Agricultural Engineering

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An assessment of the feasibility of quality indicators for the postharvest deterioration of sugarcane (Saccharum officinarum L.)
(2014) Sibomana, Milindi Sylver.; Bezuidenhout, Carel Nicolaas.; Workneh, Tilahun Seyoum.; Sobratee, Nafisa.; Rutherford, Richard Stuart.
Sugarcane deterioration remains one of the most important supply chain efficiency leverage points in the South African sugar industry. Cane quality has been identified as an issue that has the potential to improve the overall efficiency of the sugarcane supply chain. A review comparing the postharvest quality management systems and measurements in the South African sugar and fresh produce industries was conducted. The difference in postharvest handling between the two industries was found to be an important factor dictating quality management. Advances in non-destructive quality measurement techniques and sanitation strategies were found in the fresh produce industries, which could be adopted by the South African sugar industry. An empirical study of standard sugar industry cane quality parameters was also performed. Sugarcane quality parameters measured at the Felixton mill were analysed, per ward, using quality control charts and non-parametric statistical approaches. A daily analysis of these parameters, as well as the Pol % Fibre ratio, using Shewhart quality control ( x ) charts revealed that, overall, Monday deliveries were of significantly lower quality (P<0.01). This is a quantitative indicator of logistics (or management) inefficiency over the weekend. Using the Mann-Whitney test, Pol % Fibre was used to generate a grower performance index, based on high levels of statistical significance (P<0.05), which may allow stakeholders to improve operations, through identifying the levels at which individual growers deliver significantly (P≤0.05) lower quality cane in the early part of the week. This study uncovered new and significant statistical trends within the sugar industry's quality database and demonstrates the potential of Pol % Fibre as an indicator of quality inferiority in the cane supply chain. To further investigate cane deterioration in this context, two burn/harvest-to-crush delay trials involving two sugarcane varieties (N12 and N31), which were exposed to ambient environmental conditions for a period of nine days after harvest were performed. On sampling dates, each variety was tested for quality parameters such as total bacterial counts, D-lactate production, and respiration. Standard sugar industry quality parameters and Pol % Fibre were also monitored. Parameters were measured in bottom, middle and top portions of the stalks to evaluate the effect of section on the parameter changes. Trial 1 was conducted on unburnt cane in October 2012 and Trial 2 on burnt cane, April-May 2013. Stalk portion significantly (P<0.001) affected the parameters, with the top and bottom portions showing higher bacterial proliferation, respiration rates and D-lactate production compared to the middle portion in Trial 1. Trial 2 showed no significant variability in stalk portion. In Trial 1, a significant (P<0.05) declining trend was noted for Brix % DM and Pol % Fibre in the top portion. The effect of higher respiration in the cut-ends in Trial 1 was noted in significantly reduced Pol % Fibre in these cut-ends. Environmental conditions were found to be the major factor influencing quality during the cane storage period. The study concludes, from both analysis of CTS data and the results of the BHTCD trials, that Pol % Fibre can be monitored at sugar mills as an additional parameter for signalling inferior quality and deterioration of cane consignments.
A comprehensive qualitative and quantitative assessment of harvesting and other sugarcane supply chain disruptions within the Eston Mill supply area.
(2014) Kadwa, Muhammad.; Bezuidenhout, Carel Nicolaas.; Ortmann, Gerald Friedel.
The Eston Mill, which was established in 1994, is the newest in the KwaZulu-Natal sugar belt. Like for most other mills, it can be argued that there are inefficiencies in the supply chain due to systemic issues, which reduce optimum performance. The literature study involved a review of the factors which cause inconsistencies in sugarcane supply chains and the strategies implemented for improvement. This research study involved five main aims. First, a novice qualitative diagnostic analysis of the Eston sugarcane system, to identify a range of systemic issues and one pertinent problem, involving pay-weekends and subsequent labour absenteeism, was isolated for further investigation. This was conducted through explorative interviews and network analysis approaches. Secondly, based on the information from the diagnostic analysis, a model that predicts and quantifies the factors which influence daily crush rate disruptions at Eston, was developed, validated and verified. Thirdly, the extent of the pay-weekend problem area was systematically estimated in terms of frequency, variability and predictability. Fourthly, the cost of cutter absenteeism was conservatively quantified, based on two factors, namely, sugar recovery and mill operational costs. Lastly, a case study was carried out, which involved the feasibility of a mechanical harvesting system, to mitigate the impacts of labour absenteeism. The model involved the calibration of parameters for mill maintenance and operational stops, rainfall events and days in the week when slow crush rates occurred. The model captures approximately 64% of the variation observed in daily crush rates. Subsequent to the development of the model, additional cane supply disruptions, caused by cutter absenteeism, were also investigated. It was statistically verified that a significantly detectable degree of labour absenteeism occurs immediately after pay-weekends. There has been a general increased trend in cutter absenteeism from about 2007 until 2010. An economic analysis estimated the costs associated with cutter absenteeism to be approximately R1.3 million per season, for the Eston region. The alternative harvesting system case-study solution, was found to be risky. However, acquiring second-hand equipment, which was available on the market, is estimated to make the solution more feasible. Based on a literature search, this research is considered to be the most comprehensive analyses of sugarcane supply consistency at mill-scale worldwide. The model developed can be utilized to critically evaluate different sugarcane milling areas and could potentially make significant contributions to commercial sugarcane operations. The effectiveness of the model is dependent on usage in other milling areas, as well as other industries. In addition, the specific labour absenteeism coefficients for each season can possibly be investigated using other industries as well.
Developing a diagnostic heuristic for integrated sugarcane supply and processing systems.
(2019) Shongwe, Mduduzi Innocent.; Bezuidenhout, Carel Nicolaas.; Bodhanya, Shamim Ahmed.
Innovation is a valuable asset that gives supply chains a competitive edge. Moreover, the adoption of innovative research recommendations in agricultural value chains and integrated sugarcane supply and processing systems (ISSPS) in particular has been relatively slow when compared with other industries such as electronics and automotive. The slow adoption is attributed to the complex, multidimensional nature of ISSPS and the perceived lack of a holistic approach when dealing with certain issues. Most of the interventions into ISSPS often view the system as characterised by tame problems hence, the widespread application of traditional operations research approaches. Integrated sugarcane supply and processing systems are, nonetheless, also characterised by wicked problems. Interventions into such contexts should therefore, embrace tame and/or wicked issues. Systemic approaches are important and have in the past identified several system-scale opportunities within ISSPS. Such interventions are multidisciplinary and employ a range of methodologies spanning across paradigms. The large number of methodologies available, however, makes choosing the right method or a combination thereof difficult. In this context, a novel overarching diagnostic heuristic for ISSPS was developed in this research. The heuristic will be used todiagnose relatively small, but pertinent ISSPS constraints and opportunities. The heuristic includes a causal model that determines and ranks linkages between the many domains that govern integrated agricultural supply and processing systems (IASPS) viz. biophysical, collaboration, culture, economics, environment, future strategy, information sharing, political forces, and structures. Furthermore, a diagnostic toolkit based on the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) was developed. The toolkit comprises a diagnostic criteria and a suite of systemic tools. The toolkit, in addition, determines thesuitability of each tool to diagnose any of the IASPS domains. Overall, the diagnostic criteria include accessibility, interactiveness, transparency, iterativeness, feedback, cause-and-effect logic, and time delays. The tools considered for the toolkit were current reality trees, fuzzy cognitive maps (FCMs), network analysis approaches, rich pictures (RP), stock and flow diagrams, cause and effect diagrams (CEDs), and causal loop diagrams (CLDs). Results from the causal model indicate that collaboration, structure and information sharing had a high direct leverage over the other domains as these were associated with a larger number of linkages. Collaboration and structure further provided dynamic leverage as these were also part of feedback loops. Political forces and the culture domain in contrast, provided lowleverage as these domains were only directly linked to collaboration. It was further revealed that each tool provides a different facet to complexity hence, the need for methodological pluralism. All the tools except RP could be applied, to a certain extent, across both appreciation and analysis criteria. Rich pictures do not have causal analysis capabilities viz. cause-and-effect logic, time delays and feedback. Stock and flow diagrams and CLDs conversely, met all criteria. All the diagnostic tools in the toolkit could be used across all the system domains except for FCMs. Fuzzy cognitive maps are explicitly subjective and their contribution lies outside the objective world. Caution should therefore be practiced when FCMs areapplied within the biophysical domain. The heuristic is only an aid to decision making. The decision to select a tool or a combination thereof remains with the user(s). Even though the heuristic was demonstrated at Mhlume sugarcane milling area, it is recommended that other areas be considered for future research. The heuristic itself should continuously be updated with criteria, tools and other domain dimensions.
The development and evaluation of a performance-based standards approach for regulating the use of heavy vehicles in South Africa.
(2013) Nordengen, Paul Anthony.; Lyne, Peter William Liversedge.; Bezuidenhout, Carel Nicolaas.
The regulation of the use of vehicles on the road network is aimed at ensuring acceptable safety and recovery of road maintenance costs, as well as minimising congestion, road wear, excessive noise and air pollution. The traditional approach of regulating heavy vehicles is prescriptive, i.e. enforcing regulations that primarily limit the mass and dimensions of these vehicles. This approach is generally favoured because such regulations are easy to understand and enforce. However, an underlying disadvantage is that the prescriptive approach does not always adequately safeguard the dynamic performance of heavy vehicles while travelling on the road. Principle-based and performance-based standards are primarily aimed at specifying desired outcomes, rather than how these outcomes should be achieved. Under a performance-based standards (PBS) approach, performance measures (such as low-speed swept path, rearward amplification, load transfer ratio and high-speed offtracking) are utilised to specify the performance required from vehicles. Although more complex to regulate, a PBS approach has a number of potential benefits such as: (a) improved vehicle safety, (b) improved productivity, (c) reduced infrastructure wear and emissions, (d) a more optimal use of the existing road network, and (e) the encouragement of innovation in vehicle design. The aim of this research was to apply, refine and demonstrate an alternative approach to the design and operation of heavy vehicles in South Africa with improved outcomes in terms of road transport productivity, vehicle safety performance, emissions, congestion and preservation of road infrastructure. The research included the development and implementation of a PBS demonstration project in South Africa and the monitoring and evaluation of PBS demonstration vehicles operating in the forestry industry in the provinces of KwaZulu-Natal and Mpumalanga. Evaluation focused on improvements in productivity (fuel efficiency and trip reduction) and load control with reference to initial results regarding road wear and safety performance. Results show a significant improvement in payload control and fuel efficiency of the PBS vehicles compared with the baseline vehicles. This also resulted in a reduction in CO2 emissions per ton.km. Road wear assessments of PBS and baseline vehicles showed that in some cases a reduction in road wear of up to 200% per ton of payload can be achieved through the use of PBS vehicles. Safety assessment results of four PBS vehicle designs showed various shortcomings of prescriptive baseline vehicles in terms of the performance standards.
Issues pertaining to cane supply reliability and stockpiling at the Umfolozi sugar mill - model development and application.
(2011) Boote, Gordon L. N.; Bezuidenhout, Carel Nicolaas.; Lyne, Peter William Liversedge.
The co-owned Umfolozi Mill area has developed as an integrated supply chain. Cane supply reliability was identified as a potential area for productivity improvement at Umfolozi. It is important that the cane supply to a sugar mill arrives at a steady and reliable rate. A reliable cane supply ensures that the mill can operate at an optimum efficiency. Sugarcane supply reliability depends on how the mill area adapts to unforeseeable changes in the supply chain. An important aspect to this is the weather and how it affects the harvesting regimes. The sugarcane supply chain at Umfolozi is divided into two branches, road transport and tram transport. The trams account for 70 % of the cane delivered to the mill and the can is sourced from a climatically homogenous region. In the occurrence of a rainfall event of above 5 mm, infield harvesting cannot take place on the Umfolozi Flats; hence 70 % of the mill‟s supply is halted for one or more days. To address the problem, a stochastic model was created to simulate the effectiveness of an enlarged cane stockpile if it were maintained on the current tram sidings outside the mill and were crushed when wet weather prevented further harvesting. The stockpile was simulated on a first-in first-out principle and was able to supply the mill with enough cane to continue running for 24 hours. The model was then used to conduct a series of Monte Carlo simulations on which sensitivity analyses and economic feasibility assessments were carried out. Results show that the stockpile was effective in reducing the length of milling season and the number of no-cane stops. However, on further analysis into the implications of creating a stockpile it was found that 1% recoverable value (RV) was lost during the 24-hours that the cane is stored outside the mill. The loss in revenue as a result of the RV reduction had a negative impact on any savings created with the implementation of the stockpile. This result made apparent the negative impact of deterioration to the whole supply chain. Further research is required to determine more accurately the rate of deterioration, and therefore, quantify more accurately the losses that occur in the supply chain. A significant outcome of the study was the development of a mechanistic tool which drove decision making at Umfolozi Sugar Mill. It lead to the development of the modelling framework LOMZI, a simulations based framework which places more emphasis on environmental factors and risks.
Modelling sugarcane quality in the context of mill scale supply chain logistics.
(2014) Jenkins, Edwin Peter Garland.; Bezuidenhout, Carel Nicolaas.; Ortmann, Gerald Friedel.
The length of milling season (LOMS) refers to the length and timing of sugarcane crushing operations at a sugar mill. LOMS is central to the competitiveness and profitability of any sugar mill supply area (MSA). Conflicting interests between supply chain stakeholders can make adjusting the LOMS difficult. The LOMS should take into account weather conditions, cane quality, milling capacity, supply chain capabilities and other interrelated issues, such as agronomics. Previous LOMS models in South Africa were developed over a decade ago and there was scope to improve the calculation of risks by using a stochastic modelling approach. Recently, a stochastic model named LOMZI was developed to evaluate stockpiling options at Umfolozi. In this study, LOMZI was adapted and expanded to allow the LOMS for any MSA in South Africa to be investigated. However, mill area specific applications of the updated model fell outside the scope of this study. As it currently stands, LOMZI simulates a sugarcane supply chain from the point where sugarcane is cut, up to delivery at the mill. During the process of adapting LOMZI, the simulation of sugarcane quality was identified as an important area for improvement in the model and this became the focus of the study. A predictive MSA scale cane quality model was developed, based on recent weather conditions and a mechanistic understanding of sugarcane quality. The quality model was developed to simulate the daily average brix %, pol % and fibre % of sugarcane delivered to the mill. The preceding 11 weeks’ rainfall and temperature values were used to predict cane quality. A total of 98 mill-specific coefficients were calibrated from historic milling data and, for model demonstration purposes, the quality model was applied at two mills, namely Sezela and Umfolozi. Independent verifications yielded R2 values between 0.56 and 0.74. A useful method to estimate the average burn/cut to crush delay for a MSA was also identified. The quality model has been successfully integrated with LOMZI. Future work is envisaged to expand LOMZI and to model the operations of sugar mills and the RV cane payment system.
Using system dynamics to explore the poor uptake of irrigation scheduling technologies in a commercial sugarcane community in South Africa.
(2016) Jumman, Ashiel.; Bezuidenhout, Carel Nicolaas.
Abstract available in PFD file.

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