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Sugar mill machinery

Enter the cane the mill crushes and what is in it. The list below is what that implies — carrier and fibrizor, mill tandem, clarifier, evaporators, pans and centrifugals — with a rate column you fill in yourself.

How this works →

Your figures

Cane crushed(tonnes/day)

The figure a mill is always described by — TCD.

Operating hours(hours/day)

A mill runs the season continuously; the balance is cleaning.

Pol in cane(%)

Recoverable sugar in the cane. Sets the boiling house and the bagging line.

Imbibition water(% on cane)

Water added at the tandem. Every litre has to be evaporated again.

Material take-off

What to buy, at what size, and how many — worked out from the figures above.

Rates

CurrencyFabricated steel (₨/kg)Skilled labour (₨/day)

Every line is estimated from those two figures: its steel — or steel-equivalent — mass at the steel rate, stainless at 3.2×, plus its install days at the labour rate. There is no price feed behind this, so the two anchors are seeded from typical Pakistan figures as of September 2026 and are yours to correct. Type over any individual rate and yours is used instead.

Cane handling & preparation

Material	Size	No.	Total weight	Rate	Amount
Cane carrier, leveller and cutterFeeds the tandem at an even rate — a surging carrier chokes the millsRate from 48,773 kg + 20 days labour — Slat chain, drives, leveller and cutter drums	114 t/h	1set	—	estimated	19,559,091
Fibrizor / shredderPreparation index above 85% — the mills cannot recover what is not openedRate from 67,818 kg + 16 days labour — Rotor, hammers, housing and steam turbine drive	114 t/h	1unit	—	estimated	27,167,273

Cane carrier, leveller and cutter
Feeds the tandem at an even rate — a surging carrier chokes the mills
Rate from 48,773 kg + 20 days labour — Slat chain, drives, leveller and cutter drums
Size
114 t/h
No.
1set
Total weight
—
Rate(estimated)
Amount
₨ 19,559,091
Fibrizor / shredder
Preparation index above 85% — the mills cannot recover what is not opened
Rate from 67,818 kg + 16 days labour — Rotor, hammers, housing and steam turbine drive
Size
114 t/h
No.
1unit
Total weight
—
Rate(estimated)
Amount
₨ 27,167,273

Milling

Material	Size	No.	Total weight	Rate	Amount
Mill tandem, three-roller setsFive mills in tandem with imbibition applied countercurrentRate from 219,818 kg + 40 days labour — Rollers, headstocks, turbine or motor drive and gearing	114 t/h166.4 t eachsite-erected	5mill	831.8t	estimated	440,136,365
Imbibition water system28% on cane, heated and applied at the last millRate from 13,164 kg + 6 days labour — Tank, heater, pumps and spray headers	31,818 kg/h	1set	—	estimated	5,280,455
Bagasse carrier to boilerBagasse at about 30% of cane, fuelling the boilerRate from 18,836 kg + 12 days labour — Rubber belt or slat carrier with drives	34.1 t/h	1set	—	estimated	7,564,545

Mill tandem, three-roller sets
Five mills in tandem with imbibition applied countercurrent
Rate from 219,818 kg + 40 days labour — Rollers, headstocks, turbine or motor drive and gearing
Size
114 t/h · 166.4 t eachsite-erected
No.
5mill
Total weight
831.8 t
Rate(estimated)
Amount
₨ 440,136,365
Imbibition water system
28% on cane, heated and applied at the last mill
Rate from 13,164 kg + 6 days labour — Tank, heater, pumps and spray headers
Size
31,818 kg/h
No.
1set
Total weight
—
Rate(estimated)
Amount
₨ 5,280,455
Bagasse carrier to boiler
Bagasse at about 30% of cane, fuelling the boiler
Rate from 18,836 kg + 12 days labour — Rubber belt or slat carrier with drives
Size
34.1 t/h
No.
1set
Total weight
—
Rate(estimated)
Amount
₨ 7,564,545

Clarification

Material	Size	No.	Total weight	Rate	Amount
Juice heaters, MS tubeRaw juice to boiling before liming and settlingRate from 183,273 kg + 6 days labour — Shell, tubes and headers, per m²	2,618 m²	4unit	—	estimated	293,296,364
Clarifier, continuous multi-trayAbout 2.5 hours retention on mixed juiceRate from 30,726 kg + 18 days labour — Shell, trays, rake drive and flash tank	400 m³19.2 t eachsite-erected	1clarifier	19.2t	estimated	12,335,571
Rotary vacuum filter for mudRecovers sugar from the clarifier mud before it leaves as filter cakeRate from 16,836 kg + 10 days labour — Drum, screens, vacuum system and drive	454.5 m²	2filter	—	estimated	13,519,090

Juice heaters, MS tube
Raw juice to boiling before liming and settling
Rate from 183,273 kg + 6 days labour — Shell, tubes and headers, per m²
Size
2,618 m²
No.
4unit
Total weight
—
Rate(estimated)
Amount
₨ 293,296,364
Clarifier, continuous multi-tray
About 2.5 hours retention on mixed juice
Rate from 30,726 kg + 18 days labour — Shell, trays, rake drive and flash tank
Size
400 m³ · 19.2 t eachsite-erected
No.
1clarifier
Total weight
19.2 t
Rate(estimated)
Amount
₨ 12,335,571
Rotary vacuum filter for mud
Recovers sugar from the clarifier mud before it leaves as filter cake
Rate from 16,836 kg + 10 days labour — Drum, screens, vacuum system and drive
Size
454.5 m²
No.
2filter
Total weight
—
Rate(estimated)
Amount
₨ 13,519,090

Evaporation, boiling & curing

Material	Size	No.	Total weight	Rate	Amount
Evaporator body, multiple effect98,182 kg/h of water off the juice, over a quintuple effectRate from 371,127 kg + 14 days labour — Calandria, shell, tubes and vapour space, per m²	8,836 m²265.1 t eachsite-erected	5body	1325.5t	estimated	742,429,545
Vacuum pan, batchA, B and C massecuite boilings with one spareRate from 35,096 kg + 16 days labour — Pan body, calandria, stirrer and vacuum connection	250 m³17.5 t eachsite-erected	4pan	70.2t	estimated	56,312,888
Crystalliser, water-cooledC massecuite needs long slow cooling to exhaust the mother liquorRate from 28,806 kg + 8 days labour — U-trough, cooling elements and slow drive	400 m³19.2 t eachsite-erected	6unit	115.2t	estimated	69,254,460
Centrifugal, batch and continuousBatch machines on A massecuite, continuous on B and CRate from 13,763 kg + 8 days labour — Basket, screen, drive and discharge	10,625 kg/h sugar	6machine	—	estimated	33,150,000
Sugar dryer, grader and baggingHopper, dryer-cooler, grader and 50 kg baggingRate from 12,238 kg + 12 days labour — Rotary dryer-cooler, elevator, grader and bagger	10,625 kg/h	1line	—	estimated	4,925,000

Evaporator body, multiple effect
98,182 kg/h of water off the juice, over a quintuple effect
Rate from 371,127 kg + 14 days labour — Calandria, shell, tubes and vapour space, per m²
Size
8,836 m² · 265.1 t eachsite-erected
No.
5body
Total weight
1325.5 t
Rate(estimated)
Amount
₨ 742,429,545
Vacuum pan, batch
A, B and C massecuite boilings with one spare
Rate from 35,096 kg + 16 days labour — Pan body, calandria, stirrer and vacuum connection
Size
250 m³ · 17.5 t eachsite-erected
No.
4pan
Total weight
70.2 t
Rate(estimated)
Amount
₨ 56,312,888
Crystalliser, water-cooled
C massecuite needs long slow cooling to exhaust the mother liquor
Rate from 28,806 kg + 8 days labour — U-trough, cooling elements and slow drive
Size
400 m³ · 19.2 t eachsite-erected
No.
6unit
Total weight
115.2 t
Rate(estimated)
Amount
₨ 69,254,460
Centrifugal, batch and continuous
Batch machines on A massecuite, continuous on B and C
Rate from 13,763 kg + 8 days labour — Basket, screen, drive and discharge
Size
10,625 kg/h sugar
No.
6machine
Total weight
—
Rate(estimated)
Amount
₨ 33,150,000
Sugar dryer, grader and bagging
Hopper, dryer-cooler, grader and 50 kg bagging
Rate from 12,238 kg + 12 days labour — Rotary dryer-cooler, elevator, grader and bagger
Size
10,625 kg/h
No.
1line
Total weight
—
Rate(estimated)
Amount
₨ 4,925,000

Material

₨ 1,723,535,645

2361.9 t of steel to fabricate

Labour

₨ 1,395,000

558 days at ₨ 2,500 a day

Quotation total

₨ 1,724,930,647PKR

13 of 13 lines priced

2361.89 t is fabricated steel only. 8 bought-in lines — pumps, machines, proprietary units — are priced but carry no steel weight of ours, and show a dash in the weight column.

Questions

What does TCD mean?

Tonnes of cane per day — the figure every cane mill is described by. A 2,500 TCD mill crushes two and a half thousand tonnes of cane in twenty-four hours, and essentially every item in the plant is sized from it.

Why does imbibition water matter so much?

Because every litre added at the tandem to wash sugar out of the bagasse has to be boiled off again in the evaporators. Raising imbibition improves extraction and enlarges the boiling house at the same time — it is the central trade-off in a cane mill, which is why it is an input here.

How is the evaporator area arrived at?

From the water to be removed: mixed juice arrives near eighty-five percent water and syrup leaves near thirty-five, and the difference is the evaporation load. Spread over a quintuple effect, each body carries roughly a fifth of it, with the heating surface following from the load.

What is not included?

The boiler and the turbo-alternator, the cane yard and weighbridge, the distillery, the effluent plant, the sugar godown, and all civil and structural work. Those are typically half the cost of a greenfield mill and are quoted separately.