FORM 2
THE PATENTS ACT 1970 (39 OF 1970)
COMPLETE
SPECIFICATION
(SECTION 10, RULE 13)
TITLE: ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY
NAME: Mr. Tukaram Mugutrao Karne
ADDRESS: Shreyas Ornate, 95-Tulasibagwale Colony, Sahkarnagar-2, Pune: 411009, Maharashtra, India.
NATIONALITY: A SUBJECT OF THE REPUBLIC OF INDIA.
The following Specification particularly describes the nature of this invention and the manner in which it is to be performed:
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TECHNICAL FIELD
This invention relates to MULTI-ROLLER type sugarcane mill and more particularly to systems for cane crushing mill having several rollers in each mill unit.
BACKGROUND
Sugar Recovery is directly proportional to the Mill extraction. It has been studied for number of years, tried and established by several sugar experts to co-relate the Sugar Recovery with Mill extraction and concluded that Sugar Recovery increases approximately by 0.25% on increase in mill extraction by 1%. For example if mill extraction is increased to 96% from 94%, the rise in sugar Recovery will be 0.50% on cane. The highest sugar losses in the cane sugar industry are at final molasses and final bagasse. If one can minimize the sugar losses in the final bagasse at the well maintained efficient milling tandem one can improve the Sugar Recovery to the much higher level. Therefore one must concentrate efforts on minimizing the sugar losses in the final bagasse on the first priority basis. The existing designs of mills are generally having three rollers in the each mill and there are two auxiliary rollers of fabricated under feeder [UFR], grooved [GRPF] or toothed roller pressure feeders [TRPF]. Number of compressions is not enough in the existing universal type mills. The juice drained by various existing combinations of rollers is not satisfactory in the present types of mills resulting in low mill extraction, higher sugar losses in bagasse and low Sugar Recovery.
HISTORY, EXISTING MILL TYPES AND PROBLEMS FACED
The mill designed universally has mainly three rollers, feed, top and discharge. In the modern days several pressure feed devices are added on the standard 3-roller mill types. Number of mill units is increased to six and in some cases even seven from originally practiced five, to increase the mill extraction to the maximum possible level. The mill is a barbarous piece of equipment by which tremendous amount of energy is expended to extract the juice from the cane; but the bagasse, thus deprived of its juice, re-absorbs juice the moment it has released it, as it passes the axial plant of the rollers. Thus a large proportion of the benefit just obtained is lost and much of the trouble and power expended is wasted; no method has been found to remedy this inherent disadvantage of the principle of milling itself. This all happens because the juice extracted is not drained out instantly and efficiently. Therefore mill extraction is suffered, sugar loss in the bagasse is increased and ultimately Sugar Recovery is affected to the great extent.
Mill extraction and undiluted juice lost % fiber in bagasse achieved as against the number of rollers in the existing universal type mills are shown in the following table number-1:
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TABLE NO.l
Number of Mill units 3 4 5 6 7
Number of Rollers 9 12 15 18 21
Mill extraction % 91.3 93.9 95.4 95.8 96.9
Lost undil. Juice %fiber 55 44 34 32 24
DESCRIPTION: -
""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY boost up the milling efficiency to the great extent by combining five rollers in a single mill unit. A pair of TRPF rollers is added with pressure chute to achieve additional juice drainage and positive pressure feeding to the mill. This way it is possible to use only half a number of mills in the tandem.
""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY sugarcane mill is a new type of cane crushing mill having several rollers in each mill unit. The top roller TR (Top roller) is a unique bigger size roller having 100% relative size. The four bottom rollers PFR (Perforated feed roller), PMR-1PMR-2 (Perforated middle rollers) and PDR (Perforated discharge roller) have 55 to 65% relative sizes. Several rollers combined in one mill unit give very high milling efficiency. The total mill numbers required to achieve desired milling efficiency are much less in quantity as compared to that in the normal existing mill designs.
The well prepared sugar cane IPC (Incoming prepared cane) along with the dry cush-cush DCC (Dry cush-cush) enters the milling tandem at the first mill called a primary mill unit. The pair of two toothed pressure feed rollers one called as perforated toothed under feeder roller PTRUF (Perforated toothed feeder roller) for quick juice drainage and another is called toothed roller pressure feeder roller TRPF (Toothed feeder roller). The prepared sugar cane IPC (Incoming prepared cane) along with dry cush-cush DCC (Dry cush-cush) is feed to the mill Ml with positive pressure feeding force and extracts juice as well. The gravitational force drains off the extracted juice quickly and efficiently. Then the sugarcane is lead to the pair of top TR (Top roller) and perforated feed PFR (Perforated feed roller) rollers. The juice extracted is drained off quickly and efficiently through the perforations of PFR (Perforated feed roller) by the gravitational force. Then the sugar cane is guided by the trashplate TP-l(trashplate No. 1) and is feed by force to the pair of top TR (Top roller) and perforated middle roller no.l called PMR-1 (Perforated middle roller). The juice extracted by this pair of rollers is drained off quickly and efficiently through the perforations provided on the PMR-1 (Perforated middle roller). Then the sugar cane is feed to the next pair of rollers with force, called TR (Top roller) and PMR-2 (Perforated middle roller). The sugar cane is guided by the trashplate
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TP-2. The juice extracted by the pair of rollers TR (Top roller) and PMR-2 (Perforated middle roller) is drained off quickly and efficiently by the gravitational force through the perforations provided on the PMR-2 (Perforated middle roller). Then the sugar cane is feed to the pair of two rollers TR (Top roller) and perforated discharge roller PDR (Perforated discharge roller), guided by the trash plate TP-3. The extracted juice is drained off quickly and efficiently through the perforations provided on the discharge roller PDR (Perforated discharge roller). This way the juice extraction is extremely efficient and mill efficiency increases to the very high level with the less number of mill units in the milling tandem. The bagasse coming out from the mill is emerged out in the bath of dilute remaceration juice. This avoids the occlusion of air by the bagasse particles and unbroken juice cells, thereby increasing the mixing efficiency of the juice with the bagasse. The top roller TR (Top roller) is having fixed center and is directly coupled with the rigid coupling with the driving motor through an enclosed compact gearing train. The four bottom rollers are of floating type, which are working under hydro-pneumatic pressure cylinders HYDC-1-4 (Hydraulic cylinders). This way the mill settings become self-setting according to the quantity of sugar cane flowing through the mill rollers. The sugar cane after each extraction of juice at each pair of rollers is diluted by the lighter dilute juices pumped through the perforated trash beams and trash plates. The quick mill by pass system QMBS (Quick mill by pass system) allows to make a milling process continuous by bypassing any mill unit, which is facing problems, breakdowns or require adjustments. This way the mill units and whole milling tandem becomes multi-roller short milling tandem, which is continuous in operation and very efficient to improve the milling performance.
DESCRIPTION OF DRAWINGS
FIG. 1 is a somewhat diagrammatic representation of one unit of ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
By referring FIG. 1, the top roller TR (5) is a unique bigger size roller having 100% relative size. The four bottom rollers PFR (6), perforated middle rollers PMR-1(8) PMR-2 (9) and perforated discharge roller PDR (11) have 55 to 65% relative sizes. The well prepared sugar cane Incoming prepared cane IPC (1) along with the dry cush-cush DCC (2) enters the milling tandem at the first mill called a primary mill unit(16). The pair of two toothed pressure feed rollers perforated toothed under feeder roller PTRUF (3) for quick juice drainage and another toothed roller pressure feeder roller TRPF (4). The prepared sugar cane Incoming prepared cane IPC (1) along with dry cush-cush DCC (2) is feed to
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the mill (16). Then the sugarcane is lead to the pair of top roller TR (5) and Perforated feed roller PFR (6) rollers. The juice extracted is drained off quickly and efficiently through the perforations of perforated feed roller PFR (6) by the gravitational force. Then the sugar cane is guided by the trash plate TP-1(7) and is feed by force to the pair of top roller TR (5) and perforated middle roller PMR-1 (8). The juice extracted by this pair of rollers is drained off quickly and efficiently through the perforations provided on the perforated middle roller PMR-1 (8). Then the sugar cane is feed to the next pair of rollers with force, called top roller TR (5) and perforated middle roller PMR-2 (9). The sugar cane is guided by the trash plate TP-2(10). The juice extracted by the pair of rollers top roller TR (5) and perforated middle roller PMR-2 (9) is drained off quickly and efficiently by the gravitational force through the perforations provided on the perforated middle roller PMR-2 (9). Then the sugar cane is feed to the pair of two rollers top roller TR (5) and perforated discharge roller PDR (11), guided by the trash plate TP-3(12). The extracted juice is drained off quickly and efficiently through the perforations provided on the perforated discharge roller PDR (11). The top roller TR (5) is having fixed center and is directly coupled with the rigid coupling with the driving motor through an enclosed compact gearing train. The four bottom rollers are of floating type, which are working under hydro-pneumatic pressure cylinders Hydraulic cylinders HYDG-1-4 (13). This way the mill settings become self-setting according to the quantity of sugar cane flowing through the mill rollers. The sugar cane after each extraction of juice (14) at each pair of rollers is diluted by the lighter dilute juices pumped through die perforated trash beams and trash plates. The quick mill by pass system QMBS (15) allows to make a milling process continuous by bypassing any mill unit, which is facing problems, breakdowns or require adjustments. This way the mill units and whole milling tandem becomes multi-roller short milling tandem, which is continuous in operation and very efficient to improve the milling performance.
COMPARISON OF PERFORMANCE OF "EXISTING" AND "MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY

TYPE OF MILL: EXISTING-MILL
Number of Mill units 3 4 5 6
Number of Rollers 9 12 15 18
Mill extraction % 91 93 95 96
Lost undil. Juice %fiber 55 44 34 32
Moisture % final bagasse 54 51 50 49
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TYPE OF MILL: "MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY

Number of Mill units 1 2 3 4
Number of Rollers 5 10 15 20
Mill extraction % 90 93 96 98
Lost undil. Juice %fiber 59 45 32 24
Moisture % final bagasse 52 50 48 46
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I CLAIM:-
1. In the ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR
CANE SUGAR INDUSTRY the well prepared sugar cane Incoming
prepared cane IPC (1) along with the dry cush-cush DCC (2) enters the
milling tandem at the first mill called a primary mill unit (16) where the
pair of two toothed pressure feed rollers perforated toothed under feeder
roller PTRUF (3) and another toothed roller pressure feeder roller TRPF
(4) for the quick juice drainage with positive pressure feeding force and extracts juice; then sugarcane is lead to the pair of top roller TR (5) and Perforated feed roller PFR (6) rollers where the juice extracted is drained off quickly and efficiently through the perforations of perforated feed roller PFR (6) by the gravitational force; then the sugar cane is guided by the trash plate TP-1(7) and is feed by force to the pair of top roller TR
(5) and perforated middle roller PMR-1 (8) where the juice extracted by this pair of rollers is drained off quickly and efficiently through the perforations provided on the perforated middle roller PMR-1 (8), then the sugar cane is feed to the next pair of rollers with force, called top roller TR (5) and perforated middle roller PMR-2 (9), the sugar cane is guided by the trash plate TP-2(10), then the juice extracted by the pair of rollers top roller TR (5) and perforated middle roller PMR-2 (9) is drained off quickly and efficiently by the gravitational force through the perforations provided on the perforated middle roller PMR-2 (9), then the sugar cane is feeded to the pair of two rollers top roller TR (5) and perforated discharge roller PDR (11), which is guided by the trash plate TP-3(12), the extracted juice is drained off quickly and efficiently through the perforations provided on the perforated discharge roller PDR (11), the four bottom rollers are of floating type, which are working under hydro-pneumatic pressure cylinders Hydraulic cylinders HYDC-1-4 (13), this way the mill settings become self-setting according to the quantity of sugar cane flowing through the mill rollers; the sugar cane after each extraction of juice (14) at each pair of rollers is diluted by the lighter dilute juices pumped through the perforated trash beams and trash plates, the quick mill by pass system QMBS (15) allows to make a milling process continuous by bypassing any mill unit, which is facing problems, breakdowns or require adjustments; this way the mill units and whole milling tandem becomes multi-roller short milling tandem, which is continuous in operation and very efficient to improve the milling performance.
2. In the ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR
CANE SUGAR INDUSTRY there are four bottom rollers, named
Perforated feed roller PFR (6), perforated middle roller PMR-1 (8),
perforated middle roller PMR-2 (9) and perforated discharge roller PDR
(11) having diameter 55 to 65% of that of top roller (5) of perforated type
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to achieve quick juice drainage by gravitational force having shells of bottom rollers shall be made up of alloy cast iron material.
3. In the ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY there are the suitable crown pinions fitted on bottom rollers to give @7.5% more surface speed with respect to top roller(5) surface speed.
4. In the ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY the suitable common crown pinion of top roller shall drive all four-bottom rollers.
5. In the ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY there are perforated trash-beams. The trash platesl (7), 2 (10) and 3 (12) are also have suitable divergent perforated slots to facilitate re-maceration by lighter filtered juices (14).
6. In the ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY, bagasse of each mill unit will emerge in the bath of re-maceration juice(14) to avoid contact of emerging bagasse with air, thereby improving the performance of the mills to the very high level.
7. In the ""MULTI-ROLLER" TYPE EFFICIENT MILL DESIGN" FOR CANE SUGAR INDUSTRY, the top roller (5) have a fixed center and rigid coupling to avoid problems of floating, moving, misalignment, loss of power and wear and tear.
Dated this 24th Day of November 2005.

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