Processing is a crucial stage in the production of rice post-harvest. The essential objective of a rice processing framework is to eliminate the husk and the bran layers to produce an edible, white rice kernel that is adequately processed and liberated from impurities. In addition, contingent upon the client’s prerequisites, the rice should have a minimal number of broken pieces of kernels.
Most rice assortments are made out of 20% rice hull or husk, 11% grain’s bran layers, and 69% starchy and sticky endosperm, likewise alluded to as the total processed rice.
In optimal processing, this will result in the following divisions: 20% husk, 8−12% grain contingent upon the milling degree and 68−72% processed rice or white rice-edible form- fit for human consumption, depending on the assortment. Absolute processed rice contains whole grains or head rice and broken rice. The rice hull, rice germ and bran layers, and fine broken are the by-products of the rice milling process.
The quantity of outcome during milling is subject to various factors like the variety of paddy, the level or degree of milling process required, the quality of the milling mechanism utilized and other processing frameworks that perform processing of the paddy in stages. Therefore, the businesses of rice milling strive to lessen mechanical burdens and heat developed in the grain to limit grain breakage and produce consistently polished grain.
The excellent quality of the paddy and the accuracy of the rice milled are the two essential determiners for recovering the best quality rice. Thereby, to get high output, we need to follow the stringent procedures for the upkeep of the milling machinery, like:
1) Rice must not bounce back nor rotate within Bucket Elevator
The space between the elevator’s Bucket and tongue must be maintained at 2.5 – 3 mm, to be precise. If the distance between the two changes, a relatively some amount of recovery material rotates in the elevator repeatedly, affecting the machine’s productivity. Even 10 per cent of the disrupted output can cause a considerable disturbance, bringing down the production efficiency.
2) By Increasing Life of Elevator, Pulley and Belt and Bucket
The elevator’s belt must be placed accurately at the centre with respect to the pulleys located towards the two ends i.e. top and bottom of the vertical machine. Even if the belt shifts slightly to either side, the repercussion may be huge. It may cause damage to the belt, stressing down the motor of the machine and eventually reducing the possibility of achieving the optimum production level of the equipment.
For the paddy destoner mechanism, the recommended air suction level is between 70-80 megapascal, which is a must. Failure to adjust to optimum pressure measurements may lead to inefficient machine functioning and low milling output. In low or high air pressure, sheer energy will be converted into heat, but the bran shall stay unremoved. In addition, it may result in a significant amount of paddy being discharged and discarded along with the stones separated by the machines.
The grease must be changed within 72 hours according to the machines’ use in the husker and paddy de-separator. A lapse in grease changing may adversely affect the bearings and rubber roll of the device, which decreases the machine’s life and increases the broken rice percentage.
4) Pass more material with less external weight in Whiteners for increasing head rice percentage
Whitener is a machine used for removing the bran layer from the rice, rendering it a white appearance. The load of the rice material and the external weight applied to hold the rice in place are inversely related. Therefore, to maximize the device’s efficiency and check the broken rice percentage, an optimal input load of the material must be maintained. Consequently, it reduces the use of external weights. Conversely, if the input load of material or rice is less than the requirement, the external weights are applied. Less load with less weight may increase the broken percentage, causing the material to flow off the machine with the bran layer still on it. In addition, the whitening process applies pressure to the grain, which may cause cracking and breakage of some kernels. Therefore, emphasis must be laid on more material with less external weight.
5) Must maintain more shining with less broken in Silky Polisher
Considering two-stage whitening – Having two stages in the polishing process will reduce the grain’s overheating and allow the operator to set independent machine settings for each step. In addition, it will ensure higher milling and head rice recovery. In the first silky polisher machine, the water level must be high with less material weight. For the second processing machine, vice versa of the first must be followed.
6) By removing sticked Bran layer into the inner walls of the whitener/polisher’s pipeline
The sticky and oily characteristics of the bran layers removed from the brown rice tend to stick into the inner walls of the whitener/polisher’s pipeline, reducing the output of the machines. Therefore, the pipeline needs regular and thorough cleaning to address this issue. Cleaning must be carried out once in a week for a new, well-maintained machine. With the machine’s increasing age, the interval between cleaning also reduces.
7) Must Give Proper Training to Operator/Foreman
The operator’s knowledge and skill for operating the high-graded technology machines are of utmost importance. Running your milling machine with the assigned method is vital for more output to follow. Furthermore, the rice processing equipment adjusts to explicit configurations, with the processing parts varying in plan and performance. With this, monitoring maintenance and replacing spare parts regularly, as and when required, is vital. Therefore, a good and efficient operator can add a few extra years to the life of machines.
8) Tanks of the whitener and polisher must be cleaned after every use
The tanks of the whitener and polisher must be cleaned after every use. There must not be any residue or leftover stock material in the tanks, as it may negatively impact production.
9) Increase production by regularly cleaning of machines
Keeping the machines clean always is an unstated mandate. Regular and consistent cleaning with proper oiling and greasing of the rice milling machines are necessary for their upkeep and ease the devices to reach their optimum production level.
Sona Machinery Pvt. Ltd. is a leading Agro-processing machinery manufacturer and exporter specializing in rice mill projects in India and abroad and at the forefront of Rice Mill Turnkey Solutions. Specially trained Sona Machinery experts pass on their skills and expert knowledge in our innovation and training centres. Sona offers an encompassing array of training and consistent education options, either locally at the mill site or its instructional training centres. The consultancy service includes performance analysis of mills and machinery insights on improvements in machines and operations. The ready availability of reliable parts and spares of servicing mills ensures optimal and consistent output.
A 26+ years old association shining bright with a demonstrated history has explored advancement in every project it has been planning, designing, engineering, and executing that summing up to more than 10000 customers across the globe. With its immense experience, Sona Machinery Pvt. Ltd. has the expert knowledge and skill to handle operational challenges even as it is at the forefront of modifying and customizing technology in the rice milling sector. Moreover, with a mission to deliver world-class, cutting edge technology products and services to its customers, Sona Machinery is readily available to provide project management support.