Internship Report
Internship Report
Internship Report
CHAPTER 1
1.1 INTRODUCTION:
The Sugar Industry is blooming in the recent years. The Research has shown
that India is the leading manufacturer of sugars in the country. The sugar industry is
highly dependent on labour both skilled and unskilled. The production process
involves technology and competition also forces the mills to produce products so as
to with stand the customer changing the demands.
The company HR has given good co-operation to us to explain each & every
activity with required information need for the study. We have studied production
& material management paper but it’s real applicability in practice was seen in the
company.
This training period of 20 days proved to be very useful to develop my skills
and I am sure that I can complete in the job market and attain success.
1.2 OBJECTIVES:
1.3 SCOPE:
The analysis and findings will be useful to improve the welfare measures
offered by the company.
The study will enables the organization to increase the sales of SAKTHI
SUGARS LIMITED.
This study gives benefit in coming future a they put into the real life
situation.
A study on all the departments can help to improve the process and there by
overall improvement in the company’s performance can be made.
1.4 LIMITATIONS:
Sugar industry in India is well developed with a consumer base of more than
billions of people. It is also the second largest producer of sugar in the world.
Sugar industry, India is all set continue its domination at the global level.
Indian sugar industry is highly fragmented with organized and unorganized players.
The unorganized players mainly produce Gur and Khandsari, the less refined forms
of sugar. The government had a controlling grip over the industry, which has
slowly yet steadily given way to liberalization.
The production sugarcane is cyclical in unit. Hence the sugar production is
also cyclical as it depends on the sugarcane production in the country. As the
industry is fragmented one, even leading players do not control more than 4 percent
market in India. However, the situation is changing and players off late are striving
to increase their market share either by acquiring smaller mills or by going for
green field capacity additions.
Indian sugar industry can be broadly classified into to sub sectors, the
organized sector i.e. sugar factories and unorganized sector i.e. manufactures of
traditional sweeteners like gut and khandsari. The latter is considering being rural
industry and enjoys much greater freedom than sugar mills.
Since the sugar industry n the country uses only sugarcane as an input, sugar
companies have been established in large cane growing states like Uttar Pradesh,
Maharashtra, Tamil Nadu, Karnataka, Punjab and Gujarat. Uttar Pradesh leads the
tally by contributing 24 % of the country’s total sugar production and Maharashtra
stands next 20 % contribution.
The farmer’s co-operatives own and operate the largest chunk of the
industry’s total capacity. They are concentrated primarily in Maharashtra and
eastern Uttar Pradesh. The largest number of sugar companies in the private sector
is located on southern India, in the states of Tamil Nadu, Andhra Pradesh and
Karnataka.
Out of 453 sugar mills in the country, 252 are in the co-operative sector, 134
are in the private sector and 67 are in the public sector. Besides 136 units in the
private sector are in various stages of implementation. A few such units are under
implementation in the co-operative sector as well. But no new units have been
proposed in the public sector.
2.2 COMPANY PROFILE:
Sakthi Sugars Limited is one of the largest producers of white crystal sugars
in the country accounting to the capacity of 13,500 tons of cane crush per day.
Sakthi Groups is a leading industrial conglomerate in South India. Motivated by a
keen desire to diversification in new areas of business, the Sakthi Group born and
grew as a power full entity, expanding its interest into various spheres of industry.
Today it has four sugar plants with three of them in Tamilnadu located at
Sakthi Nagar, Sivagangai and Modakurichi and one plant in Orissa at Dhenkanal,
Orissa in the year 1996. These two distillery plants, undisputedly the largest in their
respective states, have aggregate capacity of 46 KLPD industry alcohols.
Sugar
Automobile parts
Bus transport
Education and IT
Foundry
Fruit beverage
Finance
Industrial alcohol
Parcel service
Soft drinks
Soya products
Social services
Sakthi Sugars Limited is the flagship company of the Sakthi Group and is
one of the largest producers of sugar in the country accounting for a capacity of
12,750 tons of cane crush per day in four sugar units. The four units include three in
Tamil Nadu and one in Orissa.
UNITS:
Sugar:
1. Tamil Nadu:
3. Soya:
4. Co-generation Plant:
Ponni Sugars
Mission:
The mission mode project under sugar production technologies aims towards
sharper and focused technological up gradation in selected sugar factories to
accomplish, interlaid the cost effectiveness of sugar production through
improvement in plant efficiency, energy saving, etc. In addition to the above, the
focus is also on improving the capital output ratio through optimization and
identification of user friendly technologies.
Vision:
Production Department
Finance Department
Cane Department
Marketing Department
Accounts Department
Stores Department
Sakthi Sugars Limited is the company of the Sakthi Group and is one of the
largest producers of sugar in the country for a capacity of 12,750 tons of cane crush
per day in four sugar units.
Only sugar factory in India which could produce super fine grade of sugar
corresponding to international standard measures at grade 85 and below by
International Commission for Uniform Method of Sugar Analysis (ICUMSA).
Crushing in the unit is done more than 8 months every year. Optimal
recovery of sugar from sugarcane is more than 10%.
In production department following process takes place in stepwise manner.
Weigh Bridge:
Cane unloaded:
The weighed cane is taken out from the vehicles and fed to the cane carrier
by the cane unloaded equipment for crushing.
Cane preparation:
The unloaded cane in the carrier is leveled by the cutting action of leveler
and finally divided into smaller pieces by the miner unit.
Mills:
The milling unit consists of 5 mills. The prepared cane juice is crushed in the
mills step by step with the addition of water to extract the maximum quantity of
juice for processing.
Boilers:
After extracting the juice the waste fibrous materials of the cane obtained is
known as bagasse. This is used as fuel in the boilers to produce steam this high
pressure steam is used for producing power.
Power house:
The high pressure steam from the boiler is used to produce electric power
through turbo generator unit. The electric power generated is used to run the mills
and other equipment’s in the factory. The low pressure steam coming out of the
turbine is used for the process.
Clarification house:
The extracted juice from the mills having pH around 5.0 is weighed in juice
weighing scale. It is pumped through primary juice heaters and heated upto 65°C.
The heated juice is treated with the lime to a pH of 9.0 and again with SO2 gas to
7.0 pH for the removal of non-sugar material (purification).
This treated juice is further heated to 100°C in the secondary juice heaters
and sent to clarifier in order to remove the formed non-sugar particles (mud) by
setting action.
The settled mud liquid is filtered in the vacuum filter and is separated into
filtered juice and mud.
The obtained clear juice from the clarifier is sent to evaporators for
concentration.
Evaporation:
The concentrated juice called syrup coming out of the evaporator is sent for
further clarification.
The syrup is clarified with phosphoric acid and flocculants and the mud
produced is separated through filters. The clear syrup is again sulphited to pH of 5.0
with S02 gas and taken to pan section for sugar crystallization.
A-Boiling is done with syrup and melt, B-Boiling with A-Molasses and C-
Boiling with B-Molasses. The molasses is sent as raw material for alcohol
production in distillery.
Centrifugal:
The boiled massecuite(sugar crystal+ liquid) from the pan is stored in the
crystallizers and sent to centrifugal.
The sugar and molasses in the massecuite are separated by the centrifugal
action in the centrifugal machines. The separated A-sugar is dried/cooled and sent
to sugar grader unit for sieving into separate sizes and sent for bagging. B & C-
sugar is again melted and reprocessed in the A- Boiling.
Sugar bagging:
The sugar is graded as L-30, M-30 and S-30 as per the Indian Sugar
Standards and sent to sugar bins for storing and bagging. The sugar is weighed to
100kgs per bag and 50 kgs per bag in the automatic weighing machine, stitched and
sent to go down.
Sugar godown:
The sugar bags are stored in the godown as stacks for marketing. 90% of the
total production is released as free sale and 10% of the total production as levy
scale under release order from the sugar directorate, Government of India.
The main product from the cane is white consumption sugar and by-products
are Bagasse powder, Filter cake and Molasses.
Manufacturing section
Engineering section.
This section consists of workshop. It maintains all the work connected with
plant and machinery.
Workshop:
In this workshop machinery work is done. The spares and materials are
fabricated using the lather machines in the workshop, shaping like square cutting
etc is also done in the workshop.
Laboratory
Manufacturing process
Go down
LABORATORY:
The factory has a separate well equipped laboratory. The lab prepares hourly
reports.
GODOWN:
The sugar bags are stored in the godown as stacks for marketing. 90% of the
total production is released as free sale and 10% of the total production as levy
scale under release order from the sugar directorate, Government of India.
LABOUR OFFICE DEPARTMENT:
Recruitment.
Preparation of salary
Promotions, transfers.
In Sakthi sugars, the personal manager takes all the above responsibilities.
Personal manager controls the time office department, hostel maintenance, security
and canteen.
Equal-Opportunities Employer:
Industrial Relations:
Sakthi Sugars provides its employees clean, safe and healthy environment
inside & outside the operational areas of its businesses. To ensure this the company
has delineated strict norms on industrial safety. The operational space of our entire
infrastructure have been intuitively designed and maintained for smooth and safe
conduct of business affairs.
Corporate Citizenship:
The Sakthi Sugars Limited acts in compliance with all relevant laws and
regulations of the state. In addition to that it has pro actively assumed the role of a
socially responsible business by extending its assistance to people in its
surrounding regions. The social welfare and development initiatives of the
company are aimed at supporting those in dire need and in turn provide them the
required assistance to enhance their quality of life, both economically and socially.
In the same way the company has been contributing extensively in the fields of
community health, family welfare, water management, vocational training,
education and literacy, development of rural roads and in the application of modern
scientific and managerial techniques for nurturing agriculture and uplifting the
farming community.
Insurance:
The company is paying Rs 300 for each employees working in the company
for any accidents met by the employees during working hours with medical leave.
Provident fund:
The fund is credited by an amount detected from their monthly salary at a
certain rate. The company is contributing 12% of the employee’s wages as
provident fund.
Pension:
This amount is received by the employee on his retirement. Here 12% of his
monthly salary is given as pension monthly. Here in this 12% (8.33% given under
family pension fund and 3.673% given under employee pension scheme).
Bonus:
TIME OFFICE:
FUNCTIONS:
Observation of employees.
CASUAL LEAVE:
10 days casual leave shall be granted with full wages or pay including DA to
the every workman.
PRIVILEGED LEAVE:
15 Days privileged leave shall be granted with full wages or pay including
DA to the every workman for every completed year.
SECURITY OFFICE:
Security office is also one of the important sections of the HR department.
There are totally 39 guards.
FACILITY TO WORKERS:
Availability of quarters.
NATIONAL HOLIDAY:
The industry gives the leave for the national holidays; fair days of national
holidays should be given to the employees, such as Independence day, Republic
Day, and Gandhi Jayanti etc.
This section will take care of all sale transactions like sale of sugar,
molasses, Bagasse and scrap material. The factory sells the sugar according to
central government notification. The central government sends the notice to the
factory every month regarding sale of sugar, without notice the sugar is not sold to
anybody. The government is giving permission for a particular period, particular for
sale of sugar. The sugar is sold to the buyer who quotes highest price. In this
section, some records like sale of sugar register, molasses register, Bagasse
registers and scrap material registers are maintained.
FUNCTIONS:
FREE SALE:
Free sale of sugar is being done to bulk purchases on the basis of tenders
called, collected, negotiated and sold.
LEVY SALE:
This is being sold to the government of Tamilnadu on levy basis. The
government then distributes the same to the public through public distribution
outlets at predetermined reasonable price.
EXPORTS:
Refined sugars and less than 45 CUMSA sugar are exported. Efforts are
taken to increase the exports in for coming years.
CANE DEPARTMENT:
The function of cane department is to supply raw materials to the sugar factory.
They provide the agricultural faculties to the4 farmers they provide the guidance
and helps the farmers regarding farming or cultivation and provides loans,
fertilizers and water facilities and also provides the inter crop seeds for planting.
Every village is engaged with the particular cane office and that office provides
those help as they require only sugarcane
1. Thirupuvanam
2. Puthuvayal
3. Paramakudi
4. Devakottai
5. Sivagangai
6. Mathakupatti
7. Kamuthi
8. V.Pudur.
Each division office has one officer, one clerk and 6-7 cane assistants. The
duty of Cane assistants to visit the farmers in their nearby villages and make a
contract with them after that the assistants measures the acres owned by the farmers
and provide the canes seeds to them based in the acre level they provide 4-4.5 tons
of cane seeds per acre they guide the farmers and offer the time period up to 12
months at the end of 12th month cane department allot workers to harvest and
transported to the factory.
SUGAR SEASON:
One sugar is 12 months from October to September. The actual crushing will
depend upon the availability of sugar cane. This will normally be about 6 months in
a year.
CANE PRICE:
The cane price is fixed for a sugar mills based on the peak period recovery of
the mill. The peak period recovery refers to the average recovery obtained from 1st
December to 31st March of the proceeding season.
Yard Department
Division Department
Research And Development
Yard department:
Main work here is weighing the loads of sugar from different villages and
sent for processing.
Division department:
It researches about the land and take the required measures and maintenance
for the development.
STORE DEPARTMENT:
It is the department which stores the industrial material and maintains it.
Purchase department receives the purchase order from the user department or from
the stores department. Then purchase department enquires the party and purchase
from the regular party or some other party and packs the material and sends to the
purchase department and they send to the storage. If there is any damage then they
will return to them within a week.
This department has technical persons to test the purchased material. It could
be done by both manual and with the help of testing told. Store department has the
storing capacity of 3000 materials. This department issues 50-60 materials per day
to other department such as processing and engineering etc. The materials stored in
this department are,
Chemicals
Spares
Coal
Bolt-nuts
Bearings
V-belts
Electrical parts
Steam joints
Lubricants
Liquid oxygen
Functions:
Waste management.
ACCOUNTS DEPARTMENT:
a. Decision Making.
Accounting system:
Journal Voucher:
Vouchers are after every transaction. Accounts Manager and Director verify
the voucher respectively. If they have any question they can ask relevant person if
they are no enquiry then they will put their signatures on voucher. Now it is time to
record these vouchers in books of accounts.
Payment voucher:
This voucher is prepared at this time of making payments to any party. Party
name is debited with the amount has been made. Payment vouchers are used for the
payment up to Rs.6000.Payments more than this are made through bank.
Credit voucher:
Stores section
Attendance Allowance:
Leave encashment is given to those employees who save their holidays and
don’t avail them. This is given to their per day salary multiply with number of days
of holidays not availed.
Cash book
Bank book
Stores purchase journal
Raw material purchase journal
Sales journal
General journal
Balance sheet ledger
Profit and loss account
Purchase return book
Sales return book
Bills payable book.
CHAPTER-4
4.1 FINDINGS:
ISSUES IDENTIFIED:
4.2 CONCLUSION:
4.3 REFERENCE:
http://economictimes.indiatimes.com/sakthi-sugars-ltd/stocks/companyid-
13135.cms accessed on 8th May 2014
http://www.moneycontrol.com/india/stockpricequote/sugar/sakthisugars/SS
accessed on 13th May 2014