REPORT: INDUSTRIAL VISIT - Satish Sugars

ACKNOWLEDGEMENT
We take this opportunity to thank our principal Rev. Fr. Daniel Fernandes and P.
G. Dean Dr. Beatrice Sequeira for giving
us an opportunity to go for an industrial visit. Special thanks to Dr. Beatrice
Sequeira, Mr. Syed Wajeed, and Jothy
William for accompanying the students and guiding us during visit.
Our heartfelt gratitude also goes out to Mr. Satish Jarkiholi for allowing us to
visit his industry and guiding us through
the various processes and machinery used. A special thank you to the employees o
f Satish Sugars for excusing our
intrusion.Finally heartfelt gratitude to all our classmates for making this trip
a memorable one.

INTRODUCTION
Industrial visit is a part of` the course, during which students visit companies
and get insight of on the internal working
environment of the company. It also provides an insight on how companies work an
d also useful information related to the
practical aspects of the course which cannot be visualized in lectures.
A group of students for a guided tour into the premises of Satish Sugars Belgaum
, providing information about the
background of the company their impact in Development of various processes and t
heir current position in the global
business scenario
Company s profile
Satish sugars limited, Belgaum was set by Mr. SATISH JARKIHOLI.
A farmer by origin, Satish s wish is to grow with the farmers. I believe in empoweri
ng farmers by supporting farming and
related industries and related industries, he says. Indeed, employment generation
and community development
are the primary goals behind the activities of his group. It provides employment
to nearly 1,500 people and has
transformed the lives of more than thousands of families in the region.
Satish Sugars Ltd. was initially set up as a Khandsari Unit in 2000-01. In 200405, the unit adopted Vacuum Pan
Technology keeping in view its economic viability, efficiency and higher return
on investment. The initial capacity of the
reformed unit was 1250 TCD. Later during the year 2006 - 07 SSL has carried out
a major substantial expansion of the
sugar unit up to 4000TCD in a record time of 8 months, and in the trail season,
the unit processed 2,00,000 tonnes of
sugarcane in 2006-07 and registered a profit of Rs.1.72 crore on a turnover of a
round Rs.11crore.
SSL has set a target of 15 lakh tonnes of cane crushing for the year 2011-12 wit
h a turnover of Rs.400crores and a net profit of Rs.20crores.
Company is setting its own records for establishments of various projects. Compa
ny is aiming to expand up cogeneration up to a 60MW & Sugar Plant capacity up to
12,000 TCD. Company also plans to expand distillery capacity up to 90KLPD.

Focus on Quality
At every stage from growing sugarcane to production of sugar, SSL ensures that q
uality reigns supreme.
The Company has the singular objective of bringing down mistakes at every level
of operation and working towards
continuous improvement in quality.
Social activities
Satish Sugars Ltd is actively involved in various social activities which includ
e
Satish sugars academy established in 2007 in order to provide quality education
Super specialty hospital and Medical College- under planning
Ayurvedic hospital and research centre under conceptualization
It's this vision of society-oriented business model is what sets Satish Sugars L
td. apart from the rest.
It also spurs us to strive for people development even harder.
We took Industrial visit with an aim to go beyond academics, these visits are ar
ranged to develop the insights
of the students attaining practical knowledge and their theoretical application
s thereof.

SUGAR PRODUCTION
Satish sugars, as the name suggests are in the business of sugar manufacture. He
nce, as expected the industry has a
large and well developed sugar producing division. The main aspect of this divis
ion of the industry that immediately caught
the eye was the minimal requirement of manual labour in the entire process of su
gar production.
Nearly all the processes were done using machines. To an untrained eye, this fea
ture indicates a fairly developed industry
and that is the view that we students had. The sugar division produces around 15
, 00,000 tonnes of sugar per year with a
turnover of Rs. 400 Crores every year.
The process that is followed in Satish Sugars for the production of sugar is a s
tandard process that is followed all over India
if not all over the world. The basic process involves crushing sugar cane and th
en boiling the extract so formed, to get sugar
crystals, which are then bleached to give it the shining white colour. One step
before sugar formation is the formation of
jiggery, which is also extensively used in India in the preparation of a number
of traditional sweet dishes.
High quality cane has a good juice content with high sugar levels (20 %+). Poor
quality cane or cane that has been
harvested early may have similar juice content but the sugar levels will be redu
ced.
CRUSHING
The method by which the sugarcane is crushed is important in determining how muc
h sugar can be obtained from a
certain amount of sugarcane. In Satish sugars, a 5 roller crusher is used which
has an efficiency of around 50 %.
This is not considered to be very efficient on the world scale, but is what is m

ost commonly found in Indian industries.

The crushers are diesel powered and the sugarcane
harvesting, because beyond that the
sucrose in the sugarcane begins to invert to many
t is important that the source of the
sugarcane is close to the industry. Satish sugars
number of farmers in and around Gokak,
an area which is heavily reliant on the growth of
e Satish sugars obtain all the sugarcane
that they need from the nearby areas.

is crushed within 24 hours of

other kinds of sugars. Hence i
obtain their sugarcane from a
sugarcane as subsistence. Henc

CONCLUSION
To sum up the knowledge gathered by visiting these industries gave us a way in w
hich the companies operate and
their marketing strategies. It was seen that these industries comply with the in
ternational standards and protocols
for efficient management and available resources, practising safety guidelines a
nd following hygienic practices in
interest of consumer welfare.
Our Visit to Satish Sugars - Belgaum brought to light how an industry runs and o
perates. All these stages involved in
final product formation were looked into detail. Also the practical difficulties
that arise in and the way in which these
problems are handled were also seen. The way in which raw materials can be proce
ssed efficiently yet cost effectively
to give rise to final product making use of available technology was witnessed.
We also learned the important role that A Microbiologist plays in various stages
of industry.
JUICE TREATMENT
The juice is filtered before it is evaporated. Once filtered the juice is treate
d with lime to precipitate some of the impurities
that may be present in the juice after the crushing. The impurities settle out w
hen lime is added. Not all impurities settle out
on the addition of lime, but it is the first step in purification. Sulphur dioxi
de is then added to the juice to neutralize it and
lend it a more pleasant colour. This can be added even at the end of the boiling
process.
When added at the end of the boiling process it is added in the form of a substa
nce called Hydros, which releases sulphur
dioxide into the juice to lend it a good colour.
JUICE BOILING
This process is done in vacuum pans in Satish sugars. The vacuum pan technology
is up to date with the techniques and
equipment used in the most sophisticated of industries around the world. The vac
uum pan maintains the temperature of
around 78oC under pressure which causes the super-saturation of sugar crystals i
n the sugarcane juice.
At the end of this process the sugar content in the juice is concentrated to alm
ost 90-95 %. Once this is done the pans are
cooled by air which encourages even crystallization. The cooling liquid is then
poured into vessels and allowed to set.
At the end of boiling, if sulphur dioxide is bubbled through the slurry then the

sugar obtains the white colour. If not, the

colour remains a shade of yellow to brown. The process of addition of sulphur di
oxide is called bleaching.
In some industries animal bones are powdered and added to encourage the rate of
bleaching, but this is now
unacceptable and not practiced anymore. After allowing the sugar cakes to set, t
he rest of the liquid is squeezed out
under pressure and the cakes are crumbled and shaken through long conveyor belts
to exclude larger and tougher lumps
and to crumble smaller lumps into fine crystals.
The sugar so formed is filled in sacs by a machine which is regulated so that a
precise amount of sugar is filled in each sack.
In Satish sugars, the sacks that were filled contained 50 Kg of sugar in each sa
ck. These sacks are then sealed and sold.
CONCLUSION
To sum up the knowledge gathered by visiting these industries gave us a way in w
hich the companies operate and their
marketing strategies. It was seen that these industries comply with the internat
ional standards and protocols for efficient
management and available resources, practising safety guidelines and following h
ygienic practices in interest of consumer
welfare.
Our Visit to Satish Sugars
Belgaum brought to light how an industry runs and ope
rates. All these stages involved in final
product formation were looked into detail. Also the practical difficulties that
arise in and the way in which these problems
are handled were also seen. The way in which raw materials can be processed effi
ciently yet cost effectively to give rise to
final product making use of available technology was witnessed.
We also learned the important role that A Microbiologist plays in various stages
of industry.