Rice Mill Consultant For Setting Up Fully Automated Pressure Parboiling Technology In India

Parboiling Technology is widely preferred for getting high-quality rice. Parboiling includes different systems to ensure the ancient process of boiled rice in paddy form. While using the fully automated pressure parboiling technology, the paddy will be soaked partially and mainly treated using high pressure. Pressure Parboiling Technology is considered as a quick process compared to the traditional parboiling method.

It is quite a convenient option to save more money. Pressure parboiling of rice mainly provides the better option for getting quality rice. In this process, the rice would be gelatinized instantly. Upon choosing the leading Rice Mill Consultant, it is quite an efficient option to set up the fully automated pressure parboiling technology in India.

Setting Up Fully Automated Pressure Parboiling Technology

Nextech Grain Processing & Engineering Solutions Pvt. Ltd is the leading consultant for providing you with the complete guidance and resources for setting the proven technology of pressure parboiling technology. Installing this unique system automatically allows getting quality rice with a simple process than traditional methods.

Trend of Fully Automated Parboiling system has been increasing and steadily picking up its pace. These overcome many drawbacks existing in batch-wise processing. New installations are looking for the best solution providers of paddy parboiling based on the demands. This provides automatically parboiling, which will complement the sophisticated technology on saving more time.

Under the Parboiling, the colours of the final rice as well as nutritional values are upto the highest quality. The right process is established here to achieve the desired end product. The Storage Silo Project Consultant is ready to help in establishing a Rice Mill Layout Plant for producing parboiled rice that mainly ranges from deep yellow to white.

Nextech assures providing the best rice parboiling plants that are available with current technology. Complete parboiling infrastructure is specially designed on the basis of process mainly carried out in the plant, demography, environmental system and based on the grain.

Three-Stage Process:

Stage 1: Pre-Hydration

With completely cleaning the paddy, it will be placed in the pre-hydration machine so the steam would enforce the low pressure for increasing porosity in the husk. This increases bonding strength.

Stage 2: Hydration

The Hot Water Hydration process is the 2nd phase for easily drawing the water-soluble vitamins as well as minerals from barn layers as well as germs. When the grain reaches saturation level, the hydration process will be stopped.

Stage 3: Gel Cook

The Gel Cook is the final stage in which the low medium pressure and steam are introduced. Water-soluble nutrients will be pressed into the endosperm. Gel cook treatment automatically locks nutrient into the grain with maintaining the quality.

Nextech is the leading Rice Mill Business and is only responsible for bringing tried, tested, proven and well-established technology of pressure parboiling to India from STUDIO TECNICO APPIANI of Italy. They offer the all-in-one solution in manual, semi-auto and auto modes of operation based on customers’ preference.

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Different Types of Rice Milling Processes & Methods

The process of removing the husk and bran layers, and producing white rice kernel that is free of impurities is referred to as rice milling. Usually, the three methods of purifying the rice are a one-step process where husk and bran removal are done together, a two-step process where husk and bran are removed separately, and a multistage process in which rice undergoes a series of different rice milling processes & methods.

The two categories in which the rice milling is divided are Village Rice Mills and Commercial Mills. Rice mills which are used for milling paddy of farmers for home consumption are called as village rice mills whereas when the rice is sufficiently milled and all the husks and stones are removed to appeal to the customers, it is known as commercial rice milling. Another objective of commercial mills is to minimize grain breakage.

Multistage Rice milling Process

The paddy is boiled partially, in order to increase its nutritional value, and this process is called parboiling. It reduces breakage and even changes the texture of cooked rice.

Pre-cleaning method: In order to attain high milling recoveries, pre-cleaning of the rice is necessary. If not done properly, the fines in the rice can create dust and can reduce the airflow through the rice grain. De-stoning is done to remove undesired stones present in the rice using a gravity separator or a de-stoner. The process includes passing the rough rice through a series of sieves and a closed-circuit aspiration system.

De-Husking: The process of removing the husk from rice grains is referred to as de-husking. The process includes directing paddy into a pair of rubber rolls, rotating in opposite directions and at different speeds. A shear force is generated on the surface of the hull because of horizontal inward pressure that is applied on rubber rolls. Removing the husk from the brown rice or unhusked paddy is known as husk aspiration.

Paddy Separation: The surface of a rice grain is smooth, whereas the surface of paddy is rough. Paddy Separator uses this difference in texture to spate brown rice from paddy.

Whitening & Polishing: A humidified rice polisher is used to polish the surface of the rice. The factors which determine the extent of whiteness are the radial velocity of the stone wheels, the grid size of the stones, and the external pressure on the outlet chamber of the whitening machine.

Weighing and bagging machines are then used to pack and weigh the rice accurately to be sold in the market.

Conclusion

With so many different rice milling processes & methods, it can be confusing if you don’t have prior knowledge of it. It’s always better to look for Rice Mill Consultants for advice so as to get better results even in the initial stage of the mill. Having more than 10 years of experience, Nextech Grain Processing & Engineering Solutions Pvt. Ltd. can provide a solution to all your queries related to the food grain industry.

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Raw Paddy Drying Solutions by Nextech

By “drying” is meant the phase of the post-harvest system during which the product is rapidly dehydrated to a so-called “backup” moisture. This desiccation is intended to sufficiently reduce the moisture content of the grain to ensure favorable conditions for storage or subsequent processing of the product.

It is possible to obtain the drying of the products by circulating more or less hot air in a mass of grains. In its movement, the air gives heat to the grains, absorbing moisture from the most superficial layers.

The water present in the surface layers of the grains evaporates much more efficiently and more rapidly than that of the inner layers.

It is therefore much more difficult to lower the water content of a product from 25% to 15% than from 35% to 25%. It would be wrong to think that this difficulty can be overcome by carrying out a rapid drying at a high temperature. Indeed, such drying conditions generate internal tensions, producing small cracks that can lead to breakage of grains during subsequent treatments.

For the drying of grains, the methods employed are, in essence, two in number:
– Natural drying
– Artificial drying

Both have advantages and disadvantages, and there is no ideal way to meet all needs.

Natural Drying

The method of natural paddy dryer, to which the techniques illustrated in the section on pre-drying operations also relate, consists essentially in exposing the beaten products to the air (in the sun or the shade). To obtain the desired moisture content, the grains are spread in thin layers over a drying area, where they are exposed to air (in the sun or the shade) for a maximum of 10-15 days. To promote uniform drying, the seeds should frequently be stirred, especially if they are exposed to direct sunlight. In addition, for the drying to be sufficient, the relative humidity of the ambient air must not exceed 70%.

Artificial Drying

The introduction of high-yielding crop varieties and the gradual mechanization of agriculture now make it possible to harvest large quantities of grain in a short period. In the tropical and subtropical humid zones, given the unfavorable weather conditions at the time of harvest, it is often difficult to safeguard the quality of the products.

To meet the need to increase agricultural production, it is, therefore, necessary to dry the products in a relatively short time, and whatever the ambient conditions. Thus, paddy dryer plant must be used. This method consists essentially in subjecting the grains to a forced ventilation of more or less heated air. It requires the use of individual devices called “dryers.”

Artificial Raw Paddy Dryer

From the point of view of construction, the essential elements of a rice dryer machine are:

– the dryer body, which contains the grains to be dried;
– The hot air generator, which allows heating the air drying;
– The fan, which allows the circulation of drying air in the grain mass.

For the artificial drying of the grains, two types of dryers are used:

– Static or batch dryers;
– Continuous dryers.
The former is inexpensive and only treat small quantities of grain; they are therefore more suited to the needs of small and medium-sized collection and processing centers.

As for the latter, they are high flow paddy drying technology that requires more complex infrastructure, additional equipment and especially a particular planning and organization. They are therefore more suitable for large centers, silos or shops, where very large quantities of product are processed. Nextech Agri Solutions is a reliable brand if you want to purchase agricultural solutions.

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Why Rice Mill Plant need a Consultant?

While ignoring the barriers of the income as well as the living standards of the people living in the state, country or city, rice is one of the grains that are affordable by the large population in any country. Besides, rice is stable food in most of the Asian countries. This is clear by now that a huge amount of quantity of this food item is traded to other countries, where the production is low.

Now the question arises that with the right rice milling machine, we can easily produce a picture where the high output, productivity and market efficiency of the mills are required. This credit for mass production definitely goes to the rice mill consultants. These professionals are hired in large number by various mill merchants who aim for better output and working.

With the presence of milling consultants, the production and quality of the crops levels get higher. Their presence makes a big difference in the working procedures and environment. Here is how the rice mill plant consultant are a necessity these days:

Being a rice industry specialist, they help the customers with the right choice of business. This implies that irrespective of customer needs to begin the cultivation business, discount, dealership, and retail rice offering business.

Obviously, the beginning of rice plant is productive and various organization take attainable study and stage as the initial step in order to guarantee the benefits to the business. Rice mill consultants facilitate the clients with the fundamental components. For instance, prerequisite arrival, outlining and development, assets and other factors that influence the day to day working of rice machine and mills.

The need of perfect land piece and its determination is fundamental as most of the plant proprietors require highly stable capacity zone for this purpose that by now, has been processed and will be processed without much ado. Expert rice consultants have a vision to this, they make deals and perform various troublesome exercise and choose right rice processing machine. They are held responsible to consider the land zone where the production will take place.

Furthermore, the design and development are vital to accomplishing the gigantic benefits from the rice processing business. Factories and mills, under their guidance, out to produce in such a way that they permit smooth and fulfilling operations along within the arranged space. Stores and Godowns are outlined and create so as to store crude paddies and arranging the rice securely.
The consultants also take care of cleaning units, parboiling domains and various fragments reserved suitably.

Keeping up with the high rice milling equipment alongside the desired amount of production is an errand for the proprietors. These two variables add advantage to the era ability of the business. The rice mill consultants set their attention in the right direction while fitting into the interests in the rice processing hardware. They generally prescribe another rice milling process machine. In the present day, the interests, machinery, and technology offer vital protection, simple upkeep process, the higher efficiency with decreased generation cost and improved productivity of the rice mill plants.

Nextech agri solutions is an all-inclusive agriculture machinery and solution providers for grains and seed industry. They provide high-quality assistance and machinery for rice mills and others.

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How to Determine the Moisture Content in Paddy?

Moisture content, as we define it, is the weight of water in rice or paddy expressed in percentage. In post-harvest handling, MC is stated on a wet basis (MCwb). Simply put, it’s percentage of water in a wet grain.
The importance of measuring moisture content

It’s imperative to determine accurate moisture content. This is done with a view to effectively manage and market paddy, for each purpose requires different moisture content.

The importance of measuring moisture content

It’s imperative to determine accurate moisture content. This is done with a view to effectively manage and market paddy, for each purpose requires different moisture content.

For e.g. 18% MC for storing grains up-to 2 weeks, 9% for long-term storage, etc.

Inaccurate moisture testing could lead to:

Grain loss if excessively dried
Increased drying costs and paddy loss if milled at high moisture content
Lower head rice, when milled at wrong moisture content
Weight loss when dried excessively
Mold development
Heat buildup in the grain
Pest infestation
Discoloration
Reduced yield
Loss of germination

How to measure paddy moisture content?

There are two widely used methods to measure moisture content. These are:

1. Primary Method: It is based on weight measurements and is ramified into 2 steps:
– Oven method
– Infrared method
2. Secondary Method: It involves measuring the electrical traits of grains using an electronic instrument

There are a number of different portable moisture meters available in the market. One simply has to make sure that the chosen meter is suitable for harvesting paddy or grains to be milled, depending on whatever you’re planning to do.

Let’s take a look at the moisture content required for different post-production activities:

Paddy Harvesting

When harvesting paddy, one needs to keep in mind that lower moisture content can possibly lead to grain shattering and higher moisture content can lead to losses owing to poor grain quality.
– Ideal moisture content: 20-25%
– Primary losses: Grain shattering and poor quality

Paddy Threshing
– Ideal moisture content: 20% for manual threshing and 20-25% for mechanical threshing
– Primary losses: Breakage/cracking, grain damage and partial threshing

Paddy Drying

The drying process should begin within 24 hours of harvest. Otherwise, there’s a very high possibility of quality deterioration and grain damage.

It should also be noted that seeds should be dried well below 12% moisture content while grains to below 14%.
– Ideal moisture content: 14% or lower
– Primary losses: Discoloration, spoilage and fungal infestation

Rice Storage
– Ideal moisture content:
14% or less if it’s to be milled or stored or a month
Less than 13% for storage up-to 12 months
12% for seed storage
– Primary losses: Pest infestation, fungal infection, loss of germination, etc.

Rice Milling
– Ideal moisture content: 13-14%
– Primary losses: Cracking and breakage

I sincerely hope this post would be helpful to all those planning to venture into the business of rice processing and milling. For any further assistance, feel free to contact Nextech Agri Solutions, one of the best Rice Mill Consultants in India.

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Paddy Drying Process In Rice Mills

At the time of harvest, the moisture content of the rice grains ranges between 18 -25%. Post the harvest, the most critical operation is paddy drying. Drying reduces the moisture content in the grain which is a requisite if it is to be stored. Delaying the drying process or drying it unevenly would result in a qualitative loss. Storing moist grains generally leads to grain discoloration or induces mold development. It further escalates the chances of pest attacks, regardless of the storage facility used. Higher moisture content also decreases the germination rate of rice seeds. The moisture should be further reduced if grains are to be stored for a longer duration.

Before starting with the drying process, certain guidelines need to be followed. The grains should be cleaned so as to avoid uneven Drying and Wet spots. Grains should be dried immediately after the harvest. Depending upon the storage duration, a certain level of moisture content should be maintained.
– 18% for a maximum of 2 weeks
– 14% or less if it’s to be stored for a month/if it is to be milled
– 13% or less if it’s to be stored for 8-12 months
– 9% or less for long-term storage

Grains with different moisture content should not be mixed if cracking is to be avoided.

The drying process involves different methods. Each method has its own elementary advantages and disadvantages.

1. Sun Drying: It is still a preferred technique in many parts of the world mainly because of its low cost. This method, however, is labor-intensive and should not be adopted if you plan to mill the grains.

2. Field Drying: This involves cutting rice panicles in the fields and stacking them into racks and piles. This method sometimes causes a massive heat build-up within the stacks and deteriorates the grains rapidly.

3. In-Store Drying: Grains with the moisture content below 18% are dried slowly inside storage bins. These bins are equipped with aeration components and pre-heated air. It controls the humidity level of the air. It is a slow and gentle drying process and takes from days to weeks.

4. Heated Air Drying: This technique involves high temperatures to rapidly dry the grains. It can be stalled whenever the desired moisture content is achieved. It can be further ramified into 3 categories:

a. Batch Dryer: Used by farmers and small rice millers, this is a labor intensive method and leads to uneven drying.

b. Re-Circulating Batch Dryer: This is put to use by commercial rice millers and cooperatives. It requires moderate capital investment.

c. Continuous Flow Dryer: Generally used by large commercial facilities.

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The Process Of Making Parboiled Rice

Everyone in the country knows what white rice or a brown rice is. However the awareness about parboiled rice is very limited. So it often happens that you are asked about what is parboiled rice when you tell someone that you consume this third of the many breeds of Rice. In simple terms, Parboiled Rice means the type of rice which is partially boiled. But boiled where? The grain is simmered in the husk.

Since the process of parboiling involves three major steps which are soaking, steaming, and drying, the other name of the grain is ‘soaking rice’. As mentioned, the first and foremost process involves drenching of the grain. The act is carried out by transferring the rice into the soaking tank, setting the machine temperature at 20-30 degree Celsius and leaving the grain for 36-48 hours as per the need of the situation. Once the drenching part is done, the rice is then shifted for steaming process which requires heating up the grain for making the grain harder. The procedure isn’t much time consuming as it depends on the manufacturer what kind of grain color he or she wants to attain considering the higher the heating temperature, the lesser the processing time. Although, steaming at high temperature increases the chances of grain getting darker in color.

The final act involves drying the grain. It must be noted that withering the grain in huge quantity isn’t easy. Especially in the case when the rice are parboiled. So, the grains are sun-baked with the help of a large number of workers who have to work actively and are required to timely turn and mix the rice. Approximately 20-40% of moisture gets reduced in the initial stage of drying while the remaining percentage later.

‘Nextech Solutions’ is the leading grain processing unit proffering top-notch consultancy services as well as high-end milling equipments.

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Different Paddy Parboiling Methods in India

Parboiling involves partial cooking of rice paddy, and soaking, gelatinizing, and drying before milling. The main objective of parboiling is to impart hardness to the grain (without hampering the husk) so that the grain can withstand the milling operations.

Parboiling Methods in India involve partial cooking of rice paddy, and soaking, gelatinizing, and drying before milling. The main objective of parboiling is to impart hardness to the grain (without hampering the husk) so that the grain can withstand the milling operations. The paddy is parboiled in the hull to soften the kernel so that the surface starch, bran, and other components can blend. After this, the water from the rice is drained and the rice is dried with steam. The dried rice then undergoes machinery procedures to polish the kernels and remove the hull.

There are three different types of Paddy Parboiling methods in India, namely:

Single-staged parboiling system which is meant for small grain and boiled cream-colored rice
Two-staged parboiling system which is meant for small grain, boiled and steamed white-colored rice
Three-staged Parboiling System which is meant for long grain rice like Basmati, etc.

A quick synopsis of Paddy Parboiling Methods in India

The raw paddy is first cleaned and then transferred to the soaking tank paddy storage bin. The raw paddy (only if its grain is long or of medium size) is then steamed for two to four minutes which is followed by the moving of processed paddy to the soaking tanks.

When the rice is in paddy form, it is soaked in water at an ambient temperature of 20-30°C and takes 36 – 48 hours to reach the requisite moisture content of 30%. On the other hand, if the paddy is soaked at a temperature of 60-65°C (hot water soaking), it reaches the moisture level in a mere two to four hours. One advantage of hot water soaking is that it reduces the steaming time which completes the Parboiling Process, quickly.

The smell, color, taste, and solubility of the components of rice depends on the water temperature and the duration for which it is soaked in the water. The timing must also not be too long and the temperature also must not be too high otherwise the components would dissolve in water, the seeds would start germinating, and starch fermentation would occur.

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