Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd- Viral Shah

Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.

Vidyabharti Trust College Of BBA & BCA, Umrakh 1

1. COMPANY PROFILE

1.1 What business the company is in?

Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd is state in

business in making of sugar.

1.2 Year of communication of business

Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd is a

co.operative sugar factory, registered under the Gujarat co.operative

societies act, 1961.the most evenly day of 31st march, 1964 witnessed the

emergence of Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd,

and the foundation of the sugar factory was made, which has flourished

and has been projecting a bright future for the sugarcane growers and

other agriculturists the area, today

1.3 Location

Sugar factory is situated at chalthan village, in south Gujarat region of

Gujarat state, 18k.m. away from the diamond and silk city of Surat. It is

situated on national highway no.8, Bombay-ahmedabad and the state

highway no.6 surat-dhulia, is hardly at a distance of 1k.m. surat-

bhusaval railway line connects with Bombay-ahmedabad main line is

also passing through chalthan and chalthan railway station is just

adjacent to factory. Our area is under tapti valley, which is gifted with

ample water either available through canal irrigation or wells. The soil is

fertile and the lands are even. The economical and atmospheric

conditions have established the agriculturists to resort banana, cotton,

vegetables, wheat, paddy, and sugarcane plantation on large scales.



1.4 Owner

The Kalyanji .j. maheta is the founder of this sugar factory. Now share

holders of the organization are the owner. All members of the society are

farmers cultivating sugarcane. They are supplying cane to our sugar

factory. Total membership is 15982, out of which, harijans 211 and

adivasis are 24. Surat district consists of 7 talukas and total villages are

188.

LIST OF SHARE HOLDERS AND NO. OF SHARES

No. of Shares No. of Shares No. of Members

1. 13492 13492

2. 3326 1663

3. 1530 510

4. 680 170

5. 420 84

6. 198 33

7. 126 18

8. 40 5

9. 18 2

10. 20 2

11. 11 1

12. 14 1

13. 17 1

19892 15982



1.5 Objectives

� To improve the social and economic pattern or the rural area.

� To changed the life style in chalthan and its surrounding rural area.

� To assist farmers in the technology planting by agriculture staff.

� To import production efficiency and to reduce the cost of production.

� To provide maximum satisfaction to his share holders.

� To provide a better quality of sugar as compare to other sugar

factory.

1.6 Number of plants

Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd has two

plants for making sugar.



1.7 Turnover

The quality of our product is well-accepted in the export market and

every year we are exporting sugar, Alcohol and Molasses in good quantity

and will directly reflect the revenue of our nation.

COMMODITIES TURNOVER (YEAR-WISE)

Year Sugar

Bags Molasses (MT) Alcohol (B.L.)

1992-93 68,355 .. ..

1993-94 .. .. ..

1994-95 .. .. ..

1995-96 10,000 .. 16,99,000

1996-97 1,08,000 5913.010 71,03,000

1997-98 .. .. 48,06,000

1998-99 .. .. 50,00,000

1999-00 .. .. 50,00,000

2000-01 .. .. 50,00,000

2001-02 82,750 .. ..

2002-03 .. .. ..

2003-04 .. .. ..

2004-05 .. .. ..

2005-06 .. .. ..

2006-07 .. .. ..

2007-08 1,88,860 .. ..

2008-09 75,000 .. ..

2009-10 .. .. ..

2010-11 .. .. ..

2011-12 23,367 .. ..



2. PRODUCT PROFILE

2.1 Number of Products

In SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI

LIMITED mainly produce sugar but the by-product is. Molasses

Production, Bagasses Production, Internal Use of Bagasses, Press Mud,

Ash.

2.2 Sales volume

No. Particulars Last year (RS.) Current year

(RS.)

1. Sugar 2792946200 2327858356

2. Molasses 255217996 159800742

3. Press mud 795458 768055

4. Bagasse 38504325 32727496

TOTAL 3087463979 2521154649

2.3 Product lines

Products

Main product By products

Sugar 1. Molasses

2. Bagasses

3. Press mud

4. Ash



Khand Udyog products & By-products

Sr. No. Particulars %

1 Sugar Propossion 12%

2 By-Products

A Molasses Production 4.5% to 5%

B Bagasses Production 30%

C Internal Use of Bagasses 26% to 28%

D Press Mud 2% to 3%

E Ash 1.55 to 2.00%

SUGAR

Sugar is a term for a class of edible crystalline carbohydrates,

mainly sucrose, lactose, and fructose, characterized by a sweet flavor.

In food, sugar almost exclusively refers to sucrose, which primarily

comes from sugar cane and sugar beet. Other sugars are used in

industrial food preparation, but are usually known by more specific

names glucose, fructose or fruit sugar, high fructose corn syrup, etc.



Byproducts of Chalthan Sugar factory:

CHALTHAN SUGAR Factory has byproducts, which are (1) Bagasse (2)

Molasses (3) Filter Mud (4) Rectified Spirit.

(1)Bagasses:

Bagasses are the fibrous matter that remains after sugarcane stalks are

crushed to extract their juice. It is currently used as a biofuel and as a

renewable resource in the manufacture of pulp and paper products and

building materials.

The cane juice is extracted in the mills and the residue is called

bagasses. It is 24-30% of sugar cane. The production of the bagasses is

29.41%. It is passed in the boilers through the bagasses carrier and is

directly fed in the furnaces of the boilers as fuel the surplus bagasses is

taken out at the end of carrier, and sold out to paper mills. The sugar in

bagasses is 0.62.



(2)Molasses:

Molasses is a viscous by-product of the processing of sugar

cane, grapes or sugar beets into sugar. The word molasses comes from

the Portuguese word melaço, which ultimately comes from Mel,

the Latin word for “honey”. The quality of molasses depends on the

maturity of the sugar cane or sugar beet, the amount of sugar extracted,

and the method of extraction.

When sugar is separated from masscult mother liquor coming out is

called the molasses. It is boiled for 3 or 6 hours to recover maximum

sugar. It is 3.5-4.5% of sugar cane. It is important for the manufacturing

of various industrial products such as distillery product chemical like

holistic acid, alcohol, etc. rectified spirit and absolute alcohol are made

from the molasses. The production of the molasses is 4.84%. The sugar

in final molasses is 1.396. So, it is sold out in distillery plant.



(3)Filter Mud:

Filter mud is also known as filter caked. Filter mud contain 3.5-4% of

sugar cane. The production of the filter mud that is 4%. It is generally

used for the fertilizer. The sugar in filter caked is 1.396.

The processing of sugar cane produces a form of filter cake mud, which

can be extracted for different uses, including animal feed and refined

wax. It can also be recycled back into the sugar milling process. Until

uses for the filter cake mud were found, sugar cane mills did not know

what to do with the mud, and factories threw out the material.



(4)Rectified Spirit:

It is manufactured by formation & distillation of molasses as per IS:

323-1959 specification. One merit tone molasses are taken in this

material 250 liter of rectified spirit come out. It is used for manufacturing

of Acetic Acid, acetone, Oxalic Acid Absolute Alcohol & other various

chemical. Special Gravity 0.8171 at 15.6 C. percent by volume 84.68at

15.6 C.

A rectified spirit, rectified alcohol, or neutral spirit is highly

concentrated ethanol which has been purified by means of repeated

distillation, a process that is called rectification. It contains 95% alcohol

by volume. Rectified spirits are used in mixed drinks, in the production

of liqueurs, for medicinal, and as a household solvent.



2.4 Raw materials

Sugarcane

Sugar cane is a tall and relatively strong class of perennial grasses that

are known to have high sugar content. Strictly speaking, there is not a

single plant that is known as sugar cane. Instead, there are as many as

thirty-seven different grasses that are sometimes considered to be part of

this particular cane family. Many of these grasses can be crossbred, thus

creating hybrids that can adapt to various types of climate conditions.

The varying types of sugar products made from sugar cane cover a wide

range. Along with basic sugar used in different recipes, commercial

enterprises can make use of the sugar to create molasses, sodas and

other soft drink products, rum, and a variety of sweeteners that are used

to slightly flavor frozen foods. The raw sugars can also be used in the

manufacturing of hard candies and other confections that may be stored

at room temperature for extended periods of time.



2.5 Growth profile

Actual crushing started in1970-71 with 1250 tons per day capacity. The

plant is of backau Wolf India make, double sulphitation process. In the

first year, factory has crushed 11600 tons of sugarcane and in the

season 1973-74 the factory has crushed 222000 tons of sugarcane with

an average of 1400 tons per day. The factory has undertaken first

expansion program in 1977-78 from 1250 TCD to 2000 TCD. In the year

1982-83, the factory has further expanded to 3500 TCD. This plant is

walchandnager make. From the season 1988-89 onwards, the factory is

further expanded to 5000 TCD and from 20.12.1988 the factory is

crushing sugarcane at the rate of 5100 TCD.

Most modern plant equipments are installed in sugar factory. Fibrize,

split carrier, donally chute, auto cane carrier, auto sulphur burner,

continuous centrifugal machine, vertical continuous crystallizer etc. are

some of the same. Over & above, the factory has installed a 40 tones high

pressure boiler for their expansion to 5000 TCD. This boiler is of texmaco

make and it is the first of its kind installed in Gujarat. The factory has

also installed a high pressure turbo alternator set, which is also the first

unit installed in Gujarat. The turbine is of APE belliss India make and

alternator is of jyoti make.

The factory has also installed continuous pan for massecuite boiling with

automation, cooling and condensing system for constant vacuum on pan

and evaporator. Also installed twin vertical crystallizer for mass cooling.



For air & water environment protection, factory has installed wet

scrubber system on all boiler and diffuser air blowing system, pressure

sand filter and pressure carbon filter system for effluent water treatment.

Factory has installed mill automation system and boiler automation

system for better result.

In order to ascertain accurate weight of all materials, factory has

installed computarizer load cell base weigh-bridge at all weigh-bridge

stations. Normal crushing days are 200. Expansion program were done

by own funds and in shortest possible time. The factory has expanded

from 1250 TCD to 5000 TCD within a short time of only 10 years.

Our authorized share capital of RS.110 lacks is distributed among 11105

members from whom the factory is receiving sugarcane for crushing at

the factory. Even though the factory started production in 1971, within a

short time of 7 years, organization has paid back the share capital of

RS.39 lacks to the government and the loan of IFCI and LIC amounting

to RS.23lacks. The factory is receiving sugarcane from 183 villages within

a radius of 32 K.M.s

2.6 Major customers

The sugar factory’s major customers are (1) government (2) share holder

of company & (3) brokers.



3. ORGANIZATIONAL STRUCTURE

3.1 Departmentation

The sugar factory use departmentation by process.

3.2 List of Departments

A. H.R department (labor department).

B. Production department.

C. Sales department.

D. Accounting department.

E. Purchase department.

F. Other department.

i. Administration department.

ii. Transportation department.

iii. Agriculture department.

iv. Distillery department.

Manager

Milling Crushing Unloading Heating Finishing



3.3 Organizational Structure

Board of Director

Chairman & Vice Chairman

Mr.Jayanti Patel & Mr.Ramanbhai

Jain

Managing Director

Mr. v.subburathinam

Chief

Accountant

Mr. Achal

Shukla

Labor officer

Mr.

Hashmukh

Administrative

officer

Mr. Harish vashi

Estate Manager

Mr. M. Patel

Distillery

Manager

Mr. Suresh Patel

1. Labor welfare officer

2. Medical officer

3. Security officer

4. Time office

1. General officer

2. Transport 3. Weigh

bridge

C.D.O C.P.

Agri.officer

Agri.Assistant

Cane quality control

Boy

Labors

Peon

Production

Supervisor

Shift

Chemist

Operator

Workers

Peon

DY.Chief

Accountant

Asst.

Accoun

Cane.

Accoun

Accountant Clerks

Cashier Peon

Clerks

Peon



4. DIFFERENT DEPARTMENTS DETAILS

4.1 Personnel Department

4.1.1 Department Chart

4.1.2 Labour Relation Activities

In the SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI

LIMITED. Relation between labours is very good so the labour relation

activities are not done. But at the startup the work organization do the

induction training.

4.1.3 Human Resource Development

For development of H.R department organize some seminar like;

� India renal foundation.

� National training and development.

� Staff society personal.

Labour officer

1. Labour welfare

2. Medical officer

3. Security officer

4. Time officer



4.1.4 Labour Welfare

� UTSAV CELEBRATING:-

� GANESH UTSAV

� NAVRATRI

� DURGA POOJA

� CABLE TV:-

� the factory is provided cable tv facility to the residents of colony.

The factory is providing financial assistance for this facility.

� TEMPLE:-

� The factory has constructed an attractive temple for lord shiva,

which is functioning.

� MEDICAL AND HEALTH:-

� Factory has promoted SANJIVANY HOSPITAL to solve the problem

arising out of scarcity of medical facilities in rural area. This is an

important step towards attachment on community goals through

cooperative efforts. This hospital aims to provide modern medical

facilities to rural poor at normal charges and intends a 130 bedded

most modern well equipped hospital is functioning. This hospital

provides all the basic facilities of hospitalization, emergency and

nursing care in a clean surrounding. The details of facilities are as

under:

� O.P.D:-

This hospital functions fully equipped O.P.D both in morning and

evening with full time surgeon, physician, orthopedic surgeon and

gynecologist to provide basic facilities. In addition to this, part time

visiting doctors provides care in dental, ayurvedic and naturopathy.



� Emergency services:-

The hospital has well equipped causality and emergency services to

cater for both medical and surgical emergencies around the clock

with technical staff and doctors.

� Indoor facilities:-

The hospital has 130 beds capacity with 50 functioning beds at

present. In addition, it has separate burns unit of two beds and ten

bedded naturopathy department.

It has well equipped two operation theatres for all minor and major

operation of various disciplines.

� X-Ray

The hospital is equipped with one X-Ray unit of 300 MA.

� Laboratory:-

Laboratory is well equipped and capable of performing all

investigations.

The hospital runs its own chemist shop which is well stocked and

provides almost all the drugs required in the hospital or prescribed

to OPD patients.

The physiotherapy department takes care of rehabilitations of the

orthopedic cases and functions under the supervision of ortho

surgeon, all free of charges, and takes care of preventive and social

aspects.

The hospital has recently opened a full time naturopathy department

with both OPD and indoor (10 beds). It is equipped with all possible

apparatus. From time to time, the hospital organizes camps at

villages to provide free medical or surgical OPD aid to the

surrounding villagers-eye camp.



� TREE PLANTATION:-

� As primary step for controlling pollution, the factory is arranging for

tree plantation, every year.

� HOUSING SOCIETY:-

� Shree Khand Udyog Cooperative Housing Society has established

with the object to provide own residence to the needy employees of

the factory. About 100 staff members are members of this society.

Construction of the residential buildings is completed.

� STAFF WELFARE:-

� The factory is keen in staff welfare activities. We have provided about

381 residential accommodations to staff and workers, which are well

constructed with enough space and ventilation arrangements, 24

hours water supply and electricity supply etc.

� The factory is also providing contributions for cultural programmers,

recreation club, library etc. As part of staff welfare, a bal mandir is

being run by the factory management for encouraging primary,

secondary and higher education activities. For family planning, the

management is donating a good amount every year.

� The factory is running the kalyanji Mehta vidhyalay at chalthan and

also making financial assistance to the educational institutions to

the nearby area.

� STAFF SOCIETY:-

� Shree khand Udyog karmachari Sahakari Mandli LTD has been

established in the factory premises. This society advances loans to

the needy members of the society at nominal interest charges. A fair

price shop is also being run by this society to provide all daily

consumable items to the workers on credit basis. All employees of

the factory are members of this society.

� The employees of the factory are also advanced bank loans on the

undertaking of sugar factory for purchasing cycles, mopeds,

television, fridge etc.

� A cooperative bank, post office and S.B.I A.T.M centre etc. are

functioning in the factory for premises to facilitate the employees.



� Thus, shree chalthan vibhag khand Udyog Sahakari Mandli Ltd. Has

not only created wide economic opportunities for common people,

but also activated the lowest state of community to participate in the

development process. We have made a unique effort to strengthen

the weaker section of the society to benefit enough to participate in

the development process by mobilizing large financial resources in

favor of them through cooperative effort and by providing them with

infrastructural facilities and scientific aptitudes.

� CANTEEN

� UNIFORM

� In sugar only security and low level worker has compulsory uniform.

� SCHOOL FOR CHILDREN EDUCATION.



4.1.5 Maintenance of Employee Records

For maintain the employee record organization use “electronic time

punching machine” it is an automatic computerize software.

4.1.6 Payroll Systems Wage and Salary Structures

OPERATIVE IN FORCE FROM 01.10.2011 TO 31.12.2011

SR.

NO.

CATEGORIES BASIC PAY FIXED

ALLOWA

NCE RS.

V.D.A.

AS PER

3585

POINTS

RS.

MINIMU

M RS.

MAXIM

UM RS.

HOUSE

RENT

RS.

1 UNSKILLED 3400-45-3850-

50-4350-55-

5175

310.00 4632.00 8342.00 10117.

00

100.00

2 SEMI

SKILLED

3500-50-4000-

55-4550-60-

5450

220.00 4632.00 8352.00 10302.

00

100.00

3 SKILLED – B 3650-60-4250-

65-4900-70-

5950

99.00 4632.00 8381.00 10681.

00

120.00

4 SKILLED – A 3800-65-4450-

70-5150-75-

6275

.. 4632.00 8432.00 10907.

00

120.00

5 HIGHLY

SKILLED

3900-70-4600-

75-5350-80-

6550

.. 4632.00 8532.00 11182.

00

140.00

CLERKS

1 CLERICAL

– IV

3650-60-4250-65-

4900-70-5950

97.00 4632.00 8359.00 10679.00 120.00

2 CLERICAL

– III

3800-65-4450-70-

5150-75-6275

.. 4632.00 8432.00 10907.00 120.00

3 CLERICAL

– II

3900-70-4600-75-

5350-80-6550

.. 4632.00 8532.00 11182.00 140.00

4 CLERICAL

– I

4000-75-4750-80-

5550-85-6825

.. 4632.00 8632.00 11457.00 140.00



SUPERVISORY

1 SUPERVISOR

– C

4000-75-4750-80-

5550-85-6825

.. 4632.00 8632.00 11457.00 140.00

2 SUPERVISOR

– B

4100-80-4900-85-

5750-90-7100

.. 4632.00 8732.00 11732.00 170.00

3 SUPERVISOR

– A

4300-95-5250-110-

6350-125-7225

.. 4632.00 8932.00 11857.00 170.00

PAY.DOC/TIME OFFICE/HN

744 Points neutralized and merged in basic pay. Above 744 points

increase up to 818 points i.e. 74 points calculated Rs. 122.10 @ Rs.1.65

w.e.f. 01.10.1989 and above 818 points increase calculate @ Rs. 1.85 per

points. Above 1231 points (with effect from 01.01.1994) increased

calculated @ Rs.2.00 per point. Up to 3340 points neutralized and

merged in basic pay above 3340 points increase up to 3371 point, i.e. 31

points calculated Rs.66.65 @ Rs.2.15 w.e.f. 01.04.2009.

4.1.7 Recruitment and Promotion

RECRUITMENT:-

When the organization need to recruitment first they give advertisement

in local newspaper then collect application and take interview to the

candidate after select the best candidate. For 5 year temporary based

and then do the permanent that employee.

PROMOTION:-

In the organization promotion done as per seniority based witch

employee has more experience that employee get promotion in the

organization. Or when the vacant place that time do the promotion for

fill up that place.



4.1.8 Performance Appraisal

PROMOTIONAL RATING SHEET

1. Name :

2. Department :

3. Position :

4. Age/Date of Birth :

5. Married/Single :

6. Present Salary :

7. Education :

8. Experience :

(a) In company :

(b) Others :

9. Date of entered Service :

10. Last increase in salary :

(a) Amount :

(b) Date :

11. Date of Next Increment :

Marks (Out of 100)

12. Attendance & Punctuality :

13. Initiative, interest in work :

14. Co-operative Spirit :

15. Speed and volume of work :

16. Reliability :

17. Accuracy :

18. Quality of work :

19. Conduct :

20. Honesty :

Total… / 900

21. Do you consider the above employee to be

(a) Capable for more responsible job? :

(b) Suitable assigned? :

(c) Confirm / Not Confirm :



22. Remarks

_______________________

___________________

Merit Rater with Designation

Head of the Department

Against Sr.No.12 to 20, put your remark by stating (i)

Excellent (ii) Good (iii) Fair (iv) Bad and (v) Very bad only, and

against Sr.No.21 by stating Yes or No.

Order………………………………………………………………………………

………………………………………………………………………………………

………………………………………………………………………………………

………………………………………………………………………………………

………………………………………………………………………………………

………..

To,

Labour Office / Head Time Keeper

MANAGING DIRECTOR

4.1.9 Safety measures

For the safety of the employee factory provide safety helmet and safety

shoos.



4.1.10 STAFF DETAILS as on 31.03.2011

Permanent staff 427

Seasonal staff 535

Distillery Unit

-Permanent

-Seasonal

53

13

Total 1028

Trainee staff 47

Grant Total 1075

March 2012

No. officer staff permanent seasonal total

1 general officer 10 0 10

2 accountant 15 0 15

3 Crain 6 1 7

4 Civil 1 0 1

5 ta.offi 2 5 7

6 engineer 15 0 15

7 manual 7 0 7

8 medical 2 0 2

9 labour welfare 1 0 1

10 security 1 0 1

11 Store 9 5 14

12 Sugar 3 0 3

13 sugar warehouse 4 4 8

14 transport 3 0 3

15 weightier 2 13 15

16 Post 4 0 4

Total 85 28 113



farming department

17 staff 12 0 12

18 freed 26 0 26

19 k kava k 0 156 156

20 testing lab 4 1 5

total 42 157 199

Worker

21 store 4 3 7

22 civil 7 0 7

23 boiler 35 0 35

24 mill 55 0 55

25 boiling 51 0 51

26 cutting 45 0 45

27 workshop 26 0 26

28 security 25 0 25

29 manufacturing 4 156 160

30 patapagi 16 0 16

31 driver 8 13 21

32 sanitation 4 0 4

33 general engineer 16 134 150

34 laboratory 0 13 13

35 sugar handling 0 9 9

total 296 328 624



distillery department

36 staff 40 19 59

37 Zone 3 0 3

total 43 19 62

zone department

38 trainee farm 10 0 10

39 trainee distillery 2 0 2

40 trainee engineer 21 0 21

41 trainee manufacturing 2 0 2

42 apprentice 16 0 16

total 51 0 51

Summery

NO. department permanent seasonal Total

1 Staff 85 28 113

2 farming 42 157 199

3 Worker 296 328 624

4 Zone 3 0 3

5 distillery 40 19 59

Total 466 532 998



4.2 Production Department


Production manager

Chief chemist

Peon

Worker

Production supervisor

Operator



4.2.2 Production Plan

WEIGH WEIGHED

MACCERATION WATER

Cane

Milling Plant

Continuous lime and Sulphitation unit

pH 7 to 7.2

Primary juice Heater 70oC

Receiving Tank

Automatic Weighment

Mixed Juice

PH 5 to 5.5

Secondary juice heater 100o to 102

oC

Bagasses

Boilers

High Press Steam

Prim over Power

Turbine

Low Pressure Steam

Condensed Low Pressure

Water

Contd.

Settler

Mud

Clear juice pH 6.9 to 7.0 Temp 95oC

Mud Mixer

Evaporators

Vacuum Filter

A Heavy & A Light

Filter

Filter

Cake

Syrup pH 6.5-6.8

Cont. Syrup Sulphiter

Sulphide syruppH

4.8-5.2

To Process Weight & Sold as

Farm Yard Manure

Crystallization

Centrifugation

MOLASSES SUGAR

Phosphoric Acid.

Excess Bailed Solid for Paper

Industries

Electricity Produced to Run the Plant

SO2 Gas



4.2.3 Month Wise Number of Workers Employed

Month Male

Total Sugar Distillery

Jan – 2011 973 58 1031

Feb – 2011 973 58 1031

Mar – 2011 972 57 1029

Apr – 2011 971 57 1028

May – 2011 970 57 1027

June – 2011 970 57 1027

July – 2011 558 41 599

Aug – 2011 558 43 601

Sep – 2011 558 43 601

Oct – 2011 956 48 1004

Nov – 2011 944 58 1002

Dec – 2011 945 58 1003

4.2.4 Month Wise Number of Days during Production Activities Was

In Operation

MONTH SUGAR DISTILLERY

Rectified Spirit

Absolute alcohol

Jan – 2011 31 28 21

Feb – 2011 28 25 22

Mar – 2011 31 30 29

Apr – 2011 30 28 28

May – 2011 31 28 23

June – 2011 12 5 10

July – 2011 -- -- --

Aug – 2011 -- -- --

Sep – 2011 -- -- --

Oct – 2011 12 -- --

Nov – 2011 30 9 7

Dec – 2011 31 30 30

TOTAL DAYS 236 183

176



4.2.5 Month Wise Product and Byproducts

MONTH

PRODUCT

BY PRODUCTS

SUGAR

(MT)

RECTIFIED

SPIRIT

(KL)

ABS.

ALCOHOL

(KL)

BAGASSES

(MT)

FITER

CAKE

(MT)

MOLASSES

(MT)

Jan – 2011 16410 1744.849 631.219 53543.403 6267.750 8991

Feb – 2011 13923 1544.611 646.493 48836.200 5603.930 7629

Mar – 2011 12476 1933.807 865.300 46587.533 5277.730 7887

Apr – 2011 13260 1813.303 837.839 54237.287 6139.470 9267

May – 2011 9575 1752.750 695.398 47312.119 5057.450 8742

June – 2011 2295.50 295.503 305.769 8452.413 941.430 2148

July – 2011 -- -- -- -- -- --

Aug – 2011 -- -- -- -- -- --

Sep – 2011 -- -- 173.034 -- -- --

Oct – 2011 1020 -- -- 6113.485 694.670 672

Nov – 2011 10046 520.717 198.347 29271.305 3866.760 5607

Dec – 2011 15498 1954.346 889.507 42856.348 4767.200 7125

TOTAL 94503.50 11559.886 5242.906 337210.093 38616.390 58068

Avg./Month 10500.389 1895.063 893.170 37467.788 4290.710 6452

Avg./ Day 400.439 63.169 29.789 1428.856 163.629 246.051



4.2.6 Month Wise Raw Material Consumption For Sugar Production

Month Sugar

Cane,(MT) Lime (MT)

Sulphur (MT)

Phosphoric Acid (KGS)

Allezine (KGS)

CAUSTIC SODA (KGS)

Jan – 2011 167700 370.00 78.000 420.000 10.500 8600

Feb – 2011 145100 300.000 73.000 1265.000 921.500 8400

Mar – 2011 132230 271.550 70.710 1025.000 130.500 5650

Apr – 2011 146470

320.000

75.000

4360

NIL

9000

May – 2011 119740 405.000 55.000 2225 411.000 2050

June – 2011 19898.940 54.300 8.580 55 NIL 8100

July – 2011 -- -- -- -- -- --

Aug – 2011 -- -- -- -- -- --

Sep – 2011 -- -- -- -- -- --

Oct – 2011 23650 63.130 13.000 1555 NIL 150

Nov – 2011 105910 234.490 51.700 4560 NIL 3850

Dec – 2011 146700 243.000 56.200 7450 NIL 9350

TOTAL 1007398.9

40 2261.47

0 481.190 22915

1473.500 55150

Avg./Month

111933.216

251.274 53.466 2546.111 368.375

6127.778

Avg./ Day 4268.640 9.583 2.039 97.097 12.178 233.686



4.2.7 Process Description For Manufacturing Of Sugar From

Sugarcane

Matured cane according to plantation calendar is harvested from the

fields, trashes, tops and roots removed and clean cane is transported to

factory by means of trucks and bullock-carts. The cane is weighed and

dumped on feeder tables by means of sling hoist cane unloaded. At mill

for maceration hot water of 75 0 C is applied to extract maximum amount

of sugar cane juice (sugar) from the cane. The residual obtained after

milling (Bagasses) is fed to boilers to generate the steam for running the

different prime movers for milling and electrical power generation.

The mixed juice obtained from mills is weighed and phosphoric acid

isadded to it. After addition of phosphoric acid mixed juice is heated to

75 0 C in multiphase vertical tubular juice heaters where from it is sent

to juice sulphitor where milk of lime and SO2 gas is mixed in it and final

pH is maintained to 7.0 (+ or - 0.2). Sulphited juice is heated to 102 0 C (+

or - 2) and then sent to Dorr or clarifier for settling to flock formed. The

overflow of the Dorr Clarifier is clear juice and underflow is mud. The

mud is filtered through vacuum filter, mud is used as manure and the

filtrate is recycled and mixed with the mixed juice for reprocessing. The

clear juice obtained from Dorr Clarifier is concentrated to 60-65 0Bx. In

vapor cell and quintuple effect evaporators. The juice so concentrated i.e.

Syrup is sent to Syrup Sulphitor where it is sulphited with SO2 and its

pH is brought down to 5.0 to 5.2. Thus sulphited syrup is sent to pans

supply tank for further processing.



A massecuite is boiled with syrup melt and A light, Dry seed footing is

taken for A massecuite boiling in vacuum pans where sugar crystals are

developed for bagging. A massecuite of 94 °Bx. And 86-88 purity is

finally dropped in the crystallizers. From crystallizer this A massecuite is

sent to centrifugal machines where sugar crystals. A heavy molasses and

A light molasses are separted, sugar is sent to graded through grass

hoppers where sugar is separated in different grains, sizes S- 30, M- 30 &

L -30 are bagged, weighed in 100 Kgs. bags for domestic market and 50

Kgs. for export.

molasses are sent to pans storage tanks. A light is used in A massecuite

and A heavy is used for boiling B massecuite. 95-96 0Bx. and 71-73

purity. After purging B massecuite B heavy molasses and B sugar is

obtained. B sugar is melted and sent to pans and fed to a massecuite

pans. B heavy molasses is sent to pan storage tanks and is used for

boiling C massecuite of 100 0Bx. and 55-56 purity. C massecuite is

purged in C for workers where final molasses solution of 45 0Bx. is used

for lubrication, molasses obtained from C fore centrifugals is final

molasses it is weighed and is stored in five steel molasses storage tanks.

‘C’ fore cured sugar is affinated with C light molasses and sent to C After

worker centrifugals where hot water is applied and C after sugar and C

light molasses is obtained. C after sugar is melted and sent to pans for A

massecuite boiling and C light molasses used for C fore magma and

boiling C massecuite.



4.2.8 Daily Reports

DAILY MANUFACTURING REPORT

SEASON: 2011-2012 DATE: 30/03/2012 CROP DAY: 163

PAGE: 1

SR.

NO.

PARTICULARS SEASON 2011-2012 SEASON 2010-

2011

TODAY TODATE TODAY TODATE

1a. Cane Crushed(MT) -

B/W

WIL

Combined

2. Sugar produced (Qtls)

3. Exp.Recovery % Cane

4. Pol in Cane

5. Fiber % Cane

6. A.W. % Cane

B/W

WIL

C

ombined

7. A.W. % Fiber

B/W

WIL

Combined

8. Mill Extraction

B/W

0.000

0.000

0.000

1830.000

********

********

0.000

********

********

********

********

********

********

********

********

********

********

********

********

0.000

217740.000

413308.270

631048.270

671360.000

10.60

12.62

13.45

29.69

31.11

30.62

223.60

229.74

227.65

95.03

95.13

95.10

95.37

95.56

95.49

2.10

2.07

1380.000

2700.000

4080.000

4150.000

9.70

12.01

16.16

32.57

31.69

31.99

201.03

196.34

197.93

93.33

93.53

93.47

95.07

95.20

95.16

2.20

2.16

319000.

000

452040.

000

771040.

000

727310.

000

9.67

11.75

13.89

30.57

30.27

30.40

218.89

218.70

218.78

94.14

94.27

94.22

94.84

94.90

94.88



WIL

Combined

9. RME (Deer)

B/W

WIL

Combined

10. Pol % Bagasses

B/W

WIL

Combined

11. Moist. % Bagasses

B/W

WIL

Combined

12. Final Molasses

(MT)

13. Expected F.M. % Cane

14. Total Lost Hours

B/W

WIL

Combined

15.Burnt cane

(MT)

16. Burnt cane %

17. F.M. Purity

0.000

********

0.000

0.000

********

60.000

********

0.000

0.000

0.000

0.000

0.000

32.92

********

********

********

********

********

********

********

********

100.000

0.000

********

********

********

********

2.08

52.11

51.94

52.00

30465.000

4.85

887.25

289.000

528.30

557478.08

88.34

32.04

18.55

15.18

81.83

14.91

11.96

80.22

88.13

91.51

83.15

0.000

100.37

1519.12

2871.86

4391.94

2047.11

2.17

52.40

52.10

52.20

321.000

6.10

9.00

2.00

4.80

3736.42

91.58

34.17

18.57

15.04

81.01

14.82

11.76

79.39

86.21

90.62

79.87

0.000

95.46

1380.000

2700.000

4080.000

2208.000

2.19

2.17

2.18

52.48

52.38

52.42

38088.0

00

5.02

726.45

386.20

522.30

437560.

62

56.75

33.16

17.65

14.38

81.47

14.02

11.20

79.94

87.20

91.00

81.70

0.000

98.78



18. P.J. Brix %

Pol %

Purity

19. M.J. Brix %

Pol %

Purity

20. Boiling House Rec.

21. RBHR (Deer)

22. Java Ratio

23. B.F.C.W. % Cane

24. Net M.J. % Cane

25. Crushing Rate/24 Hrs.

a. Inc.

Stoppages B/W

WIL

Combined

b. Exc.

Stoppages B/ W

WIL

Combined

26. Sugar Production

S-30

S-31

M-30

M-31

L-30

********

********

********

1580

0.000

0.000

0.000

250

0.000

0.000

0.000

1830

86.34

0.000

0.000

0.000

13.66

0.000

0.000

0.000

100.000

0.000

3134.09

5186.52

393370

0.000

0.000

0.000

30810

0.000

494360

0.000

671360

58.59

0.000

0.000

0.000

4.59

0.000

36.82

0.000

100.000

0.000

0.000

2945.46

5100.000

0.000

2540

0.000

0.000

0.000

0.000

3220

0.000

4150

0.000

61.20

0.000

0.000

0.000

0.000

77.59

0.000

100.000

1937.44

2873.14

4811.23

2373.86

3200.47

5567.19

177500

265940

97180

0.000

25160

2000

319060

0.000

727310

24.41

36.56

13.36

0.000

3.46

0.27

43.87

0.000

100.000



L-31

50 kg Bags

BROWN

TOTAL

27. Sugar Production %

S-30

S-31

M-30

M-31

L-30

L-31

50 kg Bags

BROWN

TOTAL

27. STEAM TO DISTILARY-

M.T

28. F.M. STOCK

[B] MILL STOPPAGES REPORT

*** NO Stoppages in mill.

MFG. CHEMIST

CHIEF CHEMIST



DAILY MANUFACTURING REPORT

SEASON: 2011-2012 DATE: 31/03/2012 CROP DAY: 164

PAGE: 1

SR.

NO.

PARTICULARS SEASON 2011-2012 SEASON 2010-

2011

TODAY TODATE TODAY TODAT

E

1a. Cane Crushed(MT) -

B/W

WIL

Combined

2. Sugar produced (Qtls)

3. Exp.Recovery % Cane

4. Pol in Cane

5. Fiber % Cane

6. A.W. % Cane

B/W

WIL

Combi

ned

7. A.W. % Fiber

B/W

WIL

Combined

8. Mill Extraction

B/W

WIL

0.000

0.000

0.000

3200.000

********

********

0.000

********

********

********

********

********

********

********

********

********

********

********

********

0.000

217740.000

413308.270

631048.270

671360.000

10.60

12.62

13.45

29.69

31.11

30.62

223.60

229.74

227.65

95.03

95.13

95.10

95.37

95.56

95.49

2.10

2.07

1740.000

3160.000

4900.000

3440.000

9.65

11.96

16.24

32.25

31.88

32.01

199.29

195.85

197.07

93.32

93.45

93.40

95.06

95.19

95.14

2.20

2.16

320740

.000

455200

.000

775940

.000

730750

.000

9.66

11.75

13.91

30.58

30.28

30.41

218.77

218.52

218.62

94.13

94.26

94.21

94.84

94.91



Combined

9. RME (Deer)

B/W

WIL

Combined

10. Pol % Bagasses

B/W

WIL

Combined

11. Moist. % Bagasses

B/W

WIL

Combined

12. Final Molasses

(MT)

13. Expected F.M. % Cane

14. Total Lost Hours

B/W

WIL

Combined

15.Burnt cane

(MT)

16. Burnt cane %

17. F.M. Purity

18. P.J. Brix %

0.000

********

0.000

0.000

********

45.000

********

0.000

0.000

0.000

0.000

0.000

32.92

********

********

********

********

********

********

********

********

100.000

0.000

********

********

********

2.08

52.11

51.94

52.00

30510.000

4.85

887.25

289.000

528.30

557478.08

88.34

32.04

18.55

15.18

81.83

14.91

11.96

80.22

88.13

91.51

83.15

0.000

100.37

1519.12

2871.86

4391.94

2047.11

2.17

52.40

52.10

52.21

360.000

6.07

6.45

0.000

2.58

4501.49

91.87

34.19

18.57

15.04

81.00

14.77

11.73

79.39

86.19

90.61

79.54

0.000

95.29

1740.000

3160.000

4900.000

2379.49

94.88

2.19

2.17

2.18

52.48

52.38

52.42

38448.

000

5.03

732.90

386.20

524.88

442062

.11

56.97

33.17

17.66

14.38

81.43

14.02

11.21

79.94

87.10

90.93

81.70

0.000

98.76



Pol %

Purity

19. M.J. Brix %

Pol %

Purity

20. Boiling House Rec.

21. RBHR (Deer)

22. Java Ratio

23. B.F.C.W. % Cane

24. Net M.J. % Cane

25. Crushing Rate/24 Hrs.

a. Inc. Stoppages

B/W

WIL

Combined

b. Exc. Stoppages

B/ W

WIL

Combined

26. Sugar Production

S-30

S-31

M-30

M-31

L-30

L-31

********

********

********

********

3200

0.000

0.000

0.000

0.000

0.000

0.000

0.000

3200

100.00

0.000

0.000

0.000

0.000

0.000

0.000

0.000

100.000

0.000

3134.09

5186.52

396570

0.000

0.000

0.000

30810

0.000

494360

0.000

674560

58.79

0.000

0.000

0.000

4.57

0.000

36.64

0.000

100.000

0.000

0.000

3160.000

5490.20

0.000

1930

0.000

0.000

0.000

0.000

3220

0.000

3440

0.000

56.10

0.000

0.000

0.000

0.000

87.79

0.000

100.000

1936.2

5

2874.9

5

4811.7

8

2373.8

9

3200.1

9

5566.7

0

177500

267870

97180

0.000

25160

2000

322080

0.000

730750

24.29

36.66

13.30

0.000

3.44

0.27



50 kg Bags

BROWN

TOTAL

27. Sugar Production %

S-30

S-31

M-30

M-31

L-30

L-31

50 kg Bags

BROWN

TOTAL

27. STEAM TO DISTILARY-M.T

28. F.M. STOCK

44.08

0.000

100.00

0

[B] MILL STOPPAGES REPORT

*** NO Stoppages in mill.

MFG. CHEMIST

CHIEF CHEMIST



4.2.9 Material Handling Equipment

A.Unloader Crain: - Use for unload sugarcane from truck.

B.Conveyer belt: - Use for Carried forward sugarcane.

C.Feeder table: - Feeder Table Chains are used for feeding sugarcane to

cane carriers.



D.Fibrizer: - fibrizer make small fiber to the sugarcane for helping in

crushed to the sugarcane.

E. Mill machine: - wipe out a juice from crushed sugarcane.

F.Bagasses elevator: - use for carry out Bagasses in Bagasses carrier.



4.3 Marketing Department


4.3.2 Record of Customers

Major customer of sugar factory is company share holder, brokers and

government. So that record keeping by manual and by using computer

software.

4.3.3 Pricing

In the sugar factory price deciding according to analyzing the other state

sugar’s market price then take a decision in the board meeting. The

factory cannot take more profit to the customer.

Factor affecting pricing:-

1. Other state sugar price.

2. Sugar cane price.

3. Government policy etc.

Sales manager

Clerk

Peon



4.3.4 Collection of Receivable

In sugar factory no credit policy is use for collection they take 100%

advance against order. Tranjection done by cash, cheque, and D.D.

4.3.5 Channel of Distribution:

In CHALTHAN SUGAR FACTORY, they follow following channel of

distribution.

In this sugar factory Marketing Department is called “Sales

Department.”

So, Chalthan sugar factory follow the channel of distribution which is

shown in above diagram.

Chalthan Sugar factory is appointed the brokers to sale the sugar.

Brokers are middleman between manufacturer and traders or

wholesalers.

Wholesaler or Trader is sale the sugar to the Retailer. And retailer sales it

to customer. So sugar factory using three level of channel of distribution.

Manufacturer

Brokers

Traders

Retailers

Customers



4.4 Finance Department


4.4.2 Sources of Funds

� There is separate types of fund:

• Loan & Advances

• Share holders’ funds

• Over draft

• Reserve account

• Taxation etc.

I/C Chief Accountant

Assist. Chief accountant

Officers

Clerks



Bankers:-

1. The Gujarat State Cooperative Bank Ltd., Ahmedabad

2. The Surat Dist. Coop. Bank Ltd.,

3. State Bank of India, Bardoli/Kadodara

4. Bank of India, Chalthan

5. Dena Bank, Bardoli

6. Bank of Baroda, Umbhel (Surat)

7. HDFC Bank, Bardoli

8. Central Bank of India, Surat

9. SBI’s ATM facility at factory campus

4.4.3 Details of Share

Shares (As on 30.3.2010):-

Members Nos. Shares Paid up shares capital (Rs. In lacks)

Producers 14,967 19,8570 99.26

Non-Producer 1 10 0.05

Cooperatives 9 25 0.15



List of Share Holders and No. of Shares:-

Composition of Share Holders:-

No. of Shares No. of Members

1 12,800

2 1866

3 558

4 188

5 81

6 37

7 19

8 7

9 2

10 4

11 1

12 0

13 0

14 1

15 0

16 0

17 2

Sr.No. No. of Members

No. of Shares Percentage of Membership to total Member

01 11,629 11,629 78.55

02 2057 4114 13.89

03 689 2063 6.45

04 217 868 1.46

05 119 595 0.80

06 54 324 0.36

07 25 174 0.17

08 7 56 0.05

09 6 54 0.05

10 1 10 0.02

Total 14804 19892 100.00



4.4.4 Details of Funds

As on 31-3-2011 SCHEDULE NO. – 1

Sr. Name of Funds Balance as on 01-04-10

Addition During the year

Deduction during the year

Balance as on 31-03-11

1 Reserve Fund 23,69,875 23,369 …… 2,391,244

2 Depreciation Fund 491,906,417 30,351,837 2,166,332 520,091,922

3 Investment Allowance Reserve

2,12,983 …… …… 212,983

4 Investment Reserve Fund

89,060 …… …… 89,060

5 Bad Debt Reserve Fund

4,92,898 …… …… 492,898

Total 495,071,233 30,375,206 2,166,332 523,278,107

Details of Funds As on 31-3-2011

SCHEDULE NO. – 2

Sr. Name of Funds Balance as on 01-04-10




1 Members Development Deposit

14,634,417 …… 4,552,945 10,081,472

TOTAL 14,634,417 …… 4,552,945 10,081,472

4.4.5 Fixed Assets

As on 31-3-2011 SCHEDULE NO. – 3

Sr. Particulars of Assets




Gross blcok as on 31-3-11

1 Land 68,09,454 ------ ------ 6,809,454

2 Land leveling road & fencing

50,69,762 ------ ------ 5,069,762

3 Buildings 7,07,68,282 5,515,901 ------ 76,284,183

4 Temporary Shed 279,038 ------ ------ 279,038

5 Sugar Plant & Machinery

548,810,888 18,982,379 775,026 567,018,241

6 Other 5,29,712 ------ ------ 529,712



Machineries

7 Workshop Machineries

6,08,376 ------ ------ 608,376

8 Weighbridge & Scales

24,20,793 249,094 ------ 2,669,887

9 Water works 21,05,308 ------ ------ 2,105,308

10 Electric Installation

8,959,411 ------ ------ 8,959,412

11 Effluent water treatment plant

5,072,733 4,056,996 ------ 9,129,729

12 Vehicles 6,612,162 588,141 676,000 6,524,303

13 Office Furniture & Equipments

2,445,984 ------ ------ 2,445,984

14 Laboratory equipment

5,25,453 ------ ------ 525,453

15 Dead stock 4,243,995 20,000 ------ 4,245,995

16 Wireless set ------ ------ ------ ------

17 Hot water treatment plant

4,86,895 ------ ------ 486,895

18 Library 50,503 11,040 ------ 61,543

19 Office Building (Surat)

352,137 ------ ------ 352,137

20 Dead Stock (Surat)

54,197 ------ ------ 54,197

21 Computer & Printers

5,164,715 683,732 ------ 5,848,448

22 Agri. Laboratory 251,127 ------ ------ 251,127

23 Dead Stock (Agri.Lab.)

179,666 ------ ------ 179,666

24 Excavator, Tractor etc.

55,15,726 ------ 1,737,278 3,778,448

25 Soil laboratory ------ 2,031,632 2,025,700 5,932

26 Cane Hard vaster

------ 11,482,322 4,587,000 6,895,322

total 67,73,16,317 43,621,237 12,04,669 711,118,552



4.4.6 Details of Investment

As on 31-3-2011 (At Cost) SCHEDULE NO. – 4

Sr. Name of Party Balance as on 01-04-10


Addition during the year


1 50 Shares of Rs.100/- each of Gum. State Co-op. Bank Ltd, Ahemdabad

5,000

------

------

5,000

2 5910 Shares of Rs.100/- each of Surat Dist. Co-op Bank Ltd. Surat

5,91,000

------

------

5,91,000

3 30 Shares of Rs.10, 000/- each of National Heavy Egg. Co-op. Ltd. Pune

3,00,000

------

------

3,00,000

4 211 Shares of Rs.100/- each of Guj. State Co-op. Marketing Society Ltd, Ahemdabad

21,100

------

------

21,100

5 1792 Shares of Rs.20/- each of Surat Jilla Sahakari Kharid Vechan Sangh Ltd. Surat

35,840

------

------

35,840

6 93 Shares of Rs.1, 000/- and 5 shares of Rs.10, 000/-each of Indian Farmers Fertilizer Co-op. Ltd. Ahmedabad

1,43,000

------

------

1,43,000

7 2 Shares of Rs.25, 000/- each of Krishak Bharti Co-op. Ltd. New Delhi

50,000

------

------

50,000

8 10 Shares of Rs.100/- each of Shree Palsana Taluka Sahakari Kharid Vechan Sangh Ltd. Kadodara

1,000

------

------

1,000

9 162 Shares of Rs.500/- each of Gujarat Co-op. Grain Growers Federation Ltd. Ahemdabad

81,000

------

------

81,000

10 734 Shares of Rs.10/- each of Gujarat Narmada Valley Fertilizer Co-op. Ltd. Bharuch

7340

------

------

7340

11 1 Share of South Gujarat Co-op. Rice Complex Ltd.(Proposeal) Rs.1000/-

1,000

------

------

1,000

12 1062 Shares of Rs.2500/- each of Indian Concrete Pipe & Construction Co. Ltd. Chalthan

27,75,000

------

27,75,000

13 Copper Sugar Ltd. Dadariya 50,000,000 ------ ------ 50,000,000

Total 54,011,280 ------ ------ 54,011,280



4.4.7 Balance Sheet of 2010-11

Last Year Figure Capital & Liabilities Rupees Rupees

Authorized Share Capital

11,000,000

22000 shares of Rs.500 each

11,000,000

Issued & Subscribed Share Capital

10,000,000

20000 Shares of Rs. 500 each

10,000,000

Paid Up Share Capital

9,946,000

19892 equity shares of rs.500 each

9,946,000

495,071,233

Reserve Depre. And Other Funds

523,278,107

14,634,417

Members Development Deposits

10,081,472

Bank Overdraft & Loans

Surat dist. Co. Op. Bank Ltd, Chalthan

23,094,888

Pledge cash credit (Sugar) 834,947

90,955,728

Crop Loan 57,159,046

470,000

N.C.D.C.Godown Loan

Buffer stock Loan( The Surat Dis. Bank)

158,514,000

Excise Loan (The Surat Dis.

Bank)

79,254,000

273,034,616

137,247,993

78,861,125

Members Deposit (Unsecured)

75,494,225

Liabilities for Sugarcane

2,110,497,716

For Sugarcane (Members)

1,144,581,021

Liabilities for Expenses and Purchases and sundry Creditors

65,747,153

For expenses and of purchase 57,468,766

30,664,488

Interest Provision 35,658,895

54,571,690

Sundry Creditors 32,562,276

681,022,822

Members Sugarcane A/c. credit

843,614,422

832,00,153

969,304,359

Profit and Loss Account

279,261

Last Year Profit 594,626

Add: Current Year Profit



315,365 203,668

594,626

798,294

381,645,886

Total

2,870,731,471

Last Year Figure paroperties and assets Rupees Rupees

Fixed Assets ( At Cost )

677,316,317

( As per Schedule No. 3) 711,118,551

54,011,280

Investments (As per Schedule No. 4)

54,011,280

143,910,752

Investments in Distillery Unit 175,901,284

Current Assets

15,095,452

Machinery Spares 15,085,984

26,724,102

Stores 31,802,018

5,681,269

Packing Stores 10,602,025

499,069

Tools & Equipments 484,935

1,499,927,685

Stock of sugar 1,283,350,847

36,242,920

Stock of Molasses 27,546,045

10,000,000

Stock of Bagas 4,000,000

105,700

Stock of Pesticides 844,661

411,817

Factory Farm Kosmadi 549,865

76,913,933

Sundry Debtors 79,188,126

1,67,16,01,947 (As per inventories certified by M.D.)

1,453,454,506



4.4.9 Operating Cycle

4.4.8 Estimation of working capital requirement

Particulars RS. RS.

A) Estimation of current assets

a) Cost of Raw Material inventory in stock

……………..

b)Cost of WIP inventory by taking its components

i) Raw material/WIP inventory ……………..

ii)Direcct labour ……………..

iii)Overhead Exp's ……………..

iv)Outstanding Receivables ……………..

TOTAL WORK IN PROGRESS (i+ii+iii+iv)

……………..

c)Cost of Finished Goods inventory

……………..

d)Amount of Debtors

……………..

e)Minimum Cash & Bank level

……………..

TOTAL CURRENT ASSETS (A)

…………….

B)Estimation of CURRENT LIABILITIES

a)amount of creditors

……………

b)Out standing exp's/Payables

……………

TOTAL CURRENT LIABILITIES (B)

……………

NET WORKING CAPITAL=(CA-CL)

NET WORKING CAPITAL=TOTAL CURRENT ASSETS-TOTAL CURRENT LIABILITIES

Customer

Cash

Work-in-

Process

Sugarcane

Sugar



4.5 Purchases Department


4.5.2 Ordering:-

The chalthan sugar factory order there requires material by following

step.

Purchase manager

Assistant manager

Clerk

Peon



1st:-sugar factory provide two kind of form. For order require equipment

& material

i. TATKAL MANGNI PATRA (EMERGENCY REQUIRE FORM)



ii. MAAL KHARID MAGNI PATRA (Goods Purchase Require Form)

By using that form any department order the requires equipment or

material.



2nd:-the form come in purchase department then classified that form

according to their requirement.

i.If there tatkal mangni patra so order place immediately.

ii.If there magni patra so that decision take on the board meeting and then

place order.



4.5.3 Classification of stores items

4.5.4 Maintenance of supplier’s database

In the sugar factory maintain supplier’s database by two factors

1. Manually

2. In computer software which name is “purchase record”

Store item

Sugarcane Other material

1. Good sugarcane

2. Burn sugarcane

3. Putrefaction sugarcane

1. Oil

2. Tools

3. Equipment

Etc.



4.5.5 System of handling rejections:-

If there any problem on goods or goods is not according to the order so

the manager send rejection latter.



4.6 Other Departments

4.6.1 Administration Department

For any paper work admin department is useful. The head of department

is MR. Harish vashi. Hear all kind of data done filing.

4.6.2 Security Department

• In the sugar factory all security done by manually.

• Head guard name is Sureshbhai dhimmar.

• There is 4 jamadar.17 day and 17 night guard.

Administrative officer

Mr. Harish vashi

1. General officer

2. Transport 3. Weigh bridge



4.6.3 Transport Department

The sugar factory also provides transport facility to the farmer for carry

the sugarcane farm to factory at some cost. The head of department is

kanakshigh gohil. Factory has 210 truck and 200 bullock cart. The price

list is given below.

TRUCK RENT PRICE LIST No. Km Rs(per.ton)

1 0-5 Rs. 57.12

2 6-10 Rs. 77.77

3 11-15 Rs. 97.22

4 16-20 Rs. 119.66

5 21-25 Rs. 139.71

6 26-30 Rs. 160.35

7 31-35 Rs. 178.60

8 36-40 Rs. 200.46

9 41-45 Rs. 219.90

10 46-50 Rs. 239.35

11 51-55 Rs. 258.80

12 56-60 Rs. 268.64

13 61-65 Rs. 296.85

14 66-70 Rs. 317.49

15 71-75 Rs. 336.91

16 76-80 Rs. 357.54

17 81-85 Rs. 376.96

18 86-90 Rs. 397.59

19 91-95 Rs. 416.91

20 96-100 Rs. 437.65

BULLOCK CART RENT PRICE LIST

Km Rs(per.ton)

1-2 30

3 34

4 36

5 38

6 42

7 46

8 50

9 54

10 58



4.6.4 Agriculture Department

Soil:-

The soil is alluvial black, plain in legal. There is no proper drainage to the

soil. The water table is raising and salt are also developing in some

places. The government has started deepening nalas and they have

prepared drainage schemes all over. The analysis of average good soil is

a. Ph 7.4 to 8.4

b. Soluble salts 0.10 to 0.50

c. Organic carbon 0.30 to 0.45

d. Available P 205 from trace to 40 kg. per hectare

e. Available potash 350 to 450 kgs.

The principal crop grown is paddy, cotton, banana, groundnut, juwar

and vegetables.

Climate:-

It is tropical monsoon type with three well defined seasons. The rainfall is

near about 44-45 with heavy rain in monsoon from the 2nd week of June

to 3rd week September. About 97% of the rainfall is receiving during

monsoon only. Half the precipitation is received in July to august. The

rainy days are around 49 days. The temperature begins to rise from

March onwards. April and May months are the hottest with maximum

temperature ranging from 99* F to 101* F and above. With the break of

monsoon in June, the maximum temperature falls down to 87* F till

September. Again the temperature shoots up to 96*F in October. With the

one set of winter, the maximum temperature falls down to 87*F and it

remains so till February. December and January are the coldest months

with maximum temperature of 53*F.

The diyrnal variation of temperature is maximum in winter, the mean

being 32*F and the least in monsoon which is about 14*F.



4.6.5 Environment & pollution control measures

In sugar factory two kind of pollution is more done.

(i) Water

(ii) Air

A) Pollution Control measures

For measure water pollution take the sample of water and check that

sample by the expert chemist.

B) Effluent Treatment

Treatment process for water pollution they use ETP plan. in this plane

they do purify water and reuse of that water.

For air pollution they do plantation of tree.

Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd- Viral Shah

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Transcript of Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd- Viral Shah