Company founded 1975 US-based machinery business experienced in worldwide sales.

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Tinytech, 1000 Ton Per Month Sugar Cane Factory, Open Pan Boiling Technology

Description

  1. Overview
    1. Inventory number: E-6340
    2. 1000 ton per month sugar cane factory
    3. Ideally suited as captive unit for 100 acres of sugarcane plantation
    4. Process based on open pan boiling technology with no complicated machinery
    5. Maintenance and repairing cost is almost negligible due to simple machinery, ensuring continuous working
    6. Sugar and concentrated sugar syrup are produced simultaneously
    7. Plant is flexible with different product combinations: sugar + concentrate, only concentrate, sugar + syrup, syrup only
    8. Combined recovery of sugar and concentrate is about 13 to 14%, more than industrial giant sugar factories
    9. Sulfur or other harmful chemicals are not used in the process
    10. Natural sugar and natural concentrate free from chemical contamination can get higher prices in the market
    11. Modern and scientific quality control techniques are used for quality
    12. Capital investment per ton of installed capacity is as low as 15% of a giant sugar mill, resulting in very low interest and depreciation costs
    13. No permanent civil construction is necessary; crushing, boiling and drying operations are carried out under the sky
    14. Only crystallization and centrifugation require a temporary roof
    15. Being a very small plant located in the farm itself, transport cost of sugarcane is negligible
    16. Cane cut in the field can go to crushing within 12 hours, giving better recovery as it does not allow time for the cane to dry
    17. Only 10 skilled persons are required to operate the plant
    18. Process is easy to understand and simple for training; even an illiterate person can grasp and master the technique of sugar making in one day
    19. If required, this plant can be moved elsewhere without much cost or loss of original construction expenses
    20. This small plant can open vast opportunities for downstream process industries consuming sugar and concentrate as raw materials
    21. These small plants contribute to rural development, provide employment, stimulate entrepreneurship and improve the standard of living in villages, ideally suitable for developing countries
  2. Milling And Clarification
    1. Sugarcane stalks are crushed in the mill with attached gear box to get cane juice
    2. Mill consists of three rollers: top roller, feed roller and bagasse roller
    3. Cane passes and is crushed first between top roller and feed roller, then immediately between top roller and bagasse roller
    4. The two rollers are adjustable
    5. Fine circular vee grooves provided on the rollers cause heavy extraction of juice and breakage of cane fibres producing fine bagasse
    6. Juice is transferred to a settling tank to separate mud and foreign matter impurities
    7. Juice goes to filtration for further clarification
    8. Juice is transferred by pump to an overhead tank from where it flows to the BEL (furnace with set of boiling pans) by gravity through pipes
  3. Juice Boiling
    1. Boiling pans are arranged on the tunnel type furnace (BEL) and juice is boiled in it
    2. Clarification process goes on while boiling
    3. On each BEL, complete set of boiling pans are arranged so that maximum heat is utilized for juice boiling
    4. Juice is first drawn to rectangular pan by opening a valve on the pipe line extending from the overhead juice tank to the boiling pans
    5. While heating and boiling the juice, a boiling process technician removes impurities and dirt by skimming as impurities accumulate on the surface of the boiling pan
    6. Herbal clarificants are sprinkled in the boiling pan frequently
    7. When required, dirt accumulated on the surface is removed by skimming
    8. As water evaporates from the juice, juice syrup is transferred from one pan to the other for greater concentration
    9. Ultimately sugar crystals are formed in the thick syrup
    10. Syrup is then transferred into crystallizer by ladles
    11. Control of juice boiling is a simple but ingenious process requiring some skill for maximum recovery of sugar and concentrate
    12. The process technician must be careful to transfer juice from pan to pan to ensure: maximum possible clarification of the juice, proper concentration of the juice into syrup and from syrup to massecuite, and development of bigger and maximum number of sugar crystals in the massecuite (RAB)
  4. Crystallizers
    1. The function of the crystallizers is to keep the RAB (thick slurry of cane juice boiled to about 90 Brix) in motion in the vessel so that it may not settle, may not form crust on the surface, may form sugar crystals while cooling, and sugar crystals may grow bigger
    2. The central shaft with four jaws arranged at 90 degree angle revolves very slowly at 3 RPM, keeping the mass in movement inside the crystallizer
    3. The seeding and cutting technique is the latest development for the crystallization processes
    4. A battery of crystallizers are required
  5. Centrifugal Machine
    1. This is a batch type machine which separates sugar and molasses by centrifugal action
    2. Liquid molasses pass through the very small holes of the screen fixed on the periphery, while sugar crystals bigger than the holes of the screen cannot pass through
    3. Sugar is retained inside the screen
    4. Sugar crystals are washed by a fine mist of water and steam sprinkling
    5. Sugar is then dried under the sun and the molasses is reboiled for concentrate making