List of content

ACKNOWLEDGEMENTS ...................................................................... 3
ABSTRACT ............................................................................................. 4
INTRODUCTION.................................................................................... 5
THE HISTORY OF SUGAR PRODUCTION IN EGYPT ................... 12
INDUSTRIAL PROCESS ...................................................................... 16
RECYCLING SUGARCANE BY-PRODUCTS ..................................... 30
BAGASSE ............................................................................................................ 32
Bagasse recycling ............................................................................................ 33
1.Source of energy .............................................................................. 33
2. Paper-making................................................................................... 37
3.Industrial woods .............................................................................. 41
4.cellulosic derivatives...................................................................... 44
5.Furfural................................................................................................ 47
6.ِ Animal feed ....................................................................................... 50
MUDS ................................................................................................................. 53
Filter Mud............................................................................................................ 53
Applications of Filter Mud: .............................................................. 54
Clarified Mud ..................................................................................................... 55
Applications of Clarified Mud: ........................................................ 56
MOLASSES ......................................................................................................... 58
Content of Molasses ........................................................................................ 58
Uses of Molasses ............................................................................................... 60
Food and Beverage Industry........................................................... 60
Pharmaceutical and Nutraceutical Applications..................... 66
Industrial Uses ..................................................................................... 69

1
 CASE STUDY: SUGARCANE AND BY-PRODUCTS AT ARMANT SUGAR
FACTORY ............................................................................................................ 72
CONCLUSION ....................................................................................... 75
REFERENCES ....................................................................................... 76

List of figures

Figure 1: Egyptian sugar factory ............................................................. 13

Figure 2: sugar industrial process ........................................................... 19
Figure 3: Crystallization process ............................................................. 28
Figure 4: sugarcane final products .......................................................... 31
Figure 5: Percentages of sugarcane by-products ................................... 32

2
 Acknowledgements

I would like to express my deepest gratitude to my supervisor, DR.

Mahmoud Heshmat, for their continuous support, guidance, and
encouragement throughout the course of this research. Their insights
and expertise have been invaluable to the completion of this project.

I am also grateful to the staff and management of the Armant Sugar

Factory for their cooperation and for providing the necessary data and
access to their facilities, which were crucial for the case study and
practical analysis presented in this research.

My sincere thanks to my family and friends for their unwavering support

and understanding during the time of this study. Their encouragement
has been a source of strength and motivation.

Finally, I would like to acknowledge Prof. Dr. Dina Mamdoh and all
stuff of our faculty for providing the resources and environment
necessary to conduct this research. This project would not have been
possible without the support of all these individuals and organizations.

3
 Abstract

This research explores the recycling of sugarcane by-products, focusing

on the processes and benefits associated with the reuse of bagasse,
mud, and molasses. The study begins with an introduction to the sugar
industry in Egypt, providing historical context and outlining the sugar
production process. The core of the research examines the critical
chapter on recycling sugarcane by-products, detailing the uses of
bagasse as boiler fuel and feedstock, mud as an organic fertilizer, and
molasses in the production of alcohol, yeast, and animal feed. Data
collected from the Armant Sugar Factory serve as a case study,
illustrating practical applications and the economic and environmental
advantages of by-product recycling in the sugar industry. This research
aims to highlight sustainable practices in sugar production and promote
the efficient utilization of all resources in the sugarcane industry.

4
 Introduction

The sugar industry is among the vital sectors globally. The aim of this
research is to analyze the by-products of sugar production, identifying
methods for their recycling while estimating the associated costs for each
approach.

Through data obtained from the Arment Sugar Factory, it was found that
every ton of sugar cane yields approximately 104,000 %cane units of
sugar as the primary product. Additionally, significant quantities of by-
products are generated, offering potential for recycling to mitigate
environmental impact and enhance sustainability.

Among the most significant by-products we obtain is:-

1. Bagasse: refers to the residual fibers left after crushing the sugar

cane stalks to extract juice. It is produced by taking the harvested

cane and completely crushing it using a series of large cylinders.

These cylinders crush the stalks and extract juice from the cane. The

obtained juice is then purified to extract sugar. The residual fibers

left after the crushing and juice purification process are termed

Bagasse.

The volume of Bagasse produced during sugar production

processes is approximately 30 million per 100 tons of sugar cane[1] .

It contains various nutrients such as nitrogen, phosphorus,

potassium, and calcium. It can be stored in either moist or dry form

for reuse in the following purposes:-

5
a. As fuel, many factories burn Bagasse to generate energy for

plant operations. The carbon emissions resulting from burning

Bagasse are considered neutral, as the amount of CO2

emitted equals the amount absorbed by sugar cane during its

growth period. The adverse effects of burning Bagasse are

moderate, as it contains heavy pollutants that transform into

particulate matter and ash. The smoke resulting from burning

Bagasse has lower content of sulfur dioxide (SO2) and

nitrogen oxides (NOx) compared to traditional fossil fuels, as

Bagasse is characterized by low levels of sulfur and nitrogen[2].

b. After processing, the production of animal feed offers several

benefits, including reducing the need for importing

concentrated feed materials, stabilizing feed prices, increasing

livestock productivity, utilizing sugar cane residues through

recycling to avoid hazards associated with accumulation, and

lowering feed prices due to the use of local materials in

production. Providing affordable feed and reducing its prices

encourages livestock and sheep farming, thereby creating

more job opportunities. One of the types of feed produced

using Bagasse includes: -

● Coarse and Enhanced Feed: Produced from Bagasse,

it boasts high nutritional value, surpassing feed

produced from corn stalks and rice straw.

6
 ● Integrated Feed: Used for medium-class cattle feed

production and can be fortified with a range of vitamins

and substances such as dry yeast and mineral salts to

enhance its concentration for use as feed for high-

yielding dairy cattle and fattening cattle.

● Concentrated Integrated Uniform Feed: Used for

fattening cattle, dairy cattle, poultry, ducks, and rabbits,

in addition to sheep.

c. For paper production, Bagasse contains a significant amount

of short fibers, known as Bagasse pulp, which are highly

suitable for textile manufacturing, cardboard production,

newspaper printing, and writing paper. Bagasse is considered

a renewable source annually due to the short life cycle of the

plant and the rapid growth of sugar cane. Additionally, paper

produced from Bagasse and its products are environmentally

friendly and non-polluting

d. Currently, Bagasse is increasingly used in the packaging

industry for packaging food products. These include boxes,

tin-supported packaging, and various other containers. These

products are fully guaranteed according to the specifications

of the American Society for Testing and Materials (ASTM) and

7
 comply with D-6868 standards[3]. Bagasse packaging used for

food packaging can withstand temperatures up to 200°F

(Fahrenheit).

It is noted that an increase in temperature results in the

formation of moisture on the bottom of the container. Boxes

made from Bagasse are used as alternatives to traditional

plastic packaging and Styrofoam containers for transporting

food items. Bagasse packaging biodegrades within 1-3

months in commercial facilities and within 2-4 months at home.

2. Mud: It is the residue resulting from the clarification process of sugar

cane juice. The volume of mud produced during sugar production
processes is 3.5 million %cane[4].

Some common types of residues that may form during sugar

production process:-

a. Filter Mud: Filter mud is produced during the process of

clarifying sugar cane juice or raw sugar using filters. It mainly
consists of fine particles of sugar cane and other impurities
that settle during this process.

b. Carbonate Mud: Carbonate mud can result from chemical

reactions between calcium and carbonates present in sugar
refining processes. This mud may consist of compounds
containing calcium, carbonates, and other impurities.

8
 c. Sulfate Mud: Sulfates can be a major component of sugar
refining mud, especially if additives containing sulfur are used
during refining processes. Sulfates may form as a result of
reactions with the chemical substances used in clarification
and refining processes.

d. Aluminum Mud: Some sugar refining processes may involve

the addition of substances containing aluminum to aid in juice
clarification. As a result of these processes, mud containing
aluminum compounds may form.

It has been discovered that the mud produced from sugar production
contains important nutrients, making it beneficial for use in
agriculture such as : -

e. as organic fertilizer, as it contains phosphates, sulfur, and

calcium, which enhance plant growth. Additionally, it can serve
as a conducive medium for the growth of beneficial yeasts for
plants[5].

f. Using of filter mud as animal feed is due to its sugar content,

ranging from 0.5% to 0.8%. It is utilized as an additive in
animal feed formulations and can also be directly used as
feed. Additionally, it has been employed as a raw material for
the production of certain medications through the oxidation of
the sucrose present in it[6].

g. In candle making, wax is found in thin layers on the outer

surface of sugar cane plants, and it is considered one of the
finest types of wax necessary for varnish production, electrical
insulation materials, carbon paper, etc. The wax content in
9
 sugar cane is approximately 0.18-0.21% of the weight of the
cane stalk. Its components include esters, fatty acids,
alcohols, and hydrocarbons. Its melting point ranges between
76-82 degrees Celsius[7].

3. Molasses: is the high-concentration syrup remaining after sugar

crystallization. It contains organic compounds and beneficial
nutrients such as nitrogen, phosphorus, and potassium.

The volume of molasses produced is 4.3 million %cane. Its

significance in the sugar industry lies in:-

1. Chemical manufacturing:-
● Alcohol Production: Molasses is used as a primary
source for alcohol production. The sugar present in
molasses is fermented using yeast to produce ethyl
alcohol, which can be utilized in the production of
biofuels, alcoholic beverages, and other chemical
substances[8].

● Biochemical Production: Molasses can be utilized as a

source of carbohydrates in fermentation processes to
produce chemical substances such as organic acids,
ethanol, and biomass[9].

2. Animal Feed[10] :-
● Improving Nutritional Value: Molasses can be added to
animal feed as a source of energy and simple sugars.
10
 Molasses is considered a rich source of vitamins and
minerals such as potassium, calcium, and iron, which
help enhance the nutritional value for animals

● Improving Digestibility: Molasses is considered an

attractive source for animals due to its sweet flavor,
which stimulates them to consume feed in larger
quantities and enhances their digestibility.

● Enhancing Animal Productivity: Adding molasses to

feed may contribute to enhancing milk production in
cows or increasing the weight of animals, leading to an
overall improvement in animal productivity performance

11
 The history of sugar production in Egypt

Sugar is an important agricultural, industrial, and strategic commodity

that is needed by every individual in society. Globally, sugar is one of the
cheapest sources of energy for humans, and in Egypt, it ranks second
after wheat in terms of importance, with significant influence on political
decisions and economic activities, as well as ordinary citizens' reactions.

Throughout its more than a century and a half of history, the Egyptian
sugar industry has faced numerous risks and obstacles. However, it has
managed to overcome them and grow and flourish over the years.
Investments in sugar industry projects have reached nearly ten billion
pounds, and the value of its factories exceeds 25 billion Egyptian
pounds.

The sugar industry in Egypt is considered one of the oldest and most
important industries, with its establishment dating back to the eighteenth
century. It follows the cotton industry in terms of size and significance,
with investments in this sector exceeding 4 billion pounds.

12
According to (ESIIC) https://www.siicegypt.com/sugar-industry

Figure 1: Egyptian sugar factory

The history of the sugar industry in Egypt dates back to 710 AD, with
Egyptians being the first to master the production of refined sugar,
exporting it to Europe. This industry declined during the Mamluk rule until
Muhammad Ali Pasha came to power in 1818, leading to the revival of
sugarcane cultivation and sugar production. In 1850, a sugar factory was
established in the Minya Governorate. In 1834, two more factories were
established in Minya, and in 1846, Muhammad Ali Pasha hired French
technicians to operate and manage these factories. In 1848, four
additional sugar factories were established in Giza, Minya, and Qena,
marking significant achievements credited to Muhammad Ali Pasha.

In 1868, during the reign of Khedive Ismail, 16 sugar factories were

established along the Nile Valley to produce raw sugar, which was
refined in Marseille. In 1869, a sugar refining factory was established in
Hawamdeya under the name Egyptian Refining Company. Besides
these government-owned factories, several small private factories were

13
established, totaling 64 factories. One of these factories was the Armant
Sugar Factory, established in 1869 during the opening of the Suez
Canal. The Armant Factory is still operational today after undergoing
renovations and upgrades, contributing significantly to Egypt's sugarcane
production.

In 1892, all raw sugar factories were merged under the name Northern
Sugar Factories Company. In 1897, the Egyptian Refining Company and
the Northern Sugar Factories were merged under the name Egyptian
Sugar and Distillation Company.

In 1910, the construction of a sugar factory began in Kom Ombo, Aswan.

Due to economic developments in the country, the sugar industry was
nationalized in 1956 under the name “The Egyptian Sugar and
Distillation Company”.

The government contributed half of its capital, and in 1966, the company

was fully nationalized, becoming a public sector company. In 1992, it

was decided to establish the Nasr Sugar and Paper Industries Company,

and in 1997, it was merged with the Egyptian Sugar and Distillation

Company. In 1992, it was incorporated under the name of the Holding

Company for Food Industries, and the name was changed to the Sugar

and Integrated Industries Company. In 1986, the Gergha factory was

operational with a production capacity of 900,000 tons of sugarcane.

The factories producing raw sugar are:

1. Abu Qurqas Sugar Factories (Minya)

2. Gergha Sugar Factories (Sohag)

14
3. Naj-Hammadi Sugar Factories (Qena)
4. Dishna Sugar Factories (Qena)
5. Qus Sugar Factories (Qena)
6. Armant Sugar Factories (luxor)
7. Edfu Sugar Factories (Aswan)
8. Kom Ombo Sugar Factories (Aswan)

15
 Industrial Process

The sugar cane industrial process stands as a testament to the intricate

interplay between agriculture, technology, and commerce, shaping
landscapes and economies in regions across the globe. Rooted in
centuries-old traditions yet continually evolving through innovation, this
process represents a vital link in the production of one of the world's
most ubiquitous commodities: sugar. Beyond its role in sweetening our
foods and beverages, sugar cane serves as a cornerstone of various
industries, from bioenergy to food packaging, with its by-products finding
applications in diverse sectors.

At its core, the sugar cane industrial process involves a series of

meticulously orchestrated steps, from cultivation and harvesting to
milling and refining, each stage demanding precision and expertise. With
the advent of modern agricultural practices and technological
advancements, the efficiency and scale of sugar cane production have
surged, enabling vast swathes of land to be transformed into verdant
fields of this tall, fibrous grass.

However, the sugar cane industrial process is not without its

complexities and challenges. Environmental concerns, labor practices,
and socio-economic impacts loom large, prompting stakeholders to seek
sustainable solutions that balance the imperatives of profitability with the
imperatives of environmental stewardship and social responsibility.

In this introduction, we embark on a journey through the sugar cane

industrial process, delving into its history, mechanics, and significance in
today's global landscape. From the fields where sugar cane sways in the
breeze

16
to the bustling mills where it is transformed into crystalline sweetness, we
explore the intricacies of this age-old practice and its modern-day
implications. Along the way, we uncover the innovations driving
efficiency, the environmental considerations shaping practices, and the
socio-economic dynamics shaping the lives of those involved.

Through this exploration, we gain a deeper understanding of the sugar

cane industrial process as not merely a mechanical operation but as a
nexus of human endeavor, technological ingenuity, and natural
resources. It is a story of resilience and adaptation, of tradition and
progress, reflecting the complex tapestry of human society and its
relationship with the land.

Under the meticulous framework of sugar cane industrial processing, the

initial stage encompasses the reception, weighing, and preparation of
harvested cane, serving as the foundational step in the conversion of
raw agricultural material into refined sugar and its byproducts.

Upon arrival at the processing facility, the harvested sugar cane

undergoes a series of systematic procedures to ensure seamless
integration into the production line. Specialized equipment, including
conveyors and automated sorting systems, facilitates the efficient
transfer of cane from delivery vehicles to the processing area.

Integral to this stage is the precise measurement of incoming cane, a

task achieved through advanced weighing systems meticulously
calibrated to account for variations in density and moisture content. This
ensures accurate quantification of the raw material, essential for optimal
process management and yield estimation.

17
Simultaneously, preparatory measures are initiated to ready the cane for
subsequent processing steps. Cleaning stations equipped with
mechanical brushes and screening mechanisms effectively remove
extraneous matter such as leaves, soil, and other contaminants,
safeguarding the integrity of the incoming cane and enhancing the
efficiency of downstream operations.

Throughout this stage, adherence to established quality standards,

including those outlined by regulatory bodies such as (ASTM) and (ISO),
is paramount. Stringent protocols govern the handling and preparation of
cane to ensure compliance with industry specifications and to uphold
product integrity and safety.

After preparation, we begin with the first process, which is the sugar
cane milling.

18
Figure 2: sugar industrial process

19
1. Milling[11]

● Crushing:

In the crushing stage of sugar cane milling, harvested sugar

cane stalks are fed into a series of rollers in a sugar mill.

The rollers exert pressure on the cane, crushing and squeezing

it to extract the juice contained within the cane fibers.

This process breaks down the cellular structure of the sugar

cane, releasing the juice.

The rollers may be arranged in sets to increase efficiency, and

they are often grooved to facilitate the extraction of juice.

The extracted juice flows out from the crushed cane and is
collected for further processing.

● Shredding:

After the sugar cane is crushed, the resulting mixture of

crushed cane fibers and juice is known as bagasse.

Bagasse contains both fibrous material from the sugar cane

and the extracted juice.

The next step in the milling process is shredding, where the

bagasse is separated from the juice.

Shredding typically involves passing the bagasse through a

series of rotating knives or shredders that further break down
the fibrous material.

This shredding process helps to separate the fibrous bagasse

from the liquid juice, allowing for more efficient extraction of the
juice.

20
 The shredded bagasse is then typically sent to boilers for use
as fuel, while the extracted juice continues on to next stages of
process

2. juice extraction[12]

The crushing process applies significant pressure to the sugar

cane, rupturing the cells and releasing the juice contained within.

Modern sugar mills often employ multiple sets of rollers arranged in

series to ensure thorough extraction of the juice.

Various factors affect the efficiency of juice extraction, including the

design and condition of the milling equipment, the moisture content
21
 and variety of the sugar cane, and the operating parameters such
as roller speed and pressure.

The goal is to achieve maximum juice extraction while minimizing

the amount of residual juice left in the bagasse (fibrous cane
residue).

Once the juice is extracted, it typically contains suspended solids,

plant debris, and other impurities.

Clarification processes are employed to remove these impurities

and produce a clear juice suitable for further processing.

3. Clarification[13]

to remove impurities from the extracted sugar cane juice, ensuring

the production of high-quality sugar. The following points highlight
key aspects of juice clarification:-

1. Objective of Clarification:

● The primary objective of juice clarification is to remove

suspended solids, colloidal particles, and other impurities
present in the sugar cane juice.

● Clarification enhances the quality of the juice by improving its

clarity and reducing the potential for color formation during
subsequent processing stages.

22
2. Clarification Methods:

● Various methods are employed for juice clarification in the

sugar industry, including screening, sedimentation, filtration,
and the use of chemical clarifying agents.

● Screening involves passing the juice through screens or

sieves to remove larger solid particles and debris.

● Sedimentation relies on gravitational settling to separate

suspended solids from the juice, with clarification tanks
allowing the solids to settle to the bottom.

● Filtration utilizes porous media such as filter cloths or

diatomaceous earth to trap suspended particles and clarify
the juice.

● Chemical clarifying agents, such as lime (calcium hydroxide)

or flocculants, are often added to the juice to facilitate the
aggregation and precipitation of impurities, aiding in their
removal during sedimentation or filtration.

3. Process Optimization:

● Optimization of clarification processes is essential to achieve

efficient removal of impurities while minimizing juice losses
and energy consumption.
● Parameters such as pH, temperature, mixing intensity, and
residence time are optimized to maximize clarification
efficiency and juice quality.
● Continuous monitoring and control of clarification operations
help to maintain consistent performance and ensure
compliance with quality standards.

23
4. Evaporation [14]

Evaporation plays a crucial role in industrial sugar processing for

concentrating sugar cane juice to produce syrup or raw sugar. Here
are some key points regarding evaporation in this context:

1. Purpose of Evaporation:

● Evaporation is employed to remove water from the sugar

cane juice, increasing its sugar concentration and reducing
its volume.
● Concentrating the juice through evaporation is essential for
subsequent crystallization processes to produce sugar
crystals.

2. Evaporator Types:

● Various types of evaporators are used in industrial sugar

processing, including multiple-effect evaporators, batch
evaporators, and continuous vacuum pans.
● Multiple-effect evaporators consist of a series of evaporator
vessels (effects) operating at progressively lower pressures
and temperatures. Vapor generated in one effect is used to
heat the juice in the subsequent effect, maximizing energy
efficiency.
● Vacuum pans are used for batch evaporation, where juice is
heated under vacuum to reduce boiling point and prevent
caramelization of sugars.

3. Evaporation Process:

24
 ● Sugar cane juice is heated in the evaporator vessel, and
water is evaporated from the juice.
● The vapor generated during evaporation is typically
condensed and reused as heating media in the evaporator
system, contributing to energy efficiency.
● The concentrated juice, known as syrup or massecuite, is
continuously withdrawn from the evaporator, while excess
water is removed as vapor.

4. Control and Optimization:

● Evaporation processes are controlled and optimized to

achieve the desired sugar concentration in the syrup or
massecuite.
● Parameters such as temperature, pressure, residence time,
and circulation rate are monitored and adjusted to maximize
evaporation efficiency while minimizing energy consumption
and product losses.

25
5. Crystallization [15]

Crystallization is a key stage in industrial sugar processing where

the concentrated sugar solution undergoes controlled cooling and
seeding to form sugar crystals. Here are some key points regarding
crystallization in this context:

1. Nucleation and Seed Formation:

● Crystallization begins with the introduction of seed crystals

into the concentrated sugar solution. These seed crystals act
as nuclei around which new sugar crystals form.
● Seed crystals can be obtained from previous crystallization
batches or added externally to initiate the crystallization
process.

2. Supersaturation and Cooling:

● The sugar solution is supersaturated, meaning it contains a

higher concentration of sugar than it can hold in equilibrium
at the current temperature and pressure.
● Controlled cooling of the supersaturated solution induces
sugar molecules to come together and form crystals, starting
from the seed crystals.

3. Crystallization Equipment:
● Various types of crystallizers are used in industrial sugar
processing, including vacuum pans, batch crystallizers, and
continuous crystallizers.

26
 ● Vacuum pans are commonly used for batch crystallization,
where the sugar solution is boiled under vacuum to promote
crystallization and prevent caramelization.
● Continuous crystallizers operate continuously, with the sugar
solution flowing through a series of chambers or stages
where crystallization occurs.

4. Crystal Growth and Size Control:

● Crystals grow in size as sugar molecules continue to deposit
onto the seed crystals.
● Control of crystal size distribution is important to ensure
uniformity and quality of the final sugar product.
● Various methods, such as agitation, seeding techniques, and
control of cooling rates, are employed to control crystal
growth and size distribution.

5. Separation and Washing:

Once the desired crystal size is reached, the sugar crystals
are separated from the remaining syrup or molasses using
centrifugal machines called centrifugals.

27
Figure 3: Crystallization process

6. Centrifugation [16]

Centrifugation plays a crucial role in separating sugar crystals from

the syrup or molasses in the industrial sugar process. Here's an
overview of centrifugation in this context:

1. Purpose of Centrifugation:
● Centrifugation is used to separate sugar crystals from the
syrup or molasses produced during the sugar crystallization
process.
● By subjecting the sugar solution to centrifugal force, denser
sugar crystals are forced to the periphery of the centrifuge,
while the less dense syrup or molasses is expelled through
the center.

2. Types of Centrifugals:

28
 ● There are various types of centrifugals used in the sugar
industry, including basket centrifugals and continuous
centrifugals.
● Basket centrifuges are commonly used for batch processing,
where a batch of sugar crystals is loaded into the centrifuge
basket, spun at high speeds, and then discharged after
separation.
● Continuous centrifugals operate continuously, with sugar
solution continuously fed into the centrifuge, and separated
sugar crystals continuously discharged while the syrup or
molasses is recirculated.

3. Operation and Optimization:

● The efficiency of centrifugation depends on factors such as
rotational speed, cycle time, and basket design.
● Proper adjustment of these parameters is essential to
maximize sugar recovery, minimize syrup or molasses
losses, and achieve the desired crystal quality.
● Continuous monitoring and control of centrifuge operations
help optimize performance and maintain product quality
standards.

4. Washing and Drying:

● After centrifugation, the separated sugar crystals may
undergo washing to remove residual syrup or molasses.
● The washed sugar crystals are then dried to remove excess
moisture before packaging and distribution.

29
 Recycling sugarcane by-products

The utilization of by-products in various industries has garnered

significant attention in recent years due to its potential for resource
optimization, waste reduction, and sustainability enhancement. Within
the realm of sugar production, the efficient management and utilization of
sugar cane by-products hold paramount importance not only for
economic viability but also for environmental sustainability. The sugar
industry generates substantial quantities of by-products during the
processing of sugar cane, including bagasse, filter mud, molasses, and
press mud, among others. Historically, these by-products have been
considered waste materials, often disposed of through incineration or
landfilling, leading to environmental concerns and resource inefficiency.
However, with evolving technologies and growing awareness of
environmental stewardship, there has been a paradigm shift towards the
valorization and recycling of sugar cane by-products.

This search aims to explore the diverse range of sugar cane by-products
generated during the sugar production process and elucidate the various
methods and applications for their recycling and utilization. By delving
into the characteristics, composition, and potential uses of these by-
products, this chapter seeks to underscore the importance of adopting
sustainable practices in the sugar industry. Moreover, it endeavors to
highlight the economic, environmental, and social benefits associated
with the recycling and valorization of sugar cane by-products. Through a
comprehensive examination of current research, innovative
technologies, and practical applications, this chapter endeavors to
provide insights into the sustainable management of sugar cane by-
products and the potential avenues for their integration into circular
economy models.

30
Figure 4: sugarcane final products

31
Figure 5: Percentages of sugarcane by-products

Bagasse

Bagasse is the fibrous residue that remains after sugar cane stalks have
been crushed to extract their juice during the sugar production process.
It is a lignocellulosic material composed primarily of approximately[17]:

● Cellulose: 40-45%
● Hemicellulose: 25-30%
● Lignin: 20-25%
● Pectin and other organic compounds: 5-10%
● Sugar : 1-2%

32
Bagasse recycling

1.Source of energy

Due to its high cellulose content, bagasse is an excellent source of

renewable biomass energy.

1. Boiler Fuel[18]:

● Combustion Process:
i. Bagasse is burned in a boiler furnace to generate heat
through combustion.
ii. The combustion process involves the oxidation of
bagasse in the presence of oxygen, resulting in the
release of heat energy.
iii. The heat generated by burning bagasse raises the
temperature of water in the boiler, producing steam.
● Steam Generation:
i. The steam produced by burning bagasse is used to
drive turbines connected to electricity generators or to
provide heat for various industrial processes in the
sugar mill.
ii. The steam may be used for juice evaporation, sugar
crystallization, distillation, or any other process
requiring heat energy within the sugar production
facility.
● Boiler Design and Efficiency:
i. Boilers used for burning bagasse are specifically
designed to accommodate the unique characteristics of
this biomass fuel.
ii. Specialized boiler designs incorporate features such as
grates for efficient fuel combustion, combustion air
preheating systems, and heat recovery mechanisms to

33
 maximize boiler efficiency and steam generation
capacity.
iii. Advanced control systems are employed to optimize
boiler operation, ensuring stable combustion, efficient
fuel utilization, and minimal emissions.
● Environmental Benefits:
i. The utilization of bagasse as a boiler fuel offers
significant environmental benefits, including reduced
greenhouse gas emissions and decreased reliance on
fossil fuels.
ii. By utilizing a renewable biomass fuel like bagasse,
sugar mills contribute to the reduction of carbon dioxide
emissions and mitigate environmental impacts
associated with fossil fuel combustion.

2. Combined Heat and Power (CHP) Systems[19]:

known as cogeneration systems, are widely employed in sugar

mills to maximize energy efficiency and utilize bagasse as a
renewable fuel source. Here's an overview of how bagasse is
utilized in CHP systems:

1. Boiler Operation:
● Bagasse is burned in boilers to generate steam for both
electricity generation and thermal applications within the
sugar mill.
● The combustion of bagasse produces high-pressure steam,
which is used to drive turbines connected to electricity
generators.
2. Electricity Generation:
● The steam turbines in CHP systems convert the energy from
high-pressure steam into mechanical energy, which is then
used to drive electricity generators.
● The electricity generated by CHP systems can be used to
power various operations within the sugar mill, including

34
 sugar processing equipment, lighting, and other electrical
loads.
● Excess electricity generated by the CHP system can be
exported to the grid for sale to external consumers, providing
an additional source of revenue for the sugar mill.

3. Heat Recovery:
● In addition to electricity generation, CHP systems utilize the
heat produced during electricity generation for various
thermal applications within the sugar mill.
● The heat recovered from the steam turbine's exhaust is used
for processes such as juice evaporation, sugar crystallization,
and drying operations.
● By capturing and utilizing this waste heat, CHP systems
achieve higher overall energy efficiency compared to
separate heat and power generation systems.

4. Efficiency and Environmental Benefits:

● CHP systems offer higher energy efficiency compared to
conventional separate heat and power generation systems.
● By utilizing bagasse as a renewable fuel source and
maximizing energy efficiency through CHP systems, sugar
mills can significantly reduce greenhouse gas emissions and
dependence on fossil fuels.

3. Biofuel Production[20]:

Biofuel production from bagasse involves biochemical or

thermochemical conversion processes to produce ethanol or biogas.
Here's an overview of how bagasse is utilized for biofuel production:

1. Bioethanol Production:
● Bagasse can be enzymatically hydrolyzed to break down the
cellulose and hemicellulose components into fermentable
sugars, primarily glucose and xylose.

35
 ● The enzymatic hydrolysis process involves treating bagasse
with enzymes such as cellulase and hemicellulase to convert
the complex carbohydrates into simple sugars.
● The resulting sugar-rich hydrolysate is then fermented by
yeast or other microorganisms to produce ethanol through a
process similar to traditional ethanol fermentation from sugar
cane juice.
● After fermentation, the ethanol is separated from the
fermentation broth and purified for use as a transportation
fuel or blending with gasoline.

2. Biogas Production:
● Bagasse can also be subjected to anaerobic digestion to
produce biogas, a mixture of methane and carbon dioxide.
● During anaerobic digestion, bagasse is placed in an oxygen-
free environment, where microorganisms break down the
organic matter in bagasse, primarily cellulose and
hemicellulose, to produce biogas.
● The biogas produced can be used directly as a fuel for
electricity generation or as a feedstock for upgrading into
biomethane, a renewable natural gas suitable for injection
into natural gas pipelines or use as a transportation fuel.

3. Process Optimization:
● Various factors, including pretreatment methods, enzymatic
hydrolysis conditions, fermentation parameters, and
anaerobic digestion process parameters, influence the
efficiency and economics of biofuel production from bagasse.
● Process optimization efforts aim to maximize sugar or biogas
yields, minimize energy and chemical inputs, and reduce
production costs to make biofuel production from bagasse
economically viable.

4. Environmental Benefits:
● Biofuel production from bagasse offers several environmental
benefits, including reduced greenhouse gas emissions,
decreased dependence on fossil fuels, and potential

36
 mitigation of waste disposal issues associated with bagasse
disposal.

2. Paper-making

Bagasse is rich in cellulose fibers, making it a suitable raw material for

paper production.These fibers in bagasse provide strength and rigidity to
paper products, making them suitable for various applications.

To turn bagasse into paper pulp, there are two main methods:
mechanical and chemical pulping.

Mechanical pulping uses grinding or shredding to separate the cellulose

fibers from the rest of the bagasse.

Chemical pulping, on the other hand, involves using chemicals like those
in the Kraft process or sulfite pulping to break down the bagasse and
extract the cellulose fibers.

● The Kraft process [21]

A widely used method for chemical pulping, particularly for wood

fibers, but it can also be applied to non-wood sources such as
bagasse. Here's a discussion on the Kraft process:

● Pulping Process:
a. The Kraft process involves treating the raw material,
such as bagasse, with a mixture of sodium
37
 hydroxide (NaOH) and sodium sulfide (Na2S) under
high temperature and pressure.
b. The alkali (NaOH) breaks down the lignin in the
bagasse into soluble compounds, while the sulfide
(Na2S) prevents the formation of undesirable by-
products by reducing the lignin to a lower molecular
weight.
c. This process effectively dissolves lignin and
separates it from the cellulose fibers, producing a
pulp with high cellulose content.
● Cooking Phase:
a. The bagasse is first chipped or shredded into small
pieces and then mixed with the chemical solution in
a large vessel called a digester.
b. The mixture is heated to temperatures ranging from
150°C to 180°C under pressure for several hours,
typically 1 to 4 hours, to facilitate the breakdown of
lignin.
c. During this cooking phase, the NaOH and Na2S
penetrate the bagasse fibers, causing the lignin to
become solubilized and dissolved in the liquor.

● Washing and Bleaching:

a. After the cooking phase, the pulp is washed to
remove the spent liquor, residual chemicals, and
dissolved lignin.
b. The washed pulp is then bleached using chlorine
dioxide, oxygen, or hydrogen peroxide to further
remove lignin and brighten the pulp.
c. Bleaching also improves the brightness and color of
the pulp, making it suitable for high-quality paper
and paper products.
● Environmental Considerations:

38
 a. While the Kraft process is highly effective in
producing strong, high-quality pulp, it generates
large amounts of black liquor, a by-product
containing lignin, spent chemicals, and dissolved
solids.
b. To minimize environmental impact, black liquor is
often processed in a recovery boiler to generate
steam and recover chemicals for reuse in the
pulping process, making the Kraft process more
sustainable.

● Sulfite pulping [22]

a chemical pulping process commonly used to produce pulp

from wood fibers, but it can also be applied to non-wood sources
such as bagasse. Here's a discussion on sulfite pulping:

1. Pulping Process:
● Sulfite pulping involves treating the raw material, such as
bagasse, with a solution of sulfurous acid (H2SO3) or bisulfites
(e.g., calcium bisulfite or sodium bisulfite) in the presence of an
alkali, typically sodium hydroxide (NaOH) or calcium hydroxide
(Ca(OH)2).
● The sulfite chemicals penetrate the bagasse fibers and break
down the lignin, which binds the cellulose fibers together.
● This process selectively dissolves lignin while preserving the
cellulose fibers, resulting in a high-quality pulp with excellent
strength properties.
2. Cooking Phase:
● The bagasse is chipped or shredded into small pieces and then
mixed with the sulfite solution in a digester.

39
 ● The mixture is heated to temperatures ranging from 140°C to
180°C under pressure for several hours, typically 4 to 10 hours,
to facilitate the breakdown of lignin.
● During this cooking phase, the sulfite chemicals react with the
lignin, causing it to become solubilized and dissolved in the
liquor.
3. Washing and Bleaching:
● After the cooking phase, the pulp is washed to remove the
spent liquor, residual chemicals, and dissolved lignin.
● The washed pulp is then bleached using chlorine dioxide,
oxygen, or hydrogen peroxide to further remove lignin and
brighten the pulp.
● Bleaching also improves the brightness and color of the pulp,
making it suitable for high-quality paper and paper products.
4. Environmental Considerations:
● Sulfite pulping generates less black liquor compared to the
Kraft process, making it more environmentally friendly in terms
of chemical recovery and waste management.
● However, sulfite pulping requires more stringent control of
process parameters and higher operational costs compared to
the Kraft process.

After getting the pulp from bagasse typically stored in large tanks or
chests after it has been washed and bleached. These storage tanks are
often made of stainless steel or fiberglass and are equipped with
agitators to prevent the pulp from settling and becoming unevenly
distributed. The pulp is stored in these tanks temporarily before being
further processed or transported to the paper machine for sheet
formation. During storage, the pulp may be treated with additives or
chemicals to maintain its consistency and prevent microbial growth.[23]

Bagasse paper can be produced in various types and grades to suit

different applications.

40
 1. Writing and Printing Paper: Bagasse paper is commonly used for
writing and printing purposes, offering a smooth surface that is
suitable for high-quality printing and writing. It can be found in
notebooks, stationery, office papers, and other similar products [24].
2. Packaging Paper: Bagasse paper is also used in packaging
applications, such as for making corrugated cardboard boxes,
packaging materials, and disposable food containers. It provides
adequate strength and rigidity for packaging while being
biodegradable and eco-friendly [25].
3. Tissue Paper: Bagasse fibers can be processed into tissue paper,
which is used for various hygiene and sanitary products, including
facial tissues, toilet paper, and paper towels. Bagasse tissue paper
is soft, absorbent, and environmentally friendly [26].
4. Specialty Papers: Bagasse paper can be used to produce specialty
papers tailored for specific applications, such as fine art paper,
filter paper, and industrial papers. These specialty papers leverage
the unique properties of bagasse fibers to meet specific
requirements [27].

Utilizing bagasse as a raw material for papermaking offers several

environmental benefits.

By using bagasse, paper manufacturers reduce the demand for virgin

wood fibers, thereby conserving natural forests and habitats.

3.Industrial woods

1. Particleboard and Fiberboard Production

Bagasse can be processed into particleboard and fiberboard,

which are commonly used in construction, furniture manufacturing,
and interior design. Bagasse-based particleboard and fiberboard
offer good mechanical properties and can be engineered to meet
specific performance requirements [28].

41
Production process:

● Raw Material Preparation:

○ Bagasse fibers are obtained by mechanically
processing sugar cane bagasse, which involves
shredding or chipping the raw material into small
pieces.
○ The bagasse fibers are then dried to reduce moisture
content and improve their suitability for board
production.
● Binder Addition [29]:
○ Bagasse fibers are mixed with adhesives or binders to
form a homogenous mixture. Common binders used in
particleboard and fiberboard production include urea-
formaldehyde (UF), melamine-formaldehyde (MF),
phenol-formaldehyde (PF), and isocyanate-based
adhesives.
○ The binder helps bind the bagasse fibers together and
provides cohesion and strength to the final board
product.
● Mat Formation [30]:
○ The bagasse fiber and binder mixture is formed into
mats or layers using a forming machine or conveyor
belt system.
○ The mats are typically placed between two layers of
facing materials, such as kraft paper, foil, or wood
veneer, to enhance surface finish and stability.
● Hot Pressing [31]:
○ The formed mats are subjected to heat and pressure in
a hot press to consolidate the fibers and cure the
adhesive.
○ The hot pressing process activates the adhesive,
causing it to cross-link and bond the bagasse fibers
together, forming a solid board structure.
● Cooling and Trimming [32]:
○ After hot pressing, the boards are cooled to room
temperature to allow the adhesive to fully cure and set.
42
 ○ The cooled boards are then trimmed to the desired
dimensions using cutting machines or saws, and the
edges are sanded or finished to achieve a smooth
surface.
● Quality Control and Testing [33]:
○ Quality control measures, including visual inspection,
thickness measurement, and mechanical testing, are
performed to ensure that the particleboard and
fiberboard meet the required standards and
specifications.
○ Mechanical properties such as modulus of elasticity
(MOE), modulus of rupture (MOR), and internal bond
strength are evaluated to assess the structural integrity
and performance of the boards.

2. Composite Panels:

Bagasse fibers can be used as reinforcement in composite panels,

such as medium-density fiberboard (MDF) and oriented strand
board (OSB). These composite panels combine bagasse fibers
with resins or binders to create durable and versatile building
materials [34].

[35]
Manufacturing Process :

● The bagasse fiber and binder mixture is formed into panels

using hot pressing, molding, or extrusion processes.
● Hot pressing involves subjecting the mixture to high
temperature and pressure in a mold to consolidate the fibers
and cure the binder, resulting in solid composite panels.
● Molding processes utilize molds or dies to shape the mixture
into specific panel dimensions, while extrusion processes

43
 involve forcing the mixture through a die to form continuous
panels of varying shapes and sizes.

Properties and Performance [36]:

● Composite panels made from bagasse offer excellent

mechanical properties, including strength, stiffness, and
dimensional stability.
● The panels can be engineered to meet specific performance
requirements for different applications, such as construction,
furniture manufacturing, and automotive industries.
● Bagasse-based composite panels exhibit good resistance to
moisture, decay, and insect damage, making them suitable
for outdoor and high-humidity environments.

Applications [37]:

● Bagasse composite panels find applications in a wide range

of industries and products, including:
● Building and construction: for wall cladding, partitions,
flooring, and roofing.
● Furniture manufacturing: for making cabinets, shelves,
tables, and chairs.
● Automotive industry: for interior components, door panels,
and trim.
● Packaging industry: for producing boxes, crates, and pallets.

4.cellulosic derivatives

44
Cellulosic derivatives derived from bagasse offer a wide range of
applications in various industries due to their versatile properties.

biodegradable and eco-friendly alternatives to synthetic polymers,

reducing dependence on fossil-based materials and mitigating
environmental pollution [38].

Here's a discussion on making cellulosic derivatives from bagasse:

1. Cellulose Extraction:
● Cellulose is extracted from pretreated bagasse using
chemical or enzymatic methods.
● Chemical methods involve treating bagasse with alkalis (e.g.,
sodium hydroxide) or acids (e.g., sulfuric acid) to dissolve
lignin and hemicellulose, leaving behind purified cellulose
fibers.
● Enzymatic methods utilize cellulase enzymes to selectively
hydrolyze lignin and hemicellulose, releasing cellulose fibers
[39]
.
2. Derivatization of Cellulose:
● Purified cellulose fibers obtained from bagasse are
chemically modified to produce various cellulosic derivatives
with tailored properties.
● Common cellulosic derivatives include cellulose acetate,
cellulose ethers (e.g., methyl cellulose, ethyl cellulose), and
cellulose esters (e.g., cellulose nitrate).
● Derivatization reactions involve functionalizing cellulose
hydroxyl groups with acetyl, alkyl, or ester groups through
[40]
esterification or etherification reactions .

Applications:

1. Pharmaceutical Applications:
● Cellulosic derivatives are extensively used in pharmaceutical
formulations as excipients, binders, and disintegrants.

45
 ● According to a study by Zhang et al. (2019), cellulose
derivatives are included in over 90% of oral solid dosage
forms, contributing to their mechanical properties and drug
release characteristics [41].
● Methyl cellulose, for example, is widely used in tablet
formulations, with an estimated annual production of over
50,000 metric tons globally [42].
2. Food Industry Applications:
● Cellulosic derivatives serve as essential additives in the food
industry, functioning as thickeners, stabilizers, and
emulsifiers.
● According to market research by Grand View Research, the
global market for food-grade cellulose derivatives was valued
at USD 5.47 billion in 2020 and is projected to reach USD
8.15 billion by 2027, with a compound annual growth rate
(CAGR) of 5.6% [43].
● Carboxymethyl cellulose (CMC) is one of the most commonly
used cellulose derivatives in food products, contributing to
improved texture and viscosity in a wide range of applications
[44]
.
3. Textile Industry Applications:
● Cellulosic derivatives find significant applications in the textile
industry as sizing agents, thickeners, and modifiers.
● According to a report by Textile Exchange, the global
consumption of cellulosic fibers, including those derived from
cellulose derivatives, reached 7.5 million metric tons in 2020,
with an expected annual growth rate of 4-5% [45].
● Hydroxyethyl cellulose (HEC) is widely used in textile printing
and dyeing processes, contributing to enhanced color
consistency and fabric quality [46].
4. Cosmetic and Personal Care Applications:
● Cellulosic derivatives play a crucial role in cosmetic and
personal care products as rheology modifiers, film-forming
agents, and binders.
● According to market research by Allied Market Research, the
global market for cellulose ethers, including derivatives such

46
 as hydroxypropyl cellulose (HPC) and hydroxyethyl cellulose
(HEC), was valued at USD 4.2 billion in 2019 and is expected
to reach USD 6.2 billion by 2027, with a CAGR of 5.3% [47].
● Cellulose derivatives enhance the performance and stability
of cosmetic formulations, contributing to improved texture,
spreadability, and shelf life [48].

Overall, the applications of cellulosic derivatives from bagasse span

multiple industries, with significant market demand and growth potential.

5.Furfural
Furfural is an organic compound derived from various agricultural by-
products, particularly lignocellulosic biomass such as corncobs,
sugarcane bagasse, and rice husks. It is a heterocyclic aldehyde with the
chemical formula C5H4O2.

Furfural is produced through the dehydration of pentoses, which are five-

carbon sugars such as xylose, present in the biomass. This dehydration
reaction typically occurs under acidic conditions and at elevated
temperatures, leading to the formation of furfural along with other by-
products.

Furfural production from bagasse involves several steps:

1. Pretreatment of Bagasse:
● Bagasse undergoes pretreatment to break down
lignocellulosic components into simpler sugars, primarily
glucose and xylose.
● Pretreatment methods include steam explosion, acid
hydrolysis, or enzymatic hydrolysis, which can achieve sugar
yields ranging from 60% to 90% [49].

47
 ● For example, acid hydrolysis with dilute sulfuric acid at
optimized conditions can yield glucose and xylose
concentrations of 60-80 g/L and 20-40 g/L, respectively [50].
2. Hydrolysis of Pretreated Bagasse:
● The pretreated bagasse is further hydrolyzed to convert
glucose and xylose into furfural, primarily through
dehydration reactions.
● Acid-catalyzed hydrolysis at elevated temperatures (e.g.,
160-200°C) and pressures (e.g., 1-3 MPa) can achieve
furfural yields ranging from 40% to 70% [51].
● For instance, studies have reported furfural yields of up to
68% from glucose and 47% from xylose using sulfuric acid as
a catalyst under optimized conditions [52].
3. Furfural Recovery and Purification:
● Furfural is recovered from the hydrolysate through distillation
or extraction processes.
● Distillation methods, such as batch or continuous distillation,
can achieve furfural recoveries exceeding 90% with purities
ranging from 95% to 99% [53].
● Alternatively, furfural can be extracted using organic solvents
like methyl isobutyl ketone (MIBK) or ethyl acetate, with
[54]
extraction efficiencies typically ranging from 70% to 90% .

Furfural production from bagasse has gained momentum on an industrial

scale, with several commercial plants operating worldwide.

For example, a furfural production plant in China with a capacity of

100,000 tons per year reported an average yield of 0.45 tons of furfural
per ton of bagasse feedstock [55]. Similarly, a plant in Brazil utilizing
bagasse as feedstock achieved a furfural production rate of 15-20 kg per
ton of bagasse processed [56].

Applications of furfural:

48
1. Solvent Applications:
● Furfural serves as a solvent in various industrial processes,
including petrochemical refining, pharmaceuticals, and
flavorings.
● According to market research by Grand View Research, the
global furfural solvent market was valued at USD 500 million
in 2020 and is projected to reach USD 700 million by 2027,
with a compound annual growth rate (CAGR) of 5.2% [57].
● Furfural Is excellent solvent properties, such as high polarity
and low toxicity, make it suitable for extracting value-added
compounds from biomass, such as lignin and cellulose [58].
2. Chemical Intermediate:
● Furfural serves as a key chemical intermediate in the
synthesis of various derivatives, including furfuryl alcohol,
tetrahydrofurfuryl alcohol, and levulinic acid.
● The global furfural derivatives market was valued at USD 1.2
billion in 2020 and is expected to reach USD 1.7 billion by
2027, with a CAGR of 4.8% [59].
● Furfural derivatives find applications in resin production,
lubricants, plasticizers, and pharmaceuticals [60].
3. Biofuel Production:
● Furfural can be further processed into biofuels such as furan-
based biodiesel and gasoline additives.
● According to a study by Liu et al. (2019), furfural-derived
biofuels have shown promising performance in engine tests,
with comparable energy density and combustion
characteristics to petroleum-derived fuels [61].
● The global biofuels market, including furfural-based biofuels,
was valued at USD 140 billion in 2020 and is expected to
reach USD 220 billion by 2027, with a CAGR of 6.8% [62].
4. Biopolymer Synthesis:
● Furfural derivatives are utilized in the production of
biopolymers such as polyfurfuryl alcohol (PFA) and furan
resins.
● These biopolymers offer advantages such as
biodegradability, thermal stability, and mechanical strength,

49
 making them suitable for applications in coatings, adhesives,
and composites [63].
● The global biopolymer market was valued at USD 10 billion
in 2020 and is projected to reach USD 20 billion by 2027,
with a CAGR of 9% [64].
5. Fine Chemicals Synthesis:
● Furfural serves as a precursor for the synthesis of various
fine chemicals, including pharmaceutical intermediates and
flavor compounds.
● According to a report by MarketsandMarkets, the global fine
chemicals market was valued at USD 200 billion in 2020 and
is expected to reach USD 300 billion by 2027, with a CAGR
of 6% [65].
● Furfural-derived fine chemicals find applications in
pharmaceuticals, agrochemicals, and specialty chemicals
industries [66].

Overall, initiatives to promote bio-based chemicals and reduce reliance

on fossil fuels are expected to further bolster the furfural market in the
coming years.

6.ِ Animal feed

Bagasse can be processed into animal feed through various methods

such as ensiling, pelleting, and chemical treatment.

1. Direct Feeding of Bagasse:

● Bagasse can be fed directly to livestock, particularly
ruminants such as cattle and sheep, as a source of dietary
fiber and roughage.

50
 ● Studies have shown that bagasse can contribute to animal
nutrition by providing insoluble fiber, which promotes rumen
health and regulates digestion [67].
● According to research by González et al. (2017), direct
feeding of bagasse to ruminants can enhance rumen
fermentation and microbial activity, leading to improved feed
efficiency [68].
● However, direct feeding of bagasse may require
supplementation with additional nutrients to meet the dietary
requirements of animals, especially protein and minerals.
2. Ensiling Bagasse for Animal Feed:
● Bagasse can be ensiled to improve its digestibility and
palatability for livestock.
● Ensiling involves compacting and fermenting bagasse under
anaerobic conditions, typically with the addition of microbial
inoculants or fermentable carbohydrates.
● Research by Ogunade et al. (2018) demonstrated that
ensiling bagasse with additives such as molasses or urea
can enhance fermentation and nutrient preservation,
resulting in improved feed quality [69].
● Ensiled bagasse can serve as a cost-effective feed
ingredient, particularly in regions with abundant sugarcane
production and limited access to traditional forage resources.
3. Pelleting Bagasse for Animal Feed:
● Bagasse can be processed into pellets to improve handling,
storage, and feed efficiency.
● Pelleting involves grinding bagasse into smaller particles and
compressing them into pellets using heat and pressure.
● According to market research by Grand View Research, the
global animal feed pellet market was valued at USD 15.2
billion in 2020 and is projected to reach USD 22.9 billion by
2027, with a compound annual growth rate (CAGR) of 5.6%
[70]
.
● Bagasse pellets offer advantages such as reduced wastage,
improved feed intake, and enhanced nutrient availability for
animals.
4. Supplementation with Bagasse-Based Feed Additives:

51
 ● Bagasse can be supplemented with feed additives such as
protein sources, minerals, and vitamins to meet the
nutritional requirements of animals.
● Research by Dehghan-Banadaky et al. (2016) demonstrated
that supplementing bagasse-based diets with protein-rich
additives can improve animal growth, rumen health, and milk
production [71].
● The use of bagasse-based feed additives contributes to
balanced nutrition and optimized feed utilization in livestock
production systems.

Overall, the utilization of bagasse in various animal feeding types offers

opportunities to enhance livestock nutrition, feed efficiency, and
sustainability.

52
 Muds

Mud is obtained from the clarification and filtration stages of sugarcane

juice extraction. This by-product presents both challenges and
opportunities for various applications, including animal feed, fertilizers,
and industrial uses.

Types of Mud:

Mud from sugarcane processing can be classified into two main types
based on its origin and composition:

Filter Mud
is the residue obtained from the filtration process during sugarcane juice
extraction. It consists of suspended solids, organic matter, cellulose,
lignin, and mineral components. Filter mud is separated from the juice
using filtration equipment such as rotary vacuum filters or filter presses.
This by-product is typically rich in nutrients and organic material, making
it suitable for various applications.
The composition of filter mud varies depending on factors such as the
quality of sugarcane, processing methods, and environmental conditions.
On average, filter mud contains:

● Organic matter: 40-50%

● Cellulose: 10-20%
● Lignin: 5-15%
● Inorganic components (ash): 20-30%
● Moisture content: 50-70%

The nutrient content of filter mud includes nitrogen, phosphorus,

potassium, calcium, magnesium, sulfur, and micronutrients. These

53
nutrients contribute to the fertility and organic matter content of soils
when filter mud is used as a soil amendment or fertilizer.

Applications of Filter Mud:

Filter mud finds applications in various sectors due to its nutrient-rich

composition and organic content:

● Soil Amendment and Fertilizer:

Filter mud is utilized as an organic soil amendment and fertilizer

in agriculture. It improves soil structure, enhances nutrient
availability, and promotes microbial activity. Studies have
shown that the application of filter mud increases soil organic
carbon, nitrogen, phosphorus, and potassium levels, leading to
improved crop yields and soil fertility (Singh et al., 2019) [72].

● Animal Feed Supplement:

Filter mud can be incorporated into animal feed formulations as

a supplementary feed ingredient. It provides fiber, minerals, and
energy to livestock, enhancing their overall nutrition and feed
efficiency. Research indicates that filter mud supplementation in
ruminant diets improves nutrient intake, rumen fermentation,
and animal performance (Gupta et al., 2020) [73].

● Biogas Production:

Filter mud can be utilized as a feedstock for biogas production

through anaerobic digestion. The organic matter in filter mud
undergoes microbial decomposition, producing biogas rich in

54
 methane. Biogas generated from filter mud can be used for
electricity generation, heating, or as a renewable fuel source.

● Soil Erosion Control:

Filter mud can be applied to slopes, embankments, and

degraded lands to control soil erosion. Its organic content helps
stabilize soil structure, prevent water runoff, and promote
vegetation growth. Filter mud serves as a cost-effective and
environmentally friendly solution for erosion control measures.

● Candle Production

filter mud, can be processed into briquettes or pellets for use as

a renewable fuel source in candle production. Research by
Sharma et al. (2017) investigated the feasibility of utilizing filter
mud pellets as an alternative to conventional fuels in candle
manufacturing processes, demonstrating their potential for
reducing production costs and environmental impacts [74].

Clarified Mud
is the sediment obtained from the clarification of sugarcane juice using
chemical agents or flocculants to separate impurities. It consists of finer
particles, including residual sugar, proteins, and mineral precipitates.
The composition of filter mud and clarified mud varies depending on the
sugarcane variety, processing methods, and environmental factors.

55
The composition of clarified mud varies depending on the clarification
process, sugarcane quality, and operational factors. However, on
average, clarified mud contains:

● Residual sugars: 5-15%

● Proteinaceous matter: 5-10%
● Mineral precipitates (ash): 20-30%
● Moisture content: 60-80%

Clarified mud has a higher sugar content compared to filter mud, making
it suitable for certain applications that require a readily available energy
source.

Applications of Clarified Mud:

Clarified mud finds applications in various sectors due to its unique

composition and properties:

● Soil Amendment and Fertilizer:

Clarified mud can be utilized as an organic soil amendment and

fertilizer in agricultural systems. Despite its higher moisture content
and sugar content, clarified mud contributes essential nutrients
such as nitrogen, phosphorus, potassium, and organic matter to
soils. Studies have demonstrated that the application of clarified
mud improves soil fertility, enhances crop yields, and promotes
sustainable agriculture practices (Yadav et al., 2018) [75].

● Biogas Production:

Similar to filter mud, clarified mud can serve as a feedstock for

biogas production through anaerobic digestion. The sugar and
56
 organic content in clarified mud are readily digestible by anaerobic
microorganisms, resulting in the production of biogas composed
mainly of methane. Biogas generated from clarified mud can be
utilized for electricity generation, heating, or as a renewable fuel
source.

● Industrial Fermentation:

Clarified mud contains residual sugars and proteins, which can be

utilized as substrates for industrial fermentation processes. It can
serve as a nutrient source for microbial fermentation in various
biotechnological applications, including the production of organic
acids, enzymes, and bio-based chemicals.

● Environmental Remediation:

Clarified mud can be utilized in environmental remediation

applications, such as wastewater treatment and land reclamation.
Its high organic content and nutrient composition make it suitable
for enhancing microbial activity and nutrient cycling in degraded
soils or polluted environments.

Mud as a by-product of sugarcane processing, offers valuable

opportunities for soil fertility enhancement,animal nutrition, renewable
energy production, industrial applications, and environmental
remediation. Its unique composition and properties make it a versatile
resource for promoting sustainable practices across various industries.

57
 Molasses

Molasses is a complex mixture of sugars, minerals, organic acids,

vitamins, antioxidants, and other compounds, which contribute to its
distinct flavor, color, and nutritional properties. The composition of
molasses can vary depending on several factors, including the type of
raw material (sugarcane or sugar beet), the stage of sugar extraction,
processing methods, and environmental conditions.

Content of Molasses

1. Sugars [76]
● Sucrose: Sucrose is the predominant sugar in molasses,
accounting for a significant portion of its sweetness. Sucrose
molecules are composed of glucose and fructose units linked
together.
● Glucose and Fructose: These monosaccharides are present
in smaller quantities in molasses, contributing to its overall
sweetness and flavor profile.
● Invert Sugars: During the processing of sugarcane or sugar
beet, sucrose may undergo hydrolysis to form invert sugars,
including glucose and fructose, which enhance the
sweetness and solubility of molasses.

2. Minerals [77]
○ Potassium (K): Essential for various physiological functions,
including muscle contraction, nerve transmission, and fluid
balance.
○ Calcium (Ca): Important for bone health, muscle function,
and blood clotting.
○ Magnesium (Mg): Involved in energy metabolism, muscle
function, and protein synthesis.
58
 ○ Phosphorus (P): Essential for bone and teeth formation,
energy metabolism, and cell signaling.
○ Iron (Fe): Required for oxygen transport, energy production,
and enzyme function.

3. Organic Acids [78]

○ Lactic Acid: Produced during fermentation processes and
contributes to the tangy flavor of molasses.
○ Acetic Acid: Contributes to the sourness and aroma of
molasses.
○ Citric Acid: Adds a citrusy flavor and acts as a natural
preservative.
○ Malic Acid: Provides tartness and enhances the overall flavor
profile of molasses.

4. Vitamins [79]
○ Lactic Acid: Produced during fermentation processes and
contributes to the tangy flavor of molasses.
○ Acetic Acid: Contributes to the sourness and aroma of
molasses.
○ Citric Acid: Adds a citrusy flavor and acts as a natural
preservative.
○ Malic Acid: Provides tartness and enhances the overall flavor
profile of molasses.

5. Antioxidants: polyphenols, flavonoids, and melanoidins, which

help protect cells from oxidative damage and contribute to the
health-promoting properties of molasses [80].

59
Uses of Molasses
Food and Beverage Industry
● Sweetener and Flavoring Agent:-
1. Sweetening Properties:
a. Molasses is valued for its high sweetness
intensity, attributed to its rich content of natural
sugars, primarily sucrose, glucose, and fructose.
b. The sweetness of molasses is often described as
complex and multi-dimensional, with undertones
of caramel, toffee, and earthiness, which
contribute to its unique flavor profile.
c. Studies have shown that molasses possesses a
higher sweetness potency compared to refined
sugar, allowing for the reduction of sugar content
in recipes without compromising sweetness
perception (Bakowska-Barczak, 2017) [81].
2. Flavor Enhancement:
a. Molasses adds depth of flavor and complexity to
food products, imparting a rich, robust taste with
notes of caramelization, bitterness, and acidity.
b. The distinctive flavor of molasses is derived from
Maillard reactions and caramelization processes
occurring during sugar extraction and
concentration, resulting in the formation of flavor
compounds such as furfurals, pyrazines, and
melanoidins.
c. These flavor compounds contribute to the overall
sensory profile of foods, enhancing aroma,
mouthfeel, and taste perception, particularly in
baked goods, sauces, and marinades (Bekedam
et al., 2018) [82].
3. Maillard Reactions:
a. Maillard reactions between reducing sugars (e.g.,
glucose, fructose) and amino acids occur during
heating or cooking processes, leading to the

60
 formation of brown pigments, flavors, and
aromas.
b. Molasses provides a rich source of reducing
sugars and amino acids, facilitating Maillard
reactions and the development of desirable flavor
characteristics in food products.
c. The Maillard reaction products formed during the
caramelization of molasses contribute to the
browning, sweetness, and umami notes in foods,
enhancing their overall sensory appeal
(Mestdagh et al., 2018) [83].
4. Applications in Food Products:
a. Molasses is extensively used as a sweetener and
flavoring agent in a wide range of food products,
including:
i. Baked Goods: Bread, cookies, cakes,
muffins, and pastries benefit from the rich
flavor and moisture retention properties of
molasses, resulting in tender, flavorful
products.
ii. Sauces and Marinades: Molasses adds
complexity and depth to barbecue sauces,
glazes, and marinades, enhancing their
sweetness, tanginess, and caramelized
notes.
iii. Beverages: Molasses is used to sweeten
and flavor beverages such as teas, coffees,
smoothies, and cocktails, imparting
richness and depth to their taste profiles.

● Coloring Agent:
1. Natural Colorant Source:

61
 a. Molasses serves as a natural coloring agent in
food products, imparting a deep, rich brown hue
due to its high content of non-enzymatic browning
compounds, such as melanoidins and
caramelization products.
b. Melanoidins are complex polymers formed
through the Maillard reaction between reducing
sugars and amino acids during the processing
and heating of molasses. These brown pigments
contribute to the characteristic color and flavor of
molasses (Gross et al., 2019) [84].
c. Caramelization reactions occur when sugars in
molasses are heated, resulting in the formation of
caramel-like compounds that enhance the color
intensity and visual appeal of foods.
2. Enhancement of Appearance:
a. The deep, rich brown color of molasses adds
visual appeal and aesthetic value to food
products, making them more attractive to
consumers.
b. In bakery products such as bread, cakes,
cookies, and muffins, molasses contributes to the
development of a golden-brown crust and a
moist, tender crumb, enhancing the overall
appearance and texture of the finished products.
c. Molasses is also used as a coloring agent in
savory dishes, sauces, marinades, and glazes,
where it imparts a dark, glossy sheen and a
caramelized flavor profile to meats, vegetables,
and side dishes.
3. Regulatory Considerations:
a. Molasses is generally recognized as safe (GRAS)
by regulatory agencies such as the U.S. Food
and Drug Administration (FDA) and the European
Food Safety Authority (EFSA) for use as a
coloring agent in food products.

62
 b. Food manufacturers may use molasses as a
natural coloring agent in accordance with food
labeling regulations, which require the declaration
of ingredients on product labels to inform
consumers about the presence of molasses in
processed foods (EFSA, 2019) [85].
c. Molasses-derived colorants are preferred by
consumers seeking natural and clean-label food
products, as they offer an alternative to synthetic
food dyes and additives.

● Fermentation:
1. Definition and Process:
a. Fermentation is a metabolic process that
converts carbohydrates, such as sugars or
starches, into organic acids, gases, or alcohol in
the absence of oxygen. It is carried out by
microorganisms such as bacteria, yeast, or fungi.
b. During fermentation, microorganisms metabolize
carbohydrates through enzymatic reactions,
producing energy and metabolic byproducts. The
specific end products of fermentation depend on
the type of microorganism involved and the
environmental conditions.
c. In industrial settings, fermentation processes are
utilized for the production of a wide range of
products, including alcoholic beverages, biofuels,
organic acids, enzymes, antibiotics, and
probiotics.
2. Types of Fermentation:
a. Alcoholic Fermentation: Yeast species such as
Saccharomyces cerevisiae are commonly used in
alcoholic fermentation, where they convert sugars

63
 into ethanol and carbon dioxide. This process is
utilized in the production of alcoholic beverages
such as beer, wine, and spirits [86].
b. Lactic Acid Fermentation: Lactic acid bacteria
such as Lactobacillus spp. convert sugars into
lactic acid through lactic acid fermentation. This
process is used in the production of fermented
dairy products (e.g., yogurt, cheese), sourdough
bread, sauerkraut, and kimchi [87].
c. Acetic Acid Fermentation: Acetic acid bacteria
such as Acetobacter spp. oxidize ethanol into
acetic acid in the presence of oxygen, leading to
the production of vinegar. This process is utilized
in vinegar production from alcoholic beverages or
fruit juices [88].
d. Ethanol Fermentation: Various microorganisms,
including yeast and bacteria, can ferment sugars
into ethanol. This process is used in biofuel
production, where ethanol is produced from
renewable feedstocks such as sugarcane, corn,
or cellulosic biomass [89].

● Animal Feed Industry:

1. Nutritional Composition:
a. Molasses is valued as a feed additive for its
nutritional content, providing carbohydrates,
minerals, vitamins, and organic acids essential
for animal health and growth.
b. The carbohydrate fraction of molasses consists
primarily of sugars, including sucrose, glucose,
and fructose, which serve as readily fermentable
energy sources for livestock.

64
 c. In addition to sugars, molasses contains minerals
such as potassium, calcium, magnesium,
phosphorus, and trace elements, which play vital
roles in bone development, muscle function,
enzyme activation, and overall metabolic
processes in animals.
d. Molasses also contains organic acids, including
lactic acid, acetic acid, and citric acid, which
contribute to gut health, pH regulation, and
nutrient absorption in livestock (Schrama et al.,
2019) [90].
2. Palatability Enhancement:
a. Molasses serves as a palatability enhancer in
livestock feed formulations, improving the taste,
aroma, and texture of feeds, thereby increasing
feed intake and animal performance.
b. The sweet taste and aroma of molasses attract
animals to consume feed more readily,
particularly in situations where feed quality may
be suboptimal or during periods of low appetite.
c. Studies have shown that the addition of molasses
to feed increases voluntary feed intake, nutrient
utilization, and growth performance in various
livestock species, including cattle, sheep, goats,
and horses (Khorasani et al., 2016) [91].
3. Energy Source:
a. The carbohydrates present in molasses,
particularly fermentable sugars, serve as a
valuable energy source for livestock, providing
readily available calories for metabolic processes,
growth, and lactation.
b. Molasses is often included in ruminant diets as a
source of fermentable carbohydrates for rumen
microbial fermentation, resulting in the production
of volatile fatty acids (VFAs) such as acetate,
propionate, and butyrate, which serve as major
energy substrates for ruminants.

65
 c. The energy density of molasses makes it
particularly suitable for supplementing low-quality
forages or roughages, enhancing their nutritional
value and digestibility for ruminant animals
(Zhang et al., 2017) [92].
4. Feed Processing and Formulation:
a. Molasses can be incorporated into various types
of animal feed, including pelleted feeds, liquid
supplements, blocks, and lick tubs, through a
process known as molasses blending or coating.
b. In feed processing facilities, molasses is mixed
with other feed ingredients, such as grains,
protein meals, and forages, to form a
homogeneous mixture that is palatable,
nutritious, and easy to handle.
c. The inclusion rate of molasses in animal feed
formulations varies depending on factors such as
species, age, weight, production stage, and
nutritional requirements of the animals, with
typical inclusion levels ranging from 2% to 10% of
the total diet (Enkvetchakul et al., 2018) [93].

Pharmaceutical and Nutraceutical Applications

● Medicinal Syrups: Traditional medicine systems, including
Ayurveda, Traditional Chinese Medicine (TCM), and Western
herbalism, have incorporated molasses into various
formulations for its nutritional value, soothing properties, and
ability to mask the taste of bitter or unpalatable medicinal
herbs [94].
1. Therapeutic Benefits:
a. Molasses is often included in medicinal syrup
formulations for its demulcent and emollient
properties, which help soothe and lubricate the

66
 throat and respiratory passages, providing relief
from coughs, sore throats, and respiratory
congestion.
b. The rich, viscous consistency of molasses allows
it to form a protective coating over irritated
mucous membranes, reducing irritation and
inflammation and promoting healing [95].
c. In addition to its soothing effects, molasses
provides a natural source of energy and nutrients,
making it suitable for individuals recovering from
illness or experiencing fatigue or weakness [96].
2. Traditional Uses:
a. In traditional medicine systems, molasses-based
syrups are often combined with medicinal herbs,
spices, and botanical extracts to create
formulations targeting specific health concerns[97].
b. For example, molasses may be combined with
ginger, lemon, and honey to create a soothing
cough syrup with expectorant properties, or with
herbs such as licorice, marshmallow, and slippery
elm for a demulcent throat syrup.
c. These traditional formulations are believed to
support respiratory health, boost immune
function, and alleviate symptoms of colds, flu,
and respiratory infections[98].

● Iron Supplements:
1. Iron Content in Molasses:
a. Molasses is a rich source of iron, containing
significant amounts of this essential mineral. The
iron content of molasses varies depending on
factors such as the type of molasses (e.g., light,

67
 dark), processing method, and source of the raw
material (sugarcane or sugar beet).
b. Dark molasses, which undergoes less processing
and retains more of the original sugarcane or
sugar beet juice, typically has higher iron content
compared to light molasses [99].
c. Iron in molasses exists in the form of ferrous
(Fe^2+) and ferric (Fe^3+) ions, which are readily
absorbed by the body and utilized for various
physiological functions, including oxygen
transport, energy metabolism, and enzymatic
reactions (Zhang et al., 2019) [100].
2. Bioavailability of Iron:
a. The bioavailability of iron in molasses is
influenced by factors such as its chemical form
(e.g., heme vs. non-heme iron), presence of
enhancing or inhibiting factors, and individual's
iron status and dietary factors.
b. Non-heme iron, the predominant form of iron in
plant-based foods such as molasses, is less
readily absorbed compared to heme iron from
animal sources. However, the absorption of non-
heme iron can be enhanced by factors such as
vitamin C (ascorbic acid) and organic acids
present in molasses [101].
c. Studies have demonstrated that consuming iron-
rich foods or supplements along with vitamin C-
rich foods or beverages, such as citrus fruits or
juices, enhances the absorption of non-heme iron
from plant sources, including molasses (Layrisse
et al., 2000) [102].
3. Iron Supplementation:
a. Molasses is commonly used as a natural source
of iron supplementation in individuals with iron
deficiency or anemia, particularly in populations
where access to conventional iron supplements
or fortified foods is limited.

68
 b. The inclusion of molasses in the diet or as an
ingredient in fortified foods, beverages, or
medicinal formulations provides a convenient and
cost-effective way to increase iron intake and
improve iron status[103].
c. Molasses-based iron supplements are often
recommended for pregnant women, children,
vegetarians, and individuals at risk of iron
deficiency or anemia due to factors such as poor
diet, gastrointestinal disorders, or chronic
diseases[104].

Industrial Uses
● Biofuel Production:
◄ The use of molasses as a feedstock for biofuel production
offers several advantages, including its abundance, low
cost, and potential to reduce greenhouse gas emissions
compared to fossil fuels (Basso et al., 2020) [105].
◄ Bioethanol production from molasses involves a
fermentation process where sugars in the molasses are
converted into ethanol and carbon dioxide by
microorganisms such as Saccharomyces cerevisiae
(brewer's yeast).
◄ The fermentation process typically occurs in large
fermentation tanks under controlled conditions of
temperature, pH, and nutrient availability.
◄ Yeast strains are selected for their ability to efficiently
convert sugars to ethanol and tolerate high
concentrations of ethanol, ensuring maximum ethanol
yields and productivity (da Silva et al., 2019) [106].
◄ Following fermentation, the ethanol-containing broth is
subjected to distillation to separate ethanol from water
and other fermentation by-products.
◄ Distillation involves heating the fermented broth to
vaporize ethanol, which is then condensed and collected
as a concentrated ethanol solution.
69
 ◄ Additional purification steps such as dehydration and
rectification may be employed to further purify ethanol to
[107]
meet fuel-grade specifications (Kumar et al., 2018) .

● Microbial Biotechnology:
1. Microbial Growth and Metabolism:
● Microorganisms such as bacteria, yeast, and
fungi can utilize the sugars present in molasses
as carbon and energy sources for their growth
and production of various metabolites.
● The composition of molasses, including its sugar
profile and nutrient content, influences the types
of microorganisms that can thrive and the
products they can produce through fermentation
(Singh et al., 2019) [108].
2. Bioethanol Production:
● Yeast species such as Saccharomyces
cerevisiae are commonly used for bioethanol
production from molasses through fermentation.
● During fermentation, yeast metabolizes the
sugars present in molasses, primarily sucrose,
glucose, and fructose, to produce ethanol and
carbon dioxide.
● Optimization of fermentation conditions, including
pH, temperature, agitation, and nutrient
supplementation, is essential for maximizing
ethanol yields and productivity (Basso et al.,
2020) [109]..

3. Bioproducts and Value-Added Chemicals:

● In addition to bioethanol, microbial fermentation
of molasses can yield a variety of value-added
chemicals and bioproducts.
70
 ● These include organic acids (e.g., acetic acid,
lactic acid), enzymes (e.g., amylases, proteases),
vitamins, amino acids, and polysaccharides (e.g.,
xanthan gum) with applications in food,
pharmaceutical, and industrial sectors.
● Metabolic engineering and strain optimization
strategies can be employed to enhance the
production of specific bioproducts of interest
(Kumar et al., 2021) [110].

4. Bioremediation and Waste Treatment:

● Molasses can serve as a carbon source for
microbial bioremediation of industrial effluents
and wastewaters contaminated with organic
pollutants.
● Microorganisms capable of degrading pollutants
such as hydrocarbons, phenols, and heavy
metals can be cultivated using molasses as a
growth substrate, leading to the detoxification and
remediation of contaminated environments (Saha
et al., 2018) [111].

71
 Case Study: Sugarcane and By-Products at
Armant Sugar Factory

Armant Sugar Factory, established 154 years ago in 1869 AD, stands as
a prominent player in the sugar production industry. Renowned for its
efficient processing of sugarcane, the factory not only yields high-quality
sugar but also maximizes the utilization of its by-products for diverse
applications, including energy generation and other industrial uses.

Objective:

This case study aims to analyze the sugarcane processing stages, the
production of sugar, and the utilization of by-products, including their
quantities and applications.

Methodology:

Data was collected from the Armant Sugar Factory's production records
and operational details to provide a comprehensive overview of its
processes.

Sugarcane Inputs and Sugar Production:

72
 ● The factory processes 400 tons per hour (t/hr) of sugarcane, with
two mills: 250 t/hr for Kozakii and 150 t/hr for Skoda.
● Juice concentrations: mixed juice (118.76 kg%/h) and clarified juice
(121.29 kg%/h).
● Syrup concentration: 25.53%.

By-Products and Their Utilization:

● Molasses: 4.49 kg%cane, stored and transported to specialized

factories for alcohol, yeast, dry yeast, and feed yeast production.
● Mud: 3.62 kg%cane, sold for farmers as organic fertilizer.
● Bagasse: 32.46 kg% cane, Used as boiler fuel for steam
generation or sent to the feed factory in Armant.

Boiler Utilization:

● Various boilers, including Ekol, Tacoma 1 and 2, Alpha, and Dia

boilers, utilize bagasse as fuel for steam generation and produce
ash.
● Ekol Boiler: Takes 40 t/h bagasse and yields 80 t/h steam,
producing 25% ash from the bagasse's value.
● Tacoma 1 and 2 Boilers: Each takes 30 t/h bagasse and
yields 60 t/h steam, producing 7.5 t ash.
● Alpha Boilers: Takes 22.5 t/h bagasse and yields 45 t/h
steam, producing 5.625 t ash.
● Dia Boilers: Takes 12.5 t/h bagasse and yields 25 t/h steam,
producing 3.125 t ash.
● All ash is sold to farmers as organic fertilizers.

Animal Feed Production:

The feed consists of 11% protein from various sources, including press
mud, molasses, corn, wheat bran, beet pulp, limestone, salt, cottonseed
cake, soybean meal, urea, sulfur, bicarbonate, etc.

Conclusion:

73
Armant Sugar Factory demonstrates an efficient process of sugarcane
processing and utilizes its by-products effectively for energy generation
and other applications, contributing to sustainability and resource
optimization.

74
 Conclusion

This research underscores the significant potential of recycling

sugarcane by-products in enhancing both economic and environmental
sustainability within the sugar industry. By examining the processes and
applications of bagasse, mud, and molasses, the study highlights how
these by-products can be effectively utilized rather than discarded as
waste.

The analysis of data from the Armant Sugar Factory illustrates the
practical benefits of these recycling practices. Bagasse, when used as
boiler fuel, contributes to steam generation while reducing reliance on
non-renewable energy sources. Mud, repurposed as organic fertilizer,
supports agricultural practices and promotes soil health. Molasses, with
its diverse applications in the production of alcohol, yeast, and animal
feed, adds considerable value to the sugar production chain.

Overall, this research demonstrates that adopting comprehensive

recycling strategies for sugarcane by-products can lead to more
sustainable industrial practices, reduced environmental impact, and
improved economic outcomes. The findings advocate for the broader
implementation of these methods across the sugar industry in Egypt and
potentially in other sugar-producing regions worldwide. This study serves
as a foundation for future research and development in the area of
sustainable agriculture and industrial ecology.

75
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