Handbook of Processing of Jaggery

PM Formalisation of
Micro Food Processing Enterprises (PM-FME)

Scheme
HANDBOOK OF
PROCESSING OF JAGGERY
AATMANIRBHAR BHARAT
Indian Institute of Food Processing

Technology
Ministry of Food Processing Industries, Government of India
Pudukkottai Road, Thanjavur
Tamil Nadu
Indian Institute of Food Processing Technology
TABLE OF CONTENTS
Page No.
Chapter 1: Introduction
1.1 Status and Market size 2
1.2 Sugarcane products market 5
1.3 Nutritive value of Jaggery 7
1.4 Medicinal properties of jaggery 7
1.5 Jaggery vs Sugar 9
Chapter 2: Processing of Jaggery Powder
2.1 Processing of Jaggery 10
2.2 Traditional production process 11
2.3 Modern scientific method of Jaggery Production 17
2.4 Modified furnace by IISR, Lucknow 21
2.5 Advantages of Modern Technology 23
2.6 Organic jaggery 24
2.7 Jaggery Production: Constraints and remedies
Chapter 3: Packaging of Jaggery Powder
3.1 Packaging materials used for Jaggery 26
Chapter 4: Export markets for Jaggery and Jaggery based products
4.1 Export status of jaggery from India 27
4.2 Major constraints identified in jaggery exports suggested by 27
APEDA
Chapter 5: Food Safety Regulations and Standards
5.1 Food Safety Regulations & Standards for cane jaggery 29
Machineries Manufacturers & Suppliers 31
Hand book of Processing of Jaggery Page 1

CHAPTER 1
INTRODUCTION
1.1 Status of Sugarcane in India
Sugarcane (Saccharum officinarum) family Gramineae (Poaceae) is widely grown crop in

India. It provides employment to over a million people directly or indirectly besides
contributing significantly to the national exchequer. Sugarcane growing countries of the
world lay between the latitude 36.7° north and 31.0° south of the equator extends from
tropical to subtropical zones. Sugar cane originated in New Guinea where it has been known
for thousands of years. Sugar cane plants spread along human migration routes to Asia and
the Indian subcontinent. Here it cross-bred with some wild sugar cane relatives to produce the
commercial sugar cane we know today.
1.1.1 Cultivation Scenario
Cultivation of sugarcane in India dates back to the Vedic period. The earliest mention of
sugarcane cultivation is found in Indian writings of the period 1400 to 1000 B.C. It is now
widely accepted that India is the original home of Saccharum species. Saccharum barberi and
Polynesian group of island especially New Guinea is the centre of origin of S. officinarum. It
belongs to family Gramineae (Poaceae), class monocotyledons and order Glumaceae sub
family Panicoidae, tribe Andripogoneae and sub tribe Saccharininea. The cultivated canes
belong to two main groups: thin, hardy north Indian types S. barberi and S. sinense and thick,
juicy canes Saccharum officinarum. Out of these, S. officinarum is highly prized.
Among the sugar yielding crops like sugarcane, sugarbeet, palms and sorghum, sugarcane is
the most important. 90% of the production comes from Bihar, Haryana, Punjab, Uttar
Pradesh, Andhra Pradesh, Karnataka, Maharashtra and Tamil Nadu; Uttar Pradesh being the
maximum producer .Indian sugarcane acreage during 2020-21 sugar season (SS) is estimated
at 52.25 lakh hectares, registering 8 percent growth, as compared to 48.41 lakh hectares
recorded during the 2019-20 sugar season.

1.1.2. Sugar cane varieties suitable for jaggery production
Co 8371 (Bhima) Co 7219 (Sanjivani)

CoM 7125 (Sampada) CoM 88121 (Krishna)
Co 8014 (Mahalakshmi) CoC 671
Co 99006 CoA 92081
CoJn 86-141 CoJn 86-600
1.1.3. Production and yield of sugar cane in major states in India

1.1.4. Production and productivity of sugar cane in major states of India

1.2. Sugarcane products market

India is the largest consumer and the second largest producer of sugar in the world. Sugar
industry is the second largest organized sector industry in the country. Since ancient times,
sugar has been produced in the local units in India using traditional Khandsari
process. Modern sugar making was introduced in India probably by Dutch. The first Sugar
Mill was started in India in Bihar in 1903, followed by another unit in 1904 in Uttar Pradesh.
By mid of the 20th century, Sugar industry expanded and before India’s independence there
were 138 sugar mills in India.
Jaggery (also called as Gurin India, Desiin Pakistan, Panelain Mexico and South America,
Jaggery in Burma & African countries, Hakuruin Sri Lanka, and Naam Taan Oiin Thailand)
and khandsariare traditional Indian sweeteners, which are produced in addition to sugar from
sugarcane.. These traditional sweeteners are the natural mixture of sugar and molasses. If pure
clarified sugarcane juice is boiled, what is left (usually possessing 65-85% sucrose) as solid is
jaggery. Khandsari sugar is a finely granulated, crystallised sugar that contains 94-98 %
sucrose.
1.2.1. Indian Market Outlook
In the early 1930’s, nearly 2/3rdof sugarcane production was utilized for production of alternate
sweeteners, jaggery and khandsari. With the introduction of sugar mills and their multiple
growth, better standard of living and higher per capita income, the sweetener demand had
shifted to white sugar, which contains purely sucrose (99.7%). Therefore, jaggery and
khandsari production got setback to some extent.
Jaggery manufacturing is done on a small scale by groups of farmers; the process has been
creating employment opportunities to the millions of people in rural areas. From time
immemorial, sugarcane crop has been known as a cash crop by Indian cultivators and so also
the preparation of jaggery. It is estimated that two thirds of the sweetening requirement in
rural areas is met by jaggery.
Thus, there are strong indications that the jaggery and khandsari cottage industry would
continue to play an important role in processing sugarcane at rural level and in creating
employment opportunities to the millions of people in rural areas. Jaggery industry is
probably the most wide spread cottage industry in India. India produces more than 70% of the
total jaggery of the world. Being an eco friendly sweetener with additional nutritional value,
jaggery holds good export potential. To sustain the market and export potential of jaggery, it
is imperative that the jaggery quality need to be sustained.

1.2.2. Utilization of Sugarcane
In India, almost 80%of the sugarcane produced is processed into white sugar, around 12% into
jiggery and khandsari, and approximately 8% is used as seed cane. The per cent utilization of
sugarcane for production of jaggery and khandsari has considerably declined from 37.20 in
the year 2008-09 to about 12% in 2017-18. This implies the need of research in jaggery
sector to produce a quality jaggery and thus to change the scenario.
.
Source: ICAR-SBI
1.2.3. Trend in per capita consumption of white sugar, gur and khandsari in India

1.3. Nutritive value of Jaggery
Jaggery is a very nutritious and healthy food and used as a main sweetener for rural and
urban people. It contains about 80-85% sucrose and 5-15% reducing sugars. Jaggery provides
necessary nutrients like-proteins, fats, vitamins (B-complex and folic acid), minerals
(calcium, iron, phosphorus, magnesium, potassium and traces of zinc, copper etc., which are
not present in sugar).
Compared to khandsari, jaggery is a wholesome diet. It contains 0.6%-1.0% minerals;

important among them are iron (11mg), calcium (0.4%), magnesium and phosphorous
(0.045%). Jaggery also contains reducing sugars including glucose and fructose (10-15%),
protein (0.25%), and fat (0.05%). Daily use of jaggery may increase human life span.
Incidence of less diabetes is reported in jaggery consuming areas compared to sugar
consuming areas.
1.4. Medicinal properties of jaggery

a) Jaggery purifies blood
One of the most popular advantages of jaggery is that it possesses the ability to purify
blood. If consumed regularly, jaggery goes a long way in cleansing blood and in leaving the
body healthy. It also helps in preventing different blood disorders and diseases by boosting
the count of hemoglobin. Jaggery also boosts immunity and thus helps in the prevention of
different blood related problems.
b) Iron content
Jaggery is quite rich in its content of folate and iron and therefore it helps in the prevention
of anemia. Jaggery powder also offers instant energy preventing weakness and fatigue of
the human body. When eaten in combination with foods that are rich in vitamin C, jaggery
helps in the absorption of iron within the body.
c) Mineral content
Jaggery is packed with minerals and antioxidants like selenium and zinc and these help in
preventing free-radical damage. These minerals and antioxidants also help in boosting the
body’s resistance to different infections.

d) Cosmetic benefits
Jaggery proves to be highly beneficial when used for a beauty treatment. It comes loaded
with several natural properties ensuring the health of the skin for a very long span of time.It
is rich in its content of different minerals and vitamins and thus offers proper nourishment
to the skin.
e) Jaggery benefits digestion
Jaggery stimulates the secretion of digestive enzymes and therefore speeds up the
procedure of digestion. Proper digestion helps in regulating bowel movement and in
preventing issues like constipation, intestinal worms and flatulence. It is quite effective in
maintaining the proper functioning of the digestive system. Properly functioning digestive
system means proper prevention of digestive issues and improvement indigestion at the
same time.
f) Jaggery increases metabolism
The high mineral content of jaggery and high levels of potassium helps in the management
of weight. This is done by reducing the retention of extra water in the human body. The
potassium content of jaggery maintains electrolyte balance, improves metabolism and
builds muscles help in weight loss.
g) Jaggery treats water retention
Minor health issues like water retention, migraine, bloating and cough and cold that are
experienced by individuals on a regular basis can easily be dealt with the help of jaggery.
The only thing that needs to be done is mixing jaggery with warm water or adding it
in tea for reaping instant benefits.
h) Jaggery balances hormone levels
Women who experience mood swings prior to having their periods can greatly benefit from
having jaggery. Mood swings are the cause of fluctuating hormone levels in the body.
Jaggery helps in the release of happy hormones called endorphins. These relax the body
making women feel better.

i) Good for Brain
Jaggery also helps in preventing major issues faced with the nervous system of the body. It
contains several natural properties which are of good help in keeping the nervous system
functioning properly. This in turn helps individuals in staying healthy and normal.
j) Treats Respiratory Problems
Having jaggery on a regular basis can help in prevention of different respiratory issues
like bronchitis and asthma. Experts are of the view that taking jaggery in the form of a
natural sweetener in perfect combination with sesame seeds can be highly beneficial for the
respiratory system in human beings. Jaggery contains properties that help in regulating the
temperature of the body and this is something that is highly beneficial for the patients of
asthma. It is also worth noting that jaggery contains anti-allergy properties as well
k) Useful in Joint Pain
For those suffering from joint pains and aches, jaggery can offer the much required relief. If
experts are to be believed, jaggery when taken along with ginger can work wonders in
alleviating joint pain. Having a glass of milk along with jaggery on a regular basis can also
help in strengthening the bones and in preventing bone and joint problems like arthritis.
1.5. Jaggery vs Sugar
Jaggery exhibits supremacy over sugar in many ways, as:
1. It is an important source of energy (383 kCal energy per100 g of jaggery).

2. Jaggery is an essential ingredient in various baked products such as-chocolates,
biscuits, breads, cakes, pastries, rolls, gajak, chikki etc.
3. It is utilized for production of several ayurvedic medicines and syrups for treating
throat and lungs infections, relaxation of muscles, nerves, blood vessels, maintaining
blood pressure, increase hemoglobin, prevents anemia.
4. The molasses present in jaggery acts as laxative and improves the digestion.
5. It used as post-partum medicine to women and domestic female animals traditionally.
6. Although, sucrose recovery in jaggery production is 3-5% lower in comparison to
sugar industry but it is compensated by recovery of reducing sugars, proteins, fats and
minerals, which are lost during sugar production in sugar mills.

CHAPTER 2
Processing of Jaggery Powder
2.1. Processing of jaggery
Sugarcane juice is an opaque liquid and varies in colour from gray dark green to light yellow
depending upon the colour of cane. In addition to various nutritional constituents, it also
contain mud, wax and several other soluble and in soluble impurities. To maintain proper
quality in jaggery, all these soluble and in soluble undesirable fractions should be removed.
However, the manufacturing process depends on the ultimate form to be produced. Also, the
minute detail of the process varies widely from state to state, in the state from one district to
another, and in some cases within a district.
2.1.1 Forms of Jaggery

Jaggery is available in the market mainly in three forms namely solid jaggery, liquid jaggery
and granular jaggery. Of the total production of jaggery in India, approximately 80% of the
jaggery is prepared in solid form and the remaining 20% is prepared in liquid as well as
granular form. Liquid jaggery is a part of diet in most parts of Maharashtra & West Bengal
and is gaining commercial importance. Liquid jaggery is widely utilized as sweetening agent
in foods and drinks in Maharashtra, Gujarat, Kerala, Andhra Pradesh, West Bengal and Tamil
Nadu. The granular jaggery is also popular particularly among rural masses.
Composition of different forms of jaggery
Composition per Types of jaggery

100g Solid (lumped) Liquid Granular
Water (g) 3-10 30-35 1-2
Sucrose (g) 65-85 40-60 80-90
Reducing sugars (g) 9-15 15-25 5-9
Protein (g) 0.4 0.5 0.4
Fat (g) 0.1 0.1 0.1
Total minerals 0.6-1.0 0.75 0.6-1.0
Calcium (mg) 8.0 300 9.0
Phosphorous (mg) 4.0 3.0 4.0
Iron (mg) 11.4 8.5-11 12
Energy (Kcal) 383 300 383

2.1.2 Granular or Powder Jaggery

It has been inferred from research that granular/ powder jaggery with low moisture content
(up to 1-2 % d.b.) increased storage life up to two years; the free flowing nature offers this
advantage. Research attempts are being made to develop better technology for jaggery
granules. Increasing pH of cane juice with lime, up to 6.0-6.2 and striking point temperature
of 120°C was found to yield quality granular jaggery with high sucrose content of 88.6 per
cent, low moisture of 1.65 per cent with good colour, friability and crystalline texture.
Jaggery in the form of granules (sieved to about 3 mm), sun dried and moisture content
reduced to less than 2 per cent and packed in polyethylene polyester bags or polyethylene
bottles, can be stored for longer time (more than two years), even during monsoon period
with little changes in quality.
2.2. Traditional production process
The unit operations involved in jaggery manufacturing process from sugarcane is presented in
the flowchart. It involve juice extraction, juice clarification, juice concentration by boiling,
cooling of concentrated juice followed by drying, powdering, packaging and storage.
Harvested
sugarcane
Juice extraction Bagasse
Lighter impurities, wax, carbon

Settling Mud
Clarifying agent
Clarification
Concentration
Cooling
Drying
Powdering & Sieving
Packaging & Storage

2.2.1 Juice Extraction

The first step in jaggery manufacture is the extraction of juice by crushing sugarcane. Three
roller cane crushers (vertical/horizontal) are used to extract juice. Vertical three roller crusher
has the juice recovery efficiency of 50- 55%, whereas, the same for horizontal crusher is 55-
60%. Therefore, the horizontal three-roller crusher is preferable. In sugar factories, the same
technique of crushing is used but with multiple crushing and application of hot water during
crushing, which increases the efficiency to the extent of 77-80%. This method is not practiced
by the jaggery farmers due to more energy requirement for producing hot water and
evaporation of this water during boiling process. One tonne of sugarcane crushed yields 650
kg of juice and 350 kg of bagasse (50% m.c., wb). The bagasse was sun dried to bring down
the moisture from 50% to 20% (wb) and after drying, 245-250 kg was obtained from 350 kg
bagasse which is used as furnace fuel for concentration of the juice.
2.2.2 Juice clarification

The extracted juice is collected in a masonry settling tank and rested for few minutes for
separation of light and heavy particles. The clear juice is drawn from a middle port of settling
tank and transferred to an iron open boiling pan made to fill only 1/3rd of its capacity. In
general, jaggery quality, storability and its acceptability depend on the clarity of the juice
used in preparation. The juice collected from settling tank is clarified during the boiling stage.
It is mostly done by using lime (calcium hydroxide). Calcium in the lime acts as a
complexing agent and forms scum, which needs to be removed frequently during boiling.
Lime addition simultaneously increases the acidic pH of juice, i.e. 5.2 – 5.4 (which depends
on harvesting status, variety of cane and soil condition) to around 6.0 to 6.4.
Addition of lime also improves the consistency of jaggery by increased crystallization of
sucrose, but at the same time it darkens the colour if added in excess. During preparation of
jaggery from over matured canes where sucrose content decreases due to inversion, addition
of lime improves the jaggery consistency. The quantity of lime to be added depends upon the
quality of lime. One kg of lime (with purity of 80-90%) is mixed with 4 litres of water and
the supernatant lime water is filtered with a thick cloth. About 60-70 ml of the resulting
solution, i.e. milk of lime is added to every 100 kg of cane juice. After the addition of lime to
adjust the pH, the juice should be boiled in a pan for about 2 hours removing scum as and
when it forms.
Among the other chemical clarifying agents, hydros is preferred next. However, hydros being
a bleaching agent, has a decolourisation effect. Addition of super- phosphate, phosphoric

acid, chemiflocks and alum are also reported. Use of these chemical clarifying agents is
specific depending on the juice as they may function as bleaching agent, electrolyte or pH
adjusting agent. Vegetable clarifying agents like mucilages of bindi, chikani, ateshevari, etc.
were used in early period. Nowadays, use of natural clarifying agents is encouraged due to
the problems like exceeding the permitted level for chemical clarifying agents and their
impact on taste and storability of the product.
A) Vegetable clarifying agents used in jaggery manufacture
Common Quantity per

Plant part used Methodology Remark
name quintal juice
Pound and extract in
Stem and root of water. Use
Deloa 40-50 g
green plant mucilaginous
extract
More effective in
Stem and root of water. Use
Bhindi 45-50 g removing colouring
green plant mucilaginous
matter
extract
Green bark of the water. Use
Phalsa 50-55 g
tree mucilaginous
extract
Green bark of the water. Use
Semul 55-60 g
tree mucilaginous
extract
Soak in water.
Dry bark of the Pound plant and rub
sukhlai 45-60 g
plant in water. Use the
extract
Grind
Good results with
decorticatedseed
juice of immature
Castor Seed with water. 70-75 g
waterlogged and
Usemilky liquid
infested canes
afterstraining
Grind decorticated Good results with
seed with water. juice of immature
Groundnut Seed 70-75 g
Use milky liquid waterlogged and
after straining infested canes
Soybean Seed Flour 30-40 g -do-

B. Chemical clarifying agents used in jaggery processing
Immediate effect on Effect on

Chemical Action
product storability
Hastens darkening
Hydros(sodium Brightens colour
Colour bleaching and process spoilage
hydrogen sulphite) temporarily
within a month
Liming to pH 6.3-6.6
results in good quality.
Useful in solidification
Removes juice acidity. Hard gur; stores
Lime(Calcium oxide) of gur from waterlogged
Helps in clarification better
lodged cane. Excess
liming results in hard gur
of dark colour
Helps in settling and
Hard gur; stores
Sodium carbonate Reduces acidity improving gur quality
better
from inferior canes.
Brightens colour Hastens process
Sodium bicarbonate Colour bleaching
temporarily spoilage
Sajji(50% sodium
carbonate, 6.4% Partial neutralization Brightens colour
Adverse effect on
sodium sulphate, of juice acidity, colour temporarily, reduces the
storage
4.5% sodium bleaching taste
chloride)
Increases natural
Super phosphate acidity, improves Reduces crystallization Reduces shelf life
colour
Improves clarification.
Brightens colour
Alum Needs neutralization Reduces shelf life
temporarily
with lime / soda

2.2.3 Juice concentration

In traditional method gur or jaggery was done with the help of a skilled person who has
sufficient knowledge and experience. Boiling of sugarcane juice is the 2nd important step in
jaggery making process. The main objective of boiling is to concentrate the juice to make
solid or granular jaggery or thick liquid jaggery, to increase the shelflife of juice. During this
process, several physical and chemical changes occur, which are closely monitored by a
skilled worker. The boiling of juice is continued in a regulated manner for more than 2.5-3 h
till the concentrated syrup attains the striking point.
The temperature at which thickened cane juice slurry becomes jaggery is known “Striking
Point”. The endpoint or striking point is usually decided manually by dropping a small
quantity of hot syrup into cold water taken in a container and it can be shaped with fingers.
Temperature plays a major role in the molding of the syrup into different forms of jaggery.
The striking point varies from product to product, for solid jaggery making it is at 118ºC,
liquid jaggery making is 106-107ºC and for granular jaggery making it is 120-122ºC.
To prevent excess frothing during boiling, small quantity of ground nut/ mustard oil is
sprinkled. It also facilitates easy flowing of hot syrup during transfer from one container to
another in the following process.
The thermal efficiency of the furnace is as low as 14.75% since the juice is boiled for longer
periods at very high temperature. Vacuum pans, or steam jacketed kettles are an alternative to
open pans to make the process energy efficient. Dried bagasse is utilized as fuel, additionally
other fuels like wood, agricultural residues and even old tyres are used.Overheating may lead
to dark color product with bitter taste.
2.2.4 Cooling and jaggery powder making

After reaching the striking point, the pan containing hot mass is removed from the furnace
and kept on a platform for 10-15 min. During that time, hot mass is thoroughly stirred with
flat wooden stirrer for uniform cooling of hot mass by natural air. Then, it is left for 5-10 min
without any further stirring to facilitate crystal formation. The moisture content of this semi
cooled mass is around 9- 10% (d.b.). The semi cooled mass containing seed crystals is then
transferred from pan to aluminium tray and the mass is converted into granules by applying
severe shearing action using wooden or stainless steel scrappers, sometimes even wooden
hammers. The shearing action exposes more surfaces for atmospheric cooling.

At this stage, to prepare 35-40 kg granules from 350-400 kg cane, 3 or 4 labourers are
required for 15-20 min to make the mass into granules. Otherwise the mass gets solidified
into different size of agglomerates or pieces.
2.2.5 Drying, powdering and sieving

Jaggery granules after preparation are dried to 1-2% (d.b.) moisture content. The initial
moisture content of granules is 10-12% (db) which is brought to 1% to 2% by sun, tray/
polyhouse drying.
The dried granules are sieved through 3 mm sieve as less than 3 mm are found to be better for
quality granular jaggery.
The jaggery powder thus produced is usually packed in 400 gauge polythene sheet or
polyethylene terephthalate (PET) bottles. Jaggery should be stored at 40-60% Relative
humidity for good keeping quality.
2.2.6 Technical drawbacks of traditional method
1. The naturally occurring enzymes and other compounds in sugarcane juice react with
each other and several other components of the juice due to uncontrolled heating
forming dark colored complex compounds.
2. Secondly, due to excessive heating, sugars in the juice caramelize and form dark
colored compounds.
3. Finally, excessive use of lime and leaching of iron from pans also result in dark color.
4. To improve the color of Jaggery, Sodium Hydrosulphite, a harmful chemical, is
normally used.
5. Hydros, bleaches colored compounds and changes the color of Jaggery to golden
yellow. It ultimately releases Sulphur dioxide in Jaggery which is harmful to health.
6. The entire process of Jaggery production is conducted manually by traditionally
skilled persons without having any scientific knowledge

2.2.7 Disadvantages of Producing Jaggery by Traditional Method
1. Even though Jaggery is a popular product, the traditional Jaggery making process has
remained a point of pain for producers, consumers and the community at large for
several reasons.
2. Completely manual process gives an unhygienic and inconsistent quality Jaggery.
3. The process being manual, has capacity limitations.
4. Many times skilled manual labour is not available thereby risking product quality
5. Due to the uncontrolled nature of manufacturing, Jaggery may contain harmful
chemicals such as SO2 and Polyacrylamides.
6. Inefficient and improper combustion in open pan boiling process produces high
particulate laden combustion gases which pollute the surrounding atmosphere.
7. The traditional process uses waste materials for fuel which produce harmful gases and
adversely affect the environment.
8. Jaggery with high moisture content has low shelf life of three months.
2.3. Modern scientific method of Jaggery Production
The jaggery producers should adopt the modern scientific technology for making quality
jaggery at low cost of production. In this method, jaggery is produced in very clean, tidy and
hygienic conditions. The utensils and equipments used in jaggery production keeps clean and
sterilized. The cemented floor of jaggery unit remains free from insects, ants, flies, bacteria,
fungi etc. The utilization of harmful and costly chemicals are avoided and herbal clarifying
agents are used for clarification of cane juice.
This process of jaggery production involves various steps such as: harvesting, pre-cleaning
and crushing of canes, filtration, clarification, heating, boiling and concentration of cane
juice, cooling of concentrated cane juice (i.e. slurry), powder making, packaging, storage and
marketing of jaggery.

Harvested sugarcane
Pre- cleaning
Crushing
Filtration
Clarification
Boiling & Concentration
Cooling
Powdering & Drying
Sieving
Packaging
Storage & Marketing
2.3.1 Harvesting of Canes

The completely ripened canes (possessing more than 16% sucrose in cane juice) are
harvested. The dry leaves are removed from the canes and the green top leaves are used as
fodder for the domestic animals. The canes should be harvested properly (i.e. from the
ground level), because jaggery production per unit area will be reduced if very long stubbles
are left in the field and more soil particles shall be mixed in cane juice, if harvesting is done
below ground level.
2.3.2 Pre-cleaning of Canes

To improve quality of jaggery, the canes should be cleaned thoroughly under high-pressure
water guns to eliminate soil and dust particles, waxes, insects and other impurities present on
sugarcane stalk. Some power drawn abrasive peeler of saw tooth type peeling unit have been
developed for this purpose, which consists of four peeling blades (possessing 15 cm long 22-
25 tapered teeth) attached at uniform spacing inside a square frame of 15cm. It can peel canes
having diameters up to 3.5cm with peeling depth of 0.2 cm. The peeling unit has efficiency of
85% with capacity of 100 kg canes per hour.

2.3.3 Crushing of Canes

After pre-cleaning canes are crushed with the help of sugarcane crushers to extract cane juice.
The cane juice is collected in clean stainless steel or plastic containers. The various types of
crushers are available in the market. These crushers can be categorized on the basis of various
aspects, such as: At present power, operated crushers are mostly used due to higher crushing
power. A power operated horizontal crusher has relatively better extraction percentage as
well as capacity.
 Based on Number of Rollers:

On the basis of rollers present in the crushers, there may be two roller, three roller and
four roller crushers. The three roller horizontal crusher exhibited best performance of about
more than 65%.
 Based on Orientation of Rollers:
On the basis of roller orientation, the crushers are of two types viz. vertical and
horizontal. The horizontal crushers were observed to be 2-4 % more efficient in juice
extraction than the vertical crushers.
2.3.4 Filtration of Cane Juice

After extraction, the cane juice is filtered. The juice filtration is carried out through a five-
layered filter. The juice travels through the underground pipes and directly reached to the
stainless steel juice-settling tank. It is settled for approximately 20 minutes. By this process,
all course impurities like-bagasse particles, leaves, dust particles etc. are removed from the
cane juice.
2.3.5 Clarification of Cane juice

The clarification of cane juice is necessary for making light coloured, crystalline, hard, less
hygroscopic and hygienic jaggery. Earlier clarification was mostly furnished by heating
method. Alum used for sedimentation of impurities, exhibited greater improvement in colour,
while utilization of phosphoric acid exhibited the best golden yellow colour of quality
jaggery. Sodium hydrosulphate makes the colour of jaggery very attractive, but from the
health point of view, the utilization of detrimental chemicals degrades the quality of jiggery.
Hence their use should be avoided. Natural clarifying agents should be used for clarification.
of cane juice. The mucilaginous extract from vegetative clarifying agents viz. Doela (wild
okra), okra, falsa or semal (40-60 grams of stem and roots of green plant per quintal of cane
juice) or 70-75 grams of caster or groundnut or 30-40 grams of soybean seeds per quintal of

cane juice are supplemented prior to heating the cane juice for its clarification. The pH of the
juice should be maintained at 6.0-6.2.
2.3.6 Boiling and Concentration of Cane juice

The juice is transferred from settling tank to boiling pans (i.e. vessels) situated over pit
furnaces. The sugarcane juice is now heated up to 80° C by firing under the boiling pan. All
impurities float up during boiling, which are removed by scumming. After that, it set to
boiling. While boiling, the sugarcane juice gets concentrated and after evaporating almost all
the water, pasty crystalline yellow substance known as slurry, is left in the boiling pan, which
becomes solid after cooling. The cane juice is concentrated until the striking temperature
reached. Scientifically, the striking point for solid jaggery is 120-122°C depending upon the
varieties, paddling and allowed to cooling.
Alternatively, the clarified juice can be concentrated by heating in steam driven energy
efficient multistage evaporators. Due to controlled boiling of sugarcane juice in stainless steel
evaporators, formation of dark coloured compounds is minimised. The juice is further
concentrated to its final consistency in a secondary concentrator to produce jaggery. The
water evaporated during juice boiling, is recovered by condensation in various stages of the
multiple effect evaporator, pre-heater and air-cooled condenser.
The bagasse is combusted in an efficient steam boiler which fulfils energy requirements of
the Jaggery plant. The remaining surplus bagasse is sold as a valuable by-product.
2.3.7 Cooling of Concentrated Cane Juice

Once the striking point reached the concentrated cane juice, (i.e. slurry) is poured into
cooling pan made up of wood or iron. The slurry is cooled here for some time and then
puddle with the help of ladle. At the moment, when the shining of slurry disappears, it is
ready for graining.
2.3.8 Powdering & drying
The mass is converted into granules by applying severe shearing action using wooden or
stainless steel scrappers, sometimes even wooden hammers. The shearing action exposes
more surfaces for atmospheric cooling; faster cooling rate causes increase in moisture
evaporation. The granules or powdered jaggery is also made in granular jaggery making
machine or in powder making machine.

The jaggery powder is dried from around 9-10% moisture content up to about 1-2% for good
keeping quality, by way of sun, tray or solar drying. Tray or solar drying will help to maintain
keeping quality intact.
2.3.9 Sieving &Packaging

Less than 3 mm sized crystals were found to be better for quality granular jaggery. The
particle size significantly affects chemical properties of jaggery.
Jaggery can be packed in attractive packaging material that should protect jaggery from
insects, dust particles, moisture and direct contact with hands, while handling and
distribution. The composition, weight, name of manufacturing agency, date of manufacturing,
date of packaging and health related aspects of jaggery etc. may be printed on the packet for
enhancing its marketing.
2.3.10 Storage and Marketing of Jaggery

The maximum returns can be obtained by selling jaggery in off-season. Thus, jaggery should
be stored in cool and dry places to avoid direct contact to moisture, because microorganisms
exhibited maximum growth at 10% moisture content and 30°C temperature. The moisture
content of freshly prepared jaggery ranged from 4-11%, while the optimum moisture for
storage should be 7-8%. The optimum relative humidity for storing jiggery is around 41-60%.
At very low temperature (1.5-3°C), jaggery can also be stored at very high relative humidity
(92-95%).
The jaggery packets can be stored and marketed easily. Jaggery marketing can be enhanced
by highlighting health related benefits of jaggery consumption over sugar.
2.4 Modified furnace by IISR, Lucknow
For heat economy, efficient modified bottom pans have been developed and 3 or 4 boiling
pans are arranged in a series (line) and flue gases pass under the entire boiling pans one after
the other and then escape through chimney. Indian Institute of Sugarcane Research, Lucknow
has developed thermally efficient two-pan and three-pan furnaces. The processing time in
these furnaces is comparatively less than the conventional furnaces. These furnaces have 2 or
3 pans for pre-heating of cane juice so that the processing time is reduced.
The modified pans have also been developed for two pan furnaces, which efficiently saves
bagasse used for evaporating per kilogram of water from the cane juice and producing per

kilogram of jaggery as well as reducing time in jaggery production. A Waste Heat Recovery
System (WHRS) has also been incorporated in IISR designed two pan furnace for recovery of
waste heat for bagasse/jaggery drying and/ or space heating. The material mainly used as fuel
in furnaces for heating the cane juice may be dried bagasse, dry leaves of sugarcane, straw
etc.
IISR 2-pan furnace
IISR improved 3-pan furnace
Modified pans for jaggery furnace

2.5 Advantages of Modern Technology

1. No manual processing or handling other than feeding sugarcane to the crusher
2. Very high shelf life of 18-24months of the powdered Jaggery produced
3. Sulfur-free, chemical-free and hygienic processing
4. Consistent product quality
5. Resource conserving product, therefore better project viability
6. Compact plant constructed with food grade stainless steel contact surfaces
7. Continuous production process
8. Fetches higher price to farmers and producers
2.6 Organic jaggery

In manufacturing of organic jaggery, the process starts from cultivation of sugar cane. In
sugar cane cultivation, the only natural organic fertilizer used is cow dung. The difference
between organic and commercial jaggery making is mainly in clarification process.
In organic jaggery making process, only organic clarifying agents and little bit of lime (to
decrease the acidity of juice) can be used. So organic jaggery will be dark coloured when
compared with commercial jaggery.
2.6.1 Challenges in producing Organic Jaggery

Farmers have not yet converted to organic sugarcane cultivation, which makes it impossible
to produce organic jaggery and label it so. Even if the processing is organic, the final food
product cannot be labelled as so, unless the raw material is organic too. This is a major
limitation for Indian Jaggery, and products made thereof, to reach global organic food
markets. Apparently, the main reason for not growing organic sugarcane is reduced crop
output per acre. To mobilize cultivation of organic sugar cane, government will have to
incentivise its farming by providing higher pricing for the crop.
2.7 Jaggery Production: Constraints and remedies

In India, jaggery industry faces many problems. Some of the serious constraints are:
i. Juice Extraction Efficiency:

The efficiency of cane juice extraction of the cane crushers is less than 60 %, which
reduce the jaggery production per unit area. Hence, there is a great need to develop gearbox
type efficient 3-4 horizontal roller scientifically improved crushers, to improve the juice
extraction efficiency more than 70 %.
ii. Non-availability of High Jaggery Producing Varieties/ Hybrids:

Although, more than 600 varieties have been developed so far in sugarcane, but there
is very limited availability of high jaggery producing varieties and hybrids of sugarcane. To
improve jaggery and khandsari industry there is an urgent need to develop such varieties and
hybrids, which can produce high jaggery and khandsari.
iii. Uncertainty in Market Prices:

There is very uncertainty in market rates of jaggery and khandsari, since if the
production is high the prices goes down and vice-versa, results into narrow margin of profit
to the jaggery producers, therefore they don’t want to take a risk and sale out jaggery
immediately at whatever may be the market price.
iv. Decreasing Consumer Awareness:

In order to increase per capita consumption of jaggery, special attention and
campaign for consumer awareness towards consumption of jaggery at national level needs to
be initiated. There is a scope to increase jaggery consumption by introducing and making
various value added products. Jaggery can be used in manufacturing bakery products,
chocolates, confectionary, beverages etc. The use of sugar can be replaced or minimized by
jaggery wherever possible.
v. Poor Storability:
Jaggery is very critical to store. The non-sucrose constituents viz. salts, proteins,
glucose, fructose and reducing sugars present in jaggery can absorb moisture from the
atmosphere. This hygroscopic nature coupled with non-availability of proper storage
structures are major reasons of poor storing ability of jaggery. About 10-25 %, losses may
occur during storage of jaggery. To reduce economical losses of jaggery, high production
technology and quality packaging along with appropriate storage technique and storage
structures should be made available to the jaggery producers.
vi. Scarcity of Labour:

In jaggery industry, large number of labourers is required for various unit operations
of jaggery processing. The unavailability of labour and higher wages is the severe problem.
To overcome acute labour problems and for hygienically jaggery production, there is an
urgent demand for automatization of jaggery processing.

CHAPTER 3
Packaging of Jaggery Powder
The major problem associated with jaggery storage is the presence of invert sugars and
mineral salts which, being hygroscopic absorb moisture particularly during monsoon season
when ambient humidity is high, and lead to spoilage.It has been estimated that more than
10% of jaggery produced in the country worth Rs. 40 crore is lost every year due to
deterioration.
The traditional packaging methods for storage in vogue e.g. inside a blanket of bhusa or
wheat straw, cloth lined with polyethylene sheet, aluminum foil, plastic containers, earthen
pots and jute bag , give far from satisfactory results. Further, at retail level, the jaggery is sold
in open and under unhygienic condition. Hence, there is need to evolve suitable packaging
technique to enhance shelf life and maintain quality of jaggery.
3.1 Packaging materials used for Jaggery
i. Glass packaging’s inert nature eliminates the risk of potentially harmful chemicals
found in some plastics that can leach into food, but this is outweighed by drawbacks
of weight, expensive nature and fragility for handling.
ii. Usage of polythene avoids film moisture absorption and liquefaction of jaggery.
Certain researchers reported that the heat sealed LDPE packets of 150 gauge was best
suitable followed by glass jar and PET jar.
iii. To control the hygroscopic nature of the powder jaggery, it can be packed in moisture
proof polyethylene-polyester laminates and PET.
iv. Three ply (PET+ Aluminium Foil +PE) packaging material helped more in checking
of inversion rate. This three ply has advantages due to its higher strength with low
water vapour transmission rate and low oxygen transmission rate.
v. Kraft Paper, PE coated / LDPE Laminates are also prevalently used nowadays
because of its salient features like visual appeal, durability, light weight and
customizable nature.

vi. Standup pouches with or without gussets and zip are the highly trending packaging
seen for jaggery powder. These are heat sealable.
vii. Depending on the packaging material and style chosen, horizontal/ vertical form, fill,
seal machine or band sealing or sachet pouch machines can be employed.

CHAPTER 4
Export Market for Jaggery and Jaggery Based Products
India is world’s second largest sugarcane grower with 354 million ton annual production and
contributes to 70% of the world’s total Jaggery production. About 88.5million TPA of
sugarcane is processed to make 9.8million TPA of Jaggery through 40000 small units
operating in the unorganized sector. Out of this about 40% is exported as interpreted from the
report published by APEDA. Jaggery export market is of Rs 7500 million and domestic
market of Rs 11000 million approximately. It is expected that this consumption can
drastically increase by adopting modern processing technology with improved quality.
4.1 Export status of jaggery from India
The table shows details of top 10 Jaggery exporters from India.
Sr No. Country Qty, MT Value, Rs. Lacs

1 SriLanka Dsr 51,210.12 12,812.82
2 Nigeria 15,150.59 11,729.73
3 Nepal 15,309.21 9,831.63
4 Malaysia 29,330.88 9,348.87
5 Tanzania Rep 27,513.08 8,172.20
6 USA 8,200.90 7,958.36
7 UAE 10,558.17 6,603.86
8 Indonesia 15,988.10 5,307.30
9 Kenya 17,327.97 5,274.39
10 Uganda 17,124.12 4,496.18
Total 2,07,713.14 81,535.34
4.2 Major constraints identified in jaggery exports suggested by APEDA
1. Lack of infrastructural facilities in jaggery production and insufficient price dissemination

in jaggery marketing
2. Unorganized production - conventional methods followed under unhygienic conditions,

without automation
3. There is no standard protocol being followed for making of Jaggery.

4. Since the demand for dark yellow Jaggery is high, producers use Sodium Hydrosulphite
& other chemicals (non-food grade and harmful to the human health) to obtain the desired
yellow colour.
5. Mostly units are using iron utensils for Jaggery making which are not permitted since iron
is prone to gathering rust and making the product food unsafe.
6. There are no packaging standards for Jaggery
7. There is no Research & Development for product development and value-addition of

Jaggery.

CHAPTER 5
Food Safety Regulations & Standards
5.1 Food Safety Regulations & Standards for cane jaggery or cane gur:
Cane Jaggery or Cane Gur means the product obtained by boiling or processing juice pressed
out of sugarcane (Saccharum officinarum). It shall be free from substances unsafe to health
and shall conform to the following analytical standards on the dry weight basis.
S. No Characteristics Permissible Limits
1. Moisture, percent. by mass, Max 7.0
2. Sucrose, percent. by mass, Min 70.0
3. Total Sugars, Min 90.0
4. Reducing sugars, percent. by mass, Max 20.0
5. Sulfate ash, percent. by mass, Max 4.0
Ash insoluble in dilute hydrochloric acid,

6. 0.5
percent. by mass, Max
Extraneous matter and water insoluble

7. 2.0
matter, percent. by mass, Max
Sodium bicarbonate, if used for clarification purpose, shall be of food grade quality
2.8.8: Sodium Saccharin (Food Grade)
Sodium Saccharin is white crystals or white crystalline powder. It is odorless or has a faint
odor. It is intensely sweet to taste, even in dilute solution. 1 g is soluble in 1.5 ml of water
and in about 50 ml of alcohol. When tested in accordance with the method specified in Indian
Standard, IS 5345, it shall conform to the following standards

S No. Characteristics Permissible Limit
Purity as C7H4NNaO3S, after drying at

1. 99.0
120°C for 4 h, percent by mass, min
2. Moisture, percent by mass, Max 15.0
3. Acidity and alkalinity To pass the test
4. Benzoate and salicylate To pass the test
5. Readily carbonizable substances To pass the test
6. Toluene sulfonamides, ppm, Max 25.0
Calcium Saccharin (Food Grade) – (2.8.12)
Calcium Saccharin is white crystals or white crystalline powder. It shall be odorless or having
a faint odor and an intensely sweet taste even in dilute solution. One gram is soluble in 1.5 ml
of water. When tested in accordance with the method specified in Indian Standard, IS 5345, it
shall conform to the following standards:
For Cane Jaggery or Cane Gur& Sodium Saccharin (food grade) and Calcium
Saccharin (food grade), the following requirements must also be complied with.
S No Characteristics Permissible Limit
Purity as C14H8CaN2O6S2, on the dry basis,

1. 99.0
percent by mass, Min
2. Moisture, percent by mass, Max 15.0
3. Benzoate and salicylate To pass the test
4. Readily carbonizable substances To pass the test
5. Toluene sulfonamides, ppm, Max 25.0

Machineries Manufacturers & Suppliers
S.No Name of the company Machinery

1 M/s. Kesavan Industries, Cane crusher
87, Dharapuram Road,
Udumalpet – 642 126, Tamil Nadu.
Phone: 04252 – 223939
2  Moon Sun Group of Companies Cane crusher
 VidurkutiGanj Road,
Bijnor - 246701,
 Uttar Pradesh, India
 Mobile :+91- 9412217161
 Email : moonsun695@yahoo.com
3  NSI Equipments Pvt Ltd Cane Crusher
 159, Saipuram,
 Opposite block Development Office,
 Delhi Road, Meerut – 250001,
 Uttar Pradesh
4 Shri. KhanderaoGhadge Churner, Juice
At/post- Kadamwadi, Boiling Pan
Tal – Karveer, Dist. Kolhapur
5  Om Kailash Estate, Juice Boiling Pan
 Yadav Road, Rajkot, Upleta - 360490,
 Gujarat, India.
 Phone :+918037401692.
 Fax : +91--9978221107.
6 Annapurna Industries Juice Boiling Pan
Gola Road, LakhimpurKheri - 262701,
Uttar Pradesh, India
 Call +91-8048424467
7 UP Small machinery corporation Drying-cum Storage

Near Kashipur Road, Gandhi Colony, Rudrapur Jaggery Bin

8 Infinity Engineering Jaggery crushing

99, Somalapuram, Ambur, Ambur Taluk, machine
Vellore-635802, Tamil Nadu, India
9 Tru Mark Enterprises Weigh filler and band
Shop no 14, grnd floor, Vighnharta Coop sealer for standup
Housing Society, Mahadev Palav Marg, Currey pouch
Road, Mumbai-400012. India
10 IPK Packaging (India) Private Limited Automatic pouch
S.F.No. 9, Jagannath Industrial Estate, packing machine
Chinnavedampatti
Coimbatore - 641049, Tamil Nadu, India
11 Best India Automatic pouch

14, 16/2, Mathura Road, packing machine
OldFaridabadSector 20, Faridabad - 121002,
Haryana, India
12 Excel Plants & Equipment Private Limited, Customized Industrial
Gate No. 611, Mouje Kuruli, M. I. D. C. Jaggery Plant
Chakan, Pune - 410501, Maharashtra, India
https://www.excelplants.com

Contact Us
Director
(Ministry of Food Processing Industries, Government of India)
Pudukkottai Road, Thanjavur - 613 005, Tamil Nadu
Phone No.: +91- 4362 - 228155, Fax No.:+91 - 4362 - 227971
Email: director@iifpt.edu.in; Web: www.iifpt.edu.in

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PM Formalisation of

Micro Food Processing Enterprises (PM-FME)

Indian Institute of Food Processing

Hand book of Processing of Jaggery Page 1

1.1 Status of Sugarcane in India

Sugarcane (Saccharum officinarum) family Gramineae (Poaceae) is widely grown crop in

1.1.1 Cultivation Scenario

Hand book of Processing of Jaggery Page 2

1.1.2. Sugar cane varieties suitable for jaggery production

Co 8371 (Bhima) Co 7219 (Sanjivani)

1.1.3. Production and yield of sugar cane in major states in India

Hand book of Processing of Jaggery Page 3

1.1.4. Production and productivity of sugar cane in major states of India

Hand book of Processing of Jaggery Page 4

1.2. Sugarcane products market

1.2.1. Indian Market Outlook

Hand book of Processing of Jaggery Page 5

1.2.2. Utilization of Sugarcane

Hand book of Processing of Jaggery Page 6

1.3. Nutritive value of Jaggery

Compared to khandsari, jaggery is a wholesome diet. It contains 0.6%-1.0% minerals;

1.4. Medicinal properties of jaggery

Hand book of Processing of Jaggery Page 7

e) Jaggery benefits digestion

f) Jaggery increases metabolism

g) Jaggery treats water retention

h) Jaggery balances hormone levels

Hand book of Processing of Jaggery Page 8

i) Good for Brain

j) Treats Respiratory Problems

k) Useful in Joint Pain

1.5. Jaggery vs Sugar

Jaggery exhibits supremacy over sugar in many ways, as:

1. It is an important source of energy (383 kCal energy per100 g of jaggery).

Hand book of Processing of Jaggery Page 9

Processing of Jaggery Powder

2.1. Processing of jaggery

2.1.1 Forms of Jaggery

Composition of different forms of jaggery

Composition per Types of jaggery

Hand book of Processing of Jaggery Page 10

2.1.2 Granular or Powder Jaggery

2.2. Traditional production process

Juice extraction Bagasse

Lighter impurities, wax, carbon

Powdering & Sieving

Packaging & Storage

Hand book of Processing of Jaggery Page 11

2.2.1 Juice Extraction

2.2.2 Juice clarification

Hand book of Processing of Jaggery Page 12

A) Vegetable clarifying agents used in jaggery manufacture

Common Quantity per

Hand book of Processing of Jaggery Page 13

B. Chemical clarifying agents used in jaggery processing

Immediate effect on Effect on

Hand book of Processing of Jaggery Page 14

2.2.3 Juice concentration

2.2.4 Cooling and jaggery powder making