Heriot-Watt University
School of Engineering and Physical Sciences
B41SP – Sustainable Processing
TSM APPLICATION FOR SUGAR MANUFACTURING
PLANT
Submitted by
Vadali Sai Vivek Sharma
H00428357
Table of Contents
Table of Contents .................................................................................................................................... 2
1 Introduction .................................................................................................................................... 3
1.1 Description of the process ..................................................................................................... 3
1.2 A “cradle-to-grave process flow diagram with boundaries of varying operational control. 6
1.3 Process input/output analysis resulting in an Aspects Map. ................................................ 7
1.4 A subsequent sustainability risk profile (SPARAIL diagram) ................................................. 7
1.5 An improvement strategy “without economics”, arising from an ‘aspects’ list in order. of
significance. ........................................................................................................................................ 8
1.6 An improvement strategy “with economic considerations” and reordered strategy
priorities. ............................................................................................................................................ 8
1.7 Changes - shown on the cradle-to-grave diagram and sustainability risk profile after the
iteration of the TSM procedure. ........................................................................................................ 8
1.8 A sustainability policy .......................................................................................................... 10
2 References .................................................................................................................................... 11
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1 Introduction
Total sustainability management (TSM) is a comprehensive approach in which the relationship
of a process with the environment is examined beyond its operating processes. It tackles the
process from cradle to grave, with the goal of achieving zero Resource Availability
Infringement (RAI).(Boroń and Kosiek, 2019) This report draws a modern-day machinery-
based large-scale sugar manufacturing plant with an operating capacity of 5000 tons of cane
per day (TCD) as a case for TSM application.
1.1 Description of the process
i. Harvesting & Transporting to the factory
Sugar's journey begins in sugarcane fields, where it is harvested using heavy machinery that would be
energy-intensive and create greenhouse gases. (Sugar Production - an overview | ScienceDirect Topics,
2020)The sugar cane is subsequently delivered to the factory through trucks or rail carriages, both of
which emit pollutants.(How Sugar Is Processed - [Link], 2020)
Figure 1 - Sugarcane Harvesting (Source : The Sugar Institute)
ii. Receipt of materials
When the sugar cane arrives at the factory, it is unloaded and weighed to determine the quantity
received. The quality of the sugar cane is also evaluated to verify that it fulfils the processing criteria.
The sugar cane will be rejected if it does not satisfy the specified specifications. Proper testing and
quality control aid in ensuring that only high-quality sugar cane is processed(Singh, 2013).Sugarcane
with acceptable quality moves to next process. (How Sugar Is Processed - [Link], 2020)
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iii. Washing
The sugar cane received is washed with water to eliminate any dirt, pebbles or other debris that
accumulates during harvesting and transportation using heavy machinery. (Sugar Production - an
overview | ScienceDirect Topics, 2020). This process serves to guarantee that the sugar cane is clean
and free of contaminants, which can have a detrimental impact on the end product's quality.
(Sugar’s Journey from Field to Table: Sugar Cane | [Link], 2020)
Figure 2 Sugar Cane Washing (Source: Arewethereyet)
iv. Cutting
Sugar cane from the washing facility is then chopped into little pieces using shredders as shown in
the schematic below. This procedure increases the surface area of the sugar cane, making juice
extraction simpler and more efficient. (Sugar Production - an overview | ScienceDirect Topics, 2020)
The cut sugar cane is then transferred to juice extraction. (How Sugar Is Processed - [Link], 2020)
v. Juice extraction
The shredded sugar cane is here pushed through a succession of rollers where sugar cane is crushed
to extract juice. (Sugar Production - an overview | ScienceDirect Topics, 2020)The juice extracted is
then collected in tanks before being delivered to the purification step of the process. The crushed
bagasse after juice extraction is sent out and dumped into landfills.
vi. Purification of juice
Clarification is the procedure by which the juice is cleansed to eliminate any contaminants. Tall
towers of 10 to 20 metres in height are used in a procedure known as sulfitation to cleanse and
lighten the colour of cane juice. At the bottom of the tower, sulphur dioxide vapour is put in and the
juice is added at the top. Carbonation or alkalization is utilised to extract soluble non-sugar elements
from sugar juice. (Singh, 2013).To purify the juice, it is boiled to denature proteins, combined with a
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slurry of calcium hydroxide, and filtered. This procedure takes several hours, and the sludge is
cleaned from the tank's bottom. The clarified juice is cooked in a series of vacuum evaporators until
it achieves a sugar concentration of 50%-65%, after which the sediment is removed with paddle
skimmers. The resultant sugar syrup is viscous and nearly as thick as honey. Sugar crystals develop
when the liquid thickens. (Sugar’s Journey from Field to Table: Sugar Cane | [Link], 2020)
vii. Crystallization
A single-stage vacuum pan is employed in the following stage of the sugar production process to
evaporate the syrup until it gets saturated with crystals of sugar created throughout seeding. This is
achieved through adding to the syrup a milky solution consisting of pure sucrose suspended in
alcohol and glycerin. (Singh, 2013).The sugar crystals in the solution act as nuclei, pulling out the
sugar in the solution and transforming it to crystals. After boiling, the mixture forms massecuite, a
dense paste of crystals of sugar and syrup that is taken to a crystallizer for further mixing and
chilling. (How Sugar Is Processed - [Link], 2020)
viii. Centrifugation
This process ensures that the sugar is molasses-free, resulting in a refined, high-quality product
suited for a wide range of applications. A high-speed centrifuge is used to separate the massecuite
mixture into sugar crystals and molasses. The centrifuge has a perforated metal cylindrical basket
that rotates at speeds ranging from 1,000 to 2,800 revolutions per minute. The molasses flows out of
the basket and is sent to the outside section of the centrifuge where it is collected and stored while
the massecuite is introduced to the centrifuge. In the meantime, the sugar crystals are kept in the
lined basket. Spring water is utilised to cleanse the crystals during centrifugation, resulting in higher-
quality sugar. (Sugar’s Journey from Field to Table: Sugar Cane | [Link], 2020)
ix. Drying
The sugar crystals are still damp after being cleaned with spring water and must be dried in big hot
air dryers, lowering the moisture content to as low as 0.02%. The dry crystals are granulated by
gently swirling them via warm air. After that, the sugar is separated by size using vibrating screens
before being stored in containers(Sugar’s Journey from Field to Table: Sugar Cane | [Link], 2020).
This technique assures that the sugar is of good quality, molasses-free, and has a constant size and
moisture content suited for a wide range of applications. This procedure ensures that the sugar is
free-flowing and easily packed. (How Sugar Is Processed - [Link], 2020)
x. Packaging
After that, the dried sugar is packed in plastic (or) HDPE bags or other containers. The container is
intended to keep the sugar fresh and of good quality by protecting it from moisture and
contamination.
xi. Distribution and use
The sugar is then distributed to wholesalers, merchants, and consumers at the end of the process.
Sugar is used as a sweetener in a variety of foods and beverages.
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1.2 A “cradle-to-grave process flow diagram with boundaries of varying
operational control.
Below schematic depicts the cradle-to grave flow of sugar manufacturing process. Green arrows
indicate inflows and Red arrows indicates outflows.
Figure 3 Cradle to Grave Process Flow
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1.3 Process input/output analysis resulting in an Aspects Map.
Figure 4 - Aspects Map
1.4 A subsequent sustainability risk profile (SPARAIL diagram)
Figure 5 - SPARAIL DIAGRAM
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1.5 An improvement strategy “without economics”, arising from an ‘aspects’ list in
order.
of significance.
i. Upgrade all the energy intensive equipment (Washers, Shredders, Conveyors and
Centrifuges) to high energy efficient state-of-the art equipment.
ii. Develop an in-situ wastewater recycling plant for the waste water from washing the
sugarcane and also from washing of whole factory and reuse the water.
iii. Develop an in-situ solid waste to energy plant for solid wastes (Bagasse & Mud) developed
from the plant and energy hence produced should be utilized inside the plant.
iv. Switch the entire source of energy to renewable energy source by developing an in-situ
solar and wind electricity generation plants.
v. Implement a system for tracking and reporting greenhouse gas emissions to promote
transparency and identify areas for improvement.
vi. Replace all the vehicles used for transportation with electric vehicles.
vii. Replace the plastics and HDPE used for packaging with bio-based and recyclable packaging
material.
viii. Implement a biodiversity conservation programme to maintain and improve natural areas
near the factory.
1.6 An improvement strategy “with economic considerations” and reordered
strategy
priorities.
i. Optimise water usage to minimise water use and related expenses, for as by installing
water-saving technology or recycling wastewater.
ii. Reduce power usage and expenditures by installing energy-efficient lighting and HVAC
systems.
iii. Use the bagasse produced from extraction process to fuel the evaporators in
crystallization process.
iv. The molasses produced from the centrifugation to be sold to bio-ethanol plants and
animal for animal feeds.
v. Improve transportation logistics to minimise fuel emissions and consumption by
employing more fuel-efficient cars or combining shipments.
vi. Form alliances with local farms to lower the expenses of procuring sugarcane.
vii. Implement a waste reduction programme to reduce disposal costs and boost resource
efficiency by lowering packaging materials or reusing waste items.
viii. Switch to bio-based and organic cleaning chemicals for cleaning the entire factory.
1.7 Changes - shown on the cradle-to-grave diagram and sustainability risk profile
after the iteration of the TSM procedure.
Following are the major changes that have been made to the process :
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i. Interaction (2) has been brought into factory perimeter by in-situ electricity generation.
ii. Interaction (6) has been mitigated by replacing cleaning chemicals with bio-based
cleaners.
iii. Interactions (18, 8 & 13) have been avoided by installing in-situ waste water treatment
plant.
iv. Interactions (15, 9 & 11) haven been addressed by installation of in-situ waste to energy
plant.
v. Interaction (22) has been ruled by replacing natural gas with bagasse fuelled evaporators.
vi. Interactions (1, 4, 5, 6, 7, 17, 21, 16) have been made efficient by switching to electric
vehicles for transportation.
vii. Interaction (22) has been ruled out by using bagasse produced in juice extraction for
fuelling the evaporators in crystallization.
Figure 6 - Cradle to Grave process Flow after TSM application
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Figure 7 SPARAIL DIAGRAM after TSM application
1.8 A sustainability policy
i. Policy Statement
Our sugar production business is dedicated to the appropriate and long-term management of our
activities, environmental, social, and economic implications. We will endeavour to constantly improve
our performance by implementing an effective Environmental Management System (EMS) in
accordance with the ISO 14001 standard, as well as engaging our stakeholders in a transparent and
collaborative way.
ii. Objectives
1. Reduce water use to 50% by the end of 2026 and the accompanying environmental
implications, including biodiversity loss, by deploying water-efficient technology and
supporting water conservation practises by installing in-situ waste water recycling plant.
2. Implementing energy-efficient technologies and optimising production processes that will
help to reduce over-all energy consumption.
3. To reduce, reuse and recycle the solid waste produced within the processes by installing and
commissioning in-situ waste to energy plant by the end of 2025.
4. To reduce the plastic usage by replacing the plastic packaging material with bio-based and
reusable packing materials phase wise by the end of 2024.
5. To minimise air emissions through the optimisation of combustion processes and the
implementation of emission control measures by regular monitoring and auditing of
associated greenhouse gas emissions.
6. To reduce the environmental implications of chemical substance usage and disposal by
responsible chemical management practises and replacing the chemical cleaner’s bio bio-
based cleaners within next 6 months.
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7. To promote community engagement in sustainable practices by conducting monthly events
in the local communities and educating the need for sustainable practices.
8. To effectively interact and communicate with our stakeholders in order to encourage
transparency, trust, and collaborative decision-making.
iii. Responsibilities
All workers and contractors working for our sugar production business are responsible for
implementing this policy. The EMS Coordinator will be in charge of ensuring that the EMS is
created, implemented, maintained, and constantly enhanced in accordance with ISO 14001.
iv. Communication
All employees, contractors, and other relevant stakeholders, including our customers and
suppliers, shall be informed of this policy. It will be posted on our website and other appropriate
communication channels.
v. Review
This policy will be evaluated on a regular basis to ensure that it remains appropriate, adequate,
and effective in achieving the standards of ISO 14001 and our sustainability goals.
2 References
Boroń, S. and Kosiek, T. (2019) ‘Total Sustainability Management. Describing the Conditions,
Requirements and Application of Sustainability Management’, Management Systems in
Production Engineering, 27(2), pp. 110–118. Available at: [Link]
0019.
How Sugar Is Processed - [Link] (2020). Available at: [Link]
publications/food-technology-magazine/issues/2020/july/columns/processing-how-sugar-is-
processed (Accessed: 30 April 2023).
Singh, J. (2013) ‘Manufacturing Jaggery, a Product of Sugarcane, As Health Food’,
Agrotechnology, 01(S11). Available at: [Link]
Sugar Production - an overview | ScienceDirect Topics (2020). Available at:
[Link] (Accessed: 30 April 2023).
Sugar’s Journey from Field to Table: Sugar Cane | [Link] (2020). Available at:
[Link] (Accessed: 30 April 2023).
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