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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 1
1. COMPANY PROFILE
1.1 What business the company is in?
Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd is state in
business in making of sugar.
1.2 Year of communication of business
Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd is a
co.operative sugar factory, registered under the Gujarat co.operative
societies act, 1961.the most evenly day of 31st march, 1964 witnessed the
emergence of Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd,
and the foundation of the sugar factory was made, which has flourished
and has been projecting a bright future for the sugarcane growers and
other agriculturists the area, today
1.3 Location
Sugar factory is situated at chalthan village, in south Gujarat region of
Gujarat state, 18k.m. away from the diamond and silk city of Surat. It is
situated on national highway no.8, Bombay-ahmedabad and the state
highway no.6 surat-dhulia, is hardly at a distance of 1k.m. surat-
bhusaval railway line connects with Bombay-ahmedabad main line is
also passing through chalthan and chalthan railway station is just
adjacent to factory. Our area is under tapti valley, which is gifted with
ample water either available through canal irrigation or wells. The soil is
fertile and the lands are even. The economical and atmospheric
conditions have established the agriculturists to resort banana, cotton,
vegetables, wheat, paddy, and sugarcane plantation on large scales.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 2
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 3
1.4 Owner
The Kalyanji .j. maheta is the founder of this sugar factory. Now share
holders of the organization are the owner. All members of the society are
farmers cultivating sugarcane. They are supplying cane to our sugar
factory. Total membership is 15982, out of which, harijans 211 and
adivasis are 24. Surat district consists of 7 talukas and total villages are
188.
LIST OF SHARE HOLDERS AND NO. OF SHARES
No. of Shares No. of Shares No. of Members
1. 13492 13492
2. 3326 1663
3. 1530 510
4. 680 170
5. 420 84
6. 198 33
7. 126 18
8. 40 5
9. 18 2
10. 20 2
11. 11 1
12. 14 1
13. 17 1
19892 15982
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 4
1.5 Objectives
� To improve the social and economic pattern or the rural area.
� To changed the life style in chalthan and its surrounding rural area.
� To assist farmers in the technology planting by agriculture staff.
� To import production efficiency and to reduce the cost of production.
� To provide maximum satisfaction to his share holders.
� To provide a better quality of sugar as compare to other sugar
factory.
1.6 Number of plants
Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Ltd has two
plants for making sugar.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 5
1.7 Turnover
The quality of our product is well-accepted in the export market and
every year we are exporting sugar, Alcohol and Molasses in good quantity
and will directly reflect the revenue of our nation.
COMMODITIES TURNOVER (YEAR-WISE)
Year Sugar
Bags Molasses (MT) Alcohol (B.L.)
1992-93 68,355 .. ..
1993-94 .. .. ..
1994-95 .. .. ..
1995-96 10,000 .. 16,99,000
1996-97 1,08,000 5913.010 71,03,000
1997-98 .. .. 48,06,000
1998-99 .. .. 50,00,000
1999-00 .. .. 50,00,000
2000-01 .. .. 50,00,000
2001-02 82,750 .. ..
2002-03 .. .. ..
2003-04 .. .. ..
2004-05 .. .. ..
2005-06 .. .. ..
2006-07 .. .. ..
2007-08 1,88,860 .. ..
2008-09 75,000 .. ..
2009-10 .. .. ..
2010-11 .. .. ..
2011-12 23,367 .. ..
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 6
2. PRODUCT PROFILE
2.1 Number of Products
In SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI
LIMITED mainly produce sugar but the by-product is. Molasses
Production, Bagasses Production, Internal Use of Bagasses, Press Mud,
Ash.
2.2 Sales volume
No. Particulars Last year (RS.) Current year
(RS.)
1. Sugar 2792946200 2327858356
2. Molasses 255217996 159800742
3. Press mud 795458 768055
4. Bagasse 38504325 32727496
TOTAL 3087463979 2521154649
2.3 Product lines
Products
Main product By products
Sugar 1. Molasses
2. Bagasses
3. Press mud
4. Ash
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 7
Khand Udyog products & By-products
Sr. No. Particulars %
1 Sugar Propossion 12%
2 By-Products
A Molasses Production 4.5% to 5%
B Bagasses Production 30%
C Internal Use of Bagasses 26% to 28%
D Press Mud 2% to 3%
E Ash 1.55 to 2.00%
SUGAR
Sugar is a term for a class of edible crystalline carbohydrates,
mainly sucrose, lactose, and fructose, characterized by a sweet flavor.
In food, sugar almost exclusively refers to sucrose, which primarily
comes from sugar cane and sugar beet. Other sugars are used in
industrial food preparation, but are usually known by more specific
names glucose, fructose or fruit sugar, high fructose corn syrup, etc.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 8
Byproducts of Chalthan Sugar factory:
CHALTHAN SUGAR Factory has byproducts, which are (1) Bagasse (2)
Molasses (3) Filter Mud (4) Rectified Spirit.
(1)Bagasses:
Bagasses are the fibrous matter that remains after sugarcane stalks are
crushed to extract their juice. It is currently used as a biofuel and as a
renewable resource in the manufacture of pulp and paper products and
building materials.
The cane juice is extracted in the mills and the residue is called
bagasses. It is 24-30% of sugar cane. The production of the bagasses is
29.41%. It is passed in the boilers through the bagasses carrier and is
directly fed in the furnaces of the boilers as fuel the surplus bagasses is
taken out at the end of carrier, and sold out to paper mills. The sugar in
bagasses is 0.62.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 9
(2)Molasses:
Molasses is a viscous by-product of the processing of sugar
cane, grapes or sugar beets into sugar. The word molasses comes from
the Portuguese word melaço, which ultimately comes from Mel,
the Latin word for “honey”. The quality of molasses depends on the
maturity of the sugar cane or sugar beet, the amount of sugar extracted,
and the method of extraction.
When sugar is separated from masscult mother liquor coming out is
called the molasses. It is boiled for 3 or 6 hours to recover maximum
sugar. It is 3.5-4.5% of sugar cane. It is important for the manufacturing
of various industrial products such as distillery product chemical like
holistic acid, alcohol, etc. rectified spirit and absolute alcohol are made
from the molasses. The production of the molasses is 4.84%. The sugar
in final molasses is 1.396. So, it is sold out in distillery plant.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 10
(3)Filter Mud:
Filter mud is also known as filter caked. Filter mud contain 3.5-4% of
sugar cane. The production of the filter mud that is 4%. It is generally
used for the fertilizer. The sugar in filter caked is 1.396.
The processing of sugar cane produces a form of filter cake mud, which
can be extracted for different uses, including animal feed and refined
wax. It can also be recycled back into the sugar milling process. Until
uses for the filter cake mud were found, sugar cane mills did not know
what to do with the mud, and factories threw out the material.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 11
(4)Rectified Spirit:
It is manufactured by formation & distillation of molasses as per IS:
323-1959 specification. One merit tone molasses are taken in this
material 250 liter of rectified spirit come out. It is used for manufacturing
of Acetic Acid, acetone, Oxalic Acid Absolute Alcohol & other various
chemical. Special Gravity 0.8171 at 15.6 C. percent by volume 84.68at
15.6 C.
A rectified spirit, rectified alcohol, or neutral spirit is highly
concentrated ethanol which has been purified by means of repeated
distillation, a process that is called rectification. It contains 95% alcohol
by volume. Rectified spirits are used in mixed drinks, in the production
of liqueurs, for medicinal, and as a household solvent.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 12
2.4 Raw materials
Sugarcane
Sugar cane is a tall and relatively strong class of perennial grasses that
are known to have high sugar content. Strictly speaking, there is not a
single plant that is known as sugar cane. Instead, there are as many as
thirty-seven different grasses that are sometimes considered to be part of
this particular cane family. Many of these grasses can be crossbred, thus
creating hybrids that can adapt to various types of climate conditions.
The varying types of sugar products made from sugar cane cover a wide
range. Along with basic sugar used in different recipes, commercial
enterprises can make use of the sugar to create molasses, sodas and
other soft drink products, rum, and a variety of sweeteners that are used
to slightly flavor frozen foods. The raw sugars can also be used in the
manufacturing of hard candies and other confections that may be stored
at room temperature for extended periods of time.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 13
2.5 Growth profile
Actual crushing started in1970-71 with 1250 tons per day capacity. The
plant is of backau Wolf India make, double sulphitation process. In the
first year, factory has crushed 11600 tons of sugarcane and in the
season 1973-74 the factory has crushed 222000 tons of sugarcane with
an average of 1400 tons per day. The factory has undertaken first
expansion program in 1977-78 from 1250 TCD to 2000 TCD. In the year
1982-83, the factory has further expanded to 3500 TCD. This plant is
walchandnager make. From the season 1988-89 onwards, the factory is
further expanded to 5000 TCD and from 20.12.1988 the factory is
crushing sugarcane at the rate of 5100 TCD.
Most modern plant equipments are installed in sugar factory. Fibrize,
split carrier, donally chute, auto cane carrier, auto sulphur burner,
continuous centrifugal machine, vertical continuous crystallizer etc. are
some of the same. Over & above, the factory has installed a 40 tones high
pressure boiler for their expansion to 5000 TCD. This boiler is of texmaco
make and it is the first of its kind installed in Gujarat. The factory has
also installed a high pressure turbo alternator set, which is also the first
unit installed in Gujarat. The turbine is of APE belliss India make and
alternator is of jyoti make.
The factory has also installed continuous pan for massecuite boiling with
automation, cooling and condensing system for constant vacuum on pan
and evaporator. Also installed twin vertical crystallizer for mass cooling.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 14
For air & water environment protection, factory has installed wet
scrubber system on all boiler and diffuser air blowing system, pressure
sand filter and pressure carbon filter system for effluent water treatment.
Factory has installed mill automation system and boiler automation
system for better result.
In order to ascertain accurate weight of all materials, factory has
installed computarizer load cell base weigh-bridge at all weigh-bridge
stations. Normal crushing days are 200. Expansion program were done
by own funds and in shortest possible time. The factory has expanded
from 1250 TCD to 5000 TCD within a short time of only 10 years.
Our authorized share capital of RS.110 lacks is distributed among 11105
members from whom the factory is receiving sugarcane for crushing at
the factory. Even though the factory started production in 1971, within a
short time of 7 years, organization has paid back the share capital of
RS.39 lacks to the government and the loan of IFCI and LIC amounting
to RS.23lacks. The factory is receiving sugarcane from 183 villages within
a radius of 32 K.M.s
2.6 Major customers
The sugar factory’s major customers are (1) government (2) share holder
of company & (3) brokers.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 15
3. ORGANIZATIONAL STRUCTURE
3.1 Departmentation
The sugar factory use departmentation by process.
3.2 List of Departments
A. H.R department (labor department).
B. Production department.
C. Sales department.
D. Accounting department.
E. Purchase department.
F. Other department.
i. Administration department.
ii. Transportation department.
iii. Agriculture department.
iv. Distillery department.
Manager
Milling Crushing Unloading Heating Finishing
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 16
3.3 Organizational Structure
Board of Director
Chairman & Vice Chairman
Mr.Jayanti Patel & Mr.Ramanbhai
Jain
Managing Director
Mr. v.subburathinam
Chief
Accountant
Mr. Achal
Shukla
Labor officer
Mr.
Hashmukh
Administrative
officer
Mr. Harish vashi
Estate Manager
Mr. M. Patel
Distillery
Manager
Mr. Suresh Patel
1. Labor welfare officer
2. Medical officer
3. Security officer
4. Time office
1. General officer
2. Transport 3. Weigh
bridge
C.D.O C.P.
Agri.officer
Agri.Assistant
Cane quality control
Boy
Labors
Peon
Production
Supervisor
Shift
Chemist
Operator
Workers
Peon
DY.Chief
Accountant
Asst.
Accoun
Cane.
Accoun
Accountant Clerks
Cashier Peon
Clerks
Peon
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 17
4. DIFFERENT DEPARTMENTS DETAILS
4.1 Personnel Department
4.1.1 Department Chart
4.1.2 Labour Relation Activities
In the SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI
LIMITED. Relation between labours is very good so the labour relation
activities are not done. But at the startup the work organization do the
induction training.
4.1.3 Human Resource Development
For development of H.R department organize some seminar like;
� India renal foundation.
� National training and development.
� Staff society personal.
Labour officer
1. Labour welfare
2. Medical officer
3. Security officer
4. Time officer
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 18
4.1.4 Labour Welfare
� UTSAV CELEBRATING:-
� GANESH UTSAV
� NAVRATRI
� DURGA POOJA
� CABLE TV:-
� the factory is provided cable tv facility to the residents of colony.
The factory is providing financial assistance for this facility.
� TEMPLE:-
� The factory has constructed an attractive temple for lord shiva,
which is functioning.
� MEDICAL AND HEALTH:-
� Factory has promoted SANJIVANY HOSPITAL to solve the problem
arising out of scarcity of medical facilities in rural area. This is an
important step towards attachment on community goals through
cooperative efforts. This hospital aims to provide modern medical
facilities to rural poor at normal charges and intends a 130 bedded
most modern well equipped hospital is functioning. This hospital
provides all the basic facilities of hospitalization, emergency and
nursing care in a clean surrounding. The details of facilities are as
under:
� O.P.D:-
This hospital functions fully equipped O.P.D both in morning and
evening with full time surgeon, physician, orthopedic surgeon and
gynecologist to provide basic facilities. In addition to this, part time
visiting doctors provides care in dental, ayurvedic and naturopathy.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 19
� Emergency services:-
The hospital has well equipped causality and emergency services to
cater for both medical and surgical emergencies around the clock
with technical staff and doctors.
� Indoor facilities:-
The hospital has 130 beds capacity with 50 functioning beds at
present. In addition, it has separate burns unit of two beds and ten
bedded naturopathy department.
It has well equipped two operation theatres for all minor and major
operation of various disciplines.
� X-Ray
The hospital is equipped with one X-Ray unit of 300 MA.
� Laboratory:-
Laboratory is well equipped and capable of performing all
investigations.
The hospital runs its own chemist shop which is well stocked and
provides almost all the drugs required in the hospital or prescribed
to OPD patients.
The physiotherapy department takes care of rehabilitations of the
orthopedic cases and functions under the supervision of ortho
surgeon, all free of charges, and takes care of preventive and social
aspects.
The hospital has recently opened a full time naturopathy department
with both OPD and indoor (10 beds). It is equipped with all possible
apparatus. From time to time, the hospital organizes camps at
villages to provide free medical or surgical OPD aid to the
surrounding villagers-eye camp.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 20
� TREE PLANTATION:-
� As primary step for controlling pollution, the factory is arranging for
tree plantation, every year.
� HOUSING SOCIETY:-
� Shree Khand Udyog Cooperative Housing Society has established
with the object to provide own residence to the needy employees of
the factory. About 100 staff members are members of this society.
Construction of the residential buildings is completed.
� STAFF WELFARE:-
� The factory is keen in staff welfare activities. We have provided about
381 residential accommodations to staff and workers, which are well
constructed with enough space and ventilation arrangements, 24
hours water supply and electricity supply etc.
� The factory is also providing contributions for cultural programmers,
recreation club, library etc. As part of staff welfare, a bal mandir is
being run by the factory management for encouraging primary,
secondary and higher education activities. For family planning, the
management is donating a good amount every year.
� The factory is running the kalyanji Mehta vidhyalay at chalthan and
also making financial assistance to the educational institutions to
the nearby area.
� STAFF SOCIETY:-
� Shree khand Udyog karmachari Sahakari Mandli LTD has been
established in the factory premises. This society advances loans to
the needy members of the society at nominal interest charges. A fair
price shop is also being run by this society to provide all daily
consumable items to the workers on credit basis. All employees of
the factory are members of this society.
� The employees of the factory are also advanced bank loans on the
undertaking of sugar factory for purchasing cycles, mopeds,
television, fridge etc.
� A cooperative bank, post office and S.B.I A.T.M centre etc. are
functioning in the factory for premises to facilitate the employees.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 21
� Thus, shree chalthan vibhag khand Udyog Sahakari Mandli Ltd. Has
not only created wide economic opportunities for common people,
but also activated the lowest state of community to participate in the
development process. We have made a unique effort to strengthen
the weaker section of the society to benefit enough to participate in
the development process by mobilizing large financial resources in
favor of them through cooperative effort and by providing them with
infrastructural facilities and scientific aptitudes.
� CANTEEN
� UNIFORM
� In sugar only security and low level worker has compulsory uniform.
� SCHOOL FOR CHILDREN EDUCATION.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 22
4.1.5 Maintenance of Employee Records
For maintain the employee record organization use “electronic time
punching machine” it is an automatic computerize software.
4.1.6 Payroll Systems Wage and Salary Structures
OPERATIVE IN FORCE FROM 01.10.2011 TO 31.12.2011
SR.
NO.
CATEGORIES BASIC PAY FIXED
ALLOWA
NCE RS.
V.D.A.
AS PER
3585
POINTS
RS.
MINIMU
M RS.
MAXIM
UM RS.
HOUSE
RENT
RS.
1 UNSKILLED 3400-45-3850-
50-4350-55-
5175
310.00 4632.00 8342.00 10117.
00
100.00
2 SEMI
SKILLED
3500-50-4000-
55-4550-60-
5450
220.00 4632.00 8352.00 10302.
00
100.00
3 SKILLED – B 3650-60-4250-
65-4900-70-
5950
99.00 4632.00 8381.00 10681.
00
120.00
4 SKILLED – A 3800-65-4450-
70-5150-75-
6275
.. 4632.00 8432.00 10907.
00
120.00
5 HIGHLY
SKILLED
3900-70-4600-
75-5350-80-
6550
.. 4632.00 8532.00 11182.
00
140.00
CLERKS
1 CLERICAL
– IV
3650-60-4250-65-
4900-70-5950
97.00 4632.00 8359.00 10679.00 120.00
2 CLERICAL
– III
3800-65-4450-70-
5150-75-6275
.. 4632.00 8432.00 10907.00 120.00
3 CLERICAL
– II
3900-70-4600-75-
5350-80-6550
.. 4632.00 8532.00 11182.00 140.00
4 CLERICAL
– I
4000-75-4750-80-
5550-85-6825
.. 4632.00 8632.00 11457.00 140.00
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 23
SUPERVISORY
1 SUPERVISOR
– C
4000-75-4750-80-
5550-85-6825
.. 4632.00 8632.00 11457.00 140.00
2 SUPERVISOR
– B
4100-80-4900-85-
5750-90-7100
.. 4632.00 8732.00 11732.00 170.00
3 SUPERVISOR
– A
4300-95-5250-110-
6350-125-7225
.. 4632.00 8932.00 11857.00 170.00
PAY.DOC/TIME OFFICE/HN
744 Points neutralized and merged in basic pay. Above 744 points
increase up to 818 points i.e. 74 points calculated Rs. 122.10 @ Rs.1.65
w.e.f. 01.10.1989 and above 818 points increase calculate @ Rs. 1.85 per
points. Above 1231 points (with effect from 01.01.1994) increased
calculated @ Rs.2.00 per point. Up to 3340 points neutralized and
merged in basic pay above 3340 points increase up to 3371 point, i.e. 31
points calculated Rs.66.65 @ Rs.2.15 w.e.f. 01.04.2009.
4.1.7 Recruitment and Promotion
RECRUITMENT:-
When the organization need to recruitment first they give advertisement
in local newspaper then collect application and take interview to the
candidate after select the best candidate. For 5 year temporary based
and then do the permanent that employee.
PROMOTION:-
In the organization promotion done as per seniority based witch
employee has more experience that employee get promotion in the
organization. Or when the vacant place that time do the promotion for
fill up that place.
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 24
4.1.8 Performance Appraisal
PROMOTIONAL RATING SHEET
1. Name :
2. Department :
3. Position :
4. Age/Date of Birth :
5. Married/Single :
6. Present Salary :
7. Education :
8. Experience :
(a) In company :
(b) Others :
9. Date of entered Service :
10. Last increase in salary :
(a) Amount :
(b) Date :
11. Date of Next Increment :
Marks (Out of 100)
12. Attendance & Punctuality :
13. Initiative, interest in work :
14. Co-operative Spirit :
15. Speed and volume of work :
16. Reliability :
17. Accuracy :
18. Quality of work :
19. Conduct :
20. Honesty :
Total… / 900
21. Do you consider the above employee to be
(a) Capable for more responsible job? :
(b) Suitable assigned? :
(c) Confirm / Not Confirm :
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Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 25
22. Remarks
_______________________
___________________
Merit Rater with Designation
Head of the Department
Against Sr.No.12 to 20, put your remark by stating (i)
Excellent (ii) Good (iii) Fair (iv) Bad and (v) Very bad only, and
against Sr.No.21 by stating Yes or No.
Order………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………..
To,
Labour Office / Head Time Keeper
MANAGING DIRECTOR
4.1.9 Safety measures
For the safety of the employee factory provide safety helmet and safety
shoos.
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Vidyabharti Trust College Of BBA & BCA, Umrakh 26
4.1.10 STAFF DETAILS as on 31.03.2011
Permanent staff 427
Seasonal staff 535
Distillery Unit
-Permanent
-Seasonal
53
13
Total 1028
Trainee staff 47
Grant Total 1075
March 2012
No. officer staff permanent seasonal total
1 general officer 10 0 10
2 accountant 15 0 15
3 Crain 6 1 7
4 Civil 1 0 1
5 ta.offi 2 5 7
6 engineer 15 0 15
7 manual 7 0 7
8 medical 2 0 2
9 labour welfare 1 0 1
10 security 1 0 1
11 Store 9 5 14
12 Sugar 3 0 3
13 sugar warehouse 4 4 8
14 transport 3 0 3
15 weightier 2 13 15
16 Post 4 0 4
Total 85 28 113
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farming department
17 staff 12 0 12
18 freed 26 0 26
19 k kava k 0 156 156
20 testing lab 4 1 5
total 42 157 199
Worker
21 store 4 3 7
22 civil 7 0 7
23 boiler 35 0 35
24 mill 55 0 55
25 boiling 51 0 51
26 cutting 45 0 45
27 workshop 26 0 26
28 security 25 0 25
29 manufacturing 4 156 160
30 patapagi 16 0 16
31 driver 8 13 21
32 sanitation 4 0 4
33 general engineer 16 134 150
34 laboratory 0 13 13
35 sugar handling 0 9 9
total 296 328 624
Page 28
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 28
distillery department
36 staff 40 19 59
37 Zone 3 0 3
total 43 19 62
zone department
38 trainee farm 10 0 10
39 trainee distillery 2 0 2
40 trainee engineer 21 0 21
41 trainee manufacturing 2 0 2
42 apprentice 16 0 16
total 51 0 51
Summery
NO. department permanent seasonal Total
1 Staff 85 28 113
2 farming 42 157 199
3 Worker 296 328 624
4 Zone 3 0 3
5 distillery 40 19 59
Total 466 532 998
Page 29
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 29
4.2 Production Department
4.2.1 Department Chart
Production manager
Chief chemist
Peon
Worker
Production supervisor
Operator
Page 30
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 30
4.2.2 Production Plan
WEIGH WEIGHED
MACCERATION WATER
Cane
Milling Plant
Continuous lime and Sulphitation unit
pH 7 to 7.2
Primary juice Heater 70oC
Receiving Tank
Automatic Weighment
Mixed Juice
PH 5 to 5.5
Secondary juice heater 100o to 102
oC
Bagasses
Boilers
High Press Steam
Prim over Power
Turbine
Low Pressure Steam
Condensed Low Pressure
Water
Contd.
Settler
Mud
Clear juice pH 6.9 to 7.0 Temp 95oC
Mud Mixer
Evaporators
Vacuum Filter
A Heavy & A Light
Filter
Filter
Cake
Syrup pH 6.5-6.8
Cont. Syrup Sulphiter
Sulphide syruppH
4.8-5.2
To Process Weight & Sold as
Farm Yard Manure
Crystallization
Centrifugation
MOLASSES SUGAR
Phosphoric Acid.
Excess Bailed Solid for Paper
Industries
Electricity Produced to Run the Plant
SO2 Gas
Page 31
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 31
4.2.3 Month Wise Number of Workers Employed
Month Male
Total Sugar Distillery
Jan – 2011 973 58 1031
Feb – 2011 973 58 1031
Mar – 2011 972 57 1029
Apr – 2011 971 57 1028
May – 2011 970 57 1027
June – 2011 970 57 1027
July – 2011 558 41 599
Aug – 2011 558 43 601
Sep – 2011 558 43 601
Oct – 2011 956 48 1004
Nov – 2011 944 58 1002
Dec – 2011 945 58 1003
4.2.4 Month Wise Number of Days during Production Activities Was
In Operation
MONTH SUGAR DISTILLERY
Rectified Spirit
Absolute alcohol
Jan – 2011 31 28 21
Feb – 2011 28 25 22
Mar – 2011 31 30 29
Apr – 2011 30 28 28
May – 2011 31 28 23
June – 2011 12 5 10
July – 2011 -- -- --
Aug – 2011 -- -- --
Sep – 2011 -- -- --
Oct – 2011 12 -- --
Nov – 2011 30 9 7
Dec – 2011 31 30 30
TOTAL DAYS 236 183
176
Page 32
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 32
4.2.5 Month Wise Product and Byproducts
MONTH
PRODUCT
BY PRODUCTS
SUGAR
(MT)
RECTIFIED
SPIRIT
(KL)
ABS.
ALCOHOL
(KL)
BAGASSES
(MT)
FITER
CAKE
(MT)
MOLASSES
(MT)
Jan – 2011 16410 1744.849 631.219 53543.403 6267.750 8991
Feb – 2011 13923 1544.611 646.493 48836.200 5603.930 7629
Mar – 2011 12476 1933.807 865.300 46587.533 5277.730 7887
Apr – 2011 13260 1813.303 837.839 54237.287 6139.470 9267
May – 2011 9575 1752.750 695.398 47312.119 5057.450 8742
June – 2011 2295.50 295.503 305.769 8452.413 941.430 2148
July – 2011 -- -- -- -- -- --
Aug – 2011 -- -- -- -- -- --
Sep – 2011 -- -- 173.034 -- -- --
Oct – 2011 1020 -- -- 6113.485 694.670 672
Nov – 2011 10046 520.717 198.347 29271.305 3866.760 5607
Dec – 2011 15498 1954.346 889.507 42856.348 4767.200 7125
TOTAL 94503.50 11559.886 5242.906 337210.093 38616.390 58068
Avg./Month 10500.389 1895.063 893.170 37467.788 4290.710 6452
Avg./ Day 400.439 63.169 29.789 1428.856 163.629 246.051
Page 33
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 33
4.2.6 Month Wise Raw Material Consumption For Sugar Production
Month Sugar
Cane,(MT) Lime (MT)
Sulphur (MT)
Phosphoric Acid (KGS)
Allezine (KGS)
CAUSTIC SODA (KGS)
Jan – 2011 167700 370.00 78.000 420.000 10.500 8600
Feb – 2011 145100 300.000 73.000 1265.000 921.500 8400
Mar – 2011 132230 271.550 70.710 1025.000 130.500 5650
Apr – 2011 146470
320.000
75.000
4360
NIL
9000
May – 2011 119740 405.000 55.000 2225 411.000 2050
June – 2011 19898.940 54.300 8.580 55 NIL 8100
July – 2011 -- -- -- -- -- --
Aug – 2011 -- -- -- -- -- --
Sep – 2011 -- -- -- -- -- --
Oct – 2011 23650 63.130 13.000 1555 NIL 150
Nov – 2011 105910 234.490 51.700 4560 NIL 3850
Dec – 2011 146700 243.000 56.200 7450 NIL 9350
TOTAL 1007398.9
40 2261.47
0 481.190 22915
1473.500 55150
Avg./Month
111933.216
251.274 53.466 2546.111 368.375
6127.778
Avg./ Day 4268.640 9.583 2.039 97.097 12.178 233.686
Page 34
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 34
4.2.7 Process Description For Manufacturing Of Sugar From
Sugarcane
Matured cane according to plantation calendar is harvested from the
fields, trashes, tops and roots removed and clean cane is transported to
factory by means of trucks and bullock-carts. The cane is weighed and
dumped on feeder tables by means of sling hoist cane unloaded. At mill
for maceration hot water of 75 0 C is applied to extract maximum amount
of sugar cane juice (sugar) from the cane. The residual obtained after
milling (Bagasses) is fed to boilers to generate the steam for running the
different prime movers for milling and electrical power generation.
The mixed juice obtained from mills is weighed and phosphoric acid
isadded to it. After addition of phosphoric acid mixed juice is heated to
75 0 C in multiphase vertical tubular juice heaters where from it is sent
to juice sulphitor where milk of lime and SO2 gas is mixed in it and final
pH is maintained to 7.0 (+ or - 0.2). Sulphited juice is heated to 102 0 C (+
or - 2) and then sent to Dorr or clarifier for settling to flock formed. The
overflow of the Dorr Clarifier is clear juice and underflow is mud. The
mud is filtered through vacuum filter, mud is used as manure and the
filtrate is recycled and mixed with the mixed juice for reprocessing. The
clear juice obtained from Dorr Clarifier is concentrated to 60-65 0Bx. In
vapor cell and quintuple effect evaporators. The juice so concentrated i.e.
Syrup is sent to Syrup Sulphitor where it is sulphited with SO2 and its
pH is brought down to 5.0 to 5.2. Thus sulphited syrup is sent to pans
supply tank for further processing.
Page 35
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 35
A massecuite is boiled with syrup melt and A light, Dry seed footing is
taken for A massecuite boiling in vacuum pans where sugar crystals are
developed for bagging. A massecuite of 94 °Bx. And 86-88 purity is
finally dropped in the crystallizers. From crystallizer this A massecuite is
sent to centrifugal machines where sugar crystals. A heavy molasses and
A light molasses are separted, sugar is sent to graded through grass
hoppers where sugar is separated in different grains, sizes S- 30, M- 30 &
L -30 are bagged, weighed in 100 Kgs. bags for domestic market and 50
Kgs. for export.
molasses are sent to pans storage tanks. A light is used in A massecuite
and A heavy is used for boiling B massecuite. 95-96 0Bx. and 71-73
purity. After purging B massecuite B heavy molasses and B sugar is
obtained. B sugar is melted and sent to pans and fed to a massecuite
pans. B heavy molasses is sent to pan storage tanks and is used for
boiling C massecuite of 100 0Bx. and 55-56 purity. C massecuite is
purged in C for workers where final molasses solution of 45 0Bx. is used
for lubrication, molasses obtained from C fore centrifugals is final
molasses it is weighed and is stored in five steel molasses storage tanks.
‘C’ fore cured sugar is affinated with C light molasses and sent to C After
worker centrifugals where hot water is applied and C after sugar and C
light molasses is obtained. C after sugar is melted and sent to pans for A
massecuite boiling and C light molasses used for C fore magma and
boiling C massecuite.
Page 36
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 36
4.2.8 Daily Reports
DAILY MANUFACTURING REPORT
SEASON: 2011-2012 DATE: 30/03/2012 CROP DAY: 163
PAGE: 1
SR.
NO.
PARTICULARS SEASON 2011-2012 SEASON 2010-
2011
TODAY TODATE TODAY TODATE
1a. Cane Crushed(MT) -
B/W
WIL
Combined
2. Sugar produced (Qtls)
3. Exp.Recovery % Cane
4. Pol in Cane
5. Fiber % Cane
6. A.W. % Cane
B/W
WIL
C
ombined
7. A.W. % Fiber
B/W
WIL
Combined
8. Mill Extraction
B/W
0.000
0.000
0.000
1830.000
********
********
0.000
********
********
********
********
********
********
********
********
********
********
********
********
0.000
217740.000
413308.270
631048.270
671360.000
10.60
12.62
13.45
29.69
31.11
30.62
223.60
229.74
227.65
95.03
95.13
95.10
95.37
95.56
95.49
2.10
2.07
1380.000
2700.000
4080.000
4150.000
9.70
12.01
16.16
32.57
31.69
31.99
201.03
196.34
197.93
93.33
93.53
93.47
95.07
95.20
95.16
2.20
2.16
319000.
000
452040.
000
771040.
000
727310.
000
9.67
11.75
13.89
30.57
30.27
30.40
218.89
218.70
218.78
94.14
94.27
94.22
94.84
94.90
94.88
Page 37
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 37
WIL
Combined
9. RME (Deer)
B/W
WIL
Combined
10. Pol % Bagasses
B/W
WIL
Combined
11. Moist. % Bagasses
B/W
WIL
Combined
12. Final Molasses
(MT)
13. Expected F.M. % Cane
14. Total Lost Hours
B/W
WIL
Combined
15.Burnt cane
(MT)
16. Burnt cane %
17. F.M. Purity
0.000
********
0.000
0.000
********
60.000
********
0.000
0.000
0.000
0.000
0.000
32.92
********
********
********
********
********
********
********
********
100.000
0.000
********
********
********
********
2.08
52.11
51.94
52.00
30465.000
4.85
887.25
289.000
528.30
557478.08
88.34
32.04
18.55
15.18
81.83
14.91
11.96
80.22
88.13
91.51
83.15
0.000
100.37
1519.12
2871.86
4391.94
2047.11
2.17
52.40
52.10
52.20
321.000
6.10
9.00
2.00
4.80
3736.42
91.58
34.17
18.57
15.04
81.01
14.82
11.76
79.39
86.21
90.62
79.87
0.000
95.46
1380.000
2700.000
4080.000
2208.000
2.19
2.17
2.18
52.48
52.38
52.42
38088.0
00
5.02
726.45
386.20
522.30
437560.
62
56.75
33.16
17.65
14.38
81.47
14.02
11.20
79.94
87.20
91.00
81.70
0.000
98.78
Page 38
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 38
18. P.J. Brix %
Pol %
Purity
19. M.J. Brix %
Pol %
Purity
20. Boiling House Rec.
21. RBHR (Deer)
22. Java Ratio
23. B.F.C.W. % Cane
24. Net M.J. % Cane
25. Crushing Rate/24 Hrs.
a. Inc.
Stoppages B/W
WIL
Combined
b. Exc.
Stoppages B/ W
WIL
Combined
26. Sugar Production
S-30
S-31
M-30
M-31
L-30
********
********
********
1580
0.000
0.000
0.000
250
0.000
0.000
0.000
1830
86.34
0.000
0.000
0.000
13.66
0.000
0.000
0.000
100.000
0.000
3134.09
5186.52
393370
0.000
0.000
0.000
30810
0.000
494360
0.000
671360
58.59
0.000
0.000
0.000
4.59
0.000
36.82
0.000
100.000
0.000
0.000
2945.46
5100.000
0.000
2540
0.000
0.000
0.000
0.000
3220
0.000
4150
0.000
61.20
0.000
0.000
0.000
0.000
77.59
0.000
100.000
1937.44
2873.14
4811.23
2373.86
3200.47
5567.19
177500
265940
97180
0.000
25160
2000
319060
0.000
727310
24.41
36.56
13.36
0.000
3.46
0.27
43.87
0.000
100.000
Page 39
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 39
L-31
50 kg Bags
BROWN
TOTAL
27. Sugar Production %
S-30
S-31
M-30
M-31
L-30
L-31
50 kg Bags
BROWN
TOTAL
27. STEAM TO DISTILARY-
M.T
28. F.M. STOCK
[B] MILL STOPPAGES REPORT
*** NO Stoppages in mill.
MFG. CHEMIST
CHIEF CHEMIST
Page 40
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 40
DAILY MANUFACTURING REPORT
SEASON: 2011-2012 DATE: 31/03/2012 CROP DAY: 164
PAGE: 1
SR.
NO.
PARTICULARS SEASON 2011-2012 SEASON 2010-
2011
TODAY TODATE TODAY TODAT
E
1a. Cane Crushed(MT) -
B/W
WIL
Combined
2. Sugar produced (Qtls)
3. Exp.Recovery % Cane
4. Pol in Cane
5. Fiber % Cane
6. A.W. % Cane
B/W
WIL
Combi
ned
7. A.W. % Fiber
B/W
WIL
Combined
8. Mill Extraction
B/W
WIL
0.000
0.000
0.000
3200.000
********
********
0.000
********
********
********
********
********
********
********
********
********
********
********
********
0.000
217740.000
413308.270
631048.270
671360.000
10.60
12.62
13.45
29.69
31.11
30.62
223.60
229.74
227.65
95.03
95.13
95.10
95.37
95.56
95.49
2.10
2.07
1740.000
3160.000
4900.000
3440.000
9.65
11.96
16.24
32.25
31.88
32.01
199.29
195.85
197.07
93.32
93.45
93.40
95.06
95.19
95.14
2.20
2.16
320740
.000
455200
.000
775940
.000
730750
.000
9.66
11.75
13.91
30.58
30.28
30.41
218.77
218.52
218.62
94.13
94.26
94.21
94.84
94.91
Page 41
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 41
Combined
9. RME (Deer)
B/W
WIL
Combined
10. Pol % Bagasses
B/W
WIL
Combined
11. Moist. % Bagasses
B/W
WIL
Combined
12. Final Molasses
(MT)
13. Expected F.M. % Cane
14. Total Lost Hours
B/W
WIL
Combined
15.Burnt cane
(MT)
16. Burnt cane %
17. F.M. Purity
18. P.J. Brix %
0.000
********
0.000
0.000
********
45.000
********
0.000
0.000
0.000
0.000
0.000
32.92
********
********
********
********
********
********
********
********
100.000
0.000
********
********
********
2.08
52.11
51.94
52.00
30510.000
4.85
887.25
289.000
528.30
557478.08
88.34
32.04
18.55
15.18
81.83
14.91
11.96
80.22
88.13
91.51
83.15
0.000
100.37
1519.12
2871.86
4391.94
2047.11
2.17
52.40
52.10
52.21
360.000
6.07
6.45
0.000
2.58
4501.49
91.87
34.19
18.57
15.04
81.00
14.77
11.73
79.39
86.19
90.61
79.54
0.000
95.29
1740.000
3160.000
4900.000
2379.49
94.88
2.19
2.17
2.18
52.48
52.38
52.42
38448.
000
5.03
732.90
386.20
524.88
442062
.11
56.97
33.17
17.66
14.38
81.43
14.02
11.21
79.94
87.10
90.93
81.70
0.000
98.76
Page 42
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 42
Pol %
Purity
19. M.J. Brix %
Pol %
Purity
20. Boiling House Rec.
21. RBHR (Deer)
22. Java Ratio
23. B.F.C.W. % Cane
24. Net M.J. % Cane
25. Crushing Rate/24 Hrs.
a. Inc. Stoppages
B/W
WIL
Combined
b. Exc. Stoppages
B/ W
WIL
Combined
26. Sugar Production
S-30
S-31
M-30
M-31
L-30
L-31
********
********
********
********
3200
0.000
0.000
0.000
0.000
0.000
0.000
0.000
3200
100.00
0.000
0.000
0.000
0.000
0.000
0.000
0.000
100.000
0.000
3134.09
5186.52
396570
0.000
0.000
0.000
30810
0.000
494360
0.000
674560
58.79
0.000
0.000
0.000
4.57
0.000
36.64
0.000
100.000
0.000
0.000
3160.000
5490.20
0.000
1930
0.000
0.000
0.000
0.000
3220
0.000
3440
0.000
56.10
0.000
0.000
0.000
0.000
87.79
0.000
100.000
1936.2
5
2874.9
5
4811.7
8
2373.8
9
3200.1
9
5566.7
0
177500
267870
97180
0.000
25160
2000
322080
0.000
730750
24.29
36.66
13.30
0.000
3.44
0.27
Page 43
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 43
50 kg Bags
BROWN
TOTAL
27. Sugar Production %
S-30
S-31
M-30
M-31
L-30
L-31
50 kg Bags
BROWN
TOTAL
27. STEAM TO DISTILARY-M.T
28. F.M. STOCK
44.08
0.000
100.00
0
[B] MILL STOPPAGES REPORT
*** NO Stoppages in mill.
MFG. CHEMIST
CHIEF CHEMIST
Page 44
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 44
4.2.9 Material Handling Equipment
A.Unloader Crain: - Use for unload sugarcane from truck.
B.Conveyer belt: - Use for Carried forward sugarcane.
C.Feeder table: - Feeder Table Chains are used for feeding sugarcane to
cane carriers.
Page 45
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 45
D.Fibrizer: - fibrizer make small fiber to the sugarcane for helping in
crushed to the sugarcane.
E. Mill machine: - wipe out a juice from crushed sugarcane.
F.Bagasses elevator: - use for carry out Bagasses in Bagasses carrier.
Page 46
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 46
4.3 Marketing Department
4.3.1 Department Chart
4.3.2 Record of Customers
Major customer of sugar factory is company share holder, brokers and
government. So that record keeping by manual and by using computer
software.
4.3.3 Pricing
In the sugar factory price deciding according to analyzing the other state
sugar’s market price then take a decision in the board meeting. The
factory cannot take more profit to the customer.
Factor affecting pricing:-
1. Other state sugar price.
2. Sugar cane price.
3. Government policy etc.
Sales manager
Clerk
Peon
Page 47
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 47
4.3.4 Collection of Receivable
In sugar factory no credit policy is use for collection they take 100%
advance against order. Tranjection done by cash, cheque, and D.D.
4.3.5 Channel of Distribution:
In CHALTHAN SUGAR FACTORY, they follow following channel of
distribution.
In this sugar factory Marketing Department is called “Sales
Department.”
So, Chalthan sugar factory follow the channel of distribution which is
shown in above diagram.
Chalthan Sugar factory is appointed the brokers to sale the sugar.
Brokers are middleman between manufacturer and traders or
wholesalers.
Wholesaler or Trader is sale the sugar to the Retailer. And retailer sales it
to customer. So sugar factory using three level of channel of distribution.
Manufacturer
Brokers
Traders
Retailers
Customers
Page 48
Shree Chalthan vibhag Khand Udhyog Sahakari Mandli Ltd.
Vidyabharti Trust College Of BBA & BCA, Umrakh 48
4.4 Finance Department
4.4.1 Department Chart
4.4.2 Sources of Funds
� There is separate types of fund:
• Loan & Advances
• Share holders’ funds
• Over draft
• Reserve account
• Taxation etc.
I/C Chief Accountant
Assist. Chief accountant
Officers
Clerks
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Bankers:-
1. The Gujarat State Cooperative Bank Ltd., Ahmedabad
2. The Surat Dist. Coop. Bank Ltd.,
3. State Bank of India, Bardoli/Kadodara
4. Bank of India, Chalthan
5. Dena Bank, Bardoli
6. Bank of Baroda, Umbhel (Surat)
7. HDFC Bank, Bardoli
8. Central Bank of India, Surat
9. SBI’s ATM facility at factory campus
4.4.3 Details of Share
Shares (As on 30.3.2010):-
Members Nos. Shares Paid up shares capital (Rs. In lacks)
Producers 14,967 19,8570 99.26
Non-Producer 1 10 0.05
Cooperatives 9 25 0.15
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List of Share Holders and No. of Shares:-
Composition of Share Holders:-
No. of Shares No. of Members
1 12,800
2 1866
3 558
4 188
5 81
6 37
7 19
8 7
9 2
10 4
11 1
12 0
13 0
14 1
15 0
16 0
17 2
Sr.No. No. of Members
No. of Shares Percentage of Membership to total Member
01 11,629 11,629 78.55
02 2057 4114 13.89
03 689 2063 6.45
04 217 868 1.46
05 119 595 0.80
06 54 324 0.36
07 25 174 0.17
08 7 56 0.05
09 6 54 0.05
10 1 10 0.02
Total 14804 19892 100.00
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4.4.4 Details of Funds
As on 31-3-2011 SCHEDULE NO. – 1
Sr. Name of Funds Balance as on 01-04-10
Addition During the year
Deduction during the year
Balance as on 31-03-11
1 Reserve Fund 23,69,875 23,369 …… 2,391,244
2 Depreciation Fund 491,906,417 30,351,837 2,166,332 520,091,922
3 Investment Allowance Reserve
2,12,983 …… …… 212,983
4 Investment Reserve Fund
89,060 …… …… 89,060
5 Bad Debt Reserve Fund
4,92,898 …… …… 492,898
Total 495,071,233 30,375,206 2,166,332 523,278,107
Details of Funds As on 31-3-2011
SCHEDULE NO. – 2
Sr. Name of Funds Balance as on 01-04-10
Addition During the year
Deduction during the year
Balance as on 31-03-11
1 Members Development Deposit
14,634,417 …… 4,552,945 10,081,472
TOTAL 14,634,417 …… 4,552,945 10,081,472
4.4.5 Fixed Assets
As on 31-3-2011 SCHEDULE NO. – 3
Sr. Particulars of Assets
Balance as on 01-04-10
Addition During the year
Deduction during the year
Gross blcok as on 31-3-11
1 Land 68,09,454 ------ ------ 6,809,454
2 Land leveling road & fencing
50,69,762 ------ ------ 5,069,762
3 Buildings 7,07,68,282 5,515,901 ------ 76,284,183
4 Temporary Shed 279,038 ------ ------ 279,038
5 Sugar Plant & Machinery
548,810,888 18,982,379 775,026 567,018,241
6 Other 5,29,712 ------ ------ 529,712
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Machineries
7 Workshop Machineries
6,08,376 ------ ------ 608,376
8 Weighbridge & Scales
24,20,793 249,094 ------ 2,669,887
9 Water works 21,05,308 ------ ------ 2,105,308
10 Electric Installation
8,959,411 ------ ------ 8,959,412
11 Effluent water treatment plant
5,072,733 4,056,996 ------ 9,129,729
12 Vehicles 6,612,162 588,141 676,000 6,524,303
13 Office Furniture & Equipments
2,445,984 ------ ------ 2,445,984
14 Laboratory equipment
5,25,453 ------ ------ 525,453
15 Dead stock 4,243,995 20,000 ------ 4,245,995
16 Wireless set ------ ------ ------ ------
17 Hot water treatment plant
4,86,895 ------ ------ 486,895
18 Library 50,503 11,040 ------ 61,543
19 Office Building (Surat)
352,137 ------ ------ 352,137
20 Dead Stock (Surat)
54,197 ------ ------ 54,197
21 Computer & Printers
5,164,715 683,732 ------ 5,848,448
22 Agri. Laboratory 251,127 ------ ------ 251,127
23 Dead Stock (Agri.Lab.)
179,666 ------ ------ 179,666
24 Excavator, Tractor etc.
55,15,726 ------ 1,737,278 3,778,448
25 Soil laboratory ------ 2,031,632 2,025,700 5,932
26 Cane Hard vaster
------ 11,482,322 4,587,000 6,895,322
total 67,73,16,317 43,621,237 12,04,669 711,118,552
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4.4.6 Details of Investment
As on 31-3-2011 (At Cost) SCHEDULE NO. – 4
Sr. Name of Party Balance as on 01-04-10
Deduction during the year
Addition during the year
Balance as on 31-03-11
1 50 Shares of Rs.100/- each of Gum. State Co-op. Bank Ltd, Ahemdabad
5,000
------
------
5,000
2 5910 Shares of Rs.100/- each of Surat Dist. Co-op Bank Ltd. Surat
5,91,000
------
------
5,91,000
3 30 Shares of Rs.10, 000/- each of National Heavy Egg. Co-op. Ltd. Pune
3,00,000
------
------
3,00,000
4 211 Shares of Rs.100/- each of Guj. State Co-op. Marketing Society Ltd, Ahemdabad
21,100
------
------
21,100
5 1792 Shares of Rs.20/- each of Surat Jilla Sahakari Kharid Vechan Sangh Ltd. Surat
35,840
------
------
35,840
6 93 Shares of Rs.1, 000/- and 5 shares of Rs.10, 000/-each of Indian Farmers Fertilizer Co-op. Ltd. Ahmedabad
1,43,000
------
------
1,43,000
7 2 Shares of Rs.25, 000/- each of Krishak Bharti Co-op. Ltd. New Delhi
50,000
------
------
50,000
8 10 Shares of Rs.100/- each of Shree Palsana Taluka Sahakari Kharid Vechan Sangh Ltd. Kadodara
1,000
------
------
1,000
9 162 Shares of Rs.500/- each of Gujarat Co-op. Grain Growers Federation Ltd. Ahemdabad
81,000
------
------
81,000
10 734 Shares of Rs.10/- each of Gujarat Narmada Valley Fertilizer Co-op. Ltd. Bharuch
7340
------
------
7340
11 1 Share of South Gujarat Co-op. Rice Complex Ltd.(Proposeal) Rs.1000/-
1,000
------
------
1,000
12 1062 Shares of Rs.2500/- each of Indian Concrete Pipe & Construction Co. Ltd. Chalthan
27,75,000
------
27,75,000
13 Copper Sugar Ltd. Dadariya 50,000,000 ------ ------ 50,000,000
Total 54,011,280 ------ ------ 54,011,280
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4.4.7 Balance Sheet of 2010-11
Last Year Figure Capital & Liabilities Rupees Rupees
Authorized Share Capital
11,000,000
22000 shares of Rs.500 each
11,000,000
Issued & Subscribed Share Capital
10,000,000
20000 Shares of Rs. 500 each
10,000,000
Paid Up Share Capital
9,946,000
19892 equity shares of rs.500 each
9,946,000
495,071,233
Reserve Depre. And Other Funds
523,278,107
14,634,417
Members Development Deposits
10,081,472
Bank Overdraft & Loans
Surat dist. Co. Op. Bank Ltd, Chalthan
23,094,888
Pledge cash credit (Sugar) 834,947
90,955,728
Crop Loan 57,159,046
470,000
N.C.D.C.Godown Loan
Buffer stock Loan( The Surat Dis. Bank)
158,514,000
Excise Loan (The Surat Dis.
Bank)
79,254,000
273,034,616
137,247,993
78,861,125
Members Deposit (Unsecured)
75,494,225
Liabilities for Sugarcane
2,110,497,716
For Sugarcane (Members)
1,144,581,021
Liabilities for Expenses and Purchases and sundry Creditors
65,747,153
For expenses and of purchase 57,468,766
30,664,488
Interest Provision 35,658,895
54,571,690
Sundry Creditors 32,562,276
681,022,822
Members Sugarcane A/c. credit
843,614,422
832,00,153
969,304,359
Profit and Loss Account
279,261
Last Year Profit 594,626
Add: Current Year Profit
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315,365 203,668
594,626
798,294
381,645,886
Total
2,870,731,471
Last Year Figure paroperties and assets Rupees Rupees
Fixed Assets ( At Cost )
677,316,317
( As per Schedule No. 3) 711,118,551
54,011,280
Investments (As per Schedule No. 4)
54,011,280
143,910,752
Investments in Distillery Unit 175,901,284
Current Assets
15,095,452
Machinery Spares 15,085,984
26,724,102
Stores 31,802,018
5,681,269
Packing Stores 10,602,025
499,069
Tools & Equipments 484,935
1,499,927,685
Stock of sugar 1,283,350,847
36,242,920
Stock of Molasses 27,546,045
10,000,000
Stock of Bagas 4,000,000
105,700
Stock of Pesticides 844,661
411,817
Factory Farm Kosmadi 549,865
76,913,933
Sundry Debtors 79,188,126
1,67,16,01,947 (As per inventories certified by M.D.)
1,453,454,506
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4.4.9 Operating Cycle
4.4.8 Estimation of working capital requirement
Particulars RS. RS.
A) Estimation of current assets
a) Cost of Raw Material inventory in stock
……………..
b)Cost of WIP inventory by taking its components
i) Raw material/WIP inventory ……………..
ii)Direcct labour ……………..
iii)Overhead Exp's ……………..
iv)Outstanding Receivables ……………..
TOTAL WORK IN PROGRESS (i+ii+iii+iv)
……………..
c)Cost of Finished Goods inventory
……………..
d)Amount of Debtors
……………..
e)Minimum Cash & Bank level
……………..
TOTAL CURRENT ASSETS (A)
…………….
B)Estimation of CURRENT LIABILITIES
a)amount of creditors
……………
b)Out standing exp's/Payables
……………
TOTAL CURRENT LIABILITIES (B)
……………
NET WORKING CAPITAL=(CA-CL)
NET WORKING CAPITAL=TOTAL CURRENT ASSETS-TOTAL CURRENT LIABILITIES
Customer
Cash
Work-in-
Process
Sugarcane
Sugar
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4.5 Purchases Department
4.5.1 Department Chart
4.5.2 Ordering:-
The chalthan sugar factory order there requires material by following
step.
Purchase manager
Assistant manager
Clerk
Peon
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1st:-sugar factory provide two kind of form. For order require equipment
& material
i. TATKAL MANGNI PATRA (EMERGENCY REQUIRE FORM)
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ii. MAAL KHARID MAGNI PATRA (Goods Purchase Require Form)
By using that form any department order the requires equipment or
material.
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2nd:-the form come in purchase department then classified that form
according to their requirement.
i.If there tatkal mangni patra so order place immediately.
ii.If there magni patra so that decision take on the board meeting and then
place order.
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4.5.3 Classification of stores items
4.5.4 Maintenance of supplier’s database
In the sugar factory maintain supplier’s database by two factors
1. Manually
2. In computer software which name is “purchase record”
Store item
Sugarcane Other material
1. Good sugarcane
2. Burn sugarcane
3. Putrefaction sugarcane
1. Oil
2. Tools
3. Equipment
Etc.
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4.5.5 System of handling rejections:-
If there any problem on goods or goods is not according to the order so
the manager send rejection latter.
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4.6 Other Departments
4.6.1 Administration Department
For any paper work admin department is useful. The head of department
is MR. Harish vashi. Hear all kind of data done filing.
4.6.2 Security Department
• In the sugar factory all security done by manually.
• Head guard name is Sureshbhai dhimmar.
• There is 4 jamadar.17 day and 17 night guard.
Administrative officer
Mr. Harish vashi
1. General officer
2. Transport 3. Weigh bridge
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4.6.3 Transport Department
The sugar factory also provides transport facility to the farmer for carry
the sugarcane farm to factory at some cost. The head of department is
kanakshigh gohil. Factory has 210 truck and 200 bullock cart. The price
list is given below.
TRUCK RENT PRICE LIST No. Km Rs(per.ton)
1 0-5 Rs. 57.12
2 6-10 Rs. 77.77
3 11-15 Rs. 97.22
4 16-20 Rs. 119.66
5 21-25 Rs. 139.71
6 26-30 Rs. 160.35
7 31-35 Rs. 178.60
8 36-40 Rs. 200.46
9 41-45 Rs. 219.90
10 46-50 Rs. 239.35
11 51-55 Rs. 258.80
12 56-60 Rs. 268.64
13 61-65 Rs. 296.85
14 66-70 Rs. 317.49
15 71-75 Rs. 336.91
16 76-80 Rs. 357.54
17 81-85 Rs. 376.96
18 86-90 Rs. 397.59
19 91-95 Rs. 416.91
20 96-100 Rs. 437.65
BULLOCK CART RENT PRICE LIST
Km Rs(per.ton)
1-2 30
3 34
4 36
5 38
6 42
7 46
8 50
9 54
10 58
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4.6.4 Agriculture Department
Soil:-
The soil is alluvial black, plain in legal. There is no proper drainage to the
soil. The water table is raising and salt are also developing in some
places. The government has started deepening nalas and they have
prepared drainage schemes all over. The analysis of average good soil is
a. Ph 7.4 to 8.4
b. Soluble salts 0.10 to 0.50
c. Organic carbon 0.30 to 0.45
d. Available P 205 from trace to 40 kg. per hectare
e. Available potash 350 to 450 kgs.
The principal crop grown is paddy, cotton, banana, groundnut, juwar
and vegetables.
Climate:-
It is tropical monsoon type with three well defined seasons. The rainfall is
near about 44-45 with heavy rain in monsoon from the 2nd week of June
to 3rd week September. About 97% of the rainfall is receiving during
monsoon only. Half the precipitation is received in July to august. The
rainy days are around 49 days. The temperature begins to rise from
March onwards. April and May months are the hottest with maximum
temperature ranging from 99* F to 101* F and above. With the break of
monsoon in June, the maximum temperature falls down to 87* F till
September. Again the temperature shoots up to 96*F in October. With the
one set of winter, the maximum temperature falls down to 87*F and it
remains so till February. December and January are the coldest months
with maximum temperature of 53*F.
The diyrnal variation of temperature is maximum in winter, the mean
being 32*F and the least in monsoon which is about 14*F.
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4.6.5 Environment & pollution control measures
In sugar factory two kind of pollution is more done.
(i) Water
(ii) Air
A) Pollution Control measures
For measure water pollution take the sample of water and check that
sample by the expert chemist.
B) Effluent Treatment
Treatment process for water pollution they use ETP plan. in this plane
they do purify water and reuse of that water.
For air pollution they do plantation of tree.