An assessment of mechanical vs manual harvesting of the sugarcane in Sudan – The case of Sennar Sugar Factory

The rehabilitation works carried out in the Sennar sugarcane factory in Sudan, improved the rates of milling accompanied by the horizontal and vertical expansions of the farm compelled Sennar factory to go for mechanical harvesting to solve the problem of labor shortage. The aim of this paper is to evaluate the current sugarcane manual and mechanical harvesting systems with regard to production efficiency, cost effectiveness, cane loading efficiency, infield losses, and the effect of trash (extraneous matter) in factory process. Different experiments were conducted to compare and contrast between the two harvesting systems. The results revealed that manual harvesting (8.98 SDG/ton) is more expensive than mechanical harvesting (4.9.5 SDG/ton); the wages for the cane cutting labor represent 74.14% of the total cutting cost, 46% of the total manual harvesting cost, and 18.9% of the total harvesting cost. Infield cane losses represent 4.72% and 4.22% of the actual yield for the manual harvesting and mechanical harvesting systems, respectively. Moreover, the results showed a significant difference between the two harvesting systems with regard to the cane weight/trailer (ton/trailer) and trash percent. On average the cane weight (ton/trailer) is 6.88 for manual harvesting and 10.12 for mechanical harvesting. The trash percent is only 3.66% for manually harvested cane while it reached 9.49 for the mechanically harvested cane. A 1% increase in trash will lead to decrease in sugar recovery by 0.1%. It could recommended that Sennar Sugar Factory as well as other sugar factories in Sudan could go for increasing the mechanical harvesting system and reducing the manual harvesting to less than 10% of the total area. The specialized cane cutter labors should be employed in other agricultural operations during the off-season to insure their availability at the start of the season. A further research is needed to reduce the infield cane losses and trash percent and to determine their effect on cane quality and factory performance for the two harvesting systems.