Located in northern province of Khyber Pakhtunkhwah (KP), Almoiz Industries Unit 1 possess crushing capacity of 11,000 tons/day on Sugar Cane & 8,500 tons/day on Sugar Beet. In addition to conventional milling Unit 1 has adopted latest diffuser technology based on technology from Belgium. This diffuser is used to extract juice from both crops i.e. Sugar Cane & Sugar Beet.
The plant is equipped with automated milling tandem.
ALMOIZ UNIT I
Almoiz’s Pride
Almoiz Industries Limited take pride in becoming the first Sugar Industry in Pakistan to develop the inhouse EPC capability to make the High-Pressure Boilers indigenously. The team (developed within the group) has tremendous capability to:
- Build High Pressure Boilers of pressure rating 65 bars and temperature rating of 490 C. The boilers are built in accordance with ASME boiler codes duly verified by the authorized ASME third party inspector from the design till the hydro testing of the complete boilers.
- Upgrade the exiting Low-Pressure Boilers (23 bars, 350 C) to the latest High-Pressure Boilers having latest robust design with increase in capacity as well for pressure rating of 65 bars and temperature of 490 C. This eventually enables the sugar mill to get altogether a boiler that is built with low capital investment as compared to the new boiler with high value of money thus ensuring profitability in the longer run and utilization of existing valuable assets.
- The team has increased the efficiency of the exiting low-pressure boilers by decreasing the flue gas temperatures of the old boilers. This basically involves the improvement in the firing system and recovering the high energy losses in the stack temperatures.
Almoiz 1 is the first Sugar Mill in Pakistan to introduce Cogeneration with high pressure boilers and back pressure/ condensing turbines. The group introduced this very efficient technology to generate electricity and heat . The boilers and the power house were so efficiently designed that they were not only able to produce electricity for inhouse use but were able to produce surplus electricity for diversified purposes. So much so, this made the whole operation so efficient that in addition to producing surplus electricity Almoiz 1 was able to save surplus sugarcane bagasse which then could be used to run other operations of the plant as well.
Unit 1 has installed the latest “Eaton Filters” that facilitate in additional filtration so that the sugar produced matches the International Standards of quality in terms of ICUMSA and the required levels of turbidity.
Unit 1 is also the pioneer in installing the latest “Falling Film Evaporators”, which are highly efficient as compared to the Conventional “Roberts” evaporators. They efficiently transfer the heat from the steam to the juice and reduce the amount of steam required for the process thus decreasing steam consumption and eventually saving bagasse for power generation.
For better operations and uniform sugar crystal size, Unit 1 has shifted the Pan Station from manual to Auto. Pan Automation has also helped Almoiz in achieving the efficiency targets and maintain the crystal size as per the requirements of the local and international customers.
The state-of-the-art Refine Centrifugal machines are imported from Japan and China. The sugar hoppers, dryers, graders and elevators are designed with such materials to prevent any contamination due to the presence of the ferrous material. High intensity magnets are also installed to catch the ferrous material.
Unit 1 produces the superheated steam from 02 Nos. 80 t/hr and 01 No 120 t/hr 65 bar (high pressure) boilers. These boilers are highly efficient as compared to the conventional 23 bar boilers. The boilers are based on the latest design of Eckrohrkessel GmbH.
For consistency in quality and efficient operations, the plant is monitored and controlled by Distribution Control Systems (DCS). Most of the variables of the plant are managed and controlled from the Central Control Room (CCR). Automation has been introduced in almost all the areas of the plant.
At Almoiz Industries Quality is ensued not at the final product level but safeguarded at all stages during process and even in purchase of raw material through constantly monitoring, assessing and adapting our process, material and ingredients to confirm that all sugar products being manufactured are free from any biological, physical or chemical hazards.
At Almoiz Industries, soon after the production of sugar and before its dispatch to final packing unit, inspection & quality analysis of finished product is used to make sure the ‘in process’ controls are in effect. Testing of each batch samples is done and all major tests including ICUMSA, Turbidity, foreign particles, bacteria etc. measurement is usually practised through Almoiz highly equipped state of the art laboratory under the supervision of highly skilled staff to ensure quality at each stage. Any product that is found not matching the degree of precision for specific grades is subject to either graded in another category approved for that specification or recycled. After identifying the quality control and graded sugar in relevant classifications of finished product, it goes to packing/bagging section with relevant marking, print and packaging quality for storage.
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