Module 1 Final 1.cane Handling and Preparation

Module 1
Cane Handling and Preparation
Table of Content
Module 1: Cane Handling and Preparation For Processing Supervisors
Unit One: Harvesting and Transportation of Cane..............................................................5

1.1 Introduction....................................................................................................................5
1.2 Cane Cutting Methods....................................................................................................6
1.2.1 Manual (Hand) Cutting and Loading......................................................................6
1.2.2 Partial Mechanization – First Level........................................................................7
1.2.3 Partial Mechanization – Second Level...................................................................7
1.2.4 Complete Mechanization........................................................................................7
1.3 Cane Transport Systems.................................................................................................8
1.3.1 In – Field Transport..................................................................................................9
1.3.2 Field – to – Factory Transport.................................................................................9
1.4 Cane Weighing...............................................................................................................11
1.5 Unloading of Cane........................................................................................................11
1.5.1 Overhead Traveling Crane.....................................................................................12
1.5.2 Hydraulic Grab.....................................................................................................13
1.5.3 Tipping Platform and Trailers................................................................................14
1.5.4 Self - Unloading Trucks and Tailors.....................................................................15
1.5.4.1 The Jackobyl.......................................................................................................15
1.5.4.2 Side - Dump Transporters..................................................................................15
1.5.5 Cane Crane or "Derrick"........................................................................................15
1.6 Washing and Cleaning Plant..........................................................................................16
1.6.1 Dry Cane Cleaning Plant (D.C.C.P).....................................................................17
1.7 Cane Storage.................................................................................................................18
Unit Two: Feed Table and Main Cane Carrier...................................................................20

2.1 Lateral Feeding Tables..................................................................................................20
2.1.1 Types of Drives.....................................................................................................22
2.1.2 Area of Lateral Feed Table....................................................................................22
2.1.3 Power Required for Drive.....................................................................................23
2.2 Main Cane Carrier.......................................................................................................23
2.2.1 Length of Horizontal Portion................................................................................24
2.2.2 Length of Inclined Portion....................................................................................24
2.2.3 Width of Carrier....................................................................................................25
2.2.4 Speed of Carriers..................................................................................................25
2.2.5 Carrier Slats..........................................................................................................25
Sugar Engineering and Manufacturing Training Team 2

2.2.6 Conveyor or Belts.................................................................................................26
Unit Three: Cane Preparation Plant...................................................................................28

3.1 Introduction...................................................................................................................28
3.2 Cane Preparation Equipments.......................................................................................29
3.2.1 Cane Levelers, Equalizers/Tumblers.....................................................................29
3.4 The Combination of Cane Propagators.........................................................................30
3.4.1 Cane Knives...........................................................................................................30
3.4.1.1 Cane Knives Designs..........................................................................................31
3.4.1.2 Other Designs.....................................................................................................31
3.4.1.3 Number of Knife Sets........................................................................................32
3.4.1.4 Types of Knives.................................................................................................32
3.5 Drive of Cane Knives....................................................................................................34
3.5.1 Speed and Direction Rotation...............................................................................34
3.5.2 Clearance of Knives..............................................................................................34
3.5.3 Balancing of Cane Knives....................................................................................35
3.5.4 Power Consumption of Cane Knives.....................................................................35
3.6. Crusher.........................................................................................................................35
3.7. Shredder........................................................................................................................37
3.7.1 Types of Shredders.................................................................................................38
3.7.2 Extraction in Shredder..........................................................................................41
7.2.3 Technical Features of Heavy Duty Shredders.......................................................42
3.8 Tramp Iron Separators..................................................................................................46
3.9 Extent of Cane Preparation...........................................................................................46
3.9.1 Preparation Index (PI)..........................................................................................46
3.9.2 Pol in Open Cells (P.O.C.)....................................................................................47
3.10 Description of Donelly Chute.....................................................................................52
3.11 Philosophy of the Control to Insure a Good Preparation............................................52
Module Introduction

Dear trainees! I welcome you to module one of the course “Cane Sugar Manufacturing” In
this module we will discuss the sugar cane harvesting methods and transportation system,
sugar cane handling in the sugar factory and cane preparation.
The module is divided into three units. The first unit deals with sugar cane harvesting
techniques. The advantage and disadvantages of the different harvesting systems and the
different systems used to transport cane from filed to factory will be discussed.
The second unit of the module focuses on the issues of weighing of cane, cane storage, cane
unloading and explain the different unloading systems. It also deals about cane table size,
driving forces of the cane table.
The third unit, the last unit of the module, is devoted on the cane preparation before milling.
The unit covers about the different machineries and instruments used to facilitate the cane
preparation process. It also discusses how to measure the preparation of the cane
experimentally.
Unit One
Harvesting and Transportation of Cane

Specific Objectives
At the end of this unit training, the trainees will be able to:
 Differentiate the different types of cane harvesting process.
 Compare and contrast the manual and mechanized harvesting system.
 Identify and explain the causes of deterioration of cane.
 Explain the reasons why cane is weigh at weighbridge.
 Describe the most common types of equipments used for unloading of cane.
 Explain the reason why cleaning and washing of cane is important
 Discuss the advantage and disadvantage of washing of cane
1.1 Introduction
Harvesting of cane consists of cutting and loading the cane on to transport that will bring it to
the cane yard of the factory.
There has been a constant evolution form the old days. Cane was trashed, cut and loaded in
special wooden carts drawn by oxen. With gradual centralization and consequent increase in
the crushing capacity of mills, transport evolved from ox-drawn cart to Lorries, tractors,
trailers as well as to transport by tramway. During the seventies however, due to the high
maintenance cost of all rail stock, locomotives disappeared completely.
To lower transport costs, the introduction of self-loading systems as well as trailers and
baskets became very popular, as the transporters were not immobilized during the loading of
stationary equipment in the field. This was probably the greatest progress made in loading
and transporting cane.
In the eighties, due to an intensive development in industrialization of the country, labor

became scarce in the agricultural sector. To enable factories to run 24 hours a day, self
powered loaders such as the Bell, Atlas, etc. became very popular. Since the laborers had to
cut cane only, without loading, their productivity increased three-fold.

If labour continues to be more and more scarce in the future, we will have no alternatives
than to move towards complete mechanization of the harvest. All these changes have
therefore brought modifications in the mode of cane handling in the factory yard.
Cane deterioration starts immediately after cutting. Therefore cane transportation and storage
time should always be kept to a minimum. Deterioration is accelerated by high temperature,
light, loss of moisture and inversion, all of which factors are greater under tropical
conditions. Losses in quality caused by delay in grinding are far higher than any mechanical
or chemical losses occurring later in the process. For instance, four days delay of cane can
cause a weight loss of 11 % through evaporation. A delay of 14 days generally causes a 48 %
loss of sugar in fresh cane. The first delay is in the field, where the cane harvester’s burn, cut,
piles it for collection and loading onto cane carts. To minimize the delay time a close
cooperation between harvesting crew and factory people is essential.
The amount of cane to be cut the next day and kept storage should be a minimum. This
reduces time between cutting and grinding. Any measure taken to control storage of cane
both in the cane field and factory cane yard is welcome because losses can run into high
figures.
Another controlled factor, as important as storage, is the moment at which, cane is cut with
respect to its maturity. The cane to be cut should be at the maximum sucrose and minimum
invert sugar content.
1.2 Cane Cutting Methods
1.2.1 Manual (Hand) Cutting and Loading
The traditional way of cutting and loading cane is manual. Undoubtedly, hand cut cane is
better suited for factory processing than mechanically harvested cane. Because a hand cut
cane is cleaner and its purities are higher since in general cane is cut lower to the ground by
hand than by machine. The cane toping is also properly done by hand cutting. This method is
still in use today where mechanization is not possible. An efficient worker can not cut and
load more than 1.5 tonnes per day.

1.2.2 Partial Mechanization – First Level
To increase the worker’s productivity, it was found that these two operations should have to
be dissociated into two different ones. Nowadays, a laborer will cut the cane only. The
loading is done with the help of loaders, such as the Bell or the Atlas. This method of work
(Partial Mechanization – First Level) has tripled the workers’ productivity.
Method Tonnes/Day
Cutting and Loading 1.5

Cutting Only 4.5
1.2.3 Partial Mechanization – Second Level
This method consists of using two types of equipment: - A harvester and a loader.
1.2.4 Complete Mechanization
For socio- economical reasons, i.e. scarcity and expensive labour, there is no other alternative
than to go towards a complete mechanization system. Unfortunately, this is not always
possible, due to the land profile, over large sugar growing regions.
Mechanically cutting and loading is a faster process. The main problem with machine
handling of cane is usually damage to the field, harming future cane crop (ratoon) particularly
this occurs when harvesting is done during the rainy season in which damage to the next
years cane can be appreciable. Where cane is machine-handled, cane washing is
indispensable, combined with stone removal, especially when the loading of cane is
mechanical, push-racking and grab loading.
The cane harvested is mechanically loaded by grab loaders into cane carts. The cane carts or
trailers are driven by tractors, which may go to a cane yard of the factory or directly to the
mill for unloading.
Mechanical harvesters are very expensive. However, they are capable of doing the work of
100 laborers (the weight of cane cut and loaded per day is around 500 – 600 tonnes)
Unfortunately, these machines have certain drawback; they cannot operate in super humid
zone, in fields a having 15 % inclination or in rocky and small fields.

The field should be well prepared in order to make full use of these equipments.
Problems linked to mechanical harvesters are great loss of sugar due to:
(a) Bits and pieces of a few centimeters left in the sugar cane fields and caused by the
fans.
(b) A few centimeters of the cane stalk remains uncut at the bottom (The richer part of the
stalk).
Soil compaction in super humid zone will cause a reduction in yield per hectare and the
maintenance cost of these machines is very high.
These machineries can perform a lot of work such as digging soil to lay irrigation pipes,
breaking stones and load cane on tippers in the fields. So, these machines are used all year
round, i.e. during crop and intercrop.
The problems usually associated with mechanical harvesters are mechanical damages to
revolving knives and drag chains caused by rocks in the fields.
1.3 Cane Transport Systems
The factory takes delivery of the cane directly at a factory weighbridge. Methods of cane
transportation are numerous and adoption of any system depends mostly on local conditions.
Transport is arranged either by railway, or more often by Lorries or by tractors and trailers.
Transport systems are more and more designed to suit mechanical harvesting and loading of
the crop.
The bulk density or weight per unit volume of cane in the truck depends on the manner in
which it is loaded. Bulk density depends on stand of cane. Straight and erect stakes will give
a more compact loading than curved or lodged canes.
1.3.1 In – Field Transport

Tractors are usually used for in – field transport. They provide good traction on rough ground
and have the lowest compacting effect, which is very important in order to minimize cane
yield reduction. These tractors work with different types of trailers and they normally travel
alongside the mechanical loaders or chopper harvesters. (See Fig.1.1) Use is also made of
front–end loaders to pick up cut cane and load it on trailers.
Figure 1.1: In – Filed Transport
1.3.2 Field – to – Factory Transport
The two principal systems of transport from field to factory:-
(a) The Rail System

(b) The Road System
(a) Railway
Capital cost involved in laying down a railway system is very high. Maintenance of railway
lines is also very expensive. The system could be economically interesting only if important
quantities of canes were transported on long distances. The in–field railway lines are
normally along the length of the field.

The disadvantage of railway transport; Useless during intercrop season and maintenance cost
excessive.
(b) Road
Road transport can be done either by tractors or by motor trucks.
For long haul distances, motor trucks are considered to be more advantageous. Their traveling
speed is faster than that of wheel tractors. Tractors are very popular in countries like
Australia where Four–Wheel–Drive tractors are used for hauling cane over distances greater
than 20 Km.
Some types of cane transporters:
(a) Lorry with fixed frame: 6 tones or 10 – 12 tonnes capacity.
(b) Lorry equipped with a self-loader system (6 tonnes): The bin is loaded on the soil and
then winched onto the truck.
(c) Lorry with articulated frame (10 – 12 tonnes).
(d) Tractors with self–loading trailers (6 tonnes).
(e) Heavy–duty type Four–Wheel–Drive (FWD) tractors with multiple trailers.
(f) Tractors with weight transfer system (10 – 15 tonnes). The wheels are towards the
rear so that at least 1/3 of the weight of the trailer and the load is transferred to the
tractor.
(g) Tractors with rear or side–loading trailers like the Jacobyl. Cane bundles are stacked
along the road and are pulled by wire ropes on the trailer. The trailers unload directly
into the cane carrier.
(h) Trailers equipped with hydraulic rear or side–tipping systems are used for chopped
cane and long cane.
(i) Brazilian type containers–without chains.

(j) Moveable bottom 20 – tonne trucks for chopped cane transport. These can be seen in
Reunion Island and also in Mauritius.
(k) Trailers fitted with chain–net systems. Very popular in Cuba.
1.4 Cane Weighing
Before going to the unloading platform, all the transporters cross the factory weighbridge.
The exact weight of cane coming to the mill must be known. The weighbridges are
increasingly equipped with sophisticated weighing devices, e.g. load-cells, so that precise
measurements can be obtained.
This is important for the following reasons:
(a) Payment to farmers and planters for the sugar produced from their cane.
(b) Chemical control and determination of factory performances.
(c) Statistical information regarding cane yields per hectare and per field and
performances of different varieties of cane.
(d) Transport statistics for determination of tones per kilometer costs of the vehicles
1.5 Unloading of Cane
Lorries and other vehicles are either unloaded on to a pile by means of a crane or are self –
discharging. Different types of unloading systems can be used depending on local conditions,
i.e. type of transport used, type of cane to be handled, whether chopped or whole stick cane.
The most common types of equipment used are:
(a) Overhead Traveling Crane
(b) Tipping Platform
(c) Hydrunloader (Hilo)
(d) Self–Loading Trucks and Trailers

(e) The Cane Crane or "Derrick"
(f) The Cane Rake
1.5.1 Overhead Traveling Crane
This is a very common system of unloading cane.
The traveling crane provides a large rectangular stacking space, which can be increased by
lengthening the gantry. Typical installations can provide two to four cranes on the same
gantry. The cane bundle is lifted with the aid of a swing bar fitted with three hooks to which
are hung the cane slings. Nowadays, special electro-hydraulic beams are used for lifting the
cane bundles. Cane slings are automatically unhooked, resulting in a gain in operating time.
Figure 1.2: Traveling Crane (Fives Cail – Babcock)
Height of lift varies from 11 to 14 m and capacity varies from 8 to 15 tonnes. The storage
capacity is around, 2,000 tonnes of cane.
Power Requirements: (Average)
Hoist Motor = 6.5 KW/t

Long Travel = 0.75 KW/t
Cross Travel = 0.2 KW/t
Width of Gantry

Typical installations are 25 to 40 meters in width. The cost of installations varies considerably
with the width of the gantry.
1.5.2 Hydraulic Grab
We can not talk about the handling by the overhead traveling crane (OHTC) with making
reference to the electro-hydraulic grab. This piece of equipment is very suitable to feed the
cane, which has been stocked in bulk, to the feeder table. For a TCH of 150, the capacity of
the grab needed is of the order of 16 m3 or 5 tonnes of cane. The weight of the grab being 4.6
tonnes, the capacity of the OHTC should then be of the order of 10 tonnes.
In general, the factory will be fed in the conventional way, i.e. by slings during the day and
by the grab at night. To achieve this, the cane should be stored in bulk during the day and the
grab will be used to feed the factory during the night. The work should be organized this way;
one OHTC will stock the cane in bulk during the day and will give back the slings to the
lorries while the other OHTC will feed the mills directly via the feeder table as usual.
During the night, after the closure of the weighbridge, only one OHTC will feed the mills by
the use of the grab from the cane stocked in bulk during the day. This method will allow the
number of slings in use to be reduced by ⅔.
Prior to the use of the grab, 1,500 slings were in use and with the utilization of the grab only
500 were used. It is very interesting to note that with utilization of the cane transports without
slings, i.e. with self-loaders and tippers, the quantity of slings in service is only 10 % of what
it was before.

Figure 1.3: Grab Loder
1.5.3 Tipping Platform and Trailers
This is a very satisfactory method of unloading chopped cane. It is also used for handling
whole stick cane. Unloading can be done either by side tip or end tip.
Hydraulic pistons normally control tipping. Special bins are used for cranes to be unloaded
on the tipping platform. The main advantage is that no cane slings are necessary.
Figure 1.4: Unloading by Tipping Truck
Hilo
The Cameco type hydraulic unloader is very common in America, Cuba and Africa.
They are generally of 16 tonnes capacity and are used to unload “Chain-Net” trailers.
Drive: 35 KW electric motor driving an oil pump.
The crane is operated by power pistons for lifting of cane bundles and adjustment of hooks.
 Hydraulic motor for mobile base
 The crane handles about 2,000 tonnes of cane/day from 6.00 a.m. to 6.00 p.m.

This unloader works behind a wall about 2.5 m high. The storage yard requires a concrete
floor on which a cane stacker or front-end loader works. The unloader could eventually be
placed in front of the cane table and tip directly into it.
1.5.4 Self - Unloading Trucks and Tailors
1.5.4.1 The Jackobyl
This is a side loading and unloading trailer. The trailer can transport up to14 tonnes of cane
which are directly unloaded on the cane table.
1.5.4.2 Side - Dump Transporters
It is essentially a box with a high hinge point and hydraulic door mechanisms. It is very
interesting for transporting and unloading chopped cane.
1.5.5 Cane Crane or "Derrick"
There are two types of derricks:
(a) The Self - Supporting Derrick

(b) The Guyed Crane
The self-supporting derricks are massive and heavy, while the guyed cranes are supported by
at least three guys, which keep clear of the swinging boom. Boom radius varies from 9 to 27
m and lifting capacity in normally about five tonnes. The cane is stored in a circular space
and maximum height of lift is about 8 m – a maximum power requirement for operation is
about 10 KW/tonne nominal/Capacity.
The cranes are operated either by steam engines or electric motors. Nowadays, these types of
cranes are no longer commercialized.

Figure 1.4: Self Supporting Derrick
Figure 1.5: Cane Derrick with Guys
1.6 Washing and Cleaning Plant
Large amounts of trash, mud sand and stones are transported together with the cane. These
are removed in cleaning plants. The cleaners may be of wet or dry type. In the wet cleaner,
the cane is washed through showers in a mud trough where powerful water jets float the cane,

while the rock and mud collect at the bottom and are carried away. The trash is also removed
by special extractors, using large quantities of high velocity air. (Power used is high).
Disposal of large quantities of wastewater resulting from the cleaning operation is an

important problem. These cleaning plants remove about 80 % of the extraneous matter
contained in the cane.
However, sugar lost during the washing process is important (2 % to 4 % on cane).These

cleaning plants are large and expensive to install. The running cost of a dry cleaning system
is less than the equivalent wet cleaner and sugar loss is less than in the wet one The dry
cleaner is however less efficient in removing soil, trash and mud.
1.6.1 Dry Cane Cleaning Plant (D.C.C.P)
In Ethiopia, 100 % of the cane harvested is manually cut and mechanically loaded, increasing
the proportion of cane trash loaded with the cane. With cogeneration projects, trash
separation from the cane is financially attractive for a factory receiving "dirty canes", if the
shredded trash is reintroduced in the final bagasse for energy production. The World Bank
had decided to finance an industrial size pilot Dry Cane Cleaning Plant (D.C.C.P.)
Pilot Plant Details
A lateral feed table 10 m wide and 15 m long and inclined at 35 0 feeds a cane layer about 400
mm thick at about 150 TCH on a slat table of the same width situated about 2 meters below.
Rocks in the cane, falling on the slat table, may be detected visually or acoustically and are
immediately removed manually. The slat table discharges its cane on a high speed rubber belt
conveyor (200 m/min) which directs a very thin layer of cane (+ trash) downwards inside a
closed compartment. A second rubber belt placed below the compartment returns the cane to
the main cane carrier. During the fall, air is blown from the bottom of the compartment
vertically across the cane layer. Most of the trash is carried away by the air and exit the
compartment through a duct placed the top of the compartment. The trash/air mixture enters a
cyclone separator from where the air is sucked by an I.D. fan driven by a 150 KW electric
motor. The trash falls at the bottom of the separator and enters 2 small shredders driven by 90
KW motors which cut the leaves and straws into tiny pieces 1 – 3 mm long. This shredded

trash is conveyed pneumatically to the chute at the exit of the last mill of the milling tandem
where it is intimately mixed with the bagasse leaving the mill before going to the boilers.
Results Obtained
 Efficiency of system 50 – 60 %
 Less wear and tear on mill rollers
 Less loss of sucrose in bagasse and BHR is higher
 Less loss of sucrose in final molasses
1.7 Cane Storage
Organization of Cane Supply throughout the Day
A cane sugar factory generally operates continuously. During the day cane transport is
generally carried on for only 12 hours. From 6:00 am to 6:00 pm so the mill will not run out
of cane, it is necessary that the factory should receive in 12 hours during a day.
Cane is stored in the factory storage yard in bulk or in bundles. In factories having a railway
transport system, cane can be stored in the wagons or containers.
Loosely stored cane is handled with electro - hydraulic grabs (range 2.0 – 2.5 m3). Special
models exist for handling chopped cane. Bulk density of stored cane varies from 200 Kg/ m 3
to 400 Kg/m3, depending whether the cane is stored loose or in bundles.
For a factory with a crushing rate of 150 TCH, tonnage of cane to be stored for the night is
about 150  12 + (3  150)
Or
P = 12A + 3A = 15A,
Where/ “A” = Cane Crushed per Hour.

Self Check Exercises
1. Discuss the factors that accelerate cane deterioration.

2. Explain the advantage and disadvantages of manual cutting and loading of cane with
partial and complete mechanization.
3. What are the advantages and disadvantages usually claimed for the use of mechanized
harvester?
4. Name the different type of equipments for the unloading of cane that can be found in
factory yard.
5. Discuss the importance of the precise measurement of cane at cane weighbridge.
6. How can the productivity of the workers cutting loading the cane be increased?
7. What are the advantages usually claimed for the use of hydraulic grab?
8. What are the advantages and disadvantages of washing of cane before milling?
9. Explain the organization of cane supply throughout the day for the sugar factory.
10. Describe the current sugar cane supply practice of Ethiopian Sugar Estates.
Unit Two
Feed Table and Main Cane Carrier

Unit Objectives
At the end of this unit training the trainees will be able to:
 Explain the importance of tumbler or kicker.
 Discuss the objective of the main cane carrier.
 Differentiate the tumbler and leveler.
 Explain the effect of shape of carrier head.
 Describe the area of lateral feed table and power required to drive it.
 Discuss and explain the main parts that the main cane carrier comprises of.
 Explain the two types of main cane carrier drives
2.1 Lateral Feeding Tables
The purpose of lateral feeding tables is to eliminate variations in quantities of cane being fed
to the mill. The table is driven by an independent prime mover equipped with a variable
speed device. An operator who regulates the speed of the lateral feed carrier controls the
amount of cane delivered to the main carrier. By assuring regular and uniform feeding, risks
of overloading and choking of the cane knives are considerably reduced.
Lateral tables were originally designed with horizontal or slight upward or downward
inclination (from 50 to 150 slopes). The table is equipped with a “kicker” or “tumbler’’ which
consists of a shaft fitted with arms arranged in a helix along its length. The object of the
kicker, whose direction of rotation is opposite to that of the carrier it self is to ensure the
regular and uniform quantities of cane are delivered to the main carrier.

Figure 2.1: Tumbler
There has been a marked evolution in the design and manufacture of lateral carriers during
these last years due to extensive use of mechanical loaders and harvesters. Lateral feed tables
with 350 upward inclinations are now very common. The new arrangement allows certain
types of transporters to unload directly on the table. This is common for chopped cane.
Most feed tables have inclination angles varying from the horizontal to 350. Most recent
installations use drag link block chain with steel slat bars (Speed: 0.20 to 0.35 m/sec). The
design incorporates a system for automatic recovery of cane spillage. Relatively, little
maintenance is required on these tables.
A rock and sand removal system has recently been invented and development to improve its
performance is being pursued.
Equalizer:
The term “Equalizer” is used to describe an apparatus designed to even out the distribution of
the cane on the carrier and to level the layer of the cane to a certain extent. This must not be
confused with the “Leveler” which is the set of knives, and which even out the layer of the
cane while cutting.

Figure 2.2: Equalizer
2.1.1 Types of Drives
The cane tables are driven by:
(a) Electric motor as prime mover, driving a hydraulic pump and a hydraulic motor. The
operator controls the speed of the hydraulic motor.
(b) Electric motor and magnetic slip couplings (Heena Drive) – Torque transmission is
achieved by establishing a controlled electro-magnetic linkage between the driving
and driven rotating assemblies.
2.1.2 Area of Lateral Feed Table
Hugot gives the following formula to determine the dimension of an efficient lateral table.
S = 0.6 A
Where / “S” = Area of Lateral Feed Table in m2

“A” = Crushing Rate of Factory in TCH
It must be noted that the area of the new type of lateral feed tables is much more important
than that which Hugot recommends.

2.1.3 Power Required for Drive
T = 0.7 S
Where / “T” = KW of the Driving Motor

“S” = Area of the Table in m2
Savannah S.E. is equipped with two lateral tables, one inclined at 35 0 and the other at 150
against the flow. The following records concerning the power installed were obtained:
Table No. 1
Inclined at 350 against the Flow
Installed KW Mean Ampere Peaks Ampere

900 (160 A) 50 65
Table Drive
Kicker Drive 75 (135 A) 60 90
Table No. 2
Inclined at 150 against the Flow
Installed KW Mean Ampere Peaks Ampere

900 (37 A) 15 32
Table Drive
Kicker Drive 75 (30 A) 10 22
2.2 Main Cane Carrier
The main cane carrier conveys the cane from the factory yard to the crusher or first mill. The
cane has to be transported from yard level to a height sufficient to ensure effective feeding of
the first mill.
The carrier comprises three sections:
(a) A Horizontal Section
(b) An Inclined Section
(c) The Head which Delivers the Cane to the First Mill Crusher
The slope of the inclined portion can vary from 150 to a maximum of 220 (i.e. from 27 % to
40 % slope). An inclination of more than 22 0 must be avoided to prevent the cane from
slipping on the conveyor.

Figure 2.3: Cane Carrier. (Fives Cail – Babcock)
2.2.1 Length of Horizontal Portion
“L” = 5  A⅓
Where/ “L” = Length of Horizontal Section of Cane Carrier in “m”

“A” = Crushing Rate of Factory (TCH)
Note: It is to be noted that very often an empirical formula is used in the sugar
industry. One should be careful because sometimes the formula does not
work and sum invested might not be necessary.
2.2.2 Length of Inclined Portion
Height from ground level of the mills to the highest point of the carrier is about:
(For a 3 Roller Mill) 4 – 5 m
If the floor level of the horizontal section of the carrier in the yard is 1 m below the ground
level of the mills and taking a slope of 20 0, the length of the inclined section will be about 18
m.
2.2.3 Width of Carrier
The width of the carrier depends on the length of the mill rollers, and is generally made the
same as that of the mill. (Usually 1,830 mm)

2.2.4 Speed of Carriers
The speed of the main cane carrier is related to the peripheral speed of the mill. Normal speed
would be equal to half-peripheral speed of the mills.
The drive is normally and electric motor equipped with “Heenan” variable speed coupling.
The speed of carrier is maintained inversely proportional to the thickness of the cane layer
feeding the first mill, so that the volume of cut cane delivered to the first mills is kept
constant.
A detector or feeler is used to measure thickness of cane layer. The feeler issues a signal,
which regulates the speed through the variable speed device.
To avoid chokes at the knives, the speed of the carrier is automatically reduced when the
knives are overloaded.
2.2.5 Carrier Slats
The apron of the cane carrier is made of overlapping corrugated steel slats. The overlapping
of the slat is curved according to a radius having its centre in the pin centre.
The rounded edge is necessary to allow the passage of the slats over the sprockets at the head
and foot of the carrier, and to give the apron the necessary flexibility.
Figure 2.4: Carrier Slats.
2.2.6 Conveyor or Belts
These are use extensively overseas and are made of synthetic rubber. They are used as main
carriers for whole cane and prepared cane. Stainless steel plates are installed to support the

belt where cutting is done over the belt. A recent development has been the introduction of
air-cushion belt conveyors in two factories in South Africa. Advantages are a longer belt life
and reduce maintenance, but the initial installation cost is high.
Figure 2.4: Effect of Shape of Carrier Head. (Straight Head)
Figure 2.5: Effect of Shape of Carrier Head (Curved Head)

1. Discuss the difference between “Tumbler” and “Leveler”

2. Discuss the objectives of the main cane carrier.
3. Describe how to avoid chokes at the knives.
4. Explain the effect of shape of carrier head to the flow of bagasse.
5. What are the characteristics of a modern weighbridge?
6. Describe power required for drive of cane carriers
7. Describe the length of the incline portion against the ground level and slope of the
incline portion?
8. What is the mathematical relationship between speed of the carrier and speed of the
mill?
9. What are the factors on which the width of carriers depends on?
10. Discuss about conveyors or belts?
Unit Three
Cane Preparation Plant
Unit Objectives
At the end of this unit training the trainees will be able to:

 Explain the objectives of cane preparation.
 Discuss the role of each of cane preparation equipments.
 Explain and discuss the two main functions of knives.
 Discuss the power consumption of the knives depends on.
 Describe the main characteristics of crusher.
 Discuss the main functions of shredder.
 Explain the technical features in selecting a heavy duty shredder.
 Discuss the philosophy of the control to ensure a good cane preparation.
3.1 Introduction
The cane is prepared by the help of sets of cane knives to open the juice cells in the cane for
extraction of juice. The prepared cane is passed through three/four mills with water imbibition
at the last mills. The juice is collected from all the mills. It is then filtered through screen to
remove the fiber particles in it before sending for processing. The mills and the cane
preparation units are driven by electric motors/steam turbine.
A good preparation of the cane being delivered to the mills or diffusers is of utmost importance
for factory performance. A fine preparation has a marked effect on the juice extraction results,
on the crushing rate capacity and on power consumed by the mills.
Object of Cane Preparation
Preparation of the cane has three main objectives.
1) To increase capacity by increase of bulk density of the feed.

2) To assist extraction at the mills by breaking down the structure of the cane.
3) To render the juice more readily available for the action of imbibition by breaking and
opening cane cells.

3.2 Cane Preparation Equipments
Cane preparation is done with the following equipment:
(a) Cane Leveler
(b) Cane Knives
(c) Shredders
3.2.1 Cane Levelers, Equalizers/Tumblers
Cane levelers are used to spread out peaks of feed, to even feed for main knifing purposes. Its
set 1000 – 1500 mm above carrier usually rotate with cane, two blades/holder and Tip speed
45 - 50 m/sec.
Equalizers are used to even out the distribution of cane on the carrier and to level the layer of
cane to certain extent.
N.B: Leveler is set of knives; which evens out the layer of cane while cutting it before
reaching the cane knives.
.
Equalizer is to throw the cane backward. An equalizer is installed when the cane is very
tangled on the carrier and when leveling knives fairly low. It's thus a secondary and
inexpensive device placed after the knives and designed to lighten their duty (See Fig. 2.2. on
page 21)
3.4 The Combination of Cane Propagators
Experience has showed that milling capacity is related to the level of preparation, but does
not vary fully in proportion to bulk density. We have discussed the various types of
equipments which are placed a head of the mills with the object of preparing the cane so that
the pressure applied at the mills will yield a max extraction. These are:-
a) Knives
b) Crushers

c) Shredders
Which combinations of these diverse machines will be most likely to give the best financial
results?
3.4.1 Cane Knives
The role of the knives is to break the rind of the cane to facilitate the disintegration of the
cells and extraction of juice. It also increases the bulk density of the cane by cutting it into
very small and short pieces. The denser the material fed to the mills, the better the milling
work will be.
Knives perform two main functions and have two advantages.
a) They favor the capacity of the mills.
b) They assist the extraction of the mills by breaking the rind of the cane resulting in
disintegration and the extraction of its juice.
However the value of knives for the two functions above is very low. Knives are not an
indispensable item of equipment; would it be possible to operate without knives? This device
gives an improvement in feeding and today it's no longer, a question of doing without them,
Capacity wise, nothing can replace them and extraction too difficult to obtain since the
crusher and wills have the object of breaking up the cane. Hence cane knives are generally,
predominantly useful to IMPROVE CAPACITY.

Figure 3.1: Cane Knives
3.4.1.1 Cane Knives Designs
Standard type of knives consists of a heavy shaft (hexa or Octa) section, threaded or fixed
arms each carrying two blades, symmetrically placed in relation to the shaft. The 2 nd arm is
offset 600 relative to the first e.g. if there are 36 arms, the knife installation will consist of 72
blades distributed in rows of 12 in 6 different axial half - planes.
3.4.1.2 Other Designs
A part from standard designed types some manufactures has introduced different modification
the principal ones have the object to:
a) Prolong working life of blades by reducing wear of cutting edge
b) Produce a self sharpening effect of knives.
c) Avoid reduction of length with wear.
d) Reduce shocks, by making them to swing on a pin.

3.4.1.3 Number of Knife Sets
There is no standard cane preparation installation. Depending on factories, there can be one,
two or three sets of knives or a combination of cane knife sets and a shredder.
3.4.1.4 Types of Knives
The most common types of knives are:
(a) MIRLEES
(b) RAMSAY
(c) HOMEMADE (Savannah S.E)
The size, of a knife is normally in the range of 500  150  16 to 20 mm. Depending
on local conditions, the blades are made from normal steel plate (16 - 20 mm thickness) or
from special very resistant steel.
New types of knives are now being used to absorb shocks caused by rocks and stones. These
are articulated blades oscillating on a swivel block. When the knife encounters any piece of
hard material, it oscillates and retracts. Knife breaking is greatly diminished.
Figure 3.2: Knife Drives by Electrical Motor (Fives Cail – Babcock)

Figure 3.3: Standard Type of Knives Installation

3.5 Drive of Cane Knives
Cane knives can be driven by:
(a) Electric Motors or
(b) Steam Turbines
The trend in the sugar industry and in modern factories is to utilize electric motors to drive cane
knives and shredders, while mills are generally driven by steam turbines. One of the advantages
of the steam turbine is that its speed regulator allows some speed variation. Drive transmission
is done directly through a flexible coupling.
3.5.1 Speed and Direction Rotation
The speed of rotation varies from 500 to 750 rpm. At higher speeds (in certain countries speed
can reach 1,000 rpm +) wear of knives is very important and power consumed is very high. The
cane preparation index is not much better than that obtained at lower speeds. Normal practice is
to make the knives rotate in direction corresponding to the movement of the cane carrier. But it
is also common to find the first set of knives rotating in a direction opposite to the movement
of the carrier.
As the cane knives rotate at high speed, wearing of the knives is important and maintenance
costs are quite high. During week-end shutdown of the mill, routine checks of the knives and of
the bolts securing them must be done.
Normally, when wear on blades is important, the blades are replaced by repaired ones. Worn-
out blades increase power consumption. The zone of maximum wear is at the top of the knives.
Repairs consist mainly in welding the sides of the blade with hard surfacing electrodes.
3.5.2 Clearance of Knives
The clearance of a knife is the interval between the circle descried by the extremity of the
blades and the highest portion of the carrier slats.

Clearance of the first set of knives is generally of the order of 450 to 520 mm. Clearance of the
2nd and 3rd knives’ sets can go from 50 mm down to 12 mm.
Clearance is adjusted by lowering or raising the metal rails on which the cane carrier chain
runs, just underneath the cane knives.
3.5.3 Balancing of Cane Knives
Balancing of the cane knife is an important operation, especially when used blades are utilized.
Blades are weighed and fixed impairs so that each arm carries two opposite blades. The weight
of the blades is more or less equal. The same must be done when a knife has to be replaced.
Two opposite blades should be removed and replaced by two blades of equal weight. Lack of
balance will cause excessive vibration on the machine.
3.5.4 Power Consumption of Cane Knives
Power consumption of a set of cane knives depends on the following factors:
(a) Tonnes of Cane Crushed/Hour

(b) Fiber % Cane
(c) Clearance of the Set of Knives
(d) Speed of Rotation
(e) The Radius of the Cutting Circle
(f) The Pitch of the Knives
(g) Quality of the Knives-Whether Worn or Not
(h) Cane Varieties
Power absorbed by a first set of knives is of the order of 7.5 to 12 KW/TFH.
For the 2nd and 3rd set of knives, power absorbed is about 15 to 25 KW/TFH.
Installed power, however, must be considerable higher so that the drive can cope with the
variations in the feeding of the cane knives – 50 % more power can be considered reasonable.

3.6. Crusher
It is a device (1st machine) applying pressure that the cane encounters on arriving at milling
plant. It consists of a mill generally of two rollers, which performs two main functions.
a) It assures the feeding of the whole tandem.
b) It prepares the cane i.e. it facilitator the grip of the rollers.
Crusher is designed for extraction but advantageous not for the total extraction of the
tandem. The unit extracts some proportion of juice. Refer the Table 3.1.
Table 3.1: Juice Extracted (Proportion) by Different Crushers.
No Crusher Extraction % Absolute Juice

1 Krajewski - 2 Rollers 40 - 50
2 Fulton - 2 Rollers 45 - 55
3 Double Crusher - 4 Rollers 60 - 70
4 Mill Crusher - 3 Rollers 60 - 80
In crusher application, three main points must be considered
1) Length of Feed Plate

2) Slope of Feed Plate about 450 least
3) Live of Feed ... this must pass through axis of crusher roll.
Figure 3.4: Fulton Crusher Rollers (Fives Cail – Babcock)
Characteristics of a Crusher
1) It possesses a surface constructed to permit it to grip the cane

2) The surface is designed to break, tear up and crush the cane

3) Its peripheral speed must be greater than first mill.
4) Surface serrated line, enclosed between two lines parallel to the axis, and
rotating this around the axis of the roll. Thus circular grooving of V - form,
separated by rider (teeth)
It's inclined 60 to 750 to horizontal (improving feeding/capacity and cane preparation).
3.7 Shredder
Although quite good and fine preparation can be obtained from an installation comprising
two or three cane knife sets, a shredder is often used to improve the preparation and
disintegration of the cane cells. The shredder is usually placed between the cane knives and
the first mill. A combination of two cane knives and a shredder usually gives very fine
preparation – Pol % open cells can go up to 90 – 95 % as compared to a preparation index of
75 % to 80 % with a knifing arrangement only.
Main function of shredder is to rupture the tissues by forcing PC of cane to pass through a
very various space thus blocking on one side and striking thus and striking them on the other
side with a powerful blouse.
The clearance between anvil bars and path of rotating hammers 25/100 mm.
Shredder speed at 500, 1000 or 1500 RPM, generally 1000 - 1200 RPM carrying hammers
which are pivoted on dices or plats.
The bagasse leaving the shredder is a mass of cell material of pith mixed with long thread
fibers. The shredder thus fulfils a ride which weather, the knives nor the mills can perform.
The disintegration of the cane is expressed by displace ability, index (DI), that is the
percentage of pol in the open cell or preparation index as calculated from laboratory
determination of pol obtainable by extraction
Example: After knives sample = 65 to 70 % PI
After shredder sample = 78 to 85 % PI and
After a heavy - duty shredder sample = 86 to 92 %

The index of preparation is defined as:
Pol Extracted by Wasshing (Cold )

IP   100
Pol Extracted After Di sin tegration
3.7.1 Types of Shredders
There are three main types of shredders:
(a) The Tongaat Shredder (See Fig. 3.5 and 3.6 (a) and 3,6 (b) )
(b) The Unigrator Shredder (See Fig 3.7)
(c) The Michael Sullivan Shredder (See Fig.3.8)
What are the differences between the three types of shredders?
1. The Tongaat Shredder
This shredder belongs to the first generation of shredders. It is vertically fed and all the
shredding is done at the metal anvil. This type of shredder is very efficient as long as no scrap
iron or another extraneous material comes in with the canes.
Figure 3.5: Section View of Tongaat Shredder

2. The Unigrator Shredder
This shredder has been designed by a Mauritian (Mr Victor Ducasse, Draughtman of Belle
Vue Harel) in 1965. He had the brilliant idea of replacing the knives of a cane cutter by a

series of hammers. The experiment was so successful that the American firm “UNICE”
bought the patent from Mr Ducasse and started to commercialese the first horizontal fed
UNIGRATOR Shredder.
Figure 3.6 (a): Unigrator Shredder
Figure 3.6 (b): Conventional Shredder
The advantages of the Unigrator are:
(a) The machine could cope in a certain way to extraneous matter arriving with canes
loaded mechanically.
(b) 80 % of the shredding is done at the cane anvil and the 20 % left with the metal avill.

(c) The power consumed per tonne of fiber was much less.
(d) This machine could operate with one cane cutter placed up front.
N.B: The only drawback was the angle of the slat carrier which, by all means, could
not exceed 80
Figure 3.7: Rock Handling by Unigrator
3. The Michael Sullivan Shredder (or The Heavy Duty Shredder)
Same as the Unigrator, this machine has an horizontal feed and can be placed anywhere along
the slat carrier, and due to its feeder drum, the angle of the carrier could be more than 80.

The circumferential speed is much higher and can exceed 100 m s -1. The preparation index
reached was about 98 %.
Figure 3.8 (a): Sullivan Cane Shredder (Heavy Duty Cane Shredder)
Figure 3.8 (b): Sullivan Cane Shredder (Alternative Shredder Arrangement)
3.7.2 Extraction in Shredder
With Shredder Without Shredder

1. Crushing Rate TCH 88 87.2
2. Sugar % Bagasse 2.55 3.05
3. Extraction 93.55 92.25
4. Amperage Taken by Mills 1100 1304
5. Amperage Taken by Shredder 175 0
6. Total Amperage 1275 1304
Review of Cane Shredding
The evolution of cane shredding practice is reviewed, leading up to modem "90 +

preparation" for both milling and diffusion. Features of modem heavy duty shredders are
described. Particular aspects covered are shredder size, power requirements, rotor
construction, hammers and the grid plate. Comments are made on some aspects of operation
and maintenance.
3.7.3 Technical Features of Heavy Duty Shredders
In selecting, installing or operating a modem shredder, several features need to be

considered. Among the more important are:
Shredder Size
Most South African shredders are 2,130 mm wide (some are wider) with a swept diameter of
either 1,525 mm or 1,780 mm. Most have eight rows of hammers although some of the 1,780
diameter units have ten rows.
The 1,525 mm units will provide 90 + PI on throughputs up to 40 or 45 tons fiber per hour.
For higher rates, the larger diameter (and possibly width) is recommended.
Preparation quality is more critical for diffusion than for milling, and this can affect a
decision on marginal sizing of the shredder and its drive.
Speed and Power Consumption
Speed of shredders is generally of the order of 800 to 1200 rpm.
The power absorbed by the swing hammer type shredder is of the order of 40 KW/TFH, while
for the unigrator type shredder, the power consumed is about 35 KW/TFH.

As for cane knives, the clearance setting between the hammer tips and the anvil plate is very
important for optimizing cane preparation index. The maintenance of hammers is also
important. Refacing of hammers must be done regularly.
Surveys reported indicate installed powers in the range 40 to 65 Kw/t fibre/h on successful
preparation lines.
Of these, only Renton systematically attempted to measure the power absorbed, but less than
half the shredders then tested were achieving 90 + PI. Measurements on those installations
indicate average power absorbed of 25 - 45 Kw/t fiber/h. Somewhat higher figures (up to 55
kw/t fibre/h) have been measured with blunted hammer tips or poor feed conditions. It is also
necessary to cater for surges and short term peaks, which justifies the higher installed powers.
Of critical importance to surge-free operation and consistently good preparation is to ensure a

steady cane feed to the shredder. This can be achieved either by the use of feeder rolls (which
can themselves prove troublesome) or by ensuring an even feed projected into the "nip" as the
shredder hammers approach the grid. The rotational mass of the rotor plus hammers of a
heavy duty shredder is sufficient to make a flywheel unnecessary. Additional power in pre-
preparation (knifing) will at best only partially reflects in reduced shredder power. Care must
be taken to avoid excessively fine knifing as this tends to cause short fiber lengths and
"pulping", which detracts from feeding in mills and impedes percolation in diffusers.
Shredder Hammers
For optimum preparation, it is important that hammer coverage be provided across the full
width of the shredder to avoid "short circuiting" of chunks of cane. The Tongaat rotor design
automatically provides full coverage, but with disc-and-spacer type rotors, club head
hammers are necessary.
Most heavy duty shredders use hammers of more than" 15 Kg. Under normal operating
conditions, the kinetic energy of the hammers and their natural periodicity are such that a
very small angle of swing occurs. As a result, wear rates on hammer bars of suitable material
should be low and Maidstone has achieved an average of 2.5 m tons cane per set of hammer
bars. The small angle of swing also means that the cost of replaceable bushes in hammers

cannot generally be justified. Maidstone's experience showed 1.5 – 2.0 mm ovality in

hammer pivot holes after 1.5 m tons cane, by which stage it was felt that the general
condition of the hammers warranted their replacement.
Rate of wear of the hammer faces appears to be more dependent on extraneous matter
(particularly sand) than cane variety. Some engineers state that extremely tight grid plate
settings (tip-to-tip) tend to increase hammer wear rates.
Most South African mills protect the working face of their shredder hammers by applying a
hard welded overlay. Provided this hard cover is not too thick, (preferably not more than 8
mm) it retains a sharp leading edge as the hammer wears, with the softer base material being
undercut as it wears more rapidly. The resulting "hook" provides ideal preparation over the
full period between hammer changes (See Fig.3.9).
a) Both Side Worn b) Mild Steel Rebuilt c) Hard Overlay to Gauge
Figure 3.9: Rebuilding Worn Hammer
In welding to refurbish worn hammers, it is desirable to work with jigs. These ensure a
constant length from pivot hole to longest extremity and also a reasonably consistent mass for
each hammer. All hammers do not need to be of identical mass, but it is essential that
hammers are replaced in dynamically balanced sets.
In order to reduce hammer maintenance costs, various replaceable hard-wearing hammer tips
have been tried.

Less hard but tougher materials have proved more successful but suffer from the same
problem as heavily applied chrome carbide hard facing: over time, the leading edge wears to
a rounded profile which then "pulps" the cane rather than shredding it. This results in poor
preparation and excessive power consumption and can also impair shredder feeding.
Grid Plate
The grid plates of most modem shredders cover a working arc of 90 degrees although South
African (and Australian) shredders range from 80 to 120 degrees. This latter is probably the
limit for a single pivoted grid plate assembly as it is of importance that the setting of the grid
plate can be adjusted over the entire working area. This is normally done by checking the gap
between extended hammers and the working surfaces of the grid across the width of the
shredder at both the inlet (first grid bar) and outlet (final grid bar). Setting is carried out by
adjusting the hinge points at both sides of the shredder and then adjusting whatever devices
are used to control the pivoting about these hinges.
The mechanism of shredding in a pocketed grid appears to be that a mattress of fibrous cane
packs within each pocket. The cane being impacted and pulled through the shredder by the
rotating hammers is then stripped against the surface of this fibrous mattress. The compacted
mattress slowly "flows" through the pockets and most of the shredding occurs against this
constantly renewed fibrous surface. This explains why the leading edges of the grid bars do
not wear nearly as fast as do the hammers. It is however important to keep reasonably sharp
edges on the grid bars to ensure that the fibrous mattress is retained within the pockets.
The grid plate can be rigidly secured but most engineers prefer to allow for some fail-safe
mechanism in the event of large tramp iron or an excessive surge of cane. Mechanisms to
allow the grid plate to move rapidly away from the rotor under such circumstances include
pneumatic, hydraulic or spring loading against adjustable stops (all of which are self re-
setting) or shear pins (which require a stop for replacement if sheared).
Conclusions
The modem heavy-duty shredder constitutes the single most important part of cane
preparation. The basic equipment parameters and maintenance requirements are well
established. Complying with these is essential for acceptable extraction rates, whether from a

milling train or a diffuser. It is therefore appropriate to conclude with a checklist provided for
improving performance and/or simplifying shredder operation:
• Check the concentricity of the grid plate regularly.

• Check grid bar clearances frequently.
• Keep control of hammer lengths and masses (use of jigs).
• Consider building a spare grid plate assembly, if none exists.
• Particularly for diffuser operation, limit knifing to just enough to prevent shredder
chokes.
3.8 Tramp Iron Separators
Tramp iron in the cane is a nuisance, which may cause severe damage to shredders
particularly the swing type hammers, and to the mill roller grooving. The cane knives, with a
larger clearance than shredders, are less affected by tramp iron.
Separation of tramp iron from cane is not very easy; it is done by a magnetic separator.
The separator can be either;
(a) Rotating Drum or
(b) Rectangular Static Magnets.
The rotating drum magnetic separator is placed in the chute between the carrier head and the
mill. This type of separator is not very efficient (60 %). When a layer of cane comes between
the iron and the magnet, the magnetic force is reduced in proportion to the square of the
separating distance between the magnet and the iron. So, very often, heavy pieces of iron
escape the separator.
On the other hand, the rectangular static magnet is placed over a high-speed belt transporting
the prepared cane from a shredder to the mill. The high speed of the belt ensures that a thin
layer of cut cane is transported, so that the magnet can be placed very near over the conveyor.
The disadvantage is that the tramp iron travels very quickly under the magnet (thus time
spent by iron under the magnet is very short.) Here again an efficiency of about 65 % can be
considered good.

3.9 Extent of Cane Preparation
3.9.1 Preparation Index (PI)
We have considered the effect of cane preparation on capacity and extraction at the milling
train. The first requirement, for any sound assessment of such effects, is to have some
quantitative measure of “Degree of preparation”. The state of disintegration of the cane is
expressed by the preparation Index (PI). (PI) is the percentage of pol in the open calls. PI is
obtained from laboratory determination of pol by extraction in cold water, relative to
complete disintegration of the cane in the cold. Some times this proportion is expressed in
brix instead of by pol. The values are thus fairly close, the free pol being slightly higher than
the free brix. The preparation index can be as follows.
After knives, PI = 65 – 70 % after conventional shredder PI = 78 – 85 %
After heavy duty shredder PI = 86 – 92 %,
Exceptionally we may obtain 94 – 95 %.
The preparation index is thus defined:
Pol Extracted by Cold Washing

PI 
Pol Extracted After Di sin tegration
3.9.2 Pol in Open Cells (P.O.C.)
How is P.O.C. Determined?
There are two of measuring the degree of preparation of the cane before milling.
The Australian method (P.O.C.) which indicates the percentage of Pol in the broken cells in
relation of the total Pol in the cane.
The South African Preparation Index (P.I) which indicates the percentage of Brix in broken
cells in relation to the total Brix in the cane.
Sampling Method
In order to have a representative sample, the cane should be sampled on the total length and
width of the cane. At least four samples should be taken to constitute a composite sample (2
Kg are necessary). When the cane is prepared through a shredder, the sampling is quite easy

but if the cane preparation is carried through a cane cutter, the sampling is very difficult due
to the presence of uncut canes.
Equipment
 A 3 - Gallon Tank on a Bench Capable of Rotating at 70 rpm

 A Jeffco or Jeffress Shredder (Laboratory)
 A Disintegrator (Reitz)
 A Polarimeter
Figure 3.10: Can for the Determination of Pol in Open Cell

Method
(a) Pol in Open Cells (P.O.C.)
1,000 gm of prepared cane are mixed with 10,000 gm of water in the 3-gallon can. The can is
then made to rotate at 70 rpm for 3 minutes. Then the sample of the juice is put into a 200
mm polarimeter tube and the reading is noted (P1).
Total Pol of the Prepared Cane
(i) 333 gm of the prepared cane are disintegrated in a Jeffco disintegrator.

(ii) Add one liter of water containing 10 mL of a sodium carbonate solution at 5 %
to prevent inversion.

(iii) Disintegrate the mixture for 10 minutes at 2,000 rpm.

(iv) Then use a 200 mm polarimeter tube and note the reading (P2)
Calculation
P1
If  R
P2
11 .93 R
Then , P.O.C 
4.58  R
Example:
P1 = 6.4
P2 = 22.21
Then, R = 0.29
And P.O.C = 81

Figure 3.11: (a): Effect of Preparation on No. 1 Mill Extraction
Figure 3.11 (b): Effect of Preparation on Total Extraction
Assuming that:

Bagasse % Cane: 30
Weight of Cane Crushed for Miller : 350,000 tonnes
Weight of Cane Crushed for Planters : 75, 000 tonnes
Total 425,000 tonnes
And if
Sucrose % Cane (Miller) : 12.87

Sucrose % Cane (Planters) : 12.57
Sucrose % Cane Average : 12.82
Sucrose in Mixed Juice % Cane : 12.38
Sucrose in Bagasse % : 0.44
BHR (Boiling House Recovery) : 88.74
Pol Sugar : 98.50
Miller’s Shares on Planters’ Sugar : 22 %
Calculation
Weight of Bagasse Produced = 30 % of 425,000 = 127,500 tonnes
If Pol % Bagasse is reduced by 0.2, this represents: 127,500  0.2 % = 255 tonnes of
Pol
Hence, Pol in Bagasse % Cane will be reduced by:
255  100
 0.06
425,000
Or
If Pol in bagasse % Cane = Pol % Bagasse  Bagasse % Cane
Therefore, Reduction in Pol in Bagasse % Cane = 0.2  30/100 = 0.06
Now if:

Sucrose in Mixed Juice % Cane

Mill Extraction   100
Sucrose % Cane
Sucrose in Mixed Juice % Cane

  100
Sucrose in Mixed Juice % Cane  Sucrose in Bagasse % Cane
12.38
Mill Extraction ( Before Im provement)   100  96.57
12.38  0.44
12.38  0.06
Mill Extraction ( After Im provement)   100  97.04
12.82
Gain in Mill Extraction = 97.04 – 96.57 = 0.47 %
Gain in Sugar on Planters’ Cane Only:
12.57 0.47 88.78 100 22

 75,000       8.5 tonnes
100 100 100 98.5 100
Gain in Sugar on Planters’ Cane Only:
12.87 0.47 88.78 100 22

 350,000       43.67 tonnes
100 100 100 98.5 100
Total Sugar Accruing to Miller = 8.50 Tonns

= 43.67 Tonns
= 52.17 Tonns
3.10 Description of Donelly Chute
The shredded canes, free of rocks and metal, will now feed the first mill through a vertical
chute (Donelly Chute) equipped with electrodes which will adjust (regulate) the speed of the
cane carriers so as to maintain a constant level of cane in the vertical chute to assure a

regular cane feeding to the milling train. The vertical chute will contribute to the good
feeding of the first mill.
3.11 Philosophy of the Control to Insure a Good Preparation
The philosophy of the control is to insure a constant and regular feeding of cane to the cane
cutter, shredder and mills and at the dame time to avoid “chokes” at the cane knives or at the
shredder level.
How cane these objectives be achieved?
By having electrodes in the vertical chute of the first mill. These electrodes will detect the
level of the prepared cane in the chute and if the chute is empty, this signal will be sent to a
PLC (Programme Logic Controller) which will increase the speed of the unigrator carrier, the
long main carrier, the shorter carrier and finally the speed of the derocking feeding table.
N.B: It is understood that all the electric drives of all these carriers are equipped with
invertors, i.e. variable speed drives. However, the power absorbed by the cane cutter on the
shredder will limit the speed of the different carriers so as to avoid chokes, e.g. for the cane
cutter: if the power of the motor exceeds a safe level, the carrier will slow down to allow the
cane cutter to cope with an eventual load, if any. The same thing will happen with the electric
motor of the shredder.
If the shredder is driven by a steam turbine, then it is the speed of the shaft of the shredder
that will be the limiting factor, e.g. If speed of shredder will decrease to under its normal
speed, this will be detected by means of a tacho generator and the signal sent to the PLC that
will slow down the speed of all the cane carriers to avoid chokes.
A mill stoppage due to a "choke" will take quite a few hours to remove the cane and restart
the milling. This is why priority is given to the power absorbed by the cane cutter and the
shredder over the level of cane in the chute.
The normal working level in the vertical chute is about 50 % - this will allow a buffer on both
sides, i.e. to constitute a litter reserve of cane and to allow enough places to stock cane while
slowing down the speed of the unigrator carrier followed by the other carriers.

An efficient system of control will decrease energy consumption of both the cane cutter and
the shredder because the feeding will be very smooth and avoid "peaks".
It is very difficult or even impossible for a manual control to be as efficient as an electronic

controller.

Figure 3:12: Typical Arrangement of a Cane Preparation Line

1. What are the different types of equipments that are involved in cane preparation?
2. What are the advantages claimed for a good cane preparation?
3. Describe fully the working principle of a Unigrator type shredder.
4. How can the level of cane preparation be measured and how it is defined?
5. Describe fully the philosophy of cane control for a good and uniform feeding to the
mill.
6. Why do you think that the cane preparation is important for mill performance?
7. Name the different factors that will influence power consumption of a set of
(a) Knives (b) Shredder
8. What are the advantages and disadvantages of a Unigrator type shredder over a
conventional shredder?
9. Name the three main types of shredder available on the market? State the main
difference between them.
10. Is there any relationship between level of cane preparation and mill extraction?

Module 1 Final 1.cane Handling and Preparation

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Module 1

Cane Handling and Preparation

Unit One: Harvesting and Transportation of Cane..............................................................5

Unit Two: Feed Table and Main Cane Carrier...................................................................20

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2.2.6 Conveyor or Belts.................................................................................................26

Unit Three: Cane Preparation Plant...................................................................................28

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Harvesting and Transportation of Cane

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 Differentiate the different types of cane harvesting process.

 Compare and contrast the manual and mechanized harvesting system.

 Identify and explain the causes of deterioration of cane.

 Explain the reasons why cane is weigh at weighbridge.

 Explain the reason why cleaning and washing of cane is important

 Discuss the advantage and disadvantage of washing of cane

In the eighties, due to an intensive development in industrialization of the country, labor

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1.2 Cane Cutting Methods

1.2.1 Manual (Hand) Cutting and Loading

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1.2.2 Partial Mechanization – First Level

Cutting and Loading 1.5

1.2.3 Partial Mechanization – Second Level

1.2.4 Complete Mechanization

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1.3 Cane Transport Systems

1.3.1 In – Field Transport

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Figure 1.1: In – Filed Transport

1.3.2 Field – to – Factory Transport

The two principal systems of transport from field to factory:-

(a) The Rail System

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Road transport can be done either by tractors or by motor trucks.

Some types of cane transporters:

(a) Lorry with fixed frame: 6 tones or 10 – 12 tonnes capacity.

(c) Lorry with articulated frame (10 – 12 tonnes).

(d) Tractors with self–loading trailers (6 tonnes).

(e) Heavy–duty type Four–Wheel–Drive (FWD) tractors with multiple trailers.

(i) Brazilian type containers–without chains.

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(k) Trailers fitted with chain–net systems. Very popular in Cuba.

1.4 Cane Weighing

This is important for the following reasons:

(b) Chemical control and determination of factory performances.

1.5 Unloading of Cane

The most common types of equipment used are:

(a) Overhead Traveling Crane

(b) Tipping Platform

(c) Hydrunloader (Hilo)

(d) Self–Loading Trucks and Trailers

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(e) The Cane Crane or "Derrick"

(f) The Cane Rake

1.5.1 Overhead Traveling Crane

This is a very common system of unloading cane.

Figure 1.2: Traveling Crane (Fives Cail – Babcock)

Power Requirements: (Average)

Hoist Motor = 6.5 KW/t

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1.5.2 Hydraulic Grab

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