Bajaj Hindusthan Limited (BHL) was incorporated on 23rd November,

1931 under the name - The Hindusthan Sugar Mills Limited – on the

initiative of Jamnalal Bajaj - a businessman, confidante, disciple and

adopted son of Mahatma Gandhi. He sought Gandhiji's blessings in this new

venture, which, apart from being a sound commercial proposition would

also meet a national need. Till then, there were barely thirty sugar factories

in the country.

The site selected for the first plant was at Golagokarannath, district

Lakhimpur Kheri in the Terai region of Uttar Pradesh (UP), an area rich in

sugar cane. The original capacity of the factory was 400 tons of cane

crushed per day (tcd). Subsequently, this capacity was increased in stages

and is currently 13,000 tcd. The distillery Unit at this plant commenced

production during the end of World War II in 1944. In the initial few years,

the major output was in the form of power alcohol as an additive to petrol,

which was then in short supply. The unit was the first to supply alcohol-

mixed petrol to the army.

In 1967, a new Company - Sharda Sugar & Industries Limited - was

established as a subsidiary of Hindusthan Sugar Mills Limited. Under this

new subsidiary, a sugar plant with a cane crushing capacity of 1400 tcd was

set up in 1972 at Palia Kalan, a large cane supplying centre at a distance of

about 70 kilometres from Golagokarannath. The objective of this new Unit

was primarily to help the cane growers of the area supply their produce to

the new location closer to their fields, thereby cutting down on

transportation costs. The capacity was subsequently increased in stages to

reach the present 11,000 tcd.

In the year 1988, The Hindusthan Sugar Mills Limited was renamed as

Bajaj Hindusthan Limited and shortly thereafter in 1990, Sharda Sugar &

Industries Limited was amalgamated with Bajaj Hindusthan Limited.

The Company embarked on an aggressive Greenfield expansion drive

in         2003-2007, starting with a plant at Kinauni, near Meerut (UP),

which was completed in a record time of just seven months as against the

industry norm of 18-24 months. This facility commenced commercial

production in November 2004.

At the end of the expansion project in 2007, BHL had ten sugar

manufacturing locations across UP with a cane crushing capacity of 96,000

tcd and was also the country’s largest ethanol producer with an output of

480 KL/ day.

In an acquisition move, the Company took over the Pratappur Sugar and

Industries Limited (PSIL), district Deoria, Eastern UP in December 2005.

This Plant, in operation since 1903, had a crushing capacity of 3,200 tcd,

which was increased to 6,000 tcd in the subsequent sugar season 2006-07.

PSIL was subsequently renamed Bajaj Hindusthan Sugar and Industries

Limited (BHSIL) and became a subsidiary of BHL. This acquisition

provided BHL a strategic foothold in the sugar-deficient region of Eastern

UP and reaffirmed the consolidation that took place in the sugar industry.

the capacity to manufacture 160 kilo-litre per day of ethanol. The total

BHSIL embarked upon significant new expansions. While the capacity of

its existing sugar plant at Pratappur was enhanced, three new sugar units

were also set up in virgin, cane-rich areas of East UP at Rudauli (district

Basti), Kundarkhi (district Gonda) and in Utraula (district Balrampur).

BHSIL then, had a crushing capacity of 40,000 tcd and a distillery with

industrial alcohol/ ethanol capacity of the Company, including its

subsidiary, was 800 KL/ day.

With the commissioning of three bagasse-based power co-generation plants

at Kundarkhi, Rudauli and Utraula, BHSIL had an aggregate power

generation capacity of 95.8 MW. Combined with the power generation

capacity of 325 MW from BHL, the Company’s total generation capacity is

420.8 MW. After meeting its own energy needs, the Company has a surplus

of 90 MW. It supplies a significant part of this surplus power to the UP state

grid.

In December 2010, BHSIL was amalgamated with BHL.

The Company’s growth initiative has been led by a strategic focus of

attaining global scales of manufacturing and cost competitiveness. Such

benchmarking provides BHL advantages of cost and higher domestic

market share where demand is expected to outstrip supply for the next few

years.

BHL is in a unique position. While its planning and processes are

benchmarked against global practices, its activities are directed at

contributing to the Indian rural economy at a local, grassroots level,

primarily in the uplifting of the farmers. The Company embarked on an

expansion, the scales of which are unprecedented worldwide, providing

tremendous opportunities of employment, infrastructure and community

development and contributing to the growth of the rural economy of UP.

Sugarcane, is broadly classified into three varieties early, general and

unapproved. Cane is sowed during February and October every year. The

first seed growth is known as the plant and subsequent growth after

harvesting from the stem is known as Ratoon. The early variety has more

sugar content than the general variety.

Every farmer within the command area of the Mill is provided with a

calendar, which tells him when he can expect a Mill Supply Ticket

(Purchy), against which he will deliver the sugarcane.

He then harvests the cane and transports it either in a bullock cart or tractor

trolley to the mill. Cane is also bought at the mill's own centers within the

command area. This cane is then transported in trucks or through rail to the

mill.

Cane is weighed using an electronic weigh bridge and unloaded into cane

carriers. It is then prepared for milling by knives and shredders. Sugarcane

juice is then extracted by pressing the prepared cane through mills. Each

mill consists of three rollers:

1. Extracted juice mixed with water is weighed and sent to the boiling

house for further processing. Residual bagasse is sent to boilers for

use as fuel for steam generation

2. This juice is heated and then treated with milk of lime and sulphur

dioxide. The treated juice is then further heated and sent to clarifiers

for continuous settling. The settled mud is filtered by vacuum filters

and filtered juice is returned to be further processed while the oliver

cake is sent out

3. The clear juice is evaporated to a syrup stage, bleached by sulphur

dioxide and then sent to vacuum pans for further concentration and

sugar grain formation. Crystals are developed to a desired size and

the crystallized mass is then dropped in the crystallizers to exhaust

the mother liquor of its sugar as much as possible. This is then

centrifuged for separating the crystals from molasses. The molasses

is re-boiled for further crystallization

Thus, the original syrup is desugarised progressively (normally three times)

till finally, a viscous liquid is obtained from which sugar can no longer be

recovered economically. This liquid, which is called final molasses, is sent

to the distillery for making alcohol.

The sugar thus is separated from molasses in the centrifuge is dried, bagged

(50 Kg and 100 Kg), weighed and sent to storage houses.

Sugar is made in different sizes and accordingly classified into various

grades i.e. large, medium and small.

Molasses:

Molasses is the only by-product obtained in the preparation of sugar

through repeated crystallization. The yield of molasses per ton of sugarcane

varies in the range of 4.5% to 5%. Molasses is mainly used for the

manufacture of alcohol, yeast and cattle feed. Alcohol in turn is used to

produce ethanol, rectified spirit, potable liquor and downstream value added

chemicals such as acetone, acetic acid, butanol, acetic anhydride, MEG etc.

The state government controls the export of molasses through export

licenses issued every quarter. Molasses and alcohol-based industries were

decontrolled in 1993 and are now being controlled by respective state

government polices. Nearly 90% of molasses produced is consumed by the

industrial alcohol manufacturers and the remaining 10% is consumed by the

potable alcohol sector.

Bagasse:

Bagasse is a fibrous residue of cane stalk that is obtained after crushing and

extraction of juice. It consists of water, fibre and relatively small quantities

of soluble solids. The composition of bagasse varies based on the variety of

sugarcane, maturity of cane, method of harvesting and the efficiency of the

sugar mill. Bagasse is usually used as a combustible in furnaces to produce

steam, which in turn is used to generate power. It is also used as a raw

material for production of paper and as feedstock for cattle.

By making use of bagasse sugar mills have been successful in reducing

dependence on State Electric Boards, for their power supply as it can

procure up to 90-95% of its total power requirement through captive

generation from steam turbines.

Fly ash:

Fly Ash is the residual output from the boiler furnace after bagasse has

completely burnt out. This fly ash is used as a substitute for firewood. It is

rich in potassium and is also used by local farmers for cultivation.

Press Mud:

Press mud, also known as oliver cake or press cake, is the residual output

after the filtration of the juice. It is mixed with spent wash from the

distillery and cultivated to produce high quality bio-manure.

Bajaj Bhu Mahashakti

Soil fertility is seriously impaired with the excessive use of chemical

fertilizers. Research conducted to study the fall in grain production indicates

that the soil is getting drained of organic carbon because of over use of

fertilizers, thus effecting soil fertility.

The gainful use of bio-manure can help address this threat. ‘Bajaj Bhu

Mahashakti’ is a plentiful source of carbon for the soil besides being rich in

NPK(Nitrogen-Phosphorus-Potassium). The use of Bhu Mahashakti

balances the soil organic carbon in the soil and thereby preserves optimum

productivity and soil fertility.

Bhu Mahashakti (Bio-compost)

“Bajaj Bhu Mahashakti” Bio-manure / Bio-compost is manufactured by

composting press mud received from cane juice filtration and spent wash

received from distilleries.

Composting Process

Composting is the biological decomposition of ligno-celluloid

organic material into a simple compound, a humus-like end-product

called “compost”. It is a rich source of organic manure.  It also helps

significantly improve the quality of the soil.

The process is aerobic which uses various micro-organisms such as

bacteria, actinomycetes and fungi to break down the higher organic

compounds, like cellulose and lignins, into simpler substances.

During composting, the micro-organisms consume oxygen while

feeding on organic matter, and multiply. Active composting

generates a considerable amount of heat. It also discharges large

quantities of carbon dioxide and water vapour into the atmosphere.

The loss of carbon-dioxide and water vapour reduces the weight of

the initial dry organic matter. Thus composting reduces both the

volume and the mass of the organic matter.

Process of Bio manure Formation

Press mud is stored in triangular shaped rows known as windrows.

Spent wash is sprayed on each windrow at specific intervals.  The

windrows are then turned.

This helps in homogenising the entire mass, maintaining uniform

temperature and moisture with effective aeration and oxygen supply.

During the composting process, the temperature goes up to 650-700

C

Due to the churning of the mixture of press mud and spent wash by

aero tillers, oxygen is supplied to bacteria, thereby accelerating the

composting process. It also dissipates the excess heat generated.

Bacteria separate carbon and other complex compounds from press

mud and spent wash.

Enhancing the effectiveness of this process requires 50-60%

moisture.

Composting Cycle

It takes typically 60 days to complete the composting cycle. During

the first five days windrow dressing, moisture reduction and

inoculation are completed. From the sixth to the 50th day, the

temperature and moisture levels are maintained by spraying spent

wash. From the 51st to the 60th day, moisture reduces curing and

aging, and the stabilisation process gets under way. This again

reduces the moisture level.

Specifications of Bajaj Bhu Mahashakti

Moisture Content  :       30%-40%

Nitrogen              :       1.8%-2.5%

Potassium           :       1.5%-2.0%

Phosphorus         :       2.0%-2.6%

Calcium              :       3.0%-4.0%

Sulphur              :       1.0%-1.5%

Magnesium         :       0.8%-1.5%

Iron                   :       0.04%-0.06%

Zinc                   :       0.025%-0.035%

Organic carbon   :       24%

Organic Matter    :       42%-50%

Others               :        2.0%-2.5%(micro nutrients etc )

pH                     :       7.0-7.4

C: N Ratio          :       Less than 18

Unique benefits of Bajaj Bhu Mahashakti

Improves the physical, chemical and biological properties of the

soil.

Improves the soil structure, air circulation and water retention

capacity of the soil.

Retains nutrients and prevents them from leaching away the plant

roots.

Contains both the micro-nutrients (calcium, sulphur, magnesium,

iron, etc.) and macro-nutrients (nitrogen, phosphorus, and potash)

essential for plant growth.

Microbes accelerate the breakdown of crop residues in the soil.  This

improves the texture of the soil and also releases the locked-up

elements.

Increase the yield and quality of field, vegetable, tree and fruit crops.

Can easily be applied as both base-dressing and top-dressing.

Improves alkaline and saline/sodic soil.

Helps the growth of the roots by improving the soil structure.

Ultimately, it betters the crop yield by improving soil fertility and

soil structure.

Useful for all types of field crops, vegetable crops, orchards, kitchen

gardens and flowers.

The quality of the sugar manufactured at bajaj hindusthan ltd. is controlled by:-

1. Maintaining process parameters strictly e.g. ph of juice, temperature of mixed

juice and syrup juice

2. Maintaining good sanitation at mills and in the boiling house

3. Using minimum, tested, good quality chemicals for processes

4. Adopting latest technologies for juice and syrup/melt clarification e.g. film type

sulphur burner, SCS, FCS and MCS

5. Avoiding direct steam application to intermediate sugar products

6. Doing experiments and special analysis to ensure optimum ICUMSA of all

intermediate products and the final product

At bajaj hindusthan ltd. We produce sugar of following grades:-

L-31, M-31, S-31, L-30, M-30 and S-30 out of which maximum

production is of 31 colour sugar. (31 is the best colour standard

fixed by the Government of India)

Sugar grading is done for colour and grain size. Sugar produced is

regularly matched with N.S.I. standards

Percentage retention of sugar is currently being maintained at 85%+

as against minimum requirement of 70%

Every year bajaj hindusthan ltd. conducts a survey of its command area to bring on

record the cane cultivated area of the farmers. This also takes care of the different

varieties of sugarcane that are grown by farmers.

Post this massive exercise, every farmer within the command area of the mill is provided

with a calendar, which tells him when he can expect a Mill Supply Ticket (Purchy) against

which he will supply the cane.

The calendar is distributed over 180 days. Based on the maturity and recovery expected

from the varieties, the distribution takes place in the calendar.

After receiving the purchy, the farmer harvests the cane and transports it either in a

bullock cart or tractor trolley to the mill gate. Farmers who stay in far flung areas supply

cane at the mill's centers. This cane is then transported in trucks or through rail to the mill.

bajaj hindusthan ltd., has a total of 1,41,155 hectares of culturable land under their

command area. This area covers 1,344 villages and has over 95 centres. It purchases cane

from over 1,13,577 farmers. Assuming a family of 5 per household the economy of over

half a million households is dependent on bajaj hindusthan ltd.