WEIGHING SUGAR CANE
Sugar cane from the garden are sent to the plant using several models of transport: trailer (cane explained), truck and lorry loss tub (cane belt), passing the weighbridge with a computerized system for data retrieval gross weight, number of plots, the location, the type of cut, the name of the executor slash and cut hours (freshness). Furthermore, the truck and trailer that had been dismantled, leaving the plant past the weighbridge out for the empty vehicle weight data collection. Space control center preparation and extraction unit
OPERATIONAL CONTROL EQUIPMENT FACTORY Control of plant equipment at each station through the space control center which is placed in the position of most flexibility for the operator to monitor the activities and equipment related to the duty officer in the field. At certain parts that are not possible for the operator to see instantly visually, equipped with CCTV cameras from the central control room. Control systems using programmable logic control (PLC) integrated with the supervisory system as a tool of control and trending data information.
HANDLING OF SUGAR CANE Various equipment loading (unloading) mounted cane adapts to existing transport models, cane transported using the trailer unloaded using a side unloader mounted on a gantry crane 2 units, then grab the cane Hydraulic gantry crane work piling up and feed on cane cross carrier. Wheel loaders used in addition to unload and stack cane loss tub in the courtyard also used as a means of leveling the playing feeder and cane carrier. To increase the capacity of the bait directly on the main cane carrier, the 2001 installed one unit of cane feeder table is equipped with a hydraulic lifter that can serve a cane cane transported by trailer and truck hydraulic tippler to serve truck or lorry loss tubs.
PREPARATION Sugar CANE Before the sugar cane mill milked on the unit, first made preparations to open the cells of sugar cane, sugar cane was fed into the 1st. play cane carrier of cross-carrier # 1, # 2 and cross carrier table Feeder mower units transported to the first (1st, cane cutter), then the 2nd. elevating cane carrier toward the second cane cutter unit (2nd, cane cutter), and then use a heavy-duty shredder hammer unit sugarcane crushed. Open-cell level achieved in the preparation unit is 90.92%.
EXTRACTION NIRA Six units of 4-roller mill types arranged in series is used as a juice extraction unit, each unit mill driven by power steam turbines. Sucrose extraction rates from this mill unit in the range of 95-96%. Nira crude from the mill is pumped into the purification station after first passing through a magnetic flow meter to monitor and record the rate of flow in units of m3 / hour, then bagasse is called bagasse to the station steam generator to be used as fuel in the boilers (boilers).
BOILER AND GENERATING ELECTRICITY 3 boiler unit with an installed capacity of each: 1 = 120 tons / hour; 2 = 80 tons / hour; and 3 = 120 ton / hour with a working pressure of each 20kg / cm2G. Potential energy generated steam used to drive 3 pieces back pressure turbo-alternator that each is able to generate power at 5MW, is also used to drive a steam turbine propulsion unit preparation (cane cutter and shredder) and extraction unit (mill). At the time of not milled (off-season) 1 unit boiler remains in operation and utilizing fuel (bagasse) the excess of the past milled to serve the needs of the steam drive turbine generators to meet the electricity needs of the housing division I s / d division VI, offices, maintenance equipment in factories and agricultural irrigation pumps.
PURIFICATION Dirt separation is done in a single tray settling vessel SRI clarifier (which has been modified into a perforated clarifier) which is a series of stages of regulation of temperature, pH, time and the addition of auxiliary materials (milk of lime, sulfur gas and flocculants). The level of turbidity (turbidity) sap reached at 70-100 degrees NTU. Sewage sludge from the clarifier is mixed with bagacillo then filtered using a vacuum filter 6 pieces of solid waste in the form of filter cake (filter cake) are then sent back to the garden as an organic fertilizer.
EVAPORATION (evaporation) Coagulation process carried out by the vessel clear sap evaporator (evaporator). In order to minimize the need for steam, evaporator station was designed with the concept of maximum vapor bleed. Vessel (evaporator) is prepared with quintuple effect system consisting of nine pieces of vessel types Roberts. Steam from the first body is used as the heating medium the second body, crystallization pan "A" and the heating vessel tersulfitir sap. Steam from the two bodies are used for the heating medium in the pan crystallization "C". Evaporator cleaned periodically every two weeks by means of a chemical for 12 hours. Brix viscous sap dijada at the level of 52-55%. Crystallization Sugar crystals made in Vacuum Pans through the enlargement process of the crystal until it reaches the desired size by inserting a thick juice (syrup), fused sugar, molasses into the pans in frigid conditions and a controlled vacuum. The resultant outcome of crystallization is in the form of massecuite (a mixture of sugar crystals with molasses). Cooking levels (crystallization) is carried out with the ABC system. Crystallization for "A" and "B" Massecuite done using batch pan equipped with a stirrer, while the "C" massecuite done with continuous pan. Nira viscous, molten sugar "B" and "C" as a cooking ingredient "A" massecuite. Food ingredients "B" massecuite coming from the "A" molasses and condensed juice. Food ingredients "C" massecuite coming from "B" molasses and seedlings using the "A" molasses.
SEPARATION OF CRYSTAL SUGAR AND MOLASSES When one cycle of crystal enlargement cooking process has been completed, massecuite of vacuum pans crystallization poured into a strike receiver while continuing its growth. Sugar crystals are separated from molasses using a perforated basket which is rotated up to a certain speed so that regardless of crystal sugar molasses due to centrifugal force (centrifugals machine). Separation "A" massecuite using batch centrifugals produce sugar crystals SHS (products) and "A" moolasses. Separation "B" massecuite using continuous centrifugals produce sugar "B" and "B" molasses, separation of "C" massecuite using continuous centrifugals produce sugar "C" and the final molasses.
HANDLING AND PACKAGING PRODUCTS After the separation process of crystal sugar products (SHS) is conditioned through a fluidized bed vibrating unit cooler with a view to lowering humidity levels and improve the quality of storage, then do the sorting of grain size using a vibrating screen. Sugar crystals sugar then accommodated in the bin for further weighing and packaging. Sensor signal sender weights on the scales used type of load cell. To ensure the accuracy of the weight of the crystals in the packaging, the working mechanism of scales and packaging machinery works integrally controlled automatically. Any information recorded and automatically deviation warning system. Quality assurance certification
STANDARDIZATION QUALITY AND SAFETY PRODUCTS To ensure the quality, safety and halal products both sugar and final molasses, applied consistently Quality & Management System which refers to standarc HACCP (SNI 01-4582-1998) and GMP STANDARD B2, has been certified by PDV the Netherland (Certifiate No. . GMP'B2 0016), HACCP and HALAL certificate from MUI.
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