Mr. Sivarami Reddy, Director, Mill Master Machinery Pvt ltd, Bengaluru, Karnataka, explains the different stages in paddy to rice processing system.
The rice processing system includes various steps like cleaning, drying, storage, and milling. When we do the cleaning before processing, we have to remove the foreign materials like dust, stones, mud balls, and immature grains from paddy. We have do any further processing with cleaned paddy only which does not have any impurities. After cleaning, we have to reduce the moisture content in the grains which should be maintained uniformly as the harvesting and sun drying process vary with each farmer. We can also prevent attack of fungus, insects, and infections. We are using different kinds of rice such as raw rice, steamed rice, and parboiled rice. For raw rice, we do the milling after harvesting, cleaning, and drying. For steamed rice, we have to apply steam on the paddy, dry it to control moisture content, and then do the milling. For parboiling, we have to soak the paddy, dry, and then do the milling process. We have to sell the product as per the requirement.
There are various stages in milling process such as hulling section, polishing section, grading, sorting, packing, and forwarding sections. For hulling, we are using automatic sheller to remove the husk and separate brown rice from the paddy. We use two rubber rolls to reduce the friction, and it is easy to remove the husk. One rubber roll will rotate clock wise and the other one in anti-clock wise. We create pneumatical pressure in between the rolls and do the de-husking. In this process we have to remove husk up to 85 to 90% without any grain damage, and so we use rubber rolls. Using the same method it is possible to remove 90% in steamed rice and parboiled rice which has more strength.
After hulling process, we have to separate brown rice and paddy. The remaining whole grains will go to the automatic sheller where the bran and whole grains are separated. After paddy separation, polishing starts where the bran layer on the brown rice. If we remove less bran, it is good for human health. Nowadays, in order to attract people and sell more products, people do more polishing to get the whitening of the gains. We are doing 3 stages of polishing, and the nutrients like protein and vitamins are also removed. When the bran is removed, the rice shape will be rough and colour a bit dull. So we use silky polishers to improve surface smoothness and improve the colour. The bran is sent to raw material section in solvent plants to extract oil, and the remains will be used in cattle feed. With health issues like diabetes and blood pressure increasing, it is not advisable to do more polishing when we consume this regularly.
After polishing, we can do grading section. Small broken pieces and quarter size grains looking like rava are found in the rice. We have to remove these broken pieces, and head rice will go to the next process. The broken pieces are used as rava and other raw materials for papad making or other rice items. After grading, we go with colour sorting. We are using RGB cameras, scanners, and ejectors to separate the immature grains, discoloured ones from white rice. In immature grains, we can find yellow, pale yellow, black and red colours which should be removed using these colour sorting machine. Then we have to do the packing. Rice is packed in different quantities.
Mill Master is coming up with modern technology for easily doing these processes which can be of use for startups also. Our machineries are fully automated, highly efficient, durable and can run for 10 to 12 years when properly maintained. They are also affordable. We manufacture paddy cleaner, destoner, automatic sheller, paddy separator machine, whiteners, silky shifter and grader, colour sorter, and packing machines. We also manufacture supporting accessories, bucket elevators, and conveying systems, belt conveyors, and machines to collect dust and bran. We are also undertaking turnkey projects, installation, and commissioning with raw materials, supporting structures, panel boards and other infrastructure.
In this system, our manufacturing system capacity ranges from 2 tons per hour to 12 tons per hour paddy machineries. We support after sales, service and spare parts in terms of processing, analysing grains and processing system. We are supplying machineries in India, Nepal, Bangladesh, and Sri Lanka, and we are providing good service. We have a strong production and R and D team with a minimum of 12 years and 24 years of maximum experience. We are providing better services with technicians who have about 16 years of experience. We are also involved in analysis of paddy and processing system for steam, parboiled, and raw rice. We can also process Basmati rice in this system.
What type of sorting and grading machines are commonly used in rice processing, and what are the benefits?
There are two types of grading and sorting machines. One is a rice plant shifter with which we can separate the small broken and quarter sized rice, and another one is length grader machine which gives the input of half, 3/4th, and head rice. The output is only head rice, and the remaining will be segregated with length grader machine. Another machine is colour sorting machine which works on the principle where rice is scanned by cameras as to which colour we want. Fully white grains are separated from the pale yellow, reddish, and blackish coloured rice which will be ejected through using the scanners. If we do this process, we get better premium price for the head rice.
Is it possible to share the approximate cost of the machines? What are the challenges and innovations in each stage of the paddy to rice processing system?
The starting price is about Rs. 35 lakhs for a 2 ton per hour capacity machine, and the price depends on the capacity. We also have 8, 10, and 12 tons capacity which will cost Rs. 1.5 crores. We also do customised machineries depending on the customers’ requirement, and the price depends on the capacity. The most important thing is designing and processing to reduce the broken pieces percentage and to get head rice yield percentage. We are making all efforts to get higher yield by using our R and D and other processes to reduce the power bill, and percentage of broken rice, and also reduce the consumables. In this process, the customer will get the lesser production cost which will help them earn more money by selling head rice and other byproducts.
How do colour sorters help improve the quality of rice, and what factors do they consider during sorting? How does drying impact the quality of rice during processing?
Colour sorter will separate only black, red, and other different colours of rice. It will separate the different colours of grains. We can get uniform white rice for packing and forwarding. With this, we can improve our brand, and whoever is using our colour sorter machine can improve their brand. What we see in supermarkets and malls the branded rice has no discoloured or immature rice. So we get premium rice and increased brand value. If we dry the grains, the moisture of all grains will be uniform, and the percentage of broken rice and quality of rice will also improve.
Can you explain the various methods of de-husking paddy till obtaining brown rice? What are the common methods of packing and storing processed rice?
In automatic rubber sheller, two rubber rolls are there to protect the grains. One rotates in anti-clock direction and the other in clock wise direction. With both rubber rolls, the paddy will pass through them, and with a little bit of friction created pneumatically, the husk will be removed easily without damage to the grain. One is normal weighing scale system, and the other one is gunny bag. We see that government FCI and CMR state organisations use gunny bag to pack the rice. Commercial people use BOPP bags to store rice for 6 to 8 months and even one year without any damage.
What maintenance and safety measures should be taken when operating the rice processing machinery?
We have to give training to the operating team and owners also on how to operate the machinery and how to take care of the machines, maintenance, and how to change the consumables. We have to teach them to take care of labour in rice mill industry. We give complete training on all these aspects.
You are into supplying machinery all over India. Do you have any branches, and how do you operate?
Yes, we have branches in Kolkata, Nagpur, Chhattisgarh, and Haryana. We have lot of channel partners such as dealers, and consultants. We have lot of people in this field.
Is there any government subsidy for your machinery? What about after sales service for the machinery?
Yes. Central government provides 25% of minimum subsidy on machinery. Different states, districts also have various slabs of subsidy up to 90%. It depends on the development the government plans to bring in these states and districts. We give one year warranty for our machinery and free service for one year. After that we offer paid service. Up to 12 or 15 years also we are with the customers and provide consumables and service. Paid service is similar to AMC.
Are there any specific machinery requirements or considerations for processing different rice varieties such as basmati or jasmine rice?
Machinery is the same for all types of paddy. We only change the specifications according to the paddy variety. We discuss with the customers or processors and change the specification accordingly. We usually change the RPM in the machines, polishing stones, and rollers. We get the sample from the customer and assemble machines according to that.
What are the costs associated with acquiring and maintaining rice processing machinery, and how can businesses manage the expenses effectively?
Main costs are labour and electricity consumption charges, and production cost which includes consumables. We are trying to reduce the labour cost and improve the automation to do the process. Our customer who wants to create a brand can speak to the buyers. We are trying to reduce removal of husk and to sell brown rice. This will improve their earnings too. People are starting to use brown rice with more fibre content, proteins, and vitamins.
Are there any environmental considerations in rice processing industry? What are the challenges in each stage of paddy to rice processing system?
No, we can do the process the entire year, and there are no environmental considerations. Our machines are installed inside the godown. We can do the processing in any environmental conditions. The major challenge is the yield of head rice. Lot of companies come up with different designs and machines. Different product output and raw materials are very imp to give good product and get good percentage of yield.
Can you explain the importance of precleaning in rice processing? What role does polishing play in improving the appearance and quality of rice?
Precleaning means the raw material we get from farmers and traders contain unwanted materials like stones, mud balls, grass, and immature grain, and other mixed grains. We have to remove them before taking up the process as otherwise the impurities will go till the final stage and damage the quality of rice. To improve the appearance and quality of rice, we have to remove the husk and improve the colour of the rice. If we do more polishing, the colour and shining will improve, but the nutrients will be lost. So it is not advisable to do more polishing for rice.
Mr Sivarami Reddy-
Director
Email: sreddy@millmasterindia.com
Phone: 9945828127
The rice processing system includes various steps like cleaning, drying, storage, and milling. When we do the cleaning before processing, we have to remove the foreign materials like dust, stones, mud balls, and immature grains from paddy. We have do any further processing with cleaned paddy only which does not have any impurities. After cleaning, we have to reduce the moisture content in the grains which should be maintained uniformly as the harvesting and sun drying process vary with each farmer. We can also prevent attack of fungus, insects, and infections. We are using different kinds of rice such as raw rice, steamed rice, and parboiled rice. For raw rice, we do the milling after harvesting, cleaning, and drying. For steamed rice, we have to apply steam on the paddy, dry it to control moisture content, and then do the milling. For parboiling, we have to soak the paddy, dry, and then do the milling process. We have to sell the product as per the requirement.
There are various stages in milling process such as hulling section, polishing section, grading, sorting, packing, and forwarding sections. For hulling, we are using automatic sheller to remove the husk and separate brown rice from the paddy. We use two rubber rolls to reduce the friction, and it is easy to remove the husk. One rubber roll will rotate clock wise and the other one in anti-clock wise. We create pneumatical pressure in between the rolls and do the de-husking. In this process we have to remove husk up to 85 to 90% without any grain damage, and so we use rubber rolls. Using the same method it is possible to remove 90% in steamed rice and parboiled rice which has more strength.
After hulling process, we have to separate brown rice and paddy. The remaining whole grains will go to the automatic sheller where the bran and whole grains are separated. After paddy separation, polishing starts where the bran layer on the brown rice. If we remove less bran, it is good for human health. Nowadays, in order to attract people and sell more products, people do more polishing to get the whitening of the gains. We are doing 3 stages of polishing, and the nutrients like protein and vitamins are also removed. When the bran is removed, the rice shape will be rough and colour a bit dull. So we use silky polishers to improve surface smoothness and improve the colour. The bran is sent to raw material section in solvent plants to extract oil, and the remains will be used in cattle feed. With health issues like diabetes and blood pressure increasing, it is not advisable to do more polishing when we consume this regularly.
After polishing, we can do grading section. Small broken pieces and quarter size grains looking like rava are found in the rice. We have to remove these broken pieces, and head rice will go to the next process. The broken pieces are used as rava and other raw materials for papad making or other rice items. After grading, we go with colour sorting. We are using RGB cameras, scanners, and ejectors to separate the immature grains, discoloured ones from white rice. In immature grains, we can find yellow, pale yellow, black and red colours which should be removed using these colour sorting machine. Then we have to do the packing. Rice is packed in different quantities.
Mill Master is coming up with modern technology for easily doing these processes which can be of use for startups also. Our machineries are fully automated, highly efficient, durable and can run for 10 to 12 years when properly maintained. They are also affordable. We manufacture paddy cleaner, destoner, automatic sheller, paddy separator machine, whiteners, silky shifter and grader, colour sorter, and packing machines. We also manufacture supporting accessories, bucket elevators, and conveying systems, belt conveyors, and machines to collect dust and bran. We are also undertaking turnkey projects, installation, and commissioning with raw materials, supporting structures, panel boards and other infrastructure.
In this system, our manufacturing system capacity ranges from 2 tons per hour to 12 tons per hour paddy machineries. We support after sales, service and spare parts in terms of processing, analysing grains and processing system. We are supplying machineries in India, Nepal, Bangladesh, and Sri Lanka, and we are providing good service. We have a strong production and R and D team with a minimum of 12 years and 24 years of maximum experience. We are providing better services with technicians who have about 16 years of experience. We are also involved in analysis of paddy and processing system for steam, parboiled, and raw rice. We can also process Basmati rice in this system.
What type of sorting and grading machines are commonly used in rice processing, and what are the benefits?
There are two types of grading and sorting machines. One is a rice plant shifter with which we can separate the small broken and quarter sized rice, and another one is length grader machine which gives the input of half, 3/4th, and head rice. The output is only head rice, and the remaining will be segregated with length grader machine. Another machine is colour sorting machine which works on the principle where rice is scanned by cameras as to which colour we want. Fully white grains are separated from the pale yellow, reddish, and blackish coloured rice which will be ejected through using the scanners. If we do this process, we get better premium price for the head rice.
Is it possible to share the approximate cost of the machines? What are the challenges and innovations in each stage of the paddy to rice processing system?
The starting price is about Rs. 35 lakhs for a 2 ton per hour capacity machine, and the price depends on the capacity. We also have 8, 10, and 12 tons capacity which will cost Rs. 1.5 crores. We also do customised machineries depending on the customers’ requirement, and the price depends on the capacity. The most important thing is designing and processing to reduce the broken pieces percentage and to get head rice yield percentage. We are making all efforts to get higher yield by using our R and D and other processes to reduce the power bill, and percentage of broken rice, and also reduce the consumables. In this process, the customer will get the lesser production cost which will help them earn more money by selling head rice and other byproducts.
How do colour sorters help improve the quality of rice, and what factors do they consider during sorting? How does drying impact the quality of rice during processing?
Colour sorter will separate only black, red, and other different colours of rice. It will separate the different colours of grains. We can get uniform white rice for packing and forwarding. With this, we can improve our brand, and whoever is using our colour sorter machine can improve their brand. What we see in supermarkets and malls the branded rice has no discoloured or immature rice. So we get premium rice and increased brand value. If we dry the grains, the moisture of all grains will be uniform, and the percentage of broken rice and quality of rice will also improve.
Can you explain the various methods of de-husking paddy till obtaining brown rice? What are the common methods of packing and storing processed rice?
In automatic rubber sheller, two rubber rolls are there to protect the grains. One rotates in anti-clock direction and the other in clock wise direction. With both rubber rolls, the paddy will pass through them, and with a little bit of friction created pneumatically, the husk will be removed easily without damage to the grain. One is normal weighing scale system, and the other one is gunny bag. We see that government FCI and CMR state organisations use gunny bag to pack the rice. Commercial people use BOPP bags to store rice for 6 to 8 months and even one year without any damage.
What maintenance and safety measures should be taken when operating the rice processing machinery?
We have to give training to the operating team and owners also on how to operate the machinery and how to take care of the machines, maintenance, and how to change the consumables. We have to teach them to take care of labour in rice mill industry. We give complete training on all these aspects.
You are into supplying machinery all over India. Do you have any branches, and how do you operate?
Yes, we have branches in Kolkata, Nagpur, Chhattisgarh, and Haryana. We have lot of channel partners such as dealers, and consultants. We have lot of people in this field.
Is there any government subsidy for your machinery? What about after sales service for the machinery?
Yes. Central government provides 25% of minimum subsidy on machinery. Different states, districts also have various slabs of subsidy up to 90%. It depends on the development the government plans to bring in these states and districts. We give one year warranty for our machinery and free service for one year. After that we offer paid service. Up to 12 or 15 years also we are with the customers and provide consumables and service. Paid service is similar to AMC.
Are there any specific machinery requirements or considerations for processing different rice varieties such as basmati or jasmine rice?
Machinery is the same for all types of paddy. We only change the specifications according to the paddy variety. We discuss with the customers or processors and change the specification accordingly. We usually change the RPM in the machines, polishing stones, and rollers. We get the sample from the customer and assemble machines according to that.
What are the costs associated with acquiring and maintaining rice processing machinery, and how can businesses manage the expenses effectively?
Main costs are labour and electricity consumption charges, and production cost which includes consumables. We are trying to reduce the labour cost and improve the automation to do the process. Our customer who wants to create a brand can speak to the buyers. We are trying to reduce removal of husk and to sell brown rice. This will improve their earnings too. People are starting to use brown rice with more fibre content, proteins, and vitamins.
Are there any environmental considerations in rice processing industry? What are the challenges in each stage of paddy to rice processing system?
No, we can do the process the entire year, and there are no environmental considerations. Our machines are installed inside the godown. We can do the processing in any environmental conditions. The major challenge is the yield of head rice. Lot of companies come up with different designs and machines. Different product output and raw materials are very imp to give good product and get good percentage of yield.
Can you explain the importance of precleaning in rice processing? What role does polishing play in improving the appearance and quality of rice?
Precleaning means the raw material we get from farmers and traders contain unwanted materials like stones, mud balls, grass, and immature grain, and other mixed grains. We have to remove them before taking up the process as otherwise the impurities will go till the final stage and damage the quality of rice. To improve the appearance and quality of rice, we have to remove the husk and improve the colour of the rice. If we do more polishing, the colour and shining will improve, but the nutrients will be lost. So it is not advisable to do more polishing for rice.
Mr Sivarami Reddy-
Director
Email: sreddy@millmasterindia.com
Phone: 9945828127