Industrial Visit Bagasse-Based Cogeneration Power Plant
Event Report: Industrial Visit in Sant Tukaram Sugar Factory (Bagasse-Based Cogeneration Power Plant)
Creative Outreach: Industrial Visit in Sant Tukaram Sugar Factory Bagasse-Based Cogeneration Power Plant
Organized By: IEEE PES Student Branch Chapter at the Department of Electrical Engineering JSPM’s Rajarshi Shahu College of Engineering
Date: 23th January 2026
Venue: Survey No 149, Kasarsai-Darumbre, Near Post Kasarsai, Taluka Mulshi, District Pune, Maharashtra, 410506
Objective:
Industrial exposure is essential for engineering students to understand how theoretical concepts are applied in real-world systems. To provide practical insight into energy generation and industrial processing, the IEEE PES Student Branch of JSPM’s RSCOE organized an industrial visit to a Sugar Factory integrated with a Cogeneration Power Plant having a crushing capacity of 3500 tons of sugarcane per day (TCD).
The main objectives of the visit were:
!)To understand the basic process of sugar manufacturing from sugarcane.
2)To study cogeneration-based electricity production using industrial by-products.
3)To observe the practical application of electrical machines, boilers, and turbines.
4)To understand sustainable and efficient utilization of energy resources.
Cogeneration Power Plant
The cogeneration plant operates on the principle of combined heat and power (CHP), where both electricity and useful thermal energy are produced from a single fuel source.
Bagasse generated from the 3500 TCD sugar crushing process is used as fuel in boilers to produce high-pressure steam. The steam drives a turbine coupled with a generator, converting thermal energy into electrical energy.
The plant has a generation capacity of approximately 15 kVA:
4 kVA is utilized internally for sugar manufacturing operations.
11 kVA is exported and sold to the grid.
This system enhances energy efficiency and reduces dependency on external power supply.
Sugar Manufacturing Process
The visit began with an overview of the sugar production process. Sugarcane is unloaded in the yard and transported to the milling section using mechanical cane carriers. The factory operates with a crushing capacity of 3500 TCD, enabling large-scale sugar production.
In the milling unit, heavy rollers crush the sugarcane to extract juice. The extracted juice is further processed to produce sugar, while the fibrous residue obtained after crushing is known as bagasse, which serves as the primary fuel for the cogeneration power plant.
By-Products and Their Utilization
The sugar factory produces several useful by-products:
1)Bagasse: Used as fuel in the cogeneration plant
2)Electricity: Used internally and surplus power sold to the grid
3)Molasses: Used for ethanol production
4)Press Mud: Used as agricultural fertilizer
Conclusion
The industrial visit provided valuable practical knowledge about a 3500 TCD sugar manufacturing plant integrated with a cogeneration power system. The visit enhanced understanding of renewable energy utilization, industrial power systems, and waste-to-energy concepts, making it highly relevant to electrical engineering education and IEEE activities.
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- Survey No 149, Kasarsai-Darumbre, Sant Tukaram Sugar Factory
- Near Post Kasarsai, Taluka Mulshi, District Pune, Maharashtra, 410506
- Pune, Maharashtra
- India 410506