Rice Mill Consultants Can Help You Putting Up A Modern Plant

Rice is the vital cereal food crop in the world, and it occupies about one-fourth gross cropped in India. Rice is the primary food crop in the country, which is mainly cultivated during humid and hot climatic conditions.

Rice is the vital cereal food crop in the world, and it occupies about one-fourth gross cropped in India. Rice is the primary food crop in the country, which is mainly cultivated during humid and hot climatic conditions. In most parts of the country, the Kharif crop is grown in rain-fed areas where it receives the heavy annual rainfall. Rice and edible starchy cereal grain have been largely produced in the world, which is about one-half of the world population, especially in the East and Southeast Asia, which is also dependent on the rice as the staple food. Based on a recent report, about 95% of the rice crop across the world cultivated is eaten by humans. Rice provides food for 65% population in the country. Rice Mill Consultants Help You Putting Up A Modern Plant.

Latest Rice Mill Technology:

With the introduction of the Latest rice mill technology, a wide number of options have been increased for the cultivation of the crops. Putting up the Rice mill plant is much more useful in the modern day for gaining good returns. Consulting the professional Rice Mill Consultant for getting the standard Rice Mill Machine Design would be an efficient choice. Now, it is much easier to introduce the modern plant with state-of-the-art technology as well as machinery. A wide number of the processes have been involved in the Rice Mill Plant Manufacturer India. In fact, the rice mills have been operated in the automatic procedures that also includes the 

  • Paddy’s Cleaning
  • Hulling
  • Whitening
  • Polishing
  • Sorting
  • Grading
  • packaging

With the introduction of automated technology, saving more time with the production of the large quantity of rice is a prominent choice. Consulting the professionals for the Rice Milling Plant Layout Design would be a much more unique way. Complete machinery set up is formed for the cleaning process of paddy, cleared of stones, immature paddy for making it clear and clean. The quality of rice produced will be in the highest quality with the use of this latest Rice Mill Plant Design. 

Latest Rice Processing Units:

New and classic designed Rice Mill Setup has been introduced, which is a much more efficient choice for performing several tasks. It mainly involved with several stages that also includes the cleaning of rice such as 

  • Pre-Cleaning
  • De-Stoning
  • De-Husking
  • Separating Paddy
  • Whitening The Rice

Most of the consumers also demand the first-class rice, so this process is helpful for processing of the whole machinery from the cleaning of the paddy till the packages. 

 

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Mill Maintenance – Grain Milling Solutions

Repairing, technical services and maintenance of the rice mills are essential as they can affect the lifetime of the milling machines and makes them work accurately for a long time. If good and regular maintenance are carried out, machines can’t be able to work for a long time.

As per the recommendation of Rice Mill Consultant, Maintenance of Rice Mill Plant Design at a decided time will monitor the active machines and pieces of equipment designed by Rice Mill Engineers & Designers to detect the possible breakdowns. Therefore, it avoids downtimes for equipment and machines because of unexpected maintenance plus loss of production and needless replacement of parts.

As an outcome, downtime and maintenance stemming from breakdowns decrease more than 25% to 30%. It facilitates eradicates slight flaws before leasing them to develop into more grave troubles. 

Grain Milling Solutions

Important and crucial maintenance of the mills can be easily attained with the help of three variant methods such as Predictive Maintenance, Unscheduled Maintenance, Preventive maintenance. Mill consultants and inspectors can arrange and choose maintenance systems as per specific requirements and local situations by making use of these methods. 

Predictive Maintenance 

This method is a new approach towards new technological developments in the rice mills. The concept of predictive maintenance is first introduced by R. kubilay Kose i 1988 in turkey at national machine design and manufacturing congress of a middle east technical university. He selected to use the term “kestirimci Bakim” for a method of predictive maintenance. 

This technique of mill maintenance allows monitoring of equipment and machines to detect possible breakdowns. As an outcome, an unscheduled shutdown of equipment and machines, unnecessary part replacement and loss of production are reduced. 

Advantages of Predictive Maintenance 

  1. Breakdown decrease by 35-34%. 
  2. Expected productive and a lifetime of equipment augmented. 
  3. Machines that are in working and good conditions are not stopped unnecessarily which ultimately saves time. 
  4. Enables corrective maintenance for critical components. 
  5. Production loss decreases considerably. Production levels go up by 20-25%. 
  6. Prevent minor flaws to become a source of bigger problems in time. 
  7. It is 8-12% more profitable than preventive maintenance. 
  8. More saving of energy. 
  9. Maintenance cost decreases significantly. 
  10. Maintenance time and downtime for machine breakdowns decrease 25-30%. Work-load and labour costs decrease. 

Unscheduled Maintenance 

It is also known as “emergency maintenance, repair maintenance and breakdown maintenance. Repair and maintenance are carried out when the pieces of equipment and machines don’t work properly or stopped working. As an outcome, loss of production at the time of repair is much high. Defects occur in machines and pieces of equipment also affect the other machines and pieces of equipment. While performing unscheduled maintenance, the equipment and mills are revisited to base or original situation and efficiency by reinstating materials and parts only after the collapse. 

Because of its disadvantages, repair maintenance is not performing by any mill until needed the most. Otherwise, scheduled maintenance techniques are essentially performed.

Scheduled maintenance 

The goal of preventive and planned maintenance is to decrease the need for emergency maintenance. It is carried out by following given methods: 

Predictive maintenance 

The method of predictive maintenance is carried out of three main steps such as measurement, analysis and repair. 

Periodical maintenance 

The goal of this technique is to prevent components of machines or equipment from failure and to improve their strength before any collapse. 

The period of maintenance for equipment and machines at mills can be classified as: 
  1. Daily
  2. Weekly
  3. Long term. 

The period of maintenance for equipment and machines are already planned as per the specification provided by the companies that install them. 

 

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How to Improve Milling Yield and Quality?

Although milling quality is a high-priority objective for rice millers, many mill owners still struggle to achieve that. The reason is evident because Improving Milling Quality is delicate, especially if you don’t have proper knowledge of milling. rice mill

Besides, milling quality is affected by a lot of other factors including environmental factors. Other factors that might affect the milling quality are grain length, grain thickness, chalkiness, and fissure. 

Rice, being the staple food of India, will surely rise in demand in the upcoming years. This has forced rice mill owners to produce as much rice as possible. 

However, improving milling yield is yet another challenge faced by rice mill owners. We at Nextech, offer full-fledged Rice Mill Consultants to help you improve milling yield and quality. 

The first step to improve the quality of milled rice is choosing a good quality paddy. Ensure that the paddy you select has the right moisture content (14%) and has high purity. 

Other characteristics to look for are:
  • Uniformly mature kernels
  • Uniform size and shape
  • Free of fissures
  • Free of empty or half-filled grains
  • Free of contaminants such as stones and weed seeds
Characteristics of a good quality milled rice:
  • High milling recovery
  • High head rice recovery
  • No discoloration

Additionally, make sure your rice mill operator is skilled enough. Often, mill operators hire an untrained apprentice to reduce the operation cost. This hampers the quality of the milled rice. 

The equipment quality also play a massive role in the milling yield and quantity. Having a poorly maintained machine or a low-quality machine can harm the quality of the rice. 

One of the best ways to improve milling yield is by reducing the grain breakage as opposed to running the mill for additional hours every day. 

Another way to enhance the milling quality is by parboiling rice. Numerous researches have shown a significant decrease in grain breakage in parboiled rice. 

For more information on how to improve milling yield and quality, contact Nextech Solutions. From complete Rice Mill Setup to producing high-quality rice, our team of expert rice mill consultants and rice mill engineers & designers can help you achieve your business goals efficiently. Contact Nextech Solutions now.

 

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How to Make Profitable Rice Milling Business

Many countries still depend on India to meet their rice needs. Being one of the top exporters of rice in the world, India provides tremendous opportunities to make a profitable Rice Mill Business. Because, of course, you cannot consume paddy in its raw form. 

Also, it’s not only about export, but rice is also the staple food in India, which means there is a huge opportunity even if you build a small rice mill that just caters to the needs of your local area.

Things to keep in mind when starting out a rice milling business

Starting a business in India is not easy, you need to acquire necessary licenses and permits from state Government, you need to create a fixed source for buying raw products, and lastly, you need a great location. 

To start with the required licenses and permits.

  • Registration of the firm
  • Udyog Aadhaar MSME registration
  • Factory license
  • No pollution certificate
  • Rice-Milling industry Acts 1958
  • PFA and ESIC registration
  • IEC registration
  • FSSAI license
  • GST registration

For a complete rice mill plant setup, you will need a minimum of 1500 sq. ft. area, however, you need to make sure the location is just right. What I mean to say is that it should be somewhere near the place where rice is grown. This will help you in two ways: one that you are assured of getting the raw materials and other is that you can save a lot on transportation cost resulting in an increase in your profit. 

Ways to make it profitable

The cost of setting up a modern rice mill plant is quite high, however, with the right steps you can easily get a high return on investment. As mentioned above, the Best Way To Make a Profitable Rice Milling Business is by ensuring that you choose a great location. Other ways to make it profitable includes:

  • Modern machinery and infrastructure (as it requires less to no maintenance)
  • Machines with high operating capacity (capacity of the machine is directly proportional to how much profit you make)
  • A proper rice mill plant layout design (for better results in rice production)

Though there is a huge opportunity in the rice milling business, we have noticed that a lot of rice mills get closed as soon as they are opened. The reason for this is simple: mill owners don’t know much about the rice business, however, they are attracted because of the money in the industry. Therefore, it is better to talk to rice mill plant consultants before you start your own rice milling plant business.

Nextech Solutions is the leading rice milling services provider in Delhi. We will not only help you make your rice milling business sustainable, but we will also help you keep your business profitable for a longer period of time.

Modern Dal Mill Plant

For every industry that aims at prospering in their field, the most important phase of their working is Production. Especially in the Food Processing Industry, trivial details like the location of the plant can influence the production factor by a large scale. Earlier known as Nextech solutions, Nextech Grain Processing and Engineering Solutions Pvt. Ltd was started 10 years ago with the vision of improving the quality of produced grains. 

The Dal Mill Plant is one of the important parts of Nextech. The use of fine and chosen machinery works delicately to produce high quality of Dal. But before moving further let’s understand certain basic concepts as mentioned below.

Milling of Pulses? 

The Dal consumed by millions of people around the globe comes in the raw form of Pulses. The pulses are dehusked and split to mold in the shape of edible dal. 

This process comprises of two general steps: 

  • Loosen the husk on pulses.
  • Removing the husk.
  • Using a machine to split the remainder into cotyledons.

The efficiency of the machinery used for the process of splitting the cotyledons marks the success of any Dal Milling project. Every kind of pulse requires an additional step that helps in better loosening of the husk. This step is known as a pre-milling treatment. The adamant cover is loosened up for better production of dal. 

Methods of Processing Pulses

The raw pulses are first brought in to clean the grain and remove any impurities or irregular sized grain. Then they are further graded into different fractions that are sent for processing. The stepwise mention of the methods used in processing pulses is provided below. 

  1. Cleaning and Grading
  2. Pitting 
  3. Pre Milling Treatment
  4. Tempering 
  5. Drying 
  6. Dehusking 
  7. Polishing

The Process of Setting Up Pulses Dal Mill

As you might have understood by now, the Dal Mill Manufacturing Process requires excellent implementation and management to produce exceptional results. 

The most important step involves rigorous brainstorming for the creation of the right business plan. The construction and implementation of a Pulses Dal Mill depend entirely on the business plan. With the years of experience, Nextech can guarantee that your search for the right resources will end at their place. 

Apart from Dal Mill Plant, Nextech is known in the market for the experienced Rice Mill Engineers and Designers that provide unique solutions for your rice production needs. A Rice Mill Consultant will be provided to study your needs and provide feasible solutions as per your guidelines. 

With Nextech, you can calmly be assured about the quality of their services.

 

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Grain Milling Technology – High Yield and Quality

The process of grounding of cereal grain into flour is known as milling. Waterwheels were the first things used for such tasks. Grains cannot be consumed in their raw form and hence it is necessary for it to undergo milling process. Grains are the main source of protein and nutrition and 70% of people in the world are dependent on it, the traditional method of grain milling is now replaced by Modern Grain Milling Technology. It is very fast as well as effective than the previous one. Nextech provides you the best Grain Milling Solutions with the latest milling technology used by the industries.

The milling provides a consistent product, a range of flours suitable for a variety of functions and flour suitable for a variety of functions and flour with predictable performance. This new technology has become a boon for the millers. The first operation of the mill is to analysing the grain. The grain then undergoes three stages.

 

  • Cleaning and conditionally- Clearing and conditioning the grain helps in removing all the impurities of the grain and it makes the grain ready for milling. 
  • Crushing or breaking – In this process, the grain breakdown in the successive stage and how it is ready to release its component parts.
  •  Reduction – This process helps in the progressive rolling and shifting of the grain. After this the refining of flour and separation of it into various categories takes place. These various categories are known as streams. 

Cleaning

The grain in its raw form contains weeds, chaff, and other materials. The high technology machines are capable of removing all the impurities and making it pure to eat. There is a disc separator in the machine which removes the husk from the grain. After that, the grain is taken to a strong blast of air for cleaning and after that, the magnetic separator removes any iron or steel from the grain. 

Extraction Rates

The figure that represents the percentage of flour production from a given quantity of grain is known as the extraction rate. For example, if 45 kg of flour is produced from 100 kg of grain, the extraction rate is 45% (45÷100×100). The extraction rate depends upon the flour production and it may vary according to it. The grain flour containing all the germ can have an extraction rate closer to 100%. But the pure white grain flour usually has extraction rates around 70%. The germ and bran of the grain have a very high rate of nutrients and hence the flour which has a higher extraction rate have a higher nutritional value.

 

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Technology Consulting and Engineering for Rice Milling Industry

Nextech solution is a grain processing and engineering centre where even technology consultancy is welcome. We have been in the market for an entire decade now being steered by our two founders who are professional and experts as far as grain processing, engineering and technologies are concerned.


Nextech solution is a grain processing and engineering centre where even technology consultancy is welcome. We have been in the market for an entire decade now being steered by our two founders who are professionals and experts as far as grain processing, engineering and technologies are concerned.

We offer a variety of services which majorly revolves around grains and to be more specific rice, not to mention that we also offer technical consultancy in the matters concerning grains.

Our dignified experts are well known through their competence and excellent results they present in every kind of activity they do in the organization. Due to proper and upright management and a well-coordinated and skilled workforce, the reputation of Nextech Solutions presides us.

Not one but many clients who we have the pleasure of serving have confessed how pleased they were after we were done with them. Offering Quality and lasting services is our core business in order to welcome our clients once and again.
Services we offer are : 

We install milling machines or any other related machineries as well as Rice Milling Plant Layout Design. More to that, we can also do modernization of existing mill plants so you don’t have to buy a new milling machine. We will digitalise the old one.

We have digitised machinery to mill the mustard seed to produce oil which is used for massage in large scale. Also the sesame seed which is known to be a great export from India to European countries is processed in our company as well. We have put up a well-designed and technologically advanced plant to help produce best quality.

Rice Milling
Our rice milling plants are well designed and suited to come out with the best quality of paddy. The milling plant is designed in a way to process a bulk amount of rice at a go therefore increasing value of output. We are the best rice milling consultants to offer proper guidance on a paddy milling plant.

Rice blending has become quite an essential thing to do in the modern rice market for both local and international levels. We offer rice blending services for even those with their own brands.
Bulk grain storage.

We are also the best storage silo consultants. Instead of buying very large pieces of land which spread out horizontally, which is expensive, we have designed silos which are not only saving your pocket but also your space for they stretch vertically and they store bulk rice.

We are known to offer the best grain milling solutions in India not to forget that we do pulse/dal milling consultancy. Dal are known to be a staple food for many people. Our milling plants are well suited to produce quality for both local and international markets.

 

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Vertical and Horizontal Silo – Bulk Storage


Storage silos are containers used for storage of bulk stock. These bulk storage silo systems are used for both short-term storages as well as for long-term storage of food products. Grain Storage Silos are cylindrical in shape and are made up of high-quality galvanized steel. Silos used for short-term bulk grain storage have conical bottom whereas the ones used for long-term storage have a flat bottom to provide the cleanup screw for the discharge purposes. Farmers that store their harvested crops in silos experience improved food security, greater consistency in grain quality, and reduced waste that leads to enhanced agricultural income.  As India’s leading rice mill plant consultants – Nextech solutions, also offer storage silos solutions that prove to be the most efficient and effective and protect the grains from being spoiled by rain and pest infestation.

Vertical Silo

The vertical silos are either circular or orthogonal in shape. The customizable diverging funnel flow at the bottom of a vertical silo enables it to handle any type of load. Stainless steel, concrete, and carbon steel plates are the most common materials that are used in the fabrication of vertical silos. The material you choose depends on the weather in your area. The common features of vertical silos include:

  • Safety Valve for pressure control
  • Silo level blade indicator
  • Blowing plant with a nozzle
  • Service platform with ladder, back guard and safety guard

Storage silo capacity of vertical silo is around 50-70 tonnes. They have higher capacity when compared to horizontal silos.

Horizontal Silo

Horizontal Silos need more ground space and they come with a mechanic extraction system. For easy removal of the stored material, the mechanic extraction system is placed below the silo. Usually, horizontal silos are installed away from direct heat and sometimes in underground spaces. Few accessories that come with horizontal silos include:

  • Warm gear
  • Lumps breaker
  • Explosion panels
  • Silo weighing
  • Needle gates
  • Bag filters
  • Under/overpressure capacity

 

Conclusion

The best grain storage silo for you depends on the space you can afford to install the silo. Consider your short-term and long-term goals and external factors that may affect your storage needs before investing in a silo. Also, there is a lot of customized silo available depending on the requirements.  It’s advisable to talk to a Storage Silo Project Consultant so that your investment won’t go in vain. Having more than 10 years of experience, Nextech Grain Processing & Engineering Solutions Pvt. Ltd. can provide Grain Milling Solutions which will help you increase your business.

 

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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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The Advanced Paddy Drying System

Paddy Drying is the basic process of yielding rice. 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. After the process of parboiling and steaming the moisture increases to 35% which is actually wet paddy. So to reduce the moisture from it various steps are involved such as field drying, sun drying, heated air drying, in-store drying.

If moisture not removed from the paddy, the quality of grain decreases. Instead of sun drying and traditional drying methods, Nextech Solutions offers advancement with Paddy Drying System such as installation & design of paddy dryer machine. This helps in the drying process efficient than traditional drying methods for safe storage.

A Paddy Dryer Machine is designed to suit all the grains. It comes with a blower and furnace digitalized with meters for controlled drying, with the air flow circulation to dry the paddy grains in a closed chamber. The machine works with two chambers or tanks one for filling in and another for discharge. This Paddy dryer Machine can be efficient Paddy Drying Solution for batch type drying and continuous drying processes.

Features of Advanced Paddy Drying Machine.
  • It is designed to suit up all the paddy grains.
  • The design includes quality material such as stainless steel which doesn’t affect any harm to the paddy.
  • Rice Mill Consultant can help you to reap all the benefits of the Paddy Dryer Machine, to use the husk, wood or biomass obtained.
  • It comes with PLC monitor system to monitor and control the temperature for the drying process.
  • Efficient drying as to reduce 5% moisture, the process is likely to run for 5 hours.
  • Can reduce the labor cost, as minimal manpower is required.
  • Also, the maintenance of this Grain Dryer is very low.
  • The Grain Dryer is designed to provide uniform steaming to maintain the quality of the paddy grains.

 

We at Nextech Solutions help you out with Rice Milling Plant Layout Design with our team of Rice Mill Engineers and Designer which will help to plan about Paddy Dryer Machine Setup. This counseling and planning about Paddy Drying Solutions with Rice Mill Engineers and Designers will help you with much profitable business.

 

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