Sugar Industry.

Hi Professionals,
Please go through the scenario and please help in setting the solution.
Scenario:
The Sugar Industry contains one plant. Sugar and Ship Sugar are the two main products and spirit, liquor, power are by-products. The production of Sugar takeplace from Oct to May of the year. Other by-products are manufactured full year.
Conflicts:
1. I'm thinking for Repetitive Manufactruing (REM) because in the specified period of time with the rate of 12,000 Tonned Cane Crushed Per Day (TCPD) production takes place. But as I told about sugar depending on brightness and the crystal size graded into various grades and at the start the quantity to be produced i.e. Planned Quantity is not finalized. After production completion and seperation of sugar as per grades and their packing into different types of bags, the actual production quantity is confirmed grade wise.
2. While producing Sugar the Bagasse get generated which is then used for Boiler Steam Generation which eventually used for Power Generation.
3. Molasses is produced as by-product/co-product which then used for producing Spirit, Ethanol.
4. From some quantity of Ethanol Liquor is produced.
By the same process with one main product three by-products/co-products are produced simultaneously. So, REM in SAP will provide solution OR PP PI will be the best option?
Please suggest me the solution utilizing your best of the experiences Industrial/SAP.
Regards,
Abu Arbab

Hi ,
As per the Situation in the Sugar Industry u should Go with the PPPI , because sugar yield is depend on the sugercane quality & the net production will come to know after the production , if u will go with the PPPI u can impliment the Material quantity calculation scenario which will give you exact production rate .One more thing U can impliment the PI sheet which is very important in the process Industry which will provide the less documentation & keep record in the systeam. U can manage the Batch in the PPPI & resource & capacity planning is quite high in the PPPI.
satish

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BOM creation for a sugar industry -reg

Hi,
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if the sugar cane is of some quality you may get 1 ton out put , if it is of different quality you may get 0.8 ton
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SAP explodes BOMs top-down not bottom-up hence this is diffcult to accomodate.
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Hi
I am working as SAP PM in a renewed US Group of Companies. After SAP deployment in two group companies we are extending SAP to our group sugar units.
Expert opinion required,
Which one is best to map Sugar production from Sugar Cane? & Why.
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May be a reference Business Blueprint of SAP PP module for Sugar manufacturing will helpful for me to understand the things.
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I would appreciate, if anyone of you could forward me the sample blueprint or document related to Sugar Industry.
[email protected]
Points will be assigned.
Thanks
Arvind.

Hi,
I would appreciate, if anyone of you could forward me the sample blueprint or document related to Sugar Industry.
[email protected]
Points will be assigned.
Thanks
Arvind.

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Hi All,
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Hi All,
configuration for a sugar industry.... Repetative manifacturing with make to stock scenario or process costing which one is best??
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Plz suggest me

Roll Out points

Hi,
Our client is a sugar industry and they have recently started a new power plant using the Baggas(crushed cane). They want to create new company code as well as new purchasing organisation for the same. Could you please mention the points like pricing procedure,material types etc i need to keep in mind while preparing the blueprint. Please mention the things which should be keeping in mind while doing this roll out.Thanks in advance.
Warm Regards
VT
Edited by: VT on Jul 21, 2009 8:18 PM

Dear,
Its difficult to give you exact points to be considered basing on differences in business existed and expected requirements, but have a look at:
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http://www.open.hr/hiz/hrusko/RolloutPresCASE3.pdf
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hi,
use PI module for sugar industires
sree

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LabVIEW programmer

Respected sir/madam,
i am D.muthukumar complete my B.E in electronics
and instrumentation engineering and i have knowledge about in
labview based automation in real time project and simulation project.So i kindly requested to you provide the opportunities in
your oraganisation and i am follow the rules and regulation of the oraganisation for improve the organisation,my knowledge and my nation.
thankyou
your's faithfully
D.muthukumar.
D.MUTHUKUMAR,
S/O V.P.Deivasigamani,
Kilangundal (P.O),
Mulanur (Via),
Erode District - 638 106
Email:[email protected]
Ph: 04202-228769.
OBJECTIVE:
To get placed in a reputed organization and to use my skills to develop the organization, my career and my nation.
PERSONAL SKILLS:
Ability to communicate in an effective and impressive manner, Quick learning capacity, Easy going and Self-Determined Team Player.
EDUCATIONAL QUALIFICATION:
Qualification Institution Year of Passing % of Marks
B.E(EIE) Erode Sengunthar Engineering College,Thudupathi/ Anna University May-2005 69.42% (Upto 7thsem)
Diploma in ECE Thiru Ramakrishna Nallammai Polytechnic, Dharapuram. April-2002 87.9%
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S.S.L.C. Govt High School, Seshayanpalayam May-1998 83.4%
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Operating System : Windows 9x, Windows NT
Languages : C
Packages : Visual Basic-6.0, LabVIEW 7.1
AREAS OF INTEREST:
 Automation using LabVIEW.
 Industrial instrumentation.
 VHDL, Microprocessor and Microcontroller Programming.
PROJECT DONE:
 Title : VIRTUAL INSTRUMENTATION BASED AUTOMATION FOR
PAPER COATING PROCESS” using LabVIEW 7.1
 Title : PICK AND PLACE ROBOT WITHOUT USING MICROCONTROLLER
 Title : VIRTUAL INSTRUMENTATION BASED WATER TREATMENT
PLANT AUTOMATION FOR BANNARI AMMAN SUGARS INDUSTRY
ACHIEVEMENTS:
 Presented a paper in a National conference on “Virtual instrumentation based harmonic analysis of Component levels in infra red spectroscopy” at Tamilnadu College of Engineering on 26.08. 2004
 Member of Rotary club and Participated in the Rotary international District 3200 conference
 Won the first prize in the District level poetry competition
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EXTRA-CURRICULAR ACTIVITIES:
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PRERSONAL DETAILS:
Age & DOB : 22 yrs, 20/04/1983.
Sex : Male.
Marital Status : Single.
Nationality : Indian.
Languages known : English & Tamil (to Read, Write & Speak).
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Reference:
 Dr.T.Shanmugam,
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 A.Vidhya,
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Hi Tom,
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Sugar industries

Hai pp gurus
Any one pls explain me about sugar industries sap pp -pi implementation.
Advance Thanks

>
kandan kandan wrote:
> Hai pp gurus
>
> Any one pls explain me about sugar industries sap pp -pi implementation.
>
> Advance Thanks
>
kandan kandan wrote:
> Hai pp gurus
>
> Any one pls explain me about sugar industries sap pp -pi implementation.
>
> Advance Thanks
General Process of Sugar Manufacturing -
Raw Materials
Sugar is a broad term applied to a large number of carbohydrates present in many plants and characterized by a more or less sweet taste. The primary sugar, glucose, is a product of photosynthesis and occurs in all green plants. In most plants, the sugars occur as a mixture that cannot readily be separated into the components. In the sap of some plants, the sugar mixtures are condensed into syrup. Juices of sugarcane (Saccharum officinarum) and sugar beet (Beta vulgaris) are rich in pure sucrose, although beet sugar is generally much less sweet than cane sugar. These two sugar crops are the main sources of commercial sucrose.
The sugarcane is a thick, tall, perennial grass that flourishes in tropical or subtropical regions. Sugar synthesized in the leaves is used as a source of energy for growth or is sent to the stalks for storage. It is the sweet sap in the stalks that is the source of sugar as we know it. The reed accumulates sugar to about 15 percent of its weight. Sugarcane yields about 2,600,000 tons of sugar per year.
The sugar beet is a beetroot variety with the highest sugar content, for which it is specifically cultivated. While typically white both inside and out, some beet varieties have black or yellow skins. About 3,700,000 tons of sugar are manufactured from sugar beet.
Other sugar crops include sweet sorghum, sugar maple, honey, and corn sugar. The types of sugar used today are white sugar (fully refined sugar), composed of clear, colorless or crystal fragments; or brown sugar, which is less fully refined and contains a greater amount of treacle residue, from which it obtains its color.
The Manufacturing
Process
Planting and harvesting
     1 Sugarcane requires an average temperature of 75 degrees Fahrenheit (23.9 degrees
In the United States, harvesting of both cane and sugar beet is done primarily by machine, although in some states it is also done by hand. The harvested cane stalks and beets are loaded mechanically into trucks or railroad cars and taken to mills for processing into raw sugar. Once there, they are cleaned, washed, milled to extract juice, filtered, and purified. The result is a clear, sugar-filled juice.
Celsius) and uniform rainfall of about 80 inches (203 centimeters) per year. Therefore, it is grown in tropical or subtropical areas.
Sugarcane takes about seven months to mature in a tropical area and about 12-22 months in a subtropical area. At this time, fields of sugarcane are tested for sucrose, and the most mature fields are harvested first. In Florida, Hawaii, and Texas, standing cane is fired to burn off the dry leaves. In Louisiana, the six- to ten-feet (1.8- to 3-meter) tall cane stalks are cut down and laid on the ground before burning.
     2 In the United States, harvesting (of both cane and sugar beet) is done primarily by machine, although in some states it is also done by hand. The harvested cane stalks are loaded mechanically into trucks or railroad cars and taken to mills for processing into raw sugar.
Preparation and processing
     3 After the cane arrives at the mill yards, it is mechanically unloaded, and excessive soil and rocks are removed. The cane is cleaned by flooding the carrier with warm water (in the case of sparse rock and trash clutter) or by spreading the cane on agitating conveyors that pass through strong jets of water and combing drums (to remove larger amounts of rocks, trash, and leaves, etc.). At this point, the cane is clean and ready to be milled.
When the beets are delivered at the refinery, they are first washed and then cut into strips. Next, they are put into diffusion cells with
After being purifed, the clear juice undergoes vacuum evaporation to remove most of the water. In this process, four vacuum-boiling cells are arranged in series so that each succeeding cell has a higher vacuum. The vapors from one body can thus boil the juice in the next one, a method called multiple-effect evaporation. Next, the syrupy solution is vacuum-crystallized to form sugar crystals. The remaining liquid is removed using centrifugaling and drying, and the sugar is packaged.
water at about 175 degrees Fahrenheit (79.4 degrees Celsius) and sprayed with hot water countercurrently to remove the sucrose.
Juice extraction pressing
     4 Two or three heavily grooved crusher rollers break the cane and extract a large part of the juice, or swing-hammer type shredders (1,200 RPM) shred the cane without extracting the juice. Revolving knives cutting the stalks into chips are supplementary to the crushers. (In most countries, the shredder precedes the crusher.) A combination of two, or even all three, methods may be used. The pressing process involves crushing the stalks between the heavy and grooved metal rollers to separate the fiber (bagasse) from the juice that contains the sugar.
     5 As the cane is crushed, hot water (or a combination of hot water and recovered impure juice) is sprayed onto the crushed cane countercurrently as it leaves each mill for diluting. The extracted juice, called vesou, contains 95 percent or more of the sucrose present. The mass is then diffused, a process that involves finely cutting or shredding the stalks. Next, the sugar is separated from the cut stalks by dissolving it in hot water or hot juice.
Purification of juiceclarification
and evaporation
     6 The juice from the mills, a dark green color, is acid and turbid. The clarification (or defecation) process is designed to remove both soluble and insoluble impurities (such as sand, soil, and ground rock) that have not been removed by preliminary screening. The process employs lime and heat as the clarifying agents. Milk of lime (about one pound per ton of cane) neutralizes the natural acidity of the juice, forming insoluble lime salts. Heating the lime juice to boiling coagulates the albumin and some of the fats, waxes, and gums, and the precipitate formed entraps suspended solids as well as the minute particles.
The sugar beet solution, on the other hand, is purified by precipitating calcium carbonate, calcium sulfite, or both in it repeatedly. Impurities become entangled in the growing crystals of precipitate and are removed by continuous filtration.
     7 The muds separate from the clear juice through sedimentation. The non-sugar impurities are removed by continuous filtration. The final clarified juice contains about 85 percent water and has the same composition as the raw extracted juice except for the removed impurities.
     8 To concentrate this clarified juice, about two-thirds of the water is removed through vacuum evaporation. Generally, four vacuum-boiling cells or bodies are arranged in series so that each succeeding body has a higher vacuum (and therefore boils at a lower temperature). The vapors from one body can thus boil the juice in the next onethe steam introduced into the first cell does what is called multiple-effect evaporation. The vapor from the last cell goes to a condenser. The syrup leaves the last body continuously with about 65 percent solids and 35 percent water.
The sugar beet sucrose solution, at this point, is also nearly colorless, and it likewise undergoes multiple-effect vacuum evaporation. The syrup is seeded, cooled, and put in a centrifuge machine. The finished beet crystals are washed with water and dried.
Crystallization
     9 Crystallization is the next step in the manufacture of sugar. Crystallization takes place in a single-stage vacuum pan. The syrup is evaporated until saturated with sugar. As soon as the saturation point has been exceeded, small grains of sugar are added to the pan, or "strike." These small grains, called seed, serve as nuclei for the formation of sugar crystals. (Seed grain is formed by adding 56 ounces [1,600 grams] of white sugar into the bowl of a slurry machine and mixing with 3.3 parts of a liquid mixture: 70 percent methylated spirit and 30 percent glycerine. The machine runs at 200 RPM for 15 hours.) Additional syrup is added to the strike and evaporated so that the original crystals that were formed are allowed to grow in size.
The growth of the crystals continues until the pan is full. When sucrose concentration reaches the desired level, the dense mixture of syrup and sugar crystals, called massecuite, is discharged into large containers known as crystallizers. Crystallization continues in the crystallizers as the massecuite is slowly stirred and cooled.
     10 Massecuite from the mixers is allowed to flow into centrifugals, where the thick syrup, or molasses, is separated from the raw sugar by centrifugal force.
Centrifugaling
     11 The high-speed centrifugal action used to separate the massecuite into raw sugar crystals and molasses is done in revolving machines called centrifugals. A centrifugal machine has a cylindrical basket suspended on a spindle, with perforated sides lined with wire cloth, inside which are metal sheets containing 400 to 600 perforations per square inch. The basket revolves at speeds from 1,000 to 1,800 RPM. The raw sugar is retained in the centrifuge basket because the perforated lining retains the sugar crystals. The mother liquor, or molasses, passes through the lining (due to the centrifugal force exerted). The final molasses (blackstrap molasses) containing sucrose, reducing sugars, organic nonsugars, ash, and water, is sent to large storage tanks.
Once the sugar is centrifuged, it is "cut down" and sent to a granulator for drying. In some countries, sugarcane is processed in small factories without the use of centrifuges, and a dark-brown product (noncentrifugal sugar) is produced. Centrifugal sugar is produced in more than 60 countries while noncentrifugal sugar in about twenty countries.
Drying and packaging
     12 Damp sugar crystals are dried by being tumbled through heated air in a granulator. The dry sugar crystals are then sorted by size through vibrating screens and placed into storage bins. Sugar is then sent to be packed in the familiar packaging we see in grocery stores, in bulk packaging, or in liquid form for industrial use.
Byproducts
The bagasse produced after extracting the juice from sugar cane is used as fuel to generate steam in factories. Increasingly large amounts of bagasse are being made into paper, insulating board, and hardboard, as well as furfural, a chemical intermediate for the synthesis of furan and tetrahydrofuran.
The beet tops and extracted slices as well the molasses are used as feed for cattle. It has been shown that more feed for cattle and other such animals can be produced per acre-year from beets than from any other crop widely grown in the United States. The beet strips are also treated chemically to facilitate the extraction of commercial pectin.
The end product derived from sugar refining is blackstrap molasses. It is used in cattle feed as well as in the production of industrial alcohol, yeast, organic chemicals, and rum.
Quality Control
Mill sanitation is an important factor in quality control measures. Bacteriologists have shown that a small amount of sour bagasse can infect the whole stream of warm juice flowing over it. Modern mills have self-cleaning troughs with a slope designed in such a way that bagasse does not hold up but flows out with the juice stream. Strict measures are taken for insect and pest controls.
Because cane spoils relatively quickly, great steps have been taken to automate the methods of transportation and get the cane to the mills as quickly as possible. Maintaining the high quality of the end-product means storing brown and yellow refined sugars (which contain two percent to five percent moisture) in a cool and relatively moist atmosphere, so that they continue to retain their moisture and do not become hard.
Most granulated sugars comply with standards established by the National Food Processors Association and the pharmaceutical industry
Srini

Industry error while doing replication of customer from R/3 to CRM

Hi,
We have production system already implemented and going for roll out for another company both R/3 & CRM.
We have generated conditional objects while doing roll out phase. From then we are getting this error.
Problem:
Customers are not getting replicated to CRM. And in SMW01 the error log says
"Industry 300 not defined for industry system SAPS
Validation error occurred: Module CRM_BUPA_MAIN_VAL, BDoc type BUPA_MAIN."
Since we are going for roll out we have done initial load of all conditional objects
like 'DNL_COND_A002' etc.
After running we did checked in R3AM1 - everything was DONE - in green colour.
But in SLG1 - Display log - there are several entries in Red colour.
Message text says -
"It is not possible to change client-independent Customizing objects
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Change of client-independent Customizing objects is not permitted in the client in which the transfer of data for table T682 is executed.
System response:
As table T682 contains client-independent Customizing, data transfer is interrupted.
Procedure for System Administration
Provide users with the appropriate authorization to execute data transfer in a client in which changes to client-independent objects is permitted."
Now queues are pilled up with the industry error and don't know how to correct these errors.
Please help.
Regards,
Dhanraj Dange

Hi pankaj,
Step 1:After completing Initial Download tranfer of data takes place from R/3 to CRM system in the form of Customers or employess.
Bulk data will be flown in the first step.
I f there are any errors ,we solve the errors and replicate them manually by using CRMM_BUPA_map.
Step2:There are few customers which are created daily in SAP SD or R/3 and these customers are transfered from R/3 to CRM .
So my question is Is this b'cos of Delta Download or Bcoz of some other Reason.
If so "Is there any specific name for this.
Regards,
divya

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