A REPORT ON THE INSTITUTIONAL TRAINING
AT
VELLORE CO-OPERATIVE SUGAR MILLS LTD
AMMUNDI, THIRUVALAM, VELLORE - 632519
INSTITUTION TRAINING
Submitted for the partial fulfillment for the award of the degree
BACHELOR OF BUSINESS ADMINISTRATION
Submitted by
Ms. N. GOKULPRIYA
Register No-30522U08016
Department Of Business Administration
AUXILIUM COLLEGE (AUTONOMOUS)
(Accredited by NAAC with A+ grade with a CGPA of 3.55 out of 4)
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Vellore - 632006
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INDEX
S.NO TOPICS PAGENUMBER
1. INTRODUCTION 2-3
2. INDUSTRY PROFILE 4-6
3. COMPANY PROFILE 7-9
4. VISION AND MISSION 10-11
5. FUNCTIONS OF 12-14
DEPARTMENT
6. ORGANISATIONAL 15-16
STRUCTURE
7. HISTORY OF SUGAR 17-20
MILL
8. SUGAR PRODUCTION 21-34
9. CONCLUSION 35-36
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INTRODUCTION
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1. INTRODUCTION
In the Company place there is a good environment and
maintenance is good and neat. Organizational structure and staff
and non-staff are workers in the organization.
This place for internship is useful for the development of the
student and for me also and the staff mindfulness and good
manner in the organization. The organizational give the absolute
guidance and concern of higher management, perfect working
the staff and department. Internship duration offered to me is
based on sugar production and department help me also in the
organizational.
The organization has many departments in the factory, like the
Administration, Accounting, Logistics, Human Resources,
Production, Marketing departments of VELLORE CO-
OPERATIVE SUGAR MILL LTD.
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INDUSTRY
PROFILE
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2. INDUSTRYPROFILE
The Sugar industry is the foremost important agricultural-based
industry. Sugarcane is primarily processed to produce sugar,
animal feed, enzymes, fuel for the boilers and sugarcane bagasse
is normally used for the manufacture of pulp and paper products.
It consists of 50% cellulose, 27% polyose, 23% lignin, and
another minor component.
Sugar consumption rate is highest in India as shown in the
statistics received from USDA foreign agricultural service.
However as per production is concerned India has notched up to
2nd position following Brazil, the largest sugar producer in the
world.
Sugar is produced in 121 Countries and the global production
now exceeds 120 Million tons a year. Sugarcane produce 70% is
produced from sugarcane, a very tall grass with big stems which
is largely grown in the tropical countries.
The remaining 30% is produced from sugar beet, a root crop
resembling a large parsnip grown mostly in the temperate
regions of the north. It accounts for providing employment to
crores of thousands in the sugar trade, in the transport of sugar
mills. Currently there are about 4 million hectares of land under
sugarcane cultivation with an average yield of 70 tons per
hectare.
India is the largest producer of sugar including traditional
sugarcane sweeteners. Gur & Khandsari are consumed mostly
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by the rural population of the country.
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COMPANY
PROFILE
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3. COMPANY PROFILE:
Vellore Cooperative Sugar Mill is located at Ammundi, was
registered and established under Tamil Nadu Co-operative
societies act in May 1976. It commenced its operation during
1976 and commissioned with a crushing capacity of 1250 TCD
in March 1977.Trial crushing was taken from March 1977 to
May 1977 by crushing 15,000 M.T as maiden crushing season,
based on the cane potential and as per the recommendation of
the government of India.
The crushing of mills was expanded from 1250 TCD to 2500
TCD with a standard economical crushing capacity of 2500
TCD during the year 1989-1990.
The factory is located at Ammundi, Vellore, Katpadi (TK), and
Vellore District on an extent of 180 acres on Katpadi - Ranipet
State High.
Company Profile of VCSM
Name of the company Vellore Cooperative Sugar Mills
Status of the company Public trading concern.
Constitution of the firm Registered under company’s act
1956.
Production Sugar (L30, M30, S30) Molasses
Press Mud, Bagasse, Electricity.
Press Mud/Filter cake This is also another type of
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product. It is sold for Rs.250 Per
ton.
Sugar storing Capacity 2 lakhs Bags
The organizational machinery is highly mechanical in the
factory and it is used for cutting, pressing, and the process for
marking the sugar juice and sugar beet in the factory.
The organization has sugar cutting in order and cutting the grass
and root beer in the process. And grass is used for heating
purposes and molasses are also used for heating only in the
organization. In the process of heating the sugar juice has a PH
level of 70 Celsius degree they maintain the level in the two
pans for heating
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VISION AND
MISSION
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4. VISION AND MISSION:
VISION:
1. To emerge as a leading sugar manufacturing unit in the
state, creating growing value for the Indian economy and
Company’s stakeholders.
2. Ensure the raw materials security and better living
conditions for cane growers and develop sugar, renewable
energy and harmonious living between communities,
society and nation with responsibility for all stakeholders.
3. To have an eminent position in manufacturing and
supplying quality white refined sugar and allied products
and thereby play an important role in the economic and
social development of the country .
MISSION:
1. To achieve international standards of excellence in all
aspects of sugar manufacture and diversified business with
focus on customers.
2. To foster a culture of participation and innovation for
employee growth and contribution.
3. To cultivate high standards of business ethics and total
quality management for a strong corporate identity and
brand equity.
4. To attain leadership in developing, adopting and
assimilating state of the art technology for competitive
advantage.
5. To maximize creation of wealth, value and satisfaction for
the stakeholders.
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FUNCTIONS OF
DEPARTMENT
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5. FUNCTIONS OF DEPARTMENT
Vellore Cooperative Sugar Mill LTD have department and it
have place and transport facility in the company. The
departments are the Administration, Financing, Human
Resources, Procurement and Logistics, Marketing& Sales,
Production, Marketing Communication, Engineering
departments of Vellore Cooperative Sugar Mill LTD.
The commissioner of sugar has also been designated as Cane
Commissioner and has to enforce the provisions under
Sugarcane Control Order, 1966 and Tamil Nadu Sugar Factories
Control Act, 1949.The commission of Sugar looks after the
development and regulation of cane supply and supervises the
working of the Cooperative Sugar Mills.
As the main function of this Department is supervision and
coordination of the working of the Cooperative and Public
Sector Sugar Mills in the state, this Department has no direct
contact with the Public.
The Sugar Industry Tamil Nadu is an important agro-based
industry next to textile industry. It plays a major role in the
economic development of rural areas in Tamil Nadu.
The Director of sugar is the Head of the Department for
regulating and coordinating the various functions relating to the
sugar mills in the state.
The departments are administration, financial, production,
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chemist, engineer, cane manager in the industry.
In the department are Executive Director, Director, chief,
Deputy Chief, assistant /manager or superintendent and workers
in organization.
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ORGANIZATION
STRUCTURE
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The organizational structure has the department and main staff
and non-staff.
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HISTORY OF
SUGAR
COMPANY
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The discovery of sugar from sugarcane known as today is
derived and dates back unknown thousands of years. It is
thought to have originated in New Guinea, and was spread along
routes to Southeast Asia and India.
The process known for creating sugarcane out the juice and
boiling it into crystal was developed in India around 350 ACE.
Its cultivation was not introduced to Europe until the middle of
ages, when it was brought to Spain by Arabs.
Columbus took the plant, nearby help, to the West Indies, where
it began to thrive in an almost favorable climate. It was not until
the eighteenth century that sugarcane cultivation began in the
United States, where it was planted in the Southern climate of
New Orleans.
The very first refinery was built in New York City around 1790
and the industry was established by the 1830s. Earlier attempts
to create successful industry in the U.S. did not takeoff; from the
late 1830s when the first factory was built, until 1872, sugar
factories closed down almost as quickly as they had opened. It
was only in 1872 a factory, built in California successfully
produced sugar.
India is the second largest producer of sugarcane next to Brazil.
Presently, about 4 hectares of land is under sugarcane cultivation
with an average yield of 70 tons per hectares. India is the largest
single producer of sugar including traditional sweetness
products, Khandsari and Gur equivalent to 26 million tons raw
materials value followed by Brazil in second place at 18.5
million tons. Even with respect of White crystal sugar India has
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ranked No.1 position in 7 out of 10.
There are 582 sugar mills operating in India with an aggregate
installed capacity of 16.2 million tons of these 205 are in the
private sector 316 in the co-operative sector and 61in the public
sectors. The organization has to get the raw materials from the
farmer and this co-operative has two ways that is the private and
public sector in the organization.
The organization followed by individual farmers is together with
the group organization for doing the sugar mill. The products are
used as raw material in industries such as liming, bleach power,
these two products have been used for juice color change and
alcohol, plastics synthetics, rubber, pharmaceuticals and paper.
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SUGAR
PRODUCTION
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SUGAR MANUFACTURING PROCESS
SHREDDING:
The shredding breaks the fibrous stalks apart, bursting the cells
that contain the sweet juice. Following this the cane is crushed
through a series of rollers, separating the juice from the leftover
fibrous material. The leftover material is used to fuel the mills
further.
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MILLING:
At the mill, the sugarcane is crushed by large rollers. The
extracted juice is then clarified to remove soil and impurities.
This juice is concentrated into syrup by boiling of excess water,
seeded with raw sugar crystals in a vacuum pan and boiled until
sugar crystals have formed or grown.
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LIMING:
Lime is used in sugar production when purifying the juice from
beet or cane sugar. Beet is sliced up and passed through a
diffuser to extract the sugar juice. Limestone is used in the
production process for this essential operation.
PRIMARY HEATING:
Mixed juice obtained from mills house is weighed on a weighing
scale. After weighting, the juice goes into juice heaters where it
is heated up to 70 degree Celsius. This is known as primary
heating.
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PROCESS:
A) SUGAR
EXTRACTION OF JUICE:
The Sugarcane is passed through preparatory devices like knives
for cutting the stalks into fine chips before being subjected to
crushing in a milling tandem comprising 4 to 6 roller mills. In
the best milling practice, more that 95% of the sugar of cane is
extracted into the juice.
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CLARIFICATION:
The treated juice on boiling is fed to a continuous clarifier from
which the clear juice is decanted while the settled impurities
known as mud is sent to a rotary drum vacuum filter for
unwanted stuff called filter cake .It is discarded or returned to
the field as fertilizer.
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EVAPORATION:
The syrup will again have treated with Sulphur dioxide before
being sent to the pan station for crystallization of
sugar .Crystallization takes place in single-effect vacuum pans,
where the syrup is evaporating until saturated with sugar. At this
point “seed grain” is added to serve as a water evaporator.
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CRYSTALLISATION:
There is a need of further reducing the Water content so that
sugar crystals are formed. The Solution is further heated in
vacuum pans until it reaches super saturation. They are then
moved from the pans to the crystallization tank.
SEPARATIONOFCRYSTALS:
The crystals are separated and the leftover material is called
molasses, which is a by -product of the manufacturing process.
Before sending the sugar to the market for sale, in most cases it
is refined. Refining involves removing further impurities.
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GRADATION&PACKING:
The final product in the form of sugar crystal is dropped through
pan section and this graded and picked in 50 kg bags. The grade
of the sugar depends on the size of the crystal viz. Small(S) and
Medium (M).
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B) CO-GENERATION:
The proposed co-generation aims at improving the energy
efficiency of the sugar factory significantly and enabling the
plant to generate surplus power from its cane crushing operation.
This surplus power is obtained from its cane crushing operation.
This surplus power will be then exported to the state electricity
grid. Energy efficiency and the export of power to the grid are
made feasible due to the availability of high pressure and high
temperature steam and by the utilization of the available
bagasse. The flowchart for generation of the power in co-
generation is as shown.
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C) DISTILLERY UNIT:
The production process mainly involves fermentation and
distillation.
FERMENTATION
Molasses is the chief raw material used for production of
alcohol. Molasses contain around 50% total sugars, of which 30
to 33% are cane sugar and the rest are reduced sugar. During the
fermentation, yeast strains of the species Saccharomyces
cerevisiae, a living micro organism belonging to class fungi
converts sugars such as sucrose or glucose present in the
molasses into alcohol. The continuous fermentation process
involves additions of fresh nutrients medium; either continuous
or intermittent withdrawal of a portion of nutrients for recovery
of fermentation products. In continuous process, fermenter is in
constant usage with little shutdown and after initial inoculation
of yeast culture further inoculation is not necessary. Hence, a
continuous fermentation process will be adopted in the proposed
unit.
DISTILLATION
After fermentation, the next stage the manufacturing process is a
separation method of distillation. After separation of alcohol
from fermented wash and it is then concentrated to 95%. This is
called Rectified Spirit (RS). For this purpose, a method of
distillation is employed. After separation of alcohol, the
remaining part is the effluent of the process i.e. spent wash and
spent lees.
Re-distillation to manufacture Extra Neutral Alcohol (ENA):
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ENA is prepared by re-distillation of the rectified spirit (RS) for
the removal of impurities like higher alcohols, aldehydes and
methyl alcohol. This is done by, remixing rectified spirit with
soft water and distilling it in the ENA column.
Anhydrous Alcohol (AA)
Anhydrous alcohol is an important product required by industry.
As per IS specification it is nearly 100% pure or water free
alcohol. Alcohol as manufactured by Indian distilleries is
rectified spirit, which is 94.68% alcohol. It is not possible to
remove remaining water from rectified spirit by straight
distillation as ethyl alcohol forms a constant boiling mixture
with water at this concentration and is known as azeotrope.
Therefore, a special process for removal of water is required for
manufacture of anhydrous alcohol.
The various processes used for dehydration of alcohol are as
follows-
i) Azeotropic Distillation
ii) Molecular Sieves
iii) Pervaporation / Vapor permeation system
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CONCLUSION
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CONCLUSION:
The use of resources in the Sugar industry is spatially organized
by the countries that produce sugar and the countries that buy or
trade sugar. The producing countries are normally tropical
countries and they are sometimes developing countries.
The trade and export of sugar shows the interconnections of the
world through one product. This ensures the consumption and
use of sugar which is in demand for more production. Though
there are consequences by the health effects and environmental
effects which can lead to many serious problems.
The interconnection of sugar is led by the farmer who farms the
sugarcane product, the workers that working the refining
process, the engineers and the exporters.
The sugar industry stands as a formidable player on the global
stage, fueled by innovation, government support, and the toil of
countless farmers. However, it must overcome pressing
challenges to ensure sustainability and prosperity.
By implementing strategic reforms and embracing innovation,
the industry can continue to sweeten India's economic
landscape.
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