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PURTI CO-
CO-OPERATIVE SUGAR MILL LTD.:
M/s Purti sugar mill is situated at Khursapar (Bela) village near about 60 KM from Nagpur at national
highway (Nagpur-Chandrapur) in Umred Taluka. This complex has been started within the leadership of
Shri. Nitinji Gadkari, Chairman, who had laid the foundation stone of this multiproduct complex, which in
the years to come would be the ideal example for whole Indian sugar industry sector. This multiproduct
following
per day)
Sugar Complex
The sugar industry began its crushing operation in 2002 with a capacity of 2500 TPD. of cane per day. But
eventually operating a sugar factory in an area where small number of farmers are planting sugar cane
which is insufficient to assure the operation of the sugar factory would not have been commercially
viable. This year the restriction of the command area has been removed by the government which in turns
helps the industry to procured the sugarcane from outside the command area.
In this region water table is very low therefore water scarcity problem is very high as compare to other
sugarcane growing region. This sugar factory has an enormous importance for the surrounding community.
Being located in the rural area, it provides employment opportunity and increases secondary business in the
area. During the harvesting season, the cane is taken to the mill mostly by tractors (single & doubled
trolley), bullock cart, and trucks. This year, most of the sugar cane came from the nearby areas like
Wardha , Nanded, Selu, which approximately takes 6 to 8 hrs, while in case of Madhya Pradesh it takes
Harvesting is done by hand. Sugarcane cutting is a hard and dirty job, but provides employment to people in
nearby areas where jobs are scarce. Sugarcane is cut at about ground level, the top green leaves are
chopped off and then the stalk is bundled. Once a complete bundle has been assembled, it is removed from
the field with the help of labourers and transferred to a larger vehicle for transport to the mill. The
harvested sugar cane should be crushed within 24 hrs. to get a good recovery of sugar. Therefore every
sugar mill has provided transportation and harvesting facility to the farmers on nominal charges, which
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In general, almost all sugar mills depend for their supplies of Social Inputs
sugar cane on large number of independent farmers, producing • Provides direct employment to about
700 to 800 workers
the crop for profits. If the yield per hectare is improved, the • Approximately 3000 families are
benefitted within 10,000 Acres of
benefit goes to the growers while if the cane is rich enough in sugarcane growing region in the nearby
area
sugar content; it becomes profitable to the mills. Therefore cane
Economic Inputs
growing and milling are essentially a joint enterprise what helps
• Support services like labour
the grower helps the miller and vice- versa. contractor (Provider)
Sugarcane considered as a alternative crop in this area , most of • Harvester (Skilled Migrated workers)
the farmers go for the cotton, some of them cultivating orange , • Hardware services
As this mill has started operating only recently, the mill at present does not have an agriculture devel-
opment department but through traditional channels, they are in touch with the farmers and purchase sugar
A view of lifting & unloading of sugarcane (Farmer). Each group of harvester consists of 8-10
members. The transporting agent gets the slip signed by the farmer and goes to the weighing and crushing
center. Weighing is located near to the crushing center. Once the weighing has being carried out, mill offi-
wherein it is crushed and the juice is extracted. The manager needs to process the cane as soon as possible
if sucrose losses are to be avoided. Typically, cane is processed within 24 hours after harvesting. Following
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Extraction of juice:The extraction is actually conducted as a counter-current process using fresh hot
the cane. The more the water is used, the more is the sugar
extracted but the more dilute the mixed juice, hence more
the sugar syrup is sent to the pan floor wherein the final
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the liner and the sugar is retained on the screen and the
the Indian sugar industry is more concentrated in rural part of India but the area is well connected with
Distillery Complex
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Co-generation Complex
powers the mill to process sugar from cane juice and alcohol
in distillery industry.
to its full capacity. the two multi fuel boiler has been
22 KG and 67 KG respectively
Purti Sakhar Karkhana is one of its kind which has a bio-diesel plant. This plant was started to cope up with
the power shortage and fuel problem. When the sugar complex was in the preliminary stage there was a lot
of vehicles and generator use to work for 24 hr. which consume huge amount of fuel and accounted for the
Bio-disel plant
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Bio-composting unit
Spent wash generated from the distillery, sludge from ETP and excess of bagasse is used as a filler
material for bio-composting, . The produced compost is then supplied to the farmers at nominal cost.
Recommendations:
1) Mill should take up a sort of programme to encouraged the nearby farmers for sugarcane plantation.
2) There are very few water irrigation schemes in this area therefore mill can think to develop water
3) As practiced in the western Maharashtra mill can think for the bio-gas generation plant.
4) Mill have to undertake few rain water, rooftop rain water and ground water recharging projects in the
area.
Acknowledgement
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RBCSM sugar factory is situated at sakharale village Tal: Walwa, and District Sangli. It began crushing
operation in 1970 within the leadership of late Rajarambapu Patil, the minister in Maharashtra cabinet who
established this society under the name of "Walwa Taluka Sahakari Sakhar Karkhana Ltd." after his
untimely demise, the society was renamed as “Shri. Rajarambapu Patil Sahakari Sakhar Karkhana”.
Initially, RBCSM began with a capacity of 1250 MT (metric tonnes) of cane per day and this continues for
nearly 7 years. But there was not much surplus left for any developmental and expansion work for the unit
therefore the capacity was increased up to 2000 MT/day in 1977 and 4000 MT/day in 1990. In 1975
Distillery attached to the sugar mill was established with a capacity of 15000 Liters/day, which further
increased up to 45000 and 75000 Liters/day consequently in 1982 and 1985. The modernization of
distillery was done in the year 2000 with increased capacity of 90000 Liters/day which proved a mile
commodities, which fixes maximum of solar energy per acre, releasing the same for human benefits in many
forms. Therefore; the potential of this sugar industrial network should be harnessed fully. This has been
achieved at some extent by RBCSM .The harvesting season is more or less common in all the sugar
producing states of India, typically ranges from as little as 2 ½ months up to 11 months. The cane is taken
to the mill mostly by tractors (single & doubled trolley), bullock cart, and trucks.
Harvesting is done by hand and its a hard and dirty job but provides a employment to the local as well as
migrated peoples which have been skilled in this job. Sugarcane cut at about ground level, the top green
leaves are chopped off and then the stalk is bundled, once a complete bundle has been assembled it is
remove from the field with the help of labourers this will then be transferred to a larger vehicle for
transport to the mill. The harvested sugar cane should be crushed within 24 hrs. to get a good recovery of
sugar. Therefore, every sugar mill has provided transportation and harvesting facility to the farmers those
are belongs to their command area. In India every sugar factory whether it is private, or co-operative has
their command area allotted to them based on their crushing capacity by the government. During the
crushing season they are allowed to procured sugarcane from command area which gives a regular supply of
sugarcane. But this restriction has been removed in Maharashtra this year. Therefore farmers can sell
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Almost all sugar mills depend for their supplies of sugar cane on Social Inputs
large number of independent farmers, producing the crop for • Established Engineering collage
and School
profits. Sugarcane holds a prominent position as cash crop in this
• Agricultural soil testing
region and that’s why most of the farmers cultivate it to make a laboratory, Nursery
profit. The mill has their own soil-testing laboratory, which is • Medical facility for the
community
equipped with all the latest sophisticated instruments and
• Subsidies/Loans for the farmers
provides a facility for soil testing and fertilizer dose
• Infrastructure like road,
recommendation to the farmers on nominal charges to increase transport etc.
better sugarcane yield in the area.
Economic Inputs
In this region, most of the farmers and the labourers are • Support services like labour
contractor (Provider)
involved in the activities, which are directly or indirectly related
• Harvester and Transporter
with sugar production, sugarcane-crushing season is for six
• Hardware services
months in this period most of the people are employed through
• Supplier of chemicals for the
harvesting, loading and transportation activity. industrial process
Achievements
The mill has their third party contractor for harvesting and transpor-
• Best sugar mill in tation. The mill provides vehicles required to transporting sugarcane
Maharashtra State: trophy from field to the mill and only manpower has to be employed by the
• Best Cane Development Award as to assure the supply of sugar cane from
- South Zone the command area. The harvesters under
• Best Technical Efficiency vest the crop and then load on to the vehi-
Award South Zone cle in presence of the crop owner (Farmer).
Liquor (distillery
Typically each group of harvester consists of 8-10 members, The transporting agent will get the slip signed
by the farmer and goes to the weighing and crushing center. Weighing is located near to the crushing
center. Once the weighing has being carried out, mill officials will note down the entry of the crop weight,
name of crop owner and the vehicle number for further procedure.
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The payment of the crop will directly be deposited in the account of each farmer in
the co-operative bank of the society. After sugar production, the waste generated
from the mill will be sent to the by-product based industry like molasses, which will
paper mill, press mud and spent wash is used as a filler material for bio-composting.
Compost manure will be sold to the farmers and to the members of the society at
nominal charges.
Molasses
Sugarcane Farm
Gur/Khandsari
Sugar Mill
Market
Market
Alcohol/Sprit
Methane Gas
Spent wash
Power supply to mill
Co-generation
Biogas Generation
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On the other hand alcohol is used to produce various industrial chemicals and
create electricity that powers the mill to process sugar from cane juice and
effluent producing bio-gas. Produced bio-gas then sent to the boiler as a fuel.
The transportation of sugar from mill to market is mostly carried out by road.
Compost manure
The area is well connected with most of the metropolitan cities of the India.
Like wise the network revolves around the sugarcane farm and plays an important role in the rural
Recommendations:
1) Mill should control air pollution caused due to unburnt particles of bagasse in the surrounding area.
2) Mill have to generate an awareness in the surrounding area to decrease the overuse of chemical
fertilizers.
3) Plenty of water is available in this area therefore most of the farmers are careless about the water
conservation practices; but, co-operative society should come up with strong policies for using common
4) Mill shall think for using excess bagasse for paper making.
Acknowledgement
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Shri. Tatyasaheb Kore Warana Co-operative Sugar Mill a unique name that stands as forerunner in the
co-operative movement in India. Tatyasaheb Kore who did a great job in the land of Warana, When an
unprecedented depression in 1951 literally ruined the farmers of this area and they had to burn out their
sugar canes rather than making jaggery and face the prospect of selling it at throwaway prices. This
shocking incident made him to set up a modern co-operative sugar mill in a barren land. WARANA is
situated next to Kodoli village. The success of this sugar mill doubled his enthusiasm and lead to the overall
development of Warana complex. The successful establishment of a co-operative sugar mill in 1959
completely revolutionized the life of Warana. With this mill Tatyasaheb Kore and his magnificent team
touched the lives of the entire weaker section. Warana's total growth is dependent on this sugar mill. This
is the parent unit from which Warana is drawing inspiration and enthusiasm for it's overall growth. Every
effort is being put to make the sugar mill an ideal one.
The Warana nagar is a small township established on the bank of Warana river. Which flows through the
taluka pahnala about 35 KM from district place Kolhapur. This area is situated in the Western Maharashtra
and is famous as a sugar belt area. The farm area is spread all over in the panhala tahsil and it is
approximately 40 KM.
Farm level activities like farming , irrigation practices, harvesting of sugarcane, transportation etc. are
more or less common in all the sugar producing states. On the other hand production of sugar and its by
Achievements product utilization is vary depend on the facilities and the
technological know how available with the mill. Basically this
• First prize for its best co-operative sugar mill and its down stream by product based
technical efficiency in the year industries are belongs to the same promoter on the other way we can
1988-89 at the National say it’s an integrated complex.
Federation of Co-operative Sugar Sugar mill capacity 7200 tonnes/day: Produced M-30, S-30, S-29
Factories Ltd. New Delhi. and S-31 grades of sugar.
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Bio-composting: During year 2002-03 21473 MT & in 2003-04 11889 MT of Warana bioearth compost
has been provided to the members
WARANA sugar mill in its own is the backbone of this complex. Which reflects from the developmental
work this mill has done for the surrounding area.
a) Employment:
• Sugar mill employs 8000 workers
• Milk mill employs 1200 workers
• Food processing mill employs 400 workers
• Warana bazaar employs 350 workers
• Farm Labours secondary Businessman.
b) Workers welfare: -The mill has provided quarters for the workers with all the essential facilities like
sanitation, filtered water supply, and cheaper electricity etc. workers can avail the credit facility from
the departmental store in Warana bazaar.
In case of an emergency medical facilities are provided at free of cost. The worker's welfare runs a
printing press. Other organisations in Warana complex too provide such amenities for their workers.
c) Educational Facility: - Warana group of cooperatives runs an engineering college; industrial training
institute (ITI), military school, primary school, physical education "Warana Vyayam Mandir" provides
facilities to the body builders and young wrestlers. The training in traditional wrestling and bodybuilding is
given to the interested youngsters around the village
d) Mahila udyog: - "Lijjat Papad Mahila Udyog Ltd" was started where workers wives were given an
opportunity to prepare the Lijjat papad during their leisure time. This not only promoted the family
income, but also kept the women busy and they identified their role in the development of the complex. On
the similar lines "Bhagini Mandal" is also in action where pickles, masalas and other edible items are
prepared and sold. The bhagini mandal at the dairy is involved in the production of plastic containers
required for all the dairy products.
a) Medical facility: -A 30-bed hospital with latest facilities started in 1992. It is now a 200-bedded
hospital, which is equipped with modern medical technologies along with expert doctors. The experts
organize periodical medical camps free of cost for the benefit of the rural mass.
b) Agriculture development: - Since 80% of the population of the study area depends on agriculture for
their livelihood, an independent Agricultural development department is looking after the whole scenario
of agricultural development. The department has a well-equipped soil-testing laboratory. The required
fertilizers, insecticides and good quality seeds are supplied to the farmers through the departmental
units existing in the villages. A full-fledge nursery is supplying good quality saplings to the farmers.
c) Warana wired village project: -This project connects 70 villages with 150 computer networking nodes
and also provides the internet facilities to the rural community, the project fulfill all the needs such as
revenue records, health cards, credit cards, agricultural goods market prices of national as well as
international markets.
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d) Irrigation facility: - Providing financial aid, technical know-how and managerial help to encourage lift
irrigation schemes on a co-operative basis. Around 65 lift irrigation schemes are functioning. Each lift
irrigation scheme is irrigates around 120 acres of land. Along with this, three large lift irrigation schemes
are working around 4600 acres of land. Due to the efficient working of these lift irrigation schemes the
sugar cane production has gone up by 2 lakh tones. Apart from this, around 5828 wells with pump sets are
also functioning, each well watering about 2-4 acres.
Sugarcane Farm
Gur/Khandsari
Sugar Mill
Paper/Cardboard Market
Market
Sludge
Spent wash
Power supply to mill
Co-generation
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Recommendation:
1) Whole Warana nagar is situated very near to this complex. Air pollution due to fly ash emission is very
high. Therefore mill should go for the pollution control equipment.
2) Bio-gas generation unit is shut down since last one year. Mill should think on it seriously. It would be
source of fuel for boiler.
3) Awareness need to be generate among the sugarcane growers for better irrigation practices and to
improve yield/ha.
4) Mill shall improve their waste water treatment facility for better waste minimization practices.
Acknowledgement:
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