Chapter 1: Harvesting and Transport of Sugarcane

• Sugar production begins with the cultivation and harvesting of sugarcane.

• Sugarcane takes about 10–14 months to mature.

• When fully grown, it is harvested manually or using machines.

• Farmers cut the cane close to the ground to get maximum sugar content.

• The harvested cane is tied into bundles and loaded onto trucks or tractors.

• It is transported quickly to the sugar factory to prevent loss of sugar.

• Freshness is very important because sugar content decreases after cutting.

Chapter 2: Crushing and Juice Extraction

• Once the sugarcane reaches the factory, juice is extracted.

• The cane is washed to remove dirt and sand.

• It is cut into small pieces by cutters.

• These pieces pass through heavy rollers.

• The rollers crush the cane and squeeze out the juice.

• Water is sprayed to extract more juice (imbibition process).

• After crushing, the leftover dry material is called bagasse, which is used as fuel in factories.

Chapter 3: Purification and Clarification of Juice

• The extracted juice contains many impurities and must be cleaned.

• Lime and chemicals are added to the juice.

• The juice is heated in large tanks.

• Impurities settle at the bottom as sludge.

• Clear juice is separated from waste material.

• This process is called clarification. It improves the color and quality of sugar.

Chapter 4: Evaporation and Crystallization

• In this stage, water is removed and sugar crystals are formed.

• Evaporation

• Clear juice is heated in evaporators.

• Water is boiled off.

• Juice becomes thick syrup.

• Crystallization

• Syrup is boiled in vacuum pans.

• Sugar crystals start forming.

• The mixture becomes thick and grainy.

• This stage decides the size and quality of sugar crystals.

Chapter 5: Centrifuging, Drying, and Packaging

• This is the final stage of sugar production.

• Centrifuging

• Crystallized syrup is put into centrifuge machines.

• Machines spin at high speed.

• Molasses is separated from sugar crystals.

• Drying

• Wet sugar is dried using hot air.

• Moisture is removed.

• Packaging

• Dry sugar is graded by size.

• Packed into bags (1 kg, 5 kg, 50 kg, etc.).

• Stored in warehouses or sent to markets.

• Now, sugar is ready for consumption.

Chapter 6: By-products of Sugar Manufacturing

• Sugar production also creates useful by-products.

• Bagasse

• Used as fuel in boilers.

• Generates electricity.

• Molasses

• Used to make alcohol and ethanol.

• Used in animal feed.

• Press Mud

• Used as fertilizer.

These by-products help reduce waste and increase profits.

Summary: Steps in Sugar Manufacturing

• Harvesting sugarcane

• Crushing and juice extraction

• Juice purification

• Evaporation and crystallization

• Centrifuging, drying, and packing

• Use of by-products

This process converts fresh sugarcane into pure white sugar.

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