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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.
23Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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.
24Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
25Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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
26Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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
27Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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
28Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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.
29Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
30Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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.
31Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
32Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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.
33Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
34Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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.
35Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
36Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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
37Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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.
38Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
39Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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
40Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan
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