Hingurana is located 12km from Ampara in the Ampara
Siyambalanduwa road. If you want to go to the factory it is in 350m from the
Hingurana roundabout. This is closed for some time but now the machines are
working again. Now this is started as private factory join with the Gal Oya plantations.
I have opportunity to visit this factory from my friend whose father is working
in here. When I go to this factory, the machines are stopped working. However
they helped me to know the procedure of making sugar. This is the things that I
understood and the thing in my memory. The photos were linked because it takes
long time to load.
First of all this machine is the
lifting method of the load
of sugar canes. It can lift 10 tons at one time. There are two machines like
this. The machines put the load in to these
plates and the chains on the plate
will move them to this channel. For one time it will put 3 tons for the
channel. In first wheel was arranging the sugar canes and burst them a little. After
that the next
wheel was chopped the sugar cane. Then cut in to pieces of the
size of near one inch. These all happens on the moving plate and then it goes
to inside of the factory.
Inside the Factory first those goes to allocating the treacle
made of sugarcane. In here the chopped cane will grind from
these machines. One
machine has three sub units which has small channels on it. When cane goes
through it, molasses will allocate to the tanks which are positions in the down
of the machine. After the waste, was coming through
moving plate. All the units
in the factory use the steam power, which produces by
this boiler. Wood takes
for the start the boiler and then uses the waste cane. Long time ago they use
the fuel for the engines but now only uses the wood. Then the heat produced was
use in this press to make steam pressure to 250
pounds per inch. Then distribute
all over the factory. There is a level to see the
water level inside the press.
Bottom of the boiler has a place to
remove charcoal.
Then we go to see the power house of the factory. It’s
also works from the
steam turbine. This turbine was rotating 6000 rounds per minutes.
Whole machines were working by these 440 volts electricity which produces form
the power house. But sometimes it takes electricity from the Celon electricity
board. But when the factory stopped working then the electricity was give to
the Celon electricity board. And also there was a
fuse to save the machines
from the variation of the electricity. That is taken from old ship and present from
the foreign county to Sri Lanka in the D. S. Senanayaka time. This fuse was keeping
the Electricity in balanced level.
Allocated molasses will pomp to this
big tank then mix
the
carbide to the tank. Carbide uses for the remove the mud and other colluviums
in the molasses. When mixing carbide, they check the pH value by this
machine. In the past, they use to this process slaked lime and the sulfur.
In the tank the weight limit comes to the 1 ton, and then automatically
releases the valve and pump to another place. And there is a
meter to count the
number of tons for the day. Then the molasses will pump to the
steam burners
and then heat for high temperature and then give high pressure such as 200
pounds per inch. Inside these burners has number of tubes, and they flow the
molasses up and down to get the temperature quickly. And also the
tubes were
bend like this because to stop the beating of the steam flux. And this big tank
use to
clean the hard water. It’s doing for save the tubes from the chemical
layers which corroded inside the tubes.
Then again there is another
tank to collect that
molasses. It is always rotating in small speed. In the tank the mud and the colluviums
go to deep and clean molasses comes up. Different levels got valves and by the
checking pump the clean molasses to another unit in the factory. Impure
molasses clean by
special machine. This machine was taken for that process. it
was a cylindrical one which rotates touching impure molasses. And inside it
there is a
vacuum system to suck the pure molasses. And the outside of the
cylinder has
plate with tiny holes. And also when rotating it will clean the
outside of the cylinder and remove the colluvium and mud. Load tයem outside the
factory.
Then the next unit supposes to do the molasses in to
pebbles. And then clean as a sugar. It is doing by given special conditions. And
put some chemicals. Those chemicals did not collide with sugar but helps to
increase the size of the pebbles. When it makes the
pebbles in correct size it
will pump to another level and other will go through again in this process.
These
molasses liquid is always mixing by using rotating axes inside the tanks.
Next step is to
remove the molasses and dry out the sugar. For that the
molasses liquid put in to high pressure and spray through the heated air. For
that it used a
rotating cylinder. Inside this cylinder have lots of
metalplates to increase the surface area. End of
this cylinder there is a hole to
collect the sugar and sugar dust will
collected separately. Then again the sugar dust will use to make liquid and
then again in to sugar pebbles.
There is some
mechanism to stop the lumpish of the sugar. And then collect to big tanks. From
bottom of the tanks there is
automatically release 50kg at one time and collect
them to gunny bags. Then after all bags goes to stores. And there is a
mechanism to cool the water for the factory. That is a
pond with sprinklers. One
channel goes to factory with cool water and another channel goes to pond with
hot water to the pond. If the heat of the pond increases the hot water channel
will change and another cool water channel will open for the pond.
There will be some missing steps and thing. If there is a
reader who knows about this processes please let them as comments. And I would
like to thank my friend Shan Lakshitha and his father Mr. Sumanasiri who works
there. And thanks for the workers in the factory, who helps me to get these knowledge.