Energy Profile: Gokak Jaggery Cluster

ENERGY PROFILE

GOKAK
JAGGERY
CLUSTER

i
ENERGY PROFILE

GOKAK
JAGGERY
CLUSTER
Certificate of originality
Original work of TERI done under the project “Advancing Energy Efficiency in the Micro, Small and Medium
Enterprise (MSME) sector in India”.

This document may be reproduced in whole or in part and in any form for educational and non-profit purposes
without special permission, provided acknowledgement of the source is made. SSEF and TERI would appreciate
receiving a copy of any publication that uses this document as a source.

Suggested format for citation

TERI. 2018
Energy Profile: Gokak Jaggery Cluster
New Delhi: The Energy and Resources Institute; 16 pp.
[Project Report No. 2017IE03]

Disclaimer
This document is an output of a research exercise undertaken by TERI supported by The Shakti Sustainable Energy
Foundation (SSEF) for the benefit of MSME sector. While every effort has been made to avoid any mistakes or
omissions, TERI and SSEF would not be in any way liable to any persons/organizations by reason of any mistake/
omission in the publication.

The views/analysis expressed in this report/document do not necessarily reflect the views of SSEF. The Foundation
also does not guarantee the accuracy of any data included in this publication nor does it accept any responsibility
for the consequences of its use.

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 Contents
ABBREVIATIONS

ACKNOWLEDGEMENTS

GOKAK JAGGERY CLUSTER

Overview of cluster....................................................................................................................1

Product, market and production capacities............................................................................1

Production process.....................................................................................................................2

Technologies employed..............................................................................................................4

Energy scenario in the cluster...................................................................................................5

Energy saving opportunities and potential.............................................................................6

Major cluster actors and cluster development activities........................................................7

 Abbreviations
Abbreviation Full form
CFL Compact Fluorescent Lamp
DG Diesel generator
EE Energy efficient
GHG Greenhouse Gas
hp horsepower
kcal/hr kilocalorie per hour
kWh kilowatt-hour
LED Light-Emitting Diode
LT Low Tension
Lit Litre
MSMEs Micro Small and Medium Enterprises
MSME DI MSME Development Institute
PV photovoltaic
SSEF Shakti Sustainable Energy Foundation
t tonne
toe tonne of oil equivalent
tph tonne per hour
tpy tonne per year
VSD Variable Speed Drive
 Acknowledgements
Shakti Sustainable Energy Foundation (SSEF) works to strengthen the energy security of India by aiding the
design and implementation of policies that support renewable energy, energy efficiency and sustainable transport
solutions. TERI places on record its sincere thanks to SSEF for supporting the project on profiling of energy
intensive Micro, Small, and Medium Enterprise (MSME) clusters in India.

TERI team is indebted to MSME-DI for providing support and information related to jaggery units in and around
Gokak. TERI extends its sincere thanks to Mr Basappa, jaggery unit owner and Mr Prakash, Phoenix Products, for
their support and co-operation in organizing the field visits and interactions with jaggery units. TERI would also
like to thank Mr Sameer Kanabargi, Phoenix Products, Belgaum, for facilitating the field visits.

Last but not the least, our sincere thanks to other MSME entrepreneurs and stakeholders for providing valuable
data and inputs that helped in the cluster analysis.
 Energy Profile: Gokak Jaggery Cluster

Gokak Jaggery Cluster

Overview of cluster
Jaggery is made from sugarcane in most parts of India. It is a
concentrated product of sugarcane juice and brown in colour. It
is colloquially called ‘gur’ or ‘gud’ in most states, but other names
such as ‘gul’, ‘vellum’, ‘khandsari’ and ‘bella’ are also common.

Gokak, in the state of Karnataka, is one of the largest clusters of

jaggery units in India. The units are spread within Gokak district
with highest concentration in areas like Kudchi and Raibag. Gokak
is close to Belgaum which is a well-known industrial cluster. Location of Gokak and Belgaum
Sugarcane is extensively grown in the region due to availability of Source: Google Maps
water throughout the year and sufficient seasonal rainfall.

There are about 120 jaggery making units in the cluster. Most of these industries are registered under the micro
and small categories. The total turnover of the cluster is estimated to be around `150 crores.

Product, market and production capacities Micro (jaggery with sugar) 79%

Jaggery is a natural, traditional sweetener made by the concentration Small (jaggery with sugar) 13%
of sugarcane juice. Jaggery, which is a natural mixture of sugar and
molasses, is consumed extensively in rural areas of the country. Small (jaggery without sugar) 8%
Jaggery contains all the minerals and vitamins present in sugarcane
juice and hence is also healthy compared to white sugar.
Distribution of jaggery units in the cluster

The cluster produces two types of jaggery: jaggery with sugar and
jaggery without sugar. Jaggery with sugar has more demand in the market. Major markets catered by the cluster are
rural areas of Mahalingpur, Kolhapur, and Gadhinglas districts in Maharashtra and Belgaum and Hubli districts
in Karnataka.

Categorization of units and estimated production

Category No. of units Production (tonne/year)
Micro units (jaggery with sugar) 95 28,500
Small units (jaggery with sugar) 15 13,500
Small units (jaggery without sugar) 10 2,700
Total 120 44,700

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 Energy Profile: Gokak Jaggery Cluster

Raw material usage in the cluster

The primary raw material for the manufacture of jaggery in the cluster is sugarcane. The sugarcane is sourced from
farmers in Belgaum and Gokak districts. Units producing jaggery with sugar, buy sugar from (sugar) industries
located in Belgaum, Gokak and Hubli districts. Some of the units also buy sugar from sugar industries in Kolhapur.
The cost of the raw materials depends upon their quality and source. Typically, the cost of sugarcane is around
`2,800 per tonne while cost of sugar is `33 per kg.

Sugarcane Sugar

Apart from sugar, small quantities of kesari, cooking oil, phosphoric acid, sodium Raw material receipt
bicarbonate, and lime are also added during the manufacturing process. (sugarcane, sugar)

Production process Crushing of sugarcane

Jaggery production is a batch process. The typical process of manufacturing jaggery

Sugarcane Juice
is shown in the flow chart. The major raw materials, namely, sugarcane and sugar, are filtraon and storage
purchased in bulk. The steps involved in jaggery making are as follows:
Sugarcane juice and
sugar mixing in pan
Extraction of juice from sugarcane
The juice from the sugarcane is extracted using a cane crusher, driven by electric
Boiling and srring of
motors. About 1.5–2 tonne of sugarcane is crushed to make a single pan of jaggery. mixture
The requirement varies upon the quality of the sugarcane and its sucrose content.
Cooling and mould
Boiling of juice for purification preparaon

The extracted juice from the sugarcane is taken for boiling. The juice is boiled in
Mixture pouring in
big open pans. While heating, the juice it is continuously stirred and dirt particles moulds
floating on the surface are taken out. Bagasse (the fibrous residue left after the
extraction of juice from sugarcane) is used as fuel for boiling. Packing and dispatch
Process flow chart

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 Energy Profile: Gokak Jaggery Cluster

Juice extraction from sugarcane Sugarcane juice boiling for purification

Purification of juice
The juice, when heated and boiled, releases many impurities which have to be removed. Proper purification of the
juice decides the colour, texture, taste, and durability of the jaggery. For purification of juice, materials like lime
and sodium bicarbonate are used. These materials help to bring the impurities to the surface of the pan. The scum
is skimmed out from the juice.

Cooling, moulding and crystallization of juice

The next step after purification of juice is concentration. Here, the juice is boiled at 100 oC. Subsequently, the pan
is removed from the furnace and stirred for some time. The boiled liquid jaggery is then transferred into a cooling
pan. As the temperature falls, the jaggery begins to crystallize. After stirring the juice slowly and intermittently, to
avoid the loss of its granular structure, the semi-solid mass is put into moulds to solidify. These lumps or moulds
are made to take the shape of a bucket. These buckets are of different sizes and weight. Typically, mould bucket size
varies from 1 kg to 30 kg. The jaggery, after cooling, is removed by inverting the moulds.

For making jaggery with sugar, the purified juice is taken in a pan for boiling and mixed with sugar in the ratio of
1:3. The juice is continuously stirred while boiling for about an hour and then poured into the moulds manually.

Cooling and moulding

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 Energy Profile: Gokak Jaggery Cluster

Technologies employed
Most of the equipment used in the manufacture of jaggery are of local make. The crushers used by the units and
the furnaces are locally manufactured.

Sugarcane crusher with dryer

The crushers used by the units are continuous type with crushing capacity of 1–2 tonne per hour. Usually, the small
scale units operating throughout the year have mechanical crushers while the rest of the micro units use manual
crushing systems. The juice produced after crushing is passed through strainers for filtration and is collected
in storage tanks. The bagasse which remains after juice extraction is passed through a continuous type dryer to
remove moisture and kept as fuel for the furnace. The micro units usually dry the bagasse in the sun.

Sugarcane crusher with dryer

Furnace
Jaggery units use traditional open pan type
furnaces for boiling the sugarcane juice. The
dried bagasse is used as fuel for these furnaces.
The calorific value of the dried bagasse is in the
range of 3,000 to 4,000 kcal/kg. While heating,
the dirt and unwanted parts, float to the surface
and are manually removed. This purified juice
is then stored in a tank for further processing.

Open pan type furnace

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 Energy Profile: Gokak Jaggery Cluster

Pumps
Mono-block centrifugal pumps with flexible plastic piping are used for juice conveying.
These pumps are small in size (of 1hp rating) and are used to transfer the juice to storage
tanks and process pans. These pumps are operated intermittently as required.

Juice pans
All the units use open pan method for jaggery making where juice is boiled in open pans.
The juice pans are made of iron sheets and are between 230–280 cm diameter and about
50 cm depth. For better colour of jaggery, galvanized iron or copper pans are also used.
Some units have two pans which are used alternately or simultaneously. The pans are
Juice pump
locally manufactured in Belgaum district.

Juice pan

Energy scenario in the cluster

Bagasse, produced from the crushed sugarcane, is used in the units as primary thermal source for heating. Moisture
from bagasse is removed by drying in the dryer, which is in line with the crusher machines. Electricity provides
the main source of energy for rotary applications like crusher motors and juice pumps. Almost all the units are
dependent on electricity from grid to meet their energy needs. The average connected load per unit depends upon
the product manufactured and installed capacity of the plant. Majority of the units have LT connection between
40–60 hp. DG set is used only as standby in case the grid supply fails in between the process. The primary energy
sources in the jaggery units among the cluster are given in the following table.

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 Energy Profile: Gokak Jaggery Cluster

Prices of major energy sources

Source Remarks Price
Bagasse In house (by product of sugarcane) NA
Electricity Low Tension (LT) connection `8 per kWh (inclusive of energy, demand charges, other
penalty/rebate and electricity duty)
Diesel From local market `65 per litre (price subjected to market fluctuations)

Unit level consumption

The unit-level energy consumption in jaggery units includes electricity and bagasse.

Unit level energy consumption

Type of jaggery unit Electricity (kWh/year) Bagasse (tpy) Diesel (ltrs/year) Total energy (toe/year)
Micro units 18,461 460 500 204
Small units 55,384 1,380 750 613

Cluster-level consumption
The overall energy consumption of the cluster is estimated to be
Small units, 44%
34,735 toe. The estimated greenhouse gas (GHG) emissions at the
cluster level is 2,742 tonne of CO2. The overall energy bill of cluster
is estimated to be `29 million/year.
Micro units, 56%

Energy consumption of the jaggery cluster (2017-18)

Type of Electricity, Bagasse Diesel Tonnes Tonnes Annual Share of energy consumption
jaggery million kT/year kL/ of oil of CO2 energy
unit kWh/year year equivalent equivalent bill
(million
`)
Micro 1.75 43.7 47.5 19,420 1,559 17.1
units
Small 1.38 34.5 18.8 15,315 1,183 12.3
units
Total 3.13 78.2 66.3 34,735 2,742 29.4

Energy saving opportunities and potential

Some of the major energy saving opportunities among the jaggery units in the cluster are discussed below.
Waste heat recovery from open pan furnaces
Thermal efficiency of open pan furnaces used in jaggery units is low. A lot of heat is wasted in the flue gases. Recovering
the waste heat would substantially improve the efficiency of the furnaces.

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 Energy Profile: Gokak Jaggery Cluster

Replacement of rewound motors with energy efficient motors

Rewinding of motors result in a drop in their efficiency by 3%–5%. It is better to replace all old motors, especially
the motor in the crusher machine, if it undergoes rewinding three or more times. The old rewound motors may be
replaced with EE motors (IE3 efficiency class). This would result in significant energy savings with simple payback
period of 2 to 3 years.

Application of variable speed drive in crusher motor

The crusher machine has two motors of around 15 hp rating. Depending on manual feed rate of sugarcane and
weight of sugarcane, load on the crusher machine is variable. The motor-driven systems are often oversized and
inefficiently controlled. Variable speed drive (VSD) could be installed for these motors with feedback of the weight
on the conveyor. Use of VSD in place of constant speed will reduce the power consumption between 10%–15%.

Rooftop solar PV plants

Jaggery units have huge roof spaces. The region receives good amount of sunlight throughout the year. Partial
load sharing is possible by implementing solar PV on the roof tops. Net metering is also permissible in Karnataka.

Lighting
T-12 tube lights (of 52W including choke) and CFL lamps (36W and 45W) are generally used by the units in the
cluster. These inefficient lightings can be replaced with energy efficient LED lighting (LED tube lights of 10W and
20W) which would provide better illumination and energy savings. Since a large number of lamps are used in the
units, the existing lighting may be replaced with EE lighting in a phased manner. Payback period for EE lighting
is generally within 2 years.

Pumps
Presently monoblock centrifugal pumps are being used in the cluster for sugarcane juice conveying. All these
installed pumps are very old with low efficiency. These pumps can be replaced with new energy efficient monoblock
pumps with high efficiency which will save energy.

Major cluster actors and cluster development activities

Major stakeholders
The MSME Development Institute (MSME DI), Belgaum, under the Ministry of MSME, Government of India, is
the key support institution for the units in the cluster.

Cluster development activities

Although a major contributor in the economy of the region, there are hardly any developmental efforts to improve
the jaggery industry in Gokak. There is a scope to establish a jaggery research center to support the production
of quality jaggery. There is a lack of awareness among unit owners regarding energy conservation and resource
efficiency. MSME-DI and some industry associations from Belgaum have reached out to jaggery unit owners in
the past for skill development activities. However, there is a need to expand these activities in the cluster.

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About TERI
A dynamic and flexible not-for-profit organization with a global vision and a local focus, TERI (The
Energy and Resources Institute) is deeply committed to every aspect of sustainable development.
From providing environment-friendly solutions to rural energy problems to tackling issues
of global climate change across many continents and advancing solutions to growing urban
transport and air pollution problems, TERI’s activities range from formulating local and national
level strategies to suggesting global solutions to critical energy and environmental issues.

The Industrial Energy Efficiency Division of TERI works closely with both large industries and
energy intensive Micro Small and Medium Enterprises (MSMEs) to improve their energy and
environmental performance.

About SSEF
Shakti Sustainable Energy Foundation established in 2009, is a section-25 not-for-profit
company that works to strengthen the energy security of the country by aiding the design and
implementation of policies that encourage renewable energy, energy efficiency and sustainable
transport solutions. Based on both energy savings and carbon mitigation potential, Shakti focuses
on four broad sectors: Power, Transport, Energy Efficiency and Climate Policy. Shakti act as a
systems integrator, bringing together key stakeholders including government, civil society and
business in strategic ways, to enable clean energy policies in these sectors.

About SAMEEEKSHA
SAMEEEKSHA (Small and Medium Enterprises: Energy Efficiency Knowledge Sharing) is a
collaborative platform set up with the aim of pooling knowledge and synergizing the efforts of
various organizations and institutions - Indian and international, public and private - that are
working towards the development of the MSME sector in India through the promotion and
adoption of clean, energy-efficient technologies and practices. The key partners of SAMEEEKSHA
platform are (1) Swiss Agency for Development and Cooperation (2) Bureau of Energy Efficiency
(3) Ministry of MSME, Government of India (4) Shakti Sustainable Energy Foundation, and
(5) The Energy and Resources Institute.

As part of its activities, SAMEEEKSHA collates energy consumption and related information from
various energy intensive MSME sub-sectors in India. For further details about SAMEEEKSHA,
visit http://www.sameeeksha.org