Ugar Sugar Works Organizational Study

THE UGAR SUGAR WORKS LTD.
1. COMPANY PROFILE
A .BACKGROUND AND INCEPTION OF THE COMPANY
Late Shri V.S. Shirgaokar
Late Shri Suresh (Babu Kaka) Shirgaokar
Ex-Chairman Emeritus, Chairman & Managing Director of The Ugar Sugar Works Ltd and Visionary of our group.
Ex. Chairman & Managing Director of The Ugar Sugar Works Ltd and Visionary of our group
Late. Shri. V. S. Shirgaokar was the founder of the UGAR SUGAR WORKS LTD. He was born on 15th April 1897 and passed away on 22nd Jan.1996. The company is located at Ugar-khurd. About sixty years ago Ugar Khurd was a small hamlet in the erstwhile princely state of Sangli. It was however blessed with two great advantages; On its south flowed the perennial river Krishna and on the north, was situated the railway station of Ugar Khurd on the meter gauge line between Miraj and Bangalore, now changed to broad gauge.
KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH
Page 1

Conditions were ideal for somebody to harness the two advantages and exploit the fertility of the loamy soil. An abortive attempt was made in late thirties to start a sugar industry. After that, the then ruler of Sangli invited the late Dr.S.R.Shirgaokar who had previous experience of setting up a sugar factory at Kolhapur, to embark on the unexplored venture which he did with great dexterity and the slumbering village of Ugar Khurd was transformed into a humming industrial township in a few years. Today, Ugar is equivalent to a mini city with a decent sized population and having agriculture concentrated employment surrounding the sugar manufacturing focussed township. Dr.S.R. Shirgaokar deputed his competent nephew Shri.V.S.Shirgaokar to purchase a sugar plant from Moholi Sugar Factory in Sitapur District in Bihar and install it at Ugar Khurd. The Ugar Sugar Works hence found a very competent navigator in one of its visionaries- Late Shri V.S.Shirgaokar. The 500 TCD plant was purchased, installed and the first crushing season was started on the 21st of April, 1942.
After a succesful innings, the late V.S Shirgaokar then passed on the reins of the group to his younger brother- Shri Suresh Shirgaokar, popularly known as Babu Kaka. Babu Kaka took the organization further ahead and it was under his able leadership that the crushing capacity of the company underwent further expansion(10,000TCD). Presently, the crushing capacity of the organization is 15,000 TCD.(Ugar & UnitJewargi). Sooner than later, the company diversified its activities and started its own distillery in the year 1962-63 and then added the liquor section in the year 1967-68. The company is producing high quality premium brands like Old Castle Whisky, Gokak Falls Whiskey, US Rum, Doctors Brandy, Gagarin Vodka and the company's brands are well accepted by the market The company has setup a new distillery plant for producing 45,000 litres rectified spirit including 10000 litres ENA per day during the year 1994-95 and this plant
KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH Page 2

running very successful thereafter. This is in addition to the existing 30000 litres per day old distiller plant. Thereafter, the company further diversified and set up a first-in-its-kind-in in India Co-Generation Power Plant of 44 MW. This was based on the principle of bagasse based renewable sources of energy used as fuel. Out of which 28 MW are being exported to the grid and the rest of the 16 MW are used for captive consumption.
Page 3

B. PROFILE OF THE BUSINESS UNIT:
Name Website Established First crushing session Location of the unit : THE UGAR SUGAR WORKS LTD. : www.ugarsugar.com : September 11, 1939 : 21-04-1942 : THE UGAR SUGAR WORKS LIMITED Ugar-Khurd, dist: Belgaum : Central Bank of India Bank of Baroda Union Bank of India United Western Bank Ltd. ICICI Bank Ltd IDBI Bank Ltd UTI Bank Ltd Rabo India Finance Pvt.Ltd. : THE UGAR SUGAR WORKS LTD Ugar-Khurd 591316 Dist: Belgaum Karnataka Ph (08339) 272230 (5 lines) Fax: (08330) 272232 E-mail: helpdesk@ugarsugar.com : Mahaveer nagar, Sangli 416416 Phone (0233) 2623717, 2623716 Fax (02330 26236217) : M/S P.G.Bhagwat : Chartered Accountants, : Manoj Arcade, Tilakwadi Belgaum-590006
Name of the concerned banks
Address for the correspondence
Registered office
Auditors
Page 4
C. BOARD OF DIRECTORS:
Shri. R. V. Shirgaokar Shri. P. V. Shirgaokar Shri. S. S. Shirgaokar Shri. N. S. Shirgaokar Shri. C. S. Shirgaokar Shri. B. N. Kalyan Shri. A. B. Kage Shri. S. N. Inamdar Shri. V. Balasubramania Shri. M. R. Desai Shri. M. G. Josh Shri. D. B. Shaha Shri. B. S. Patil
(Chairman & Mentor) (Executive vice Chairman) (Managing Director) (Joint-Managing Director) (Joint-Managing Director) (Director) (Director) (Director)
(Director) (Director) (Director) (Director) (Director)
Page 5
D. NATURE OF BUSINESS CARRIED

The main business of the parent company are manufacturing of: Sugar Power Indian made foreign liquor Industrial and potable alcohol and Ethanol The Ugar Sugar works limited is the single location manufacturer of sugar in southern India with a licensed capacity of 10000 TCD. Ugar manufactures more than 1.5 million bags of sugar annually. The company has two distilleries with a total capacity of 75000 bulk liter per day. Some of well known brands in the market place are old castle premium whiskey, old castle Rum, US Rum vetted malt whiskey, sandpiper whiskey, gentlemans whiskeys, Ugar directories brandy, gagrin vodka and US gin.
Page 6

E. CANE :
Crushing Details (The Ugar Sugar Works Ltd) S.No 1 Particulars Cane crushed-Lac MT Sugar Production: Lac (Qtls) Recovery - % 2008-09 11.37 2009-10 14.27 2010-11 15.99 2011-12 13.22 2012-13 11.38
12.86
16.56
18.12
15.80
12.11
10.96
11.54
11.26
11.86
10.53
Cane / R & D Department The Ugar Sugar Works Limited has a separate Research & Development Department recognized by the Ministry of Science and Technology, New Delhi in 1978. The emphasis of agricultural R and D is understandably on sugarcane. The main objective of the Research and Development wing is to make a continuous effort to identify more dual purpose sugarcane varieties with high sucrose, high yielding potential and reasonably high fibre content. COM-88121 and Co-85019 are getting good acceptance by the cultivators. Co-7508 shows a good promise in saline soils. Co-95020 is the suitable variety for the Cogeneration plant. CoC-671 variety dominated other varieties for more than one and half decades. The R & D Section can rightly claim the credit for the introduction of the CoC-671 variety in Northern Karnataka as also some areas of the adjoining state of Maharashtra. Co-86032 and Co94012 are also high yielding and high sucrose sugarcane varieties introduced recently. Co89014 & Co-88025 are in the pipeline. Ugar's R & D department won the prestigious S.V.Parthasarathy Award eight times in nine years since its inception in 1985 for very effective R & D work in the agriculture of sugarcane. Recently it was also awarded by SISSTA, Chennai on 13th August, 2005. We are launching a massive programme of soil amelioration and popularization of green manuring crops like Dhiancha (Sesbania aculata) and Sunnhemp (crotolaria juncea) and ploughing them in the soil while still green. The work with Wheat, Soybean and Sunflower is reasonably successful as a rotation of crop
Page 7

and useful indications are likely to be obtained this year. Experiments on wheat under the guidance of CIMMYT (South America), ICARDA (Middle East), Agarkar Institute Pune (MACS), U.A.S. Dharwad and ICAR, New Delhi are laid on a big scale & the stand of crop is excellent. Vinayak (DWR-162) wheat variety identified by our R & D Wing is not only popular in this part of country but in Indonesia, it is also released as 'Devata' and has spread like wild fire. Our work on wheat has been internationally acknowledged.
His excellency, the President of India, A.P.J.Abdul Kalam in his speech. mentioned the raising Jatropha curcas (Raton Jyot) cultivation as one of the "Ten Immediate Missions" for achieving the goals of rural development, apart from producing Bio-diesel. Hence about 15000 seedlings have been planted by The Ugar Sugar Works Ltd as a source of Bio-diesel.
Page 8

F. VISION,MISSION,OBJECTIVES AND QUALITY POLICY
VISION:
We are dedicated to deliver overall value to our customer by delivering high quality products, exceptional financial performance to our share holder & complete satisfaction to cane growers, employees & stakeholders.
MISSION:
Ugar sugar will serve hard to retain its place as one of Indias premier sugar companies through sustained research, development & expansion of its operation of core compliance at global efficiency of cost, quality & standard of customer servicing and diversification to Liquor, co-generation to achieve competitiveness.
Page 9

QUALITY POLICY:
We at the Ugar sugar works Ltd. Engaged in producing white crystal sugar, Industrial and potable Alcohol and Ethanol and power from nonconventional source of energy. We strive to be at the forefront of Indian sugar industry by adopting latest technology, disciplined quality management system and continual improving on product quality.
Page 10

OBJECTIVES: Producing efficiently the best quality sugar satisfying domestic and intentional norms. Maximization of power generation through non-conventional source of energy for self-consumption and to support rural power supply through grid. Producing the best quality spirit suitable for industrial and potable use and ethanol. Bringing the overall productivity and efficiency throughout the organization, especially by value addition of its-product in sugar, effluent waste, etc. Motivation through training and retraining of the employees for improving operational performance.
Page 11

G. PRODUCTS/SERVICES PROFILE:
The Ugar sugar works limited is the manufacture of the White Crystal Sugar. Along with sugar some other main products manufactured in Ugar Sugar Works Ltd.
SUGAR POWER DISTILLERY PRODUCTS BIO-GAS OTHER BY PRODUCTS
Page 12

SUGAR:
The Ugar Sugar Works Limited is the largest single location manufacturer of sugar in southern India with a licensed capacity of 10000 TCD. Ugar manufacturers more than 15 million bags of sugar annually. The main product of sugar manufacturing process is white crystal sugar. This white crystal sugar is manufactured in the following grades:
GRADES:
GRADE M-30 S-30 SS-30 SIZE (1400 MICRONS) (600 MICRONS) (800 MICRONS) % PRODUCED IN LAST SEASON 10% 40% 50%
Quality of sugar is measured with the help of four important parameters. Namely Sugar Poll, Moisture, Temperature & Color. The sugar is said to be of good quality when it have sugar poll 99%, moisture 0.4%, temperature below 40 for bagging and color 100120(below 100 for export)
KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH Page 13
POWER:
Source of energy (i.e. Bagasses) out of which 28 MW is used for captive consumption. For these process they use 3 high capacity turbines imported from japan.
Page 14
DISTILLERIES:
The Ugar Sugar Works Limited has two distilleries with a total capacity of 75000 bulk liters per day. Some of its well known brands in the market place are old castle premium whiskey, old castle rum, US rum, vetted malt whiskey, sand piper whiskey, gentlemans whisky, Ugar directors Brandy , gargrin vodka and US gin.
Page 15

BY PRODUCTS:
BAGASSE:
Bagasse is a residual material left after the extraction of juice from sugar cane. In Ugar sugar, it is captivelly used as a fuel by which the industry is self-sufficient for its fuel requirement. The excess is saved to the tune of 5% of weight of the cane crushed. The saved Bagasse can be selectively used as fuel in the lean period/off-season to the interested parties.
BIO-GAS:
The companys 1 MW Bio-gas power generation plant for Utilizing Bio gas available from distillery effluent treatment plan jointly set up with Indian institute of science Bangalore and national bio-energy board.
FINAL MOLASSES:
It is highly viscos left over material containing sugar reducing sugar and organic/inorganic impurities. It is a raw material for distilleries of our organistaion.
FILTER CAKE:
Filter cake commonly known as press mud is the suspended impurities Separated during the process of cane juice clarification by the sulphitation process. The material is used as manure and the factory managers to sell the filter cake to the cane growers at concessional rates and achieves recycling of the matter back to fields.
The fermentation sludge is dried and separated. It is used for poultry feeds. Fuel oil is separated from the distillery section (mixture of higher alcohol) and used for amyl alocohol/perfumes. Carbon di-oxide is also produced in the fermentation process. It is scrubbed and filled in the cylinders. It is used for industrial purpose.
Page 16

H. AREAS OF OPERATION:
Ugar sugar works limited areas of operation is on national and regional basis. The Ugar Sugar Works Limited manufactures and sells sugar, and industrial and potable alcohol; and generates and distributes electricity in India. The company offers white crystal sugar, as well as byproducts, such as bagasse, filter cakes, and final molasses. It also provides various distillery products, including Indian made liquor products under the Old Castle Premium Whisky, U.S. Whisky, U.S. Brandy, U.S. Gin, Ugar XXX Rum, Gokak Falls Whisky, Milan Whisky, Hawk Gin, and Gagarin Vodka brands; ethanol; rectified spirit; malt spirit; arrack; and extra neutral alcohol. In addition, the company offers sugar confectionary in the form of sugar ships under the filmi shakkar name. Further, it operates a 44 megawatts bagasse based co-generation power plant. The company also exports its products. The Ugar Sugar Works Limited was founded in 1939 and is based in Ugar Khurd, India.
I. OWNERSHIP PATTERN:
Ugar sugar works limited is a private limited company.
Page 17

J. INFRASTRUCTURE:
The city is accessible by both road and railroad. By roads it connects to Kolhapur, Belgaum, Bijapur, Bagalkot, Miraj, Athani. By rail, it connects to two nearest towns Miraj in the north, and Belgaum in south. Since this Railroad connects Bangalore and Bombay, Ugar is conveniently connected to most of India. Belgaum, the district headquarter, about 100 KM from Ugar has the nearest operational airpor
Ugar currently has two distilleries and Indian Made Liquor (IML) units in our premises at Ugar Khurd. The first one is an old distillery of capacity 30,000 LPD , while the second one is a newly constructed distillery from Praj Industries, Pune having a capacity of 45,000 LPD. The Praj distillery runs on the continuous fermentation technology. The whole unit of distillation process is having material of construction in copper, which gives a very good quality of spirit. This plant is having a high level of computerisation and automation.
In these distilleries, we are also having Malt Spirit and Malt Grain Spirit. We are producing Malt Spirit and Malt Grain Spirit as per ISI Standards. These spirits are given to the IML Division for blending.
Page 18
K. AWARDS:
Mr. S V Parthasarathy's Award for outstanding performance in sugar industry for the season 1984-85
National Safety Award 1984 for largest Accident free Period
Page 19

L. ORGANISATION CHART:
The Ugar sugar works organization has been divided into many department and qualified and well-experienced managers head each department. They have subordinates to assist them and to share workload of each department.
BOARD OF DIRECTOR
CHAIRMAN & MENTOR
EXECUTIVE DIRECTOR
MANAGING DIRECTOR
JOINT MANAGING DIRECTOR
JOINT MANAGING DIRECTOR
MANAGERFINANCE
COMPANY SECRETARY
IT DEPARTMENT
MANAGER A&P
SUGAR GODOWN KEEPER
WORK MANAGE R
MANAGER CANE
MANAGE R R&D
DEPUTY MANAGER PERSONNEL CHIEF ENGINEER MECHANICAL CHIEF ENGINEER COGENERATION
TIME OFFICE
WATCH & WARD
DEPUTY CHEIF ENGINEER (ELECTRICAL)
DEPUTY CHIEF ENGINEER (COGENERATION)
PROJECT ENGINEER
Page 20

M. PROCESS FLOW CHART & DESCRIPTION OF EACH PROCESS:
a) Sugarcane is harvested and clean sugarcane is loaded in the vehicles and brought to the factory. The gross weight is taken and sugarcane is unloaded on the feeder table with the help of electric crane. The tare weight of the vehicle is taken to arrive at the weight of the sugar cane. b) Cane is fed to cane carries from the feeder table. The preparatory devices viz. kickers, cutters, fibrizer etc. are installed on the carrier for the preparation of cane. The prepared cane is taken to mills by second carries where juice is extracted using compound ambition process and hot water is applied for maximum extraction before last mill. Mixed juice is strained and sent for processing water for ambition and mixed juice both are weighted in automatic weighing scale and mass flow meter respectively. Bagasse (residue of cane after juice extraction) is used as fuel in the boiler and surplus bagasse saved in the form of bales. c) Mixed juice is clarified by sulphitation process by heating at 70oc in a juice heater. Phosphoric acid, sulphur dioxide gas and milk of lime are used as a clarificants. These are thoroughly mixed in juice sulphiter. Then the sulphited juice is heated to 105oc in another juice heater. This juice is passed on to continuous clarifies through flash tank for settling. The settled mud is filtered with the help of vaccum filter where the filterates are separated and sent back to process. Hot condensate water is used to wash the cake with minimum sugar content is sent out as bye product Decanted clear juice from clarifier is taken to evaporator (multi effects). The concentration is increased to syrup consistency. The heat required for heating and evaporation is used from exhausted steam and the bled vapours from the evaporators. Exhaust steam is obtained from prime mover turbine of power generation. d) The syrup from evaporators is bleached by using sulphur di oxide. The sugar is produced from further concentration of this syrup and sugar melt by evaporation in vaccum pan. The necessary seed crystals are taken in the pan and boiled with syrup at about 60oc. This give A massecuite. A massecuite from the pan is discharged into crystallizers. Then the sugar crystals are separated from the surrounding film of mother liquor in centrifugal machine. The separated liquor is called as A Heavy molasses and dried with superheated water wash is dropped on the Hopper and elevated to the top of grader by bucket elevator and graded according to the size and then it is bagged in A Twill bag 100kg. net. e) A Heavy molasses is subjected to second boiling to get B massecuite there by Bsugar and E heavy molasses B-sugar is used as seed or melted. B heavy molasses is subjected to third boiling to get C Massecuite and thereby C-sugar and final molasses. C-sugar is melted and used. Final molasses is weighted and stored in steel tanks (non duty paid). It is then sold as bye product.
Page 21

CANE YARD
UNLOADING
Water for cane washing

FEEDER TABLE CUTTER
Meceration water Steam for Mill Drive Power Bagasse
MILLS
JUICE
BOILER NO.1
BOILER NO.2
JUICE WEIGHING SCALE
Excess bagasse
WEIGHTED JUICE
J.H.PRI HEATER
SO2 GAS
LIME
STEAM POWER TURBINE
JUICE SULPHITER CLARIFIER OF DORR
72 c to
102 c
Mud juice
J.H SEC HEATER
OLIVE FILTER
DISP
Clear juice
EVAPORATOR SO2 GAS
SYRUP SULPHITOR SYRUP WEIGHING SCALE
Superheated wash water

A MOL
B M/C VACCUM PAN A BOILING
CRYSTALLISER
A CENTRIFUGALS
B CENTRIFUGALS
WHITE SUGAR
B-SUGAR
B-MOL C M/C CSUGAR FINAL MOL
GRADING
WHEIGHING& PACKING
CRYSTALLISER
Page 22
N. QUALITY CONTROL TOOLS

The quality control tools used by the Ugar sugar works limited are:
5S CONCEPT KAIZEN SGA/QUALITY CIRCLE SIX SIGMA TQM(TOTAL QUALITY MANAGEMENT) ISO 9001(INTERNATIONAL ORGANISTION FOR STANDERDIZATION)
Page 23
1. 5S CONCEPT: 5S is the name of a workplace organization methodology that uses a list of five Japanese words which are Seiri, Seiton, Seiso, seiketsu and Shitsuke. Translated into English, they all start with the letter S. The list describes how items are stored and how the new order is maintained. PHASES OF 5S: There are 5 primary phases of 5S: SORTING, STRAIGHTENING, SYSTEMATIC CLEANING, STANDERDISING, AND SUSTAINING. 1. SORTING: Eliminates all unnecessary tools, parts, and instruction. Go through all tools, materials, and so forth in the plant and work area. Keep only essential items and eliminate what is not required. 2. STRAIGHTENING: The place for each item should be clearly labeled. Items are arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible. There is need to workers to bend repetitively to access materials. Each tool, part, supply, or piece of equipment are kept close to where it will be used. 3. SYSTEMATIC CLEANING: Keep the workplace tidy and organized. At the end of each shift, clean the work area and be sure everything is restored to its place. This make it easy to know what goes where and ensures that everything is where it belongs. 4. STANDARDIZING: Work practices should be consistent and standardize. All work stations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station. 5. SUSTAINING: Maintain and review standards. Once the previous 4 Ss have been established, they become the new way to operate. Maintain focus on this new way and do not allow a gradual decline back to the old ways.
Page 24
2. KAIZEN: Kaizen stands for improvement or change for the better, refers to philosophy or practices that focus upon continuous improvement of processes in manufacturing, engineering, supporting business processs, and management. By improving standardized activities and processes, kaizen aims to eliminate waste. IMPLEMENTATION OF KAIZEN: The Toyota production system is known for kaizen, where all line personnel are expected to stop their moving production line in case of any abnormality and, with their supervisor, suggest an improvement to resolve the abnormality which may initiate a kaizen.
The cycle of kaizen activity can be defined as: Standardize an operation Measure the standardized operation (find cycle time and amount of in-process inventory) Gauge measurements against requirements and increase production Standardize the new, improved operations Continue cycle ad infinitum
Page 25
3. SGA/QUALITY CIRCLE: A quality circle is a volunteer group composed of workers, usually under the leadership of their supervisor, who are trained to identify, analyze and solve work-related problems and present their solutions to management in order to improve the performance of the organization, and motivate and enrich the work of employees. The term quality circles derives from the concept of PDCA (Plan, DO, Check, Act) circles developed by Dr. W. Edwards Deming. Quality circles are not normally paid a share of the cost benefit of any improvements but usually a proportion of the savings made is spent on improvements to the work environment.
Page 26
4. SIX SIGMA: Six sigma is a business management strategy originally developed by Motorola, USA in 1986. As of 2010 [update], it is widely used in many sectors of industry. Six sigma seeks to improve the quality of process outputs by identifying and removing the cause of defects and minimizing variability in manufacturing and business process. The term six sigma originated from terminology associated with manufacturing, specifically terms associated with statistical modeling of manufacturing processes. METHODS: Six sigma projects follow two project methodologies inspired by Demings Plan-Do-Check-Act cycle. DMAIC is used for projects aimed at improving an existing business process. DMAIC is pronounced as duh-may-ick. DMADV is used for projects aimed at creating new product or process designs. DMADV is pronounced as duh-mad-vee
Page 27
5. TQM (TOTAL QUALITY MANAGEMENT): TQM is an integrative philosophy of management for continuously improving the quality of products and processes. It is used around the world.
TQM functions on the premise that the quality of products and processes is the responsibility of everyone who is involved with the creation or consumption of the products or services offered by an organization. In other words, TQM capitalizes on the involvement of management, workforce, suppliers, and even customers, in order to meet or exceed customer expectations.
Page 28
6. ISO 9001 (INTERNATIONAL ORGANIZATION FOR STANDARDIZATON): ISO, is an international standard-setting body composed of representatives from various national standards organizations, Founded on February 23, 1947.
The organization which today is known as ISO began in 1926 as the International Federation of the National Standardizing Associations (ISA).
ISO is a voluntary organization whose members are recognized standard authorities, each one representing one country. The bulk of the work of ISO is done by the 2700 technical committee, subcommittees and working groups.
Page 29
O. EXPANSION DETAILS:
Enclosed below are the details of the Ugar Sugar Works expansion plans :
Green Field Project : Unit Jewargi EOU Project for manufacture of sugar ships
Ugar Sugar - Ugar Quality Packaging
Greenfield Project-Jewargi
Location : Malli Village, Taluka: Jewargi, Dist: Gulbarga, State: Karnataka. It is about 15 kms from Sindagi on the State Highway No.12
Land Area :
The land measuring about 162000 sq. mtrs shall be required for the entire factory and administrative setup
Main Product :
White crystal Sugar
By Products :
a) Cogeneration b) c) Press-mud
Power
(Electricity) Molasses
Licenced Capacity :
Sugar 3500 TCD (expandable to 5000 TCD) Cogeneration Power Plant 15MW
Page 30

The land acquisition and machinery procurement work has been completed. The crushing details for the season 2012-2013 are as below.
Total Crushing (Lac MT)
3.35
Total Sugar Bagging (Lac Qtls)
3.31
Recovery - %
9.82
Power Export :
Total export 2,14,67,000 units. Due to the multi fuel boiler, power export will be done during off-season too in future.
Sugar Ship EOU

EOU for the Manufacture of Sugar in the form of Ships The Ugar Sugar Works Ltd. set up a 100% Export Oriented Unit for the manufacture of sugar in the form of ships at Ugar. The plant and machinery for this EOU has been imported from Europe & has been installed. The successful product trials have been taken & commercial production has begun. This hi-tech unit has been accredited with ISO 22000, which is a universally accepted food standard world wide. Currently, we are exporting this product to Europe & the Middle East. In order to place orders, kindly contact us at :
ship.sales@ugarsugar.com
Page 31
Ugar Quality Packaging Pvt. Ltd

The Ugar Sugar Works Ltd is diversifying into the business of printing & packaging through its latest Joint Venture company Ugar Quality Packaging Pvt. Ltd.(UQPPL). This company will be a 100% Export Oriented Unit (EOU) and shall cater to the entire printing/packaging needs of Ugar's Fragies Sugar Ship EOU project. In addition to sourcing to Ugar, UQPPL will also look for potential business from customers belonging to diversified industry backgrounds. This new plant has been set up at Ratnagiri, Maharashtra and commercial production has started from October 2007. The finished goods coming out of this plant will be triangular cartons, master cartons, boxes & other printing and packaging material of international export quality.
Page 32
P. NEW PROJECT: First time in India - Zero Pollution at Ugar's Distilleries.

The Ugar Sugar Works Ltd., has installed and commissioned a full fledged waste water treatment plant for treating 3.6 lacs litres per day of effluent generated from a 30,000 litres per day alcohol production capacity. The treatment system consists of Biomethanation followed by Evaporation & a Dryer System supplied by M/ s. SSP (Pvt). Ltd., Faridabad. This technology has been adopted for the first time in India by The Ugar Sugar Works Ltd. The Technology Development Board of the Ministry of Science & Technology, Government of India has celebrated 11th May, 2006 as a Technology Day at the Hotel Ashoka, New Delhi. Our Chairman Mr. R.V.Shirgaokar & Manager Projects Dr. S.M.Pattanshetty of The Ugar Sugar Works Ltd., were called specially to attend the function. The efforts made by the company were very well appreciated by Mr. Montek Singh Ahuluwalia, Dy. Chairman Planning Commission, Honorable Minister Mr. Kapil Sibbal, of Ministry of Science & Technology, Dr. Mahendra Pal, Sr. Scientist. Technology Development Board, New Delhi & Dr. R. A. Mashelkar, Director General, CSIR, New Delhi, Chairman of Central Pollution Control Board.
The photograph (L) shows Mr. R.V .Shirgaokar, explaining the working details of the plant to Mr. Montek Singh Ahuluwalia, Dy. Chairman Planning Commission & Mr. Kapil Sibbal, Honourable Minister of the Ministry of Science & Technology. Photograph
Page 33

(R) shows a model of the SSP plant.
The system has three advantages namely:
1) 100% achievement of the pollution control parameters prescribed by ministry of Environment, Government of India and State Pollution Control Board as a distillery unit comes under highly polluting industry under 17 categories.
2) The byproduct is a complete water soluble, fine, brownish colour powder containing mainly potash and other nutrients useful for agriculture purpose, which is a value added product
3) The 100% treated effluent water is recycled for other processes in the factory thereby saving fresh water requirement
The plant is under operation since January 2003. The company has also placed an order for its additional plant of 7 lac litres per day of effluent treatment suitable to a 45,000 litres per day of distillery capacity.
Page 34
Q. WELFARE ACTIVITIES: EDUCATION HOSPITAL FACILITIES RECREATION
Education
Ugar Sugar Works has contributed whole-heartedly in the field of education, towards the betterment of the residents of this region. Following are the highlights of the Education Trust programs, in which Dr. Shirgaokar and Shri Babukaka Shirgaokar are founder members: Bal Mandir
This is a playschool for the young children
Page 35

Shri Hari Vidyalaya
Shri Hari Vidyalaya is a school, which is home to over 3000 students. This school has a curriculum which covers the following mediums of instruction under the primary and secondary sections : English Medium
Marathi Medium
Kannada Medium
Shri Hari Vidyalaya Pre-University & Degree College
This college is operating for a number of years at Ugar Khurd. It has Arts, Commerce and Science (first year) facultys for a Bachelors Degree. It houses over a 1000 students
Shri Babukaka Shirgaokar Technical Educational Trusts
Industrial Training Institute (ITI)
The ITI was started in the year 1994 in honour of our then MD, Shri Babukaka Shirgaokar. This institute provides technical training in the following disciplines :
Page 36
Fitter
Electrician
Instrument Mechanic
Computer Technology Trade
Cutting and Sewing
Total strength of the ITI currently is 150 students. The following courses have been offered by the trust :
Health Aid (Nursing)
Diploma in Computer Awareness for School Children Various certificate courses Diploma in Computer Applications for college students, job holders & professionals
Cutting and Sewing
Page 37
Hospital:
The Dr. Shirgaokar Hospital is very well equiped in the following areas :
State of the art laboratory
X-Rays units
An air-conditioned operation theatre
Dental and Orthopedic section
Accomodation for 32 indoor patients (32 beds)
Qualified staff of doctors and nurses to take care of the patients.
Treatment at subsidised rates
Eye camp every week
Page 38
Facilities:
Listed below are some of the key facilities provided by Ugar Sugar Works :
Employees Society
a)Provisional Stores b) Loan at minimum rate of interest.
Hospital
a) Treatment at subsidised rates. b) 32 beds maternity hospital with qualif ied staff.
Education Facilities
a) Kids Playschool, Primary & Secondary School b) College c) Technical Institute (ITI) d) Health Aid (Nursing Course)
Medical Aid
Medical aid given for major treatment.
Quarters
Approximately 132 apartments and 400 quarters provided on rent free basis.
Biogas
Biogas supplied to workers colony (for 85 quarters at concessional rate)
TV Cable connection
TV Cable connections are given at nominal charges.
Medical Camp
Organising various types of medical camps viz Eye,

Page 39

Dental, Tubectomy, Blood donation, EN T, Diabetic Detection Camp etc.
Workers day
Celebrating workers day on 2nd October every year and felicitating the retired workers and high performers during the year.
Training Programme
Organising Workers / Staff Training Programme.
Ugar Wartha
Circular of monthly Ugar Magazine.
Alcoholics Anonymous Group Meeting
Conducts the Alcoholics Anonymous meeting for the group of fellows, who desires to give away drinking through the intergroup (self-supported) of General Service office of Alcoholics Anonymous (India). Meeting held twice in a week.
Sakhar Shala Project
The non formal school runs for the childrens of the Harvesting workers(Gabali) during crushing season to bridge the gap of academic year and to keep touch with education during stay at factory(work) site, with the help of social organisations like Lions Club & Mahila Mandal.
Shri Vinayakrao Shirgaokar Pratishhtann
Provides Education, Loan / Medical Aid.
Dr. Shirgaokar Educational Trust
Provides Education, Loan & Scholarships to the workers children
Page 40

Recreation:
Gymkhana :
Performs recreation activities.
Provided Books Library.
Table Tennis
Carrom
Badminton
Skating
Cricket
Gymnasium Hall
Page 41
2. INDUSTRY PROFILE: a. MAJOR COMPETITORS AND COMPETION ANALYSIS: INDUSTRY COMPETITORS:

SYMBOL PRICE CHANGE %CHANGE HIGH LOW PE DE VOLUME Mawana 0 0% 28.80 27.65 8.38 3.58 83983 27.90 Sugars Ltd.(Old) Dalmia Bharat 0.23 1.60% 14.53 14.00 6.41 1.72 2660 14.53 Sugar and Industri Ponni Sugars 150.15 N.A. 150.15 150.15 6.76 0.99 56 150.15 (Erode) Ltd. Rajshree 0 0% 37.95 37.00 8.56 N.A. 358 37.00 Sugars & Chemicals Ltd. Dhampur 0.40 1.32% 31.70 30.00 7.70 4.07 9443 30.65 Sugar Mills Ltd. Thiru Arooran 0 0% 60.00 60.00 28.36 N.A. 5050 60.00 Sugars Ltd. Piccadily 1.95 8.47% 24.95 23.25 3.07 N.A. 11650 24.95 Agro Industries Ltd. Dharani 0.80 3.96% 21.10 21.00 5.05 4.76 8 21.00 Sugars & Chemicals Ltd. SBEC Sugar 12.07 N.A. 12.07 12.07 0.00 N.A. 100 12.07 Ltd. DCM Shriram 2.70 9.27% 31.80 31.80 4.92 4.71 11 31.80 Industries Ltd. KCP Sugar & 0.10 0.59% 16.85 16.40 4.91 N.A. 831 16.80 Industries Corporati
Page 42
The Ugar Sugar Works- Comparative Analysis
Today
1 Month
3 Months
1 Year
3 Years
Ugar Sugar Works Ltd.
-2.16%
0.55%
-1.54%
-23.85%
-29.26%
BSE Smallcap
-0.95%
0.3%
-12.5%
-18.81%
-47.6%
CNX NIFTY JUNIOR
-2.98%
-4.65%
-16.47%
4.63%
-14.45%
Page 43

3. SWOT ANALYSIS:
STRENGTH:
1. Involved in the manufacture of white crystal sugar for over 65 years hence well-established. 2. It has installed a full- fledged waste water treatment plant. The treatment system consists of Biomethanation followed by Evaporation & a Dryer System, a technology that has been adopted for the first time in India. 3. It has good R&D capabilities. 4. It has come up with a lot of innovation like auto cane feeding system before the mills. 5. As a Diversification cum Tax Saving Measure the Company has decided to set up Four Wind Mills in Tamilnadu for Wind Power Generation.
WEAKNESS:
1. Volatility in sugarcane prices. 2. Sugar industry is obliged to supply 10% of its production at substantial concessional price, much below the cost of production, to the Government for supply to the Public Distribution System (PDS).
OPPORTUNITY:
1. Scope for technology upgradation. 2. Opportunities in terms of export to new emerging markets.
THREATS:
1. Vulnerable to political interests 2. Being in an agro based Industry, inherent risks of the vagaries of monsoon and other natural calamities.
Page 44

4. ANALYSIS OF FINANCIAL STATEMENTS: BALANCE SHEET OF LAST 6 YEARS:
Particulars SOURCES OF FUNDS : Share Capital Reserves Total Total Shareholders Funds Secured Loans Unsecured Loans Total Debt Total Liabilities APPLICATION OF FUNDS : Gross Block Less : Accumulated Depreciation Less:Impairment of Assets Net Block Lease Adjustment Capital Work in Progress Investments Current Assets, Loans & Advances Inventories Sundry Debtors Cash and Bank Loans and Advances Total Current Assets Less : Current Liabilities and Provisions Current Liabilities Provisions Total Current Liabilities Net Current Assets Miscellaneous Expenses not written off Deferred Tax Assets Deferred Tax Liability Net Deferred Tax Total Assets Contingent Liabilities
Mar-13 Mar-12 Mar-11 Mar-10 Mar-09 Mar-08 11.25 105.09 116.34 333.07 23.50 356.57 472.91 438.86 261.37 5.96 171.53 0.00 4.50 2.49 423.43 13.07 15.81 12.90 465.21 11.25 90.27 101.52 267.03 17.73 284.76 386.28 394.61 241.08 3.26 150.27 0.00 6.94 0.08 423.70 31.19 26.94 16.30 498.13 11.25 76.45 87.70 289.89 22.96 312.85 400.55 385.27 216.82 0.00 168.45 0.00 7.13 1.39 348.60 33.91 23.72 19.78 426.01 11.25 72.43 83.68 314.53 33.99 348.52 432.20 382.32 188.31 0.00 194.01 0.00 2.96 1.39 320.22 29.58 26.65 37.00 413.45 11.25 9.00 92.47 65.14 103.72 74.14 263.70 282.79 20.41 29.38 284.11 312.17 387.83 386.31 372.27 223.01 155.90 139.41 0.00 0.00 216.37 83.60 0.00 0.00 0.52 128.83 23.71 18.78 191.71 193.11 30.00 35.93 19.27 28.26 49.10 39.76 290.08 297.06
151.18 8.49 159.67 305.54 0.00 5.14 15.56 -10.42 473.64 40.45
247.89 8.40 256.29 241.84 0.00 4.12 17.18 -13.06 386.07 43.44
188.65 1.56 190.21 235.80 0.00 0.00 8.24 -8.24 404.53 10.20
163.05 8.74 171.79 241.66 0.00 15.15 22.97 -7.82 432.20 39.00
112.17 126.58 14.81 10.73 126.98 137.31 163.10 159.75 0.00 0.00
4.21 4.12 20.08 8.77 -15.87 -4.65 387.83 386.31 44.77 14.34
Page 45

5. STP STRATEGIES:
Page 46

6.
LEARNING EXPERIENCE:
The project undertaken has helped a lot in understanding the concept of employees welfare in the industry. Overall the employees through the survey have pointed a picture conveying the satisfaction in the various dimensions in the company . Work culture in The Ugar Sugar works limited is very friendly; people have freedom to take decision which makes them more innovative without any fear.
I spent more time with my training officer Mr. Patil sir who is very friendly; he helped me in all the theoretical part. He is very cool minded he suggested me what to do what not to do. By Patil sir I learned how to communicate with others calmly.
Page 47
Page 48
Page 49

Ugar Sugar Works Organizational Study

Uploaded by

Copyright:

Available Formats

Ugar Sugar Works Organizational Study

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ugar Sugar Works Organizational Study

Uploaded by

Copyright:

Available Formats

THE UGAR SUGAR WORKS LTD.

A .BACKGROUND AND INCEPTION OF THE COMPANY

Late Shri V.S. Shirgaokar

Late Shri Suresh (Babu Kaka) Shirgaokar

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

Name of the concerned banks

Address for the correspondence

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

(Director) (Director) (Director) (Director) (Director)

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

D. NATURE OF BUSINESS CARRIED

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

SUGAR POWER DISTILLERY PRODUCTS BIO-GAS OTHER BY PRODUCTS

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

National Safety Award 1984 for largest Accident free Period

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

JOINT MANAGING DIRECTOR

JOINT MANAGING DIRECTOR

SUGAR GODOWN KEEPER

DEPUTY MANAGER PERSONNEL CHIEF ENGINEER MECHANICAL CHIEF ENGINEER COGENERATION

WATCH & WARD

DEPUTY CHEIF ENGINEER (ELECTRICAL)

DEPUTY CHIEF ENGINEER (COGENERATION)

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

KLS INSTITUTE OF MANAGEMENT EDUCATION AND RESEARCH

THE UGAR SUGAR WORKS LTD.

Water for cane washing