the effects of final molasses and sugar · pdf filethe effects of final molasses and sugar...

THE EFFECTS OF FINAL MOLASSES AND SUGAR

PURITY VALUES ON THE CALCULATION

OF 960 SUGAR

AND FACTORY RECOVERY INDEX

BY

Heera Singh

Worthy Park Estate Ltd.

INTRODUCTION

The objective of this paper is not to test the accuracy of Quality Control Methodologies ,therefore no standard deviation evaluation was done. Rather it characterizes the effectsof sugar and final molasses purities on some sensitive calculated values.

Sugar Purity is calculated using Sugar Pol % and Moisture % and with Final Molasses purity,are critical analytical results in the formula used to calculate the Copps Factor and Tonne 960Sugar which is used for F.R.I. determination.

Sugar Factory Laboratories during cropping period are required daily to analyze Raw Sugarfor Pol% and Moisture % and Final Molasses for Purity. Portion of these samples areuniformly composited for weekly recheck at S.I.R.I. Central Laboratory. The results are sentto Factories with the comparative values. The to date data in Report No. 34 for Week Ending30‐07‐11 during the 2010/2011 crop were used in the statistical calculations in this paper. Itmust be noted that there are some slight difference in statistical values in S.I.R.I. reports forsome Factories, but this in no way alters the objective this paper is intended to demonstrate.

This paper consists of four sections. The first being a list of formulae used, followed by sugarand final molasses analyses used in the recalculated values and comparing with the valuesreported. The final two sections consist of analytical compliance information followed bysuggestions and conclusion.

SECTION 1 – FORMULAE USED

Refractometer Purity of Final Molasses = Pol % ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ x 100Refractometer Brix

Hydrometer Purity of Final Molasses = Pol % ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ x 100

Hydrometer Brix

Purity of Sugar = Pol% Sugar‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ x 100

100 ‐Moisture % Sugar ( 0Brix )

Copps Factor = 97 (Purity of Sugar – Purity of Final Molasses)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Purity of Sugar ( 97‐ Purity of Final Molasses) x 100‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

96

Tonne 960 Sugar = **Tonne Commercial Sugar x Pol % Sugar x Copps Factor‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

100

Note: ‐ ** Tonne Commercial Sugar is actual from scale weight.

Formulae are from A Manual of Analytical Methods for use in the Control Laboratories of Raw Sugar Factories ‐ Third Edition of the Chemical Control Committee of J.A.S.T. April 1983.

Factory Recovery Index (F.R.I. ) = Tonne 960 Sugar Calculated Made‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐x 100

Tonne J.R.C.S Core

SECTION 2‐ PRESENTATION OF FINDINGS

DIFFERENCES IN SUGAR POL % ANALYTICAL RESULTS AT THE FACTORIES COMPARED TO S.I.R.I.

98.1

98.2

98.3

98.4

98.5

98.6

98.7

98.8

98.9

99

Factory 'A' Factory 'B' Factory 'C' Factory 'D' Factory 'E' Industry

98.77

98.71

98.4 98

.79 98

.98

98.69

98.89

98.85

98.44

98.84

98.97

98.75

Factory Sugar Pol %

S.I.R.I. Sugar Pol %

SECTION 2‐ PRESENTATION OF FINDINGS CONTINUED

DIFFERENCES IN SUGAR MOISTURE % ANALYTICAL RESULTS AT THE FACTORIES COMPARED TO S.I.R.I.

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5


0.34

0.4

0.34

0.3

0.24 0.

32

0.32

0.49

0.47

0.3

0.3

0.38

Factories Sugar Moisture %

S.I.R.I. Sugar Moisture %


EFFECTS OF SUGAR PURITY VALUES CALCULATED USING THE ANALYTICAL RESULTS FROM SUGAR FACTORIES AND S.I.R.I

98.4

98.5

98.6

98.7

98.8

98.9

99

99.1

99.2

99.3

99.4


99.11

99.11

98.74

99.09

99.22 99.01

99.21

99.34

98.9 99.14

99.27

99.13

Sugar Purity Calculated from Factories SugarPol % and Moisture % Analyses

Sugar Purity Calculated from S.I.R.I. SugarPol % and Moist. % Analyses


DIFFERENCES IN S.I.R.I. FINAL MOLASSES REFRACTOMETER PURITY VERSUS FACTORIES RESULTSNOTE ONLY TWO FACTORIES ARE REPORTING REFRACTOMETER PURITY

0

5

10

15

20

25

30

35

40


32.26

36.54

35.36

36.4

31.87

34.8

32.69

35.92

36.49

37.55

28.07

35.07

Factories Final Molasses Purity

S.I.R.I. Final Molasses Refractometer Purity


DIFFERENCES IN 96 0 SUGAR CALCULATED VALUES USING S.I.R.I. SUGAR POL %, MOIST. % AND FINAL MOLASSES REFRACTOMETER PURITY COMPARED WITH THAT REPORTED BY FACTORIES

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

Factory A Factory B Factory C Factory D Factory E

31,031

16,126

41,683

28,680

22,079

31,099

16,163

41,778

28,746

22,039

Factories Calculated Tonne 96 Deg . Sugar as stated in S.I.R.I. Report

Calculated 96 Deg. Sugar Based on S.I.R.I.Pol % , Moist % and Refractometer Final Molasses Purity


REVENNUE INCREASE (+) /DECREASE (‐) USING TONNE 96 0 SUGAR CALCULATED WITH S.I.R.I. SUGAR POL %, MOIST. % AND FINAL MOLASSES REFRACTOMETER PURITY AND COMPARING WITH FACTORY REPORTED

Factories Factories Calculated Tonne 960Sugar as stated in S.I.R.I.

Report

Calculated 960

SugarBased on

S.I.R.I.Sugar Pol %, Moisture % Final

Molasses Refractometer

Purity

Tonne 960Sugar Difference

Price per Tonne 96 Deg. Sugar

$36,000JD Revenue Gain + Less –

In Million JD

Factory ‘A’ 31,031 31,099 + 68 +2.45

Factory ‘B’ 16,126 16,163 +37 +1.33

Factory ‘C’ 41,683 41,778 +95 +3.42

Factory ‘D’ 28,680 28,746 +66 +2.38

Factory ‘E’ 22,079 22,039 ‐40 ‐1.44

Industry 139,599 139,864 +265 +9.54


DIFFERENCES IN F.R.I. VALUES USING TONNE 96 0 SUGAR CALCULATED WITH S.I.R.I. SUGAR AND FINAL MOLASSES ANALYSES VALUES AND COMPARING WITH THAT REPORTED BY FACTORIES

75

80

85

90

95

100


97.97

87.62

80.21

92.59

96.28

89.42

98.18

87.82

80.39

92.8

96.11

89.59

Factory Reported F.R.I.

Calculated F.R.I. Using 96 Deg.Sugar Evaluated from S.I.R.I.Sugar Pol %, Moist. % andRefractometer Purity


COMPARISON OF S.I.R.I. FINAL MOLASSES PURITY HYDROMETER WITH REFRACTOMETER

0

5

10

15

20

25

30

35

40


30.55 33

.89

35.62

35

26.87

33.56

32.69

35.92

36.49 37.55

28.07

35.07

S.I.R.I. Final Molasses Hydrometer Purity

S.I.R.I. Final Molasses Refractometer Purity


EFFECTS OF TONNE 960 SUGAR CALCULATED VALUES USING S.I.R.I. REFRACTOMETER AND HYDROMETER FINAL MOLASSES PURITIES AND FACTORIES SUGAR POL % AND MOIST. %

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

Factory A Factory B Factory C Factory D Factory E

31,014

16,101

41,704

28,682

22,024

31,046

16,119

41,721

28,722

22,036

Calculated Tonne 96 Deg. Sugar with S.I.R.I. Hydrometer Purity and Factories Sugar Pol % and Moist. %

Calculated Tonne 96 Deg. Sugar with S.I.R.I. Refractometer Final Molasses Purity and Factories Sugar Pol % andMoist. %


TABULATION OF THE INDUSTRY TONNE 96 0 SUGAR CALCULATED WITH S.I.R.I. SUGAR AND FINAL MOLASSES RESULTS COMPARED WITH THAT FROM THE FACTORIES SHOWING INCREASE / DECREASE

Details of Analytical Results used in

Recalculation of Figures for the Industry

Industry Calc. Tonne 960 Sugar with S.I.R.I.

Analyses

Industry Tonne 960

Sugar Reported by Factories

Tonne Increase (+) / Decrease (‐)

Total Tonne 960 Sugar recalculated using S.I.R.I.

Pol %

139,798 139,599 + 199


Moist. %

139,713 139,599 + 114


Refractomter Purity

139,686 139,599 + 87


Hydrometer Purity

139,582 139,599 ‐17

SECTION 3

ANALYTICAL PROCEDURE AT THE VARIOUS SUGAR FACTORIES COMPARED WITH THE INDUSTRY STANDARDS

SUGAR POL% DETERMINATION AT THE VARIOUS FACTORIES COMPARED TO THE INDUSTRY STANDARD

Factories Sugar Pol Determination Industry Standard

Factory ‘A’ JAST Manual Method , Celite Filter Aid – NIR Pol Reading

Compliant

Factory ‘B’ JAST Manual Method ,Octopol Reagent‐NIR Pol

Reading

Non Compliant

Factory ‘C’ JAST Manual Method ,Dry Lead Reagent‐ NIR Pol

Reading

Non Compliant

Factory ‘D’ JAST Manual Method , Octopol Reagent‐ NIR Pol

Reading

Non Compliant

Factory ‘E’ JAST Manual Method ,Celite Filter Aid‐ NIR Pol Reading

Compliant

S.I.R.I. JAST Manual Method ,Celite Filter Aid‐ NIR Pol Reading

Compliant

SECTION 3 CONTINUED


SUGAR MOISTURE % DETERMINATION AT THE VARIOUS FACTORIES COMPARED TO THE INDUSTRY STANDARD

Factories Sugar Moisture Determination

Industry Standard

Factory ‘A’ JAST Manual Method ‐Oven Compliant

Factory ‘B’ JAST Manual Method ‐Oven Compliant

Factory ‘C’ JAST Manual Method ‐Oven Compliant

Factory ‘D’ JAST Manual Method ‐Oven Compliant

Factory ‘E’ JAST Manual Method ‐Oven Compliant

S.I.R.I. JAST Manual Method ‐Oven Compliant

SECTION 3 CONTINUED


FINAL MOLASSES PURITY DETERMINATION AT THE VARIOUS FACTORIES COMPARED TO THE INDUSTRY STANDARD

Factories Final Molasses Purity Determination

Industry Standard

Factory ‘A’ Hydrometer Purity Non Compliant

Factory ‘B’ Hydrometer Purity Non Compliant

Factory ‘C’ Refractometer Purity Compliant

Factory ‘D’ Hydrometer Purity Non Compliant

Factory ‘E’ Refractometer Purity Compliant

S.I.R.I. Refractometer/Hydrometer Compliant

SECTION 4

SUGGESTIONS

1. Standardize the entire Industry analytical equipment, apparatuses, filter aid andprocedure for Sugar Pol % determination.

2. Standardize the entire Industry analytical equipment, apparatuses, filter aid andprocedure for Final Molasses Refractometer Purity determination.

3. Enforce the Industry Standard of Refractometer Purity methodology for FinalMolasses determination.

4. Implement in the Industry where it is not in place the recording of three numericaldigits after the decimal for Refractometer Final Molasses Purity, Sugar Pol %,Moisture % , F.R.I. And Tonne 96 0 Sugar. See the following tabulation.

SECTION 4 ‐SUGGESTIONS CONTINUED

Factories Factories Calculated Tonne 960Sugar as stated in

S.I.R.I. Report

Calculated 960 SugarBased on S.I.R.I.Sugar Pol %, Moisture % Final Molasses

Refractometer PurityFactory ‘A’ 31,031 31,099Factory ‘B’ 16,126 16,163Factory ‘C’ 41,683 41,778Factory ‘D’ 28,680 28,746Factory ‘E’ 22,079 22,039Industry 139,599 Cal. Value =139,864

Added Value= 139,825

5. Revise the Manual of Analytical Methods for use in the Control Laboratories ofRaw Sugar Factory. The Second edition was in 1965 with the third 1983 , twentyeight years ago.

6. S.I.R.I. to consider accommodating Collaborative Refractomter Final MolassesAnalyses if practically possible. Frequency every crop can be benched markedsimilar to the present procedure employed for cane and sugar.

SECTION 4‐ CONCLUSION

With the application of the Industry Standard Technological Information, Scientific Data andMathematical Calculations the analytical results of Sugar Pol %, Moisture % and FinalMolasses Refractometer Purity all have varying effects on the calculated values of Tonne 960Sugar and F.R.I. For the 2011 crop this study shows that the analytical variance with SugarPol % having the most significant effect on the Tonne 960 Sugar Calculated Value at +199Tonne. The Moisture % was second at +114 Tonne while the Refractometer Final MolassesPurity having the least effects at +87 Tonne. These values ultimately impacts on dollar valuefor the revenue earned.

The Standard Refractometer Final Molasses Purity Value shows a plus one hundred and four(+104) Tonne 960 Sugar for the Industry compared to that derived using the HydrometerPurity in the formula and is advantageous for the remainder of Factories to comply with thatstandard.

The F.R.I. value was affected by the variation of recalculated amount of 96 0 Sugar and wasbetween + 0.17 to + 0.21 %.

By observing standard operating procedures with analytical methodologies, standardstatistical procedures for data evaluation, instrumentation validation, reagent/materialscertification, analyst certification, laboratories facilities certification and sample tracking willguarantee Factories Laboratory and S.I.R.I. Laboratory producing comparable sugar and finalmolasses analytical results with negligible and highly acceptable levels of effects in thecalculation of tonne 96 o sugar and F.R.I.

ACKNOWLEDGEMENT

Thanks to the Director of Worthy Park Factory for allowing me time to do thispaper. Grateful to members of S.I.R.I.’S Statistical, Analytical and TechnologyDepartments and my Wife and Son for their respective assistances.

THANKS FOR YOUR ATTENTION

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