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CHAPTER-I
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INTRODUCTION TO INDIAN SUGAR INDUSTRY
The sugar industry occupies a major portion in the (organization) industries of India. The sugar industries have rank second next to cotton and textile industries. The sugar industry started since 1830. China is the first producer of sugar in the world. It provides highest direct employment opportunities.
Today India has become largest sugar producer in the world. India produces 190-200 lakh metric tone of sugar per year.
The sugarcane is being grown in many states of India like Maharashtra (First place), Uttar Pradesh, Gujarat, Karnataka. In Karnataka the sugar cane is mostly grown around Bagalkot, Bijapur, Belgaum, Mandya districts and coastal areas. The Sugar cane can be grown in all types of soil but higher yield can be obtained in black fertile soil.
Total India’s Consumption
190-200 Lakh metric tones per year. Per capita consumption of sugar by Indian population 15% per year.
Problems of sugar industry
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For understanding financial ratios in business which shows the strength or weakness of the company. The following points to be noted.
India Overtakes Brazil in Sugar Production
2007 will mark a major change in the sugar market as Brazil, the traditional powerhouse in the arena, surrenders its crown over to the new leader, India. India is predicted to cultivate 33 million tones by the end of this year, nearly 20% of the entire world’s production.
Brazil’s dominance in the sugar market dates back a few decades, when Brazil overtook the title from Cuba. The tropical climate and good soil in the region gave the tiny Caribbean island a strong advantage over its competitors. Over the past two decades, however, the communist regime has destroyed the country’s sugar industry and today Cuba is a skeleton of its former self in terms of sugar production.
70% of Brazilian sugar is produced in the state of Sao Paolo, the lowest cost producer in the world as of 2005, at about 10 cents/lb. The strong Brazilian
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Real has changed the dynamics of the industry, though, as the currency strength has caused export prices to rise about 30%, placing it on a more equal footing with other competitors such as Thailand and India, which can produce a pound of sugar for around 18 cents. Brazil is also the world’s largest consumer of sugar, with per capita consumption around 55 kg/year, just beating out Mexico and far out passing the United States at 29 kg/year.
Much of this disparity is due to the ethanol industry, which in Brazil is far more advanced than any place else on the planet. The majority of cars sold in Brazil today can be run off pure sugar ethanol as the refueling infrastructure is already in place. The percentage of sugar in the ethanol is also around 50%, and increases as crude oil becomes more expensive.
India, which has less farmland than Brazil, also has poorer soil, poorer climate, and poorer infrastructure. It does, however, have one significant advantage on Brazil, a cheaper labor force, especially in the agriculture labor. This has allowed the country to compete in a very difficult industry. Also, the de-regulation of the Indian business structure that has allowed the flourishing of technology companies is now expanding to the agriculture arena as well. India has been increasing its sugar production at a rate far faster than any other country in the world for several years. Total sugar production has nearly doubled in the past 3-4 years, moving the country from a distant 3rd, to become the new king of the sugar industry.
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HISTORY OF NIRANI SUGARS LTD.
M/s. Nirani Sugars Limited (NSL), a company incorporated on the 6th Dec, 1995 under the Companies Act, 1956 has applied for Term Loan of Rs. 15.90 crores to Sugar Development Fund(SDF) for meeting part of the capital cost of its project envisaging modernization & up-gradation of existing sugar factory with an installed capacity of 1250 TCD to 3750 TCD with substantial investment at Kulali cross Mudhol Tq. Dist: Bagalkot, Karnataka State, NSL has included in the scope of the project, the co-generation of surplus power also at a total project cost of about Rs. 97.00 crores. (Sugar unit Rs. 53.00 crores and cogeneration unit Rs. 44.00 crores). Total Cost of the Project, for the Sugar plant expansion Rs. 5300 Lakhs,(Rs. 42.00 Crores for sugar and 11.00 crores loading from co-generation plant cost) consisting of an Equity Contribution of Rs. 5.30 Crores Promoters, Rs. 15.90 crores equity from Sugar development fund of Govt. of India & the balance of Rs. 31.80 crores funded through Term Loans from the Financial Institutions/Banks.
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The funding for the cogeneration plant costing Rs. 4400.00 Lakhs is envisaged by obtaining Rs. 3080 Lakhs from IREDA, Rs 440.00 Lakhs from promoter’s contribution and Rs. 880 Lakhs from sugar development fund.
M/s. Nirani Sugars Limited (NSL) is a company registered under the Indian Companies Act, 1956, initially as Private Limited Company, vide registration certificate number 08/19340 of 1995 dated 06.12.1995 by the registrar of companies in Karnataka, Bangalore, Subsequently, the company has been converted into Public Limited Company vide Certificate of Incorporation dated 15.02.2002 by ROC, Karnataka, Bangalore.
The unit was originally established in the year 1997-98 as a modern Khandasari Sugar unit with a crushing capacity of 500 tonnes of cane per day and later converted into white crystal sugar unit. This is one amongst the earliest Khandasari unit in the country, which started with a new technology like:
Subsequently making use of the Government of India’s liberalized policy, vide Govt. of India notification DCS/S/14/DTD 02-06-1998, which permitted Khandasari sugar units to use vacuum system, they modernized the
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unit quickly by adding vacuum pans and vacuum evaporators. The capacity of the plant was increased in stages to its present capacity of 1250 TCD during 2005-06. The plant runs fairly efficiently and is self sufficient in fuel and power. It has recorded an average sugar recovery of over 11 percent during 1999-2000 crushing season.
M/s. Nirani Sugar Litd. Now proposes to expand the sugar factory from the present capacity of 1250 TCD to 3750 TCD by adding a new plant of 2500 TCD, retaining the existing plant also. Also 16 MW Cogen Power Plant is part of the expansion. The project appraisal was done by Mitcon Consultancy Services Limted, Pune.
BACKGROUND OF PROMOTERS
The key promoter of the company also Chairman of the company, Mr. Murugesh R. Nirani is Member of the Legislative Assembly (MLA), Government of Karnataka.
PROMOTERS:
M/s. Nirani Sugars Limited promoted by the following Directors:
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constituency in Assembly of Karnataka, He hails from an agricultural family from Bilagi Taluk of Bagalkot District. He started his carrier as an industrialist by settling up a modern Khandasari sugar plant at Mudhol.
Mr. M.R. Nirani has also co-promoted a 2500 TCD sugar plant at Badagandi village in Bilagi taluk viz. Bilagi Sugars Limited in which he holds the position of Managing Director. This unit has just successfully completed trial runs and started commercial operations (during January 2006). Mrs. M.R. Nirani has also been recognized and awarded Bharat Udyog Ratna award from govt. of India. He has the credit of taken over a sick mini cement plant of 100 TPD capacity at Mudhol and successfully put into commercial operation with an increased capacity of 200TPD within a short span of time. His social services contributed in setting up residential schools, D.Ed. college at Mudhol.
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As could be observed the company is a family concern and the overall management of the Company rests with Chairman Shri. Murugesh R. Nirani who is assisted by the other Board of Directors.
Factory Premises:
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Factors Behind Establishment
Objectives of Nirani Sugars Ltd.:
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Company profile | ||
Name of the company | : NIRANI SUGARS LIMITED. MUDHOL | |
Address | : Â NIRANI SUGARS LIMITED. | |
KULALI ROAD, | ||
MUDHOL - 587313 | ||
DIST: BAGALKOT | ||
Regd. Office | : # 2053, High Point- II | |
45 Palace Road, | ||
Bangalore – 560 001 | ||
Branch Office | : Bijapur | |
Status of Company | : Sole trading concern. | |
Constitution of the firm | : Registered under companies act 1956 | |
Financial Institutions | : K.S.I.D.C | |
K.S.F.C | ||
Bankers of the Company | : I.C.I.C.I Bank Jamakhandi | |
S.B.I Mudhol Br. | ||
Indian Bank Lokapur. | ||
Grameen bank Mudhol. | ||
Products | : Sugar (L30, M30, S30) | |
Molasses, Press Mud, Bagasse. | ||
Electricity. |
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Board of Management
1. | Sri. Murugesh R. Nirani | - | Chairman&Managing Director |
2. | Sri. Sangamesh R. Nirani | - | Executive Director. |
3. | Sri. Hanamanth R. Nirani | - | Director. |
4. | Smt. Kamala M. Nirani | - | Director. |
5. | Sri. S.V. Kariyannavara | - | Chief Executive officer. |
6. | Sri. S.C. Itnal | - | General Manager (Plant) |
7. | Sri. B.S. Kandekar | - | General Manager (Cane) |
8. | Sri. Suresh. Dhabade | - | Deputy G.M ( Plant) |
9. | Sri. M.S. Heggalagi | - | Manager (Public relations) |
10.Sri. M.M . Hiremath | - | General Manager(Accounts) |
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Future plans of Nirani Sugars Ltd.
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C & MD
Board of Directors
CEO
Administration        A/Cs Dept. Production Dept. Civil Division. Cane        Personal Dept.
C. A. DÂ Â Â Â Â Â Â Â Dept. C. A. DÂ Â Â Â Â Â Â Â Development
General A/C        Cane A/C        Engineering        Production        Warehouse
Share section  Computer        Sales        Purchase        Store        Time section
section        section        section        section
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DEPARTMENTS OF ORGANIZATION
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MECHANICAL DEPARTMENT
Meaning
It is a season in which the maintenance of machineries, repairs and over all operation are rendered by the workers. It is to manufacture sugar by using machines.
Structure:
Work Manager
Chief Engineer
Asst. Engineer | Asst. Engineer | Asst. Engineer | (According to Shift) | ||
Asst. Engine er | |||
Trainee. | e | Trainee. Engineer | Trainee. Engineer |
Fitters | Fitters | Fitters | ||
Mechanics        Mechanics        Mechanics
Work shop attender | Work shop attender | Work shop attender | ||
Turbine attender | Turbine attender | Turbine attender | ||
Shifts : 6 a.m – 2 p.m
2 p.m – 10 p.m
10 p.m – 6 a.m
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Functions
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CHEMICAL SECTION
Meaning
It means to take chemical tests before producing sugar and manufacturing of sugar from sugar cane.
Structure
Chemical Department | (According to | |||||||||
Shift) | ||||||||||
Lab Chemist | ||||||||||
Lab Incharge | ||||||||||
Manufacturing | Manufacturing | Manufacturing | ||||||||
Chemist | Chemist | Chemist |
Functions :
M30 – Medium
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S30 – Small
Responsibilities :
The responsibility of this department is to test the product of the sugarcane and quality of sugar.
Chemicals used:
Cleaning Chemicals :
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HUMAN RESOURCE DEPARTMENT
This department is concerned with recruitment selection and placement.
In Nirani SugarsLtd. The personnel manager takes all the above responsibilities and undertakes the activities concerned with him.
Suitable candidates are selected to a particular job according to their qualification and experience. There is no necessary to give training to the workers on separate machine other than actual production process. Hence training is given on the job only.
Manager and Supervisor are continuously inspecting every worker to access their performances and there is better scope for hard workers.
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LIST OF EMPLOYESS
Statement of number of employees.
Sl No | Designation | Total |
1 | Executive Director | 1 |
2 | Finance Director | 1 |
3 | General Manager | 1 |
4 | General Manager Cane | 1 |
5 | General Manager Project | 1 |
6 | General Manager Production | 2 |
7 | Chief Accountant | 1 |
8 | General Accountant | 2 |
9 | Petty cashier | 1 |
10 | Excise Accountant | 1 |
11 | CDO G.M Cane | 1 |
12 | Accountant cane | 4 |
13 | Cahier | 1 |
14 | Instrumental Engineer | 1 |
15 | Chief Engineer | 1 |
16 | Assistant Engineer | 3 |
17 | Deputy Engineer | 1 |
18 | Chief Chemist | 1 |
19 | Lab incharge | 1 |
20 | Shift chemist | 3 |
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Sl No | Designation | Shift | Total |
21 | Security Guards | 6x3 | 18 |
22 | Token | 1x3 | 3 |
23 | Recovery | 1x3 | 3 |
24 | Crane office | 2x3 | 6 |
25 | Table operator | 1x3 | 3 |
26 | WBO | 1x3 | 3 |
27 | Mill oil man | 1x3 | 3 |
28 | Mill helper | 5x3 | 15 |
29 | Boiler | 11x3 | 33 |
30 | BTD | 1x3 | 3 |
31 | Welder | 1x3 | 3 |
32 | Electrical | 5x3 | 15 |
33 | Fitter | 12x3 | 36 |
34 | Turbine operator | 1x3 | 3 |
35 | Turbine oil man | 1x3 | 3 |
36 | Juice | 7x3 | 21 |
37 | Pan | 8x3 | 24 |
38 | C/F | 9x3 | 27 |
39 | Godown | 1x3 | 3 |
40 | Lab helper | 1x3 | 3 |
41 | Store | 1x3 | 3 |
42 | Lab chemist | 1x3 | 3 |
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TIME OFFICE
Meaning
It means which arrange the working time of the workers in shift manner. Maintain it accurately.
Structure
Time officer
Time keeper
Functions :
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Procedure of the time office of the factory.
The factory worker is divided in to three shifts as follows
1st Shift        6 a.m – 2 p.m
2nd Shift 2 p.m – 10 p.m
3rd Shift  10 p.m – 6 a.m
General office Time
Lunch | 08.30 a.m | to | 5.30 p.m |
Leaves | 1.00 p.m  to | 2.00 p.m. | |
Monthly 4 leaves | |||
Weekly 1 leave. | |||
Holidays | All Govt. Holidays. |
Responsibility :
The responsibility of this section is to set the time of labours through which the work of factory moves smoothly.
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WATCH AND WARD SECTION
Meaning
It means to safe guard men, material, information and to avoid damages to the company.
Structure
Security Organization
Security Officer
Table Work
Or
Security Guard
Supervisor
Security Guards
Table Work
Or
Security Guard
Supervisor
Security Guards
Functions
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Book Maintainans
Responsibility
The responsibility is to provide strict security for the factory areas so that no one can take materials of the factory and to protect the factory.
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SALES DEPARTMENT
Meaning
It is the department which handles sales process of the company.
Structure :
Sales officer
Central Excise officer
Salesman | Salesman | |
Godown Keeper | Godown Keeper | |
Loading supervisor | Loading supervisor | |
Sugar House Clerks
Sugar loading
labours
Sugar House Clerks
Sugar loading
labours
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CENTRAL EXCISE ACT SEC 173 G RULE 53
Maintaining the documents under Central Excise Act.
Reporting to the Govt. Authority about production of Sugar & Molasses
Central Excise Tax For per bag total Rs. 87.55
71 Rs – Central Government
14 Rs. – State Governement
1.55 Rs. – Education cess
1 Rs. – Higher Education cess
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Sales process of Sugar
Bagging
Godown
Tender
Dealer
D.D
Sales process of Molasses
Molasses
Tender
Distilleries/Dealers
D.D
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PRODUCTION INFORMATION
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FINANCE DEPARTMENT
GENERAL ACCOUNT SECTION
Account department is very important which connect transaction relating inflow and outflow of funds inside and outside the factory by maintaining the books of records in the organization.
Structure of Account Section
Commercial
General Manager
Manager
Administrative | Sales | ||||||||||
A/c Manager | |||||||||||
Manager | Manager | ||||||||||
Chief Accountant | Chief A/c | A/c Clerk | Computer A/c | ||||||||
Accountant
Cane Accountant | Commercial Accountant | ||||||||||||||
Cane Purchase | Sales A/c | Purchase A/c | |||||||||||||
Clerk | |||||||||||||||
Sales A/c | Godown | Godown | |||||||||||||
Fertilizer | |||||||||||||||
Keeper | Clerk | ||||||||||||||
Seeds | |||||||||||||||
Diesels | 34 | ||||||||||||||
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Functions:
CURRENT ASSEST
CURRENT LIABILITIES
DEPRICIATION
CHARTERED ACCOUNTANT OF NIRANI SUGARS LTD.
1. SHIVANAGI AND COMPANY BELGAUM.
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PROFIT & LOSS ACCOUN AS ON 31STÂ MARCH 2007
PARTICULARS | ANNEXURE | 31-3-2007 | |||||
31-3-2006 | |||||||
I. INCOME | |||||||
Sales | -- | 175241529.75 | 23361256.59 | ||||
Cost of materials Consumed | 6 | 130058837.87 | 2441734.95 | ||||
45182691.90 | 25802991.54 | ||||||
II.INOME REVENUE | |||||||
Other Income | 7 | 30467563.80 | 89960.36 | ||||
75650255.70 | 25892951.90 | ||||||
III.EXPENDITURE | |||||||
Manufacturing | 8 | 11961674.00 | 3944693.80 | ||||
Sales & Administrative | -- | 4140989.82 | 376397.93 | ||||
Interest & finance Expenditure | 9 | 15773412.44 | 10769355.00 | ||||
Depreciation | 5 | 7002283.36 | 5833544.67 | ||||
38878359.62 | 24311531.40 | ||||||
IV.PROFIT/LOSS BEFORE TAX | 36771896.08 | 1581420.50 | |||||
V.PROVIION FOR TAX | 0.00 | 0.00 | |||||
VI.PROFIT AVAILABLE FOR APPROPRIATION | 36771896.08 | ||||||
1581420.50 | |||||||
VII. APPROPRIATION (Tr to P&L A/c) | 36771896.08 | ||||||
1581420.50 | |||||||
1581420.50 | 36771896.08 | ||||||
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CANE DEVELOPMENT DEPARTMENT
Structure
General Manager cane
Deputy Manager cane
suppliers
Deputy Manager cane
suppliers
Cane Manager
Development
Total procurement area is divided into 9 circles
Cane officer
Cane supplier | Cane development | |
Officer | ||
Circle Clerk
Field Assistant
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STORE SECTION
It means storing of the equipment required to the factory for the smooth flow of process.
Structure
Purchase officer
Store officer
Store Accountant
Store Keeper
Asst Store Keeper
Store clerk
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Manufacturing Process
Meaning
Manufacturing process means conversion of raw material or semi finished goods into finished product which is usable at source.
For the manufacture of sugar from sugarcane there are five different stages and they are as follows.
The work centers in the sugar manufacturing are :
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CRUSHING OF SUGARCANE
After harvesting, the sugarcane is bought to the factory in bouldles. There sugarcane is weighed in weigh bridge & then is cut into pieces in the leveler, further fine fibres are obtained from these pieces by passing them in the fabrizer. The preparatory index is 75% to 80% after this milling is carried on by passing the prepared fibre cane through the sets of mills, i.e,. the prepared fibre cane is carried out through cane elevator & fed ito the 1st mill, same is continued to the second mill. They can extract the primary juice once again, same is taken in the process ill. Weighed water is also added in the crushing for better extraction of juice. After crushing, the bagasse is sent to the boiler as fuel & juice set for processing weighment.
JUICE CLARIFICATION
The weighed juice is heated in juice heaters at 700Â C. To this raw juice lime and sulphur is added simultaneously. It is heated at 900-980Â C & thus heated sulphited juice taken to clarifier tank. The mud contained in juice settles & clear juice is decanted out from the clarifier and sent for evaporation. The juice thus evaporated gets concentrated to form thick syrup. The syrup thus obtained is again taken for sulphitation for bleaching to a pH of 5.0-5.2.
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CRYSTALLATION
The syrup of 5.0-5.2 pH is taken to pan floor for boiling where the syrup attains super saturation stage. In such a condition sugar crystals are formed & it is hardened to form a mass called massecuit. The massecuit is dropped in crystallizer & colled to complete the process of crystallization.
CURING
In centrifugal the massecuit is cured i.e. sugar crystals is separated from mother liquor in high speed centrifugal machine. Now the sugar falls on the hopper. On the hopper by using hot air blower the sugar is dried. The molasses is collected in separate tank & used for further boiling to recover more sugar.
GRADING
The dried sugar after passing through elevator goes to the grade for gradation. The sugar falls into the bins with this fall sugar is packed in bags.
The graded sugar is bagged, weighed for 100 Kg & they are stitched, numbered and stocked in the sugar godown in different lots as per grade and colour.
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In the manufacturing process the sugar industry is divided into four parts.
Here the juice is extracted from the sugarcane.
Here the bagasse is handled. It will produce steam generation. This steam is used for production of electricity.
Here there are different sections.
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Structure
BOILER UNIT
Boiler Attender
Water man
Fire man
Helpers
SUB SECTION
Mechanical Head
Mill section | (Extraction of juices) |
Boiler
Clarification        (Juice)
Boiling House | (Pan Centrifugals) |
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Parameter of boiler water
pH | - | 9.5 to 100 | |
TDS | - | Below 2000 ppm | |
Total Hardness | - | Nil | |
p-alkalinity | - | 10% | TDS (Below 150 ppm) |
m- alkalinity | - | 90% | TDS |
OH-caustic alkalinity | - | 150 ppm (more than 60 ppm) | |
PO4 | - | 15 ppm to 30 ppm | |
SO3 | - | 50 ppm to 30 ppm | |
SiO2 | - | Below 10 ppm |
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Role of chemical department in manufacturing process
Meaning
It means to take chemical tests before producing sugar and manufacturing of sugar from sugar cane.
Functions :
S30 – Small
Chemicals used in manufacturing process
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Cleaning chemicals
INSTRUMENTS USED IN CHEMICAL DEPARTMENT
10.pH meter
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Role of store department in manufacturing process.
Meaning :
It means storing of the equipment required by the factory for the smooth flow of manufacturing process.
Functions :
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ROLE OF CANE DEVELOPMENT DEPARTMENT
It acts as foundation to the manufacturing process.
Functions :
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SWOT ANALYSISÂ :
STRENGTHS
WEAKNESSES
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OPPORTUNITIES
THREATS
which might make them to leave the organization.
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FINDINGS
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The project was carried with the respect to the environmental forces that influenced to the firms business activities. In liberalization, Privatization, and Globalization (L.P.G) era almost small scale industries are moving towards sick units and some close down in India. Village industries have lack of good research and development support, that’s why they could not able to under take the environmental analysis. Because of various reasons.
Nirani Sugars Ltd. Mudhol is having a good and efficient department, which is well maintained. I have thoroughly studied all the department during my study period while studying about the department I have found some necessary findings, which are not concentrated by the management.
The findings of the study are :
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SUGGESTIONS:
The factory should maintain the records and documents of departments. The factory should keep all records at the time supervision.
Means of communication should be made through telephone, Internet, websites and also fax. Good means of combination system like transport facility should be made easy to deliver the goods in time.
3. Computerization:
Now a day’s computerization has become a crucial aspect of every organization. All departments of the organization should be computerized to keep day-to-day transaction and records, which are necessary for the factory to run a business successfully.
4. Application of techniques :
The factory must go for interpretation by applying the modern techniques.
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Important suggestion for the welfare of Agriculturists
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CONCLUSION
A careful study of NIRANI SUGARS LTD. it is one of the leading sugar industry in North Karnataka, which produces sugar and by products and supplies all over Karnataka and other states.
All the departments play a vital role in every organization. A function of all the departments provides materials to the factory without wheels of machines cannot move.
The overall study that emerges in this firm has been maintained well and efficient department in the management. It’s all sections are working efficiently. The production capacity of sugar has been improved. The overall performance of all the departments is well systematic.
In the course of study. I have not only acquired theoretical knowledge and also practical knowledge in the factory.
I conclude that all the department functions should have modern techniques towards other departments.
Lastly I am thankful to our co-ordinator Dr. N.G. Chichadi and Nirani Sugars Ltd. Mudhol for providing me to undertake in-plant training.
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INDEX
Chapter I – Introduction
Chapter II – Departmental study
Chapter III – Project study
Chapter IV :-
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