bhairavnath sugar works ltd Katraj, Pune, Maharashtra

Bhairavnath Sugar Works Limited operates with four factories/units. The Units located at Sonari (Unit I), Vihal (Unit II), Lavangi (Unit III) and Washi (Unit IV) with a total capacity of 9750 TCD (Tonnes Crushing Per Day). The Company commenced its commercial production in 2008-09 at Post Sonari, Tal. Paranda, Dist. Osmanabad by setting up a 2500 TCD Sugar plant. Now the plant has a capacity of 3500 TCD. Beside this plant the Company has set up 2500 TCD Sugar Plant at Vihal in 2011-12 and has also set up another 2500 TCD Sugar Plant at Lavangi, Tal. Mangalvedha, Dist. Solapur, in 2014-15. Company has entered into Collaboration Agreement for running sugar factory with Shivshakti Shetkari Sahakari Sakhar Karkhana Ltd, Washi, Dist. Osmanabad having capacity of 1250 TCD in 2012-13. Further, the company has increased the capacity of plant to 2500 TCD and running the same from year 2013-14. Sugar manufacturing process Sugar manufacturing process at our plants takes place under strict quality control measures. We are always among the first to adopt latest equipment and technology to ensure that our product quality is best. The sugarcane is harvested and the cane is loaded either in a bullock cart, truck or tractor trolley to the factory. Cane is weighed using an electronic weigh bridge and unloaded into cane carriers. It is then prepared for milling by knives and shredders. Sugarcane juice is then extracted by pressing the prepared cane through mills. Extracted juice mixed with water is weighed and sent to the boiling house for further processing. Residual bagasse is sent to boilers for use as fuel for steam generation. This juice is heated and then treated with milk of lime and sulphur dioxide. The treated juice is then further heated and sent to clarifies for continuous settling. The settled mud is filtered by vacuum filters and filtered juice is returned to be further processed while the Oliver cake is sent out. The clear juice is evaporated to a syrup stage, bleached by sulphur dioxide and then sent to vacuum pans for further concentration and sugar grain formation. Crystals are developed to a desired size and the crystallized mass is then dropped in the crystallizers to exhaust the mother liquor of its sugar as much as possible. This is then centrifuged for separating the crystals from molasses. The molasses is re-boiled for further crystallization. Thus, the original syrup is desugarised progressively (normally three times) till finally, a viscous liquid is obtained from which sugar can no longer be recovered economically. This liquid, which is called final molasses, is sent to the distillery for making alcohol. The sugar thus is separated from molasses in the centrifuge is dried, bagged (50 Kg and 100 Kg), weighed and sent to storage houses. Sugar is made in different sizes and accordingly classified into various grades i.e large, medium and small. Quality of Sugar: At Bhairavnath Sugar Works Limited we produce white crystal sugar. This white crystal sugar is manufactured in the following grades: M 30 S 30

Press mud is commonly known as filter cake / press cake and is used as manure by the farmers. Press mud is the residue of the filtration of sugarcane juice. The clarification process separates the juice into a clear juice that rises to the top and goes to manufacture, and a mud that collects at the bottom. It is combustible and also used in brick kilns for brick making. When mixed with the spent wash generated by the distilleries, the resultant product is enriched organic manure, which has the capability to improve yields in farms. The use of filter cake as a soil conditioner is common among sugar planters.

Molasses, from the Latin word melaceres, meaning honey-like, is thick dark syrup. Molasses, an important by-product of the Sugar Industry. During the sugar making process, juice extracted from sugarcane or sugar beets is boiled down until the sugars crystallize and precipitate out. It is the only by-product obtained in the preparation of sugar through repeated crystallization. The syrup left over after crystallization is referred to as molasses. Molasses is mainly used for the manufacture of alcohol, yeast and cattle feed. Alcohol in turn is used to produce ethanol, rectified spirit, potable liquor and downstream value added chemicals such as acetone, acetic acid, butanol, acetic an-hydride, etc.

Fly Ash is the residual output from the boiler furnace after bagasse has completely burnt out. This bagasse ash is generally spread over farms and dump in ash pond which causes environmental problems also research states that Workplace exposure to dusts from the processing of bagasse can cause the chronic lung condition pulmonary fibrosis, more specifically referred to as bagassosis. So there is great need for its reuse, also it is found that bagasse ash is high in silica so it can be used as substitute to construction material. This fly ash is also used as a substitute for firewood. It is rich in potassium and is also used by local farmers for cultivation.