1. i
TABLE OF CONTENTS
CHAPTER
NO.
TITLE PAGE
NO.
SUMMARY iv
LIST OF TABLES vi
LIST OF FIGURES vi
1. INTRODUCTION 1
2. BRIEF DESCRIPTION OF THE MANUFACTURING PROCESS 2
2.1 PROCESS FLOW 2
2.1.1 MILL HOUSE 3
2.1.2 BOILER HOUSE 3
2.1.3 POWER HOUSE 3
2.1.4 CLARIFICATION AND EVAPORATION HOUSE 4
2.1.5 BOILING AND CURING HOUSE 4
2.2 DRIER HOUSE 5
2.3 UTILIZATION OF BY-PRODUCT 5
3. PLANT PROCESS DESIGN 6
3.1 TYPES OF PROCESS DESIGN 7
3.1.1 PRODUCT FOCUSED 7
3.1.2 PROCESS FOCUSED 7
3.2 FACTORS AFFECTING PROCESS DESIGN OF A PLANT 8
3.2.1 NATURE OF PRODUCT DEMAND 8
3.2.2 DEGREE OF VERTICAL INTEGRATION 8
3.2.3 PRODUCTION FLEXIBILITY 9
3.2.4 DEGREE OF AUTOMATION 9
3.2.5 PRODUCT QUALITY 9
4. PLANT PROCESS 11
4.1 PLANT PROCESS FOR SUGAR PRODUCTION 12
4.1.1 FIXED RATES IN SUGAR PRODUCTION 13

2. ii
4.1.2 MACHINERY MAINTENANCE 13
4.1.3 QUALITY TESTING OF CANE 14
4.2 PLANT PROCESS FOR POWER GENERATION 15
4.2.1 POWER ALLOCATION 18
4.2.2 POWER MAINTENANCE 18
4.3 PLANT PROCESS FOR ETHANOL PRODUCTION 19
4.3.1 RECTIFIED SPIRIT 20
4.3.2 ANHYDROUS ALCOHOL 21
4.3.3 SPENT WASH 22
4.3.4 SOIL TESTING 24
4.4 PLANT PROCESS FOR BIOCOMPOSITION 25
4.5 PLANT PROCESS FOR EFFLUENT TREATMENT PROCESS 27
4.5.1 ETP MAINTENANCE 28
5. EMPLOYEE PRODUCTIVITY IN PLANT 29
5.1 WORK MEASUREMENT AND LABOR STANDARD 29
5.2 LEARNING CURVE 30
5.3 PRODUCTIVITY 30
5.3.1 LABOR PRODUCTIVITY 31
5.4 EMPOWERING WORKERS 31
6. STOCK AND INVENTORY MAINTENANCE OF A PLANT 32
6.1 STOCK MAINTENANCE 32
6.2 INVENTORY MAINTENANCE 33
7. CONCLUSION 34

3. iii
SUMMARY:
Rajshree sugars and chemicals Ltd., was established by MR. Varadharaj in the year of
1989. Rajshree Sugars & Chemicals Limited (RSCL) is a public limited company listed on
National Stock Exchange (NSE) and Bombay Stock Exchange (BSE). The company has interests
across integrated fields such as Sugar, Distillery, Power and Biotechnology.
RSCL with its Corporate Office in Coimbatore has three modern sugarcane based integrated bio-
refinery complexes located at Varadharaj Nagar in Theni District, Mundiampakkam in
Villupuram District, Gingee in Thiruvannamalai District of Tamil Nadu and 1 unit at Zaheerabad
in Medak District of Andhra Pradesh with easy access to Tuticorin, Chennai and Visakhapatnam
ports. A corporation achieves a position of leadership only when its Vision is Steadfast and its
spirit Unremitting Resolute.
The Refinery Complex in Theni District is around 413acres with well reputed machineries and
equipments. In that they have allocated 150 acres for Green build development and the
remaining 263 acres for production process. The factory consists of 221 employees and 32
officers, in addition to this they also have indirect and contract labors. The factory activity is
fully based on the norms provided by Government and also by CISMA (Sugar Industry
Association).
Production of factory is fully based upon Monsoon; therefore factory is simultaneously facing
both RED (Low profit, High loss) and GREEN (High profit, Low loss) Period. Currently they are
in the state of facing turnover period (2 to 3% of profit) and they are expecting a forward growth.
The Factory has got ISO 9002 Certification and it is capable to produce sugar not only based on
domestic level expectation but also based on consideration provided by ICUMSA (As per
ICUMSA, if it is ICUMSA -100 means pure white sugar, ICUMSA -150 means which is less
pure white sugar). Whenever the factory meets the condition to export sugar they started to
follow ICUMSA norms for production and for Domestic Level distribution, the Factory has

4. iv
Allocated certain team in Chennai and Coimbatore in order to acquire and retain their customers,
Institutions (Pepsi & Coke) and Retailers.
Rajshree sugars and chemicals Ltd.., not only involved in sugar production but also involved in
power generation, ethanol production, Bio-organic from the wastage of distillation process. Thus
the plant is very efficient to produce useful product from the wastage.

5. v
LIST OF FIGURES
LIST OF TABLES
TABLE
NO.
NAME PAGE
NO.
3.2.5 SUGAR QUALITY 10
4.2 TURBINE CAPACITY 17
4.3.3 SPENT WASH PARAMETERS 24
FIGURE
NO.
NAME PAGE
NO.
3 PROCESS DESIGN OF A PLANT 7
4 OVERALL PROCESS OF A PLANT 11
4.1 SUGAR PRODUCTION PROCESS 12
4.2.1 POWER GENERATION FROM CANE 15
4.2.2 BOILER PROCESS FOR POWER GENERATION 16
4.3 ETHANOL PRODUCTION PROCESS 19
4.5 EFFLUENT TREATMENT PROCESS 27

6. 6
1. INTRODUCTION:
Rajshree Sugars and chemicals Ltd consist of 3 Units for their Production as
Sugar and Power Production unit, Distillery unit, Fertilizer unit. It is a type of Stream and
Electric drive plant. The capacity of the plant is rated at 2500 TCD. The plant works for 7 days a
week and 24 hours a day and it is stopped for a day per month for cleaning and servicing
purpose. The plant runs 8 months a year. One Sugar year from October to September .The
Factory is operating with 3 Shifts as,
1. I Shift - 5:00 AM to 1:00 PM
2. II Shift - 1:00 PM to 9:00 PM
3. III Shift - 9:00 PM to 5:00 AM
Some General Shifts as,
1. General Shift - 8:00 AM to 5:00 PM (for Factory Operation)
2. General Shift - 9:00 AM to 5:30 PM (for Administrative Operation)
Production Details of factory as follows:
Cane Crushed Per day - 3000 Tones (Average)
Sugar Produced Per day - 3000 Bags (Average)
1 Bag - 100 Kg
Size of Sugar - 600-900 Microns
Grade of Sugar - S-30
Ethanol Produced Per day - 45 Kilolitres
Power Produced Per day - 1, 00,000 Units

7. 7
The Power produced is being used for their captive consumption such as sugar production,
cooling tower operation and distillery and fertilizer plant. There are 4 types of processes
involved in plant as follows:
1. Process for Sugar Production
2. Process for Power generation and usage
3. Process for Ethanol Production
4. Process for Bio-composition
2. BRIEF DESCRIPTION OF THE MANUFACTURING PROCESS:
2.1PROCESS FLOW:
The Government of India has considered a 2500 TCD plant as a minimum
economical unit. In actual practice, economic viability or other wise of a plant is more related to
other factors, such as the initial capital cost, the period of gestation, between the time of the
project has been conceived and the time of its commission, the availability of cane within the
economic distance and a steady crush during the working season with a minimum of 200 to 250
days. Since most of those factors are variable, there have been instances where plants of a lesser
capacity have proved economically unviable while many 2500 TCD plants proved economical.
Generally process adopted in the manufacture f sugar in a sugar mill is Double Sulphitation
Process. Sugar factory consists of the following five main stations:
1. Mill House
2. Boiler House
3. Power House
4. Clarification and Evaporation House
5. Boiling and Curing House

8. 8
2.1.1 MILL HOUSE:
It is a cane crushing unit which consists of cane carrier, cane cutter having
and cutting knives, milling tandem (4 to 6 mills of 3 or 4 roller each) bagasse carrier and
conveyor. The sugar factory of 2500 TCD crushing capacity per day has only four mills 33” x
66” size rollers. There are 4 rollers in each mill. Cane feeding to the cane carrier is done by
mechanical unloading cranes.
As the cane carrier moves, the cane kicker evens out the load in the cane carrier and then two
sets of cane knives cut the cane into small pieces. This process of cane cutting is called ‘cane
preparation’. These cane pieces, then, pass through different mills and juice is extracted. The
mills are run by steam turbines, which are driven by the high pressure steam generated by the
boilers.
2.1.2 BOILER HOUSE:
There are 3 boilers in the factory, which generated steam by burning of
baggase. The Steam is used in mill house for running mill turbine, power house, boiling house,
curing house etc. In a sugar factory of 120 tons per hour crushing capacity have two boilers of 35
tons per hour steam generation each are used. The steam required by the Sulphitation process
varies from 44 – 55% of the cane is crushed per hour. The steam that generated in the boiler is
used directly by the mills where the heat energy is converted into mechanical energy and the
exhaust steam is taken to the process for evaporating water in the juice.
2.1.3 POWER HOUSE:
The major portion of the steam generated by the boilers is utilized for the
production power by the turbo – alternators. This power is sufficient for the running of different
electrical units of the sugar factory. Steam after converting its energy to electrical energy comes
out from turbo-alternator as exhaust steam. This exhaust steam is utilized in heating and boiling
the juice.

9. 9
2.1.4 CLARIFICATION AND EVAPORATION HOUSE:
The juice extracted by the mills is weighed by juice weighing scale and
thereafter it is heated in juice heaters to final juice temperature of 105 degree Celsius in different
temperature stages depending upon the clarification process. Juice is heated in juice heaters by
the exhaust steam coming out of the turbo-alternator, mill turbines and by the steam vapors
collected from the different bodies of the evaporators.
Clarification is carried out in the following ways: Juice is first heated to a temperature of 65-70
degree Celsius and the required lime and sulphur dioxide gas is added to it. The treated juice is
passed through clarifier, where in clear juice and mud is separated. Mud is taken to vacuum filter
in which filter cake is separated and sent out side. The filtered juice from vacuum filter is taken
back to mixed juice. Clear juice from clarifier is taken to evaporator for evaporating its water
content. The evaporators-set consists of five bodies. V’th body is kept under 25”vacuum. First
body is heated by exhaust steam, and other bodies by the vapors of the previous body. The total
water evaporated in the evaporator is 75-80%. The juice after evaporation is called syrup. This
syrup is normally of 60 brix. The syrup is then sulphited in syrup Sulphitation tower.
2.1.5 BOILING AND CURING HOUSE:
Sulphited syrup is kept at the pan floor in the storage tanks. There are
five pans of 60 tons capacity each in sugar factory of 2500 tons crushing capacity. The syrup in
these pans is boiled under vacuum. Three massecuites boiling systems is normally adopted, in
which A, B and C massecuites are formed. A- Massecuite after boiling is dropped into
crystallizers and then from crystallizers, it is taken to A-centrifugal machines for curing, where
A-sugar, A-heavy and A-light molasses are separated. ‘A’ sugar is bagged after drying and A-
light and A-heavy molasses are pumped to pan floor and are used for making A-Massecuite and
B-Massecuite respectively.
B-Massecuite boiled in B pans is dropped into B- Crystallizers and it then cured in B-
Centrifugal machines. B-heavy molasses and B- single cured sugar are separately obtained. B-
single cured used for seed. B-heavy molasses are pumped to pan floor and are use in making C-
Massecuite in C- pans. C-Massecuite is dropped into C-Crystallizers where it is cooled for
around 20-24 hours. From C- Crystallizers, C-Massecuite is then taken to C-fore worker

10. 10
centrifugal machines for curing. Final molasses and C- single cured sugar are obtained. ‘C’
single cured sugar is again cured in another centrifugal machine in which C-double cured sugar
and C-light molasses are separated. C-light molasses are taken to pan floor and are used in
making C-Massecuite. C-double cured sugar is melted and is using in making ‘A’ Massecuite.
2.2 DRIER HOUSE:
Sugar discharged from ‘A’ machine dropped on to grass hopper conveyors.
By letting hot air in hoppers the sugar is dried and taken to grader in which different grades of
sugars are separated and bagged as per grains size.
2.3 UTILIZATION OF BY-PRODUCT :
The three principal by-product of a sugar industry are bagasse, molasses
and press cake. These three by - product alone consists about 40% of the weight of the total cane
crushed. Bagasse itself accounts for about one-third of the weight of the cane crushed. Proper
and economic utilization of these by – Product cans reduced the cost of production of sugar to
some extent.
Besides bagasse, molasses are used in the production of industrial alcohol and potable spirits.
Almost 80% of the total quantity of molasses produced is utilized for this purpose and the
balance 20 % are utilized for cattle feed and other purpose. The Filter cake is used as manure in
agricultural lands.

11. 11
3. PLANT PREOCESS DESIGN:
Fig 3
Process Structure
 Services
 Manufacturing
 Layout
Customer Involvement
 Low involvement
 High involvement
Resource Flexibility
 Specialized
 Enlarged
Capital Intensity
 Low automation
 High automation
Strategy for change
 Process reengineering
 Process improvement
Effective
Process design

12. 12
3.1 TYPES OF PROCESS DESIGN:
Designing of a plant is the important activity of a plant. The
effective process design could be obtained with the help of four factors as Process structure,
Customer involvement, Resource flexibility and Capital intensity. The plant follows 2 types of
process design as:
 Product focused
 Process focused
3.1.1 PRODUCT FOCUSED:
In Product focused, the processes are arranged based on the sequence of
operations which is required to produce a product.
In this plant, in order to get a final product (Sugar) they are focused to arrange the process based
on sequence as Weighing and Sampling , Preparation, Milling, Clarification, Evaporation,
Crystallization , Centrifugal Separation and Drying .
3.1.2 PROCESS FOCUSED:
In Process focused, Processes are arranged based on the type of process
which means that jobs move from department to department based on the particular job’s
processing requirements.
In this plant, in order to maintain the equipments efficiently to get the effective product, the
machineries have been maintained by using the concept called process focused. In this, the
equipments have been moving from process department to other department which include both
mechanical and electrical for effective maintenance.

13. 13
3.2 MAJOR FACTORS AFFECTING PROCESS DESIGN OF A PLANT:
There are 5 major factors which affect the plant designing process as,
 Nature of Product/Service demand
 Degree of vertical integration
 Production flexibility
 Degree of automation
 Product/Service quality
3.2.1 NATURE OF PRODUCT/SERVICE DEMAND:
Production process must have adequate capacity to produce
the volume of product that customers need. Provisions must be made for expanding or
contracting capacity to keep pace with demand patterns. Some types of processes are more easily
expanded and contracted than others. Product price affects demand, so pricing decisions and the
choice of processes must be synchronized.
In this production process, the raw material is completely depends upon the nature/ monsoon. So,
the demand for the raw material is also based upon the monsoon but the demand for the product
is always open because it’s a consumable one .Therefore the demand for the product is always
high on the other hand the price for the product decreases (as per economy) .
The plant which is also based on production of ethanol ; therefore this plant faces either double
profit or double loss which means that there is a price increment in ethanol that automatically
leads to increase the price of sugar and vice-versa.
3.2.2 DEGREE OF VERTICAL INTEGRATION:
Vertical integration is the amount of production and
distribution chain that is brought under the ownership of the company. This determines how
many production processes need to be planned and designed. Decision of the integration is based
on cost, availability of capital, quality, technological capability and more. Strategic outsourcing

14. 14
(lower degree of integration) is the outsourcing of processes in order to react quicker to changes
in customer needs, competitor actions, and technology.
3.2.3 PRODUCTION FLEXIBILITY:
Product flexibility is ability of the production system to
quickly change from producing one product to another. Volume flexibility is the ability to
quickly increase or reduce the volume of product produced.
In this plant, both the product and volume flexibility are maintained effectively. They have
machineries which are capable to produce maximum 8Lakh tons of sugar and minimum to
lower level. Their machines are very capable to adjust both their product and volume flexibility.
So that, they can maintain their production flexibility in an efficient manner.
3.2.4 DEGREE OF AUTOMATION:
Automation refers to the process of using automatic
equipment in manufacturing. It have both advantages and disadvantages .Automation helps the
manufacturing unit to improve their product quality, improves product flexibility and it also
reduces labor and related costs. It also lead to give some disadvantage as equipment can be very
expensive, integration into existing operations can be difficult.
In this plant, they are using semi-automated technique because of huge investment is required for
automation and they also wish to give employment opportunities to the people who are in the
rural side. These are the major reasons for this plant to use semi-automated technique.
3.2.5 PRODUCT QUALITY:
Old view point of product quality is that high quality
products must be made in small quantities by expert craftsmen and the new view point is that
high quality products can be mass produced using automated machinery. Automated machinery
can produce products of incredible uniformity. The choice of design of production process is
affected by the need for superior quality.

15. 15
In this plant, the quality of sugar has been tested based on color, size, sulphur & lime content,
black and dust particles as follows:
Table 3.2.5
If the produced sugar has achieved the specified quality then it will undergo for packing and
storing, if not the production will be re-generated to get the appropriate product.
These are the five major factors which affecting the process designing of a plant but the plant
managers has involved in curious prediction and analysis to overcome these factors; that help
them to overcome those factors and also help them for an efficient plant design .
Content Contains
Color Less than or equal to 150
Size 720 micron
Sulphur content 30ppm
Lime content 50ppm
Non-Sugar 0.1
Black & Dust particles Avoiding this by using
Magnet

16. 16
4. PLANT PROCESSES:
Rajshree sugars and Chemicals Limited (RSCL) involved in 5 major process as follows:
1. Process for Sugar Production
2. Process for Power generation and usage
3. Process for Ethanol Production
4. Process for Bio-Composition
5. Process for Effluent Treatment Plant (ETP)
Process for sugar production is the primary process and the other 4 process could be considered
as a dependent process because wastage from each production acts as an initiator for further
process, represented in the form of fig as follows;
Sugar cane
(1)Sugar production Bagasse Filter cake Molasses
(MP) (BP) (BP) (BP)
Extra Vapor (2) Power Generation
(BP) (MP) (3)Ethyl Alcohol Spent wash
(MP) (BP)
(5) Effluent Treatment Process
(4)Organic manure production
Fig 4
Whereas,
MP-Main Product
BP-By Product

17. 17
4.1 PLANT PROCESS FOR SUGAR PRODUCTION:
Cane
Baggase
Mixed Juice Mud’s
Filtercake
Clarified Juice Filtrate
Water
Syrup
Water
Massecuite First andSecondMolasses
Final Molasses
Raw Sugar
Fig 4.1
WEIGHING AND SAMPLING
PREPARATION
MILLING
CLARIFICATION FILTRATION
EVAPORATION
CRYSTALLIZATION
CENTRIFUGAL SEPARARTION
DRYING

18. 18
The flow sheet is arranged so that the sugar follows a vertical
line in the figure, while the various unwanted constituents are eliminated as shown by the
horizontal branches. Thus in the milling process, the juice is separated from the fiber or insoluble
portion of the cane, which forms the baggase. The clarification process removes suspended and
some of the colloidal and soluble material; the evaporation process removes most of the water
from the juice. At the vacuum pans, further water is removed and the sucrose is allowed to
crystallize from solution under controlled conditions; the overall result of the pan stage and
centrifugal operations is thus the separation of crystal sugar from the remaining soluble
impurities, which are eliminated as final molasses.
The raw sugar so separated contains approximately 98-99% of sucrose and is refined generally in
a separate refinery.
4.1.1 FIXED RATES IN SUAGR PRODUCTION:
Crushing capacity - 2500TCD
Days of operation - 200-250 days
Total crushing of cane (Tons) - 6 to 8 lakhs
Press mud produced (3.5%) - 21,000 to 28,000 MT
Molasses produced (4.5%) - 27,000 to 36,000 MT
Moisture content of press mud - 70%
4.1.2 MACHINERY MAINTENANCE:
The maintenance of machinery is based on 4 types as
shutdown, annual, preventive and running maintenance. The shutdown maintenance will be
taken place either weekly once or monthly once. The Annual maintenance will be taken place at

19. 19
the end of the year. The Preventive and the Running maintenance will be taken place often
manner. In this plant, the Repair and Maintenance could be occurring; they could overcome this
with the help of stock and the knowledge of people; it could be done by internal manpower itself.
But in the case of capital maintenance; it could be done by external manpower, which could
happen rarely to this plant. The Machinery cost is less than Rs.1,00,000 means the plant can
overcome it with the help of GM, if the money exceed than that means for further processing
they have to wait for the approval from the top level management (from head office). They are
also maintaining an alarm system to indicate an occurrence of danger. In this way, they are
maintaining the machinery in an efficient manner.
4.1.3 QUALITY TESTING OF CANE:
While the plant is in the time of shut down, they are
undergoing the process called quality testing of cane. In this, they are collecting the sample of
different types of sugar cane for testing their quality. They are measuring the length, width and
height of the cane; after that they involve in the process of crushing to get the juice and the juice
is undergoing for testing process; through the taste and also the particles present in the juice they
are predicting the nature of the sugar.
If the prediction satisfies them; then they insist the farmers to grow the same kind of sugarcane
for their production. If not they again undergoes certain testing procedures to predict the lacking
things based on that they are providing advice to the farmers to grow the cane by providing the
required soil, required manure, required fertilizers etc… In this way they are not only keeping
the friendly relationship to the farmers for their earnings but also getting a qualified cane for
their sugar production.

20. 20
4.2 PLANT PROCESS FOR POWER GENERATION:
Rajshree Sugars and chemicals Ltd .., also involved in power
generation process from bagasse. The plant have a capability to produce 10MW power; in that,
they are using only 4MW for their production as well as consumption purpose and the remaining
6MW could be sent to TNEB Gird.
Plant Crushing Capacity per day - 2500 tons
Plant Crushing Capacity per hour - 105 tons
105 tons of cane can produce - 28.5 tons of baggase
1 ton bagasse can produce - 2 tons of streams
Therefore, 28.5 tons of bagasse can produce - 57 tons of streams
1 ton stream can produce - 317 units of electricity
Therefore, 57 tons of streams can produce - 18,069 units of electricity
This indicates that the plant has a capability to produce 18KW power per hour. Therefore the
plant is producing 432KW power per day. The overall flow of process for power generation in
this plant as follows,
Sugarcane Milling Bagasse Steam Generation Power Generation
Power to sugar unit Power to TNEB Grid
Fig 4.2.1
From the above process we could say that the bagasse could be used for stream generation but
not in a direct manner; it undergo some process as, first the bagasse will be sent to boiler, from
the boiler the stream will be generated, in that 95% steam could be sent to turbine (from this
turbine, the condensed water could be sent to boiler) and the remaining 5% could be sent to
process (which involve in the conversion of juice into syrup & the remaining vapor could be
condensed). This condensed vapor again sent to boiler. The boiler requires make up water only at
the time of startup stage else it will automatically use condensed water for its process. The way,
boiler helps the plant to generate electricity as follows;
Sugar ProductionProcess

21. 21
Condensed Water Condensed Water
Sugarcane
Milling Baggase
Su
5% 95%
Back Pressure Back Pressure
Exhaust Pressure Exhaust Pressure
Turbine 1 Turbine 2
Extreme Pressure
Extreme Pressure
Fig 4.2.2
Makeup
Water
Water Tank
Boiler 3Boiler 2Boiler 1
Sugar Preparation Process
Steam Generation (100%)
Condense

22. 22
Sugarcane undergoes first process called Milling, from this
the juice and bagasse will be get separated. The obtained bagasse will be sent to 3 boilers, the
capacity of first 2 boilers is 32 tons/hr and the capacity of the third boiler is 55 tons/hr. From
these boilers, the boiled water goes into steam header often called Steam Generator. Steam
Generator can convert cent percent of water into steam. After this conversion, 95% steam will be
sent to Turbines and the remaining 5% will be sent to Sugar Production process.
Therefore, the turbines have got 95% steam from the steam generator and now the process of
turbines will be take place. There are 2 Turbines as Backpressure come extraction and
Condensing come extraction. Both turbines contain 3 kinds of pressure as Inlet pressure,
Extraction pressure and Exhaust Pressure. The capacity details as follows:
Table 4.2
From Turbine 1 both the extreme and the exhaust pressure will be sent to sugar production
process and from Turbine 2 only the extreme pressure will be sent to sugar production process
and the exhaust pressure will be get condensed as water. This water will be passed to the water
tank. The Water tank collects water from Turbine 2 condensation, Sugar production process
condensation and also getting water from the makeup sources. This water again sent to the
boilers for further processing. In this way they are generating power to the plant.
Type of Turbines Backpressure
come extraction
Condensing come
extraction
Requirement of
power
and capacity
6MW
46 tons/hr
6MW
30 tons/hr
Inlet pressure 5.5MW 4.9MW
Extraction
pressure
7Kg/cm^2 1.5Kg/cm^2
Exhaust pressure 1.5Kg/cm^2 -

23. 23
4.2.1 POWER ALLOCATION:
The plant is generating 10MW power but they are only 4MW and the
remaining 6MW will be sent to TNEB grid. From this 4MW, they are allocating 22 units/ton of
cane which leads as;
1 ton of cane requires - 22 units
3000 tons of cane requires - 66,000 units
Therefore for single production they require 6KW power for cane production. For distillery
process, they are allocating 120-150 units/KL of alcohol which leads as;
1 KL of alcohol requires - 120-150 units
45 KL of alcohol requires - 5,400 - 6,750 units
Therefore for single production they require 5-6KW power for alcohol production. And the
remaining power could be used for general consumption purpose.
4.2.2 POWER MAINTENANCE:
The electricity maintenance is also based on 4 types as
shutdown, annual, preventive and running maintenance. The shutdown maintenance will be
taken place either weekly once or monthly once. The Annual maintenance will be taken place at
the end of the year. The Preventive and the Running maintenance will be taken place often
manner. In this plant, the Repair and Maintenance could be occurring; they could overcome this
with the help of stock and the knowledge of people; it could be done by internal manpower itself.
But in the case of capital maintenance; it could be done by external manpower, which could
happen rarely to this plant. The electricity cost could be less than Rs.50,000 means the plant can
overcome it with the help of GM, if the money exceed than that means for further processing
they have to wait for the approval from the top level management (from head office). They are
also maintaining an alarm system to indicate an occurrence of danger. In this way, they are
maintaining the electricity in an efficient manner.

24. 24
4.3 PLANT PROCESS FOR ETHANOL PRODUCTION:
In the sugar preparation process, they are getting final
product sugar as well as some waste in the form of molasses. This molasses could be send to
distillery process which involves fermentation and distillation for the production of either alcohol
or ethanol. Fermentation is the process of conversion of sucrose in molasses into alcohol and
Distillation is the process by which they are separating alcohol from it. The maximum capacity
of distillery is to produce 45KL/day. It could produce 5 kinds of products as,
 Rectified spirit
 Neutral spirit
 Absolute alcohol
 Impure spirit
 Spent wash
Rectified Spirit (RS) Absolute Alcohol (AA)
Impure Spirit Neutral Spirit (NS)
NS AA Spent Wash (waste)
Flow chart 4.3
Sugar ProductionProcess
Molasses(ByProduct)Sugar (MainProduct)
Fermentation
DistillationProcess
Organic manure

25. 25
Rectified spirit is the primary distillation product which
consists of 95% alcohol and 5% water and also includes lots of impurities as aldehyde, ketones
etc…which is highly acidified one. From the rectified spirit 10KL neutral spirit has been
recovered by doing further distillation process. This neutral spirit consist of same percent of
alcohol and water with less impurities, this could be apt for drinking purpose. Absolute alcohol is
the dehydration process which is obtained directly by dehydrating the obtained molasses, it
contains 99.4% alcohol and this could be called as ethanol. Impure spirit is nothing but the last
part of distillery product, which is full of impurities. 1 ton cane can produce 45kg of molasses
which means it have the capability to convert 2500 tons of cane to 112, 500 kg of molasses.
Therefore 1 ton molasses can produce 240L yield of alcohol.
4.3.1RECTIFIED SPIRIT:
The schizosaccharomyces pombe yeast is initially propagated
in the propagation vessels and then transferred to the fermenter. Molasses diluted with water to
the desired concentration is metered continuously in to a single tank fermenter. During
fermentation process, yeast cells convert sugar in to alcohol. Fermentation is an exothermic
reaction heat is evolved during this fermentation and it is removed by continuous cooling
through plate type heat exchanger. Temperature is maintained between 32-35 degree Celsius.
Small quantities of urea and DAP are added in the fermenter as nutrients to the yeast cells.
Viable cell population of 300 – 400 million cells/ml is maintained in the fermenter by continuous
aeration and yeast recycling.
The fermented wash passes through series of hydro cyclones, which removes grit, iron fillings
and heavy particulate matter. The material settled at the bottom of the hydro cyclone is fed to the
bottom of the analyzer column to strip the alcohol present in it. The overflow from the hydro
cyclone is fed to the yeast separators to separate the yeast and de-yeasted wash. Yeast cells
separated by the separators are re-cycled back to the fermenter to maintain the yeast cell
population. De-yeasted wash is stored in prop III vessels. The wash is preheated to 85 – 90
degree Celsius in the beer heater, plate type mash heater and spent wash cooler and it is fed to
top of the degasifying column. Steam is applied to the analyzer through re-boiler to maintain the
analyzer column bottom temperature at 107 -108 degree Celsius.

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The de-yeasted wash is heated in each plate of analyzer column and the enriched alcohol vapor
goes up. Due to difference in specific gravity and boiling point the spent liquor is collected at the
bottom of the analyzer column and it is let out as spent wash to the storage lagoon. Small
quantity of a vapor with impure gases is separated from the top of the degasifying column and
fed to the degasifying condenser. The reflex is diluted with water and fed to the aldehyde
column. The steam is applied directly to the bottom of the head spirit column to maintain the
temperature at 92 – 95 degree Celsius. The condensate is returned back as reflux to the top of the
head spirit column. The enriched head spirit is tapped from the top of the column. It is then
cooled in cooler and sent to storage tank as “Impure Spirit”.
The major portion of vapors are collected at the top of the analyzer column at 96 to 98 degree
Celsius and fed to rectification column for further concentration. Fusel oil is separated at 88 to
92 degree Celsius at the fusel oil separating trays and cooled in the decanter. The alcohol vapor
is then condensed in beer heater and principle condenser. The condensate is recycled back to the
top of the rectification column. The alcohol content gets enriched in the top of the column. It is
then tapped and cooled in cooler and sent to the storage tanks as “Rectified spirit”. The liquid
obtained from the bottom portion is fed to exhaust column for further concentration.
In the exhaust column liquid, which is fed from head spirit column and rectification column, are
concentrated. Then this concentrated alcohol vapor is fed to the rectification column for further
purification. The water from the bottom of the exhaust column is drained as spent less. Direct
steam is applied to maintain the bottom temperature at 105 degree Celsius. The spent less is
reused as inhibition water during sugar manufacturing process. The final product is known as
Rectified spirit and it contains above 95% alcohol.
4.3.2 ANHYDROUS ALCOHOL:
Production of anhydrous alcohol from rectified spirit with the
molecular sieve dehydration utilizing pre concentration column: The rectified spirit, before
sending in for dehydration process, it is heated and water is stripped in the pre concentration
column through a pre-heater. The mixture of alcohol and little water is sent to molecular sieve in
the form of vapor.

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The molecular sieves are hard granular substances, cylindrical extrudates manufactures from
classy like silica gel material such as potassium alumino silicates. They are graded according to
the nominal diameter of the myriad of internal pores, which make up the interstitial passageways
is 3 Angstroms. Thus, the passageways in the structure have a diameter that is of molecular
scale. The water molecule has a mean diameter less than 3A, while the ethanol molecule has a
mean diameter greater than 3A.
In addition, the water molecules can be absorbed on the internal surfaces offered by the
passageways within the molecular sieve structure. It is the physical property of the sieves, which
make them useful for the separation of mixture of ethanol and water. Water molecules can
invade the inner structure of the molecular sieve bends and be absorbed thereon, while the
ethanol molecules are too large and pass out of the vessel leaving the water behind. Thus,
dehydration of ethanol takes place in the molecular sieve technology.
In this technology, the re-generation of beads is done by one bed under vacuum; while the other
bed is producing anhydrous ethanol vapor under pressure with an automated operation, the feed
of vapor to the molecular sieve system can be taken directly from the pre concentration column
passing through a super heater. The pre-concentrated column is operated at a pressure sufficient
to economically operate a re-boiler. The re-covered ethanol and water from the re-generation
phase is fed back to the pre-concentration column for recovery. Thus, there is no generation of
effluent except the condensate water from steam is cooled and then taken back for process.
4.3.3 SPENT WASH:
The spent wash is the waste which is obtained in this process.
Based on extensive research work carried out on treatment of distillery spent wash in many parts
of the world, it has been learnt that spent wash is a valuable by-product generated from
distilleries. It is essentially a plant extract derived from sugarcane containing microbial residues.
Spent wash is also a rich sucrose of organic matter and nutrients like nitrogen, phosphorous,
potassium, calcium and sulphur. In addition to this, spent wash contains micronutrients such as
iron, zinc, manganese, boron and molybdenum.
In contrary to the general belief, distillery spent wash does not contain any toxic heavy metals
and hazardous constituents. After realizing the value of the distillery spent wash and its

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importance as organic input for sustainable agriculture, a commercial scale viable
“Biocomposting Technology” has been developed. This technique uses the principles of solid-
state fermentation for treating distillery spent wash comprehensively and economically. Also this
technology achieves zero pollution and returns to earth those elements that are absorbed by
sugarcane during its growth.
In this plant, they have introduced this aerobic solid state fermentation technology for distillery
effluent treatment. Their Biocomposting production unit is the first and only ISO 9002 certified
unit in India for adopting a quality system for organic manure production from distillery spent
wash. The characteristics of spent wash as follows;
PARAMETERS VALUES
pH 4-4.5
Total solids 2,20,000-2,30,000 mg/l
Nitrogen 500-700 mg/l
Phosphates 2,000-5,000 mg/l
Potassium 20,000-25,000 mg/l
Sulphates 11,000-15,000 mg/l
Chlorides 11,000-14,000 mg/l
Spentwashquantity 6-7 L/L of alcohol
Table 4.3.3

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In this way, the plant is producing 8% alcohol and 6-7 Liters of spent wash from every wastage
of cane (molasses). Finally the plant sends 10KL of neutral spirit only for bottling unit, also
sends absolute alcohol to petroleum units as IOC, BBC, HP and they also sends the impure spirit
to the rubber and paint industries.
4.3.4 SOIL TESTING:
The plant also involved in the process of soil testing. They
are focusing towards their farmers who provide cane to them. They undergo 10 analyses as
Electrolytic Conductivity (EC) – below 1, Power of Hydrogen (PH) - 6.5to8.5, Organic carbon -
0.8, Nitrogen - 180kg/acre, Phosphorous - 5kg/acre, Potassium - 115kg/acre, Iron - 10ppm,
Manganese - 5ppm, Zinc - 1ppm, calcium carbonate - 3ppm. If any of these is missing or lower
or higher than the optimum level then they undertaking certain process to overcome that in a
good manner. They are also involved in doing some mapping technique for predicting the future
condition of the soil. In this way they are maintaining their soil efficiency in an effective manner.

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4.4. PLANT PROCESS FOR BIOCOMPOSITION:
The compost yard of RSCL; the ground at the site is hard and
compact. The entire 9 acres of compost yard has been lined with 150 micron thick LDPE sheets
and provided with 6 inched thick Reinforced concrete cement (RCC) platform to avoid ground
water pollution. The compost yard has s gentle slope towards the centre and the leachates are
collected at one end in the collection tanks
In this process, a mixed population of micro-organisms in a moist aerobic environment
decomposes the organic matter present in the sugar industry press mud and distillery spent wash.
This biotechnological process has two unique features distinguishing it from other conventional
composting processes. One is the use of a specially developed microbial consortium containing
organic matter decomposing bacteria, actinomycetes and fungi that rapidly degrades spent wash.
The other is the use of a machine called “Aero tiller”. This machine agitates, aerates and shreds
the composting mass and spreads the microbial inoculums uniformly over the entire length of
windows.
In this process, press mud heaps are formed into windows, which are triangular in shape with 1.5
meter height and 3.5 meter width at the bottom. These windows are sprayed with a measured
quantity of spent wash where the press mud act as a solid matrix. The ration of spent wash to
press mud in the composting mixture varies according to the amount of spent wash being
produced, but it is usually around 2 to 3:1. Windows are inoculated with the microbial starter
culture and the application of pent wash over the press mud windows is carried out at specific
intervals for 8 to 9 weeks.
The aerotiller machine turns the windows at least thrice a week followed by trimming and spent
wash application. Because of the aero tilling operation, lumps of press mud are shredded to
uniform fine particles thereby increasing the surface area of the press mud for the spent wash
absorption. The mixing also provides air for prosper growth of micro organisms. During
aerotiller operation, the gases evolved due to the microbial metabolism are also vented. The
machine also facilitates the contract of substrate and microbes. The entire composting process
requires 12-13 weeks duration depending on ambient condition.

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During the compositing process, pH, Temperature and Carbon to Nitrogen ratio are monitored.
Due to exothermic decomposition reactions, the temperature of windows rises up to 70 degree
Celsius and it is maintained between 50 -70 degree Celsius for a period of 7 weeks. The rate of
rise in temperature and the duration for which it hovers between 50 -70 degree Celsius is a good
index of compositing activity.
There is a sharp decrease absorbed in the C: N ratio of the press mud windows during the
compositing process. The moisture content in the windows is always maintained between 50%
and 60% through periodic spraying of spent wash. After 9 weeks water is applied instead of
spent wash to cure the compost. The stable compost material is obtained after 12 weeks duration.

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4.5 PLANT PROCESS FOR EFFLUENT TREATMENT PROCESS (ETP):
ETP is the final process of RSCL. It involves the process of
collecting the wastage water from the sugar plant and the collected water gets stored in 2
Collection Tank. From the collected tank the water could be sent to the Oil Catcher; in this, oil
which is contained in the wastage water gets removed with the help of manpower. Now, the oil
free water could be sent to the Flaculator; here they equal the level of water (Flowing power of
water) and also maintain the water pH level by adding alum and lime. This water could be sent to
Flash Mixer; here the water is stirred properly to equalize the content of lime and alum in the
water. The stirred water could be sent to the Settling Tank; here the primary sludge gets settled
and from that the water will be removed; the settled sludge could be passed to the sludge settling
tank. Now the water will be passed to the aeration tank; they are preparing the aerated tank by
settling the cow dunk, sand and some micro organisms, the tank also gets air from 2 tanks,
therefore the combination of all will help the micro organisms to grow and help them to clean the
sludge from the water. Now, the final water with limited sludge will be passed to clarifier; it
contains the blades which is in the rotating motion; the rotating blades also helps the water to
settling down the sludge; from this the pure water will be passed to the farm, garden and further
plants around the plant; remaining sludge will be passed to sludge settling tank.
Sludge 2
Sludge settling tank Sludge 1
Collection Tank Oil Catcher Flaculator Flash Mixer Settling Tank
From Sugar Plant Clarifier Aeration
Purified Water
Farm
Fig 4.5

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The sludge settling tank consists of 16 sludge drying beds. The beds which receive sludge from
primary settling tank and clarifier. The collected sludge will be get dried while drying, they are
filtering the little amount of water presented in the sludge and then they are passing the filtered
water again to the clarifier and to the settling tank; and from the settling tank the same process
will be carried out to get the purified water. The process could occur in a cyclic manner.
4.5.1 ETP MAINTENANCE:
The plant is maintaining an ETP in the way as shutdown, annual,
preventive and running maintenance. In all maintenance they involve in the common process of
cleaning the tank by drying out the sludge and removing it. After removal they involve in the
process of cleaning it with water; after that they involve in painting all tanks in order to prevent
the corrosion of air blowers and blades in settling tank and clarifier. The remaining tank requires
painting into to prevent the formation of algae.
The head office also involve in maintaining ETP by setting online water measuring system; in
that they are measuring, how many amount of water from the wastage has been coming to ETP
and from that how many liters they are purifying; like that all kind of details are measured by
them in a simultaneous manner. They did this by setting the online measuring meter at the inflow
and at the outflow of ETP. In this way, the plant is measuring ETP maintenance in an efficient
manner.
These are the five major processes which are being running and maintaining by RSCL not only
in an efficient but also in an effective via in all their 4 branches.

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5. EMPLOYEE PRODUCTIVITY IN PLANT:
5.1 WORK MEASUREMENT AND LABOR STANDARDS:
Work Measurement refers to the process of estimating the
amount of worker time required to produce one unit of output. A goal of work measurement is to
develop labor standards that can be used for planning and controlling operations.
In this plant, the work measurement of an employee is depending upon the raw material and the
machineries. Here, they are fixing 36 hours for production as constant; therefore if there is a
surplus in raw material both the workers and the machineries could be operate in a rapid manner
else both could operate either at a moderate speed or at a slow speed; in-order to cover the
fixed working hours.
A Labor standard is the number of worker-minutes required
to complete an element, operation or product under ordinary operating conditions. Labor
standards are used for cost estimation, pricing of product and services, incentive pay system,
capacity planning, production scheduling. A Labor standard can be determined by using one or
more of the following approaches as Time study, work sampling, predetermined time standards
and subjective method.
In this plant, they are estimating the labor standard by using time study and work sampling
methods. The plant prefers time study when they need to produce large quantity of output. This
directly represents the seasonal time of cane. The plant also prefers work sampling; when the job
required producing relatively small quantities of output. This directly represents the time of non-
season.

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5.2 LEARNING CURVE:
Learning curve is the process of calculating the learning
capacity of an employee as we know that at the starting stage workers are unfamiliar with their
jobs so the time takes to produce first few unit is high as if the worker started to learn their jobs
then their output per day increases up to a point then their output level off to a rather constant
rate.
This plant is analyzing the workers learning situation with the help of learning curve. Through
this they are estimating an average, total and an exact number of labor–hours required per unit
for N-units in a production run. The learning curve analysis has been undertaken in a hierarchy
manner as section head, management head and unit head. Through this the plant could easily
finding capacity of an employee in an active manner and further proceedings has been
undertaken by them to make them more effective.
5.3 PRODUCTIVITY:
Productivity means amount of products produced with the
resources used. Productivity varies with the amount of production relative to the amount of
resources used. Higher productivity leads to higher standard of living that is why the plant is
carrying more about productivity.
Productivity = Quantity of product produced
Amount of resources used
The plant is producing cent percent productivity because they are converting the whole raw
materials into the complete product as they required. For e.g.: if the plant is getting 18 tons of
sugar cane means the plant could exactly able to produce 18 tons of sugar. So here there is no
need for improvement in productivity.
Cost plays one of the major roles in productivity. When the cost of the resource increases and the
profit is to remain the same, some combination of the following must occur: output is increased,
resource usage is decreased and price of output is increased. In this plant, they are facing the
conventional cost as Rs.30 based on sulphur requirement, lime requirement etc...

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5.3.1 LABOR PRODUCTIVITY:
For some firms, production labor represents very small part
of the firm’s total costs. For other firms like this plant, direct labor cost remains a significant cost
and the need to improve labor productivity is still a serious concern. This plant considering the
major variables which affecting labor productivity is physical work environment, product
quality, employee job performance.
5.4 EMPOWERING WORKERS:
It is the employees who have the control of, and know the most
about, the details of production. In this plant, they are getting employees to accept this
responsibility by conveying authority from managers to workers. They are maintaining a better
employee relationship management. This could be considering as a huge and important power
for this plant.

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6. STOCK AND INVENTORY MAINTENANCE OF A PLANT:
6.1 STOCK MAINTENANCE:
The plant is maintaining stock only for the materials which is
being used for daily purpose and also the cost of those materials should be under Rs.10, 000 if it
above that this; then that will be gets under the control of head office which is in Chennai. This
indicates that the plant can purchase the things without getting permission from the head office if
it is below 10,000 else they have to get permission from them to buy the required material. As
per the norms provided by head office, the plant is maintaining stock for certain items as follows:
 Consumables
 Electricals
 Packing Materials
 Tools
 Bearings
 Ferrous
 Civil
 Fuel
 Lubricants
 Chemicals
 Automobile units
 Spares
They are maintaining the stock items only by using Numeric system. Maximum limit for them to
place order is from 15 - 20 Lakhs. They are undertaking some procedure for placing an order as
purchase requisition  AGM  GM Stock purchase order to stock handler  placing an
order in the areas like Chennai, Coimbatore, Madurai and Theni. In this via, 2 days once they are
placing an order for their requirement.
They are maintaining this stock in an efficient manner as receiving order  checking order as
that of requirement  if it is excess then they will resend it, if it is less then they will hold on the
bill and the stock till complete arrival. Each bill consist of several items; if any of those has been

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not yet received that particular bill cannot not be updated till an arrival of an item. Therefore
updating the bill in computer representing the order has been placed successfully.
After the arrival of an items then they will undergo the process of checking in-order to find any
defects, if there is no defects then that will undergo for the next stage if not it could be resend.
After checking, the items could be sent to dispatching and assemble process. Then the updated
bill could be sent to accounting department for further process.
6.2 INVENTORY MAINTENANCE:
The plant is maintaining inventory for finished goods, which
is essential in produce-to-stock positioning strategies, necessary in level aggregate capacity
plans, and with the help of this they are displaying their products to their customers. We could
also say that the factory is maintaining independent demand inventory system, which means
demand for an item carried in inventory is independent of the demand for any other item in
inventory.
The plant consists of Bin system. They are classifying the bin based upon rupee as 50 and 100.
The system will work as per that of settings provided by them, if they set it as for Rs.50 means
the system automatically started to allocate the sugar in that manner to the inventory and for
Rs.100 same as that of Rs.50. They considered the size of bin as 1 Bin=1000 quintal.
This plant consists of 4 allocations for inventory and their maximum potential for each inventory
is 12,000 lots. For the first two inventories their allocated capacity is 1, 40, 000 quintals and for
the last two inventories their capacity is 1, 65, 000 quintals which was approved by government.
They are allocating the lot based on either 2 cross 3 or 3 cross 5. Fifty is the maximum height
capacity for their inventory. As per the First In First Out (FIFO) they are dispatching it as per
customer requirements.
In this way, the plant is maintaining their stock and inventory system in an effective manner.

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7.CONCLUSION:
It was a complete useful experience working at Rajshree Sugars and Chemicals Limited.
The friendly welcoming employees and the space they have created for a trainee allowed me
with full opportunities to know and learn myself as a worker. This experience brought out my
strength and also the areas I needed to make up. It added more confidence to my Professional
approach built a stronger attitude and taught me how to work in team as a player. The primary
objective of an internship is to gather a real life working experience to work and put their
theoretical knowledge in practice. This was my first real experience to work in major factory.
During my 1 month of training, I have developed a lot of confidence and courage in this
industry.
My experience at the factory was highly educative one. I went to different departments of the
factory and got a lot of varied experience. In all departments I get to learn many things which
will be helpful for me in my future.
I also learned values and importance of this industry and experienced that this is much superior
field than most of the other field. Now I have more confident and more likely to do any work
now.
During my training, I thoroughly enjoyed the challenges that came along every single day. I
learned that this is just the beginning of the road and I have to travel a long distance to be a
successful person in this filed but I must say that this experience will prove an objective in my
carrier in the sugar industry.