillery has expanded from the initial 13,500,000 litres to the present 27,500,000 litres per annum.

Effluent Treatment Plant

This plant, the first of its kind in the country, produces enormous quantity of bio-gas which is used in the Distillery as a substitute for imported Furnace oil.

An integrated Effluent Treatment System combining anaerobic primary treatment under bio- methanisation process, evaporation by concentration process and aerobic bio-composting technique has enabled achievement of "zero pollution" in our Distillery Unit..

2. Sivaganga Sugar Unit

Sakthi's second sugar unit of 2500 TCD capacity is the most modern sugar factory in India with Auto-Setting mills and computer aided controls for the operation of Boilers and other equipment. It has crushed over 700,000 tonnes of cane in the season 1994-95.

Foundry Division and Research Centre

This wing is equipped with the most modern facilities like experimental foundries, plane engineering workshops₁testing laboratories and equipment like the scanning electron microscope, direct-reading spectrometer, including computerised production machinery.

This foundry manufactures zero-error castings which include Nodular (SG) Iron castings, conforming to International Standard.

The foundry unit has expanded its capacity to 3000 tonnes per month.

Technical Specifications

Clarification Process : Liming and Sulphitation

Crushing capacity in TCH : 250 TCH

Preparatory Devices : 2 sets of Knives

Mills : (two tandems, each of 18 rollers) 6 mills in each Tandem, Make : WIL/ISGEC

Boiler :4 nos. (two 20 T/Hr and two 40 T/hr) Make : 'WIL'

Duration of season : 7 to 8 months in a year (October - May)

Total cane crushed in 1997-96: 849,350 MTs. (upto 22.4.98)

Recovery percentage cane : 9.70%.

Distillery Unit : Production capacity of 90,000 litres per day.

Factory Farm

i) Total area : 20 Hectares

ii) Cane cultivating area : 18 Hectares

iii) Major Varieties : CO.B6032, MC.707, CO.8021

iv) Average yield/hectare : 115 MT per hectare

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