Lyla Lindsey
Australia is one of the world's largest producers of raw sugar, generating 4.6 million tons of it annually, over 70% of which is exported. The process of turning sugarcane into raw sugar crystals begins with shredding the cane into fibrous material. The shredded cane is then fed through a series of crushing mills that squeeze out the juice, leaving behind bagasse, the fibrous material. When the crystals grow to about 1mm in size, the syrupy mixture is discharged and spun at high speed in a centrifuge to separate the syrup from the sugar. The raw sugar is then tumble-dried before being stored.
| Characteristics | Values |
|---|---|
| Raw sugar production | 4.6 million tons per year |
| Percentage exported | Over 70% |
| Sugarcane used | 15 million tons |
| Ratio of sugarcane to raw sugar | 7:1 |
| Cane crushing season | June to November |
| Mills | 8 in North and Central Queensland |
| Raw sugar production | More than 2 million tons |
| Percentage of raw sugar exported | 80% |
| Sugar industry location | Queensland and northern New South Wales |
| Percentage of sugar produced in Queensland | 95% |
| Percentage of sugar produced in New South Wales | 5% |
| Australia's rank in world exports | 2nd largest exporter |
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What You'll Learn
Sugarcane to raw sugar
Sugarcane is the raw material used to produce raw sugar in Australia. The process of converting sugarcane into raw sugar crystals begins with shredding the cane into fibrous material. This shredded cane is then passed through a series of crushing mills that extract the juice, leaving behind the fibrous residue known as bagasse. Approximately seven tonnes of sugarcane are required to produce one tonne of raw sugar, though this ratio can vary depending on factors such as the type of cane, its CCS (commercial cane sugar) content, and the season.
The extracted juice is then processed to form sugar crystals. Once the crystals reach about 1mm in size, the syrupy mixture is discharged into a centrifuge, which spins at high speed to separate the syrup from the sugar. The raw sugar is then tumble-dried before being stored in the mill's bulk sugar bins.
Australia's sugar industry is concentrated primarily in Queensland, with about 95% of the country's sugar production occurring in this state. The industry generates an impressive output, producing 4.6 million metric tons of raw sugar annually, of which over 70% is exported. Australia is the second-largest exporter of raw sugar globally, with Asia being a major focus for exports, including key markets such as South Korea, Indonesia, Japan, and Malaysia.
The sugar milling process also yields valuable by-products such as bagasse and molasses. Bagasse is the fibrous material remaining after the cane has been crushed, while molasses is the syrup left after sugar crystals have formed. These by-products have various industrial applications and can be used to generate electricity and produce ethanol, respectively.
The Australian government has a vested interest in sustaining the country's raw sugar export industry, particularly in Queensland, where it contributes $2 billion to the state's economy annually. The industry adheres to strict guidelines and regulations to ensure sustainability and effective operations.
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The shredding process
The shredder itself is a large and robust machine, designed to handle the volume and toughness of the sugarcane feedstock. It consists of a series of sharp, rotating blades or teeth that work to tear and shred the cane into the desired fibrous state. The shredder's speed and force can be adjusted to optimise the shredding process, depending on factors such as the type of cane and its condition.
Maintenance of the shredder is also critical to ensure uninterrupted operations during the crushing season. Scheduled maintenance breaks, typically every two to three weeks, are utilised to inspect and service the shredder, keeping it in optimal condition. This includes sharpening or replacing blades, addressing any mechanical issues, and ensuring the machinery is free of debris and buildup that could impact its performance.
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Crushing and squeezing
The process of turning sugarcane into raw sugar crystals begins at the shredder, which tears the cane into fibrous material. The shredder is a key piece of machinery in the process. The shredded cane is then fed through a series of crushing mills that squeeze out the juice and leave the fibrous material, known as bagasse. Wilmar Sugar, Australia's largest sugar producer, with eight mills in North and Central Queensland, crushes about 15 million tonnes of sugarcane each year to make more than two million tonnes of raw sugar. This represents more than half of the nation's total raw sugar production.
Sugar manufacturing works on a ratio of 7:1, meaning that approximately seven tonnes of cane are required to produce one tonne of raw sugar. This ratio can vary depending on various factors, such as the type of cane, the commercial cane sugar (CCS) content, the season, and other factors. The cane-crushing season typically runs from June to November, during which the mills operate 24 hours a day, seven days a week, with planned stops every two to three weeks for scheduled maintenance.
The bagasse, or fibrous material left after the cane has been crushed, is a byproduct of the sugar manufacturing process. Another byproduct is molasses, which is the syrup that remains after sugar crystals have been formed. These crystals form a syrupy mixture, which is discharged into a centrifuge when the crystals reach about 1mm in size. The centrifuge spins at high speed to separate the syrup from the sugar.
The raw sugar then undergoes tumble drying before being transferred to the mill's bulk sugar bins for short-term storage. This raw sugar is then further refined to produce refined sugar products. Australia's raw sugar industry is one of the largest in the world, producing 4.6 million metric tons (10.1 billion pounds) of raw sugar annually, with over 70% of it exported.
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Syrup separation
The sugar-rich solution is then boiled down to form a thick syrup, to which "'seed'" sugar crystals are added and grown into larger crystals of raw sugar. Centrifuges, or centrifugals, are then used to separate the raw sugar crystals from the syrup (molasses). The high-speed centrifuges function similarly to a washing machine during its spin cycle.
The raw sugar crystals are then dried and stored in bulk bins at the mills before being transported to a bulk sugar terminal for export or refining. The molasses, or dark brown syrup, left over from the final centrifuging can be recycled through the sugar beet processing cycle to remove and utilise as much sugar as possible.
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Tumble drying
Sugar in Australia comes from sugarcane, which is grown in the hot and sunny climate of coastal Queensland and northern New South Wales. Sugarcane is harvested between June and December, and once cut, the pieces of cane are sent to a sugar mill. Here, the cane is shredded and crushed to separate the sweet juice from the fibrous stalk, which is called bagasse. The juice is then filtered and heated to remove water and any impurities, resulting in a dark brown liquid called molasses.
The next step is crystallisation. When the crystals grow to about 1mm in size, the syrupy mixture is discharged into a centrifuge, which spins at high speed to separate the syrup from the sugar. The raw sugar is then tumble dried before being transferred to the mill's bulk sugar bins for short-term storage. The tumble drying process involves spinning the sugar in huge drying centrifuges to remove any remaining moisture. This step ensures that the sugar is dry and free-flowing, making it easier to store, package, and transport.
After tumble drying, the raw sugar crystals are kept dry and stored in large sheds, ready for export or sale to refineries. The refineries further process the raw sugar to make it fit for human consumption. This involves melting and sterilising the sugar using UV light before spinning it in centrifuges once more. Finally, the refined sugar is packaged and sold to consumers or used by food and drink manufacturers.
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Frequently asked questions
Raw sugar is the product of sugarcane before it is refined.
Sugar manufacturing works on a ratio of 7:1, meaning seven tonnes of sugarcane are needed to produce one tonne of raw sugar. The process starts with a shredder, which tears the cane into fibrous material. The shredded cane is then fed through a series of crushing mills that squeeze out the juice, leaving the fibrous material (called bagasse). The juice is then crystallised and put into a centrifuge, which spins at high speed to separate the syrup from the sugar. The raw sugar is then tumble-dried before being stored.
Most of the sugar produced in Australia (around 95%) is grown in Queensland, with about 5% in northern New South Wales. Wilmar Sugar is Australia's largest producer, with eight mills in North and Central Queensland producing more than half of Australia's raw sugar.
Australia produces 4.6 million tons of raw sugar annually, with over 70% exported. Wilmar Sugar produces over two million tonnes of raw sugar each year, crushing about 15 million tons of sugarcane.
