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

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

Fundamental formula :

Input = output

Cane +   Added water  = Gross mixed juice +   bagasse

If the cane is 100 then 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

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

A.W \% \text{cane} = \frac{\text{Quantity of added water} \times 100}{\text{Cane crush}}

M.J \% \text{cane} = \frac{\text{Quantity of Mixed juice} \times 100}{\text{Cane crush}}   ( Note: Here to take Net M.Jc in MT)

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

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

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

\text{Sugar in bagasse \% cane} = \frac{\text{pol \% bagasse} \times \text{bagasse \% 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.

\text{Mill Extraction (M.E)} = \frac{\text{Sugar (pol) in M.J \% cane}}{\text{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 the last expressed juice.

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

Fiber % cane:

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

Added water%fiber

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

Reduced Mill extraction :

Noel Deer and Mittal

Noel Deer proposed formula to reduce the extraction to common basis of 12.5% fiber, which is called Reduced Mill Extraction (RME Noel Deer)

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

Then juice loss 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 of fiber will \frac{(1 - e) \times (1 - f)}{f}

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

R.M.E.(Noel Deer) = 100timesfrac{(7-V)}{7}

Where

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

\text{RME (Mittal)} = 100 \times \left[ 1 - \frac{12.5 \times P_{bc}}{P_{c} \times F_{c}} \right]

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

  •  Pbc = 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

\text{Clarification Efficiency} = \frac{\text{Non sugars removal \% cane} \times 100}{\text{Non sugars in M.J \% 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} timesfrac{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

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