Godavari Bio-refineries Ltd

CHAPTER 1

INTRODUCTION

1.1 Introduction

Bio-refining company that produces sugar, other foods, biofuels, chemicals, power,
compost, waxes, and related products, using sugarcane as the primary feedstock. Our aim is to
engage in research and innovate by continuously making new products and entering new markets
in order to derive the maximum value from our feedstock. Our research areas include sustainable
farming, transformation of biomass (chemical, mechanical and biological), product development,
and process optimization. Founded in 1939, we have been pioneers in the growing, processing,
and utilization of biomass to make a wide variety of products.

In working on the next generation bagasse-based biorefinery and also the biotransformation of
sugar to biopolymers.

Work closely with over 20,000 farmers in over 200 villages, applying scientific, agricultural and
technological solutions to our cane development program. In close collaboration with K. J.
Somaiya Institute of Applied Agricultural Research (KIAAR) at Sameerwadi, our scientists and
agriculturists help farmers employ best practices that enable environmental and financial
sustainability over the short and the long term.

In Industry manufacture, pack, and distribute sugar to retail, industrial and export customers.
Launched in October 2014, Jivana, our retail brand, aims to provide good quality foods to Indian
homes whilst uplifting lives of the farmers who nurture these products from the start. All Jivana
products are responsibly grown and harvested.

Using molasses, a by-product of sugar production, as a feedstock, we are among the larger
producers of ethanol in India. A pioneer in the use of ethanol as a feedstock of the production of
chemicals, we make various chemicals, such as acetaldehyde, ethyl acetate, crotonaldehyde,
MPO, paraldehyde. Our products are used in thousands of everyday products including
adhesives, solvents, inks, flavours, plastics, and several others.

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Research center is recognised by the Council of Scientific & Industrial Research (CSIR). We
believe that using renewable agricultural feedstock is fundamentally different from using fossil
resources. In the use of fossil resources, the earth always has less of what it had before, after the
use. In the use of renewable feedstock cultivated from the earth, good planning can ensure that
the earth has the ability to generate resources and regenerate itself.

The company invests a lot of its time and resources in working with the community, furthering
education, healthcare and rural development.

1.2 Company Profile

Figure 1.2: Company Profile

Name: Godavari Bio-refineries Ltd

Address : sameerwadi

Tq: Mudhol Dist: Bagalkot

Phone no: (08350)260046.

Total area: 800 acres in sameerwadi.

Establishment: In the year 1972 at sameerwadi.

Area of operation: 162 villages.

Working hours : General shift=8.30am – 6.00pm

Morning shift=4.00am – 12.00pm

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Afternoon shift=12.00pm – 8.00pm

Night shift=8.00pm – 4.00am

Number of employees : 750 working in one shift it mean eight

hours

Foundation stone at : on 6th june 1971.

Web: www.somaiya.com

Production stated : 20th april 1972.

Factory capacity : cane crushing is 15000 tons per day.

1.3 Vision & Mission

 To be a world class organization.
 To be an integrated bio-refinery.
 To be the leading integrated producer of sugar and downstream products.
 To continuously add value to the biomass that the company processes, make new
products and enter new markets in order to derive maximum value from feedstock.
 To work on different biomass that provide similar or superior potential.
 To understand and exceed customer needs and expectations.
 Provide superior returns toshareholders through efficient management, innovation and
teamwork.
 To participate in, and contribute to the allaround development of the community in
which the company operates.
 To be a place where individuals aspire to and can make a difference. Where good
performance is applauded and of which people are proud to be a part of.
 To work on the triple bottom line. Social, environmental, and financial with innovation
running through all that we do.
 To help our farmers employ best practices that enable environmental and financial
sustainability over the short and long term.

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 To create Food Brands that will provide consumers purity in foods for a better living.
We will do this by building a competitive and efficient supply chain with a diverse
portfolio, that will provide consumers branded food products of the best quality.

1.4 Departments of
Industry
 Manufacturing department
 Information technology
 Time office department
 Purchase and store department
 Engineering department
 Research and development
 Agriculture department
 Finance department
 Sales and marketing department
 Human resource department

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CHAPTER 2

PRODUCTS OF INDUSTRY
2.1 Main Products-White Crystal Sugar

The main product of the sugar manufacturing process is white crystal sugar. These white crystal
sugar is manufactured following grades:
 L-30 : Large size sugar
 M-30 : Medium size sugar
 S1-30 : Small size sugar
 S2-30 : Very small size sugar

2.2 Branded Food Products

2.2.1 Jivana Classic Sugar :

Figure 2.2.1: Jivana Classic Sugar

Jivana Classic Sugar is made from superior quality sugarcane. Our company has been in
operation for over 75 years. We employ eco-friendly farming practices, certified production
processes, and stringent quality control measures to ensure purity, hygiene, and consistency in
our sugar. The optimum-sized Jivana sugar crystals melt easily, giving the desired sweetness in
each spoon and ensuring there’s no wastage.

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2.2.2 Jivana Raw Sugar :

Figure 2.2.2 : Jivana Raw Sugar

Jivana Raw Sugar is a grainy golden brown sweetener made from premium cane and has a higher
content of natural minerals in comparison to refined sugar. Its mild caramel flavour goes well
with hot & cold beverages, desserts and cakes. Our manufacturing unit in Karnataka applies
innovative processes to ensure we retain the inherent goodness of cane in this natural sugar.

2.2.3 Jivana Jaggery :

Figure 2.2.3 : Jivana Jaggery

Jivana Jaggery is a delicious & wholesome sweetener made by clarifying thick sugarcane juice
using lady finger extracts. This natural process enables Jivana Jaggery to be Chemical Free.

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2.2.4 Jivana Salt :

Figure 2.2.4 : Jivana Salt

Jivana Iodised Sea Salt comes from Gujarat. Our salt is harvested using Sea Water in salt pans by
applying a Natural Solar Evaporation Method that is safe and helps retain the required goodness
in the salt. Jivana Sea Salt is Iodised and rich in macro minerals like magnesium and calcium that
are vital for health.

2.3 By- Products Sugar Manufature

 Bagasse: Bagasse is the by product of sugar left behind after crushing of a sugar cane. It
is used as a fuel in the sugar factory boiler. Excess bagasse finds use as raw material in
paper manufacturing industry.
 Molasses: Molasses is a by-product of sugar refining chiefly used for alcohol
production. The entire molasses is output is routed to the distillers unit, which is
mentioned by the organization.
 Press mud: Press mud is the by-product generated by cane juice filtration during sugar
manufacture. Currently press mud is used as a fertilizer in sugarance cultivation.
2.4 Chemicals
 Bio-Gas: The company 1MW Bio-Gas power generation plant for utilizing Bio-Gas
available from distillery a fluent treatment plant jointly setup with Indian institute of
science Bangalore and national energy board.
 Distillery product: The Godavari Biorefineries Ltd has two distillery with a total
capacity of 2,00,000 bulk liters per day.

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 Ethanol: Ethanol is a high octane fuel which is used primarily as a gasoline additive and
extender. The reduction in the use of methyl tertiary butyl ether (MTBE) due to its
environmental problems caused by ground water contamination and surging prices for
petroleum based fuels are dramatically increasing the demand for ethanol and the
interest in ethanol production in the united states. Ethanol can be produced from
carbohydrates such as sugar, starch and cellulose by fermentation using yeast or other
organisms.
 Spirit: Methylated spirit is non drinkable largely used individual alcohol spirit. This is
prepared from ethyl alcohol mixed with pyridine or methyl alcohol. That is mixing o f
certain percentage (5% methyl alcohol makes ethyl alcohol toxic such that people cannot
drink it .it is manufactured by fermentation of molasses by yeast and then it is separated
out by distillation processes. Methylated spirit is used as solved in the paint industries. It
is used in the pharmaceutical and fermentation industries as sterilizing agent as well as
solvent. It is also used in the plastic industries as basic raw material . all this industries
growth is 8-10% per annum. On that base methylated spirit demand also proportionately
increase. There is a good future for existing as well as new entrepreneurs .

 Bhumi Labh :

Figure 2.4 : Bhumi Labh

Bhumilabh, an organic bio-compost, manufactured & marketed by Godavari Biorefineries

Ltd, ensures higher fertility, greater yield & reduction in the use of chemical fertilizers.

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Bhumilabh is a high quality 100% natural product that enriches the soil and helps in
providing with Healthy Fruits, Vegetables, Flowers, Crops, Cereals, Plants, Gardens, etc.
Across the world, prolonged use of chemical fertilizers has depleted the fertility of the soil
& resulted in reduced crop yields & nutrient deficiencies. Farmers have realized this and are
now switching over to Organic Farming.
Bhumilabh is the unique answer to soil health. Humus is the fuel that enhances the soil life.
It improves the Biological & Physical properties of the soil & also the growth of beneficial
microbes. Improved soil health results to the healthy growth and development of the plants.
Bhumilabh performs this balancing act & helps to reduce dependence on chemical inputs, it
is ideal for all types of soil, in all seasons.

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CHAPTER 3
KEY LEARNINGS
3.1 Key Learnings

Sl No. Departments Learning

1 Manufacturing department Sugar production process:

1.Juiceextractionprocess
2.Purification of juice
3.Crystallization
4.Centrifugaling
5. Drying and packaging
Steam generating
Power producing
2 Time office department Time management

3 Purchase and store department Placing order for raw materials according to
customer requirements.

4 Production department Knew about producing in this industry products

like sugsr, salt, bagasses, molasses, press mud,
bio- gas, distillery products, ethanol, spirit,
bhumilabh
fertilizers
5 Agriculture department Fertilizers

6 Quality control Checking size and acid content of finally

produced sugar
7 Safety Importance of safety

Table 3.1 : Key Learnings

Department of Mechanical Engineering, AGMRCET,

Varur
 Godavari Bio-refineries

3.2 Challenges Faced

 We faced new challenges in this industry, in first week completely visit overall plant,
when knows that the plant will be like this.
 In second week completely visit manufacturing sections like Juice extraction process,
Purification of juice, Crystallization
 Centrifugaling , Drying and packaging sections, when after visited all this sectors know
about how much steps involved for making sugar.
 In third week completely visit to boiler sections and also coal handling system, first we
reading instructions written on the boiler, how to use coal in this boiler, which type of
boiler, how to produce steam, how to operate the boiler. Coal handling system in this
system how to came coal from chain stockers, how to unloading, preparation,
transferring to boilers that will be known after visiting this all this area or area.
 Finally we visiting to power generating sections here two units is there, one units will be
produce 24MW and another produces 21MW power will be produced in this industry.

Department of Mechanical Engineering, AGMRCET,

Varur
 Godavari Bio-refineries

CONCLUSION
 The Godavari Bio-refineries Ltd started crushing operation in the year 1971-72 with
capacity 1500 TCD, now it has expanded to 16600 TCD. The GBL is the highest cane
consuming sugar factory in Karnataka and one of the largest sugar factories in India.
 The factory has increased the cane cultivation area and also improves the cane yield. Hence
the management has planned capacity expansion and higher co-generation.
 During the internship training, I got an opportunity to work 1 month and to get hands on
experience of the process control. The factory has many challenges and hurdles towards
becoming a sugar complex with better byproduct utilization. There is a every scope for
establishment of co-production facilities.
 The management is contributing towards the social economic development of the region.
The employee welfare has been providing educational and health facilities are needed to
families.
 My stint of around 1 month training was very truthful. I appreciate the concern and
cooperation extended by employees, staff and officers of the company.

Department of Mechanical Engineering, AGMRCET,

Varur