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CHAPTER 1

Introduction

The word sugar originates from the Sanskrit word sharkara which means sugar. It may also be
traced through all the Aryan languages, as schaker in Persian, sukkar in Arabic, sincer in
Assyrian, zucchero in Italian, sucre in French, zucher in German, saccharum in Latin and
ozucarin Spanish etc stand as Testimony for its origin from sharkara. Sugar is a major form of
carbohydrates and is found probably in all green plants. It occurs in significant amounts in most
fruits and vegetables. There are three main simple sugars Sucrose, Fructose and Glucose.
Sucrose is in fact a combination of fructose and glucose and the body quickly breaks down into
these separate substances. All energy stored in food is derived originally from the sun and it is
made by green plant life.

The sun's energy acts upon the green chemical "chlorophyll" in the leaves of plants to produce
sugars and starches from the carbon-dioxide in the atmosphere and the water from the roots by a
process known as Photosynthesis. These carbohydrates (starches and sugar) acts as a plants food
and energy supply. The energy need of human body is largely dependent on the carbohydrates
that are derived from plants. The sugar is one of the essential commodities of the life which
plays very important role in the dietary of human beings as it quickly raises the level of glucose
in the blood.

The sugar can be produced by many of the sources, but two are the main sources for production
of sugar in Pakistan i.e. Sugarcane and Sugar Beet. The other sources are Maple, Palm, Coconut
and Apple, but these sources are costly and their production is in negligible quantities. But, the
main crop which is being used for production of Sugar all over the world is Sugarcane. In a nut
shell, the process for sugarcane refining is carried out in following steps Pressing of sugarcane
to extract the juice.
Boiling the juice until it begins to thicken and sugar begins to crystallize.

Spinning the crystals in a centrifuge to remove the syrup, producing raw sugar. Refining the
raw sugar by washing and filtering to remove remaining non-sugar ingredients and color.
Crystallizing, drying and packaging the refined sugar. For the sugar industry, capacity
utilization is conceptually different from that applicable to industries in general.

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CHAPTER 2
RAW MATERIALS

The raw material used in sugar production varies depending on the type of sugar being produced.
For the production of cane sugar, the primary raw material is sugar cane. Sugar cane is a tall
grass that grows in tropical and subtropical regions, and it contains high levels of sucrose, which
is the main component of sugar. The sugar cane is harvested, transported to the sugar mill, and
then crushed to extract the juice, which is the starting point for sugar production.

Beet sugar, on the other hand, is produced from sugar beets, which are root vegetables that are
primarily grown in temperate regions. The beets are harvested, washed, and then sliced into thin
strips. These strips are then treated with hot water, which extracts the sugar from the beets. The
resulting juice is then purified and concentrated in a process similar to that used for cane sugar
production.

In both cane sugar and beet sugar production, other materials may be used in the process. For
example, lime is often added to the juice during the clarification process to remove impurities.
Additionally, sulfur dioxide may be used to preserve the juice and prevent fermentation during
transportation and storage.
Overall, the raw materials used in sugar production are primarily sugar cane or sugar beets, with
other materials used in the refining process to ensure high-quality and pure sugar.

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Properties:
Table 1: sugar-cane properties
Sucrose 10% - 20% by weight
Content
Texture Fibrous texture
Water Content 70% - 75% of water
Color Vibrant Green Color
Slightly yellow or brown as they get
mature
Odor Mild
Grassy Smell

Fig1: Sugarcane

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CHAPTER 3

PRODUCTION OF SUGAR

3.1 METHODS OF MANUFACTURING:

1) Traditional process

2) Modern Process

3.1.1 Traditional process for Production of Sugar-cane:

1. Introduction:
The traditional process of sugar production has been used for centuries to extract sugar from
sugarcane. This method involves a series of steps that start with harvesting the sugarcane and
end with the production of raw sugar crystals. The traditional method is a labor-intensive process
that requires specialized equipment and skilled labor to extract the maximum amount of sugar
from the sugarcane. Despite the availability of more modern methods of sugar production,
traditional sugar production remains an important industry in many countries and is valued for its
cultural significance and traditional practices.

In this process, sugarcane is crushed to extract the juice, which is then clarified, boiled, and
crystallized to produce raw sugar crystals. The process requires a significant amount of water
and energy, but it produces a high-quality sugar that is rich in flavor and nutrients.

Overall, the traditional process of sugar production is a testament to the ingenuity of early sugar
producers and continues to play an important role in the global sugar industry today.

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Fig 2 Sugar Production

2. Production of Sugar Using Traditional process:

The Traditional process of sugarcane involves several streps as mentioned below.

Process:

The traditional process of sugar production involves several steps that can be summarized as
follows:

1. Harvesting: Mature sugarcane is harvested by hand or with specialized equipment.

2. Crushing: The sugarcane is crushed to extract the juice. This is typically done using
mechanical rollers or presses.

3. Clarification: The sugarcane juice is then clarified to remove any impurities or solids. This can
be done using a variety of methods, such as filtration or settling.

4. Boiling: The clarified juice is boiled in large vats or pans to evaporate the water and
concentrate the sugar. As the juice boils, impurities rise to the surface and are skimmed off.

5. Crystallization: Once the juice has reached the desired concentration, it is transferred to
cooling pans where it is further crystallized. As the juice cools, sugar crystals form and are
separated from the remaining syrup, known as molasses.

6. Drying and Packaging: The raw sugar crystals are then dried and packaged for distribution.
The drying can be done using a variety of methods, such as air-drying or heating.

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The traditional process of sugar production is a labor-intensive and time-consuming process that
requires specialized equipment and skilled labor. While modern methods of sugar production
have largely replaced traditional methods, many countries still rely on the traditional process for
their sugar production, particularly in regions where modern equipment and infrastructure may
be less accessible.

Fig 3: Diagrammatic Representation:

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3.2.1Production of Sugar Using Modern Process:

The modern Method of production od sugar is also known as “beet sugar” method.

Process:

The modern process of sugar production, also known as the beet sugar method, involves several
steps that can be summarized as follows:

1. Harvesting and Slicing: Sugar beets are harvested mechanically and sliced into thin strips.

2. Extraction: The sliced beets are then soaked in hot water to extract the sugar from the cells.

3. Clarification: The extracted juice is then clarified to remove any impurities or solids. This can
be done using a variety of methods, such as filtration or settling.

4. Concentration: The clarified juice is then concentrated using a multiple-effect evaporator or

vacuum pan. This process removes most of the water and increases the concentration of sugar in
the solution.

5. Crystallization: The concentrated juice is then cooled and seeded with sugar crystals to
encourage the formation of more crystals. The crystals are separated from the remaining syrup
using centrifuges or filters.

6. Drying and Packaging: The sugar crystals are then dried and packaged for distribution. The
drying can be done using a variety of methods, such as air-drying or heating.

The modern process of sugar production is more automated and efficient than the traditional
process, allowing for larger quantities of sugar to be produced in a shorter amount of time.
However, it requires specialized equipment and infrastructure, making it less accessible in
certain regions. Additionally, some argue that the modern process produces a lower-quality sugar
compared to the traditional process.

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3.3 Process flow Sheet:

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CHAPTER-4

Storage and handling

Sugar is a stable and non-perishable product that can be stored for long periods of time if stored
and handled properly. Here are some guidelines for storage and handling of sugar:

1. Storage Conditions: Sugar should be stored in a cool, dry, and dark place to prevent exposure
to moisture, light, and heat, which can cause clumping and discoloration. Ideal storage
temperatures for sugar range from 50 to 80 degrees Fahrenheit (10 to 27 degrees Celsius). It is
important to keep sugar away from any strong-smelling or volatile substances, as it can absorb
odors easily.

2. Packaging: Sugar should be stored in airtight containers, such as plastic or glass jars, to
prevent moisture and air from entering the container. Paper bags can also be used but are not
recommended for long-term storage as they are not airtight.

3. Handling: Sugar should be handled with clean, dry hands or utensils to prevent contamination.
Any spills should be cleaned up immediately to prevent attracting pests and rodents.

4. Shelf Life: Granulated sugar has an indefinite shelf life if stored properly. Brown sugar and
powdered sugar have a shorter shelf life due to their higher moisture content, but can still last for
several months if stored properly.

5. Quality Control: To ensure the quality of stored sugar, it is recommended to periodically

check the sugar for any signs of clumping, discoloration, or odor absorption. If any of these
issues are present, the sugar should be discarded.

In summary, proper storage and handling of sugar is essential to maintaining its quality and shelf
life. By following these guidelines, sugar can be stored for long periods of time and used for
various purposes, including baking, cooking, and sweetening beverages.

4.1 Waste products

Sugar production generates various waste products that can have environmental and health
impacts if not managed properly. Here are some of the most common waste products generated
by the sugar production process:

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1. Bagasse: Bagasse is the fibrous residue left after sugarcane is crushed to extract its juice. It is
often used as fuel for steam boilers to generate electricity, or as a feedstock for the production of
paper and other products.

2. Molasses: Molasses is a byproduct of the sugar crystallization process. It is a thick, dark syrup
that is often used as a sweetener or as a feedstock for the production of rum, ethanol, and other
products.

3. Wastewater: Sugar production generates large quantities of wastewater that are high in organic
matter and nutrients. This wastewater can be a significant source of pollution if not properly
treated before discharge into waterways.

4. Air emissions: Sugar production can also generate air emissions, including particulate matter,
sulfur dioxide, and greenhouse gases. These emissions can contribute to local air pollution and
global climate change.

5. Ash: Some sugar production methods generate ash as a byproduct of the combustion of
bagasse. This ash can contain heavy metals and other pollutants and must be managed carefully
to prevent environmental contamination.

To minimize the environmental impact of sugar production, many sugar producers have
implemented waste management strategies, such as the use of bagasse for energy generation, the
treatment of wastewater before discharge, and the capture and use of greenhouse gas emissions.
Additionally, some sugar producers have implemented sustainable production practices, such as
using organic farming methods and minimizing the use of pesticides and fertilizers, to reduce the
environmental impact of sugar production.

Fig 4: Storage of Sugar

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CHAPTER-5

PROBLEMS IN SUGAR INDUSTRY

Sugar prices have doubled over the last 15 months. In 2008-09, particularly, a larger part of the
sugar cane was used for making gur than in earlier years. This exacerbated the sugar shortage,
even though cane production that year saw only a 20 per cent drop from the previous season,
sugar production tanked 43 per cent. India’s current sugar consumption is between 20-22 million
tonnes, and this level was exceeded in 2006-07 and 2007-08. Initially prices in the world market
were higher than Indian prices and the exporters were a happy lot. India is expected to close the
current sugar season with production at 16-16.5 million tonnes, whereas demand is at 22 million
tonnes, leaving a gap of around 7 million tonnes.A recent FAO report predicts a sharp fall in
sugar production in India in the year 2009. The country has contracted to import 3.8 million
tonne of sugar so far this season, of which, 1.8 million tonne have arrived. India is the fourth
lowest cost sugar producers in the world after Australia, Brazil and Thailand. India’s cost of
sugar production is one-fourth of that in Europe. India’s sugar sector faces a fall in prices, rising
raw material costs, limited export capacity and a lack of flexibility to produce ethanol for
biofuel, analyst Licht said. Sugar is the second largest agro-based industry in India. The industry
provides employment to about two million skilled and semi-skilled workers besides those who
are employed in ancillary activities, mostly from rural areas. Though the industry contributes a
lot to the socioeconomic development of the nation, it is plagued with a number of problems
such as cyclical fluctuations, high support prices payable to farmers, lack of adequate working
capital, partial decontrol and the uncertain export outlook. Global sugar prices have fallen
sharply because of a huge glut of production driven by the world’s leading producers such as
Brazil, India and Thailand.

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CHAPTER-6

CONCLUSION

sugar production is an important global industry that has evolved significantly over time. The
traditional process of sugar production involved a labor-intensive process of manually extracting
juice from sugarcane and evaporating it to produce sugar. However, modern sugar production
methods have become more efficient and automated, with the use of large-scale machinery and
advanced technology.

While sugar production is an important source of economic activity and employment in many
countries, it also generates waste products that can have negative environmental impacts if not
managed properly. Bagasse, molasses, wastewater, air emissions, and ash are all common waste
products generated by sugar production that require careful management to minimize their
impact on the environment.

Overall, the production of sugar plays an important role in the global food and beverage industry,
and has significant economic and cultural significance in many countries. However, as with any
industry, it is important to continue to innovate and adopt sustainable practices to ensure that
sugar production is environmentally responsible and socially equitable for all stakeholders
involved.

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REFERENCES

1. Solomon, S. "The Indian sugar industry: an overview." Sugar Tech 13 (2011): 255-265.

2. Dr. Adya Prasad Pandey, "Indian sugar industry-a strong industrial base for rural India"
(2007).

3. Dryden's Outlines of Chemical Technology: For the 21st Century Ed by M. Gopala

Raoand Marshall Sittig (2021): 314-319.

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