In the quiet town of Paonta Sahib in Sirmaur district, where vast sugarcane fields stretch towards the horizon, a centuries-old tradition continues to thrive — the art of jaggery making. In the Shivpur and Haripur Tohana localities, skilled artisans practice this time-honoured craft, producing a natural sweetener renowned for its rich taste, purity and health benefits. The jaggery made here is not only a staple in Indian households but also finds its way to international markets, including Canada, Australia and the United States.
For months, workers have toiled over roaring furnaces, meticulously transforming fresh sugarcane juice into golden blocks of jaggery. However, as the sugarcane harvesting season nears its end, so does this labour-intensive process. In just a few days, the rhythmic sounds of crushing machines and the bubbling of boiling juice will fade, marking the conclusion of another jaggery-making season.
The process begins with the careful selection of sugarcane, harvested at peak ripeness to ensure maximum sweetness. Farmers transport the freshly cut stalks to jaggery-making units, where large mechanical crushers extract the sweet juice. The juice is immediately collected in large containers and transferred to massive iron cauldrons placed over traditional furnaces. Since the process relies entirely on natural methods, it is crucial that the juice is processed swiftly to prevent fermentation.
At the heart of jaggery making lies the slow-boiling technique, which blends both art and science. The extracted juice is heated over open flames fuelled by bagasse — the fibrous residue left after juice extraction. This sustainable approach eliminates the need for coal or firewood, making the process eco-friendly. Over the next four to five hours, the juice is carefully boiled, allowing the water to evaporate while the natural sugars concentrate.
As the juice boils, impurities rise to the surface as froth, which is carefully skimmed off to maintain purity. Unlike industrial jaggery, which often involves chemical processing, the artisans here use neem bark as a natural clarifying agent. This traditional technique enhances the taste, texture, and nutrient content of the final product.
Once the liquid thickens into a deep golden-brown syrup, skilled workers continuously stir and monitor it to prevent scorching. When the syrup reaches the perfect consistency, it is poured into wooden or metal moulds, where it cools and solidifies into 2-kg blocks. Within hours, these hardened blocks are carefully packed and stored for sale.
Zero-waste approach
One of the most remarkable aspects of this process is its zero-waste approach. The leftover bagasse is dried and reused as fuel, ensuring sustainability. Even the impurities skimmed from the juice are repurposed as livestock feed. The process generates minimal smoke and no noise pollution, making it environmentally friendly and economically viable for small-scale farmers.
As winter fades and the sugarcane harvest comes to an end, jaggery-making units will soon shut down until the next season. With only a few days left, workers are rushing to prepare the final batches, ensuring there is enough stock to meet demand in the coming months.
Jaggery remains an indispensable part of Indian cuisine, valued for its natural sweetness and health benefits. Rich in iron, calcium, and magnesium, it is recommended in Ayurveda for boosting immunity, aiding digestion, and providing natural energy. Whether mixed with warm milk, added to traditional sweets, or used as a substitute for refined sugar, jaggery’s place in Indian households is irreplaceable.
Preserving a timeless craft
For the artisans of Paonta Sahib, jaggery making is more than just a livelihood — it is a cultural heritage, a seasonal ritual passed down through generations. As they pack up their tools and extinguish their furnaces, they do so with the certainty that in just a few months, when the next sugarcane harvest begins, the fires will be lit once again, and this age-old tradition will continue to sweeten lives.
