Softcopy Project

MBA II
Shivaji
University, Kolhapur
Introduction of the Study and Methodology

1.1 Introduction
India is mainly agricultural country. India is one of the largest producers of sugar.
Agriculture is the main occupation of people in rural areas. Sugar industry is the
second agro based industry in India next to the textile industry. India has now
emerged as one of the largest producer of sugar cane and sugar in the world next to
Brazil.
There are 453 sugar mills in India. Co-operative sector has 252 mills and private
sector has 134 mills. Public sector boasts of around 67 mills. The sugar industry is
largely base on sugarcane production without a nominal percentage of sugar beet.
However, in the world context, sugar beet contributes about 16 percent to the sugar
production. Now, for sometime past the industry has been under crisis mostly due to
divergent views of the government and the sugar mill owners on the actual volume of
surplus lying un-cold with the mills.
Production of refined white sugar obtained from sugarcane is the largest segment
of sweetening industry in India. It is mainly grow for sugar and sugary production. It
is an important source of income and employment for the farming community of the
country. It also forms essential item for industries like sugar, chipboard, paper,
barrages, confectionery, and uses in chemicals, plastics, paints, synthetics,
insecticides, and detergents. Sugarcane production in the country has increased over
time.
India with almost similar soil and climatic condition is obtaining about 53 per
cent higher cane yield than any country. As it is one of the cash crops of the country,
therefore, efforts should make to improve its productivity.
Because of these efforts, substantial improvement can take place in its yield.
Improved seed production, quality control, and distribution depend largely upon the
availability of skilled and competent local manpower, which presented in insufficient
in most developing countries. The other traditional sweeteners are comprised of gur,
shaker and desi.
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Shivaji University, Kolhapur
1.2 Objectives of the study

1) To study the working of Rajarambapu Sahakari Sakhar karkhana related to
production process of sugar.
2)
To study the quality reports related to sugar.
3) To study the sugar recovery and sugar production from last six year.
4)
To study the production of sugar for different year.
Importance of the study:

1)
It enables to understand the meaning and significance of production process of

sugar.
2) To study helps in the knowing production process of sugar.

3) To know how they use new advanced technology.
4)
To get valuable and visible knowledge through fieldwork.
1.3 Scope and Limitation of Study

1) Topical Scope :
Topical scope of the study is limited to A study of production process of sugar with
special references to Rajarambapu Patil Sahakari Sakhar Karkhana Ltd. Sakharale
(Islampur).
2) Conceptual scope :
The conceptual scope related to concept of production process of sugar industries.
This will help to understand the production process of organization.
Limitation of the study:

1) Time required to study the subject is limited.
2) It is not possible to get all the financial information of the enterprise.
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3)
The information and data, which is made available by personnel in the

organization is used for study.
1.4 Research Methodology

Research methodology is important and base of every research project the
concept research methodology refers to the systematic study of investigation.
Following are research methodology.
Data Collection
1)
Primary Data:The primary data was obtained from the concerned department staff &
department head by way of general conversion & discussion oral.

2) Secondary Data:Secondary data means data that are already available i.e., they refer to data
which have already been collected and analyzed by someone else.
It includes the following
Reference Books
Annual Reports of the company
Financial statement of the company
Other records of the company
Theoretical Background
2.1Concept of Production Management
Products are the goods and services produced and processes are the facilities
skills technologies used to produce them. Production processes are essential to
produce product and available processes limit what products can be produced.
Production function or operation function is the primary function of an industrial
enterprise it is known as conversion process or transformation process which
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transforms some of the inputs (raw materials and components) into outputs which are
useful for consumer.
A process is sequence of activities that is intended to achieve some result
typically to create added value for the customers. A process converts inputs into
output in a production system. It involves the use of organizations resources to
provide something of value. No product can be provided without a process and or no
process can exist without a product or services.
Processes underlie all work activities and are found in all organizations and in
all functions of an organization. Deciding what processes to use is an essential issue in
the design of a production system. A process decision involves many different choices
in selecting human resources, equipment and machinery, and materials. Process
decisions are strategic and can affect an organizations ability to complete in the long
run.
Definition:
1.
It is also known as conversion process or transformation which transforms some

of the inputs such as raw material and component into output which are useful for
the consumer
2. A process is a sequence of activities that is intended to achieve some result,
typically to create or added value for the customers.
2.2 Types of Process:

Basically, processes can be categorized as follows:1. Conversion Process :
In the conversion process the raw material are converting in to the finished
products. For example converting iron ore into and then to steel. The conversion
process could be metallurgical or chemical or manufacturing or construction process.
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2. Manufacturing Process :
Manufacturing process converts inputs like materials labour and capital in some
tangible outputs. Manufacturing processes are the primary processes and can be
grouped under three basic categories namely forming, machining and assembly. The
main objective of each process is to change the shape or physical characteristics of the
raw materials. Lets us discuss in detail each of them:
i.
Forming Processes :
These processes change the shape of the raw material in to the shape of the
work piece without removing or adding material. These includes casting, forging,
stamping, embossing, spinning
ii.
Machining Process :
Machining processes involve basically metal removal, by turning, drilling,
grinding, shaping, boring, etc it also includes chip less machining processes such as
electro discharge machining (EDM) electrochemical machining (ECM) chemical
milling, laser drilling etc,
iii.
Assembly Process :
Assembly process involves joining of parts or components to produce
assemblies having specific functions. Examples of assembly processes are welding,

brazing, soldering, riveting, fastening with bolts and nuts and joining using adhesives.
2.3 Objectives of Production Management :

Production is an organized activity and each organized activity has its own
objectives. This helps to evaluate its performance against the set has its own
objectives. This helps to evaluate its performance against the set objectives of the
production management is stated as:-
1. Right quality :
The quality of the product is established based upon the customers needs are
translated into product specification by the design or engineering department. The
manufacturing department then translates this specification into measurable
objectives.
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2. Right quantity :
The manufacturing organization should produce the product at the right number.
If the products are produced excess of demand the capital will be blocked up in the
form of inventory and if it is produced in quantity short of demand, these will be
shortages products. Thus the decision is to be taken regarding how much to produce.
3. Manufacturing cost :
Manufacturing costs are established before the product is actually
manufactured. The manufacturing department has to manufacture the products at the
pre-established cost in any case: any variation between the actual cost and the
standard should be kept at minimum.
4. Manufacturing schedule :
Timeliness of delivery is one of the important parameter to judge the
effectiveness of production department; there are many reasons like non-availability
of materials at right time, absenteeism, machine break down etc. Which affect the
timely completion of the products? So the manufacturing department should organize
its activities in such a way that the products will be manufactured.
To achieve the above objectives, the manufacturing production department has
to make the optimum utilization of various inputs like men, material, machinery. So to
have as better utilization of resources, the production department has to achieve the
other objective, which is lower in the hierarchy. These objectives are called
intermediate objectives.
2.4 Intermediate objectives:

Machinery and equipments
The objective concerned to these areas is that the machine and equipment
should be such that they should be able to produce the products as per the
specification and accuracy required the total cost of procurement and running cost
should be minimum. Once the machines are procured and put to productive use, and
then the next objective is to utilize these resources to the maximum extend.
Materials :
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The material should be made available when required as per the specification
(shape, size, quality, etc) and at the most economical price. The production
department should aim at maximum utilization of the material with minimum wastage
and scrap.
Manpower :
Manpower is an important resources or input to production and the success of
production depends to a greater degree upon the type of manpower and organizations
have. Thus there should be a perfect matching between the workers and jobs and the
manufacturing department climate should be channelized into constructive outputs.
Supporting services :
This helps indirectly to achieve the other objectives and adequate provision of
the services helps to utilize other inputs effectively. The objectives should be set for
each of the services like water steam power, material handling etc.
2.5 Types of Production System:

The production system of an organization depends upon the types of products
that is offer to customer basically the production system can be classified as follows:
1.
Make to stock production :

In this type of production system manufacture stocks to the finished goods for
easy supply. This system insures immediate delivery of quality goods at reasonable
price.
Example:
Automobile, bearing, ready to wear garments nuts and bolts, television etc.
Normally customers do not like delay delivery so management has to maintain in
stocks. Management must have good knowledge or information regarding the demand
of product. Make to stock items are generally mass consume and passes through
multiple channel before the reaching end user. These distribution channels act as the
most important source of information regarding demand for the product and with the
help of information from distributing channels production planning is done. There is
no direct contact between the producer and the end user. So the distributing system
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acts as eyes and ear of the organization to support demand forecasting and demand
analysis.
2.
Make to order :In this type of production system production starts only after confirmation of
the orders and the products from the customer of product hence the delivery period is
long. In this type production system the final product is usually made from parts and
components. The process of order starts only after when the customer specified his
requirement of the products.
Example: - Tailor clothings special purpose machines very expensive products are
usually made by order.
3. Assemble to order production system :In this type of production system the manufactures stocks standard components
parts and assemble the selected parts and components only after the customer places
the order as the components are manufactured and stock the only time require is to
assemble before delivery to the customer.
2.6 Classification of Production System:

According to the volume of production quality and production standardization
production activities are classification are as follows:1.
Job shop production :It is characterized by manufacturing of one or few quantity of products
designed and produced as per the specification of customer within the prefixed time
and cost the distinguishing features of job shop is low volume and high variety of
products.
Example: - Space vehicle, aircraft department special purpose machines, large turbo
generators, material handling machines etc.
A job shop is typically made of general purpose machines arranged into
different departments. Each job demands and unique technological requirements,
demands processing on in a certain sequence. Job order production applies to situation
where products are to be manufactured again specific requirements of the customer.
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Characteristics:1.
2.
3.
High verity of product and low volume.

Use of general purpose machines and facilities.
Large inventor of materials, tools and parts.
2. Batch Production :It is defined as the form of manufacturing in which the job process through the
functional department in lots or batches and each lot may have different rating. Batch
production is producing limited number of products at regular interval and stocked
waiting sales. Batch production aims at satisfying the continuous customer demand
for an item. However, the plant is capable of production as per the demand rate batch
production plants includes foundries, plastic modeling units, press shops, chemical
and pharmaceutical units.
Characteristics:1. Shorter productions run.
2. Amount of supervision require is less.
3. Plants and machineries are flexible.
3.
Continuous Process:This is used when a very highly standardized product is desired in high volumes.
These systems have almost no variety in output and hence there is no need for
equipment flexibility. A continuous process is the extreme end of high volume,
standardized production with rigid line flows. The process often is capital intensive
and operate round the clock to maximize equipment utilization and to avoid expensive
shutdown ad clock to maximize equipment utilization and to avoid expensive shut
downs and shut ups.
Example:
Product made in continuous process systems includes petroleum products, steel,
sugar, flour, paper, cement, fertilizers etc.
4.
Process Industry :
Process manufacturing is defined as the production that adds value by mixing,
separating, forming and performing chemical reactions. It may be carried out in either
batch or continuous process industries manufacture highly standardized non discrete
products in extremely large volume using a continuous process. Plant location, plant
capacity, long range plan for materials, manpower, energy and waste disposal are
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important aspects in the process industries. In process production the process

generally follows a specific and fixed sequence of operations.
Example:
1.
2.
3.
4.
Plants and equipments with zero flexibility.

Material handling is fully automated.
Large investment.
Unit cost is low due to high volume.
5.
Mass production :Manufactures of discrete parts of assemblies using a continuous process are
called Mass production. The machineries are arrange in a lines, material handling is
departments will be replaced by assembly lines, material handling is atomized which
reduces the cost. Automobile assembly like is a typical example of mass production,
products and process are standardize typically.
Characteristics:1. Large volume of products.
2. Lower in process inventory.
3. Extent of supervision required is less.
Production
Finance
Production
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Marketing
Personnel
Supplier
Competitors
Government
Subsystems of organizational system

a) Marketing:To create the demand for the companys products or services and satisfy the
needs of the customers through companys through various activities like market
research, marketing planning, sales administrating and advertising.
b) Finance:To plane allocate the finance to various activities of the organization and to meet
the long term and short term financial requirement of the enterprise.
c) Personnel:The objective of the personnel function is to match the jobs and skills of the
personnel and create harmonious climate where in each and every individual in the
organization contributes positively towards the achievement of organizational goal.
Introduction of the Company.

a) Name of the Unit
Name
Rajarambapu Patil Sahakari Sakhar Karkhana.
Address
A/P- Sakhrale, Tal- Walwa, Dist- Sangli
Pin Code
415414
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Registration No. :
S.A.N/P.R.G (As Date 17-08-1963
Industrial License No. :
125/N-211/69L.C, Date 10-9-1969
Organization Type
Co-operative
Founder
Loknet Rajarambapu Patil
Guidance
Hon. Minister Jayantrao Patil
Chairman
P.R. Patil
Product
Sugar and Foreign Liquor
Major raw material:
Sugar Cane
Time Schedule of Working

Shifts
1) 12pm to 8pm
2) 8pm to 4am
3) 4am to 12pm
4) General Shift- 8am to 5pm
Marketing Territory:
All India and Foreign
Made of Transport :
By Truck and Railway
b) LOCATION
About 6 kms. From Peth Naka at National Highway No. 4
Nearest railway station: Karad (SC Railway), Distance 40 kms.
c) History of the company

In the year 1968, under the leadership of Late Rajarambapu Patil, the Minister
in Maharashtra (cabinet), established this society under the name of Walwa Taluka
Sahakari Sakhar Karkhana Ltd and stated a sugar factory 1250 TCD in 1970. After
this untimely demise, the society was renamed as Rajarambapu Patil Sahakari Sakhar
Karkhana, which is now operating under the dynamic leadership of Shri. Jayant Patil
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minister for finance of planning (M.S.) for the last 20 years, out of which for 10 years
he was an officiating chairman of this organization. The present chairman and the
members of board do get valued guidance from him in management decision and
policy making. Factory had constructed some co-operative lift irrigation and policy,
scheme and increased the sugarcane area of the Walwa Taluka. Day by day there was
gradually increase in sugarcane area and is expanded 1250 TCD sugar factory to 2000
TCD in the year 1977, subsequently 2000 TCD to 4000 TCD in the year 1990.
WATEGAON UNIT NO. 2
It has purchased 1000 MT capacity plant and machinery with license from M/s
Manama Sugar Mills Ltd., Pandlam, and Kerala. This factory is established under the
relocation/expansion/modernization scheme.
LOCATION
-Wategaon-surul, Taluka-walwa, District-sangli.
EFFICIENCY AWARDS
Company has received following awards like best cane development awards south
zone. Best financial management awards south zone.
YEARS
1999.2000
NAME OF AWARD
Overall Best Sugar Factory in Maharashtra
Best-Technical Efficiency in South-zone
Best-cane Development in South-zone
Best-Financial Management in South-zone
2000.1

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2000.2

Overall Best Sugar Factory in Maharashtra
Overall Best Distillery in Maharashtra
2002.3

Best-Financial Management in South-zone
2003.4
2004.5
2005-06
Best Technical Efficiency in South Zone
2006-07
2007-08
2008-09
2009-10
Sangli District Industrial Safety Committee
2010-11
Sangli District Industrial Safety Committee
2011-12
SUGAR EXPORT
2002-03 season it has exported 2,39,500Qtls. To Malaysia, Singapore, and Jakarta&
Madagascar and in @003-04 seasons it has exported L 50,000 Qtls. Sugar to
Indonesia, Malaysia, and Sri-lanka, Singapore etc.
ISO 9001-2000 ACTIVITIES

The organization has adopted the international standard organizations I.S.O 900 J2000 Certificate since the year 2000 and implemented it across sugar and its hiproduct business.
COMPUTERIZATION
It has made computerization since 1984; it has made necessary medications in
technology. It has networked for factory & office in multi-user environment.
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It has online accounting. Cane registration, and cane billing program working under
Novell-Network & FoxPro. Also web based solutions for total sugar factory is under
construction. The computer systems are as under:
DETAILAS
Unit No. 1
Unit No.2
Machines
60
Printers
36
U.P.S.
18
It has decided to make online computerization at all offices, by product units,

Wategaon Unit, all sub gut offices & Lift irrigations schemes. It has given work for
making detail B.P.R> to M/s I.C.I.C.I Info Tech, Thane.
CANE DEVELOPMENT
A) Irrigation Facilities:
No of lift irrigation schemes
39 on Warana & Krishna

rivers
No of Members
15842 Nos.
Total Investment
4126 Lacks.
Power Required
26000 HP
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Area in command
50000 Acres
Area around sugarcane
12000 Acres.
The main sources of irrigation are lift irrigation from Krishna &Warana rivers. There
are 39 lift irrigation schemes of Warana & Krishna river which irrigates 50,0000 acres
of land in the area of operation. 15.842 fanners are the shareholders of this lift
irrigation schemes. Total investment for these schemes is Rs. 41.26 crores, this
investment are made without any aid, grant or subsidy from state government. Total
horse power required for these schemes is approx. 26,000 HP.
B) Cane Production:
In the area of operation of Rajarambapu Patil S. S. K. Ltd., sugarcane is grown in
20,000 to 25,000 hectors with an average yield of about 80 tons to 90 tons per hector.
Co- 740, Coc-671, Co-8014, Co-86032 is early high sugared varieties grown in this
area.
Variety wise % is as under

TYPES
PERCENTAGE
Co-86032
71.27
CoC-671
19.30
Co-8014
6.20
ACTIVITIES:
1. Modern methods of agriculture
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2.
3.
4.
5.
6.
7.
Modern method of sugar cultivation

Undertaking of the project- Educational, Medical, Agricultural and public
Charitable purpose
Creating/Establishing/Running Hospitals, Medical charity and welfare.
Educational aid-Montessori/School/Colleges/Research.
Granting aid-Research in high yielding varieties of seeds, manures, fertilizers,
insecticides etc.
8. Fair shops- Agricultural equipments, chasing, modern methods for agriculture
9. Activities for general uplift of the rural and agricultural community.
10. To run the cottage industries- training, guidance
11. Preservation of cultural heritage, traditional art & craft
12. Dairy and poultry farming, animal husbandry
13. To undertake and carry irrigation projects
14. Survey of minerals and natural resources in the region
15. Survey of manpower in the region
16. To run the institution of grant aid for the care of orphans, handicapped, retarded
children, old and disabled people and similar weak, poor & needy persons
17. To encourage young people for providing social services
18. To give scholarships and prizes to the students achieving excellences
SOCIAL ACTIVITIES
It is a co-operative sugar factory, therefore, it always give some aid/facility to
its members as well as all people of Walwa Taluka. The following are some of the
features
Primary schools.
Wresting centres.
Libraries.
Farmers.
Students (concession fees).
Sr.
Names
Designation
Village/Town
Chariman
Kurlap
no.
1
Shri. Pandurang Ramrao Patil
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2
Shri. Vijay Balwantrao Patil

Vice-
Sakharale
Chairman
3
Shri. Jayantrao Rajaram Patil
Director
Kasegaon
(Home Minister Maharashtra

state)
4
Shri. Jagdish Shamrao Patil
Director
Kameri
Shri. AnandraoTukaram Patil
Director
Gotkindi
Shri Shankarrao Sampatrao
Director
Islampur
Patil
9
Shri. Kartik Mansingrao Patil
Director
Borgaon
10
Shri. Pradip Rajaram Thorat
Director
Narsinhpur
11
Shri. Shrikant Nabhirakabade
Director
Karandwadi
12
Shri. Viraj Shankarrao Shinde
Director
Ashta
13
Shri. Lalaso Bapuso Patil
Director
Dhavali
14
Shri. Dilip Ramchandra Patil
Director
Yelur
15
Shri.ShivajiraoYeshwant
Director
Karandwadi
Rethare Dharan
Salunkhe
16
Shri. Anandrao Dattu Patil
Director
17
Shri.Jagnnath Yashwant Patil
Director
Burli
18
Shri. Bhimrao Shamrao pawar
Director
Kundal
19
Shri. Prakash Ramchandra
Director
Kundal
Economical
Navekhed
Pawar
20
Shri. Deelip Bapurao Patil
Backward
Representative
21
Shri. Jalinder Narayan Mahar
Co-operative
Kasegaon
Society
Representative
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22
Shri. Babaso Danaji Dhole

Backward
Kasegaon
Class
Representative
23
Shri. Laximan Bapu Mali
Other
Ashta
Backward
24
Mrs. Padmavati Shankarrao
Ladies
Bagani
Patil
representative
25
Mrs. Megha Madhukar Patil
Director
Islampur
26
Mrs. Suvarna Krushna Patil
Director
Shigaon
27
Shri. Vasantrao Maruti Kadam
Director
Bahe
28
Shri. Tanaji Rangrao Kharade
Worker
Islampur
representative
29
Shri. Mohan Anandrao Shinde
Director
Ashta
30
Shri. Rajendra Baburao
Director
Navekhed
Chavan
BOARD OF DIRECTORS:
d) FINANCIAL POSITION
PRODUCTION-Factory commissioned and Trial season was successfully completed
during season 2002-03, In 2003-04,, In 2003-04 season it has crushed 2.36.263 MT,
and produced 2,71,562 qtls. Sugar with 11.49% recovery and in 2004-05 season it has
crushed 3,58,562 MT, and produced 4,24,635 qtls. Sugar with 11.84% recovery.
CO-GENERATION PLAN- It has established 2 Nos. boilers with 45 k.g/cm2
working pressure & 510oc temperature and 6 MW back pressure type turbo alternator
set. In addition to this factory has decided to establish one identical 6 MW turbo
alternator set to generate electricity. It has entered it to Energy Purchase Agreement
with M.S.E.B to export 6.9 MW surplus, power at rate of Rs. 3.05 per unit. These
projects will commerce in November, 2005.
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Financial Information (as 31-03-2006): Total share capital: Rs 608.72 lakhs.

Share capitalDetails
No. Members
Members
Capital(In Lakhs)
12.369
Co-operative
227
Societies total
12,596
604.88
3.84
608.72
AREAS OF OPERATION AND SHAREHOLDERS

No. of villages: 108
No. of shareholders: 2369
ASSETS OF FACTORY
1. Unit- I Sakhrale
: Rs. 66604.47 Lakhs.
2. Distillery
: Rs 1685.16 Lakhs.
3. Acetone
: Rs 500.34 Lakhs.
4. Unit-II
: Rs 7142.67 Lakhs.
5. Petrol Pump
: Rs 4.99 Lakhs.
e) MANPOWER
Sr.
Name Of Department
No.
No. Employees
Unit No. 1
Unit No.2
General
63
Accounts
54
Computer
Civil & Irrigation
45
Sanitation
10
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Agriculture-Office
39
Field staff
211
Cane yard
63
25
Vehicle
34
10
Time & Labour
10
11
Watch & Ward
33
12
Store & Purchase
28
13
Sugar godown
10
14
Manufacturing
215
119
15
Engineering
344
189
16
Distillery
52
17
Liquor
28
18
Environment
21
Total
1264
372
Total 163 Direct Emlpoyee
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f) ORGANIZATION CHART
Shareholders
Board of Directors
Managing Director
Production
Personal
Marketing
Department
Department
Department
Finance
Selling and
Department
Distribution
Department
Production
Manager
Labor
Welfare
Marketing
Manager
Chief
Accountant
Officer
Asst.production
Manager
Manager
Retailer
Security
Sales
Accountant
Supervisor
Officer
Production
Supervisor
Workers
Workers
Lab Assistant
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Analysis and Interpretation of Data

a) Production Process of Sugar:
The organization use continuous process for the production of sugar from
sugarcane.
Process flow of sugar production:
Water
Juice
Cane unloading
Cleaning
Cane
breaking
Cane milling
Straine
r
breaking
Bagasse
Lime & phosphors acid

Clarifier
Volume
Evaporator
Clarifier
Water
Boilers
Steam Wash
Mud filtration
Crystallizer
Syrup
Seeding
Massecuit
Solution
Centrifugal
Filter cake
Sugar crystals
Water Wash
Water
Cane Sugar A&B

Massecuit
Black strap molasses
Cane Sugar
Dryer
Bulk
storage
Bulk load
out
Process flow diagram of sugar production

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Steps of Production process of sugar

Step 1 Cultivation of the Sugarcane:Sugar cane is a sub-tropical crop that prefers lots of sun and lots of water
provided that is roots are not waterlogged. It typically takes about 12 months to reach
maturity. Where it differs from many crops is that it re-grows from the roots so the
plant lasts many cycles before it is worn out.
Step 2 Crushing:The production of sugar begins with the harvesting of sugar cane a relative of
bamboo. The cane stalks are cut into lengths of approximately 20cm and are called
billets. The billets are transported to the mill, either by truck or light rail.
On reaching the mill they are crushed through a series of large rollers. This
produces raw juice (brown in color) and cane fiber called bagacillo (pronounced
bag-a-sillo) This bagasse is burnt by the mill in large boilers, to produce highpressure, super-heated steam to run turbines and produce electricity. The exhaust
steam is then used in other stages of production.
Important points to remember during crushing are:Cane must be crushed within 24 hours of being cut. After this time the sugar
begins to invert into different sugars that will not set solid.
Crushing efficiency is the most important factor in good sugar yields. Every
possible amount of juice need to be squeezed from the cane.
Step 3 Juice extraction:The next step is juice extraction. The prepared cane is fed to 1st mill for the
primary extraction where prepared cane is ruptured and juice extracted. In order to
extract further residual juice rupturing operation is repeated in 3 or 5 times in multiple
mills tandem. This juice obtained is termed as secondary juice.
Primary and secondary juice are mixed then strained in rotator screen for Cushand Cush removal. Before last mill bagasse is leached or washed with hot water for
making bagasse free of sugar. Mixed juice i.e. primary and secondary washed
bagasses are analyzed for various parameters.
The juice collected at the first and secondary mill is sent to the boiling house where it
is clarified and concentrated by boiling.
Step 4 Juice Clarification:AGIMS, Sangli
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MBA II
Cleanliness is vital to the whole process. Once the juice has been heated,
impurities will speed up the inversion of sugar and lead to reduced yields. All boiling
pans and tools need to be thoroughly cleaned between uses.
Carbon dioxide and milk of a lime are added to the liquid sugar mixture and it
is heated to the boiling point, as the process of clarifying begins. As the carbon
dioxide travels through the liquid it forms calcium carbonate, which attracts non-sugar
debris (fats, gums, and wax)
From the juice, and pulls them away from the sugar juice. The juice is then
pushed through a series of filters to remove any remaining impurities.
The extracted juice contains several impurities both dissolved and dissolved
which includes like glucose, salts, fructose. It is necessary to remove these impurities
otherwise they interface in the process of filtration. Extracted juice is weighted and
analyzed for P2O5, CaO phosphate level made up then heated up to 75C in the juice
heater heated juice is limited up to PH 9.5 to 9.8 by milk of time.
Addition and neutralized with boiling SO2 gas up to 7.00+/-PH. Treated juice is
heated further up to boiling point and send to clarifier for setting. Analysis for clear
juice for PH, CaO, color. Transmitter is done to understand effectiveness of
clarification.
After setting clear juice obtain juice send for evaporation and muddy juice for
filtration.
Step 5 Muddy juice filtration:Muddy juice is drawn from clarifier for mixed with bagicillo and send for
filtration in to vacuum filtrate. The filtrate obtained is treated separately in
conventional liming and sulphitation process and soiled waste disposed as press mud
for bio-earth purpose.
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Step 6 Evaporation -:
The clear juice which results from the clarifying process is put under a
vacuum, where the juice boils at a low temperature and begins to evaporate. It is
heated until it forms into thick, brown syrup.
Clear juice obtained from clarifier is thin about 15 and 16 brix to concentrate
thin juice. The process of evaporation is carried out in multiple effects, evaporator
bodies under the vacuums. To obtained thick juice syrup of about 60-62 brix syrup is
bleached in to sulphitation tower by blowing so2 gas up to Ph 5.1 to 5.2 waste gas
recovered in gas absorption tower.
Step 7 Crystallization:By evaporating what little water is left in the sugar syrup, crystallization takes
place. Inside a sterilized vacuum pan, pulverized sugar is fed into the pan as the liquid
evaporates, causing the formation of crystals. The remaining mixture is a thick mass
of large crystals, which is sent to a centrifuge to spin and dry the crystals. The dried
product is raw sugar, still inedible. The crystallization process is carried out in three or
four boiling system or four boiling system. Three boiling systems consists of
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massecuite viz A, B, C boiling system consist of three massecuite viz A, B1, B2, and
C. All massecuite system are carried out under the vacuum in single evaporator body,
each massecuite boiling consists of concentration, seeding, washing, and then
growing the crystals.
Step 8 Sugar formation and grading:Sugar crystals are separated from mother liquor of masscults by centrifugal
machines. Four type of centrifugal machines are used for four various masscults.
From A massecuite final sugar is taken out, from B1, B2 and C massecuite sugar is
melted and reused in process for A massecuite is dried, cooled, and packed in jute
bags after weightiest, then stitched and send to godawn for packing.
Step 9 Steam and power generation:In addition to above steam and power required for manufacturing process
steam generated in boiler by using bagasse as fuel. System is used for power
generation and exhaust obtained used for process, excess bagasses bales and send for
paper mill. Planning to supply excess power to grit. At present power generated
according to actual consumption in sugar distillery unit.
Step 10 Co-products management:Sugar cane is main raw material for cane sugar production. Bagasse, press,
mud and final molasses are by products. Bagasse is used as fuel for steam generation;
excess is baled and used for paper production in our paper mill, loose excess bagasse
is sold in open market. Press mud, filter mud is used in our bio earth plant for manure
production. Same is sold to our cane growers. Molasses is stored in steel tanks and
used in our distillery for production of alcohol and ethanol. Excess molasses is sold in
open market.
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Step 11 Solid liquid waste management:Boiler ash and sugar are the soiled waste. Boiler ash is collected stored in
separate pot in karkhana premises and used either for land filling and bio-earth plant.
Dust sugars are collected by wet scrubber system and recycle in process.
Excess hot water collected in centralized M.S tank cooled in mini spray pond
and reused as raw water. Cold waste water treated in effluent treatment plant based on
extend aeration, cooled, polished and reused as make up to spray pond and as raw
material in sugar factory at various places as per quality. Excess treated water is given
to share holders for their irrigation need.
By- Products of Sugar
Bagasse : Used as fuel

Mud filter cake :Used as fertilizer
Final molasses : Used in Distillery for preparation of
- Rectified sprit
- Ethanol
The by-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. The
company uses PRESSMUD waste products from the sugar Mill for the production
of these by-products. Press mud 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 Bagasse can be used as a raw
material for Paper mills and paper board mills.
The company has developed a system in 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 riches with
Nitrogen, Phosphorous and Potash.
Table No.4.1 Crushing Sugarcane in (Quintal)

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Crushing of sugarcane in the organization from year 2008 to 2014
Crushing
Season
2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014
Crushing
Sugarcane in
Quintals
8,62,110
8,66,112
9,51,428
8,54,264
8,96,402
9,21,289
Graph
No.4.1
The above table and graph indicates that the total crushing of sugarcane for the
last six years. In the year of 2010-2011 the crushing of sugar cane maximum that is 9,
51,428 quintal, but in the year of 2008-2009 the crushing of sugar is minimum which
is 7, 10,080 quintal. The main reason of minimum of these crushing of sugar is
different types of diseases affect on sugar plants like lokari mava, tambera, toldhad.
Table No. 4.2 Recovery of Sugarcane

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The organization has continuously maintained average sugar recovery. It is about 11%
Crushing Season
2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014
Sugarcane
Recovery
12.21%
12.15%
11.78%
12.28%
12.73%
13.01%
Graph No.4.2
The above table and graph shows that the sugar recovery of last six years in
the organization. It shows in percentage (%). In the year of 2012-2013 and 2013-2014
the organization has maintain good sugar recovery than rest of years which is 13.01%
Average Recovery of sugar % cane:

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1) The average recovery of sugar in percentage for year of 2008-2009

Total sugar made
Recovery =
100
Cane crushed
105289.620
=
100
862110.170
= 12.21%
2) The average recovery of sugar in percent year of 2009-2010
Total sugar made
Recovery =
100
Cane crushed
105289.420
=
100
866112.171
= 12.15%
Total sugar made
Recovery =
100
Cane crushed
112150.000
=
100
951428.249
= 11.78%
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Total sugar made
Recovery =
100
Cane crushed
104962.700
=
100
854264.979
= 12.28%
Total sugar made
Recovery =
100
Cane crushed
114151.640
100
896402.195
= 12.73%
Total sugar made
Recovery =
100
Cane crushed
120193.000
100
9212896.00
= 13.01%
The proportion of sugar produced by weight of cane processed usually expressed as a

percentage. The sugar recovery must be 10% minimum average recovery and
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maximum 15%. 10% recovery means that for every 100kg of cane processed 10 kg of
sugar is produced.
Table No.4.3 Total Sugar Production in (Tonnes)

The total sugar production in the organization from year 2008 to 2014
Crushing
Season
Total sugar
production in
(Tonnes)
2008-2009
10,52,896
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014
10,52,894
11,21,500
10,49,627
11,41,516
12,01,930
Graph No. 4.3
The above table and graph shows that sugar produced in the organization in
last five years. In the year of 2013-2014 the organization has produced maximum
sugar due to availability of sugarcane. But in the year of 2008-2009 the production of
sugar was less.
Table No.4.4 Total Molassess Production in (Tonnes)
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Crushing
Season
Total Molassess
Produced in (Tonnes)
2008-2009
21,904
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014
31,454
35,139
34,713
35,071
31,421
Graph No.4.4
The above table and graph shows that molasses produced in the organization
in last five years. In the above graph it is clear that in the year of 2010-2011 the
organization has produced highest molasses as compare to other years. Which was
35139 tones. But in the year of 2008-2009 the organization has produced lowest
molasses due to less crushing of sugarcane.
Test report 4.1 Year 2010-2011
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Following are some test reports of the sugar factory regarding to sugar test parameter
researcher has studied the test reports of some sample given below:
Report No.: GS-Feb-82-83
Date: 26-2-2011
Sample condition: Crystalline white sugar
Sample Description: ST-6544 S-30, M-30 season 2010-2011
Sr.
Test
M-30
No. parameter
Season 2010& unit
2011
1.
Colour, IU
133 at PH
6.70
2.
Sulphardioxide 17%
mg/kg
3.
Polarization%
99.90%
S-30
Season 20102011
130 at PH
6.70
17%
4.
0.0128%
Moisture%
0.0353%
99.91%
Test method
adopted
ICUMSA GS
2/3-10
ICUMSA GS
2/A/7-33
IS: 15279
ICUMSA GS
2/A/3-15
Above table shows the test parameter and test method use to maintain the quality
of sugar in year 2010-2011. The test parameter of sugar are Colour IU (International
uniform),Sulphardioxide in percentage, Polarization%, Moisture%. There are different
international test are adoted by organization such as ICUMSA GS 2/3-10, ICUMSA
GS 2/A/7-33, IS: 15279, ICUMSA GS 2/A/3-15. Here M-30 is medium sugar grade,
and S-30 is small sugar grade. The colour, IU of sugar is tested by method ICUMSA
GS 2/3-10 (International Commission Uniform Method of Sugar Analysis). In M-30
sugar colour, IU 133 at PH 6.70 and S-30 is 130 at PH 6.70. The percentage of
sulphardioxide for M-30 season 2010-2011 is 17% and S-30 is 17%. The polarization
means from the limitation of sugar into sugarcane. Polarization% M-30 is 99.90% and
S-30 is 99.91%. The test use is IS (Intermational Standard), ICUMSA International
Commission Uniform Method Analysis) and IU (International Uniform). The
percentage of moisture for M-30 is 0.0353% and S-30 is 0.0128%.
So, by using above test method the quality of sugar maintain.
Remark: The above test report conforms to S-30 & M-30 with respect to elements
specified.
Test report 4.2 Year 2013-2014

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Report No.: ST- 3585
Date: 8-8-2014
Sample Description: ST-6549, S-30, season 2013-2014
Sr.
No.
Test parameter &

unit
1.
Colour, IU
S-30
Test method
Season Adopted
2013-2014
110
ICUMSA GS 2/3-10
2.
3.
Sulphardioxide mg/kg
Polarization%
12.90%
99.76%
ICUMSA GS 2/1/7/9-33
ICUMSA GS 2/3-1
4.
Moisture%
0.027%
Above table shows the test parameter and test method use to maintain the quality of
sugar in year 2013-2014. The test parameter of sugar are Colour IU (International
uniform),Sulphardioxide in percentage, Polarization%, Moisture%. There are different
international test are adopted by organization such as ICUMSA GS 2/3-10, ICUMSA
GS 2/1/7/9-33, ICUSMA GS 2/3-1, ICUMSA GS 2/1/9-15. Here the one type of grade
adopted S-30 is small sugar grade. The colour, IU of sugar is tested by method
ICUMSA GS 2/3-10 (International Commission Uniform Method of Sugar Analysis).
In S-30 sugar colour, IU 110. The percentage of sulphardioxide for S-30 season 20132014 is 12.90%. Polarization% S-30 is 99.76%. The test use is IS (Intermational
Standard), ICUMSA International Commission Uniform Method Analysis) and IU
(International Uniform). The percentage of moisture S-30 is 0.027%.
So, by using above test method the quality of sugar maintain
Remark: The above test report conforms to S-30 with respect to elements specified.
Test Report -4.3 Year 2014-2015
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Report No.: ST-3633
Date: 26-12-2014
Sample Description: ST-6760, S-30, M-30 season 2014-2015
Sr.
No.
1.
2.
Test parameter &

Unit
3.
Colour, IU
Sulphardioxide
mg/kg
Polarization%
4.
Moisture%
M-30
S-30
Test method
Season
Season
adopted
2014-2015
2014-2015
88
93
ICUMSA GS 9/1/3-8
18.88%
21.21%
99.83%
99.85%
ICUMSA GS 2/3-1
0.022%
0.024%
Above table shows the test parameter and test method use to maintain the
quality of sugar in year 2014-2015. The test parameter of sugar are Colour IU
(International uniform), Sulphardioxide in percentage, Polarization%, Moisture%.
There are different international test are adopted by organization such as ICUMSA GS
9/1/3-8, ICUMSA GS 2/1/7/9-33, ICUMSA GS 2/3-1, ICUMSA GS 2/1/3/9-15. Here
M-30 is medium sugar grade, and S-30 is small sugar grade. The colour, IU of sugar
is tested by method ICUMSA GS 9/1/3-8 (International Commission Uniform Method
of Sugar Analysis). In M-30 sugar colour, IU is 88 and S-30 is 93. The percentage of
sulphardioxide for M-30 season 2014-2015 is 18.88% and S-30 IS 21.21%.
Polarization% M-30 is 99.83% and S-30 is 99.85%. The test use is IS (International
Standard), ICUMSA International Commission Uniform Method Analysis) and IU
(International Uniform). The percentage of moisture for M-30 is 0.022% and S-30 is
0.024%.
So, by using above test method the quality of sugar maintain.
Remark: The above test report conforms to S-30 & M-30 with respect to elements
specified.
Finding, Suggestions and Conclusion

5.1 Findings
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MBA II
The organization use of continuous process of production. Sugar factory has

process focused for production system.
The sugar factory produces different type of by product like Bagasse, Mud filter
cake, Final molasses.
In the year of 2010-2011 the organization total crushing of minimum sugarcane
for the last year six year. The year of 2010-2011 crushing of minimum sugarcane.
Because main reason of minimum of these crushing of sugar is different type of
diseases effect on sugar plant.(Table No. 4.1)
The organization has maintain good sugar recovery that rest of year 2013-2014
which is 13.01%. (Table No. 4.2)
The organization has produced last six year. In the year of 2013-2014 produce
maximum sugar due to availability of sugarcane. (Table No. 4.3)
The molasses produced in the organization in last six years. The year of 20102011 the organization has produced highest molasses as compare to other years.
(Table No. 4.4)
The test report of sugar year of 2010-2011 the percentage like sulphardioxide for
M-30 season 2010-2011 is 17% and S-30 is 17%, Polarization% M-30 is 99.90%
and S-30 is 99.91%, moisture for M-30 is 0.0353% and S-30 is 0.0128%.
(Test report 4.1)
S-30 season 2013-2014 is 12.90%, Polarization% S-30 is 99.76% and percentage
of moisture S-30 is 0.027%. (Test report 4.2)
M-30 season 2014-2015 is 18.88% and S-30 IS 21.21%, M-30, Polarization% M30 is 99.83% and S-30 is 99.85% and percentage of moisture for M-30 is 0.022%
and S-30 is 0.024%. (Test report 4.3)
5.2 Suggestion:
1) The sugar factory needs to maintain good sugar recovery to each year.
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2) The organization takes special effort to increase the maximum crushing of

sugarcane.
5.3Conclusion:
From the overall study of production process of sugar with special
references to Rajarambapu Patil Sahakari Sakhar Karkhana Ltd. Islampur, the
researcher understood the concept of production process and also understood the
test reports regarding to the selection of material & test parameter and test
method use to maintain the quality of sugar in different year. Researchers also
understood how to determine sugar recovery.
Bibliography:
AGIMS, Sangli
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MBA II
S.A. Chunawalla, D. R. Patel, (2010) Production and Operation Management,

Himalaya Publishing House.
S. Chand, (2013) Industrial Engineering and Production, S. Chand & Company
Pvt. Ltd.
K. Aswathappa, (2012) Production & Operation Management, Himalaya
Publishing House
Research Methodology, Kothari C.R. & Garg Gaurav, (2014) by New Age
International Publishers, Limited New Delhi. Third Edition
Web bibliography:
1) http://www.bing.com/search?
q=rajarambapu+sugar&qs=SC&sk=OS1&pq=rajaram+bapu+s&sc=314&sp=2&cvid=e81b48c52ad146bbaeb52e58a09bc741&FORM=QBRE
2) http://rajarambapusugar.com/
3) http://www.sucrose.com/lcane.html
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MBA II

Introduction of the Study and Methodology

Shivaji University, Kolhapur

1.2 Objectives of the study

To study the quality reports related to sugar.

To study the production of sugar for different year.

Importance of the study:

It enables to understand the meaning and significance of production process of

2) To study helps in the knowing production process of sugar.

To get valuable and visible knowledge through fieldwork.

1.3 Scope and Limitation of Study

Limitation of the study:

Shivaji University, Kolhapur

The information and data, which is made available by personnel in the

1.4 Research Methodology

department head by way of general conversion & discussion oral.

Shivaji University, Kolhapur

It is also known as conversion process or transformation which transforms some

2.2 Types of Process:

Shivaji University, Kolhapur

assemblies having specific functions. Examples of assembly processes are welding,

2.3 Objectives of Production Management :

Shivaji University, Kolhapur

2.4 Intermediate objectives:

Shivaji University, Kolhapur

2.5 Types of Production System:

Make to stock production :

Shivaji University, Kolhapur

2.6 Classification of Production System:

Shivaji University, Kolhapur

High verity of product and low volume.

Shivaji University, Kolhapur

important aspects in the process industries. In process production the process

Plants and equipments with zero flexibility.

Shivaji University, Kolhapur

Subsystems of organizational system

Introduction of the Company.

Rajarambapu Patil Sahakari Sakhar Karkhana.

A/P- Sakhrale, Tal- Walwa, Dist- Sangli

Shivaji University, Kolhapur

S.A.N/P.R.G (As Date 17-08-1963

Industrial License No. :

125/N-211/69L.C, Date 10-9-1969

Loknet Rajarambapu Patil

Hon. Minister Jayantrao Patil

Sugar and Foreign Liquor

Major raw material:

Time Schedule of Working

All India and Foreign

By Truck and Railway

c) History of the company

Shivaji University, Kolhapur

Best-cane Development in South-zone

Shivaji University, Kolhapur

Best-cane Development in South-zone

Best-Technical Efficiency in South-zone

Best-cane Development in South-zone

Best Technical Efficiency in South Zone

Best Technical Efficiency in South Zone

Best Technical Efficiency in South Zone

Best Technical Efficiency in South Zone

Sangli District Industrial Safety Committee

Sangli District Industrial Safety Committee

Best Technical Efficiency in South Zone