Claims:1. A system for obtaining at least 98 % sugarcane juice extraction from a milling tandem, the system comprising:
a plurality of milling units comprising a first milling unit enabled for primary extraction of sugarcane to obtain primary juice and a series of milling units from a second milling unit enabled for extracting a secondary juice wherein an imbibitions water is applied to a bagasse which is sent before the last mill unit characterised in that the mill extract obtained from the last milling unit is transferred to the bagasse of the preceding mill and such cycle of mill extract transferring is continued to second milling unit to extract the secondary juice;
a screening equipment enabled for screening the secondary juice obtained from the second mill;
a heating equipment for heating the screened secondary juice by second body vapours and spreading the heated secondary juice is spread on the bagasse which is sent before the first mill to weaken the juice cells and make the bagasse permeable for effective lixiviation and osmosis phenomenon,
a diffuser carrier introduced between a fibrizer and the first milling unit wherein the diffuser carrier is obtained by modifying an existing rake carrier characterised in that the heated secondary juice spread on the bagasse carried by the diffuser carrier is further diffused from the lower perforated plate and is further collected for mixing;
wherein the extract obtained from the first mill with the secondary juice to form a mixed juice and further sent for processing to produce by-products.

2. The system of claim 1, wherein the preparatory index for the cane preparation is maintained 86% to 90%.

3. The system of claim 1, wherein all mills are adopted with moisture reduction system by trash plate modification.

4. The system of claim 1, wherein deep maceration grooves are adopted by feed roller, lotus type top roller and lotus type discharge rollers.

5. The system of claim 1, wherein the screening equipment is a baby DSM screen.

6. The system of claim 1, wherein the heating equipment is a direct contact heater and is enabled to heat up the secondary juice to temperature with a range of 750 to 850 C.

7. The system of claim 1, wherein the temperature of imbibitions water used for the last mill is in the range of 800 C to 900 C.

8. A method of obtaining at least 98 % sugarcane juice extraction from a milling tandem, the method comprising:
obtaining a primary extraction juice from the first milling unit;
application of an imbibitions water to a bagasse which is sent before the last mill unit characterised in that the mill extract obtained from the last milling unit is transferred to the bagasse of the preceding mill and such cycle of mill extract transferring is continued to second milling unit to extract the secondary juice;
screening the secondary juice obtained from the second mill by a screening equipment;
heating the screened secondary juice by a heating equipment by using second body vapours and spreading the heated secondary juice on a bagasse which is sent before the first mill;
spreading the heated secondary juice on the bagasse present on a diffuser carrier which is placed between a fibrizer and the first milling unit wherein the diffuser carrier is obtained by modifying an existing rake carrier characterised in that the heated secondary juice spread on the bagasse carried by the diffuser carrier is further diffused from the lower perforated plate and is further collected for mixing;
mixing the extract obtained from the first mill with the secondary juice to form a mixed juice and further sent for processing to produce by-products.
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
A SYSTEM AND METHOD OF OBTAINING SUGARCANE JUICE EXTRACT FROM A MILLING UNIT

APPLICANT:
Shree Kurmdas Industries,
an Indian entity having address as
Plot No. 90/4, P.C.N.D.T.A., Times of India Road,
Bhosari, Pune, Maharashtra, India

The following specification describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application does not claim priority from any other patent application.

TECHNICAL FIELD

The present invention relates to a field of sugarcane extraction from milling tandems and more particularly relates to sugarcane extractions by the use of a diffuser carrier and imbibitions techniques to obtain 98 % sugarcane extraction.

BACKGROUND

The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
Sugarcane industries forms a major sector in the field of food processing and technology and which are further employed for productions of products obtained from sugarcane comprising sugar, jaggary, bagasse and the like. All above products are produced from the sugarcane juice obtained from the extracting unit. The amount of the products is directly proportional to the quantity of sugarcane juice extracted from the extraction unit. Therefore, the amount of extracted sugarcane juice plays a pivotal role for the production of the byproduct.
Currently, the sugarcane industries are able to extract sugarcane juice up to 97% from the sugarcanes. Therefore, the sugarcane industries are facing the loss of the 3 % sugarcane juice which can be used for producing the by-products. Such loss is therefore undesirable and unwanted for the company.
Such situations create a need to develop systems and methods which involve in extraction of the sugarcane juice to a maximum level to increase the economy of the company.
Therefore, there is a long-standing need for a system and method for obtaining maximum sugarcane juice extract from a milling unit.

SUMMARY

This summary is provided to introduce concepts related to method and system for generating call reports by automatic segregation of calls based on categories and the concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
In an implementation, a system for obtaining at least 98 % sugarcane juice extraction from a milling tandem, the system comprising a plurality of milling units comprising a first milling unit enabled for primary extraction of sugarcane to obtain primary juice and a series of milling units from a second milling unit enabled for extracting a secondary juice wherein an imbibitions water is applied to a bagasse which is sent before the last mill unit characterised in that the mill extract obtained from the last milling unit is transferred to the bagasse of the preceding mill and such cycle of mill extract transferring is continued to second milling unit to extract the secondary juice. The system may further comprise a screening equipment enabled for screening the secondary juice obtained from the second mill. The system may further comprise a heating equipment for heating the screened secondary juice by second body vapours and spreading the heated secondary juice is spread on the bagasse which is sent before the first mill to weaken the juice cells and make the bagasse permeable for effective lixiviation and osmosis phenomenon. The system may further comprise a diffuser carrier introduced between a fibrizer and the first milling unit wherein the diffuser carrier is obtained by modifying an existing rake carrier characterised in that the heated secondary juice spread on the bagasse carried by the diffuser carrier is further diffused from the lower perforated plate and is further collected for mixing. The extract obtained from the first mill with the secondary juice to form a mixed juice and further sent for processing to produce by-products.

In another implementation, a method of obtaining at least 98 % sugarcane juice extraction from a milling tandem, the method comprising obtaining a primary extraction juice from the first milling unit. The method may further comprise application of an imbibitions water to a bagasse which is sent before the last mill unit characterised in that the mill extract obtained from the last milling unit is transferred to the bagasse of the preceding mill and such cycle of mill extract transferring is continued to second milling unit to extract the secondary juice. The method may further comprise screening the secondary juice obtained from the second mill by a screening equipment. The method may further comprise heating the screened secondary juice by a heating equipment by using second body vapours and spreading the heated secondary juice on a bagasse which is sent before the first mill. The method may further comprise spreading the heated secondary juice on the bagasse present on a diffuser carrier which is placed between a fibrizer and the first milling unit wherein the diffuser carrier is obtained by modifying an existing rake carrier characterised in that the heated secondary juice spread on the bagasse carried by the diffuser carrier is further diffused from the lower perforated plate and is further collected for mixing. The method may further comprise mixing the extract obtained from the first mill with the secondary juice to form a mixed juice and further sent for processing to produce by-products.

BRIEF DESCRIPTION OF DRAWINGS
The detailed description is described with reference to the accompanying Figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
Figure 1 illustrates a layout of the current milling tandem with an embodiment of the present subject matter.
Figure 2 illustrates a method for obtaining at least 98 % sugarcane juice extraction from a milling tandem with an embodiment of the present subject matter.

DETAILED DESCRIPTION

The present invention relates to a field of sugarcane extraction from milling tandems and more particularly relates to sugarcane extractions by the use of a diffuser carrier and imbibitions techniques to obtain 98 % sugarcane extraction.
For the purpose of the current invention “a milling unit” may be a mechanical structure enabled to extract sugarcane juice and may also be used as “a mill” in the current disclose.
The sugarcane extraction system described in the present invention is developed to produce an extract more than 98% of the total sugarcane fibre. Such extract may be enabled primarily due to the introduction of a diffuser carrier which is a modification of an existing rake carrier. Further, the extraction may also depend upon the use of imbibitions water to the bagasse of the last mill such that the extract of the last mill is transferred to the bagasse of the preceding mill. Such cycle of transferring the mill extract to the preceding mill is continued up to the second milling unit. The total juice obtained from the second milling unit may be referred as secondary juice which is the total extract obtained from the milling units other than the first milling unit.
Referring Figure 1, a layout of the current milling tandem is illustrated with an embodiment of the present subject matter. The milling tandem may comprise a plurality of milling units, a diffuser carrier, a screening equipment, a heating equipment and other ancillary parts.
The plurality of milling units may comprise a first milling unit and a series of milling units starting from the second milling unit. In an embodiment, the number of milling units may be either one of 4, 5 or 6. The present invention is enabled to produce more than 98 % milling extract at all milling units with their respective arrangements in the milling tandems. For Example, an extraction system with 5 milling units may require a single TRPF or GRPF whereas an extraction system with 4 milling units may require both TRPF and GRPF.
The first milling unit is employed for the primary extraction which may constitute to a maximum milling extract and the series of milling extract from the second milling unit together produce a secondary juice extract.
The bagasse which is to be fed to the last milling unit may be sprayed with imbibitions water with a temperature in the range of 800 to 900 C. The juice obtained from the last mill is later fed to the bagasse of preceding mill and the same process is continued upto the second mill. Referring figure 1, the imbibitions juice from the fourth mill is transferred to the bagasse of the third mill and the imbibitions juice from the third mill is transferred to the bagasse of the second mill. The juice obtained from the second mill may result in the secondary juice.
The secondary juice may be further screened by a screening equipment which may be a baby DSM screen. The screen juice may be then pumped to a direct contact heater and is heated up to a temperature of 750 to 850 C by second body vapours. Such heated secondary juice is then spread at one or more points across the diffuser carrier carrying the crushed sugarcane. Such application of heated secondary juice may weaken the juice cells of the sugarcane and make the sugarcane cells permeable for effective lixiviation and osmosis phenomenon.
The diffuser carrier may be a modified rake which is employed to diffuse the dispensed secondary juice from the bottom plate. The diffuser carrier is such that it is enabled to carry the crushed sugarcane as well as it may dispense the secondary juice from the bottom plated which may be perforated. Such diffused secondary juice is then collected and mixed with the extract obtained from first mill.
In an embodiment, to achieve a milling extract of more than 98%, following parameters may be taken into consideration. The parameters may comprise cane quality, preparatory index, primary extraction, individual mill extraction, moisture percentage in bagasse, speed of mill, mill imbibitions, mill hydraulic and top roller lift, juice drainage from mill roller, mill roller arching and chevron grooves and mill hygiene conditions.
In another embodiment, cane quality parameter may further comprise effect of fibre percentage, effect of polarization (pol) percentage and the freshness of the sugarcane. The Fibre % may have desired effect on mill extraction and subsequently on Reduced Mill Extractions (RME). As fibre % increases, bagasse loss increases and RME (D) increases but sugar loss in bagasse increases from 0.2528 at 12.0% fibre to 0.3265 at 15.5 % which may be observed from the table below.
Pol%cane=14.2 Fib%Cane 15.5 14.5 13.5 12.5 12.0
Bag moist=48.0 M E 97.70 97.96 98.00 98.15 98.22
Bag Pol%=1.06 RME(D) 98.22 98.18 98.16 98.15 98.13
Sugar loss in bagasse 0.3265 0.3054 0.2844 0.2633 0.2528

Therefore, considering the fibre % factor, suitable setting and imbibitions may be adopted. At particular extraction as load on mill increases i.e. Pol% Cane increases, the Pol % bagasse increases. Similarly, as Pol % cane decreases, Pol% bagasse decreases at that same extraction. Therefore, Imbibition temperature and quantity is to be increased as Pol% of cane increases for better washing affectivity. Further, Fresh cane and stale cane have different impact on mill extraction. The desired mill extraction may be easily achieved by crushing fresh cane while more efforts are required for getting good mill extraction by crushing stale cane.
In yet another embodiment, cane preparation is one of the main parameter to be maintained at 86-90 % to achieve Mill extraction of 98%. The Preparatory Index (PI) shall be achieved with latest modern equipments above 86 % + to achieve primary extraction of about 74-75%. The power at preparatory devices may be kept excess which will help to maintain PI at increased fibre% or at blunt hammer & knives by adjusting clearance setting of preparatory devices.
In yet another embodiment, the primary extraction shall be above 80% for five milling tandem. To achieve PE of this kind, diffuser carrier may be adopted. Since all secondary juice is taken before first mill, the mill capacity about 5% suffers than normal working. Hence, the feeding devices play major roll in achieving capacity. Preferably GRPF having 10 – 15 % higher diameter than mill shall be adopted to achieve capacity. To have better juice drainage from GRPF, lotus type top roller and UFR with maceration knives to bottom roller.
In yet another embodiment, the present system may adopt Moisture reduction system (MRS) for all mills by trash plate modifications such that moisture % bagasse shall be achieved from first mill to last mill.
In yet another embodiment, considering mill size and crushing capacity, the present system may adopt mill roller peripheral speed as low as possible from 9 to 12 m/sec. The low speed with feed roller maceration grooves and Top roller (except last mill) & discharge roller as lotus has great effect on juice drainage and hence reduction in moisture of bagasse is achieved. To adopt low speed, heavy arching of all three mill rollers and chevron grooves to feed and top roller are essential.
In yet another embodiment, imbibitions is important factor contributing to increase Mill extraction. The effective imbibitions depends on mixing of juice/water with each particle of bagasse, quantity of imbibitions water, temperature of imbibitions water , method of application of imbibitions water on bagasse blanket and type of tray used for spraying imbibitions water on full width of bagasse carrier. The box type imbibitions tray developed by VSI has found good results for rake carriers. The imbibitions quantity shall be 37 – 45 % on cane and temperature shall be about 850- 900C.
In yet another embodiment, free floating of top roller and equal lift of both ends of roller is essential. Simultaneously, optimum hydraulic loading is necessary. The Specific Hydraulic Pressure (S.H.P.) of each mill is given as follows:
Mill wise Specific Hydraulic Pressure (T/dm2)
No. of Rollers Specific Hydraulic Pressure in (T/dm2)
I II III IV V VI
15 Rollers 26 23 25 27 29 ---
18 Rollers 25 22 24 25 26 28

If Preparatory Index is more than 87 – 90 %, the specific hydraulic pressure will be reduced by 2 to 4 Ton/dm² observing free floating of top roller.
In yet another embodiment, to improve juice drainage, the current system may adopt deep maceration grooves to feed roller and lotus type and for Top rollers (except last mill) & lotus type discharge rollers or add maceration grooves. Also sequence of mill pitch, differential groove angles and feeding devices are to be judiciously selected as per mill size and capacity.
In yet another embodiment, to have close mill setting for higher extraction means positive grabbing of bagasse by rollers and pushing inside mill against mill hydraulic, needs heavy arching up to 2/3 groove depth for three rollers of mill and chevron grooves to top and feed discharge roller are essential.
Referring figure 2, a method for obtaining at least 98 % sugarcane juice extraction from a milling tandem is illustrated with an embodiment of the present subject matter.
At step 201, a primary extraction juice from the first milling unit is obtained.
At step 202, secondary juice extract is obtained by application of imbibitions water to a bagasse which is sent before the last mill unit. The mill extract obtained from the last milling unit is transferred to the bagasse of the preceding mill and such cycle of mill extract transferring is continued to second milling unit to extract the secondary juice.
At step 203, the secondary juice obtained from the second mill is screened by the screening equipment.
At step 204, heating the screened secondary juice by a heating equipment by using second body vapours and spreading the heated secondary juice on a bagasse which is sent before the first mill;
At step 205, the secondary juice is spread on the diffuser carrier which is placed between a fibrizer and the first milling unit wherein the diffuser carrier is obtained by modifying an existing rake carrier characterised in that the spread secondary juice on the diffuser carrier is collected.
At step 206, the extract obtained from the first mill and the secondary juice may be mixed to form a mixed juice and further sent for processing to produce by-products.
Although implementations for method and system for detecting anomalies in data volume captured pertaining to consumption of services have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as examples of implementations for detecting anomalies in data volume captured pertaining to consumption of services.