TRAINING PROJECT REPORT ON AGRO-INDUSTRIAL

ATTACHMENT
AIA-414
THE AJNALA COOPERATIVE SUGAR MILLS LIMITED

Semester -8th
“Bachelor of Science of Agriculture Honours”

SUBMITTED BY SUBMITTED TO:

Name: Pawandeep kaur P. G. DEPARTMENT OF

Registration no.: 2017.K/A.1179 AGRICULTURE

College roll no.: 17101166 KHALSA COLLEGE

University roll no.: 17110012531Amritsar

 ACKNOWLEDGEMENT

Successful achievement of any target involves interest and efforts of many people and without them project
should not be expected to fulfil. On accomplishment of this Agro-industrial attachment, I would like to
express my deep sense of thanks and gratitude to those who always helped me without any hesitation and
excuses
.
Primarily, I would like to thank good for being able to complete this module with success. Then I would like
to thanks Indian council of agriculture research (ICAR) members who decided to give practical knowledge
and to improve entrepreneurial skills in students. I owe a deep sense of gratitude to Dr. Mehal Singh
(principal) Khalsa college Amritsar and doctor Mrs. Randeep Kaur Bal head agriculture department. there
overwhelming attitude towards students is so encouraging and inspirational.

Further, I would like to express my gratitude toward the Mr. Satwinder Singh and whole staff of the Ajnala
cooperative sugar mill for their cooperation, who gave us their precious time to guide us about the whole
milk processing plant. I really appreciate their efforts towards completion of my training.

I am extremely thankful to workers who cop- operated with me during hard times of COVID – 19. I would
give a heartiest thank to my parents and friends those who helped me with their valuable suggestions and
guidance in various faces of completion of my project. It is the kindness of these acknowledged persons that
this report file sees the light of the day. I submit this report of mine with great humility and utmost regards.
 PREFACE
Training has become the most integral part of studies to get a wider and deeper view of education. This
report is the result of my training at Ajnala cooperative sugar mill ltd. from 07/12/2020 to 02/01/2021
included in agroindustry attachment – 2 (AIA – 415). This training is a part of my course B. Sc. Agriculture
(Semester – 8th) pursuing at Khalsa College Amritsar.

My training in this industry indulge and assist me to get knowledge about the processing of sugarcane for
sugar production, its establishment and basic needs of the middle men and big farmers. The report is
prepared with to include all the details regarding the project one carried out. I wish that my efforts will help
me in getting the positive results from the authority.
 CERTIFICATE

The report entitled ‘Om Milk Foods’ is submitted to P.G. Department of Agriculture, Khalsa College,
Amritsar is an original work and has not been copied from elsewhere. If any part is found copied, the report
may be rejected.

Signature of student (Pawandeep kaur) :

University Roll No.:17110012531

College Roll 17101166

REMARKS BY THE EVALUATION COMMITTEE

INDEX
Sr. No. Topic Page no.
1 Introduction 7
2 History of mill 8
3 Current status of sugar industry 8-10
4 About the ajnala cooperative sugar mills 11-12
5 Infrastructure of mill 12-14
6 Mill layout 15-16
7 Survey and bond 16-20
8 Whole process of manufacture sugar 20-21
9 Token Gate 22-24
10 Cane processing 24-33
11 Crystallisation of sugar 33-36
12 Grading , Bagging , Storage of sugar 37-38
13 Marketing of sugar 38-40
14 The sugarcane seed farm 40-44
15 Seed sampling 45-48
16 Economics of the mill 48-54
17 SWOT analysis 54-57
18 Feedback 58
19 Conclusion 58
SUGAR MILL:-

A sugar cane mill is a factory that processes sugar cane to produce

raw or white sugar. The term is also used to refer to the equipment

that crushes the sticks of sugar cane to extract the juice.

1. INDRODUCTION:

The Ajnala Cooperative Sugar Mills Ltd was registered vide Letter No. 21 dated 4-4-1977and started its‟
first crushing season in the year 1990-91. This mill was built by company by the name of SUMAC and they
planned the layout and constructed the building with proper space for each station kept in mind.

The table below represents brief information about Ajnala sugar mill.

S.no Particulars Details

1. Plant/ factory name The Ajnala co-op Sugar

Mills Ltd.
2. Location Village Bhala Pind, Tehsil
Ajnala, Distt. Amritsar.
3. Factory nature Co-operative
4. Total expenditure during Rs 2698.00 lacs.
installation
5. Total area 123 acres

This mill was established to serve for the farmers of the Punjab by following (Objectives):-

1. To eliminate duopoly of the private mills by setting up these mills and giving a strong competition to
them.
2. To increase the income of the farmers by processing the cane they grow in their fields.
3. To provide guidance to the farmers about proper cultivation of sugarcane and providing them proper
knowledge about new technology periodically.
4. To facilitate the farmers by making them wait less for unloading there canes by having a high processing
capacity of the canes per day.

Other objective of the mill was to reduce cost of the repair of machinery, to increase the efficiency of the
mill.
2. HISTORY OF MILL:
Origin of sugar industry and sugar itself is not quite cleared yet as many believes that sugar industry
originated from Persia in 7th century while other believes it was founded by Europeans during the crusades
in 11th century.

Sugar was considered as a luxury item in the late 15th century to the early 17th century when Spanish and
Portuguese had expanded sugarcane cultivation in Puerto Rico, Cuba and Brazil
and shipped it back to Europe to refine. In the 17th century, the British Government developed sugarcane
cultivation areas and sugar mass production on West Indian islands, since then sugar became a popular
product for all classes. The sugar industry is one of the oldest food processing industries in the world, with
more than 100 countries and territories participating in the value chain. The scale of global sugar production
is about 174.8 million tonnes in crop year 2013/14 and achieves average growth rate of 2 %/year. Sugar can
be made from two main ingredients:

Sugarcane – 75-80% of the global supply and it is mainly grown in tropical countries.

Sugarbeet – 25-30% of the global supply and it is grown in temperate countries.

Some countries such as the U.S. or China can plant both of them since they have large areas. Sugarbeet is a
short rotation plant on the other hand it typically takes about 12 months to 16 months to plant and harvest
sugarcane and roots of the predecessor can be used to re-grow sugarcane for upto certain years depending
upon variety as well as soil health and health of previous crop, after this period the sugarcane begins to lose
its sugar content and become un economical for the grower.

3. CURRENT STATUS OF SUGAR INDUSTRY

Sugar trading volume on the world market is around 55-60 million tonnes, of which the largest producing
countries are Brazil (22% of total production), India (15%), China (8%) and Thailand (6%). As a result of
greater domestic demand than production in India and China, the supply of sugar on the international market
depends heavily on the two remaining countries, namely, Brazil and Thailand.

 Sugar industries are the backbone of the economic development of Agro-industrial sector of the
nation. In India, Sugar industry is the second largest agro-based industry and it contributes
significantly to the socio economic development of the nation. Indian sugar industry is also a major
sector to create employment probably 7.5 per cent in Indian economy (2014).
 The sugar industry plays a leading role in global market being the world‟s second largest producer
after Brazil, producing nearly15% and 25% of global sugar and sugarcane respectively.
 The sugar industry produces around 300-350 million tonnes (Mt) cane, 20-22 Mt white sugar and 6-8
Mt jaggery to full-fill the domestic demands of sweeteners. The industry is able to export around
1300 MW of power to the grid.
 Sugar industry is also involve to make avail of sugar complexes by manufacturing sugar, bio-
electricity, bio-ethanol, bio-manure and chemical. These contribute about 1 per cent to National
GDP. Sugar industries in India remains regulated and are a source of livelihood for 50 million
farmers and their families.
 It provides direct employment to over 5 lakh for both skilled as well as labourers but also to semi-
skilled labourers in sugar mills and allied industries across the nation. The annual turnover of the
sugar industry in India was estimated at Rs.41,000 crore and it has been paying taxes to the
government Rs.2,500 crore per annum in year 2013-2014.

State wise in India Uttar Pradesh is highest in terms of sugarcane planting area and sugarcane production.
The table below represents state wise area under sugarcane plantation and yield as well as total sugarcane
production in India in year(2015-16) and (2016-17) along with total area under irrigation in year(2016-17).
State Area % of Produ % of Yield Area % of Produ % of Yield Under
All - ction All - All - ction All - Irrigati
India India India India on(%)
2014-
15*
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Uttar 2.16 49.22 144.78 47.20 67029 2.17 44.02 145.39 41.72 67029 95.4
Prades
h
Mahar 0.63 14.42 50.64 16.51 80006 0.99 20.03 73.68 21.15 74650 70.5
ashtra
Karnat 0.35 8.07 23.54 7.68 66500 0.45 9.13 37.83 10.86 84075 99.4
aka
Tamil 0.21 4.73 17.22 5.61 83002 0.25 5.12 25.49 7.32 10105 100.0
Nadu 9
Bihar 0.24 5.52 15.42 5.03 63639 0.24 4.95 12.65 3.63 51837 79.3
Gujara 0.17 3.85 11.95 3.90 70710 0.16 3.19 11.12 3.19 70828 94.5
t
Harya 0.10 2.32 8.64 2.82 84706 0.09 1.89 6.69 1.92 71957 100.0
na
Andhr 0.10 2.35 7.85 2.56 76252 0.12 2.48 9.35 2.68 76664 92.4
a
Prades
h
Punjab 0.09 2.01 7.25 2.36 82409 0.09 1.83 6.61 1.90 73411 97.7
Uttara 0.09 2.12 6.48 2.11 69645 0.10 1.97 5.89 1.69 60772 98.7
khand
Madh 0.09 2.10 4.73 1.54 51413 0.10 2.09 5.28 1.52 51272 99.9
ya
Prades
h
Telang 0.03 0.59 2.16 0.70 82885 0.04 0.71 2.41 0.69 68714 100.0
ana
West 0.02 0.48 2.08 0.68 98881 0.02 0.35 2.08 0.60 11923 84.6
Benga 2
l
Assam 0.03 0.73 1.16 0.38 36219 0.03 0.60 1.04 0.30 25245 1.5
Odish 0.01 0.28 0.81 0.27 65440 0.01 0.18 0.58 0.17 64415 100.0
a
Others 0.05 1.23 2.01 0.66 @ 0.07 1.46 2.37 0.68 @ -
All 4.39 100.00 306.72 100.00 69886 4.93 100.00 348.45 100.00 70720 90.2
India

The above table is evident that sugarcane processing industry is very important for the farmers of India since
it is a very large quantity of sugarcane that is processed in India thus providing income to a large amount of
population of individuals in Indian agriculture. Sugar factories in India have capacities ranging from 1250
tonne cane crushed per day (TCD) to 10000 tonne cane crushed per day. The Indian sugar industry has
developed indigenous capabilities for design, manufacture, supply, operation and maintenance, R&D and
cane development. The major stakeholders of this industry in India are Ministry of Agriculture, Govt. of
India, Ministry of Consumer Affairs, Food and Public Distribution, federations of co-operative and private
sector sugar factories at the national and the State levels, sugarcane growing farmers, equipment and
technology suppliers, research institutions, consultants and service providers, financial institutions and
Central / State Governments.
Status of Installed Sugar Factories in India

Sugar factories in India have capacities ranging from 1250 tonne cane crushed per day (TCD) to 10000
tonne cane crushed per day. The Indian sugar industry has developed indigenous capabilities for design,
manufacture, supply, operation and maintenance, R&D and cane development. The major stakeholders of
this industry in India are Ministry of Agriculture, Govt. of India, Ministry of Consumer Affairs, Food and
Public Distribution, federations of co-operative and private sector sugar factories at the national and the
State levels, sugarcane growing farmers, equipment and technology suppliers, research institutions,
consultants and service providers, financial institutions and Central / State Governments.

Sugar factories in India are spread over the entire country; however 92% of them are located in 9 States viz.,
Uttar Pradesh, Bihar, Punjab and Haryana in the north, Maharashtra and Gujarat in the west and Karnataka,
Andhra Pradesh & Tamil Nadu in the south. More than 80% sugar factories are below 3500 TCD capacity.
About 44% of the Indian sugar factories are in the co-operative 9% in Public sectors and rest 47% in the
private sector.

Table below represents total number of sugar manufacturing industries in India.

States Private Public Co-op Total

Assam 1 - 2 3
Orissa 4 - 4 8
Bihar 13 15 - 28
Uttar 116 14 28 158
Pradesh
Uttarakh 4 2 4 10
and
Punjab 8 - 16 24
Haryana 3 - 13 16
Andhra 29 1 14 44
Pradesh
Tamil 27 3 16 46
Nadu
Maharas 59 - 168 227
htra
Gujarat 4 - 22 26
Madhya 15 2 5 22
Pradesh
Kerala 1 - 1 2
Rajastha 1 1 1 3
n
Karnata 47 3 24 74
ka
Puduche 1 - 1 2
rry
Goa - - 1 1
Chhattis - - 3 3
garh
West 2 1 - 3
Bengal
All India 335 42 324 701

Maharashtra has the highest number of sugar factories in India where as it is lowest in Goa. Punjab still does
has considerable number of sugar factories ( 24 ) that‟s why is very important industry in Punjab and help in
making a considerable share in GDP of Punjab.
4. ABOUT THE AJNALA COOPERATIVE SUGAR MILLS

About Mill

Located In: Bhalla Pind

Address: Ajnala, Punjab

Factory Name: The Ajnala Co-operative Sugar Mills Ltd.,

Bhalla Pind, Punjab

Operational status: Working

Factory Nature: Co-op

Nearest Railway Station: Amritsar 17 km

Nearest Airport:: Raja sansi 08 Km

Nearest Hotels: i) Radisson Blue Amritsar 08 km.

ii) M.K.International, Amritsar 20
Km

Area of Land

Plant and Machinery 25.0 Acres

Cane Yard 11.6 Acres
Residence Colony 22.2 Acres
Offices 2.4 Acres
Cane Farm 60 Acres
Surplus Land 1.4 Acres
Total 123.0 Acres

Achievements of Sugarfed-

During the year 2018-19 sugar mills crushed 219.98 lacs quintals sugar cane with an average recovery of
9.94% and crushed 223.53 lacs qtls. in the crushing season 2017-18 with average recovery of 9.48%. State
Govt. has given Rs.215.00 crores as financial assistance towards cane payment for the year 2017-18.
Mission of sugar fed -

To increase the profitability of the running Cooperative Sugar Mills and to revive the sick Cooperative
Sugar Mills.

5. INFRASTRUCTURE OF MILL

a) Mill processing unit- the mill processing unit includes a large building inside which all the processes of
making sugar from the cane are carried out-
it includes mill tandem unit, juice clarifying unit, boiler house,vapour cell unit, sugar grading unit,
sugar packing unit.

b) Kissan Aaram ghar- Kissan aaram ghar is the infrastructural

facility provided to the farmers by the mill for staying at night
or for the rest of the farmers as it takes a long time, to the mill
unloading unit from the token gate itself.
This is provided near to the lines of the cane loaded trolley
from which they can have a watch on their tractor-trollies.

Kissan Aaraam Ghar

c) Storage shed for sulphur- it was a shed for the storage of

chemical sulphur which is used in the sulphitation
of juice and syrup.

Sulphur Storage Shed

d) Storage Godowns for sugar- These godowns were large storage houses built for the storage of
sugar bags. The godowns were built with cemented floor to avoid the storage loss of the sugar. It has
only one gate but did not have any window or other gate to avoid ventilation of air.
e) Workshop- there was also the provision of workshop for the storage of any machinery related
things. It had many large machines and equipments used for the repair of any working machinery in
the unit and all the replaceable materials of the machines working in the mill were found there. The
In-charge of the workshop keeps the record of all the materials placed in the workshop or the
materials/equipments which the workshop made available to the mill.

f) Store- The store was built close to the workshop and contains smaller machinery parts, nuts, bolts,
bearings and such other things.
Piles of different materials were present therein- such as coco peat, gas cylinders and many other
things
g) Dispensary- there was also the provision of dispensary to face
any mishappening which could occur in the mill area. It had all
the necessary First-Aid and medicine facility for the treatment
of any patient, who got hurt inside the mill premises

h) Gurudwara- Gurudwara was also built at the one side of

the mill premises for the workers or men who stay permanently in the mill for years.

i) ATM- An automatic teller machine was also there for the use by any famer or any worker in the
mill.
j) Cooperative bank – the mill also had the bank facility available inside.

Cooperative Bank

k) Mill‟s shop- The shop is present at the front periphery of the mill, to the side of the Amritsar- Ajnala
Road.
6. MILL LAYOUT:
This mill built on area of about 125 acres and mill includes following complexes in its total area.

1. Plant machinery – This is the area in which main processing of canes takes place and cane juice is
converted into white sugar.

Picture – Outer view of plant machinery shed.

2. Office/ Administration – In these area main executives of the mills have their office and control the
functioning of the mill.
3. Cane yard – Tractors of the farmer carrying the canes for crushing waits for their turn in this area. There is
also a canteen, washroom and waiting room for the facilitation of the farmers.

Picture – A view of cane yard

4. Cane seed farm – This is the area behind the mill where sugarcane for seed purpose for the farmers is grown.

5. Residential colony – This is the area in which some workers of the mill who live far from the mill reside.
 Picture – 1. residential colony, 2 children playing residential colony‟s park

Area distribution of the each complex of the mill is as following:-

S.no Land Acres

Distribution

1. Plant & 25.0

Machinery
2. Cane Yard 11.6
3. Cane seed Farm 60.0
4. Office/ 2.4
Administration
5. Residence 22.2
Colony
6. Surplus Land 13.4
Total 125.0

7. SURVEY AND BOND

Survey – Survey is the collection of the details about sugarcane plantation data in the region of the mill.
During survey a detailed data about most of the aspects of sugarcane plantation is collected. This data helps
in preparation of cane slips/parchi for each of the cultivator of sugarcane.

Surveyor – The person appointed by the mill to do the survey of the region is called surveyor. His job is to
go to villages in that region where sugarcane grows and register the farmer who is willing to dispose the
cane at the mill.

Functioning of the surveyor:

1. A certain number of villages are allotted for each surveyor.

2. Then the surveyor has to register the farmers who are willing to supply their canes to the mill. This will
help in recording of area under canes and expected yield.

3. Surveyor has to collect detailed information about each farmer by making 6 to 7 rounds at his farm.
4. In order to ensure that there are proper rounds made by surveyor, GPS of surveyor‟s mobile is tracked by
mill.

The surveyors‟ work under 1st – 7th round to a single farmer is briefed as following:-

• 1st – 3rdround: a. To record the farmer‟s is willingness to grow sugarcane crop.

b. To record the total area under sugarcane crop.

c. To recommendthe best season / time to sow the crop i.e., spring, autumn and
that too early /mid/late.

d. To recommend the best suited variety as per the needs of farmer and also
according the requirements of mill. Example, some farmers keep some part
of their produce for jaggery making / juice extraction
.
e. To deliver the information about trusted (registered/certified) source of cane
seed and chemical for seed treatment.

f. To recommend the appropriate fertilizer dosage & application as per variety,

soil. Example, recommendation of DAP at sowing time if deficiency is seen in
soil.

4th –5th round: a. To check any disease infestation & recommend the appropriate treatment.

Fungal Diseases Treatment recommended

● Smut Seed treatment by

Bavistin (Carbendazim
or Tebuconazole)

● Wilt Bavistin

● Red stripe Bavistin

● Pokkah Beong Bavistin

b. To check any insect/pest infestation & recommend the appropriate treatment

Insect/pest Chemical control

 recommended

● Black Bug Chlorpyriphos @ 2

liters in 400 liters water
per acre

● Sugarcane Pyrilla Chlorpyriphos @ 2

liters in 400 liters water
per acre

● Top Borer Coragen @ 150 ml in

400 liters water per
acre

● Shoot Borer Coragen @ 150 ml in

400 liters water per
acre

● Gurdaspur Borer Rogue out infected

canes

c. To recommend the best suitable intercrop & their cultural practices that can be planted without affecting
yield of sugarcane crop.

d. To identify that whether farmer is doing Organic Farming or Conventional

farming.

e. To check any of the deficiency or toxicity symptoms of certain nutrients and

if seen any, recommend optimum nutrient source.

• 6th – 7th round : a. To check brix, with the help of brix meter with objective of seeing the current

situation of crop. Brix meter is used by extracting a few drops from cane and measurements can be seen on
its‟ screen. It is done to make sure that the cane that‟s going to mill has a minimum brix of 18%
.
b. To check the final status of the crop, about any bacterial/fungal/viral disease, insect/pest attack,
deficiency/toxic symptoms.]

Picture – final cane survey report of year 2019-20 and 2020-21

After the completion of survey, bound was done with farmer.

Bound – In this, farmer is bonded with the contract in which contains variety and amount of sugarcane
being supplied to the mill.

Procedure – a. Before one month of harvesting, surveyor visits the farmer and confirms that
if farmer is willing to sell his cane at mill or not.

b. If farmer confirms his selling at mill, surveyor bounds thefarmer for his sugarcane selling.

c. Also, surveyor note down these things with all the things noticed in 7 rounds at time
of bond:

○ Expected Yield farmer will deliver at mill.

○ Brix of cane. (preferably should be more than 18%)

d. Then, surveyor provides farmer a calendar which determines him about expected
Mill Supply Ticket (Parchi system) against which he can deliver cane.

e. After all that, Mill Supply Ticket was issued to all the bounded farmers telling about the
date on
which they have to deliver the cane.

f. This Mill Supply Ticket was then delivered to farmers‟ house by Surveyor.

Picture – Final bond report of year 2019-20 and 2020-21

Parchi for Bringing Cane produce to mill

Mill Supply Ticket issued to farmer included this information :

●About Farmer – ○Name of Farmer ○Fathers‟ Name ○Mobile-No

. ○Village

○Division ○Bank name ○Account No.

●About delivery - ○Date ○Variety ○Season ○Group

○Grower code ○Parchi No. ○Approx. Weight allowed

○No. of trolley out of total trolleys issued.

On date issued for delivery, each farmer was supposed to deliver the cane within 3 days from the date. The
defaulter has to get special permission from S. Bikramjit Singh Khehra, CCDO ( ChiefCane Development
Officer )of mill to get permission to unload is cane after his allotted date. If a farmer is unable to supply the
amount of sugarcane as mentioned in the bond, he has to pay fine according to the amount of cane.

8. WHOLE PROCESS OF MANUFACTURING SUGAR:

CANE WEIGHMENT
↓
CANE PREPARATION

Imbibition of water ↓
JUICE EXTRACTION THROUGH MILLING
Bagasse ↓
JUICE WEIGHMENT

STEAM BOILER ↓
(Electricity generation for sugar Plant)
WEIGHED JUICE RECEIVING TANK
↓

RAW JUICE HEATING (65ºC-72ºC)

↓

Addition of SO2 gas → JUICE SULPHITATION ← Addition of Milk of Lime

↓
SULPHITED JUICE HEATING (102ºC)
↓

JUICE CLARIFIER (Decanter)

 CLEAR JUICE MUDDY JUICE
↓ ↓

JUICE HEATER ( 105-106ºC ) ROTATORY VACCUM FILTERS

↓ ↓ ↓

EVAPORATORS FILTER CAKE FILTRATE

↓ ↓ ↓

SYRUP USED AS MANURE JUICE WEIGHMENT TANK

SYRUP SULPHITER So2 gas
↓

TANK - A (AH)
Grain / Seed added

PAN-A1 PAN-A2 PAN-A3

CENTRIFUGAL MACHINES

DRY WHITE SUGAR – A MOLASSES – A

↓ ↓

GRADING TANK – B (BH)

↓ ↓

BAGGING PAN – B1
↓

STORAGE SUGAR – B MOLASSES – B

↓ ↓

SUGAR MELTER TANK – C (CH)

↓ ↓

MELTED SUGAR SENT BACK TO PAN – A SUGAR – C FINAL MOLASSES

↓
STORAGE TANK

(For quality improvement)

SUGAR MANUFACTURING PROCESS FLOW CHART


9.TOKEN GATE – ENTRANCE OF MILL:

Sugarcane to be delivered was entered in the mill through Token Gate, whose‟ in-charge was CDI
(CaneDevelopment Inspector). There were two CDI Harpal SinghandAnuraj Singh who worked in
shifts(day and night). They guided us through the mill made us to interact with other working staff in the
mill and helped us in getting knowledge about different sectors of the mill.

According to the knowledge provided to us by the CDI and our observations we concluded following were
the duties of CDI:-

* To check the Mill Supply Ticket fordate if the farmer delivered cane within time limit or not.

* To note the time of delivery on Mill Supply Ticket.

* To verify the varietyof cane delivered respective to the variety written onMill Supply Ticket.

* To check the brixof the delivered cane so that cane below 18% can‟t go inside. (due to protocol of mill,
otherwise it will go in loss)

* To check the condition of delivered cane with respect to quality, dryness&currentcondition of cane
i.e., healthy/greenish mould if older/black mould.

* After checking above parameters, CDI write down the Token No. & Line No. on Mill Supply Ticket of
respective farmer & inform the farmer.

Cane Yard – After getting permission from CDI, farmer carried his tractor-trolley in one of the lines
allotted by CDI at Cane Yard. The features observed about cane yard are listed below.

• Cane yard was located in an area of 11.6 acres.

• It had the capacity of 250 cane loaded tractor-trollies at a time, comfortably. And
forcefully 320-330 in congested way
.
• Drums ¾th full of soil were used as indicator of lines made for disciplinary purpose,
keeping ¼ of drum below ground level & rest above.
• There were no proper concrete roads leading to a number of problems like tires got stuck in muddy
soil in rainy days, unevenness in lines.

Though, farmers had to follow discipline of queues to avoid any kind of disputes &
violence.

Picture – A view of cane yard

Other than these normal lines, there was a special passage straight to the weighment area known as
“SPECIAL LINE”.

Special Line –○ The criteria for allotting through this special line was having total yield more
than 20,000 Quintals.

○ After every 5 trollies from normal line, 1 trolley from special line was passed to
Weighment & unloading.

○ The purpose of this line was to ease large farmers having much larger area under
sugarcane cultivation.

Picture – a view of special line

Cane weighment

o When the farmer‟s turn arrives, he took his tractor to the cane weighment area.
o At this area a large platform was built which recorded the weight of the canes along with the tractor
and trolley.

Picture –weighment area

10. CANE PROCESSING

After the farmer brought there cane to the unloading area the main process of sugar starts from there.

1. Cane unloader:

• After weighing of sugarcane the trolley containing sugarcane was parked under the cane unloader.

• There were 3 cane unloaders from which first two were used extensively and the remaining third one was
rarely being utilized
.
• The cane unloader took about 5 to 7 minutes to unload a trolley.

• During the unloading the cane unloader picked canes from the trolley and drops
the canes on a conveyor belt which takes the canes for cutting and chopping.

• The conveyor belt is of 102 m in length with 620 slates and 6 inches of pitch.
• After unloading, the returning trolley was also weighed in order to calculate the weight of trolley and
sugarcane.
 Cane Unloading Dock

2. Chopping, cutting and fiberizing:

 After the unloading of sugarcanes, the canes are moved towards the chopping machine which has 32
blades and chops the canes into small pieces.
 The chopper machine was powered by a 150 HP motor which runs at 585 RPM.
 After cutting the canes are moved towards the cutting machine which have 42 blades and it cut the
canes into even smaller pieces.
 The cutting machine was powered by a 250 HP motor which runs at 585 RPM.
 These smaller pieces are then moved towards fiberizer by the help of conveyor belt. The fiberizer
makes the fibres of the canes without forcing the juice to come out of the canes.
 The fiberizer was powered by 400 HP motor.
 When the canes passes through fiberizer the canes looks like small fine threads.
 After this process the canes are ready to be crushed for juice extraction.

Picture – 1- Canes being crushed, 2- worn out blades of cane chopper

 3 Cane milling:

Picture – 1- A wide angle view of all mills, 2- A view of milling rollers when not being used

 There were 3 mills which used to extract the juice from the canes.
 Each mill had following parts for its core function:
 Rang carrier – It carried fiberized canes above the milling rollers and it was placed at 85o angle from
the shaft.
 Shaft – it was placed at the end of the rang carrier which carries the fiberized cane towards the
milling rollers.
 Top roller – It was one of the three milling roller and it provides weight and pressure to other two
mills at its bottom.
 Feed roller – It was second roller and it receives the fiberized canes from the shaft and bring that
canes between the 3 rollers for crushing and extraction of juice.
 Discharge roller – This was the last roller and it discharge the bagasse and transfer it to the rang
carrier of next mill
 Each of the 3 mills used to have a set of these core parts along with pipe for water supply and a pan
for juice collection.
 Each mill had its own different way of juice extraction which is explained below:-

Milling Unit 1.
Mill no. 1:

In this mill about 65% of the juice is extracted from the canes
.
• For juice extraction, fiberized canes were fed to the rang carrier which drops the canes to the feed roller
which brings the canes between two mills for crushing.

• During crushing in this mill a mixture of water and juice from 3rd mill was added to the roller for helping
in extraction of juice as much as possible.

• The juice extracted from this mill was then transferred to the juice collection tank.
• The bagasse remaining was then transferred to the next mill.

 

Mill no.2:

• In this mill about 85% of the juice is extracted from the canes.

• Crushed canes were fed to the rang carrier which drops the canes to the feed roller which brings the
canes between two mills for crushing.

• During crushing in this mill water at 80 to 900 was added to the roller for helping in extraction of
juice as much as possible.
• The juice extracted from this mill was then transferred to the juice collection tank.

• The bagasse remaining was then transferred to the next mill.

•
➢Mill no.3:

• About 2% of the juice is left in bagasse after crushing from this mill.

• For juice extraction, fiberized canes were fed to the rang carrier which drops the canes to the feed roller
which brings the canes between two mills for crushing.

• During crushing in this mill water at 80 to 900 was added to the roller for helping in extraction of juice as
much as possible.

• The juice extracted from this mill was then mixed with water and supplied to the mill no. 1.

• The bagasse remaining is then transferred to the boiler as fuel.
4. Boiler house:

Boiler Attendant – Avatar Singh

The bagasse obtained after the extraction of juice from the mill

tandem was transferred to boiler department through bagasse

carriers.

Boilers- Boilers are used for the generation of high-pressure

steam from the burning of bagasse.

The boilers are cleaned twice, every 8 hours to remove the

burnt over residues or ash, left in the combustion region.

Boiler Meters

Bagasse for sale -The extra bagasse left after the fulfilment of the need of the bagasse in the boilers, it was
thrown out of the boiler house in an open are from where it was made available to the farmer for use it as a
crop manure or for other burning purposes
5. Juice filtering:
• The juice collected from mill station 1 and 2 is then transfer to the juice filter machine.
• At this machine the juice is passed through a mesh of steel which filtered the juice and separated the
bagasse and transferred to the rang carrier of fir mill station.
• After the filtration of juice the juice was then send to the juice weighment tank.

Picture – Juice filter

6. Juice weighment and heating:

• The filter juice was weighed at this point.
• The filtered juice was then transferred to the juice heater number one.
• At this point the juice was heated to 65 to72o C.
• After heating the juice was then sent to sulphation tank.

Picture – Juice weighment counter

H1- Raw Juice Heater- this heater increases the temperature of the raw juice.
 H2- Sulphiter Heater- then the juice goes to the heater 2 for further increasing the temperature.

Juice Sulphiter

Juice Clarifier- It was a large vessel fitted with 4 chambers in which the Sulphited juice moves
slowly and gets clarified.

Juice Clarifier

 H3- HEATER 3-It then increases the temperature of the clarified juice.
 Then the juice goes to 2 semi-kestners
These work with the pressure system and evaporate the water content of the juice and concentrate the
juice.

 Vapour cell also further concentrated the juice through evaporation process and heat consumed came
from the steam.

Clarified Juice In Test Tubes

7. Juice sulphation and heating:

• The juice at this point contains a lot of dirt and mud inside of it which is needed to be separated for making
a good quality of sugar.
• This process of clarification of juice is done through the process sulphation and liming.
• In this process the sulphur dioxide gas is added to the juice along with milk of lime.

 Sulphation:
• In this process the raw juice is heated at 70 degree Celsius along with continuous contact with sulphur
dioxide gas.
• The pH of raw juice is brought down from 5.2 to 4.5.
• Then the pH of raw juice is increased by addition of lime after this process the pH of juice becomes 7.5.
• The pH of limed juice is further brought down by addition of Sulphur dioxide gas at pH of 6.9.

Picture – A worker showing us a sample of industrial grade sulphur used in sulphation

process





➢Juice heating
• After the sulphation process the juice was then transferred to the heater number 2.
• At this heater the juice is heated at 102o C.

8 Juice clarification and heating:

 Juice clarification
• After the heating, the juice was then transferred to the decanter where juice clarification takes place.

• At the decanter the heated juice is let to settle.

• After the settling of the juice, the mud remains at the bottom portion of the decanter and the juice is above
the mud.

• The mud settled at the bottom of the decanter is then transferred to the rotary vacuum filter.

• At this filter the remaining juice in the mud is separated and transferred back to the heater number 1.

• From decanter the clarified juice is then transferred to the heater number 3.
 Picture – A senior worker showing us some samples of clarified juice straight from decanter


➢Juice heating:
• After the clarification of the juice, the juice is then heated to the temperature of about 105 o C.

8. Water evaporation:

Picture – A view of evaporation quads station.

 Pressure evaporation:

• The clarified juice is then transferred to the semigation tank and then to the evaporation tank.

• At both of these tanks water from the clear juice is evaporated by applying steam pressure.
• After the utilisation of steam pressure at these two tanks, the steam pressure decreases and becomes
insufficient for further utilisation in water evaporation.

➢Vacuum evaporation:

• After going through evaporation tank, the juice comes to the quads station.
• There were 4 tanks at this station thus suggesting its name.
• At this station water from the juice is evaporated by means of vacuum.
• With each subsequent quads tank the vacuum increases.
• At end of this process the juice become syrup and ready for crystallisation.

9.Quads-These bodies work on the basis of vacuum process. The vapour from the last cell goes into a
condenser.

Syrup- At this stage the juice after evaporation process gets transformed into syrup

Syrup sulphiter- the syrup is Sulphited using SO2 & also the pH is maintained in the sulphiter and the

Quads
Sulphited syrup goes into Pan Station.

At this stage the syrup should have 60°C temperature.

10. CRYSTALLISATION OF SUGAR:

Sugar crystallisation is done by at the pan station of the mill. The process of sugar crystallisation is also
done through pressure and heat.

❖Proper sugar crystallisation process is done at Pan A, B and C.


➢Pan A:

Picture – Juice being crystallised at Pan A

• After evaporation the juice turns into the syrup with sugar content of about 60%.
• The syrup us transferred to the Pan A.
• Pan A has 3 Pans under it named Pan 1, Pan 2, and Pan3. Each of these Pans serves the same purpose.
• In Pan A a mix of powdered sugar called seeds mixed with alcohol is poured through an inlet.
• Due to vacuum and heat, the sugar crystals start forming and grow in size after a few hours.
• A worker periodically check the consistency of the syrup inside the Pan by a sampler provided at the Pan.
• When sugar crystals become prominent and syrup becomes viscous and this thick crystallised paste is
called massquit.
When the massquit is formed, then the crystallised syrup is transferred to the centrifuge where sugar
crystals are separated from the molasses.

Picture – sugar crystal along with molasses sample from Pan A

 Pan B:

• After the separation of molasses and sugar from Pan A, the molasses from Pan A is transferred to B heavy-
1 (BH-1) tank.
• From BH-1 tank the molasses is transferred to Pan B and this Pan division has only one Pan.
• Same as in Pan A at Pan B again sugar crystals are formed by same process.
• But sugar crystals formed at Pan B are not of commercial quality.
• So, after centrifugation of sugar made at Pan B its sugar is melted and transferred back to Pan A.
• The separated molasses from Pan B is then transferred to BH-2 tank.

 Pan C:

• After the separation of molasses and sugar from Pan B, the molasses from Pan B is transferred to B heavy-
2 (BH-2) tank.
• From BH-2 tank the molasses is transferred to Pan C and this Pan division also has only one Pan.
• Same as in Pan A and Pan B again sugar crystals are formed by same process.
• Sugar crystals formed at Pan C are also not of commercial quality.
• Again, after centrifugation of sugar made at Pan C its sugar is melted and transferred back to Pan A.
• The separated molasses from Pan C is then transferred to molasses tank at the back of the mill rather than
for further processing
 Picture – sugar crystal and molasses sample from Pan C

Centrifuging:
• After crystallisation at every pan the sugar molasses syrup is then transferred to the centrifugal machine for
separation of molasses from the sugar crystals.

• For this the sugar molasses syrup was transferred to the centrifugal tub inside the centrifugal chamber.
• After the transfer the centrifugal tube was then rotated at very high RPM in order to separate the molasses
from the sugar crystals.

• The machine‟s RPM was increased gradually at different speed stages. Those speeds were:-

o 50 RPM
o 200 RPM
o 750 RPM
o 1480 RPM

• At 1480 RPM water was added into the centrifugal tub, this water removes remaining sticky from the sugar
crystals thus white sugar remains inside the centrifugal tub.

• The separated molasses was then transferred to B Heavy tanks or to the molasses containers at the backside
of the mill.
 Picture – A top-down view of centrifugal station with 5 centrifuges installed for each Pan.

Drying of sugar crystals:

• The sugar after separation from molasses and water was then transferred to the conveyor
belt which shakes the sugar crystals.
• There were fans blowing air to the sugar at the conveyor belt that dries the water out of
the sugar.
• Shaking of crystals cause larger sugar crystals to come at top and smaller sized crystals
falls down through a steel mesh.

• Those tiny sized sugar crystals were then transferred into the jute bag and used as seed sugar.

Picture –shaking conveyor belt

12. GRADING, BAGGING AND STORAGE OF SUGAR:-

After drying of the sugar the sugar become pure white and it was then separated into different sections
according to their sizes and this separation of sugar is called grading.
Grading–The dried sugar was then categorizedon the basis of sizethrough vibrating screens and then it was
graded through grading machine in which sugar crystals were first taken to a certain height and then dropped
from there by elevator where there were fitted the grading sieves.

- Sugar grader.

These grading sieves separate sugar produced into 4 categories according to their size. These sizes were as
following:

Grade category Size ( diameter in mm)

● Seed Less than 0.9 mm

● S-30 0.9 mm
● M-30 1.4 mm
● L-30 3.5 mm

In this table above „S‟ is small size, „M‟ is medium size and „L‟ is large size whereas the number besides the
alphabet „30‟ represents the quality of the sugar. 30 is the standard sugar quality of this mill and this sugar is
pure white and very little amount of impurity in it. As the number increases say „31‟ the quality of the sugar
will further increase and quality decrease with decrease in number.

Bagging –

 After grading the sugar is packed into the bags of 50 kg of different colors.
 The bags were color coded according the size of the crystals.
 Bags were color coded as following:-

S.no Size of sugar Bag color/type

1. Seed Jute bag
2. Small Blue
3. Medium White
4. Large Jute bag
 Picture –Bags being filled at grading station

Storage of Bags: the sugar bags after being sealed were loaded in trollies and after that, were again
unloaded in Sugar Godowns.

There were three large godowns constructed near the grading and packaging area of the sugar department

Godowns For Sugar Storage

13. MARKETING OF SUGAR:

The marketing of sugar was done in two ways

o Through Online Tender system- after the sufficient production of sugar in the mill for sale.
Each day, tender is placed @ e-procurementpunjab.com to invite online bids for purchasing of their
product by the buyers.
The mill places its minimum selling of the product which is normally 3000-3100/quintal.
A deadline for a tender is also placed within which,the product should be sold.
A committee of 4-5 members of the mill decide the selling rates of the sugar or the other products of
the mill.after the calculation of cost and returns of the product manufactured, its price is fixed.
o Through Mill‟s shop at the road side- the shop sells sugar produced in the mill at both rates (at
wholesale and also at Retail).
Also, the products of the shop are assured of its quality

„Fateh sugar‟ made by Sugarfed Punjab is also being sold here.

the shop sells various products of all these companies such as bottled milk,ice-creams, flour, sugar,
ghee, butter, curd, mustard oil
Workers & salary data

The data about workers & salary in time of crushing season and annually, are given below.

Workers

Class of workers Annual Seasonal

General 70 35
Engineering 40 100
Labour 60 140

Salary:

 In the seasonal duration, the total salary of the workers including officials amounts to -
Rs. 1-1.5 crores/month.

 In the off-season, the total salary of the workers and officials corresponds to 60-70
lakhs/month.

Products of Mill

Sugar- White/ Refined sugar

 White sugar is sugar which has been refined and washed so that it has a white appearance and no
molasses flavour.
 It contains 99.9% sucrose.
 It is normally consumed in households and being relatively neutral in flavour, it is used as an
ingredient in various edible processed foods and beverages.

Packed Sugar in Polybags

Bagasse

 Bagasse is the fibrous matter that remains after sugarcane stalks are crushed to extract their juice.
 It is dry pulpy residue left after the extraction of juice from sugar cane. Bagasse is used as a biofuel
and in the manufacture of pulp and building materials
 Bagasse

Molasses

 Molasses or black treacle is a viscous by-product of refining sugarcane into sugars.

 Molasses varies by amount of sugar, method of extraction, and age of plant. Molasses is primarily
used for sweetening and flavouring foods.
 It is a defining component of fine commercial brown sugar.
 Similar products include treacle, honey, maple syrup, corn syrup, and invert syrup.
Mud Cake

 It is mixed with bagasse and a cake is formed

 This mud cake is used for burning in the brick kilns
 It is also used in the fields for manuring by the farmers

14. THE SUGARCANE SEED FARM

The Sugarcane Seed Farm was located at the back of the mill where sugarcane for seed sets was grown for the
farmers. This farm used to be operated under the guidelines issued by Punjab sugarfed.

Field Distribution of Sugarcane Farm:

Land distribution Area (in acres)

1. Spring Sugarcane 24
2. Autumn Sugarcane 16
3. Sugarcane on trial 05
4 Total area under 45
Sugarcane plantation
5. Passage & Farmsteads 10
Total Trees (mainly 06
Eucalyptus)

The main objective of this farm was:-

○ To produce seed of both season sugarcane (spring & autumn

○ To conduct trials for unreleased varieties.
 With Mr. M.P. Singh, Farm Supervisor and fellow students

About farm supervisor– Mr. M.P. Singh is the farm supervisor of The Sugarcane Seed Farm since 1998.
He is from Uttar Pradesh and came in Punjab under the recruitment of Punjab Sugarfed. He regulates and
observes the operations at the farm and makes sure that each and every aspect for farm operation is under
the guidelines of Punjab Sugarfed.

We got to know about different varieties and farm practices for sugarcane cultivation. He was a very kind
and humble person and he provided all possible knowledge about the farm as much it was possible for him.
Mr. M.P. Singh‟s monthly salary is Rs.45,000.

Field layout–The picture below showsField layout of the farm provided at the entrance gate of the farm
showing cane farms‟ land distributionand providing placement and layout of the fencing wire around the
farm, the dimensions all around, passage to walk, Tube well and number plots and there dimensions.

Picture – Field layout

Agricultural practices followed at farm –

All the agricultural practices from variety to be planted, seed source, seed rate, area per variety, fertilizer
dose& chemical recommendations, sowing method of canes, number of irrigations, weedicide
recommendations etc. followed at farm are decided by „Punjab Sugarfed‟.

➢Crop rotation– In 5 acres of land, rotation was done with wheat crop. 15 acres of land was

left as fallow every year for a short period of time for fertility recovery of the land.

➢Varieties grown– CoP-12211, Co-118, Co-85, CoPb-92, CoPb-93, CoP-13182, CoP-1503,

CoP-1527.
Out of which,
○CoP-1503 (Karnal variety) &CoP-1527 were on trials at this farm.
○ CoP-12211 & CoP-13182 were new varieties
○ Co-85 was grown only in 2 acres.

➢Land preparation–

Rotavator– This tractor drawn implement was used as primary cum secondary tillage implement
with objective of breaking stubbles, for mixing wheat stubbles into field, to improve soil health, texture,
aeration. This is increases the organic matter in the soil which help in adding nutrients & enhancing soil
properties such as texture and pore space. Rotavator retained soil moisture and increases soil porosity and
aeration which enhances germination and growth of the crop.

Disc harrow– It was used to till the soil in fields which break the clumps or clods in soil and chop weeds
and leftover of previous crop to incorporate them in soil and use them as green
manure. This will reduce the input of biomass in the field and helps in efficient crop residue management at
this farm. The type disc harrow available on farm was tractor trailed offset disc harrow with smooth discs.
Harrow was mounted to the tractor by 3 m point linkage and used in preparation of fields before preparing
beds.

Cultivator– This farm implement was used to loosenup the soil and preparing beds for seed. It was also
used for secondary tillage purposes. It also help in removal weeds and exposure of
larvae of insect pest to the sunlight and destroy them.

➢Seed source– The seed for the cane seed farm was sourced from agriculture department at

Kapurthala&Karnal, Every year fresh seeds were used sowing of the crops as ratoon cropping was strictly
prohibited at this farm.

➢Seed rate– The seed rate used was 35 quintal per acre for 3 budded sets.

For tissue culture, the rate was 8,000 single bud sets per acre.

Plantation techniques –

a. Paired Row Trench Planting –According to Mr. M.P., this methodwas best to sowsugarcane.
Paired row trench maker was used in this method to prepare paired rows in the field. The distance
between two trenches were 4 feet. Two rows of sugarcane 30 cm apart in 20-25 cm, were planted.
This method was recommended by Mr. M.P. Singh to the farmers as according to him this method
help in saving water.
 Paired row trench planter

b. Sugarcane Cutter Planter – In this method, whole of the sugarcane was fed by labor sitting on the
sugarcane cutter planter and this machine automatically cut the canes evenly into pieces and dropped them
into furrows were also made simultaneously. Fertilizers and chemicals were also applied simultaneously.

Sugarcane cutter planter

Sugarcane

○Tissue culture plantation –

Quatro Sugarcane Single Bud Cutter Seed Preparation In Pro Trays

The laboratory prepared seeds were used in this method for cane plantation and growing. The machine used
to cut the cane into pieces was “Quatro Sugarcane Single Bud-cutter”. After they were transferred into
thepro trays and as seedsbecome matured enough, it was planted in the farm manually by laborers.
➢Intercropping –Generally, they grow intercrop every year but this year they avoided it.

Every year they grow Mustard as their intercrop and sold at local mandi at the price of Rs. 60,000. The
reason behind intercropping was to increase Crop income. Dhaincha was also grown as green manure crop
and later turned into the soil for soil quality improvement. Being a leguminous crop, dhaincha also fulfilled
nitrogen need of crop by fixing atmospheric nitrogen making it available to cane crop.

➢Fertilizer application – They applied only a little urea as excess urea can lead to lodging of

cane crop. And only recommended dose of DAP was applied at time of sowing. These recommendations are
also provided by Sugarfed.

➢Irrigation – There were 3 motors installed for irrigation purpose through underground

pipelines. The irrigation frequencies were variable according to seasons. In summers, irrigation was given
every 7-12 days interval. In rainy season, irrigation frequency was adjusted according to rainfall.


➢Weeds control – They spray 800 g Sencor 70 WP per acre in 200 liters of water for weed control.
2,4-D & atrazine was also used as weedicides.

Other chemicals used were- Chlorpyriphos for soil treatment and Coragen as insecticide.

 Harvesting–The harvesting was done with the help of sugarcane harvester and manually by

laborers. And loading of caneinto trollies was done by laborers at a rate of Rs. 42-50
per quintal.

Harvesting and loading of copb-92

➢Yield– The average yield per acre was 400-450 quintal/acre.

In case of intercropped field, yield was 350 quintal/acre.

Seed & tissue culture bud setts selling– If any of the farmer came to cane farm of mill to get seed from
the mill, he had to meet Mr. M.P. first. Farmer had to specify the variety and quantity he wanted, then he
was provided with certain variety and quantity after the permit was done. The rate of seed and tissue culture
of cane farm is noted below.

In case of seed-oriented bud setts –They purchase it at Rs. 425 per quintal.
They sold it to farmers at Rs. 310 per quintal. (subsidy)
In case of tissue culture-oriented bud setts–They purchase it at Rs. 4 per plant.
They sold it to farmers at Rs. 2 per plant.(subsidy) If farmer was willing to sow and sell his cane production
to the Ajnala mill, then facility of loan was available for him. The loan was that, at time of payment of his
production next year, the dues of seed material buying was deducted at that time.

15. SEED SAMPLING:

Seed sampling is collection of seeds from a lot in such a manner that the collected seed properly represents
the whole lot for defining the quality of the seed lot.

Seed sampling is performed at mill in February-marchevery year. Last year it was performed by Harpal
Singh, Cane development officer. He got seed samplings‟ 10 days training from agricultural experts atPune.

Seed sampling objectives –

• o To get uniform representative sample of seed from a seed lot.

• o To minimize the risk of planting low quality seeds.
• o To verify the quality standards of seeds for the cane requirements of mill.

Seed source – It was transported from High-Tech Limited Company, Maharashtra.

Procedure followed –

1. Harvest of previous season or year was taken as seed material.

2. Canes were completely cleaned and its leaves and other plant material were removed.
3. Then it was cut using the machine.

Machine used for cutting-

Quatro Sugarcane Single Bud Cutter

Working of machine – One laborer inserted a cane into the machine for cutting purpose into a
single bud.

Labourer Inserting the Cane into Machine for Cutting Purpose

After that, single bud cut was collected in a container for further purposes.

Seed sampling done at farm mill–

It was done in two ways –

1) Chip budding
2) Single budding

1) Chip budding–

Single budded eye was kept in pro-trays covered with a mixture of coco-peat and other minerals required for
proper germination and growth.

Chip Budding In Pro-Trays

The chip budding resulted in a very effective way of growing seed material as samples and checking the
performance of cane planting material.
 Resulted Plant Growth from Chip Budding

2) Single budding –

○ It was performed in moist jute bags and these bags were kept in closed room.
○ It can also be performed in pro-trays.
○ It was first treated in Bavistin (Carbendazim 50 WP) 30% as prevention for fungal diseases.
○ After 13 days, foliar spray of 13 : 13 : 13 ( N:P:K ) was given.
○ After 20 days, foliar spray of 19 : 19 : 19 ( N:P:K ) was given and Zinc & Iron were also given.

Result Of Single Budding

Cost & returns of seed sampling–

○ Cost of plants prepared through seed sampling – Rs 1.5 per plant

(this included all the labour costs, seed material, chemical & fertilizer application,
transportation costs)
○ Returns – The plant prepared was sold at rate of Rs 1 per plant.
(due to subsidy)
○ Cost of plants prepared through tissue culture – Rs 4 per plant
○ Returns of plant prepared through tissue culture – Rs 2 per plant (due to subsidy)
SR. NAME OF GOVT. INDIVIDUAL SOCIETIES SUGARFED
NO. THE MILL (Growers)
NO OF AMOUNT NO OF AMOUNT NO OF AMOUNT NO OF AMOUNT
MEMBERS MEMBER MEMBER MEMBER
S S S
1 AJNAL 1 1099.38 6998 221.38 77 12.32 0 0.00
A
2 BATAL 0 0 28138 138.21 775 3.80 0 0.00
A
3 BHOGP 1 14610.5 23480 47.52 2028 8.03 0 0.00
UR 8
4 BUDHE 1 428.93 22254 428.91 491 39.59 0 0.00
WAL
5 FAZIL 1 420.76 12655 310.90 199 14.25 0 0.00
KA
6 GURD 1 120.00 10940 274.40 71 0.52 1 132.00
ASPUR
7 MORIN 1 144.37 31591 308.27 607 6.60 0 0.00
DA
8 NAKO 1 1143.09 6680 109.36 390 45.61 0 0.00
DAR
9 NAWA 1 368.30 19990 828.46 449 6.04 0 0.00
N
SHAHR
TOTAL 8 18335.41 162726.0 2667.41 5087.00 136.76 1.00 132.00
(A) 0

16. ECONOMICS OF THE MILL

This mill was used to function under the guidelines of Punjab Sugar federation of co-operative mills Ltd.

The economics of this farm is described according to the data available on the database of the sugarfed
Punjab punjabsugarfed.in. It was evident at the mill that mill was already going under a huge loss from
many years. This huge loss was due to accumulation losses born by low sales and harsh prices in sugar
market.

Shares of Punjab‟s sugar mills:

The following table is split into two for proper presentation, and this table represents data about shareholders
of all co-operative sugar mills in Punjab.

SR. NAME OF SHARE TOTAL %age Share

NO. THE MILL DEDUCTION Capital
MONEY
NO OF AMOUNT NO OF AMOUNT Govt. Others
MEMBER MEMBER
S S
1 AJNAL 0 0.00 7076 1333.08 82.47 17.53
A
2 BATAL 360 0.56 28913 142.57 0.00 100.00
A
3 BHOGP 0 170.77 25509 14836.9 98.47 1.53
UR 0
4 BUDH 0 117.04 22746 1014.47 42.28 57.72
EWAL
5 FAZIL 0 83.08 12855 828.99 50.76 49.24
KA
6 GURD 0 0.00 11013 526.92 22.77 77.23
ASPUR
7 MORIN 0 19.31 32199 478.55 30.17 69.83
DA
8 NAKO 0 81.34 7071 1379.40 82.87 17.13
DAR
9 NAWA 4992 293.75 20440 1496.55 24.61 75.39
N
SHAHR
TOTAL 5352.00 765.85 167822.0 22037.43 83.20 16.80
(A) 0

The above table represents that Ajnala sugar mill‟s 82 % of the share belongs to government so that‟s why
the mill require strong attention of the government to sustain itself. The focus of the government should be
strongly towards the improvements of this mill.

➢Average sugar sale realisation:

AJNALA BATAL BHOGP BUDHE FAZILK GURDA MORIN NAKOD NAWAN Total
A UR WAL A SPUR DA AR SHAHR
Average Average Average Average Average Average Average Average Average Average
Rate Rate Rate Rate Rate Rate Rate Rate Rate
Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls.
2961.00 3006.75 2956.73 2993.60 2852.82 2987.06 2980.10 2931.59 2949.85 2964.20

Fortheye BATAL BHOGP BUDHE FAZILK GURDA MORIN NAKOD NAWAN Total
ar2015- A UR WAL A SPUR DA AR SHAHR
16
AJNALA

Average Average Average Average Average Average Average Average Average Average
Rate Rate Rate Rate Rate Rate Rate Rate Rate
Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls.
2616.46 2685.25 2681.61 2675.25 2539.90 2642.82 2608.07 2613.06 2577.12 2619.49

Forthey BATALA BHOGPU BUDHE FAZILK GURDAS MORIND NAKOD NAWAN Total
ear2016- R WAL A PUR A AR SHAHR
17
AJNALA
Average Average Average Average Average Average Average Average Average Average
Rate Rate Rate Rate Rate Rate Rate Rate Rate
Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls.
3452.41 3499.23 3515.58 3515.68 3443.37 3487.64 3444.15 3396.18 3497.57 3475.58

Forthey BATALA BHOGPU BUDHE FAZILK GURDAS MORIND NAKOD NAWAN Total
ear2017- R WAL A PUR A AR SHAHR
18
AJNALA
Average Average Average Average Average Average Average Average Average Average
Rate Rate Rate Rate Rate Rate Rate Rate Rate
Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls.
3447.67 3570.44 3520.87 3523.32 3481.82 3449.34 3365.94 3525.00 3509.64 3479.54

Fortheye BATALA BHOGP BUDHE FAZILK GURDA MORIN NAKOD NAWAN Total
ar2018- UR WAL A SPUR DA AR SHAHR
19
AJNALA
Average Average Average Average Average Average Average Average Average Average
Rate Rate Rate Rate Rate Rate Rate Rate Rate
Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls. Rs./Qtls.
2987.24 3028.98 3006.17 3006.61 2994.63 3012.29 2984.52 2988.88 2977.44 2996.65

By observing the above data I was able to figure out that sale of sugar was increasing from year 2015 to
2017 but same cannot be said about Ajnala sugar mill since its sales were fluctuating in these years.
But from year 2017 to 2019 I was able to figure out those average sales as well as sales at Ajnala sugar mill
were drastically decreasing.
This data shows us that Ajnala sugar mill‟s sales were pretty unstable from last few years and this can
explain why there is huge loss in this mill.

 Cost of production

The following table represents the cost of production of sugar per quintal from year 2013-2018.

Sr. Name of 2013-14 2014-15 2015-16 2016-17 2017-18

No. the Mills
1 Ajnala 4720.24 5390.38 4527.12 4886.62 5264.74
2 Batala 4695.76 4992.54 4481.97 4542.30 5000.44
3 Bhogpur 4121.36 4726.61 4062.05 4062.90 4276.93
4 Budhewal 4290.76 4344.58 4292.20 4585.54 4861.57
5 Fazilka 4923.15 5227.55 5234.69 5962.82 5578.16
6 Gurdaspu 4666.41 4979.67 4931.65 5198.17 5188.28
r
7 Morinda 4220.34 4266.65 3932.97 4969.44 4896.41
8 Nakodar 4325.51 4410.55 4437.82 4475.09 5247.36

9 Nawansh 3763.94 4102.23 4005.08 4026.01 4485.65

ahr
Average 4414.16 4715.64 4433.95 4745.43 4977.73

The above table and chart represents that cost of production of 1 quintal of sugar was all time high during
year 2014-15 and then it started to decrease till 2016 an then cost started to rise.
This shows that how the margin for making profit is getting decreased year by year which is not sustainable
for these sugar mills.
  Loan statement

To function properly the mill required financial support in order to clear its due whether it is for
payment to the farmers or for mill‟s repairing and acquisition of new machinery.
The following loan statement was available on Punjab sugarfed database and this data represents loan
statement of all co-operative sugar mills in Punjab which operates under Punjab sugarfed.

THE PUNJAB STATE FEDERATION OF COOP. SUGAR MILLS LTD DETAIL OF LOAN
RECEIVED FROM GOVT AS ON 11.09.19
(Rs. IN LACS)

DATE FROM PURPOSE AMOUNT

29.03.1995 GOVT. INSTALLATION & MODERNISATION OF ETP & AIR

POLLUTION EQUIPMENT 40.25
23.03.2000 GOVT. OTS 991.00
09.08.2001 GOVT. OTS 2923.00
28.01.2002 GOVT. OTS 452.50
30.03.2002 GOVT. OTS 905.00
18.09.2002 GOVT. OTS 1357.50
10.01.2003 GOVT. OTS 452.50
28.03.2003 GOVT. OTS 452.00
14.02.2003 GOVT. CANE PAYMENT FOR 2001-02 500.00
20.02.2003 GOVT. -DO- 3000.00
24.02.2003 GOVT. -DO- 1500.00
17.04.2004 GOVT. CANE PAYMENT FOR 2003-04 430.00
27.04.2004 GOVT. CANE PAYMENT FOR 2002-03 770.00
28.04.2006 GOVT. CANE PAYMENT FOR 2002-03 & 2003-04 1810.00
30.12.2006 GOVT. SALARY FOR 5 MILLS (UNDER LIQUIDATION) 1200.00
26.11.2007 GOVT. LAND PAYMENT BUDHLADA 670.00
01.04.2008 GOVT. PAYMENT OF SDF LOAN 2441.52
27.03.2009 GOVT. REFUND OUT OF RS.670.00 LACS BUDHLDA -8.10
22.04.2011 GOVT. LIABILITY OF JAGRAON & BUDHLADA 4600.00
27.06.2011 PAID LIABILITY OF JAGRAON & BUDHLADA -6.00
09.11.2011 GOVT. VRS PATIALA,FARIDKOT,T.TARN, ZIRA 5000.00
20.12.2011 GOVT. VRS PATIALA,FARIDKOT,T.TARN, ZIRA 3200.00
16.07.2012 GOVT. CANE PAYMENT 2011-12 3045.33
08.08.2012 GOVT. CANE PAYMENT 2011-12 3045.33
05.12.2012 GOVT. CANE PAYMENT 2011-12 3045.34
10.01.2013 GOVT. COMPENS. PATIALA & ZIRA RETRENCHMENT 354.00
15.01.2013 GOVT. INTEREST ON CANE PAYMENT 2011-12 384.00
23.01.2013 GOVT. INTEREST ON CANE PAYMENT 2011-12 293.00
04.02.2013 GOVT. REFUND OUT OF RS.293.00 LACS -197.45
24.06.2013 GOVT. CANE PAYMENT 2012-13 9560.00
11.07.2013 GOVT. SALE OF PLANT & MACHINERY JAGRAON -1971.42
22.11.2013 GOVT. SALE OF PLANT & MACHINERY BUDHLADA -1470.08
29.04.2014 GOVT. CANE PAYMENT 2013-14 1800.00
24.06.2014 GOVT. CANE PAYMENT 2013-14 2000.00
04.07.2014 GOVT. CANE PAYMENT 2013-14 14848.73
22.10.2014 GOVT. REFUND OF GOVT. LOAN -50.00
06.05.2015 GOVT. CANE PAYMENT 2014-15 5000.00
03.06.2015 GOVT. CANE PAYMENT 2014-15 5000.00
04.07.2015 GOVT. CANE PAYMENT 2014-15 5000.00
18.08.2015 GOVT. CANE PAYMENT 2014-15 9000.00
01.09.2015 GOVT. CANE PAYMENT 2014-15 9056.00
03.06.2016 GOVT. CANE PAYMENT 2015-16 4500.00
04.07.2016 GOVT. CANE PAYMENT 2015-16 4500.00
04.08.2016 GOVT. CANE PAYMENT 2015-16 4500.00
29.08.2016 GOVT. CANE PAYMENT 2015-16 4300.00
28.07.2017 GOVT. CANE PAYMENT 2016-17 2450.00
17.10.2017 GOVT. CANE PAYMENT 2016-17 2000.00
15.11.2017 GOVT. CANE PAYMENT 2016-17 2500.00
26.03.2018 GOVT. CANE PAYMENT 2016-17 4615.79
07.05.2018 GOVT. CANE PAYMENT 2017-18 2500.00
22.05.2018 GOVT. CANE PAYMENT 2017-18 2000.00
10.08.2018 GOVT. CANE PAYMENT 2017-18 3500.00
29.10.2018 GOVT. CANE PAYMENT 2017-18 1000.00
20.11.2018 GOVT. CANE PAYMENT 2017-18 2500.00
01.01.2019 GOVT. CANE PAYMENT 2017-18 3500.00
22.01.2019 GOVT. CANE PAYMENT 2017-18 6500.00
11.09.2019 GOVT. CANE PAYMENT 2017-18 & 2018-19 5518.00
156807.74
Loan of Bhogpur CSM converted into share capital -4295.40
Loan of Rs.4599.23 also converted into share capital on -4599.22
22.12.16
147913.12

This loan statement is evident that these mills are not performing well since these mills require
loans even to pay to the cane farmers.
  Profit and Loss Statement:
Due to various unfortunate factors this mill is operating under huge losses. These losses is making
difficult for the mills to sustain themselves for longer period.

The following table represents the amount of profit and losses borne by co-operative mills in Punjab.

OPERATIONAL COOPERATIVE SUGAR MILLS (Rs. IN LACS) AUDITED Amended on 29.10.2018

SR. NAME OF THE 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
NO. MILL

1 AJNALA -506.34 -616.59 30.12 208.13 -717.86 -1114.83 -968.90

2 BATALA -452.04 -609.37 -46.78 488.84 -856.18 -814.40 -959.97

3 BHOGPUR -328.28 -517.72 103.51 806.18 -632.66 -483.33 -585.72

4 BUDHEWAL -364.31 -417.47 42.14 -85.02 -183.84 -653.48 -403.10

5 FAZILKA -255.21 -971.17 -62.68 -209.79 -640.59 -980.45 -1344.57

6 GURDASPUR -533.17 -501.08 375.32 298.64 -1137.01 -1257.57 -1372.40

7 MORINDA -820.15 -804.63 553.56 303.39 -364.12 -1253.85 -1220.08

8 NAKODAR -632.53 -503.30 87.10 -106.73 -771.80 -1128.41 -1029.38

9 NAWAN SHAHAR -633.69 -675.26 667.32 1387.44 -257.10 -506.83 638.89

TOTAL -4525.72 -5616.59 1749.61 3091.08 -5561.16 -8193.15 -7245.23

SR. NAME OF 2013-14 2014-15 2015-16 2016-17 2017-18 ACCUMULATED UPTO 31.03.2018
NO. THE MILL

1 AJNALA -2479.04 -4479.28 -2755.78 -2017.48 -5588.70 -26555.58

2 BATALA -2243.70 -3208.37 -2225.74 -1246.94 -3372.25 -17293.07

3 BHOGPUR -1575.66 -3354.90 -1839.95 -371.83 -2203.09 -12245.63

4 BUDHEWAL -1975.80 -2750.27 -3197.50 -278.05 -2734.74 -13428.50

5 FAZILKA -2339.38 -3363.68 -3722.10 -2119.26 -3398.36 -20621.38

6 GURDASPUR -3080.63 -5551.90 -3200.21 -3185.42 -4931.13 -26117.61

7 MORINDA -2431.20 -3724.35 -3426.77 -1256.28 -4113.45 -19849.86

 8 NAKODAR -1796.32 -3183.32 -2020.77 -723.57 -2909.57 -16082.73

9 NAWAN SHAHAR -2921.67 -5536.02 -2150.89 -299.67 -5614.39 -15606.04

TOTAL -20843.40 -35152.09 -24539.71 -11498.50 -34865.68 -167800.40

Due to insufficient returns and high costs of production there was a huge amount of loss
accumulated at the mill till year 2018 as per the data.

During my training period I also figured out that situation is not getting better but it is still
getting worsened.

These mills required immediate attention from the government to invest in these mills and
encourage the mill staff to make some innovations at the mill to increase its production and
reducing the cost of the production to achieve better margins.

17. SWOT ANALYSIS:-

1.Strength:
• Location – The mill is located at the perfect geographic area to fetch the end motive of the
business. The area is very suitable as supply of the sugarcane is available enough for smooth
running of the tentative objective of the mill.

• Well Planned Setup – This mill was built by company named SUMAC. This company has a
well-planned infrastructure of the mill building. They have planned and properly mapped space
for each and every operation. Each & every station of the mill is properly designed which makes
the process of mill smooth. The availability of water along with water waste treatment, sugar
storage tractor parking and other essential features of the mill

• Facilities for the farmer–Washrooms, waiting room, canteen, nearby ATM, bank facility etc
proper facilities are available for farmers thus improving the experience of the farmers as they
have to spend a considerable amount of time in mill while waiting for their turn to unload their
produce in the mill.

• Proper infrastructure – Proper infrastructure is available in most of the areas for efficient
functioning of the mill. There were proper arrangements for efficient working conditions for
processing of canes that could be from taken gate to unloading to processing to packing and
storage, every stage has proper provisions for proper functioning at every division of the mill.
 Farmer‟s trust – Many reports has been heard that farmer‟s payment was delayed but there is
surety that there payment will be ultimately be paid unlike private mills were there is huge
uncertainty in the payment of the farmers. So that‟s why farmers have a trust on these co-
operative sugar mills that there payment will be guaranteed to be paid to them.

2.Weakness:

• Lack of innovation –There is great need of innovations at this sugar mill in order to make it
sustainable for long term. Since new technologies are being introduced regularly there is great
opportunity to use that technology for the improving the efficiency of this mill. But due to lack
of proper support from government and superiors of the mill there is no such thing called
innovation at this mill.

• Out-dated staff – It was common trend in every department of the mill that most of the staff at
superior posting was aged individuals who were serving this mill for more than 30 years. This is
not a positive thing for the mill because there should me more recruitment of young and fresh
staff as they are more aware of the current trends and are capable for estimating the future trends
of the world. Young staff also has knowledge about the new technologies and new subjects about
agriculture. There should be certain ratio between fresh and aged staff to maintain the efficiency
of the workflow and expansion of the mill.

• Lack of technically skilled labour – It is a genuine problem in the mill since I was able to
observe that every working individual was posted to a certain section at the mill and in most
cases that individual had knowledge about that specific section only and that knowledge was not
even complete. If they were asked why certain process happens or why specific task was being
carried out, they were unable to answer such question. The labourers were only doing they were
told to do and they were not capable enough to make any decision about process by their own.

• Out-dated machinery – Only certain important and core machinery of the mill were
periodically updated but other machinery was not used to be updated that much. Such example of
this was pan station, pans at there were able to perform there function but there physical
condition was not looking quite good. The pan station clearly needed some kind of upgrades but
was totally neglected. I still repeat that machinery regarding core mechanics and safety of the
mill were periodically upgraded.

• No proper maintenance – There was steam leakage at certain points in the mill piping due to
lack of maintenance. This leakage decreases the efficiency of the mill as steam was going to be
utilised in heating of certain stations at the mill. This leakage cause increase in usage of water
and bagasse at boiling station to generate more steam to meet the demand of the mill stations.
This leakage could be corrected by regular maintenance and replacement of pipeline at the mill.
This leakage was one of the many examples of maintenance ignorance at the mill. Repairs were
usually done only when there was critical problem at the mill or there was accumulation of
certain small dysfunctions at mill or both.
• Delayed payment – The mill was already working under loss and there was not enough
income at mill to fulfil payments of the farmers and to pay to the workers of the mill at the same
time. Because of this there was delay in the payment of the farmers which cause farmers to lose
their interest in growing of sugarcane.

• Less market rate – The mill had to fix the rate of sugar for making profit for the mill. But the
rate of sugar in the market is generally lower than offering of the mill‟s rate this cause people to
avoid purchase from this mill and they prefer private mills over this mill. This marketing strategy
causes a deadlock situation for the mill as they can‟t lower the rate but they cannot keep doing it
because this cause deterioration of the stock prepared. So at the end mill has to sell the sugar at a
loss.

3.Opportunities:

• Demand - Demand of sugar in Punjab as well as in India is increasing with increasing in

demand of processed as well as preserved foods since these industries use sugars as raw material;
the demand of sugar is significantly increasing every year.

• Supply – Due to location of this mill it is easy for the farmers take their produce to the mill
hassle free as proper roads are built which are interconnected with many regions around the mills
and making easy for farmers from different regions to bring their produce to the mill. Due ease in
transportation a very large population of farmers grows sugarcane which is ultimately supplied to
the mill for processing. Due to exposure of the people to the technology in this area; farmers are
able to produce a very good quality of produce for the mill
.
• New technologies – New technologies are being introduced at a very rapid pace in these days
so it is very important for mills to adopt these technologies and integrate them in the mill to
increase its efficiency for increasing the production rate and value of it. There is much
development in agricultural sector which leads to introduction of new as well as improved
methods of sugar preparation.

• High yielding and better canes – All agricultural universities across the India is emphasising
on developing new varieties of sugarcanes which are better in terms of following traits:-

i. Yield
ii. ii. Quality
iii. iii. Disease and pest tolerance
iv. iv. Stress tolerance, etc These traits of canes helps in increase in yield and quality of the
canes thus boosting in the investment at sugar mills.

• Molasses – There is a great opportunity of this sugar mill to open a distillery which can make
use of the molasses produced by processing cane juice to make alcohol. This distillery could act
as additional source of income and better disposal of molasses.
• Cogen power plant – There is a potential at this mill to establish a cogen power plant which
can be used to supply the electricity to the grid for earning from it. It was estimated by the staff
of the mill that cogen power plant could help to generate enough electricity for the villages
around the mill and further to Ajnala and this can generate enough income to make this mill
profitable again with a greater margin.

4.Threats:

• Less market rate – The mill had to fix the rate of sugar for making profit for the mill. But the
rate of sugar in the market is generally lower than offering of the mill‟s rate this cause people to
avoid purchase from this mill and they prefer private mills over this mill. This marketing strategy
causes a deadlock situation for the mill as they can‟t lower the rate but they cannot keep doing it
because this cause deterioration of the stock prepared. So at the end the mill has to sell the sugar
at a loss

• Competition – There is very strong competition between co-operative and private sugar mills
and this competition leads competitive pricing and thus decreases the profit margin of the mills.
It was seen in private mills that they used to buy sugarcane at low price and also sell the sugar at
low prices this made tough for co-operative mills to make more profit and sustain for longer
period.

• Farm laws – New farm laws introduced by centre government has made a significant impact
on the arrival of cane at the mill. These laws provides upper hand to private mills to conduct
their business tax free and this makes possible for the private mills to set even more competitive
prices which in turn will cause further damage to the business conditions of the co-operative
mills. With these laws private mills can set more profitable prices for the farmers which
decreases cane arrival at co-operative mills and if this happen for a longer period of time, this
will inevitably causes co-operative mill to shut down and government can pull back there support
from these co-operative mills as these mills would become liabilities for the government,

• Crop diversification – Crop diversification is being emphasised across India and this
diversification of crops can lead to less people cultivating sugarcane and more shift to other
crops. Though crop diversification is beneficial for agriculture of India but it is not beneficial for
the sugar mills.

• Ground water depletion – Ground water is depleting in Punjab region at an alarming rates
which is detrimental for agriculture of Punjab. Due to depletion of ground water, there would be
decrease in sugarcane production which basically the raw material of the mill. Ground water is
also necessary for functioning of the mill as water is required in boiler for producing steam
which derives most of the functions of the mill by acting as heat source for different stations.

• Political influence – It is sad reality of the Punjab that co-operative mills generally influenced
by local ruling party. This influence hinders in fluency in the working of the mill and this affects
the growth of the sugar mil.
18. FEED BACK
In my whole training session, every officer, employee and worker helped a lot to complete my
industrial attachment report. Structure of mill is good but there are some of the risky points
inside the plant, at those points no precautions are taken while working. Thereafter a permanent
storage for the ash should be there because due to lack of storage for ash it affects the cleaniness
of the mill. The no. of dustbins in the mill should be increased as I have seen many people just
throwing the waste in open which can cause many problems like it can give rise to the various
bacteria born diseases. The cogeneration plant in large level should be established so that
electricity for whole Amritsar district can be supplied from mill itself as a result it will boost the
economy of the mill to the new heights and can help industry to get out of the debts.

19. CONCLUSION:

At last I would like to conclude that I have learnt many valuable things in this agro-industrial
training along with the practical knowledge of sugar processing. In this training along with
practical knowledge I had learnt some moral values too as there are few senior employees too in
the industry who taught some moral values along with the technical/practical knowledge in the
industry. I have learnt in detail process of sugar manufacturing during my whole training in
Ajnala cooperative sugar mill. Thereafter the current status of economics is not too good ,mill is
in debt of the 300 crores. Major reason for this debt is the higher production cost and less selling
price. Production cost is high because due to political pressure the any quality sugarcane is
accepted in the mill which do not have required brix level i.e. 18 brix.

Finally I would suggest government should take some strict action to cover up this problem
otherwise mill can go to more high debt. Which can cause various problem in future. Payments
of the farmers should be done on the time otherwise the farmers can stop cane farming and can
shift to other crops which is a big threat for the mill.