Daily Manufacturing Report (DMR) Cum Chemical Control (Sugar Lab) Calculation Sheet

Formulas for Calculating Sugar Industry Daily Manufacturing Report (DMR) With Simple Online Calculator

Fundamental formula :

In put = out put

Cane + Added water = Gross mixed juice + bagasse

If cane is 100 than 100 + Added water% cane = M. J. % cane + Bag. % cane.

Drit correction % M.Jc

Quantity of Drit in MT = Gross mixed juice x Drit correction % M.Jc

Net M.Jc in MT = Gross mixed juice – Qty of Drit in MT

$Bagasse % cane = \frac{ Quantity \ of \ Bagasser \times 100}{Cane \ crush }$

_{( Note: Here to be take Net M.Jc in MT)}

Sugar balance :

Sugar (pol) in cane =Sugar (pol) in mixed juice + Sugar (pol) in bagasse

Sugar (pol) % cane = Sugar (pol) in M.jc % cane + Sugar (pol) in Bagasse%cane

$Sugar \ in \ M.J. % cane = \frac{Sugar (pol) % M.J \times M.J.% Cane}{100}$

$Sugar \ in \ baggase % cane = \frac{pol %bagasse \times bagsse%cane}{100}$

Mill Extraction (M E).

The quantity of sugar extracted in the mixed juice per 100 sugar in cane i.e. percentage of sugar extracted in the mixed juice out of total sugar in cane.

$Mill \ Extraction (M.E) = \frac{ Sugar(pol) in M.J %cane }{Sugar(pol) in cane }$

Fibre % Bagasse :

Bagasse = fiber + Moisture + Brix

Fiber= Bagasse – Moisture – Brix

If bag =100 Then, fibre % bag = 100 – moist %bag – Brix % bagasse

Moisture % bag & Pol% Bag. are determined directly by analysis of bagasse.

Brix% Bagasse

While determining brix % bagasse, it is assumed that purity of residual juice in bagasse is same as purity of last expressed juice.

$Brix % Bagasse e= \frac{ Pol % Bagasse \times 100}{Purity \ of \ L.E.J }$

Fiber % cane:

$Fibre % cane = \frac{ Fibre % Bag \times Bag % cane}{100 }$

Added water%fiber

$Added \ water % Fiber = \frac{ A.W % / Cane \times 100}{Fiber% Cane }$

Reduced Mill extraction :

Noel Deer and Mittal

Noel Deer proposed formula to reduce the extraction to common basis of 12.5% fiber, that is called as Reduced Mill Extraction (RME _{Noel Deer})

For unit juice in cane ‘e’ is mill extraction.

Then juice lose in bagasse will be (1 – e )

Assume that unit cane contains ‘f’ fiber, then unit cane contains (1-f) juice.

Therefore juice lost per unit cane will be (1-e) (1-f).

The unit cane contains ‘f’ fiber.Therefore juice lost in bagasse per unit fiber will $\frac{(1- \ e) \times (1- \ f) }{f}$

$R.M.E.(Noel Deer) = 100\times\frac{(7-V)}{7}$

Where $V = \frac{(1-e)\times(1-f)}{f}$

$RME \ (Mittal )= 100\times \ [1- \frac{12.5 \times Pbc }{Pc \times Fc}]$

P_bc = Pol in Bag. % cane, Pc = Pol% Cane, Fc = Fiber. % Cane.

Clarification Factor:

Good clarification means better sugar, less losses and unsatisfactory clarification means (results in) production of inferior quality of sugar with poor keeping quality and higher manufacture losses.

N .S. in M.J.% cane = Bx.% M.J. x M.J.% cane – Pol% M.J. x M.J. % cane.

Pol in CJ % cane = Pol in M.J. % cane – Pol in F.C. % cane.

$Brix \ in \ C.J.% cane = \frac{Pol \ in \ C.Jc % cane \ X \ 100}{ C.Jc Purity}$

N.S. in C.J. % cane = Bx.in C.J.% cane – Pol in CJ % cane

Non sugars removal %cane = Non sugars in M.J % cane – Non sugar in c.Jc % cane

$Clarification \ Efficency = \frac{ Non \ sugars \ removal %cane \ X \ 100}{ Non \ sugars \ in \ M.J % cane }$

Clarification Factor = 100 – Clarification efficiency

Theoretical Final Molasses % cane :

Non Sugars % F.M = Brix % F.M – Pol % F.M

$Theoretical \ F.M % cane = \frac{Non \ sugars \ in \ C.Jc % cane \ X \ 100}{ Non \ sugar % F.M}$

Expected Recovery

$SJM Factor = \frac{S \ (J \ - \ M)}{J(S \ - \ M )}$

S = Purity Of final product(sugar)

J = M.Jc Purity

M = Final Molasses Purity

Expected Recovery = Pol in C.Jc % cane x SJM factor – Unknown losses (Note:Here to be take estimated unknown losses )

Pol balance

Pol % cane =Pol in M.J.% cane+ Pol in Bag % Cane

$Pol \ \ in \ M.J.% cane = \frac{ Pol % M.J. X M.J. % Cane}{100}$

$Pol \ in \ Bag.% cane = \frac{ Pol % Bag. \ X \ Bag. % Cane}{100}$

$Pol \ in \ F.C.% \ cane = \frac{ Pol % F.C. \ X \ F.C. % Cane}{100}$

$Pol \ in \ F.M.% \ cane = \frac{ Pol % F.M. \ X \ F.M. % Cane}{100}$ (Note : Here to be take Theoretical Final Molasses % cane)

$Pol \ in \ Sugar \ % cane = \frac{ Pol % Sugar \ X \ Sugar. % Cane}{100}$ (Note : Sugar % cane means recovery%cane )

Total Losses =Pol % cane – Pol in Sugar % cane.

Total Losses = Losses in (Bag. + F.C + F.M. + Unknown)

Unknown losses = Total losses – Determined losses

Unknown losses = Total losses – Losses in (Bag. + F.C + F.M.) (Note: It may differ 0.01 to 0.02 from estimated unknown losses)

Boiling House Control

E.S.G ( Equivalent Standard Granulated) Factor :

a) The term Standard Granulated used to indicate the finest commercial product and considered as equivalent to pure sugar

b) The term E.S.G is used to indicate the finess of the commercial sugar and denoted by sugar(product) in very clean form. The commercial sugar is expressed in terms of standard granulate.

c) E.S.G form for commercial sugar apply S-J-M formula where S=100, M= actual purity of molasses and J= purity of sugar.

Boiling House Recovery (BHR)

The value of ration of sucrose (pol) in commercial sugar produced to the sucrose (pol) in mixed juice.

$Actual \ Boiling \ House \ Recovery = \frac{ Sugar \ (pol)\ in \ Sugar % cane}{Pol \ in \ MJ % cane}$

$Sugar \ in \ Sugar % cane = \frac{Pol \ in \ Sugar \ X \ Recovery %cane}{100}$

Basic boiling house recovery (BBHR):

The theoretical Boiling House Recovery as calculated by S-J-m formula in which J in purity of M.J. and S=100 and m=28.57

$BBHR = \frac{100 \ (J \ - 28.57)}{J (100 \ -28.57)}\times \ 100$

Reduced Boiling House Recovery (Noel Deerr)

$R \ _{85ND} = \frac{100(85 \ - Mv)}{85(100 \ - Mv )}$

Where Mv =Virtual Final molasses purity

$Mv = \frac{100 \ J(1-R)}{100-RJ}$

Where R = BHR = sugar in pol % cane / Pol in M.Jc %cane

J= M.Jc Purity (Unit value)

Reduced Boiling House Recovery (Gundurao)

$R_{{85G.R}} = r + K \ \times \frac{M}{1-M} \ \times\frac{17-20J}{17J}$

Where r = BHR

K = N.S. in clear juice % cane / N.S.in M.J.% cane

M = Final molasses purity

J = M.Jc Purity

In the next revision of the article will provide all formulas related to chemical control calculation.

Online calculation sheet for Daily Manufacturing Report (DMR) in sugar process industry

Click Here

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Post Author: siva alluri

The aim of this Blog "sugarprocesstech" is Providing basic to advance knowledge in sugar process industry and providing maximum calculation regarding capacity and equipment design online calculators .

28 thoughts on “Daily Manufacturing Report (DMR) Cum Chemical Control (Sugar Lab) Calculation Sheet”

premkumar

(April 29, 2017 - 11:25 am)

nice shiva thank you

GalI Gangadhara Rao

(May 1, 2017 - 4:45 pm)

Good Work – Commendable contribution to the Industry ^ Congratulations and Best Wishes.

siva alluri

(May 2, 2017 - 3:44 am)

Thank you very much Mr.Gangadhara Rao sir and Mr.prem kumar sir for your valuable comments.
The “www.sugarprocesstech.com” invites to all sugar technologists to share your knowledge, achievements in your working organization and new developments and technologies in sugar industry and its concerned units. It is very much helpful to show your identity to the world at the same time it will helpful to another technologist to enhance their insight and enhance great execution in there working. This website also provides the basic knowledge in sugar industry technologies and equipment design calculation with online calculators.

S R Shreehari

(May 25, 2017 - 7:25 am)

Really commendable job done sir. Similarly why don’t u work out on sugar refinery DMR and allied calculations ?

siva alluri

(May 29, 2017 - 4:13 pm)

in our next update we will provide sugar refinery DMR

anil bansude

(August 14, 2017 - 10:05 am)

very good format

ENGINEER ASIF ALI SADHAYO

(August 18, 2017 - 7:27 am)

GOOD WORK DEAR

G Sathish Babu

(September 6, 2017 - 10:36 am)

Well..wasy way to made DMR

siva alluri

(September 6, 2017 - 3:14 pm)

Thank you sir
The “www.sugarprocesstech.com” invites to all sugar technologists to share your knowledge, achievements in your working organization and new developments and technologies in sugar industry and its concerned units. It is very much helpful to show your identity to the world at the same time it will helpful to another technologist to enhance their insight and enhance great execution in there working. This website also provides the basic knowledge in sugar industry technologies and equipment design calculation with online calculators.
sugarprocesstech@gmail.com

Arvind Kumar Singh

(August 25, 2018 - 9:13 am)

Very nice

siva alluri

(August 26, 2018 - 2:49 pm)

Thank you Mr.Arvind Kumar Singh

Shaikh ekbal

(September 28, 2018 - 2:22 am)

How use this calculator plz send me details

siva alluri

(September 28, 2018 - 4:13 pm)

It is online free calculator
If enter inputs in yellow colour cell then we will get results automatically

Anoop Chaturvedi

(May 26, 2020 - 6:25 am)

Thanks for creating this wonderful calculation sheet. Its not only useful for freshers but also very useful for all working at any level.
Wonderful work for Sugar Ind.

siva alluri

(June 21, 2020 - 9:58 am)

Thank you sir

SYED SABIR RAZA

(August 18, 2020 - 7:48 am)

Good work done carry on please

siva alluri

(August 18, 2020 - 12:15 pm)

thank you

B D Pachore

(December 13, 2020 - 10:51 am)

I think, in this calculations, formula used for Clarification Efficiency is wrong. The correct formula should have been as,
Clarification Efficiency = Non Sugars in Clear Juice % Cane / Non Sugars in MJ % Cane X 100

Ali ghulam

(January 5, 2021 - 9:46 pm)

Reducing sugar juice and syrup formula also add plz

Abebaw Gebeyaw

(March 17, 2021 - 7:36 am)

So Fantastic 👍‼️

siva alluri

(March 30, 2021 - 5:47 am)

Thank you

Abera Terefe

(June 20, 2021 - 1:58 pm)

I want your pdf

Abebaw Gebeyaw

(August 14, 2021 - 6:50 am)

wow………. it is so Fantastic format !!!!!

Thank you very much DearSivaRamaKrishna Alluri !!!!!

siva alluri

(September 2, 2021 - 8:33 am)

Thank you

SAKTHIVEL SUBRAMANIYAN

(November 12, 2021 - 4:10 am)

Sir, Please post the calculation DMR for sugar in case of B Heavy and Syrup diversion for Ethanol with different ratios

siva alluri

(January 2, 2022 - 9:08 am)

will be provided

Basavaraj

(July 18, 2023 - 10:52 am)

Recovery in case of BH diversion and Syrup diversion for ethanol is same as tradition method, only thing your have to subtract available sugar in Syrup % cane from Original recovery to get net Plant recovery., Pol balance includes Available sugar in Syrup and available molasses in Syrup., In case of B-Heavy in place of FM take BH purity for calculation.,

AMILA

(February 17, 2022 - 11:40 am)

Dear Mr. Siva,
thank you very much for all this valuable infomation. for my education purpose can you please suggest any books for further learning?
thank you,
Amila

Daily Manufacturing Report (DMR) Cum Chemical Control (Sugar Lab) Calculation Sheet

Formulas for Calculating Sugar Industry Daily Manufacturing Report (DMR) With Simple Online Calculator

Fundamental formula :

Sugar balance :

Mill Extraction (M E).

Fibre % Bagasse :

Added water%fiber

Reduced Mill extraction :

Noel Deer and Mittal

Clarification Factor:

Theoretical Final Molasses % cane :

Expected Recovery

Pol balance

Boiling House Control

E.S.G ( Equivalent Standard Granulated) Factor :

Boiling House Recovery (BHR)

Basic boiling house recovery (BBHR):

Reduced Boiling House Recovery (Noel Deerr)

Reduced Boiling House Recovery (Gundurao)

Online calculation sheet for Daily Manufacturing Report (DMR) in sugar process industry

Post Author: siva alluri

Related Posts

28 thoughts on “Daily Manufacturing Report (DMR) Cum Chemical Control (Sugar Lab) Calculation Sheet”

premkumar

GalI Gangadhara Rao

S R Shreehari

anil bansude

ENGINEER ASIF ALI SADHAYO

G Sathish Babu

Arvind Kumar Singh

Shaikh ekbal

Anoop Chaturvedi

SYED SABIR RAZA

B D Pachore

Ali ghulam

Abebaw Gebeyaw

Abebaw Gebeyaw

SAKTHIVEL SUBRAMANIYAN

Basavaraj

AMILA

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