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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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.

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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.

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

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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

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 organization’s 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.

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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.

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. Let’s 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 :

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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 customer’s needs are

translated into product specification by the design or engineering department. The

manufacturing department then translates this specification into measurable

objectives.

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

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other objective, which is lower in the hierarchy. These objectives are called

intermediate objectives.

2.4 Intermediate objectives:

Machinery and equipment’s

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 :

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.

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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

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 clothing’s 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

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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.

Characteristics:-

1. High verity of product and low volume.

2. Use of general purpose machines and facilities.

3. 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

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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

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

generally follows a specific and fixed sequence of operations.

Example:

1. Plants and equipment’s with zero flexibility.

2. Material handling is fully automated.

3. Large investment.

4. 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.

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Supplier Competitors Government

Subsystems of organizational system

a) Marketing:-

To create the demand for the company’s products or services and satisfy the

needs of the customers through company’s through various activities like market

research, marketing planning, sales administrating and advertising.

b) Finance:-

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Production

Production

Finance

Marketing Personnel


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

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

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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

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

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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 NAME OF AWARD

1999-2000 ‘Overall Best Sugar Factory in Maharashtra’

‘Best-Technical Efficiency in South-zone’

‘Best-cane Development in South-zone’

‘Best-Financial Management in South-zone’

2000-01 ‘Best-cane Development in South-zone’

2000-02 ‘Overall Best Sugar Factory in Maharashtra’

‘Overall Best Distillery in Maharashtra’

‘Best-Technical Efficiency in South-zone’


‘Best-Financial Management in South-zone’

2003-04 ‘Best-Technical Efficiency in South-zone’


2005-06 ‘Best Technical Efficiency in South Zone’

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2009-10 ‘Sangli District Industrial Safety Committee’

2010-11 ‘Sangli District Industrial Safety Committee’


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 J-

2000 Certificate since the year 2000 and implemented it across sugar and its hi-

product 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.

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 6

Printers 36 6

U.P.S. 18 6

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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

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

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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

2. Modern method of sugar cultivation

3. Undertaking of the project- Educational, Medical, Agricultural and public

4. Charitable purpose

5. Creating/Establishing/Running Hospitals, Medical charity and welfare.

6. Educational aid-Montessori/School/Colleges/Research.

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7. Granting aid-Research in high yielding varieties of seeds, manures, fertilizers,

insecticides etc.

8. Fair shops- Agricultural equipment’s, 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.

no.

Names Designation Village/Town

1 Shri. Pandurang Ramrao Patil Chariman Kurlap

2 Shri. Vijay Balwantrao Patil Vice-

Chairman

Sakharale

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3 Shri. Jayantrao Rajaram Patil

(Home Minister Maharashtra

state)

Director Kasegaon

4 Shri. Jagdish Shamrao Patil Director Kameri

7 Shri. AnandraoTukaram Patil Director Gotkindi

8 Shri Shankarrao Sampatrao

Patil

Director Islampur

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

Salunkhe

Director Karandwadi

16 Shri. Anandrao Dattu Patil Director Rethare Dharan

17 Shri.Jagnnath Yashwant Patil Director Burli

18 Shri. Bhimrao Shamrao pawar Director Kundal

19 Shri. Prakash Ramchandra

Pawar

Director Kundal

20 Shri. Deelip Bapurao Patil Economical

Backward

Representative

Navekhed

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21 Shri. Jalinder Narayan Mahar Co-operative

Society

Representative

Kasegaon

22 Shri. Babaso Danaji Dhole Backward

Class

Representative

Kasegaon

23 Shri. Laximan Bapu Mali Other

Backward

Ashta

24 Mrs. Padmavati Shankarrao

Patil

Ladies

representative

Bagani

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

representative

Islampur

29 Shri. Mohan Anandrao Shinde Director Ashta

30 Shri. Rajendra Baburao

Chavan

Director Navekhed

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.

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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.

Financial Information (as 31-03-2006): Total share capital: Rs 608.72 lakhs.

Share capital-

Details No. Members Capital(In Lakhs)

Members 12.369 604.88

Co-operative 227 3.84

Societies total 12,596 608.72

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. Employees

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No. Unit No. 1 Unit No.2

1 General 63 3

2 Accounts 54 1

3 Computer 7 2

4 Civil & Irrigation 45 5

5 Sanitation 10 0

6 Agriculture-Office 39 0

7 Field staff 211 0

8 Cane yard 63 25

9 Vehicle 34 7

10 Time & Labour 10 5

11 Watch & Ward 33 5

12 Store & Purchase 28 7

13 Sugar godown 10 3

14 Manufacturing 215 119

15 Engineering 344 189

16 Distillery 52 0

17 Liquor 28 0

18 Environment 21 1

Total 1264 372

Total 163 Direct Emlpoyee

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f) ORGANIZATION CHART

Shareholders

Board of Directors

Managing Director

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Production Personal Marketing Finance Selling and

Department Department Department Department Distribution

Department

Production Labor Marketing Chief

Manager Welfare Manager Accountant Sales

Officer Manager Asst.production Retailer Accountant

Manager Security Supervisor

Officer

Production Workers

Supervisor Workers

Lab Assistant


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:

Raw

Juice

Lime & phosphors acid

Water

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Water

Cane unloading CleaningCane breaking

breaking

Cane milling

Bagasse

Strainer

Volume Clarifier Evaporator Clarifier

Boilers

CrystallizerCentrifugal


Steam Wash

Syrup

Sugar crystals

Water Black strap molasses

Process flow diagram of sugar production

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 high-

pressure, super-heated steam to run turbines and produce electricity. The exhaust

steam is then used in other stages of production.

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Mud filtration

Filter cake “C”

Massecuit

Seeding

Solution

Water Wash

Cane Sugar A&B

Massecuit

Cane Sugar

Dryer

Bulk storage

Bulk load out


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 Cush-

and 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:-

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 75’C in the juice

heater heated juice is limited up to PH 9.5 to 9.8 by milk of time.

AGIMS, Sangli


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.

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.

AGIMS, Sangli


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

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 bagasse’s 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.

AGIMS, Sangli


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.

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

AGIMS, Sangli


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)

Crushing of sugarcane in the organization from year 2008 to 2014

Graph

No.4.1

AGIMS, Sangli

Crushing Season

Crushing Sugarcane in Quintals

2008-2009 8,62,110

2009-2010 8,66,112 2010-2011 9,51,428

2011-2012 8,54,264 2012-2013 8,96,402 2013-2014 9,21,289


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

The organization has continuously maintained average sugar recovery. It is about 11%

Graph No.4.2

AGIMS, Sangli

Crushing Season

Sugarcane Recovery

2008-2009 12.21% 2009-2010 12.15% 2010-2011 11.78% 2011-2012 12.28% 2012-2013 12.73% 2013-2014 13.01%


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:

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%

AGIMS, Sangli


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%


Total sugar made

Recovery = × 100

Cane crushed

104962.700

= × 100

854264.979

= 12.28%

AGIMS, Sangli



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

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

AGIMS, Sangli

Crushing Season

Total sugar production in (Tonnes)

2008-2009 10,52,896

2009-2010 10,52,894

2010-2011 11,21,500

2011-2012 10,49,627 2012-2013 11,41,516

2013-2014 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 Molasses’s Production in (Tonnes)

Graph No.4.4

AGIMS, Sangli

Crushing Season Total Molasses’s

Produced in (Tonnes) 2008-2009 21,904

2009-2010 31,454

2010-2011 35,139 2011-2012 34,713 2012-2013 35,071 2013-2014 31,421


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

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

AGIMS, Sangli

Sr. No.

Test parameter & unit

M-30Season 2010-2011

S-30 Season 2010-2011

Test methodadopted

1. Colour, IU 133 at PH 6.70

130 at PH 6.70

ICUMSA GS 2/3-10

2. Sulphardioxide mg/kg

17% 17% ICUMSA GS 2/A/7-33

3. Polarization% 99.90% 99.91% IS: 15279

4. Moisture% 0.0353% 0.0128% 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


Report No.: ST- 3585

Date: 8-8-2014


Sample Description: ST-6549, S-30, season 2013-2014

AGIMS, Sangli

Sr. No.

Test parameter & unit

S-30 Season 2013-2014

Test methodAdopted

1. Colour, IU 110 ICUMSA GS 2/3-10

2. Sulphardioxide mg/kg 12.90% ICUMSA GS 2/1/7/9-33

3. Polarization% 99.76% ICUMSA GS 2/3-1

4. Moisture% 0.027% ICUMSA GS 2/1/3/9-15


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 2013-2014 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


Report No.: ST-3633

Date: 26-12-2014


Sample Description: ST-6760, S-30, M-30 season 2014-2015

Sr. No.

Test parameter & Unit

M-30 Season 2014-2015

S-30 Season 2014-2015

Test method adopted

1. Colour, IU 88 93 ICUMSA GS 9/1/3-82. Sulphardioxide 18.88% 21.21% ICUMSA GS 2/1/7/9-33

AGIMS, Sangli


mg/kg3. Polarization% 99.83% 99.85% ICUMSA GS 2/3-1

4. Moisture% 0.022% 0.024% ICUMSA GS 2/1/3/9-15

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

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)

AGIMS, Sangli


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 2010-

2011 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% M-

30 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.

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.

AGIMS, Sangli


Bibliography:

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

AGIMS, Sangli


Web bibliography:

1) http://www.bing.com/search?

q=rajarambapu+sugar&qs=SC&sk=OS1&pq=rajaram+bapu+s&sc=3-

14&sp=2&cvid=e81b48c52ad146bbaeb52e58a09bc741&FORM=QBRE

2) http://rajarambapusugar.com/

3) http://www.sucrose.com/lcane.html

AGIMS, Sangli

http://www.bing.com/search?q=rajarambapu+sugar&qs=SC&sk=OS1&pq=rajaram+bapu+s&sc=3-14&sp=2&cvid=e81b48c52ad146bbaeb52e58a09bc741&FORM=QBRE



http://www.sucrose.com/lcane.html

http://rajarambapusugar.com/