Sugar Industry is the one which impact all the populations of the area in there day to day life and has transformed the local area socio- economically. The first crushing season began in 1986 with the capacity of 1000 TCD. The factory has increased its crushing capacity constantly. Today the capacity is 2500 TCD. Sugar Industry is the one which impact all the populations of the area in there day to day life and has transformed the local area socio- economically. The first crushing season began in 1986 with the capacity of 1000 TCD. The factory has increased its crushing capacity constantly. Today the capacity is 2500 TCD. INDUSTRIAL TRAINING2

Capacities of each division Sugar-2,500 TCD Distillery-15,000 lit/day Biogas-30,000 m 3 Electricity-6 MW INDUSTRIAL TRAINING3 SHRIRAM SUGAR FACTORY Sugar plant Distillery plant Biogas plant Electric power plant

INDUSTRIAL TRAINING4 This division is established in the year of 1990 in the sugar factory. The working is quite simple. The molasses coming out of factory is sent in large tanks where fermentation process is carried out. The type of fermentation process used is continuous fermentation process. The total distillery capacity is liters per day. This division consist two plants. The capacity of each one is different as given below. First plant: liters per day Second plant: liters per day The total process carried out is very simple. After fermenting the liquid it comes into large columns where in first it’s heated and in another it’s rapidly cooled. This process gives the alcohol from which further products are designed.

INDUSTRIAL TRAINING5 The biogas is the side product of the company. The waste liquid coming out of distillery is processed in two large tanks and biogas is produced. The daily production of biogas is nearly about 30,000 cubic meters per day. The design used for the biogas production is very simple and conventional one. The biogas department is mainly meant for controlling the activities related with the biogas production. In two large tanks different chemicals are also used to activate the reaction process of biogas formation. This produced biogas is circulated and used in boilers as fuel which saves the bagas.

INDUSTRIAL TRAINING6 ELECTRIC POWER PLANT BOILER SECTION TURBINE SECTION POWER DISTRIBUTION There are four boilers and two turbines which produces 6 MW electricity per hour. Among these 3 MW electricity is being used in the factory itself and remaining 3 MW electricity is hinged to power grid in nearby area. There is another one power plant working on diesel which is being used during offseason to supply electricity to residential colony of employees.

BOILER TURBINE MakeTaxmacoBuckau Wolf No.41,2,3 Evaporation Capacity TPH 2114 Super heater outlet Temp. 0 C Pressure32 kg/cm221 kg/cm2 Type & furnace Spreader stroker with dump grate H.S. furnace with E.C.C. INDUSTRIAL TRAINING7

8 Sugar manufacturing Process department Manufacturing department Chemical & Quality department Maintenance department Maintenance department Packing & Storing department These are the various departments under the sugar manufacturing plant. The factory produces export quality sugar grades S-30.The factory had a crushing over 4,22,624 M.T. till 27/06/2011. The factory had a crushing duration of over 180 days in this season and has consistently recorded an average sugar recovery of around 11.22%.

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10 The cane is first weighted on the way-bridge,then the vehicle move towards the lift cranes. By the use of lift cranes the cane is pulled up from the vehicle and fall on the feeder table which is oscillating continuously. The cane then come on to the carrier which leads to kicker in which the bunch of cane is separated and then the leveler in which cane is cut into small pieces and fed to crusher. The crusher is a massive machine which hammers the cane so as to open the sugar cells. In the crusher there are 96 hammers and weight of each hammer is 8 kg. Then the crushed cane moves ahead to mills.There are 4 mills in which the juice is extracted.For juice extraction the crushed cane has to pass through the three rollers which are TRPF (Toothed Roller Pressure Feeder).The 3 rollers are namely Feed,Top,Discharge. On the top roller hydraullic pressure is applied. The clearance between the rollers should not be more than 10mm.For further mills the water is sprinkled on cane for extracting the sugar in crystal form.This is known as Imbibitions The cane is first weighted on the way-bridge,then the vehicle move towards the lift cranes. By the use of lift cranes the cane is pulled up from the vehicle and fall on the feeder table which is oscillating continuously. The cane then come on to the carrier which leads to kicker in which the bunch of cane is separated and then the leveler in which cane is cut into small pieces and fed to crusher. The crusher is a massive machine which hammers the cane so as to open the sugar cells. In the crusher there are 96 hammers and weight of each hammer is 8 kg. Then the crushed cane moves ahead to mills.There are 4 mills in which the juice is extracted.For juice extraction the crushed cane has to pass through the three rollers which are TRPF (Toothed Roller Pressure Feeder).The 3 rollers are namely Feed,Top,Discharge. On the top roller hydraullic pressure is applied. The clearance between the rollers should not be more than 10mm.For further mills the water is sprinkled on cane for extracting the sugar in crystal form.This is known as Imbibitions

INDUSTRIAL TRAINING11 This station is used for the purification and clarification of the juice. When the raw juice leaves the Diffuser it is very dark and contains many impurities, which must be removed before it can be processed further. In the 1st Carbonatation tanks, Milk of Lime and Sulphur Dioxide Gas are added to the juice. This acid/alkali mixture assists in removing the impurities, by forming a precipitate, which allows the solid matter to separate out from the liquid. The juice is fed into a large vessel [Clarifier] to allow this process to take place. The clear juice is pumped on to the 2nd Carbonatation Tank where it has more Sulphur Dioxide Gas injected and finally filtered through some G.P. This station is used for the purification and clarification of the juice. When the raw juice leaves the Diffuser it is very dark and contains many impurities, which must be removed before it can be processed further. In the 1st Carbonatation tanks, Milk of Lime and Sulphur Dioxide Gas are added to the juice. This acid/alkali mixture assists in removing the impurities, by forming a precipitate, which allows the solid matter to separate out from the liquid. The juice is fed into a large vessel [Clarifier] to allow this process to take place. The clear juice is pumped on to the 2nd Carbonatation Tank where it has more Sulphur Dioxide Gas injected and finally filtered through some G.P.

INDUSTRIAL TRAINING12 The slurry from the Clarifier is pumped into the Vacuum Filters. These are cloth covered rotating drums that use a vacuum to draw the slurry onto the cloth, yet allowing the juice to pass through. As the drum passes through the lower bowl the slurry is sucked onto the cloth. As it revolves out of the slurry, there are water sprays, which rinse the sucrose out of the slurry. This sugar solution is fed back into the Carbonatation stage of the process. The clear juice is pumped into the Evaporators. At this stage the juice has quite a low density. It is what we call Thin Juice and is 84% water. To prepare the juice for crystallization the water content has to be reduced to about 32%. To remove all this water, it has to be evaporated off. Since energy is very expensive, we use the steam only once in the 1st Effect Evaporators. As the juice boils, vapour is produced and this is used to heat up the 2nd Effect Evaporators. This process is repeated 5 times and so for the price of one unit of energy. We can achieve 5 times the heating capacity.

INDUSTRIAL TRAINING13 The juice is batch-fed into four Vacuum Pans. These are kept under a vacuum so that the juice can be boiled at a lower temperature, generally 80C. This enables us to make the pure white crystals of the highest quality. The juice is firstly boiled until the water content is about 20%. A calculated amount of finely ground sugar crystals, about the size of Icing Sugar, are added to this concentrated syrup. The crystals are then allowed to grow, at a controlled rate, until they are the correct size for Granulated Sugar. When the crystals have reached this optimum size, the pan contents are fed into a receiver ready for the final stage of the process. The syrup mix is now called massecuite. The residual syrup goes through this process three times, to extract as much sugar crystal as possible. The remaining syrup is Molasses. Massecuite from the White Pans is fed into one of seven Centrifugals. These machines use centrifugal force to separate the crystals from the syrup. A batch of massecuite is spun until most of the syrup has been removed, then a light spray of clean water is used to polish up the crystals. The centrifuges will rotate at 1500r.p.m. attaining speeds of 170 m.p.h. Each basket produces approximately 250 kilos of sugar from every batch.

INDUSTRIAL TRAINING14 This is the very important and essential division of Shriram sugar factory. All subparts of engineering like design, production and quality are united in the same division. The main purpose of engineering department is that to correct any engineering problems arising in sugar factory. The problems may involve conditions like problems in valves, problems in pumps, electronic and electric faults, and stoppage of any working unit, etc. To correct the problems or to produce any component engineering division makes the use of following machines. 1. Lathe machine (2 in number) 2. Shaper machine (1 in number) 3. Drilling machine (1 in number)

The main function of a lathe is to remove metal from a piece of work to give it the required shape and size. In the sugar factory all the lathe machines used are of centre lathe type. The main function of a lathe is to remove metal from a piece of work to give it the required shape and size. In the sugar factory all the lathe machines used are of centre lathe type. INDUSTRIAL TRAINING15 The lathe can perform the different operations like turning, chamfering, polishing, grooving, facing, knurling, filing, forming, spinning etc. In the sugar factory, the parts like valves, pumps etc are processed on the lathe machine as per the operations required. The lathe can perform the different operations like turning, chamfering, polishing, grooving, facing, knurling, filing, forming, spinning etc. In the sugar factory, the parts like valves, pumps etc are processed on the lathe machine as per the operations required.

The shaper is a reciprocating type of machine tools intended primarily to produce flat surfaces. These surfaces may be horizontal, vertical, or inclined. In general, the shaper machine can produce any surface composed of straight line element. Modern shapers can also generate contoured surfaces. The shaper is a reciprocating type of machine tools intended primarily to produce flat surfaces. These surfaces may be horizontal, vertical, or inclined. In general, the shaper machine can produce any surface composed of straight line element. Modern shapers can also generate contoured surfaces. INDUSTRIAL TRAINING16  Base, columns, cross rails, saddle, table, ram, and tool head are the main parts of the machine. Shaper can perform different operations like machining horizontal surface, machining vertical surface, machining angular surface, cutting slots and keyways, machining irregular surface, machining spines or cutting gears. Shaper works on the principle of quick return mechanisms.  In the sugar factory machine used is a horizontal shaper machine and it’s used to machine the different surfaces.  Base, columns, cross rails, saddle, table, ram, and tool head are the main parts of the machine. Shaper can perform different operations like machining horizontal surface, machining vertical surface, machining angular surface, cutting slots and keyways, machining irregular surface, machining spines or cutting gears. Shaper works on the principle of quick return mechanisms.  In the sugar factory machine used is a horizontal shaper machine and it’s used to machine the different surfaces.

The radial drilling machine is one of the important machine tool in the workshop. Although it was primarily designed to originate the hole, it can perform number of similar operations. In a drilling machine holes can be drilled quickly and at low cost. The hole is generated by the rotating cutting edge of a cutting tool known as the drill which exerts large force on the work clamped on the table. The radial drilling machine is one of the important machine tool in the workshop. Although it was primarily designed to originate the hole, it can perform number of similar operations. In a drilling machine holes can be drilled quickly and at low cost. The hole is generated by the rotating cutting edge of a cutting tool known as the drill which exerts large force on the work clamped on the table. INDUSTRIAL TRAINING17  As the machine tool exerts vertical pressure to originate a hole it is loosely called as “drill press”.  The different operations performed on the lathe are as drilling, reaming, boring, counter boring, counter sinking, spot facing, tapping, lapping, grinding, trepanning etc.  As the machine tool exerts vertical pressure to originate a hole it is loosely called as “drill press”.  The different operations performed on the lathe are as drilling, reaming, boring, counter boring, counter sinking, spot facing, tapping, lapping, grinding, trepanning etc.

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