SUGAR

 MANUFACTURING  
PROCESS  
 SUGAR  
•  General  term  indica-ng  sweet  carbohydrates  
•  Mono-­‐,  di-­‐  and  poly-­‐saccharides  
•  Obtained  from  plant,  largely  sugarcane  and  
sugar  beet  plant  
•  Sugar  consists  of  several  types  as  seen  from  
the  standard  of  whiteness  through  ICUMSA  
(Interna'onal  Commission  for  Uniform  
Methods  of  Sugar  For  Analysis)  
 SUGAR  
•  Three  types  of  sugar  in  Indonesia:  
ü Raw  sugar,  ICUMSA value : 600 – 1200 IU  
ü White  sugar  
•  White sugar 1, ICUMSA value : 250 IU
•  White sugar 2, ICUMSA value : 250 – 350 IU
•  White sugar 3, ICUMSA value : 350 – 450 IU  
ü Refined  sugar  
•  Refined sugar 1, ICUMSA value : < 45 IU
•  Refined sugar 2, ICUMSA value : 46 – 80 IU
 
MANUFACTURING  PROCESS  
 Harves-ng  of  Sugarcane  
•  Fully  mature  
•  Two  types:    
–  Manual  
–  mechanical  
 Transport  and  Handling  
•  Animal  driven  carts  
•  Trolleys  
•  Trucks  
 Material  Handling  and  Storage  
•  Stored  in  cane  yards  
•  Carried  from  cane  yard  to  feeding  area  by:  
–  Hook/chain  
–  Cranes  
–  Reelings  
–  Conveyer  belt  
–  Carry  
–  Huge  suc-on  truck  
Washing  
 CuMng  of  Canes  
•  To  aid  the  cane  crushing  
•  Cane  knives  to  cut  cane  into  small  pieces  
 Shredding  
•  To  remove  leaves  and  nodes  
•  Hammer  mill  shredder  
EXTRACTION  OF  JUICE  
 CRUSHING  
•  Cane  crushed  to  
break  hard  stucture  
•  Cells  containing  
juice  are  ruptured  
•  Increase  efficiency  
of  juice  extrac-on  
•  Subjected  to  crusher  
with  corrugated  
blades  
 
 MILLING  
•  3  roller  mills  
connected  in  
ceries:  
–  Top  roller  
–  Feed  roller  
–  Discharge  roller  
•  5-­‐7  in  number  
•  Extract  the  juice  
from  crushed  cane  
Water  inhibi=on  
PRODUCTS  OF  MILLS  
 USE  OF  BAGASSE  
•  Stored  in  bagasse  storage  
•  Used  as  fuel  to  generate  steam  
•  Steam  used  for:  
–  Genera-ng  electricity  
–  Evapora-on  of  juice  before  crystalliza-on  
 CLARIFICATION/DEFECATION  
•  To  remove  non-­‐sugars  and  impuri-es  
–  Liming  
–  Sulphita-on  
–  Phosphata-on  
–  Carbona-on  
 
 FILTRATION  
•  Mud  from  clarifier  
s-ll  contain  some  
residual  juice  
•  Filtered  to  extract  
residual  juice  in  
Rotary  Vacuum  
Filters  
 
 EVAPORATION  
•  Juice  evaporated  to  obtain  super  saturated  
solu-on  
•  Increase  concentra-on  of  juice  from  15  ᵒbrix  
to  65  ᵒbrix  
•  Juice  preheated  to  around  107  –  110  ᵒC  
•  Two  types  of  evaporatos  
–  Single  effect  evaporators  
–  Mul-ple  effect  evaporators  
 EVAPORATION  
•  Steam  used  to  evaporate  
juice  
•  1  liter  steam  to  evaporate  
4  liters  juice  
•  Steam  temperature  113  –  
130  ᵒC  at  1st  pan  and  55  ᵒC  
at  last  pan  
•  Each  subsequent  vessel  
with  decreasing  pressure  
•  Last  pan  being  under  
almost  a  total  vacuum  
Forward Feed Multiple-Effect Evaporators
T >  T2  >T3  
1  

P   1 >  P2  >  P3  

Vapor,  T1   Vapor,  T2   Vapor,  T3  

TF  
 

TS  
 
Mul-ple  Effect  Evaporator  
 CRYSTALLIZATION  
•  Carried  out  in  single  effect  high-­‐vacuum  boiling  
pans  
•  Brix  are  increased  from  65ᵒ  to  75ᵒ  by  boiling  at  60  
ᵒC  
•  Two  stages  of  crystalliza-on  
–  The  establishment  of  the  core  of  sugar  crystals  
–  The  growth  of  sugar  crystals  
•  Massecuite  
–  Mixture  of  crystals  and  mother  liquor  (molasses)  
resul-ng  from  the  crystalliza-on  
•  Transferred  to  crystallizer  at  low  temperature  
 CENTRIFUGATION  
•  Separate  sugar  from  molasses  
•  Centrifuge  operates  at  100  –  1800  rpm  
•  Molasses  pass  through  perfora-ons  
•  Sugar  crystals  are  washed  with  85ᵒC  
 DRYING  AND  PACKAGING  
•  Sugar  tumbled  
through  large  
cylindrical  dryers  
•  Sor-ng  
•  Packaging  
REFINING  
REFINERY  PROCESS  
RECEIVING  AND  STORAGE  
 AFFINATION  
•  Mixture  of  raw  sugar  with  high  purity  syrup  
(85  %)  called  magma  
•  Melt  outermost  layer  of  the  raw  sugar  crystal  
at  50  ᵒC  
•  Centrifuga-on  to  remove  resul-ng  syrup  from  
mel-ng  of  the  outer  layer  
 MELTING  
•  Affinated  sugar  
dissolved  with  hot  
condensate  to  
concentra-on  of  72  ᵒbrix  
•  Melted  at  85  ᵒC  in  batch  
or  con-nuous  melter  
 PURIFICATION  
•  Remelt  may  contain  some  impuri-es  and  
colorants  
•  Liming  
1.  Par-al  
2.  Complete  
•  Carboniza-on  
•  Colorants  remover  by  decoloriza-on  
 DECOLORIZATION  
•  Two  methods  
1.  Granular  ac-vated  
carbon  (GAC)  
2.  Ion  exchange  resine  
 
EVAPORATION  AND  CRYSTALLIZATION  
•  Sugar  syrup  evaporated  up  to  super  satura-on  
•  Crystalliza-on  
•  Centrifuga-on  to  obtain  refined  sugar  crystals  
 DRYING  AND  STORAGE  
•  Bucket  elevator  on  conveyor  
•  Hot  air  for  drying  
•  Sieving  
–  Fine,  medium  and  bold  grains  
•  Storage  in  godowns  
–  Cool,  dry,  moisture  and  odor  free  
 PACKAGING  
•  Containers  opaque,  air-ght,  moisture/odor  
proof  
•  Glass  canning  jars  or  cans  for  liquid  sugars  
 RAW  AND  REFINED  SUGAR  
•  Raw  sugar  
–  Obtained  directly  from  sugarcane  juice  without  
refining  
–  Most  natural  sugar  
–  Brown  in  color  due  to  molasses  
•  Refined  sugar  
–  Have  white  luster  and  transparent  
–  Bleached  to  remove  color  and  other  impuri-es  
 FACTORS  AFFECTING  SUGAR  
STORAGE  
•  Temperature  
•  Moisture  
•  Quality  of  sugar  
•  Light  
•  Grain  size  and  distribu-on  
•  Compression