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17Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan

Administration Department

Lt. Col. (R) Muhammad Riaz, DGM (HR & A) being the head of the department

supervising administration department. He act as Liaison Officer for the Mills and

responsible for all kinds of administrative works. The administration department has

following sections in it:-

i. Security & Safety Section

Maj. (R) Zia Ahmad Khan, Chief Security Officer is incharge of Security

and safety section. The main responsibility of this section is to provide the

security to the Mills assets and safety guidelines to the Mills employees.

He had arranged Rescue 1122 Training Programme on Safety Measures

to educate the Mills employees. He also acts as number two of DGM (HR

& A). In the absence of DGM (HR & A), Chief Security Office officiates as

head of the department. He is reported to DGM (HR & A)

ii. Civil Works Section

Syed Munir Hussain Shah, Civil Works Supervisor is responsible for all

kind of civil works directed to him by the DGM (HR & A). He himself

alongwith his team comprising of Clerk, Masons & Labourers complete all

civil jobs assigned to them. He is direct report to DGM (HR & A)

iii. Establishment Section

Mr. Muhammad Amjad Jam, Deputy Personnel Manager is incharge of

this section and he is responsible for keeping personal files record of the

employees, all other record like PESSI (Pakistan Employees Social

Security Institution) record, EOBI (Employee’s Old-age Benefit Institution)

record, Labor Department record and all other kind of office record. He is

direct reported to DGM (HR & A).

iv. Transport Section

Syed Niaz Hussain Shah, Transport Incharge is handling all the matters

related to Transport. He also supervises the auto workshop’s staff. He

maintained all vehicles record. Presently, the company own Seven

Tractors, One Bus, Two Toyota Hiaces, One Pajero, Three Corolla Cars,

Two Honda City, Ten Suzuki Cultus Cars, Two Shahzor Mini Truck, Sixty

Yamaha Motorcycles, etc.

v. Masjid

There is very beautiful Masjid constructed by the Company which is

enough for 1000 persons. The staff for Masjid is one Khateeb / Imam

Masjid, one Moazzan, One Khadim Masjid and one Helper Masjid.


At the start of crushing season, the field staff contact the growers and advised them to

remain ready for supply of sugarcane. They try their best to make available the

continuous supply of sugarcane to the Mills to avoid any stoppage of crushing.

Because, due to shortage of sugarcane, the seasons, nowadays of 90-100 days which

was previously of 150-200 days and every second is very precious for the sugar mills

during the season. The management is also dislikes the stoppage in crushing during

season.

The field staff emphasize the growers to repay the loan as soon as possible, because,

this is the only way (supply of sugarcane by grower) to recover the loan from growers.


Chemical Department

Engr. Muhammad Rahat Saeed, DGM (Production) is head of the department and he is

responsible for all boiling / chemical procedures apply on the sugarcane juice. The

chemical department is totally responsible for production of sugar from juice. They apply

methods, heat and some chemicals to transform the sugar from sugarcane. The

complete process of production of sugar is as under:-

Processing of sugar cane in a sugar mill for manufacturing of white

sugar:.

CANE TIPPERS

Loaded cane trolleys are tilted by hydraulic jacks into feeding tables. Feeding

tables transfer cane into carrier # 01.

CANE CUTTER # 01

Motor 1000KW, Knives 40 Nos. It is driven by electric motor. It performs the

duty of cane chopping and leveling. Its clearance is about 2 Ft.

CANE CUTTER # 02

Motor 850KW, Knives 40 Nos. It cuts the cane into small pieces, its clearance

is about 10”

CANE CUTTER # 03

Motor 1000KW, Knives 80 Nos. It completely cuts the cane into small pieces

at minimum clearance of 2”.

SHREDDER

Steam Turbine 3000KW, Swinging Hammers 88 Nos. It shreds the cane and

raptures all the sugar cane cells to open position.

MILLS TENDEM

Mills tendem consists of 05 Mills driven by steam turbines having power

850KW each. Shredded cane is passed through series of 05 mills for

extraction of juice. Imbibition water is sprayed on last mills for maximum

extraction of juice. This extracted mixed juice is filtered through rotary screens.

Screened juice is sent to Boiling House for processing and bagasse from last

mills is sent to boilers as fuel.

BOILERS 03 NOS. (CAPACITY 80TON/HOUR EACH)

Main object of boiler is to produce steam at pressure 23Kg/cm and2

temperature of 350ºC. Bagasse is fed to boilers, furnaces where it is burnt and

produces steam at the rate of 80 Ton/hour each. Surplus bagasse is sent to

bagasse yard, which is sold out. In case of shortage of bagasse, furnace oil is

burnt as standby fuel.

POWER HOUSE

Steam Turbine Generators 02 Nos., Capacity 5MW each. Steam produced by


boilers is used for the operation of steam turbine generators. 10MW power is

used for the operation of all electric motors installed in Mills.

JUICE HEATERS

1. Condensate & Primary Juice Heaters (04 Nos.) (H.S. 350m each)2

Screened juice is passed through juice heaters in series and temperature

is raised upto 65ºC by using steam / vapours.

2. Defecations Tanks

Here milk of lime (M.O.L.) is added in heated juice and after some retention

time, juice is passed through secondary juice heaters.

3. Secondary Juice Heaters (03 Nos.) (H.S. 350m each)2

Limed mixed juice is passed through secondary juice heaters and

temperature is raised upto 105ºC for further treatment in juice clarifiers.

4. Juice Clarifier (03 Nos.) (Capacity 170m each)3

After secondary heating poly electrolyte is used before entering of juice in

clarifiers it stays there for 1 to 1:30 hours to complete the reaction between

M.O.L. and impurities of the juice. The impurities settle down in the clarifier.

Settling is speedy by addition of poly electrolyte. The clear juice from

clarifier is decanted and passed through rotary screens. This filtered juice

is sent to series of evaporators. Settled impurities (Muddy Juice) is taken

out from the bottom of the clarifiers and is sent to vacuum filters for

filteration.

VACUUM FILTERS (04 NOS.) FILTERING AREA (58M EACH)2

Muddy juice taken from clarifiers is mixed with Bagacillo in Mud Mixer and sent

to the troughs of vacuum filters. Vacuum filter drum rotates and mud climbs

over the drum. Hot water is sprayed by Nozzles on the drum. Remaining juice

and washing water is sucked through tubes by vacuum. Sucked filtered juice

is returned to defecation tank and mud is sent out by scrapping the mud from

drums of vacuum filters. It is manure for cane growers.

EVAPORATORS (07 NOS.)

Decanted juice from juice clarifier called clear juice is taken into series of

evaporators. It is boiled with help of exhaust steam (obtained from turbines of

mills and power house). The thick juice obtained from evaporators called

syrup is fed to pans.

VACUUM PANS (RAW SIDE) FOR A, B & C MASSECUITES.

Batch Pan (04Nos.) Capacity 70Ton each.Conti Pan (02 Nos.) Capacity 68m each.3


Conti Pan (02 Nos.) Capacity 102m each.3

The syrup is fed into pans where it is again boiled to produce mixture of

crystals and molasses called A Massecuite. Prepared massecuite is dropped

into crystallizers.

MASSECUITE CRYSTALLIZERS (13 NOS.) (RAW SIDE)

Prepared massecuite from pans is sent into crystallizers for further

crystallization by motion of massecuite by scrolls driven by gear and motor.

The massecuite is transferred to centrifugal station by massecuites pumps.

Centrifugal K-1100 (25 Nos.) (Raw Side)

Massecuite is passed through centrifugals which separates crystals of sugar

and molasses. First separate molasses, “A” Heavy is again boiled in B-Pans

for B-Massecuite. B-Massecuite is again passed through centrifugals for

separation of sugar crystals and molasses. This obtained molasses called B-

Heavy is again boiled in C-Pans for C-Massecuite. C-Massecuite is again

passed through centrifugals for separation of sugar crystals and final

molasses. This final molasses is sent out in molasses ponds for sale as a raw

material for distilleries and sugar crystals separated from B & C Massecuite

are used as seed in pans and sugar crystals obtained from A-Massecuite are

taken into sugar remelter.

SUGAR REMELTER (CAPACITY 30TON/HR.)

Here sugar is remelted by using hot water and steam with 02 Nos. stirrers.

This remelt is called raw liquor. This raw liquor is sent to Talo station.

TALO CLARIFIER

Raw liquor before taking into clarifier is treated with phosphoric acid, colour

quest, lime sucrate and talo float. These chemicals are used to remove

remaining impurities in sugar. In talo clarifier with some retention time these

impurities float up in clarfier and clear liquor is taken out from bottom side.

Floated impurities called scum is removed from clarifier by scraper driven by

gear and motor. The clear (fine) liquor is sent to pan station. The removed

serum is sent back to defecation tank.

REFINE PANS (05 NOS.) (CAPACITY 70 TON EACH)

Fine liquor is taken into pan. It is boiled for some time to get required brix for

crystallization. Very small fine crystals seed (obtained from the sugar grader

not bagable) is fed into it. Required crystal size is obtained by further boiling

called the refine massecuite. Prepared massecuite is dropped into

crystallizers. From which it is pumped to refine centrifugals for separation of

crystals and molasses.

REFINE CENTRIFUGALS TSK (03 NOS.)

Refine centrifugals are automatic batch type centrifugals which separates fine

sugar crystals and molasses. This molasses is reused for making more refine


massecuites. Fine crystals (Sugar) is dropped into hopper which shift it to

sugar dryers.

SUGAR DRYER (02 NOS.)

While sugar passes through these dryers, remaining moisture is removed by

blowing hot air through them. Hot air is passed by fans called blowers fitted for

this purpose.

SUGAR ELEVATORS. (02 NOS .)

Elevators lift the dried sugar through buckets at some height and feed to sugar

grader for its size wise separation.

SUGAR GRADERS (02 NOS.)

Here, sugar travels over graders moving to and for. At sugar grader frames of

screens of different mesh are fitted. Through which fine, very small crystals

(seed) and extra large size crystals are separated and sugar crystals of

required size drop into sugar bins.

SUGAR BINS (03 NOS .)

Sugar bins are used for holding bag able sugar.

AUTOMATIC WEIGHING MACHINE (02 NOS.)

Automatic weighing machines are installed under sugar bins, machine drops

sugar after 50Kgs accurate weight into poly propylene bag attached under it

manually. The weight of these bags is re-checked by electronic weighing

scales kept under. After that the bags sewing is done by sewing machines (02

Nos.) fitted over wooden conveyors. These sewed bags are sent to sugar

godown where it is stacked upto the height of 50 layers by sugar stacker.


Electrical Department

Engr. Nadeem Ghafoor, DGM (Electrical) is head of the department and he is

responsible for all electrical and instrumental jobs of the Mills. The electrical department

have two section in it:-

1. Electrical Section

2. Instrument Section

Mills have 02 Steam Turbo Generators and 02 Diesel Generators for standby supply of

electricity at Power House Section. 02 Steam Turbo Generators having capacity of 5

MW each provides the electricity during the season to the Mills. Various electrical

panels are installed at Power House and all electricity matters are controlled from

Power House.

At the time of start up, the electrical department do not depend on WAPDA, therefore

electrical department takes the start up of Mills on Generator’s supply. They just start

the boilers motors on Generator and when the boiler gets start, it supply the steam to

the steam turbo generators, which runs and provides the electricity to all Mills, then the

power supply of boilers taken on Steam Turbines and the Diesel Generators kept

powered off.

The instrument section is responsible for the repair and maintenance of all instruments

available in the Mills.


Information Technology Department

Mr. Omair Ahmad, Manager (I.T.) is head of the department and doing maximum efforts

to introduce advanced technology in the best interest of the Mills. To avoid any

inconvenience during the crushing season, he introduced Wireless networking of work

stations and fiber-optic cable networking as alternative to that. The job is under process

and will be completed within couple of days.

The I.T. Department is also looking-after the database and keeps its record daily on

DVD, which sent to the head office for record on daily basis. In addition to this, the

repair and maintenance of I.T. equipment is also its responsibility.

He and Mr. Umer Sharif, Deputy Manager (I.T.) very enthusiastically changing the

previous (non-developed) pattern. Before their joining, there was simple networking,

which becomes out of order off & on and the management faces trouble as a result

thereof.

During the season, single second is very precious and cannot be wasted. Therefore,

they convinced the management to lay down the fiber-optic cable and WAN to get rid of

this problem. The management understand the issue and approved the case as it was

proposed.


Laboratory

Mr. Muhammad Amjad Khan, Manager (Lab.) is head of the Laboratory department. In

the laboratory, different type of laboratory tests related to water, sugarcane, juice,

bagasse, molasses, etc. are conducted. He is directly responsible to the General

Manager, but as per nature of his duty, he should have to report the Directors and CEO

at any time regarding production, recovery of sugarcane etc. These lab. Tests helps the

management in decision making.


Mechanical Department

Engr. Muhammad Nawaz Sandhu, DGM (Technical) is head of the Mechanical

Department. In view of the employees, this department is one of the biggest department

of the Etihad Sugar Mills Limited.

The Mechanical Department has following sections in it:-

i. Mill House

ii. Boiling House

iii. Boiler House

iv. Workshop

v. Steam Turbine

vi. Welding Section

vii. Fabrication Section

Mill House

This section contains 05 Mills alongwith steam turbines. In the Mill House, juice from the

bagasse extracted and bagasse sent to the boilers and juice sent to the boiling house

for further process. In this section, heavy machinery is installed. The following

machinery is installed at Mill House.

Boiling House

In the boiling house section, chemicals, heat and other processes are applied at juice

for transformation into sugar. Most of the machinery is installed in this section and this

section is biggest mechanically as compared to the other mechanical sections. The

following machinery is installed in Boiling House:-

Boiler House

This section of mechanical department has 03 boiler of 80 Ton / hr capacity. Each boiler

generates 80 Ton steam in single hour, which become 240 Tons per hour from all three

boilers. In the boilers, water is boiled and steam generated as a result thereof.

Workshop

In the workshop, the Mills have its machinery for repair / maintenance of plant. There

are many Molder machines, Laithe Machine, Binding Machine etc. All the mechanical

jobs are completed here.

Steam Turbine Section

The section is responsible for repair & maintenance of all the steam turbines installed in

the Mills at Power House, Mills House and Boiling House.

Welding Section


All the welding jobs are carried out by this section. This section has various mobile

welding plants for completion of jobs at the plant.

Fabrication Section

In the sugar mill, there are various mechanical tricks, to implement these tricks,

fabrication section offers its services.


ETIHAD SUGAR MILL, RAHIM YAR KHAN

Consolidated Income Statement

For the years ended 30-09-(8-)

2010 2009 2008

Net S ales 9,901,225,775 10,801,461,407 5,344,240,796

(7,515,692,484 (8,818,583,211Cost of Sales ) ) (4,527,891,865)

Gross Profit 2,385,533,291 1,982,878,196 816,348,931

Administrative Expenses (219,495,198) (215,740,080) (140,329,553)

Distribution & Marketing Expenses (20,014,879) (135,778,796) (7,624,033)

Other operating expenses (115,552,852) (91,141,209) (4,272,079)

Other operating income 24,438,859 70,322,340 102,200,217

Workers' profit particiation fund - - (7,152,207)

Workers' welfare fund - - (2,713,414)

(330,624,070) (372,337,745) (59,891,069)

Operating Profit 2,054,909,221 1,610,540,451 756,457,862

(1,127,467,695Finance cost ) (816,217,951) (697,959,899)

Share of loss of associated company (405,913) - -

Profit before taxation 927,035,613 794,322,500 58,497,963

Taxation (339,381,836) (309,869,960) (35,310,805)

Net Profit 587,653,777 484,452,540 23,187,158


ETIHAD SUGAR MILL, RAHIM YAR KHAN

Consolidated Balance Sheet

As on 30-09-2010

2010 2009 2008SHARE CAPITAL &RESERVESShare Capital 442,840,570 381,254,260 315,361,900Reserves 1,548,014,772 1,129,798,008 718,536,715Minority interest (6,345,583)Total Share Capital &Reserves 1,990,855,342 1,511,052,268 1,027,553,032NON-CURRENT LIABILITIESSubordinated loan fromDirector 260,900,000 260,900,000 260,900,000Long term loans 3,375,777,778 3,600,000,000 3,017,702,890Liabilities against assetssubject to finance lease 329,960,452 353,881,872 328,038,520Deferred liabilities 878,242,713 585,574,775 387,284,676Deferred Income 3,945,104 7,890,204 12,132,409Total Non-current Liabilities 4,848,826,047 4,808,246,851 4,006,058,495CURRENT LIABILITIESShort term borrowings 3,765,402,741 1,970,380,636 2,316,752,803Current portion of non-currentliabilities 693,564,179 154,934,612 447,164,952Trade and other payables 803,490,123 1,726,633,296 551,987,795Interest and mark-up accrued 180,218,438 101,105,342 172,013,779Provision for taxation 49,990,394 54,087,075 39,000,000Total Current Liabilities 5,492,665,875 4,007,140,961 3,526,919,329Total Liabilities 12,332,347,264 10,326,440,080 8,560,530,856NON-CURRENT ASSETSProperty, plant andequipmentOperating fixed assets 6,829,407,871 6,049,189,068 4,507,512,438Capital work in progress 25,573,823 256,839,123 1,244,965,955Store & spares held for capitalexpenditure - 12,296,025 131,086,097

6,854,981,694 6,318,324,216 5,883,564,490Investment property 350,753,636 212,290,716 566,283,676Investments 394,847,861 375,000 375,000Goodwill 608,310,693 581,931,578Long term depsoits 48,877,275 37,731,155 34,673,790Total Non-current Assets 8,257,771,159 7,150,652,665 6,484,896,956CURRENT ASSETSStores, spares and loose tools 424,291,134 371,253,099 224,711,294Stock in trade - finished goods 1,436,296,905 876,391,873 914,974,191Trade debts 36,588,056 222,970,512 186,199,993Advances, deposits,prepayments and otherreceiveables 2,169,390,789 1,681,912,007 654,057,273Tax refunds from government 1,431,700 1,431,700Cash and bank balances 6,577,521 21,828,224 95,691,149Total Current Assets 4,074,576,105 3,175,787,415 2,075,633,900Total Assets 12,332,347,264 10,326,440,080 8,560,530,856

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