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The biggest Sugar Mill in the Philippines "in the making"

BUSCO is located 35 kilometers away from the heart of Bukidnon.

BUSCO is now on the threshold of sustaining a 5.0 Million bags annual production. The culture of continuing improvement has been deeply incalculated and ingrained on the executives, officers, staff, and employees of Busco Sugar Milling Co., Inc.

Everyone in Busco pushes for improvement in productivity, efficiency and the latest proven technology every year, as evidenced by successive double digit growth every year for 5 years now.
Perhaps the 5-year growth of the Bukidnon Sugar Industry will illustrate this statement more clearly: --Bukidnon milled 1,817,054 tons cane in CY-98-99 and after five years, Bukidnon milled 3,817,986 tons cane or a fantastic increase of 110%, more than double in 5 years, in terms of sugarcane milled. On the other hand, Busco milled 1,337,060 tons cane in CY 98-99 and after five years, Bukidnon milled 3,817,986 tons cane or a fantastic increase of 93.87%, slightly less than double. But in terms of sugar produced, Busco increase was 115%, much more than doubling its sugar production in 5-years,110% more than double in 5 years. Every off-milling season, is a time to introduce planned changes. The whole millsite is a beehive of activity of so many engineers, contractors, suppliers, skilled tradesmen, specialists and workers of all kinds buildings, wrecking and rebuilding foundations, structures, buildings, machineries and entire stations. In many cases, what was installed say seven months ago will now be demolished or dismantled, relocated and re-assembled in a new place requiring re-piping, re-wiring, re-working, recabling, for controls. And there are several of such activities done simultaneously. It is a sight to beholdhow bits and pieces are done by so many in so short a time to make a modernize, effective, harmonious whole! Perhaps, it is akin to the Philharmonic Orchestra which consists of many kinds of musical instruments: string, wind, percussion and so forth, but played by experts, under the baton of renowned conductors, performing compositions of masters, and which produce awe-inspiring symphonies. Busco people enjoy such challenges. The vision of its leadership must be brought to realization. It will be! The whole of Bukidnon and the neighboring towns of other provinces have seen such consistent, reliable and unified effort of building the solid foundation of a vibrant and re-invigorated sugar resources and dreams to growing the sugar canes needed by the sugar mills. The mutually satisfying synergy among the sugarcane growers, the Planters Associations, the community in general and Busco Sugar Milling Co., Inc. have catapulted the Bukidnon Sugar Industry into limelight.

The dream continues. For now, Busco is looking at a second milling tandem with a 6000 TCD capacity in the next two years. This will bring up its milling capacity to 20,000TCD, the biggest sugar mill in the country. The confluence of favorable events and the blessings of God have given Busco the enviable opportunity of taking the sugar industry into the cutting edge of productivity, efficiency and technology. This makes Busco a powerhouse for the economic development of this part of Mindanao, the creation and proper distribution of wealth of opportunities to about 350,000 people who live-off the industry or its ancillary businesses. It is a very big blessing bestowed upon Busco Sugar Milling Co., Inc. but it is also a very big responsibility on its stockholders, officers, staff and employees.

The first sugarmill in Bukidnon was erected in Butong, Quezon, Bukidnon sometime in 1975. It was erected by the Marubeni Corporation of Japan for Bukidnon Sugar Milling Co., Inc. with a capacity of 4000 TCD. It had its first milling season on December 21, 1976 to May 22, 1977 for which it crushed 148,530.96 tons cane and manufactured 260,056.00 piculs raw sugar with an average of 1.75 piculs sugar per ton cane. The area planted was 1,908 hectares from 54 planters, mostly from big farms around the mill. In the succeeding years, the sugar cane agricultural development prospered progressively such that after six years, for CY 1981-82, the mill crushed 894,752.04 tons cane and manufactured 1,488,254 piculs sugar. The mill was serving 1,167 planters cropping about 14,000 hectares. It was about the limit of the capacity to mill for a 4000 TCD Mill. Therefore , the company undertook a capacity expansion program from 4000 TCD to 6000 TCD. Af ter the second year of expansion to 6000 TCD, the mill

attained its highest productio n of 1,574,768 piculs raw sugar from 18,795.67 hectares.

The assets bought from the APT includes also a 230 hectares property situated in Barangay Butong, Quezon, Bukidnon which is 11 kilometers away from Poblacion Quezon, Bukidnon and 140 kilometers away from Cagayan de Oro City.

Bu sco Sugar Milling Co., Inc. was registere d with the Securitie s and Exchange Commissio n with an authorize d capital of P800 Million and a paid up capital of P400 Million on September 16, 1988. Up

on takeover, the new owners embarked on a rehabilit ation and expansion program.

In keeping with their commitments to the sugarcane planters, it conducted its initial milling campaign, on schedule, for CY 1988-89. Since then, it has successfully completed fourteen (14) milling campaigns producing about 11.15% of the total national sugar production each year. Plant modernization and capacity expansion continued without let-up. For Crop Year 1992-93, Busco has already reached a capacity of 10000 TCD and crushed a total of 1,752,164.29 tons cane and manufactured 3,358,800 L-Kgs., marking the biggest productions then in the history of the sugar industry in Bukidnon. This Crop Year 2002-2003, Busco has hit a high of 14,538.83 tons cane milled and sugar produce of 1,450,713.62 kilos on January 7, 2003. Since its construction in 1975 until its capacity expansion reached 10000 TCD in 1993, Busco had a total of three units of 1.7 MW steam turbine generators rated at 460V 3PH 60HZ. In addition, two Diesel Gensets were commissioned rated at 750 KW and 400 KW at 480V used as stand-by units. Shortly thereafter, an 8,000 KW steam turbine generator rated at 4160V 3PH 60 HZ was commissioned in April 1994 to supply the additional energy demand. All of these equipment including the mill drives requiring super-heated steam for the prime mover power, are supported by four Boilers with three Boilers rated at 60 TPH with 20 kg./cm2 pressure and one 70 TPH with 31 kg./cm2 pressure. To complete its cogeneration facility, a 10 MVA 416/69 KV outdoor substation interconnecting with the National Power Corporation Mindanao Grid was commissioned on April 4, 1995 to supply 4 MW of its excess power to NPC.

A total of 3,770,212 KW have been exported to the NPC Mindanao Grid during the initial year of co-generation. The acquisition of the NASUREFCO Refinery by Busco further added 2.2 MW steam turbine generator and a 50-tons per hour Clarke Chapman Boiler. The Bukidnon Milling District is now the second biggest sugarcane milling district in the entire Philippin es. It encompass es the towns of Quezon, Valencia, Malaybala y, Lantapan, Cabanglas an, Sumilao, Impasugon g, San Fernando, Maramag, Pangantuc an, Don Carlos, Kitaotao, Dangcagan , Kibawe, Kadingila n, and Damulog, all within the province of Bukidnon and with its expansion in Wao,

Lanao Del Sur and Banisilan , North Cotabato, in the heartland of Mindanao.

Busco Milling District generates some P 3.5 B in the form of revenue from raw and refined sugar and molasses. It contributes over P 300 M to the government in the form of taxes. Consistent with its Corporate Vision, Busco has acquired the existing 550 MT NASUREFCO Refinery at P310 Million in an open bidding with APT. The Refinery was turned over to Busco last June 27, 1996. Its vision of forward integration has been substantially achieved. After the turnover, Busco has acquired the services of consultants from the Tate and Lyle Ltd. to assess the refinerys machinery and equipment. A little over a year of rehabilitation works were done, the refinery has started its initial year of operations on July 1997 and has a targeted production of 2,000,000 bags refined sugar every season. With technology shared in refining process from Central Azucarera de Don Pedro in Batangas, Busco reached 12,000-13,000 bags mark refining capacity last September 1999. The refinery attained a production of 1,880,343 L-kg. of Refined Sugar in its first milling operation from September 1, 1997 to August 31, 1998 and a production of 2,101,958 L-kg. of Refined Sugar in the second year from September 1, 1998 to August 31, 1999. On the third year, CY 1999-2000, 2,762,251 Lkg. of Refined Sugar was produced and 2,856,772 L-kg for CY 2000-2001. Busco will continue to move to new levels of efficiency and quality. Its sugar refinery is already equipped with the latest technology in pan automation. A Siemens vacuum pan automation system is already in place improving product quality and steam economy. A Hoechst automatic filter press is installed at its filter station, substantially reducing sugar losses thereat. This had helped increase its refining yields to very high levels. In terms of product quality, Busco refinery now produces about 80% throughput in the form of Bottlers Grade and Premium Grade Refined Sugar. But Busco did not forget to look for avenues to improve its milling services to the sugarcane growers of Bukidnon. Before Crop Year 1999-2000 ha d started and in its preparation for the turn of century milling season, the raw house milling tandem has been enhanced further by upgrading another 2 sets of steam turbines and reduction gears from 600 KW to 900 KW. This has strengthened Buscos milling capacity and sucrose extraction even further. For Crop Year 2002-2003, Busco has milled 2,592,320.120 tons cane from 60,000 hectares of 10,238 sugarcane farmers or

planters and has manufactured 4,973,106.19 kilobags raw sugar with an average LKG/TC of 1.92. Compared to the other biggest sugar producers, again, Busco remarkably made it ranked the second biggest sugar producer in the country today. We are on target with our mission to excel. We will be there within the first decade of the 21st Century.


Sugar Production
The process adopted in the manufacture of sugar is Double Sulphitation Process. Sugar Factory consists of the following five main stations: 1. Mill House 2. Boiler House 3. Power House 4. Clarification and Evaporation House 5. Boiling and Curing House MILL HOUSE: Mill house is the cane crushing unit which consists of cane carrier, cane cutter having cutting knives, milling tandem, bagasse carrier and conveyor. Cane feeding to the cane carrier is done by unloaders and feeder table. As the cane

carrier moves, the cane kicker evens out cane load in the cane carrier and then two sets of cane knives cut the cane into small pieces. This process of cane cutting is called 'cane preparation. These cane pieces then, pass through different mills and the juice is extracted. The mills are driven by D.C.motors. The residue which comes out of the mill after extraction of juice is called bagasse. BOILER HOUSE: Boiler generates steam by burning the bagasse. The steam is used in powerhouse, boiling house, curing house. The steam required by the Sulphitation process varies from 42 - 45 % on cane crushed per hour. POWER HOUSE: The high pressure steam generated by the boiler is utilized for production of power by the turbo-alternators. The power produced is used for captive needs and the surplus power is exported to the government grid. The low pressure steam that comes out from the turbo alternator is utilized for boiling the extracted juice. CLARIFICATION AND BOILING HOUSE: The juice extracted by the mills is measured by juice flow system. The measured juice is heated in juice heater in two stages. First the juice is heated by the vapours from fourth and third bodies of evaporator in different heaters. This heating is called primary heating. The heated juice is treated with milk of lime and sulphur-di-oxide to coagulate maximum impurities and sent for secondary heating. The secondary heating is done with vapours from second body of evaporator and vapours from the first body or exhaust steam. The treated juice is passed to clarifier, where in clear juice is removed from the top and settled mud at the bottom is separated. To extract sugar from the mud, it is taken to vacuum filter in which juice and filter cake are separated. Juice is taken back to process and the mud is disposed as solid waste. Clear juice from clarifier is taken to evaporator for evaporating its water content. First body is heated by exhaust steam, and other bodies by the vapours of the previous body. The total water evaporated in the evaporator is 75-80 % percent. The juice after evaporation is called as syrup. This syrup is normally of 60 % solids of its total weight. The syrup is then sulphited in syrup Sulphitation tower.

BOILING AND CURING HOUSE: Sulphited syrup is taken to pan floor for making sugar crystal. Three massecuites boiling systems is normally adopted, in which, A, B and C Massecuites are boiled. A-massecuites is formed by boiling syrup, sugar melt ,A light molasses and on B-single cured sugar as seed. This A-Massecuite is boiled till it attains the required size of sugar crystal and it is dropped into crystallizers and cooled. After exhaustion of sugar in solution, the A massecuite is passed on to the centrifugals for separating sugar crystals from the massecuite. The separated 'A' sugar is bagged after drying. A-Light and A-Heavy molasses are pumped to pan floor and are used for making A - and BMassecuite respectively. B-Massecuite boiled in B pans is dropped into B- Crystallizers and then it is cured in B-Centrifugal machines. Bheavy molasses and B-single cured sugar are obtained separately. B-single cured sugar is used as seed for A massecuite. B-heavy molasses is used for making C-Massecuite in C-pans. C-Massecuite is dropped into CCrystallizers where it is cooled. C-Massecuite is then taken to C-fore worker centrifugal machines for curing. Final molasses and C-single cured sugar are obtained. 'C' Single cured sugar is again cured in another centrifugal machine in which C-double cured sugar and C-light molasses are obtained. C-light molasses are taken to pan floor and is used in making C-Massecuite. C-double cured sugar is melted and is used in making 'A' Massecuite. Sugar discharged from 'A' Machine is dropped on to grass hopper conveyors. By passing hot air in hoppers the sugar is dried and taken to grader in which powder and roris are separated. The required grade sugar is bagged.

Bagasse is the biomass that is the base for Cogeneration in Sugar Industry.

Biomass is the fiber left over after the juice has been squeezed out of sugarcane stalks. As Biomass can produce more heat energy it is used as a fuel source to produce the required energy for sugar manufacturing operations. When burned in large quantities, the energy produced through Biomass can be used for the sugar mill with enough power to spare. In this method, the usage of raw materials is totally averted and creates Green Power resulting in Greener and Non-polluting Environment.