The process that begins the production of sugar is the reception and preparation of the sugar cane. The sugar cane is received in the mill, weighed and sampled to determine its quality, then the sugar cane is arranged in the milling train, at this point the cane stems are broken and defibrated with preparation machines to start milling.
Milling is the process by which the juice contained in the fiber of cane is extracted or separated, passing through a series of mills where the bagasse bed is squeezed and washed. One of the processes of support of the manufacture of sugar in the Ingenio Ofelina is the generation of steam, where high pressure steam is generated to be used in the turbines that drive the mills and the turbogenerators of electric energy. The steam is generated by the boilers after the combustion of the final bagasse or diesel.
Once the juice of the cane has been squeezed, it is diluted and heated to a level close to its boiling point which is reached after 105 ° C. During the process, the lime juice is added and passed to other heaters to continue the process.
The next step to warming is clarification. During the clarification the insoluble solids are separated from the diluted juice. The solids are evacuated from the clarifier at the bottom, while the clear or clarified juice is extracted from the top.
The sludge evacuated from the clarifiers is then filtered to separate the juice still contained, and passed through filters responsible for holding the filter cake, filtering the juice.
The clear juice on its part goes to the evaporation stage, this process allows to evaporate the greater amount of water contained in the clear juice to obtain syrop.
Crystallization is the process in which sucrose crystals are formed through the use of seed material. In the pans, massecuites are obtained with different proportions of crystals and molasses, components that are then separated in the centrifuges.
Centrifugation is the process through which the crystals of sucrose contained in the massecuite resulting from crystallization are separated from the molasses.
Molasses from the last cristalization stage is removed as a by-product, final molasses, which is stored for sale as raw material in the production of alcohol, food and others.
The drying process is carried out with hot air to remove as much moisture as possible from the sugar.
The process of refining the sugar starts from the liquor coming from the raw sugar, this is passed through a filter in charge of making the separation insoluble solids present in the liquor.
Next in the clarification process, the insoluble solids are separated from the liquor. The sludge (solid) is evacuated from the underside of the clarifier while the clarified liquor is withdrawn from the top.
During the clarification process flocculant is used, its action helps to float the insoluble solids contained in the liquor, so the mixture of decoloration aids and calcium saccharate enter the process.
The clarified liquor passes to a machine in which it is discolored using a tank with activated charcoal. The activated charcoal retains the coloring agents in the liquor, in addition the reffinery has a complex system of traps filters that guarantee the purity of the liquor, which results in a filter liquor.
The filter liquor is then sent to the refining pans where the contained sucrose crystallizes resulting in the refining massecuite. The centrifugation and drying are the last processes of the production of refined sugar, in the centrifugation the syrup is separated from the crystals of refined sugar and in the drying process the moisture is removed by the use of hot air.
The process culminates with the product packaging in the packaging room, where our sugar is fractionated in 1 lb (453grs), 2lbs (907grs), 5lbs (2.26kg), 100lbs and Big Bags (2000lbs), to meet the demand for sugar consumption at commercial and industrial level.
The production process of rice in CEGRACO begins with the arrival of the raw material from the fields of Panama, receiving annually rice from farms, individuals and third party farmers. Knowing the quality of the product is an important step, so we take a sample that is subsequently analyzed to determine percentage of moisture and impurities.
If the rice has the qualities that qualify it as fit for consumption, it is directed to the dryers, where it regulates the humidity of the rice to a percentage suitable to be stored in silos, without risking the quality of raw material.
We have a storage capacity of 465 thousand quintals, distributed in 13 silos, which allow us to classify the rice according to its characteristics effectively.
The raw material passes from the silos to a reserve tank in mills, and later to the huskers, in this process the husk of the brown rice is eliminated. To guarantee the quality of the product that goes to the next process the rice is classified in special tables that determine if the shell has been completely eliminated.
Then the product passes through three polishers, where the whole grain and the broken grain are whitened and preserved, which is later separated into a machine whose base allows to separate the whole grain from the broken and the smaller parts. Subsequently, the whole grain and the broken one are classified according to their color, discarding everything that is not white through a tube. From now on, the rice is separated according to quality and color in our 4 reserve tanks.
Next, grains are selected according to their quality and prepared for packaging, where special, integral, first and second rice is packed.
Our presentations in the market are:
Special - Del Oro - 1lb, 2lb, 4lb, 5lb, 20lb
Special - Gold Star - 2lb, 5lb
First - Premier- 1lb, 2lb, 4lb, 5lb, 20lb, 25lb
First - Estella del oro - 2lb, 5lb
Integral - Integral - 2lb
Second - Favorite - 5lbs.
Industrias de Natá (INASA) has two independent feed production lines, the first dedicated to the production of pelleted and extruded feed for shrimp and fish. In this line, extruded special feed is now being produced for calves and horses.
The second line is intended for the production of feed for the livestock sector, poultry, horses, pigs and cattle. They are made in both flour and pellets.
The production of feed requires the national and imported acquisition of very high quality raw material for it production. Before being processed all the raw material is evaluated in our Laboratories of Quality Control.
In the aquaculture industry, the farming of the species is divided into initiator, growth and terminal stage; by sow is divided into extensive, semi intensive and extensive, crop requirements vary in each phase and therefore the formulas are special for each case.
Everything starts with the panelists in charge of adjusting the formula and the ingredients that will be used to produce the food, which are poured through pipes to the hoppers.
The system weighs all the macro materials that will be used and sent to a pre-milling, which unifies the grains to start the grinding process passing through rupture cylinders that convert the grain into flour.
The flour obtained from the milling is added to a pallet mixer where the system tells the operators when to add the micro ingredients and liquids carried by the formula, then mixed for a few minutes and discharged to an elevator. Every 30 minutes a moisture sample of the product from the mixer should be taken.
The mixed feed is discharged into the pelletizer, where it passes through a matrix and converts to the feed either into a ¼ inch or 2.2mm pellet, when the pellet is added the oil, to create some impermeability when it enters the water.
To create the micro pellet, the pellet is passed through a separate blade so that it is cut smaller, in case of the pellet the micro pellet is passed through an extra process so that these are crushed.
In fish feed, this after leaving the mixer must pass directly through an extruder, which provides buoyancy to the food.
The system tells the operator that the pellet has come out and immediately proceeds to activate the cooling machine. The pellet reaches this point reaching temperatures of up to 90C ° to 100C °, then falls into a conditioner which retains the pellet for 20 min, and then automatically discharges into a chiller that regulates it at room temperature. The quality staff checks the temperature at which the pellet is coming out of the chiller.
After cooling it goes to the packaging where it is being downloaded by sensors where it is weighed and the label is placed and sewed for storage in the finished product warehouse.