International Journal of Applied Agricultural Research ISSN 0973-2683 Volume 4 Number 3 (2009) pp. 203 214 Research India Publications http://www.ripublication.com/ijaar.htm Prospects of Jaggery Industry in Karnataka - A Case Study G.B. Jayamala, M. Chowde Gowda, H.N. Ramya, M. Shankar and P.N. Krishnamma Dept. of Agril. Engineering, University of Agricultural Sciences, Bangalore 560 065 Karnataka has been playing a key role in sugar industry since 1950s with rapid expansion during 1990s and onwards. Sugar cane cultivation on 0.16 million hectares during 1980-81 has increased to 0.48 million hectares during 2006-07 i.e., over three fold increase in two and a half decades. Cane yield per hectare was 66 tones during 1979-80 has increased to 105 tones during 2006-07 i.e., 59 per cent increase. During 1980-81 number of sugar factories were only 23 has increased to 63 i.e., nearly three fold increase. Similarly in respect of sugar recovery percent there is a spectacular increase by 0.42 per cent from 1980-81 [1]. Karnataka is one of the major sugarcane growing states in the country producing 48.96 million tones of cane and ranking fifth in area as well in production and stands second in the productivity. The recovery percentage is about 10.79 per cent. The major sugarcane growing districts in Karnataka are Belgaum (43 %), Bagalkot (16 %), Bijapur (10 %), Mandya (5 %) and Mysore (4 %). There are 63 sugar industries in Karnataka, out of which two industries are under government sector, 21 are managed by co-operatives and the remaining 40 are owned by private management. Out of 63 sugar industries, 33 sugar industries are located in northern three districts of Karnataka viz. 19 in Belgaum, 11 in Bagalkot and 3 in Bijapur. The data in Table 1 indicates that up to the year 2000 there were only 34 sugar mills in Karnataka crushing cane and from 2000 onwards 15 new mills have commissioned and other 14 are in the pipeline. It is also clear that no sugar mills exist before 1930 in Karnataka. The entire cane grown prior to 1930 was used for making jiggery. During last two decades (Table 2), the scenario of sugarcane cultivation and processing in Karnataka has changed prominently as compared to the India as a whole. Some of the prize winning farmers in Bagalkot and Belgaum districts of Karnataka have harvested up to 360 tones/ha. The state has large potential to increase the productivity of cane as well as sugar recovery level. The above facts show that technology and do-how exist in Karnataka to achieve a much higher level of productivity and quality production.
204 G.B. Jayamala et al Table 1: Sugar mills established during different periods in Karnataka. Sl.No. Year of establishment No. of sugar mills 1 1930-40 2 2 1941-50 1 3 1951-60 1 4 1961-70 3 5 4971-80 13 6 1981-90 6 7 1991-2000 8 8 2000-2007 15+14* Total number of sugar factories 63 *14 Sugar factories are likely to commence crushing soon Table 2: Progress of sugarcane industries in India and Karnataka over last two and a half decades [1]. SL. Particulars 1980-81 2006-07 % increase No over 1980-81 1 No. of sugar mills - India 314 553 76 2 No. of sugar mills - Karnataka 23 63 174 3 Area under sugarcane in ha-india 26,48,000 43,61,000 65 4 Area under sugarcane in ha- Karnataka 1,56,000 4,80,000 208 5 Cane yield tone/ha - India 48.0 64.6 35 6 Cane yield tone/ha - Karnataka 66.0 105.0 59 7 Sugar recovery percent -India 9.98 10.36 0.38 8 Sugar recovery percent - Karnataka 10.37 10.79 0.42 Need for establishment of jaggery industry in Karnataka Jaggery, which is still dominating in the preparation of food items in the rural area, is of ancient origin. Jaggery making is a rural based agro-industry located at the convenient place of the farmers and helping them to avoid the harassment that the farmers has to undergo in transporting cane to the sugar mills, cost of transportation involved and delay in payments made by the sugar mills [2]. According to the estimates made two third of the sweeteners required in the food habits of rural populace is met by jaggery because of the facts that it is not only a chief sources of sweetening in the food habits of rural mass but has considerable linkage in the rural economy. By 2020 the Indian population would be around 1360 million. Considering an average of 40 kg of sweeteners consumption per head per year, the country would produce 54 million tones of sweetener to meet the demand, of which over 40 per cent is met by jaggery alone. This industry requires very less capital investment for establishment and operation and does not require any sophisticated machinery and
Prospects of Jaggery Industry in Karnataka 205 equipment as compared to sugar industry and hence, production of jaggery is within the reach of sugarcane farmers or a small entrepreneur [3]. Further, it is estimated that crushing sugarcane for jaggery, fetches three times more profitable than supplying to sugar mills [4]. Over 55-60 per cent of the sugarcane produced in Karnataka is crushed for jaggery production. Apart from creating an employment opportunity to the rural people the jaggery industry provides highly nutritious product at lower cost to the rural poor [5 & 6]. It is therefore, imperative to establish this industry in the state by introducing modern equipment and technology; (i) to strengthen the economic status of the rural community, (ii) to encourage decentralized production of jaggery with available locally made equipment and machinery, (iii) to encourage the farmer to harvest the cane with his convenient avoiding transportation cost of cane to the sugar mill and (iv) to create ready market in the neighborhood. Apart from this there will be flexibility in shifting jaggery production into value added sweeteners like, khandsari (brown sugar), rab (massecuite), liquid jaggery, powdered jaggery etc. which might be more advantages to the jaggery producers. Choice of Jaggery Production and consumption of sugar has increased enormously in the world. The average consumption of sugar per capita differs from country to country. The wealthiest countries like U.K., U.S.A., Canada, Sweden and Australia consume an average of about 50 kg per capita of sugar a year, while the under developed countries like India, Pakistan and China consume an average of 15 kg or less per capita. Much of the sugar in the diets of the high-consuming countries is from manufactured foods like confectionery, soft drinks and bakery products. Dietary sugar is a mixed blessing because it makes the food more attractive and appetizing, but excess consumption leads to sever health problems of human beings. Because of this, more attention is paying towards the development of alternate sweeteners from sugarcane. Jaggery is considered to be the best alternative sweetener as we could see from Table 3 that it has a good source of minerals like calcium, iron and phosphorus and other medicinal properties as compared to sugar which serves the purpose of only sweetening agent. Production of jaggery is cheap and simple as compared to sugar. It can be produced at farm level with semiskilled workers without any complicated machineries and equipment. The phenomenal expansion of sugar industry in Karnataka had little impact on the jaggery industry. The jaggery industry in Karnataka continues to be an industry of grate importance and relevance. There is a considerable demand for jaggery in the market for local consumption and also for export, hence option for producing good quality jaggery with advanced practices is imminent which enhances the consumption rate, fetch higher market and improve the economy of the cultivators, jaggery makers and traders [7].
206 G.B. Jayamala et al Table 3: Composition in sugar and jaggery made from sugarcane [8]. Item Moisture (g) Sucrose (g) Reducing Sugar (g) Protein (g) Fat (g) Calcium (mg) Phosphorus (mg) Iron (mg) Total minerals (g) Energy kcl Sugar 0.40 99.50 --- --- --- --- --- --- 0.05 398 Jagger 3-10 60-85 5-15 0.40 0.10 8.00 4.00 11.4 0.6-1.0 383 y 0 Option of processing sugarcane for jaggery Comparative analysis made on processing of cane for sugar and jaggery (Table 4) shows that crushing of sugarcane for jaggery is more advantageous than production of crystal sugar. It is clear from the data that more sucrose is recovered in sugar industry due to higher juice extraction but certain minerals which are considered to be important for health and nutrition point of view are lost. In case of jaggery making sucrose recovery relatively low due to lower juice extraction but it is supplemented by recovery of reducing sugars and minerals which make it more nutritious and health friendly. Table 4: Loss of cane constituents during processing of jaggery and sugar [8]. Constituents Approximate % Percent loss during processing of cane of cane weight Jaggery Sugar Sucrose 8-13 3-4 0.7-1.9 Reducing sugar 0.3-2.5 0.1-1.0 0.3-2.5 Minerals (Ca, Mg, Fe, Mn, P) 0.1-0.2 0.0 0.1-0.2 Proteins and Fats 0.1-0.15 0.2-0.3 0.1-0.15 Over view of sugarcane processing industries in Karnataka Jaggery making is a vast cottage industry under the decentralized sector in Karnataka. Most of the jaggery units in state are operated by the farmers for crushing their own crop. Some of the jaggery units operate purely on commercial basis by purchasing cane from the farmers. Jaggery units in Karnataka supply over 40 per cent demand of the sweetener in the state besides providing employment to the rural people. Despite its vast magnitude, the jaggery industry has serious drawbacks in terms of poor quality production, lack of standardization in quality production, wasteful utilization of heat energy, excessive loss of product due to improper processing and poor hygienic conditions of the units, improper packing and storage. Jaggery Processing The jaggery units operates for 5-6 months in a year engaging skilled /semiskilled man power available in the locality on contract basis with some experience on jaggery
Prospects of Jaggery Industry in Karnataka 207 processing. The major advantage of establishing jaggery unit by the farmer is timely harvesting and crushing of matured sugarcane with a limited haulage is under his control, there by he can get quality product with higher yield. Figure 1 depicts the unit operations of typical jaggery processing industry. Figure 1: Flow chart showing typical jaggery processing operation in Karnataka.
208 G.B. Jayamala et al (i) Juice extraction The extraction of juice should be taken as far as possible from fresh cane and in any case not later than 24 hours after harvest to prevent inversion of sucrose into glucose and fructose and formation of other harmful substances. The juice should be collected after straining through a fine sieve or muslin cloth to remove suspended impurities and should be boiled as quickly as possible (within 8-10 hrs) to avoid biodeterioration losses. Jaggery manufacturing in Karnataka is done by farmers themselves for their own consumption as well as for marketing using three roller horizontal type power crushers and 2 or 3 open pan juice boiling furnace systems. It is observed that in the existing cane crushing system about 50-55 per cent juice is extracted and the remaining 25-30 per cent is remain with bagasse due to poor extraction and will be burnt with bagasse as fuel. Juice extraction in jaggery industries is done by dry crushing process where whole cane is fed in to crusher without saturation. The crusher should be capable of giving at least 65 to 70 per cent juice extraction otherwise there will be loss of sugar in the bagasse [9&10]. The studies made at various institutions suggested that addition of fourth roller to the existing crusher may improve juice extraction efficiency. As a result four roller horizontal type power driven crusher has been developed [11&12] it gave up to 64 per cent juice extraction at 3.7 mm roller gap and at 3.3 m / min. roller speed [13]. On the contrary, the study of Yadav [14] indicated reduction in 3-4 per cent crushing efficiency by introducing power operated four rollers horizontal crusher due to higher operating speed of rollers. (ii) Juice boiling In jaggery industries, boiling of cane juice is the second important operation. Conventionally jaggery is made by boiling sugarcane juice in the underground furnace constructed using locally available materials. Most of the jaggery industries in Karnataka continued to use the conventional furnace system with an expansion of two or three open pans fitted over it. The thermal efficiency of conventional furnaces is very poor. Single pan furnaces for jaggery making were familiar in 1940 s and later in 1960 s double pan furnaces which were superior over single pan furnaces in consuming less fuel energy and higher production were introduced. Later in the year 2000 the triple pan furnaces which were improved version of double pan furnace were introduced in the state [15]. During last two decades considerable work has been done by various institutions to improve the thermal efficiency of existing juice boiling furnaces [16,8 &17]. These improved designs drastically reduced fuel combustion (bagasse), human labour, drudgery and inconvenience otherwise involved in the traditional furnaces including loading and unloading of cane juice at different stages of boiling and concentration process. Further, it was observed that the new designs of furnaces resulted in saving up to 11 per cent fuel (bagasse) and about 20 per cent increase in jaggery production with reduced chimney smoke [3]. Despite the development of improved furnaces, the whole bagasse available in the jaggery industry is consumed to concentrate juice and overall heat utilization efficiency of these improved furnaces is merely 20 per cent which is too low. To achieve maximum heat utilization efficiency, Mohan Naidu [9] made the following
Prospects of Jaggery Industry in Karnataka 209 suggestions; (i) provide chimney with good draft to escape burnt gases, (ii) provide a baffle wall in the furnace to prevent escape of heat through the chimney passage, (iii) use galvanized iron open pans to prevent reaction of iron with the juice constituents forming dark coloured substances, (iv) construct furnace in such a way that the heat should spread uniformly throughout the bottom of the open pan and (v) make provision to remove ash in the furnace periodically to provide proper air flow with better combustion. (iii) Juice clarification The main objective of clarification is to make juice clear and light in colour. It also helps in preventing charring or overheating during concentration. Jaggery prepared from clarified juice is light in colour, crystalline in structure, hard, less hygroscopic and hygienic. Freshly extracted juice is acidic in nature with ph of around 5.2. Boiling of this juice under acidic condition will invert the sucrose leading to problems in solidification and development of dark coloured jaggery. Hence before boiling the juice ph is to be adjusted to 6.8 with the addition of a clear solution of lime (CaOH). The clarification of juice depends on the composition of juice that affects the quality of jaggery. Besides sugar, it contains suspended impurities in the form of coarse particles and colloids, soil particles, wax, fat, protein, gum and other colouring matters which are extracted from the cane during juice extraction and they remain in colloidal form [23]. On vigorous boiling, the non-sugars float on the surface of the boiling juice in the form of scum which is to be removed as and when formed periodically. When the clear juice starts boiling, any one of the available organic clarificants such as Deola, Bhendi, Castor, Groundnut, Soybean, Phalsa may be added to further clarify the syrup and improve the colour of jaggery, storability and marketability. Chemical clarificants are generally used as a supplement to the vegetable clarificants to give more luster and brilliance to the jaggery. Most of these chemical clarificants are polyacrylamide based compounds, while some are ion exchange resins. These chemical clarificants adversely affect the health of human beings since traces of chemicals remain in the final product [18]. All these chemicals (except lime) brighten jaggery initially, but become dull during storage. (iv) Evaporation and concentration of juice After the scum is removed, the juice is boiled briskly by gradually raising temperature of 100 to 105 ºC for an hour or little more for evaporating most of the water content in it. When the temperature reaches 105 ºC the juice starts frothing. At this time onwards the fire will be regulated to prevent caramelization and spilling over the sides of the pan. The temperature of boiling starts raising fast from 105 ºC; during this period the syrup will be constantly stirred to prevent charring and spilling over the sides of the pan. At this stage ground nut/ castor/ mustard oil of 20-25 ml is added to prevent frothing to certain extent and to facilitate easy flow of jaggery from the pan to the cooling platform. The optimum temperature to reach striking of syrup is between 118-120 ºC.
210 G.B. Jayamala et al (v) Cooling and molding of syrup Cooling and molding process after removal from the evaporation pan influence the mechanical strength of jaggery [19]. Once the striking point is achieved the pan is removed from the furnace and the syrup is poured on the cooling platform. Then, this hot syrup constantly stirred with the help of ladle for aerating and cooling the liquid syrup which helps in producing a crystalline material. Then this cooled syrup in the form of semi-solid liquid is poured into wooden / metal molds of required shape and sizes which are kept moist. This syrup solidifies in the molds and on cooling they are removed and dried in an open air. In case of making round balls by hand manually, the semi-solid syrup is cooled well and balls will be prepared with the help hand gloves. (vi) Standardization of shape and size of jaggery molds The size, shape and weight of jaggery moulds vary according to the needs of the consumers and market demand. In Karnataka pellets, round balls, cubes, cakes and buckets type of molds weighing between 50 g (pellets) to 30 kg (buckets) are commonly made. Shape and size of the jaggery molds play an important role in effective drying and storage, easy handling and packing, minimizing losses during transportation and distribution, and attracting the consumers. Over sized molds create problems in handling storage and transportation, while, smaller size molds crumble resulting into coarse powder. Because of this diversity in the shape and size of jaggery does not attract for development of standard size molds, however, a standard molding frame has been developed [20] to produce brick shaped jaggery weighing 125, 250 and 500 g. Patel et al. [21] reported that the smaller size bucket shaped jaggery molds of 1 kg and 2 kg were superior in respect of keeping quality. The brick shaped jaggery has highest bulk density and less porosity. Both the factors are desirable for better storage space utilization. Compressive stress of brick shaped jaggery is higher which can withstand greater stack height during storage and transport. In addition the brick shaped jaggery can be easily packed, stored and distributed without any loss during handling and meets the consumer s acceptance (vi) Jaggery storage Production of jaggery is a seasonal and is stored over a fairly long period of 6-8 months. During storage jaggery undergoes various physical, chemical, biological and microbiological changes depending upon the type of storage and conditions under which it is stored. Physical changes include colour impairment such as darkening, loss of texture and change in taste caused by biochemical disintegration of some of the jaggery constituents and weight loss due to desiccation. Chemical deterioration includes biochemical changes in the jaggery composition, particularly those responsible for inversion of sucrose and discolourisation. Damage from insects and ants in particular, is the most and important form of biological spoilage. Fermentation and biochemical degradation caused by yeasts and moulds are the usual forms of microbial deterioration. All these changes in stored jaggery can be minimized through well designed storage structures and controlling storage conditions provided the jaggery meets the quality requirements before being stored.
Prospects of Jaggery Industry in Karnataka 211 Over 3 million tones of jaggery are stored annually for consumption during and after the monsoon in the country. Out of this about 2 million tones is stored at the domestic level and one million tones on a large scale by traders [8]. It has been estimated that about 10 per cent loss takes place in quality and quantity during monsoon which will amount to a loss of over 3,00,000 lakh tones of jaggery in storage alone. At normal ambient temperature, good quality jaggery can withstand atmospheric relative humidity up to 65 per cent and poor quality jaggery up to 50 per cent. Thus, every kind of jaggery can be safely stored up to 50 per cent R.H. Locally available materials like cane trash, furnace ash, palm leaves mat, rice husk and groundnut husk have been used as storage blankets for storing of jaggery in jaggery making units, trade centers and retailers in Karnataka. Though most of these blankets impart partial protection to jaggery against moisture during storage but are not hygienic. Baboo and Solomon [8] suggested improved practices for safe storage of jaggery: (i) Moisture content of jaggery should be less than 6 per cent before storage, (ii) Fresh jaggery should not be covered with polythene sheet or air tight material and sufficient ventilation should be provided, (iii) Storage of jaggery in polythene lined gunny bags found to be safe and (iv) Use of chemical clarificants, inferior, premature or over mature cane makes the jaggery unfit for storage particularly during monsoon. Under the prevailing temperature conditions in the country, loss of jaggery colour and flavor is natural and cannot be prevented even under proper storage conditions. Experiments conducted at various institutions in the country indicate that cold storage is most suited as compared to ordinary storage of jaggery. However, for minimizing deterioration in quality during cold storage, wrapping of jaggery (palm leaves mat or alkathene + hessian cloth) is necessary.. In cold storage jaggery can be stored as fresh for a year or so. Considering the amount of jaggery production and its ever-increasing demand within the country and export market, there is a need to develop and expand cold storage technology and warehouse network for long term storage of jaggery (vii) Grading of jaggery The problem of grading jaggery is indeed difficult because of the wide variation in its quality, its complex chemical composition and the marked deterioration it undergoes during storage. Presently there is no recommended grading criterion in force, which could be used to classify quality of jaggery in the trade centers of Karnataka. Sometimes liquefied jaggery of obnoxious and unpleasant odor / smell is consumed by economically poor people, as there are no standards to classify good and poor quality jaggery. Quality parameters of jaggery in terms of its colour, texture and taste varies from place to place and its end use as to whether to be used for table or for cooking purpose. Some people prefer to have jaggery with light golden yellow colour and medium soft texture and sweet in taste, while others prefer to have brown or brownish yellow colour with crystalline structure Baboo and Solomon [22] reported grading of jaggery based on NR values (Table 5). According BIS specifications jaggery should be prepared in the form of solid molds which shell be of firm consistency. It shall be golden yellow to light brown in colour, free from dirt and other extraneous matter and substances deleterious to health. Shell be sweet to taste
212 G.B. Jayamala et al and shall not possess sour, salty or any other objectionable taste. The jaggery shall also comply with requirements given in Table 6. Table 5: NR Values for grading of jaggery [22]. NR Values Grade Quality > 65 A 1 Excellent 60-65 A 2 Good 45-60 B Medium < 45 C Poor Table 6: Standard requirement for sugarcane jaggery. Sl No Characteristic Requirements Methods of test Grade-1 Grade-2 1 Sucrose (db) % by mass, Min. 80 70 IS 1152:1976 2 Reducing sugars (db) % by 10 20 IS 5982:1970 mass, Max. 3 Moisture % by mass, Max. 5 7 IS 5982:1970 4 Water soluble matter (db) % by 1.5 2.0 IS 5982:1970 mass, Max. 5 Sulphated ash (db) % by mass, 3.5 5.0 IS 1679:1970 Max. 6 Sulphur dioxide (db) ppm, Max. 50 50 IS 5982:1970 7 Ash insoluble in dilute HCI (db) % by mass, Max. 0.3 0.3 IS 12923:1990 (viii) Diversification of jaggery production Shifting of jaggery production into value added product by inclusion of nutritive substances like puffed rice, gram, various kinds of nuts, popped grain amaranth, etc., as source of micro-nutrients and energy will not only increase demand for this kind of jaggery but also will be a cheap source of nutrition to the poor and malnourished children. In Karnataka as well as in several parts of the country, the farmers prepare jaggery spiced with ginger, elachi and such other desirable spices, especially for their home consumption, since some of these spices and condiments have nutritional values; such product will be a value added food and have very high market. Jaggery is also made in the forms other than solid molds such as rab, kakavi (liquid jaggery) and khandsari (powdered jaggery). Technology has been developed for making kakavi on commercial scale. An advantage of this technology is that jaggery storage problem is alleviated. Kakavi is liked for table purposes in western India. Rab is a semi-solid liquid form of jaggery. The crystals are gradually developed upon storage. The rab crystals are more
Prospects of Jaggery Industry in Karnataka 213 nutritious than mill sugar as it contains, iron, phosphorus and calcium. The biggest advantageous of making rab is that it can be made in any type of sugarcane particularly when jaggery does not set well. Khandsari made from jaggery in the form of coarse powder is brownish in colour. It is highly nutritious and facilitates easy drying, handling, storage, transport and distribution. (ix) Organic jaggery Increasing consciousness about the health hazard caused by the excessive use of agrochemicals in modern agriculture has brought about a major shift in consumer preference towards safe and quality food. As a result, the demand for organic food is growing at an increased rate, especially in the developed countries. In Karnataka, there is a shift towards organic food by higher income group of consumers. Therefore, the health conscious consumers prefer the organic jaggery traditionally manufactured in the villages since time immemorial. The processing techniques of organic jaggery are as old as our culture. An account of its nutritive content, keeping quality and assured market growing of sugarcane only with organics and preparation of jaggery with organic clarificants assumes importance in order to produce quality jaggery as there is a growing demand for organic jaggery with in the state and in the export market. References [1] B.S. Nadagoudar, P. Ramana Gowda and P.C. Ravi, Prospects and retrospect s of sugar industries in Karnataka. Proc. All India seminar on mechanized cultivation of sugarcane and safety-quality management in sugar industry. March 10-11, 2007, IEI-Bangalore, pp. 145-149. [2] Kanchanvasdev, Gur makers from upthrive in Punjab. Tribune News Service. Feb. 7, 2003. [3] Anonymus, An improved gur making plant. IISR, Lucknow, 2006b. [4] Anonymous, Jaggery making more profitable for farmers. The Hindu Daily News Paper. Sunday November, 2004. [5] H.S. Shivaramu, C. Shankaraiah, Usha Ravindra and M.S. Nagaraju, Status, problems and prospects of jaggery making in cauvery command area of Karnataka, RRS, Mandya, 2002c [6] Jaswant Singh and Harinarain Shahi, Jaggery and khandsari industry in India. Indian farming. 2002, pp. 59-60. [7] N.G. Malleshi, Primary processing of sugarcane for jaggery and value added products. Proc. on the out-come report of brain storming session held at CFTRI, Mysore on employment opportunities in farm and non-farm sectors through technologies intervention with emphasis on primary value addition, 2006, pp. 17-21. [8] B. Baboo and S. Solomon, Nutritive sweeteners from sugar crops. Development of jaggery, khandsari and syrup industry in India. Sugarcane:
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