Extension, Advisory and Consultancy Services provided by Sugar Technology Department

The Sugar Technology Department gives Extension, Advisory and Consultancy Services to sugar and allied by-product industries by visiting more than 250 member as well as non-member sugar factories every year. During consultancy visits, efforts are made to improve various technical efficiencies that reduces production cost and increase profitability. It is possible by improving the capacity utilization, minimizing the total losses, improving the sugar quality and conservation of steam, power & water.

Improvement in capacity utilization of the factories.

Minimizing of the down-time.

Minimizing the losses by improving performance at each station.

Guiding the factories in improving sugar quality.

Minimizing the steam and power consumption.

Optimization of use of chemicals.

Considering the factories for automation in different units.

Considering the factories in staffing pattern.

Guiding the factories to solve the mud problem.

Preparation of Detailed Project Reports (DPR) of sugar factory

Preparation of DPR of Refined of sugar.

Preparation of DPR of Effluent Treatment Plant.

Balancing of Plant and Machinery for capacity utilization and improvement in technical performance.

Guiding the sugar factories to solve the low recovery problem.

Guiding the sugar factories in minimizing the waste water.

On site, colour audits of various intermediate items of sugar processing like juice, massecuite, molasses, magma, sugar etc. and improving the colour of sugar by adopting appropriate measures.

Improvement in capacity utilization

	Cane Quality Fresh cane Follow up of harvesting programme
	Cane Preparation - 80 +
	Primary Extraction - 70 to 72
	Use of Imbibition Water Temperature - 70-72 ^oC % Cane - 25-30 %
	Mill Extraction - 95 +
	Reduced Mill Extraction - 96 +

Reduction of Sugar Losses

Standard Total Sugar losses in Sugar Processing.(1.8 to 2.0 %)
	Bagasse loss
	Filter cake loss
	Final Molasses loss
	Unknown sugar loss Keeping less time in cane harvesting and crushing Keeping proper Mill sanitation to avoid microbial growth Precise control over temp., pH & retention time Avoiding the leakages, spillages and entrainment

Improvement in Sugar Quality

Sugar quality was improved to suite international market by taking following extensive efforts
	by Optimizing liming and sulphitation process
	Decreasing turbidity of Clear juice
	Improving Clear juice colour from 13000 to 7000 IU
	Making required modifications in equipments like Juice Sulphiter,Clarifier & centrifugal machines
	Developing new boiling methods
	Avoiding colour formation during processing
	Improvement at centrifugal section
	Improving storage conditions to avoid colour formation
Sugar Colour was reduced from 200-225 IU to below 90 IU

Conservation of steam, power & water

By adopting following techniques
	Evaporator Working Profuse Vapour Bleeding Installation of Steam Economy equipments Exhaust Pressure and Temperature Working of PRD unit Optimum vacuum
	Working of Pans Use of second body Vapours for boiling Use of continuous pan to reduce steam demand Optimum vacuum
	By reducing miscellaneous steam demand
	Power reduction By installing modern condensing cooling systems, Dino drive for crystallisers and Modern centrifugal machines
	Water conservation We provide detail project report for ETP modifications, Avoiding the leakages, spillages of water Re-circulation of cooling water (Oliver vacuum pump, Sulphur Burner cooling, Turbine cooling , etc.) Avoiding excess floor washing