SUGAR INDUSTRY IN PAKISTAN – Problems, Potentials

By Syed Jamil Ahmed Rizvi, FCMA

SYNOPSIS

The industry employs more than 100,000 labour force while more than 9 million people
of rural population are involved in the production of sugarcane. The existing mills are
sufficient enough to produce the country’s requirement of sugar until the next three
years. DFIs should not entertain any application from whosoever politician or otherwise
for setting up a new sugar mill in the country. Rather they should concentrate for
financing of minimum working capital requirement of 67 operating mills, who are in dire
need of such finance. An approximate amount of Rs. 2.7 billion will have to be
earmarked by the commercial banks to finance for working capital requirement of these
alive units.

Unfortunately, Pakistan’s sugar industry is mostly owned by political personalities and

majority of the sugar mills were setup with the help of DFIs normally trapped with the
working capital crisis. Consequently, some of the mills have already been closed and it
is feared that some more sick units will also close down. A collapse of sugar mill is a
loss of national assets, reduction in the sales tax revenue and an increase in
unemployment.

Loss of production of refined sugar due to excess quantity of raw cane diverted for seed
and Gur manufacturing (37% instead of 25%) works out to 482,269 tons that could have
made available possible a total sugar production of 2,911,633 tons both from cane and
beet. Under such avoidable circumstances, the country could have needed to import only
about 113,587 tons, which might result to save precious foreign exchange of
approximately $ 208.830 million. Advance planning to foresee the situation for the
previous year and control of proper utilization of cultivated sugarcane could have easily
avoided the current sugar bonanza.

The Government should take up cost studies at the growing sugarcane stage for the
purpose of fixing the support price for the growers. Cost studies for production of
refined sugar both in terms of variable cost and fixed cost of production in each sugar
mill, should also be undertaken to control the retail prices. Cost audit rules and
compulsory maintenance of cost accounting records for sugar industry, in line with the
international cost accounting models in other countries of the world, will prove to be a
great help in this direction.

The net amount of foreign exchange amounting to Rs. 7.509 billion saved as a result of
total exports of Rs. 19.772 billion during the last six years from 1994 to 1999 has been
eaten away by the import of 900,000 tons during the current year 1999-2000 estimated to
cost Rs.13.509 billion to the government exchequer.

1
With the proper utilization of poor cane crop for the season 2000 – 01, the situation for
shortage of sugar may be reduced to 461,610 tons, which needs a foreign exchange of
US $ 114 million.

The situation would be worse and get out of control if 37.5% of cane production for the
on-going season is diverted for seed and Gur manufacturing instead of 25% estimate for
which a hefty foreign exchange of US $ 241 million will be needed to import 972,843
tons. The Government should impose restrictions on excess production of Gur
equivalent to 12.5% of sugarcane production.

Since de-zoning, the incentive of sugar mills to direct resources for development of good
variety cane in its area has almost diminished because the grower who have borrowed
money from a sugar mill for development is free to take his sugarcane to any mill
irrespective of which mill advanced the loan for development. It is also one of the causes
of sickness of sugar industry. Large interest of the growers of the area and those
associated with such project, which collapses due to non-availability of cane is badly
affected. Closure of a sugar mill reduces GDP and increase poverty of masses.

Balanced policy for cultivation of four major cash crop – wheat, cotton, rice and
sugarcane. An incentive should be provided to the growers for cultivation of sugarcane
on 1.150 million hectares. Indian variety of seed which has totally degenerated and
diseased affect the production yield should be avoided.

Two economic theories (1) principle of supply and demand governed by market forces
and (2) Government control of retail price can not work together and will further widen
the sugar crisis in the country.

HEADLINES

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Sugarcane is the fourth largest cash crop grown in Pakistan which contributes to the
agriculture economy the crop value of Rs. 48,292 million. Its share in the large-scale
industry is 18% and 1.9% in GDP. Sugar industry’s contribution to the Government
exchequer in Federal excise duty is 11.2%. Average yield of sugarcane is 44 tons against
the world average of 60 tons per hectare. Pakistan’s sugar mills crushing capacity is 58
million tons of sugarcane capable to produce 5 million tons of refined sugar and 3 mill
tons of molasses. The mills still have utilized capacity of 34%.

Pakistan witnessed shrinkage of cane planted area by 12.5% which resulted a shortfall in
sugarcane production during 1999-2000 as compared to the bumper crop of 55.191
million tons of last season 1998-99. Present sugarcane varieties are not yielding
reasonable production and is also one of the prevailing sugar crisis.

Average selling price of white crystal sugar remained Rs.14,920 against the average cost
of Rs.14,850 during the last 5-years from 1995 to 1999. In India sugarcane price at the
mill gate is Rs. 19 per 40 Kg while retail price of sugar in that country is Rs. 18 per kilo.

Pakistan imported 900,000 tons during the previous year 1999-200 estimated to cost Rs.
15.509 billion to the Government exchequer. The on-going season will face a shortfall
of 972,843 tons for which a hefty foreign exchange of US $ 241 million is required to
import the low quality sugar mainly from India as compared to international quality
certification for white crystalline sugar of Pakistan.

Pakistan has potential to further develop an area of 13,224 hectares along the main feeder
canal from Indus river in Sindh with the help of utilization of 34% idle capacity of
Pakistani mills who can export 50,000 tons of sugar to Arab World for exchange of half
a million barrels of crude oil for Pakistan.

Sales Tax on market prices is causing hardship for poor people of Pakistan. Two
economic theories (1) principle of supply and demand due to abolition of de-zoning in
free market forces and (2) Government control of retail price can not work together and
further widen the sugar crisis in the country.

INTRODUCTION:

3
Sugar Industry is an agro-based industry, which provides employment to the landless
rural population and has a great impact on the economy of the country.

The three principal bye-products of a sugar industry are bagasses, molasses and press
cake which along constitute about 40 per cent of the weight of the total cane crushed.
Proper and economic utilization of these bye-products can reduce the cost of production
of sugar to some extent. Bagasse is a source of energy fuel for sugar industry which is
used to fire boilers for juice heating. Bagasse is also being used for making Medium
Density Fibre Board (MDFB) at some industries which is a substitute for natural wood.
In Pakistan, utilization of sugar bye-products has not received much attention as
compared to other countries of the world.

Average yield of sugarcane in the world is around 60 tons per hectare while in Pakistan,
it has been worked out to 43.86 tons per hectare. India with almost similar soil and
climatic conditions had achieved about 61% higher yield for the year 1996-97. Within
Pakistan even, there exists a large gap between yield obtained at the farmers’ fields and
those obtained on experimental stations. There is, therefore, still a great scope to achieve
much higher yield at the common farm level in Pakistan. In Sudan a north African
country yield per hectare is 78 tons while it is 115 tons per hectare in South African
country - Zambia.

Two types of process are generally used in sugar factories. (1) Defecation remelt
carbonation (DRC); (2) Defecation remelt carbonation and sulphitation (DRCs). These
two are clarification process.

Pakistan is producing high quality sugar of international standards but it is costlier due to
various factors. International prices of sugar had declined due to higher output over the
demand. It was $225 per ton at the start of 1998 while it had come down to $ 188 per ton
on 12.9.1999. World output of 136 million tons of sugar had been forecasted for the
season 1999-2000.

Molasses may be utilized for production of power alcohol, industrial alcohol and
portable spirits. Press cake of sulphitation factories are used as manure and that of
carbonation factories are usually burnt. Sugar is commonly used as a sweetener. It is one
of the worlds valuable nutritious foods and is the main source of carbohydrates and
provides inexpensive calories for human body.

Sugarcane is the fourth largest cash crop grown in Pakistan which contributes to the
agriculture economy the crop value of Rs. 48,292 million. A 78 per cent of this
sugarcane was utilized and crushed by 73 sugar mills for the season 1998-99, producing
3.531 million tons of refined sugar which was capable to contribute substantial amount to
the federal government revenue towards sales tax and road cess for Provincial
government revenue. The industry employs more than 100,000 labour force while more
than 9 million people of rural population are involved in the production of sugarcane.

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The sugar industry, which is the second largest in the country after textiles, has a
potential of great economic significance for the country.

In Pakistan normally season starts in November and ends in April while in Zambia it
starts in April and finishes in December.

TABLE I: Projections of Demand & Sugar Production Capacity

Population in Domestic Projected Sugar Sugar surplus
Year Million Consumption Prod. Capacity (shortage)
in tons In tons Tons
1998-99 134.51 2959000 3530850* 571850
1999-00 137.51 3025220 2414746* (610474)
2000-01 140.94 3100680 3304360 203680
2000-02 144.47 3178340 3304360 126020
2002-03 148.08 3257760 3304360 46600
2003-04 151.78 3339160 3304360 (34800)
2004-05 155.58 3422760 3304360 (118400)
Per capita consumption 22 kg [Excluding Beet Production] * Actual
Economic Survey 1999-2000

Sugar Mills’ Capacity

In Pakistan 76 Sugar Mills are operating having crushing capacity of 361,300 tons of
cane per day (TCD). Seven Sugar mills extended capacity but they are unable to utilize.
Based on 160 days season these sugar mills have a total crushing capacity of 58 million
tons of sugarcane capable to produce 5 million tons of refined sugar and 3 million tons of
molasses.

In order to enable the country to be self-sufficient in sugar, a minimum area of 1.150

million hectares should remain under sugarcane cultivation, which can produce 50
million tons at an average yield of 43.86 tons per hectare. The Government should
insure that at least 76% of the sugarcane grown in the country is utilized by all sugar
mills. It means that a total of 38.3 million tons if compulsorily utilized by the mills can
easily produce white refined sugar of 3.3 million tons per season at an average sucrose
recovery of 8.62%. Pakistan present population is 13.5 million head count. With an
average growth rate of 2.5% per annum, the population of the country will grow year to
year as shown in graph and table I. The per capita consumption of sugar in Pakistan is
about 22 kg. The estimated domestic consumption is provided in table I and graph IA.
Keeping in mind the balance production of agricultural sector and peculiar problems the
sugar industry face due to being its status of political industry, and its seasonal nature the
minimum production of 3.3 million tons per season will be sufficient enough to meet not
only the domestic demand but also make surplus sugar available during the next three
years as shown in the table.

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It is very important point that by utilizing 38.3 million tons of cane against their normal
plant capacity of 58 million tons of sugarcane, the mills would still have unutilized
capacity of 34%. This clearly signals that the existing mills are sufficient enough to
produce the country’s requirement of sugar until the next three years. The Government
should focus its policy for increasing the production of sugarcane on the existing area
under cultivation and sugar output by the available mills. It should not encourage further
increase in the number of sugar mills. All development Financial Institutions (DFIs),
banks, and other financial institutions should make a firm policy that Pakistan has
surplus sugar capacity and limited crop on the maximum area of 1.150 million hectares
due to balancing of other cash crops such as wheat, cotton and rice. They should not
entertain any application from whosoever whether politician or otherwise for setting up a
new sugar mill in the country. Rather they should concentrate for financing of minimum
working capital requirement of 67 operating mills, who are in dire need of such finance.
An approximate amount of Rs. 2.680 billion will have to be earmarked by the
commercial banks to finance these alive units. As for as nine closed or dying units such
as Bachani, Thatta, Dadu, Kiran, Larkana, Tharparkar, Thar, Pasrur and Qand Ghar are
concerned, respective DFIs should seriously look into the causes of their closure. Causes
of closure of these mills may predominantly be that of non-availability of cane, lack of
BMR, loan default, compounded by mismanagement or otherwise. The purpose of
accountability and macro economic development are two separate things and have multi-
dimensional effects on the health of financial sector and welfare of the population. The
cases of accidental defaulters who are unable to pay their loans due to cost over-runs
because of delay in project implementation, lack of BMR, financial mismanagement,
diverting of working capital towards subsidiary company should be handled in such a
way so as to serve the national interest. Those sugar mills trapped in the accidental
defaulters, who employ a good number of people and contribute substantial amount to
the exchequer should be given a chance for restructuring their loan liabilities. The
compounded mark-up should be waived and the principal amount of loan rescheduled,
payable within three years time, so that the health of the banking sector could be restored
and objective of revival of sugar industry is achieved.

Table II: Sugarcane cultivation, Crushing and Sugar production

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 Area Sugarcane Yield Cane No. Utilisation Sugar Recovery
Year Planted Production Per crushing of % Produced %
Hectares tons hectare Tons Mills by Sugar Tons
tons Mills
1985-86 779800 27856300 35.72 12063292 40 43.30 1102316 9.14
1986-87 762000 29925800 39.27 14485439 41 48.40 1255839 8.67
1987-88 841600 33028800 39.25 20304087 44 61.47 1743505 8.59
1988-89 876900 36975700 42.17 21707520 45 58.71 1817935 8.37
1989-90 854300 35493600 41.55 20501339 48 57.76 1828904 8.92
1990-91 883800 35988700 40.72 22603696 51 62.80 1908838 8.44
1991-92 896000 38865000 43.38 24795815 53 63.80 2296698 9.26
1992-93 884600 38058900 43.02 27274806 61 71.66 2375289 8.71
1993-94 962800 44427000 46.14 34181899 63 76.93 2900523 8.49
1994-95 1009000 47168447 46.75 34193290 66 72.49 2983101 8.72
1995-96 963100 45229700 47.00 28151434 66 62.24 2449598 8.70
1996-97 964511 41998409 43.54 27152918 68 64.65 2378751 8.76
1997-98 1056200 53104200 50.28 41062268 71 77.32 3548953 8.64
1998-99 1155100 55191100 47.78 42994911 71 77.90 3530931 8.21
1999-00 1010000 46363000* 45.90 28982711 67 62.51 2414746 8.33
*Economic Survey 1999-2000 Source: PSMA

Sugarcane Production Yield and Sucrose Recovery

From Table II, it is obvious that sucrose recovery plays a critical role in increasing sugar
production. The Government may take necessary steps to insure that the cane growers
use improved varieties of sugarcane possessing high sucrose contents and resistance to
disease and pests and our research institutes evolve high sucrose content varieties of
sugarcane. Each mill should have vigilant cane department, which should see that fresh
cane supplies from the fields are brought to the mills on the very same day these are cut
by the farmers. They should be advised to transport their cane to the mills as soon as
possible to avoid losses of weight and of sucrose content.

Improved yield per hectare is a dominant factor augmenting the sugarcane production
and increasing the income of growers. Area under cane cultivation, production and per
hectare yield for the past fifteen years are shown in Table II.

From table II, it is observed that the area, production and yield per hectare of sugarcane
have reasonably improved. Lower productivity in Pakistan is due to insufficient
irrigation water, inadequate input of fertilizer, and also lack of proper spraying of
insecticides and pesticides.

The Government had raised the minimum support prices of sugarcane per 40 kg
from Rs. 24 to Rs. 35 for Punjab and Rs. 36 for Sindh on March 3, 1997. As a result
there was a bumper sugarcane crop of 55.191 million tons in the year 1998-99. Due to
the price increase and the burden of interest on long term and short term loans and
refusal of commercial banks to provide working capital finance to some of the sugar
mills because of their loans default position attributable to financial mismanagement or
otherwise, the high level of cane growers arrears payment for the bumper season 1998-99

7
were delayed extraordinarily. This had resulted in the shrinkage of cane-planted area by
about 12.5% in 1999-2000 season.

Sugarcane planted during the season 1999-2000 on an area of 1.010 million hectares
against the area of 1.155 million hectare for the previous season 1998-99. Sugarcane
production of the year 1999-2000 was 46.363 million tons as compared to 1998-99
bumper crop of 55.191 million tons resulting a short fall in sugarcane production by
16%. Out of the cane crop grown this year, sugar mills had utilized and crushed 28.983
million tons of cane and produced 2.415 million tons of refined sugar at an average
recovery of 8.33 percent in the season 1999-200.

In Pakistan present sugarcane varieties are not yielding reasonable production and led to
the prevailing sugar crisis. The Government may consider to import high yielding
varieties of sugarcane for averting any sugar crisis in the country for the future.

Table III: Sugarcane Yield Per hectare per ton in various countries.
Countries 1989-90 1991-92 1996-97

USA 77.44 76.80 75.19

Mauritius 70.33 72.83 71.39
India 66.06 64.14 70.30
Brazil 62.02 61.74 67.42
Pakistan 41.55 43.38 43.54
Cuba 59.98 57.04 34.83
Source: DAWN EBR July 12-18, 1999

Initial Working Capital

Unfortunately, Pakistan’s sugar industry is mostly owned by political personalities and

majority of the sugar mills were setup with the help of DFIs normally trapped with the
working capital crisis. Consequently, some of the mills have already been closed down
and it is feared that some more sick units will also close down. A collapse of sugar mill
is a loss of national assets, reduction in the sales tax revenue and an increase in
unemployment. It is the prime responsibility of entrepreneurs to arrange for working
capital required for smooth start and uninterrupted production during a season. A
minimum cash of Rs. 40 million is required to rotate the crushing and production cycle in
the first month of a season. Setting up a project is one thing, which in most cases, is
financed by DFIs, but availability of working capital is the life blood for a project. Some
companies prefer to use the option of borrowed funds both from commercial banks and
by way of using suppliers’ credit, which does not help the company in long-term survival
of the project. Availability of the working capital plays a critical role.

Improvement in sugarcane yield per hectare, increase in sucrose content, maximum

utilization of plant capacities and, above all, availability and efficient use of working

8
capital will help the country in the production of surplus sugar during the next three
years as shown in table I.

Previous Crop Crisis 1999-2000

Sugarcane production - Total 46,363,000 tons = 100%

Crushed by 67 Sugar Mills 28,982,711 tons = 62.5%
Diverted for Seed and Gur making 17,380,289 tons = 37.5%
Total Sugarcane 46,363,000 tons = 100%
============ ====

Loss of production of refined Sugar due to excess quantity of raw cane diverted for seed
and Gur manufacturing (37.5% instead of 25%) works out to 482,269 tons that could
have made available possible a total sugar production of 2,911,633 tons both from cane
and beet. Under such avoidable circumstances, the country could have needed to import
only about 113,587 tons, which might result to save precious foreign exchange of
approximately $ 208.830 million. Advance planning to foresee the situation for the
previous year and control of proper utilization of cultivated sugarcane could have easily
avoided the current sugar bonanza.

Prospects and failure for the on-going season 2000-2001 (Nov. 2000 to Mar 2001)

According to Agriculture Ministry sugarcane has been planted on 926,000 hectares. It

means that there is reduction of 84,000 hectares in cane-cultivated area by 8.3%. The
crop position for the on going season is estimated as follows:

Sugarcane production at avg. yield (926000 Ha @ 43.86 tons) 40,614,360 tons

Less diverted for seed and Gur making @ 25% standard 10,153,590 tons
Balance available for crushing = @ 75% 30,460,770 ton
White spoon sugar at avg. recovery of 8.62% (max) 2,625,718 tons
Avg.sugar production from Beet 13,352 tons
Total Minimum target 2,639,070 tons
Annual estimated Domestic demand 3,100,680 tons
Minimum short fall (461,610 tons)
===========

Past Five Year Performance of Three Public Sector Companies

There are 38 public limited companies listed with Karachi Stock Exchange. Out of
these, three companies viz-a-viz Dewan, Fecto and Crescent have been selected as
sample companies whose average selling price of sugar and cost for the last five years

from 1995 to 1999 are provided in table IV.

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 Table IV: Average Sales and Cost Price (Ex-mill) Per Ton
Sample Companies Selling Price(Rs) Cost (Ex-mill) Rs.

Dewan 15,011 14,791

Fecto 14,589 14,785
Crescent 15,082 15,144

Year wise selling and cost price of these three combined companies are shown in table V
which indicates that cost per ton of sugar had gone up to Rs. 17,775 in 1996-97
representing 67.3% increase from the base year. However, the average retail price of
sugar in the open market during this year was Rs. 21.26 against of the price of Rs.16.76
for the previous year as shown in table VI.

Table V: Yearwise Sales and Cost Price Per Ton of Sample Companies and
Yearly Increase from the Base Year
Sales Price % Increase Cost Price % Increase
Year Per ton from Base Year Per ton from Base year
Rs 1994-95 Rs 1994-95
1994-95 11,670 - 10,624 -
1995-96 14,630 25.4 13,454 26.6
1996-97 14,099 20.8 17,775 67.3
1997-98 18,274 56.6 16,053 51.1
1998-99 15,585 33.5 16,234 52.8

Average selling price of white crystal sugar of three combined sample companies in
public sector for the period of five years from 1995 to 1999 has been worked out to Rs.
14,920 per ton while their combined average cost arrived at Rs. 14,850 per ton. This
shows that these producers of sweetner commodity for human body have not only
survived in crisis of this political industry which had been emerged from year to year but
also slightly crossed the break-even point as reported in the consolidated marginal
Income Statement as well as graph showing break-even point of three companies for 5-
years from 1995 to 1999. They appear to be good performance companies from the view
point of cost control amidst peculiar crisis due to political

decisions predominantly taken due to its status of being political industry.

10
 Consolidated Marginal Income Statement
Rs. “000” %
Sales Revenue 13035929 100
Less: Variable Costs 10380213 80
Marginal Income 2655716 20
Less: Fixed Costs 2595053 20
Operating Profit 60663 0
====== ===

Fixation of Sugarcane Support Price and System of Payment of Quality Premium

Sugarcane growers are negatively motivated for earning more money based on price
structure ignoring the importance of adopting recent technologies for increasing yield of
sugarcane per hectare thus hampering the national economy. Late maturing and better
quality cane is being produced of unapproved variety. Sugarcane growers interested in
growing good quality cane are being discouraged due to existing payment procedure of
quality premium based on average recovery of bad and good cane both thus benefiting
those who are growing bad quality cane of unapproved varieties at the cost of good
grower planting good quality cane. As shown in table VI sugarcane support price for the
season 1997-98 increased to Rs.36 per 40 kg as against the previous season price of
Rs.24.50 per 40 kg thereby shooting by 46.94% in Sindh. However, sugar had been sold
in the open market at retail price of Rs.19.54 per kg during 1997-98 as compared to
Rs.21.26 per kg in the previous year. In India sugar cane price at the mill gate is Rs. 19
per 40 kg while retail price of sugar in that country is Rs. 18 per kilo.

The Government should take up cost studies at the growing sugarcane stage for the
purpose of fixing the support price for the growers. Cost studies for production of refined
sugar both in terms of variable cost and fixed cost of production in each sugar mill,
should also be undertaken to control the retail prices. Cost audit rules and compulsory
maintenance of cost accounting records for sugar industry, in line with the international
cost accounting models in other countries of the world, will prove to be a great help in
this direction.

Cost audit should be taken p both in letter and spirit. Cost audit is not punitive in nature.
It is rather suggestive and derives its force from the maxim ‘prevention is better than
cure’. It identifies areas of weaknesses, invisible losses and unaccounted inefficiencies
which ultimately result in adverse effects on the financial health of an organization. Cost
audit helps in getting early warning signals for remedial action. We have experienced a
horrible national indebtedness, massive default of bank loans and failure of corporate
sector on account of mismanagement of national resources.

Comparison of Cane Support Prices with Sugar Price

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Table VI: Yearwise Sugar and Sugarcane Prices 1989-90 to 1999-2000 compared
with average price of sugar in open market.
Average
Actual
Year Sindh % Punjab % Quality % Price per %
Rs/40kg change & change premium change kg change
NWFP (open
market)
1989-90 14.00 - 13.75 - 0.19 - 11.76 -
1990-91 15.75 12.50 15.25 10.90 0.19 - 11.26 (4.25)
1991-92 17.00 7.94 16.75 9.83 0.22 15.79 11.62 3.20
1992-93 17.75 4.41 17.50 4.48 0.22 0.00 12.29 5.76
1993-94 18.25 2.82 18.00 2.86 0.22 0.00 12.91 5.04
1994-95 20.75 13.70 20.50 13.89 0.27 22.73 13.74 6.43
1995-96 21.75 4.82 21.50 4.88 0.27 0.00 16.76 21.98
1996-97 24.50 12.64 24.25 12.79 0.27 0.00 21.26 26.85
1997-98 36.00 46.94 35.00 44.33 0.32 18.52 19.54 (8.09)
1998-99 36.00 0.00 35.00 0.00 0.50 56.25 19.09 (2.30)
1999-00 36.00 0.00 35.00 0.00 0.50 0.00 20.53 7.54
Source: PSMA Report 1999 Economic survey 99-00

Sugar Trade A Source of Forex Earnings

Table VII: Balance of Sugar Trade – Imports VS Exports

IMPORTS EXPORTS BALANCE OF TRADE
FISCAL Tons Value Tons Value Tons Value
YEAR ”000”Rs “000”Rs “000”Rs
1993-94 47669 444105 121565 1204964 73896 760859 Favourable
1994-95 5188 68761 315886 3770558 310698 3701797 Favourable
1995-96 3214 50239 29134 350066 25920 299827 Favourable
1996-97 681083 9861825 - - (681083) (9861825) Adverse
1997-98 110990 1685859 210632 2897750 99642 1211891 Favourable
1998-99 10097 152591 906602 11549170 896505 11396579 Favourable
Sub-Total 858241 12263380 1583819 19772508 725578 7509128 Favourable
1999-00*
Arrived by 720000
15/11/2000
In transit 80000
Brown Sugar 100000 13509000 Nil Nil (900000) (13509000) Adverse
Total L/Cs 900000
opened
Grand Total 25772380 19772508 (5999872) Adverse

Table VII shows that net amount of foreign exchange amounting to Rs. 7.509 billion
saved as a result of total exports of Rs.19.772 billion during the last six years from 1994
to 1999 has been eaten away by the import of 900,000 tons during the current year 1999-
2000 estimated to cost Rs.13.509 billion to the government exchequer. In other words
this huge amount of Rs. 13.509 billion nullified the foreign exchange savings as a result
of surplus production of wheat for the import of sugar. Pakistan’ agrarian economy thus
faced negative compulsions.

12
Contribution in Government Revenue

Sugar industry’s average annual contribution to the Government exchequer in respect of

Federal Excise duty of Rs. 5,430 million represents 11.2% of the total average of Federal
Excise duty collection for the last 9-years as reflected in table VIII.

The estimated sugar production for the current season facing the series of crisis is
worked out to 2.128 million tons, which may contribute GST between Rs. 4.468 billion
to Rs. 4.915 billion. Hence the government revenue from sugar
industry will decline by 18% for the year 2000-2001.

Table VIII:
Revenue from
Sugar
industry Federal Excise Sugar Industry
Fiscal Year Rs. Million Duty Collection Contribution
July - June Rs. Million %

1991-92 4,540 30,334 15.0

1992-93 5,100 35,169 14.5
1993-94 5,445 34,591 15.8
1994-95 5,552 43,691 12.7
1995-96 5,831 51,104 11.4
1996-97 5,000 55,297 9.0
1997-98 (Est) 4,920 62,011 7.9
1998-99 (Est) 7,415 60,904 12.2
1999-00 (Est) 5,071 63,000 8.0
Total 48,874 436,029
===== ======

Average P.A. 5,430 48,448 11..2%

Source: Economic Survey 1999-2000

By-products of Sugar – Equally lucrative and a source of foreign exchange earnings

In Pakistan around 70% of the molasses produced is exported. During the last 12 years
from 1988 to 1999 a quantity of 12 million tons of molasses exported valuing more than
Rs. 16 billion. This shows that sugar industry exports about One million tons of
molasses earning a foreign exchange of Rs. 1.3 billion per annum.

The remainder of molasses is used for industrial alcohol and poultry feeds. The bye-
product of molasses, is exported in raw as well as processed form. The processed form
of molasses is industrial alcohol. Pakistan had made export of fermentation ethyl alcohol
(not denatured) of 71 million litres valuing Rs.718 million during the last 12-years

13
from1988 to1999. From these statistics we can say that sugar industry exports 6 million
litres valuing average forex earnings of Rs.60 million per annum.

If all molasses is converted into alcohol, the country could earn more foreign exchange
through its exports; or if blended with gasoline will provide gasolhol, which may reduce
oil import bill to some extent.

Middlemen making Pakistani Sugar Costlier

Those sugar mills who were in operation in the previous season are also striving hard for
working capital finance for purchase of cane and initial start up expenses for the cane
crushing. Some of the sugar mills are forced to make agreements with the middlemen
who would purchase sugarcane from the growers at the rate of Rs.36 per 40 kg on
commission basis and sell it out at the rate of Rs.40 to Rs. 55 to sugar mills. Such
middlemen also receive commission from cane growers and pay to poor growers lesser
than the support price. This situation would definitely increase the ex-factory cost of
sugar production, which may be avoided if sugar mills are provided initial working
capital finance by the commercial banks.

It happened for the first time in the history of Pakistan that sugar an essential commodity
for human consumption as well as pharmaceutical products and other commercial usages
is sold at very exorbitant rates ranging from Rs. 27 to Rs. 40 per kilogram. As compared
to this, the retail price of sugar in India is not more than Rs. 18 per kilogram.

Gur manufacturing a cause of tax revenue losses

One of the major reasons for the shortfall in sugar production is Gur manufacturing. The
demand of Gur has increased for the last five years due to influx of Aghan refugees who
use Gur for meeting their nutritious requirement. But it should be noted that whitened
Gur is injurious to the health of human body due to use of unapproved chemicals to
change the colour of Gur to whitening.

In the previous season 1999-2000, the Government of Pakistan had lost more than Rs.
One billion towards sales tax revenue due to non-production of white spoon sugar of
about 482,269 tons.

The situation for current season is very much alarming which is heading to create a big
quantum of shortfall in sugar production. But here we restrict to the loss of white
crystalline refined sugar due to excess diversion of sugarcane by 12.5% for Gur
manufacturing. This will result a loss of white sugar production of 437,620 tons that will
render a minimum loss on account of sales tax revenue to the Government for the sum of
Rs.919 million to Rs.1011 million, which can be avoided easily by imposing restrictions
on Gur manufacturing above the 25% allowed standard both for seed and Gur.

Sugar Integrated Projects

14
In various countries of the world, sugar is produced through big sugar integrated estates.
In order to provide an interesting background for agro-industrial undertaking for one of
the largest project in the world and another which is the second largest in Africa the
profiles of these sugar giants are presented below:

The proposal for the development in the Sudan of one of the world’s largest integrated
sugar estates was formally accepted in June 1972. The underlying and at that time
original concept was to harness in a multinational project the resources of Arab oil
wealth, Western Technology and expertise and the fertile soils of Africa in order to
create a major agro-industrial undertaking that might serve the forerunner of others to
come and given the necessary infrastructure development, lead in the fullness of time to
the Sudan realizing its full agricultural export potential as the “Bread basket of the Arab
World.”

Following the signing of agreement between the Government of Sudan and Lonrho
Limited, a publicly quoted U K company, Kenana Sugar Company Limited was
incorporated in 1975. The immediate objective was the creation, on what was previously
scrubland of an irrigated sugarcane plantation with an area in excess of 35,300 hectares
together with associated infrastructure and a factory capable of crushing 17,000 metric
tons of cane per day to yield at full production upwards of 300,000 metric tons of sugar
per annum. Import substitution and the resultant savings in scarce foreign exchange were
primary considerations in the decision to proceed with the Project that was to become
Kenana and a major milestone, the achievement by the Sudan of self-sufficiency in sugar
production.

Kenana’s impact on the social and economic development of Sudan has been significant
in a number of areas:-

 Creation on a large scale of employment opportunities for Sudanese nationals.

 Reduction in the Sudan’s deficit in its balance of trade and balance of

payments on current account.

 Transfer of technology into the Sudan.

 Impetus to sugarcane research and development in the Sudan.

Some facts and figures about the Kenana Project will give a measure of the size of the
scheme and the magnitude of achievement in this agro-based industry.

Location: Near Rabak on the east bank of the White Nile, some 250 km south of
Khartoum and 1200 km from Port Sudan.

Irrigation Works: 4 Pump Stations, with a capacity of 44 cubic metres a second

and a total lift of between 40 and 43 metres, carry the waters of the White Nile
along 29 km of Main Canal to command the plantation area onto which they are

15
 fed by gravity along some 300 km of secondary canals following the contours of
the Estate.

Irrigation requirement: 800 million gallons per day.

Estate Roads: 250 km of major roads supplemented by a network of 1500 of

infield roads. Maximum length of cane haul to factory: 35 km.

Electricity Generation: During crop: 40 megawatts. Off-crop: 20 megawatts.

Harvesting: Mechanical 50%. Hand cut 50%.

Workforce: 6,000 permanent employees, with an additional 9,000 seasonal

workers engaged for the duration of the crop.

Crop Statistics per Season:

1. Area harvested 33,600 hectares

2. Yield per hectare 77.7 tons
3. Cane harvested 2.6 million tons
4. Sugar production 269000 tons
5. Sugar recovery as a percentage of cane crushed. 10.35%
6. Crushing season 154 days
7. Average Cane crushed per day 16800 tons

Profile of Second largest Sugar estate cum factory/refinery complex: The project
was commissioned by Tate Lyle PLC London which is number one sugar industry in the
world. This is known as Nakambala Sugar estate located some 100 km from Lusaka,
capital city of Zambia.

An integrated, irrigated cane sugar estate cum factory/refinery complex has the similar
infrastructure equivalent to about one third of Kanana Sugar estate of Sudan. The
Nakambala sugar estate plants cane on 10,000 hectares of land. Sugarcane of more than
1 million ton is harvested at average yield of 115 tons per hectare. The factory produces
132,000 tons of sugar at an average sucrose recovery of 12.15%. Every year increase in
plantation area is made in view of corresponding increase in the country’s population.
Management of the Zambia Sugar Company shoulders the challenging responsibility to
keep Zambia itself self-sufficient in sugar.

Exchange of Sugar Commodity with Crude Oil

The purpose for writing brief profile of large sugar estates operating in the world is
despite the fact that Pakistan does not have adequate means to introduce large scale
farming either at NGO level or Government level, or private sector, it may approach oil
producing countries to finance large scale cultivation in addition to 1.150 million
hectares owned by small growers. If Arab countries financiers such as Saudi Arabia,

16
Kuwait, Dubai, Abu Dhabi, Qatar, Bahrain, and Muscat develop an area of 13224
hectares, it will solve unemployment problem of rural population and reduce poverty.
Reason being is that the writer has observed that whether in abroad or Pakistan, smooth
production from sugar mills changes entirely the socio-economic development of the
specific area where a sugar mill operates. It brings prosperity for the rural population at
large as well as urban population at small.

Alternatively Islamic development Bank normally also finances such large-scale

cultivation projects under the Islamic mode of financing.

The sugarcane so produced from this scheme may be utilized by the under-utilized and or
closed sugar mills, which may give an additional output of refined sugar of 50,000 tons.
The commodity valuing $ 15 million may be exported to Arabian countries in exchange
of about half a million barrels of crude oil for Pakistan.

Sugar Industry Contribution in Large Scale Manufacturing and Gross Domestic

Product.

Sugar industry’s share during the last five years from 1996 to 2000 was Rs.249,629
million in large scale manufacturing of Rs. 1,394,461 million, which in term of average
percentage is 18%. Pakistan’s total GDP at market prices for these five years was
Rs.13,364,078 million, out of which sugar industry’s average contribution was 1.9%.
These indicators clearly show the incredible performance of sugar industrial sector
performance in national economy. Year wise indicators are provided in table IX.

Table IX:

17
 Value of Sugar
large Total industry
Avg. Cost of scale Sugar Gross Contribu
Sugar market sugar at mfg at industry Domestic tion
Production price current current Contribu- Prod at In GDP
(excluding per ton market Factor- tion in Market at
Beet) prices. cost LSM Price Market
Rs. Rs. Rs. Rs. price
Year Tons Million Million Million % Million %

1995-96 2,449,598 14,630 35838 226,482 15.8 2,141,842 1.7

1996-97 2,378,751 14,099 33538 255,798 13.1 2,457,381 1.4
1997-98 3,548,953 18,274 64854 284,725 22.8 2,677,656 2.4
1998-99 3,530,931 15,585 55030 308,110 17.9 2,913,514 1.9
1999-00 2,414,746 25,000 60369 319,346 18.9 3,173,685 1.9
Source: Pakistan Economic Survey 1999-2000
FC: Factor cost MP: Market price LSM: Large scale manufacturing

CONCLUSION

Hard ground reality is that under the limiting economic factors affecting the sugar
industry such as area under cultivation, lower yield, low sucrose recovery compounded
by the arrear of cane growers payments, increasing trend of closure of sugar mills owing
to multiple causes, lack of working capital finance and above all diverting a big portion
of cane production for Gur manufacturing, it appears very difficult to meet the domestic
requirement. However with the proper utilization of poor cane crop for the season 2000-
2001, the situation for shortage of sugar may be reduced to 461,610 tons as computed
under prospects and failure and will definitely be met by importing this sweetener
commodity at the high international price of $ 248 per ton which needs a foreign
exchange of $ 114 million.

The situation would be worse and get out of control if 37.5% of cane production for the
on-going season is diverted for seed and Gur manufacturing instead of 25% estimate and
decline of sucrose content from average recovery of 8.62% to 8.33% as witnessed during
the previous crisis season 1999-2000. In that case shortfall of white sugar has been
worked out to 972,843 tons for which a hefty foreign exchange
of $ 241 million will be needed to import the sugar to feed a population of 140.94 million
during the year 2000-01.

Since de-zoning, the incentive of sugar mills to direct resources for development of good
variety cane in its area has almost diminished because the grower who have borrowed
money from a sugar mill for development is free to take his sugarcane to any mill
irrespective of which mill advanced the loan for development. It is also one of the causes
of sickness of sugar industry. Large interest of the growers of the area and those

18
associated with such project, which collapses due to non-availability of cane is badly
affected.

In this situation some mills who can not offer immediate hard cash payment to the
growers of its zone normally start starving for the raw material and are ultimately closed
which results collapse of an important national asset, loss of revenue to Government
exchequer, unemployment of the rural population living nearby such mill. Thus closure
of a sugar mill reduces GDP and increase poverty of masses.

The Government should seriously think about this critical problem and make remedial
measures alongwith those suggested below to avert the crisis in future.

a) Balanced policy for cultivation of four major cash crop – wheat, cotton, rice and
sugar. An incentive should be provided to the growers for cultivation of
sugarcane on 1.150 million hectares.

b) Indian variety of seed which has totally degenerated and diseased affect the
production yield should be avoided. Instead the government should import high-
yielding varieties of sugarcane from other countries for averting any sugar crisis
in the future.

c) The government should make a publicity campaign for minimizing use of Gur
so that a substantial quantity of cane becomes available for crushing and making
white spoon sugar.

d) The State Bank of Pakistan should earmark a sum of about Rs. 2.7 billion and
direct all commercial banks to finance working capital requirement of operating
sugar mills in every season through proper and vigilant loaning methods.

e) Sales Tax @ 15% is fixed on ex-factory price of Rs. 14 per kilo in case of
supplies to registered person. A move to charge the sales tax on the price other
than the fixed price of Rs.14/= will further create problem for the consumers
whose purchasing power is already very low due to industrial sluggishness and
stagnant economy. It is suggested that sales tax should not be charged on market
price.

f) The Government should impose restrictions on excess production of Gur

equivalent to 12.5% of the expected cane production of 40.614 million tons
from the current year crop 2000=2001 to reduce the shortage of sugar in the
country as well as earn sales tax revenue of more than one billion Rupees.

g) The support prices of sugarcane can not work at all through the free market forces
due to the simple reason that retail price of sugar is controlled by the Government
and further, the support prices of other cash crops such as wheat, rice and cotton
are also fixed by the Government. Two economic theories (1) principle of supply

19
 and demand governed by market forces and (2) Government control of retail
price can not work together and will further widen the sugar crisis in the country.

h) The provincial Governments should fix the support price of Rs.40 per 40 kg
for purchase of sugarcane at the factory gate as well as at the cane purchase
centres under section 16 of the Sugar Factories Control Act, 1950.

The writer is Director Research of

Institute of Cost and Management
Accountants of Pakistan (ICMAP)

ABOUT THE AUTHOR

Mr. Syed Jamil Ahmed Rizvi is a fellow member of ICMAP. He served in the second
largest sugar integrated project of Africa jointly owned by Tate & Lyle PLC U.K.
and Government of Zambia. He also served in one of the largest sugar integrated
project of the world which is located in Sudan. In Pakistan he worked in five sugar mills
in Government and Public Sector Companies. Mr. Jamil Rizvi had done consultancy
work in private sector sugar companies. He normally contributes research based
articles. He wrote research based study on Role of Micro Credit in the Economic
Revival and Poverty Alleviation. Mr. Rizvi has written research report on the Role of
Small and Medium Enterprises in GDP and Macro Economic Development of Pakistan
and comparative research case study of SAARC and South Asian Countries on General
Sales Tax or Value Added Tax under the joint research programme of ICMAP and
FPCCI. He also contributes article for leading newspaper and Pakistan Gulf &
Economist.

INSTITUTE OF COST AND MANAGEMENT ACCOUNTANTS OF PAKISTAN

20
NO. SJAR/Aart.Sugar/Memo-19 December 12, 2000

MEMORANDUM

To: Badruddin Fakhri Saheb From: Syed Jamil Ahmed Rizvi

CC: Executive Director

Subject: Article on Sugar Industry in Pakistan - Problems, Potentials

Please refer to your discussion on the above subject. Indeed it is a matter of great
pleasure for me to write a research-based article on sugar industry’s crisis prevailing very
dangerously these days, which has engulfed the agro-based industrial sector. Farmers
have started burning their standing cane crops. Every day sugar mills are being closed
after sustaining of colossal losses in the initial heating of boilers with furnace oil. The
Government has adopted two parallel economic theories, which will further widen the
crisis. The situation is so burning that is very difficult to control simply due to lack of
planning and vision for the on-going season. The blunder mistake was that sugarcane
support price was not increased by the Government and let this governed by the free
market forces while Economic Coordination Committee (ECC) has been trying to control
the retail price of sugar by import.

Keeping in mind the sensitive nature and the current gravity of situation of the second
largest industry after textiles, I have tried my level best to cover various factors affecting
the destruction of this important contributor in large-scale industries, Government
revenues and GDP. I have used deep research methodology highlighting problems with
their simultaneous solutions so as to make the reader understand the real situation.
However, solutions have also been summarized in conclusion. Since the article is not
only informative, it is built-up on the reliable facts and figures which made it lengthy.
Due to its comprehensiveness a synopsis and headlines have been prepared. Tables and
graphs have also been provided to support the write up and depicting the picture in a
simple and quick understanding by a normal reader. The contents summary is given
below:

Contents Page

A. Synopsis 1-2

B. Headlines 3

C. Introduction 4-5

21
D. Sugar Mills’ Capacity 5-6

E. Table II Sugarcane Cultivation, Crushing and Sugar

Production 1986 – 2000. 7

F. Sugarcane Production Yield and Sucrose Recovery 7-8

G. Initial Working Capital 8-9

H. Previous Crop Crisis 1999 – 2000 9

I. Prospects and Failure for the on-going Season 9

J. Past Five Years Performance of Three Public Sector Companies 9 - 11

K. Fixation of Sugarcane Support Price and System of

Quality Premium. 11

L. Comparison of Cane Support Prices with Sugar Price 12

M. Sugar Trade a Source of Forex Earnings 12 - 13

N. Contribution in Government Revenue 13

O. Bye-products of Sugar – Equally Lucrative and a Source

of Foreign Exchange Earnings 13 - 14

P. Middlemen making Pakistani Sugar Costlier 14

Q. Gur Manufacturing a Cause of Tax Revenue Losses 14 - 15

R. World Sugar Integrated Projects 15 - 16

S. Exchange of Sugar Commodity with Crude Oil 17

T. Sugar Industry Contribution in LSM & GDP 17 - 18

U. Conclusion 18 - 20

V. About the Author 20

W. Graph I – Population Growth 21

X. Graph IA – Domestic Sugar Consumption 21

22
Y. Graph Sugar Industry Contribution in LSM 22

Z. Break Even Chart of 3 Sample Companies’ Consolidated

Operations for 5 Years from 1995 – 1999 23

Hope you will find the article interesting. You will agree with me when I say that
immediate printing not later than 7 days may only be useful for this hot burning topic
otherwise late printing will loose its utility. Reason being is that the topic is not
academic. It is the practical phenomenon, which the country is facing and very difficult
for the government to control the situation. The topic is that of general, public interest,
Labour, Government, growers, sugar-mills, banks, DFIs and tax authorities.

Normally a research based article or case study takes minimum period of 3 to 4 months
for national cause and 6 to 9 months for International Publication. But for completing
this task within such a short time I am personally grateful for the prompt and active
cooperation of three good performing public quoted companies – Fecto, Dewan and
Crescent sugar who have provided their five year published accounts. Pakistan Sugar
Mills Association, Sindh Zone has provided their five years annual reports very quickly.
Special thanks to Finance Manager as well as General Manager of Fecto Sugar Mills for
providing various data are acknowledged.

It is worth mentioning that Mr. Muhammad Nasiruddin Ahmed, a senior fellow member
of ICMAP who has 38 years financial and management accounting experience as
Manager Operations Accounting, Head of Group Accounting, Head of Group Financial
Analysis and Superintendent – Accounting Research in Zambia Consolidated Copper
Mines Limited, which is a major player in the Zambia economy contributing between 70-
80 percent of GDP has also reviewed the article and gave his useful suggestions in its
presentation.

Hard labour rendered by Mr. Azhar Hasan Farooqi, P.S. to Director Research and other
staff are highly appreciated in assisting me for preparation of this article.

Thanks and best regards,

Syed Jamil Ahmed Rizvi, FCMA

Director Research

23
 Graph I - Population Growth

160
140
120
100
Population 80
in Million
People 60
40
20
0
1981

1991

1999

2000

2001

2002

2003

2004

2005
Year

Graph IA - Domestic Sugar Consumption

4
3.5
3
Domestic Sugar
Consumption in 2.5
Million Tons
2
1.5
Available Sugar
Production 1
Capacity in Million
Tons (Excld. 0.5
Beet)
0
1999 2000 2001 2002 2003 2004 2005
Year

Availability Sugar capacity in 1999 and 2000 represents actual capacity utilized

24
 SUGAR INDUSTRY CONTRIBUTION IN LARGE SCALE
MANUFACTURING

350000

300000

250000

200000

150000

100000

50000

0
1995-96 1996-97 1997-98 1998-99 1999-00

Value of Large Scale Manufacturing at Current Factor Cost (Rs. Million)

Cost of Sugar at Current Market Price (Rs. Million)

25