How Millions of Tons of Sugar Cane Convert Into Sugar in Factory : From field to table

1. Cultivation and Harvesting:
Sugar cane cultivation starts with selecting suitable land and planting cane stalks. The crop requires specific climatic conditions, including warm temperatures and adequate rainfall. After about 12 to 18 months of growth, the sugar cane reaches maturity and is ready for harvesting.
2. Harvesting Methods:
Harvesting methods vary across regions and technologies available. Manual harvesting involves workers cutting the cane manually using machetes. Mechanical harvesting, on the other hand, utilizes specialized machinery to cut and load the sugar cane.
3. Transportation to the Factory:
Once harvested, the sugar cane needs to be transported to the processing facility quickly to prevent deterioration. Trucks, rail, or even conveyor belts are used for transportation, depending on the proximity of the fields to the factory.
4. Cleaning and Preparation:
At the factory, the sugar cane undergoes cleaning to remove debris, dirt, and leaves. This is typically done using conveyor belts and washing systems. The cleaned cane is then prepared for milling.
5. Milling:
Milling is the process where sugar cane is crushed to extract the juice. This is usually done using heavy machinery such as crushers and shredders. The cane is passed through multiple rollers to squeeze out the juice, leaving behind the fibrous residue known as bagasse.
6. Juice Extraction:
The extracted juice undergoes filtration to remove any remaining solid particles. It is then clarified to remove impurities and suspended solids. This is typically achieved through the use of chemicals and filtration systems.
7. Evaporation and Concentration:
The clarified juice is heated in evaporators to remove excess water, resulting in a thick syrup known as cane juice concentrate. This concentrate is further processed to increase sugar concentration through multiple stages of evaporation.
8. Crystallization:
The concentrated syrup undergoes crystallization to form sugar crystals. This is achieved by cooling and seeding the syrup in vacuum pans. As the syrup cools, sugar crystals form and grow, while impurities remain in the syrup.
9. Separation and Drying:
Once crystallization is complete, the mixture of sugar crystals and molasses undergoes separation in centrifuges. Centrifugal force separates the sugar crystals from the molasses, which is a byproduct. The separated sugar crystals are then dried to remove any remaining moisture.
10. Packaging and Distribution:
The dried sugar crystals are transferred to packaging facilities where they are packaged into various consumer-ready formats such as bags, boxes, or containers. These packaged products are then distributed to retailers and consumers worldwide.
11. Byproduct Utilization:
Throughout the process, various byproducts such as bagasse and molasses are generated. Bagasse can be used as a biofuel for energy generation or as a raw material in paper and pulp production. Molasses finds applications in animal feed, alcohol production, and as a sweetening agent in various food products.
12. Quality Control:
At every stage of the process, rigorous quality control measures are implemented to ensure the final product meets regulatory standards and consumer expectations. This includes testing for purity, moisture content, and sugar concentration.
From the fields to the factory, each step in the journey of sugar cane processing involves careful planning, precise execution, and innovative technologies to bring the sweetness of sugar to our tables