Capacity Utilization of Sugar Millsin
SAARC Countries
An Exclusive Comparative
Review of Sugar Industry
In Pakistan and India
Research Department
Institute of Cost and Management
Accountants of Pakistan (ICMAP)
Contents
Page
Executive Summary .............................................................................................3
Chapter 1: A Comparative Review of Pakistan and Indian Sugar Industry ...............11
(a) Synopsis .....................................................................................................12
(b) Sugarcane Cultivation Area.....................................................................13
(c) Sugarcane Yield ........................................................................................16
(d) Sugarcane Production ..............................................................................21
(e) Sugar Production ......................................................................................24
(f) Sugar Recovery Ratio................................................................................27
Chapter 2: Capacity Utilization of Sugar Mills in Pakistan and India .......................31
(a) Preamble .....................................................................................................32
(b) Industry Snapshot .....................................................................................32
(c) Historical Progress of Industry ...............................................................33
(d) Scale and Size of Industry ........................................................................35
(e) Size of Sugar Plants ...................................................................................40
(f) Installed Crushing Capacity of Sugar Mills ..........................................46
(g) Capacity Utilization of Sugar Mills ........................................................51
(h) Increasing Number of Sick Sugar Mills in India...................................56
Chapter 3: Sugar Industry in Other SAARC Countries: ................................................59
(a) Bangladesh .................................................................................................60
(b) Nepal ...........................................................................................................65
(c) Sri Lanka .....................................................................................................69
Appendices ............ ....................................................................................................................73
– Sugar Statistics of SAARC Countries ............................................................74
– Installed Capacities of Pakistani Listed and Non-Listed Sugar Mills .....78
– References .........................................................................................................79
2
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Executive Summary
This exclusive comparative review of the sugar industry in Pakistan and India has
been undertaken by the Research Department of Institute of Cost and Management
Accountants of Pakistan (ICMAP) with special focus on installed and utilized
capacities of sugar mills in both countries.
This Research Report is divided into following three Chapters:
Chapter –1:
This Chapter presents a ‘Comparative Review’ of the sugar sector in Pakistan and
India with specific reference to sugarcane cultivation, yield, production, sugar
production and recovery ratio. This would be helpful in understanding the main
part of this report related to capacity utilization.
Chapter – 2:
This Chapter forms the main part of our Research Paper, providing a detailed
review of the size and scale of the Pakistani and Indian sugar industry, the installed
capacities of sugar mills and the capacity utilization achieved by the sugar industry
in both countries.
Chapter – 3:
This Chapter provides useful facts and statistics on the sugar industry in other
SAARC countries viz. Bangladesh, Nepal and Sri Lanka. Although the size of the
sugar industry in these countries in limited, rather negligible, but still inclusion of
their details is an attempt to make this report comprehensive.
3
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Contrasting Aspects of Pakistan and Indian Sugar Industry
It is an established fact that the size of Indian sugar sector, both in terms of
sugarcane and sugar production, is far larger than Pakistan. ICMAP research
substantiate this fact by concluding that Pakistan’s total sugar industry,
comprising of around 80 sugar mills, is far smaller in number than each of the two
Indian States i.e. Maharashtra (having 195 sugar mills) and Uttar Pradesh (154
sugar mills).
Let us have a look below at some ‘contrasting’ aspects of Pakistani and Indian
sugar industry, which have revealed as a result of this comparative research:
1) The sugar production capacity of India at 23.90 million tons (2009) is almost
four times greater than sugar capacity of Pakistani sugar mills, which is
around 6.24 million tons (2009).
2) Unlike Pakistan’s privately-owned sugar sector, the ownership structure in
India is much diverse. There are privately-owned sugar mills at one extreme,
and cooperative factories, on other extreme, which are owned by farmers
and managed by government. ICMAP research reveals that private sector in
India is visible in number i.e. in States of UP, Tamil Nadu, Andhra Pradesh,
Karnataka and Bihar. The Cooperative sector is dominating in States of
Maharashtra, Gujrat, Punjab & Haryana.
3) Installed capacities of Pakistani sugar mills are evenly distributed with 47%
share in ‘Small-sized’ segment (capacity below 1500 TCD to 5500 TCD) and
41% share in ‘Medium-sized’ segment (capacity between 5501 TCD to 9500
TCD). In contrast, around 88% the Indian sugar mills are in the ‘Small-sized’
segment with capacities ranging between 2500 TCD to 5000 TCD. This points
towards the fact that the Indian sugar industry need modernization/
rehabilitation and capacity expansions.
4
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
4) Pakistan is well ahead of India in the ‘Large-sized” segment (above 9500
TCD) with 12% share in overall sugar industry, as compared to only 1.4% of
large sugar plants in India. All eight (8) large sugar plants in India are in the
‘private sector’. It is interesting to note that Sindh province of Pakistan do not
have any large sugar plant, whereas Punjab and NWFP have 8 units and 2
units, respectively.
5) The capacity utilization rate of Pakistani sugar mills fell down to 51.4%
during 2008-09, from 80% achieved last year. ICMAP research shows that
this sharp decline in capacity utilization was mainly due to 21.7% shortfall in
sugarcane production from 64 million tons in 2007-08 to 50 million tons in
2008-09. Similarly, the capacity utilization rate of Indian sugar mills also
declined to 63% during 2008-09 from 117% last year. The reason is identical to
Pakistan i.e. around 17% shortfall in sugarcane production from 348 million
tons in 2007-08 to 289 million tons in 2008-09.
6) Our research indicates that during last five years [FY 2004-05 to FY 2008-09],
the average capacity utilization of Indian sugar mills have been 95.2% as
compared to 58.7% of Pakistani sugar mills. The highest capacity
utilization of 81% by Pakistani sugar mills was achieved during FY 2007-08,
whereas highest capacity utilization of 132% by Indian sugar industry was
in FY 2006-07.
Pakistan Sugar Industry
We now summarize below the salient findings of sugar industries in Pakistan
and India, separately. The main report may be referred for detailed review:
1) The annual crushing capacity of 81 sugar mills in Pakistan is around 72
million tons (2009). Although the annual sugar production capacity is 6.2
million, our industry is not able to meet the annual domestic consumption of
5
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
around 4 million tons. In 2008-09, the sugar production was 3.21 million tons
(as per PSMA figures, whereas USDA puts this figure at 3.51 million tons).
2) The sugar industry in Pakistan is pre-dominantly owned by the private
sector, mostly in hands of influential families, having political connections.
Out of 81 sugar mills, 40 mills (49%) are located in Punjab, 32 mills (40%) in
Sindh and 09 mills (11%) in NWFP. About 46% (37) of sugar mills in Pakistan
are Listed on Stock Exchange whereas 54% (44) are in Non-Listed sector.
3) There are 38 ‘Small-sized’ sugar mills in Pakistan within capacity range
between 1500 TCD to 5500 TCD, out of which Sindh Province has highest
number with 22 small sugar plants, followed by 11 in Punjab and 5 in NWFP.
Similarly, there are 33 ‘Medium-sized” sugar plants with capacity range
between 5500 TCD to 9500 TCD – Punjab leads with 21, followed by 10 in
Sindh and 2 in NWFP. There are only 10 “Large-sized’ sugar Plants in
Pakistan [9500 TCD and above]. Out of them, 10 are in Punjab, 2 in NWFP
whereas Sindh has no large-size sugar mills.
4) The ‘Non-Listed’ sector dominates the ‘Small-sized” and “Large-sized”
segments of sugar industry of Pakistan with 28.4% (out of 47%) and 7.4%
(Out of 12%), respectively. The ‘Listed’ Sector has large share in the
‘Medium-sized’ segment with 22.2% (out of 41%).
5) The ‘Listed’ sector is more prominent in Sindh Province with 19% share in
total installed capacity, as against Punjab with 12% share. On the other hand,
‘Non-Listed’ sector is dominant in number in Punjab Province with 36%
share, as compared to 24% of Sindh.
6) The capacity utilization of Pakistani Sugar mills has fallen down sharply to
51.4% during 2008-09 from 80% in 2007-08. The main reason is shortage of
raw material (sugarcane). Optimum utilization of capacity is only possible if
sugarcane production is increased by 4 % to 5% annually.
6
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Indian Sugar Industry
1) The annual sugar production capacity of 582 sugar mills in India is 23.9
million tons (2009), showing 5% increase from 22.48 million last year.
ICMAP research shows that the highest increase in capacity during last five
years [2005-2009] is in Uttar Pradesh i.e. 62% which is mainly due to private
sector initiative as 61% of 154 sugar factories in this State are in private sector.
The capacity increase is only 3% in Maharashtra State where cooperatives are
more dominant.
2) The States of Maharashtra and Uttar Pradesh (UP) alone constitute 56% of
the total sugar mills in India and if Karnataka State is also included, the share
reaches 65%. This means that these three States are critical to the Indian sugar
industry.
3) Out of 624 installed factories (only 582 are functional) in India, about 51% are
in the ‘Cooperative sector’, whereas 39% are in ‘Private sector’ and 10% in the
‘Public sector’.
4) About 88% of sugar factories in India are in the ‘Small-sized’ segment with
crushing capacity in the range between 2500 TCD to 5000 TCD. ICMAP study
shows that 75% private, 94% cooperatives and 98% public sector units are in
the small-scale segment. Moreover, all the 8 Large-sized sugar mills have
been established by the Private Sector.
5) There are presently 206 Sick/closed sugar factories across India, with two
major sugar producing States of Maharashtra and UP share 107 sick units
(50% of 206 sick units). Out of them, 61 are Private and 145 belong to the
cooperative sector. This high proportion of sickness in cooperatives is
seemingly due to highly regulated environment and lack of profit motive.
Private sector is better placed in taking advantage of multiple outputs like
electricity generation, bio-diesel etc.
7
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
6) The capacity utilization of Indian sugar mills has fallen down sharply to 63%
during 2008-09 from 117% in 2007-08. The main reason is shortage of raw
material (sugarcane) and high fluctuations in cane area under command.
ICMAP research shows that highest shortfall of 68% in capacity utilization
during 2008-09 (as compared to last year) is in Andhra Pradesh State,
followed by 65% in Maharashtra, 62% in Karnataka, 52% in UP, 34% in Gujrat
and Punjab, and 23% in Tamil Nadu.
Sugar Industries in SAARC Countries
The sugar industry in other SAARC countries viz. Bangladesh, Nepal and Sri
Lanka is quite insignificant, as compared to the sugar industry of Pakistan and
India. An attempt has been made in this study to provide a snapshot of the sugar
industries in these three SAARC countries, with special focus on installed
capacity and capacity utilization of sugar mills. A summary is given below:
Bangladesh Sugar Industry
1) There are 15 operating sugar mills in Bangladesh with total installed sugar
production capacity of 21,044 tons per day. Bangladesh has no private
crushing mills and all the sugar factories are in the public sector, under the
control of Bangladesh Sugar & Food Industries Corporation (BSFIC).
2) The performance of all 15 sugar mills has been quite steady with 70%
capacity utilization during the period 2005 to 2008. During 2006-07 and 2007-
08, capacity utilization was above 85%.
3) As annual sugar production is not sufficient to meet the local demand,
Bangladesh imports substantial amount of sugar from other exporting
countries. Imports are made by both public and private sector. During 2007-
08, sugar production stood at 0.16 million tons against target of 0.20 million
tons. The local demand of sugar for 2010 is estimated at around 1.3 million
tons.
8
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
4) The main reason for low sugar production is attributed to low availability of
sugarcane in view of drastic decline in cultivation area of sugarcane
throughout the country.
Nepal Sugar Industry
1) There are 12 Sugar mills in Nepal – two mills are in Public sector (which are
closed) and 10 mills in the Private sector (functional). The combined capacity
of 8 private sugar mills is 20,750 TCD which is equal to annual crushing
capacity of 3.11 million tons.
2) The sugarcane production of Nepal is around 1.62 million tons with yield of
35 tons per hectare. However, in 2008-09 the cane production fell down to
59,000 tons.
3) Nepal sugar mills produce around 0.10 million tons of sugar annually, which
is not sufficient to meet the annual domestic demand of 0.16 million tons.
Resultantly, nearly 50,000 tons of sugar are imported annually, mainly from
India.
4) The sugar capacity utilization of Nepalese sugar mills has always remained
below 50 percent and ICMAP research shows that utilized capacity is
declining gradually, leading to increased imports.
Sri Lanka Sugar Industry
1) The sugar industry of Sri Lanka is quite negligible with only four installed
Sugar mills, out of which two are closed and not currently producing sugar.
2) The total cane crushing capacity of four sugar mills (two closed and two
functional) is 8250 TCD. The two operational sugar factories (Pelwatte &
Sevanagala) have total capacity of 5050 TCD which is equal to annual
capacity of 1.01 million tons.
9
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
3) The total sugar producing capacity of two operational sugar mills is 440 tons
per day or 88,000 tons per annum. Pelwatte has 330 tons capacity whereas
Sevanagala has 110 tons capacity.
4) The capacity utilization of the two sugar mills in Sri Lanka is below 50
percent and there is further room for increasing capacity utilization.
10
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
CHAPTER – 1
A Comparative Review
of
Pakistan and Indian
Sugar Industry
11
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Synopsis ofComparitive Study
� Maharashtra State of India alone produces more sugarcane than Pakistan.
� Total Sugar Produced in Pakistan is almost half of the Sugar produced in
Maharashtra State.
� Maharashtra and Punjab (India) have higher cane recovery than Sindh and
Punjab (Pakistan)
� Maharashtra and Punjab have higher cane yields than Sindh and Punjab
despite similar land.
� Pakistan’s Punjab has larger cultivation area than Indian’s Punjab.
� Sugarcane cultivation area in India and Pakistan has declined by 12% and
17%, respectively, during 2008-09 from last year due to shift in farmers
preference.
� Sugarcane production in both India and Pakistan has declined by 17% and
21%, respectively, during 2008-09 from last year due to reduction in the
cultivation area.
� Sugar production in both India and Pakistan has declined by 38% and 32%,
respectively, during 2008-09 from last year due to shortage of sugarcane.
� Punjab shares 65% in total sugarcane production of Pakistan.
� Sindh has better sugarcane yield than Punjab.
� Sindh has better cane recovery than Punjab.
12
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Sugarcane Cultivation Area
Sugarcane cultivation area in both India and Pakistan has declined by 12% and
17%, respectively, during 2008-09 as compared to last year due to shift in farmers
preference.
Pakistan India
Sugarcane occupies around 5 percent
of the total cropped area in Pakistan.
Normal area under cultivation is one
million hectares.
Sugarcane occupies around 4 percent
of the total cropped area in India.
Normal area under cultivation is 124
million hectares.
During FY 2008-09, sugarcane was
sown in area of 1045,000 hectares, as
against 1242,000 hectares last year,
showing decline of 16 percent.
During 2008-09, sugarcane was sown
in area of 4408,000 hectares, as against
5043,000 hectares last year, showing
decline of 13 percent.
The largest area where sugarcane
cultivation is made in Pakistan is
Punjab Province. In 2008-09, sugarcane
was sown in area of 675,000 hectares,
as against area of 827,000 hectares in
2007-08.
The largest area where sugarcane
cultivation is made in India is Uttar
Pradesh State. In 2008-09, sugarcane
was sown in area of 2058,000 hectares,
against 2179,000 hectares in 2007-08.
13
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 1
Pakistan – Cultivation Area
(000 Hectares)
PAKISTAN 2004 – 05 2005 – 06 2006 – 07 2007- 08 2008 - 09
Sindh 215 183 215 309 264
Punjab 645 625 712 827 675
N.W.F.P 106 99 102 105 105
Balochistan 0.40 0.30 — 0.50 0.79
Total – Pakistan 966 907 1,029 1,242 1,045
Source: ICMAP Research
TABLE – 2
India – Cultivation Area
(000 Hectares)
INDIA 2004 – 05 2005 – 06 2006 – 07 2007- 08 2008 - 09
Uttar Pradesh 1955 2156 2247 2179 2058
Maharashtra 324 501 1049 1088 770
Tamil Nadu 232 336 391 352 323
Punjab 86 84 99 111 105
Other States 1065 1796 1348 1313 1152
Total – India 3662 4201 5134 5043 4408
Source: ICMAP Research
14
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Pakistan’s Punjab has larger cultivation area than Indian’s Punjab
The cultivation area in the Pakistani Punjab is much higher as compared to the
Indian Punjab. This can be observed from the following Table-3. The average
cultivation area in Pakistani Punjab during the last five years (2005-2009) is 697
thousand hectares, whereas the average cultivation area of Indian Punjab is only 97
thousand hectares during the same period. This may be due to preference of
farmers.
TABLE – 3
Cultivation Area of
Pakistani Punjab and Indian Punjab
(000 Hectares)
Years Pakistani Punjab Indian Punjab
2004-05 645 86
2005-06 625 84
2006-07 712 99
2007-08 827 111
2008-09 675 105
Average 697 97
Source: ICMAP Research
15
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Sugarcane Yield
Sugar cane is a water intensive crop and its yield per hectare is highly sensitive to
optimal water allocation along with appropriate weather conditions.
Pakistan India
Pakistan is fifth largest sugarcane
grower, but its yield is one of the
lowest in the world. In the top ten list
of sugar producing countries, Pakistan
stands at 9th position after USA in
yield.
India is second largest sugarcane
grower and its average yield is 66-70
tons/hectare, which is higher than
world average of 65 tons/hectare.
Pakistan’s average cane yield has
remained between 45-50 tons /
hectare, which is 15-20 tons less than
world’s average yeild of 65 tons /
hecter.
India’s cane yield is comparatively less
than other top ten sugar producing
countries such as Colombia, Brazil,
Australia, China and Mexico.
Pakistan is also far behind India which
has an average yield of around 70 tons
per hecter.
The tropical Indian states viz. Andhra
Pradesh, Karnataka & Tamil Nadu
have higher sugarcane yields as
compared to the sub-tropical regions.
Sindh Province is the most productive
region, as compared to Punjab in terms
of sugar cane yield and recovery rate.
However, in terms of aggregate
acreage it is far behind Punjab.
Cane yields in certain Indian states
also vary across regions. For example,
in Maharashtra, yields are lower in the
Western region as compared with
Eastern Maharashtra.
16
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Sindh has better sugarcane yield than Punjab
The agro-ecological conditions in Sindh such as longer growing season and a
humid climate are best suited for sugar cane plantation. In general, with the
exception of drought season, the overall average yield per hectare and recovery
rate in Sindh has always remained higher than Punjab. Table-4 shows that average
yield of Sindh for last five years (2005-2009) is 55.65 tons per hectare, whereas
average yield of Punjab for the same period is only 48.20 tons per hectare – which is
7.45 tons lesser than Sindh.
TABLE – 4
Sugar Cane Yields in Pakistan
(Tons Per Hectare)
Provinces 2004 – 05 2005 – 06 2006 – 07 2007- 08 2008 - 09 2009 – 10 Average
Sindh 43.52 61.40 58.27 60.00 55.94 54.82 55.65
Punjab 45.47 46.30 52.73 48.73 47.40 48.62 48.20
N.W.F.P 45.43 41.60 47.00 45.11 44.84 42.72 44.45
Balochistan 7.50 3.33 0 6.00 5.00 5.00 4.47
Average (Pak) 44.80 49.77 52.67 51.28 49.39 48.72
Source: ICMAP Research
Note: Since the sugarcane acreage and production in Balochistan is very negligible,
so we have calculated the sugarcane yield of Pakistan by dividing the total
yield of three provinces by 3, instead of 4. By doing this, our yield matches
with that of PSMA and other agencies. Otherwise if we divide the total yields
of four provinces by 4, the total yield of Pakistan decreases appreciably.
17
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
The government agricultural policy, however, is to prioritize Sindh as a cotton-
growing region, hence it is diverting the incentive structures away from sugar cane
cultivation. Similarly, the growth rate in sugarcane production in Sindh has
exceeded Punjab in recent years. However, because of its larger area under
sugarcane, the Punjab produces major share of national output.
Indian States of Maharashtra and Punjab have higher sugarcane
yields than the Pakistani Provinces of Sindh and Punjab despite
similar land
The Sindh Province of Pakistan is located in the same geographical and climatic
region as Maharashtra State in India. However, the sugar yield is much higher in
Maharashtra as compared to Sindh. ICMAP research indicates that the average
yield in Maharashtra is around 72 tons per hectare, whereas in Sindh it is only 56
tons – a difference of about 16 tons per hectare.
Similarly, sugar cane yield in the Indian East Punjab is around 60 tons per hectare,
whereas in our Punjab it averages 48 tons/hectare – a difference of 12 tons per
hectare. (Please see Table-5). Yields in Pakistani Punjab, remained below 40 tons /
hectare for about 10 years and recently started rising to over 45 tons. However,
individual farmers obtained yields of 120 tones / hectare.
TABLE – 5
Maharashtra vs. Sindh – Yield Comparison
(Average 2005- 2009)
PAKISTAN
(Provinces)
Yield INDIA
(States)
Yield Difference
(tons/ht)
Sindh 56 Maharashtra 72 16
Punjab 48 Punjab 60 12
Source: ICMAP Research
18
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 6
Pakistan – India Yield Comparison
(Tons / Hectare)
Years India Pakistan
2000-01 68.49 45.41
2001-02 67.38 48.06
2002-03 63.58 47.33
2003-04 59.39 50.00
2004-05 64.74 45.04
2005-06 66.93 49.77
2006-07 69.03 52.67
2007-08 69.04 51.28
2008-09 61.82 49.39
Average 65.60 48.77
Source: ICMAP Research
Reasons for low yield in Pakistan
Table-6 compares the sugarcane yields in Pakistan and India for the last 10 years.
The Research Department studied several articles/ papers by agricultural experts
and organizations (such as Sugar Farmer Association and Weed Science society of
Pakistan) and came to the conclusion that low yield in Pakistan is mainly due to the
following reasons:
(a) Shortage of Irrigation water
(b) Cultivation of unapproved cane varieties
(c) High input prices
19
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
(d) Unavailability of inputs at required stage of cultivation
(e) Poor crop management practices
(f) Lack of facilities for cane research & development
(g) Weed infestation
(h) Conventional planting methods or late planting
(i) Early and late harvesting
(j) Lack of Credit facilities
(k) Excessive rationing
(l) Poor drainage
On the other hand, India patronizes its sugarcane scientists by allocating to them
adequate budget and necessary resources for research, development and crop
management. Further it provide easy credit facilities, on time availability of
suitable fertilizer, subsidized electricity for tube well irrigation and better
marketing system which facilitate farmers to enhance sugarcane production and
yield. Also, it strives hard to explore surplus sugar whenever it is economically
feasible.
20
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Sugarcane Production
Sugarcane production in both India and Pakistan has declined by 17% and 21%,
respectively, during 2008-09 as compared to last year due to reduction in the
cultivation area.
Pakistan India
Pakistan’s share in the total world
production of sugarcane is around 3
percent.
India’s share in the total world
production of sugarcane is around 19
to 20 percent.
The average sugarcane production in
Pakistan is around 51 million tons.
The average sugarcane production in
India is around 288 million tons, which
is 5.65 times more than sugarcane
production in Pakistan.
Punjab leads the country in cane
production with an average of 33.68
million tons (2005-2009). Sindh is
second with average of 13.34 million
tons.
Uttar Pradesh state of India leads the
country with an average sugarcane
production of around 125 million tons,
followed by Maharashtra with 55
million tons and Tamil Nadu 35
million tons.
Sugarcane production has declined by
18.80% from 63.91 million tons in 2007-
08 to 51.89 million tons in 2008-09. The
main reason was shortage of irrigation
water, shifting of area to rice crop, less
use of DAP and non-payment of dues
to farmers by sugar mill owners on
time.
The sugarcane production of Uttar
Pradesh alone is about 2.44 times
higher than the total production of
Pakistan. Even Maharashtra produces
more sugarcane than Pakistan.
Sugarcane production has declined by
20% from 340.56 million tons in 2007-
08 to 272 million tons in 2008-09.
21
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Punjab shares 65% in total sugarcane production of Pakistan
Although Sindh leads Punjab in sugarcane yield per hectare, Punjab shares 65% in
the total sugarcane production of Pakistan. As per Table-7 the average sugar cane
production of Punjab during last six years (2004-2009) is 33.68 million tons, as
compared to 13.34 million tons of Sindh and 4.66 million tons of NWFP. The
average cane production of Pakistan is around 52 million tons.
TABLE – 7
Sugar Cane Production in Pakistan
(In Million Tons)
Provinces 2004 – 05 2005 – 06 2006 – 07 2007- 08 2008 - 09 Average
Sindh 9.36 11.24 12.59 18.79 14.76 13.34
Punjab 29.33 28.97 37.54 40.30 32.29 33.68
N.W.F.P 4.82 4.10 4.80 4.79 4.80 4.66
Balochistan 0.03 0.01 0.00 0.03 0.04 0.02
Total 43.54 44.32 54.93 63.91 51.89 51.72
Source: ICMAP Research
Maharashtra State alone produces more sugarcane than Pakistan
The sugarcane production in both India and Pakistan have declined during 2008-09
as compared to last year, as can be seen in Table-8. An interesting fact is that sugar
cane production in Maharashtra State of India alone is much higher than the
overall production of sugarcane in Pakistan. This shows the magnitude of the
sugar industry of India.
Table-9 indicates that the average sugarcane production in Maharashtra State is
around 55 million tons, as against average cane production of 34 million tons of
Punjab and only 13 million tons of Sindh.
22
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 8
Pakistan – India Comparison
Sugarcane Production(Million Tons)
Years India Pakistan
2000-01 295.96 43.62
2001-02 297.21 48.04
2002-03 281.57 52.05
2003-04 233.84 53.80
2004-05 237.09 43.54
2005-06 281.17 44.32
2006-07 355.52 54.93
2007-08 340.56 63.91
2008-09 272.00 51.89
Average 288.32 50.68
Source: ICMAP Research
TABLE – 9
Comparison of Indian States with Pakistan
(Average 2005- 2009)
(Million Tons)
PAKISTAN
(Provinces)
Sugarcane
Production
INDIA
(States)
Sugarcane
Production
Sindh 13.34 Maharashtra 55.10
Punjab 33.68 Punjab 5.80
Uttar Pradesh 124.59
Tamil Nadu 34.63
Source: ICMAP Research
23
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Sugar Production
Sugar production in both India and Pakistan has declined by 38% and 32%,
respectively, during 2008-09 as compared to last year due to shortage of
sugarcane.
Pakistan India
Pakistan’s share in total world
production of sugar (157 million tons
in 2008-09) is only 2.15 percent.
India’s share in total world production
of sugar (157 million tons in 2008-09) is
12.32 percent.
Average sugar production in Pakistan
during last ten years (2001 –2009) is
around 3.37 million tons.
Average sugar production in India
during last ten years (2001-2009) is
around 19.34 million tons, which is
5.74 times higher than Pakistan.
Punjab Province leads the country in
sugar production. During 2007-08, its
share was 62% in the overall sugar
production of Pakistan.
Maharashtra State leads the country in
sugar production. During 2007-08, its
share was 34% in the overall sugar
production in India.
24
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 10
Pakistan – India Comparison
Sugar Production
(Million Tons)
Years India Pakistan
2000-01 2.47 18.51
2001-02 3.20 18.53
2002-03 3.65 20.14
2003-04 4.00 14.00
2004-05 2.92 12.70
2005-06 2.59 19.27
2006-07 3.52 28.30
2007-08 4.74 26.33
2008-09 3.20 16.30
Average 3.37 19.34
Source: ICMAP Research
Total Sugar Produced in Pakistan is half of Sugar Produced in Maharashtra
Because of huge market, the sugar produced in India is over five and half times
greater than Pakistan. It is interesting to note that the total production of sugar in
Pakistan is only half of the sugar produced in only one State of India, which is
Maharashtra. Table-11 and Table-12 gives statistical picture of this fact.
25
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 11
Pakistan – Sugar Production
(‘000’ Tons)
PROVINCES 2004 – 05 2005 – 06 2006 – 07 2007- 08
Sindh 754 902 1,068 1575
Punjab 2,047 1,566 2,267 2,952
N.W.F.P 121 119 186 226
Balochistan 0 0 0 1
Total – Pakistan 2,922 2,587 3,521 4,754
TABLE – 12
India – Sugar Production
(‘000’ Tons)
STATES 2004 – 05 2005 – 06 2006 – 07 2007- 08
Maharashtra 2217 5197 9095 9065
Uttar Pradesh 5037 5784 8475 7319
Karnataka 1040 1943 2659 2897
Tamil Nadu 1126 2170 2599 2191
Other States 3271 4173 5500 4856
Total – INDIA 12,691 19,297 28,328 26,328
26
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Sugar Recovery Ratio
Sugar Recovery Ratio is an important indicator of technical efficiency of the
Sugar Mills with regard to the conversion of raw sugarcane into sugar.
Pakistan India
The recovery percentage of sugar from
cane is on a lower side as compared to
International standard.
The cane recovery of Indian mills is
well over 10% and meets the world
standard of 10.50%.
The average sugar recovery in
Pakistan is 8.79% as compared to
world standard of over 10.50%.
The average sugar recovery in India is
10.34%, with recovery rate varying
from State to State.
Pakistan is far behind India which has
an average sugar recovery of 10.34%
(2001-2008)
The period of November to March (150
days) is an ideal one for sugar recovery
in general, more particularly in Bihar
and Utter Pradesh.
Sindh Province has higher cane
recovery ratio than Punjab and NWFP.
The average cane recovery of Sindh for
the last five years (2004-2008) is 9.45%
as against 8.64% of Punjab and 8.03%
of NWFP.
The months of April, May and June are
very hot in Uttar Pradesh, Bihar and
Punjab, leading to drying of sucrose
content and lesser recovery.
Sindh has better cane recovery than Punjab
The geographical and climatic conditions in Sindh make it a naturally favorable
region for sugarcane cultivation. Like sugarcane yield, the recovery ratio of sugar
mills in Sindh is also far better than Punjab. As per Table-13 the average sugar cane
recovery in Sindh during last five years (2004-2008) is 9.45% as compared to only
8.64% of Punjab and 8% of NWFP.
27
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 13
Sugar Cane Recovery in Pakistan
(In Percentage)
Provinces 2004 – 05 2005 – 06 2006 – 07 2007- 08 Average
Sindh 9.53 9.83 9.14 9.33 9.45%
Punjab 9.00 8.10 8.53 8.93 8.64%
N.W.F.P 8.6 7.69 8.23 7.62 8.03%
Source: ICMAP Research
Indian States of Maharashtra and Punjab have higher cane recovery
than the Pakistani Provinces of Sindh and Punjab
The Sindh Province of Pakistan is located in the same geographical and climatic
region as Maharashtra State in India. However, the sugar recovery is much higher
in Maharashtra as compared to Sindh. ICMAP research shows (see Table-14) that
average recovery in Maharashtra is 11.60% as against 9.45% of Sindh i.e. a
difference of about 2.15%. Similarly, sugar cane yield in the Indian East Punjab is
around 10% as compared to only 8.63% of Pakistan Punjab.
TABLE – 14
Maharashtra vs. Sindh(Average 2005- 2008)
PAKISTAN
(Provinces)
Recovery (%) INDIA
(States)
Recovery (%) Difference
(%)
Sindh 9.45% Maharashtra 11.60% 2.15%
Punjab 8.63% Punjab 10.00% 1.37%
Source: ICMAP Research
28
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 15
Pakistan – India Comparison
Sugar Recovery Ratio (%)
Years India Pakistan
2000-01 10.48 8.39
2001-02 10.27 8.71
2002-03 10.36 8.74
2003-04 10.57 9.15
2004-05 10.17 9.10
2005-06 10.21 8.60
2006-07 10.15 8.69
2007-08 10.56 8.98
Average 10.34 8.79
Source: ICMAP Research
Reasons for low cane recovery in Pakistan
Table-15 gives a comparative view of the sugar recovery ratios in Pakistan and
India for the last 10 years. Indian recovery ratio has all along remained over 10%
whereas Pakistan has never crossed 10% ratio. A study of available material
indicates that there are a number of factors leading to low recovery rate by the
mills, however ICMAP research concludes that there are two basic reasons:
(a) Role of Middlemen
The sugarcane quality is deteriorated due to time loss in its transportation
from field to Mill-gate. It is estimated that recovery ratio reduces by 0.1% for
each day in transit. The role of middlemen is important here who purchases
29
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
cane from the growers at government fixed prices and sells them at higher
rates to millers, thus causing inordinate delay in delivery.
Sometimes, the farmers are also willing to engage middlemen to market their
cane to highest bidder in order to get higher price for their crops. In certain
cases, sugarcane is transported at long distance and can be as several weeks
old by the time it is milled.
(b) Mill Efficiency in Juice Extraction
Mill inefficiency in juice extraction is another reason. Juice extraction
efficiency of the current mill stands around 90-92 per cent instead of the
usual 98 per cent. Cane is also mixed with trash that affects the mill efficiency
in extraction rate of sugar.
Note: It is to be added here that the higher prices of sugarcane due to negative
role of middlemen leads to high cost of production of sugar by mills and
escalation of sugar prices in country.
30
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
CHAPTER – 2
Capacity Utilization
of
Sugar Mills inPakistan and India
31
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
1) Preamble
There are around 81 sugar mills in Pakistan with an estimated total installed cane
crushing capacity of 600,000 tons per day (TCD), which is equivalent to annual
crushing capacity of 72 million tons (on the basis of 120 days crushing season in
Pakistan). The annual sugar producing capacity (on the basis of 8.6% national
average recovery ratio) is around 6.2 million tons, which is greater than the annual
domestic consumption of 4 million tons. According to an estimate, the sugar mills
have capacity to produce 6 to 7 million tons sugar annually.
The question is why we are facing consistent sugar shortages and crisis, when our
industry is fully capable of not only meeting the domestic demand, but also of
producing surplus sugar for export? One of the main reasons, apart from shortage
of sugarcane, is that the sugar industry is not fully utilizing its installed capacity.
This Chapter analyses the reasons of low capacity utilization of sugar mills in
Pakistan and also gives a comparative review of the capacity utilization by the
sugar mills in India. An attempt has been made to provide historical and current
statistics on installed and utilized capacities, not only in Pakistan and India, but
also in other SAARC countries viz. Bangladesh, Sri Lanka and Nepal.
Before, we move forward let us have a brief look on the sugar industry dynamics
in Pakistan and India.
2) Industry Snapshot
Pakistan
2.1 The sugar industry in Pakistan is the second largest agro-industry after
textiles.
2.2 About 120,000 workers (skilled, semi-skilled, managerial) are directly
associated with the sugar industry. The industry also provides indirect
employment to around 4 million workers.
32
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
2.3 It accounts for 8 percent of the total value-added in the large-scale
manufacturing industries.
2.4 The sugar industry contributes around Rupees 15 to 20 billion annually
towards national exchequer in shape of General Sales Tax (GST), federal,
provincial and local taxes.
India
2.5 The sugar industry in India is the second largest agro-industry, after textiles.
2.6 More than 50 million farmers and their families are dependent on sugarcane
for their livelihood. An estimated 0.5 million workers are directly employed
for sugar cane cultivation and harvesting.
2.7 The Indian sugar industry generates surplus exportable energy through
cogeneration and contributes in reducing the energy deficit that India is
currently facing.
2.8 The sugar industry is also the primary source of raw material for the alcohol
industry in India.
2.9 The annual economic contribution of the sugar industry to the exchequer
through principal indirect taxes amounts to more than Indian Rupees 2800
crores (equivalent to Pak Rs. 50.4 billion)
3) Historical Progress of Industry
Pakistan
3.1 At Independence, there were only two small sugar mills, built in 1936-38, one
in NWFP and other in Punjab, having total crushing capacity per day (TCD)
of 5020 TCD, producing 8000 tons sugar.
33
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
3.2 During the next two decades (1950 to 1970), 16 more sugar mills were
established. The expansion of processing capacity started in 1949 with the
building of the Premier Sugar Mill at NWFP. By end 1970, the TCD capacity
of 18 sugar mills enhanced to 76,550 TCD.
3.3 During the next two decades (1970 to 1990), 33 more units were set up, which
raised the number of sugar mills in the country to 51, with total crushing
capacity of 211,850 TCD.
3.4 In 1980s, due to generally pro-business policy environment, liberal
sanctioning and credit regime, private investment flowed into the industry.
Major growth in capacities was witnessed in late 1980's and early 1990's,
when the government opened up industrial sector for private investment.
3.5 By the year 2004, 25 more units were established, enhancing the number of
sugar mills to 76, with total crushing capacity of 355,150 TCD. In 1998, the
government introduced a three-year ban on construction of new sugar mills
in the country. As a result, further mills were not established.
3.6 At present, there are around 80 sugar mills in the country with the total
production capacity of around 6 to 7 million tons of sugar.
India
3.7 Indians knew the art of making sugar since the fourth century. However by
1920s scientific sugar processing by vacuum pan method started but initially
the development was slow. Country met its sugar requirement through
imports. In mid 20s number of sugar mills sprang up in UP and Bihar.
3.8 The advent of modern sugar processing industry in India began in 1930 with
grant of tariff protection. During 1930-31 there were 30 sugar mills in India
with capacity of producing 120,000 tons sugar. These mills faced competition
from Japanese sugar, which was ruling Indian market.
34
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
3.9 Sugar production picked up under the ‘Sugar Industry Protection Act of 1932
and within five years i.e. by 1935-36, the country became self-sufficient in
1935. The number of sugar mills increased to 135 with total production
capacity of 934,000 tons of sugar. The private sector was quite instrumental
in this rapid growth of the sugar industry.
3.10 The era of planning for industrial development began in 1950-51 and
Government laid down targets of sugar production and consumption,
licensed and installed capacity, sugarcane production during each of the Five
Year Plan periods.
3.11 At present, there are around 626 sugar mills in India with total production
capacity of more than 25 million tons of sugar. Out of these 626, only 589 are
operational and rest are sick units.
4) Scale and Size of Industry
Pakistan
4.1 Sugar industry in Pakistan is mostly located in Punjab and Sindh Provinces,
with few mills located in the NWFP. Previously, Punjab was partly
dependent on supply of sugar from Sindh, but later it became self-sufficient
in sugar production with the establishment of large-scale sugar plants.
4.2 ICMAP research shows that out of total 81 sugar mills in Pakistan, 72 mills
(89%) are located in Punjab (49%) and Sindh (40%). Furthermore, 37 out of 81
(i.e. 46%) sugar mills are in the Listed sector, whereas 44 (54%) are in Non-
Listed sector. Table-1 gives province-wise number of mills:
35
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 1
Pakistan - Number of Sugar Mills in Provinces
Province Listed Non-Listed Total Share in Total
Sindh 17 15 32 40%
Punjab 16 24 40 49%
N.W.F.P 04 05 09 11%
Total 37 44 81 100%
ICMAP Research
4.3 Out of 40 sugar mills in Punjab, 40% are Listed and 60% Non-listed. In Sindh,
out of 32 mills, 53% are Listed and 47% Non-listed. NWFP has 9 sugar mills,
out of which 4 are Listed and 5 Non-listed.
4.4 The sugar industry is Pakistan is pre-dominantly owned by the private
sector, mostly in hands of influential families, having political connections.
India
4.5 About half of the total sugar mills of India are located in its two major States
viz. Maharashtra and Uttar Pradesh (UP). Until 1950s, the sugar industry
was almost confined to the states of UP and Bihar. In early 1960s the industry
dispersed into South India, West India and Northern parts.
4.6 ICMAP research shows that out of 624 installed sugar mills in India, 245 mills
i.e. 39% are in Private sector, 62 (10%) are in Public sector and 317 mills i.e.
51% in cooperative sector. (Table-2)
36
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 2
India - Number of Sugar Mills in States
Sector Number of Mills Share in Total
Private 245 39%
Public 62 10%
Cooperatives 317 51%
Total 624 100%
4.7 Unlike Pakistan’s privately owned sugar industry, the ownership structure
is much more diverse in India. The Indian sugar industry is marked by co-
existence of different ownership and management structures. At one
extreme, there are privately owned sugar mills that procure sugarcane from
nearby cane growers, and at the other there are Cooperative factories, which
are owned by farmers and managed by government. There are state owned
cooperative mills as well.
4.8 ICMAP research indicates (please see Table-3) that ‘Private sector’
dominates the ‘Cooperatives’ in the Indian states of UP, Andhra Pradesh,
Tamil Nadu, Karnataka and Bihar. However, in the states of Mahrashtra,
Gujrat, Punjab and Haryana, the ‘Cooperatives” dominate in number over
private. If sick units are excluded, there are 582 functional sugar mills in
India as per official data.
4.9 The size of Indian sugar sector, both in terms of sugarcane and sugar
production, is far larger than Pakistan. ICMAP research shows that
Pakistan’s total sugar industry comprising 81 mills, is far smaller in
number than each of the two Indian States i.e. Mahrashtra (having 195
sugar mills) and UP (154 sugar mills).
37
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 3
State-wise Number of Sugar Mills in India
No. State Public Private Cooperative Total
1. Maharashtra 0 30 165 195
2. Uttar Pradesh (UP) 33 94 28 154
3. Karnataka 3 31 23 57
4. Andhra Pradesh 1 27 15 43
5. Tamil Nadu 3 21 16 40
6. Punjab & Haryana 0 10 28 38
7. Bihar 15 13 0 28
8. Gujarat 0 1 22 23
9. Madhya Pradesh 2 5 5 12
10. Uttrakhand 2 4 4 10
11. Orrisa 0 4 4 8
12. Assam 0 1 2 3
13. Rajasthan 1 1 1 3
14. Kerala 0 1 1 2
15. Pondicherry 0 1 1 2
16 West Bengal 1 1 0 2
17. Chhattisgarh 0 0 1 1
18. Goa 0 0 1 1
19. Nagaland 1 0 0 1
All India 62 245 317 624
ICMAP Research
38
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
4.10 It is understood from our analysis that the increased share of public andsemi-public sector companies (cooperatives) in India is due to the fact that‘sick’ or ‘bankrupt units’ are kept afloat through continued lending frompublic sector banks and state government subsidies. However, the numberof private sugar mills is increasing in different Indian states.
4.11 ICMAP research shows (Pls. See Table-4) that the States of Maharashtra andUP alone constitute 56% of the total sugar mills in India and if KarnatakaState is also included, the share reaches 65 percent. This means that thesethree States are critical to the Indian sugar industry.
TABLE – 4
Top 10 States and their Shares in
Total Number of Sugar Mills in India
No. State Public Private Cooperative Total Share (%)
1.. Maharashtra 0 30 165 195 31.25
2. Uttar Pradesh (UP) 33 94 28 154 24.68
3. Karnataka* 3 31 23 57 9.13
4. Andhra Pradesh 1 27 15 43 6.90
5. Tamil Nadu** 3 21 16 40 6.41
6. Punjab & Haryana 0 10 28 38 6.09
7. Bihar 15 13 0 28 4.49
8. Gujarat 0 1 22 23 3.68
9. Madhya Pradesh 2 5 5 12 1.92
10. Uttrakhand 2 4 4 10 1.60
Total – All India 62 245 317 624 96.15%
ICMAP Research
* Mysore State was renamed as ‘Karnataka” in 1973
** Madras State was renamed as ‘Tamil Nadu” in 1968
39
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
5) Size of Sugar Plants
Pakistan
5.1 ICMAP study reveals interesting facts about the sugar size plants and their
share in the small, medium and large-scale segments of the sugar industry in
both India and Pakistan. A break-up of Province-wise and crushing
capacity-wise of sugar mills in Pakistan is given in Table-5 below:
TABLE – 5
Break-up of Province-wise and Capacity-wise
Number of Sugar Mills in Pakistan
Size of Plant Sindh Punjab NWFP Total Share
(%)
SMALL-SIZE SEGMENT
Below 1500 TCD Nil 01 01 02 2.5%
1501 TCD to 3500 TCD 07 04 02 13 16.0%
3501 TCD to 5500 TCD 15 06 02 23 28.4%
47%
MID-SIZE SEGMENT
5501 TCD to 7500 TCD 07 09 Nil 16 19.8%
7501 TCD to 9500 TCD 03 12 02 17 21.0%
41%
LARGE-SIZE SEGMENT
9501 TCD & above Nil 08 02 10 12%
TOTAL – ALL INDIA 32 40 09 81 100%
ICMAP Research
40
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
5.2 As per our study, the installed capacities of Pakistani sugar mills are evenly
distributed between small-sized and medium-sized segments with 47% and
41% shares, respectively. The small-size segment has been classified into
sugar mills having capacity below 1500 TCD to 5500 TCD, whereas the
medium-size segment is considered in the range between 5501 TCD to 9500
TCD.
5.3 This capacity distribution of sugar mills in Pakistan is quite in contrast
with the Indian sugar Industry, where about 88% of the sugar mills are in
the “Small-sized segment” with capacities ranging between 2500 TCD to
5000 TCD (Please refer to ICMAP Analysis in Table-7, under the head
“India” of Section 5 of this chapter.)
5.4 The study further reveals (Table-6) that the highest number of ‘Small-size”
sugar plants are in Sindh Province i.e. about 27%, followed by 14% in Punjab
and 6% in NWFP. Similarly, the highest number of ‘Medium-size” sugar
mills are located in Punjab with 26% share. Sindh is second with 12%
followed by NWFP with only 2.5%. Punjab leads in ‘Large-scale’ sugar
plants with 10%. It is quite interesting that there is no sugar mill in Sindh
with capacity of above 9500 TCD.
41
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 6
Break-up of Capacity-wise Number of
Listed and Non-listed Sugar Mills in Pakistan
Provinces Small-size
(1500 to 5500
TCD)
Medium-size
5501 to 9500
TCD)
Large-size
(9500 TCD
& above)
Total Share
(%)
SINDH
LISTED 08 09 Nil 17 21.0%
NON-LISTED 14 01 Nil 15 18.5%
(27%) (12%) (0%) 39%
PUNJAB
LISTED 05 08 03 16 19.8%
NON-LISTED 06 13 05 24 29.6%
(14%) (26%) (10%) 50%
NWFP
LISTED 02 01 01 04 4.9%
NON-LISTED 03 01 01 05 6.2%
(6%) (2.5%) (2.5%) 11%
TOTAL 38 33 10 81 100%
ICMAP Research
Listed (Small-size) = 08 (Sindh) + 05 (Punjab) + 02 (NWFP) = 15/81 = 18.5%
Listed (Medium-size) = 09 (Sindh) + 08 (Punjab) + 01 (NWFP) = 18/81 = 22.2%
Listed (Large-size) = 00 (Sindh) + 03 (Punjab) + 01 (NWFP) = 04/81 = 5.0%
Non-Listed (Small-size) = 14 (Sindh) + 06 (Punjab) + 03 (NWFP) = 23 /81 = 28.4%
Non-Listed (Medium-size) = 01 (Sindh) + 13 (Punjab) + 01 (NWFP) = 15 /81 = 18.5%
Non-Listed (Large-size) = 00 (Sindh) + 05 (Punjab) + 01 (NWFP) = 06 /81 = 7.4%
42
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
5.5 ICMAP research indicates that ‘Non-Listed” sugar mills dominate with
28.4% share in the “Small-size” segment, whereas “Listed” sector has share
of 18.5%. The position in the “Medium-size” segment is reversed with
“Listed” sugar mills on top with 22.2% as against 18.5% of “Non-listed”
sector. In the “Large-size” segment, Non-Listed” sector again takes lead
with 7.4% as compared to only 5% of the “Listed” sector. (Please see Table-7).
TABLE – 7
Share of Listed and Non-Listed Sugar Mills in
Small, Medium and Large Scale Segments
Size of Plant Listed Non-Listed Total
SMALL-SIZE SEGMENT 18.5% 28.4% 47%
MEDIUM-SIZE SEGMENT 22.2% 18.5% 41%
LARGE-SIZE SEGMENT 5.0% 7.4% 12%
TOTAL – ALL SEGMENTS 46% 54% 100%
5.6 The study reveals that Pakistan is well ahead of India in the “Large-scale”
segment, with 12% share in its overall sugar industry, as compared to only
1.4% of large sugar plants in India. This is further discussed at length in the
following paragraphs.
India
5.7 In 1993, the Indian Government stipulated 1250 TCD capacity as the
minimum size for licensing new sugar mills. This was because of the fact that
about 70% of sugar mills were having capacity in the range between l250
TCD to 2500, and 15% sugar factories had capacity below l250 TCD.
43
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
5.8 After de-licensing in 1998, the entrepreneurs were allowed to set up sugar
factories with focus on larger integrated plants to secure economies of scale.
However, they were required to maintain a radial distance of 15 kms from
the existing sugar factory.
5.9 Incentives were provided by the government for setting up fresh capacities,
instead of expanding the existing capacities. This resulted in creation of a
fragmented supply base in India, with an average installed capacity of 2500
TCD, which is far lower than world minimum economic size of 10,000 TCD.
Later, the average plant size in India increased to around 3,500 TCD.
5.10 The new sugar mills in India are presently set-up with an initial installed
capacity of 5,000 TCD, with capacity expandable upto 7,500 to 10,000 TCD or
above. However, cane availability is the limiting factor behind increasing
plant sizes.
5.11 ICMAP research shows that around 88% of sugar factories in India are in the
“Small-size Segment” with crushing capacity in the range between 2500
TCD to 5000 TCD. Majority of them i.e. 297 factories, (51% share) are in the
cooperative sector, alone. Moreover, 64 out of 582 sugar mills are in the
“Medium-size Segment” with 11% share and only 8 sugar factories are in
“Large-scale” with only 1.4% share. Table-8 shows a break-up of sector-
wise and crushing capacity wise number of functional sugar factories in
India (Official quote is 624 sugar mills including sick units).
A large small-size segment of 88% points towards the fact that the Indian sugar
industry need modernization/rehabilitation and expansion of capacities. It is
needless to state that sugar factories having higher capacities enjoy economies of
scale, which lowers their cost of production, thus improving their viability and
international competitiveness.
44
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 8
Break-up of Sector-wise and Capacity-wise
Number of Functional Sugar Factories in India
Size of Plant Private Co-operative Public Total Share (%)
SMALL-SIZE SEGMENT
2500 TCD 53 131 44 228 39.2%
2501 TCD to 5000 TCD 99 166 17 282 48.5%
88%
MID-SIZE SEGMENT
5001 TCD to 10,000 TCD 43 20 1 64 11%
LARGE-SIZE SEGMENT
10,000 TCD & above 8 — — 8 1.4%
TOTAL – ALL INDIA 203 317 62 582 100%
Source: 11th Five-Year Plan of India & ICMAP Research
5.12 It is further observed from Table-8 that around 75% private, 94%
Cooperatives and 98% Public sugar factories are in the small-size segment.
Moreover, all the eight large-scale sugar mills in India have been established
by the ‘Private sector’.
5.13 Sugar plant size is the main criteria for determining productivity and
viability of sugar industry. However, majority of the Indian sugar factories,
especially the “Cooperatives”, are having small plant sizes with outdated
machineries and technology. They need modernization and upgradation.
45
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
6) Installed Crushing Capacity of Sugar Mills
Pakistan
6.1 At independence in 1947, the country had only two small sugar mills withtotal cane crushing capacity per day of 5020 TCD, producing around 8000tons of sugar. Please see Table-9.
6.2 ICMAP research shows that during the next two decades i.e. 1970 and 1980,there was phenomenal increase in installed capacity i.e. 263% between 1950 -1960 and 320% between 1960 - 1970. The number of sugar mills increased to18 with total installed capacity of 18220 TCD.
6.3 Major growth in capacities was witnessed in late 1980s and early 1990s whenthe industrial sector was opened for private investment. By 1990, the numberof sugar mills increased to 51 with total estimated capacity of 211,850 TCD.By the year 2000, there was further raise in the capacity to 355,150 TCD withsetting up of 25 more new sugar mills.
TABLE –9
Installed Cane Crushing Capacity of
Pakistani Sugar Mills (1950 to 2009)
Year Total Number
of Mills
Crushing Capacity
Per Day (TCD)
% Share increase in
Capacity after every 10 years
By 1950 2 5,020 —
By 1960 6 18,220 263%
By 1970 18 76,550 320%
By 1980 33 125,950 65%
By 1990 51 211,850 68%
By 2000 76 355,150 68%
By 2004 76 501,400 41%
By 2009 81 549,900 10%
Source: ICMAP Research
46
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE –10
Installed Annual Sugar Production Capacity of
Pakistani Sugar Mills (1950 to 2009)
Year Total No. of
Operational Mills
Sugar Production
Capacity (Tons)
% Share increase
In Capacity after
every 10 years
By 1950 2 —
By 1960 6 —
By 1970 18 710,996
By 1980 33 1,420,716 100%
By 1990 51 2,267,642 60%
By 2000 76 3,550,079 57%
By 2004 76 5,505,372 55%
By 2009 81 6,235,866 13%
Source: ICMAP Research
6.4 ICMAP study reveals that the sugar production capacity has also increased
by 100% during period from 1970 to 1980 (see Table-10). By 1970, the annual
sugar capacity stood at 710,996 Tons, which increased by 100% to 1,420,716
tons by end 1980s. From 1980-1990, capacity enhanced by 60%; from 1990-
2000 it further raised by 57% and during period 2000-2009 the capacity
increased by 68%, reaching around 6.2 million tons.
6.5 The total installed daily crushing capacity (TCD) of 80 sugar mills in Pakistan
in 2008-2009 was 549,900 Tons, which is equal to annual capacity of around
66 million tons (549,900 x 120 days). Table-5 shows that Punjab has the
highest share of 60 percent in the total crushing capacity of Pakistan. Sindh
and NWFP have the share of 32% and 8% respectively.
47
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 11
Province-wise Installed Capacity (TCD)
(2008-2009)(Value in Tons)
PROVINCE INSTALLED CAPACITY SHARE IN TOTAL
SINDH 173,200 32%
PUNJAB 330,100 60%
N.W.F.P 46,600 8%
TOTAL 549,900 100%
Source: Pakistan Sugar Mills Association & ICMAP Research
6.6 The break-up of installed capacity (TCD) by Listed and Non-listed sugar
mills is given in Table-8. It can be noted that the ‘Listed’ sugar mills share 47
percent of total installed capacity in Pakistan, whereas the “Non-listed’
sector has a share of 53 percent.
TABLE – 12
Break-Up of Installed Capacity (TCD) by
Listed and Non-Listed Sugar Mills(Value in Tons)
Province Listed Non-Listed Total Share of
Listed
Share of
Non-Listed
Sindh 106,200 67,000 173,200 19% 12%
Punjab 130,500 199,600 330,100 24% 36%
N.W.F.P 22,700 23,900 46,600 04% 5%
TOTAL 259,400 290,500 549,900 47% 53%
Source: ICMAP Research
48
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
6.7 ICMAP research shows that ‘Listed” sector is more prominent in Sindh
Province with 19% share in total installed capacity, as against Punjab with
12% share. On the other hand, ‘Non-Listed’ sector is dominant in number in
Punjab Province with 36% share, as compared to 24% of Sindh.
6.8 The sugar industry was on the list of ‘specified industries’, requiring prior
approval of government before installation or any expansion in installed
capacity. This requirement was done away with in 1987, after which new
units were established at much faster rate (The number of sugar mills
increased from 41 to 76 during 1985 to 2000). Accordingly, installed capacity
increased manifold.
India
6.9 ICMAP research indicates that the installed sugar production capacity in
India shows phenomenal double-digit growth in each decade from 1950 to
2000 i.e. 47% (1950-1960), 35% (1960-1970), 79% (1970-1980), 67% (1980-1990)
and 64% (1990-2000). The installed capacity increased from 1.67 million tons
in 1950s to 16.18 million tons in 2000. (Please refer Table–13)
6.10 The installed sugar capacity in 2008-2009 stands at around 23.9 million tons,
showing 5% increase from last year. During 2005-2009, the capacity
increased in range of 4% to 8%.
49
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 13
Installed Annual Sugar Production Capacity of
Indian Sugar Mills (1950 to 2009)
Year Total No. of
Operational Mills
Sugar Production
Capacity (Tons)
% Share increase
In Capacity after
every 10 years
By 1950 139 1,670,000 —
By 1960 174 2,450,000 47%
By 1970 220 3,303,000 35%
By 1980 299 5,910,000 79%
By 1990 377 9,850,000 67%
By 2000 423 16,180,000 64%
By 2005 400 18,985,000 17%
2005-06 453 19,808,000 4%
2006-07 501 21,392,000 8%
2007-08 516 22,480,000 5%
2008-09 582 23,900,000 6%
Source: ICMAP Research
6.11 A State-wise break-up of installed sugar capacity is given in Table-14.
ICMAP research shows that the highest increase in capacity during last five
years (2005-2009) is in the State of Uttar Pradesh i.e. around 62%, which is
mainly due to presence of highest number of private sugar mills. In UP there
are total 154 sugar mills, out of which 94 mills (61%) are in private sector. The
situation is different in Maharashtra and other states where cooperatives are
more dominant.
50
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 14
State-wise Break-up of Installed
Sugar Capacity (Tons) in India
No State 2005- 06 2006-07 2007-08 2008-09 %
Increase
2005-2009
1.. Maharashtra 7,009,000 7,052,000 7,161,000 7,220,000 3%
2. Uttar
Pradesh (UP)
5,234,000 6,542,000 7,326,000 8,470,000 62%
3. South India 3,986,000 4,211,000 4,395,000 4,600,000 15%
4. Punjab &
Haryana
1,220,000 1,220,000 1,220,000 1,220,000 Nil
5. Other States 2,359,000 2,367,000 2,378,000 2,390,000 1.3%
ALL INDIA 19,808,000 21,392,000 22,480,000 23,900,000
Source: ICMAP Research
7) Capacity Utilization of Sugar Mills
Pakistan
7.1 The sugar industry in Pakistan is presently working at 50% capacity, with
capacity utilization rate at around 51.4% during 2008-2009, showing a
decline of 28.6% from last year (see Table-15).
ICMAP research shows that main reason for this sharp decline in capacity
utilization is around 21.7% shortfall in the sugarcane production in the country –
i.e. from 64 million tons in 2007-08 to 50 million tons in 2008-09. This attributes
to about 17% decline in cane cultivation area from 1.24 million hectares (07/08) to
1.03 million hectares (08/09).
51
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE –15
Capacity Utilization of Pakistani Sugar Mills
(2004 to 2009)
Year Installed
Crushing
Capacity (TCD)
Utilized Capacity
(Cane Crushed)
(TCD)
Capacity
Utilization (%)
2008-09 549,900 282,716 51.4%
2007-08 549,900 439,808 80.0%
2006-07 549,900 337,366 61.4%
2005-06 541,900 250,755 46.3%
2004-05 493,400 267,515 54.2%
Source: ICMAP Research
7.2 Table-16 indicates that the year 2007-08 was a peak year for the sugar
industry, with sugar mills in both Sindh and Punjab provinces achieving
more than 80% capacity utilization. Sindh improved from 56% in 2006-07 to
81% in 2007-08, and Punjab 67% to 84% during same period. During 2008-09
the capacity utilization has come down sharply to around 50 percent.
TABLE –16
Province-wise Capacity Utilization of
Pakistani Sugar Mills during 2007-08
Province Installed
Capacity
(TCD)
Utilized
Capacity
(TCD)
Utilization
(%) in 2007-
2008
Utilization
(%) in 2006-
2007
SINDH 173,200 139,475 81% 56%
PUNJAB 330,100 275,530 84% 67%
NWFP 46,600 24,803 53% 40%
Source: ICMAP Research
52
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
7.3 ICMAP research indicates that basic reason for capacity under-utilization is
due to the fact that during last decade there has been unplanned expansion of
sugar industry without corresponding increase in the raw material
(sugarcane). The cost of production has also increased considerably.
7.4 The new mills established in haste are in the capacity range of 3000 TCD to
4000 TCD, which according to experts are uneconomical and against the
principles of economies of scale. The trend in the world is to establish mills in
capacity range from 10,000 TCD to 20,000 TCD through ‘vertical expansion’,
as compared to standard capacity of 4000 TCD in Pakistan.
7.5 In order to improve capacity utilization, there is immediate need to
accelerate sugarcane production by 4% to 5% annually, so that the sugar
mills in the country have sufficient cane available for crushing, thus leading
to optimum utilization of capacity.
7.6 ICMAP study points that the Millers are not in favor of current “de-zoning
system”, which has given free hand to farmers to sell their inferior quality
sugarcane to any mill. This has resulted in un-competitiveness and un-
profitability of the sugar mills.
India
7.7 The capacity utilization of India sugar industry during 2008—2009 stood at
63%, which shows a marked decline from 117% of last year (see Table-17).
ICMAP research shows that main reason for this sharp decline in capacity
utilization of Indian sugar mills is due to 17% shortfall in the sugarcane
production in the country – i.e. from 348 million tons in 2007-08 to 289 million
tons in 2008-09. This attributes to about 12% decline in cane cultivation area
from 5 million hectares to 4.4 million hectares.
53
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE –17
Capacity Utilization of Indian Sugar Mills
(2004 to 2009)
(Value in ‘000’ Tons)
Year Installed
Capacity (Tons)
Utilized Capacity
(Tons)
Capacity
Utilization (%)
2008-09 23,900 15,000 63%
2007-08 22,480 26,328 117%
2006-07 21,392 28,328 132%
2005-06 19,808 19,267 97%
2004-05 18,985 12,691 67%
Source: ICMAP Research
7.8 The main reason for under capacity utilization is shortage of raw material
and high fluctuations in cane area under the command. The Indian sugar
industry is of the view that the government should increase the radial
distance between sugar mills from present 15K.m. to 25K.m.
7.9 The capacity utilization of sugar mills in different states of India is given in
Table-18. It can be noted that there was a very sharp decline in capacity
utilization in all the states, which is mainly due to steep fall in sugar
production from 26 million tons in 2007-08 to 15 million tons in 2008-09.
54
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE –18
State-wise Capacity Utilization (%) of
Indian Sugar Mills (2005 to 2009)
No. Indian States 2005-06 2006-07 2007-08 2008-09
1 Maharashtra 74% 129% 127% 62%
2. Uttar Pradesh 111% 130% 100% 48%
3. Karnataka 126% 157% 164% 102%
4. Tamil Nadu 141% 165% 129% 106%
5. Gujarat 109% 132% 127% 93%
6. Andhra Pradesh 136% 180% 143% 75%
7. Punjab 49% 71% 78% 44%
Source: ICMAP Research
7.10 ICMAP research shows that highest shortfall of 68% in capacity utilization
during 2008-09 was witnessed in the Andhra Pradesh State, followed by
Maharashtra 65%, Karnataka 62%, UP 52%, Gujarat and Punjab 34% each
and Tamil Nadu 23%. The sugar production also fell sharply.
7.11 Despite the shortfall in capacity utilization, the sugar mills in Karnataka and
Tamil Nadu States managed to operate above 100% capacity, which is far
better than UP State where the situation seemed not good for sugar industry
with only 48% capacity utilization. The sugar production in UP State fell
sharply from 7.32 million tons in 2007-08 to 4.10 million tons in 2008-09.
ICMAP research shows that the year 2008-09 was not a good year for both
Pakistan and India with marked decline in capacity utilization from last year i.e.
for Pakistan, capacity utilization fell from 81% to 51% whereas for India it
reduced from 117% to 63%. The main reason behind this is attributed to
shortages in supply of sugarcane.
55
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
7) Increasing Number of Sick Sugar Mills in India
7.1 According to official Indian estimates, during 2008-09, as many as 206 sugar
mills across India are sick, with two major producing states of Maharastra
and Uttar Pradesh accounting for over half of them. Out of these mills, 61 are
private whereas 145 belong to the co-operative sector. The State-wise break-
up of the sick sugar mills in India is given in Table-19.
TABLE – 19
State-wise Number of Sick Sugar Mills in India
(2008-09)
No State Sick Units
1. Maharashtra 63
2. Uttar Pradesh (UP) 44
3. Tamil Nadu 23
4. Karnataka 22
5. Other States 54
Total Sick Units 206
ICMAP Research
7.2 ICMAP study reveals that there is rapid tendency of sickness in the Indian
sugar mills, especially those in the ‘Cooperative sector’. It can be observed
from Table – 20 below that there were only 38 sick sugar units during 2002-
03, which sharply raised to 144 in 2003-04.
56
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 20
Year-wise Detail of Sick Sugar Mills in India
States 2002 - 03 2003 - 04 2004 - 05 2005 - 06 2006 - 07 2007 - 08
Uttar
Pradesh
03 19 16 16 14 23
Maharastra 12 49 89 47 25 24
Punjab &
Haryana
0 01 05 05 08 08
South India 10 33 26 22 19 20
Other States 13 42 39 41 39 38
Total 38 144 175 131 105 113
7.3 The share of sick units in the total established sugar mills (total 624 as per
official figure) comes to around 33% which is quite high. The main reasons
for the closure/sickness of these mills are :
(a) Non-availability of adequate raw material (sugar cane)
(b) Poor recovery from sugarcane
(c) Un-economic size of sugar plants
(d) Lack of modernization of Plants
(e) High cost of working capital
(f) Declaration of high state advisory cane price by some states
57
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
7.4 According to KPMG study (2009) the chronic reasons for sickness of Indian
sugar mills are:
(a) Shortage in sugarcane supply
(b) Obsolete technologies
(c) Low capacity utilization
(d) High cost of production
(e) Poor financial performance
(f) Discriminatory government policies
7.5 According to an Indian study, high proportion of sick units in ‘cooperative
sector’, may be due to highly regulated environment and lack of profit
motive. Private sector is better placed in taking advantage of multiple
outputs like generation of electricity, bio-diesel etc due to their large size.
7.6 The cooperative sugar mills do not opt for power co-generation due to non-
availability of adequate finance, while the private sector units have access to
cheaper source of funds.
7.7 At end-2009, the Maharashtra government started liquidating 31 cooperative
sugar factories and also framed a lease policy for sick units. According to
latest news, it is studying the UP model of selling loss making sugar
cooperative mills to private sector (UP has offered to sell or transfer the
management of 25 loss-making co-operative mills to private sector)
58
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
CHAPTER – 3
Sugar Industry inOther SAARC Countries
BangladeshNepal
Sri Lanka
59
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Bangladesh
1.1 Bangladesh has no private crushing mills. All the sugar mills are in public
sector and under the control of Bangladesh Sugar & Food Industries
Corporation (BSFIC). From 1972-73 to 2008-2009, BSFIC has contributed
about Taka 2.9 million to national exchequer in the form of duties and taxes.
1.2 Around 5 million people are directly or indirectly benefited by the sugar
industry in Bangladesh through cane cultivation, employment in by-product
based industries and trade & commerce. In addition, 12,633 officers, staff and
workers are employed under BSFIC.
1.3 There are 15 operating sugar mills in Bangladesh (Table-1) with total
installed sugar production capacity of 21,044 tons per day.
1.4 Before 1947, there were only three sugar mills in Bangladesh with total cane
crushing capacity of 3,900 TCD. When Bangladesh was part of Pakistan (East
Pakistan), 9 more sugar mills were established during period 1954 to 1970,
raising the crushing capacity to 13,128 TCD. After Bangladesh’s
independence in 1971, three more units were set up, which enhanced the
crushing capacity of Bangladesh sugar industry to present level of 21,044
TCD or 2.63 million tons annually.
1.5 The crushing capacity utilization of fifteen sugar mills of Bangladesh has
been quite steady and it remained over 70% during the period 2005 to 2008,
as shown in Table-2.
60
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE –1
Installed Cane Crushing Capacity of
Sugar Mills in Bangladesh (1947–2009)
Name of
Sugar Mills
Year of
Establishment
Cane Crushing
capacity (TCD)
Before Pakistan Era (1947)
1. North Bengal Sugar mill
2. Setabgonj Sugar mill
3. Carew & Co.
1933
1933
1938
1500
1250
1150
Total Crushing Capacity 3,900
Pakistan Regime (1947-1971)
4. Rangpur Sugar mill
5. Thakurgaon Sugar mill
6. Zealbangla Sugar mill
7. Jaypurhat Sugar mill
8. Rajshahi Sugar mill
9. Kushtia Sugar mill
10. Mobarakgonj Sugar mill
11. Shampur Sugar mill
12. Panchagar Sugar mill
1954
1958
1958
1962
1965
1965
1967
1967
1970
1500
1524
1016
2032
2000
1524
1500
1016
1016
Total Crushing Capacity 13,128
Independent Bangladesh (1971 -2009)
12. Faridpur Sugar mill
13. Nator Sugar mill
14. Pabna Sugar mill
1976
1984
1996
1016
1500
1500
Total Crushing Capacity 4,016
Total Cane Crushing Capacity 21,044
61
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE –2
Crushing Capacity Utilization of
Bangladeshi Sugar Mills (2004 to 2008)
Year Installed Crushing
Capacity (TCD)
Utilized Capacity
(TCD)
Capacity
Utilization (%)
2007-08 21,044 18,300 87%
2006-07 21,044 18,680 89%
2005-06 21,044 14,825 70%
2004-05 21,044 11,316 54%
Source: ICMAP Research
1.6 The total sugar production capacity of Bangladesh sugar industry at present
is around 210,440 tons per annum based on 125 Effective Crushing Days
(ECD) and 8% sugar recovery rate from Cane (calculation = 21,044 x 125 x
8%). Table-3 shows the sugar production capacity and capacity utilization of
the Bangladesh sugar industry for the last five years.
TABLE –3
Sugar Capacity Utilization of
Bangladeshi Sugar Mills (2004 to 2008)
Year Installed Sugar
Capacity (Tons)
Sugar Production
(Tons)
Capacity
Utilization (%)
2007-08 210,440 163,840 78%
2006-07 210,440 165,000 78%
2005-06 210,440 133,280 63%
2004-05 210,440 106,650 51%
Source: ICMAP Research
62
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
1.7 For full capacity utilization, the sugar mills require annually about 2.50
million tons sugarcane, majority of which is collected from private growers
in the mill zone at government- fixed price.
1.8 Average annual sugar production in Bangladesh, during the last 37 years
(upto 2008) was 1,46,603 tons with an average(weighted) sugar recovery rate
of 7.60%.
1.9 The annual demand for sugar in Bangladesh during 2010 is around 1.3
million tons, of which the state-owned sugar mills have the capacity to
supply only 0.21 million tons. A substantial portion of the local demand
(i.e. 1.09 million tons) is met through imports. It is estimated that annual
sugar demand would rise to 1.58 million tons by 2015, and 1.86 million
tons by 2020.
1.10 The annual sugar production is not sufficient to meet the local demand.
During 2007-08, the fifteen sugar mills under BSFIC produced 0.16 million
tons of sugar, against set target of 0.20 million tons.
1.11 The main reason for low sugar production is attributed to low availability of
sugar cane in view of drastic decline in cultivation area of sugarcane
throughout the country. During 1993-1994, the cropping area was about 0.45
million acres which has now squeezed to about 0.2 million acres, as farmers
shifted to other cash crops.
1.12 The other factors of low sugar production in Bangladesh are lower yield,
poor quality, obsolete machinery, setting up of locally made sugarcane
crushers in mill areas and collective bargaining agents. The Bangladesh
government has taken initiatives to increase sugar cultivation including
providing substantial amount of subsidy to farmers, raising the prices of
sugarcane etc.
63
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
1.13 BSFIC is encouraging farmers to cultivate relay crops like tomato, potato,
radish, cabbage and cauliflowers in between two lines of sugarcane, in
addition to announcing prizes for farmers achieving highest production of
sugarcane.
1.14 Bangladesh mainly depends on state and private sector import of sugar. A
duty of US$ 58 (Taka 4000@68/Dollar) on raw sugar import and US$ 73
(Taka 5000) on white sugar import is imposed.
1.15 The Bangladesh government is planning to generate around 100 MW power
from the country’s 15 state-owned sugar mills by using sugarcane’s bagasse.
About 0.5 million tons bagasse is produced by BSFIC mills annually, 95% of
which is used for generating power for the mills.
64
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Nepal
1.1 Sugarcane is one of the leading cash and industrial crops of Nepal. The
sugarcane production of Nepal is around 1.62 million tons, with yield of 35
metric tons per hectare, which is very low.
1.2 There are 12 Sugar Mills in Nepal – two mills under public sector and 10 mills
under private sector. Both the public sector sugar mills viz. (1) Birgunj Sugar
Mills and (2) Lumbini Sugar Mills have been closed down. Birgunj was
closed down for privatization and not producing sugar at present (Table-4).
TABLE – 4
Public Sector Sugar Mills of Nepal
No Name of Sugar Mill Crushing Capacity
(TCD)
Annual Crushing
Capacity (Tons)
1 Birgunj Sugar factory Ltd 2500 375,000 Closed
2 Lumbini Sugar Mills 1250 150,000 Closed
Total 3,750 525,000
1.3 The Nepal government established Birgunj Sugar Mill and Lumbini Sugar
Mill in the mid nineties. After the liberalisation of Nepalese economy in early
1990s, licenses were given to private sector. As a result, several sugar mills in
private sector were established including Sri Ram Sugar Mill, Eastern Sugar
Mill, Vashulinga Sugar Mill, Mahalaxmi Sugar Mill and Everest Sugar Mill.
1.4 The combined capacity of 8 private sector sugar mills (see Table –5) is 20,750
TCD which is equal to annual crushing capacity of 3,112,500 tons (20,750
TCD x 150 days). Recently, Vasulinga Sugar mill has been closed down. The
total capacity of two public sector mills is 3,750 TCD.
65
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE – 5
Crushing Capacity of Private Sector Sugar Mills of Nepal
No Name of Sugar Mill Crushing Capacity
(TCD)
Annual Crushing
Capacity (Tons)
1 Eastern Sugar Mills 2500 375,000
2 Everest Sugar Mills 3000 450,000
3 Indushankar Chini Udyog 3000 450,000
4 Sri Ram Sugar Mills 3000 450,000
5 Mahendra Sugar Mills 3000 450,000
6 Bagmati Sugar Mills 1250 187,500
7 Mahalaxami Sugar Mills 2500 375,000
8 Vasulinga Sugar Mills
(closed)
2500 375,000
Total 20,750 3,112,500
Source: Nepal Sugar Mills Association
1.5 The sugar capacity utilization of Nepalese Sugar mills has always remained
below fifty percent, as shown in Table–6. The capacity is declining gradually
and during 2007-08 it stood at 31%. The main dependence of the Nepalese
sugar industry is on imports from India and other countries.
66
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE–6
Sugar Capacity Utilization of
Nepalese Sugar Mills (2001 to 2008)
Year Capacity Utilization (%)
2007-08 31%
2006-07 34%
2005-06 32%
2004-05 42%
2003-04 42%
2002-03 43%
2001-02 40%
Source: Department of Industries – Nepal
1.6 The main reason for under-utilization of Nepalese Sugar Mills is lack of raw
materials and political disturbance. Sugarcane cultivation has decreased
largely due to inadequate motivation to farmers. The cost of production is
also very high due to lesser capacity utilization.
1.7 The current annual domestic demand for sugar in Nepal is around 0.16
million tons, while annual domestic production is around 0.10 million tons.
As such, Nepal’s sugar supply is hardly adequate to meet domestic demand.
The remaining amount is fulfilled through imports. Nepal imports nearly
50,000 metric tons of sugar from India and abroad.
1.8 The private sector is the major supplier of sugar in the market although,
National Trading Limited and Salt Trading Ltd. are also involved in sugar
procurement and supply.
67
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
1.9 Sugar imports are subject to customs tariff of 15%, which has been reduced
from 25% in order to meet the shortage of sugar in the country. The private
sector is now encouraged by Nepalese government to import sugar to meet
the local consumer demand, especially in festival seasons.
1.10 The consumers are often forced to buy sugar at higher prices due to its
frequent shortage.
68
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
Sri Lanka
1.1 Sri Lanka is not a major producer of sugar and relies mainly on imports. The
share of local sugar production in total demand is only 10%, whereas 90%
sugar is imported. At present, the average annual sugar imports is around
400,000 MT, costing around Nepalese Rupee 20 billion. During 2007-08,
country incurred cost of Nepalese Rupee 22.3 billion on importing 575,000
tons sugar.
1.2 In 1970, sugar production was 9,000 tons (4% of domestic consumption)
whereas sugar imports stood at 244,000 tons. By 1994, sugar production
raised to 72,275 tons (13% local consumption) whereas imports also soared to
491,000 tons. In 2005, production further improved to 54,000 tons and
imports were 418,000 tons. During 2007-08, sugar produced declined to
38,000 tons. All sugar produced is locally consumed. Table-7 gives history of
sugar produced and imports made:
TABLE –7
Sugar Produced and Imported by Sri Lanka
(1970 to 2008)
Year Sugar Produced
(Tons)
Imports Made
(Tons)
1970 9,000 244,000
1994 72,275 491,000
2005 54,000 418,000
2008 38,000 575,000
Source: ICMAP and Sri Lankan newspapers
69
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
1.3 Sri Lanka consumes around 62,000 tons of sugar every month i.e. 744,000
tons annually. The per capita consumption is around 30 Kg, increasing from
20 Kg in 1998.
1.4 During 1970s, sugarcane was cultivated in 25,000 hectares in different parts
of Sri Lanka i.e. Kantale (3,800 hactares) Hingurana (5,600 hactares),
Pelawatta (4,500 hactares), Sevanagala (4,600 hactares) and Moneragal (5,700
hactares). Kantale and Hingurana sugarcane plantations were closed due to
various reasons. At present. total extent under sugarcane is 15, 000 hectares.
1.5 Sugar marketing has been privatized. Sugar cane growers sell their cane to
the factory, by weight and at a price set by the factory. The Millers do not pay
for sugar content and quality of cane.
1.6 The sugar recovery rate is very low at an average of 8.4%, mainly due to the
poor quality of cane and low level of processing efficiencies.
1.7 Smaller size of sugar mills and low levels of processing efficiencies and
capacity utilization has led to high cost of production of sugar.
1.8 Sri Lanka’s sugar industry operated under a high degree of trade protection
in 1980s. In the 1990s, as trade protection was gradually withdrawn, the
industry became less able to compete. As a result, the state-owned ‘Sri Lanka
Sugar Company Ltd. (SLSCL)’ was commercialized by putting its assets in
three separate companies viz. (1) Sevenagala, (2) Hingurana, and (3) Kantale.
1.9 There are four sugar factories in Sri Lanka, out of which two factories are
closed and not currently producing sugar. The closed sugar factories are
(1) Hingurana, and (2) Kantalaj. The sugar mills presently in operation are
(1) Pelwatta, and (2) Sevanagala.
1.10 The closed sugar mills viz. Hingurana and Kantalaj are state-owned and
established during 1960s. Hingurana (old name was Gal Oya Sugar Mill)
was privatized in 1993 whereas Kantalaj was privatized in 1994. Both of them
were later re-possessed by the government due to labor disputes and high
factory losses. They are presently out of operation and slated for liquidation.
70
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
1.11 At present only Pelwatte and Sevanagala Sugar Industries are operational
and producing sugar for local consumption. Sevangala Sugar Factory was
privatized in 1992.
1.12 The total cane crushing capacity of the four sugar factories (two closed and
two functional) are given in Table-8. As can be seen, the combined daily
crushing capacity of these two functional mills is 5,050 TCD or 1.01 million
tons annual capacity (200 crushing days season).
TABLE – 8
Crushing Capacity of Sugar Mills in Sri Lanka
No Name of Sugar Mill Crushing Capacity
(TCD)
Annual Crushing
Capacity (Tons)
Closed Sugar Mills
1 Hingurana Sugar Mill 2000 400,000
2 Kantalaj Sugar Mill 1200 240,000
Total 3,200 640,000
Functional Sugar Mills
3 Pelwatta Sugar Mill 3300 660,000
4 Sevanagala Sugar Mill 1750 350,000
Total 5,050 1,010,000
Source: ICMAP Research
1.13 The total sugar production capacity of Pelwatta and Sevangala Sugar Mills is
440 tons per day or 88,000 tons per annum. Pelwatta has 330 tons capacity
whereas Sevangala has 110 tons capacity. The sugar capacity utilization of
these two sugar factories is given in Table–9.
71
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]
TABLE –9
Sugar Capacity Utilization of Sugar Mills in Sri Lanka
Year Installed Sugar
Capacity (Tons)
Sugar Production
(Tons)
Capacity
Utilization (%)
2007-08 88,000 37,988 43.17%
2006-07 88,000 32,000 36.36%
2005-06 88,000 56,000 63.64%
2004-05 88,000 54,000 61.36%
Source: ICMAP Research
1.14 ICMAP research shows that capacity utilization of the only two functional
sugar factories in Sri Lanka is below fifty percent and there is further room
for increasing capacity utilization.
1.15 The size of existing sugar factories and their deficiencies in maintenance are
the major hurdles in achieving economies of scale, required to be price
competitive with imports. In addition, cane quality, insufficient supply and
regular disruptions in mills operations are also impeding factors in the way
of optimum operating efficiencies by the sugar factories.
1.16 There is no proper institutional body to develop sugar industry in Sri Lanka.
Although, the Ministry of Plantation Industries looks after the sugar affairs,
it is mainly dealt by Sugarcane Research Institute (SRI), which is also
responsible for providing technical guidance for sugar industry
development. However, there is no representation of sugar manufacturers
in the Institute.
1.17 There is no apex body to oversee and facilitate the functions such as planning
and implementation of sugar industry development, promotion of
investment, administration of development funds, allocation of lands, fixing
cane sugar and by-product prices, determining tax/tariff rates, licensing,
arbitration in labour disputes, etc.
72
Capacity Utilization of Sugar Mills in SAARC Countries – A Comparative Review [ICMAP Research]