OPERATIONS MANAGEMENT

(23MSP08)

NAME: JANA VISHNU.S

REG NO: 23MBA068
CLASS: I MBA-B
SUBMISSION DATE: 23-01-2024
MINI PROJECT: 01
INTRODUCTION:
This project will provide a holistic overview of the sugar production
process, encompassing cultivation practices, harvesting techniques, refining
methods, and the various types of sugar produced. A Comprehensive Exploration
of the Sugar Production Industry," aims to delve deep into the intricacies of this
vital sector, un-revaling the complexities of sugar production from field to table.

COMPANY PROFILE:
The First Sugar Unit near Sathyamangalam of Erode District, Tamil Nadu
State, started its commercial production in the year 1986 with an initial capacity
of 1250 Tonnes of Cane Crush per Day.
Its present capacity is 4000 TCD and has an imported facility to produce 300MT
Refined Sugar per day with ICUMSA less than 20 IU. Its an ISO 9001:2008
certified Unit.
The Second Sugar Unit, near Nanjangud in Mysore District of Karnataka State,
started the commercial production in the year 1992 with an initial cane crushing
capacity of 2500 TCD and its present capacity is 7500 TCD. A Sugar Refinery
Plant with a capacity of 500 MT per day has been installed.
The Cane crushing capacity of 2500 TCD of the third Sugar Unit in Kunthur
Village near Kollegal in Karnataka, has been enhanced to 3600 TCD, with a Co-
Generation Plant of 20 MW of Power Generating Capacity.

The Fourth Sugar Unit comprises of 5000 TCD Sugar Plant and 28.8 MW Co-
generation Plant at Kolundampattu Village, Thandarampattu Taluk,
Tiruvannamalai District in the year 2010. The unit also has a 500 Tonnes/Day
Refined Sugar production facility.

The Sugar Unit V comprising of 3600 TCD Sugar and 25 MW Co-generation

Plant at Vengur Village, Tiru-koilur Taluk, Villupuram District. The new 25 MW
Co-generation power plant has been synchronized with Tamil-Nadu Electricity
Board Grid.
Industry type:

Sugar industry comes under the Agri-based industry. India is the second
largest producer of sugarcane in the world. This industry provides employment
for more than 4 lakh persons directly and a large number of farmers indirectly.
The sugar industry is a seasonal industry because of the seasonality of raw
materials.

Types of products:

1.Bagasse

Bagasse refers to the dry residue left after the juice is extracted from the
Sugarcane. One of the key uses of bagasse is to produce electricity. When used
to produce electricity it serves as a great renewable source of energy. It is even
stored and used to generate electricity throughout the year. However, storage
poses a challenge. Bagasse is also used to produce particleboard which is also
known as chipboard. Furfural is also produced, which is a flammable chemical
substance. It can also produce methane gas. In addition to all this, it is also used
as cattle feed. In places, efforts are being made to make packaging material out
of bagasse.

2.Molasses:

Molasses is one of the most important by-products of sugar production from

Sugarcane. In fact, the importance of the production of ethanol has taken the
centre stage and there are discussions to divert the entire production of Sugarcane
to produce Molasses so that it can be processed to produce ethanol.Molasses
refers to the effluent produced after the continuous crystallization process. It can
also be used to produce acetic acid, yeast and Rum.
3.Filter mud:

Filter mud refers to the impurities which are removed through filtration of the
juice. This forms cakes of mud and efforts are being made to identify the most
rewarding usage of it. Refined wax can also be used as it contains fatty acids and
lipids. It is also used as cattle feed.

Location advantage’s:

1.Reduced Transportation Costs;

Proximity to sugarcane fields reduces transportation costs for bringing the

raw material (sugarcane) to the processing facilities. This is particularly important
since sugarcane is bulky and perishable, and transportation over long distances
can be expensive.

2.Optimized Supply Chain;

Locating the sugar industry near sugarcane fields allows for a more
streamlined supply chain. Sugarcane can be harvested at its peak freshness,
minimizing losses during transportation and ensuring optimal sugar content for
processing.

3.Minimized Losses and Deterioration:

Sugarcane begins to deteriorate rapidly after harvesting. By situating

processing plants near the fields, the time between harvesting and processing is
minimized, reducing losses due to spoilage or deterioration.
4.Employment Opportunities:

The sugar industry being close to sugarcane fields creates job

opportunities for local communities. Employment opportunities can range from
agricultural labour for sugarcane cultivation to processing plant jobs, thereby
contributing to rural development.
5.Optimal Agricultural Practices;

Proximity enables closer collaboration between the sugar industry and

sugarcane farmers. This collaboration can lead to better agricultural practices,
including improved cultivation techniques, pest control, and sustainable farming
methods.

Product design :

1.Brand Identity:
Develop a strong brand identity that reflects the values and image of your
product. Choosen a memorable and relevant brand name that resonates with
your target audience.

Packaging Design:

Create eye-catching and functional packaging. Consider using sustainable

materials to appeal to environmentally conscious consumers. Ensure that the
packaging protects the sugar from moisture and contaminants.

1.Labeling:

Clearly display nutritional information, including calorie content, sugar type,

and any health-related information. Include any certifications, such as organic or
fair trade, prominently on the label.

2.Product Variety:

If you offer various sugar products, consider designing a cohesive packaging

system that ties the different products together. Differentiate packaging colours
or labels for various sugar types (white, brown, raw, etc.).
3.Target Audience:

Understand your target audience and design packaging that appeals to their
preferences. Consider the demographics, lifestyle, and values of your target
market when making design decisions.

4.Functional Design:

Ensure that the packaging is easy to open, pour, and reseal. Consider
innovative packaging designs that improve user experience and convenience.

TECHNOLOGIES USED IN A SUGAR COMPLEX:

1.MOISTURE CONTROL UNIT (MCU):

Moisture % Bagasse plays a very important role in Milling and Plant

efficiency. Lot of work has been done in this field. As compared to Bagasse Drier
units, MCU is an arrangement developed with a view to reduce moisture content
of Bagasse to some extent. Moisture Control Unit is showing promising results
and hence may be used as a tool to improve overall profitability of the plant.
“Moisture Control Unit” is designed to reduce moisture of bagasse coming out
from discharge nip of each mill which results in additional drainage of juice and
reduces final bagasse moisture. This ultimately improves overall performance of
whole tandem in terms of overall mill extraction and final moisture% Bagasse.

2.HIGH PRESSURE BOILERS:

The fact that increases in boiler pressure increases the steam fuel ratio is
an established one. This increase in steam fuel ratio is mainly due to high inlet
temperature of feed water by regenerative heating (Regenerative Cycle Efficiency
is higher than the cycle efficiency without regeneration) and higher boiler
efficiency due to the design parameters of high-pressure boiler. In general, the
system efficiency or the power plant efficiency is more in case of high pressur
eco-generation than that of low pressure, keeping other system routes same.
3. AUTOMATION:

Sugar Manufacturing Process can be controlled and automated using a

Distributed Control System (DCS). Some of the Automation generally used in the
sugar Industry are as follows: a) Bagasse belt conveyor speed control, b) Mill
drive speed control, c) Boiler operation control, d) Turbines Operation control, e)
Raw Juice Flow control

4.STEAM ECONOMY DEVICES:

Central Flashing System: Condensate is flashed from one effect to

another through Central Flashing Device to effectively recover the additional heat
and reduce overall consumption of vapours. Condensate Heaters: Excess heat in
condensate was to be recovered which otherwise is wasted in atmosphere at boiler
station. Direct Contact Juice Heaters: use of Direct Contact Juice Heaters for Low
temperature approach and easy maintenance. Molasses Conditioners for direct
contact heating of molasses under vacuum for perfect dissolution of crystals.
Heated Wash Water System: For Batch Centrifugal Machines by spray shot of hot
water, which was heated by live steam, replaced by PTHE using 2nd body
condensate and heated by 1st body condensate and achieving temperature 110 to
1120 C. Sugar Melting: Traditionally B & C sugar is melted by using hot water
and steam. Sugar Melter was designed to use hot water/superheated wash water
to melt the sugar to minimize the steam consumption. Pan Washing: Washing is
crucial for the efficient Batch Pan Operations to avoid Massecuite circulation and
formation of secondary grain. It Exhaust Steam is used for washing purpose. Uses
of vapours of Effect 1 for this purpose has gained popularity.

5.FALLING FILM EVAPORATORS:

These are comparatively newer evaporators & have gained popularity in

sugar industry due to their short retention time, working at high temperature,
better heat transfer coefficient & low energy consumption. Falling film
evaporation is among the most cost-efficient and energy-saving evaporation
methods. It is especially well suited to give low energy consumption. A falling
film Evaporator may consist of one or more liquid stages in a series. If a number
of stages are used, the concentration of dry solids will be increased through the
plant.

PROCESS FOLLOWED:

• Extraction of Juice: The sugarcane is passed through preparatory devices like

knives for cutting the stalks into fine chips before being subjected to crushing in
a milling tandem comprising 4 to 6 roller mills. In the best milling practice, more
than 95% of the sugar of cane is extracted into the juice.

• Clarification: The treated juice on boiling fed to continuous clarifier from

which the clear juice is decanted while the settled impurities known as mud is
sent to rotary drum vacuum filter for removal of unwanted stuff called filter cake.
It is discarded or returned to the field as fertilizer.

• Evaporation: The syrup will again have treated with sulphur dioxide before
being send to the pan station for crystallization of sugar. Crystallization takes
place in single-effect vacuum pans, where the syrup is evaporating until saturated
with sugar. At this point “seed grain” is added to serve as a nucleus for the sugar
crystals, and more syrup is an water evaporates.

• Centrifugation: The massecuite from crystallizer is drawn into revolving

machines called centrifuges. The perforated lining retains the sugar crystals,
which may be washed with water, if desired. The mother liquor “molasses” passes
through the lining because of the centrifugal force exerted and after the sugar is
“purged” it is cut down leaving the centrifuge ready for another charge of
massecuite.
• Gradation & Packing: The final product in the form of sugar crystal is dropped
through pan section and this sugar is graded and picked in 50 kg bags. The grade
of the sugar depends on the size of the crystal viz. Small (S) and Medium(M).

OPERATION STRATEGY:

AUTOMATION:
The vacuum pan in the sugar factory constitutes a unit with well-defined
borders to the surroundings and therefore especially suitable for automation. For
a more efficient sugar production, the first step is to automate vacuum pans
because about one third of the total energy amount is used within the sugar
processing house. There-fore a quick return of investment is assured.

The main requirements to an automation control system strategy that enables

efficient automation of the vacuum batch pans are:

• Proven performance and reliability in sugar applications.

• High availability
• Robust design, high degree of protection
• Low initial investment due to modular design
• Flexibility

The vacuum pan automation is design as an event controlled sequential control.

Variations in the juice quality, disturbance variables in the steam and vacuum
control are taken into account. The individual process steps are determined by the
technology of the sugar boiling process. For every technological step there is a
step in the sequential control.

Steps like seeding, graining, or boiling are difficult to handle manually and
contain a wide range of improvement for better product quality and energy
saving. That is if "strike hold" becomes necessary, decreasing the vapor steam set
point is more efficient instead of opening the water valve. Automatically
controlled and reproducible seeding and graining steps enables the crystals to
grow close to the physical possible maximum speed without generation of
undesired fine grain or what is called false grain.

Once the full cycle program is started, no further operation by the operator is
needed. Only seeding has to be carried out manually where the automatic slurry
system is available in the plant. Disturbances in the process like no juice
available, milli is full or a total vacuum breakdown is announced and the program
runs same position in order to keep the strike alive.

Changing from automatic to manual operation may be carried out at any time.
For pans, which are not fully equipped with remote, operated valves, a par cycle
mode is available. A park cycle mode covers the most important process steps
starting with "seeding" and finishing with "tightening." Both mods are possible.

TYPES OF LAY-OUT:

PROCESS LAYOUT: Also known as functional layout, it involves grouping

similar equipment or activities together. Different sections of the sugar
manufacturing process, such as crushing, clarification, evaporation, and
crystallization, are organized separately. Allows for specialized equipment and
expertise in each section.

PRODUCT LAYOUT: It is also called line layout, It arranges the equipment and
workstations in a linear sequence. Ideally suited for continuous and standardized
production processes. Enables a smooth and sequential flow of raw materials
through different stages of sugar production.
COMBINATION LAYOUT: Integrates both process and product layouts to
leverage their respective advantages. Certain stages of sugar production may be
organized based on functional similarities (process layout), while others follow a
sequential arrangement (product layout).

FIXED POSITION LAYOUT: Applicable when large and heavy equipment is

involved, and it is impractical to move them. The equipment remains stationary,
and the raw materials, labour, and other resources are brought to the fixed
location.
CELLULAR LAYOUT: A hybrid layout that combines elements of both process
and product layouts. Production is organized into cells, where each cell is
dedicated to a specific task or process. Enhances flexibility and allows for easier
adaptation to changes in production requirements.

GEOGRAPHICAL LAYOUT: Based on the geographic distribution of the

production units. Suitable for large sugar complexes where different processing
units are located in different areas due to logistical or resource considerations.

PRODUCTION PLANNING AND CONTROLLING:

1.FORECASTING:

Utilize historical sales data, market research, and collaboration with sales
and marketing teams to forecast future demand. Consider seasonal variations,
economic trends, and external factors that might impact sugar consumption.
Implement forecasting models and software to enhance accuracy.

2.CAPACITY PLANNING:

Conduct a detailed analysis of the sugar mill's capacity, taking into account
the efficiency of machinery and the workforce. Regularly assess and upgrade
equipment to maintain or increase production capacity. Factor in maintenance
schedules and downtime when planning for maximum output.

3.RAW MATERIAL PLANNING:

Develop strong relationships with sugarcane suppliers and farmers to ensure

a steady supply of high-quality raw materials. Implement a system to monitor the
quality of incoming sugarcane and establish guidelines for acceptance. Create
contingency plans for potential disruptions in the supply chain, such as weather-
related issues affecting crop yields.

4.PRODUCTION SCHEDULING:

Utilize advanced scheduling tools that consider the constraints of

production, such as batch sizes, processing times, and machine availability.
Optimize scheduling to minimize changeovers and downtime, improving overall
efficiency. Incorporate flexibility in schedules to accommodate unexpected
changes in demand or disruptions.

5.QUALITY CONTROL:

Implement a robust quality control system at various stages of production,

including raw material inspection, processing, and final product testing.
Regularly train staff on quality standards and procedures. Quickly address and
rectify any deviations from quality standards to maintain product consistency.

6.INVENTORY MANAGEMENT:

Employ an inventory management system that integrates with production and

sales data. Set optimal inventory levels to avoid excess storage costs while
ensuring timely deliveries. Implement first-in, first-out (FIFO) or other
appropriate inventory rotation methods to minimize waste.
7.COST CONTROL:

Implement cost accounting systems to track production costs accurately.

Conduct regular cost-benefit analyses to identify areas for improvement. Explore
energy-efficient technologies and sustainable practices to reduce operational
costs.

PRODUCTIVITY:

1.CIVILIZATION AND HARVESTING:

i. VARIETY SELECTION: Choosing high-yielding sugar cane varieties that are

resistant to pests and diseases is crucial. Research and development efforts focus
on developing improved varieties.

ii. CROP MANAGEMENT: Implementing modern agricultural practices,

including precision farming, proper irrigation, and fertilization, helps maximize
yields.

iii. HARVESTING TECHNIQUES: Efficient harvesting methods, such as

mechanical harvesting, reduce labour costs and improve speed, especially in
large-scale plantations.

2.TRANSPORTATION AND PROCESSING:

i. LOGISTICS: Developing an efficient transportation system to move harvested

sugar cane from the fields to the processing facility is essential for minimizing
losses and maintaining quality.
ii. Milling technology: Investing in advanced milling technologies improves
extraction rates and reduces energy consumption during the sugar extraction
process.
3.WATER MANAGEMENT:

i. IRRIGATION: Implementing smart irrigation practices helps conserve water

and ensures that sugar cane receives the optimal amount of moisture for growth.

ii. WATER RECYCLING: Recycling and reusing water in various stages of

production reduce overall water consumption and contribute to sustainability.

MAINTENANCE PROCEDURE:

Sugar industries play a crucial role in processing and refining sugar from raw
materials. To ensure optimal functioning and longevity of the equipment
involved, effective maintenance procedures are essential. These procedures
encompass a range of activities aimed at preventing breakdowns, minimizing
downtime, and enhancing overall operational efficiency.

1.PREVENTIVE MAINTENANCE:
Regular inspections: Routine inspections of key machinery such as crushers,
evaporators, and centrifuges are conducted to identify potential issues before they
escalate. This involves checking for wear and tear, lubrication levels, and
monitoring the condition of critical components.
Lubrication Management: Proper lubrication is vital for the smooth operation of
machinery. Regular checks and scheduled lubrication routines are implemented
to prevent friction-induced damage and extend the life of moving parts.
Cleaning Procedures: Cleaning processes are integral in preventing the
accumulation of impurities and contaminants in equipment. Regular cleaning of
filters, pipes, and other components helps maintain hygienic conditions and
prevents deterioration.
2.PREDECTIVE MAINTENANCE:
Condition monitoring: Utilizing advanced technologies such as vibration analysis
and thermography, sugar industries employ condition monitoring to detect subtle
changes in equipment performance. This allows for timely intervention before a
major breakdown occurs.
Predictive analytics: Leveraging data analytics, predictive maintenance models
are employed to forecast potential failures based on historical data. This aids in
planning maintenance activities in a more strategic and cost-effective manner.
3.CORRECTIVE MAINTENANCE:

Breakdown response: Despite preventive measures, breakdowns may still occur.

Quick and efficient response to these incidents is crucial to minimize downtime.
Sugar industries implement structured procedures for identifying, isolating, and
repairing faults promptly.
Spare parts management: Maintaining an inventory of critical spare parts is
essential for rapid corrective maintenance. Regular assessments of spare part
availability and ordering systems are in place to ensure a seamless response to
unexpected failures.

STORAGE MANAGEMENT SYSTEM:

The storage management system in sugar industries plays a pivotal role in

ensuring the efficient handling, preservation, and distribution of raw materials
and finished products. Effective storage management is essential for maintaining
the quality of sugar products and optimizing overall operational efficiency.

➢ RAW MATERIAL STORAGE: One crucial aspect of storage management

in sugar industries is the systematic storage of raw materials, primarily
sugarcane. The storage facilities should provide protection from
environmental factors, such as moisture and pests, to prevent quality
 deterioration. Adequate space and proper ventilation are essential to avoid
spoilage and maintain the freshness of the sugarcane.
➢ WAREHOUSING INFRASTRUCTURE: Sugar industries require well-
designed warehouses to store various intermediate products and by-
products, such as bagasse and molasses. These facilities must be equipped
with appropriate shelving, temperature control systems, and safety
measures. Efficient warehousing ensures smooth production processes and
minimizes the risk of contamination or spoilage.
➢ FINISHED PRODUCT STORAGE: Storage of the final sugar products
demands careful planning to preserve quality and meet market demand.
Specialized storage areas with controlled temperature and humidity levels
are crucial for preventing clumping, caking, or crystallization of the sugar.
Inventory management systems can help track stock levels, ensuring timely
production and delivery.

QUALITY POLICY:
These policies are essential to ensure a standardized and systematic
approach to quality control across all aspects of sugar production. Here are some
key quality control policies in the sugar industry:

QUALITY MANAGEMENT SYSTEM:

Establishing a comprehensive QMS that outlines the organizational
structure, responsibilities, procedures, and resources required for effective quality
control. This includes documentation of standard operating procedures (SOPs)
for each stage of production.

QUALITY ASSURANCE POLICY:

Implementing a quality assurance policy that emphasizes the commitment
to meeting or exceeding customer expectations. This policy outlines the
company's dedication to continuous improvement, compliance with regulatory
standards, and the use of best practices in sugar production.
CONTINUOUS IMPROVEMENT POLICY:
Adopting a policy that encourages a culture of continuous improvement.
This involves regular reviews of processes, identifying areas for enhancement,
and implementing changes to optimize efficiency and quality. Key performance
indicators (KPIs) are monitored to measure and track improvements.

TYPES OF QUALITY CONTROL:

1.CANE QUALITY ASSESSMENT: The first step in sugar production involves

assessing the quality of sugarcane. This includes evaluating factors such as
sucrose content, moisture levels, and impurities. Modern sugar mills often use
advanced technologies like NIR (Near-Infrared) spectroscopy to accurately
measure these parameters.
2.IMPURITY REMOVAL: Juice clarification is a key step to remove impurities
and non-sugar components. Quality control involves monitoring the effectiveness
of clarification agents, sedimentation, and filtration processes. Analysing
clarified juice for colour, pH, and turbidity ensures optimal results.
3.CENTRIFUGATION: Centrifugation is used to separate sugar crystals from
molasses. Quality control involves monitoring centrifuge speed, time, and
discharge rates to ensure efficient separation. Regular calibration of centrifuges
is essential to maintain consistent product quality.
4.LABORATORY TESTING: Throughout the production process, samples are
collected for laboratory testing. Analytical methods such as HPLC (High-
Performance Liquid Chromatography) are used to quantify sugar content, while
other tests assess impurities, colour, and acidity. These results guide adjustments
to the production process to maintain quality.

CONCLUSION:
This project has provided a comprehensive exploration of the operations
and strategies employed by our production company. Through meticulous
analysis and evaluation, we have gained valuable insights into key aspects such
as production processes, resource management and market trends. The findings
underscore the importance of adaptability and technological integration in the
dynamic landscape of the production industry.