Abstracts

By Aftab Ahmad
Chief Executive
Pangrio Sugar Mills Limited

Introduction

The urgency of discussing the issue of cost reduction was never so pertinent as it is today. Prices of sugar and molasses, in the local as well as world markets, are crashing down unabated while we continue to pile-up huge stocks of expensive sugar and molasses at our mills. No one knows, what future has in store for us during next season.

PSST deserves full compliments for pooling of resources to highlight the burning topics for discussion from its august platform.

Costs are key consideration for any investment decision not only in sugar-industry but in any business activity. Cost reduction, therefore, becomes corner-stone of cost management strategy. Because from here onwards, we can plan our profitability.

A review of literature on this subject shows that PSST itself, in past, has contributed significantly, through various seminars/workshops and annual conventions in form of research papers on energy conservation and optimization of milling performance. I can recall straight-away a paper entitled “Impact of effective maintenance management over milling performance” read in PSST Convention in 2004. Similarly, a research paper was presented in PSST Convention in 1966 on the topic of “Factors Affecting Cost of Operation”. Pakistan Sugar Mills Association has also been reviewing and compiling data/information on various issues including rising costs of production in its Annual Reports and other monographs.

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INTERNATIONAL SUGAR SCENRIO
AND
ITS CHALLENGES TO DOMESTIC INDUSTRY

By Mr..Sajid Hussain Naqvi
Chief Executive
Indus Sugar Mills Limited

Sugar prices are once again under great pressure from surplus stocks within the country and our immediate neighbor. Further increase in production of up to 20% is expected in the next season. What will be the prices then & what should we do are the natural questions in everybody’s minds concerned with sugar.

A CASE STUDY OF REGULAR AND IRREGULAR CRUSHING
AT LAAR SUGAR MILLS LTD.

By Altaf Waheed
R.D.

Last two crushing campaign i.e. season 2005-06 and 2006-07 were hit by shortage of sugarcane in sindh in general and district Thatta in particular.

In these two seasons supply was irregular in early part of the season resulting in long milling stopping while supply was sufficient to meet the crushing capacity in the later part of the season. Irregular crushing was considered to be 50% crushing means 100% capacity with Nil stoppage.

At Larr Sugar Mill a study was conducted to assess the impact of irregular crushing on various important control parameters of sugar processing.

The challenges in these parameters effect the quality of sugar and total losses. Any variation in total losses results in variation in cost of production. The effects of this change in cost of production is analyzed in the conclusion.

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By Mr. Muhammad Makki. (Chief Chemist)
& Mr. Sayed Sabir Raza.(General Manager)

The prevention of loss of sugar by entrainment, in vapours from multiple effect evaporators is very significant in considering today’s sugar’s production loss. This loss is very important from two aspects.

• Loss of sugar to drain means a non-recoverable monetary loss to mill owners.
• The sugar loss to condensation system will increase the pollution of spray ponds/cooling towers water to such an extent which reduces the temperature gradient difference and makes the system ineffective if no fresh water or a little fresh water is added to the system.

Due to installation of higher capacity plants this problem has emerged more severe in the first and last vessels of quadruple & quintuple evaporator sets.

Hamza Sugar Mills is the biggest sugar mill in Pakistan with a crushing capacity of 23500 T.C.D, having two process houses. Efforts were executed to install innovative designed arrestors at vapours cells & last effects of Quadruple evaporators sets in both the process houses i.e. Madina and Hamza process houses. These arrestors device is more effective whose efficiency never deteriorated with time. This paper deals with innovative designed of arrestors and their results having a direct impact on the performance of evaporators, turbines and boilers at Hamza Sugar Mills Tehsil Khanpur district Rahimyarkhan.

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By Mr. Muhammad Iqbal Javaid
General Manager(Technical)
Shahtaj Sugar Mills Ltd.
Mandi Bahauddin

Circulation of juice through cush-cush either in the form of loose juice or soaked in cush cush is a standard phenomena in milling. A study has been made to qualify the amount of cush-cush, its pol percentage and possible recovery of juice from cush-cush. Further methodology to separate the juice from Cush Cush by a three rollers mill dia 500 mm x 700 mm and its impact on sugarcane milling efficiency will also be discussed.

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By Ranjit Singh Saluja

This Australian Technology is being practiced widely in Indian Sugar Mills. Paper describes the basic fundamentals of feed ability of Mill and then it explains why this Technology is more Economical & Technically viable. Paper also describes the Lotus Design of these Rollers, which further improves the Technical results of Power Consumption and over all extraction. The system is best suited, where capacity increases up to 20-25% is desired in Conventional Mill without significant increase in Mill turbine capacity with least Expenditure. 

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By Noor Ullah Khan (ASO, Agricultural Research Institute (ARI) )
    & Ghulam Rasool (Research Officer, Dera Ismail Khan)

The ratooning ability of 12 sugarcane candidate varieties was studied under agro-ecological conditions of D.I.Khan for two years during 2003-05 and 2004-06. The experiment was conducted at Agricultural Research Institute (ARI), D.I.Khan. During 2003-05 ratoon crops, variety S-96-SP-302 produced statistically significant higher cane yield of 79.39 t/ha-1 followed by variety CPHS-35 with cane yield of 76.55 t/ha-1 while the lowest cane yield of 41.94 t/ha-1 was recorded in varieties S-86-US-340 and NSG-311 respectively. During 2004-06 ratoon trial, NSG-311 and S-96-SP-302 performed best by variety CPHS-35 with cane yield of 67.61 t/ha-1 while the lowest cane yield of 34.17 t/ha-1 was recorded in Malakand-17.

In case of sugar recovery %, variety S-96-SP-302 was on the top of the list in 2003-05 ratoon trial by exhibiting the highest sugar recovery of 9.55% as against the minimum recovery of 8.04% noted in variety Q-88. While in 2004-06 ratoon crop the maximum significant sugar recovery of 10.26% was recorded in NSG-311 followed by CPHS-35 with sugar recovery of 9.80% as against the lowest sugar recovery of 7.93% noted in variety LRK-2001. Findings of the research revealed that candidate varieties S-96-SP-302, CPHS-35 and NsG-311 are better sugarcane ratooner varieties under agro-ecological conditions of D.I.Khan. Thus the farmer would get maximum return by maintaining these varieties as ratoon crop with better crop management practices at their fields.

Keywords:
Ratooning, Sugarcane, Varieties, Ratoon crop, Cane yield and Sugar recovery

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By *Dr. Muhammad Afzal, *Dr. Arshad Ali Chattha, *Javed Iqbal,
**Muhammad Bilal

Abstract
Sugarcane is a high nutrients uptake cash crop than other field crops. In addition to its huge requirements for NPK, it uptakes Aluminum, Boron, Calcium, Chloride, Copper, Iron, Magnesium, Manganese, Molybdenum, Sodium, Silicon, Sulphur and zinc in minor quantities. In Pakistan Zinc, Iron and Boron deficiencies are observed at some places and these micro-nutrients are being used. The time is not far-away when deficiencies for other trace elements will have to be dressed through soil or foliar applications. The deficiency symptoms of macro as well as micro-nutrient symptoms are noticed on leaves and canes. The disorders can often be identified visually. However, infectious diseases, chemical injuries, environmental stress (temperature, drought, flooding and lightning), over fertilization and nutritional imbalances make sometime inaccurate visual identifications. Yet efforts are made by different nutritional experts to identify such nutrient deficiencies on sugarcane plant in Pakistan and cane world. The deficiency symptoms are identified in the present study with photographs of symptoms.



* Sugarcane Research Institute, Faisalabad.
** Ph.D. Scholar, Deptt. of Agronomy, U.A.F.

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By *Dr. Shahid Bashir, *Dr. Arshad Ali  Chattha,
* Dr. Muhammad Afzal
*Javed Iqbal, *Muhammad Zafarullah Khan

Abstract
Response of ratooning ability of spring planted six varieties of sugarcane to different six harvesting dates was tested at Sugarcane Research Institute, Faisalabad during 2005-2006. Maximum cane yield was produced by the varieties CPF-237 (73.26 t ha-1), HSF-240 (72.91 t ha-1)   and  HSF-242 (74.31 t ha-1)  of ratoon crop from 1st February harvested plant crop.  As far as the quality is concern, all over the ratoon crop gave 27% more sugar yield over the fresh planted crop.

Keywords :  Sugarcane, Variety, ratooning, agronomic, characters, Pakistan.

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By *Dr. Arshad Ali Chattha, **Muhammad Bilal,
**Muhammad Umer, *Ghulam Mustafa Wains and *Fayyaz Ahmad

Introduction
Sugarcane is one of the important cash crops of Pakistan and it is an old energy source for human beings and more recently a replacement of fossil fuel for motor vehicles. Out of 12 major cane growing countries of the world, Brazil has highest area (5.34 m. ha). The largest cane producers are Brazil, India, China, Thailand and Pakistan, accounting for more than 50% of world production. Sugarcane production is 56.8 m.t. against the installed capacity of 68 million tones of the existing sugar mills as 70% is utilized by the mills, 20% is utilized for gur making which always has been more attractive and 10% is utilized for seed and fodder. The only 40 m.t. will be available for crushing thus there will be shortage of 28 m.t. To feed such a huge industry, cane production rather cane yield / ha will have to be increased from the existing area as the area cannot be increased due to competition with other crops. Thus 28 million tones more cane is required to run the industry satisfactorily. The yield will have to be increased from existing 53.21 t/ha to 66 t/ha to get required amount of cane for the industry. For this much vertical increase industrialists will have to think and manage the supply of quality cane. It is only possible if industrialists establish their own farms or take the farms on lease. Other-wise either they will have to purchase the costly cane by competing with each other. They have spent millions of rupees in the industry and millions of people are engaged in this industry. Many other industries like ethanol, feed, paper, confectioneries, vinegar, chipboard, win-board and ply etc. are dependent on this industry. Future is surely of sugarcane crop and therefore, of sugar industry. Hence, this industry can not be ignored.

* Sugarcane Research Institute, Faisalabad
** Ph.D. Scholars, U.A.F.

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By *Dr. Muhammad Azhar Munir, Dr. Muhammad Yasin,   Javed Iqbal,
**Muhammad Bilal and Dr. Arshad Ali Chattha

Abstract
The present study comprised of a field experiment with 24 sugarcane promising varieties having two sets (set-I and set-II) was conducted to compare their yield and quality in autumn season during 2004-05 & 2005-06.  The experiment was laidout in randomized complete block design with 3 repeats having net plot size of 5 x 9.6 m2.   The data revealed that all the varieties of set-I (13 varieties) gave significantly different yield from one another. The variety S96-SP-302 gave the maximum yield of 121.80 t ha-1 which was  statistically at par with S96-SP-1215 producing cane yield of 116.75 t ha-1 as against test varieties; HSF-240 and CPF-237 producing stripped cane yield of 99 and 104.5 t ha-1 , respectively.  S2002-US-637  and S2002-US-698 of  set-II (11 varieties ) gave higher yields of 109 and 105.5 t ha-1 than that of test varieties CPF-243 and SPF-245 producing can yields of 103 and 98 t ha-1 , respectively. 

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By Engr. Mohammad Sarfaraz Khan
Technical Manager
Bawany Sugar Mills Ltd.
(Dewan Mushtaq Group)
Talhar, District Badin.

Abstract
Energy Conservation is the most demanding, discussing and implementing issue in the current scenario of sugar industry. In fact, by and large, every management is willing to induct technological developments to improve their plant productivity at an optimum level. At present, this is being going-on with leaps & bounds.

Massive capitals are involved for the induction of such technologies. No-doubt marked influence will attain by the plants after such activities. As for as existing plants are concerns, there are lot of other areas full of efficiency improvement opportunities are needs to be concentrate for plant productivity.

In order to attain, optimum productivity in parallel with the induction of over seas technological developments, in-house activities will definitely enhance over all effectiveness. The presentation will broadly discuss steam distribution system and their allied features for energy efficiency improvements.

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By Ranjit Singh Saluja

Abstract

Steam Economy and Energy Conservation had been discussed at various platforms in Pakistan. But fact remains that practicability and difficulty in getting desired results have seldom been discussed. Author has tried to explain every measure with reference and methodology, so that these can be actually practiced. Author based on long experience in India, Pakistan & few other countries, has given some proposals, which have not been practiced in Pakistan Mill so far.

It is expected that by adopting these measures, a substantial saving in steam and power can be achieved. Some of proposals are tailored made and hence should be practiced only after study of all the implications.

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By Chris Henderson, FOSS Process Centre Pacific,
FOSS Pacific, 9 Eldershaw St, Everton Park, Qld 4053, Australia

Within the last few years the practical application of FOSS NIR technology to measurement of sugar cane parameters on-line offers sugar cane processors an automated and low cost analysis tool. FOSS NIR is installed in many countries to analyse core sampled cane or factory shredded cane and importantly is provided pre-calibrated with multiple analysis parameters. The technology can provide accurate “delivery by delivery” cane quality and composition results for sugar cane to, for example, improve process management and design, reduce operating costs, increase factory extraction and recovery. Feedback of objective information to growers and harvesting groups can improve delivered cane quality, reduce transportation costs and provide a basis for better on farm management. Information from NIR is used as an objective, approved cane quality measurement for payment. NIR is coming of age in practical application across the global sugar industry. 

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By Ghazanfar Ullah Khan
Director Technical
KSB Pumps Company Limited

The purpose of the paper is to draw attention of END USERS in sugar industry towards very simple nut important aspects of selection and operation related to pumps and pumping requirements. Based on experience gained through interaction with the sugar industry and after analysis of failures reported by the end users a set of generic recommendations have been compiled. As a step forward attention is drawn towards the concept of LIFE CYCLE COST which is essential for ensure resource optimization and for carrying out a cost benefit analysis on factual basis. Attention is always diverted towards common reason of failure which the author believes can be easily controlled and can results in

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By Muhammed Yousuf Khan
General Manager (Technical)
A Bawany Sugar Mills Limited

Whenever transfer of liquids in employed in a system a large number of variables are involved that result in a high energy loss. If an overall system is considered than an interesting situation is that though the efficiencies of the independent components appear to be high, yet the cumulative efficiency of the system is low this can be seen in the fallowing simple example:

• Pump Efficiency =0.65
• Transmission Efficiency =0.85
• Drive Efficiency =0.80
• Piping system Efficiency =0.7
• Accumulated Efficiency =0.65*0.85*0.8*0.7=0.33

This clearly shows that there is a strong case of energy conservation when a pumping system is involved. The article is written with an idea to discuss various aspects of Pumping phenomena, so that the need & scope of energy conservation in this area is properly appreciated. In this manner Pumping principles can be applied for total solution of Energy Conservation in a pumping system.

Energy losses in Centrifugal Pumps can be reduced by concentrating on the fallows areas.

• Application of pumping phenomenon and working principle such as cavitation and air binding, effects of properties of fluids and maintaining minimum flow.
• Selection of Pump type, Impeller type; Size and Speed, Diffuser or Volute Casing, correct assessment of specific speeds, suction head & system’s head.
• Maintenance to avoid: cavitation, continuous use of worn out impellers, defective pump casings, leakages due to shaft wearing and incorrectly selected sealing devices, improper repair, inappropriate mounting of bearings and other defects such as misalignment, imbalance, and uneven foundation, correct material selection& appropriate sizing of spares
  

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By
Engr. Abdul Aziz Tahir,
General Manager, Colony Sugar Mills Ltd.

Abstract
About ten years before, disposal of stacked Bagasse was a problem of a sugar factory, now it is a value able commodity, talking in Gaga Joules rather in tons because of its energy worth. A ton of cane enters the mills with energy content of 2.2 G Joules in the form of Bagasse, equivalent to 37% of the cane purchase price. Now it is the responsibility of the Technologist to save a considerable part of it during factory operations to shares the purchase cost of the cane. This paper is a bunch of tinny energy calculations related to unit operations and heat transfer steps involved in sugar making to show the impact of energy conservation on cost of production during milling operations.

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By M. Moinuddin Ali Khan
General Manager QAD
Peoples Steel Mills Limited

Abstract
According to Metals Handbook there are well over 100,000 engineering materials from which to choose. An incorrectly chosen material can lead not only to failure of the part but also to unnecessary cost. Selecting the best material for a part involves more than selecting a material that has the properties to provide the necessary performance in service; it is also intimately connected with the processing of the material into the finished part.
Experts suggests a four level approach to materials selection

• Level 1. Based on critical properties, determine whether the part will be made from metal, plastic, ceramic, or composite.
• Level II. Determine whether metal parts will be produced by a deformation process (wrought) or a casting process; for plastic determine whether they will be thermoplastic or thermosetting setting polymers.
• Level III. Narrow options to a broad category of material. Metals can be subdivided into categories such as carbon steel, stainless steel, and copper alloys.
• Level IV. Select a specific material according to a specific grade or specification.
  

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