SUGAR INDUSTRY

1
 Introduction to Sugar Industry
The sugar industry subsumes the production, processing and marketing of sugars
(mostly sucrose and fructose). Globally, most sugar is extracted from sugar cane
(~80% predominantly in the tropics) and sugar beet (~ 20%, mostly in temperate
climate, like in the U.S. or Europe).

2
 Introduction to Saccharides
Saccharides, also known as carbohydrates, are organic compounds
composed of carbon, hydrogen, and oxygen.
They serve as a major source of energy and play crucial roles in living
organisms.

3
 Properties of Saccharides
Chemical Composition: Saccharides consist of monosaccharides,
disaccharides, and polysaccharides with varying linkages and functions.

Solubility and Sweetness: They have diverse solubility properties and can
range from sweet to tasteless.

Structural Diversity: Their structures vary, allowing for a wide range of

functions in biological systems and industrial applications.
Uses of Saccharides in Food Industry
Sweeteners: Saccharides like glucose, fructose, and sucrose are used to
sweeten various food products.
Thickening Agents: Polysaccharides such as starch and pectin are used for
thickening and stabilizing food products.
Preservatives: Saccharides are used as natural preservatives to extend the
shelf life of foods.

4
 Applications of Saccharides in
Pharmaceuticals
Drug Delivery: Hydrogels and micro/nanoparticles made from saccharides
are used for controlled drug delivery.
Stabilizing Agents: Saccharides are used to stabilize proteins and vaccines
during manufacturing and storage.
Oral Cavity Applications: Saccharides play a role in various oral delivery
systems, like films and buccal patchesa.

Role of Saccharides in Biofuels and Renewable

Energy
Biofuel Production: Enzymatic conversion of saccharides is used to
produce bioethanol and biodiesel.
Saccharides, particularly those derived from plant biomass, have emerged
as a promising feedstock for biofuel production.
5
Renewable Energy Source: Saccharides contribute to the renewable
energy sector through biomass conversion.
These renewable carbohydrates can be converted into various types of
biofuels, such as bioethanol and bio butanol, through fermentation and
other processes.

Industrial Applications of Saccharides in

Manufacturing
Adhesives: Polysaccharides are used in the production of adhesives for
various industrial applications.
The most explored polysaccharides for adhesive development are starch,
chitosan, dextrin, gum arabic etc.
Textile Industry: Saccharides are used in sizing agents and fabric printing
due to their biodegradable nature.
A versatile component that has made its way into the core of the textile
business is starch, a carbohydrate obtained from a variety of plants.
Its main function throughout the various stages of production is to enhance
and strengthen the texture of fabrics. 6
Packaging Materials: Biopolymers derived from saccharides are utilized
for sustainable packaging solutions.
Starch is a good source of biodegradable material for food packaging,
originating from wheat, corn, rice, and potatoes. It is widely viewed as a
sustainable substitute to plastics for food packaging.

Sucrose
Sucrose, a disaccharide composed of glucose and fructose, is one of the
most familiar and widely used sweeteners
Its unique properties make it a key ingredient in numerous food and
beverage products, as well as industrial applications.

7
 Structure and Chemical Properties of Sucrose
Molecular Structure: The molecular structure of sucrose consists of
glucose and fructose units linked by a glycosidic bond.
This complex arrangement contributes to its characteristic sweetness and
solubility in water.

Crystalline Properties: Sucrose forms crystalline structures with distinct

properties, making it suitable for various food applications, including
confectionery and baking.
Its ability to form crystals impacts the texture and mouthfeel of products.

8
 Physical Properties of Sucrose
Solubility: Sucrose exhibits high solubility in water, contributing to its use in
preparing syrups, beverages, and other liquid products.
Understanding its solubility is crucial for designing formulations in the food
and beverage industry
Hygroscopic Nature: The hygroscopic nature of sucrose allows it to absorb
and retain moisture, affecting the stability and texture of food products.
It is a key consideration in food preservation and shelf-life management.
Melting Point: Sucrose has a relatively high melting point(185°C – 187°C),
which impacts its behavior during cooking and processing.
Controlling the melting properties of sucrose is essential in culinary
applications.

Role of Sucrose in Food and Beverages

Sweetening Agent: Sucrose serves as a primary sweetening agent in a
wide range of food and beverage products, enhancing flavors and
providing a pleasant taste profile.
9
:Texture Modifier Its ability to contribute to the texture and mouthfeel of
products makes it invaluable in applications such as baking, confectionery,
and dairy products.
Preservation: Sucrose plays a role in food preservation by influencing water
activity, microbial growth, and the overall stability of preserved products.

Health Effects of Sucrose Consumption

Metabolism: Sucrose consumption affects metabolic processes, including
insulin response and energy storage, influencing overall energy balance
and health outcomes. 10
Dental Health: Excessive sucrose intake has implications for dental health,
contributing to caries formation and oral health challenges, especially in
high sugar diets.
Nutritional Balance: Understanding the role of sucrose in the context of
overall diet and nutrition is vital for maintaining a balanced and healthy
eating pattern.

Industrial Uses of Sucrose

Pharmaceutical Applications:It is used in medications to impart taste to
unpalatable chemicals. It is found in chewable tablets, syrups, dry syrups,
sachets and mouthwash. 11
In the pharma industry, sucrose is used as an excipient, i.e., an inactive
substance that acts as the dosage carrier for an active drug.
Biotechnology: In biotechnology, sucrose serves as a carbon source in
fermentation processes for producing various bio-based products,
including enzymes, organic acids, and biofuels.
Chemical Industry: Sucrose contributes to the production of chemicals,
such as high-fructose corn syrup and ethanol, through advanced
processing and refining techniques.

Importance of Sugar Industry

The sugar industry holds significant importance for several reasons:
Economic Impact: The sugar industry is a major contributor to the
economy in many countries, providing employment to millions of people,
both directly and indirectly.
It also generates substantial revenue through exports and domestic sales.
Agricultural Sector Support: Sugarcane cultivation supports the agricultural
sector by providing farmers with a reliable source of income.
In many regions, sugarcane is a primary cash crop, and its cultivation
12
supports rural economies.
Food and Beverage Industry: Sugar is a key ingredient in various food and
beverage products, including confectionery, bakery items, soft drinks, and
processed foods.
The availability of sugar influences the production and pricing of these
goods.
Trade and Commerce: The sugar industry plays a crucial role in
international trade, with countries importing and exporting sugar to meet
domestic demand and capitalize on market opportunities.
Sugar trade agreements and tariffs can significantly impact global trade
dynamics.
Environmental Impact: The sugar industry can have environmental
implications, both positive and negative.
Sustainable sugarcane cultivation practices can contribute to soil
conservation, biodiversity preservation, and carbon sequestration.
However, issues such as deforestation for sugarcane expansion and water
usage can also arise.

13
 Sugar Production Process
Climate Requirements:
Temperature: Sugarcane thrives in warm, tropical climates with
temperatures ranging between 20°C to 30°C (68°F to 86°F) throughout the
growing season.
Sunlight: It requires abundant sunlight for photosynthesis, typically around
6 to 8 hours of direct sunlight per day.
Rainfall: Adequate rainfall is essential, with an annual precipitation of 1000
to 1500 mm (39 to 59 inches) distributed evenly throughout the growing
season.
However, irrigation may be necessary during dry periods.
Humidity: Sugarcane prefers high humidity levels, ideally above 60%, to
support optimal growth and development.

Soil Requirements:
Texture: Sugarcane grows well in well-drained soils with medium to heavy
texture, such as loam, clay loam, or sandy loam. 14
These soils retain moisture while allowing excess water to drain away.
pH Level: The ideal soil pH for sugarcane cultivation ranges from slightly
acidic to neutral, between 6.0 to 7.5. Soil pH influences nutrient
availability and plant growth.
Organic Matter: Soil rich in organic matter helps retain moisture and
nutrients, promoting vigorous growth and higher yields.
Fertility: Sugarcane requires fertile soils with adequate levels of essential
nutrients, particularly nitrogen, phosphorus, and potassium.

Cultivation Practices
Land Preparation:
Ploughing: The land is ploughed to break up the soil, remove weeds, and
create a seedbed for planting.
Harrowing: Harrowing follows ploughing to further break up the soil, level
the field, and incorporate organic matter or fertilizers.
Ridging: In some regions, ridges or furrows are formed to facilitate
irrigation and drainage.
15
 Planting
Sett Preparation: Sugarcane setts or seed pieces are prepared by cutting
mature cane stalks into sections, each containing one or more nodes
Spacing: Setts are planted in rows with adequate spacing to allow for
plant growth and mechanical operations.
Spacing typically ranges from 90 to 120 cm (36 to 48 inches) between
rows and 30 to 60 cm (12 to 24 inches) between setts within rows.
Depth: Setts are planted at a depth of 5 to 10 cm (2 to 4 inches) in the
soil, ensuring proper contact with the soil for rooting.
Crop Management
Irrigation: Depending on rainfall patterns and soil moisture retention,
irrigation may be necessary to supplement water requirements, especially
during dry periods.
Weed Control: Regular weeding is essential to minimize competition for
nutrients, water, and sunlight. Mechanical cultivation and the use of
herbicides are common weed control methods.
Fertilization: Sugarcane requires adequate nutrients for healthy growth
and high yields. Fertilizers containing nitrogen, phosphorus, and
potassium are applied based on soil nutrient levels and crop 16
requirements.
 Pest and Disease Management
Pest Control: Sugarcane is susceptible to pests such as aphids, borers,
and nematodes. Integrated pest management (IPM) practices, including
biological control, cultural practices, and chemical control when necessary,
are employed to minimize pest damage.
Disease Management: Common diseases affecting sugarcane include
smut, rust, and mosaic viruses. Disease-resistant varieties, crop rotation,
sanitation, and chemical treatments are used to manage diseases and
prevent outbreaks.

17
 Harvesting
Following are some methods of sugar harvesting:

Manual Harvesting:
Traditional Method: In many regions, sugarcane is still harvested manually
using machetes or cane knives.
Workers cut the mature cane stalks close to the ground, leaving a small
portion of the stalk for regrowth.
Labour-Intensive: Manual harvesting is labour-intensive and requires a
skilled workforce.
It is commonly practiced in small-scale or traditional farming operations.

18
 Mechanical Harvesting:
Mechanical Harvesters: In modern commercial sugarcane farming,
mechanical harvesters are often used to streamline the harvesting process
and increase efficiency.
Process: Mechanical harvesters cut the sugarcane stalks at the base and
transport them to waiting trucks or trailers for transportation to the
processing facilities.
Efficiency: Mechanical harvesting reduces labour costs and speeds up the
harvesting process, allowing for larger areas to be harvested in a shorter
time frame.

19
 Harvesting Considerations
Timing: Sugarcane is typically harvested when it reaches full maturity,
usually between 12 to 18 months after planting, depending on the variety
and growing conditions.
Quality: Careful attention is paid to harvesting practices to minimize
damage to the cane stalks and preserve sugar content.
Proper harvesting techniques help ensure high-quality cane for processing.

20
 Transportation Methods
Trucks: Harvested sugarcane is loaded onto trucks or trailers for
transportation from the fields to the processing facilities, such as sugar
mills or refineries.
Railways: In some regions, railways are used to transport sugarcane from
the fields to the processing facilities.
Specialized railcars designed for carrying bulk cargo, such as sugarcane,
are employed for efficient transport.
Waterways: In areas with access to navigable waterways, barges or boats
may be used to transport sugarcane from the fields to the processing
facilities, especially in coastal regions or areas near rivers.

21
 Transportation Considerations
Efficiency: Efficient transportation is crucial to minimize delays and
ensure timely delivery of harvested sugarcane to the processing facilities,
where it is processed into sugar and other products.

Infrastructure: Adequate infrastructure, including well-maintained roads,

railways, and waterways, is essential to facilitate the transportation of
sugarcane from the fields to the processing facilities.

Storage: Depending on the distance and timing of transportation,

harvested sugarcane may need to be temporarily stored in designated
storage yards near the processing facilities before processing.

By employing appropriate harvesting methods and efficient transportation

practices, the sugarcane industry can optimize the supply chain and
ensure a steady flow of raw material to the processing facilities for sugar
22
 Sugar Processing
Sugar processing involves several intricate steps that transform sugarcane
into the sweet granulated sugar we consume.
From the extraction of juice to the final refining and packaging processes,
each step plays a crucial role in delivering the high-quality sugar.

23
Extraction of Juice from Sugarcane
Sugarcane is harvested and transported to the processing plant.
The cane is cleaned to remove dirt and debris.
It is then crushed to extract the juice. This can be done through various
methods such as milling, shredding, or crushing rollers.
The extracted juice contains impurities like fibres, wax, and other organic
materials.

24
 Methods of Extraction
Mechanical Extraction: Large machines crush the harvested sugarcane to
squeeze out the juice, ensuring maximum extraction.
Chemical Treatment: In some cases, chemicals like Lime (calcium oxide or
calcium hydroxide) and phosphoric acid are used to aid in the efficient
separation of juice from sugarcane fibers.
Juice Filtration: The extracted juice undergoes filtration to remove solid
impurities, resulting in pure sugarcane juice.

Purification and Crystallization

Purification Techniques: The juice is purified by the Defecation,
Carbonation, Sulphitation, Extra Bleaching.
-Defecation: It is a process in which the juice is treated with 2-3% Ca(OH) 2
solution or water and heated with steam. This process removes organic
acids (oxalic acid) as soluble calcium salts and phosphates as insoluble
calcium phosphates
25
-Carbonation: The defecated juice contains excess lime and calcium
sucrate. To neutralize excess lime and to recover sucrose from calcium
sucrate, carbonation is done which includes the treatment with CO 2 gas in a
cylindrical vessel.

-Sulphitation: It involves the treatment of juice with SO2 gas.

The objectives of sulphitation are:
Neutralization of any Ca(OH)2 still left in the juice.
Bleaching of coloring matter of the juice left after defecation.

The purified juice is concentrated by boiling under reduce pressure in

multiple effect evaporators
Crystallization Process: The concentrated juice is seeded with sugar
crystals, initiating the crystallization process.
As the crystals grow, the remaining liquid, known as molasses, is
separated from the sugar crystals. 26
 Refining
Final Refining: The raw sugar crystals undergo further refining to remove
any remaining impurities and achieve the desired level of purity.
This refining process may involve additional filtration, recrystallization, and
washing with water.
Once the sugar reaches the desired purity, it is dried to remove excess
moisture.
The sugar crystals are washed and further purified to achieve the desired
level of purity and appearance.
Granulation: The refined sugar is dried, cooled, and separated into
granules of specific sizes for packaging.

Packaging
The refined sugar is then packaged into various sizes and types of
containers, such as bags, boxes, or bulk containers, depending on market
demand.
Packaging includes labelling with nutritional information, expiration dates,
27
and branding.
The packaged sugar is then distributed to retailers for sale to consumers.

Quality Control
Throughout the entire process, quality control measures are implemented
to ensure the final product meets food safety standards and consumer
expectations.
Additionally, waste products generated during processing, such as
bagasse (fibrous residue from sugarcane), may be utilized for purposes
such as energy generation or animal feed, contributing to the
28
sustainability of the sugar processing industry.
 Beet Sugar
Beet sugar is produced from sugar beets, a root vegetable with a high
sugar content. The process of producing beet sugar is similar to
sugarcane processing but differs in the initial extraction stage. Here's an
overview:
Harvesting: Sugar beets are harvested from fields, usually in the late
summer or early fall when they have reached maturity.
Cleaning and Slicing: The harvested beets are thoroughly cleaned to
remove dirt and debris.
They are then sliced into thin strips to increase the surface area for
extraction.
Extraction of Sugar: The sliced beets are soaked in hot water to extract
the sugar from the cells.

29
Purification and Crystallization: The extracted beet juice undergoes a
process similar to that of sugarcane juice, including clarification,
concentration, crystallization, and separation of sugar crystals from
molasses.
Refining and Packaging: The raw sugar crystals are further refined to
achieve the desired purity level, dried, and packaged for distribution and
sale.
Beet sugar is a common alternative to cane sugar and is widely used in
food and beverage production.

30
 Other Sugar Sources
Apart from sugarcane and beet sugar, there are several other sources
of sugar, including:
Corn: Corn syrup and high fructose corn syrup are derived from corn
starch through enzymatic conversion.
Maple: Maple syrup or sugar is produced from the sap of certain maple
tree species.
Coconut: Coconut sugar is derived from the sap of coconut palm trees.
Date: Date sugar is made from dried dates ground into a powder.
These alternative sugars offer different flavours and nutritional profiles
compared to cane and beet sugar and are used in various culinary
applications.

31
By-Products of the Sugar Industry
The sugar industry produces several by-products, which are often utilized
in various ways to minimize waste and maximize efficiency:
Bagasse :It is the cellulosic material left after the extraction of juice.
It is used as boiler fuel, as a raw material for the manufacture of celutex,
good quality paper and board (called chip board)
Molasses: The syrupy by-product remaining after crystallizing sugar from
sugarcane or sugar beets.
Molasses is used in the production of alcohol, animal feed, and as a
flavouring agent in food products.
Press mud: A residue obtained during the clarification process of
sugarcane juice. It is rich in organic matter and nutrients and is commonly
used as fertilizer or soil conditioner in agriculture.
Filter cake: A solid residue obtained from filtering sugar juice. It is often
used as a soil amendment or animal feed supplement.

32
These by-products play a significant role in the sustainability and
economic viability of the sugar industry, contributing to the circular
economy by finding valuable uses for materials that would otherwise be
discarded.

33
Sugar Production Process

34