National Federation of Co-operative Sugar Factories Ltd.

1. National Federation of Co-operative Sugar Factories Ltd.

2. National Federation of Cooperative Sugar Factories Limited (NFCSF) was registered on December 2, 1960 as an apex organization of all cooperative sugar factories in India. NFCSF was set up as a promotional body for the establishment of cooperative sugar factories in India and for provision of technical advice to the cooperative sector of the sugar industry. Today it guides and provides consultancy services to all sectors.

3. NFCSF was established at a time when India’s standing in the world sugar scenario was negligible. It was the establishment of NFCSF which changed the scenario. India became the world’s largest producer of sugar during 1982, 1988 to 1993, 1995, 1996 and 2000 with cooperatives’ shareof the sugar production during the said years being 55% to 61%. India’s share in global sugar production also increased to 15%. Today India is the second largest producer of sugar in the world next to Brazil.

4. Establishments 1969 - The Indian Sugar and General Industry Export Import Corporation Ltd. now renamed as Indian Sugar Exim Corporation Ltd. (ISEC) established by NFCSF in collaboration with Indian Sugar Mills Association to look after the export of sugar initially, and then export / import of sugar and other products of the sugar industry such as molasses and alcohol.

5. 1974- National Heavy Engineering Cooperative Limited promoted by NFCSF for manufacturing of sugar plants, including high pressure boilers, continuous centrifugals and all other machinery required by sugar factories. 1977- Technical and Promotional Cell of NFCSF for Techno Commercial & Managerial Consultancy services. 2000- Research, Development and Training Centre of NFCSF.

6. Identity * An apex body of all cooperative sugar factories in India making it the LARGEST sugar cooperative in the world. * An autonomous organization governed by the Multi-State Cooperative Societies Act of Government of India.

7. * It is the LARGEST affiliation of sugar factories in the world. * It represents over 50 MILLION farmers and their dependents who are involved in sugarcane cultivation.

8. Objectives * Promote agri – business / rural upliftment. * Stabilize past achievements * Foster faster growth for future vis-à-vis challenges. * Developing and researching new technical areas in sugarcane growth and production & Trans- forming Sugar Factories into Sugar Complexes. * Undertaking trunkey projects for conversion of sulphitation process to produce sulphurless sugar. * Taking up trading in Carbon on behalf of member factories to reduce green house emissions and increase revenue.

9. Progress of Indian Sugar Industry at a Glance

10. Areas of Specialization * Improvement in agricultural practices in sugarcane cultivation and development of sugar rich cane varieties towards optimum yields of sugarcane / sugar per hectare and to reduce cost of cultivation. For this purpose, NFCSF has a Standing Committee with Experts from all over India which studies and analysis the reports on varietal trials conducted at regular intervals in sugar factory areas.

11. * Installation of cost effective new sugar factories with selection of suitable sites, plant and machinery with technical specification, plant layout and project planning, scheduling & implementation. * Implementation of projects on turn-key basis * Technological upgradation of existing sugar factories and rehabilitation of

12. of working sick sugar factories for optimum productivity & energy conservation. * Promotion of by-products with co-products of sugar factories for value addition – bagasse based paper / particle board plants; bagasse / bio-mass based co- generation (surplus electricity power generation) – and sugarcane molasses based distilleries for alcohol, ethanol and other alco-based chemical industries and production of sulphurless sugar and refineries. * Assist in selection, purchase, installation and maintenance of plant and machiney.

13. * Assist in selection of high calibre manpower for all activities. * Assist in standardizing the accounting and costing systems / practices. * Undertake publication of market information of sugar and allied industries. * Conduct conferences, seminars / workshops towards promotion of finance interfaced sugarcane agri-business for better Return on Investment (ROI).

14. * Undertake various other conducive business activities for the benefit of sugar factories / industry. * Pre-despatch inspection of critical machinery and equipment at manufacturers’ works as per national / international standards. * Application of modern technology in sugar process for white sugar below 100 ICUMSA, Very High Purity (VHP) raw sugar. * Financial Management.

15. Process system adopted include • * Double Sulphitation. • * Filtrate Clarification by phosphotation. • * Syrup Clarification by phosphotation. • * Refined sugar from single cured ‘B’ sugar. • * Defico remelt process for the production of sulphurless sugar. • * Detailed Project Reports for • - New sugar complexes. • - Modernization of existing factories. • - Rehabilitation of sick factories. • - Bagasse based by-products. • - Molasses based by-products i.e.R.S./ENA/ Ethanol etc. • * Financial Restructuring and monitoring for successful implementation.

16. Tasks & Functions New Sugar Factories - Inception to commissioning - Project and feasibility report - Cane development - Plant site selection - Basic engineering for plant & machinery - Project scheduling - Plant layout - Inspection of machinery at manufacturers’ works - Manpower Planning / Selection - Inventory Control - Selection of workshop equipment - Financial Management

17. Working Sugar Factories - Basic engineering for modernization / expansion - Energy conservation – Reduction in steam consumption & power consumption - Improvement in working efficiency - Improvement in quality of sugar - Optimization of capacity utilization - Advice on technological up-gradation - Trouble shooting - Improve milling and boiler performance - Improve sugar quality and process approaches - Conserve steam, power and fuel

18. - Analysis of break downs for remedial measures - Investigate reasons for low recovery - To achieve zero fresh water consumption & zero effluent - Financial Management Sugarcane Development - Varietal development and improvement in agricultural practices - Soil analysis - Ratoon Management - Promotion of inter-cropping for value addition

19. Co-products • - Paper factories / particle board plants • - Alcohol producing units / Ethanol • Co-generation • Research & Development • - Sugarcane quality (varieties) & yield per hectare. • - Sugar quality vis-à-vis international standard. • - Inventory control • - Reduction in conversion cost • - Steam, fuel and power conservation. • - Application of sugar co-products for value addition by-products

20. Commissioning of New Projects / Expansion of Existing Projects • 200 Nos. new factories & expansion of capacity • 20 Nos. Ethanol projects. • 20 Nos. Bagasse based Co-generation projects. • - About 15 for syrup & melt / filtrate clarification / syrup clarification / raw sugar refining. • - A list of detailed project reports prepared from January, 2007 to till date is enclosed at Annexure-I.

21. Strength • High Calibre taskforce • Professionally qualified workforce • More than four and half decades of all round experience. • Specialized professional in each field. • - Complete consultancy for sugar available under one roof.

22. Associates - M/s. DEC International, New Delhi for Project Management & Engineering Services. - M/s. Avant-Garde Associates, Chennai for Co- generation of Power. - M/s. Sri Engineers Pvt. Ltd., New Delhi for Distilleries and Ethanol Plants. - M/s. Diftech Group, New Delhi for Melt / Filtrate / Syrup Clarification Systems and Raw Sugar Refining. - M/s. Environment Synergies/Quality Tonnes, Bangalore for Carbon Trading. - M/s. Eco-Invest Carbon Credit SA C/o Bungee India Pvt. Ltd., Mumbai for Carbon Trading. - M/s. Overseas Infrastructure Alliance (India) Private Ltd., Mumbai for overseas projects.

23. Global Exposure • - Indigenous expertise in sugar industry has enabled India to export complete sugar plants all over the world. • - NFCSF has an exposure to the world’s sugar industries covering – • USA Ethiopia (Tendahu & Fincha) • Australia Sudan • Brazil Bangladesh • Vietnam Nepal • Colombia Reunion • Thailand Mauritius • Pakistan Fiji • South Africa Mozambique • Kenya Nigeria • Madagascar (Mananjary and Sakaraha)

24. Representation - Governing Council and Board of Management of National Cooperative Development Corporation. - Advisory Board of National Sugar Institute. - Development Council for Sugar Industry, Government of India. - Indian Sugarcane Development Council. - Bureau of Indian Standards, Sugar Industry Sectional Committee. - Indian Sugar Exim Corporation Ltd. - Standing Committee of Reserve Bank of India on Industrial Finance for sugar industry.

25. - Governing Council of National Cooperative Union of India. - Sugar Technologist’ Association of India. - Ministry of New & Renewable Energy, Government of India. - Sub-Committee to fix up technical efficiency norms for Indian sugar factories. - Sub-Committee to frame guideline specifications for sugar plants of capacities ranging from 1,250 to 10,000 tonnes of cane crush per day. - Sub-Committee to fix up minimum national standards for Pollution Control in Sugar Sector of Indian Industries. - Standing Committee, Screening & Sub- Committee for disbursement of SDF loan for sugar cane development, expansion, modernization, co-generation and ethanol projects etc.

26. NFCSF is an active member of - ICUMSA – International Commission of Uniform Methods of Sugar Analysis. - ISO – International Sugar Organization. - ISSCT – International Society of Sugar Cane Technologists. - GSA – Global Alliance for Sugar Trade Reform and Liberalization.

27. S.No. Name of the Factory Description Crushing Capacity 1. Ethiopia two project Consultancy for execution & monitoring 12000 TCD & 8000 TCD 2. Mananjary & Sakaraha Sugar Complex, Madagascar Feasibility study reports for two-sugar complex. 2500-3500 TCD & 3500 –5000 TCD. 3. The Nandi Sahakari Sakkare Karakhana Ltd. Karnatka Detailed project report for rehabilitation cum expansion 3500-5000 TCD 4. Star Applied Mechanics (P) Ltd.B-36, Sector-2, Noida-201301 Preparation of DPR of new sugar plant in Bihar 3500-5000 TCD 5. M/s. PRTL Pvt. Ltd. C-6/13 Shrinathji Chambers. 3rd floor, VIA Char Rasta, GIDC, Vapi-396194 Gujarat Feasibility Report for Co generation - The Project at Present under Implementation with NFCSF

28. 6. M/s. Sahakari Khand Udyog Mandal Ltd.Gandevi Dist – Navsari, Gujarat 396 360 Preparation of Notice Invited Tender for Modernization and Incidental cogeneration of 1.0 MW 6000 TCD 7. M/s. Shree Sayan Vibhag Sahakari Khand Udyog Mandli Ltd. Surat, Gujarat Preparation of DPR for Modernisation, Balancing and Optimization of Sugar Plant. 6000 TCD 8. M/s. Shree Kantha Vibhag Sahkari Khand Udyog Mandli Ltd.Gujarat Preparation of DPR of new sugar plant 2500-3500 TCD 9. M/s. Shree Narmada Khand Udyog Sahakari Mandli Ltd. Distt. Narmada, Gujarat Preparation of DPR for Modernisation, Balancing and Optimization of sugar plant. 5000 TCD

29. 10 The Kovur Cooperative Sugars Limited, Distt- Nellore – 524005, Andhra Pradesh Rehabilitation cum Modernization & Balancing of Sugar Plant. Along with 8 MW cogeneration 2500 TCD 11 The Chodavaram Coop. Sugars Limited. Govada– 531 023, Andhra Pradesh Rehabilitation cum Modernization & Balancing of Sugar Plant. Along with 22 MW cogeneration 4400 TCD 12 SHAHABAD COOPERATIVE SUGAR MILLS (HARYANA) Consultancy cum inspection agency for 24 MW cogeneration project 5000 TCD 13 Shri Malaprabha Sahakari Sakkare Karkhane (N),Mugutkhan Hubli-591153, Distt. - Belgaon Consultancy for defico remelt process. 4000 TCD 14 MAA MAHAMAYA S.S.K. Ambikapur chatishgarh Consultancy cum inspection agency 2500 TCD

30. PREPARATION OF DETAIL PROJECT REPORTS BY NFCSF OF JANUARY- 2007 TO TILL NOW

37. Advanced Technologies being adopted successfully • 1. Shredder / Fibriser : Improving P.I. to 92% • AC / DC Electric Drive for mills • i. Conventional Mills : Three Roller Mills • with trash plate • ii. Diffuser • iii.Two Roller Mill – Trash plate less • Advantage of Two Roller Mill - • (a) 30% less power consumption • (b) High Primery Extraction – 74% when used as 1st mill • Low moisture % bagasse when used as last mill • iv.4 Roller Pinion less / Independent AC Drive for feed, Top & discharge roller with planetary Gear Box mounted motor. • (4) AC – VVVF Drives for Cane carrier, Inter Rake Carrier, Main Bagasse carrier etc., Centrifugal pumps.

38. High Pressure Boiler – • i) Pressure & Temp. of Steam 105 kg/cug2 & 540ºC • ii) Capacity 170 T/hr with Travelling grate • iii) Steam Fuel Raio = 2.7 • iv) Thermal efficiency = 72% (on GCV) • v) Flue gas temp = 150ºC • vi) AC- VVVF drives for ID/FD/SA fans. • vii) Auto combustion control system • viii) DCS control for complete Boiler from control • room • ix) ESP for flue gas emission control • x) With recovery units economizer, Air heater, • super heaters etc.

39. 6. Double Extraction condensing Turbo Generating sets to suit the above boiler parameters 7. Evaporator system design to bring down the steam consumption % cane = 36% i. Using flash Heat Recovery systems ii. Extensive vapour Bleeding schemes iii. Using Direct contact juice heaters

40. 8.Single entry low water consumption condensers - • made of SS body & SS tailppee • Reducing power consumption to 2 KW / TCD or below at injection pumps & spray pumps • Low head pumps for Injection & spray • DCS control system for condensers & pans 9.DC/AC electric driven centrifugal machines. 1. Batch type centrifugal 1250 kg/ charge – 1400 rpm Machine capacity 1500 kg/charge – 1250 rpm 2. No. of cycles / hours 20 – 22 3. High Gravity factor 2000 / 2400 Continuous machine of NK 1100 – 2000 rpm of NK 1503 - 1730 rpm

41. 10. Cold water Recirculation, surplus condensate cooling & recirculation to Reduce the frash water consumption to zero. 11. Continuous pan – Horizontal vertical type & vertical type 12. Plantery Gear Boxes for Crystellizer drive etc. 13. Juice flow stabilization system 14. Filtrate clarification system 15. Sulpher less sugar production – Defeco Remelt process 16. Megensen type sugar grader 17. For colour Improvement Vibro screen - at MJ, filtrate, Melt juice & lime 18. Pan circulators & Automation for pan station 19. Thin Film type sulphur burners

42. 20. Plate type wide gape heat exchangers for ` condensate heat recovery Power consumption reduced upto 22 KWH / TCH for steam driven plants and 26 KW/TCH for electric driven plants by providing various AC – VVVF drives, improving power factor, planetary gear boxes, automation, devices to reduce power consumption at centrifugal station, injection & spray pumping station, ID/FD/SA fan drives by ACVVVF etc. 22. Cogeneration : Based on (i) Bagasse Bio-mass : rice husk, wheat straw, cane trash, Mustered husk & straw,coconut shel, coconut straw, banana trees, pine fruits & stems, other grasses etc.

44. THANK YOU NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LIMITED ‘ANSAL PLAZA’ BLOCK-C, 2ND FLOOR AUGUST KRANTI MARG, NEW DELHI-110049 (INDIA) Tel. : 26263425, 26263436, 26263696 Fax : 011-26263658, e-mail : nfcsf@spectranet.com