Distillery Divisions

Sakthinagar Distillery Unit This unit was set up

in the year 1972 with the initial capacity of 9
million litres of industrial alcohol per annum and
by stages the capacity has been raised to 27.5
million liters.

• It is the largest Industrial Alcohol

manufacturing distillery in the state of
Tamil Nadu, India.
• A substantial portion of the raw material-
molasses is being supplied from our two
Sugar Units at Sakthinagar and
• Rectified Spirit
Sivaganga in the state of Tamil Nadu,
India.
• Extra Neutral Alcohol / Neutral Spirit
We manufacture & supply Rectified Spirit and
Extra Neutral Alcohol / Neutral Spirit

Dhenkanal Distillery Unit

A new distillery unit of 10 million litres capacity for manufacture of Industrial Alcohol was set up in
1996 near Dhenkanal Sugar Unit of Sakthi Sugars. It is the largest disillery unit in the State of
Orrisa, India.

Pollution Control Division

In an effort to bring to India, state of the art technology for the treatment of distillery effluent,
Sakthi Sugars entered into collaborations with M/s Societe Generale Pour Les Techniques
Nouvellus (SGN) of France and M/s Smogless of Italy in the year 1985. A Pollution Control
Division was set up in the company and the division started activiely offering solutions to
distilleries, breweries and dairies. The disposal of treated effluents in a most scientific manner -
composting with press mud, HRTS and ferti-irrigation - all methods approved by NEERI (National
Environmental Engineering Research Institute) Pune, India and PCB (Pollution Control Board)
India.

Primary Treatment Plant (SGN Anaerobic Fixed Film Bio-Methanisation)

The first Bio-Methanisation plant for primary treatment of distillery effluent was installed at
Sakthinagar in the year 1987 and this was the first biggest digester erected in India at that time.
This system is based on SGN Anaerobic Fixed Film Bio-Methanisation Process by which the
effluent is treated efficiently with a BOD reduction of 90% and COD reduction of 65%. The bio-
gas generated during the process is utilised in the boiler as fuel replacing furnace oil,
saving substantial fuel costs.

Sakthi Sugars has commisioned 15 similar effluent treatment plants in distilleries across the
country, which have helped not only to save money by conserving substantial amounts of furnace
oil, but have also helped reduce pollution.

Sakthi Sugars has completed a project at Thailand offering consultancy services for establishing
a similar bio-gas plant. Sakthi Sugars is now looking forward to similar projects from Asian
countries.
 Austoft 7000 Harvester

The Austoft 7000 harvester is a chopper harvester

Austoft 7000 Harvester
with a cleaning system. This harvester is used to cut
green cane (with leaves). It cuts one row of cane at
a time. The cane is fed between the crop dividers
and cut at the root zone by base cutter blades. The
cane is then fed through the roller train and is cut by
the chopper drums into small cane pieces of 10 to
12". It is then cleaned in the primary extractor
before being conveyed on the elevator. It is then
cleaned again with the secondary extractor and
loaded onto a vehicle for transportation. In ideal
conditions, the harvester can cut nearly 400 tonnes
of sugarcane per day.

Pre-requisite for mechanical cane harvesting is 5 feet planting

Salient features of 5 feet row cane planting system

Articulated Infield Cane Transport specially

made for India by Sakthi Sugars Ltd.,

Tractor (70 HP)

Articulated Infield Cane Transport

Benefits of Using Mechanical Harvesters:

Benefits for the farmers:

• Large areas could be harvested in a single day.

• While manual harvesting leaves about three to four inches of cane in the ground, the
mechanical harvester can cut the crop 1" below the ground level, giving an additional
yield of about one to two nodes of cane. This results in a higher yield and recovery of
sugar.
• The crop is cut evently, avoiding the operation of stubble shaving, resulting in cost
savings for the farmers.
• The entire operation is done by two operators for the harvesters, three for the transporter,
one mechanic and a supervisor. This results in saving in labour as normallly about 600
labourers are needed to harvest 400 tonnes in a single day.
• The cane can be delivered to the factory within 1 to 2 hours of harvest, which avoids
weight loss and sucrose inversion.
 5 feet planting Dressed cane
Field preparation for 5 feet planting loaded onto
a vehicle

Benefits for the factory:

• The feeding of the cane to factory can be maintained at a uniform rate, in manual
harvest, the cane is cut in the morning dressed and loaded during the afternoon and
transported to the factory in the evening. This result in heavy cane accumulation in the
evenings, which is normally cleared during next day morning. The mechanical harvesting
can be done for twenty hours of the day and cane can be supplied to the factroy within
two hours from the cutting time. This will enable fresh cane supply to the factory.
• The feeding of cane to factory need not depend on the availability of labour. Even in
summer and festival season the cane crush can be maintained at a uniform rate.
• The number of trucks can be reduced at least by 40%. This is due to higher tonnage
being handled by trucks. This leads to reduced transport costs.
• The crushing season can be shortened with results in improvement of average recovery
of sugar recovery.

Co-generation Plant :

• A 32 MW Co-generation plant with multi-fuel

boiler facility has been established in the year
2003 at Sakthinagar Sugar Unit within the
factory premises. The company has entered into
an agreement with Tamilnadu Newsprint and
Paper Limited for receiving fuel against bagasse
supply. A 2MW incidental Co-generation plant is
established at Sivaganga Sugar Unit within the
sugar factory premises.

Ethanol Plant :
 • In the Distillery Unit at Sakthinagar, an Ethanol Plant with a
capacity to produce 15000 KL of Anhydrous Alcohol has
been established in the year 2002.

Growth in terms of Crushing Performance

• Mills equipped with Auto Setting facilities.

• Best export quality of Sugar produced.
• Scientific farming
• Continuous R&D in sugar rich, pest resistant and high yielding sugarcane varities
• Mechanisation of cane harvesting.
• Efficient Sugar manufacturing method used thereby reducing the sugar loss.
• Factory sites are maintainted neat and clean - Hygiene at its best.

Shareholding pattern

Sakthi Sugars has set up sugar units in different parts of India.

Sakthinagar Unit
Crushing Capacity 7500 tonnes / day
Total Sugar Produced (1998-
13,82,100 quintals
1999)
Total Cane Crush (1998-1999) 14,23,252 Metric Tonnes

Sivaganga Unit
Crushing Capacity 4000 tonnes / day
Total Sugar Produced (1998-1999) 4,66,825 quintals
Total Cane Crush (1998-1999) 4,87,409 Metric Tonnes
 Dhenkanal Unit
Crushing Capacity 2000 tonnes / day
Total Sugar Produced (1998-1999) 2,00,496 quintals
Total Cane Crush (1998-1999) 2,38,339 Metric tonnes

High Rate Transpiration System: Trees species compatible with distillery Effluents
The high rate transpiration system (HRTS) is a land application system wherin wastewater is
applied in specially
designed field layouts with wide ridges and furrows, and planted with trees bestowed with higher
transpiration capacity.
The HRTS envisages the use of dynamic multicomponent soil system as a live filtration device to
renovate pretreated wasterwater through absorption, ion exchange, precipitation, and stabilisation
of pollutants through microbial degradation. Also the earthworms present in the system provide
aerobic conditions for the stabilisation of organic contents in the wastewater through a network of
furrows.

The plants, e.g. Bamboo (Dendrocalamus strictus), Neem (Azadirachta Indica) and Shishum
(Dalbergia Sissoo) transpire
water equivalent of 7 to 13 times of potential evapo transpiration from the soil matrix alone. Thus,
HRTS permits the
disposal of 250-450 cubic Mt. of wastewater per hectare of land per day. As all the wastewater is
utilised in this process,
the ground water pollution problem is avoided. The nutrients present in the wastewater are used
by the plants and partly
retained int the soil matrix with positive impact on the soil ecosystem.

HRTS for M/s. Sakthi Sugars Ltd

Sr.No Particulars Details

01 Location Sakthinagar, Tamil Nadu, India.
02 Wastewater generated 1000 m³/day
03 Type of Soil Loamy sand, rocky below
04 Groundwater table 40-70 meters
05 Land required @ 100 m³ / hectare 10 hectares
Sugarcane, mango, tapioco, coconut, prosopis,
Prominent plant species growing in the
06
area
Tamarind, paddy etc.
07 Availability of land Adequate

Trees planted in HRTS Area at Sakthinagar

01 Neem 1094
02 Casuarina 6202
03 Pungan 1381
04 Eucalyptus 6636
 05 Bamboo 64
06 Maramalli 42
07 Teak 2811
08 Red Sandal 146
09 Mangiyam 549
10 Mahogany 40
. Total 18965
Area Covered under HRTS 12.23
Area covered under KORAI 3.00
Total area 15.23

Advantages of HRTS :
- Works on natural treatment processes and could be thus termed as eco-friendly
- Facilitates development of forest and green belt around factory premises
- Generates sink potential for air pollutants
- Low-energy and cost requirements compared to conventional wastewater treatment systems
- Ease of installation and simplicity of operations
- Biomass generation and revenue returns

Sakthi Sugars plans greenfield project in TN; to invest Rs. 320 cr.

Staff Reporter

This will include about Rs. 60 crore for new sugar factory

COIMBATORE: Sakthi Sugars Limited plans to invest about Rs. 320 crores this year towards setting up co-
generation plants, a new sugar factory in the State and expansions.

Its Managing Director and Vice-Chairman, M. Manickam, told presspersons here recently that this would include
about Rs. 60 crores for the new sugar factory and Rs. 260 crores for the co-generation plants.

Sakthi Sugars proposed to start a new factory in the State with a crushing capacity of 3,500 tonnes a day.

Govt. approval awaited

The exact location for this project was yet to be finalised. It would be in Tamil Nadu and the company awaited the
State Government's approval for the project.

It would become operational in June or September next year. The company had three sugar factories in Tamil
Nadu.

Apart from the new project, the crushing capacity of the Appakudal (Erode District) plant would be increased
from 7,500 tonnes a day to 9,000 tonnes.

The total cane crushing was likely to go up from about 27 lakh tonnes in 2005-06 to about 37 lakh tonnes this
year.

Nearly 40 per cent of its production was exported in the last fiscal, he said.