Sugar Industry Project
Sugar Industry Project
Sugar Industry Project
MUDHOL
EXECUTIVE SUMMARY
KIMS,KUD,DHARWAD. Page 1
NIRANI SUGARS LTD. MUDHOL
India is the largest consumer and second largest producer of sugar in the world. The Indian sugar
industry is the second largest agro-industry located in the rural India. Indian sugar industry has been a
focal point for socio-economic development in the rural areas. The industry not only generates power
for its own requirements but surplus power for export to the grid based on by-product-Bagasses. It also
produces ethyl alcohol, which is used for industrial and potable uses, and can be used to the manufacture
of ethanol, an ecology friendly and renewable fuel for blending with petrol.
The unit was originally established in the year 1997-98 as a modern Khandasari
Sugar unit with a crushing capacity of 500 tones of cane per day and later converted into white crystal
sugar unit. This is one amongst the earliest Khandasari unit in the country, which started with a new
technology like:(a) High pressure boiler (32.0 ATA) (b) Multiple effect pressure evaporator system
with falling –film evaporator and also with captive power generation.
M/s.Nirani Sugar Litd. Now proposes to expand the sugar factory from the present capacity of 7500
TCD to 15000 TCD by adding a new plant of 7500 TCD, retaining the existing plant also. Also 62 MW
Cogen Power Plant is part of the expansion. The project appraisal was done by Mitcon Consultancy
Services Limited, Pune.
The study has been conducted on “Measuring effectiveness of distribution channel of
Nirani sugars limited”, It is a Descriptive Research.
PROJECT TITLE:
“Measuring effectiveness of distribution channel of NIRANI SUGARS LIMITED”
OBJECTIVES:
To study the distribution channel of Nirani sugars limited,Mudhol.
“To find out the feasibility of establishing new depots by the company.”
“To understand factors influencing buying decision”.
“To find out the packaging method adopted by sugar factories”.
METHODOLOGY:
KIMS,KUD,DHARWAD. Page 2
NIRANI SUGARS LTD. MUDHOL
Research Design
It is a Descriptive Research. The study was based on both Primary and Secondary Data.
Secondary data
In this study, Secondary Data is used for exploratory research and secondary data
includes data collection from interaction with the company guide and with the officials and with the,
organizations Data, Brochures/newsletters, Reviews and Internet information websites.
MEASUREMENT TECHNIQUE:
Questionnaire:
Questionnaire is a formalized instrument for asking information directly from the
wholesaler.During this research questionnaire will be used as measurement technique for getting
information from the wholesaler’s and retailer’s of Bagalkot district.
Sampling Plan
Sampling unit : WHOLESALER & RETAILER.
FINDINGS
Price is the main factor considered by the most wholesalers and the retailers, while placing
orders.
S1 is the most selling sugar grade in the local market by the wholesaler and retailers irrespective
KIMS,KUD,DHARWAD. Page 3
NIRANI SUGARS LTD. MUDHOL
86% of retailers are ready to buy the sugar , if Nirani sugars limited setup new depot in their
respective area.
85% of retailers are not facing any stock problem, indicating the present distribution channel is
working fine.
Recommendation
The company itself develop a cost effective eco packaging materials and distributing them
to retailers and wholesalers, this mechanism not only helps Nirani sugars to build its brand
and creates awareness about its brand.
The Nirani sugar should go ahead with its proposed area to service up to new depots
nearing delivery location as the majority of retailers have shown acceptability towards to
buy sugar from Nirani sugar industry.
The Nirani sugar should focus expanding its market, even on export market as it is facing
stiff competition in local market.
Conclusion:
Present distribution channel of Nirani sugar’s limited is working well.
KIMS,KUD,DHARWAD. Page 4
NIRANI SUGARS LTD. MUDHOL
INDUSTRY BACKGROUND
KIMS,KUD,DHARWAD. Page 5
NIRANI SUGARS LTD. MUDHOL
“India is the largest consumer and largest producer of sugar in the world.”
The sugar industry is proud to be an industry, which spreads the taste of sweetness to the mankind.
Sugar is generally made from sugarcane and beet. In India, sugar is produced mainly from sugarcane.
India had introduced sugarcane all over the world and is a leading country in making sugar from
sugarcane.
‘Saint Vishwamitra’ is known as the research person of the sugarcane in religious literature.We can find
the example of sugarcane in Vedic literature also as well as sugarcane.We can also find the reference of
sugar and the sugarcane in Patanjali’s Mahabashya and the treaty on the grammer of ‘Panini’.Greek
traveler ‘Niyarchus’ and Chinese traveler ‘Tai-Sung’ have mentioned in their travelogue that the people
of India used to know the methods of making sugar and juice from sugarcane the great Emperor
Alexander also carried sugarcane with him while returning to his country.
Thus from different historical reference and from some ‘Puranas’ it can be concluded that method of
making sugar from sugarcane was known to the people of Bihar.The historical evidence of sugar
industry prospering in ancient India concrete and this has helped to develop and prosper the co-operative
sugar movement in India.
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NIRANI SUGARS LTD. MUDHOL
The first sugar mill in the country was set up in 1903 in the United Provinces. There are 566
installed sugar mills, of which 453 were in operation in the year 2002-03 and utilized 194.4 million
tones of sugarcane (69% of total cane production ) to produced 20.14 million tons of sugar. About 5
lakhs workmen are directly employed in the sugar industry besides many in industries, which utilize by-
products of sugar industry as raw material.
India is the largest consumer and second largest producer of sugar in the world. The
Indian sugar industry is the second largest agro-industry located in the rural India .Indian sugar industry
has been a focal point for social-economic development in the rural areas. About 50 million sugarcane
farmers and a large number of agriculture labors are involved in the sugarcane cultivation and ancillary
activities , constituting 7.5% of the rural population. Besides, the industry provides employment to about
2 million skilled/semi skilled workers and others mostly from the rural areas. The industry not only
generates power for its own requirement but surplus power for export to grid based on by-products –
Bagasses.It also produces ethyl alcohol, which is used for industrial and potable uses, and can be used to
manufacture Ethanol, an ecology friendly and renewable fuel for blending with petrol.
The sugar industry in the country uses only sugarcane as input: hence sugar
companies have been established in the large sugarcane growing states like Uttar Pradesh,
Maharashtra ,Karnataka, Gujarat,Tamilnadu,and Andhra Pradesh.In sugar year 2003-04, these six states
contributed more than 85% of total sugar production in the country: Uttar Pradesh, Maharashtra and
Karnataka together contribute more than 65% of total production. The Govt of India licensed new units
with an initial capacity of 1250 TCD up to the 1980s and with the revision in minimum economic size to
2500 TCD, the Govt de-licensed sugar sector in the year 11.September. 1988. The entrepreneur have
been allowed to set up sugar factories of expand the existing sugar factories as per the techno-economics
feasibility of the project. However, they are required to maintain a radial distance of 15 kms from the
existing sugar factory . After de-licensing, a number of new sugar plants of varying capacities have been
set up and the existing plants have substantially increased their capacity.
There are 566 installed sugar mills in the country as on March 31st 2005, with a production capacity
of 180 lack MTs of sugar, of which only 453 are working. These mills are located in 18 states of the
country.
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NIRANI SUGARS LTD. MUDHOL
COMPANY BACKGROUND
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NIRANI SUGARS LTD. MUDHOL
M/s. Nirani Sugars Limited (NSL), a company incorporated on the 6th Dec, 1995 under the
Companies Act, 1956 has applied for Term Loan of Rs. 15.90 crores to Sugar Development Fund(SDF)
for meeting part of the capital cost of its project envisaging modernization & up-gradation of existing
sugar factory with an installed capacity of 1250 TCD to 3750 TCD with substantial investment at Kulali
cross Mudhol Tq. Dist: Bagalkot, Karnataka State, NSL has included in the scope of the project, the co-
generation of surplus power also at a total project cost of about Rs. 97.00 crores. (Sugar unit Rs. 53.00
crores and cogeneration unit Rs. 44.00 crores). Total Cost of the Project, for the Sugar plant expansion
Rs. 5300 Lakhs, (Rs. 42.00 Crores for sugar and 11.00 crores loading from co-generation plant cost)
consisting of an Equity Contribution of Rs. 5.30 Crores Promoters, Rs. 15.90 crores equity from Sugar
development fund of Govt. of India & the balance of Rs. 31.80 crores funded through Term Loans from
the Financial Institutions/Banks.
The funding for the cogeneration plant costing Rs. 4400.00 Lakhs is
envisaged by obtaining Rs. 3080 Lakhs from IREDA, Rs 440.00 Lakhs from promoter’s contribution
and Rs. 880 Lakhs from sugar development fund.
M/s. Nirani Sugars Limited (NSL) is a company registered under
the Indian Companies Act, 1956, initially as Private Limited Company, vide registration certificate
number 08/19340 of 1995 dated 06.12.1995 by the registrar of companies in Karnataka, Bangalore,
Subsequently, the company has been converted into Public Limited Company vide Certificate of
Incorporation dated 15.02.2002 by ROC, Karnataka, Bangalore.
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NIRANI SUGARS LTD. MUDHOL
The unit was originally established in the year 1997-98 as a modern Khandasari Sugar unit with a
crushing capacity of 500 tonnes of cane per day and later converted into white crystal sugar unit. This is
one amongst the earliest Khandasari unit in the country, which started with a new technology like:
(a) High pressure boiler (32.0 ATA)
(b) Multiple effect pressure evaporator system with falling –film evaporator and also with
captive power generation.
Subsequently making use of the Government of India’s liberalized policy, vide Govt. of
India notification DCS/S/14/DTD 02-06-1998, which permitted Khandasari sugar units to use vacuum
system, they modernized the unit quickly by adding vacuum pans and vacuum evaporators. The capacity
of the plant was increased in stages to its present capacity of 1250 TCD during 2005-06. Now the plant
has increased to 7500 TCD.(2008-2010). The plant runs fairly efficiently and is self sufficient in fuel
and power. It has recorded an average sugar recovery of over 11 percent during 2008-2009 crushing
season.
M/s. Nirani Sugar Litd. Now proposes to expand the sugar factory from
the present capacity of 7500 TCD to 15000 TCD by adding a new plant of 7500 TCD, retaining the
existing plant also. Also 62 MW Cogen Power Plant is part of the expansion. The project appraisal was
done by Mitcon Consultancy Services Limted, Pune.
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NIRANI SUGARS LTD. MUDHOL
MISSION
1.We will provide products of superior quality at competitive price and ensure sustained profitability and growth.
2.We will protect the interest of all concerned promoters, shareholders, customers, distributors, employees and
community.
3.We believe in fair trade practice, standards and strive for total customer’s satisfaction, keeping the environment
eco friendly.
4.We believe that our people are most valuable assets for personal and organizational growth.
5.We will treat our people with dignity and look after the safety and welfare of individuals and there families.
7.Sugar industries are providing ethanol which can be added in diesel and diesel is major requirement of the
nation.
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COMPANY PROFILE
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NIRANI SUGARS LTD. MUDHOL
BOARD OF MANAGEMENT
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ORGANIZATION CHART
Chairman and MD
General
Electrical Mechanical Laboratory Cane
Account
Department Department Department Account
I.T
Department
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NIRANI SUGARS LTD. MUDHOL
PRODUCTION DEPARTMENT
Production department is most important part of the factory and it is divided into two departments
namely:
1. Engineering department
2. Manufacturing department
1. Engineering department:
The engineering department maintains all the work connected with plant and
machinery. Engineering department aims at enhancement of feeding capacity of factory. The department
is assisted by workshop.
Workshop:
Spares are fabricated using the lathe machine in the workshop and shaping like square,
cutting, fabricating etc. are done in the workshop. 75% of works of machinery are done in workshop.
This department has the following machines:
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2. Manufacturing department:
Manufacturing department is divided into 3 sections namely:
a) Laboratory department
b) Manufacturing department
c) Go-down
a) laboratory department:
Laboratory department plays a significant role in sugar production. The key
activity of laboratory is checking the content of sugar in the sugarcane and fixing the correct shape and
size of sugar. The laboratory prepares hourly reports which advice in the addition of other chemicals in
the production.
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NIRANI SUGARS LTD. MUDHOL
PURCHASE DEPARTMENT
Purchase success and failure of any company depends on the cost of
materials, the proper buying of materials and procurement of materials at the right time from the right
source is having greater importance in any business. There is a need for separate department for buying
the materials know as Purchasing department.
The purchase section also connected to administrative department. In this section 3 workers are
working including purchase officers. This section is purchase all types of materials for the factory, plant
and machinery.
This department also maintains the quality of raw materials, by taking the sample of cane to
laboratory test then if the raw material will below standard then will be rejected, otherwise the raw
material will be purchased at the particular price.
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SALES DEPARTMENT
Meaning
It is the department which handles sales process of the company.
Structure :
AGM
Salesman Salesman
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Sugar:
This unit is producing two different grades of sugar. They are S-30, M-30
grades. Production department sends weekly the report of sugar balance to “Karnataka Sugar
Federation” by telegram or letter by examining the sugar balance. Karnataka Sugar Federation sends
“released order” to the factory. The release order quantity differs every month. After receiving the
releasing order, the sales department sells the sugar through tender. The release order is the base of the
tender.
Molasses:
Molasses is the mother liquor in the massecuite which is separated from
crystals by mechanical means. The mother liquor is separated before the washing of crystals is termed
by light molasses. These are again classified as A, B, C etc. According to the grade of massecuite from
which they are obtained.
The heavy molasses obtained from the last grade of massecuite is termed as final
molasses or waste molasses.
Recovery is assumed to be 4% on cane crushed and the sale price is assumed to be 600/- per M.T.
Bagasses:
Bagasses is the residue of cane after crushing in one mill or a train of mills bagasse are named
successively as first mill bagasse, second mill bagasses and so on to last mill bagasses or final bagasses
or simply bagasse.
Bagasses produced are used in the generation of electricity and in the boiler house.
Surplus is however sold. The surplus bagasse is estimated at 3% cane crushed. The price assumed at Rs
400/- per M.T.
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NIRANI SUGARS LTD. MUDHOL
Varieties of sugarcane:
At present COC-671, CO-8011 are very popular and the quality of sugarcane on the area where it
is grown. The oyher different qualities of Sugarcanes are: CO-94012, COC-86032, CO-8014 etc.
Here more than 85% of sugarcane of variety COC-671 that is mainly grown in this area. And this
variety is considered as the best and which provides good recovery.
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NIRANI SUGARS LTD. MUDHOL
MECHANICAL DEPARTMENT
Meaning
It is a season in which the maintenance of machineries, repairs and over all operation are
rendered by the workers. It is to Manufacture sugar by using machines.
Structure:
Work Manager
Chief Engineer
Turbine attender
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CHEMICAL SECTION
Meaning
It means to take chemical tests before producing sugar and manufacturing of sugar from
sugar cane.
Structure
Chemical Department
Lab Incharge
Responsibilities:
The responsibility of this department is to test the product of the sugarcane and quality of sugar.
Chemicals used:
1. Sulphor
2. Lime
3. H2O2 (Hydrogen peroxide)
4. Orthophosporic acid
5. Alcohol.
6. Turckey red oil.
Cleaning Chemicals :
1. Caustic soda.
2. Washing soda.
3. Common salt.
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STORE SECTION:-
It means storing of the equipment required to the factory for the smooth flow of process.
Structure
Purchase officer
Store officer
Store Accountant
Store Keeper
Store clerk
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NIRANI SUGARS LTD. MUDHOL
SECURITY DEPARTMENT
Security department works under M.D secretariat and office supervision. It is also considered in
administrative department. It works around 3 shifts as under:
1st shift - 8am to 8pm
2nd shift – 8pm to 8am
Organization chart of security department are done on the requirement of the factory as given
below:
Security officer
Supervisor
1. They are maintaining peace and discipline within the factory premises.
2. To maintain works attention.
3. They check the incoming raw materials as per voucher.
4. The incoming materials are checked and if they are right, they will record inwards then they seal the
bill and leave inside.
5. The out going materials with proper gate pass will be recorded in outwards and they are sent
outwards.
6. If they are returnable they are recorded in books of returns and are returned
7. Check the loaded and unloaded vehicles and collect notes.
8. Submit daily activity report to the managing director.
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NIRANI SUGARS LTD. MUDHOL
There are about 530 employees working in this organization. There is a separate department called
“TIME OFFICE DEPARTMENT” for the maintenance of time in this organization.
Functions of time office department
1) Maintaining working bell.
2) Arranging duty to workers.
3) Distribution of salary according to workers attendance.
4) Sanctioning of leaves to workers.
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Objectives
Methodology
Analysis
Suggestions.
Recommendation
Questionnaire
Bibliography
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NIRANI SUGARS LTD. MUDHOL
PROJECT TITLE:
“Measuring effectiveness of distribution channel of NIRANI SUGARS LIMITED”
OBJECTIVES:
To study the distribution channel of Nirani sugars limited,Mudhol.
“To find out the feasibility of establishing new depots by the company.”
“To understand factors influencing buying decision”.
“To find out the packaging method adopted by sugar factories”.
METHODOLOGY:
Research Design
It is a Descriptive Research. The study was based on both Primary and Secondary Data. The Primary
Data was collected through asking the questions consisting of following categories.
Open-ended questions.
Close –ended questions.
KIMS,KUD,DHARWAD. Page 27
NIRANI SUGARS LTD. MUDHOL
Secondary data
In this study, Secondary Data is used for exploratory research and secondary data
includes data collection from interaction with the company guide and with the officials and with the,
organizations Data, Brochures/newsletters, Reviews and Internet information websites.
MEASUREMENT TECHNIQUE:
Questionnaire:
Questionnaire is a formalized instrument for asking information directly from the wholesaler and
retailer of Bagalkot District namely Kerur,Jamakhandi,Mudhol,Mahalingpur,Kaladgi and
Banahatti During this research questionnaire will be used as measurement technique for getting
information from the wholesaler’s and retailer’s of Bagalkot district.
The sampling units will be the Retailer and Wholesaler of Bagalkot District namely Kerur,
Jamakhandi, Mudhol, Mahalingpur, Kaladgi and Banahatti.
Sampling Design
The research was mainly opted on wholesaler and retailer’s survey and company.
The sample selected for Retailer survey was of cluster sample. Sample size of 70
respondents, and the sample selected for wholesaler was 20 respondents.
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NIRANI SUGARS LTD. MUDHOL
Sample Character
Respondents who sell sugar in there wholesale and Retail outlet were sources of data
collection.
. Sampling Plan
Sampling unit : WHOLESALER & RETAILER.
Sampling Method : Convenience Sampling
Sampling Size : 70 Retailers Respondents,20 Wholesaler.
Sample Area : Bagalkot,Kerur, Jamakhandi, Mudhol, Mahalingpur, Kaladgi and Banahatti
KIMS,KUD,DHARWAD. Page 29
NIRANI SUGARS LTD. MUDHOL
RETAILERS
YES
NO
97%
ANALYSIS
The data reveals that 97% of the retailers are aware about the different grades of sugar practiced
by sugar mills and only 3% of retailers are not aware about the different grades of sugar.
KIMS,KUD,DHARWAD. Page 30
NIRANI SUGARS LTD. MUDHOL
Sales of different grades of sugar from Retailers.
Sales of different
2% grades of suagr
1%
M-30
0% 20%
S1
S2
18% 58% M-30 and S1
M-30 and S2
S1 and S2
1% All three
Analysis.
From the above graph and table we get that 58% of the retailers will sell S1 grade sugar
only and 18% retailers will sell M-30 and S1 graded sugar,20%of the retailers will sell S1 & S2 graded
sugar, and 2% of retailers will sell M-30 grade sugar and 1% ,1% of retailers will sell only S2 and all
three graded sugar.
Interpretation-
From the above analysis we get that most of the retailers will prefer to sell S1 graded
sugar more than the other two grade sugars.(M-30 and S2).
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19%
30%
11% quality
40% price
availability
service
Analysis-
♦ From the table we get that out of 70 retailers 28 i,e 40% retailers consider price as main
factor,21 i,e 30% retailers consider quality as main factor,13 i,e 19% retailer consider service as
main factor and 8 i,e 11% retailer consider availability as main factor.
Interpretation-
♦ From graph we can get that most of the retailers who are in business irrespective of number of
years in business will consider price as the main factor ,then they will look for the quality, then
they will look in to the availability and service provided by the wholesaler.
♦ By this we can get that their is sufficient supply of sugar in the market, just retailers look for
good price and good quality of the sugar.
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Stock problem
YES
14%
NO
86%
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Stock problem
YES
14%
NO
86%
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14%
86%
♦ The data reveals that 86% of the retailers are ready to buy the sugar from the Nirani
sugars company if it set up new depots in there area
♦ 14% retailers not accepted to buy the sugar from the Nirani sugars limited if it set
up new depots in there area. So its good to set up new depots in there area.
KIMS,KUD,DHARWAD. Page 36
NIRANI SUGARS LTD. MUDHOL
Wholesaler;
Factors influencing the wholesaler during purchase of the sugar from the company.
♦ The data reveals that 60% of the wholesalers will consider price as the prime factor while
purchasing of sugar from the sugar factories.
♦ 25% of the wholesalers look for the quality factor as the major factor, and 15% of the
wholesalers will consider availability as the main factor.
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KIMS,KUD,DHARWAD. Page 38
NIRANI SUGARS LTD. MUDHOL
yes
20%
no
80%
KIMS,KUD,DHARWAD. Page 39
NIRANI SUGARS LTD. MUDHOL
FINDINGS
Price is the main factor considered by the most wholesalers and the retailers, while placing
orders.
S1 is the most selling sugar grade in the local market by the wholesaler and retailers irrespective
86% of retailers are ready to buy the sugar , if Nirani sugars limited setup new depot in their
respective area.
85% of retailers are not facing any stock problem, indicating the present distribution channel is
working fine.
Packaging method used by the most of the wholesaler as 100kg,50kg and 25kg.(most as 100 kg)
Packaging method used by the most of the retailers as 1kg, 2kg and 5kg.
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NIRANI SUGARS LTD. MUDHOL
Recommendation
The company itself develop a cost effective eco packaging materials and distributing them
to retailers and wholesalers, this mechanism not only helps Nirani sugars to build its brand
and creates awareness about its brand.
The Nirani sugar should go ahead with its proposed area to service up to new depots
nearing delivery location as the majority of retailers have shown acceptability towards to
buy sugar from Nirani sugar industry.
The Nirani sugar should focus expanding its market, even on export market as it is facing
stiff competition in local market.
KIMS,KUD,DHARWAD. Page 41
NIRANI SUGARS LTD. MUDHOL
QUESTIONNAIRE(wholesaler)
NAME: _____________________________________
NAME OF THE SHOP: _________________________
Yes no
2) From how many years are you into the business of selling sugar?
a. 0-2 years
b. 2-5 years
c. 5-10 years
d. 10+years
_____________________________________________________________________
4) What factors you consider while buying sugar?
a. Quality b. price. c. availability d. service e. others
6) Name of grade of sugar sold by you. ( among these 1) M-30, 2) S1, 3) S2? )
a. only 1 b. only 2 c. only 3 d. 1 and 2
e. 1 and 3 f. 2 and 3 g. all three
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7) What is the average sale per day?
_________________________________________________________________________
8) Name the areas from which retailers come in your shop to buy sugar.
_______________________________________________________________________
_______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
If yes, how?
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NIRANI SUGARS LTD. MUDHOL
_____________________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
QUESTIONNAIRE(Retailer)
NAME: _____________________________________
NAME OF THE SHOP: _________________________
Yes no
2)From how many years are you into the business of selling sugar?
e. 0-2 years
f. 2-5 years
g. 5-10 years
h. 10+years
_____________________________________________________________________
4) If the NIRANI Sugars company setup its own depot in your area do you buy from them?
Yes No
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6) Are you aware of grading of sugar?
Yes No
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
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NIRANI SUGARS LTD. MUDHOL
16) Have you faced any stock problem?
Yes No
b) If yes, give reason .
_____________________________________________________________________
_____________________________________________________________________
BIBLIOGRAPHY:
Reference Books:
Websites:
http://www.goole.com
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