SUGAR

MANUFACTURING
PROCESS
Sugar Introduction, Raw and Refined
Sugar, Factors Affecting Sugar
Storage

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 INTRODUCTION
Sugar
• General term indicating sweet carbohydrates
• Mono-, di- and poly-saccharides
• Obtained from plants, largely sugarcane & sugar
beet plant
• Pakistan 12th largest producer of sugar
• Per capita consumption of sugar is 25kg
• More than 81 sugar mills in Pakistan

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MANUFACTURING PROCESS

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 Harvesting Of Sugarcane
• Fully mature
• Two types
– Manual
– Mechanical

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 Transport and Handling
• Animal driven carts
• Trolleys
• Trucks

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 Material Handling and
Storage
• Stored in cane yards
• Carried from cane yard to feeding area by
– hook/chain
– Cranes
– Reelings
– Conveyer belt
– Carry
– Huge suction truck

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 Washing

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 Cutting of Canes
• To aid the cane crushing
• Cane knives to cut cane into small pieces

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 Shredding
• To remove leaves and nodes
• Hammer mill shredder

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 Extraction of juice

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 CRUSHING
• Cane crushed to
break hard structure
• Cells containing juice
are ruptured
• No juice extracted
• Increase efficiency of
juice extraction
• Subjected to crusher
with corrugated
blades
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 FLOW DIAGRAM

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 MILLING TANDEMS
• 3 roller mills
connected in series
– Top roller
– Feed roller
– Discharge roller
• 5-7 in number
• Extract the juice from
crushed cane

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 PRODUCTS OF MILLS

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 FLOW DIAGRAM

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 USE OF BAGASSE
• Stored in bagasse storage
• Used as fuel to generate steam
• Steam used for
– Generating electricity
– Evaporation of juice before crystallization

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 FLOW DIAGRAM

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CLARIFICATION/DEFECATION
• To remove non-sugars and impurities
– Liming
– Sulphitation
– Phosphatation
– Carbonation

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 FLOW DIAGRAM

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 FILTRATION
• Mud from
clarifier still
contain some
residual juice
• Filtered to
extract residual
juice in Rotary
Vacuum Filters

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 FLOW DIAGRAM

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 EVAPORATION
• Juice evaporated to obtain super saturated
solution
• Increase concentration of juice from 15ᴼ
brix to 65ᴼ brix
• Juice preheated to
around 107-110ᴼC
• Two types of evaporators
– Single effect evaporators
– Multiple effect evaporators
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MULTI-EFFECT EVAPORATOR

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 CONT…
• Steam used to evaporate juice
• 1 liter steam to evaporate 4 liter
juice
• Steam temperature 113-130ᴼC
at 1st pan and
55ᴼC at last pan
• Each subsequent vessel with
decreasing pressure
• Last pan being under almost a
total vacuum
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 FLOW DIAGRAM

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 CRYSTALLIZATION
• Carried out in single effect high-vacuum boiling
pans
• Brix are increased from 65ᴼ to 75ᴼ by boiling at
60ᴼC
• Three stages of crystallization
– Nucleation
– Initiation
– elongation

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 CONT…
• Massecuite
– mixture of crystals and mother
liquor (molasses) resulting from the
crystallization
• Transferred to crystallizer
at low temprature

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 FLOW DIAGRAM

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 CENTRIFUGATION
• Separate sugar from molasses
• Centrifuge operates at 100-1800 rpm
• Molasses pass through perforations
• Sugar crystals are
washed with 85ᴼC water
• Raw sugar and molasses

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 FLOW DIAGRAM

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 DRYING AND PACKAGING
• Sugar tumbled through
large cylindrical dryers
• Sorting
• Packaging

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 REFINING

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 RECEIVING AND STORAGE

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 AFFINATION
• Mixture of raw sugar with high purity syrup
(85%) called magma
• Melts outermost layer of the raw sugar crystal at
50ᴼC
• Centrifugation to remove resulting syrup from
melting of the outer layer

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 MELTING
• Affinated sugar dissolved
with hot condensate to
conc. of 72ᴼ brix
• Melted at 85ᴼC in Batch or
continuous melter

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 PURIFICATION
• Remelt may contain some impurities and
colorants
• Liming
1. Partial 2. Complete
• Carbonization
• Colorants remover by decolorization

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 DECOLORIZATION
• Two methods
1. Granular activated carbon (GAC)
2. Ion exchange resine

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 EVAPORATION &
CRYSTALLIZATION
• Sugar syrup evaporated up to super saturation
• Crystallization
• Centrifugation to obtain refined sugar crystals

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 DRYING AND STORAGE
• Bucket elevator on conveyer
• Hot air for drying
• Sieving
– Fine, medium and bold grains
• Storage in godowns
– Cool, dry, moisture and odor free

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 PACKAGING
• Containers opaque, airtight, moisture/odor proof
• Glass canning jars or cans for liquid sugars

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 RAW & REFINED SUGAR
• Raw sugar
• Obtained directly from sugarcane juice without
refining
• Most natural sugar
• Brown in color due to molasses
• Refined sugar
• Have white luster and transparent
• Bleached to remove color and other impurities

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 FACTORS AFFECTING
SUGAR STORAGE
• Temperature
• Moisture
• Quality of sugar
• Light
• Grain size and distribution
• Compression

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