Jaggery from Sugar Cane

Uploaded on : June 2010

Product and its applications

Sugar industry in India is a well developed industry and one of the largest sectors after Textile. It provides rural employment opportunities and plays an important role in the economy. Jaggery is also manufactured from sugarcane juice and is widely consumed in households, eateries, restaurants, sweetmeat shops etc. In crude form it has industrial applications also. In rural areas it is also a substitute for sugar. Sugar is a costly product as compared to jaggery; manufacture of sugar involves many technicalities and is capital intensive. Production of jaggery is simple and does not call for large investment.
Jaggery is a typical Indian product and finds wide application in day to day life food preparations. It is a rural industry and can be produced in sugar cane growing regions such as Maharashtra, U.P, Gujarat, Bihar etc.

Know how has been developed by CFTRI and is available. Compliance under PFA Act is mandatory.

Industry Profile and Market Assessment

Jaggery is one of the traditional items of various ingredients in Indian way of cooking. The demand for jaggery is there both in the riral as well as urban areas. It finds applications in day to day cooking. Unlike sugar the market of jaggery is seasonal during the harvesting of sugar cane. It has a low shelf life and is generally available foe approximately six months in a year. Traditionally the unit is a rural industry and should be located near the area of its cultivation to reduce the transportation cost. The unit does not require elaborate infrastructure and generally the sugarcane juice is cooked in open pans. The requirement of utilities is 40 HP and 3000 lts of water will be needed for production purpose. Production of jaggery is confined to the sugar cane growing belt as such the units are mostly located in UP, Bihar, Maharashtra and Tamil Nadu.

Since it is an item of food consumption its market is ever growing and any new unit may not face any difficulty in marketing its product.

Manufacturing Process & Know How

Jaggery making is a simple process comprising crushing of sugarcane for juice extraction, filtration and boiling of juice for concentration and then cooling and solidifying to give jaggery blocks. The juice is extracted in conventional crusher; this is then filtered and boiled in shallow iron pans. During boiling chemical bleaching agents or natural vegetable items like Bhindi (Lady finger) are added to clean the juice and the extraneous matter is constantly removed to give a bright golden colour. The boiled juice is then left to cool in iron/ Aluminum pots to form the jaggery blocks. The size of these moulds is specific and depends on the weight of the block of jaggery varying from 1kg onwards. The blocks are packed in jute cloth and dispatched. The yield rate of jaggery is about 10%, 100kg of sugarcane yields 10kg of jaggery.

 

              Process Flow Chart

Know how is available with Central Government research Laboratories. The machinery is all indigenously available.

The production capacity envisaged is 200 tonnes per season keeping in view the market

Plant and Machinery

The product does not require many items of machinery. Keeping in mind the production capacity of 200 tonnes per year the unit will require the following machines. The main plant and machinery required comprise

• Double roller sugar cane crusher with electricals - 1 nos.
• Storage Tanks - 4 nos
• Steel pans for boiling - 2 nos
• Weigh bridge 100 kg . - 1. nos.
• Iron Scrapper with long handle - 4nos.
• Laboratory Equipment. - 1 set

The total cost of machinery is estimated to be Rs.1, 72,000/-.

The unit will also require miscellaneous assets such as furniture, fixtures, storage facilities, sealing m/c etc. the total cost of these is estimated to be Rs. 1, 00,000/-.

The power requirement will be 40 HP.

Raw material and Packing Material

The basic raw material for the unit is good quality full grown matured Sugar Cane. For producing 200 tonnes of jaggery the unit requires 2000 tonnes of sugar cane. The extraction of juice from sugar cane works out to about 45%. There shall not be any problem in availability of proper variety of sugarcane from the cane producing states. Other ingredients like Soda/ Bhindi (Lady's finger) are all locally available. The unit will also require jute gunny bags for packing. The price of raw material and packing material at full capacity utilization is estimated to be Rs. 12.00 lakhs per year. At 60% capacity in 1st year the cost works out to Rs7.20 lakhs.

Land and Building

For smooth operation of the unit, it will require a small plot of land 500 sq.mts with a built up area of 300 sq. mts including storage facility. The same may cost approx. Rs. 6.00 lakhs.

Manpower

For smooth functioning of the unit the requirement of man power is expected to be around 10 persons.

Skilled Workers	4
Helpers	6
The annual salary bill is estimated to be around	Rs.2.40 lakhs

Sales Revenue: (100% capacity)

As against the rated capacity of 200 tonnes the capacity utilization in first year is taken as 60%. Assuming a sale price of Rs.13,000/- per ton the annual sales revenue at rated capacity is Rs.26.00 lakhs. The same at 60% utilization is Rs.15.60 lakhs.

Cost of Project

Particulars	Rs. lakhs
Land & Building	6.00
Plant & Machinery	1.72
Other assets	1.00
Preliminary expenses	1.00
Margin money	0.30
Contingencies	0.75
Total	10.77

Means of Finance

Promoters Contribution	3.27
Term Loan	7.50
Total	10.77

Profitability:(60% capacity)

Sales	15.60(Rs. lakhs)
Raw material	7.20
Salary	1.60
Utilities	0.60
Repairs & Maintenance	0.03
Stores & Spares	0.04
Selling & Admn expenses	2.15
Depreciation	0.99
Interest on T.L	0.82
Interest on W.C	0.10
Cost of production	13.53
Profit	2.07

Requirement of Working Capital

This is a seasonal activity and sugar cane is available on credit. Main requirement is for post sales for which a lump-sum provision of Rs.1.0 lakhs is made comprising margin of Rs.30,000/-.

Break Even point

54%

Machinery Suppliers

• M/S S P Engg. Works Kanpur
• M/S A M S Engg. Station Road , Patna.
• M/s Siwan foundry, Siwam.Bihar.
• M/S Sahayog Steel Fabrications.Bhojraj para, Gondal
• GM/S Septu India P Ltd. Begampur, Khatola, Gurgaon

Contact for more information

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com