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कर्मवीर शंकरराव काळे सहकारी साखर कारखाना लि., गौतमनगर

स्थापना: १९५६

सहकारी तत्वावरील आशिया खंडातला दुसरा सहकारी साखर कारखाना सातत्याने ऑडीट वर्ग 'अ' संस्था वसंतदादा शुगर इंस्टीट्युट पुणे यांचे तर्फे राज्यपातळीवर गळीतासाठी 'हायेस्ट रिड्युसड ओवरऑल रिकव्हरी' चे प्रथम क्रमांकाचे बक्षीस व सन २०१०-११ चा 'सर्वोत्कृष्ट ऊस विकास पुरस्कार' प्रदान, पांढरी शुभ्र दाणेदार साखर निर्मितीशिवाय दर्जेदार स्पिरीट/देशी मद्य निर्मिती, बायोगॅस निर्मिती, तसेच प्रदूषण नियंत्रण योजना, कंपोस्ट खत निर्मिती प्रकल्प इत्यादी .

Details of Sugar Factory & Bye-Products	Detail Information
Name & Address	Karmaveer Shankarrao Kale Sahakari Sakhar Karkhana Ltd.Gautamnagar PO: Kolpewadi, Taluka – Kopargaon, Dist-Ahmednagar(M.S.) Phone : (02423) 261210 to 261215. Fax : (02423) 261219 (Sugar Division), 261217 (Distillery Division) E-Mail : kskssk1953@gmail.com Or kosakasugar@rediffmail.com (Sugar Division) kosakabhingari@rediffmail.com (Distillery Division)
Constitution & Type	Co-Operative Society. Registration No. G-260 dated 4th June 1953.
Product & Capacity	Sugar : 4,000 TCD Rectified Spirit : 45,000 LPD Potable Country Liquor : 2,25,000 LPD
Year of commencement of production	Sugar : 1955-1956 Rectified Spirit : 1976-1977 Country Liquor : 1978-1979 Biogas Generation : 1992-1993 Bio-Composting : 1999-2000
Proposed Project	Co-Generation from Bagasse Capacity : 18.00 MW Estimates Project Cost : 125.00 Crores

Successful Development of Sugar Factory

Ours is a second co-operative sugar factory in India established in Ahmednagar district of Maharashtra just after independence in 1953 and started its commercial production of sugar in 1956 with initial capacity of 800 TCD. Based on increasing availability of sugar cane in area of operation, the karkhana(factory) has expanded its crushing capacity to four times from 800 TCD to 4000 TCD. It is one of the progressive sugar factory in the region and has achieved good results since its establishment under the able guidance & leadership of founder Chairman - Hon’ble Late Shri Shankarraoji Kale Saheb.

Factory Renamed in 2013

The Kopargaon Sahakari Sakhar Karkhana Ltd.,Gautamnagar was renamed as ‘ Karmaveer Shankarrao Kale Sahakari Sakhar Karkhana Ltd.’ in 2013.

The Co-operative Societies Act was enacted in India in 1904 with limited objective to provide cheap credit to the farmers and save them from exploitation of money lenders. It was only in the early 1930’s that the co-operative movement penetrated into sugar sector.

The second co-operative sugar factory to be set up in Maharashtra was ‘The Kopargaon Sahakari Sakhar Karkhana Ltd.,Gautamnagar, Post-Kolpewadi, Tal.-Kopargaon Dist. Ahmednagar under the Bombay Co-operative Societies Act, 1952 having Registration No. G-260 dated 4/6/1953.

Dr. Dhananjayrao Gadgil, Vaikunthbhai Mehta, Ganpatrao Autade & V.P.Varde supported the founder member Shri Shankarrao Deoram Kale, who was well educated at that time. Shankarrao Kale started counselling poor farmers by going door to door to develop faith, confidence & optimism in their hearts about co-operative movement.
The management of society started sugar factory on the modest way with the crushing capacity of 800 TCD per day with cane plantation area 1325 hectors. Crushing operations started on 15/02/1956 in the presence Dr. Dhananjayrao Gadgil.
However, the intial crushing capacity of sugar factory was 800 MT per day, but area under sugarcane increased gradually and management of the sugar factory expanded the crushing capacity from time to time. The present crushing capacity of our sugar factory is 4000 MT. per day.

Cane Development Activity

A large number of sugar complexes are coming up due to the liberalization and introduction of new sugar policy of the Government. Therefore, sugarcane acreage per sugar mill is declining for producing a large quantity of sugarcane to run the mills to their full capacity, there are two options either to increase the sugar production vertically or increase area under sugarcane. The possibility to the second option is limited as area under agriculture is decreasing day by day. The only option left therefore is to increase production vertically by the use of innovative technologies. Following cane development activity adopted & implemented in area of operation by sugar factory to produce sugarcane.

1) Planning for season wise planting & harvesting
A scientific season planning & harvesting schedule is adopted by the sugar factory for adequate production of sugarcane coupled with increase in sugar recovery. The factory suggested the farmers to plant maturity wise harvesting of sugarcane based on the analysis made by refracto meter.

2) Supply of quality seed
Quality seed assumes great signiﬁcance in any crop production. There is a need to change the variety of seedlings after every three to four years to maintain the purity of varieties and to get good recovery. The factory follow three tier seed programme and supplies quality seeds to the cane growers on credit basis.

3) Drip Irrigation
The cane can be grown under well, bore well, lift & canal irrigation. The factory management has given prime importance to water saving strategy in sugarcane cultivation and adopted drip irrigation system. As a result 35 to 55% water is saved.
For installation of drip system loans are made available by sugar factory from Union Bank of India. The incentive is given to the cane growers to adopt drip system on a large scale.
4) Supply of Chemical fertilizer
Chemical fertilizers are supplied by the sugar factory on credit basis. SuppIy of weedicide, micronutrient, press-mud and compost on credit basis.

5) Sugarcane Trash
Sugarcane trash can be used as a mulch and as a source of organic manure. In operational area considering water shortage and drought situation factory adopted practice of trash mulching in ratoon crop which benefits water saving. Factory gives incentive for trash mulching.
6) Promoted for green manuring
The application offym (farm yard manure) has been suggested before sugarcane planting, but due to its inadequate availability farmers did not add it. Considering this fact sugar factory supplies the green manurity crop seeds of Sunheamp & Dhaincha on 50% subsidy from last 10 to 15 years. Considering all these cane development activities sugar factory has been awarded- The Best Cane Development Award In Central Zone of Maharashtra by Vasantdada Sugar Institute (VSI, Pune) for 2010-2011.

Considering all these cane development activities sugar factory has been awarded- The Best Cane Development Award In Central Zone of Maharashtra by Vasantdada Sugar Institute (VSI, Pune) for 2010-2011.
Besides assisting the farmers in their main profession we also promote them to take up dairy & poultry activities as subsidiary business to raise their earnings thereby to improve their standards of living.

DISTILLERY DIVISION :-
Our Management has a cost conscious approach always. To reduce the cost of sugar it is essential to develop various by-products to increase income. Keeping this object in mind we have set up molasses based Alcohol Production Plant in 1976 & Country Liquor manufacturing unit in 1979 affiliated to sugar factory. The molasses is the residual obtained from the process of manufacturing sugar. The annual capacity of our distillery for manufacturing industrial alcohol is 90 lac Itr. It is recently expanded to 135 lac Itr. The spent wash generated through this process is hazardous for human health and creates pollution. In order to avoid pollution the spent wash is used in biogas plant for primary treatment as well as to generate methane gas.

Country Liquor Bottling Unit

Karkhana also has a country liquor bottling unit established in 1979. At present country liquor unit works in two shifts. The performance of the distillery & country liquor unit is excellent. It is one of the most reputed country liquor manufacturing units in the state in terms of quality and production.

SPENT WASH ZERO LIQUID DISCHARGE (ZLD) PROJECT

Our molasses based distillery unit was established in the year 1976 with an installed capacity 35 KLPD. After that in the year 2012-13 Management has up-grade distillery unit capacity upto 45 KLPD. It is batch fermentation and atmospheric distillation system. The raw spent wash generation from atmospheric distillation is around 500m3/day (5.00 lakh ltrs.) For the treatment of spent wash in the existing distillery Karkhana has adopted bio-methanization followed by bio-composting system. For composting there is lack of pressmud in offseason upto 5 to 6 months due to which it is difficult to run distillery throughout year.

As per directions given by Ministry of Environment & Forest, New Delhi and Pollution Control Board to reduce spent wash generation and for effective treatment of spent wash our Management has decided to up-grade its existing effluent treatment system by installing Multiple Effect Evaporator Plant (MEE) to concentrate spent wash followed by Incineration Boiler for achieving Zero Liquid Discharge”.

The Management has also decided to install TG Set for electricity generation which will be used for distillery and exhaust system from TG Set will be used for distillery and evaporation plant. Incineration Boiler having capacity 15 M.T. and Turbine having capacity 1.5 M.V. The Management has also decided to installed Condensate Polishing Unit (CPU) for treatment of Evaporation process condensate and spent lees. After treatment in CPU treated water will reused for Distillery Cooling Tower makeup or for fermentation process. In this way distillery will able to achieve “Zero Liquid Discharge”.

- संगणक -