Detailed Project Report (DPR) on jaggery powder and solid jaggery (gur) manufacture from sugar cane (cap-400 tcd)

JAGGERY POWDER AND SOLID JAGGERY (GUR) MANUFACTURE FROM SUGARCANE (CAP: 400 TCD)  
 [CODE NO. 2050]

Jaggery or gur is a specific type of sugar popular in India. It is normally manufactured from either sugar cane or date palms, but recent trends in its manufacture have resulted in jaggery made from the sap of coconut and sago palms. While jaggery is useful in cooking, it is also an ancient part of Ayurvedic medicine and has spiritual significance in India too.

This type of sugar is considered unrefined and is produced by boiling raw sugar cane or palm juice in iron pans. It is then formed into blocks. Because it does not go through additional processing, it does retain some of the natural vitamins and minerals of the ingredients used, though boiling the juice does deplete some of these. Many people do consider jaggery healthier than more refined sugar since it is less stripped of natural nutrients.

In traditional Indian medicine, called Ayurveda, this sugar has several purposes. It may be prescribed for use for people with sore throats. It has some use in the treatment of bronchial or lung infections, and in fact in research has shown to possibly offset some of the lung damage caused by silicosis, a disease of the lungs that occurs when people are exposed for a long time to silica powder.

When sugar from sugarcane was introduced cannot be definitely stated, but brown sugar or gur (Jaggery) was the first known form of sugar manufactured from sugarcane as well as from wild date palm (phonnix sulvestris), palmyra palm (Borassus flapellifar), toddy palm (Caryota urens) and other palms that contain 12-14% sugar in their sap tapped for the purpose. Fermented toddy sap yields a beverage commonly used in India. An about one lakh tonne of brown sugar or gur is still produced from palm sap in India. Gur has always been and is still being recommended in Ayurvedic Medicinal system for nutritive quality and as a much safer form of sugar than pure white (centrifugal) sugar for regular consumption. In the Indian sub-continent the gur is commonly used in preference to molasses free white sugar for many sweet prepartions because of its specific taste. In fact, the findings of a British scientist, John Yadkin, have shown that heavy consumption of highly clarified white sugar or pure sucrose obtained from the modern sugar mills is largely responsible for hyperinsinulism and coronary heat diseases in human beings. Gur is safe from this aspect.

Gur (Jaggery) production in India is more than 1.5 times of that of white sugar production (a decade back it was double). Nearly half of the total cane production is utilised for gur produced by open pan method; its production by vacuum process has not been yet successful. Gur production is 10-12% from cane in open pan and about 15% in vacuum process. Even at higher price than white sugar the gur (that contains 70-75% sucrose, 14-16% invert sugars, 5% moisture, and 5% other ash creating material) is still preferred for many special dishes and also in daily use. Besides Indian many countries of Central Americal (Costa Rica, Mexico), sough Americal (Brazil, Columbia) and Asia (including Pakistan, Indonesia, Japan) use this kind of non-crystalline sugar called variously (Repodura, Chancaca, Pancoa, Mascasvado, Popiton, Jaggery, etc.) Asian countries are the largest consumers (80-) of these forms of sugar.

Gur (Gul, gud, vellum, bella), is the product obtained on concentrating sugarcane juice with or without prior purification, into a solid or semi-solid state. It is produced almost throughout India and forms an important item of the Indian diet. The manufacture of gur holds a very important place in the rural economy of the country. Uttar Pradesh accounts for c. 45 percent of the total production of gur while Punjab and Haryana account for some 10 percent. The States of Maharashtra, Andhra Pradesh, Mysore and Tamil Nadu together account for some 30 percent of the total production of gur in the country.


COST ESTIMATION

Plant Capacity                                              (400 TCD)                                       
Land & Building (4 Acres)                           Rs.7.60 Cr
Plant & Machinery                                         Rs. 12.00 Cr
W.C. for 3 Months                                         Rs. 5.09   Cr
Total Capital Investment                             Rs.25.04 Cr
Rate of Return                                              13%
Break Even Point                                         67%

INTRODUCTION    
ADVANCES IN JAGGERY INDUSTRY    
TABLE COMPOSITION OF CANE `GUR' & PALM `GUR'    
SPECIFICATION OF JAGGERY POWDER    
PROPERTIES AND CHARACTERISTICS OF JAGGERY POWDER    
COMPARISON CHART OF NUTRITIVE VALUE OF JAGGERY,
  KHANDSARI AND SUGAR    
PROPERTIES    
TABLE-JUICE CONSTITUENTS OF SOME VARIETIES OF SUGARCANE    
ANALYSIS OF JUICE OF MATURE (GOOD) SUGARCANE    
COMPOSITION OF SUGAR CANE JUICE    
USES & APPLICATION    
USES AND APPLICATION OF JAGGERY POWDER    
B.I.S. SPECIFICATIONS    
MARKET SURVEY    
PRODUCTION OF GUR/JAGGERY    
APPARENT CONSUMPTION OF JAGGERY (LACS MT.)    
ESTIMATED DEMAND IN LACS MT.    
DEMAND SUPPLY GAP    
JAGGERY PRICES SHOOT UP, IN LINE WITH THOSE OF SUGAR    
CURRENT DEMAND    
DEMAND GROWING    
GOOD RESPONSE    
JAGGERY EXPORT DATA    
PRESENT MANUFACTURERS/SUPPLIERS OF JAGGERY    
VARIETIES OF SUGARCANE
TABLE 1-SUGARCANE VARIETIES IN CULTIVATION OR RECOMMENDED
  FOR CULTIVATION    
DIFFERENT FORM OF JIGGERY AND THEIR PRODUCTION METHOD    
MANUFACTURING PROCESS OF SOLID JAGGERY    
PROCESS FLOWSHEET OF GUR/JAGGERY MANUFACTURING    
MANUFACTURING PROCESS OF JAGGERY POWDER    
PROCESS FLOW DIAGRAM OF JAGGERY POWDER    
BLOCK DIAGRAM OF JIGGERY POWDER PLANT
METHOD OF MANUFACTURING DIFFERENT TYPE OF JIGGERY    
UNIT OPERATION OF JIGGERY MANUFACTURE    
PLANT LAYOUT    
TURNKEY CONSULTANTS    
SUPPLIERS OF PLANT AND MACHINERIES FOR JAGGERY    
SUPPLIERS OF RAW MATERIALS    


APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET