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

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

  1. 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 }
  • A.W \ % cane= \frac{ Quantity \ of \ added \ water \times 100}{Cane \ crush }
  • M.J \ % cane= \frac{ Quantity \ of \ Mixed \ juice\times 100}{Cane \ crush }      ( Note: Here to be take Net M.Jc in MT)

Daily Manufacturing Report (DMR) for sugar process industry - sugarprocesstech

2. 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}

3.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 }

4. 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 }

5. Added water%fiber

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

6. 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}]
  •  Pbc = Pol in Bag. % cane,  Pc = Pol% Cane,  Fc  = Fiber. % Cane.

     

    7. 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

    8. 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}

   9. 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 )

    10. 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)

    11. Boiling House Control

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

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

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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 .

13 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

    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

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