Internship Report

.

Internship report on

Etihad Sugar Mills LimitedRahim Yar Khan

Submitted by:M. Asif Akram

Submitted on:9 Sept, 2011

Internship report on Etihad Sugar Mills Limited, Rahim Yar Khan

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Dedications

I dedicated this efforts to my

Parents & Teachers

Who guide

&Encourage me during the

Preparation of this report

And I want to say

My Parents & Teachers


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Acknowledgement

All the thanks and praises for Allah who bestowed guidance and wisdom to mankind

and enabled me to complete this work. I am very thankful to all my Superiors i.e. Mr.

Muhammad Amjad Jam, Deputy Personnel Manager, Haji Shaukat Ali, Deputy Chief

Accountant, Mian Farooq Masood, Accountant, who helped me a lot to produce this

report.

I am thankful to my department who accepted my request to do internship in Etihad

Sugar Mills Limited, Rahim Yar Khan. I am also grateful to all employees of the Etihad

Sugar Mills Limited who guide me during the course of internship. The behavior of all

the department supervisors is very good to me because they gave me a lot of time to

guide me the mechanism of all departments in which I worked.

I am also thankful to the management of Etihad Sugar Mills Limited, Karamabad, Rahim

Yar Khan, who gave me all the valuable support and opportunities to complete 06

weeks Internship programme and compile this report.


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Tables of Contents

Description Page #

Letter of undertaking 2

Dedication 3

Acknowledgement 5

Introduction to the sugar and sugar industry

Province-wise name of sugar mills in Pakistan

6

6

Introduction to organization

Company’s products

Competitors

Company’s information

Organizational chart for management

Introduction to the higher management

08

08

08

09

10

10

My Internship Programme 11

Departments of the organization

Accounts Department

Organizational Chart of Accounts Department

Administration Department

Organizational Chart of Administration Department

Cane Department

Organizational Chart of Cane Department

Chemical Department

Processing of sugar cane in a sugar mill for manufacturing of white sugar.

Organizational Chart of Chemical Department

Electrical Department

Organizational Chart of Electrical Department

I.T. Department

Organizational Chart of I.T. Department

Laboratory Department

Organizational Chart of Laboratory Department

Mechanical Department

Organizational Chart of Mechanical Department

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13

14

15

18

19

22

23

23

27

28

29

30

31

32

33

34

41

SWOT Analysis 68

Conclusion 70

Recommendations for improvement 71

References 72


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Introduction to sugar and sugar industry

The word sugar originates from the Sanskrit word sharkara which means sugar. It may

also be traced through all the Aryan languages, as schaker in Persian, sukkar in Arabic,

sincer in Assyrian, zucchero in Italian, sucre in French, zucher in German, saccharum in

Latin and ozucarin Spanish etc stand as Testimony for its origin from sharkara.

Sugar is a major form of carbohydrates and is found probably in all green plants. It

occurs in significant amounts in most fruits and vegetables. There are three main simple

sugars Sucrose, Fructose and Glucose. Sucrose is in fact a combination of fructose and

glucose and the body quickly breaks down into these separate substances.

All energy stored in food is derived originally from the sun and it is made by green plant

life. The sun's energy acts upon the green chemical "chlorophyll" in the leaves of plants

to produce sugars and starches from the carbon-dioxide in the atmosphere and the

water from the roots by a process known as Photosynthesis. These carbohydrates

(starches and sugar) acts as a plants food and energy supply. The energy need of

human body is largely dependent on the carbohydrates that are derived from plants.

The sugar is one of the essential commodities of the life which plays very important role

in the dietary of human beings as it quickly raises the level of glucose in the blood.

The sugar can be produced by many of the sources, but two are the main sources for

production of sugar in Pakistan i.e. Sugarcane and Sugar Beet. The other sources are

Maple, Palm, Coconut and Apple, but these sources are costly and their production is in

negligible quantities. But, the main crop which is being used for production of Sugar all

over the world is Sugarcane.

In a nut shell, the process for sugarcane refining is carried out in following steps

Pressing of sugarcane to extract the juice.

Boiling the juice until it begins to thicken and sugar begins to crystallize.

Spinning the crystals in a centrifuge to remove the syrup, producing raw sugar.

Refining the raw sugar by washing and filtering to remove remaining non-sugar

ingredients and color.

Crystallizing, drying and packaging the refined sugar

Beet sugar processing is similar, but it is done in one continuous process without the

raw sugar stage. The sugar beets are washed, sliced and soaked in hot water to

separate the sugar-containing juice from the beet fiber. The sugar-laden juice is then

purified, filtered, concentrated and dried in a series of steps similar to cane sugar

processing.


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For the sugar industry, capacity utilization is conceptually different from that applicable

to industries in general. It depends on three crucial factors the actual number of ton of

sugarcane crushed in a day, the recovery rate which generally depends on the quality of

the cane and actual length of the crushing season.

In Pakistan, the sugar industry possesses the organized and unorganized players. The

unorganized players mainly produce Gur and Shakkar, the less refined forms of sugar

and the organized players are Sugar Mills owners.

In the world, the Brazil is a country that is largest producer of sugarcane as well as

Refined Sugar.

Province-wise name of Sugar Mills in Pakistan

According to Pakistan Sugar Mills Association (PSMA), there are 78 Sugar Mills in

Pakistan (39 in Punjab, 32 in Sindh and 7 in NWFP). Province-wise sugar mills are

listed below:- And in what ranking our organization is working now a day?

Punjab province

1. Abdullah Sugar Mills Limited

2. Abdullah Sugar Mills Limited (Shahpur)

3. Adam Sugar Mills

4. Ashraf Sugar Mills Limited

5. Baba Farid Sugar Mills Limited

6. Brothers Sugar Mills Limited

7. Chanar Sugar Mills Limited

8. Chaudhry Sugar Mills Limited

9. Colony Mills Limited

10. Colony Sugar Mills Limited

11. Cresent Sugar Mills Limited

12. Etihad Sugar Mills Limited

13. Fatima Sugar Mills Limited

14. Fecto Sugar Mills Limited

15. G. Samundri Sugar Mills Limited

16. Hamza Sugar Mills Limited

17. Haq Bahu Sugar Mills (Pvt) Limited

18. Haseeb Waqas Sugar Mills Limited

19. Huda Sugar Mills (Pvt) Limited

http://www.psmaonline.com/psma/members/members1.aspx?xyz=120&abc=2




















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20. Hunza Sugar Mills Limited

21. Husein Sugar Mills Limited

22. Indus Sugar Mills Limited

23. Ittefaq Sugar Mills Limited

24. JDW Sugar Mills Limited

25. JDW Sugar Mills Limited (Unit II)

26. Kamalia Sugar Mills Limited

27. Kashmir Sugar Mills Limited

28. Kohinoor Sugar Mills Limited

29. Layyah Sugar Mills Limited

30. Madina Sugar & Chemicals (Pvt) Ltd.

31. National Sugar Mills Limited

32. Noon Sugar Mills Limited

33. Pattoki Sugar Mills Limited

34. Ramzan Sugar Mills Limited

35. Safina Sugar Mills Limited

36. Shahtaj Sugar Mills Limited

37. Shakarganj Mills Limited

38. Sheikhoo Sugar Mills Limited

39. Tandlianwala Sugar Mills

Sindh province

1. Abdullah Shah Ghazi Sugar Mills Limited

2. Al Abbas Sugar Mills Limited

3. Al Noor Sugar Mills Limited

4. Ansari Sugar Mills Limited

5. Army Welfare Sugar Mills Limited

6. Bachani Sugar Mills Limited

7. Bawany Sugar Mills Limited

8. Dadu Sugar Mills Limited

9. Dewan Khoski Sugar Mills Limited

10.Dewan Sugar Mills Limited

11.Digri Sugar Mills Limited

12.Faran Sugar Mills Limited


































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13.Habib Sugar Mills Limited

14.Khairpur Sugar Mills Limited

15.Kiran Sugar Mills Limited

16.Larr Sugar Mills Limited

17.Matiari Sugar Mills Limited

18.Mehran Sugar Mills Limited

19.Mirpurkhas Sugar Mills Limited

20.Mirza Sugar Mills Limited

21.Najma Sugar Mills Limited

22.Naudero Sugar Mills Limited

23.Pangrio Sugar Mills Limited

24.Ranipur Sugar Mills Limited

25.Sakrand Sugar Mills Limited

26.Sanghar Sugar Mills Limited

27.Seri Sugar Mills Limited

28.Shahmurad Sugar Mills Limited

29.Sindh Abadgar Sugar Mills Limited

30.T. M. K. Sugar Mills

31.Tharparkar Sugar Mills Limited

32.Thatta Sugar Mills Limited

NWFP Province

1. Almoiz Industries Limited

2. Bannu Sugar Mills Limited

3. Chashma Sugar Mills Limited

4. Frontier Sugar Mills Limited

5. Khazana Sugar Mills Limited

6. Premier Sugar Mills Limited

7. Saleem Sugar Mills Limited

.





























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Introduction to Organization

Etihad Sugar Mills Limited, Karamabad, Rahim Yar Khan was established on 1st June,

2006 as a Private Limited Company and is listed at Lahore Stock Exchange of Pakistan.

The company is engaged in the manufacturing and sale of sugar. The company’s site is

situated at Mouza Karamabad Abad, Tehsil & District Rahim Yar Khan. Its head office is

situated at Lahore. Total number of employees during off-season are 620 and during

season it raises to 1140 excluding contractor’s labour. The mills covered total 100 Acres

out of which 74 acres is for Mills plant, yard and offices, rest of the 26 acres are for

colony, quarters, grounds, hostels and Masjid.

Organization’s Products

The company’s main product is White Refined Sugar, however it has also following by

products:-

1. Bagasse

2. Molasses

3. Press Mud

Competitors

Although, 78 sugar mills are installed in Pakistan, out of these 77 are the competitors for

Etihad Sugar Mills Limited, but the most competition is lying in following nearest sugar

mills:-

1. JDW Sugar Mills Limited, Sadiqabad

2. JDW Sugar Mills Limited (Unit-II), Sadiqabad

3. RYK Mills Limited, Liaqatpur

4. Hamza Sugar Mills Limited, Khanpur

5. Ghotki Sugar Mills Limited, Ghotki

6. SGM Sugar Mills Limited, Ghotki

7. Ashraf Sugar Mills Limited, Bahawalpur


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Company’s information

Board of Directors

Ch. Muhammad Shakeel Chief Executive Officer

Makhdum Omar Shehryar Director

Ch. Muhammad Shabbir -do-

Ch. Adil Shabbir -do-

Ch. Tahir Jamil -do-

Haji Muhammad Ibrahim -do-

Ch. Riaz Ahmad Abid -do-

Mr. Rashid M. Chaudhry -do-

Company Secretary

Mr. Zafar Iqbal, General Manager (Finance & Accounts)

Head Office

3-Bawa Park, Upper Mall, Lahore

Tel: 042-35751865-6, 042-35758724-7

Fax: 042-35751867

Site (Operations)

Mouza Karamabad, Tehsil & District Rahim Yar Khan.

Tel: 068-5678531-2, 5678534-6

Fax: 068-5678533

Internal Auditors

Mr. Aziz Khan Lodhi, Chie Auditor (at head office)

Mr. Muhammad Usman Zakki, Senior Internal Auditor (at site)

Mr. Zahid Mehmood Iqbal, Internal Auditor (at site)

Banks

National Bank of Pakistan

Muslim Commercial Bank

Bank Al-falah

Faysal Bank


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Organization Chart for Management

Introduction to the higher management

Chief Executive Officer (Ch. Muhammad Shakeel)

The CEO has his office at Head Office, Lahore and also visit Site once quarterly. He is

answerable to Chairman.

Director (Ch. Muhammad Shabbir)

The Director has its office at Site and he look-after over all working of Site and

answerable to CEO. At Site, he has full powers. At Site, he takes final decisions.

General Manager (Ch. Nasir Ahmad)

His office is at Site. He is overall General Manager of the Site. He is technical man and

just qualified upto DAE (Mechanical) but he has about 40 Years of service tenure in

different Sugar Mills of the Pakistan. He is answerable to the Director as well as CEO.

At Site, he takes technically final decisions related to Mechanical, Laboratory, Electrical

and Chemical Departments only. He also participate the other meetings related to

Administration, Cane and Finance Departments. But the most of the hold on these three

departments is of Director.


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General Manager Finance & Accounts (Mr. Zafar Iqbal)

He sits at head office. Being the head of the Finance & Accounts Department, he directs

the head office & site finance & accounts department. He often comes at site and check

the procedures and to observe the working of his department.


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My Internship Programme

Change all the dates according to internship letter and also paste a scan copy of the

letter?

By the grace of Almighty ALLAH, I did my internship in Etihad Sugar Mills Limited for the

period of 06 weeks starting from 24th May, 2010 upto 3rd July, 2010. The department wise

duration is as under:-

Administration 24-05-201 28-05-2010

Cane 29-05-2010 31-05-2010

Chemical / Production 01-06-2010 04-06-2010

Electrical 05-06-2010 -

Information Technical 07-06-2010 -

Laboratory 07-06-2010 -

Mechanical 08-06-2010 12-06-2010

Finance 14-06-2010 03-07-2010

During my internship programme, my supervisor Mr. Muhammad Amjad Jam had deputed me to

observe the working of all sections / department but not to interfere in any activity. So he

directed me to follow the above schedule and he informed the concerned heads of the

departments as well, regarding my internship programme.

I attended all departments and observed its working, which surely extended my knowledge and

after conducting my internship programme, I am feeling that I can start my professional career in

a good manner. My observation during internship programme is hereunder please:


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Departments of the Organization

The Etihad Sugar Mills Limited has its following departments to functioning well:-

1. Accounts

2. Administration

3. Cane

4. Chemical / Production

5. Electrical

6. Information Technology

7. Laboratory

8. Mechanical

Accounts Department

Mian Muneer Ahmad Ch., DGM (Finance) is head of the department and he is

supervising all the departmental matters. He is directly report to the General Manager

(Finance) at Head Office as well as General Manager (Site).

The main function of finance and accounts department to look after all the related

matters and keep the record of all accounts and finance activities. The department is

using computerized software for all kind of transactions. The formats being used by the

Mills for cash receipt voucher, bank / cash payment voucher and sample of

computerized voucher are hereunder:-

This department has three sections in it:-

1. Accounts

2. Finance

3. Cane Accounts

4. Main Store

5. Store Account

Accounts Section

The sectional incharge is Haji Shaukat Ali Deputy Chief Accountant, he deals all

payments for local purchases, other purchases, salaries etc. He is doing all jobs with

the help of the staff under his command i.e. Accountants, Assistant Accountants,

Accounts Clerks and Accounts Assistants. All the salaries and other accounts

transactions are carried out on computerized software.

Finance Section

In this era of information technology, Etihad Sugar Mills Limited is also fully computer

technology in almost all of its sections. The finance section of this department keeps the

record of all receipts and also arranges the funds in coordination with the head office.


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The cheques are also prepared in this section. As the department is computerized,

therefore, the manual record keeping is not undertaken.

Cane Account

Mian Khalid Shaheen, Senior Accounts Officer (cane) is sectional incharge and deals

with all cash payment of sugarcane and loan cheques. He himself and his team

comprising of Accountant, Accounts Assistant and Accounts Clerks are enough to deal

the growers. The growers approach him to know the actual status of loan, payment,

deduction, etc. He also uses computerized software for this purpose. The cash payment

of sugarcane is made after seeing the original CPR (Cane Payment Receipt)

Procedure of payment of sugarcane to the grower

The cane reaching the mill is weighted and voucher is prepared in quadruplicate. The

voucher shows the net weight of cane and its payment. The first copy of voucher is given

to the grower and second copy is sent to the cane department. The third copy is sent to

the cane account section and the last copy is sent to the carriage contactor.

If the grower has taken loan from the Mills, the software automatically deducts amount

of first supply and adjusts the growers account. If the grower did not taken loan from

Mills, he can take cash from the Cash Counter.

In case of loanee’s supply of sugarcane, he would not be able to get cash of sugarcane

supplied by his, until the loan is recovered by the Mills. He is in an emergency, he will

submit a written request to the DGM (Cane) to allow him to get cash from the cash

counter. If the DGM (Cane) allowed, he can collect cash even he had taken loan,

otherwise, the loan account will be adjusted against supply of sugarcane.

Store Account

Mr. Abdul Waheed Khalid, Accounts Officer (Store) handling this section. This section

maintains the record of machinery and different parts used in the project .The purchases

and consumption of different parts is adjusted monthly and annually. The main account

section pays all the suppliers’ bills. When some items are purchased and received in the

store, the store in charge prepare the Goods Receiving Note (GRN) showing the amount

and quantity of items received. The receiving report is sent to the main account section.

This section then makes arrangement for payment to the supplier.


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Administration Department

Lt. Col. (R) Muhammad Riaz, DGM (HR & A) being the head of the department

supervising administration department. He act as Liaison Officer for the Mills and

responsible for all kinds of administrative works. The administration department has

following sections in it:-

i. Security & Safety Section

Maj. (R) Zia Ahmad Khan, Chief Security Officer is incharge of Security

and safety section. The main responsibility of this section is to provide the

security to the Mills assets and safety guidelines to the Mills employees.

He had arranged Rescue 1122 Training Programme on Safety Measures

to educate the Mills employees. He also acts as number two of DGM (HR

& A). In the absence of DGM (HR & A), Chief Security Office officiates as

head of the department. He is reported to DGM (HR & A)

ii. Civil Works Section

Syed Munir Hussain Shah, Civil Works Supervisor is responsible for all

kind of civil works directed to him by the DGM (HR & A). He himself

alongwith his team comprising of Clerk, Masons & Labourers complete all

civil jobs assigned to them. He is direct report to DGM (HR & A)

iii. Establishment Section

Mr. Muhammad Amjad Jam, Deputy Personnel Manager is incharge of

this section and he is responsible for keeping personal files record of the

employees, all other record like PESSI (Pakistan Employees Social

Security Institution) record, EOBI (Employee’s Old-age Benefit Institution)

record, Labor Department record and all other kind of office record. He is

direct reported to DGM (HR & A).

iv. Transport Section

Syed Niaz Hussain Shah, Transport Incharge is handling all the matters

related to Transport. He also supervises the auto workshop’s staff. He

maintained all vehicles record. Presently, the company own Seven

Tractors, One Bus, Two Toyota Hiaces, One Pajero, Three Corolla Cars,

Two Honda City, Ten Suzuki Cultus Cars, Two Shahzor Mini Truck, Sixty

Yamaha Motorcycles, etc.

v. Masjid

There is very beautiful Masjid constructed by the Company which is

enough for 1000 persons. The staff for Masjid is one Khateeb / Imam

Masjid, one Moazzan, One Khadim Masjid and one Helper Masjid.


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vi. Horticulture

Mr. Muhammad Hanif Ramey, Incharge Horticulture is supervising the

section and he also working for the landscaping in the Mills. He and his

team comprising of ten Baildars and Malis is doing look-after of the plants

of the Mills.

vii. House Keeping (Hostels)

As this project is newly established, its colony is under approval session

from the Chairman, and there is only three hostels according to the status

of the officers (i) HODs Hostel, (ii) Officers Hostel (iii) Labour Hostel. The

hostels are being handled by Mr. Muhammad Asif Saftain, Incharge

General Administration, who is directly reported to DGM (HR & A)

The HODs hostel (luxury type) consisting of 25 Rooms, AC fitted, Single

Beds with Mattresses and Bed Sheets, attached bath. The Mess for HODs

is in the hostel. There are 05 Guest Rooms also for the guests to stay at

night, who visit the Mills.

The officer’s hostel is the hostel, where Foremens and Officers level

employees are residing. In the officer’s hostel, there are 32 rooms. These

rooms are also of high standard, but less than the HODs. Two Mess

containing two dining hall, kitchens are included in this hostel.

The Labour Hostel is like a simple hostel, where total number of rooms is

16. These are big rooms and about 30-35 employees are residing in a

room. Their standard like a army barrack, where 30 iron cots are laid

down.

viii. Time Office

Time office is a section, where attendance of all mills employees are

maintained and keep it recorded on daily basis. Mr. Shahid Pervez,

Incharge Time Office is doing supervision and the time office is functioning

with 03 time keepers and 03 time office clerks. The time office inchagre is

answerable to DGM (HR &A) in coordination with Deputy Personnel

Manager.

ix. Telephone Exchange

Mr. Muhammad Abdul Jabbar, Senior Telephone Operator is supervisor of

telephone exchange. Total 4 personnel are deputed in telephone

exchange round the clock shift-wise (03 operators and 01 lineman). He is

also answerable to DGM (HR & A)


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x. General Administration

Mr. Muhammad Asif Saftain, Incharge General Administration is directly

reported to DGM (HR & A). In the general administration, he looks after

cleanliness of the Mills, and perform routine general duties. All the

sweepers and their supervisor are under is command. He is responsible

for all general administrative issues.


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Cane Department

Ch. Abdul Rauf Gujjar, DGM (Cane) being the head of the department leading the Mills

toward the progress. The main purpose of Cane Department is to provide the maximum

services (required by the growers) i.e. loan, guidelines regarding crop, etc. at the door

step of the grower. In this regard, the Cane Department has opened Circle Office at

every famous place / station. Presently, Etihad Sugar Mills Limited has their 25 circle

offices on the following stations.

1. Iqbalabad

2. Fateh pur Punjabian

3. Chowk Bahadarpur

4. Rahim Yar Khan

5. Kotsmaba

6. Tranda Sway Khan

7. Khanpur

8. Sadiqabad

9. Rukan Pur

10. Sardargarh

11. Sheikh Wahan

12. Rajanpur

13. Zahir Pir

14. Sehja

15. Feroza

16. Shah Pur

17. Abad Pur

18. Jajjab Abbasian

19. Head Haji Pur

20. Garhi Ikhtiar Khan

21. Kotla Pathan

22. Bhondi

23. Shahbaz Pur

24. Machi Goth

25. Chowk Swetra

Every circle office possesses one Field Officer, one Cane Supervisor and one

Fieldsman.

The cane department has the following section in it:-

i. Cane Section

The cane office is the location, where the DGM (Cane) and ancillary staff is

present for the convenience of the growers.


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ii. Programme Section

The programme office is a technical office of cane department, where the

programme is maintained that how many units will be allowed to come in mills

per day, how much sugarcane will we have, etc. This office is being handled

by the Programme Officer, Programme Assistant and Programme Clerks.

iii. Loan Section

The Loan office provides the requisite guidelines to the growers. This section

keeps the record of loanee growers and also provide the information to the

field staff at the time of loan recovery. This section is handled by Loan Officer

and Loan Assistant.

iv. Yard Section

During the season, the main function of cane department at site is performs

by the yard staff. Yard is the heart of the mills, at which, every one has

vigilant eyes. The mechanical department also observes how many units are

available in the yard for crushing at the time. They rotate the mills speed on

the arrival of sugarcane at said date / time. When the trolley / truck (or any

unit) enters in the premises of the Mills, firstly he attends the token post, from

where he gets the token, then he reaches to the yard and then it unloads the

sugarcane after fulfillment of codal formalities i.e. clearance of documents

and weightment etc.

The process of cane department regarding handling of growers starts from here.

After exhaust of crushing season, the cane department immediately meets the grower

to convince them for sowing of sugarcane crop. This process takes about one month

and after this, the staff of cane department holds the survey work. In the sugar industry,

the word survey mean the how much sugarcane is sowed by the growers in the

respective. The survey is collected department wise and summarized at the programme

office of cane department.

All the relation / correspondence of Mills and growers took place through field staff. All

announcements are also brought to the notice of growers through field staff. The grower

contacts the filed staff at the respective circle office regarding any matter.

During the loan documents submission, the growers contact circle officer and get the file

completed for loan, after completion of process, the grower is informed to collect the

cheque for loan amount from accounts department of Mills after provision of requisite

documents i.e. original CNIC. The loan may be in shape of cash, pesticides, seeds,

diesel, implements, fertilizers etc.


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At the start of crushing season, the field staff contact the growers and advised them to

remain ready for supply of sugarcane. They try their best to make available the

continuous supply of sugarcane to the Mills to avoid any stoppage of crushing.

Because, due to shortage of sugarcane, the seasons, nowadays of 90-100 days which

was previously of 150-200 days and every second is very precious for the sugar mills

during the season. The management is also dislikes the stoppage in crushing during

season.

The field staff emphasize the growers to repay the loan as soon as possible, because,

this is the only way (supply of sugarcane by grower) to recover the loan from growers.


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Chemical Department

Engr. Muhammad Rahat Saeed, DGM (Production) is head of the department and he is

responsible for all boiling / chemical procedures apply on the sugarcane juice. The

chemical department is totally responsible for production of sugar from juice. They apply

methods, heat and some chemicals to transform the sugar from sugarcane. The

complete process of production of sugar is as under:-

Processing of sugar cane in a sugar mill for manufacturing of white

sugar:.

CANE TIPPERS

Loaded cane trolleys are tilted by hydraulic jacks into feeding tables. Feeding

tables transfer cane into carrier # 01.

CANE CUTTER # 01

Motor 1000KW, Knives 40 Nos. It is driven by electric motor. It performs the

duty of cane chopping and leveling. Its clearance is about 2 Ft.

CANE CUTTER # 02

Motor 850KW, Knives 40 Nos. It cuts the cane into small pieces, its clearance

is about 10”

CANE CUTTER # 03

Motor 1000KW, Knives 80 Nos. It completely cuts the cane into small pieces

at minimum clearance of 2”.

SHREDDER

Steam Turbine 3000KW, Swinging Hammers 88 Nos. It shreds the cane and

raptures all the sugar cane cells to open position.

MILLS TENDEM

Mills tendem consists of 05 Mills driven by steam turbines having power

850KW each. Shredded cane is passed through series of 05 mills for

extraction of juice. Imbibition water is sprayed on last mills for maximum

extraction of juice. This extracted mixed juice is filtered through rotary screens.

Screened juice is sent to Boiling House for processing and bagasse from last

mills is sent to boilers as fuel.

BOILERS 03 NOS. (CAPACITY 80TON/HOUR EACH)

Main object of boiler is to produce steam at pressure 23Kg/cm2 and

temperature of 350ºC. Bagasse is fed to boilers, furnaces where it is burnt and

produces steam at the rate of 80 Ton/hour each. Surplus bagasse is sent to

bagasse yard, which is sold out. In case of shortage of bagasse, furnace oil is


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burnt as standby fuel.

POWER HOUSE

Steam Turbine Generators 02 Nos., Capacity 5MW each. Steam produced by

boilers is used for the operation of steam turbine generators. 10MW power is

used for the operation of all electric motors installed in Mills.

JUICE HEATERS

1. Condensate & Primary Juice Heaters (04 Nos.) (H.S. 350m2 each)

Screened juice is passed through juice heaters in series and temperature

is raised upto 65ºC by using steam / vapours.

2. Defecations Tanks

Here milk of lime (M.O.L.) is added in heated juice and after some retention

time, juice is passed through secondary juice heaters.

3. Secondary Juice Heaters (03 Nos.) (H.S. 350m2 each)

Limed mixed juice is passed through secondary juice heaters and

temperature is raised upto 105ºC for further treatment in juice clarifiers.

4. Juice Clarifier (03 Nos.) (Capacity 170m3 each)

After secondary heating poly electrolyte is used before entering of juice in

clarifiers it stays there for 1 to 1:30 hours to complete the reaction between

M.O.L. and impurities of the juice. The impurities settle down in the clarifier.

Settling is speedy by addition of poly electrolyte. The clear juice from

clarifier is decanted and passed through rotary screens. This filtered juice

is sent to series of evaporators. Settled impurities (Muddy Juice) is taken

out from the bottom of the clarifiers and is sent to vacuum filters for

filteration.

VACUUM FILTERS (04 NOS.) FILTERING AREA (58M2 EACH)

Muddy juice taken from clarifiers is mixed with Bagacillo in Mud Mixer and sent

to the troughs of vacuum filters. Vacuum filter drum rotates and mud climbs

over the drum. Hot water is sprayed by Nozzles on the drum. Remaining juice

and washing water is sucked through tubes by vacuum. Sucked filtered juice is

returned to defecation tank and mud is sent out by scrapping the mud from

drums of vacuum filters. It is manure for cane growers.


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EVAPORATORS (07 NOS.)

Decanted juice from juice clarifier called clear juice is taken into series of

evaporators. It is boiled with help of exhaust steam (obtained from turbines of

mills and power house). The thick juice obtained from evaporators called

syrup is fed to pans.

VACUUM PANS (RAW SIDE) FOR A, B & C MASSECUITES.

Batch Pan (04Nos.) Capacity 70Ton each.Conti Pan (02 Nos.) Capacity 68m3 each.Conti Pan (02 Nos.) Capacity 102m3 each.

The syrup is fed into pans where it is again boiled to produce mixture of

crystals and molasses called A Massecuite. Prepared massecuite is dropped

into crystallizers.

MASSECUITE CRYSTALLIZERS (13 NOS.) (RAW SIDE)

Prepared massecuite from pans is sent into crystallizers for further

crystallization by motion of massecuite by scrolls driven by gear and motor.

The massecuite is transferred to centrifugal station by massecuites pumps.

Centrifugal K-1100 (25 Nos.) (Raw Side)

Massecuite is passed through centrifugals which separates crystals of sugar

and molasses. First separate molasses, “A” Heavy is again boiled in B-Pans

for B-Massecuite. B-Massecuite is again passed through centrifugals for

separation of sugar crystals and molasses. This obtained molasses called B-

Heavy is again boiled in C-Pans for C-Massecuite. C-Massecuite is again

passed through centrifugals for separation of sugar crystals and final

molasses. This final molasses is sent out in molasses ponds for sale as a raw

material for distilleries and sugar crystals separated from B & C Massecuite

are used as seed in pans and sugar crystals obtained from A-Massecuite are

taken into sugar remelter.

SUGAR REMELTER (CAPACITY 30TON/HR.)

Here sugar is remelted by using hot water and steam with 02 Nos. stirrers.

This remelt is called raw liquor. This raw liquor is sent to Talo station.

TALO CLARIFIER

Raw liquor before taking into clarifier is treated with phosphoric acid, colour

quest, lime sucrate and talo float. These chemicals are used to remove

remaining impurities in sugar. In talo clarifier with some retention time these

impurities float up in clarfier and clear liquor is taken out from bottom side.

Floated impurities called scum is removed from clarifier by scraper driven by

gear and motor. The clear (fine) liquor is sent to pan station. The removed


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serum is sent back to defecation tank.

REFINE PANS (05 NOS.) (CAPACITY 70 TON EACH)

Fine liquor is taken into pan. It is boiled for some time to get required brix for

crystallization. Very small fine crystals seed (obtained from the sugar grader

not bagable) is fed into it. Required crystal size is obtained by further boiling

called the refine massecuite. Prepared massecuite is dropped into

crystallizers. From which it is pumped to refine centrifugals for separation of

crystals and molasses.

REFINE CENTRIFUGALS TSK (03 NOS.)

Refine centrifugals are automatic batch type centrifugals which separates fine

sugar crystals and molasses. This molasses is reused for making more refine

massecuites. Fine crystals (Sugar) is dropped into hopper which shift it to

sugar dryers.

SUGAR DRYER (02 NOS.)

While sugar passes through these dryers, remaining moisture is removed by

blowing hot air through them. Hot air is passed by fans called blowers fitted for

this purpose.

SUGAR ELEVATORS. (02 NOS.)

Elevators lift the dried sugar through buckets at some height and feed to sugar

grader for its size wise separation.

SUGAR GRADERS (02 NOS.)

Here, sugar travels over graders moving to and for. At sugar grader frames of

screens of different mesh are fitted. Through which fine, very small crystals

(seed) and extra large size crystals are separated and sugar crystals of

required size drop into sugar bins.

SUGAR BINS (03 NOS.)

Sugar bins are used for holding bag able sugar.

AUTOMATIC WEIGHING MACHINE (02 NOS.)

Automatic weighing machines are installed under sugar bins, machine drops

sugar after 50Kgs accurate weight into poly propylene bag attached under it

manually. The weight of these bags is re-checked by electronic weighing

scales kept under. After that the bags sewing is done by sewing machines (02

Nos.) fitted over wooden conveyors. These sewed bags are sent to sugar

godown where it is stacked upto the height of 50 layers by sugar stacker.


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Electrical Department

Engr. Nadeem Ghafoor, DGM (Electrical) is head of the department and he is

responsible for all electrical and instrumental jobs of the Mills. The electrical department

have two section in it:-

1. Electrical Section

2. Instrument Section

Mills have 02 Steam Turbo Generators and 02 Diesel Generators for standby supply of

electricity at Power House Section. 02 Steam Turbo Generators having capacity of 5

MW each provides the electricity during the season to the Mills. Various electrical

panels are installed at Power House and all electricity matters are controlled from

Power House.

At the time of start up, the electrical department do not depend on WAPDA, therefore

electrical department takes the start up of Mills on Generator’s supply. They just start

the boilers motors on Generator and when the boiler gets start, it supply the steam to

the steam turbo generators, which runs and provides the electricity to all Mills, then the

power supply of boilers taken on Steam Turbines and the Diesel Generators kept

powered off.

The instrument section is responsible for the repair and maintenance of all instruments

available in the Mills.


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32

Information Technology Department

Mr. Omair Ahmad, Manager (I.T.) is head of the department and doing maximum efforts

to introduce advanced technology in the best interest of the Mills. To avoid any

inconvenience during the crushing season, he introduced Wireless networking of work

stations and fiber-optic cable networking as alternative to that. The job is under process

and will be completed within couple of days.

The I.T. Department is also looking-after the database and keeps its record daily on

DVD, which sent to the head office for record on daily basis. In addition to this, the

repair and maintenance of I.T. equipment is also its responsibility.

He and Mr. Umer Sharif, Deputy Manager (I.T.) very enthusiastically changing the

previous (non-developed) pattern. Before their joining, there was simple networking,

which becomes out of order off & on and the management faces trouble as a result

thereof.

During the season, single second is very precious and cannot be wasted. Therefore,

they convinced the management to lay down the fiber-optic cable and WAN to get rid of

this problem. The management understand the issue and approved the case as it was

proposed.


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34

Laboratory

Mr. Muhammad Amjad Khan, Manager (Lab.) is head of the Laboratory department. In

the laboratory, different type of laboratory tests related to water, sugarcane, juice,

bagasse, molasses, etc. are conducted. He is directly responsible to the General

Manager, but as per nature of his duty, he should have to report the Directors and CEO

at any time regarding production, recovery of sugarcane etc. These lab. Tests helps the

management in decision making.


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36

Mechanical Department

Engr. Muhammad Nawaz Sandhu, DGM (Technical) is head of the Mechanical

Department. In view of the employees, this department is one of the biggest department

of the Etihad Sugar Mills Limited.

The Mechanical Department has following sections in it:-

i. Mill House

ii. Boiling House

iii. Boiler House

iv. Workshop

v. Steam Turbine

vi. Welding Section

vii. Fabrication Section

Mill House

This section contains 05 Mills alongwith steam turbines. In the Mill House, juice from the

bagasse extracted and bagasse sent to the boilers and juice sent to the boiling house

for further process. In this section, heavy machinery is installed. The following

machinery is installed at Mill House.

Boiling House

In the boiling house section, chemicals, heat and other processes are applied at juice

for transformation into sugar. Most of the machinery is installed in this section and this

section is biggest mechanically as compared to the other mechanical sections. The

following machinery is installed in Boiling House:-

Boiler House

This section of mechanical department has 03 boiler of 80 Ton / hr capacity. Each boiler

generates 80 Ton steam in single hour, which become 240 Tons per hour from all three

boilers. In the boilers, water is boiled and steam generated as a result thereof.

Workshop

In the workshop, the Mills have its machinery for repair / maintenance of plant. There

are many Molder machines, Laithe Machine, Binding Machine etc. All the mechanical

jobs are completed here.

Steam Turbine Section

The section is responsible for repair & maintenance of all the steam turbines installed in

the Mills at Power House, Mills House and Boiling House.

Welding Section


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All the welding jobs are carried out by this section. This section has various mobile

welding plants for completion of jobs at the plant.

Fabrication Section

In the sugar mill, there are various mechanical tricks, to implement these tricks,

fabrication section offers its services.


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39

ETIHAD SUGAR MILL, RAHIM YAR KHAN

Consolidated Income Statement

For the years ended 30-09-(8-)

2010 2009 2008

Net Sales 9,901,225,775 10,801,461,407 5,344,240,796

Cost of Sales (7,515,692,484) (8,818,583,211) (4,527,891,865)

Gross Profit 2,385,533,291 1,982,878,196 816,348,931

Administrative Expenses (219,495,198) (215,740,080) (140,329,553)

Distribution & Marketing Expenses (20,014,879) (135,778,796) (7,624,033)

Other operating expenses (115,552,852) (91,141,209) (4,272,079)

Other operating income 24,438,859 70,322,340 102,200,217

Workers' profit particiation fund - - (7,152,207)

Workers' welfare fund - - (2,713,414)

(330,624,070) (372,337,745) (59,891,069)

Operating Profit 2,054,909,221 1,610,540,451 756,457,862

Finance cost (1,127,467,695) (816,217,951) (697,959,899)

Share of loss of associated company (405,913) - -

Profit before taxation 927,035,613 794,322,500 58,497,963

Taxation (339,381,836) (309,869,960) (35,310,805)

Net Profit 587,653,777 484,452,540 23,187,158


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Consolidated Balance Sheet

As on 30-09-2010

2010 2009 2008SHARE CAPITAL & RESERVESShare Capital 442,840,570 381,254,260 315,361,900Reserves 1,548,014,772 1,129,798,008 718,536,715Minority interest (6,345,583)Total Share Capital & Reserves 1,990,855,342 1,511,052,268 1,027,553,032NON-CURRENT LIABILITIESSubordinated loan from Director 260,900,000 260,900,000 260,900,000Long term loans 3,375,777,778 3,600,000,000 3,017,702,890Liabilities against assets subject to finance lease 329,960,452 353,881,872 328,038,520Deferred liabilities 878,242,713 585,574,775 387,284,676Deferred Income 3,945,104 7,890,204 12,132,409Total Non-current Liabilities 4,848,826,047 4,808,246,851 4,006,058,495CURRENT LIABILITIESShort term borrowings 3,765,402,741 1,970,380,636 2,316,752,803Current portion of non-current liabilities 693,564,179 154,934,612 447,164,952Trade and other payables 803,490,123 1,726,633,296 551,987,795Interest and mark-up accrued 180,218,438 101,105,342 172,013,779Provision for taxation 49,990,394 54,087,075 39,000,000Total Current Liabilities 5,492,665,875 4,007,140,961 3,526,919,329Total Liabilities 12,332,347,264 10,326,440,080 8,560,530,856NON-CURRENT ASSETSProperty, plant and equipmentOperating fixed assets 6,829,407,871 6,049,189,068 4,507,512,438Capital work in progress 25,573,823 256,839,123 1,244,965,955Store & spares held for capital expenditure - 12,296,025 131,086,097

6,854,981,694 6,318,324,216 5,883,564,490Investment property 350,753,636 212,290,716 566,283,676Investments 394,847,861 375,000 375,000Goodwill 608,310,693 581,931,578Long term depsoits 48,877,275 37,731,155 34,673,790Total Non-current Assets 8,257,771,159 7,150,652,665 6,484,896,956CURRENT ASSETSStores, spares and loose tools 424,291,134 371,253,099 224,711,294Stock in trade - finished goods 1,436,296,905 876,391,873 914,974,191Trade debts 36,588,056 222,970,512 186,199,993Advances, deposits, prepayments and other receiveables 2,169,390,789 1,681,912,007 654,057,273Tax refunds from government 1,431,700 1,431,700Cash and bank balances 6,577,521 21,828,224 95,691,149Total Current Assets 4,074,576,105 3,175,787,415 2,075,633,900Total Assets 12,332,347,264 10,326,440,080 8,560,530,856


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Comparative Horizontal Common Size Income Statement

For the years ended on 30-09-2010

Net Sales 185% 202% 100%

Cost of Sales 166% 195% 100%

Gross Profit 292% 243% 100%

Administrative Expenses 156% 154% 100%

Distribution & Marketing Expenses 263% 1,781% 100%

Other operating expenses 817% 645% 100%

Other operating income 24% 69% 100%

552% 622% 100%

Operating Profit 272% 213% 100%

Finance cost 162% 117% 100%

Share of loss of associated company 100%

Profit before taxation 1,585% 1,358% 100%

Taxation 961% 878% 100%

Net Profit 2,534% 2,089% 100%


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SHARE CAPITAL & RESERVESShare Capital 140% 121% 100%Reserves 215% 157% 100%Miniority interest - - 100%Total Share Capital & Reserves 194% 147% 100%NON-CURRENT LIABILITIESSubordinated loan from Director 100% 100% 100%Long term loans 112% 119% 100%Liabilities against assets subject to finance lease 101% 108% 100%Deferred liabilities 227% 151% 100%Deferred Income 33% 65% 100%Total Non-current Liabilities 121% 120% 100%CURRENT LIABILITIESShort term borrowings 163% 85% 100%Current portion of non-current liabilities 155% 35% 100%Trade and other payables 146% 313% 100%Interest and mark-up accrued 105% 59% 100%Provision for taxation 128% 139% 100%Total Current Liabilities 156% 114% 100%Total Liabilities 144% 121% 100%

NON-CURRENT ASSETSProperty, plant and equipmentOperating fixed assets 152% 134% 100%Capital work in progress 2% 21% 100%Store & spares held for capital expenditure - 9% 100%

117% 107% 100%Investment propertyInvestments 105,293% 100% 100%Goodwill 107% 103% 100%Long term depsoits 141% 109% 100%Total Non-current Assets 233% 138% 100%CURRENT ASSETSStores, spares and loose tools 189% 165% 100%Stock in trade - finished goods 157% 96% 100%Trade debts 20% 120% 100%Advances, deposits, prepayments and other receiveables 345% 268% 100%Tax refunds from government 6% 6% 100%Cash and bank balances 7% 23% 100%Total Current Assets 196% 153% 100%Total Assets 144% 121% 100%


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Consolidated Income Statement

For the years ended 30-09-(2010)

2010 2009 2008

Net Sales 100.00% 100.00% 100.00%

Cost of Sales 75.91% 81.64% 84.72%

Gross Profit 24.09% 18.36% 15.28%

Administrative Expen0ses 2.22% 2.00% 2.63%

Distribution & Marketing Expenses 0.20% 1.26% 0.14%

Other operating expenses 1.17% 0.84% 0.26%

Other operating income 0.25% 0.65% 1.91%

Operating Profit 27.93% 23.11% 20.22%

Finance cost 11.39% 7.56% 13.06%

Share of loss of associated company 0.00% 0.00%

Profit before taxation 39.31% 30.66% 33.28%

Taxation 3.43% 2.87% 0.66%

Profit after taxation 42.74% 33.53% 33.94%


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Consolidated Balance Sheet

As on 30-09-(2010)

2010 2009 2008SHARE CAPITAL & RESERVESShare Capital 4% 4% 4%Reserves 13% 11% 8%Miniority interest 0%Total Share Capital & Reserves 16% 15% 12%NON-CURRENT LIABILITIESSubordinated loan from Director 2% 3% 3%Long term loans 27% 35% 35%Liabilities against assets subject to finance lease 3% 3% 4%Deferred liabilities 7% 6% 5%Deferred Income 0.03% 0.08% 0.14%Total Non-current Liabilities 39% 47% 47%CURRENT LIABILITIESShort term borrowings 31% 19% 27%Current portion of non-current liabilities 6% 2% 5%Trade and other payables 7% 17% 6%Interest and mark-up accrued 1% 1% 2%Provision for taxation 0% 1% 0%Total Current Liabilities 45% 39% 41%Total Liabilities 100% 100% 100%NON-CURRENT ASSETSProperty, plant and equipmentOperating fixed assets 55% 59% 53%Capital work in progress 0.21% 2% 15%Store & spares held for capital expenditure 0.12% 2%

56% 61% 69%Investment property 3% 2%Investments 3% 0% 0.004%Goodwill 5% 6% 7%Long term depsoits 0.40% 0.37% 0.41%Total Non-current Assets 11% 8% 7%CURRENT ASSETSStores, spares and loose tools 3% 4% 3%Stock in trade - finished goods 12% 8% 11%Trade debts 0.30% 2% 2%Advances, deposits, prepayments and other receiveables 18% 16% 7%Tax refunds from government 0.01% 0.01% 0.30%Cash and bank balances 0.05% 0.21% 1%Total Current Assets 33% 31% 24%Total Assets 100% 100% 100%


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Future prospects of the organization

Etihad Sugar Mills Limited focuses on the future growth of sugar mills in sugar industry,

for which they are planning to start corporate farming at about 1000 acres initially.

Vision

To be the lead in sugar industry by building the company’s image through quality

improvement, competitive prices and meeting social obligations.

Mission

1. To endeavour to be the market leader by offer high quality sugar to our valuable

customers at competitive prices.

2. To continue improving operating performance and profitability thereby ensuring

growth for the company.


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SWOT Analysis

Following are some points of strengths and weaknesses for internal environment and

opportunities and threats for external environment of the bank respectively.

Strengths

Problem solving and understand management attitude.

Lecture programme on fire fighting and safety measures is delivered to the employees to avoid any disaster situation.

Strong and healthy working relationship with growers.

Nearest growers are like to supply their sugarcane to Etihad Sugar Mills Limited and

they avoid to go other sugar mills having long distance as compared to Etihad Sugar

Mills Ltd.

Due to provision of loans to the growers, the growers are bound to their sugarcane

to Etihad Sugar Mills Limited.

Due to payment at the spot, the growers supply their sugarcane to Etihad Sugar

Mills Limited, because they want payment for the urgencies.

Provision of guidelines to the growers to have better yield per acre.

Due to nearest sugar mills of rahim yar khan city, it just takes 25 minutes to travel to

Mills or to the city. However, other competitors are away and minimum travel

required is one hour.

Weaknesses

Limited number of circle offices at nearest main stations only

Due to price war in sugar mills, the benefits goes toe the grower and the sugra mills

management had to pay extra money to the grower.

Salary package of lower staff is low as compared to other sugar mills.

Mills colony yet not been constructed and employees forcefully residing in city away

from mills about 30 KM and travel on daily basis who residing in city area.

No school for employee’s children is present there.


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Opportunities

Expansion of circle offices in outer stations, where circle office not exists.

Outreach to growers especially far flung areas.

The land of the vicinity is very fruitful for the sugar Mills.

The area at Etihad Sugar Mills Limited is shining area of the Punjab for production of

sugarcane.

Threats

Changes in policies suffer the growers as well as employees.

Most of the staff is illiterate but is experienced.

Lack of non-technical knowledge.

No electronically connection with circle offices except mobile phone.

Non provision of proper transport to the field staff.


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Conclusion

To summarize the things I would like to say that in a short span of time Etihad Sugar

Mills Limited, Rahim Yar Khan has developed itself maximum, but still some

development is required and is under process. Although, it is achieving a land mark

amongst all the competitors of the area. Its first operation was started on 28 th

December, 2006. Due to installation of Etihad Sugar Mills Limited, the nearest famous

station is Iqbalabad, which has developed rapidly, before installation of this Mills, it was

just like a small town (non-developed) now due to installation of this Mills, there is a

Bank recently opened with the name of DAWOOD Islamic Bank and many other

developments taken place.

Since, this mills is newly installed and yet not completed its construction, installation and

other jobs, therefore, have some loss and some profits in the season. Insha ALLAH, this

mill will recover all previous losses within 2-3 crushing seasons only.

This sugar mills is situated at KLP road and this facility has own only by Hamza Sugar

Mills Limited and RYK Mills Limited, both the JDW units are away from KLP and Ghotki

Sugar Mills is also away from KLP, this help the easy transportation of machinery etc.

So in the end I just want to say that Etihad Sugar Mills Limited is a good place a Sugar

Mill and to excel in the sugar industry with its promising location and products.

In the future, this Mills will be a market leader sugar mill of the area.


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Recommendations for Improvement

1. Mark-up free loan to the growers may be given to bring improvements in sugar industry as well as in Rahim Yar Khan District.

2. Maximum sowing of sugarcane may be ensured to avoid stoppages due to no-cane during the seasons.

3. I.T. section of Etihad Sugar Mills Limited, required to taken on line the circle office for instant updation of grower’s record.

4. Gifts may be given to the trolley / truck drivers, this will help to increase in supply of sugarcane by the growers.

5. The salary of lower staff may be improved so that they can perform duty without any tension.

6. Mechanical staff may be directed to remain vigilant to avoid any mechanical stoppage, which will discourage the growers and they shall supply their sugarcane to another sugar mills.

7. Increase in the number of circle offices to cater the needs of ever increasing no of potential growers.

References Used

Nawaz, Muhammad. (n.d.) Mills’ employees. Retrieved from

Saeed, Rahat. (n.d.) Mills’ employees. Retrieved from

Khan, Zia Ahmad. (n.d.) Mills’ employees. Retrieved from

Amjad, Muhammad. (n.d.) Mills’ employees. Retrieved from

Ali, Shaukat. (n.d.) Mills’ employees. Retrieved from

Masood, Farooq. (n.d.). Mills’ employees. Retrieved from

Qasim, Muhammad. (n.d.) Mills’ employees. Retrieved from

Rehman, Naveed. (n.d.) Mills’ employees. Retrieved from


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51

Internship Report

Documents

production of sugar

sugar acts

word sugar

sugar beets

sugarladen juice

raw sugar stage

manufacturing of white

sugar industry provincewise