Formulas for Calculating Sugar Industry Daily

Manufacturing Report (DMR)  With Simple Online

Calculator
Contents  [hide ]
 1 Formulas for Calculating Sugar Industry Daily Manufacturing Report (DMR)  With
Simple Online Calculator
o 1.1 Fundamental formula :
o 1.2 Sugar balance :
o 1.3 Mill Extraction (M E).
o 1.4 Fibre % Bagasse :
o 1.5 Added water%fiber
o 1.6 Reduced Mill extraction :
o 1.7 Noel Deer and Mittal
o 1.8  Clarification Factor:
o 1.9 Theoretical Final Molasses % cane :
o 1.10 Expected Recovery
o 1.11 Pol balance   
o 1.12 Boiling House Control
 1.12.1 E.S.G ( Equivalent Standard Granulated) Factor :
 1.12.2 Boiling House Recovery (BHR)
 1.12.3 Basic boiling house recovery (BBHR):
 1.12.4 Reduced Boiling House Recovery (Noel Deerr)
 1.12.5 Reduced Boiling House Recovery (Gundurao)
o 1.13 Online calculation sheet for Daily Manufacturing Report (DMR) in sugar
process industry

Fundamental formula :
In put = out put
Cane +   Added water  = Gross mixed juice +   bagasse
If cane is 100  than 100 + Added water% cane = M. J. % cane + Bag. %
cane.
Drit correction % M.Jc
Quantity of Drit in MT = Gross mixed juice x Drit correction % M.Jc
Net M.Jc in MT = Gross mixed juice – Qty of Drit in MT
       ( Note: Here to be take Net M.Jc in MT)

Sugar balance :
Sugar (pol) in cane =Sugar (pol) in mixed juice +   Sugar (pol) in
bagasse
Sugar (pol) % cane = Sugar (pol) in M.jc % cane + Sugar (pol) in
Bagasse%cane

Mill Extraction (M E).

The quantity of sugar extracted in the mixed juice per 100 sugar in cane
i.e. percentage of sugar extracted in the mixed juice out of total sugar in
cane.

Fibre % Bagasse :

Bagasse  =  fiber + Moisture  +  Brix

Fiber= Bagasse   – Moisture   – Brix
If bag =100 Then,   fibre % bag = 100  –  moist %bag –   Brix %
bagasse
Moisture % bag & Pol% Bag. are determined directly by analysis of   bagasse.
Brix% Bagasse

 While determining brix % bagasse, it is assumed that purity of residual

juice in bagasse is same as purity of last expressed juice .

Fiber % cane:
Added water%fiber

Reduced Mill extraction :

Noel Deer and Mittal

Noel Deer proposed formula to reduce the extraction to common basis

of 12.5% fiber, that is called as Reduced Mill Extraction (RME   N o e l D e e r )
For unit juice in cane ‘e’ is mill extraction.
Then juice lose in bagasse will be (1 – e )
Assume that unit cane contains ‘f’ fiber, then unit cane contains (1-f)
juice.
Therefore juice lost per unit cane will be (1-e) (1-f).
The unit cane contains ‘f’ fiber.Therefore juice lost in bagasse per unit

fiber will 

Where   

 P b c  = Pol in Bag. % cane,  Pc = Pol% Cane,  Fc  = Fiber. % Cane.

 Clarification Factor:
Good clarification means better sugar, less losses and unsatisfactory
clarification means (results in) production of inferior quality of sugar
with poor keeping quality and higher manufacture losses.
N .S. in M.J.% cane = Bx.% M.J. x M.J.% cane   –  Pol% M.J.  x  M.J. %
cane.
Pol in CJ % cane =   Pol in M.J. % cane –  Pol in F.C. % cane.

 
N.S. in C.J. % cane = Bx.in C.J.% cane –   Pol in CJ % cane
Non sugars removal %cane = Non sugars in M.J % cane – Non sugar in
c.Jc % cane

 Clarification Factor = 100 – Clarification efficiency

Theoretical Final Molasses % cane :

Non Sugars % F.M = Brix % F.M – Pol % F.M

Expected Recovery

S = Purity Of final product(sugar)

J = M.Jc Purity
M = Final Molasses Purity
Expected Recovery = Pol in C.Jc % cane x SJM factor – Unknown
losses  (Note:Here to be take estimated unknown losses )

Pol balance   
Pol % cane  =Pol in M.J.% cane+  Pol in Bag % Cane    

  (Note : Here to be take

Theoretical Final Molasses % cane)
  (Note : Sugar % cane
means recovery%cane )
Total Losses   =Pol % cane  –   Pol in Sugar % cane.
Total Losses =   Losses in (Bag. + F.C  + F.M. + Unknown)
Unknown losses = Total losses – Determined losses
Unknown losses = Total losses –  Losses in (Bag. + F.C  + F.M.) (Note:
It may differ 0.01 to 0.02 from estimated unknown losses)

Boiling House Control

E.S.G ( Equivalent Standard Granulated) Factor :
a) The term Standard Granulated used to indicate the finest commercial
product and considered as equivalent to pure sugar
b) The term E.S.G is used to indicate the finess of the commercial sugar
and denoted by sugar(product) in very clean form. The commercial
sugar is expressed in terms of standard granulate.
c) E.S.G form for commercial sugar apply S-J-M formula where S=100,
M= actual purity of molasses and J= purity of sugar.

Boiling House Recovery (BHR)

The value of ration of sucrose (pol) in commercial sugar produced to

the sucrose (pol) in mixed juice.

Basic boiling house recovery (BBHR):

The theoretical Boiling House Recovery as calculated by S-J-m formula
in which J in purity of M.J. and S=100 and m=28.57

Reduced Boiling House Recovery (Noel Deerr)

Where Mv  =Virtual Final molasses purity

Where R = BHR = sugar in pol % cane / Pol in M.Jc %cane

J= M.Jc Purity (Unit value)

Reduced Boiling House Recovery (Gundurao)

Where   r  =  BHR
K   = N.S. in clear juice % cane /  N.S.in M.J.% cane
M = Final molasses purity
J = M.Jc Purity
In the next revision of the article will provide all formulas related to
chemical control calculation.