case studies sugar
TRANSCRIPT
SINET
Indian Sugar Sector Network
Case Study (Draft)
Within the initiative
Sustainable Industrial Networks and Its applications on Micro
Regional Environmental Planning (SINET)
Partner Organizations
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PURTI COPURTI COPURTI COPURTI CO----OPERATIVE SUGAR MILL LTD.OPERATIVE SUGAR MILL LTD.OPERATIVE SUGAR MILL LTD.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
complex is spread over 250 Acres and consist of the
following
• Sugar complex -capacity 2500 TPD/day (tons
per day)
• Distillery complex- capacity Sprit– 45,000 KLPD
(kilo liters per day) Ethanol– 1,20,000 KLPD
• Co-generation complex( capacity 220 MW)
• Bio-disel complex capacity (3000 liters/day)
• Bio-composting unit
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
more than 12 to 15 hrs.
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
ultimately provides secondary employment to the nearby communities.
A view of the sugarcane field A view of the sugarcane field A view of the sugarcane field A view of the sugarcane field
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Social InputsSocial InputsSocial InputsSocial Inputs • Provides direct employment to about
700 to 800 workers • Approximately 3000 families are
benefitted within 10,000 Acres of sugarcane growing region in the nearby area
Economic InputsEconomic InputsEconomic InputsEconomic Inputs
• Support services like labour
contractor (Provider) • Harvester (Skilled Migrated workers) • Hardware services • Besides cotton and orange; it gives
option to the farmers as a cash crop
In general, almost all sugar mills depend for their supplies of
sugar cane on large number of independent farmers, producing
the crop for profits. If the yield per hectare is improved, the
benefit goes to the growers while if the cane is rich enough in
sugar content; it becomes profitable to the mills. Therefore cane
growing and milling are essentially a joint enterprise what helps
the grower helps the miller and vice- versa.
Sugarcane considered as a alternative crop in this area , most of
the farmers go for the cotton, some of them cultivating orange ,
which in this area, gives a good income to the farmers.
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
cane from nearby areas. The harvesters which are
deployed by the mill are mostly from the area where
the sugarcane growing and harvesting is a traditional
business like western Maharashtra, Maratwada &
Andhra Pradesh. They are largely migrated
workers who live nearby to the factory in small
tents (Zopadi). They harvest the crop and then load
it on to the vehicle in presence of the crop owner
(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-
cials will note down the entry of the crop weight,
name of crop owner and the vehicle number, for fur-
ther procedure. The payment of the crop will directly
be deposited in the account of each farmer or can be
paid directly . The sugarcane vehicles is then unloaded
at the crushing centre with the help of lifters, the
lifted bundle of sugarcane is then conveyed
to the cane leveler where it is cut and chipped. The
cut cane blanket is then fed to tandem of mill,
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
are the steps, which are involved in the manufacturing of sugar.
A view of lifting & unloading of sugarcane A view of lifting & unloading of sugarcane A view of lifting & unloading of sugarcane A view of lifting & unloading of sugarcane
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Extraction of juice:The extraction is actually conducted as a counter-current process using fresh hot
water being pumped at one end in the opposite direction to
the cane. The more the water is used, the more is the sugar
extracted but the more dilute the mixed juice, hence more
energy will be required to evaporate the juice. In many
factories, the cane is crushed in a series of large roller
mills similar to a mangle [wringer] and the sweet juice
extracted. Generally juice looks pretty dirty, because of
contamination with soil particles from the fields, small
fibers and
the green extracts from the plant. There are several
important aspects to extraction which involve the energy
balance of the mill, the efficiency of extraction and
therefore ultimately the profitability of operations. The
fibrous cane material after the extraction of juice is
called the bagasse
Clarification: -The extracted juices are then heated to
60-65o c in juice heater and passed to reaction tank where
the liming and sulphitation takes place. This limed and
sulphited juice is pumped back to a ‘clarifier’ after heating
to 100o c. which remains there for about 3 hr. During this
stage in the clarifier, the heavy insoluble impurities, mostly
soil and mud are precipitates which are then pumped to a
vacuum filter, which remove the liquid portion from the
mud, while the solid muddy portion is taken out of the
mill building. This is used as manure or can serve as raw
material for the extraction of crude wax.
Boiling: -The raw juice is now clarified and is called the
clarified juice. It is then passed through a set of
evaporator which boils the excess water under vacuum
concentrating it gradually, as it passes from one
evaporator to another. Finally concentrated juice called
the sugar syrup is sent to the pan floor wherein the final
crystallization takes place, under vacuum. The evaporation
is carried out under vacuum.
Tandem millTandem millTandem millTandem mill
Juice extraction by counter current Juice extraction by counter current Juice extraction by counter current Juice extraction by counter current
Removal of press mud Removal of press mud Removal of press mud Removal of press mud
Juice boiling section Juice boiling section Juice boiling section Juice boiling section
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Crystallization: - A viscous solid mass consisting of
sugar crystals and mother liquor is dropped in
the crystallizer and it then passes through the pug mills
to centrifugal machines. Due to very high gravity factor,
the viscous mother liquor passes through the opening in
the liner and the sugar is retained on the screen and the
sugar is then dropped in hopper.
Grading & Packaging:-
The sugar is then passed on to a unit called grader, which
grades the sugar in different grades and in different
sizes as per the Indian sugar standards. At present, Purti
is producing S-30 which is around Rs. 30– 100 less than
M-30 grade of sugar. The sugar is bagged in the
pre-stamped gunny bags, weighed; the grades and number
marked on the bags and these bags are stored in godowns
and are finally sold. The transportation of sugar from mill to market is mostly carried out by road. Though
the Indian sugar industry is more concentrated in rural part of India but the area is well connected with
most of the metropolitan cities in India.
Distillery Complex
The by-product generated from the production of sugar is
sent to the down stream industry. Molasses, generated
from sugar manufacturing finds its way to the distillery
industry which is adjacent to the sugar complex, where it
is used as a raw material to produce various industrial
chemicals, alcohol, and power biofuels. Presently M/s Purti
Co-operative Sugar Mill has a well equipped distillery
complex for production of Sprit and Ethanol with installed capacity of 45,000 KLPD of sprit and 1,20,000
KLPD of ethanol which is an important basic feed stock
for manufacture of various chemicals. These chemicals
are good substitutes for petrochemicals and petrol based
chemicals in India. The waste water produced is treated
in the effluent treatment plant and then treated water
is recycled for on-site use, sent back to the river or used
to irrigate the cane-farms.
Molasses stream Molasses stream Molasses stream Molasses stream
A view of the DistilleryA view of the DistilleryA view of the DistilleryA view of the Distillery
Packaging facility Packaging facility Packaging facility Packaging facility
Sugar crystal formationSugar crystal formationSugar crystal formationSugar crystal formation
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Co-generation Complex
The fibrous cane material left after the extraction of juice,
called bagasse goes to the boiler, wherein the same is burnt
producing steam and electricity. At present M/s Purti
Co-operative Sugar Mill is producing 2 MW electricity that
powers the mill to process sugar from cane juice and alcohol
in distillery industry.
M/s Reliance Industries has recently signed an electricity
purchase
agreement of 220 MW with Purti. The bagasse is being
stored into a open ground. The construction of full fledge
co-generation plant is ongoing. Very soon it will start working
to its full capacity. the two multi fuel boiler has been
constructed with installed capacity i.e. working pressure
22 KG and 67 KG respectively
Bio-Disel Complex
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
extra cost to the mill, which prompted Mr. Gadkari chairman
of this mill and he had started the bio-disel plant with an
installed capacity of 3000 liters as a solution to the problem.
This complex has started to make biodisel from cotton seed
oil and Jatropa (local name karanji) cotton seed which is
locally available in good quantity and quality. Presently all the
vehicles ,generators and other instruments which need
petroleum fuel are running on biodisel produced by M/s Purti
Co-operative Sugar Mill.
A view of the bioA view of the bioA view of the bioA view of the bio----disel plantdisel plantdisel plantdisel plant
Electricity GridElectricity GridElectricity GridElectricity Grid
CoCoCoCo----generation unitgeneration unitgeneration unitgeneration unit
4 KG Cotton seeds
1 KG oil Seed cake (as cattle feed)
Bio-disel plant
900 gm. Bio-disel (90-95 % recovery) Glycerin 100 gm. (5-10 %)
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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
reservoirs and provides a irrigation facility on subsidized rate.
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.
5) It is highly recommended that mill should established agriculture development department.
Acknowledgement
Mr. Nitinji Gadkari, Chairman
Mr. Sudhir Diwe, Managing Director
Mr. D. R. Jadhav, Works Manager (Sugar)
Mr. Sandeep Mendjoge, Sr. Executive Admin.
M/s Purti Sakhar Karkhana Ltd.
2nd floor, Khadi Gramodyog Bhavan, Gandhisagar,
Mahal, Nagpur-440 002
Maharashtra, India
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SHRI RAJARAMBAPUSHRI RAJARAMBAPUSHRI RAJARAMBAPUSHRI RAJARAMBAPU CO CO CO CO----OPERATIVE SUGAR OPERATIVE SUGAR OPERATIVE SUGAR OPERATIVE SUGAR MILL LTD.MILL LTD.MILL LTD.MILL LTD.
(RBCSM) (RBCSM) (RBCSM) (RBCSM) :
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
stone for the mill.
This co-operative sugar mill has an enormous
importance for the surrounding community. This
complex is a multi-product complex moved around
the sugarcane farm. The sugarcane is one of those agricultural
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
their crop to any mill offering them good price.
A view of A view of A view of A view of the RBCSM the RBCSM the RBCSM the RBCSM factoryfactoryfactoryfactory
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The mill has their third party contractor for harvesting and transpor-
tation. The mill provides vehicles required to transporting sugarcane
from field to the mill and only manpower has to be employed by the
transporting contractor. The owner of the
vehicle is from the operational area. In
every season the mill provides the catalogue
of the crop to be harvested in succession so
as to assure the supply of sugar cane from
the command area. The harvesters under
supervision of the agriculture devel-
opment officer (ADO) of the mill will har-
vest the crop and then load on to the vehi-
cle in presence of the crop owner (Farmer).
Social InputsSocial InputsSocial InputsSocial Inputs
• Established Engineering collage and School
• Agricultural soil testing
laboratory, Nursery • Medical facility for the
community • Subsidies/Loans for the farmers • Infrastructure like road,
transport etc.
Economic InputsEconomic InputsEconomic InputsEconomic Inputs
• Support services like labour contractor (Provider)
• Harvester and Transporter
• Hardware services
• Supplier of chemicals for the industrial process
Almost all sugar mills depend for their supplies of sugar cane on
large number of independent farmers, producing the crop for
profits. Sugarcane holds a prominent position as cash crop in this
region and that’s why most of the farmers cultivate it to make a
profit. The mill has their own soil-testing laboratory, which is
equipped with all the latest sophisticated instruments and
provides a facility for soil testing and fertilizer dose
recommendation to the farmers on nominal charges to increase
better sugarcane yield in the area.
In this region, most of the farmers and the labourers are
involved in the activities, which are directly or indirectly related
with sugar production, sugarcane-crushing season is for six
months in this period most of the people are employed through
harvesting, loading and transportation activity.
Liquor (distillery Liquor (distillery Liquor (distillery Liquor (distillery
AchievementsAchievementsAchievementsAchievements
• Best sugar mill in Maharashtra State: trophy
• South zone Best Technical
Efficiency Award In Maharashtra State From Maharashtra State Sugar Mill Association Ltd, Mumbai
• Best Cane Development Award
- South Zone • Best Financial Management
Award • Best Technical Efficiency
Award South Zone
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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Sugar Industry Network of RBCSM:
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
then be sent to the distillery industry. Bagasse is used as a fuel in boilers or in
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.
Sugarcane Farm
Harvesting, Loading & Transportation of Sugarcane
Sugar Mill
Molasses Sugar Press mud
Packaging
Market
Boiler
Methane Gas
Distillery
Alcohol/Sprit
Spent wash
Biogas Generation
Excess spent wash
Power supply to mill Co-generation
Ash
Composting
Bagasse
Manure
Supply to members and farmers
Chemical enrichment
Gur/Khandsari
Market
Branded manure
Land filling
MolassesMolassesMolassesMolasses
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On the other hand alcohol is used to produce various industrial chemicals and
supplied to the other industries. Bagasse is burnt as fuel in to boilers to
create electricity that powers the mill to process sugar from cane juice and
alcohol in distillery. Anaerobic digestion is being used to process left-over
effluent producing bio-gas. Produced bio-gas then sent to the boiler as a fuel.
The sugar produced is then packaged and stored.
The transportation of sugar from mill to market is mostly carried out by road.
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
economy of this area.
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
property water sources.
4) Mill shall think for using excess bagasse for paper making.
Acknowledgement
Mr. Jayantrao Patil (Chairman) Mr. N. S. Kadam (Managing Director) Mr. G. S. Nikam (Environment Engineer) Mr. Abasaheb N. Salunkhe (Agri. Development Officer) Mr. Subbash N. Patil (Soil-Lab and Green House Incharge) Mr. Vilas Patil (Manager Civil & Irrigation)
Shri. Rajarambapu Co-operative Sugar Mill Ltd
Tal: - Walwa, Dist: - Sangli, Maharashtra
India
Compost manureCompost manureCompost manureCompost manure
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SHRI TATYASAHEB KORE WARANA SHRI TATYASAHEB KORE WARANA SHRI TATYASAHEB KORE WARANA SHRI TATYASAHEB KORE WARANA COCOCOCO----OPERATIVE SUGAR OPERATIVE SUGAR OPERATIVE SUGAR OPERATIVE SUGAR
MILL LTD (WARANA)MILL LTD (WARANA)MILL LTD (WARANA)MILL LTD (WARANA):
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.
Generally sugar sector divided into two activities
1) Farming of sugar cane (farm level activity)
2) Production of sugar & By-product utilization
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
product utilization is vary depend on the facilities and the
technological know how available with the mill. Basically this
co-operative sugar mill and its down stream by product based
industries are belongs to the same promoter on the other way we can
say it’s an integrated complex.
Sugar mill capacity 7200 tonnes/day: Produced M-30, S-30, S-29
and S-31 grades of sugar.
Cogeneration: Bagasse being used as a fuel in boiler and the energy
produced is being used within the plant for the production of sugar.
excess amount will be sent to the grid.
Distillery: 9468878 liters of alcohol has been produced during
2003-04 season with near about 240.3 liter/tones of recovery.
Paper mill: - In 2003-04 1856 MT of paper has been produced.
But due to shortage of electricity, environmental consideration and
wastewater management paper mill was in operation for 88 days only.
At this point of time paper mill has been handover to M/s Sidharth
core board, Pune
AchievementsAchievementsAchievementsAchievements
• First prize for its best
technical efficiency in the year
1988-89 at the National
Federation of Co-operative Sugar
Factories Ltd. New Delhi.
• Awarded by Vasantdada Sugar
Institute, Pune for its best
technical efficiency and higher
reduce mill extraction in
Southern region of Maharashtra.
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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.
Other peripheral activities:
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.
Sugar Industry Network of Warana:
Sugarcane Farm
Harvesting, Loading & Transportation of Sugarcane
Sugar Mill
Molasses Sugar Press mud
Packaging Market Boiler Paper Mill
Market
Waste water (ETP)
Distillery
Alcohol/Sprit
Spent wash
Excess spent wash
Power supply to mill
Sludge
Co-generation
Ash
Composting
Bagasse
Manure
Supply to members and farmers
Chemical enrichment
Gur/Khandsari
Paper/Cardboard
Market
Branded manure
Land filling
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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:
Mr. Vinayrao Kore (Chairman) Mr. V. S. Chavan (Managing Director) Mr. Zaware (Public Relation Officer)
Shri. Tatyasaheb Kore Warana Co-operative Sugar Mill Ltd.
Warananagar, Tal: Panhala, Dist: Kolhapur, Maharashtra
India