FORM 2
THE PATENTS ACT-1970
(39 of 1970) and
The Patent Rules, 2006
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
1. TITLE OF THE INVENTION
An improved process for manufacturing of Jaggeryfrom sugar cane 2. APPLICANT
a) Name Vithal Dhansing Nimbalkar
b) Nationality Indian
c) Address Chaitanya Kimya
Near Shivpushpa Apt., Anandnagar, Singhgad road,
Pune-411051
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the nature of invention and the manner in which it is to be performed:

Title:
An improved process for manufacturing of Jaggery from sugar cane.
Field of invention:
The present invention relates to an improved process for manufacturing of jaggery from sugar cane. More particularly it relates to production of high quality non chemical jaggery (in Powder and Solid form) from sugar cane. Still more particularly it relates to the said process for preparation of Non Chemical, solid jaggery or jaggery in powder form.
Background of invention:
Traditionally sugar cane is the most preferred source for producing jaggery. It is made by a process, whereby the syrup is prepared by boiling the raw sugar cane juice in a large pan till the evaporation of the said sugarcane juice to evaporate liquid therein, thereafter clarifying the said syrup to get semi solid mass. The preparation relies heavily on unhygienic process. Mostly traditional methods are relied on to produce jaggery.
The conventional method for preparation of jaggery starts from extracting sugarcane juice from the cane which is collected in tanks and then transferred to pans in batches. A small quantity of lime (say about 200 gms./200 Its. of sugarcane juice) is added to the sugarcane juice and set to boil. As the liquid begins to boil the mud is separated out. As the temperature of the liquid raises it begins to foam and gradually the foam is removed till it gets vanished. At a certain stage the juice begins to boil, which is identified by formation of bubbles. By raising the stirring spoon one will observe that the consistency of the juice is still liquid-like. Upon further boiling the juice gets converted into thick viscous liquid.
The viscous liquid is simmered in pans until the water is evaporated and the viscous liquid so obtained undergoes a clarification process where natural

vegetable clarifying agents are added so that the juice separates. The boiling liquid is then moved from one Pan to another until the liquid becomes hard and eventually turns into a solid.
For making Jaggery, the viscous liquid is further boiled until the liquid becomes even thicker. While stirring a small portion of the boiling liquid is poured in a mug of water and cooled. While cooling it is made into a ball of Jaggery. This ball is hit against the inner surface of the cauldron and the sound is heard. If the sound is loud and clear, it is understood that the Jaggery is ready. However instead of making a loud clang, if the ball makes a damped sound, it is understood that the liquid needs further boiling. Using this simple traditional technique, Jaggery makers since ages have found the perfect temperature at which the sugarcane juice turns to Jaggery.
Once the right temperature is reached the boiling is stopped and the liquid is then transferred into a flat pan, to facilitate faster cooling. The liquid is stirred in the pan and when it cools down sufficiently, it is transferred into various moulds of different shapes and sizes. The Jaggery is then left aside to solidify and after a day it is extracted out of the mould and is ready for use.
For making powdered Jaggery, the molded solid Jaggery is broken in to pieces and then broken jaggery is manually ground and screened to get powdered Jaggery.
Drawbacks of the known process:
In the conventional process for the preparation of jaggery is fraught with following drawbacks.

i) The juice extraction efficiency is very low which affects the overall
productivity of Jaggery, ii) All the bagasse is burnt in the furnace for boiling the juice for
converting into Jaggery. Due to this no power is produced in the
plant, hence for running the plant equipment external power is
required to be purchased, iii) Crusher Rollers are of cast Iron, due to which quality of Juice
extracted is not good as it gets contaminated. By using
contaminated Juice, the quality of Jaggery gets affected, iv) Lots of chemicals are added while boiling of the Juice in the open
Pan, which are harmful for human consumption. v) Due to boiling of juice by heat from burning bagasse in furnace, the
nearby area of the furnace is very hot and not comfortable for
operators. vi) The Juice / Syrup and final products are handled manually, which is
very unhealthy and unhygienic. vii) Man power required for operation of the plant is more viii) Large space is required for plant ix) Manual operation takes more time to make powdered and solid
Jaggery, x) The manufacturing process is very much laborious.
The main object of the present invention is to provide an improved process for production of non chemical Jaggery from sugarcane which has greater efficiency having distinct economic advantage over the conventional process.
Another object is to provide a process which is more hygienic compared to the conventional process.

Stitl another object is to provide almost automatic process with minimum human interference thereby reducing the manpower considerably as compared to the conventional process.
Yet another object is to provide environment friendly process for the
production of Jaggery which is capable of producing Jaggery in various forms suitable for different consumption as per need of the market and consumer.
Accordingly the present invention provides an improved process for the preparation of Jaggery which comprises;
i) fiberising the sugar cane using fibreriser or shredder, extracting the sugarcane juice using sugarcane mills and transferring the sugarcane juice to the juice storing tanks, extracting the juice further by spraying hot water imbibition at a temperature ~70°C on fiberised sugar cane passing through Mills;
ii) heating the raw juice so obtained in a juice heater to a temperature of about -12 °C, adding to the boiled juice a dose of lime to adjust the pH of the juice in the range of 6.9 to 7.0, heating the pH adjusted juice to the temperature of 102 °C;
iii) adding the Lime dose in the reaction tank, transferring the juice obtained in step (ii) to short term retention clarifier tank to separate the muddy juice and clear juice, adding a mud settling agent in the retention clarifier clarifier to ease out separation of mud from Juice;
iv) mixing the separated muddy juice with bagacilfow, separating the clear juice from mud using conventional methods exemplified by Vibro screen followed by Rotary vacuum filter;
v) transferring the clear juice to a second darifier (Secondary clarification) to further clarify the juice by treatment with a herbal clarifier, filtering the Juice, heating the said clarified juice to a temperature of105 °C

vi) feeding the heated juice to a multi effect evaporator for evaporating
the juice under vacuum to obtain the syrup of 60 degree Brix,
clarifying the syrup by conventional methods; vii) Transferring the syrup to syrup tanks for feeding to vacuum boiling
pans to convert the syrup to jaggery; viii) Converting the jaggery produced in the pans to the powdered or
solid form.
In one of the embodiments of the present invention the herbal clarificant may by powder of ladies fingers (Bhendi in vernacular)
In still another embodiment the sugar cane crushing mid comprises stainless steel shell rollers.
In further embodiment the boiling pans are open pans provided with external heating coils or vacuum pans for boiling the syrup.
In still another embodiment the exhaust steam or vapours from evaporators or hot water is used as heating media for the open pans and vacuum Pans.
In yet another embodiment the mud settling agent may be soya milk.
In a feature of the present invention the mud separated may be used further as manure.
In a feature of the invention the Jaggery obtained may be converted to various forms of desired use such as powder, coarse powder and solid lumps as the case may be.

In still another feature the bagasse is used for steam generation. The steam generated is used for Turbo generator for generating the power required for the plant operation and also low pressure steam is used for the purpose of heating in the process equipments.
Detailed description of the process:
The process provided by the present invention is carried out in following steps as detailed in Chart No. 1 accompanying this specifications.
(1) CANE PREPARATION AND MILLING
The sugar cane collected from the field is fed to cane carrier by means of overhead cranes. By means of fiberiser or cane shredder the cane is shredded in to fibers. This prepared cane is crushed in the three Roller Mills (driven by electrical motor through planetary gear box) to extract Juice from Sugar cane. Mills consist of three rollers-Top roller, Feed roller and discharge roller. The Rollers are made up of Stainless steel shells. Cane passes through these rollers and is crushed first between feed and top roller & then between Top and discharge Rollers. The rollers are adjustable. Fine circular "V grooves provided on the rollers causes' heavy extraction of juice From Cane and then juice is transferred to Juice tanks. From this Juice tanks, Juice is pumped to Clarification and boiling house section.
2) Steam and Power Generation-
The bagasse extracted out of Milling Plant is used in Boiler for Steam Generation. The steam generated is used for Turbo generator for generating the power required for the plant operation and also low

pressure steam is used for the purpose of heating in the process
equipments.
3) Juice Clarification section
In the Clarification section following steps are followed -
Step A- Raw Juice Heating
In Juice heaters (high velocity, vertical, shell and tube heat Exchanger type) Raw Juice is heated from 35 to 72 °C by using low pressure steam or Vapours from Evaporators.
Step 2- Reaction Tank
At Reaction Tank, Milk of Lime dose is added as per requirement of Juice pH.
After reaction tank, treated juice gets is heated in Juice Heaters up to the temp of 102 °C with 18 degree Brix and then transferred to short retention clarifier (Magnetic Clarifier).
Step 3- Short retention Clarifier (Magnetic Clarifier)
In this clarifier, the mud is separated ( by use of Settling agent like Soya bean Milk ) and clear juice at a temp of 98 °C is drained for further process. By using Rotary vacuum filter, the juice is separated from Muddy Juice. The mud is further used as manure.
After processing the clear juice in magnetic clarifier, it is passed through a Vibro screen where fine Bagasse particles &mud particles from juice are separated.

The clear juice from the magnetic cfarifier is further send to the Secondary Clarifier, where a dose of Bhendi powder and phosphoric acid (Food Quality) is added and again clear juice and fine Bagasse particles are separated. The juice separated in the secondary clarifier is send to Bag filter for removal of Bagasse /Mud particles. The outlet temp of Juice from Secondary clarifier is 105°C.
The clear Juice from secondary clarifier is further send to Bag Filters for separation of Baggase and Mud particles. The clear juice removed at Rotary vacuum filter and Bag filters is added in to the process at mixed juice tank at milling station.
Step 4 -Evaporation
The cleared Juice is then sent to Evaporator set for evaporating water from clear Juice. The Evaporator set is of two to three bodies (Double or Triple Effect Evaporator)
Evaporators are shell and tube type heat exchangers in which Juice passes through tubes and steam / vapours are applied in calendria for heating of juice for evaporation of water. Vapours from Calendria are condensed in the MJS condensers and condensed water is recycled in through spray pond.
The condensate extracted from calendria is used for process.
Evaporator sets are operating under pressure / Vacuum and by evaporation process. Juice gets converted in to Syrup Form (60 degree Brix at 42 °C) . The syrup produced in Evaporators is then stored in Syrup Storage tanks.

4) SYRUP BOILING:
The syrup boiling is done by two alternative methods as below -
a) Method I - By using vacuum pans
b) Method II - By using open pans.
In method i the Syrup boiling Pans are working under vacuum, which makes boiling faster and uses less steam.
Vacuum Pans are shell and tube type heat exchangers in which Juice passes through tubes and steam / vapours are applied in calendria for Boiling of Syrup. After boiling process is completed thick concentrated Syrup (at 50 to 55 °C temp and 60° Brixs) is dropped out of Pan. Vapours from Calendria are condensed in the MJS condensers and condensed water is recycled in through spray pond.
In case of method II Open Boiling Pans in which the external coil type tubes are used for circulation of steam at the bottom cone of the Pan and syrup is boiled in the Open Pan.
Syrup is first drawn to the Pan by simply opening valve of the pipe line extending from the overhead syrup tank to the boiling pan. In case of open Pan boiling, while heating and boiling the syrup, the process technician goes on removing impurities and dirt by scumming, as impurities go on accumulating on the surface of boiling juice in the pan. (In case of open pan a stirrer is used for effective heat transfer / Boiling). Ultimately jaggery mass is formed from the thick syrup, the outlet temp of mass is 117 °C and 92°Brix . Then it is transferred into Water cooled Pulveriser. Control of juice boiling is really ingenious process, which requires experience and skill for maximum recovery of jaggery. The

process technician has to be very careful with a view to ensure (i) Maximum possible clarification of juice (ii) Proper concentration of syrup.
a) In case of open Pan boiling, during the boiling, all impurities come on the surfaces which are removed by scumming. While boiling, up to 117 °C, the sugarcane juice gets concentrated and after evaporating almost all the water, pasty yellow substance is left in the boiling pan which becomes solid after cooling. This is jaggery.
b) For making powder jaggery, the jaggery in semi liquid form is scraped in water cooled pulveriser and then it is passed through powder making machine and then dried through drying machine. For making proper powder of Jaggery addition of Sodium Bicarbonate is done in the Powder making machine. The dry Jaggery powder is then packed in polythin bags of 250 gms 500 gms and 1000 gms for commercial distribution.
c) A special purpose Jaggery powder making machine is used for making Jaggery Powder, the constructional details of which are as
under-
The Machine consists of following parts
- Stirrer
- Stirrer driving arrangement
- Fabricated body of the machine
- Bottom tray
- Material inlet pipes
- Material outlet pipes
- Powder screening unit
The working details of the machine are as under

- The viscous Jaggery produced after boiling in Pans is conveyed to the bottom tray of the machine through inlet pipes
- The level of jiggery in the tray is kept to the minimum, so that operation of stirring and scrapping of Jaggery is effective.
- After bottom tray gets filled with the material, the stirring and scrapping operation is started by switching on the machine, which rotates the various stirrers and scrappers.
- At the beginning time, the machine is run at slow speed, so that Jaggery material gets homogenous.
- Then slowly the stirrer level is lowered down and stirring and scrapping operations are on.
- The stirring and scrapping operations are controlled accurately, so that no lumps are formed and uniform powder is produced.

d) Powder drying, screening - The powder from powder making machine is then passed through dryer and the stored is storage tank properly
e) The powder is then weighed and packed in polythin bags in automatic weighing and packing machine.
For making solid jaggery, the Jaggery powder is then transferred in batches to automatic molding machine. The details of automatic molding machine are as under -. The Machine is having following parts—
- In let feeding hopper
- Power Pack unit
- Hydraulic Cylinders
- Tray holding unit
- Molds of different sizes.
- Filling of Jaggery on the tray

- Pressing of Jaggery in the mold
Transferring of molded jiggery on the conveying system.
The operational details of the machine are as under-The Powdered jaggery is filled in the Inlet hopper. Then the Power pack unit is started and in the following sequence the hydraulic Cylinders are operated by means of timer fitted in the Power pack unit.
- The trays are transferred from holding unit to the main pressing u
nit.
Jaggery Powder is poured on the trays up to desired level.
- The mold is then Pressed on the material from top and bottom.
- After proper pressing , the jiggery powder gets rectangular lumps forms of desired weight (i.e. 500 grams, 1 kg, 2 kg, 5kgs etc -)
- After work of pressing unit is completed, the molded Jaggery is transferred to Rolling Conveyor system.
From Rolling Conveying system Jaggery molded lumps are send for packing unit.
The present invention has following advantages.
a) The Juice extraction in the Milling plant is increased.
b) Increased Jaggery production per ton of cane crushed, (i.e. increase in recovery to the extent of 2 %)
c) Enhanced quality of the Jaggery produced.
d) No contamination because of use of Stainless steel material for the equipment.
e) The Jaggery produced is without use of any harmful chemicals or bleaching agents, hence it is very much suitable for human consumption.

f) During vacuum Pan boiling process temp does not exceed 105 °C, hence there is no inversion of Glucose, which retains nutritional and medicinal properties of sugar Cane.
g) The process provided by the present invention is Economical, Hygienic and Eco friendly.
h) No human touch while handling product in the plant hence hygienic
product. i) The molding of solid jiggery is done through automatic molding
machine j) Due to this method of Jaggery production, the storage life of the
product is increased and keeping product for longer time is
possible.

I claim:
1. An improved process for the preparation of Jaggery which comprises;
a) fiberising the sugar cane using fibreriser or shredder, extracting the sugarcane juice using sugarcane mills and transferring the sugarcane juice to the juice storing tanks, extracting the juice further by spraying hot water imbibition at a temperature ~70°C on fiberised sugar cane passing through Mills;
b) heating the raw juice so obtained in a juice heater to a temperature of about ~72 °C, adding to the boiled juice a dose of lime to adjust the pH of the juice in the range of 6.9 to 7.0, heating the pH adjusted juice to the temperature of 102 °C;
c) adding the Lime dose in the reaction tank, transferring the juice obtained in step (ii) to short term retention clarifier tank to separate the muddy juice and clear juice, adding a mud settling agent in the retention clarifier to ease out separation of mud from Juice;
d) mixing the separated muddy juice with bagacillow, separating the clear juice from mud using conventional methods exemplified by Vibro screen followed by Rotary vacuum filter;
e) transferring the clear juice to a second clarifier (Secondary clarification) to further clarify the juice by treatment with a herbal clarifier, filtering the Juice, heating the said clarified juice to a temperature of - 105 °C
f) feeding the heated juice to a multi effect evaporator for evaporating the juice under vacuum to obtain the syrup of 60 degree Brix, clarifying the syrup by conventional methods;
g) Transferring the syrup to syrup tanks for feeding to vacuum boiling pans to convert the syrup to jaggery;

h) Converting the jaggery produced in the pans to the powdered or solid form.
2. An improved process for the preparation of Jaggery as claimed in claim 1 wherein the herbal clarificant is powder of ladies fingers (Bhendi in vernacular).
3. An improved process for the preparation of Jaggery as claimed in claim 1 wherein the sugar cane crushing mill comprises stainless steef shell rollers.
4. An improved process for the preparation of Jaggery as claimed in claim 1 wherein the boiling pans are open pans provided with external heating coils or vacuum pans for boiling the syrup.
5. An improved process for the preparation of Jaggery as claimed in claim 1 wherein the mud settling agent is soya milk.