Documente Academic
Documente Profesional
Documente Cultură
Submitted by
Roll No.
CERTIFICATE
Coordinator Head of
(T & P) Department Of Mechanical Engineering
Examined by:-
Date:-
ACKNOWLEDGEMENT
Thanking You.
DECLARATION
Respected sir,
You’re sincerely,
Gade Yogesh Baban
INDEX
2. Company Profile 9
3. Layout Of Company 11
Operations In Industry
4.1 Sugar Making
4. 13
4.2 Operations Of Engineering Division
4.3 Biogas And Distillery Division
Other Products
5.1 Liquor
5. 23
5.2 Bi-product
5.3 Fertilizer
6. Conclusion 26
the facility to import raw sugar without export obligation as well as import of white
sugar 10 lakh tonnes by Government agencies, both at zero% customs duty. The
Centre is also planning to bring back Gar under the Sugarcane (control) order, 1996
to ensure adequate cane supplies to sugar mills.
2) COMPANY PROFILE
This is one business which impact all the populations of the area in there day
to day life and has transformed the local area socio- economically.
The first crushing season began in 1986 with the capacity of 1000 TCD. The factory
has increased its crushing capacity constantly. Following are capacity wise details of
various products manufactured
LOCATION:
1) We are commited to produce and supply the products to meet our customer
needs.
Shriram sugar
factory
Electric power
Sugar plant Distillery plant Biogas plant
plant
The sugar plant is meant for the sugar production which involves the various
departments as shown below.
Sugar
manufacturing
Distillery and biogas plant has following departments as shown in the diagram
Distillery and
biogas plant
Manufacturing Quality
Process plant Chemical plant
plant department
Packing
department
Electric power plant is off course made for the production and distribution of
the electricity. The various sections under this are as shown below.
Electric power
plant
4) OPERATIONS IN INDUSTRY
The factory produces export quality sugar grades S-30 with an ICUMSA value
less than 100. The factory had a crushing over 4,22,624 M.T. till 27/06/2011. The
factory had a crushing duration of over 180 days in this season and has consistently
recorded an average sugar recovery of around 11.22%. The Company has the most
sophisticated equipments as per global standards to generate the best quality sugar.
The juice obtained from crushing is known as 'mixed' or 'raw juice'. Such juice
is pumped to the process house where it is heated up to 65/76 degrees centigrade and
treated with Lime and Sulphur Dioxide Gas. After this treatment, the juice is further
heated to 100 degrees centigrade in juice heaters. The heated juice is then sent to
Clarifiers where the precipitate of Tricalcium Phosphate, Calcium Sulphate settles
down and the clarified juice floats on the top.
The clarified juice is treated in Evaporators and the syrup is mixed with
Sulphur Dioxide gas in Sulphitation tanks. The output is known as 'Sulphured Syrup'
from which sugar crystals are obtained. The sugar crystals of desired grade i.e. 'Grade
A' are obtained in three stages. In the first stage 'nucile' is passed through the syrup to
obtain 'C' grain. The 'C' grain is washed to obtain 'C' Grain Massecuite' which is
boiled in Vacuum Pan and passed through Crystallizers and Centrifuges to obtain 'C'
Grain Sugar and final Molasses. The final Molasses is stored separately and the 'C'
Grain Sugar is further processed to obtain 'B Grain Sugar' and light Molasses. 'B
Grain Sugar' is further processed to obtain 'A Grain Sugar', to be bagged in 100Kg.
packs.
1. Diffusion
After leaving the Slicers the cassettes are pre-heated and fed into the R.T.
Diffuser. (Imagine a large teapot with tea leaves in it. This is the same principle).The
diffuser works on a counter-flow basis and is similar to a scroll inside. Inside the
diffuser it is important that the conditions are right. The main elements are
temperature, pH and retention time. The correct balance of these three operating
parameters is imperative to allow the maximum extraction of the sucrose molecules
and still maintain a well-structured cossette for pressing into pulp for Animal Feed
Shreds.
The whole process of sugar making can be represented by the flow charts as
described below
2. Carbonatation
This station is used for the purification and clarification of the juice. When
the raw juice leaves the Diffuser it is very dark and contains many impurities, which
must be removed before it can be processed further. In the 1st Carbonatation tanks,
Milk of Lime and Carbon Dioxide Gas are added to the juice.
This acid/alkali mixture assists in removing the impurities, by forming a
precipitate, which allows the solid matter to separate out from the liquid. The juice is
fed into a large vessel [Clarifier] to allow this process to take place. The clear juice is
pumped on to the 2nd Carbonatation Tank where it has more Carbon Dioxide Gas
injected and finally filtered through some G.P.
3. Filtration
The slurry from the Clarifier is pumped into the Vacuum Filters. These are
cloth covered rotating drums that use a vacuum to draw the slurry onto the cloth, yet
allowing the juice to pass through. As the drum passes through the lower bowl the
slurry is sucked onto the cloth. As it revolves out of the slurry, there are water sprays,
which rinse the sucrose out of the slurry. This sugar solution is fed back into the
Carbonatation stage of the process.
4. Evaporation
The clear juice is pumped into the Evaporators. At this stage the juice has
quite a low density. It is what we call Thin Juice and is 84% water. To prepare the
juice for crystallization the water content has to be reduced to about 32%.
To remove all this water, it has to be evaporated off. Since energy is very
expensive, we use the steam only once in the 1st Effect Evaporators. As the juice
boils, vapour is produced and this is used to heat up the 2nd Effect Evaporators.
This process is repeated 5 times and so for the price of one unit of energy. We
can achieve 5 times the heating capacity.
5. Crystallization
The juice is batch-fed into four Vacuum Pans. These are kept under a vacuum
so that the juice can be boiled at a lower temperature, generally 80C . This enables us
to make the pure white crystals of the highest quality. The juice is firstly boiled until
the water content is about 20%. A calculated amount of finely ground sugar crystals,
about the size of Icing Sugar, are added to this concentrated syrup. The crystals are
then allowed to grow, at a controlled rate, until they are the correct size for
Granulated Sugar.
When the crystals have reached this optimum size, the pan contents are fed
into a receiver ready for the final stage of the process. The syrup mix is now called
massecuite. The residual syrup goes through this process three times, to extract as
much sugar crystal as possible. The remaining syrup is Molasses.
6. Centrifuging
Massecuite from the White Pans is fed into one of seven Centrifugals. These
machines use centrifugal force to separate the crystals from the syrup.
A batch of massecuite is spun until most of the syrup has been removed, then a light
spray of clean water is used to polish up the crystals.
The centrifuges will rotate at 1500r.p.m. attaining speeds of 170 m.p.h. Each
basket produces approximately 250 kilos of sugar from every batch.
A Mascuit boiling
Crystallisation
Dry seed
Centrifugal M-30 S-30
Crystallisation
Centrifugal
This is the very important and essential division of Shriram sugar factory. All
subparts of engineering like design, production and quality are united in the same
division.
The main purpose of engineering department is that to correct any engineering
problems arising in sugar factory. The problems may involve conditions like problems
in valves, problems in pumps, electronic and electric faults, and stoppage of any
working unit, etc.
To correct the problems or to produce any component engineering division
makes the use of following machines.
1. Lathe machine
The main function of a lathe is to remove metal from a piece of work to give it
the required shape and size. This is accomplished by holding the work securely and
rigidly on the machines and then turning it against cutting tool which will remove
metal from the work in the form of chips. To cut the material properly the tool should
be harder than the material of the work piece. Work piece should be rigidly held on
the machine and should be fed or progressed in a definite way relative to the work.
There are various types of lathe machines. In the sugar factory all the lathe
machines used are of centre lathe type. The lathe machine consist the different parts
like bed, headstock, tailstock, carriage, feed mechanism etc. The back gear
arrangement is provided to provide a variable range of speeds. The different
accessories and attachments like carriers catch plates, chucks, face plates, angle
plates, mandrels etc. The lathe can perform the different operations like turning,
chamfering, polishing, grooving, facing, knurling, filing, forming, spinning etc.
In the sugar factory, the parts like valves, pumps etc are processed on the lathe
machine as per the operations required.
In the sugar factory machine used is a horizontal shaper machine and it’s used
to machine the different surfaces.
The radial drilling machine is one of the important machine tool in the
workshop. Although it was primarily designed to originate the hole, it can perform
number of similar operations. In a drilling machine holes can be drilled quickly and at
low cost. The hole is generated by the rotating cutting edge of a cutting tool known as
the drill which exerts large force on the work clamped on the table. As the machine
tool exerts vertical pressure to originate a hole it is loosely called as “drill press”.
Drilling machines are of number of types as portable drilling machine,
sensitive drilling machine, upright drilling machine, radial drilling machine, gang
drilling machine etc. The basic parts of the lathe are as base, column, and radial arm,
and drill head, spindle speed and feed mechanism. Different types of tool holding and
work holding devices are also used in the working of the drilling machine.
The different operations performed on the lathe are as drilling, reaming, boring,
counter boring, counter sinking, spot facing, tapping, lapping, grinding, trepanning
etc.
1. Boiler
There are totally four boilers in the factory out of which the specification of
one boiler is as mentioned as below.
Specifications:
Boilers
Nos. 4 1,2,3
Evaporation
21 14
Capacity TPH
Multistage impulse
Type Multistage impulse
550mm
Inlet Pressure
21 kg/cm2 32 kg/cm2
.
3. Compressor
4. Pumps
5. Generators
Biogas division
The biogas is the side product of the company. The waste liquid coming out of
distillery is processed in two large tanks and biogas is produced. The daily production
of biogas is nearly about 30,000 cubic meters per day.
The design used for the biogas production is very simple and conventional one.
The biogas department is mainly meant for controlling the activities related with the
biogas production. In two large tanks different chemicals are also used to activate the
reaction process of biogas formation.
This produced biogas is circulated and used in boilers as fuel which saves the
bagas.
Distillery division
This division is established in the year of 1990 in the sugar factory. The
working is quite simple. The molasses coming out of factory is sent in large tanks
where fermentation process is carried out. The type of fermentation process used is
continuous fermentation process.
The total distillery capacity is 15000 liters per day. This division consist two
plants. The capacity of each one is different as given below.
5) OTHER PRODUCTS
5.1) Liquor
Country Liquor
In CL we have Tie-up with M/s. Rama Marketing, Kolhapur and M/s. Silver
Oak Traders, Pune for Marketing. We are producing Royal Santra, Royal Cafe,
Mumbai Santra, Maharanjan Santra, Maharanjan Cafe, Ghungaru Santra, Deccan
Queen Santra, Deccan Queen Cafe, Santra, Robby Santra, Golden Jacks, Doctor
Blendy etc. and these products are very much demanded all over Maharashtra.
5.2) Bi-Products
The Bi- Product of Sugar Mill is MOLASSES. Molasses of the sugar unit is
sold to the Distillery Unit and is used for the manufacturing of Industrial Alcohol.
(Molasses fluid)
The Company uses “PRESSMUD”, waste products from the Sugar Mill for the
production of these bio-products. Press mud has got nutrients which increase the
fertility of the soil if used in preparing fertilizers. “BAGASSE”, another waste
material is used as a fuel in boilers for generation of steam required during the
manufacturing process of Sugar, generation of electricity and operation of plants.
Surplus Bagas can be used as a raw material for Paper mills and Paper Board Mills.
The Company has developed a system in which Press mud (waste of Sugar factory) is
used for Bio-composting. The composting process after completion is ready for use as
manure. This is then packed in plastic bags for distribution. It is highly rich with
Nitrogen, Phosphorous and Potash.
(Biocompost)
This solution has been efficiently tested by the expertise in all the leading
sugar factories worldwide.
5.3) Fertilizers-
Chemical Fertilizers
The sugar factory also provides fertilizers to the cane producing farmers in the
industrial area. These fertilizers are tested fine so as to improve the fertility of the soil
and to give a good crop. It is usually prepared using micro food particles, bacteria and
other chemicals form the sugar factory. For time to time supply of manure, the sugar
factory has started centers for manure distribution in the work areas in
Girvi,Pimprad,Aasu,Pawarwadi,Jadhavwadi,Dudhebawi.
They provide better soil structure due to their movement through the soil. This
causes better mixing of soil layers which leads to better plant root development,
better drainage and reduced erosion, and better aeration and water holding
capacity. There are nearly 200 different species of earthworm .There are many
species of native earthworms, but these seldom occur in developed soils.
6) CONCLUSION
From this Industrial training, I got familiar with the primary objective to go
through practical experience, a sound appreciation and understanding of the
theoretical principles learnt as an undergraduate at the University. This Industrial
training was oriented towards developing the skills, knowledge and attitudes needed
to make an effective start as a member of the engineering profession. Also I have been
introduced with a