Sugar Technology

2. Sugar Technology Muhammad Waqas Whatsapp +923058055403 Email waqas324tts@gmail.com

4. Sugar is white crystalline ,sweet and soluble carbohydrate • Mono &Di saccharides • Glucose honey, fruits , vegetables • GA lactose milk and milk products • Fructose honey and fruits • Disaccharides • Sucrose (Table sugar) glucose + fructose • Maltose glucose +glucose • Lactose(Milk sugar) glucose + GA lactose • polyols sugar alcohol • Oligosaccharides • 8-10 glucose unit • Polysaccharides • Polymers of glucose(starch) Sugar

5. Sugar is produced by • Sugarcane • sugar beet • In 2016 combined world production of these 2 crops that were 2 billion tons • Average consumption of sugar is 24kg/person/year Production of sugar

6. Etymology

7. Originally people chew raw sugarcane to extract its sweetness • Indian First discovered to crystallized the sugar in Gupta Dynasty in 350 AD. • During Muslim Agricultural evolution Arabs adopted techniques of sugar production from India then refine • In late 18th century production of sugar became mechanized • In 1768 sugar was identified in sugar beets History of sugar

8. At the time of independence , There were 2 mini sugar mills in Pakistan • One is in Rahwali • Second is in Takhtbai • In 1949-1950 premier sugar mill in Mardan Sugar industry in Pakistan Capacity 600-1200 TCD(Tones crushed per day) Sugar Production per year 10000Tons

9. In 1956, Six(6) Sugar Mills were established • Capacity 11,250 TCD(Tons Crushed Per Day) • In 1960-70, three(3) Sugar Mill were established • In 1970-80,Fifteen(15) Sugar Mills established having Capacity 30,500 TCD • Sugar Mills only in Rural areas • Sugarcane 5th largest crop in term of area cultivated • There are 78 Sugar Mill now in Pakistan • Having Capacity 3,65000 TCD • 31,625 Tons Sugar produce Daily • 130 Million Tons of Sugar is produce Annually • Working days of sugar mill 180 days Sugar industry in Pakistan

10. Sugar Production

11. Byproducts of Sugarcane Bagasse Press Mud Molasses

12. Bagasse is a fibrous material • Bagasse is 25-30% of total crushed sugarcane • It is utilized in sugar industry • Itself use as fuel for boilers to generate steam • The surplus bagasse can be utilized in paper industry • Also further use for utilization of electricity Bagasse

13. Molasses is Dark colored heavy liquid from which no further sugar can be crystallized by regular method • It is 3.5 to 4% of total sugarcane crushed • It is used in fermentation industry • It is use for the production of Ethyl Alcohol , sprits , yeast and also use live stock feeding Molasses

14. Press mud is 3-8% of total cane crush. • It is rich in organic matter use as fertilizers to fertile the soil Press Mud

15. Problems Face by Sugar Industry Over capitalization Mushroom growth of sugar mills Surplus installed crushing capacity Under utilization of capacity Low price and high cost of production Low yield per hector Low sucrose content Requirement of working capital Political intervention Taxation

16. Sugarcane Processing

18. For preparation of sugar • Seed for next crop • In 24 hours must be process otherwise Deterioration OR • Sucrose Glucose + fructose 1. Harvesting

19. Manually Harvesting • Mechanical Harvesting

20. Transport it to sugar mill • After reaching at sugar mill then unload 2.Loading

21. After cleaning then step is Milling • In milling breaking of hard structures using knives ,shredders , Crushers/ Combinator • Extraction of Juice using multiple set of 3 roller mills /4rolls/5rolls/6rolls 3.Cleaning & Milling

22. Conveyors transport the sugarcane from one roller mill to the other roller mill conveyor Imbibition • Imbibition is the process in which water or juice is applied to the crushed Cane • TO enhance the extraction of juice

23. Straining • To remove the large particles • Clarification • heat(95d Celsius)+Lime & Phosphoric Acid Precipitation(impurities) By • Gravity • Centrifugation (Filter mud) Straining and Clarification

24. The clarified juice is passed through heat exchangers to pre-heat the juice and then to Evaporation Station • Evaporation Station consist of series of Evaporators(Typically 5) terms as Multiple Effect Evaporators • Steam from the large boiler is used to heat the 1st evaporator and steam from the water evaporated in 1st evaporator is use to heat the 2nd evaporator • This heat transfer process is continue to 5 Evaporators and as the temperature decreases from evaporator the pressure inside each evaporator also decreases which allow the Juice to boil at low temperature • Evaporation Station produce a serum with about 65% solids and 35% water Evaporation Station EvaporationEvaporation is done in 2 stages

25. The serum is clarified with Lime and Phosphoric Acid and goes to Vacuum Pan for crystallization Continue…

26. In Vacuum pan syrup is Boiled until it reaches the Super Saturation Stage • At this point crystallization process is initiated by Seeding(with Isopropyl Alcohol/sugar) Vacuum Pan Crystallization The mixture of liquor and crystals is known as Massecuite

27. When vacuum pan reaches to its maximum capacity the contents of vacuum pan are Discharged into crystallizers that process is Strike • From the crystallizer Massecuite which actually Massecuite(A) is transferred to high speed centrifuge which separate the crystals from the liquid(A) that is Molasses(A) • The liquid of molasses is shifted to vacuum pan reboil remassecuite(B) and yield 2nd batch of crystals shifted to crystallizers and Transferred to centrifuge • The molasses(B) again goes to vacuum pan reboil to crystallized sugar and form Massecuite(C) • The Massecuite again recrystallize and the centrifuges Continue …

28. This final molasses in known as Black Strap Molasses which is heavy viscous Material used primarily as supplement in cattle feed. • After crystallization the crystals of sugar is dried by using • Fluidized Bed Drier Continue …

29. Packaging