Nextech Solutions offers complete solutions right from the green field stage to the finished product, in terms of plant layout, Consultancy services, Designing, Detailed Engineering & Project Coordination for the following:
Rice is a vital food for more than half of the world’s population, the importance of rice as a food crop has been increasing with increase in population. Rice is obtained by milling Paddy in a paddy/rice mill. Modern Rice Mills are scientifically up-to-date units, using the most modern plant machinery and technology. The manufacturing process employed in a Modern Rice Mill is a continuous and fully automatic process, consisting of Paddy fine Cleaning, Hulling, whitening, polishing, colour sorting, length grading and Packing. The Cleaning section consists of raw paddy cleaners, de-stoner and dust blowers, where the dust, mud, stones and immature paddy are removed to make it completely free from the foreign materials. Rice produced in a Modern mill is of superior quality in terms of higher yields, appearance, elongation and better cooking characteristics and hence find greater customer acceptance. Further, the bye-product of such Mills i.e. Rice bran, find great demand as raw material among solvent Extraction Plants.
There could be two stages of paddy drying in a modern mill. During the paddy arrival season, the moisture percentage in freshly harvested paddy is 18% and above, the paddy should be dried to bring down the moisture percentage of 14% which is ideal for storage purpose. The other stage where paddy needs drying is after parboiling or/and steaming process. After the parboiling process, the paddy moisture increased to the tune of 35% which is virtually wet paddy. The ideal moisture for milling is 12% hence the parboiled paddy needs to be dried to bring to the desired 12% before milling. Similarly, while making steamed rice, the paddy moisture increases to the tune of 22% after the steaming process. Paddy needs to be dried up to the desired 12% before milling. There are two types of paddy dryers available, LSU dryers with batch type drying and other is LSU dryers with continuous type drying process.
There are mainly three types of rice popular among rice eaters all over world. - Raw Rice - Steamed Rice - Parboiled Rice Raw rice is produced by milling the paddy as such. Steamed rice is produced after paddy is passed through a process called steaming. Parboiled rice is produced after paddy is passed through the complete parboiling process. Parboiled literally means partially boiled. It is the process of partial cooking of the paddy grain (with husk). This process is done by applying steam to the raw paddy in small tanks, soaking of steamed paddy in water for several hours and then again steaming of soaked paddy. This paddy is dried to bring the moisture level down to the desired milling moisture level of 12%. The cracks produced in the rice kernels get gelatinized during the parboiling process and this results in lesser broken percentage during milling. The rice grains become hard during this process and it becomes ideal to withstand the milling pressures exerted during the Milling process. The parboiling plant uses steam produced by a boiler in a modern rice mill unit.
In modern day rice business, especially among rice exporters and domestic players with their own brands, the rice re-processing and blending has become an important part of modern rice mills.
While producing different types of rice in their milling units, the rice is bound to break and the percentage of brokens depends on many factors viz; variety of paddy, moisture of paddy, type of rice being made, etc.. apart from the full rice kernel, which is called the head rice or “wand” in trade, the broken rice has been categorized in further following categories for Basmati paddy:-
Wand – is the full grain i.e. the head rice with average length of 7.2mm
Second wand – average length about 6.5 mm
Tibar – it is the 3/4th grain , average length about 5.6 mm
Dubar – it is the half grain, average length about 4.8 mm
Mogra – average length 4 mm
Kinki – average length 2.6 mm
Nakku – average length 1.2 mm
These fractions may vary in different paddy varieties but needs to graded for length from the mixed brokens produced during milling process. Since these fractions are also packed in brands, these need to be packed separately. With ever increasing volumes, millers are bound to have separate rice re-processing/ grading units to meet the market demand. This type of a unit solves dual purpose, not only own brokens, but unfinished rice from open market can be purchased and processed and sold in their own brands and second, in case of bulk orders when the milling plant capacity falls short, such plants can be used to process, blend and re-pack the head rice (after purchasing unfinished rice from small millers).
With ever increasing land prices it is becoming difficult to buy land for grain storage purpose. So, instead of going horizontally it is sensible to go vertically for the bulk storage purpose. Food grain storage in bulk in silos is the need of the hour, it not only saves space but also prevents spillage wastage and more importantly the pilferage. It also avoids the need of gunny bags, worries from changing climate and rains.
Sesame seed is another commodity which is exported from India to European countries. With stringent quality norms, one needs a better designed and technologically advanced plants to meet the norms. The cleaning sorting units add value to the product quality and make it export worthy. The sesame is exported in form of raw seed as well as hulled seed with pre defined specifications from various foreign buyers.
Different spices have different physical characteristics. Various spices sell in brands in domestic market and various spices are exported from India. With stringent quality norms, one needs a better designed and technologically advanced plants to meet the norms. The cleaning sorting units add value to the product quality and make it export worthy.
Pulses / Lentils are the staple diet of people in many countries.Lentils are called Dal(s) in india. Dal millers in India cater to domestic as well exports demand. The inherent characteristics of different dal seeds differ from each other and hence require different processes for milling. Different dals have different physical characteristics as well. Various Pulses/Lintels/Dals sell in brands in domestic market. With cutthroat domestic competition the brand with stringent quality norms would get market volumes and hence a better designed and technologically advanced plant is the need of the hour to meet the quality norms. The cleaning sorting and grading units add value to the product quality and make it premium market worthy.
Pulses are the staple diet of people in many countries. Dal millers in India cater to domestic as well exports demand. The inherent characteristics of different dal seeds differ from each other and hence require different processes for milling. Different dals have different physical characteristics as well. Various Pulses/dals sell in brands in domestic market. With cutthroat domestic competition the brand with stringent quality norms gets market volumes and hence a better designed and technologically advanced plant is the need of the hour to meet the quality norms,which eventually leads to better market penetration and larger volumes.The cleaning sorting and grading units add value to the product quality and make it premium market worthy.
Commercial production of any food grain for exports purpose OR for the premium domestic market is not achievable without the colour sorting equipment. Colour sorter is an optoelectronic machine which uses high-resolution CCD sensors (camera in layman language) to detect the defects i.e. the discoloured or damaged grains from the incoming stream of the commodity and uses compressed air to deflect the defects from the incoming stream to segregate it from the good and healthy grains. It is not possible to do this by manual sorting for bulk production. Colour sorters are an integral part of our designs for rice milling, sesame sorting, spices sorting, pulses milling/sorting units etc.
With ever increasing milling as well as bulk handling capacities, it is no longer possible to control and handle the process flow manually i.e. with the help of simple/conventional electrical control panels. In order to have a lesser breakdown and higher uptime, millers have been adapting the SCADA (Supervisory control and data acquisition) & PLC (programmable logic control) systems. The system uses software with pre-defined logic to control the complete process. The mill is controlled through a computer. All the information about process control like, production, break down time, the reason for break down, duration under breakdown etc.. is easily assessable.