PROCESS/ EQUIPMENT FOR MAKING SUGARCANE MOLASSES(Panucha)
1. Overview
2. Types
3. Life cycle
4. Process of planting
5. equipment used to extract
6. common problem
7. pest
8. cost
Sugarcane (Saccharum spp.) is a tropical, perennial grass known for its high sucrose
content, primarily used for sugar production. In addition to sugar, sugarcane is also
used to produce by-products like molasses, rum, ethanol (for biofuel), and bagasse
(used as fuel or in paper manufacturing). Sugarcane is one of the world’s most
widely cultivated crops, especially in countries like Brazil, India, China, and Thailand.
Lifecycle of Sugarcane
Sugarcane has a unique lifecycle that spans about 12-24 months, though it can
continue producing through successive ratoons (re-growth cycles) after initial
harvesting. Here’s a breakdown of the stages:
Stages of Growth
1. Germination (2-4 weeks):
After planting, the buds (or “eyes”) on cane stalks sprout, sending out roots and
shoots.
This stage is critical, and moisture is essential for successful sprouting.
2. Tillering (3-4 months):
Tillering refers to the production of additional stalks (tillers) from the base of the
plant, helping increase plant density.
This stage also benefits from regular watering and nutrient application to promote
maximum shoot growth.
3. Stem Elongation (6-18 months):
As the plant matures, stalks grow vertically, storing sucrose in the stems.
This is the most critical stage for sucrose accumulation, with cell elongation and
division filling the stalks with juice.
4. Maturation (3-4 months before harvest):
The plant stops growing in height, and the cane stalks reach their maximum sucrose
content.
Leaves dry out, and moisture levels decrease, indicating the cane is ready for
harvest.
5. Harvesting:
When the stalks reach peak sucrose content, they are ready for cutting. Sugarcane
is typically harvested between 12-18 months after planting in tropical climates and
between 18-24 months in subtropical climates.
Types of Sugarcane
Different varieties are cultivated for their unique properties:
a. Saccharum officinarum: High sucrose content, primary type for commercial
sugar production.
b. Saccharum spontaneum: A wild variety used in breeding due to its disease
resistance and ability to grow in harsher environments.
c. Saccharum robustum: Known for thick, robust stalks, commonly used in
hybridization.
d. Saccharum sinense: Predominantly grown in China with moderate sugar yield
but strong disease resistance.
Hybrids are often created using these types to optimize yield, resilience, and
adaptability for various climates.
Sugarcane Extraction Process and Equipment
The process of extracting sugar from sugarcane involves multiple steps and specific
equipment:
1. Harvesting Equipment and Process
1.1 Manual Harvesting: Workers cut the cane with machetes or knives, especially in
countries with less mechanization. This method is labor-intensive but allows
selective harvesting.
1.2 Mechanical Harvesting: Harvester machines cut the cane at ground level, strip
leaves, and chop stalks into manageable lengths. Mechanical harvesting is efficient
but requires level fields.
2. Cleaning and Milling Process
2.1 Cleaning: Cane stalks are cleaned to remove dirt, debris, and leaves, usually
using water jets or by hand.
2.2 Milling: The cleaned stalks are then crushed in a series of mills (heavy rollers) to
extract juice. Typical mills include:
2.3 Three-Roller Mill: Simple but effective, these mills use three rollers to crush and
press cane stalks.
2.4 Four-Roller Mill: Adds an additional roller to increase juice extraction.
2.5 Diffusers: For large-scale extraction, diffusers use hot water to wash sucrose
from shredded cane, resulting in higher juice yield.
3. Juice Clarification and Filtration
The extracted juice contains impurities and is clarified using lime to separate
impurities. This is done in clarifiers that precipitate non-sucrose solids.
3.1 Filters and Centrifuges are used to separate the purified juice from solids (known
as “mud” or “filter cake”).
4. Evaporation and Crystallization
4.1 Evaporators: Concentrate the juice by heating it to evaporate water, resulting in
a thick syrup.
4.2 Crystallizers: The syrup is then seeded with sugar crystals, promoting the
formation of larger sugar crystals as it cools.
5. Separation and Drying
Centrifuges separate sugar crystals from molasses.
Dryers remove remaining moisture from the crystals, producing raw sugar ready for
refining or direct sale.
Growing Season for Sugarcane
Sugarcane has a specific growing season, depending on its tropical or subtropical
environment:
1. Tropical Regions: Planting usually takes place during spring, with the harvest
occurring in the fall.
2. Subtropical Regions: Planting occurs in the autumn, with harvesting the following
spring.
Ideal Growing Conditions
3. Temperature: Prefers a warm climate with temperatures between 20-35°C.
4. Rainfall: Requires about 1,500-2,500 mm of rainfall, but waterlogged soil should
be avoided.
5. Sunlight: Requires about 8-12 hours of daily sunlight for photosynthesis and
sucrose formation.
Cultivation and Maintenance of Sugarcane
To achieve healthy growth and maximize yield, the following practices are crucial:
a. Land Preparation: Plow the soil to aerate and incorporate organic matter,
improving root development and moisture retention.
b. Seed Cane Selection: Use disease-free, high-yielding varieties to ensure
healthy growth.
c. Fertilization: Apply nitrogen, phosphorus, and potassium during different
growth stages:
d. Nitrogen: Vital for tillering and vegetative growth.
e. Phosphorus: Encourages root development, especially during the
germination stage.
f. Potassium: Aids in stalk strength and sucrose formation.
g. Irrigation: Sugarcane needs consistent watering, especially during
germination and tillering. Avoid waterlogging, which can lead to root rot.
h. Weed Control: Use mulching or selective herbicides to control weeds. Weeds
compete with sugarcane for nutrients and can reduce yield if left unchecked.
i. Pruning: Removing older leaves increases sunlight penetration and reduces
humidity, minimizing fungal infection risks.
Pests and Diseases in Sugarcane
Sugarcane is susceptible to various pests and diseases, which can significantly
impact yield.
Common Pests
a. Sugarcane Borers: These larvae bore into stalks, reducing juice quality.
Control involves the use of biological agents like parasitoid wasps and
carefully timed pesticide applications.
b. Termites: Attack roots and basal parts of the cane, often combated with soil
treatments and crop rotation.
c. White Grubs: Feed on roots, affecting stability and growth. Soil treatments
and introducing natural predators help manage these pests.
Common Diseases
a. Red Rot: A fungal infection causing red streaks inside stems and reducing
sucrose. Managed through crop rotation and resistant varieties.
b. Smut: A fungal disease producing black, whip-like structures on stalks.
Treated by using disease-free planting material and controlling plant density.
c. Leaf Scald: Bacterial disease causing white streaks and leaf drying. Disease-
free seeds and crop rotation help in prevention.
Challenges in Sugarcane Cultivation
Some of the main challenges include:
a. Climate Variability: Sugarcane growth is heavily influenced by weather, with
droughts or floods impacting yield and growth stages.
b. Soil Degradation: Continuous monoculture can lead to nutrient depletion.
Fertilization and crop rotation with legumes can help restore soil fertility.
c. Water Management: Sugarcane is water-intensive. Irrigation is necessary in
regions with inadequate rainfall, but over-irrigation can cause root issues.
d. Labor Costs: In regions where manual harvesting is standard, labor costs can
be high. Mechanization is beneficial but can be expensive.
