CHAPTER I

Introduction

The demand and economical profit of sugar shows the necessity of a

sugar mill in the industry. With the availability of the raw materials and the

suitable climate favors the researchers to conduct a proposed plan of a sugar mill

using engineering and scientific process.

The proposed plan is manufacturing plant that is designed to produce an

economical value of sugar without suffering the quality of the product. The study

aims to show the feasibility of operating an industrial plant with an engineering

processes and managerial skills learned from the academe.

The industrial plant is proposed to operate in Barangay Malinis, Lemery,

Batangas after fitting for a marketing location of the said plant. The project also

aims to develop the skills of the student for the preparation in their future

profession.

The project’s scope is only limited on the study of its operation and

economic feasibility. The study also serves information and be a reference

material for related studies.

1.2 Subject of the Report

This project study is divided into three chapters namely Introduction,

Design Proper and Economic Analysis.

Introduction is comprised of the inception of basic ideas to come up with

the selected design of industrial plant. Another component is the review of

related literature which includes the existing plants’ profile that serves as

reference in the design and location of the sugar manufacturing plant.

 On the other hand, Design Proper is composed of seven parts-- scope of

the design of the selected plant, design basis, the sequence of plant production

process, diagram of the process, specification of the equipment, plant layout and

capacity.

The project study will be based on the factors that determine the design of

the proposed industrial plant. The processes involved in the sugar manufacturing

are discussed for the better understanding of the study. The processes will be

based on the capacity of the raw material that can be converted into its product

form, the sugar. Since the essence of designing is the determination of the

dimensions, calculations for the specification of the machineries and equipment

will be presented for the reference of selection on the catalogue. The equipment

that will be included in the study include carrier, shredder, milling train, boiler,

mixed juice tank, heaters, clarifier, evaporators, vacuum pans, centrifuges, rotary

driers, crystallization machine, silos and packaging equipment.

The project study will undergo into engineering approach of solving and

calculations.

Lastly, Economic Analysis includes the cost overview of the design

project, observation, conclusion and recommendation.

This part discusses the series of stages in designing the sugar

manufacturing plant:

A. Inception Stage

During this stage, basic concepts and knowledge helped the designers

come up with the chosen design of the industrial plant. Review of related

literature discussed the essential and reliable information and background that

served as reference in designing, planning and selecting the location of the

industrial plant.

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 The proponents decided to design a sugar manufacturing plant based on

their knowledge and expertise. Moreover, several parameters were also

considered which includes the plant location, plant layout, materials of

construction, structural design, utilities, buildings, storage or warehouse, material

handling, safety, waste disposal and local laws of code.

A. Research Stage

In this stage, the group reviewed related articles and researches to gather

essential information regarding sugar production, its manufacturing processes

and the equipment involved. Moreover, the proponents also interviewed experts

in the field who have knowledge in designing industrial plant. These information

were used as basis of carrying out the additional phases of the design of the

project.

B. Design Stage

At this stage, the proponents employed sharing of ideas to ensure the

reliability of the design for the operation of the sugar manufacturing plant. The

complete process and flow diagram together with the plant layout were prepared

in detail. Moreover, specification of materials and equipment to be used in the

process was determined during the equipment selection.

C. Economic Analysis Stage

During the economic analysis stage, capital cost estimate for the proposed

plant was made. Capital cost includes of land cost, construction `and building

cost, cost of equipment and miscellaneous expenses. Moreover, operation and

maintenance cost of the sugar manufacturing plant during its useful life is also

taken into consideration.

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1.3 Review of Related Literature

The history of sugar production is intricately linked to the evolution of two

rather unsavory reflections of man’s inhumanity to man, those being colonialism

and slavery. Early European settlers in the Caribbean soon began planting sugar

cane and building sugar mills to process the output. Sugar cane is a delicate

plant, and there was always a need for plenty of fertilizer, irrigation, and a

workforce that would work long hard hours of backbreaking labor without

complaint – or without choice, as in the case of slaves. The colonialists brought

almost 12 million West Africans to the Caribbean in chains in the holds of slave

ships during the four and half centuries between 1450 and 1900

The early sugar business was defined by the notorious “triangular trade”.

Sugar from the Caribbean was taken to England for refining and rum production.

Cloth, firearms, and rum were in turn shipped down to West Africa as capital for

the slave trade. The slave ships then look their degraded human cargo to places

like Haiti and Barbados to exchange them for yet more sugar.

The production process for sugar was exacting, and the slaves lived and

worked in unspeakably difficult conditions. They spent weeks on end in the fields,

bent over at the waist, hacking away at the tough stalks, some as tall as 20 feet,

with razor-sharp machetes. After harvesting, the cane was taken to a mill, where

it was ground through rollers to extract the precious juice. This was followed by

laborious cooking in witch-type cauldrons that had to be tended around the clock.

Timing was of the essence, since cane juice spoils quickly. After extraction, the

juice was poured into molds, with the excess drained off to make molasses. The

hardened bricks of raw sugar were shipped off to Antwerp or London refineries

for processing.

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A. Raw Materials

Figure 1. Sugarcane
(Source: Greenopedia, 2018)

Sugar is a broad term applied to a large number of carbohydrates

present in many plants and characterized by a more or less sweet taste. The

primary sugar, glucose, is a product of photosynthesis and occurs in all green

plants. In most plants, the sugars occur as a mixture that cannot readily be

separated into the components. In the sap of some plants, the sugar mixtures

are condensed into syrup. Juices of sugarcane (Saccharumofficinarum) and

sugar beet (Beta vulgaris) are rich in pure sucrose, although beet sugar is

generally much less sweet than cane sugar. These two sugar crops are the

main sources of commercial sucrose.

The sugarcane is a thick, tall, perennial grass that flourishes in

tropical or subtropical regions. Sugar synthesized in the leaves is used as a

source of energy for growth or is sent to the stalks for storage. It is the sweet

sap in the stalks that is the source of sugar as we know it. The reed

accumulates sugar to about 15 percent of its weight. Sugarcane yields about

2,600,000 tons of sugar per year.

The sugar beet is a beetroot variety with the highest sugar content,

for which it is specifically cultivated. While typically white both inside and out,

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some beet varieties have black or yellow skins. About 3,700,000 tons of sugar

are manufactured from sugar beet.

Other sugar crops include sweet sorghum, sugar maple, honey,

and corn sugar. The types of sugar used today are white sugar (fully refined

sugar), composed of clear, colorless or crystal fragments; or brown sugar,

which is less fully refined and contains a greater amount of treacle residue,

from which it obtains its color.

B. The Manufacturing Process

1. Planting and Harvesting

Figure 2. Sugarcane Harvesting

(Source: Viet Nam News, 2018)

Sugarcane requires an average temperature of 75 degrees

Fahrenheit (23.9 degrees) In the United States, harvesting of both cane

and sugar beet is done primarily by machine, although in some states it is

also done by hand. The harvested cane stalks and beets are loaded

mechanically into trucks or railroad cars and taken to mills for processing

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into raw sugar. Once there, they are cleaned, washed, milled to extract

juice, filtered, and purified. The result is a clear, sugar-filled juice.

Celsius) and uniform rainfall of about 80 inches (203 centimeters)

per year. Therefore, it is grown in tropical or subtropical areas.

Sugarcane takes about seven months to mature in a tropical area

and about 12-22 months in a subtropical area. At this time, fields of

sugarcane are tested for sucrose, and the most mature fields are

harvested first. In Florida, Hawaii, and Texas, standing cane is fired to

burn off the dry leaves. In Louisiana, the six- to ten-feet (1.8- to 3-meter)

tall cane stalks are cut down and laid on the ground before burning.

In the United States, harvesting (of both cane and sugar beet) is

done primarily by machine, although in some states it is also done by

hand. The harvested cane stalks are loaded mechanically into trucks or

railroad cars and taken to mills for processing into raw sugar.

2. Preparation and Processing

After the cane arrives at the mill yards, it is mechanically unloaded

and excessive soil and rocks are removed. The cane is cleaned by

flooding the carrier with warm water (in the case of sparse rock and trash

clutter) or by spreading the cane on agitating conveyors that pass through

strong jets of water and combing drums (to remove larger amounts of

rocks, trash, and leaves, etc.). At this point, the cane is clean and ready to

be milled.

After being purified, the clear juice undergoes vacuum evaporation

to remove most of the water. In this process, four vacuum-boiling cells are

arranged in series so that each succeeding cell has a higher vacuum. The

vapors from one body can thus boil the juice in the next one, a method

7
called multiple-effect evaporation. Next, the syrupy solution is vacuum-

crystallized to form sugar crystals. The remaining liquid is removed using

centrifuging and drying, and the sugar is packaged. Water at about 175

degrees Fahrenheit (79.4 degrees Celsius) and sprayed with hot water

counter currently to remove the sucrose.

3. Juice extraction pressing

Figure 3. Sugarcane Juice Extraction and Pressing

(Source:Alamy, 2018)

Two or three heavily grooved crusher rollers break the cane and

extract a large part of the juice, or swing-hammer type shredders (1,200

RPM) shred the cane without extracting the juice. Revolving knives cutting

the stalks into chips are supplementary to the crushers. (In most countries,

the shredder precedes the crusher.) A combination of two, or even all

three, methods may be used. The pressing process involves crushing the

stalks between the heavy and grooved metal rollers to separate the fiber

(bagasse) from the juice that contains the sugar.

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 As the cane is crushed, hot water (or a combination of hot water

and recovered impure juice) is sprayed onto the crushed cane counter

currently as it leaves each mill for diluting. The extracted juice, called

vesou, contains 95 percent or more of the sucrose present. The mass is

then diffused, a process that involves finely cutting or shredding the stalks.

Next, the sugar is separated from the cut stalks by dissolving it in hot

water or hot juice.

4. Purification of Juice—Clarification and Evaporation

Figure 4. Clarification System

(Source: Chemical System Technologies, 2008)

The juice from the mills, a dark green color, is acid and turbid. The

clarification (or defecation) process is designed to remove both soluble

and insoluble impurities (such as sand, soil, and ground rock) that have

not been removed by preliminary screening. The process employs lime

and heat as the clarifying agents. Milk of lime (about one pound per ton of

cane) neutralizes the natural acidity of the juice, forming insoluble lime

salts. Heating the lime juice to boiling coagulates the albumin and some of

the fats, waxes, and gums, and the precipitate formed entraps suspended

solids as well as the minute particles.

The sugar beet solution, on the other hand, is purified by

precipitating calcium carbonate, calcium sulfite, or both in it repeatedly.

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Impurities become entangled in the growing crystals of precipitate and are

removed by continuous filtration.

The muds separate from the clear juice through sedimentation. The

non-sugar impurities are removed by continuous filtration. The final

clarified juice contains about 85 percent water and has the same

composition as the raw extracted juice except for the removed impurities.

To concentrate this clarified juice, about two-thirds of the water is

removed through vacuum evaporation. Generally, four vacuum-boiling

cells or bodies are arranged in series so that each succeeding body has a

higher vacuum (and therefore boils at a lower temperature). The vapors

from one body can thus boil the juice in the next one—the steam

introduced into the first cell does what is called multiple-effect evaporation.

The vapor from the last cell goes to a condenser. The syrup leaves the

last body continuously with about 65 percent solids and 35 percent water.

The sugar beet sucrose solution, at this point, is also nearly

colorless, and it likewise undergoes multiple-effect vacuum evaporation.

The syrup is seeded, cooled, and put in a centrifuge machine. The

finished beet crystals are washed with water and dried.

5. Centrifuging

Figure 5. Sugar Centrifugal Machine

(Source: Elmschrat, 2009)

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 The high-speed centrifugal action used to separate the massecuite

into raw sugar crystals and molasses is done in revolving machines called

centrifugals. A centrifugal machine has a cylindrical basket suspended on

a spindle, with perforated sides lined with wire cloth, inside which are

metal sheets containing 400 to 600 perforations per square inch. The

basket revolves at speeds from 1,000 to 1,800 RPM. The raw sugar is

retained in the centrifuge basket because the perforated lining retains the

sugar crystals. The mother liquor, or molasses, passes through the lining

(due to the centrifugal force exerted). The final molasses (blackstrap

molasses) containing sucrose, reducing sugars, organic nonsugars, ash,

and water, is sent to large storage tanks.

Once the sugar is centrifuged, it is "cut down" and sent to a

granulator for drying. In some countries, sugarcane is processed in small

factories without the use of centrifuges, and a dark-brown product (non-

centrifugal sugar) is produced. Centrifugal sugar is produced in more than

60 countries while non-centrifugal sugar in about twenty countries.

6. Drying and Packaging

Figure 6. Sugar Bagging Machine

(Source: Elocom, 2018)

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 Damp sugar crystals are dried by being tumbled through heated air

in a granulator. The dry sugar crystals are then sorted by size through

vibrating screens and placed into storage bins. Sugar is then sent to be

packed in the familiar packaging we see in grocery stores, in bulk

packaging, or in liquid form for industrial use.

C. By-products

The bagasse produced after extracting the juice from sugar cane is

used as fuel to generate steam in factories. Increasingly large amounts of

bagasse are being made into paper, insulating board, and hardboard, as well

as furfural, a chemical intermediate for the synthesis of furan and

tetrahydrofuran.

The beet tops and extracted slices as well the molasses are used as

feed for cattle. It has been shown that more feed for cattle and other such

animals can be produced per acre-year from beets than from any other crop

widely grown in the United States. The beet strips are also treated chemically

to facilitate the extraction of commercial pectin.

The end product derived from sugar refining is blackstrap molasses. It

is used in cattle feed as well as in the production of industrial alcohol, yeast,

organic chemicals, and rum.

D. Quality Control

Mill sanitation is an important factor in quality control measures.

Bacteriologists have shown that a small amount of sour bagasse can infect

the whole stream of warm juice flowing over it. Modern mills have self-

cleaning troughs with a slope designed in such a way that bagasse does not

hold up but flows out with the juice stream. Strict measures are taken for

insect and pest controls.

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 Because cane spoils relatively quickly, great steps have been taken to

automate the methods of transportation and get the cane to the mills as

quickly as possible. Maintaining the high quality of the end-product means

storing brown and yellow refined sugars (which contain two percent to five

percent moisture) in a cool and relatively moist atmosphere, so that they

continue to retain their moisture and do not become hard.

Most granulated sugars comply with standards established by the

National Food Processors Association and the pharmaceutical industry,

E. Existing Sugar Plant in the Philippines

CRYSTAL SUGAR COMPANY, INC.

Figure 7. Crystal Sugar Company, Inc.

(Source: CSCI-MIS, 2012)
Crystal Sugar Company, Inc. derived its name from the Crystal Spring of

North Poblacion, Maramag, Bukidnon, its main source of water - the lifeline of

every sugar mill.

Crystal Sugar Company, Inc. is a 100% Filipino owned corporation

situated at North Poblacion, Maramag, Bukidnon. The total plant area is 57.059

hectares which houses is manufacturing, administration and other facilities. The

plant has a rated capacity of 12,000 metric tons of cane per day.

The Company was conceived to service the growing requirements of the

sugarcane farms of the Bukidnon District which then covered about 40,000

hectares with approximately 13,000 active sugarcane farmers.

Through negotiations with the Victorias Milling, Company, Inc.

Management and Technical Services represented by its then Vice-President, the

13
late Caesar Ramos, the Hamakua Sugar Mill in Hawaii which was up for sale

was bidded and finally acquired by Crystal Sugar Company, Inc. on September

20, 1994.

Dismantling machineries and equipment were undertaken by the

engineers of Victorias Milling Company, Inc. with the joint supervision of Crystal

Sugar Company, Inc. These were consequently shipped to Cagayan de Oro City,

hauled to Maramag, Bukidnon where they were erected by Victorias Milling Co.

Engineering Services, as the Crystal Sugar Company, Inc.

Crystal Sugar Company, Inc. was inaugurated by the then newly installed

President of the Philippines, His Excellency Joseph Ejercito Estrada. The first

inaugural mass was celebrated on December 8, 1998 attended by Ambassador

Manuel V. Nieto, with Mr. Pablo L. Lobregat, President and Mr. Javier T.

Sagarbarria, Vice-President/Resident Manager.

Crystal Sugar Company, Inc. caters to seven (7) planters Association

namely: SGABI, ABSFI, BPA, SPAB, USPBA, AND COEMPC.

The official start of milling was February 26, 1998.

The Mill Set-Up

The crushing plant is an Australian made "Walker 4-tandem, 5-roller mill

with a capacity of 12,000 tons per day. It has a reduced Sucrose Extraction of

95% and designed to produce very high Pol-low color centrifugal cane sugar.

One of the major features of the factory is the efficient use of energy

(steam). The same steam is utilized three times: the first stage is for the

generation of electricity, the second stage is to drive the mill turbines and the last

for the processing of sugar.

The powerhouse is capable of co-generating electricity with the National

Power Corporation to provide electricity to the Mindanao Grid. Future plans of

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Crystal Sugar Company, Inc. include supplying power to the local Electric

Cooperative during the off milling season.

Engineering Services

Crystal Sugar Company, Inc. has its Engineering Services Department. It

caters to the other sugar mills and the different industries in Mindanao. Presently

it is servicing sugar farmers, by manufacturing farm implements, irrigation

facilities and undertaking fabrication and machining jobs.

Sharing Policy / Quedanning

Crystal Sugar Company, Inc. is adopting the established sharing

arrangement of the Philippine Sugar Industry. Presently, the Mill retains 36% of

the sugar and molasses produced while 64% goes to the farmers.

The farmers are issued Quedans (Warehouse receipts) which states the

name of the planter and sugar produced in 50 kilogram bags. Quedans are

classified as "A" for the U.S. Quota, "B" for the Domestic Market, "C" for the food

processors who export their products, and "D" for revenue.

Environmental Commitment

Crystal Sugar Company, Inc. is one of the very few mills in the country

which has a wet scrubber facility in its Boiler Pollution Abatement System. This is

shown by the white smoke being emitted by the Boilers. It also has a waste water

pollution control system design of which conforms to the standards required by

the Department of Environment and Natural Resources (DENR).

Economic Impact

The existence of Crystal Sugar Company, Inc., has made cane sugar

production more viable and profitable. Sugarcane plantations are ever expanding

in all directions. Farm workers are getting scarce every crop year, their pay hike

15
demands are more than what planters can afford. Lifestyles are getting to be

lavish as shown by bigger and new homes, latest vehicle models, business

establishments and resorts sprung up like mushrooms all over the district.

CAGAYAN ROBINA SUGAR MILLING COMPANY (CARSUMCO)

Figure 8. CAGAYAN ROBINA SUGAR MILLING COMPANY (CARSUMCO)

(Source: Roentgen Separation, 2014)

Cagayan Robina Sugar Milling Company (CARSUMCO), a sugar division

of Universal Robina Corporation (URC), an ISO 9001:2000 certified compay, is a

raw sugar mill and refinery plant with main office at Suite 2201, Robinsons

Equitable Tower, No. 1 ADB Avenue corner Poveda Street, Ortigas Center,

Pasig City. The plant site is situated at Sto. Domingo, Piat, Cagayan about 32

kilometers away from Tuguegarao City, along the Tuguegarao-Piat National

Highway and only   7kms away from the famous and miraculous Basilica Minore

de Nuestra Sra de Piat (Our Lady of Piat).This is more or less 530 kilometers

north of Manila.

The raw sugar mill and the integrated refinery were constructed in 1976.

The plant was originally owned by a group of retired military officers headed by

the late Gen. Eulogio Balao. It was originally named as Cagayan Sugar

16
Corporation (CASUCO). The plant was acquired at the onset of crop year 1990-

1991 by Universal Robina Corporation.

The refinery plant was integrated with the raw sugar mill and was

designed to operate under the Carbonation Process of sugar refining. It has a

melting capacity of 250 MT per day with an equivalent production of 4,300 bags

refined sugar per day at 50kg/bag. Most of the time,  the refinery operates

simultaneously with the raw sugar mill in order to reduce operating expenses by

taking advantage of the common/dual utilization of steam and electric power

generated by the existing raw sugar mill steam and power plant.

The principal finished goods produced are raw and refined sugar. Most of

the raw sugar produced is directly processed as refined sugar and the remaining

raw sugar is stored in the sugar warehouse in bulk or 50 kg/bag. The final

molasses, a by-product in the sugar manufacturing process, is stored in the

molasses tank at the plant site.

The sugar cane milled is owned and delivered to the mill by the sugarcane

planters. Sugar and molasses manufactured from the sugarcane is shared by the

Mill and the Planter in accordance with a pre-established sharing scheme.

The raw sugar mill has a milling capacity of 4,000 tons cane per day using

the conventional type mill tandem.

ROXAS HOLDINGS INC.

Figure 9. Roxas Holdings, Inc.

(Source: Foodevolution, 2018)

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 A Roxas Holdings, Inc. (RHI) is the largest integrated sugar business and

the bioggest ethanol producer in the Philippines.

The group has close to a century of leadership in the Philippines sugar

industry and it also one of the first few movers in the emerging ethanol business

in the country.

The group manages Central Azucarera Don Pedro, Inc. in Nasugbu,

Batangas; and the following plants in Negros Occidental: Central Azucarera de la

Carlota, Inc. and Roxol Bioenergy Corporation, both in La Carlota City, and San

Carlos Bioenergy, Inc.

TYPES OF SUGAR

1. “Regular” or white sugar, extra fine or fine sugar

Figure 10. White Sugar

(Source: ChewTheWorld, 2018)

“Regular” or white sugar, as it is known to consumers, is the sugar

found in every home’s sugar bowl, and most commonly used in home food

preparation. White sugar is the sugar called for in most cookbook recipes.

The food industry stipulates “regular” sugar to be “extra fine” or “fine” because

small crystals are ideal for bulk handling and not susceptible to caking.

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2. Fruit Sugar

Figure 11. Fruit Sugar

(Source: Shutterstock, 2018)
Fruit sugar is slightly finer than “regular” sugar and is used in dry mixes

such as gelatin and pudding desserts, and powdered drinks. Fruit sugar has a

more uniform small crystal size than “regular” sugar. The uniformity of crystal

size prevents separation or settling of larger crystals to the bottom of the box,

an important quality in dry mixes.

Figure 12. Bake’s Special Sugar

(Source: King Arthur Flour Company, Inc., 2018)

The crystal size of Bakers Special is even finer than that of fruit sugar.

As its name suggests, it was developed specially for the baking industry.

Bakers Special is used for sugaring doughnuts and cookies, as well as in

some commercial cake recipes to create a fine crumb texture.

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3. Superfine, Ultrafine, or Bar Sugar

Figure 13. Superfine Sugar

(Source: Joe Pastry, 2012)

This sugar’s crystal size is the finest of all the types of granulated white

sugar. It is ideal for delicately textured cakes and meringues, as well as for

sweetening fruits and iced-drinks since it dissolves easily. In England, a sugar

very similar to superfine sugar is known as caster or castor, named after the

type of shaker in which it is often packaged.

4. Confectioners or powdered sugar

Figure 14. Powdered Sugar

(Source: Whole New Mom, 2018)
This sugar is granulated sugar ground to a smooth powder and then

sifted. It contains about 3% cornstarch to prevent caking. Powdered sugar is

ground into three different degrees of fineness. The confectioners sugar

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available in supermarkets – 10X – is the finest of the three and is used in

icings, confections and whipping cream. The other two types of powdered

sugar are used by industrial bakers.

5. Coarse Sugar

Figure 15. Coarse Sugar

(Source: Oath, Inc., 2018)

As its name implies, the crystal size of coarse sugar is larger than that

of “regular” sugar. Coarse sugar is recovered when molasses-rich, sugar

syrups high in sucrose are allowed to crystallize. The large crystal size of

coarse sugar makes it highly resistant to color change or inversion (natural

breakdown to fructose and glucose) at cooking and baking temperatures.

These characteristics are important in making fondants, confections and

liquors.

6. Sanding Sugar or Granulated Sugar

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 Figure 16. Granulated Sugar
(Source: Oath, Inc., 2018)

Another large crystal sugar, sanding sugar, is used mainly in the

baking and confectionery industries as a sprinkle on top of baked goods. The

large crystals reflect light and give the product a sparkling appearance.

7. Muscavado Sugar

Figure 17. Muscovado Sugar

(Source:Gourmet Sleuth, 2018)
Muscovado sugar, a British specialty brown sugar, is very dark brown

and has a particularly strong molasses flavor. The crystals are slightly coarser

and stickier in texture than “regular” brown sugar.

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 8. Liquid Sugar

Figure 18. Liquid Sugar

(Source: Tate and Lyle Sugars, 2018)

There are several types of liquid sugar. Liquid sugar, sucrose is white

granulated sugar that has been dissolved in water before it is used. Liquid

sugar is ideal for products whose recipes first require sugar to be dissolved.

Amber liquid sugar is darker in color and can be used in foods where brown

color is desired.

Forms and Uses of Sugar

Brown sugars are granulated sugars, either containing residual molasses, or

with the grains deliberately coated with molasses to produce a light- or dark-

colored sugar. They are used in baked goods, confectionery, and toffees.

1. Granulated sugars are used at the table, to sprinkle on foods and to

sweeten hot drinks, and in home baking to add sweetness and texture to

cooked products. They are also used as a preservative to prevent micro-

organisms from growing and perishable food from spoiling, as in candied

fruits, jams, and marmalades.

2. Invert sugars and syrups are blended to manufacturer’s specifications and

are used in breads, cakes, and beverages for adjusting sweetness, aiding

moisture retention and avoiding crystallization of sugars.

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3. Liquid sugars are strong syrups consisting of 67% granulated sugar

dissolved in water. They are used in the food processing of a wide range of

products including beverages, hard candy, ice cream, and jams.

4. Low-calorie sugars and sweeteners are often made of maltodextrin with

added sweeteners. Maltodextrin is an easily digestible

syntheticpolysaccharide consisting of short chains of glucose molecules and

is made by the partial hydrolysis of starch. The added sweeteners are

often aspartame, saccharin, stevia, or sucralose.

5. Milled sugars are ground to a fine powder. They are used as icing sugar,

for dusting foods and in baking and confectionery.

6. Molasses is commonly used to make rum, and sugar byproducts are used

to make ethanol for fuel.

7. Polyols are sugar alcohols and are used in chewing gums where a sweet

flavor is required that lasts for a prolonged time in the mouth.

8. Screened sugars are crystalline products separated according to the size

of the grains. They are used for decorative table sugars, for blending in dry

mixes and in baking and confectionery.

9. Sugar cubes are white or brown granulated sugars lightly steamed and

pressed together in block shape. They are used to sweeten drinks.

10. Syrups and treacles are dissolved invert sugars heated to develop the

characteristic flavors. They are used in a range of baked goods and

confectionery including toffees and licorice.

11. In winemaking, fruit sugars are converted into alcohol by

a fermentation process. If the must formed by pressing the fruit has a low

sugar content, additional sugar may be added to raise the alcohol content of

the wine in a process called chaptalization. In the production of sweet wines,

fermentation may be halted before it has run its full course, leaving behind

some residual sugar that gives the wine its sweet taste.

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Health effects

Some studies involving the health impact of sugars are effectively

inconclusive. The FAO meta studies and WHO studies have shown directly

contrasting impacts of sugar in refined and unrefined forms and since most

studies do not use a population that do not consume any free sugars at all, the

baseline is effectively flawed. Hence, there are articles such as Consumer

Reports on Health that stated in 2008, "Some of the supposed dietary dangers of

sugar have been overblown. Many studies have debunked the idea that it causes

hyperactivity”.

1. Addiction

Sugar addiction is the term for the relationship between sugar and the

various aspects of food addiction including bingeing, withdrawal, craving and

cross-sensitization. Some scientists assert that consumption of sweets or

sugar could have a heroin addiction-like effect.

2. Alzheimer's disease

Claims have been made of a sugar–Alzheimer's disease connection,

but debate continues over whether cognitive decline is attributable to dietary

fructose or to overall energy intake.

3. Blood glucose levels

It used to be believed that sugar raised blood glucose levels more

quickly than did starch because of its simpler chemical structure. However, it

turned out that white bread or French fries have the same effect on blood

sugar as pure glucose,[citation needed] while fructose, although a simple

carbohydrate, has a minimal effect on blood sugar. As a result, as far as

blood sugar is concerned, carbohydrates are classified according to their

glycemic index, a system for measuring how quickly a food that is eaten

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raises blood sugar levels, and glycemic load, which takes into account both

the glycemic index and the amount of carbohydrate in the food. This has led

to carbohydrate counting, a method used by diabetics for planning their

meals.

4. Cardiovascular disease

Studies in animals have suggested that chronic consumption of refined

sugars can contribute to metabolic and cardiovascular dysfunction. Some

experts have suggested that refined fructose is more damaging than refined

glucose in terms of cardiovascular risk. Cardiac performance has been shown

to be impaired by switching from a carbohydrate diet including fiberto a high-

carbohydrate diet. Switching from saturated fatty acids to carbohydrates with

high glycemic index values shows a statistically-significant increase in the risk

of myocardial infarction. Other studies have shown that the risk of developing

coronary heart disease is decreased by adopting a diet high in

polyunsaturated fatty acids but low in sugar, whereas a low-fat, high-

carbohydrate diet brings no reduction. This suggests that consuming a diet

with a high glycemic load typical of the "junk food" diet is strongly associated

with an increased risk of developing coronary heart disease.

The consumption of added sugars has been positively associated with

multiple measures known to increase cardiovascular disease risk amongst

adolescents as well as adults. Studies are suggesting that the impact of

refined carbohydrates or high glycemic load carbohydrates are more

significant than the impact of saturated fatty acids on cardiovascular disease.

A high dietary intake of sugar can substantially increase the risk of heart and

vascular diseases. According to a Swedish study of 4301 people undertaken

by Lund University and Malmö University College, sugar was associated with

higher levels of bad blood lipids, causing a high level of small and medium

low-density lipoprotein and reduced high-density lipoprotein. In contrast, the

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amount of fat eaten did not affect the level of blood fats. Incidentally quantities

of alcohol and protein were linked to an increase in the good HDL blood fat.

5. Hyperactivity

There is a common notion that sugar leads to hyperactivity, in

particular in children, but studies and meta-studies tend to disprove this.

Some articles and studies do refer to the increasing evidence supporting the

links between refined sugar and hyperactivity. The WHO FAO meta-study

suggests that such inconclusive results are to be expected when some

studies do not effectively segregate or control for free sugars as opposed to

sugars still in their natural form while others do. One study followed thirty-five

5-to-7-year-old boys who were reported by their mothers to be behaviourally

"sugar-sensitive." They were randomly assigned to experimental and control

groups. In the experimental group, mothers were told that their children were

fed sugar, and, in the control group, mothers were told that their children

received a placebo. In fact, all children received the placebo, but mothers in

the sugar expectancy condition rated their children as significantly more

hyperactive. This result suggests that the real effect of sugar is that it

increases worrying among parents with preconceived notions.

6. Obesity and diabetes

Controlled trials have now shown unequivocally that consumption of

sugar-sweetened beverages increases body weight and body fat, and that

replacement of sugar by artificial sweeteners reduces weight. Studies on the

link between sugars and diabetes are inconclusive, with some suggesting that

eating excessive amounts of sugar does not increase the risk of diabetes,

although the extra calories from consuming large amounts of sugar can lead

to obesity, which may itself increase the risk of developing this metabolic

disease. Other studies show correlation between refined sugar consumption

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and the onset of diabetes, and negative correlation with the consumption of

fiber. These included a 2010 meta-analysis of eleven studies involving

310,819 participants and 15,043 cases of type 2 diabetes. This found that

"SSB, sugar-sweetened beverages may increase the risk of metabolic

syndrome and type 2 diabetes not only through obesity but also by increasing

dietary glycemic load, leading to insulin resistance, β-cell dysfunction, and

inflammation". As an overview to consumption related to chronic disease and

obesity, the World Health Organization's independent meta-studies

specifically distinguish free sugars from sugars occurring naturally in food.

The reports prior to 2000 set the limits for free sugars at a maximum of 10%

of carbohydrate intake, measured by energy, rather than mass, and since

2002 have aimed for a level across the entire population of less than 10%.

The consultation committee recognized that this goal is controversial.

However, the Consultation considered that the studies showing no effect of

free sugars on excess weight have limitations.

7. Tooth decay

In regard to contributions to tooth decay, the role of free sugars is also

recommended to be below an absolute maximum of 10% of energy intake,

with a minimum of zero. There is "convincing evidence from human

intervention studies, epidemiological studies, animal studies and experimental

studies, for an association between the amount and frequency of free sugars

intake and dental caries" while other sugars consumption is normally

associated with a lower rate of dental caries. Lower rates of tooth decay have

been seen in individuals with hereditary fructose intolerance.

Also, studies have shown that the consumption of sugar and starch

has different impacts on oral health with the ingestion of starchy foods and

fresh fruit being associated with low levels of dental caries.

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1.4 Location of Selected Plant Site

The industrial plant is proposed to operate in Barangay Malinis, Lemery,

Batangas after fitting for a marketing location of the said plant. The project also

aims to develop the skills of the student for the preparation in their future

profession.

Figure 19. Location Map

(Source: Google Map, 2018)

LOCATION: Batangas Province

ADDRESS: Barangay Malinis, Lemery, Batangas
TREATMENT CLASSIFICATION: Trade and Industrial

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 DESCRIPTION: Vacant lot
Property: Government Owned

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