Sugar Journey From Sugar Plant to Our Plates:- Kay Iron Works

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Harvesting of sugarcane:-

Sugarcane requires an average temperature of 23.9 degrees Celsius and 80 inches of annual rainfall. As a result, it is only cultivated in tropical or subtropical climates. Sugarcane matures in around 6 to 7 months in a tropical climate but it takes a long time in the subtropical climate.

In India, the harvesting of cane sugar is done primarily by hand. The harvested cane stalks are loaded manually into trucks and trolleys in India and taken to mills for processing into raw sugar.

Preparation for processing of sugar cane:-

The cane is mechanically unloaded and superfluous soil and pebbles are removed once it reaches the mill yards. The cane is washed by either flooding the carriers with water (in the event of sparse rock and garbage clutter) or distributing it on vibrating conveyors which pass through powerful jets of water and combing drums (to remove larger amounts of rocks, trash, and leaves, etc.).

Swing-hammer type shredders (1,200 RPM) shred the cane without extracting the juice, or two or three strongly grooved crusher rollers shatter the cane and remove a major percentage of the juice. The crushers are supplemented with revolving blades that break the stalks into pieces. (The shredder comes before the crusher in most nations.) It’s possible to employ a mix of two or even all three ways. Crushing the sugar cane with heavy metal rollers removes the juice from the sugar canes.

Hot water is sprayed onto the crushed cane counter as it leaves each mill for diluting as the cane is crushed. After the extracted juice, contains 95 percent or more of the sucrose in the original.

The mill juice is acidic and turbid, with a dark green hue. The clarifying (or defecation) process is used to remove soluble and insoluble contaminants such as sand, dirt, and pulverized rock that was not eliminated during the preliminary screening step.

Purification of the juice from impurities and Evaporations:-

Sedimentation separates the mud from the clear juice. Continuous filtering is used to eliminate non-sugar contaminants. Except for the eliminated contaminants, the final clarified juice includes 85% water and has the same composition as the raw extracted juice.

Vacuum evaporation is used to remove around two-thirds of the water from this clarified juice. With around 65 percent solids and 35 percent water, the syrup leaves the last body in a continuous stream.

The next phase in the sugar manufacturing process is crystallization. In a single-stage vacuum pan, crystallization takes place. The syrup is evaporated until it is sugar-saturated. Small grains of sugar, or “strike,” are added to the pan as soon as the saturation point is reached. Seeds are tiny grains that act as nuclei in the production of sugar crystals.

The crystals continue to develop until the pan is completely filled. The thick combination of syrup and sugar crystals, known as massecuite, is released into enormous containers known as crystallizers when the sucrose concentration reaches the necessary level. As the massecuite is progressively agitated and cooled, crystallization continues in the crystallizers.

Crystallization of sugar:-

Massecuite from the mixers is allowed to flow into centrifugal, where the thick syrup, or molasses, is separated from the raw sugar by centrifugal force.

Centrifugal are rotating devices that employ centrifugal force motion to separate the massecuite into raw sugar crystals and molasses. A centrifugal machine is made up of a cylindrical basket hanging on a spindle with perforated sides coated with wire cloth and metal sheets with 400 to 600 holes per square inch within. The basket spins at rates ranging from 1,000 to 1,800 revolutions per minute.

Centrifugaling:-

After centrifugation, the sugar is “cut down” and transferred to a granulator to dry. Sugarcane is processed in tiny factories without centrifuges in some nations, yielding a dark-brown product known as non-centrifugal sugar. More than 60 countries manufacture centrifugal sugar, but only roughly twenty countries generate non-centrifugal sugar.

Drying and Packaging:-

In a granulator, wet sugar crystals are tumbled via hot air to dry. The dried sugar crystals are subsequently separated into storage containers by size using vibratory screening. Sugar is subsequently shipped to also be packaged in groceries packaging, bulk container, or in liquid form for industrial application

If you are looking to start your own sugar plant then Kay iron Works is the best supplier and manufacturer of sugar plant machinery and equipment. We have earned accolades for providing the best turnkey solutions for sugar plants of different capacities. Our sugar plants include a comprehensive range of equipment, components, spares and accessories — all conforming to international quality standards. We provide both on-site as well as off-site fabrication job. The most important factor that we take duly into consideration is the pursuance of environmental and safety specifications. In our entire fabrication jobs, we consciously endeavor to ensure that our plants meet the environmental specifications laid down by local and international legislation.

Silent Features of Our Sugar Plants:

1. Highly reliable
2. Require less maintenance
3. Fully automatic plant from sugar cane unloading to sugar bagging house
4. Crystal white sugar production through sulphation/carbonation process
5. Equipped with both air pollution control as well as water pollution control equipment
6. Effluents and emissions within prescribe limits
7. List of sugar mill machinery manufactured by us Mill House & Power House
8. Mill House E.O.T. Crane & Gantry
9. Cane Unloaders, Table Feeders
10. Cane Cutters, Cane Levelers & Kickers
11. Cane Carriers, Inter carriers with Chains, Slats. Bagasse Elevators complete
12. Headstocks, Crown Pinions, Scrappers, Trash Plates, Coupling
13. Bagasse Baling Presses
14. All Types of Chains, Slats. Rakes, Sprockets
15. Power House Crane & Gantry

Boiling House; Clarification House; Bagging House And Centrifugal Accessories

Complete Boiling House Equipment up to10,000 Tons Per Day Crushing Capacity such as;

• Automatic Juice Weighing Scales. Water Weighing Scale. Molasses Weighing Scales
• Juice Heaters — Conventional & Dynamics
• Semi — Kestners. Falling Film Evaporators. Evaporator bodies, quad set
• Juice Sulphitation Unit, Milk of Lime Station,Carbonation Tanks
• Lime Kilns
• Sulphur Burners — Conventional and Digital
• Fabricated Right Angle Valves & Double Beat Valves
• Clarifiers & Filters
• Calendria Vacuum Pans, Continuous Pans for A, B & C Massectiites
• Barometric Condensers, Multijet Condensers
• Crystallizers -Air Cooled, Water Cooled, Seed & Vacuum. Vertical Crystallizers
• Automation of Pans, P.H. Control, Sulphur Burner, Molasses Conditioners etc.
• Screw Conveyors.
• Sugar Melter — Horizontal & Vertical, Magma Mixers
• Sugar Elevators, Sugar Graders, Hoppers
• Molasses Storage Tanks, Spray pond
• Complete Plant Staging and Process Piping. Misc. Tanks

Boilers

• Staging & Ducting, M.S. Chimney
• Return Bagasse Carrier with Chain, Slats etc.
• IBR Pipe Line