AUTOMATION IN JAGGERY MAKING USING PLC

CHAPTER 1
INTRODUCTION

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1.1 Project Statement:

“AUTOMATION IN JAGGERY MAKING USING PLC”

1.2 Project Objective:

The purpose of the project is, “ to automate the process of Jaggery making using PLC
which reduces the man power and provide safety which helps in increased in total
profit of the plant.”

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CHAPTER 2
BASIC CONCEPT

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1.1 Introduction to Conventional Jaggery Making process:

Fig. 1. Process of Jaggery making

Historically, the sugar cane cultivators used crushers which were ox-driven. Nowadays
all the crushers are power-driven. These crushers are located in fields near the sugar crop.
The cut and cleaned sugar cane is put into the crusher. The extracted sugar cane juice is
collected in a big vessel. A certain quantity of the juice is transferred to a smaller vessel for
heating on a furnace.

The vessel is heated for about one hour. Dried wood pulp from the crushed sugar cane is
used as fuel for the furnace. While boiling the juice, some lime is added to it so that all the
wood particles are collected on top of the juice in a froth during boiling which is skimmed
off. Finally the juice is thickened and reduced to nearly one- third of the original volume.
This hot liquid is golden in colour. It is stirred continuously and lifted with a spatula to
observe whether it forms a thread or drips drop wise while falling. If it forms many threads, it
has completely thickened. Now it is poured into a shallow flat bottomed concrete tank to cool
and solidify. The tank is large enough to allow only a thin coat of this hot liquid to form at its
bottom, so as to increase the surface area for quick evaporation and cooling. After cooling
down the jaggery becomes a soft solid which is now pressed into the desired shape for selling
at the market.

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The quality of the jaggery is judged by its colour; brown means it is higher in impurities
and golden-yellow implies it is relatively pure. Due to this grading scale there are
malpractices of adding colour or harmful chemicals to simulate the golden colour.

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2.2.Problems in conventional process

1) Required large manpower:
There are four main steps in the Jaggery making process. These are crushing,
processing of juice, filling and packing.

In the crushing part there are 4 to 5 peoples are required. In the process of juice
there are 4 peoples are required. One is the supervisor and another 3 are working for
separation of molasses. In the filling process there are 4 peoples are required. And at the last
stage that is for packaging of Jaggery there are 3 peoples are required. Hence the total man
power required is 15.

2) Lack of safety:
The crushing machine is of high power approximately 15 HP. Safety should be
provided to the machine. The machine should be covered with the metal sheet. But they do
not take care of it. Hence, there are chances of accident.

At the process tank, the molasses is separated by the metal containers. At this
stage the temperature of juice is about 800C.Hence there is a chances of burning.

3) Exerted Heat:
The temperature of juice at the boiling stage is about 900C. It is a very high
temperature where the continuous vapours are exerted.

4) Separation of molasses:
At the process tank, the molasses is separated by the metal containers. At this
stage the temperature of juice is about 800C.Hence there is a chances of burning.

5) Less profit:
As the large man power is required, from the total profit almost all the profit
goes in to the salary of workers. Hence, it gives less profit.

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CHAPTER 3
AUTOMATION IN JAGGERY MAKING

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3.1.Block diagram

Fig. 2 block diagram of automatic Jaggery making process.

At the first stage, the sugarcane is put in to the crushing machine. Here, before putting
it into the machine pushing assembly is mounted. The double acting cylinder is placed for
pushing the sugarcane into the machine. After the crushing the juice which is collected is
filtered out and collected into the storage tank. The stored juice is then taken for the boiling.
When the boiling is start, from that time after 15 to 20 min, molasses is come upon the juice.
It has to be remove. Because it is waste material and it degrades the quality of Jaggery. After
removing the molasses the juice again heated continuously up to 2 hours. At this stage juice
is continuously agitated. After 2 hours, the accurate quality of juice is maintain for the proper
Jaggery. After that this Jaggery is taken for the filling in different pots. And filled pots are
then taken for storage.

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3.2.Process Diagram

Fig. 3 Process diagram of Automatic Jaggery making process

At the first stage, the sugarcane is put in to the crushing machine. Here, before
putting it into the machine pushing assembly is mounted. The double acting cylinder is
placed for pushing the sugarcane into the machine. The sugarcane is passes through the
machine by two steps. The juice which is collected is filtered by using filter. And the waste
material that is bagase is collected in the storage box. The filtered juice is then collected in
storage tank. The limit switch is placed on top of the tank at the particular level. When juice
in the storage tank reaches to that particular level, limit switch close and give signal to the
control valve C2. This valve opens until all the juice has been collected in to the process tank.
When all juice is collected in to the tank heating coils starts heating. After 15 to 20 minutes,
the molasses come upon the juice. At that time control valve C3 gets open and all molasses is
removed. After that the stirrer is starts agitating the juice up to 1 and half hours.

When the juice is converted in to the perfect liquid Jaggery, it is taken for the
filling. The conveyor belt is placed bellow the process tank. The process tank is provided
with the control valve at the bottom side. The control valve is opened for the particular time.

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3.2.1 Crushing
Most artisanal sugar producers use a simple crusher consisting of three metal
rollers. This is driven by either animal or diesel power. Figures 1 and 2 show both types in
operation in Bangladesh. A crusher driven by a single ox can be expected to process around
50kg of cane per hour. A 5HP diesel set could increase this to around 300kg per hour. In
these pictures the rollers are set vertically; many machines have horizontal rollers. Suppliers
of this machinery are given at the end of this technical brief.

Fig. 4 Crushing System

Important points to remember during crushing are:

 Cane must be crushed within 24 hours of being cut. After this time the sugar begins to
'invert' into different sugars that will not set solid.

 Crushing efficiency is the most important factor in good sugar yields. Every possible
amount of juice needs to be squeezed from the cane.

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3.2.2 Storage of Juice

Fig. 5 Storage of Juice

The juice which is crushed is then collected in to the storage tank. The limit
level switch is mounted on the upper side of the tank. When the level of juice reaches to a
particular level the control valve which is at the bottom side of the tank is opened.

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3.2.3 Juice Treatment

Fig.6 Treatment of Juice

Juice should be filtered through a cloth before boiling in order to remove any
solids such as dirt or particles of cane.

Large-scale sugar processors add lime to the juice in order to coagulate

impurities which then settle out. (This is rarely done at the artisanal level.) The juice is then
neutralised with sulphur dioxide. Small-scale producers add a variety of clarificants to the
juice including wood ash. All of these have the effect of settling out impurities. Many
producers also add 'Hydros' (sodium hydrogen sulphate) at the final stages of boiling. This
releases sulphur dioxide into the juice and lightens the colour of the final product. (Note that
a high sulphur content often remains in the final product.)

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3.2.4 Cooling

Fig. 7 Cooling

When the final jaggery is produced, the temperature of that product is high about
0
118 C. Hence it takes more time to cool. For reduction in temperature of product it should be
cooled in dryer. Here we use screw dryer for cooling purpose. When final product is made, it
comes in to the screw dryer. At this stage temperature will reduce to about 75 0C. Then
product will taken for filing.

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3.2.5 Filling

Fig. 8 Filling process

When the juice is cooled in screw dryer, it is taken for the filling. The conveyor
belt is placed bellow the process tank. The process tank is provided with the control valve at
the bottom side. The control valve is opened for the particular time. And at that time the pot
is placed exact bellow the valve. When the valve is closed the conveyor starts and IR sensor
which is placed on the conveyor belt detects the next pot.

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3.3 Inputs & Outputs

3.3.1 INPUTS:

1 )Level limit switch

2) Proximity sensor

3) RTD

3.3.2 OUTPUTS:

1)Three phase AC motor

2)Single phase AC motor

3) DC motor

4) Solenoid valve

5)Double acting cylinder

6) Solenoid operated air valve

7)Heating coil

8) Wiper motor

3.3.3 CONTROLLER:

1)PLC

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3.4 Components
Input components

3.4.1 Level limit Switch:

Fig. 9 Level limit switch

In electrical engineering a limit switch is a switch operated by the motion of a

machine part or presence of an object.

They are used for controlling machinery as part of a control system, as a

safety interlocks, or to count objects passing a point.[1] A limit switch is an electromechanical
device that consists of an actuator mechanically linked to a set of contacts. When an object
comes into contact with the actuator, the device operates the contacts to make or break an
electrical connection.

Standardized limit switches are industrial control components manufactured with a

variety of operator types, including lever, roller plunger, and whisker type. Limit switches
may be directly mechanically operated by the motion of the operating lever. A reed
switch may be used to indicate proximity of a magnet mounted on some moving
part. Proximity switches operate by the disturbance of an electromagnetic field, by
capacitance, or by sensing a magnetic field.

Specifications:

1) Type: Float type

2) Durability: 3,00,000 operations
3) Operating Speed: 1 to 500 mm/s
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3.4.2 Proximity Sensor:(M-18 DC-NF TNi)

Fig. 10 Proximity Sensor

Dual source and dual receivers are used for self compensation of changes in
alignment, light source intensity and component efficiency. The transmitted beams from
two infrared sources are superimposed onto an internal beam splitter. 50% of the overlapping
sample and reference signal is passed through the gas measuring path and reflected back onto
the measuring detector. The presence of combustible gas will reduce the intensity of the
sample beam and not the reference beam, with the difference between these two signals being
proportional to the concentration of gas present in the measuring path. The other 50% of the
overlapped signal passes through the beam splitter and onto the compensation. The
compensation detector monitors the intensity of the two infrared sources and automatically
compensates for any long term drift. It is used to detect moulds for filling of Jaggery.

Mean time between failures may go up to 15 years.

Specifications:
1)Type: Inductive PNP(NO)

2)Sensing distance: 0.8 mm

3)Supply Voltage: 05 to 40 VDC

4)Max. Load: 200 mA

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3.4.3. RTD:

Fig. 11 RTD
Resistance thermometers, also called resistance temperature
detectors (RTDs), are sensors used to measure temperature by correlating the resistance of the
RTD element with temperature. Most RTD elements consist of a length of fine coiled wire
wrapped around a ceramic or glass core. The element is usually quite fragile, so it is often
placed inside a sheathed probe to protect it.

The RTD element is made from a pure material, typically platinum, nickel or
copper. The material has a predictable change in resistance as the temperature changes and it
is this predictable change that is used to determine temperature.

They are slowly replacing the use of thermocouples in many industrial

applications below 600 °C, due to higher accuracy and repeatability. It is used to measure the
temperature of the process fluid i.e. sugarcane juice.

Specifications:
1) Type: PT 100

2) Temperature range: -2000C to 8500C

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3.4.3.i) Signal Conditioning of RTD:

Fig. 12 RTD signal conditioning

Input
Processing
output

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Output Components
3.4.1 Cane feeding Three phase AC Motor:

Fig. 13. Three phase AC Motor

An electric motor converts electrical energy into a mechanical energy which is

then supplied to different types of loads. A.C. motors operate on an a.c. supply, and they
are classified into synchronous, single phase and 3 phase induction, and special purpose
motors. Out of all types, 3 phase induction motors are most widely used for industrial
applications mainly because they do not require a starting device.
A 3 phase induction motor derives its name from the fact that the rotor current is
induced by the magnetic field, instead of electrical connections.
The operating principle of a 3 phase induction motor is based on the production
of r.m.f. This motor is connected to the crusher for rotating the wheels of crusher.

Specification:
1) Power: ½ HP

2) Speed: 40 rpm with geared

3) Supply voltage: 440 VAC

4) Current: 1.2 Amp

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3.4.2 Agitator Single Phase AC motor:

Fig.14 Single Phase AC motor

An AC motor is an electric motor driven by an alternating current (AC). The AC

motor commonly consists of two basic parts, an outside stationary stator having coils
supplied with alternating current to produce a rotating magnetic field, and an
inside rotor attached to the output shaft producing a second rotating magnetic field. The rotor
magnetic field may be produced by permanent magnets, reluctance saliency, or DC or AC
electrical windings.

Less commonly, linear AC motors operate on similar principles as rotating

motors but have their stationary and moving parts arranged in a straight line configuration,
producing linear motion instead of rotation. It is used to agitate the juice to avoid overflow.

Specifications:

1)Power: 1/35 HP

2) Supply Voltage: 230 VAC, 50 Hz

3) Speed: 1280 rpm

4) Load current: 0.35 A

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3.4.3 Gate valve DC Motor:

Fig.15 DC Motor
A DC motor is any of a class of electrical machines that converts direct current
electrical power into mechanical power. The most common types rely on the forces produced
by magnetic fields. Nearly all types of DC motors have some internal mechanism, either
electromechanical or electronic, to periodically change the direction of current flow in part of
the motor. Most types produce rotary motion; a linear motor directly produces force and
motion in a straight line.

DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's speed can be
controlled over a wide range, using either a variable supply voltage or by changing the
strength of current in its field windings. Small DC motors are used in tools, toys, and
appliances. The universal motor can operate on direct current but is a lightweight motor used
for portable power tools and appliances. Larger DC motors are used in propulsion of electric
vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of power
electronics has made replacement of DC motors with AC motors possible in many
applications. It is used to rotate the gate valve.

Specifications:
1) Speed: 30 rpm
2) Supply voltage: 12 VDC
3) Current: 1 A

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3.4.4 Solenoid Valve:(1TO-900/2W)

Fig.16 Solenoid Valve

A solenoid valve is an electromechanically operated valve. The valve is controlled
by an electric current through a solenoid: in the case of a two-port valve the flow is switched
on or off; in the case of a three-port valve, the outflow is switched between the two outlet
ports. Multiple solenoid valves can be placed together on a manifold.

Solenoid valves are the most frequently used control elements in fluidics. Their
tasks are to shut off, release, dose, distribute or mix fluids. They are found in many
application areas. Solenoids offer fast and safe switching, high reliability, long service life,
good medium compatibility of the materials used, low control power and compact design.

Besides the plunger-type actuator which is used most frequently, pivoted-armature

actuators and rocker actuators are also used. It is used to transfer the juice from storage tank
to reactor tank.

Specifications:
1) Type: 2/2 way

2) Supply voltage: 12 VDC

3) Valve size: ½ “

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3.4.5. Double acting cylinder:

Fig.17 Double acting Cylinder

A double-acting cylinder is a cylinder in which the working fluid acts

alternately on both sides of the piston. In order to connect the piston in a double-acting
cylinder to an external mechanism, such as a crank shaft, a hole must be provided in one end
of the cylinder for the piston rod and this is fitted with a gland or 'stuffing box' to prevent
escape of the working fluid.

Double-acting cylinders are common insteam engines but unusual in other

engine types. Many hydraulic and pneumatic cylinders use them where it is needed to
produce a force in both directions. A double-acting hydraulic cylinder has a port at each end,
supplied with hydraulic fluid for both the retraction and extension of the piston. A double-
acting cylinder is used where an external force is not available to retract the piston or where
high force is required in both directions of travel.

Specifications:

1) Double acting cylinder 1:

1. Bore size:16 mm
2. Stroke length:25 mm

2) Double acting cylinder 2:

1. Bore size:25 mm
2. Stroke length:90 mm

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3.4.6 Solenoid operated air valve:

Fig.18 Pneumatic Solenoid Valve

Specifications:

1) Solenoid operated air valve 1: (Pushing assembly)

1) Supply voltage: 230 vdc

2) Type: 5/2 solenoid valve
3) Operating pressure: 2 to 10 bar

2) Solenoid operated air valve 2: (Filling)

1)Supply voltage: 24 VDC
2)Type : 3/2 solenoid valve
3)Operating pressure: 0.15 to 0.80 mpa

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3.4.7. Heating coil:

Fig. 19 Heating Coil

Electric heating is any process in which electrical energy is converted to heat.
Common applications include space heating,cooking, water heating and industrial processes.
An electric heater is an electrical device that converts electric current to heat.[1] The heating
element inside every electric heater is an electrical resistor, and works on the principle
of Joule heating: an electric current passing through a resistor will convert that electrical
energy into heat energy. Most modern electric heating devices use nichrome wire as the
active element; the heating element, depicted on the right, uses nichrome wire supported by
ceramic insulators.

Alternatively, a heat pump uses an electric motor to drive a refrigeration cycle,

that draws heat energy from a source such as the ground or outside air and directs that heat
into the space to be warmed. Some systems can be reversed so that the interior space is
cooled and the warm air is discharged outside or into the ground. Heat pumps can deliver
three or four units of heating energy for every unit of electricity purchased, with the amount
of heating energy delivered being a function of equipment efficiency as well as the
temperature difference between the ground (or outdoor air) and the building interior. It is
used to heat the juice in the reactor rank.

Specifications:
1) Power: 750 w

2) Supply voltage: 230 vdc

3) Current: 0.83 Amp

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3.4.8: Gate valve

Fig.20 Gate Valve

A gate valve, also known as a sluice valve, is a valve that opens by lifting a round or
rectangular gate/wedge out of the path of the fluid. The distinct feature of a gate valve is the
sealing surfaces between the gate and seats are planar, so gate valves are often used when a
straight-line flow of fluid and minimum restriction is desired. The gate faces can form a
wedge shape or they can be parallel. Gate valves are primarily used to permit or prevent the
flow of liquids, but typical gate valves shouldn't be used for regulating flow, unless they are
specifically designed for that purpose. Because of their ability to cut through liquids, gate
valves are often used in the petroleum industry.
Specifications:
1) Valve size: 1 inch

2) Material: Brass

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3.4.9. Screw dryer Wiper motor:

Fig.21 Wiper Motor

Wiper Motor, the power source of the wiper blade, is the core of the whole wiper
system. Therefore, the quality of the wiper motor must be guaranteed to ensure its
performance. The wiper motor is a permanent-magnet direct current (DC) one. It is equipped
on the front windscreen glass with the mechanical parts of the worm gear. The worm gear
functions to slow down and increase torque. Its output shafts spur four-bar linkage, by which
the movement is changed from rotary to swinging.

Three-brush structure is adopted to make speed change more convenient. The

intermittent relay, by which the interval is controlled, utilizing the return of switch contacts
and the charge-discharge function of the resistor-capacitor in the relay, drives the wiper to
wipe in a certain cycle. The wiper blade tape, the tool to clean the rainwater and the filth on
the glass, presses the surface of the glass with springs. Only when the tip of the blade is in a
certain angle with the glass, can the required function be realized.

Specifications:
1) Speed: 100 rpm

2) Supply voltage: 24 vDC

3) Current: 1 Amp

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Controller
3.4.1. PLC(Controller):

Fig.22 PLC controller

A programmable logic controller, PLC, or programmable controller is a digital

computer used for automation of typically industrial electromechanical processes, such as
control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are
used in many machines, in many industries. PLCs are designed for multiple arrangements of
digital and analog inputs and outputs, extended temperature ranges, immunity to electrical
noise, and resistance to vibration and impact. Programs to control machine operation are
typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a
"hard" real-time system since output results must be produced in response to input conditions
within a limited time, otherwise unintended operation will result.

Before the PLC, control, sequencing, and safety interlock logic for
manufacturing automobiles was mainly composed of relays, cam timers, drum sequencers,
and dedicated closed-loop controllers. Since these could number in the hundreds or even
thousands, the process for updating such facilities for the yearly model change-over was very
time consuming and expensive, as electricians needed to individually rewire the relays to
change their operational characteristics. Here we are using PLC of AB 1100.

Specifications:

1) No of inputs: 10
2) No of outputs:12
3) Voltage:0 to 10 v
4) Current:4 to 20 ma

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3.4.2: Control Panel:

Fig.23 Control Panel

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3.4.3: PLC Input Output list:

3.4.3.i) Input list:

1) I:0/0 – Start

2) I:0/1 – Stop

3) I:0/2 – Auto/Manual

4) I:0/3 – Select Switch 1

5) I:0/4 – Tank high level

6) I:0/5 – Limit Switch

7) I:0/6 – Proximity Sensor

8) I:0/7 – Select switch 2

9) - Temp. Sensor RTD (analog)

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3.4.3.ii) Output list:

1) O:0/0 – Pushing cylinder 1

2) O:0/1 – Crusher

3) O:0/2 – Storage solenoid valve

4) O:0/3 – Stirrer

5) O:0/4 – Molasses gate valve 1 open

6) O:0/5 – Molasses gate valve 1 close

7) O: 3/0 – Heater

8) O:3/1 – Reactor tank gate valve 2open

9) O:3/2 – Reactor tank gate valve 2 close

10) O:3/3 – Screw dryer wiper motor

11) O: 3 /4 – Pneumatic cylinder 2

12) O: 3/5 – Conveyer

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3.5: Mimic Representation:

Fig. 24 Mimic Representation

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CHAPTER 4

SOFTWARE DESIGN

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4.1: Sequential flow chart:

Fig.25 Sequential Flow Chart(SFC)

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4.2: Flow Chart:

Fig. 26 Flow Chart

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4.3: Software Design:

Ladder Logic Program:

According to the IEC 61131-3 standard ladder diagram are schematic

representation of control logic circuit in the form of rungs of ladder. The ladder diagrams
are also called because the complicated diagrams resembles rungs of a wooden ladder.
The ladder diagram is constructed to show the sequence of the event. Ladder diagrams
once learnt for a particular controller can be inter operable with any other programmable
languages mentioned in IEC 61131-3.

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CHAPTER 5

TESTING AND RESULTS

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5.1:Testing and Results:

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CHAPTER 6

PROJECT DETAILS

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6.1Budget of Project:

Components Cost

Sensors Rs.2370/-

Actuators Rs.9950/-

Hardware Rs.7450/-

Electronic Circuitry Rs.1000/-

Other Rs.1000/-

Total Rs.21,770/-

Table no. 1 Budget of project

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6.2Work Distribution

Table no.2 Work distribution

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6.3 Project Activity:

Table no. 3 Project Activity

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CHAPTER 7
ADVANTAGES AND
FUTURE SCOPE

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7.1: Advantages:
 Required less man power

 Provide safety

 More profit

7.2: Future Scope in Jaggery making

 Bagasse is used for paper industry

 Molasses is used for cattle feed

 Using Viscosity Sensor improve Quality of Jaggery

 Packaging.

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CHAPTER 8
CONCLUSION

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8.1Conclusion

 As we seen, because of some drawbacks conventional Jaggery making process is not

safety and less profitable. And providing automation approach to the process it
becomes safe and profitable.

 It also helps in the improving the mass of product.

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CHAPTER 9
REFERENCES

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9.1. References

 Parshv organic Jaggary production Centre, Halondi

 Principle of Process Measurement, B. G. Liptak

 Principle of electrical machine, V. K. Mehata

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