1. National Federation of Co-operative Sugar Factories Ltd.
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2. National Federation of Cooperative Sugar Factories Limited (NFCSF) was registered on December 2, 1960 as an apex organization of all cooperative sugar factories in India. NFCSF was set up as a promotional body for the establishment of cooperative sugar factories in India and for provision of technical advice to the cooperative sector of the sugar industry. Today it guides and provides consultancy services to all sectors.
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3. NFCSF was established at a time when India’s standing in the world sugar scenario was negligible. It was the establishment of NFCSF which changed the scenario. India became the world’s largest producer of sugar during 1982, 1988 to 1993, 1995, 1996 and with cooperatives’ share of the sugar production during the said years being 55% to 61%. India’s share in global sugar production also increased to 15%. Today India is the second largest producer of sugar in the world next to Brazil.
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4. Establishments
The Indian Sugar and General Industry Export Import Corporation Ltd. now renamed as Indian Sugar Exim Corporation Ltd. (ISEC) established by NFCSF in collaboration with Indian Sugar Mills Association to look after the export of sugar initially, and then export / import of sugar and other products of the sugar industry such as molasses and alcohol.
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5. 2000- Research, Development and Training Centre of NFCSF.
1974- National Heavy Engineering Cooperative Limited promoted by NFCSF for manufacturing of sugar plants, including high pressure boilers, continuous centrifugals and all other machinery required by sugar factories.
1977- Technical and Promotional Cell of NFCSF for Techno Commercial & Managerial Consultancy services.
2000- Research, Development and Training Centre of NFCSF.
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6. Identity
* An apex body of all cooperative sugar factories in India making it the LARGEST sugar cooperative in the world.
* An autonomous organization governed by the Multi-State Cooperative Societies Act of Government of India.
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7. * It is the LARGEST affiliation of sugar factories in the world.
* It represents over 50 MILLION farmers and their dependents who are involved in sugarcane cultivation.
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8. Objectives * Promote agri – business / rural upliftment.
* Stabilize past achievements
* Foster faster growth for future vis-à-vis challenges.
* Developing and researching new technical areas in sugarcane growth and production & Trans- forming Sugar Factories into Sugar Complexes.
* Undertaking trunkey projects for conversion of sulphitation process to produce sulphurless sugar.
* Taking up trading in Carbon on behalf of member factories to reduce green house emissions and increase revenue.
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9. Progress of Indian Sugar Industry at a Glance *
Area under sugarcane
2.4 mln hec.
5.0 mln hec.
Sugarcane production
110.0 mln tonnes
340.6 mln tonnes
Total number of working factories
174
516
Total number of cooperative sugar factories in operation 30
249
Average daily crushing capacity
1172 tonnes
3586 tonnes
Annual production of sugar
3.02 mln tonnes
26.3 mln tones
Per capita sugar consumption
4.8 kg.
19.1 kg.
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10. Areas of Specialization
* Improvement in agricultural practices in sugarcane cultivation and development of sugar rich cane varieties towards optimum yields of sugarcane / sugar per hectare and to reduce cost of cultivation. For this purpose, NFCSF has a Standing Committee with Experts from all over India which studies and analysis the reports on varietal trials conducted at regular intervals in sugar factory areas.
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11. * Implementation of projects on turn-key basis
* Installation of cost effective new sugar factories with selection of suitable sites, plant and machinery with technical specification, plant layout and project planning, scheduling & implementation.
* Implementation of projects on turn-key basis
* Technological upgradation of existing sugar factories and rehabilitation of
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12. of working sick sugar factories for optimum
of working sick sugar factories for optimum productivity & energy conservation.
* Promotion of by-products with co-products of sugar factories for value addition – bagasse based paper / particle board plants; bagasse / bio-mass based co- generation (surplus electricity power generation) – and sugarcane molasses based distilleries for alcohol, ethanol and other alco-based chemical industries and production of sulphurless sugar and refineries.
* Assist in selection, purchase, installation and maintenance of plant and machiney.
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13. * Assist in selection of high calibre manpower for all activities.
* Assist in standardizing the accounting and costing systems / practices.
* Undertake publication of market information of sugar and allied industries.
* Conduct conferences, seminars / workshops towards promotion of finance interfaced sugarcane agri-business for better Return on Investment (ROI).
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14. * Financial Management.
* Undertake various other conducive business activities for the benefit of sugar factories / industry.
* Pre-despatch inspection of critical machinery and equipment at manufacturers’ works as per national / international standards.
* Application of modern technology in sugar process for white sugar below 100 ICUMSA, Very High Purity (VHP) raw sugar.
* Financial Management.
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15. Process system adopted include * Double Sulphitation.
* Filtrate Clarification by phosphotation.
* Syrup Clarification by phosphotation.
* Refined sugar from single cured ‘B’ sugar.
* Defico remelt process for the production of sulphurless sugar.
* Detailed Project Reports for
- New sugar complexes.
- Modernization of existing factories.
- Rehabilitation of sick factories.
- Bagasse based by-products.
- Molasses based by-products i.e.R.S./ENA/ Ethanol etc.
* Financial Restructuring and monitoring for successful implementation.
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16. - Inception to commissioning - Project and feasibility report
Tasks & Functions
New Sugar Factories
- Inception to commissioning
- Project and feasibility report
- Cane development
- Plant site selection
- Basic engineering for plant & machinery
- Project scheduling
- Plant layout
- Inspection of machinery at manufacturers’ works
- Manpower Planning / Selection
- Inventory Control
- Selection of workshop equipment
- Financial Management
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17. Working Sugar Factories
- Basic engineering for modernization / expansion
- Energy conservation – Reduction in steam consumption & power consumption
- Improvement in working efficiency
- Improvement in quality of sugar
- Optimization of capacity utilization
- Advice on technological up-gradation
- Trouble shooting
- Improve milling and boiler performance
- Improve sugar quality and process approaches
- Conserve steam, power and fuel
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18. - Analysis of break downs for remedial measures
- Investigate reasons for low recovery
- To achieve zero fresh water consumption & zero effluent
- Financial Management
Sugarcane Development
- Varietal development and improvement in agricultural practices
- Soil analysis
- Ratoon Management
- Promotion of inter-cropping for value addition
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19. - Paper factories / particle board plants
Co-products
- Paper factories / particle board plants
- Alcohol producing units / Ethanol
Co-generation
Research & Development
- Sugarcane quality (varieties) & yield per hectare.
- Sugar quality vis-à-vis international standard.
- Inventory control
- Reduction in conversion cost
- Steam, fuel and power conservation.
- Application of sugar co-products for value addition by-products
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20. Commissioning of New Projects / Expansion of Existing Projects
200 Nos. new factories & expansion of capacity
20 Nos. Ethanol projects.
20 Nos. Bagasse based Co-generation projects.
- About 15 for syrup & melt / filtrate clarification / syrup clarification / raw sugar refining.
- A list of detailed project reports prepared from January, 2007 to till date is enclosed at Annexure-I.
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21. Strength High Calibre taskforce Professionally qualified workforce
More than four and half decades of all round experience.
Specialized professional in each field.
- Complete consultancy for sugar available under one roof.
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22. Associates
- M/s. DEC International, New Delhi for Project Management & Engineering Services.
- M/s. Avant-Garde Associates, Chennai for Co- generation of Power.
- M/s. Sri Engineers Pvt. Ltd., New Delhi for Distilleries and Ethanol Plants.
- M/s. Diftech Group, New Delhi for Melt / Filtrate / Syrup Clarification Systems and Raw Sugar Refining.
- M/s. Environment Synergies/Quality Tonnes, Bangalore for Carbon Trading.
- M/s. Eco-Invest Carbon Credit SA C/o Bungee India Pvt. Ltd., Mumbai for Carbon Trading.
- M/s. Overseas Infrastructure Alliance (India) Private Ltd., Mumbai for overseas projects.
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23. Global Exposure
- Indigenous expertise in sugar industry has enabled India to export complete sugar plants all over the world.
- NFCSF has an exposure to the world’s sugar industries covering –
USA Ethiopia (Tendahu & Fincha)
Australia Sudan
Brazil Bangladesh
Vietnam Nepal
Colombia Reunion
Thailand Mauritius
Pakistan Fiji
South Africa Mozambique
Kenya Nigeria
Madagascar (Mananjary and Sakaraha)
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24. Representation
- Governing Council and Board of Management of National Cooperative Development Corporation.
- Advisory Board of National Sugar Institute.
- Development Council for Sugar Industry, Government of India.
- Indian Sugarcane Development Council.
- Bureau of Indian Standards, Sugar Industry Sectional Committee.
- Indian Sugar Exim Corporation Ltd.
- Standing Committee of Reserve Bank of India on Industrial Finance for sugar industry.
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25. - Governing Council of National Cooperative Union of India.
- Sugar Technologist’ Association of India.
- Ministry of New & Renewable Energy, Government of India.
- Sub-Committee to fix up technical efficiency norms for Indian sugar factories.
- Sub-Committee to frame guideline specifications for sugar plants of capacities ranging from 1,250 to 10,000 tonnes of cane crush per day.
- Sub-Committee to fix up minimum national standards for Pollution Control in Sugar Sector of Indian Industries.
- Standing Committee, Screening & Sub- Committee for disbursement of SDF loan for sugar cane development, expansion, modernization, co-generation and ethanol projects etc.
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26. NFCSF is an active member of
- ICUMSA – International Commission of Uniform Methods of Sugar Analysis.
- ISO – International Sugar Organization.
- ISSCT – International Society of Sugar Cane Technologists.
- GSA – Global Alliance for Sugar Trade Reform and Liberalization.
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27. The Project at Present under Implementation with NFCSF
The Project at Present under Implementation with NFCSF
S.No.
Name of the Factory
Description
Crushing Capacity 1.
Ethiopia two project
Consultancy for execution & monitoring
12000 TCD & 8000 TCD 2.
Mananjary & Sakaraha Sugar Complex, Madagascar
Feasibility study reports for two-sugar complex.
TCD & 3500 –5000 TCD. 3.
The Nandi Sahakari Sakkare Karakhana Ltd. Karnatka
Detailed project report for rehabilitation cum expansion
TCD 4.
Star Applied Mechanics (P) Ltd.B-36, Sector-2, Noida
Preparation of DPR of new sugar plant in Bihar 5.
M/s. PRTL Pvt. Ltd.
C-6/13 Shrinathji Chambers. 3rd floor, VIA Char Rasta, GIDC, Vapi Gujarat
Feasibility Report for Co generation -
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28. M/s. Shree Kantha Vibhag Sahkari Khand Udyog Mandli Ltd.Gujarat 6.
M/s. Sahakari Khand Udyog Mandal Ltd.Gandevi Dist – Navsari, Gujarat
Preparation of Notice Invited Tender for Modernization and Incidental cogeneration of 1.0 MW
6000 TCD 7.
M/s. Shree Sayan Vibhag Sahakari Khand Udyog Mandli Ltd. Surat, Gujarat
Preparation of DPR for Modernisation, Balancing and Optimization of Sugar Plant. 8.
M/s. Shree Kantha Vibhag Sahkari Khand Udyog Mandli Ltd.Gujarat
Preparation of DPR of new sugar plant
TCD 9.
M/s. Shree Narmada Khand Udyog Sahakari Mandli Ltd.
Distt. Narmada, Gujarat
Preparation of DPR for Modernisation, Balancing and Optimization of sugar plant.
5000 TCD
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29. The Chodavaram Coop. Sugars Limited. Govada– 531 023, Andhra Pradesh 10
The Kovur Cooperative Sugars Limited, Distt- Nellore – , Andhra Pradesh
Rehabilitation cum Modernization & Balancing of Sugar Plant. Along with 8 MW cogeneration
2500 TCD 11
The Chodavaram Coop. Sugars Limited. Govada– , Andhra Pradesh
Rehabilitation cum Modernization & Balancing of Sugar Plant. Along with 22 MW cogeneration
4400 TCD 12
SHAHABAD COOPERATIVE SUGAR MILLS (HARYANA)
Consultancy cum inspection agency for 24 MW cogeneration project
5000 TCD 13
Shri Malaprabha Sahakari Sakkare Karkhane (N),Mugutkhan Hubli , Distt. - Belgaon
Consultancy for defico remelt process.
4000 TCD 14
MAA MAHAMAYA S.S.K.
Ambikapur chatishgarh
Consultancy cum inspection agency
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30. PREPARATION OF DETAIL PROJECT REPORTS BY NFCSF OF
JANUARY TO TILL NOW
S.N.
Name of the Factory
Description
Crushing Capacity
ORDER DATE 1
Chaddha Sugar & Industries Ltd.
Preparation of DPR of new sugar plant
7500 TCD
January –2007 2.
Palwal Coop. Sugar mills,
Preparation of DPR for modernization and balancing of sugar plant.
2200 TCD
January-2007 3.
The Bagpat Coop. Sugar Mills Ltd.,
Implementation of scheme for saving of steam /bagasse
2500 TCD 4.
DIVERA SOLUTION LIMITED
Preparation of DPR of new sugar plant along with cogeneration
February-2007 5.
The Ajnala Cooperative Sugar Mills Limited,
Preparation of DPR for incidental Co-operation
2 MW
March-2007 6.
Bhoramdeo Shahakari Shakkar Utpadak Karkhana.
Preparation of DPR for Expansion of sugar plant
2500 TCD To 3500 TCD.
Aprial-2007
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31. SAHAKARI SAKKAR KARKHANA RAHELI SAGAR,
Name of the Factory
Description
Crushing Capacity
ORDER DATE 7.
ELDUEIM SUDAN
Preparation of detail project report of new sugar plant with 36 MW cogeneration & 60 KLPD distillery
10000 TCD
May 8.
SAHAKARI SAKKAR KARKHANA RAHELI SAGAR,
Preparation of DRP for new sugar plant
2500 TCD
July –2007 9.
Shree Vadodara District coop. Sugarcane Grower’s Union Ltd.
Preparation of DPR for expansion, modernization & balancing
2500 TCD TO 3500 TCH
10.
Kisan Sahakari Chini Mills Ltd. Sneh Road Najibabad
Report of Environmental Impact Assessment Study
50KLPD+30 KLPD+30 KLPD
JUNE-2007
11.
Danteshwari mama SSK.
Preparation revised NIT of Sugar Plant
1250 TCD
June-2007
12.
SHAHABAD COOPERATIVE SUGAR MILLS
Revised DPR of expansion, balancing along with cogeneration
4000 TCD to 6000 TCD
August -2007
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32. Batala Coop. sugar Mills ltd. Preparation of report of energy audit.
Name of the Factory
Description
Crushing Capacity
ORDER DATE
13.
Batala Coop. sugar Mills ltd.
Preparation of report of energy audit.
Existing plant
August-2007
14.
The Gurdaspur Coop. Sugar Mills Ltd.
September -2007
15.
THE ASSANDH COOP. SUGAR MILLS
Agreement of consultant& inspection
2500 TCD
September-2007
16.
Maa Maha Maya S.S.K
17.
THE NOWGONG COOP. SUGAR
Detailed Project Report of revival
1250 TCD
October –2007
18.
THE MORINDA COOP.SUGAR MILLS LTD.
VALUATION FOR OLD MILL TANDAM
Ø28” x 56 “ lg. Milling tandem
December -2007
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33. NAYAAGARH SUGAR COMPLEX LIMITED
Name of the Factory
Description
Crushing Capacity
ORDER DATE
19.
NAYAAGARH SUGAR COMPLEX LIMITED
DPR FOR EXPANSION CUM MODERNISATION along with cogeneration
1250 TO 2500 TCD
Decenber-2007
20.
THE PALWAL COOP.SUGAR MILLS LTD
EXPANSION ALONG WITH COGENRATION
1250 TCD TO 2500 TCD
February-2008
21.
Chadha Sugar & Industries Ltd.
Preparation of DPR of new sugar plant
5000 TCD expandable to TCD.
22.
NASIK SAHAKARI SAKHAR KARKHANA LTD.
Preparation of DPR for expansion cum modernization and co-generation
1250 TCD to 2500 TCD
23.
SHAHABAD COOPERATIVE SUGAR MILLS
Revised DPR for balancing along with cogeneration
5000 TCD
24.
OVERSEAS INFRASTRUCTURE ALLIANCE (India) Pvt. Ltd.
Technical Consultancy for overseas project
Three projects.
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34. THE JIND COOP.SUGAR MILLS LTD EXPANSION ALONG WITH COGENRATION SN
Name of the Factory
Description
Crushing Capacity
ORDER DATE
25.
THE JIND COOP.SUGAR MILLS LTD
EXPANSION ALONG WITH COGENRATION
1250 TCD TO 2500 TCD
March-2008
26.
Nanauta coop. Chini mills Ltd.
DPR for five effect evaporator for existing distillery
Existing plant
April 2008
27.
The Haryana Coop. Sugar Mills Ltd. Rohtak.
Agreement of consultant& inspection
3500 TCD
May 2008
28.
Mananjary & Sakaraha Sugar Complex, Madagascar
Feasibility study reports for two sugar complex.
TCD & 3500 –5000 TCD.
November-2009
29.
The Nandi Sahakari Sakkare Karakhana Ltd. Karnatka
Detailed project report for rehabilitation cum expansion
TCD
December-2008
30.
Star Applied Mechanics (P) Ltd.B-36, Sector-2, Noida
Preparation of DPR of new sugar plant in Bihar
31st December-2008
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35. Feasibility Report for Co generation - 1st.January-2009SN
Name of the Factory
Description
Crushing Capacity
ORDER DATE
31.
M/s. PRTL Pvt. Ltd.
C-6/13 Shrinathji Chambers. 3rd floor, VIA Char Rasta, GIDC, Vapi Gujarat
Feasibility Report for Co generation -
1st.January-2009
32.
M/s. Sahakari Khand Udyog Mandal Ltd.Gandevi Dist – Navsari, Gujarat
Preparation of Notice Invited Tender for Modernization and Incidental cogeneration of 1.0 MW
6000 TCD
January-2009
33.
M/s. Shree Sayan Vibhag Sahakari Khand Udyog Mandli Ltd. Surat, Gujarat
Preparation of DPR for Modernisation, Balancing and Optimization of Sugar Plant.
34.
M/s. Shree Kantha Vibhag Sahkari Khand Udyog Mandli Ltd.Gujarat
Preparation of DPR of new sugar plant
TCD
February-2009
35.
M/s. Shree Narmada Khand Udyog Sahakari Mandli Ltd.
Distt. Narmada, Gujarat
Preparation of DPR for Modernisation, Balancing and Optimization of sugar plant.
5000 TCD
March-2009
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36. The Chodavaram Coop. Sugars Limited. Govada– 531 023, Andhra Pradesh SN
Name of the Factory
Description
Crushing Capacity
ORDER DATE
36.
The Kovur Cooperative Sugars Limited, Distt- Nellore – , Andhra Pradesh
Rehabilitation cum Modernization & Balancing of Sugar Plant. Along with 8 MW cogeneration
2500 TCD
February-2009
37.
The Chodavaram Coop. Sugars Limited. Govada– , Andhra Pradesh
Rehabilitation cum Modernization & Balancing of Sugar Plant. Along with 22 MW cogeneration
4400 TCD
38.
SHAHABAD COOPERATIVE SUGAR MILLS (HARYANA)
Consultancy cum inspection agency for 24 MW cogeneration project
5000 TCD
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37. Advanced Technologies being adopted successfully
1. Shredder / Fibriser : Improving P.I. to 92%
AC / DC Electric Drive for mills
i. Conventional Mills : Three Roller Mills
with trash plate
ii. Diffuser
iii.Two Roller Mill – Trash plate less
Advantage of Two Roller Mill -
(a) 30% less power consumption
(b) High Primery Extraction – 74% when used as 1st mill
Low moisture % bagasse when used as last mill
iv.4 Roller Pinion less / Independent AC Drive for feed, Top & discharge roller with planetary Gear Box mounted motor.
(4) AC – VVVF Drives for Cane carrier, Inter Rake Carrier, Main Bagasse carrier etc., Centrifugal pumps.
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38. High Pressure Boiler –
i) Pressure & Temp. of Steam 105 kg/cug2 & 540ºC
ii) Capacity 170 T/hr with Travelling grate
iii) Steam Fuel Raio = 2.7
iv) Thermal efficiency = 72% (on GCV)
v) Flue gas temp = 150ºC
vi) AC- VVVF drives for ID/FD/SA fans.
vii) Auto combustion control system
viii) DCS control for complete Boiler from control
room
ix) ESP for flue gas emission control
x) With recovery units economizer, Air heater,
super heaters etc.
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39. i. Using flash Heat Recovery systems
6. Double Extraction condensing Turbo Generating sets to suit the above boiler parameters
7. Evaporator system design to bring down the steam consumption % cane = 36%
i. Using flash Heat Recovery systems
ii. Extensive vapour Bleeding schemes
iii. Using Direct contact juice heaters
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40. 8.Single entry low water consumption condensers -
made of SS body & SS tailppee
Reducing power consumption to 2 KW / TCD or below at injection pumps & spray pumps
Low head pumps for Injection & spray
DCS control system for condensers & pans
9.DC/AC electric driven centrifugal machines.
1. Batch type centrifugal 1250 kg/ charge
– 1400 rpm
Machine capacity 1500 kg/charge
– 1250 rpm
2. No. of cycles / hours 20 – 22
3. High Gravity factor / 2400
Continuous machine of NK – 2000 rpm
of NK rpm
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41. 11. Continuous pan – Horizontal vertical type & vertical type
Cold water Recirculation, surplus condensate cooling & recirculation to Reduce the frash water consumption to zero.
Continuous pan – Horizontal vertical type & vertical type
Plantery Gear Boxes for Crystellizer drive etc.
Juice flow stabilization system
Filtrate clarification system
Sulpher less sugar production – Defeco Remelt process
Megensen type sugar grader
For colour Improvement Vibro screen - at MJ, filtrate, Melt juice & lime
Pan circulators & Automation for pan station
Thin Film type sulphur burners
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42. 22. Cogeneration : Based on (i) Bagasse
Plate type wide gape heat exchangers for ` condensate heat recovery Power consumption reduced upto 22 KWH / TCH for steam driven plants and 26 KW/TCH for electric driven plants by providing various AC – VVVF drives, improving power factor, planetary gear boxes, automation, devices to reduce power consumption at centrifugal station, injection & spray pumping station, ID/FD/SA fan drives by ACVVVF etc.
Cogeneration : Based on (i) Bagasse
Bio-mass : rice husk, wheat straw, cane trash, Mustered husk & straw,coconut shel, coconut straw, banana trees, pine fruits & stems, other grasses etc.
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43. 11/21/2018

44. THANK YOU NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LIMITED
‘ANSAL PLAZA’ BLOCK-C, 2ND FLOOR
AUGUST KRANTI MARG,
NEW DELHI (INDIA)
Tel. : , ,
Fax : ,
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