OCCASION

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 1.0 IM ¡M
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MICROCOPY RFSOLUTION ItSI CHARI

NSlmN'M MIHI ill m -UNI'AM • • I'» ' '*'
M^k^HMaM^MaMAMMMMMMhMAMWMiM«IWHÌMMI

01% \
JAMAICA SUGAR INDUSTRY SURVEY

PHASE ONE

PREPARED TOR THE UNITED NATIONS INDUSTRIAL

DEVELOPMENT ORGANIZATION

July 1971

SANDERSON fc PORTER, INC.

N«w York, N. Y.
 m

CONTENTS

P»I<

PREFACE

INTRODUCTION

ACKNOWLEDGEMENTS

GLOSSARY OF TERMS

SYNOPSIS

RECOMMENDED PLAN OF ACTION 10

Amalgamation li
Processing 11
Crop Duration 12
Factory Employment 14
Central End-Factory 14
Transportation and Storage 16
Cane Supply /Mechanization 16
Jamaica Machinery Cooperative 17
Crop Diversification IS

AGRICULTURAL ASPECTS 21
Transportation 24

TECHNOLOGICAL ASPECTS 26

CURRENT STATE OF THE INDUSTRY 2»

Economics 28
29
The Rural Population
31
Training/Wages
34
Cost of Spare Parts and Equipment Repair!
35
Condition of Machinery
37
Causes of Machinery Failure
Assessment of Outside Repair Facilities 39

tue
 CONTENTS (Continued)

42
FACTORY PROFILES
Appleton 45
54
Bernard Lodge
63
Bybrook
72
F rome
•2
Gray's Inn
89
Hampden
97
Holland 105
Innswood
113
Investigation Technique!
122
Jamaica Estate«
131
Long Pond
139
Monymusk 148
New Yarmouth 156
Serge Island 163
Sevens 172
Worthy Park
181
CENTRAL END-FACTORY
193
THE JAMAICA MACHINERY COOPERATIVE 193
Purpose 197
Formation and Operation 200
Maintenance and Training 203
Inventory Control of Parti 204
Safety

STORAGE TECHNIQUES AND 205

TRANSPORTATION OF SYRUP
208
BY PRODUCT UTILIZATION

aâg£MftKJtA/Mt. Jk. ft/IAXX JV tlH£

 CONTENTS f Continued )

ESTIMATED INVESTMENT AND

WORKING CAPITAL REQUIREMENTS 213
Improvements to Sugar Processing Facilities 213
Conversion to Syrup Producing Units 214
Central End-Factory 215
215
Syrup Storage
Jamaica Machinery Cooperative 215
Cane Transportation Sector 215
Working Capital Requirements 215
Summary- Estimated Capital Investment 217

ECONOMIC AND FINANCIAL CONSIDERATIONS 218

223
BENEFITS
226
CONCLUSIONS
229
PROGRAM CONTINUITY

jgMRrmanta, a FQATIWiHiC»
 EXHIBITS

Letter

PERCENTAGE CONTRIBUTION OF THE SECTORS TO

GROSS DOMESTIC PRODUCT AT FACTORY COST
(CURRENT PRICES) 1965-1969 ($000)

B SUGAR PRODUCTION AND EXPORTS: 1965-1969

C AVERAGE EXPORT PRICE OF SUGAR: 1964-1969

($ PER TON)

BALANCE OF PAYMENTS: 1966-1969 CURRENT

ACCOUNT ($ MILLION)

HOURS LOST IN GRINDING DUE TO FAILURE OF MA-

CHINERY DURING 1970

COMPARISON OF RANGES FOR DAILY WAGE RATES

BETWEEN THE SUGAR AND OTHER INDUSTRIES,
JAMAICAN DOLLARS, 1969

WAGE RATE STRUCTURE WITHIN THE SUGAR INDUSTRY

1969 (JAMAICAN DOLLARS)

BIBLIOGRAPHY

IM.INC.

-_1
 PREFACE

The first phase - the fact finding mission of the Jamaican sugar
industry - has been completed. This study, undertaken by
Sanderson fi, Porter, Inc. for the United Nations Industrial D« -
velopment Organization has re.ulted in a comprehensive plan of
action together with concrete recommendations for program con-
tinuity.

Sanderson fi. Porter is pleased to have been a part of this molt

worthwhile endeavor.

JU unrnnnH A PQWJ1HI.JBC
 INTRODUCTION

Previous studies undertaken by various Government appointed

Commissions in 1959, 1962, 1964. and 1966 have reported the
recent decline of sugar production in Jamaica. All have employed
a common approach. They have been almost unanimous in attri-
buting the decline either to the cost of production, to the decline
in cane quality and tonnage per acre, to the reduction of skilled
and unskilled workers available to the sugar industry, to the reve-
nue realized from marketing of domestically consumed and ex-
ported sugar or to a combination of these factors. The most note-
worthy undertaking wa. that of the Sugar Industry Enquiry Com-
mission, more commonly known as the "Mordecr ^^'^
named after the Chairman of the Committee which executed this
study in 1966.

The report wa. very well presented, contains a great deal of in-
formation, and covers in detail the cross section «Í •^*£«
mentioned. A. a result the problem, of the 3••***?^"'
are well defined and formulated. However the definitivact on
program to correct these conditions and to increase the ""*«
production to its former annual output is not offered by any of the
published studies.

implantation of a r.vit.Uzation program for the .uga,• lnd«.tr»

,. a complicated t«k. An integrated approach mu.t be °««««|
one that Uclude. «he field, of agriculture, of technology -^
to a modern "heavy" indu.try. and o. human '.«••»£ R»"1 "8
th.. and in order to effect .uch 'P^^t-
the Jamaican Government reque.ted the "»•'""J" ' oroaram
Nation. Indu.trial Development Org.nUat.on <UN'D°>;Jhe ^«g
developed by UNIDO and it. original .peof.cat.on.have a h
project goa, improvement of the per^«. *». .--», ^
reducing production costs, AIIO i"»D u«
was a two phase program:

(ANOCMON * ^°"TJL",1.N-C
 Phase One: A fact-finding mission of two months duration
in Jamaica. Findings gathered during this period would result
in positive recommendations to the Jamaican Government for an
action program to revitalize the national sugar industry.

Phase Two: This phase would last for an undetermined

duration" The recommendations generated in the first phase
would be implemented to ensure optimum operations.

The first phase of the Jamaica Sugar assistance program demanded

a multi-disciplined approach. The range of talents included sugar
technology, sugar chemist ry, and mechanical engine« ring in terms
of sugar processing equipment. AH had to be coordinated and in-
tegrated to develop viable answers to this agri-industrial economic
segment.

The team provided by Sanderson & Porter, Inc. , to execute this

assignment included:

R. L. Steere Officer-in-charge
Sugarcane Agronomist/Project
F. le Grand
Director
E. Delden Sugar Technologist
D. Haggerty Mechanical Engineer
Coordinator/Editor
K. J. Skoog

The team was augmented by the extensive technical and personnel

resource of the home office. The combined efforts are presented
in this report.

Thi«, report I. organised in traditional divi.ion. "* •"•£>£ l"

keeping with the .ugge.ted report outhne of the Unit. '""»»••
Since a trem.ndou. .mount of ». data wa. ••••«*£'^"" • .
that thi. would be the mo.t conci.« and orderly manner ,n pre.ent
ing our findings.

Throughout the report, w. have u.ed Jamaican dollar., in«¡J ""£

used as they are the standard in Jamaica.

• * * <? « " • ° 1 *_ .Ü? wT» *»JJ^C-

 ACKNOWLEDGMENTS

We would indeed be remi.s if we did not gratefully acknowledge

the tremendous cooperation we received from all sector, during
the course of the assignment. Special thanks must be extended
to:

Hon. Robert Lightbourne, Minister of Trade and Industry

O. J.M. P.

Mr. W. D. Roberts, C. D., Chairman. The Sugar Industry

Authority
J. P.

Mr. Lloyd Perkins, LL. B Secretary, The Sugar Industry

Authority Board
(Lond.)
Chief Sugar Technologist, The
Dr. Ian Sang s ter, B.S.C.,
Sugar Industry Authority
Dr. RER, Nat.
Secretary/Stenographer, The
Mrs. Cynthia Hunt
Sugar Industry Authority

Vice Chairman, The Sugar

Mr. R. D. C. Henriques
Manufacturers' Association
{of Jamaica) Ltd.

Manager, The Sugar Manufacturers'

Mr. C. S. Robert»
Association (of Jamaica) Ltd.

Director, Research Department,

Mr. T. Chinloy The Sugar Manufacturers' Asso-
ciation (of Tamalea) Ltd.

Chairman, The All-Island Jamaica

Mr. R. P. Lord Cane Farmers' Association

• ANOCMON » P»OWTC«. IMC.

Mr. Cecil Abrahams Director of Productivity Centre
Jamaica Industrial Development
Corporation

Mrs. Pinkie Bower• Administrative Officer, Productivity

Centre, Jamaica Industrial Develop-
ment Corporation

Mr. Warren Cornwell United Nations Representative,

Kingston, Jamaica

In addition, the study could not have been made without the support
of the General Managers, the Factory Managers, the Engineers
and the Chemists of every sugar factory in Jamaica The total
effort is appreciated as it facilitated the progress of the work and
made it more meaningful and effective. This was a true team
effort in that all parties involved were vitally concerned with
"doing something for Jamaica"

MNOISION » POMTCM.INC.
 CLOSSARY OF TERMS

A short Glossary oí frequently used termi if provided for the con«

venience of the layman who is unfamiliar with sugar technology:

Bagasse: The fibrous residue from cane after juice

extraction in the milling tandem, and utilized for steam
generation which in turn is used for sugar processing.

Brix: Brix is the percentage by weight of solids in a

puTe" sucrose solution as determined by the Brix hydro-
meter.

Cane: The part of the cane plant which is used for sugar
•pToductlon and consisting of the cane stalk with the tops
removed. Adherent foreign matter such as soil, leaves
and other non-millable cane matter is included in the
gross weight of cane to be processed.

Centrifugals: The machinery to separate the sugar crys-

tals from the massacuite. The resulting products from
the centrifuging operation are therefore sugar and mol-
asses.

Clarifier: The machinery to clarify the sucrose con-

taining mixed juice which is obtained from cane after
extraction by the milling tandem. Juice is clarified
by application of heat and milk of lime; the resultant
products from theclarification process are clarified
juice and filter cake (mud).

Clarified Juice: One of the resulting intermediate pro-

duct. during sugar procsing and obtained after the
clarification process.

I. INC.
Evaporator; The machinery where evaporation takes
place, a process for removal of water from a solution
through the application of heat from steam.

Fiber: The dry water-insoluble matter in sugarcane.

Filter: The machinery for separation of the insoluble

matter from the treated mixed juice after the clarifica-
tion process.

Filtercake: Also called mud. The insoluble matter ob-

tained by the filter from the treated mixed juice.

Juice Heaters: The machinery to heat sugar containing

juice by an exchange of heat from steam through a
system of piping filled with juice.

Massacuite: The concentrated syrup or molasses in

which the sugar has been rorcentrated to a point where
it will crystallize. Massacuites are designated by A,
B, or C, indicating their relative purity or the number
of crops of crystals of sugar which are to be removed.

Milling Tandem: The machinery used for the extrac-

tion of (mixed) juice from sugarcane. The tandem may
contain one or more sets of knives, a shredder, a
crusher and several three relier mills.

Mixed Juice: Also called diluted juice. The sucrose

containing juice obtained from the milling tandem and
conveyed into the rest of the factory for further process-
ing.

Molasses: The residue left after the crystals have been

separated from the mother liquors, the massacuites.
Molasse, are designated as A and B, corresponding
with the massacuites. The final molasse» is the liquid
residue from which no more sugar can be removed
economically.

Preevaporator: An evaporator vessel utilizing exhau»t

•team and any deficiency of this type of «team augmeni.il
with live steam, and delivering vapor to the first vessel
of the multiple evaporator.

Sucrose; Also called polarization (Pol). The pure

chemical compound, also known as saccharose or cane
sugar. The value is determined by direct or single
polarization of the normal-weight solution in a sacchari-
meter.

Sugar: One of the products in crystalline form obtained

from the sugar processing. Normally raw sugar, a
brown product having 96 degrees polarization or higher
is specified.

Syrup: The concentrated juice from the evaporator«, be-

fore crystallization has removed any sugar.

Vacuum Pans: The machinery used for concentration

of syrup or molasses to a point where sugar will crys-
tallize and the crystal will grow.

Vapor Cell: An evaporator vessel utilizing exhaust steam

and delivering vapor to heat exchangers or similar equip-
ment other than the multiple evaporator. The purpose of
this system is to secure a higher density for juice in a
separate stage.

The foregoing glossary has been taken from the standardi-

zation of terms, definitions, calculations and control
methods developed by the Committee on Uniformity of Re-
porting Factory Data of the International Society of Sugar
Cane Technologists. These terms and definitions were
published in "Sugar" under the title "System of Cane Sugar
Control of the International Society of Sugar Cane Technolo-
gist,. " They have also been adapted from the "Cane Sugar
Handbook" by Spencer and Meade.
 SYNOPSIS

In recent years high production costs have plagued the Jamaican

sugar industry. As a result, profits, at best, have been marginal.
These high production costs are the result of many contributing
factors at each level of the production cycle. To significantly re-
duce total production costs the efficiency at each of the various
levels of production must be improved to the greatest extent
possible. This report presents a comprehensive plan for accom-
plishing that end.

The first phase of the UNIDO assistance program revealed that

a major portion of the equipment used by the various sugar
factories in Jamaica has exceeded its economic life span, making
maintenance costs, as well as time lost due to machinery failure
during the crop season, high. In addition, due to the compara-
tively small size of many of the plants, economies of scale are
not being realized. In order to benefit from large economies of
scale, it has been recommended that many sugar factories be
converted into syrup producing units. The syrup in turn would be
processed into sugar by a new and large end-factory. This cen-
tral crystallizing unit will be located at a deep water port to
facilitate the shipment of sugar in large efficient bulk carrying
vessels.

At the same time it has been proposed to increase the daily

grinding capacity for most milling units in order to reduce the
duration of the crop season. Shortening of the crop season will
result in cane of a higher sucrose content than the cane now being
processed. The increased milling rate and the higher annual
production will optimize the utilization of arable land; a resource
in short supply in heavily populated Jamaica.

It has been further recommended, that in order to decrease the

production costs of sugar, a centrally located production center
for machinery be established. Its main task would be to repair

lANDCNiON_a pomrjLjm, ijj*c.

sto
and maintain the machinery used by all processing units. This
production center would own, maintain and lease the major agri-
cultural equipment needed for growing and transporting cane. At
the same time it would be responsible for the training of factory
and field workers as well as supervision personnel. Finally, the
production center would centralize the stocking of spare parts in
order to benefit from the price reduction through mass purchasing,
minimize total capital tied up in inventories, and minimize parts
outages and resultant downtime.

Many hours are lost during the trop due to inadequate supplies of
cane to the mills. This lack of cane together with "stale cane"
points up the poorly organized transportation system. Reorgani-
zation of the cane transportation system, together with an increase
in the productivity of the cane cutter is vital to the future stability
of the agricultural sector in Jamaica.

The execution of the second phase of the assistance program is

essential. Only then can the recommended plan of action pre-
sented in Phase One be implemented and thus enable the Govern-
ment of Jamaica to revitalize the sugar industry.

• A N p i m § o * j> ?$s y§s> !a.c-

 IC

RECOMMENDED PLAN OF ACTION

The basic objectives of the program were to:

Maximize sugar output per acre to optimize the limited

land resources.

Minimize cost oí production so that Jamaica could compete

with other sugar producing countries in the fulfillment of
its quota granted by the International Sugar Agreement.

To attain these objectives some facts become evident:

Amalgamation of the sugar factories must be effected.

This is to be done in such a manner that the mountainous
terrain would not be a hindrance. Mere amalgamation
by concentration of cane supply to one plant is unaccept-
able as the high costs of cane transportation greatly
outweigh the decreased cost obtained from the larger
processing plant.

Equipment stnadardization and training of workers must

be promoted.

Savings resulting from modernization should be such that

the investments needed would be self-liquidating.

A coordinated effort must be made by the industry to cut

costs, especially in the importation of parts, thus keeping
the Balance of Payments in check.

The profession of the sugar worker has to be upgraded.

lANOMtON a »»OUTfflL. l.»tÇ.

 11

Production of by-products from sugar such as animal feeds,

electrical power and motor fuel, particle board, paper to
name a few, should be studied. This could improve the
public image of the sugar industry and also prove beneficial
in monetary terms as well.

Amalgamation

In the developing countries, at present, factories processing

2,000 tons of cane per day are considered the smallest units
capable of profitable operation. This, in contrast to 4000 tons
in the developed countries. The major reason for this is the
lower wage rates in the developing countries. As many of the
factories in Jamaica are too small for economical operation,
amalgamation to larger units is necessary.

Cane consists of approximately 20 per cent soluble solids and 15

per cent fiber. The balance is moisture. Accordingly cane is
not an easily transportable commodity, even for moderate dist-
ances. Transportation costs, however, can be significantly re-
duced when the water content has been removed.

This recommendation was made only after careful consideration

of several alternatives. One of these alternatives, and the more
obvious one, would be to close a number of the smaller plants,
and to increase the capacity of a single centrally located plant to
process all the cane in an area. However, this alternative is not
compatible with the topography of Jamaica where cane is often
grown in specific valleys served by their own processing plant.
Cane cannot be transported from these valleys to a centrally lo-
cated processing plant in the lar:ie road trailer trucks required
for economical transportation because adequate roadways do not
exist for such vehicles. Accordingly, the recommendation calls
for the production of syrup as an inte rmediate product by some of
the existing smaller factories. This syrup would be transported
in small tank trucks, suitable for the road conditions m Jamaica
to a centrally located crystallizing unit.

Processing

In order to facilitate amalgamation, cane »hould b« ground in th«

IANSCMION a fO»Te«.INC.
 12

present processi ng plants. The juin: obtained would be

clarified and concentrated into syrup of 72 degrees Rrix.
The resultant product, with most water removed, would be
transported to a new central end-factory. There it would un-
dergo further crystallization, to be stored and finally bulk
loaded for export. Stated differently, the crystallization
process (pans and c rystallize rs) and the separation process
(centrifuges) would be eliminated at several plants. These
processes would be performed at the central plant, thus avoiding
the transportation problems on mountainous and narrow roads,
and reducing overall production costs. Also, as about 60 per
cent of the total maintenance cost in the present lac tories is used
to repair the milling, clarification, evaporation stations and the
boiler plant, every factory participating in this new concept
would benefit from a maintenance standpoint as well.

C rop Duration

In order to reduce production costs at each fa«, tory even further,

the grinding capacity would be increased within the optimum
time span of the crop period. Sugar production, or syrup pro-
duction, per hour will increase substantially when the crop
duration is shortened.

This should be done whether a spec ¡fie plant is to remain a

crystallizing unit or is to be converted into a syrup producing
unit. This is because the volume of cane passed per crop
season to a great extent determines the profitability ot the
processing plant. Consequently, the max,munì cane tonnage
possible should be processed by each plant. Thus shortening the
c rop season essentially by eliminating the rainy period will
increase the sugar content and subsequently improve daily sugar
production.

The sugar content of the cane processed should no» be so low »hat
the cost of processing plus the price of cane purchased from the
farmer exceeds the anticipated export sale price. It must be
kept in mind that the purchase cost of cane will decline as he
average sugar content decreases. This sugar content level is
essentially dictated by the length of the crop season; less sugar
in a long season (and as a result partly during the rainy "a"nJ
and conversely, more sugar during the short and correspondingly

SA
NOCRSON & «dTCMNC.
 13

dry season. Accordingly, the period recommended to be elimin-

ated is the rainy season. During this period large amounts of
soil are admitted together with the cane for prot essing causing
excessive abrasion and necessitating repairs to the grinding
equipment. The shortening of the crop season vx i 11 both increase
the yearly output of sugar and reduce maintenant e i osts as well.

The average purchase price of sugarcane will dei line with a

lengthened crop season. However, as the cost of purchasing cane
which, incidentally, is a one-time cost, is far greater than the
cost of processing; a factory can still reali/e a profit per ton of
cane processed during a farily prolonged grinding season.

Today, even the larger factories are growing only about half of
their required annual cane supply. The balance is purchased
from independent groweis. F rom this it becomes evident that
some break -even point exists for each fat tory. It would be un-
profitable to extend the grinding season beyond this break-even
point due to the already discussed decrease in the sugar content
and the resultant inferior quality of cane. Also, the break-even
point for the fat tory may not be consistent with the break-even
point for the grower. Therefore, the optimum grinding season
and sugar yield per acre should be determined at wording to the
national interest with due regard given to the starte land resour-
ces available.

It is to be emphasized that in order to increase the daily grinding

capacity for each plant to the level suggested in this report, the
full cooperation of the mill owners is essential. The level pro-
posed reflects a short and reasonable grinding season within the
climatic limitations of Jamaica. To begin implementing these re-
commendations, a comprehensive and meaningful dialogue should
be held between the responsible leaders of the Government, the
mill owners, and the cane growers so as to establish an acceptable
crop season duration and to ensure reasonable profitability for
all concerned. Naturally, a mill owner will not wish to reduce
the crop season beyond hi» point of optimum profitability. How-
ever, if this becomes necessary, any investments made beyond
this point should be regarded as a social cost, made in the national
interest. Mill owners also should realize the benefits to be de-

lANDtMON * *0«TC*.IMC.
 14

rived from shortening the crop season; namely, better scheduling

of repairs and less wear and tear on machinery. Therefore a
compromise agreement is necessary from all quarters in order
to start revitalisation of the industry.

Factory Employment

At present the sugar industry is a seasonal industry. With the

modern technology and improving socio-economic conditions of
the seventies, skilled workers will be averse to accepting season-
ally oriented employment. By reducing the size of the operations
at the small processing plants, the number of persons required
to work in the tat tory during the season will be reduced. Later
the same workers can be employed for repair and maintenance
during the out-of-crop season. Fay scales for year round employ-
ment should be adjusted to be favorable to other industries. The
sugar industry will then be able to retain its workers. Such a
factory schedule, also, should have a minimal effect on agri-
cultural employment as most of these workers attend to their
own holdings during the early and final stages of the crop.

Central End-Factory

Similarly, the central end-factory will operate on a year round

basis, i.e. ten months per year, allowing two months for general
maintenance. This will permit permanent employment of the
skilled work force.

The end-fat tory should be located at a port so that sugar can be

loaded quickly and directly into the large ocean-going vessels
now used for bulk transport. The present bulk loading facilities
are inadequate for effective loading. Some installations are
capable of handling only 600 tons of sugar per day. As such
delays in port nearly equal actual transportation to the United
States Market. By placing the bulk loading station for the central
end-factory at a port, preferably Kingston, ocean transportation
costs can be greatly reduced and the profitabiligy for growing
sugar cane and sugar manufacturing can be augmented.

The cost of such a facility is estimated at about $4. 4 million.

In addition, in order to run the factory during the entire year,

SANDMION4 PORTtR.IHC.
 15

a tank storage installation should be included at a cost of $1. 3

million. This would enable the sugar industry to provide more
than just seasonal employment

An alternative would be to process the syrup into crystal form

by those units remaining crystallizing plants. Tanks could be
erected at these crystallizing units to receive the syrup. This
syrup would be processed after the crop has terminated. How-
ever, due to a longer processing period, time alloted for equip-
ment maintenance will be even less than is the case at present.
In addition, the sugar produced for export w-ill still be located
inland. An investment of about $1. Í million would be needed for
tanks, with no other major capital investment required. Also,
the larger factories will become oriented toward more permanent
employment. The capital investment required for shortening
the crop season may become more attractive to these c rystallizing
units and the expected bagasse excesses could be more readily
utilized as fuel. In any event, it must be remembered that syrup
is a perishable product. This alternate has a disadvantage in
that all syrup must be stored and processed after the regular
grinding period has ended. The original plan, that of construct-
ing a central end-factory, involves less danger of syrup spoilage
since crystallization would be on a year around basis.

Another alternative would be to increase the capacity of the end-

factory. By the end-factory processing more syrup, the crys-
tallizing units would receive lesser amounts and would be able
to process the syrup during the regular crop season. This ap-
proach would reduce the need for syrup storage fac ilities and
lessen the chances of spoilage. However, the capital investment
for this scheme would be high and the sugar would still be pro-
duced inland, causing shipping problems.

Previously it was stated that in order for a plant in a developing

country to be profitable the minimum processing capacity is
2, 000 tons of cane per day. It should be added that those plants
which are recommended for conversion into syrup production,
process well below this daily minimum. To attain this goal nearly
$6,0 million must be invested in the central end-factory
and syrup storage tanks, Furthermore, at least half of the total
amount designated for increasing the daily grinding capacity

SANDERSON & FORTtH.INC.

 16

must be spent on the syrup producing units. Therefore, a total

of aproximately $6.6 million must be expended to make the re-
commendations economically viable.

Transportation and Storage

The syrup produced by the processing plants will still have to be

transported to the central end-factory for final processing. Al-
though the weight of the syrup will be greater than the weight of
sugar now transported, it will occupy the same volume as sugar.
Also, it has the advantage of pump loading.

To receive and store the syrup, tanks must be erected at the pre-
sent ports of shipment. Every day the production of the syrup fac-
tories will be shipped by tank truck to these storage facilities.
The tanks would be emptied into a shallow draft vessel or barge
fitted with tanks for transport to the central end-factory. This
will take advantage of the existing waterways and will reduce
transportation costs. This subject is fully covered under the
chapter entitled "Storage Techniques and Transportation of
Syrup. "

Cane Supply/Mechanization

The conversion of the present factories into syrup producing units

will be the most viable and economical plan to revitalize the
Jamaican Sugar Industry However, such a plan can only succeed
when a constant supply of sugarcane is furnished to these plants.
An integrated coordination between the daily capacity of the fact-
ory, harvesting and loading, and transportation of the cane be-
comes essential to optimize sugar production. As a result it is
also recommended that some simple form of mechanization be
adapted. This would aim towards increasing the daily produc-
tivity of the cane cutter. A moderate investment for a harvesting
machine, and the cane cutter working in conjunction with the
machine, would both lighten the task of cane cutting and provide
a constant flow of cane to the processing plants.

sANCtxioN a FO»TI»,INC.
 17

As just stated only a limited harvesting method is recommended

at this time. This is because harvesting machines presently
on the market have some limitations especially when working
with recumbent cane, the type now found in Jamaica Erect
growing varieties of cane should be introduced in order to effect-
ively utilize currently available machinery However it may
take years to replace the high yield recumbent cane for a similar
erect growing variety

This approach would also utilize the present transportation and

loading equipment provided that some fundamental organizational
concepts for these operations can be developed. Thus, from all
indications, simple mechanization appears to be logical, and in
the national interest for social as well as monetary reasons.

It should be mentioned that the idea of converting into syrup plants

is not new. This development started during the past 20 years and
has proven successful in other parts of the world, especially in the
United States and Venezuela In Jamaica, the plan is logical as
it will integrate the present small sized processing units into an
industry where costs can be kept in pace with the competitive
price obtained for the output. At the same time, Jamaica will
utilize its already available capital resources, namely, its cane
crushing facilities to the fullest extent.

Finally, the factories which are considered the best possible

choices for conversion to syrup plants are Bybrook, Gray's Inn,
Hampden, Innswood, Jamaica Sugar Estates, Long Pond, Serge
Island, and Worthy Park. Detail« of conversion costs are shown
in the factory profiles.

Jamaica Machinery Cooperative

To eliminate the high costs associated with machine maintenance

a central repair facility should be established. Such a step would
reduce maintenance costs and benefit foreign exchange as well.
lie JMC would be represented by all corner, of the industry. It
would own, operate, maintain and lease all the major cane nar-

lANpiRioN a rQRT.*lUN.&„
 18

vesting and transportation equipment, It would also operate the

central repair facility for equipment.

As an adjunct to these areas of responsibility, the JMC would

develop a comprehensive training program for factory, field and
supervisory personnel.

The JMC would have solid jurisdiction over the purchase and
stocking of spare parts and equipment required by the Industry.
This would eliminate the duplicity and costly individual factory
inventories that now exist.

Until this report is formally submitted by UNIDO to the Jamaican

Government, we are unable to specifically query private factory
owners with regard to accepting the proposed Jamaica Machinery
Cooperative. However, we feel that they would be amenable to
this plan..

Crop Diversification

The Government and the sugar industry should realize that for
economic reasons the syrup producing plants eventually may have
to close. Exported sugar will face intensified price competition
from sugar produced in other nations. In the decade« to come
Jamaica may only retain a few large plants While annual pro-
duction for domestic consumption may decrease, the balance, if
it remains competitive, would be exported. However, at this
point in time, a sound and conscientiously executed plan for
diversification into crops other than sugar should be considered.
Such a program conceivably may solve the problems of Jamaica s
agricultural sector in the years to come.

An interesting footnote to the above is the case of Barbados. For

many years it h*. depended on a single crop, sugar, as the key
to its economy. As a result overall prosperity has not been
achieved. Although Barbados does get preferential prices from
Britain, a. Jamaica get. from Canada and the Dominican Repub-
lic and Puerto Rico get from the United States, the seasonal
nature of the crop, the decline of world prices and the •jfventof
mechaniaation are combining to cause unemployment. The Bar-
badian Government, in an effort to boost the economy, ha. .pon-

»ANOKx.ON a f %1XMiO*SL*
 19

sored some public works programs and urged small farmers to

experiment with truck crops. In 1970 for example, onions were
grown commercially for the first time. This is the possible be-
ginning of successful agricultural diversification.

It must be remembered that diversification into crops other than

sugarcane and its derivative products is not easy. These commo-
dities, being perishable by nature, require an intensive marketing
and transportation system in order to prevent a total crop loss.
A start in this direction has been made by the formation of the
Agricultural Marketing Corporation, which is responsible for local
collection, storage and distribution of vegetables This opera-
tion has proven successful in that vegetables are now in plentiful
supply at the major consumption centers of Jamaica. The company,
however, sustained a deficit during the initial three years of its
operation since export of its produce was nearly non-existent.
Export and quality of product is essential to profitable operations,
as are sophisticated skills, a commodity that is scarce in a de-
veloping country.

Similar problems face the small citrus industry. Only a small

quantity of production is canned as fruit slices for export. The
major portion of the crop filters to an already saturated local
market.

Poultry production has nearly reached self sufficiency. Export

is difficult because of the relatively high prices paid for feed
grains and protein based ingredients which must be imported.

Beef, as well as dairy production is increasing. However, the

present return per acre from these commodities is lower than
the present return per acre from sugarcane. Thus the replace-
ment of sugarcane by livestock would lower the national income
from the agricultural sector; a factor which can be ill afforded.

Worthy Park Estates is currently experimenting with crops such

as mahogany, coffee and cacao but without any »PP*•» eC••C
success. Diversification is failing partly from the lack of exper-
tise but mainly from the difficulty to secure overseas marke s
at reasonable prices. These crop, must be exported as the local
market can only absorb a fraction of the production.

lANCCRION » f OWTJ^INC^
 20

For these and other reasons, and based on this experience, a plan
to integrate Jamaica's agricultural sector into the changing econo-
my of tourism and mining should be considered. Diversification
should concentrate on crops which can be exported as well as on
crops which can be utilized by the tourist industry. The latter
could replace the heavy imports of commodities now needed to
sustain this industry.

The approach to c rop dive rsification might not only cover the
agricultural education and extension services, but also could
include the details for marketing, quality control, and the establish-
ingrf the necessary agro-industrial complexes to service both a
modem tourist trade and the export of produce with high quality
standards.

This plan may take several man years to develop and would
cover numerous disciplines. Successful application of the program
may take decades. The sugar industry development, recommended
in this report, presents not only a viable end in itself, but also
a sound interim approach leading to such a diversification program.
Implementation should effect a smooth and gradual transition into
a diversified economy during the years to come.

lANDcniOH .*-.*£ &tMVltt£-t« i

 21

AGRICULTURAL ASPECTS

The future existence of the Jamaican sugar industry will depend

heavily on its ability to supply a constant annual production of
sugarcane containing as high a sugar content as is possible. This
sugar content and cane tonnage per acre only will be realized
through the proper application of modern agricultural technology.

The Jamaica Sugar Manufacturers Association was cognizant of

the need for agricultural research several decades ago. As a re-
sult, their research activity has gained international recognition.
The institution is well staffed wi h dedicated scientists versed
in all fields of modern agricultural research including soils, fer-
tilizers, chemistry, pathology, entomology, variety selection
and agricultural engineering. In addition, by providing financial
support, Jamaica is participating in an extensive regional cane
breeding experimentation program that is being conducted in
Barbados. The benefits Jamaica has received from this research
have been high cane tonnages per acre and a high sugar content
in cane. This no doubt will continue in the future. Therefore,
the sugar yield per acre, now favorable when compared with other
sugar producing areas in the Caribbean, can be expected to re-
main competitive.

Future profitability will also depend on the ability to mechanize

the necessary field operations other than cane harvesting. During
the past few year, the Estates have begun to level the cane fields
and relocate field drains. Longer rows in larger acreages will
facilitate the efficient working of the mechanical equipment. Tin,
land conversion process is continuing. In the near future it is
anticipated that the major part of the cane acreage will have been
converted and will be able to accept mechanized equipment.

SANOERSON.A. lOfiXiA*»*0;«»
 22

The production of the total land suitable for the cultivation of crops
is limited. The Agricultural Census/Survey of 1960-61 by the De-
partment of Statistics indicates:

Total Land Area ¿. 8 million ac res

Land in Farms 1. 7 million ac res
Cultivated Area 545, 300 acres
Grassland 495, ¿00 acres
Ruinate 355, 000 acres

It is impossible to obtain an accurate estimate of the total area of

land occupied by the cane farmers and sugar estates. The Cane
Farmers Association estimated that the total acreage held by its
members is about 78,000 acres. The estimate is not reliable in
that it was based on random samples of larger farms only. The
total sugar cane planted by the estates is estimated at approxi-
mately 90, 000 acres, and their aggregate holdings over ¿00, 000
acres.

Tangible data regarding capability and usage of estate lands has

been prepared by the Research Department of the Sugar Manu-
facturers Association. The survey covers 1J estates including
the larger ones. It provides a useful overview of estate land usage
patterns and trends. This data shows that:

the total area of the 1 3 estates is 17¿, 000 acres of which

only 94, 000 acres are arable;

approximately 80 per cent of the arable land is allocated

for cane cultivation.

From the foregoing and from our own investigation it is evident

that sugar production occupies an appreciable proportion of the
good arable land available on the island. There is no evidence
of any area of suitable land that is not put to productive use. On
the contrary some of the land under cane is too steep or too poor
for other cultivation -- particularly with tractors -- and might
be retired to pasture or some other use.

It should also be added that some of the estates and large farms
are reclaiming salt rmrshes and other lands to add to the area
under sugar.

SANOtHSON,» VBitWÄ*5;.
rita
 ¿\

Ora--«* *i •'• land is poor espe.iallv m a large section of St.

r a e- Dar- Tr.is land :• .»axr.p>. and used only to a limited
eVe- tor's.aar.ane production The baiarne i. a.rd for cattle
'.'s-£ T'-•."* i<:v.or.. rr.av be utilized tor general agriculture,
;r*'-'S'-d:Vi sugarcane product.or. after a reclamation program i»
ur.de rta<e r.

.s .ove red ;a:e r ander t-e Holland fa. tory profile

T'hi ? oo:

Irr <a-:o- ia.l ties »re limited to overhead apparatus *hu h

dra^a-erírorr. t-..rna-or r.-er, The .vatem .. rather costly
a-d - Vd3-b-:il economi, val-e ir. o-her -nan level cane growing
areà: What.ral radiali and ;-, d:.tr.b .v.on pattern, hoover,
« adequate to prod.ce a s.gar >ield »hi.r, , ompare. favorably
«it, that of other rr.a;or ..gar prod., mg areas m the Caribbean.

T- < all s.gge.ts th.t tr.e Storie, are able to pay reasonable
. ".,.,,„,.„ a pri.e 'hat essentially i» based on
or. es to the . ane growers * Prur .._„
^e ar -3-'e- ' the . ane Tni. in turn, i» dependent upon
>•-., ?ri",e .itimatelv received by the processor for sugar and
molas ?e*

T'rxi.. :t tornes apparent tnat the -gar yield per acre *"'•*«".
able er.o-.ah to provide an adequate return to the grower Th...
ot o irse"' . s ba.ed oh the prem i se tnat tne prese nt marke t.
!
• • .. „-; •« ut
* ;. i1 lcont-nje and. indeed. will
ot:er-r.¿ arele re nf. a. «s -gar pri.es
-*' "'•" *•'' °"I'-'Jt
tr.e average price received for the
rease .tare is
( •

e r.v re rop villi improve according.'/.

'amai a proposes to average a yearly sugar production of .00 .

oh, or more. Tn.s is not ar, impossible goal. To reac h Ou.
h
.latea, certaih .loping .u.a. no. under cane -«.v«.»"- -
io be abandoned vmen full field mechanization *,ü be ,n '"«J;
Ire higher sugar yield per acre, hoover. *hu h . an be expei ted
.ro, improved technology a. vieil as from the int roduc -„on o
better yielding varieties, .hould compensate for the lo., ,n .»gar
ane at reage in the future

4
11, f ti i " " * POHll «•.'! ^..«^
 24

As Jamaica is rather small, the present pruitssin^ facilities are

fairly centrally located within ea> h c ane growing area. On the
average, most of the fields are located within a ten-mile radius
from the factory. Although the distarne between th-- cane growing
areas and the processing locations aifec ts the efíic ieru y of c ane
transportation, the mountainous terrain forms an additional na-
tural limitation. Cane that is grown in the valleys having their
own processing facilities is separated from the Island's road
system by fairly steep mountain ranges. It i an be said that trans-
portation of cane from these areas to a centrally loc ated proc easing
plant is at best difficult.

T ransportation

Cane transport is one of the major problems and expenses in cane

production. The factories are invariably centrally located with
respect to the estate lands. The individual farmers occupy the out-
er fringes of the area. As just mentioned on the larger holdings
it is possible for a farmer's cane to be as nnu h as ten miles from
the factory making transportation costs prohibitive. The situation
worsens when a farmer must employ an outside transporter if he
himself has inadequate vehicles.

Much of the problem is due to the fact that in recent years it has
been decided that only the factory would c onstitute the poi nt of
delivery of cane. Prior to this some tadones had estábil shed
delivery out-stations, where the cane was accepted. This both
reduced haulage and minimized congestion.

Compounding the problem is that farmer transport costs have

risen due to slower turn-round of vehicles at the fac tory. At
some factories it has been physically impossible to improve
delivery facilities leading to delays in the factory yard and
increased charges by transporters.

Transportation problems often result in stale cane. This is a

problem that gives the sugar manufacturer cause for concern.
It become, more acute a. the number of individuals involved in
producing the cropincrea.es. In general the problem stem, from
three main causes:

SA NCOSON.» r°JlTIf»tf.Çw..
m
 -•*¥• ?°M*mb^,miw&-''s<ì> w^e^'ía

25

delays in loading cut cane in the field,

irregularity of transport, and

delays at the factory.

Stale cane is harmful to both grower and manufacturer in that

quality is affected and efforts to eliminate any cause for delay
between cutting and processing, must be of primary importance.
As Jamaican sugar has a good reputation, nothing should be
tolerated which will jeopardize the good quality of the sugar
produced. Thus the first step to avoid stale cane is to effect
close co-ordination of harvesting and transport operations. This
applies equally to estate and farmer

In short, the present sugar content in cane, and the cane tonnage,
per acre, are adequate for successful competition with other
major producing areas. Also, sugarcane growing operations are
fairly well organized. Subsequent operations such as harvesting,
cane transportation, processing, and especially the delay between
cane curning and grinding, cause measurable sugar content
losses. For a harvesting procedure which employs burning,
rapid and well planned handling of the cane from burning to
processing is essential to preserve the sugar content. The
recommendations of the report take this into account.

..„.(..ON a *0"TCA.INC.
 26

TECHNOLOGICAL ASPECTS

Examining factory weekly and crop reports it is evident that

Jamaica's technological expertise in sugar processing is at a par
with other major sugar producing areas of the world. The per-
centage of undetermined losses is within an acceptable range. The
material balances provided in each factory profile do not reveal
any maior shortcomings in processing skills by the factory staffs.

The measure of factory control is based on the sugar content pre-

sent in cane at the time of processing. It does not take into account
the possible sugar losses that occur between burning and process-
ing. It accounts only for the chemical and mechanical losses of
sugar during processing and for the divis.on in the form of crystal-
line sugar or sugar in the form of blackstrap.

Crystal recovery, in the form of Boiling House Efficiency, is

sometimes low. This is especially true in the smaller factories.
Similarly, sugar extraction by the milling tandem at the customary
low linear speed of the rollers n.»eds some improvement This is
indicative of equipment ineff ic.enc íes that exist especially in the
back part of the factories.

Annually, the Research Department of the Jamaica Sugar Manu-

facturers Association publishes factory control data for each pro-
cessing plant. This information provides comparisons between
existing plants and suggests additional improvements for sugar
recovery. This organization also provides some assistance when
special difficulties in chemical control may occur.

The training and expertise of the factory staffs employed car»be

regarded as being high. The College of Tropical Agriculture n
Trinidad, which iater merged with the University of the West Indes,
has provided exclusive training for sugar technologists Jhe C_°
lege itself has been heavily engaged in cane P'0""""^^,^
utL.vion research and i. well nuited for such educational curricula.

IANDCIIION » FORTCÄ.INC.
 27

The Jamaican Government also has recognized the need for an

agency having broad powers, being able to oversee all aspects
of sugar production. This entity, the Sugar Industry Authority,
conducts processing research as one of its functions. The labora-
tory is headed by a Ph. D. in carbohydrate chemistry. The funda-
mental principle of this laboratory is to design standards of
cane acceptance by the processor and to improve c ane quality by
reducing the time between cane burning and processing. The
latter, actually, is a management concept, and as previously
discussed, is reliant on the available transportation system.
However, the laboratory may succeed in improving management
controls by establishing accurate standards for cane quality. Also,
the work already initiated by the laboratory will be augmented by
adopting the recommendations regarding improvement of the
cane transportation system.

At some future date the laboratory will assist the individual pro-
cessors in various phases of cane processing and in the investi-
gation of possible applications of sugarcane by-products. As such
it will supplement the Research Department of the Jamaican Sugar
Manufacturers Association which is already making great strides
forward in this sector.

Finally, it should be noted the Sugar Industry Authority recently

has created and staffed an Economics and Statist.es Section. I his
was necessary since neither the Research Department ot the
Tamaica Sugar Manufacturing Association nor its own processing
laboratory were capable of prov.d.ng any meaningful mtormation
in this field. Thus, the industry, now, has the proper tools to
project economic trends and prii ing structures.

* PORTCf*. IMC.
 28

CURRENT STATE OF THE INDUSTRY

Economics

Domestic agriculture, as well as agriculture for export, is an im-

portant function of the social sector as well as in the monetary
field. Exhibit A compares the contribution of exportable agricul-
tural'commodities to other sectors of the Jamaican Gross Domestic
Product. Sugar and bananas are the principal agricultural commo-
dities exported. The total output of each has been reduced drasti-
cally over recent years explaining the decline in the percentage
contribution to the Gross Domestic Product for this sector.

The drop in annual sugar production is shown in Exhibit B. Sugar

exports fell from 424,000 tons of sugar valued at $31, ¿bb 000 in
1965 to 302, 000 tons valued at $28, S84. 000 in l'ïbQ; a moderate
monetary loss considering the large decline in tonnage produced.
This is illustrated in Exhibit C, which shows the average export
price for sugar dropping sharply after 1%4 but increasing from
1968 to 1969. The principal price increase affected sugar export-
ed to the United States. This rose $24.00 per ton during the 1U,<-
1969 period.

Jamaica, under the new International Sugar Agreement «hould have

obtamed a larger share of the sugar quota for the l mted States a^
this favorable price. However, it was unable to take a vantage o.
this increased market potential due to a lack of available ugat.
A quota of 180,000 tons was allotted to the West Indies by the b ted
States. Jamaica, historically the largest sugar-producer in his
region, was able to provide only 60, 778 tons. Had suga re-
duction not declined more than 20 per cent from 1%8 to 19 ,
Jamaica would have been able to export at least Us ave age ton-
nage of the previous years. Thus, taking advantage of the in-
creased export price of $120. 50 per ton. Jamaica could have pro
fited by more than $3. 5 million in foreign exchange.

« A Nocma*.fc,p£ IWtfVÄ0..«.
 29

The decline in sugar output and the failure to capitalize on the im-
proved price structure for export sugar reflects on the utilization
of the Island's available resources. This is especially true as
Jamaica show» an increasing deficit in Us Balance of Payments
(Exhibit D). Not only did reduced sugar production have an influ-
ence on widening the deficit in the Balance of Payments, but also
on the gross domestic product in the rural areas.

The large majority of workers are employed in the field as cane

cutters and loaders and are remunerated by task performed.
Therefore, the earnings of this group are closely related to the
amount of cane available for harvesting. As no data about agri-
cultural employment is available, it »s assumed that ^0,000 cane
cutters and loaders are employed during the crop season Again
assumed, they contribute up to four times as much to the Gross
Domestic Product as the some b, 000 factory workers employed by
the industry itself. Decline in sugar production would have caused
a resultant decline in the consumption of basic commodities in the
rural areas of Jamaica lowering the standard of living in this re-
gion.
In summary, the continued decline cannot be attributed to natural
causes. However, such factors as: migration of the population
from rural to urban areas; human relations; wages; cost and
methods for harvesting and loaü.ng of cane; and cost and type
of equipment employed for sugar processing are most often
mentioned by the knowledgeable people of the industry as being
the causes for the continued reduced sugar production.

Each of these factors will be discussed in greater detail on the

following pages.

The Rural Population

Jamaica has only limited land resources, a ^[OÍ.2^Zm

acres. It already has a large population, one ^h^ l" ^"V
at a high annual rate. The Island's topography, with a large
mountain ranges, reduces the amount of arable land tU 7 m1
acres. This is less than one acre per capita. A>^^result *
essential that the maximum monetary yield be obtained from
land.

_-.«<-> M A POHTCW, INC.

 30

Jamaica has been growing sugarcane for centuries. The rural

population is familiar with this crop, and is assisted by a private-
ly sponsored research station. Sugarcane and bananas are the
only crops which are produced on a large scale and for which agri-
cultural technology is on a par with other countries. Agricultural
technology is presently very limited for other crops. Therefore,
sugar production cannot be allowed to collapse completely as the
effect on the development of the country would be disastrous.

Sugarcane is furnished by three mam suppliers: t he Estates which

also own the sugar manufacturing plants, the independent large
cane holdings, which do not own grinding faolit.es but who employ
a varying number of agricultural laborers; and s mall independent
farmers who deliver only a very meager amount of cane every year.
About half of all cane is produced by the sugar manufacturing com-
panies. Seventy-five per cent o: the farmers produce only 2- per
cent of the total cane crop. Among this group is a large number
who produce cane from very small acreage. I hese holdings gen-
erally are located on the steep mountain sites where growing con-
ditions are difficult and transportation to the processing site cum-
bersome. These farmers rely mainly on manual labor tor their
production. The commodity of time is plentiful as he has no other
employment available to make his free time productive. he small
remuneration received from growing cane on this marginal^ type of
arable and otherwise unproductive land means a pos.t.ve although
very small contribution to the Jamaican economy. Kven the small
amount of cane produced means a small disposable income to this
farmer.

•therefore, the growing of cane by the small farmers must be

allowed to continue a, it make« use of the most marg mal land re
sources, and it provides some income to a large segment ot he
population. Furthermore, the small farmer can •r"**•*
Income by working for the Estates during the seasoru »e arm
ing ties the small grower to the location where the ma,«r por
tion of sugarcane i. produced. As a result, the grow ng ot c.ne
by the small farmer is actually beneficial to the sugar industry
in general.

~---«r>N & POBTt". INC.

 31

Training/Wages

To attract the needed factory workers, the industry itself has ini-
tiated what is known as a "helpers" system for on-the-iob training.

During the training period, the helpers receive practical instruc-

tions in the basic factory skills. No form of specialization is intro-
duced nor are any promotion steps offered for an apprentice to
proceed through a specific range of job training. The result is
that the apprentice receives instruction in the basu skills only.
The training necessary to maintain the more sophisticated machin-
ery which has been installed during recent years is not available.

The present level of basic training and the resulting lack of incen-
tive wage rates causes migration to other industries where such
incentives do exist. As a result, the other industries do not even
provide che basic training; finding it cheaper to hire a person
having these fundamental skills from the -ugar industry and then
providing the specialized training at higher wage rates. This mi-
gration is extremely costly to the sugar industry.

The need for specialized technical training becomes evident when

studying the cause of machinery break-downs. (Exhibit E). One
factory, Worthy Park, has an outstanding record as compared to
the other factories. This can be explained by the fact that Worthy
Park has very unsophisticated machinery and is only moderately
electrified. The level of training needed to repair and keep the
machinery operational is lower than at other factories where more
modern equipment has been installed during recent years. It also
suggests that although the present training for maintenance of
machinery that is 30 or 40 years old is adequate, the training for
repairing and effectively maintaining the modern and more sophis-
ticated machinery now in use is inadequate.

The difference in wage rates between the sugar industry and the
other industries must also be regarded as a reason for worker
migration. Exhibit F illustrates the wage rates tor the other in-
dustrie» while Exhibit G shows the wage structure for comparative
skill, in the sugar industry. Upon comparison, it is not surpris-
ing that persons with mechanical skills leave their employ with the
sugar industry.

VVifl ASAMt. V. "«WtfWW '. ttf*..

 32

The sugar industry has maintained that any significant changes in

the wage structure for factory employees would be impossible due
to the average price received for sugar. With the present system,
containing numerous production units, this may be true. But with
larger (and thus fewer factories) the cost factor for workers per
ton of sugar would change substantially and allow wages compara-
ble to other industries.

Comparative wages are not only important in the factories, they

are as important to the man in the field, especially the cane
cutter. The average age of a cane cutter is just under 50, making
it evident that there is no influx of youth to this profession. The
reasons are twofold: either the wage rates are unfavorable or
some social aspects make the job unattractive

As the processing facilities can function properly and profitably

only when a regular supply of cane is guaranteed, adequate man-
power able and willing to cut cane is necessary to supply these
factories.

There appears to be a "stigma" attached to the profession of cane

cutting in Jamaica. It is regarded by the young population as an
undesirable occupation. Cane cutting is a difficult task requiring
•kill. A cane cutter must maintain an adequate output in order to
make a worthwhile income. Without skill output is unsatisfactory
since a worker is paid on a task basis If his output is poor his
daily take-home payment can be low. In contrast, a tractor driver
has an easier task to perform. His work is light, rather clean,
and his skill requirements are not much greater than a good cane
cutter. Yet the tractor driver receives a wage far superior to the
cane cutter.

Both tasks are essential for sugar production. Failure in either

section will automatically signal a failure in sugarcane supply
to the factories. Processing time lost due to failure in the can«
supply sector is dramatically shown below.

i r* r «* • *•% *•
 33

Out of Cane Total Crop Time

Name of Factory Hours Hours

Monymusk 348 5,496

New Yarmouth 435 5,006
Appleton 1,236 4,311
Jamaica Sugar Estate 581 4,793
Bernard Lodge 208 5,257
F rome 1 458 4,411
F rome 2 361 4,435
Worthy Park 427 3,973
Gray's Inn 935 4,473
Seven« 618 5,806
Long Pond 865 5,488
Inni wood 185 5,309
Hampden 620 4,934
Serge Island 854 3,430
Bybrook 590 5,427
Holland 722 4,833

Total 9,443 77,382

Source: Time Account 1970 Crop

Sugar Producers Association of Jamaica, Ltd. 1970.

The lack of enthusiasm for cane cutting in Jamaica is contradicted

by the fact that Jamaican cane cutters are willing to and do per-
form well when engaged in this activity outside of their country.
For example, about 8,000 Jamaican agricultural workers, essen-
tially cane cutters, migrate to Florida at the beginning of each
crop season. These workers cut an average of seven tons of cane
per working day. In contrast his counterpart in Jamaica cuts an
average of 3-1/2 to three tons per day. Of course the average
age of the cane cutter in Florida is lower than the cutter in Jamaica.
This may explain the discrepancy In daily output per worker. How-
ever, each cane cutter in Florida is interested only in his output,
and aa a result his dally earnings.

The important role performed by the cane cutter should be pro-

moted in the national Interest. Jamaica's population, already 20
per cent unemployed, doe« not warrant the replacement of man-

• ANOcnaON * powTCw. INC.

 34

power. Ways and means must be sought to advance cane cutting

to a position that is both honorable and rewarding. Many cane
cutters are small farmers but cut cane to supplement their in-
come. When the rainy season starts, however, this same in-
dividual will leave his employment to tend his farm. Toward this
end some form of mechanization would be useful.

Countries with higher standards of living completely mechanize

their cane harvesting due to the lack of available labor. True,
mechanical harvesting is often more expensive than manual har-
vesting. The cane cutter can sever precisely the top of the stalk
at the right height and cut the cane exactly at soil level The
machine, however, has to be set for cutting the top at an average
height and cutting the stalk at about soil level. The amount of
extraneous matter, which has an adverse effect on sugar recovery,
is mugh higher for mechanically harvested cane than for manually
harvested cane. Ideally, the cane cutter should work in conjunction
with the machine. Cane topping should be performed manually
while the severing of the stalk at soil level, and loading of the cane,
may be performed mechanically. Employing the joint operation
will lighten the task of the cane cutter and will increase his pro-
ductivity considerably. At the same time it secures the optimum
sugar production from scarce land resources.

Cost of Sparc Parts and Equipment Repairs

A great variety of field as well as processing equipment is available

to and used by the sugar industry. The Jamaica Sugar Industry is
presently comprised of 15 processing plants. With the exception of
five, each has a production capacity that is only marginal for econo-
mic survival. Each plant has its own individuality. Due to this
great selection of machinery, stocking of spare parts becomes
expensive and presents real problems as Jamaica is fairly isol-
ated from the United Kingdom and the United States. However,
it receives the majority of the necessary spare parts from these
nations. The result is a large inventory of parts kept separately
at each mill, and most important, they are not always interchange-
able. Even the most standard items, such as valves, are stocked in
great quantities at each mill in order to be available when needed.
The result is a high priced spare parts inventory, possibly exceed-

ÍÍNfirRinN * POWTF» "NC

 35

ing $100, 000, for a factory producing 17, 000 tons of sugar and
represents a capital investment of six per cent for spare parts on
the value of sales. Even then, all the spare parts cannot be
stocked due to physical limitations of plant size, and have to be
ordered separately when needed. This causes delays in repair
and maintenance schedules.

In addition, the industry has almost completed a change from man-

ual to mechanical cane loading without regard to standardization.
Many types of tractors and several types of loaders are u«ed.
This also will eventually generate a similar spare part problem.
As standardization of equipment is essential, future modifications
or expansion programs should keep this in mind

A side effect of the variety of machinery is the high cost of repairs

and maintenance during the out-of-crop season. Workers are
trained to maintain only one piece of equipment and cannot easily
be moved from factory to factory. Moreover, the specialized
training required, and discussed earlier, to effect repair of a
specific piece of equipment, is rot available.

The high cost of repairs in the factories has been discussed at

length in the Mordecai report. They can be attributed to the small
economies of size of some plants, their individualistic approach in
purchasing machinery and parts, and the marginal skills of the
workers. As there are more sugarcane estates than sugar pro-
cessing factories, the non-standardization of equipment may in-
crease repair costs even further in the future.

Condition of Machinery

As stated previously, there are at present 15 operational sugar

factories in Jamaica. Three others recently have been shut down
and the equipment sold. The existing factories can be graded as
passing, fair and good.

The age of the equipment ranges anywhere from the early 1900's
to the 1970's. A few of the factories, particularly Moneymusk,
Frome, Bernard Lodge, New Yarmouth, Appleton and Sevens
have pursued vigorous modernization programs. However, at
times the programs were delayed due to lack of funds. Others

cAMorQ^nM fK ppiPTro tNr

 36

have made a small attempt at modernizing while some have made

no attempt whatsoever. The latter group has replaced equipment
only when forced to by the failure of the original equipment.

For ease of identification we have divided the factories into three

groups: A, B, and C. Ratings for each group shall be A-good,
B-fair, and C-poor.

In grouping the 15 factories, we find: three factories having an

"A" or "good" rating; three factories having a "B" or "fair" rat-
ing; and nine factories having a "C" or "poor" rating. Thus,
60 per cent of the factories are considered to be in poor condition.
This, then, is indicative of the ousting state of the Jamaican
sugar industry.

Each factory was visited and a complete survey made to determine

the mechanical condition of the equipment. Since the factories were
visited during the off-crop season, the equipment was not running.
Therefore, the assessment of the condition of the machinery was
solely dependent upon the experience of the members of the Team.

To check further on the validity of this assessment, an investiga-

tion was made of the lost time during the crop for mechanical,
electrical and steam difficulties as this lost time is a valuable
yardstick in evaluating the condition of the equipment. In Florida
and Louisiana the maximum allowance for mechanical, electrical
and steam difficulties is three per cent. Taking into consideration
the age of the equipment and the lack of skilled labor it was agreed
that an extra allowance of two per cent be made for these conditions
raising the maximum allowance to five per cent for Famaica.
Using this figure as a point of reference, and estimating the lost
time as a percentage of the net grinding time, (i. e. days of crop
minus lost time for weather, labor disputes, out of cane, holidays,
end of run, and other miscellaneous causes), the grouping of the
factories was established as follows:

2 Factories 0-5 per cent lost time

6 Factories 5-10 per cent lost time
7 Factories 10-17 per cent lost time

Therefore, 87 per cent of the factories exceeded the maximum

• ANCtllON k FOBTIH.INC.
 37

allowable downtime. Even raising the allowance to ten per cent

shows that 47 per cent of the factories still fail to meet even this
limit.

Statistics at times can be misleading and possibly it is unfair to

judge the different factories on the above basis. The fact remains,
however, that there is an ultimate point in material fatigue for any
piece of equipment. The oldest piece of equipment observed was
built in 1911. Thus, it has been in operation 59 years. No records
have been maintained but if someone had taken the time to keep
such records on the costs of repair and maintenance, both labor and
parts, the total amount spent on keeping certain pieces of machinery
operational could prove staggering.

Causes of Machinery Failure

Just after World War II, marketing for Jamaican sugar was nor-
malized by long term agreements with the United Kingdom for
quantity and price. These agreements, amended from time to
time, have promoted the growing of sugarcane. The price paid for
sugar favored production in large plants. Jamaica had more than
30 operational plants at that time.

Normally, the factories which have closed down continued to grow

cane. The crop is transported to the operating plants. Rather
than installing larger sized machinery to augment the daily grind-
ing capacity, these factories instead increased the length of the
grinding period in order to process the larger cane supply with the
existing equipment.

During the early sixties, cane growing was encouraged by the

Government. The resulting increase in cane supply was supported by
a sudden spurt in the sugar price. As this increase in the cane
supply could have been considered temporary, it was understandable
that the factory management was hesitant to install additional equip-
ment.

Subsequently, and dating from this time, extensive prolongation

of the crop period has been practiced. Instead of using the machinery
four months per year, and devoting the balance to reconditioning,
management is faced with grinding periods often in excess of seven

SANOEHSON ft POÄTC», INC.

 39

months. Wear and tear of machinery during such a prolonged crop

period is heavier than for a grinding of normal duration. The short
time now allotted for reconditioning of machinery further aggravates
the repair situation. Due to these and other facts the quality of re-
pair has worsened rapidly.

Expansion of the crop season occurred in the periods marked by

rainfall. Normally, when cane was loaded manually, the wet
weather did not have a very significant effect on the amount of ex-
traneous matter adherent to the cane.

This situation has changed during the past few years.

Cane burning prior to harvesting has recently been initiated. Nov;

the workers are able to harvest more cane per day and as a result,
increase their daily remuneration. Also, mechanical cane loading
by means of grabs has been introduced. This has augmented the
cane cutting force with the workers formerly employed for manual
loading.

Burned cane now harvested during the wet periods of the prolonged
crop season often is left for several days in the field before being
processed. This increases the tons cane per ton of sugar ratio;
the indicator for cane quality. Furthermore, the mechanical load-
ing of cane during these wet periods causes heavy amounts of ex-
traneous matter to adhere to the cane and to enter the factory.
Soil, especially, has a very abrasive action and causes significant
increases in the wear and tear of machinery until the clarification
process is complete. Carrier chains and sprockets, juice pumps
and mill rolls wear much more quickly than before. Soil also re-
duces the combustion quality of bagasse and results in difficulty
in maintaining steam pressure and forcing an increase in utiliza-
tion of fuel oil; an expensive commodity in Jamaica.

Thus, an already tight repair schedule has become even more

strained in recent years. Subsequently, the cost of repairs has
skyrocketed and machine parts have to be replaced at ever increas-
ing rates.

The grinding season must be reduced in order to stabilize the

Jamaican sugar industry in the future. The shortening of the dura-
tion for the crop season will, to a great extent, achieve the following:

lANCtKION * PORTER, INC.

 39

Promote better machinery repair schedules.

Significantly reduce the abrasive wear of machinery by

• oil.

Prolong the life expectancy of equipment and parts,

lowering the production cost at the same time.

Shortening of the crop season will also:

Eliminate cane processing during the wet periods when

supply of cane cutters is at its lowest level.

Shorten the delay in time between cane burning and

processing, thus increasing the cane quality.

Limit cane processing to the period when cane has as

optimum ripeness as possible, again increasing cane
quality.

Make more effective use of the cane transportation

equipment and cause fewer breakdowns. The effi-
ciency of this equipment is greatly reduced when
used during wet season.

For the reasons just stated, shortening of the grinding season to a

more normal time span is essential to the future of the industry.

Assessment of the Outside Repair Facilities

There is only one independent repair facility on the Island equippiîr3.

to handle the heavy equipment of the sugar industry. Located in
Kingston, the Kingston Iron Works (K. I. W. ) houses its offices,
workshops and foundry in one central location. The shops are
equipped with most of the machares and tools necessary to repair
the factory equipment as well as to fabricate new equipment, such
as vacuum pans, evaporators, juice heaters, and clarifiers. It
cannot manufacture power units or allied equipment.

In addition to »erving the sugar industry K. I. W. serves the bauxite

and the other industries on the Island. The work for the sugar

•ANDERSON a POUTER. INC.

 40

industry represents a small portion of its annual income with

the bauxite industry contributing the major portion. It also manu-
factures and ships finished products to many of the sugar producing
nations in the Caribbean, Central and South America. K. I. W.
intends to pursue a major reliabiliution program aimed at mod-
ernizing the foundry, machine, and fabrication shops in an effort
to improve its efficiency and reduce costs.

There are a few smaller repair facilities that serve the sugar in-
dustry specializing in boiler repairs, electrical repairs and in-
strument calibration and repair. None of these is capable of or
attempts to undertake the major foundry or machine shop work.

The quality of the work of K. I. W. is classified as fair to good.

As in every industry, complains of inconsistent quality of both
materials and workmanship are common but despite these diffi-
culties the industry relies heavily on K. I. W.

Of common concern is the high cost of repair and material. Lower

prices can be obtained abroad but import restrictions do not allow
the factory operators to take advantage of them. An excellent
example of lower off-island costs is that some factories have import-
ed new mill rollers from Barbados, made possible through the
CARIFTA agreement, at a lower cost than the same roller supplied
by K. I. W. Even though there is shipping cost involved the Barbados
price is still much cheaper. However, and not withstanding the
CARIFTA agreement, if K. I. W. is unable to fill an order the fac-
tory in question generally is issued an import permit for the mater-
ial or work required.

It is extremely doubtful, even after modernization, that K. I. W.

will be able to stabilize or lower their prices. The higher cost of
new machinery today may force further increases in price. In
addition, since the other industries constitute the major portion of
K.I. W. *s annual income, it is understandable that they would
cater to these industries as sugar mill repair work is only seasonal
in nature.

There are two options to circumvent the existing high prices. One
is relaxation of the import restrictions on the sugar industry,
thereby allowing the factory operator to obtain services, material

SANDERSON & PORTCM.INC.

•te.
 iiuìijijPgw pN^^SfcÉ

41

or part» anywhere in the world at Attractive price«. The second

it to form the Jamaica Machinery Cooperative that will be allowed
both import relaxation and include a central repair facility solely
for the sugar industry.

iAN«cmoN a pomtt•.•«?..
 '^mm^tmmiÊmUÊÊÊaÊaiÊÊÊi

42

FACTORY PROFILES

The profiles and discussions for each factory which follow are
based on detailed technical information provided by the Chief En-
gineer and Fabrication Superintendent of the factories and on the
personal observations and impressions of the Team members visit-
ing the plants.

An example of methods used for the evaluation of each plant is in-

cluded only in the discussion of the Innswood Plant. For all other
plants a diagram indicating the optimum duration for the grinding
season based on sugar content in cane during the 1970 crop is in-
cluded. Incidentally, this crop was one of the wettest in history
but the short duration of the project prevented calculation for
the optimum duration of a grinding period based on the average
of the past five crop seasons and the correlation with rainfall
during these years.

The average yield per acre was fairly low for 1970 when compared
with previous years, especially the fifties. During the latter
period cane was harvested and loaded manually. This resulted in
a minimum amount of extraneous matter. The 1970 values for
yield «%re selected as the most recently available date and re-
flect the losses which are suffered from mechanical operations
in the growing and harvesting process. The values experienced
for 1970 will reflect future production performance more realis-
tically than the adaptation of such values from the prevailing
earlier years.

In addition, a table indicating present capacity of each piece of

major machinery is incl- ded for each factory as a- e tables
and figures indicating the material balance, heat »»Unce and
steam requirements. These are shown to substantiate the re-
commendations for each plant.

^NhrRiON A_i»0»TfB..I.1Ä-.
 43

During the investigation, it was found that, on the whole, the

laboratories are well equipped for performing the routine analyses
needed for an effective factory control. Large factories have more
and more modern equipment than the smaller ones Each factory
spends about the same amount per ton of sugar prodm ed for
laboratory equipment.

All factory technical personnel possess degrees either from the

University of the West Indies, which offers a bachelors degree
m sugar chemistry and technology, the older [). I. C. T. A. degree
from the Imperial College of Tropical Agriculture, which was the
forerunner of the University of the West Indies, or a technical
degree from England.

Sugar analyses, intermediate product analyses and their reporting

are performed according to the standards set by the International
Society of Sugar Technologists.

In addition, in our discussion of each plant capacity changes are

mentioned only for those items of machinery that require re-
placement or modification. For example, boiler capacities to
convert to syrup production are considered adequate unless
specifically mentioned (Note the case of Worthy Hark which calls
for a new boiler to reach its projected capacity.

The location of each factory has been determined historic ally;

not by any modern plant location analysis. Years ago several
small animal driven factories were located in each valley. Ruins
of some still exist. With the advent of the steam engine, and for
subsequent economic reasons these factories were amalgamated
with one factory remaining in a valley. Where the land was rela-
tively flat, these factories further amalgamated into larger units
(Monymusk and Frome). In other areas, the topography pre-
vented this concentration as the mountain ranges and the relatively
poor road system prevented effective cane transportation.
Accordingly the location of the present facilities has been governed
by the prevailing topography- The existing factories and their
ownerships follow:
 44

Owner Factory

Jamaica Sugar Estate• Ltd. Jamaica Sugar Estatei

Scaforth Sugar k Rum Ltd. Serge Island

Gray's Inn (Ja. ) Central

Factory Ltd. Gray's Inn

Trelawny Estate« Ltd. Long Pond

Hampden Estates Ltd. Hampden

J. Wray k Nephew Ltd. Appleton

Holland Estate Ltd. Holland

The West Indies Sugar Co. Ltd. F rome

The West Indies Sugar Co. Ltd. Monymusk

Sevns Ltd. Sevens

New Yarmouth Ltd. New Yarmouth

Worthy Park (Factory) Ltd. Worthy Park

Innswood Estate Ltd. Innswood

Bernard Lodge Sugar Company Bernard Lodge

United Estates Ltd. Bybrook

It would have been improper for u. to di.cu.. our specific

recommendation, with the owner, during the course °' h« '
However, it is our opinion that our r«commen^0n"j;1".
accepted by the vast majority - if not all." of the owners.

MNDCRIONI "OBTtH.IKC.
_£-£-
 45

APPLETON
Saint ElUbeth P»rlth

ïïTXVN
 4b

Apptcton
The recommendations for Appleton are interrelated with tho.e for
the Holland Plant. Appleton and Holland both could be converted
into 8yrup producing units, or the Holland factory would be closed
down; its cane supply being sent to Appleton for processing. If
Holland closes, then Appleton would remain a sugar unit at least
for the present.

Should Appleton become a syrup unit, the present hourly grinding

rate should be reduced from 67.5 to 60 T.C.H. or 1,440 T.C.D.
Permitting a 25 per cent lost time factor for all purposes, the new
grinding rate will effect a reduction of the crop duration to 134
days. The above recommendations were based on evaluation of
the data on the following pages.

To suggest this grinding rate of 60 T.C. H. the following was con-

sidered.

The mills, juice heater., filters, vacuum pans, C crystallizer.

and the high and low grade centrifugals all are of sufficient capaci-
ty to obtain the proposed grinding rate. The clarifier, though, is
too small to adequately increase its capacity, and small polycell
clarifier should be added. The enlargement of the clarificaron
station will improve the quality of sugar, lessen its ash content
increase polarization, and render a better color than is presently
obtained.

The capacity of the syrup supply tanks is also too small. At least
500 cubic feet of capacity should be added. The estimated cost for
improvements needed to attain 60 T. C. H. e"lclentlyeAltJ"
crystallizing or a syrup producing unit is $12,000 ($10,000 and
$2,000 for clarifier and syrup tanks, respectively).

Although the above offer, a solution for Appleton, it i. not the opti-
mum avenue to follow in that the problem, facing the Holland fac-
tory have to be re.olved .imultaneously.

To keep the Holland facility in operation will involve continual and

increasing government .ub.idization. At the .ame time the
nearby modern plant at Appleton will lo.e financially in that it

• A NDIMONI POBTM.INC.
 47

will have an insufficient cane supply to operate profitably due to

high depreciation factors.

Accordingly, it is recommended that the Holland Plant be closed.

The cane now harvested by Holland should be transported to

Appleton. The topography of this area is fairly flat so cane trans-
portation will be neither difficult nor costly. The merger of cane
from Holland together with cane for Appleton will ensure delivery
of about 230, 000 tons per season (based on the deliveries for the
1970 crop) for Appleton.

The grinding period should be 140 days in order to pass the com-
bined quantity of cane from Holland and Appleton. This means that
the grinding capacity for Appleton be increased to 91. 2 T. C. H. or
2,200 T.C.D.
To simply add cane supplies to be processed by the present mechani-
cal facilities of Appleton, without the upgrading of the factory, would
be unrealistic and would be contrary to the national interest. Just
adding the cane supply from Holland will extend the crop duration
far into the rainy season. The resulting decrease of sucrose con-
tent will eliminate any advantages from the large economy of size
for the facility.
Upgrading Appleton easily can be effected by using the equipment
presently available at Holland. The mechanical requirement, for
the proposed increase in grinding capacity for Appleton will be a.
follows:
Milling: The milling tandem has adequate capacity to
attain the proposed grinding rate.

Juice Heaters: The juice heater, also are of sufficient

capacity.
Clarification: The clarification station must be enlarged
by installing the 16' diameter "Dorr" clarifier now .t
Holland. Filter capacity is large enough to attain the
proposed grinding rate.

IANOCMON a *0"TE«.tNe.
 48

Evaporators: The capacity of the evaporation station

must be enlarged. The easiest solution would be to add
the #2 vessel (2,500 square feet heating surface), now
at Holland and designate this vessel as the last vessel
in the Appleton station. The original #1 and #2 vessels
at Appleton would be utilized as a double effect pre-
evaporator, followed by a quadruple effect, with each
vessel having 2, 500 square feet of heating surface.
This solution would be the cheapest alternative. How-
ever, further calculations have to be performed to de-
termine the pressures and types of steam to be used and
whether the preevaporator should be coupled in parallel or
if each vessel should work separately. Finally, the
types and amount of vapor which should be removed from
the preevaporators to be used for the juice heaters and
the new quadruple effect would have to be determined.

Vacuum Pans; The addition of Holland's pan #3 (600

cubic feet capacity and 1, 000 square feet heating sur-
face) should be adequate to increase Appleton to the
proposed grinding rate. However, the capacity for the
syrup and molasses holding tanks have to be increased.

Centrifugals; The addition of the single "Western

States" fully automatic machine now at Holland will
bring Appleton to the required capacity. In addition,
the low grade continuous "Western States" centrifugal
presently at Holland must be added to the capacity of
the station at Appleton.

Aside from the question of ownership of equipment it is «'^»^

that $50, 000 would be required to disassemble the designated equip-
ment at Holland and reinstall it at nppleton.

I. INC.
 °*
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51

APPLETON: ACTUAL CAPACITY IN TONS CANE PER

DAY FOB MAIN EQUIPMENT IN EACH
PPQCESSING STATION _

Station Average T. C. D.

Milli 2,208

Juice heater« 3,970

Clarifiera 1,050

Filtert 2,268

Evaporator« 1,610

Vacuum pan« 1,780

960
Syrup supply tanks

A and B molasses supply tank« 2,304

C cryitallizeri 2,160

High grade centrifugal» 1,875

Low grade centrifugals 2,160

 APPLETON: HEAT BALANCE FOR THE EVAPORATION,
STATION SHOWING THE STEAM CONSUMPTION IN B. T. U. NEEDED
T0 nnTAIN PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Pounds Per Cent
B. T. U. per Hour Brix
Cal r,,ia»inn for Flow of Heat
139,094 15.63
1 Juice to Evaporator 10 psi
Exhaust to # I 38,850 x 945 36,713,250
Add Flash from heaters 139,094
695,470
(245-240)
Available for Evaporation 37,408,720
Evaporation 37, 408, 720-:-952 39,294

99.80 21.78
Transfer to # 2
37,408,720
2 Vapor from #1 0 psi
To heaters k pant 25, 000 x 952 23.800, 000
13,608,720
Balance
Add Flash 99,800 (240-215) 2.495,000
Available for Evaporation 16, 103,720
16,601
Evaporation 16, 103,720 -Ì-970
83, 199 26. 13
Transfer to # 3
16, 103,720
3 Vapor from # 2
To heater. 2,500 x 970 10" 2.425,000_
13,673,720
Balance
1.414,383
Add Flash 83,199 (215-198)
15,093,103
Available for Evaporation
15,382
Evaporation 15,093,103 -:- 981.2
67,817 32.05
T ransfer to # 4
15,093,103
4 Vapor from #3 18
1.424.157
Add Flash 67,817, (198-177)
16,517,260
Available for Evaporation 16.600
Evaporation 16,517,260 -Ï-995
51,217 42.44
T ransfer to # 5
16,517,260
5 Vapor from # 4 26"
_2ff202.33l
Add Flash 51,217 (177-114)
18.719,591
Available for Evaporation 18.316
Evaporation 18,719,591 -:- 1»022
32.901 66.07
Leaving # 5 as Syrup
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54

BERNARD LODGE
Saint Catherine Parish

"tmmm$L¿:'W9&i

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 h-*

Bernard Lodge

From evaluation of the technical data contained on the following

pages, and according to the quality of cane, Bernard Lodge should
remain a crystallizing unit. The crop duration should be shortened
to 135 days to optimize sugar production. The cane grinding rate
should be increased from 134 to 178 tons per hour resulting in an
increase of 3, 200 to 4,275 tons of cane per day.

The factors which will enable Bernard Lodge to attain the proposed
grinding rate are as follows:

Milling; The present mill tandem is capable of attaining

the prescribed daily cane grinding capacity.

Juice Heaters: The heating arrangement is inadequate.

The present low juice velocity in the heaters is partially
responsible for the poor performance in this station.
Also, the design of the juice heaters is unsuitable to
operate on the vapor (at 5 p. s.i. ) from the first vessel
of the evaporators.

Adopting the higher daily cane grinding rate, the juice

velocity in the heaters would be increased to a satis-
factory rate. Concurrently, the heat transmission co-
efficient would be improved considerably when utilizing
exhaust steam of 10 p. s. i. The heater station would
have adequate capacity to accommodate the increased
grinding rate, provided the steam source for heating
is changed.

Clarification: The present ' Bach" clarifier is too

small and is capable of only handling 2, 000 tons of
cane per day. Also, the high number of compartments
in the clarifier causes a heat loss resulting in de-
creased efficiency in juice clarification. It would not
be advisable to convert the present clarifier capacity
to accommodate the prescribed cane grinding rate.
A 12-foot diameter polycell type clarifier should b«
purchased Instead.

I, INC.
 56

The filter also is insufficient. A second unit of the

same size should be installed.

Evaporation: The performance of the installed equip-

ment is efficient bul in too small iur even the present
grinding capacity. The most economical solution would
be to utilise the present first vessel with a 10, 000 square
foot heating surface as a preevaporator. At the same
time the exhaust steam pressure should be increased to
15 p.s.i. so that the preevaporator can bleed vapor of
about 10 p. s. i. to the heaters. A new first vessel
with a 6, 500 square foot heating surface should be in-
stalled to complete the station. The new combination
would provide 38,600 square feet of heating surfac«
to service the expected flow of 340,000 pounds of juice
per hour. This allows an evaporation rate of 6.2 pounds
per square foot per hour.

Pans: The pans are capable of handling the increased

grinding capacity but it would be advisable to add a few
molasses holding tanks. These can be fabricated
locally.

Crystallizers: The capacity of the C crystallisers

is adequate, provided that they are operated in a con-
tinuous arrangement. This means that all crystallizers
would be interconnected, alternatively in front and
rear, and top and bottom with an o^rfbw. The last
crystallizer would overflow continuously into the pugmill
of the centrifugals. To accommodate such a system
a new strike receiver would be needed to receive the
pan load. This receiver would have 1, 200 cubic feet
of capacity with a mechanical stirring device (not water
cooled) and would discharge continuously into the first
crystallizer.

Centrifugals; The capacity for the A and B sugar is

sufficient to accommodate the new grinding rate. The
capacity of the low grade sugar station may be con-
sidered adequate as each machine can exceed the 60
cubic feet oí massacuite per hour capacity; the value

lANOmiON a POKTCH, IMC.

 57

used for th« calculation. Depending on the screen

typ« med, the continuous centrifugali may reach a
capacity as high a• 120 cubic feet of C maasacuite
per hour.

Capital Coati Capital investment« estimated to achieve

the mentioned grinding rate are:

Clarification $ 20,000
Filter 40, 000
Evaporator 35,000
Cryitallisar 5.000

Total $100,000

MIC.
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 59

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60

BERNARD LODGE: ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
PROCESSING STATION

Sutton Average T. C. D.

Milli S.040

Juice heaters 2,47*

Clarifiera 2,880

Filters 2,650

Evaporatore 3,200

Vacuum pant 4,000

Syrup supply tanks 4,000

A and B molasses tanks 3,600

C crystallisers 3,860

High grade centrifugals 4,320

Low grade centrifugals 3,900

 61
BERNARD LODGE - HEAT BALANCE FOR EVAPORATION
STATION SHOWING THE STEAM CONSUMPTION IN B. T.U. , NEEDED
TO OBTAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Pounds Per Cent
Calculation for Flow of Heat B.T.U. per Hour Brix

# 1 Juice to # 1 255, 313 13. 36

Exhaust to # 1 (10 psi) 64, 300 x 952 61,213,600

Add Flash from preheater 255, 313 x
(240-227) 3,319,069+
Available for Evaporation 64,532,669
Evaporation 64, 532,669 -:- 960 67,221

Transfer to # 2 188,092 18. 13

# 2 Vapor from # 1 64,532,669

To heaters 31, 000 x 960 29.760,000-

Balance 34,772,669
Add Flash 188,092 (227-210) 3.197.564+
Available for Evaporation 37,970,233
Evaporation 37,970,233 -:- 973 39,023

149,069 22.13
Transfer to # 3

# 3 Vapor from # 2 37,970,233

Add Flash 149,069 (210-190) 2,981,380+

Available for Evaporation 40.951,613
Evaporation 40, 951,613 -:-98S 41.449-

107,620 31.60
Transfer to # 4

# 4 Vapor from # 3 40,951,613

Add Flash 107,620 (190-134) 6,026,720+

Available for Evaporation 46,978.333
Evaporation 46,978, 333 -:- 1022
61.653 55.32
Leaving Syrup from # 4
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 63

BYBROOK
Saint Catherine Parish

3Î8&*

i, it*e.
 64

Bybrook

Bybrook should be converted to a syrup producing unit. At the same

time, the crop duration should be shortened from 226 to 184 days
per season in order to optimize production with the existing equip-
ment. A grinding rate of 1, ^80 I". C. D. or 70 T. C. H. is projected.

Limiting factors are:

Milling: The present tandem has a maximum capacity of

62 T. C. H. for cane having 1^. t per cent fiber. This fiber
content was very high during 1^70. It is felt that the tan-
dem could achieve 70 T. C. H. , providing the fiber ton-
tent will return to its normal average of 13.8 per tent.
Whether the fiber content will actually return to the
normal average is debatable. Mechanically loaded i ane
will contain more extraneous matter than the hand loaded
cane. Therefore, 1 Î. 8 per cent fiber may not be attained.
In this event the milling tandem will be too small. For
this reason, the milling tancem should be replaced by
a diffusion plant. For the present, the grinding rate
can be adjusted to 70 T. C. H. for cane having 1 5. b per
cent fiber. This action will result in a slightly higher
than normal loss of sugar in the bagasse.

Juice Heaters: Capacity is ample to achieve the in-

creased grinding rate.

Clarification: The capacity of the present clarifier

is inadequate. This can be ine reased by adding some
polycell trees to the existing ones. The filter is of
ample capacity for the increased grinding rate.

Evaporation; The evaporator's capacity is too small

to accommodate the projected grinding rate. The pre-
sent quintuple effect performs very efficiently. It
provides an overall evaporation of 6.55 pounds per
square foot per hour, producing a syrup with 61 de»
grees Brix density or higher.

SA NoewsoN a *O«T»».INC.
 65

Keeping in mind the likely high fiber content in cane for

the future, the most practical solution to increase the
evaporation station would be to add one new vessel. In
this manner the evaporation station could function as
two triple effects as compared with the quintuple effect
now in operation.

The following arrangement is suggested to accommodate

the 13, 340 square feet of total heating surface:

Stage #1 One existing vessel with 3, 170 square feet

heating surface.

One new vessel with 2, 000 square feet

heating surface.

Total for first stage 5, 170 square feet

heating surface.

Stage #2 One existing vessel with 2, 500 square feet

heating surface.

One existing vessel with 2, 000 square feet

heating surface.

Total for second stage 4, 500 square feet

heating surface.

Stag« #3 - One existing vessel with I, 835 square feet

heating surface.

On« existing vessel with 1, 835 square feet

heating surface.

Total for third stage 3, 670 square feet

heating surface.

Capital Costs; Capital costs to convert Bybrook into

a syrup unit are estimated at about $18, 000 for the
evaporator vessel ($12, 000 for the vessel and $6,000
for change of piping arrangement). To remain a

• ANDMION a POSTIB.tNC.
 64

crystallising unit and still grind 70 T. C. H. for optimum

•tifar production, an additional $45, 000 will be needed
to purchase pan lupply tanks, high grade and low grade
centrifugal» ($2,000, $15,000, and $18,000 respectively).

IANDCMON * Ponrcn.tNe
Ipii^ppp

ss MONTHLY RAINFALL, INCHES

MSCD ON V YCA* WAN 67

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 69

BYBROOK: ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
PROCESSING STATION

Sutton Average T. CD.

Milling tandems 1,488

Juice heaters 1,670

Clarifier« 1 320

Futen 2 040

Evaporators » 280

Vacuum pans 1 ,420

Supply tanks, syrup 700

Supply tanks, molassei 1 200

C crystallise» 1 952

High grade centrifugals 1 416

Low grade centrifugals 1 ,3*6

 BYBROOK: HEAT BALANCE FOR THE EVAPORATION 70
STATION SHOWING THE STEAM CONSUMPTION IN B. T U NEEDED
TO OBTAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Poundß Per Cent
Calculation for Flow of Heat B. T.U. per Hour Brix
#1 Juice to No. 1 10 psi 10b.423 13.23
Exhaust to # 1 (15 psi) 23750
x 945 22,443,750
Add Flash from pre-heater 532.115
Available for Evaporation 22.975,865
Evaporation 22975865 -:- 952 24,134
Transfer to #2 82.289 17. 11

n Vapor from #1 4 P§i 22,975,865

To Heaters 7500 x 952 7, 140.000

Balance 15,835,865
Add Flash 82289 (240 x 225) 1.234.335
Available for Evaporation 17,070,200
Evaporation 17070200 -:- 962 17,744
Transfer to # 3 64,545 21.81

#3 Vapor from #2 0 psi 17,070,200

To Heaters 5380 x 9621 5,175, 560
Balance 11,894,640
Add Flash 839.085
Available for Evaporation 12.733,725
Evaporation 12733725-:- 970 13,127
Transfer to # 4 51,418 27. 38

U Vapor from # 3 10" 12,733,725

Add Flash 51418 (212-195) 874,105
Available for Evaporation 13,607,830
Evaporation 13607830 -:- 982 13,857
Transfer to # 5 37,561 37.48

#5 Vapor from # 4 26" 13,607,830

AddFlash 37561 (195-134)
8° BPR 1,464.880
Available for Evaporation 15,072.710
Evaporation 15072710 -:- 1022 14,748

Leaving # 5 as Syrup 22.813 61.71

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Westmorland Parish

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•*«•!•••« a Po»tt•.•«••
 73

From«

The From« factory it a well balanced processing unit. To optimize

•ugar production the crop season should considerably be shortened.
A grinding rate of 312 T.C. II. or about 7, '00 ton» of une per day
should be established. Also, the factory should remain a crystal-
lizing unit. To obtain the proposed grinding rate, the following fac-
tors are to be considered:

Milling: The two tandems now in operation do not need

major modifications.

Juice Heaters: The higher juice velocity in the heaters

will cause an increase in the heat transmission coeffi-
cient due to a decrease in scale formation on the tubes.
The juice velocity, however, is already quite high for
the present grinding rate. 1 he station's capacity, es-
pecially the juice pumps, will definitely be too small
to accommodate the proposed rate. Two new juice
heaters, one for each tandera, each having 1,600 square
feet of heating surface and provided with stainless steel
tubes, should be installed.

Clarification: The clarifier capacity will become too

small. The multi-feed 22fot diameter "Dorr can be
converted easily to a five compartment unit thus add-
ing one tray.

The present filters have an adequate capacity for the in-

creased grinding rate.

Evaporation and Pans: No changes or additions are indi-

cated except possibly for syrup and molasses storage.
An additional row of tanks may be installed above the
existing tanks. Syrup and rrolasses would require
additional tank capacities of 5,000 cubic feet each in
• order to avoid stagnation in the operation of the pan
floor.

Crystalliserst Capacity is ample to facilitate the in-

creased grinding rat«.

• AMOcnaON a POATCW.IWC.
 74

Centrifugals! Presently, the capacity for A tugar cur-

ing la too low to reach the target of 312 T. C. H., espec-
ially when considering 20 hours of curing per day. The
installation of an additional machine trust be considered
but it is not necessary immediately.
The present capacity is adequate for the low grade sugar
curing.

Capital Costi The necessary investment to reach the

312 T. C. H. grinding operation is estimated as follows:

Tuie e Heaters $20,000

Conversion of Clarifier 5, 000
Supply Tanks for Syrup
and Molasses 6.000

Jota! $31,000

• ANemiON a PO»TC».INC.
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 %%siämmAj*sm

77

FF OME: ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
rnvvu

Station Av erage T. C. D.

Milling tandems 9,840

Juice heaters 6,98*

ClarUieri 6,800

Filters 10,600

Evaporators 7,680

Vacuum pans 8,66»

Supply tanks, s y rup 2, 400/3,600*

Supply tanks, molasses 3, 600/4,320*

C crystallisers 10,464

High grade centrifugals 6,720

7, »60
Low grade centi ifugals

* One tank can either be utilised for syrup or molasses

 78
FROME: HEAT BALANCE FOR EVAPORATION STATION
#1 SHOWING THE STEAM CONSUMPTION IN B. T. U. , NEEDED TO
ORT AIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice,

Content Pounds Per Cent
Calculation for Flow of Heat B.T.U. per Hour Brix

250, 970 13.74

#1 Juice to #1

Exhaust to #1 (30 psi) 85, 000x928. 2 78,897,000

Available for Evaporation 78,897,000
Evaporation 78, 897, 000 -*- 949 38. 136

167,834 20.54
Transfer to No. 2

#2 Vapor from #1 (12 p»i) 78,897,000

To Heaters 47,000*949 44.603.000

Baiane« 34, 294, 000
Add Flash 167,834 (244-221) 3.860.182
Available for Evaporation 38,154,182
Evaporation 38,154,182 <- 963.6 39, 595

128,239 26.88
Transfer to #3

#3 Vapor from #2 (3 pal) 38,154,182

To heaters 11,000x963.6 10.599,600

27,554,582
Balance
Add Flash 128,239 (221-198) 2. 949. 970
Available for Evaporation 30,504,552
31.089
Evaporation 30,504,552 -:- 981.2
97,150 35.49
Transfer to #4

#4 Vapor from #3 (10" vacuum) 30,504,552

Add Flash 97, 150 (198-134) 6.217.600

Available for Evaporation 36,722,152
Evaporation 36,722,152 -i- 1,022 A», »H
61,219 56.32
Leaving #4 as Syrup
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 80
FROME: HEAT BALANCE FOR EVAPORATION STATION
# 2 SHOWING THE STEAM CONSUMPTION IN B. T. l\ NEEDED TO
OBTAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Pounds Per Cent
B.T.U. per Hour Brix
Calculation for Flow of Heat
258,800 13.74
# 1 Juice to # 1

Exhaust to #1 (30 pai) 81000 x 928. 2 75,184,200

Available for Evaporation 75,184,200
79,224
Evaporation 75184200-:- 949
179.576 19.80
Transfer to # 2
75,184,200
# 2 Vapor from # 1 (12 pai)
To Heaters 40,000 x 949 37,960,000
37,224,000
Balance
AddFla.h 179,576 (244-221 4.130,248
Available for Evaporation 41.354,448
42.916
Evaporation 41354448 -:- 963.6
136,660 26.02
Transfer to # 3
41,354,448
# 3 Vapor from #2(3 pai)
10,599.600
To heaters 11,000 x 963.6
30,754,848
Balance
Add Flash 136,660 (221-198) 3,143.180
33,898,028
Available for Evaporation
34, 547
Evaporation 33898028 -:- 981.2
102,113 34.82
Transfer to # 4
33,898,028
# 4 Vapor from # 3 (10" vac)
6r 535,232
Add Flash 102,113 (198-134)
40,433,260
Available for Evaporation 39.562
Evaporation 40433260 -:- 1022
61,551 54», S4
Leaving # 4 a» Syrup
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 82

GRAY'S INN
Saint Mary Pari«h

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WOTM

•áNSIMlOK A »onte*, »«e.

 81

Gray'« Inn

It is recommended that Gray's Inn be converted to a syrup produc-

ing unit. At the time time the crop season should be of 95 days
duration. In order to optimize sugar production the grinding rate
•hould remain at 56 T. C. H. To process this hourly grinding rate,
the following limitations are apparent:

Milling: Sufficient capacity available.

Juice Heaters; Sufficient capacity available.

Clarification; The capacity of the present clarifier is

insufficient and a polycell clarifier, having 12' diame-
ter should be installed. This new equipment should be
able to service the cane grinding capacity, while the
other clarifier can serve as an alternate or it can be
sold. . The filtration station is of sufficient capacity to
service the grinding rate.

Capital Cost; An estimated $10,000 will be needed to

•nact the changes needed in the clarification station.
 •Bf&rtWaWS" •4

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 86

GRAY'S INN: ACTUAL CAPACITY IN TONS CANE PEB

DAY FOF MAIN EQUIPMENT IN EACH
PROCESSING STATION

Station Average T. C. D,

Mill tandemi 1,680

Juice heaters 1,462

Clarifier! 765

Filtert 1,878

Evaporation 1,560

Vacuum pant 2,230

Syrup supply tank« 1,500

A and B molai tea au pply tankt 1,500

C crystallize• 1,450

High grade centrifugala 3,480

Low grade centrifugala 2,012

 87
GRAY'S INN: HF AT BALANCF. FOE EVAPORATION STAI ION
SHOWING THE STEAM CONSUMPTION IN B. 1. V. , NEEDED TO OBTAIN
THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat K vapo ration Juice

Content Pounds Per Cent
Calculation for Flow of Heat B.T. t!. p< r Hour Brix

#1 Juice to #1 7 pti 103,128 13.64

Exhaust Steam to #1 (15 pti) 23,500

x 945 22,207,500
Add Flash from Juice Heater 103, 128
(250-233) 1,753, 176
Available for Evaporation 23,960,676
Evaporation 23,960,676 -:- 956 25,063

Transfer to #2 78,065 18.01

#2 Vapor from #1 0 pii 23,960,676

To Juice Heater 9,700 x 956 9.273,200

Balance 14,687,476
Add Hash. 78,065(233-215) 1,405. 170
Available for Evaporation 16,092,646
Evaporation 16,092,646 -:- 970 16,590

Transfer to #3 61,475 22.88

#3 Vapor from U 12' 16,092,646

Add Flash 61,475 (215-194) 1.290.975

Available for Evaporation 17,383,621
Evaporation 17,383,621 -:-934. 3 17,660

43,815 32. 10
Transfer to #4

#4 Vapor from #3 26' 17,383,621

Add Flash 43,815 (194-134) 2.628,900

Available for Evaporation 20,012,521
Evaporation 20,012,521 -:- 1022 19,581

24,2 34 58.04
Syrup Leaving #4
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MICROCOPY fW SOLU HON HS! CHAM

NA'inN/li Mll'l •'•!] (il . I AMI !.1(. 11 , !•!! • A
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HAMPDEN
Saint Jamei Parith

c3w«ITHy »AUK
[^jiviieoK
cJAPPkSTSM dû IMNSWOOO

JAMAIOA
 90

Hampden

It is recommended that the crop season be reduced to 136 days, based

on the per cent sucrose distribution in cane in order to optimize pro-
duction. Thus, a grinding rate of 8Ì T. C. H. or 2,000 T.C.D. must
be obtained. It is further proposed that Hampden be converted into
a syrup producing unit. Also, as Hampden is prominent in rum
production its bagasse surplus may actually prove more beneficial.
Presently, a large volume of fuel oil is used to produce steam for
sugar as well as rum ma nula t luring. The elimination of the pan-
boiling and centrifugal stations more than likely will allow adequate
steam production for both operations, using the surplus bagasse
rather than fuel oil. In addition, the da rifu ation and evaporation
stations will still be in operation after the conversion, thus continu-
ing to serve the raw material needed for Hampden's strongly
flavored rum production.

In order to attain the proposed grinding rate the following are to be

considered:

Milling: The milling tandem itself is capable of produc-

ing 2, 000 T. C. D. , assuming 1 5 per cent fiber in cane.
A speed of 48 f. p. m. is required to obtain the proposed
rate. At this speed only the first two mills are slightly
underpowered. By adjusting the mill roller setting it
would be possible to produce I, 000 T. CD. under the
present conditions and without need for a major change
in the milling equipment. A slightly higher sucrose loss
may be expected in the bagasse but this easily could be
eliminated with a moderate increase in imbibition water
up to 25 per cent of weight on cane.

Juice Heaters: Presently, the juice velocity in the

heaters is too low. resulting in a low heat transmission
rate. With the increased grinding rate, the juice
velocity will increase to about 5 f. p. s. The present
low heat transmission rate will then be automatically
corrected resulting in increased steam consumption for
this station.

IANOCMON » *0«TK«.INC.
 91

Clarification: The present capacity of the clarifier is

adequate to meet the im reased cane grinding rate. The
filter now is able to handle slightly below 2, OUU T.C.D. ,
but it can be expected to meet the striali overload with-
out creating any serious problems.

Evaporation: The present capacity of this station is

definitely too small to service the proposed grinding rate.
The accumulated data did not indicate whether vapor is
taken from the first vessel for servicing the juice heat-
ers. If not, it should, as the heating surfaces of vessels
#1 and #2 allow an extraction of 6, 000 pounds of vapor
per hour.

Without adequate bleeding of vapor, these vessels will

perform inefficiently; ¿4,700 pounds per hour of exhaust
steam are admitted to vessel #1 for evaporation of
only 19,997 pounds per hour of water. This poor per-
formance is also illustrated by the low average evapora-
tion rate of 5.0 pounds per square foot per hour for the
first vessel.

In the future a "dead ended" preevaporator should be

installed and heated by exhaust steam with the vapor
bleeding only to the juice heaters. The advantage of
the proposed system is that •. he juice now entering the
quadruple already has high density and the evaporation
load per square foot of heating surface can be relative-
ly small. The new vessel must evaporate 20,000-
23, 000 pounds of water per hour to obtain a satisfactory
density for the syrup. Therefore, the vessel should
contain about 2, 500 square feet of heating surface.

Capital Coats: The coat for the new evaporator ia esti-

mated at $12, 500.

IANDENION a PO»TI»,INC.
 MONTHLY RAINFALL, INCHES
MKO ON \?\Q ACTUM. FIGURES 92

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 93

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 ¡ii..Mèr»ík,

HAMPDEN: ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
PROCESSING STATION

Station A verage T. C.D.

MÜU 1. 6 32

Juice heaters

Clarifiera

Filters

Evaporation

Vacuum pans

Syrup supply tanks

A and B molasses tanks

C crystallizers

High grade centrifugals

Low grade centrifugals

 95
HAMPDEN- HEAT BALANCE FOR THE EVAPORATION

Heat Evaporation Juice

Content Pounds Per Cent
B.T.U. per Hour Brix
r.alfulation tor Flow_of_HeaL
122,967 13.98
10 pBi
jfl Juice to #1
23,341,500
Exhaust to #1 (15 p.i) 24,700x945
Deduct for Heating Juice 122,967
4,303,845
(240-205) 19,037,655
Available for Evaporation 1 19.997
Evaporation 19,037,655 -:-952
102,970 16.69
Transfer to #2

2 pei 19,037,655
#2 Vapor from #1

Add Flash. 102,970(240-220) 2,059,400

21,097,055
Available for Evaporation 21,862
Evaporation 21,097,055 -:- 965
81, 108 21. 19
Transfer to #3
21,097,055
#3 Vapor from #2 10"

2r027,700
Add Flash. 81,108 (220-195) 23,124,755
Available for Evaporation 23,548
Evaporation 23,124,755 -:- 982
57,560 29. 86
Transfer to #4
23,124,755
#4 Vapor from #3 26"

3,511,160,
Add Flash. 57,560(195-134) 26,635,915
Available for Evaporation 26.062
Evaporation 26,635,915 -:- 1.022
31,498 54.57
Leaving #4 as Syrup
 I
96
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97

HOLLAND
Saint Elizabeth Parish

~T.N -ÜiWfc(

lANoenaoN & POUTCH.INC.

 98

Holland

As stated under the Appleton factory profile, the cane supply to

Holland and Appleton is too small to service both factories econo-
mically. With Appleton being the more efficient factory, it is felt
that the cane supply presently utilized by Holland should be trans-
ferred to Appleton and that Holland be closed. Some of the equip-
ment now in Holland could be utilized by Appleton to increase its
cane grinding capacity and to maximize the cane supply now pro-
cessed in both factories,

In order for Holland to optimize its sugar production, the grinding

period would have to be reduced from 180 to 1 Ì4 days. Allowing
for 25 per cent lost time, 45 T. C. H. will be reduced to 35 T. C. H.
or 840 T.C D. This hardly can be regarded as favorable. For
this reason and because of the inadequate cane supplies, the
closure of Holland is economically practical.

If, however, it is decided to keep Holland operational, the follow-

ing factors, and based on the proposed grinding rate, must be
considered:

Milling: The milling tandem has adequate capacity to

meet the grinding rate.

Juice Heaters: The capacity for the juice heaters also

is adequate.

Clarification: The present clarifier has the exact ca-

pacity to handle the projected cane grinding rate. The
present 8' x 6' filter is of insufficient capacity. The filter
should be replaced by a new 8' x 10' unit for reasons of
future maintenance.

Evaporators: The capacity of this station is regarded

as adequate.

Vacuum Fana: This station has adequate capacity.

Pan Supply Tanks: This station has adequate capacity.

1 A
iHCHioN a POWTCw.iNC.
 99

0 Crystalliz1rsi Tnis station has

adequate rapacity.

Centrifugals; Although the high grade centrifugal is

of adequate capacity, the operation of this station is very
delicate as only one machine is available. The instal-
lation of a second unit is recommended to eliminate the
chance of total failure.

The low grade i entrifugals are of adequate capacity to

meet the proposed grinding *-ate.

Capital Costs: Total capital cost needed for the con-

tinuation of Holland, at the proposed grinding rate, is
estimated at $68, 000 ($*5, 000 and $H, 000 for filter
and c entrifugals, respectively).

As stated previously, the closure of Holland is recommended.

This recommendation has taken into account the projected future
potential of Saint Elizabeth Parish for sugar production especially
when mechanization is introduced.

The possibility of planting 10-15, 000 acres of cane in the area served
by two syrup units processing 4,000 T.C.D. must be visualized.
These units should house diffusion plants instead of the conventional
nulling tandems. This because the price of a diffusion pant is
less, and its yearly maintenance < osts are lower. , mal » hile
a modern and well-equipped nulling tandem might reach tr
cent of sucrose extraction, a diffusion plant can «asily obtain
per cent extraction. The ì por cent difference may Vf•
extra 1. 200 tons of sugar from the proposed acreage. This shoulu
have a value of more than $100,000 annually.

• h» «H . of lamaican sugar must remain competitive

In summary, the prie e ot Jamaican » g oresent status
with the price of sugar produced in other areas. Th^Pr"en*s'tlv|,
of equipment at Holland, however, is inadequate to •*>*g«^
contribution to the future expansion of sugar f^«•^• 9
This future production will be better served W- ° ^;
using the diffusion method rather than juice extraction by the mill
ing tandem of Holland.

• ANDERSON ft POUTCRJNC.
 MONTHLY RAI NT ALL. INCHES 100
•ASCO ¿N \<J\Q ACtuAL FIGURCS

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102

HOLLAND- ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
PROCESSING STATION __

Station C apacity T C D.

Mills 1,368

Juice heaters 3,816

Clarifier« 768

Filters 678

Evaporators 900

1,540
Vacuum pans
1.000
Syrup supply tanks

A and B molasses tanks 1.020

C crystallieers 1.415

High grade centrifugals 1, 100

1 825
Low grade centrifugals
 103

HOLLAND: HEAT BALANCE FOR THE EVAPORATION STATION-

SHOWING THE STEAM CONSUMPTION IN B. T. U. NEEDED TO OBTAIN
THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL.

Heat Evaporation J uic e

Content Pounds Per Cent
Calculation for Flow of Heat B. T.U. per Hour Brix

fI Juice to §1 95,992 12.74

Exhaust to #1 29,700 x 945 28,066,500

Add flash from heater 95,992
(240-235) 479.960
Available for Evaporation 28,546,460
Evaporation 28, 546,460 -:- 956 29,860

Transfer to # 2 66,132 18.49

2 Vapor from #1 28,546,460

To heaters and pans 12,000x956 11,472,000

Balance 17,074,460
Add flash 66, 132 (235-207) 1,851,696
Available for Evaporation 18,926, 156
Evaporation 18,926,156 -:- 975 19,411

Transfer to # 3 46,721 26. 17

f3 Vapor from # 2 18,926, 156

Io heaters 8, 500 x 975 8,287,500

Baiane e 10,638,656
Add flash 46,721 (207-184) 1,074,583
Available for Evaporation 11,713,239
Evaporation 11,713,239 -:- 991 11,819

Transfer to #4 34,902 35.03

H Vapor from # 3 11,713,239

Add flash 34,902 (184-124) 2.094, 120

Available for Evaporation 13,807,359
Evaporation 13,807,359 -:- 1.028 13,431

L eaving # 4 as Syrup 21,471 56.95

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105

INNSWOOD
Saint Catherine Parish

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MNDCRION « "»TI», INC.

 106

Innswood

Based on the accumulated technii al data on the existing cane quali-

ty, and on the actual sugar production, Innswood should be con-
verted to a syrup producing unit. At the same time, the crop
duration should be shortened to 118 days per year lasting from Feb-
ruary 1 to May 29. Shortening of the season will increase sucrose
in cane from 10.01 to 10.84 per i ent. It is estimated that 0.89
per cent of this additional sucrose will be available for sugar produc-
tion, or an additional 1, 590 tons of sugar valued at $150,000 will
be realized.

To attain this goal the hourly grinding rate must be increased while
the lost time is reduced. The lost time factor may be decreased
significantly simply by shortening the i rop season. Additionally,
the time reduction for machinery operation would result in better
maintenance schedules for the plant. These reductions and savings
would effect a total production of ¿¿0, 7 00 tons of cane during the
proposed i rop period, or 9} T. ( . H.

In order for Innswood to produce its projected T. C. H. rate, the

following factors must be considered:

Milling: The milling plant is able to produce effectively

with the existing power.

luice Heaters: Juice velocity through the heaters is low.

The increased capacity will ine rease the juice velocity
from 4. 55 to 6. 96 f. p. s. , an ideal condition for this
station.

Clarifier: By continuing the use of a i oagulant and by

i hanging the Oliver filter to a Rapifloc system, the fil-
tered juice could be sent directly to the evaporator.
This arrangement provides adequate clarification capa-
city during average rainfall years. An additional poly-
cell clarifier should be installed in the future.

Evaporation: The capacity must be increased by adding

a preevaporator vessel in front of the present quadruple
effect. With a proper cleaning schedule, the evaporation

tANDERION & »«ORTÏR.INC.

 107

rate could he increased from the present 4. 75 to 6.00

pounds per square foot per hour which would accommodate
1, 970 tons of cane per day. To reach 2, 400 T. C. D.
a preevaporator with about '>, 500 square feet of
heating surfai e ¡should be added.

In addition, to increase syrup from 52 to 72 degrees

Brix, a flash evaporator has to be placed after the
quaduple effect.

The new grinding rate will produce 5^.2 tons of

bagasse. This is based on the quantity of bagasse
as being equal to une weight multiplied by per tent
fiber in cane divided by per i e..c fiber in bagasse.
With both turbo-alternator sets in use, the hourly steam
requirements (based on i 5 pounds of steam per indicat-
ed horsepower allowing for losses and that one pound
of bagasse will produce 2. 5S pounds of steam) are esti-
mated at 12 3, 250 pounds. Present boiler capacity
rated tor production of I 55, 000 pounds of steam per
hour, is sufficient.

Capital Costs: It is estimated that the following capital

expenditures for processing equipment will be needed
to convert Inns wood to a syrup unit proi essing 2, 400
T.C.D.: $20, 000 for the preevaporator, $12,000
for the poiycell clarifier ano $50,000 for the complete
flash evaporator arrangement. Therefore, the total
capital investment for processing equipment may be
estimated at $t>2, 000.

• ANDERSON & POHTtW, INC.

 Ifl w 108
> > MONTHLY RAI ff ALL, INChTS
<< BASCO ON -\0 YEAR H£AN
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 IM NÉIMMHÉMi

no

INNSWOOD: ACTUAL CAPACITY IN TONS CANE PER

DAY FOK MAIN EQUIPMENT IN EACH
PROCESSING STATION

Station Average T. C. D.

Milling tandem 2,400

Juice heater 2,400

Clarifier 1,560 - 1,800

Filter 2, 740

Evaporator 1, 970

Vacuum pan 2, 185

Supply tank, syrup 580

Supply tank, molasses 2 430

C crystallizer 1 ,560

High grade centrifugal 2 ,050

Low grade centrifugal 1 ,725

 111

INNS WOOL): HEAT BALANCE KOK ..Ht: EVAPORATION STATION

SHOWING THE STEAM CONSUMPTION IN B. I'.U. NEEDED TO OBTAIN
THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Hrat Evaporation Juice

Content Pounds Per Cent
Calculation for E low, of Heat B. T. U. Per Hour Brix

" 1 Juice to # 1 5 psi 119551 13.96

Eshaust to #1 (10 psi) 29000 x ^52 27,608.000

Add Flash from preheater (2 30-22M
1 19551 478,204
Available for Evaporation 28,086,204
Evaporation 2 8086204 -:- 960 29256

Transfer to # 2 6000 Bq. ft. 90295 18.48

#2 Vapor from # I 0 psi 28,086,204

To heater 9000 x 960 8,640,000

Balance 19,446,204
Add Flash 90295(226-2 12) 1,264,130
Available for Evaporation 20,710,334
Evaporation 20710334 -:- 970 21350

68945 24.20
Transfer to # 3 4500 sq. ft.

* 3 Vapor from # 2 10" 2 0,710, 334

l.> heaters 5400 x 982 5,302,800

Balance 15,407,534
Add Flash 68945 (212-194) 1^241,010
Available for Evaporation 16,648,544
16953
Evaporation 16648544 -:- 982
51992 32.09
Transfer to # 4 3500 sq. ft.

*f4 Vapor from # 3 26 16,648,544

Add Flash 51992 (194-134) 8° BPR 3,119.520

Available for Evaporation 19,768,064
19342
Evaporation 19768064 -:- 1022
32650 51,11
Out of # 4 Syrup 3500 sq. ft.
 •MMIÉiMHillÉ

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 in

Investigation Techniques

As stated previously, the information received for each plant was

too voluminous to include in this report. Therefore, the methods
used in the evaluation of eat h processing plant are included only
for the Innswood plant. Calculations for the other plants were made
in a similar manner and formed the basis upon which the recom-
mendations for each plant were i.iade.

The dimensions of the mills are UV'xbO". Each is powered by a

300 h.p. engine. Linear speed for the rollers is 45. b5 f. p. m.
With It) per cent fiber in cane, this tandem is capable of grinding
100 T. C. H. The engine capacity of M)0 h.p. per mill is adequate
to attain this grinding capacity.

Therefore, the maximum daily grinding capacity is 24x100 or

2,400 T. C. D. Present amount of cane processed: 220,709 tons.
Effective number of hours available for grinding: 2, 207 or 84
per cent of total time. Lust time during grinding season: 420
or H> per cent of total time. Total time during season: 2,627
or 100 per cent of total time or 10'* days. In the event that cane
supplies increase by 20 per cent in the future, total grinding time
will have to be extended to 131 d^ys.
Juit
«LÜ£aierB: Chianti! y of juice to the heaters amounts
to ÌÌ7, 727 pounds per hour with 14. 58 per cent Brix in
juice.

One cubic foot of juice weighs 65. 92 pounds.

Juice velocity through heaters 1 or 2 is calculated at

4. 55 f.p. B. ; somewhat low. This velocity will increase
to 6. 92 f. p. s. and will be correct when grinding 100
T.C.H.

Heat transmission coefficients:

Present, K = 230 - 32 or 143 Future 230 - 32 or 162

0.9+2.2 O- 9+iii.
4755 6.96

• A NfitHION * *0»TK».INC.
 114

Future heating surface required:

HS = 117,727 x 0.9 x 2. 3 log 230 - 85 or I, 500 square

lb2 230 - 215 feet

Capacity of the juice heating station is capable of grind-

ing 100 T.C. H.

When using two heaters in series the steam consumption

by these heaters will be:

117,727 x 0. 9 x (215-85) or 14,400 pounds per hour.

958

Clarifier: Presently installed is "Bach" 20 foot diameter

having a volume of 4, 700 cubic feet.

Quantity of juice flowing to the clarifier equals 118, 880

pounds per hour or 1, 803 cubic feet per hour. Thus, the
retention time for juice in the clarifier is 4,700 or 2. 6 hairs.
1,803

A three hour retention time for juice is considered opti-

mum. Therefore, the capacity for the clarifier is rated
at 65 T. C. H. ; or I, 560 T. C D. If the juu es are of very
good quality; the minimum retention tune for juice may
be reduced to 2. 25 hours. In this case the clarifier
may be rated_2._6_ x 65 - 75 T. C. H. ; or 1, 800 T. C. D.
2. 25
Filter: A "Dorr Oliver" filter, 8'xl2' having a filtra-
tion area of 300 square feet is presently installed. As-
suming a cake thickness of ¿" and 20 r. p. h. for the drum,
the amount of filter cake produced equals 3,709 pounds
per hour having a volume of 106 cubic feet per hour dried
cake.

Required
iequi area for optimum filtration: 106x12 or 255 square
20x0.25
feet.

Present station capacity: 300 x 65 - 76. 5 T. C. H. ; or 1, 840

T. C. D. 255

IANBCRION a *0*TC».INC.
 115

Filtration capacity may be increased if more than 4"

thickness for cake is allowed. In this case the per cent
sucrose lost in flltercake will slightly increase. Under
this circumstance the capacity of the filter can be in-
c reased to: 114 T. C H; or ¿, 740 T. C. D.

Evaporators: Total heating surfa^ e (H. S. ) at present

equals 17, 500 square feet in the form of a quadruple
effect with bleeding of vapor from the first and second
vessel.

//EA TE* A/o /

U e ATet A/OS, 2ANUO

5' p*i
op ZI I
VACUUM VACUO Ht

- # r-
¿,5oo L_ SCOO
99- FT Sa FT

Total evaporation obtained equals 83,289 pounds per hour

io»i evdpui«u pounds per hour
with an evaporation rate of Mf ¿8J or ^ F

per square foot. *'»'

Th. result 1. low for thl. equipment and ^£»~*»

rate may be six pounds per square foot per hour i in
."stations are leaned well and/or more frequently.

MNDIMON A «UTIMNC.
 '•'«

116

The ultimate rapacity may be augmented to produce

6 x 65 82 T. C. H. or 1, 970 T. C. D.
4.75

Pan Supply Tankt.: Installed are -

4 tanks with a total content of 580 cubic feet for

syrup.

4 tanks with a total content of 2,025 cubic feet

for A molasses.

4 tanks with a total content of 2,025 cubic feet

for B molasses.

Capacity for syrup tanks 580 x 24, or 580 T. C. D.

24

Capacity for A+B Molasses tanks^050 x 24, or

40
2,430 T. C. D.

The quantity of nyrup produced is 385 -^ fe ^^hoTr*'

Retention time for syrup storage is only 5|£ -1.5 hours.
385
This time span is Insufflent and storage capacity must
be at least adequate for one complete pan load. The A
pan having 500 cubic feet of volume, will utilize 900
cubic feet of syrup at the actual Brix (before evaporation
in the pan).

Vacuum Fans: There are four pans.

Pan Number J_ A -Ì —
Calandria Calandria Calandria Calandria
Type A B c Gram
Masaacuite Type
Heating Surface, 800 800
750 740
Square Feet
Strike Volume, 500 500
500 700
Cubic Feet

• ANOCfvaoN t FOHTCH.INC.
 '".»*tó*JA-'

117

Pan Number

Pan Schedule -
Strike Volume,
Cubic Feet 500 500 500 500

Type of Strike A B C Grain

Duration of Strike,
Hours A i b 2

Volume of Strike,
Cubi< Feet per Day:

mc.A, 3,600-
Strikes 7.2
Hours 18

Me B, 2,250-
Strikes *•6
Hours 13.5

me. C, 2,200-
Strikes 4.4
22.0
Hours

Grain f Magma- 1.5+6.0

Strikes 15
Hours

Total Cubit Feet per Day - H, 050

Per Cent of Time

available for pan 63
occupation - 75 5b 92

Per Cent of Time

still available for 37
pan occupation - 25 44

lANOtMON a PO«T«A.!"C.
 *i
a

118

Average time for pan oc. i upation: 71.4 per cent.

Average time available ior pan oi cupation: ¿8. 6 per cent.

Pan station capacity: UJO x 65 01 T. C. II. , equivalent

71.4
to a grinding capacity of 2, 18T I.e. D.

Crystallizers; There are five water cooled units for

serving mas sacuite C, each having an adequate volume
to receive a templete pan load. Daily. 4. 4 C type
strikes are produced. While one c rystallizer is being
purged, another must be empty to re« eive the next pan
load. Therefore, 3 ì c rystallizers are filled at all
times.

Retention time for the massacuite is ^_5 x 24 or 19

4. 4
hours. This is the minimum allowable time permitted
for effective cooling of massacuite by water cooled
units.

Therefore, the capacity for the crystallizer station

can be rated as 65 T. C H. or 1. 5o() T. C. D.

miDlE^^ñ^1^ *Jre8ently installed equipment

includes;

Six W. L. 42«'x24" 1.200 r.p.m. with manual sugar

discharge.
One W.L. 42"x24" 1,200 r.p.m. with semi-automatic
sugar discharge.

Total amount of massacuite to be cured equals 5,850

cubic ieet per day.

Capacity for each! basket:

t i t. 8.
a W*H cubic
, nbic feet.
itei. Assuming
an actual operation of 20 hours daily, and b and 1U
cycles per hour for the manual and •eml-auuto"*;""
equipment respectively, the capacity for the station
can be rated as:

IANOMIO N ft PORTEft.lMC.
 *i

119

(6x8.38x16x20) 4- (l.x8. Ï8xl0x20) or 7,710 cubic feet

per day.

Actual amount of massacuite to be processed: 5, 850

cubic feet per day.

Station capacity: 7,710 x 65 : 85.15 T.C.H. or 2.050

T.C.D. 5,850

Low Grade Centrifugals: There are at present two con-

tinuous W. S. , fully automatic low grade centrifugals.
The capacity of continuous centrifugal« depends on the
type used, the quality of the massai uite. and whether
steam is applied continuously during curing.

A safe capacity of bO ruble feet per hour per machine

can be assumed. Therefore. Station capacity would
equal 2x50x20 or 2,400 cubi< feet per day based one
one day a« being equivalent to 20 hours of active curing.

Station capacity is adequate to produce:

2,400 x 65 - 72 T.C.H. or 1,725 T.C.D.
2,200

|AN«C*IO« * *0*TC«,INC.
 '*ì

120

INNSWOOD: STEAM REQUIREMENTS IN POUNDS PER HOUR

NEEDED FOR Vì\F CONVERSION OF THE
FACTORY INTO A SYRUP PHODUC1NG UNIT,
TAKING INTO ACCOUNT IHK INCREASE IN THE
HOURLY GRINDING CAPACITY IN ORDER TO
SHORTEN THE CROP DURATION

Pounds per hour

¿9,000
Present required steam consumption:

Estimated allowance tor radiation and

2,900
condensation, 1 0%
31,900
Present total steam requirement:

Total future steam requir, in- :.t, inclusive

steam needed by juice heaters, in order
to reach 100 T. C. H. grinding capacity
50, 000
(rounded off):

Quantity oí syrup concentrated to 52

32,094
degrees Brix:
23,179
And concentrated to 11 degree* Brix:

Quantity of water evaporated between

52 and 11 degrees Brix at present 8,915
grinding rate:

Quantity of water evaporated between

52 and 72 degrees Brix with future 14,000
grinding rate:

Future quantity of steam required by

a single effect flash evaporator, 15,000
allowing for heat losses:

Total requirement needed in the form

of steam to produce syrup of 72 degrees 65,000
brix at the increased grinding rate:
 121

INNSWOOD: SUGGESTED OPERATIONALAND DESIGN

PRINCIPLE FOR A FLASH EVAPORATOR
TO CONCENTRATE SYRUP FROM 52 TO
72 DEGREES BRIX

Specifications: Í65 tubes, each bei rig 7 feet long between

plates and having 1-1/2 inch O. D.

Vapor pipe diameter 22 inches in urder to

maintain a vapor velocity of 165 fps. and
based on a vapor volume of 4 il eft/sec
(sp. volume of vapor at 26 inches vacuum
174 cf/lb). Approximate quantity of in-
jection water needed for condensation:
750 gpm.

MATCH
M.J,

9ooo*M*.

HVTWUl.
 122

JAMAICA SUGAR ESTATES

Saint Thomas Parish

DWOITMV »MM

d
J. '"—:gfJÎHIIt
JAMAICA d
^5
djMONVMUBK

IANDIMON * poNTCn.INC
Jamaica Estates

It is recommended that the Tamaua Estates factory be converted

to a syrup producing unit. Based on the sut rose distribution in
cane the grinding capacity should ne increased from 77.5 T. C. H.
to 97. 0 T. C. H. or 2, 330 T. C D. The proposed grinding rate may
be limited by the following causes:

Milling: The linear speed lor the rollers is inadequate

due to the present power supply for the milling operation.
There are two alternatives which can remedy this condi-
tion:

The existing first engine i an remain to provide power to

the combination crusher and the first mill. A new 300
h. p. turbine should be installed to power the second mill.
The second existing engine should remain to power the
third and fourth mills. With this system the linear speed
can be increased from 2'J to 40 f. p. m. and provide ade-
quate power for the proposed grinding rate. At some
future date the two existing engines should be replaced
by a 600 h. p. turbine. The total investment needed for
these improvements may amount to $180, 000.

The second alternative would be to incalí a uine diffusion

plant for 2, 000 T. C. 1). Stu h an installation would allow
two of the; existing mills to dewater the bagasse and make
it suitable for firing the boilers. A shredder should also
be installed in front of the diffusion plant together with
one mill in order to extract -\ part of the juice. The
first expressed iui« e < an be mixed with the juice obtained
from the diffusion plant. The price for the diffusion plant,
including installation and remodelling, is estimated at
$450, 000.

Comparing the alternatives and although a difference of

$270,000 is apparent, the diffusion plant will increase
the actual reduced extraction by 4 per c ent recovering
an additional 750 tons of sugar annually valued in ex-
cess of $70,000. This is based on the actual reduced
extraction of 92.6; probable extractionof 06.6; sucrose
in cane 10.2; cane ground ¿10,000 tons; fat tor for avail-
able sue ro.se . 89; and a prit».' tor sugar $94 per ton.
Therefore the installation of a diffusion plant, will prove
more beneficial than the replacement of the units now
powering the present milling tandem.

Juice Heaters: The present .station has an adequate cap-

acity. Vapor supplied to the heaters is received from
the third evaporator vessel, a rathe» r unusual arrange-
ment. This vessel supplies vapor having a vacuum of
about 11 inches mercury, <t situation which makes it very
difficult for steam traps to operate without fault. Also,
the vapor consumption for the heaters, calculated at
640,000 cubic feet per hour, requiring large diameter
piping, about 1 8" I. I). , in order to maintain an ac eep-
table vapor velo» ity.

Clarification: The clarifier capacity is too small for the

proposed grinding rate. A small polycell type clarifier
should be added.

In addition, the filter is too small. Variations in cake

thickness may prove adequate to bring this station to
capacity, accepting the slightly ine reased sucrose loss
in »ake.

Evaporators; The station's performance is excellent.

The overall evaporation rate of 1. ¿^ pounds per square
foot per hour is high. No further improvement tan be
expected from the present I 0, S00 square feet of heating
surface. The present density of syrup is only b<? degrees
Brix. This verifies that the * apa» ity ol this station has
been reat hed. A vaporcell should be installed in front
of the existing quadruple effect. This < ell would provide
all the vapor needed by the heaters while a juice with a
higher density than at present would ho sent to the quad-
ruple effect. A cell, with L, -M)0 square feet heating
surface would produce the needed vapor for the heaters
and also concentrate the juice from the present 13.22
to 15. 50 degrees Brix. At the same time the evaporation
load for the quadruple effect decreases from 119, 622 to
102,100 pounds per hour.

9ANDCRSON & POKTCB.INC.

•..ÄftÄ".'-

125

The last vessel should be replai ed by a new one having a

5, 000 square foot heating surfat e as the vapor cell ins-
tead of the third vessel will now supply vapor to the heat-
ers. The present last vessel is the exact size to serve
properly as the vapor i ell. Only one new vessel with a
5, 000 square foot heating surface will be needed increas-
ing the total capacity for the evaporation station to
21,000 square feet of heating surface. This is considered
adequate to service the proposed grinding rate of
2, 3 30 T. C. D.

Capital Costs: The costs involved to increase the grind-

ing rate to 2, 330 T. C. D. and change the factory to a syrup
producing unit are estimated as follows:

Turbine for third mill ine hiding

secondary gearing and installation $40,000

Clarifier 10,000

Vapor Cell 25,000

Total $75,000

• ANDERSON « PORTKR.INC.

WimSBM^i^y... WPfW»
=H
 127

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US

JAMAICA ESTATES: ACTUAL CAPACITY IN TONS CANE

PER DAY FOR MAIN EQUIPMENT
IN EACH PROCESSING STATION.

Station Capacity T. C. D.

Mills 1,872

Juice heaters 6,330

Clarifier* 1,800

Filters 1,451

Evaporators 1,680

Vacuum pans 2,280

Syrup supply tanks 1,440

A and B molasses tanks 3,456

C cry stalli «er s 3,720

High grade centrifugals 2,590

Low grade centrifugals 2,110

 129
JAMAICA ESTAIS: Lib:A". BAl./'J'nT r'UH IHK r VAPORATION
STATION SHOWING 1'HE STEAM CONSUMPTION iN Il.T.U. NEEDED TO
OBTAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Pounds Per Cent
B. T.U. per hour Brix
Calculation for Flow of Heat_

157,157 13.22
#1 Juice to #1 4. 7 5 psi

Exhaust to #1 (10 psi) 33,200 x 951 31,573,200

Add flash from pre-heater 157, 157 x
(235-230) 785,785
Available for Evaporation 32,358,985
33,707
Evaporation 32,358,985 -:- 960

123,450 16.82
Transfer to #2

2-1/2' 32,358,985
#2) Vapor from #1

Deduct for heaters 3, 500 x 960 3,360,000

28,998,985
Balance
Add flash 123,450 (230-210) 2.469,000
Available for Evaporation 31,467,985
32,307
Evaporation 31,467,985 -:- 974
91,143 22.79
Transfer to #3
31,467,985
#3) Vapor from #2 H"
1,458,288
Add flash 91,143 (210-194)
32,926,273
Available for Evaporation
33,495,
Evaporation 32,926,273 -:- 983
57,648 36.03
Transfer to #4
32,926,273
#4) Vapor from #3 26"

Deduct for heaters 16,000 x 983 15.728.000

17,198,273
Balarle
__3. 458, 880
Add flash 57,648 (194-134)
20,657,153
Available for Evaporation
20.212
Evaporation 20,657,153 -:- 1,022
37,436 55.49
Leaving #4 as Byrup
 •tMHkli

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 131

LONG POND
Trelawny Parish

Yfillrci

• A NOIKION * POMTIW.IMC
 HZ

Long Pond

Judging from the per cent au«:rose distribution in cane it is recom-

mended that the crop duration to be shortened to 151 days and the
grinding rate increased to 95 T. C. H. or 2, 280 T. C. D. Also, Long
Pond should be promoted to a syrup producing unit as this move
would be in the interest of the larRe distilling facility now employed
by Long Pond. The increased grinding capacity, the elimination
of power requirements by pans and centrifugals and the resulting
bagasse surplus will allow the bagasse to be baled and stored in
the back of the end-factory. Here it , an be utilized for one boiler
after the completion of the cane « rop and for continuation of the
distilling plant. Similarly, with decreased steam consumption for
syrup production during crop, the present boiler facility will be
able to deliver an increased steam supply to the distilling units
during this period.

To obtain the proposed grinding rate, the following factors are to

be considered:

Milling: The present capacity of this station is adequate.

Juice Heaters: This station has also an adequate capa-

city.

Clarification: The preset clarifier capacity is inade-

aTuTteT Instead of adding a third clarifier unit it would
be preferable to install a new polycell type clarifier
which will replace both outdated units. One 16' diameter
polycell type clarifier will easily handle the projected
cane grinding rate.

The present capacity of the filtering station is adequate

for the proposed cane grinding rate.

Evaporators: The total « apacity for present operations

is adequate but will be barely sufficient for future re-
quirements. To secure some margin of safety, a new
vessel should be added to the existing evaporation station.
The easiest and most inexpensive way in which to achieve
efficiency is to add one vessel having a 2, 400 square

• ANOCRSON * ponrtm, INC.

 133

foot heating surface as the last vessel, and use the exist-
ing first vessel as a preevapo rator. This will enable the
evaporation station to handle ¿, 500 T. C. D. , and will se-
cure a Brix for syrup of high density.

Capital Cost: The estimated capital cost to increase the

capacity and to operate as a syrup producing unit is $41, 000
($16,000 and $25, 000 for clarifier and evaporator improve-
ment, respectively). It should be noted that the present
vacuum pans may be utilized by the central end-factory
as Long Pond recently has been renovated. These pans,
however, maintain their vacuum by means of double stage
steam ejectors; a system whic h is of a doubtful value for
maintaining vacuum effectively since the degree of vacuum
completely depends on the working pressure for the
boilers. Efficiency drops rapidly with even the slightest
reduction in steam pressures. Also, there is little
flexibility to ensure the needed evaporation rate at the
beginning of each pan strike with the result that the syrup
may bee orne overheated and darkly colored. In the
event the pans will be included for the erection of the
central end-factory, the stea.m ejectors should be replaced
by Nash type individual rotary vacuum pumps ($6, 000
for four pumps).

• ANOCRSOM & POftTCR.INC.

 S*
SS
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MONTHLY RAINFALL, INCHES
134
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 135

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 136

LONG POND: ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
PROCESSING STATION

Station Average T. C. D.

Mill« 2,256

Juice heaters 2,348

Clarifier« 1,850

Filter! 2,508

Evaporation 2,050

Vacuum pan» 2,420

Syrup supply tanks 2,250

A and B molasse* tanks 2,200

C Crystallizers 4,000

High grade centrifugals 3,900

Low grade centrifugals 3,050

 137
LONG POND: HEAT BALANCE FOR THE EVAPORATION
STATION SHOWING THE STEAM CONSUMPTION NEEDED TO OB-
TAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Pounds Per Cent
B.T.U. per Hour Brix
emulations for Flow of Heat
163, 538 13.42
fl Juice to #1

exhaust to #1 (15 psi) 43,200 x 945 40,824,000

Add Flash from pre-heater 163, 538
(249-240)
1.471,842
Available for Evaporation 42,295,842
Evaporation 42,295,842 -:- 952 44,428_

119, HO 18.42
f ransfer to #2
42,295,842
f2 Vapor from #1
19.992,000
To Heaters 21,000 x 952
22,303,842
Balance
Add Flash. 119,110 (240-220) 2f382,200
24,686,042
Available for Evaporation
25,581
Evaporation 24,686,042 -:- 965
93,529 23.46
Transfer to #3
24,686,042
*f s Vapor from #2
2,338,225
\dd Flash. 93,529 (220-195)
27,024,267
Available for Evaporation 27,519
Evaporation 27,024,267 -:- 982
66,010 33.24
Transfer to H
27,024,267
#4 Vapor form #3
4,026,610
Add Fias. 66,010 (195-134)
31,050,877
Available for Evaporation 30.382
Evaporation 31,050,877 -:- 1,022
35,628 61.59
Leaving #4 as Syrup.
 X

38

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 139

MONYMUSK
Clarendon Parish

[^•vmeotc

eJiMMJ»»\jWBW rv ^
QNVMUtK

lANOCHtON ft PORT«». »HC.

 140

Monymusk

The crop duration should be reduced to 130 days per season.

Accordingly, an average grinding rate of 312 T. C. H. or about
7 500 T C D. based on the 1970 cane supply, must be obtained.
Monymusk'should remain a crystallizing unit. The following fac-
tor, are to be considered to increase the grinding rate from 204
to 312 T.C.H.:
Milling: The speed of the mills should be increased
f^mlhe present 49. 9 f. p. m. to 55.0 f. p.m. The
faster speed will require the utilization of 67 5 h. p.
per mill instead of the present 600 h. p. The mere ed
power delivery is within the capability of the existing
.team turbines. The maximum speed for the first mill
i. estimated to be at 6. 05 r.p.m. delivering 56 4 f.p.m.
As the proposed grinding rate will require 55. 0 f. p^rn.
at 5. 9 r. p. m. no additional .-apital investment for mill
ing appears to be necessary.

Juice Heaters: The present capacity of this station is

^ ^sufficient to service the ine reasedgrinding
rate. The juice velocity in he heaters, however, is
rather low for the present cane grinding capacity
(4. 4 f. p. s. ) and the ine reased grindm* rate more than
lm correct this with a resulting increase •^•>
mission rate. Therefore, the presen .UUon »
quate for servicing the proposed grinding rate.

Clarification: The present capacity of ** £¡£^' A

insufficient."A small polycell unit should be added
12 foot diameter unit could service 5 m -^2 000
and would be adequate for reaching the im.rea.ed
T.C.D.
/ fV,Q filters will be too low.
Similarly, the capacity °\**•e" WqnAre foot filter-
The installation of a new 10 x20 (62 q ^.^
ing area) is recommended. This win o
capacity to 340 T. C. H.

INC.
•ANDCH.O N a ÍOKTIH,
 141

Evaporation; Heat balance data reveals that the present

quadruple effect is functioning very efficiently. This is
mainly due to the bleeding of vapor from the #1. 2, and
3 vessels. However, the present installation will be too
small to service the proposed grinding rate.

The most practical solution would be to convert the pre-

sent installation into two quadruple effects; the first
effect comprising the present la, lb, 2a and 2b vessels,
while two new vessels would be added to operate in con-
junction with the present #3 and 4 vessels to form the
second quadruple effect. The two new vessels each
should have 7,500 square feet of heating surface.

The new arrangement will be comprised of:

Ouadruple #1: 7, 500+7,500+6,875 + 6,875 or 28, 750 square

feet total.

Ouadruple #2: 10, 000+7,500+7, 500+7, 500 or 32,500 square

feet total.

About 20, 000 pounds of vapor per hour can be obtained

from the first vessel of quadruple #1 and about 5,000
pounds of vapor per hour can be bled from the second
vessel of quadruple #2, for use by the juice heaters.
The rest of the heaters will be supplied by exhaust
steam.

Pan Floor: Tanks would have to be added as was sug-

gested for the Frome installation. Five additional
tanks, each having 750 cubic foot capacity would be need-
ed for syrup while four additional tanks of the same size
are needed for the A and B molasses. Also, one pan
having 2,000 cubic foot massacuite capacity will have
to be added.

Crvstallizer»: This station c ould handle the increased

grinding rate fairly well.

lANOIDION * PO«TÏ*,INC.
 tttmímm

142

Centrifugals: The present capacity to service the expect-

ed increase in flow for A and B Massacrate is sufficient.
The installation of one additional machine is preferred to
handle the needed capacity for the C Mas sacuite.

Capital Cost; The cost to increase the different stations

to the proposed grinding rate is estimated as follows:

Clarifier $ 10,000

Filter 35,000

Evaporation, inclusive of pumping

arrangement and condensor equip-
ment 100,000

Pan floor supply tanks 5,000

Vacuum pan 45,000

Low grade centrifugal 20.000

Total $215,000

• ANOCNSON A FOWTCW.INC.
 ÎT
MONTHLY RA irr ALL, INCHES 143
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 145

MONYMUSK: ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH Í
PROCESSING STATION

Station Average T. C. D.

Milling tandemi 6,800

Juice heaters 7, 200

Clarifier» 5. 000

Filter« 4, 512

Evaporator« 5, 000

Vacuum pan« 6, 550

Supply tank« for lyrup 3, 744

Supply tank« for A and B

mola «se« 4, 598

C crystallize• 6, 920

High grade centrifugal« 7 585

Low grade centrifugal* 6 ,720

 146
MONYMUSK: HEAT BALANCE FOR EVAPORATION STATION
SHOWING THE STEAM CONSUMPTION IN B. T. U. NEEDED TO OBTAIN
THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Pounds Per Cent
Calculation for Flow of Heat B. T. U. Per Hour Brix

#1 Juice to #1 392,515 13.95 i

Exhaust to # 1 (30 pei) 89500 x 928.2 83,073,900
Available for Evaporation 83,073,900
evaporation 83073900 -:- 941 88,282

Transfer to # 2 304,233 18.00

# 2 To Heaters 10,000 x 941 9,410,000

Balance 73,663,900
Add Flash 304233 (257-235) 6.703,972
Available for Evaporation 80, 367,872
Evaporation 80,367,872 -:- 955 84,154

Transfer to # 3 220,079 24.88

# 3 Vapor from # 2 80,367,872

To Heaters 26250 x 955 25.068,875

Balance 55,298,997
Add Flash 220079 (235-208) 5.942, 133
Available for Evaporation 61,241, 130
Evaporation 61,241,230 -:- 976.2 62.734

157,345 34.70
Transfer to # 4

# 4 Vapor from #3 61,241,130

To Heaters 15,000 x 976,2 14,643,000

Balance 46,598,130
Add Flash 157,345 (208-134) 11.643.530
Available for Evaporation 58,241,660
56.987
Evaporation 58,241,660 -:- 1022
100.00 54.56
Out of # 4
lu
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NEW YARMOUTH
Clarendon Parish

dî««*«!

KINSSTOM 'tfllflt

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in

• MDCNtONi *©*TI«.»"C.
 MHH

14Q

New Yarmouth

It is recommended to shorten the crop duration of New Yarmouth

to 134 days per season. To process the cane tonnage, the grinding
rate would have to be increased from the present to 120 T. C. H.
or 2, 880 T. C. D. Also, New Yarmouth should remain a sugar
crystallizing unit. The proposed cane grinding rate will prove
beneficial to the steam requirement of the factory as well as the
adjoining distilling operations due to the increased availability
of bagasse.

The following points should be noted:

Milling; The present milling tandem has just enough power

and capac ity to reach the proposed cane grinding rate.

Juice Heaters: The juice heaters have sufficient capacity

for the future cane grinding rate.

Clarification: The present clarifier is too small. A

possible solution would be to modify the present clari-
fier into a polycell type unit, or to add another small
polycell type unit.

The capacity of the filtration station will be somewhat

small. The resulting moderate increase in loss of su- U)

crose of the filter mud will not warrant investment

for an additional unit.

Evaporators: The present capacity of this station would

be too small to handle the proposed cane grinding. A
new dead-ended vessel (vapor cell) should be installed.
The vapor cell, with a 2,500 square foot heating surface,
is supplied by 25 p. s. i. exhaust steam and will exhaust
vapor at about 10 p. s. i. for feeding the vacuum pans.
A vapor connection to the rest of the evaporation station
will not be possible since the vapor cell is dead-ended.

A free vapor exhausting arrangement should be provided

in the event the vacuum pans become inoperative. Other-
wise the evaporation rate of the vapor cell will be signi-
ficantly reduced.

SANDE»»ON * POHTM.INC.
 150

Vacuum Pan st Either a new pan shoul t be added or an

existing small pan should be replaced by a larger unit.
The latter is preferred because there are fewer compli-
cations in securing the structural support and available
spacing. A pan having a capacity oí 1, 400 cubic feet
and a heating surface of 2, 500 square feet is recommend-
ed for this purpose. In order to provide adequate capaci-
ty for syrup and molasses storage a second floor of
tanks should be erected.

C Crystallizers: Enough capacity is available.

Centrifugals: The present capacity of the high grade as

well as the low grade centrifugal stations is adequate to
meet the proposed cane grinding rate.

Capital Costs: A total estimated cost of $56, 000

($8,000, $15,000, $25, 000 and $8, 000 for clarifier,
evaporator, vacuum pans and syrup supply tanks, res-
pectively) is needed to effect the proposed changes.

' in

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153

NEW YARMOUTH? ACTUAL CAPACITY IN TONS CANE

PER DAY FOR MAIN EQUIPMENT IN
EACH PROCESSING STATION.

Station Capacity T. C. D.

Mill* 2,600

Juice heaters 3,850

Clarifier! 1.735

Filters 1,650

Evaporators 2,280

Vacuum pans 2,160

Syrup supply tanks 1,440

A and B molasses tanks 1,200

C e rystallizer s 4, 000

High grade centrifugals 3, 100

Low grade centrifugals 3,025

 154
NEW YARMOUTH: HEAT BALANCE FOR THE EVAPORATION
STATION SHOWING THE STEAM CONSUMPTION IN B. T. U. NEEDED TO
OBTAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice

Content Pounds Per Cent
Calculation« for Flow of He*t B. T.U. per Hour Brix

Juice to #1 171,849 14. 12

#1
Exhaust to #1 (25psi) 49,200x933 45,903,600
Add flash from heater 171, 849 (250-
242) 1,374,792
Available for Evaporation 47,278, 392

I Evaporation 47,278, 392 -:- 951

Transfer to #2
49,714

122,135 19.86

Vapor from #1 47,278,392

#2
Deduct for heaters et'. 2^,000x951 22 824,000
Balance 24,454 392
Add flash. 122. 135 (242-235) 854,945
Available for Evaporation 25,309,337
Evaporation 25, 309, 337 -:- 957 26,446

95,689 25.35
Transfer to # 3

Vapor from #2 25,309,337

#3
Deduct for heater 11,750x957 11.244,750
14,064,587
Balance
Add flash 95,689 (235-215) 1,913,780
Available for Evaporation 15,978,367
Evaporation 15,978,367 -:- 970 16,472

79,217 30.63
Transfer to # 4
15,978,367
#4 Vapor from #3
Add flash. 79,217 (215-180) 2.772,595
Available for Evaporation 18,750,962
18,902
Evaporation 18,750,962 -:- 992
60,315 40.23
Transfer to # 5
18,750,962
#5 Vapor from # 4
Add flash 60,315 (180-134) 2.774,490
Available for Evaporation 21,525,452
21,062
Evaporation 21,535,452 -:- 1.022
39.253 61.81
Leaving # 5 as Syrup
 i 155

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 156

SERGE ISLAND
Saint Thoma» Pari ih

lANOitioN a >o*Ti«,ine.

jn^., A... II
 157

Serge Island

This factory should be converted to a syrup producing unit, the

crop duration reduced to 155 days, and the grinding rate reduced
to 32 T. C. H. or 1, 100 T. C. D. The following considerations
should be given to reach the grinding rate of 1, 100 T. C. D. for
this syrup producing unit:

Mills: Tandem capacity is limited due to the inadequate

power of the engine driving the last mill. The other mills
are sufficiently powered. The "Fletcher" engine now driv-
ing the last mill should be replaced by a steam turbine of
250 h.p. , complete with gear reduction to bring the mill-
ing tandem to the required capacity.

Juice Heaters: Sufficient capacity is available to attain

the new cane grinding rate.

Clarification: Both the clarifier and the filter have ade-

quate capacity for the proposed cane grinding rate.

Evaporators: The present capacity is sufficient provid-

ing the system for operation of this station will be changed.
From the heat balance diagram, it can be seen that the
quantity of vapor bleeding from vessel #1 to the heaters
is much larger than the heating surface the vessel can
provide. Thus, only a limited amount of vapor can be
supplied to vessel #2 and the rest of the evaporation sta-
tion.

To correct this situation all vapor produced by vessel #1

should be used by the rest of the vessels of this station.
In this case the juice heater«, as well as the flash evap-
orator for concentrating syrup to 72 degrees Brix, should
be supplied with exhaust steam. This arrangement should
work satisfactorily since no steam supply would be needed
for the pans.

Capital Costs: An estimated $50, 000 is needed for the

last mill's turbine including the required gear reduction.

lANDCRION ft *0*TC«,INC.
 IO (A

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 159

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 *ñ

160

SERGE ISLAND ACTUAL CAPACITY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
PROCESSING STATION.

inT.C.D.
Capacity in
Station
985
Mills

Juice heaters 1,770

Clarifier s 1.215

1.535
Filters
1,200
Evaporators
I, 510
Vacuum pans
648
Syrup supply tanks

A and B molasses tanks 385

1,320
C tryHt'iUiaei'H
1,970
High grade centrifugals
1,600
Low grade centrifugals
 — I

'I

161

SERGE ISLAND: HEAT BALANCE FOR THE EVAPORATION

STATION SHOWING THE STEAM CONSUMPTION IN B. T. U. NEEDED TO
OBTAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL—

Heat Evaporation Juice

Content Pounds Per Cent
Cauculation for Flow of Heat B. T.U. per Hour Brix

#1) Juice to # 1 88,909 16.32

Exhaust to #1 20, 500x945 19,372,500
Add flash from heater 88,909 444.545
(230-225)
Available for Evaporation 19,817,045
Evaporation 19, 817, 045 -:- 962 20.600

Transfer to #2 68, 309 21.24

#2) Vapor from #1 19,817,045

Deduct for heater 11, 000 x 962 10,582,000
Balance 9.235,045
Add flash 68, 309 (22 5-215) 683,090
Available for Evaporation 9,918, 135
Evaporation 9,918,135 -:- 970 10.224

58,085 24.98
Transfer to # 3

#3) Vapor from #2 9,918,135

Add flash 58,085 (215-200) 871,275
Available for Ecapo ration 10,789,410
Evaporation 10,789,410-:- 980 11.009

47,076 30.82
Transfer to #4

#4) Vapor from #3 10,789,410

Add flash 47, 076 (200-132) 847.368
Available for Evaporation 11,636,778
Evaporation 11,636,778-:- 992 11.730

35, 346 41.05

Transfer to # 5

#5) Vapor from #4 11,636,778

Add flash 35,346 (182-134) lp696,608
Available for Evaporation 13,333,386
Evaporation 13,333,336 -:- 1.022 13.046

22, 300 65.06

Leaving #5 at syrup

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 163

SEVENS
Clarendon Parish

• ANOIRION * PO*TCft,INC.
 164

Sevens

According to the distribution of sucrose in cane, and to optimize

sugar production, the crop season should be reduced from the
present 258 days to 139 days. The reduced crop season would
signal an increase in the grinding rate from the present 90 T.C.H.
to 130 T.C.H. or 3,120 T. C. D. and Sevens should remaina sugar
producing plant.

The following factors for reaching the proposed cane grinding

capacity are to be considered:

Milling: The present linear speed of the mill rollers

is too low. Linear speed must be increased from 39 to
49 f. p.m. (assuming 14 per cent fiber in cane) which
will require 375 h. p. per mill.

The third and fourth mills are driven by a 1, 000 h. p.

steam turbine and as a result are adequately powered.
The first mill (actually a three roller crusher) and the
second mill are powered by a 650 h. p. steam engine,
which is in poor condition. This unit is underpowered
and should be replaced by a turbine identical to the one
now driving the third and fourth mills.

With the proper mill settings and with the suggested

speed, it is recommended to install feeder rolls in front
of each mill. Presently, only the last mill has a feeder
roll while the crusher has an underfeeder (Mayo type).

As the sugar extraction may become somewhat low with

the suggested cane grinding rate and roller speed, the
installation of a new mill complete with gears and an
independent 400 h. p. steam turbine placed at the end
of the milling tandem should be considered.

Because of cost, installation of an additional mill is

preferred over a diffusion plant since the present mill-
ing tandem is fairly new and in relatively good condi-
tion. Future improvements may involve changing the
three roller crusher into a mill, and installing a
shredder in front of the tandem.

• ANOCHSON * PORTCW.INC.
 ^1

165

Juice Heater«: The juice heater station has adequate

capacity to service the proposed grinding rate.

Clarification: Presently six trays and 44 polycell ele-

ments are installed in the "Bacìi" clarifier. The addi-
tion of another 16 cone trees, thus increasing the number
to 60 trees, is recommended. This change, together
with the newly installed "Graver" clarifier should attain
the proposed cane grinding rate. The presently installed
combination of a polycell "Bach" and "Graver" clarifier
is not an ideal situation as the retention time required
for juice differs for each type of installation.

Normally, the S'xlb' vacuum filter is capable of handling

2, 500-3, 000 T. C. D. In the past, the per cent of cake
on cane weight has been relatively high for Sevens. This
probably has been due to the small capacity of the clari-
fier station. With the installation of the "Graver" this
situation would be remedied and no radical changes in
the filter station are anticipated.

Evaporators: The present evaporation station, consist-

ing of a vapor cell with a quadruple effect (five vessels)
performs effectively. An increase in ti e heating surface
for the fourth and fifth vessel of the quadruple effect is
recommended. The present tubes are rather short
(5'-6') and by adding a l'-6" belt to the calandria, 71
tubes can be accommodated. An increase of 845 square
feet for each vessel or a total increase of 1,700 square
feet in heating surface would be the result.

The change in tube length may have a two-fold effect:

First, it would increase the overall heating surface of
the evaporation station and effect a 7 per cent gain in
performance. Secondly, the longer tubes would increase
juice velocity in the pipes. The present juice velocity
in the short pipes is rather low, possibly accounting for
the heavy incrustations experienced by Sevens. The
installation of seven foot tube lengths and the improve-
ment in juice velocity may result in a reduction of these
incrustations.

IANOIRION & POftTCR.INC.

 — .
•VI

166

Vacuum Pans: The present capacity will be adequate to

service the proposed cane grinding rate.

The capacity of the storage tanks for syrup and molasses

is insufficient. Present capacity should be doubled by
installing a second level of tanks above the existing ones.

Crystallizers; The crystallizers have adequate capacity

to obtain the proposed grinding rate.

Centrifugals: The high grade centrifugals are of adequate

capacity but the capacity for the low grade centrifugals
is insufficient. Using screens with a larger open area
may bring the capacity of the low grade centrifugals to
adequacy.

Capital Costs: The following costs are estimated to

upgrade Sevens and allow it to produce the proposed grind«
ing rate:

One 1,000 h. p. turbine, complete with

gears and installation $ 60, 000

Feeder Rolls 8,000

One mill, complete with 400 h. p. tur-

bine, gears and installation 90,000

Seven foot Stainless Steel Tubes for

fourth and fifth vessel of quadruple
effect 20,000

Supply Tanks for syrup and molasse» 8, 000

Total $186,000

IANDIMOK ft P»0*TKM,INC.
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 168

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 169

SEVENS: ACTUAL CAPACTIY IN TONS CANE PER

DAY FOR MAIN EQUIPMENT IN EACH
PROCESSING STATION, .

Station Capacity T.C.D.

2,472
Mills
4,278
Juice heater*
2,715
CUriiiert
1,464
Filters
2,425
Evaporators
2,620
Vacuum pan»
1,000
Syrup supply tanks

A and B molasses tanks 1,592

3,675
C crystallisers
3,385
Hi|h grade centrifugals
2.W0
Low grade cent rifugals
 170
SEVEN- HEAT BALANCE FOR THE EVAPORATION STATION
SHOWING THE STEAM CONSUMPTION IN b. T. U. , NEEDED TO OBTAIN
THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL.

Heat Evaporation Juice

Content Pounds Per Cent
B. T.U. per Hour Brix
Calculation for Flow of Heat

164,642 15. 53
pre) Juice to pre
Exhaust to pre 19,000 x 943 17,917,000
Available for Evaporation 17,917,000
Evaporation 17.917,000 -:- 955 18,761
145,881 17,52
Transfer to #1

#1) Exhaust to #1 35,750, x 943 33,712,250

Available for Evaporation 33,712,250
Evaporation 33,712,250 -:- 955 35,300
110,581 23. 12
Transfer to #2

33,712,250
#2) Vapor from #1
Deduct for heaters 5,739 x 955 5,480,745
28,231,505
Balance
Add flash . 110,581 (235-225) 1. 105.810
Available for Evaporation 29,337,315
30,448
Evaporation 29, 337, 315 -:- 963. 5 31.90
80,133
Transfer to #3
29,337,315
#3) Vapor from #2
Deduct for heaters 15,000x96 3.5 14,452,500
14,884,815
Balance
Add flash. 80, 133 (225-200) 2.003,325
16,888,140
Available for Evaporation
17,232
Evaporation 16,888,140 -:- 980 40.64
62,901
Transfer to #4

t ä% 16,888,140
#4) Vapor from #3 » ,_,' ,
Add flash. 62,901 (200-134) -V5M^-
Available for Evaporation 21,0JV.t>uo
20.586
Evaporation 21,039,606 -:-1.022

42,31? 60,42
Leaving as syrup
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 172

WORTHY PARK
Saint Catherine Parish

COLONO »ON»

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ItNOttlON * POWTt«. »NC.

 173

Worthy Park

This factory differs from all other processing units in Jamaica.

Not only is the factory and its cane growing area very isolated
but the quality of cane that is processed is superior compared to
the cane quality produced in other areas. Worthy Park is situat-
ed in a valley and at high elevation where the prevailing cool
nights promote an optimum cane maturity.

The cane grinding capacity of the plant should be increased from

50.8 T.C.H. to 60 T. C. H. or 1,44 0 T. C. D. to optimize sugar
production. In addition, Worthy Park should be converted to a
ayrup producing unit.

Milling: The present tandem is underpowered for the pro-

posed grinding rate. The peripheral speed of the mill
rollers should be increased from 30 t.p.m. to 45 f. p. m.
which would allow the production of 1, 600 T. C. D. (with
15 per cent fiber in cane) in a ?,5"x4Z" mill.

To augment the peripheral roller speed, the present

steam engine should be replaced by three 375 h. p. steam
turbines, and driving two mills by a change in gearing
so as to allow a maximum roller speed of 45 f. p. m.
An alternative, but less practical solution, would be
employing two 550 h.p. turbines and driving three mills.

Juice Heaters: The present capacity is sufficient to ob-

tain the proposed cane grinding rate.

Clarification: The clarifier capacity is too small for the

even presenfgrinding capacity. The excellent quality of
the juice obtained is the only reason why the present
grinding capacity can be maintained. For future use, a
second clarifier should be added to insure adequate
juice clarification. The installation of a 12" diameter
polycell unit is therefore recommended.

The present 8«x8» "Emco" filter has limited capacity,

but should be able to handle the mud load expected from
1, 440 T. C. D. , providing a cake thickness of more than
1 /4" is acceptable.

• ANOiRiON« Ponrcn.iNC
 174

Evaporators- The quintuple effect presently is working

at optimum i apa< it y due to tht removal and efficient use
of the first and sei onci type of vapors. An additional
preevaporator should he installed to service the increased
grinding rate. Vessel #1 could he operated as the pre-
evaporator, with a new vessel, having about ¿,000 square
feet heating surface replacing the operation of the present
first vessel.

Capital Costs: I he rapita! t osts necessary for achieving

the proposed cane grinding capacity ran he estimated as
follows:

Turbines for mills with high speed gears $ 50,000

Reduction change tor main gears 25,000

Foundations for turbines and gears 25,000

Clarifier 10,000

Evaporator 15,000

Total $125,000

Should it be decided not to convert the present plant to a syrup

producing unit, and to optimize sugar production at 1 , 440 I . C. D.,
one of the present coil pans should be replaced by a large 1. 000
cubic foot calandria pan at an estimated cost of $25, 000. Fur-
thermore, the capacity of syrup and molasses tanks should be
increased by 550 cubic feet at an estimated cost of $3, 000. The
existing t rystallUers should be equipped with water cooled
"Blanchard" units and the station should be arranged for continuous
flow of massacuites adding a strike receiver at an estimated cost
of $8, 000.

Although the centrifugals for high and low grade sugar have ade-
quate capacity for servicing 1,440 T. C. D. , both stations are out-
dated and the machinery should be repladed. The cost of one 54
"Roberts", fully automatic centrifugal for high grade sugar ~nd
two continuous centrifugals for low grade sugar is estimated at

• ANCcnsoN a PORTER.INC.
 175

$35 000 and $30. 000, respectively. Thus, the modernization of a

factory processing only 1.440 T. C. D. would amount to about
$1000. 000 in additional capital expenditure.

The manufacturing process at Worthy Park .s ^^ ^^ "

neither steam turbines nor generators are used " ^^
aeneration. Electric power is produced by diesel units as the
r^aTs no" 8erved by the Jamaica Public Service and the sugar
company supplies electricity both during the crop and the out-of
crop season to the community in the valley.

Worthy Park does not have sufficient boiler "V""^**•'

lam for processing 1. 440 T. C D. It may have equate capacity
to institute the improvements ^ -ching 40 r c D. .^

syrup producing unit.

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 177

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 178

w«»THV PARK- ^TU^

ACTUAL CAPACITY IN TONS CANE PER
WORTHY PARK. ^^ EQmpMENT IN EACH

PROCFg«I?"-i STATION _ —

Avera|eT.C.D.
Station
984
Milli
1,676
Juice heaters
633
Ciarlile«
1,073
Filter«
1,220
Evaporation
1,220
Vacuum pane
528
Syrup »upply tankt
1,1*2
A and B molane« tankt
762
C cryatallUert
1,440
High grade centrifugali
1,885
Low grade centrifugali
 179
WORTHY PARK. HEAT BALANCE FOR THE EVAPORATION
STATION SHOWING THE STEAM CONSUMPTION IN B. T.U. NEEDED
TO OBTAIN THE PRESENT DEGREE OF EVAPORATION IN EACH VESSEL

Heat Evaporation Juice,

Content Pounds Per Cent
B. T. U. per Hour Brix
[calculation for flow of heat
100.493 16. 16
(#1 Juice to evaporatori
exhaust steam to #1 34,000x945 32, 130,000
available for evaporation 32, 130,000
evaporation 32, 130, 00-:-932 33,750

66,743 24.33
transfer to #2

#2 Vapor from #1 32, 130,000

to heaters and pans 20, 000 x 952 19.040,000
13,090,000
balance
add flash. 66,743 (240-220) 1, 334,860
available for evaporation 14,424,860
14.932
evaporation 14. 424, 860-:-966
51.811 31.34
transfer to #3
14,424,860
#3 Vapor from #2
to heaters 8,000 x 966 7.728,000
6,696,860
balance
add flash, 51,811 (220-204) 828,976
available for evaporation 7,525,836
7,709
evaporation 7, 525, 836-:- 976. 2
44,102 36.82
transfer to #4
7,525,836
#4 Vapor from #3
970.244
add flash. 44,102 (204-182)
8,496,080
available for evaporation 8,564
evaporation 8,496,080-:- 992
35,538 45.69
transfer to #5
8,496.080
#5 Vapor from #4 1.705,824
add flash. 35,538(182-134)
10,201.904
available for evaporation
evaporation 10,201.904-:- 1,022
63.54
syrup leaving #5
 180 I
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 181

TF.NTRAL END-FACTORY

From this investigation it has been concluded that the Holland

factory be closed and its cane ground at the Appleton factory. Topo-
graphic conditions in the area should not prove a deterrent to trans-
portation irom the Holland Estate to the Appleton Factory. This
would enable Appleton to produce about 25, 000 tons of sugar annually,
for which it has the machine capability.

The same arrangement was broahced for Serge Island and the
Jamaica Sugar Estates. In this case, however, road and topo-
graphical condition, cause transportation difficulties, makingramal-
glmation of Serge Island and Jamaica Estates not feasible * any
eve^t both factories should be converted to syrup producing units.
,» addition, and a. -^^¿^Z?^ ^P-
^ and T^^ZZiSÏÏr'tZZi* units. Worthy Park,
Gray s lÏnTong Pond, Inn.wood, Hampden and Bybrook together
witVjamaìca^gar EsUte. and Serge Island, would be converted
it
romodernization
s;r;:oducing «.*.. xr %zizr*££¿=~
programs Thus, fortuitously, «Yin
Aooleton
to our overall recommendations. In the long ^¿£'%*£•'
New Yarmouth and Sevens would eventually convert to syrup pro
Suction when sugar production costs will b-^ P»^^£o'
their present si,e Concurrently ^J^^cTy UUu'ng plants
and the ^^¿Z^^^r^rn^ from the
in Jamaica; the latter being PP ^ no >ugar
smaller syrup producing pUnU. J^^^ due to insufficient
plants have plans for meaningful modernisa««
return on investment.

The new end-factory would proue.^^^^J^^l^

be con.tructed at a centrally lTO*te#d|d6eP•^n^ble Jamaica
bulk-load ship, can be accommodated. This will
to remain competitive in ita exports

The end-factory will function ^^.^^^7^ ye",

five o.r cent downtime for ***£££%' ^ ngVhi.'time
290 effective working day. can be realized uu
 182

242 128 tons of syrup may be processed into 125,000 torn, of sugar
This is based on the assumption that four full shifts of workers will
be utilized to assure non-stop production. Shifts would rotate so
that no employee would work more than 40 hours per week.

The end-factory's required daily consumption of syrup is estimated

to be 920 tons. Daily syrup producing capacity for all P»'tic^Ung
units has been estimated at I, 681 tons. The daily requirement for
syrup storage is estimated at 761 tons; this being the difference be-
Zeel total daily output and consumption of syrup Therefore at
the end of the average crop season (144 days), 10^ 584 t0nS_£ 8£"P
must be stored so that the effective working days of the end-facto.y
can be fully utilized.
The .torage facilities that would be required, and their iocation..
are as follows:
Storage Capacity
Location U. S. Gallona

4,662,300
Bowden
5,692,000
Salt River
3,041,000
Falmouth
8,245,600
Ocho Rios

Tan., holding one million Ü. S f^^J^t^Je^tttorras

several syrup storage units wou be located a th. ^ ^^
well to assure continuous production, ihe u
ed aa follows:
Number of Units
Location
4
Bowden
5
Salt River
Falmouth 2
7
Ocho Rios
Site of end-factory __4

22
Total
Th. dally quantity oí Intermediate material, produced in th. end-
factory Ü illu.trated on the next page.

SANDCftSON * PORTCR.INC.
 183

END-FACTORY: AMOUNT OF MATERIALS TO BE PROCESSED,

PRINCIPAL EQUIPMENT AND CAPACITIES,
AND POWER REQUIREMENTS _____

(Based on a daily input of 920 tons of 72 degrees Brix syrup and a

daily output of 467 tons of sugar, at 97 degrees polarization and
0.70 per cent moisture, and 214 tons of final molasses at 88 de-
grees Brix (42,700 U. S. gallons.)

Required boiler capacity, pounds per hour 45,000

(Based on total water evaporation in pans of
35 000 pounds per hour with an allowance to
meet an estimated peak load of 45, 000 pounds
per hour at the beginning of pan loads. )
14,419
A Massacuite, cubic feet per day
9,376
B Massacuite, cubic xeet per day
8,054
C Massacuite, cubic feet per day
23,795
Total A and B Massacuite, cubic feet per day
2,000
Required strike volume per pan, cubic feet
2
Number of pans required for A and B Massacuite
1
Number of pans required for C Massacuite

Number of pans required for magma and

1
grain development
500
Heating surface required for syrup, square feet
(Bases on expected volume for syrup of 0. ¿Bi
cf. s. and a required syrup velocity of four feet
per second in the heater requiring 0.07 square
feet per pass. )

Steam consumption (10 p. .. i. ) required by heater

700
pounds per hour
(Based on 2" O. D. heater tubes, «ou* tub« per
pa,.. 20 passes, requiring a total of 80 tubes
prov ding 500 square feet of total heating surface. )

• ANOCHSON a POWTC". INC.

• •
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láé ¡22
112.5

^^^~ |36 WÊÊÊÊ

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11.25 114
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MICROCOPY RtSOLUllON USI CHAW

NATIONAL HIIW AH ''I ' ! ANI 'AI.I. i-PI. - .1
 184

Crystallizers for A and B Btrikes, units of

2, 000 cubic feet each:
(One crystallizer is equal to the volume of Pugmlll
to feed A and B centrifugals. Two »mall crystal-
lise rs are required for magma and grain storage. )

Crystalizers for C strike, water cooled, units of

2, 000 cubic feet each
(Based on Mas sacuite cooling period of 24 hours)

A and B centrifugals, 48"x30", units required

(Or seven 42"x30" units. )

C centrifugals, continuous, units required

(Based on output of 60 cubic feet of Massaculte
per hour. )

Syrup pumps, 150 gpm, 100' head, 7.5h.p.

units required
(Ail pumping units duplicated to aa.ure continuous
plant operation. Pump head corrected for losses
In syrup heater. )

A molasses pumps, 50 gpm, 75« head, 4 h.p,

units required

B molasses pumps, 50 gpm, 75» head, 4 h.p.

units required

Magma pump, "Rota-type", 40 gpm, 100" head

gear motor, 10 h.p. units required

Final molasses pumps, 35 gpm, 20«head, 5 h.p.

unit» required
(For transferring final molasse, from centrifugals
to weighing •cale. )

Final molasses pumps, 35 gpm, 20« head, 5 h.p.

units required
(For transferring final molasse, from weighing
scale to storage tank. )

MNOCMON ft *0»TC». l»C.

• >•,.*;.£. * jjn

185

Based on the quantity of cane processed for 1970, together with the
material balance calculated for each factory, and the assumption
of 72 degrees Brix for stored syrup, syrup production as shown be-
low can be anticipated.

Syrup Syrup
Shipping Produced Produced
Name of Unit Port Long Tons U. S. Gallons

Jamaica Sugar Estates Bowden 34,870

Serge Island Bowden 17,298 10,304,750

Bybrook Salt River 28,655

Inns wood Salt River 35,027 12,579,100

Hampden Falmouth 34,027 6,721,350

Long Pond Ocho Rios 41,605

Worthy Park Ocho Rios 30,702
Gray's Inn Ocho Rios 19.944 18.222.340

Total 47.827.540

This volume does not represent the required storage space for
• yrup. The actual space is less as the end-factory also will con-
sume syrup during the crop season.

The end-factory must be totally electrified. Several systems for

power generation providing electricity as well as process steam
have been evaluated. These include diesel, gas turbine and steam
turbine. A diesel unit, compared to a similar size steam turbine,
Is much lower in capital cost requirements. It is capable of pro-
ducing the required process steam through recovery of heat nor-
mally lost in the exhaust and from the jacket water cooling system.
A high thermal effic iency can be obtained. But the advantages ar«
offset by the disadvantages.

As the factory would operate ten months a year, the steam must be
available throughout this period. Diesel plants are unable to
operate, continually, for such a length of time span without main-
tenance. As a result a second diesel unit would be needed

• áNOCKtON a Ponrcn.iNC.
 **

186

increasing the capital cost significantly In addition, in case

a breakdown occurs, the steam supply would be lost entirely shut-
ting down production in the entire plant A standby steam generator
plant would be needed to avoid such a possibility This again in-
creases the capital costs. Finally, diesel maintenance costs are
higher than those for steam turbines, completely ruling out a diesel
plant. A gas turbine also was considered as the initial capital
cost is low. But high operating costs and low thermal efficiencies
ruled this out as well

A steam plant similar to the existing systems at the projected syrup

producing factories, is recommended. Steam requirements at the
end factory have been calculated at 45, 000 pounds per hour; elec-
trical load is estimated at 1, 200 kilowatts per hour, These value*
may vary slightly once the final design has been established

The power plant should consist of one package type, oil fired
(Bunker "C") boiler with a rating of 50, 000 pounds of steam per
hour. The turbine (50 cycles) would be designed to operate at 150
to 250 p. s. i. with a back pressure of 10 p. s. i Special considera-
tions should be given to the turbine design as the quantities of ex-
haust steam can vary considerably, and provisions must be made
to compensate for these fluctuations to avoid costly blow-off of
steam*

The entire plant concept would be based upon the steam requirements
for sugar processing rather than electricity generation.

Piping would be designed to allow a direct and constant steam flow

from the boiler to the boiling pan via a pressure regulator. Nor-
mally, the pans would be fed through the exhaust of the turbine,
but in the event of a malfunction, the by-pass line can be used to
supply the factory.

During a major breakdown, or during the off-season, power must

be furnished by the Jamaica Public Service Company or by a stand-
by 300 to 350 k. w diesel-generator set.

Capital expenses for the purchase and installation of the power plant
for the end-factory are estimated to be $625, 000.
 187

Finally, as the end-factory will be located at a deep harbor port,

consideration should be given to the feasibility of purchasing Bunker
"C" oil in bulk form. With proper storage facilities, delivery could
be effected by either a tanker or barge resulting in considerably
lower fuel costs.

The total cost for the end-factory, excluding the power plant, is
estimated at $3. 8 million inclusive of construction. The centri-
fugals now located in those plants which will convert to syrup pro-
cessing might be removed from those plants and installed at the
end-factory. This would reduce the estimated cost to $3. 5 million.

The approach will help to preserve the individual autonomy of the

sugar producing companies. Under this new program these
companies will sell their syrup production to an intermediate
processor who in turn will sell the crystallized product to refiners.
Presently, the crystallized product is sold by pooled arrangement«
to refiners. An intermediate step, to reduce production costs
would not be objectionable to the individual sugarcane processor.
The sugar producers have long recognized their strength by a
common effort. The entire sugar production has been sold through
one marketing organization and negotiations with sugar importing
countries are carried out on a regional basis.

lANBIRION • POUT*». INC.

 IM

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 189

END FACTORY: ESTIMATED QUANTITIES OF SYRUP WHICH

COULD HAVE BEEN PRODUCED BY DIFFER-
ENT UNITS FROM THEIR CANE DELIVERIES
DURING THE 1970 CROP (SYRUP AT 72
DEGREES BRIX)

Name of Unit Syrup produced, long tons

Worthy Park 30,702

Jamaica Sugar Estates 34,870

Gray's Inn 19,944

Long Pond 41,605

Innswood 35,027

Hampden 34,027

Serge Island 17,298

Bybrook 28,655

Total quantity of syrup which could have been produced,

long tons: 242,128

Average time per unit after crop duration has been

l
shortened, days: **

Average production of syrup per day,

long tons: 1,681

Average production of syrup per day,

U.S. gallon«: 332,050

Source: Production data from units and own calculations

 189

END FACTORY: ESTIMATED QUANTITIES OF SYRUP WHICH

COULD HAVE BEEN PRODUCED BY DIFFER-
ENT UNITS FROM THEIR CANE DELIVERIES
DURING THE 1970 CROP (SYRUP AT 72
DEGREES BRIX)

Name of Unit Syrup produced, long ton«

Worthy Park 30,702

Jamaica Sugar E• tatet 34,870

Gray'i Inn 19,944

Long Pond 41,605

Inntwood 35,027

Hampden 34,027

Serge Island 17,298

Bybrook 28,655

Total quantity oí iyrup which could have been produced,

long ton«: 242,128

Average time per unit after crop duration hat been

144
shortened, days:

Average production of ayrup per day,

long tons: 1,681

Average production of ayrup per day,

332 050
U.S. gallon.: '

Source: Production data from unita and own calculation»

 i 190

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oh
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8
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 192

PROPOSED DIAGRAM FOR STEAM AND ELECTRICITY GENERATION

TO BE US ED FOR PROCESSING BY THE CENTRAL END-FACTOKY

^
füruRC

•MKAOC tOt LCR n MIMM BOIUR

1

180/250
0/250 150/250
Ml« FCC» WATCH

60000 LM./MR S0000 LM./H* 10

•bCCO llNC MIO
] PRCMUftC
H Mtouecft

I ,_-J
•ftftM MM
p^- Ì >
48000 I.M.A*.
150/290 Mio

»TEAM tUR» I HC
MON-COMDCNSINO 48000 LM./HA, Î
1000 M* 10 rata

CANOor eictck
CCTMC «CT

CONNCCTION t» rfAHAltâ*
run« KRviec «M©
\ .._

T
10
FACTORY
 193

THE JAMAICA MACHINERY COOPERATIVE

(JMC)

In order to eliminate some of the high costs associated with ma-

chine maintenance, which are a result of the small economies of
size for each plant, the low efficiency of labor, the lack of machin-
ery standardization and spare parts, as well as the lack of job
specialization for the factory worker, a centralized machinery
facility should be established. This would reduce both repair costs
and foreign exchange expenditures, benefitting the Balance of Fo-
ments.

The name suggested is the Tamalea Machinery Cooperative

(JMC).

Purpose

The primary purpose of the JMC would be to relieve the financial

problems of the sugar manufacturers. Secondly, a central repair
facility for maintenance and purchasing of parts and equipment
would result in overall monetary savings.

It is the intent that the JMC eventually would become self-supporting

and become a profitable venture in itself.

The policies under which the JMC would operate would be well for-
mulated and in accordance with Jamaican laws and regulations.
A Board of Directors with a representation as shown on the attached
organization chart, on the following page, is proposed.

The Sugar Industry Authority representing the national

and international sugar Interests of Jamaica.

The Sugar Manufacturers' Association representing each

Individual sugar processing facility.

IANDIMON a *0*Ti».IMC.
 PROPOSED ORGANIZATION CHART FOR THE
JAMAICA MACHINERY COOPERATIVE ...

CHAIRMAN
194
MINISTERIAL RANK
( Caw«rnn*nt Appointât )

SQARD Of PIRECTQRS
• Sugar Industry Authority
Htmbar • Sugar .':anu facturar* Association
»atibar • All-Island Jamaica Cana »arman Association
Htnbar • lnttraitod Labor Unions

TtClWlCAL ADVISORY SOAM>

CM.f «minwt fro» all •«••* HtâMi

MANAGER MANAGER MANAGER 1

1
TRAINING DETARTMNT ACCOUNT;«: DETARTMNT PURCHASING DEPARTMENT!

CLERICAL STATT CLERICAL STATT

STORIS

TRAINING SUFtiRVISO* TRAIN»« SUftRVISOt

TMISINO MTCSVISO«
factory Equipant K144U Manag««*** Tfâlaiat
fUìé m* Transatti Muir*«««

ISOM
SKILLED SUPERVISO** I
I WISOIS I
SKILLED SITEWISOIS

MAINTES AND "EfA U STATT 1

TRMKIES ASI) RETA IR STATF i
• »>oa»T«a».»we.
 195

The All-Island Jamaica Cane Farmers' Association re-

presenting the interests of all cane farmers.

The Unions representing all field and factory workers.

The Chairman appointed by the Ministerial Office under

which the JMC would be governed. The Chairman would
have an arbitrary function in all matters. He would have
no financial interest, directly or indirectly, with the su-
gar industry.

Specific responsibilities of the JMC would be as follows:

To own, operate, maintain, repair and lease to the

manufacturers and cane growers the mechanical equip-
ment needed by each operation. This would initiate
a concerted effort in equipment standardization opti-
mum utilization by growers of limited cane holdings.

To own, operate, maintain, repair and lease to the

sugar manufacturers the required transportation equip-
ment in order to optimize the utilization of capital in-
vested and to promote standardization of equipment.

To own, operate, maintain, repair and lease to the sugar

manufacturers and sugar cane estates the required
equipment for cane cultivation in order to optimize the
capital investment utilized in this sector.

To provide central repair facilities for effective and

economical repair of equipment.

To provide a central warehousing system to reduce the

stock needed for all processing plants and estates and
to profit from volume buying.

To provide central training facilities so as to offer

specialization for skills particularly needed by the sugar
Industry.

IANDIHION a PORTE*. IMC.

 1%

Once organized and functioning, the JMC would prove beneficial

to the producer as well as to the grower for a number of reasons:

The centralized system will relieve the individual fac-

tory and estate from the rebponsibility of maintaining
and upgrading the skills required to repair the equip-
ment.

Only the central repair facilities can be equipped with

modern tools and testing equipment. Better supervisors
will ease the severe maintenance and repair problems
now resulting in excessive repair costs.

The central warehousing for standard parts will great-

ly reduce the time lost in procuring these supplies.
Availability of parts upon request will reduce "frozen"
capital now held in the form of spare parts at each fac-
tory and estate.

Inventory control of parts would be computerized and

the information made available to all interested parties.
There are computers in Jamaica which have time
available to process the information effectively.

Collective purchase of parts will result in a substan-

tial lowering of price per unit of spare parts. This
saving, together with the lesser quantity needed, will
have a beneficial effect on the Balance of Payments.

The central training facility operating in conjunction

with the central repair facility will ease the skilled man-
power shortage. Central repair facilities of the magni-
tude proposed and coupled with an effective practical
training program, could restore the prestige for em-
ployment in the sugar industry.

The formation of the JMC is a practical step toward curbing the

rapidly increasing costs of maintenance and repairs.

SANOcntON a POft-rcn.iNc.
 197

Formation and Operation

To form the JMC, offshore financing plus a contribution from the

Jamaican Government will be necessary. In its early stages, the
JMC would have to be tmbsidized annually by the Jamaican Govern-
ment. (See next page. )

In addition to the capital necessary for the construction and equip-

ping of the central repair facilities, other funds must be made
available for purchase of the field and transportation equipment now
owned by the individual sugar manufacturers. This equipment
will be leased back to the manufacturers as it is required. How-
ever, and to give them a voice in control of the equipment, each
sugar manufacturer should secure equity in the JMC by donating
some equipment to the JMC without any charge. The size of the
equity would depend on the amount of equipment contributed.

Initially, the monies derived by JMC would be solely from the

rental of field and transportation equipment and from the repair
work performed in the central repair facility. Eventually, it
should realise substantial sums from the equipment and repair
facilities and from the sale of spare parts. Outlays of cash are
illustrated on the page following the next page.

With proper direction, the JMC tan become a very profitable

organization. After meeting the repayment schedule for the initial
financing, profits can be shared between the sugar manufacturers
and the Jamaican Government. A certain part of the income must
be put into an equipment replacement fund for worn and old equip-
ment.

As already stated, the JMC will own, operate, maintain, repair

and loan the necessary equipment to load, possibly harvest and
transport the cane to the factory. At the beginning of the crop,
the sugar manufacturers will inform the JMC of their equipment
requirements. The JMC would schedule the equipment to be
brought to an area, complete with operators, maintenance and re-
pair crews in accordance with these equipment requests. Equip-
ment and crews would remain on the estate until the crop season
is complete. At that time the workers and machines would be re-
turned to the central facilities.

lANOmiONI POMTIR, INC.

 JAMAICA MACHINERY COOPERATIVE
CASH FLOW DIAGKAM DURING PHASE ONE,
THE FORMATIVE STAGE
19«

«MRU» CONTRIBUTION
¡ON I

LÏ riMMtM
3 urn» covtiwMjrt wtstD*
tenitNMüT or JAKAICA

urnrt w J.M.C.

tmemn nan v* IWA» MTATU or:

MMAL 10 1« WOA* MTATU OTi
Cultivation l«¿il»mtnt
UM CvUlvatlm tqwtpMflt RMVMtlnl CoulpMnt
«Mvattlnf. Iqulpmtnt Uaélnt t^ulpïtnt
ft«Mf*rtatlon t«jul«««ni
trMMHtutlen tfvl»Mftt

3
CgtmUL «fA» AMD TMIMINB WIWÍM
 JAMAICA MACHINERY COOPERATIVE
CASH FLOW DIAGR/ M DURING PHASE TWO,
THE FINA;, STAGE

199

mmm COSTHUUTK*
oovr'rrsrrr or JAMAICA

••-

norm

3=*
SOCAR ESTATES tQUIfMWT WftACDWI TO»

JAMAICA y.tcmsrv
CO-CWV.TTVE

t > ^ SALE Of STARES TO

SMTAl tO THE SWA» ESTATES Of i THE IÜCAR ESTATES
Untf Cultivation EaulpaMt
Rêivtatlnt Equipment
U**"ln| Equlprant
Tranaportatlon E<pilpM*t

SALES TROM CENTRAL

urA» rAcnnus
\ t

Z2
•*-

1 Ajmsunutm COSTS
coir or •»*»• TRAIRA« COSTS

:
COST or onuATiNC COST Or 0TERAT11« A*,*»
ctirrva. ntsn rtfum WAlSTAtMVG EÇVWMT
WTHKG c«or

i a momrmm.mm.
 200

Similarly, the tugar manufacturers and estates would inform the

JMC of their plans for cultivation and planting so necessary man-
power and machines can be supplied.

At the end of the crop, repair and maintenance will be performed

by the same crew who operated and maintained the equipment dur-
ing the crop.

The end of the crop would also signal the beginning of factory main-
tenance. Reshelling of mill rollers, regrooving of new shells,
machining of turn plates, and major overhaul of equipment would
be performed at the central facility.

Many mills have machinery that is common to all. The present

practice of purchasing spare parns on an individual basis, re-
presents substantial capitalization. Under a centrally governed
system, the same spare parts and even some large items now
purchased in finished form could be purchased unfinished in larger
quantities at substantial savings. They could be finished in the
central machine shop as required. Most commonly used items
such as valves, nuts, bolts, washers, welding rods, evaporator-
pan-boller tubes, cane knives and many other items could be
stocked in smaller quantities than is now the case.

Maintenance and Training

The Jamaican Government has expressed concern about the rising

costs of repairs and maintenance. A similar concern was expressed
in the Mordecai report which indicated that during a five-year
period, manufacturing costs increased 20 per cent while maintenance
costs increased 35 per cent. In another report - "Study of
Machinery; Repair and Maintenance Problems of the Sugar Industry",
in Tamalea for UNIDO, by M. S. Sahni, maintenance difficulties
were also delineated.
Both reports are concerned essentially with statistics; while
alarming they have not discussed the problems which face the
Chief Engineer in a sugar factory who is responsible for the repair
and maintenance of the plant during the off-crop season as well as
for efficient operation of the mechanical and electrical equipment
during the crop. His skill, ability and experience has a direct
influence on the success, or the failure, of sugar production.

SANDCflSON ft POR-TCM.INC.
 201

Preparing a factory for a crop is difficult. It is standard practice

to disassemble, inspect, and repair if necessary each piece of
equipment in the fac tory. To accomplish this task the Engineer must
overcome the following: lack of a skilled staff; excessive delivery
time for spare parts; high cost of spare parts; budget limitations.

Despite these difficulties the plant is usually ready in time. Many

of the older factories, still in operation, are testimonials to the
skill of their engineers.

There is no quick and easy answer to solving these maintenance

problems. However, a training and modernization program is
. essential. This is most important in that it would take at least
five years before any meaningful benefits «ould be realized.
Therefore, a program must be developed as soon as possible.
Existing factories must continue in the hope of survival until the
fruits of the program can be realized.

Training is the simplest answer to the maintenance problem. In

addition to training, monetary inducements must be offered to re-
tain skilled labor in the sugar industry. In addition, as there is
certainly a limit as to how many skilled tradesmen the other in-
dustries will be able to employ, the sugar industry must be pre-
pared to attract and hold the excess labor when these workers be-
come available.

A training center should be established at the site of the central

repair facility of the JMC. An experienced training supervisor
should be in c harge of the overall program while individual assist-
ants would be in charge of three spec ial training sections. One
section would concentrate on skills needed in the factory. A second
on the skills necessary in repair and maintenance of transportation
equipment. The third on training of middle management.

A Technical Advisory Board, consisting of the Chief Engineers

of all the factories, would advise on the curriculum as to the skill«
to be taught and the methods of training to be employed. This will
prove Invaluable as the Engineers1 intimate association with the
problema of the factory will be an asset to the training program.

SANDERSON A FORTin.iNC.
 202

Essentially the Technical Advisory Board would be responsible for:

Determining the general methods for and the extent of

repairs.

Designing of maintenante and repair forms to be used

throughout the industry.

Determining the areas and industrywide methods for

training workers.

Determining the type and inventory of parts needed for

an effective maintenante program.

Discussing particular problems facing certain factories

in order to determine solutions in accordance with the
common approach.

Training would take place during the off-crop season. Each factory
would send a specific quota of trainees to the center. As repair
work in the factories must continue, a rotating schedule would be
developed to allow most of the employees to participate.

To provide equipment for the training program, each factory would

supply various pieces of mai hinery for repair. As time progresses,
and as funds allow, the school would pur« hase machinery for train-
ing purposes. Also, the equipment manufacturers usually are most
helpful in making training equipment available.

Training would be on a practical basis. No reading or writing tests

would be required since training courses requiring technical read-
ing are usually unsuccessful. Although many people can read and
write they have extreme difficulty in comprehending even the most
elementary technical literature. As there are limitations in the
simplification of technical terms, technical reading skills should
not be included in the curriculum for mechanics. However, techni-
cal reading would be a requisite for the middle management positions.

Certificates would be presented at the successful completion of each

course. These would be graded to establish standards of compe-
tence. A passing grade in one course would be required before a
perscr. could apply for other courses or for a higher position.

• ANDERSON * FORTH», INC.

 203

Once a trainee has reached semi-skilled status, a number of

approaches should be considered so as to retain his skills in the
sugar industry:

The school could be located near a large urban area and

quarters provided for the trainee either free of charge
or at a nominal cost. In this manner the increasing
trend of young people to move from rural to urban areas
can be satisfied. If crop duration is shortened to four
months, the remaining eight months can be spent in or
near the city.

Before training begins, the student would agree that in

return for his training he would work in the sugar indus-
try for at least five years.

The Government, in conjunction with the sugar industry,

would initiate a public relations program in which the
importance of the sugar industry, and the sugar worker,
to Jamaican national development would be fully em-
phasized.

Legislation might be introduced making it unlawful for

a sugar trainee to be employed by another industry
within the stipulated five-year employment period un-
less that industry is willing to make some compensation
for this employment.

Inventory Control of Parts

Lengthy delivery schedules for equipment and spare parts is com-

mon to all machinery users in the world. In efforts to reduce In-
ventories most manufacturing firms keep only a minimum amount
of parts on the shelf. In many instances spare parts are not manu-
factured until an order is ree ieved.

Inflationary trends during the late sixties greatly increased the

price of machinery parts. The Jamaican sugar industy, already
experiencing high costs for spare parts, should attempt to reduce
the amount of spares. Normal wear and tear must be expected
and cannot be avoided. However, replacements due to the negli-
gane r of a semi-skilled tradesman can now be avoided by worker
training.

SANDCNSON a rOMTIS,INC.
 204

The JMC can be a valuable asset in another area also. Purchasing

large quantities of spares will dictate better discount rates and
storage at the JMC warehouse will reduce the monetary values of
the inventories now stocked at each factory.

Safety

A final item that needs mentioning is the current lack of conscien-

tious safety precautions in the Jamaican sugar factories. A few
factories have tried to develop some sort of safety program but
other, and ostensibly more important work has taken priority over
safety. It is doubtful whether any Tamaican sugar factory could
pass a routine safety inspection as instituted in a more developed
country. The importance of safety cannot be over-emphasized.
Adopting proper saft ty measures will, in addition to benefiting
management, almost certainly result in the reduction of lost
grinding time. Thus, safety should form an integral part of the
JMC's overall training curriculum.

lANOtMON â f*OftTC*,INC.
 205

STORAGE TECHNIQUES AND TRANS PORT ATICM OF SYRUP

Syrup must be stored away from the cane producing units so the
central end-factory can function on a year round basis. As long
as certain precautions are taken, syrup produced from cane can
be stored for a certain period of time without deterioration.

Syrup with a density range of 55- 62 degrees Brix normally under-

goes deterioration rapidly. For storage, the density must be
increased to 72 degrees Brix for two reasons. First, a higher-
Brix means more removal of water. As a result, less volume is
needed for the storage tanks. Secondly, the concentration of solids
in the syrup must be increased to such a degree that it becomes
unfavorable for bacterial growth. In order to prevent spontaneous
crystallization of sugar, the density of syrup should not be in-
creased beyond 72 degrees Brix. As the purity of syrup seldom
exceeds 80 or 81, 72 degrees Brix should be adapted as the opti-
mum for preservation of syrup.

To eliminate any possibility of condensation, the temperature of

the syrup at the time it is introduced into a tank should be as low
as possible The water droplets formed by condensation fall into
the syrup. This dilutes the syrup and forms minute areas of a
medium favorable for batterial growth. Thus, sterilized syrup,
after leaving the flash evaporato?, would have to pass through a
cooler prior to storage. The flash evaporator and cooler would
have to form a hermetically closed system to prevent reinfection
of syrup.

To reduce any chance of moisture further it would be advisable to

insulate, if not the whole outside of the tank, at least the top of
the tank, with a one-ine h thick layer of styrofoam. A continuous
stream of air must be circulated through the empty space above
the liquid level. The air should be slightly hotter than the ambient
temperature. This air layer, having a lower relative humidity,
 206 I
would then absorb and eliminate the water saturated air from the
tank. The inlet and outlet f JT the air * inflation system should be
mounted in domes on opposite sides of the top of the tank to pre-
vent liquid from entering the system when the tank is totally filled.
Also, a large quantity of low pressure air should be used to
"sweep clean" the entire inside of the tank.

Every morning a disinfectant would be atomized into the tank to

disinfect the top and the still exposed sides of the tank as well as
the surfac e of any syrup. Tw: types of disinfectants would be used
on Alternate days; formaldehyde on the first day and any other
type of commercial disinfectant on the second day. The reason for
utilizing more than one type of c ommerual disinfectant is to pre-
vent the buildup of resistance of bacteria against a certain type of
disinfectant. Syrup can then be kept for prolonged storage, as no
bacterial growth can occur when these precautions are taken.

The syrup would be introduc ed irto the tank through a pipe in the
bottom in order to prevent formation of foam; foam being a source
of bacterial growth. The stored syrup should have a pH range
between 6. 5 and 7. 0. The bottom of the. tank would be convex in
order to permit total drainage, and the tanks would be thoroughly
steam c:leaned when emptied.

Each tank should be filled to capacity, leaving no air space at the

top. Discharge will take place through a discharge pipe with
valves located outside the tank. The syrup can be regarded as be-
ing deposited in layers when the tank is being filled. The design
of the discharging system will ensure the processing of the oldest
syrup at all times. Sample cocks would be located in front of
the discharge valves to permit a bacteriological testing at regular
intervals.

The inside of the tanks should be coated with Epoxy or other

permanent bakélite, paint or fiberglas to prevent direct contact
between syrup and metal. Contact may discolor and, resultingly,
may cause difficulty in the ultimate refining of the sugar.

Maintenance and operational charges per ton of sugar for this type
of storage facility would be negligible.

lANOEHION •> PORTI», INC.

 207

Finally, the syrup would be transported to the storage tanks by tank

trucks. These tanks should be made of stainless steel and have
provision for cleaning and sterilizing the inside with steam. A
small drain cock should also be installed to drain the condensate
which should be returned to the processing plant. Materials other
than syrup, such as molasses or oil, should not be transported in
these tanks.

The capacity of tank trucks to be used will depend on the road con-
ditions. Taking into account the width and length for vehicles pre*
• ently allowed by Jamaican law, and based on a weight assumption
of 11. 3 poinds per gallon of syrup, a maximum load of 33 long tons
of syrup is considered feasible.

This new transportation scheme utilizing the vehicles and stain-

less steel tanks is presently in successful operation in Central
Palmar, Venezuela. In fact Mr. Delden, a Team Member, has
been and continues to be a consultant to this operation.

ÉAÜÜN
 208

BY-PRODUCT UTILIZATION

Shortening of the crop duration will require a higher grinding rate

and will produce larger quantities of bagasse each hour Also,
the establishment of syrup producing units will lower the total
process steam requirements of the factories. To maintain steam
balance, it may be necessary to reduce live steam requirements
proportionately lowering the amount of bagasse utilized by the
boilers. This, coupled with the increased grinding rate, will re-
sult in considerable amounts of surplus bagasse. Conservative
estimates place the excess as being between .65 to 19.84 tons per
hour depending on the factory.

During the crop, it is common practice to store certain quantities

of bagasse. This is used during mill stoppages in order to main-
tain steam pressure. It is assumed that approximately ten per
cent of the hourly bagasse production is designated for storage.
Anything in excess of ten per cent will cause major storage prob-
lems for most factories.

A shortened crop duration will utilize approximately I, 520 effective

grinding hours. At the excess bagasse rates of . 65 to 19. 84 tons
per hour, stockpiles could conceivably amount to between 1, 600
and 50, 000 tons and the total quantity for the combined factories
could reach 280, 000 tons. If collected in one area, it would cover
an area of one square mile at a height of four and a half feet. This
must be avoided.

A certain amount must be stored, requiring a second handling opera-

tion which cannot be avoided. However, once the bagasse exceeds
the storage capacities subsequent handling costs will become pro-
hibitive.

Today, bagasse is baled in many parts of the world. Again, the

labor and equipment needed to prepare, and later reahred the

Alili »ON a PO WTC». IMC.

 209

bales become expensive. However, this method has had some

measure of sue cess when a paper or board plant is closely lo-
cated to the sugar factory. Pelleting also has been fairly
successful especially in the preparation of cattle feed, but un-
less the pelleting plant is situated near the sugar mill, economics
of transportation become a factor Neither method should be
overlooked untilthe possibility of their application is studied thor-
oughly.

A quick, single handling system is to convert the bagasse into elec-

tricity through steam generation. The solution, though not simple,
should be studied closely, especially in the light of new equipment
requirements.

Years ago a few of the factories adopted the American Standard of

60 cycles per second for electric generation. Some had the fore-
sight to convert to 50 cycles since at that time Jamaica was using
both the 40 and 60 cycle systems and decided to standardize its
8> stem at 50 cycles, the European standard. Thus, the 60 cycle
plants cannot be interconnec ted with the Jamaican power grid.

Two of the 50 cycle factories, Monymu* and Frome, can and

have supplied power to the grid when Jamaica Public Service
encountered difficulty meeting Jamaica's demands for power.

Other factories generating at 50 cycles, have agreements with

Jamaica Public Service to purchase power during the off-crop
season while the generating equipment is being maintained, and
for an emergency standby during the crop.

Shortening the c rop season, increasing the hourly grinding rate,

and increasing the exc ess of bagasse will change the power picture.
It may be feasible to install power generation equipms nt at some
of the factories to utilize the excess bagasse; this is especially
true since, after review, nine factories may have possibilities fox-
generating power.
 210

Presently, Jamaca Public Servire has sufficient power to meet its

needs. It probably would reject any thought (if purchasing unwanted
power. Yet this power would be generated by a seasonal and inex-
pensive fuel. To allow it to remain m stockpiles or be incinerated
would mean a waste of a natural resource. Many other sugar pro-
ducing nations depend on bagasse tor electrical generation, Their
power plants are strategically lo* ated so bagasse can be trans-
ported from the sugar factory to the power plant by conveyor. Dur-
ing the off-crop season, the plants run on fuel oil.

Electric generation is one method of effectively utilizing bagasse.

Another possibility is converting it into semi-fini shed pulp for
paper production. Boiler capactv already exists at each factory.
Capital costs for depithung the bagasse and the cooking vessels for
pulping is moderate. Production costs apart from the purchase of
chemicals used during the cooking also will be moderate.

A study made in 1966 evaluated the feasibility of establishing paper

making and pulp producing facilities in Jamaica and concluded that
bagasse quantities were insufficient to warrant paper production
in Jamaica. The projected heavy surpluses may change this out-
look.
Today .Jamaica utili.es only a fract ion ol its "-kstrap njolas.eB
for rum production. I he rest is exported to the I nited S ates and
to Great "Britain where it is usee mainly m the blending o animal
feed At the same time, Jamaica imports all ot its motor fuel.
Therefore, conversion of locally produced blackstrap into absolute
alcohol should be considered.

Certain countnes, notably Bra,il. have used a blend »'»^"l

and gasoline as motor fuel for several decades. rh.s xtendthe
use of a natural resource, and a, the .»- ..me cur a, fore g„
exchange expenditure» for fuel. Jamaica, also, could fmd th..
very advantageous.

The „o,„ng pans which .^^caHed B, ^ -V•^Ä..

units can be converted into a triple ettec lor ar,o<,m(,nt In
molasses by a simple alteration ££^ be
addition, a rectifying column producing ^ ^ classes
the only new equipment required. Most of the existing mol
and syrup tanks, as well as the crystallise», may be utilised
 211

fermenters. The additional power required for alcohol production

can be provided by a portion of the same excess bagasse.

Another by-product, yeast, may also be recovered. This product

would stimulate the broiler and beef industry in Jamaica. Success-
ful yeast recovery has been proven previously in Bolivia.

Minerals cannot be produced from sugarcane or its by-products;

only organic compounds suchas lactic and citric acids. Pro-
duction, however, is highly sophisticated and requires a com-
petent pathological staff and microbiologists. The market for
these products are too limited in Jamaica to warrant production
and,export is practically impossible as large scale facilities in
other countries have already captured the existing markets.

Waxes are made occasionally from filtermud, a by-product in

itself from sugar production. However, synthetic waxes are less
expensive to produce and more consistent in quality.

Furfural production has also been discounted in that an efficient

operation would require ^00, 000 tons of bagasse annually. Trans-
portation of this bagasse to a central location would incur pro-
hibitive costs.

Animal and chicken feed is produced to some extent, using molasses

and imported grain. However, utilization of molasses for this
purpose is very limited.

Fertilizers are not produced from sugarcane or its products.

Sometimes filtercake (aged and seasoned) is used as a nutrient
and is spread over the land mainly to ease the disposal problem.

Particleboard is produced by one small plant in the vicinity

of Spanish Town. The plant (one of the smallest production units
possible) is only in production part time as the local demand for
the product is very limited. After t ransportation, it would be
non-competitive elsewhere and < an be marketed only in Jamaica.

Some bagasse is used for the production of baseballs near Mon-

tego Bay. The factory utilized only 100 tons of bagasse for this
purpose last year.
 212
I
Jamaica should realize that it is ble «»ed with climatic conditions
(yearly rainfall and distribution) and soil resources which make
the country ideally suited for cane production. The resultant pro-
ducts, carbohydrates in the form of crystallized sugar or black-
strap molasses and fiber, should be included among its natural
resources. These overall resources should be utilized to the
fullest extent, to benefit the further development of the nation.

i, i*e.
 213

ESTIMATED INVESTMENT AND WORKING CAPITAL

REQUIREMENTS

The capital costs for the proposed improvements to the

industry are summarized below and broken down into a number
of specific categories:
- Improvements to sugar processing facilities
- Conversion to syrup producing units
- Central End Factory
- Syrup Storage
- Jamaica Machinery Cooperative
- Cane Transportation Sector
- Working Capital

Improvements to Sugar Processing Facilities

Total
Estimated
Primary Elements Involved Expenditure
Factory

Bernard Lodge Clarification, Filter

Evaporator, Crystallizer $ 100,000

F rome Juice Heaters, Clarifier

Conversion, Syrup and
Molasses Supply Tanks 31,000

Monymuak Evaporation System,

Clarifier Filter, Supply-
Tanks, Vacuum Pan,
215,000
Centrifugal

Appleton Disassemble Holland

equipment, Transport and
re-assemble at Appleton SO, 000
 214

New Yarmouth Clarifier, Evaporator,

Vacuum Pans, Syrup
Supply Tanks 56,000

Sevens Turbine (1000 H. P. )

One Mill, Stainless
Steel Tubes, Supply
Tanks, Feeder Rolls 186.000

TOTAL $ 638,000

Converaion to Svrup Producing Units

Bybrook Evaporator Vessel fe

Piping, Flash Evaporator 48, 000

Pre-Evaporator, Polycell
Inns wood 62,000
Clarifier, Flash Evaporator

Polycell Clarifier, Flash

Grays Inn 40, 000
Evaporator

Pre-Evaporator, and
Hampden 42,500
Flash Evaporator

Clarifiers, Evaporator
Long Pond Improvements including
71,000
Flash Evaporator

Turbine, Flash
Serge Island 80,000
Evaporator

Turbine, Clarifier,
Jamaica Estetas
Vapor Cell, Flash
105,000
Evaporator

Turbines, Main Gears,

Worthy Park Foundations, Clarifier,
155.000
Flash Evaporator
TOTAL 603,500
 215

Central-End Factory
The detailed requirements for the central end-factory are esti-
mated at $3. 8 million including construction. In addition the
associated power plant will cost approximately $625, 000 giving
a total factory outlay of $4.425 million.

Syrup Storage
Twenty two syrup storage tanks distributed between Bowden,
Salt River, Falmouth, Ocho Rios and the end-factory will be
capable of handling 22, 000, 000 gallons of syrup. Estimated
expenditure for these tanks is $1, 320, 000.

Jamaica Machinery Cooperative

To establish a centralized machinery facility with the benefits
to efficiency as mentioned earlier will require approximately
$1, 250,000.

Cane Transportation Sector

BaBed upon our experience in other developing countries we
estimated an investment in the transportation sector is approxi-
mately $75/ton of daily cane grinding capacity. The combined
rate Ji all factories isV 336 T. C. D. The investment necessary
for improvements in this sector is therefore estimated at
$3, 100,000.

Working Capital Requirements

The concept of running the end-factory on a year round basis will
reouire tne storage of a sufficient quantity of syrup during the
Slay average harvesting season to last for the projected 2 90
dav end-flctory production span. As mentioned earlier in the
report IM. anticipate that the peak requirement wilbe.appro«-
-"ly HO, 000 to.;^^^£^Z>oi
IS entf^rT» wiU r create I wo^ng cplUl need for a
longer duration than is presently the case.
 216
I
To estimate the peak working capital requirement it has been
assumed that without any improver« nts it costs, very roughly,
about $7 per ton for cane production and about $2.60 per ton to
process the cane into sugar. Of this, $9,60, over $8 00 is
expended in production, initial processing, and transportation
to the storage facilities. The 110, 000 tons of in-process in-
ventory of syrup will yield approximately 57, 000 tons of sugar.
Assuming it takes 11 tons of cane to produce one ton of sugar,
approximately $5 million will be required in working capital
funds to finance peak in-process inventory costs. (11 x $8 00 /
ton x 57,000 tons).

On the other hand the working capital presently tied up on a

permanent basis in spare parts inventories will be consderably
reduced with the formation of the J. M. C. However, an overall
peak working capital requirement of from $6 to $7 million dollars
should be anticipated. Also, as the plans are implemented it
will evolve that working capital problems, to a large extent will
be shifted from the smaller producers to the end-factory Under-
standably, these are very broad estimates given to indicate the
scope of the working capital requirements in this project A
detailed cash flow analysis based upon a detailed cost analyse
is essential as part of Phase II to accurately estimate the specific
working capital needs.

A common practice of sugar producers is to **»* •c"a*r*

working capital by marketing sugar futures. In brief, a cer am
percentage of the output, for instance 50 per cent may_ be sold
using the futures medium before it is processed and -hipped,
thereby providing part of the funds necessary for raw materials,
salaried utilitie','spare parts inventories, l»-P~«" ^^
tories, etc. This method of financing peak working capital needs
could also be used under the recommended plan.
 217

Summary - Estimated Capital Investment

Improvements to Sugar Processing Facilities $ 638,000

603,000
Conversion to Syrup Producing Units
4,425,000
Central End-Factory
1,320,000
Syrup Storage
1,250,000
Jamaica Machinery Cooperative
3,100,000
Cane Transportation Sector

Permanent Working Capital (excluding peak

requirements financed
through futures) 3, 500, 000

$ 14,836,000
Total Estimated Capital Requirement

:»IQN
 218

ECONOMIC AND FINANCIAL CONSIDERATIONS

In the final analysis the success of any plan to improve the

Jamaican agricultural picture will be the impact its implemen-
tation will have upon improving the nations economic outlook.
While experimentation with agricultural diversification can and
must be undertaken, sugar is and will remain for many years
the dominant agricultural crop. Quite frankly no alternative
has yet been found to replace sugar with its intensive require-
ments for labor and its large income potential. Therefore, it
is incumbent that the necessary steps be taken and the necessary
capital invested to improve the performance in this ailing sector.
A comprehensive practical program such as the one presented
in this report must be undertaken to improve efficiency at each
level of production.

It i. unfortunate that, as an analytical base for P««*"««.'«»'»

and efficiency, 1969 and 1970 were not typical and do not prov.de
representative =..t figures. A number of firm, including even
the comparatively Urge Frome.nd Monymusk operation» opera.
ted at a to»» due to condition» outside their control. In 1969 an
unofficial strike, cane fires and flood producing rains during
part of the harvest season accounted for the short fall. In 1970
£„r climatic conditions contributed to the most unfavourable
cane to sugar ratio in years.

Accordingly, instead of spending an excessive amount of time

Lalvzing 969 and 1970 production costs, the more meaningful
cos figures from the detailed Mordecai report of December 12,
1966 hive been analyzed to ascertain the relative breakdown of
the various cost factors.

During the 1965 crop, «he latest one for which detailed' £' ««
available, the average production co.t per ton of Sugar
reported as follows:
 219

PER CENT
DOLLARS/TON OF TOTAL
COST FACTOR
PRODUCTION
3.73 39.4
»¡Field Workers
* Supervisory Staff .77 8.1
* Sub-Total Production Labor 4.50 47.5
* Equipment maintenance )
including upkeep of )
1.05 11.1
tractors, machinery )
cars, etc. )
Direct Costs (including
.66 7.0
fertilizers)
.65 6.9
Overheads
* Sub-Total average production 72.5
6.86
costs

PROCESSING
0.79 8.3
Factory Workers 3.8
Supervisory Staff 0.36
1.15 12.1
Sub-Total Factory Labor 4.4
Spare Parts 0.42
0.15 1.6
Machinery 2.9
Depreciation 0.27
.84 8.9
Sub-Total all machinery
Overheads (Insurance, F.A.S. 6.4
taxes, office supplies, etc. 0.61
Sub-Total average processing 27.5
2.60
cost
9.46 100%
TOTAL COST
*Note5 These factors will be improved with the implementation
of the recommendations In this report.
 220

Adding the total costs of production and processing reveals an

average cost of $9. 46 expended per ton of cane during 1965. The
Figures above represent average costs involved. However, it
must be noted that there was a great variation in production costs
between the various estates. This was essentially due to the broad
range of size, management expertise, and relative efficiency. As
such, the cost for producing a ton of cane, while averaging $6. 86
actually ranged between $5. 21 and $8.04, a difference of $2 83 per
ton. Thus, if we assume a ratio of 11 tons of cane per ton of sugar,
the imp*:t on the end cost of a ton of sugar could be as much as
$31.13.

Similarly, the cost of cane processing ranged between $2, 35 and

$3 30 per ton This was predicated upon plant size efficiency and
management expertise. Again assuming the 11 to 1 ratio, the end
cost of a ton of sugar could have further varied by as much as
$10.45. Such wide variations in production and processing costs
figures per ton of sugar indicate a great deal of room for efficiency
improvement. Through the broad base program recommended in
this report, production and processing costs will be reduced sig-
nificantly.

From the reported data it is apparent that this is a highly labor

intensive product and that labor constitutes the major cost factor.

Insiders often quote the following reasons for low productivity of

labor in Jamaica:

- Inefficient supervision
- Featherbedding methods of the unions
- Lack of adequately trained personnel
- The reluctance of labor to adapt labor saving mnovaUon*.

In light of this high labor intensive product, the W«^^^°£

costs attributable to labor emphasizes the critici •V»«•¿f
improving labor productivity. It is absolutely_ •«•nt»l *the
Jamaican Sugar Industry to increase ^^^^Z^n
ible stage in order to reduce it. overall Uboc.^ ion
competitive and indeed, even to survive, As the ma-^ ^ £dationB
of the labor cost is attributed to cane cutting, th ^^^
in this study call for a gradual mechanization of <•£•"£\
with harvesting equipment being financed and maintained by
M.C.
 221

Another factor important to the future of the industry is the need

for considerable investment , Another factor that is vital o the
future of the industry is the need for meamngful investment n
training. The extensive training program recommended in th s
report will have a signifient and needed impact on productivity.

The Suear Industry Welfare Board with the cooperation of the

EsUteTand Urmers, makes a very useful contribution particularly
Estates ana i»f»»» » However, consideration
in the fields of housing and medical care. * owever' M
must be directed to upgrading environmental condit-- -- no ably

--Asas:-
No machine, human or mechanical, can o per*
out adequate energy.

years, mainly due to the efforts of the suga ec0nomy

Lsociatio, ^^:^::^^:;^^^e^
wiU^^^e a ^iirUr plinthe future.

The cost figures stated earlier also highlight the need 'ce-
ment, in the maintenance and factory P^^^e cosîs have
Specific requirements for sigmficantlymproving these&re
been spelled out at length in other sections of this reoo
therefore not repeated in this section
« of capital investment for the plan outlined
Regarding the sources of i apitai in . wiU have to be
it is anticipated that the Government of Jamaica w ^
involved to a substantial degree .n the eqmty in ode ^ ^
attive project package can be develo ed and pr ^
terested lenders. A reasonable examples wo ^
component at 40% to 50% of the «P^»^^ the Specific
government supplying half the equity. analysis will be
requirements a fully detailed cost and financial.n y^ ^^
necessary in Phase II of ** ^abeeT^reá duri'.g this analy.i*
of the investment funds which cou Id be ^ ^.^ Development
and once it has been completed inci International Finance
S
Bank, the World Bank and "l* ££°*iona of several Major
Corporation, the International Banking

i wr.
 22?

U. S. Commercial Banks, the Caribbean Development Bank, the

Inter American Development Bank, Bola m- Barclays Finance
Corporation, Barclays Overseas Development Corporation, and
others. Working closely with and soliciting the advice of know-
ledgeable local commercial bankers during the financial analysis
will help to assure that all pertinent areas have been covered.
The importance of developing a sophisticated investment project
proposal must be reemphasized particularly since the industry
under consideration is at present of marginal profitability.
 223

BENEFITS

The short term benefits from the recommendations of the report

are threefold:
Increase in sugar production by the shortening of the
crop season and fully utilizing scarce land resources.

Increase in productivity per man hour for factory

operations by taking advantage of large econom.es of
size in the central end-factory.

Increase cane quality and annual sugar P~^lty

by improving the transportation system for cane.

„ad every factory reduced U..crop .«„on tc.the =^•

span during the past crop (1970) Ja•aica monetary terrn8
itToutput by about 16,000 tons of sugar .In mane V
this would have meant an increase of some $1.
, > f the laree ei onomies of scale in the central
Taking advantage nof the large *, ker r time
end-factory would ***"" ^^^«on together with
unit. Also, the improvement ""£? warehoUsing of parts
the greater savings ^ ^^,s would not necessarily
and with ^-P^^r;n o" sugar produced,
increase the variaDie ».uni. r
.u u „.fim derived from shortening the crop
To some extent the benefits derive . dail cane
season (or stated differently ^^^"^tion per acre

to serve this goal-

 224

This improved system will result in reducing the time between cane
burning and grinding, and in turn will improve the quality of cane
to be processed. Assuming this improvement in quality amounts
to a reduction of about one ton of cane needed per ton of sugar
produced, for the 1970 crop season, such a reduction would have
realised a gain in excess of 36, 500 tons of sugar yielding approxi-
mately $3.4 million.
Summarizing the benefits to be gained through implementation of
this program, and based on the foregoing 1970 figures an addi-
tional and immediate $4. 9 million in cash in-flow would have
accrued to the economy of Jamaica. In addition, the direct coet
savings resulting from training, amalgamation, centralization
of maintenance, and improving production and P"ce..in|5 effi-
ciency will be substantial and will have a tremendous impact on
the profitability of the industry and its contribution to the
economy.

:• i»r
 ESTIMATE Oí PRESENT SUGAR PRODUCTION AND EXPEC"
SUGAR PRODUCTION AFTER SHORTENING OF THE CROP
MIRATION. AND THE RESPECTIVE RETURNS, 1970

Bern,rd Worthy Jamaica Gray

New Lodge F rome Park Sugar Inn
Monymuik Yarmouth Appleton Eatatei

433.536 779,134 154.803 209.839 127

734.275 280,611 142,725
Cane Ground During W». T°ni
189 176 197
191 215
»0 119 140 148 120
Total Crop Duratiti» 1970. Dayt 134 13«
130 134
Projected Crop Duration, Day«
50.8 77 S
67.5 133.6 252 9
203.7 E9.0 312 60 97
Actual Capacity, Tona/hour 65 178
ìli HO
Projected Capacity. Tont/r>our
1227 12. 50 10. 24
12.64 9,90
10.33 10. »6 12.79 12.59 10. 83
Actual Sucrose in Can«, Percent 12.76 10.45
11.01 11.23
Projected Sucroae in Can«, Pareen«
78,279 17,180 17 283
15,596 33,392 18 279
59. 171 24,105 81,596 17,303
Sugar Projected in 1970, Tone 15,744 35,247
«3, IM 25,394
Sugar Expected torn Shortened Crop.T om
3 155 440 7,397,366 1,623,510 !.'"•")
iw
Actual Sugar Value, DolUre
5, 592.321
5,971,16*
2,277,922
2.399,733
1.473,822
1,417, 80S î:îU:A T.•.« »."*.»« « '*5
Expected Sugar Value, Dollari
175,401 313,456 11.623 94,122
121.S11 13,986
378,945
Gain from Shortened Crop , DnlUre

1
SECHI* 1
 I
PRODUCTION ANO EXPECTED 11»
RTENINO Or THE CHOP
'E RETUHN». |»T0

urthy Jamaica Cray'a •arg« To4al

ark Sugar Inn •avana Pwté laniwawl Hamnéan lalMMl •yarooh Holla** Or
A
EliMU

4,803 104.I» 117,41» 941, »4 1M.474 110,70* 101,111 44.4a» ITS,»! M.4II 4,113,44»

176 1*7 in 111 III tu 104 14* It* IN 144

141 no 117 I» 191 lit IM ISI IM IS4 14«

o.l 77 » §4.4 •t.7 •9.4 41.1 41.S 44.4 »1.1 44.1 • I. II

40 •7 44 IM W 14« I) 4S na

12. SO 10.14 4.41 14. H 10.47 14.41 14.77 lt.lt 11.17 14.44 11.41
12. »4 10.1) • 41 11.14 10.71 14. M 11.11 11.14 11.79 11.41 11.41

17, 140 17,111 4,141 10,147 14,1*7 17,11a 4, »71 I*,47* 7,110 Ml, 144
17,441
17, 30J 1«, 179 4,447 10,4*4 17,410 17.44* •,»44 17,01* 7,3*4 114,114
II, 1*1

(,M0 1,411,141 447.M4 |,»4*,441 I.414.MI 1,444.494 l,*9»,l*l •04,440 1.SS4.9M *7I.»4» 94,111.114
i5.Ul 1,717,9*» 414,7*1 l,4*l,»91 1.4*1.441 1.444.14» I.700.M1 • 11,404 1,*04,4S7 *4S. 1*4 94,114,044

11,419 44,111 14,417 44,114 17,911 114,744 *1,»70 1,444 »1.47» 14.171 I, »44.799

I SECT I •N 2 |

•ANDCRSON ft «»OUT« «. | NC.

 226

CONCLUSIONS

.. *• ».». r.vpaled the Jamaican sugar plants to be

This investigation has revealed me comp«t-
in .uch condition that optimum sugar V"?^•*^ clnnot be
Hive with other maJ0r world ^^^\^" oi foreign
achieved in their P»'«\'^ï planned and detailed steps
exchange revenue may be lost unless wtu P
for improvement are undertaken.
A ir, this reDort is practical as it will
The plan of action proposed n *hl8££r* * cane processing
utilize the portions of the existmg factone. £ P ^^
wh ile economies of .cale «n be obtat^d from 8 ^.^
lan q
located sugar crystallization^. The P J nation8 and
in a competitive position with other sugar pnjc ^ {or
change the Jamaican sugar industry from a hab ^ ^
the future development of the Island At the 8am^ ^^ ^
increase in annual production, ^f^ln increa9e in annual wages,
efficient production faciliti«;.. wül.du. UUan ^ ^ .^

• T apital expenditure»
tl
For increased sugar P^ ^^ nations
are necessary in the milling. cU""ca"• on, Some investments
of most plants converting t-^^ are to remain sugar
m».t also be made to upgrade the V^J^ may aUo be needed
factories. More cane tran.portatu*equip pre8ently. the
when adapting the higher daily *•*••^ In addition, capital
utilization efficiency of t -^ • 1 ^ ^ centrally located
investments are required for constr

T
„jyMtÄ»—~jtojU "9^ i^'«i^-
 227

crystallizing plut, for syrup storage and bulk »«orage -u«»r taciu-
tici, a» well ai for transportation modes.

The concentration and crystall.zation processes now undertaken at

rt. individual plants will rever, lo «he , entrai end-faCory.

The central end-fac.ory will reuuire --nUally the -^

of persons now employed during «he , rop•" ^• ra.
perform «he -ystalUsatior, ;en, „ «, --««•- '„,£. wlll
tions. Labor savings for the eiimin H sections

rm^;n^r^^:ÄE;:,:::5tr-d:-
-:hrV:^rreXrr:o;hi::d=nance and repatr
costs in the present sugar factories.

Afactor that is difficult to ^^^^^^^^^

which training will have on total sugar^output A of

in training, spare parts ^^^¡^te^VLy prove very

the TMC has been recommended and s*OU ^.^
beneficial and profitable to the Tatnaican^ sug ^^
should be regarded as an integral part of the

The plan for the establishment of ^^¡X^^^

is geared toward reducing costs, im ""in*p The formation of
ing Jamaica competitive in the export market.
JMC is aimed at these objectives.
of the syrup plants will have
Eventually, the processing machinery^^ when thi. occurs, nurr-
to be replaced as most of it is anl"» . diffusion units, espec-
er ous milling plants shou d be r epU J^^ __.
ially when cane is harvested oy

,„,he future, sugarcane harvesting jf J^ñ1"^"^*

throughout the world. lamaua shou>°J equipmen« and
111 mean that large 1-""""°'^"^ produce «he annual sugar
highly skilled workers will be needed £ P miy drain the
output. It will also mean ,ha.»»£*£. cin De manufactured
Balance of ^--^ ^UcensLg agreement, coupled

w\th r^iniu1;1 active, of the JMC

»ANOCKSON ft *o RTIH.INC.
 228

TO re.ch .hi. go.., i« »m be -»-y .o coTb,ne edu .tio„ wuhs

paction of equipment and pa. s A. . r..»l«. . » ^
such as King««. Industrial Works. Ltd win
th. future need, of the^industry ..« h. ^.nly pro^ sugar ^^
»peci.hzed training program, A revi, ,.,inin. facility and
try could support it» own central "P"' "»" l"'n "£^ foryfictory
undertake fabrication of simple "d «^'J^'aTe manufactured
and field operation. Whether or no, hese^» « (hey

Ärsui riheTaCr/f -¿u. «- » >-» -

national economy.

AHhough total mechanisation of the ^^^^«X«»

po.tponed .nd the need to P^^^d.. for the industry
equipment may prove too heavy harvesting mechan,za«.on is
., thi. time, it must be realized ^ ^ ^^ ,
ir.evit.ble. Total mechanization w'» P diversification of
machinery development and on «•»
lachvnery aeveiupw- ,orP»»•;,
irultu-al »^
sector. when the
c rops contributing to Jamaica's ^r^ltu cane growing will
Lm e arrives, -loping areas now acceptabl. for • „,„ wlll
time
prove unstable for harvesting me hani.aU ^ the
0
have to be utilized for ^"PV ^^^ in reduced annual
initiation oí total mechamaation may r suit other than
outputs unless ^o:^V::^:^n .^ ^ _,_
sugarcane, can
cal harvesting.
th. Jamaica sugar industry will require
In summary, to revitalize — 7. $1 5> 0 million,
a capital investment approximating »i
 229

DPnr.wAM CONTINUITY

«... o« - - UN.» :-—T^r;^%rruÄr

fact finding mission should be augmentea oy

An economi« .pecL.lUed l* "/"^oT"-"

port system. Me wouiu /.. „ „vruD transpor-

i. *~,. ^an*> transportation, syrup n»» K

and sugar.
i. i •-• to assist with the design of every
A sugar technologist to a88l8t w He would also
plant converting to syrup P'oducU^to^W
develop the centrally located end-factory.

A civil engineer.
¡alitimi in steam generation
An electric*! engineer «P«^1"* ^ a8 fucl for
to fully investigate the use of bagasse
electric generation.
. i- «^ in either inventory
Three management -P«".', «Ä ^-
control, computer .cience or techm

Antransportation
..--" engineer
»'^t^ZVZ"^«'-
ana
 230

A mechanical engineer with some training experience

to develop the Jamaica Machinery Cooperative with
present as well as future work loads in mind. He
would also assist in quantifying the value for re-
utilization of equipment in the end-factory.

Trained technicians of Jamaican nationality to fully

comprehend the nature of the program.

ÄV. ~E'V¿ ¿i, äeve.op.n, ,he ind..„y ove, «he ne«

15 years.
e
In most aevel0pi„g -» ^^y £Ä '--
but it is not assembled P'0?"1* n° y
of the Team, the Gov-

commencement of Phase Two.

•«;i*ri list
Prepare a Adetailed lis by by factory,
y coveringbethespeci
spare
.
parts used in «factory. The ^ ^
bricaUon
ficd according to the '* st
be placed on computer cards for easy

Prepare a detailed listing of ^ ^^^^

by JMC

Initiatea preliminary stud,^^"^w^ld

whether electricity production from bag
be in the national interest.
pecide whether additional finery £11111.. wou^be
desirable. Such a decision will be b ^ 9hould
e
Jamaica is to remain a ««PP» h {or market9 using
vigorously engage itself m t he.« u8 ln the
Europ n M1
Aïtf-A-
ket.
" "

,ANO.ef».»oN * J'JU'XS«-'"«-
 231

Discuss with the sugar producers and Estate owners

the possibility of introducing mechanical harvesting.

Consider the Sugar Industry Authority as the vehicle

to coordinate and assemble thi* information.

comes just another report.

The first Ph.se report on ^^J 1^ canno.be ..-^

Î.;A£5Î. indUry. m... be ,« ».-,

A comprehensive -»mmendaUon for «^^^nTe

w». just offered. However, the pom. ,n^urn ^^ ^
Two'might actuaUy -"^U^'e O o^pilfon ,o Phase Two
ina this interim period from Phase nult be provided in
8t art, it is essential that some g form of -^J^ plans and
Jamaica. A continuing effort is nee e s > and c(jn.
to provide a market place from which to gh^ ^^ ^^^
cepts for ultimate fruition, tor « desirable and
one of providing such continuity, appears hig y
should be strongly considered.
., „„„tiallv involve itself with
This interim Continuityprogram £«* «^J sugar industry;
developing the approach to revltal u ties . the cutter,
an approach that would be accepUble to all' P ^ Thi8
the owner, the industry in ^"^ the industry in formulation
program would also lend assistaneto inventory control,
li Certain management techniques such a ^^
transportation, scheduling of manpowe
ance, and so forth.
,^ k„ the formulation of a viable
The program's ultimate goal ^¿J^ Inning Phase Two. For
and totally acceptable *"••*£*yeffective, this meaningful
indeed, for Phase Two to be ab.• utoly
Interim Continuity Program is critica

,*N0tMON^r.^HC.
EXHIBITS

• AK0E««O»**°«TeH..«C.
 EXHIBIT A
PERCENTAGE CONTRIBUTION OF THE SECTORS^TO GRO.S
DOMESTIC PRODUCT AT FACTORY COST
(CURRENT PRICES) 1965-1969
($000)

1966 1967 1968 1969

Indern! Sector 1965

11.6 11.4 10.3 9.0

Agriculture, Forestry and Pishing 11.6 3.2
4.7 4.7 4.2
4.0 2.9
Expert Agriculture 3.9 3.7 3.3
DoHKSiic Agriculture
3.8 2.3
2.6 2.6 2.4
Livestock, Hunting and Fishing
Ì.6 0.4
0.4 0.4 0.4
0.4 11.6
Forestry mtd Logging 9.6 9.6 9.6
Mining, Quarrying and Refining •.7 14.6
15.4 14.9 15.3
15.0 12.9
Manufacturing .. 10.7 I0.S 12.5
10.7 1.3
Construction and Installation 1.4 1.4 1.3
1.3
Electricity, Gas and Water ..
Transportation, Storage and 7.4 7.6 7.4
7.4 7.5
Communication 13.9 13.5 13.6
14.4 14.1
Distributive Trades 4.6 4.6 4.7
4.4 4.6
Financial institutions 33 3.0 3.0
3.4 3.4
Ownership of Dwelling! S.9 9.2 9.3
' 7.5 7.1 12.6
Ctntral and Local Govern«*«» 13.9 13.1 »3.1
14.4
MivccIlaiKOus Service*
100.0 100.0 »00.0
100.0 100.0

1969.
Sourc«t Economic Siirvty. J»m*lc».

MnTia,)MS.
 EXHIBIT B
SUGAR PRODUCTION AND EXPORTS: 1965-1969 I

31,266
37.8S6
i960 30,176
mi 34,00»
m* 28,58-1

19*9.
Sourctt Economic Surv.y, J*m*lc»,

m^noamuoté #©«T««.
 EXHIBIT C
AVERAGE EXPORT PRICE OF SUGAR: 1964-1969
($ PER TON) ___

Dntinatioo

Jnitcd Kingdom
U.S.A.
Casata
Amnf« Net Price

Sourcot Economic »urvoy, JäW»IC», 1969

a mamrtm, me.
BAMOC"SON
 EXHIBIT D
BALANCE OF PAYMENTS: 1966- 1969
CURRENT ACCOUNT
($ MILLION)

1966 1967 1968 1969«

Credit Debit Net ¡Credit Debit Net Credit'Debit) Net Credit ¡ Debit : Net

GOODS .. •• ' 164.2; 203.2- -39.9 165.4 217.2-51.8 1S4.8 276.9 -92.1; 217.7 319.O.-101.Í
-92.1-, 217.7, 319.3-101.(
Merchandise (f.o.b.) •• 164.2- 203.2- -39.0 165.4 217.2-51.8, 184.8, 276.9
Ncn-Mor.etarygold .. • a • •
-6.7, 157.6 157.1 O.í
114.4' 11S.0 -3.6 121.4 132.8- -11.4 146.8 153.5,
StRVICtS .. •• -31.31, 24.9 59.S-34.S
16.0 34.2 -18.2' 1S.2 42.0,- -23.S 22.S 54.r-
1
Freight and other transportatioa 3.-' -3."
2.4, -2.4 2.6 -2.6¡
Merchandise Insurance .. 10.4J 63.0, 77.9| 12.5, 65.-'
Travel .. •• 36.4 8.4¡ 4S.0, 57.8¡ 8.6! 49.2¡ 73.4, 55.7|-44.C
10.6; 49. S¡- -39.2! 11. lj
6.6! 40.2 -33.6, 8.0, 44.o; -36.0
Investment Income .t
8.0i 2.2 5.8, 9.2' 2.o: 7.2 9.7¡ 2.0Ì 7.7J 10.8, I.2¡ 9.t
, Government (not included elsewhere) 34.0¡ -3. 7 32. S| 24.2 8."
Other Services .. •• 27.4 30.6¡ --3.2 23.2! 33.6¡ -5.4! 30.3, 12.0, 13.11 -1.;
-10.S, 11.6 23.1| -11.
9.4 19.8 -10.4. 10.4- 21.2, i!
(i) non-merchandise insurance
18.0 10.8 j 7.2¡ 17. S¡ 12.4, 5.4¡ 18.7¡ IO.9; 7. 21.0', IO.9'; 10.1
(ii) other .. ••
5.4j 10.4 15.6, 5.6 10.0,
16.2J 6.0; 10.2; 19.C C.l io.?
15.8 2.4l 14.7
1.0 12.8; 14.3| 1.0 13.3, 17.1J
TäANSI'LRS .. ..
Private .. . i. 14.0 1.0 I3.«j 13.8; 1.91 5.7¡ -3.S
4.4 -2.6 1.8! 4.6 I.9; 5.0] -3.1
Official 1.8
-53.2i 347.8 436.4-SS.6, 354.3 4S4.5-50.2
294.41 326.6-32.0' 302.4, 355.8
TOTAL CURRENT ACCOUNT

•Tnritloul

Sources Economic Survey, Jamale», 1969

,ANl««.ONÄPO«T«»...NC.
 EXHIBIT E
HOURS LOST IN GRINDING DUE TO FAILURE OF MACHINERY
FIRING 1970 _ —

Time Lost, Per Cent

Hours of Total Time, Hours
Factory
7.8 3,607
Monymusk 280

9.1 3,153
New Yarmouth 288

9.3 2,114
Appleton 197

Tamalea Sugar 2,708

323 11.9
Estates
18.0 3,246
Bernard Lodge 583

10.4 2,923
F rome 1 303

3.9 3,237
F rome 2 127
1.7 3,048
Worthy Park 52
2,288
209 9.1
Gray's Inn
9.8 3,618
Sevens 355
3,090
246 .8.0
Long Pond
3,305
394 11.6
Inns wood
3,312
128 3.9
Hampden
1,922
157 4.8
Serge Island
3,283
9.0
Bybrook 297
1,911
266 13.9
Holland

Factory Report 1970.

 H 0
1
4»
1 1
1 1 i
S <M U O N Ovo N O o-* CO.*
« 3 C N »• ^ n ONO o co CM CO
C C -H t • • • • t • % • t
t «h »- 1- (M N «- CM CM ON r\i-
OSa »• f»

6
4 »
* 2 •» 1 1 1 1 l
U fl 0
•n B 3 -* O CM O VOVO CO .tf ^M3
M .TO vo 00 f-vO no\ CM vO O C\
/ 9H0 t t • • • • • • • •
•K-
«< u vovo t- n
»• »•
ON
f»
CM «>o
f~
ON CM
w
m b
Z cr-
w i-i— %
w
en ti
a o 1 l
H • •» -H
W < 4* H 4* rvo v£<0 ^
(Q <*3« -*NO <• tr\ co
NVk • • • • • 1 1
9 •« * v n CM.» r\
§ U U
H m ido
< Z «
OS <
£9
Ü < • 4» l l 1
n O 0 oo
ONO ONO
00 o • » • • 1
• ( •
CM-Í <M-t

~a «• • » "

1 1
3?
H B5 H 1
Sog 00 no oo oo
co o• o• 00
• •
«4 t ,¿t vO
CM vô t-wo •
W
O r* 2
5w
l l

I
OS M • 1
wo *r\eo v0 00 oo co
OQ ON 00
• • • « 1 1
• • r»oo
è< o-

3é
Cu w
D • 1 1 l 1 >»
cl
Q
ooo
2 1« • 00 o nm
O M n** 00 O
o *> so »n • * • • U
Ü S un • • • • 3
9* O
H (A « 9* r~
£
H I
oo
M
u i u
¡B V « •A <0
•ri cu
ESCRIPTIO

0 fc C
« *"+ •»
u « **
0 fc >> «n C c *> el
U H
•p a> i- +¿ el
P. 4) U
JOB

H ^ >: 0 > « •<•i £

u H
i3 -H 0 1 a (4
fc h £ *3 *
I a o o
Q X
O 1
.ANOf".ON«-a«"««-'NC
 EXHIBIT G
l^p.
W\GE RATE STRUCTURE WITHIN THE SUGAR INDUSTRY
(JAMAICAN DOLLARS)

The data below represent the minimum and maxim«- »;» ^

the lo estates operating in W. they dc not represent a ran.e
¿càie applicable to all estate».

All figures are obtained from the compilation of 1 ^ Wage Rates

which is the most up-to-date source available.

Field
Rate
Job
$0.53-0.58 per ton
Manual Cane Cutting (Green Cane)
0. t>0-0. b3 per ton
Manual Cane Cutting (Burnt Cane) 0.42-0.46 per ton
Manual Cane Loading 1.65-2.75 per 8-hour day
Tractor Drivers (Wheel)
Tractor Drivers (Crawler) 1.80-3. 5e» per 8-hour day
(D4thit and Larger) 3*. 00-4. 00 per 8-hour day
Mechanical Loader Operators 2.54 per 8-hour day
Railway Drivers

Factory
1 30-2. o 6 per 8-hour day
Sugar Curer 2*70-3.40 per 8-hour day
Mill Engine Operator 1*48-3.50 per 8-hour day
Electrician 1*58-3.50 per 8-hour day
Welder 1*35-3.50 per 8-hour day
Carpenter 1*70-3.03 per 8-hour day
Cane noisi
tane Hoist w^-
Operator
j „m,nt bv results, replacing
The,. U an ,»cr«.*^^^. Je. **»«<« >"*"
hourly paid rates. For instance,
operators are paid as follows:
3. 50 for first 100 tons plu. 0.03
Mechanical Loader Operator per ton thereafter.

ill load 300 ton. in an 8-hour day.

An average operator will lo*d 3uu
 EXHIBIT G (Continued)

Averag e daily earning« in the Sugar Industry:

In Cropt
Factory $2. 96
Harvesting 2. 55
Cultivation 2. 68

Out-of-
Factory 2 .66
Cultivation 1 .71

, L u A*t-> nn the average number of man-days

in th, deriv..ion o the above d^. « Ü,. «. ^ ^ ^ „,

attendance records covering <*<. v

tates.

In Crop; $5.33 man-days per man-week

Factory 4.61 man-days per man-week
Harvesting 4. 52 man-days per man-week
Cultivation

Out-of-Crop: 4. 38 man-days per man-week

Factory 4.51 man-days per man-week
Cultivation
u -4 f pressine a diversity of wage rates
A more representative method of £*r..« B oniy ^ y„ high.
U by weighted --age« rather ttan y ^ & ^^ 3ob.
est and the very lowest rates in
, • H from th. 1969 compilation of Wage Rages.
The data below as derived from the

for each estate.

Field rates were ^£S£^*~

in-crop reaping non-staff empi y
for each estate.
i.t. e a. Crane Operator,
Where a range exists, e. g. ^ %
it indicate, that at least one esta
wage range for that job.
 EXHIBIT G {Continued)

Wage rates are expressed throughout in

Jamaican Dollars, and represent remun-
eration per 8-hour day unless otherwvse
stated.
Rate per Da]
Job

rane Handling at Factory

$2.19
(a) Cane Yard Foreman 2.33-2.38
(b) Crane Operator 1.29-1.78
(c) Others

Milling
i. 95-2. 98
(a) Mill Foreman 2.11
(b) Mill Feeder 1.38-1.89
(c) Other

Gene ratio" of Steam

3.81
(a) Boiler Foreman 2.48-2.58
(b) Boiler Attendant 1.58-1.88
(c) Other

Clarification Evaporation and

CTY§tallU»tionr etc>-
2.38
(a) Pan Supervisor 3.00-3.06
2.33-2.35
(b) Pan Boiler
(c) Evaporator Attendant 1.55-2.00
(d) Others

running Vessel» 1.58-3.21

Cleaning Evaporators per vessel

Curing Sugar 2.80

1.88-2.02
(a) Curing Foreman
(b) Centrifugal Attendanti
 EXHIBIT G {Continued)

Sugar Store
$0. 24 per ton
(a) Marking, Bagging, etc. 1.13-1.22
(b) Laborer»

1.35-1.53
Sampler

RumDUtiUerj
3.10-3.43
Distillery Foreman 1.98-2.17
(a)
(b) Still Attendant 1.46-1.51
(c) Setting Wash
1.36-1.37
Fermenting Loft Attendant 1.43-1.53
(d)
1.35-1.75
(e) Can Pit Attendant
(£) Other

Tradesmen
3.75
Chargehand. - All Trade. 3.14-3.28
I 2.60
(a) Welder
II 2.18
Welder
III
Welder
3.31-3.28
(b) Electrician 1 2.67
Electrician II 2.21
Electrician 111
2.89
I 2.46
(c) Plumber
II 2.07
Plumber
III
Plumber
2.89
I 2.23
(d) Tin.mith
11 2.00
Tinsmith
111
T in.mith
2.89
1 2.46
(«) BUck.mlth
II 2.07
Black.mith
BUck.mlth HI
 EXHIBIT G (Continued)

(f) Machinist I $3.25

Machinist II 2.63
Machinist III 2.21

(g) Mechanic I 3.08-3.13

Mechanic II 2.54-2.55
III 2.12-2.13
Mechanic

I 3.02-3.04
(h) Carpenter
II 2.52-2.55
Carpenter
III 2.12
Carpenter

I 1.96-3.03
(i) Mason
II 2.51
Mason
III 2.06
Mason

1 3.30
(j) Rigger» 2.91
Riggers II
2.20
Riggers III
2.61
(k) Painters I
2.34
Painters II
1.99
Painters m
2.86
(1) Coopers i
2.54
Coopers ii
2.23
Coopers m
3.00
(m) Fitters i 2.33
Fitters II 2.07
Fitters m
1.68-1.74
(n) Assistants
1.33-1.56
(o) Helpers

Reaping Operations
0.55 per ton
Manual Green Cane Cutter 0. 63 per ton
Manual Burnt Cane Cutter 0.43 per ton
Manual Cane Loader 2.29-2.34
Tractor Driver (Wheel) i--ff-rl 2.65-2.77
Tractor T> î ~./r*awler-D4
Driver(Crawier ^ and larger; 3.32
Mechanical leader Operator 2.54
Railway Driver g Federa.

Source: Private Communication with the Sug»r

tion of Jamaica.
 WTRLIOGRAPHY

AGRICULTURE OF SUGARCANE A.C. Barnes

Leonard Hill, Ltd., London, 1954

SUGAR IN JAMAICA C A. Bloomficld

ECONOMIC SURVEY OF JAMAICA, 1969 Central Planning Unit

T£2£ S^^""-• -va^^rland W»

PRINCIPLES OF SUGAR TECHNOLOGY P. «onig

Elsevier Publishing Company, Amsterdam

HANDBOOK OF CANE SUGAR ENGINEERING Hugot

Elsevier Publishing Company, Amsterdam

CANE SUGAR HANDBOOK Spencer and Meade

John Wiley and Sons, New York 19b.

REPORT OK THE SUGAR ENOU.HV COMMISSE , —

Government of Jamaica, I9bb

PBocEEDINos or THE «ET»« or THE BRIT,S„ WSST

INDIES SUGARCANB TECHNOLOGISTS

pROCEEDIN0S O. TH«««««- Or T„E -MAICAN

SUGARCANB TECHNOLOGISTS ^^

PROCEEDINGS O. ^fSo^^ ^^^

SOCIETY OF SUGARCANE TECHNO

ANNUAL REPORT Or ^^S^^* ' "*'

The Sugar Manufacturers A«»oci

TIB.I«-
tANDlMO" » *°*
 BIBLIOGRAPHY ( Continued )

THE FINANCIAL TIMES April 29, 1970, December 22, 1970

August 26, 1970

ANNUAL REPORT AND ACCOUNTS 1965 1970

Tate and Lyle

INVESTORS CHRONICLE AND S.E.G. March 12, 197L AufUit 7,1970

FOREIGN AGRICULTURAL CIRCULAR "SUGAR FS 3-70"

United States Department oí Agriculture, December, 1970

• * NocMSON a momrtm,i»c.
t t