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Title: National%20Federation%20of


1
National Federation of Co-operative Sugar
Factories Ltd.
2
National Federation of Cooperative Sugar
Factories Limited (NFCSF) was registered on
December 2, 1960 as an apex organization of all
cooperative sugar factories in India. NFCSF was
set up as a promotional body for the
establishment of cooperative sugar factories in
India and for provision of technical advice to
the cooperative sector of the sugar industry.
Today it guides and provides consultancy
services to all sectors.
3
NFCSF was established at a time when Indias
standing in the world sugar scenario was
negligible. It was the establishment of NFCSF
which changed the scenario. India became the
worlds largest producer of sugar during 1982,
1988 to 1993, 1995, 1996 and 2000 with
cooperatives share of the sugar production
during the said years being 55 to 61. Indias
share in global sugar production also increased
to 15. Today India is the second largest
producer of sugar in the world next to Brazil.
4
Establishments 1969 - The Indian Sugar and
General Industry Export Import Corporation Ltd.
now renamed as Indian Sugar Exim Corporation
Ltd. (ISEC) established by NFCSF in
collaboration with Indian Sugar Mills
Association to look after the export of sugar
initially, and then export / import of sugar
and other products of the sugar industry such
as molasses and alcohol.
5
1974- National Heavy Engineering Cooperative
Limited promoted by NFCSF for manufacturing of
sugar plants, including high pressure boilers,
continuous centrifugals and all other machinery
required by sugar factories. 1977- Technical
and Promotional Cell of NFCSF for Techno
Commercial Managerial Consultancy
services. 2000- Research, Development and
Training Centre of NFCSF.
6
Identity An apex body of all cooperative sugar
factories in India making it the LARGEST sugar
cooperative in the world. An autonomous
organization governed by the Multi-State
Cooperative Societies Act of Government of
India.
7
It is the LARGEST affiliation of sugar
factories in the world. It represents over
50 MILLION farmers and their dependents who are
involved in sugarcane cultivation.
8
Objectives Promote agri business / rural
upliftment. Stabilize past achievements Foster
faster growth for future vis-à-vis
challenges. Developing and researching new
technical areas in sugarcane growth and
production Trans- forming Sugar Factories into
Sugar Complexes. Undertaking trunkey projects
for conversion of sulphitation process to produce
sulphurless sugar. Taking up trading in
Carbon on behalf of member factories to reduce
green house emissions and increase revenue.
9
Progress of Indian Sugar Industry at a Glance
1960-61 2007-08
Area under sugarcane 2.4 mln hec. 5.0 mln hec.
Sugarcane production 110.0 mln tonnes 340.6 mln tonnes
Total number of working factories 174 516
Total number of cooperative sugar factories in operation 30 249
Average daily crushing capacity 1172 tonnes 3586 tonnes
Annual production of sugar 3.02 mln tonnes 26.3 mln tones
Per capita sugar consumption 4.8 kg. 19.1 kg.
10
Areas of Specialization Improvement in
agricultural practices in sugarcane cultivation
and development of sugar rich cane varieties
towards optimum yields of sugarcane / sugar per
hectare and to reduce cost of cultivation. For
this purpose, NFCSF has a Standing Committee
with Experts from all over India which studies
and analysis the reports on varietal trials
conducted at regular intervals in sugar factory
areas.

11
Installation of cost effective new sugar
factories with selection of suitable sites,
plant and machinery with technical
specification, plant layout and project
planning, scheduling implementation.
Implementation of projects on turn-key basis
Technological upgradation of existing sugar
factories and rehabilitation of
12
of working sick sugar factories for optimum
productivity energy conservation. Promotion
of by-products with co-products of sugar
factories for value addition bagasse based
paper / particle board plants bagasse /
bio-mass based co- generation (surplus
electricity power generation) and sugarcane
molasses based distilleries for alcohol, ethanol
and other alco-based chemical industries and
production of sulphurless sugar and
refineries. Assist in selection, purchase,
installation and maintenance of plant and
machiney.
13
Assist in selection of high calibre
manpower for all activities. Assist in
standardizing the accounting and costing systems
/ practices. Undertake publication of market
information of sugar and allied industries.
Conduct conferences, seminars / workshops
towards promotion of finance interfaced
sugarcane agri-business for better Return on
Investment (ROI).
14
Undertake various other conducive business
activities for the benefit of sugar factories /
industry. Pre-despatch inspection of critical
machinery and equipment at manufacturers works
as per national / international standards.
Application of modern technology in sugar
process for white sugar below 100 ICUMSA, Very
High Purity (VHP) raw sugar. Financial
Management.
15
Process system adopted include Double
Sulphitation. Filtrate Clarification by
phosphotation. Syrup Clarification by
phosphotation. Refined sugar from single cured
B sugar. Defico remelt process for the
production of sulphurless sugar. Detailed
Project Reports for - New sugar
complexes. - Modernization of existing
factories. - Rehabilitation of sick
factories. - Bagasse based by-products. - Molass
es based by-products i.e.R.S./ENA/ Ethanol
etc. Financial Restructuring and monitoring for
successful implementation.
16
Tasks Functions New Sugar Factories - Inceptio
n to commissioning - Project and feasibility
report - Cane development - Plant site
selection - Basic engineering for plant
machinery - Project scheduling - Plant
layout - Inspection of machinery at
manufacturers works - Manpower Planning /
Selection - Inventory Control - Selection of
workshop equipment - Financial Management
17
Working Sugar Factories - Basic engineering for
modernization / expansion - Energy conservation
Reduction in steam consumption power
consumption - Improvement in working
efficiency - Improvement in quality of
sugar - Optimization of capacity
utilization - Advice on technological
up-gradation - Trouble shooting - Improve milling
and boiler performance - Improve sugar quality
and process approaches - Conserve steam, power
and fuel
18
- Analysis of break downs for remedial
measures - Investigate reasons for low
recovery - To achieve zero fresh water
consumption zero effluent - Financial
Management Sugarcane Development - Varietal
development and improvement in agricultural
practices - Soil analysis - Ratoon
Management - Promotion of inter-cropping for
value addition
19
  • Co-products
  • - Paper factories / particle board plants
  • - Alcohol producing units / Ethanol
  • Co-generation
  • Research Development
  • - Sugarcane quality (varieties) yield per
    hectare.
  • - Sugar quality vis-à-vis international standard.
  • - Inventory control
  • - Reduction in conversion cost
  • - Steam, fuel and power conservation.
  • - Application of sugar co-products for value
    addition by-products

20
  • Commissioning of New Projects / Expansion of
    Existing Projects
  • 200 Nos. new factories expansion of capacity
  • 20 Nos. Ethanol projects.
  • 20 Nos. Bagasse based Co-generation projects.
  • - About 15 for syrup melt / filtrate
    clarification / syrup clarification / raw sugar
    refining.
  • - A list of detailed project reports prepared
    from January, 2007 to till date is enclosed at
    Annexure-I.

21
  • Strength
  • High Calibre taskforce
  • Professionally qualified workforce
  • More than four and half decades of all round
    experience.
  • Specialized professional in each field.
  • - Complete consultancy for sugar available under
    one roof.

22
Associates - M/s. DEC International, New Delhi
for Project Management Engineering
Services. - M/s. Avant-Garde Associates, Chennai
for Co- generation of Power. - M/s. Sri Engineers
Pvt. Ltd., New Delhi for Distilleries and
Ethanol Plants. - M/s. Diftech Group, New Delhi
for Melt / Filtrate / Syrup Clarification
Systems and Raw Sugar Refining. - M/s.
Environment Synergies/Quality Tonnes, Bangalore
for Carbon Trading. - M/s. Eco-Invest Carbon
Credit SA C/o Bungee India Pvt. Ltd., Mumbai for
Carbon Trading. - M/s. Overseas Infrastructure
Alliance (India) Private Ltd., Mumbai for
overseas projects.
23
Global Exposure - Indigenous expertise in sugar
industry has enabled India to export complete
sugar plants all over the world. - NFCSF has an
exposure to the worlds sugar industries
covering USA Ethiopia (Tendahu
Fincha) Australia Sudan Brazil Bangladesh Vi
etnam Nepal Colombia Reunion Thailand Mauriti
us Pakistan Fiji South Africa Mozambique Keny
a Nigeria Madagascar (Mananjary and Sakaraha)
24
Representation - Governing Council and Board of
Management of National Cooperative Development
Corporation. - Advisory Board of National Sugar
Institute. - Development Council for Sugar
Industry, Government of India. - Indian
Sugarcane Development Council. - Bureau of Indian
Standards, Sugar Industry Sectional
Committee. - Indian Sugar Exim Corporation
Ltd. - Standing Committee of Reserve Bank of
India on Industrial Finance for sugar
industry.
25
- Governing Council of National Cooperative
Union of India. - Sugar Technologist
Association of India. - Ministry of New
Renewable Energy, Government of
India. - Sub-Committee to fix up technical
efficiency norms for Indian sugar
factories. - Sub-Committee to frame guideline
specifications for sugar plants of capacities
ranging from 1,250 to 10,000 tonnes of cane
crush per day. - Sub-Committee to fix up minimum
national standards for Pollution Control in
Sugar Sector of Indian Industries. - Standing
Committee, Screening Sub- Committee for
disbursement of SDF loan for sugar cane
development, expansion, modernization,
co-generation and ethanol projects etc.
26
NFCSF is an active member of - ICUMSA
International Commission of Uniform Methods of
Sugar Analysis. - ISO International Sugar
Organization. - ISSCT International Society of
Sugar Cane Technologists. - GSA Global
Alliance for Sugar Trade Reform and
Liberalization.
27
 
The Project at Present under Implementation with
NFCSF
28
 
29
 
 
30
PREPARATION OF DETAIL PROJECT REPORTS BY NFCSF
OF JANUARY- 2007 TO TILL NOW
S.N. Name of the Factory Description Crushing Capacity ORDER DATE
1 Chaddha Sugar Industries Ltd. Preparation of DPR of new sugar plant 7500 TCD January 2007
2. Palwal Coop. Sugar mills, Preparation of DPR for modernization and balancing of sugar plant. 2200 TCD January-2007
3. The Bagpat Coop. Sugar Mills Ltd., Implementation of scheme for saving of steam /bagasse 2500 TCD January-2007
4. DIVERA SOLUTION LIMITED Preparation of DPR of new sugar plant along with cogeneration 2500 TCD February-2007
5. The Ajnala Cooperative Sugar Mills Limited, Preparation of DPR for incidental Co-operation 2 MW March-2007
6. Bhoramdeo Shahakari Shakkar Utpadak Karkhana. Preparation of DPR for Expansion of sugar plant 2500 TCD To 3500 TCD. Aprial-2007
31
S. Name of the Factory Description Crushing Capacity ORDER DATE
7. ELDUEIM SUDAN Preparation of detail project report of new sugar plant with 36 MW cogeneration 60 KLPD distillery 10000 TCD May - 2007
8. SAHAKARI SAKKAR KARKHANA RAHELI SAGAR, Preparation of DRP for new sugar plant 2500 TCD July 2007
9. Shree Vadodara District coop. Sugarcane Growers Union Ltd. Preparation of DPR for expansion, modernization balancing 2500 TCD TO 3500 TCH July 2007
10. Kisan Sahakari Chini Mills Ltd. Sneh Road Najibabad Report of Environmental Impact Assessment Study 50KLPD30 KLPD30 KLPD JUNE-2007
11. Danteshwari mama SSK. Preparation revised NIT of Sugar Plant 1250 TCD June-2007
12. SHAHABAD COOPERATIVE SUGAR MILLS Revised DPR of expansion, balancing along with cogeneration 4000 TCD to 6000 TCD August -2007
32
S. Name of the Factory Description Crushing Capacity ORDER DATE
13. Batala Coop. sugar Mills ltd. Preparation of report of energy audit. Existing plant August-2007
14. The Gurdaspur Coop. Sugar Mills Ltd. Preparation of report of energy audit. Existing plant September -2007
15. THE ASSANDH COOP. SUGAR MILLS Agreement of consultant inspection 2500 TCD September-2007
16. Maa Maha Maya S.S.K Agreement of consultant inspection 2500 TCD September-2007
17. THE NOWGONG COOP. SUGAR Detailed Project Report of revival 1250 TCD October 2007
18. THE MORINDA COOP.SUGAR MILLS LTD. VALUATION FOR OLD MILL TANDAM Ø28 x 56 lg. Milling tandem December -2007
33
S. Name of the Factory Description Crushing Capacity ORDER DATE
19. NAYAAGARH SUGAR COMPLEX LIMITED DPR FOR EXPANSION CUM MODERNISATION along with cogeneration 1250 TO 2500 TCD Decenber-2007
20. THE PALWAL COOP.SUGAR MILLS LTD EXPANSION ALONG WITH COGENRATION 1250 TCD TO 2500 TCD February-2008
21. Chadha Sugar Industries Ltd. Preparation of DPR of new sugar plant 5000 TCD expandable to 10000 TCD. February-2008
22. NASIK SAHAKARI SAKHAR KARKHANA LTD. Preparation of DPR for expansion cum modernization and co-generation 1250 TCD to 2500 TCD February-2008
23. SHAHABAD COOPERATIVE SUGAR MILLS Revised DPR for balancing along with cogeneration 5000 TCD February-2008
24. OVERSEAS INFRASTRUCTURE ALLIANCE (India) Pvt. Ltd. Technical Consultancy for overseas project Three projects. February-2008
34
SN Name of the Factory Description Crushing Capacity ORDER DATE
25. THE JIND COOP.SUGAR MILLS LTD EXPANSION ALONG WITH COGENRATION 1250 TCD TO 2500 TCD March-2008
26. Nanauta coop. Chini mills Ltd. DPR for five effect evaporator for existing distillery Existing plant April 2008
27. The Haryana Coop. Sugar Mills Ltd. Rohtak. Agreement of consultant inspection 3500 TCD May 2008
28. Mananjary Sakaraha Sugar Complex, Madagascar Feasibility study reports for two sugar complex. 2500-3500 TCD 3500 5000 TCD. November-2009
29. The Nandi Sahakari Sakkare Karakhana Ltd. Karnatka Detailed project report for rehabilitation cum expansion 3500-5000 TCD December-2008
30. Star Applied Mechanics (P) Ltd.B-36, Sector-2, Noida-201301 Preparation of DPR of new sugar plant in Bihar 3500-5000 TCD 31st December-2008
35
SN Name of the Factory Description Crushing Capacity ORDER DATE
31. M/s. PRTL Pvt. Ltd. C-6/13 Shrinathji Chambers. 3rd floor, VIA Char Rasta, GIDC, Vapi-396194 Gujarat Feasibility Report for Co generation - 1st.January-2009
32. M/s. Sahakari Khand Udyog Mandal Ltd.Gandevi Dist Navsari, Gujarat 396 360 Preparation of Notice Invited Tender for Modernization and Incidental cogeneration of 1.0 MW 6000 TCD January-2009
33. M/s. Shree Sayan Vibhag Sahakari Khand Udyog Mandli Ltd. Surat, Gujarat Preparation of DPR for Modernisation, Balancing and Optimization of Sugar Plant. 6000 TCD January-2009
34. M/s. Shree Kantha Vibhag Sahkari Khand Udyog Mandli Ltd.Gujarat Preparation of DPR of new sugar plant 2500-3500 TCD February-2009
35. M/s. Shree Narmada Khand Udyog Sahakari Mandli Ltd. Distt. Narmada, Gujarat Preparation of DPR for Modernisation, Balancing and Optimization of sugar plant. 5000 TCD March-2009
36
SN Name of the Factory Description Crushing Capacity ORDER DATE
36. The Kovur Cooperative Sugars Limited, Distt- Nellore 524005, Andhra Pradesh Rehabilitation cum Modernization Balancing of Sugar Plant. Along with 8 MW cogeneration 2500 TCD February-2009
37. The Chodavaram Coop. Sugars Limited. Govada 531 023, Andhra Pradesh Rehabilitation cum Modernization Balancing of Sugar Plant. Along with 22 MW cogeneration 4400 TCD February-2009
38. SHAHABAD COOPERATIVE SUGAR MILLS (HARYANA) Consultancy cum inspection agency for 24 MW cogeneration project 5000 TCD February-2009
37
Advanced Technologies being adopted successfully
  • 1. Shredder / Fibriser Improving P.I. to
    92
  • AC / DC Electric Drive for mills
  • i. Conventional Mills Three Roller Mills
  • with trash plate
  • ii. Diffuser
  • iii.Two Roller Mill Trash plate less
  • Advantage of Two Roller Mill -
  • (a) 30 less power consumption
  • (b) High Primery Extraction 74 when used as
    1st mill
  • Low moisture bagasse when used as last mill
  • iv.4 Roller Pinion less / Independent AC Drive
    for feed, Top discharge roller with planetary
    Gear Box mounted motor.
  • (4) AC VVVF Drives for Cane carrier, Inter Rake
    Carrier, Main Bagasse carrier etc.,
    Centrifugal pumps.

38
  • High Pressure Boiler
  • i) Pressure Temp. of Steam 105 kg/cug2
    540ºC
  • ii) Capacity 170 T/hr with Travelling grate
  • iii) Steam Fuel Raio 2.7
  • iv) Thermal efficiency 72 (on GCV)
  • v) Flue gas temp 150ºC
  • vi) AC- VVVF drives for ID/FD/SA fans.
  • vii) Auto combustion control system
  • viii) DCS control for complete Boiler from
    control
  • room
  • ix) ESP for flue gas emission control
  • x) With recovery units economizer, Air heater,
  • super heaters etc.

39
6. Double Extraction condensing Turbo
Generating sets to suit the above boiler
parameters 7. Evaporator system design to bring
down the steam consumption cane
36 i. Using flash Heat Recovery
systems ii. Extensive vapour Bleeding
schemes iii. Using Direct contact juice heaters
40
  • 8.Single entry low water consumption condensers
    -
  • made of SS body SS tailppee
  • Reducing power consumption to 2 KW / TCD or
    below at injection pumps spray pumps
  • Low head pumps for Injection spray
  • DCS control system for condensers pans

9.DC/AC electric driven centrifugal machines. 1.
Batch type centrifugal 1250 kg/ charge
1400 rpm Machine capacity 1500
kg/charge 1250 rpm 2. No. of
cycles / hours 20 22 3. High Gravity factor
2000 / 2400 Continuous machine of NK
1100 2000 rpm
of NK 1503 - 1730 rpm
41
10. Cold water Recirculation, surplus
condensate cooling recirculation to Reduce
the frash water consumption to zero. 11.
Continuous pan Horizontal vertical type
vertical type 12. Plantery Gear Boxes for
Crystellizer drive etc. 13. Juice flow
stabilization system 14. Filtrate
clarification system 15. Sulpher less sugar
production Defeco Remelt process 16.
Megensen type sugar grader 17. For colour
Improvement Vibro screen - at MJ, filtrate,
Melt juice lime 18. Pan circulators
Automation for pan station 19. Thin Film type
sulphur burners
42
20. Plate type wide gape heat exchangers for
condensate heat recovery Power consumption
reduced upto 22 KWH / TCH for steam driven
plants and 26 KW/TCH for electric driven plants
by providing various AC VVVF drives, improving
power factor, planetary gear boxes, automation,
devices to reduce power consumption at
centrifugal station, injection spray pumping
station, ID/FD/SA fan drives by ACVVVF etc. 22.
Cogeneration Based on (i)
Bagasse Bio-mass rice husk, wheat straw, cane
trash, Mustered husk straw,coconut shel,
coconut straw, banana trees, pine fruits
stems, other grasses etc.
43
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44
THANK YOU
NATIONAL FEDERATION OF COOPERATIVE SUGAR
FACTORIES LIMITED ANSAL PLAZA BLOCK-C, 2ND
FLOOR AUGUST KRANTI MARG, NEW DELHI-110049
(INDIA) Tel. 26263425, 26263436, 26263696 Fax
011-26263658, e-mail nfcsf_at_spectranet.com