Professional Documents
Culture Documents
MD.ASIF
Submited by :
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Date :30:05:2009
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Md. Asif MBA(general)1st sem.Roll no.25
• PROJECT PREVIEW
• INTRODUCTION
• MARKETABILITY
• RAW MATERIALS
• MANUFACTURING PROCESS
• THE PRODUCTS
• LOCATION OF THE UNIT
• UTILITIES
• SCHEDULE OF INTEREST
• COMMENTS ON FINANCIAL STATEMENTS
• PUFFD RICE
• DESCRIPTION OF OPERATIONS
• PROCESS DEFINITION
• ENERGY CONSERVATION IN THE RICE MILL
• INTRODUCTION
• PROCESS
• PARBOILED RICE PROCESSING
• ENERGY SAVING OPPORTUNITIES
• POLLUTION CONTROL
• PROBLEMS FACED IN GENERAL
• OBSERVATIONS
• SUMMARY OF THE OUTPUTS OF THE STUDY VISIT
STUDY VISIT TO M/S NITYAKALI RICE MILL
23-30 MAY, 2009
PURPOSE
PARTICIPANTS
ADDRESS
FACTORY :ALAMGANJ,P.O-NUTANGANJ,
DIST – BURDWAN,WEST BENGAL
CAPACITY SHIFT
CAPACITY SHIFT
IN M.T INSTALLED
CAPACITY
RICE IS THE STAPLE FOOD OF INDIAN . ONCE UPON A TIME RICE WAS
PROUNDED IN DHEKIS WHICH PRODUCED BRAN COATED COLOURED RICE.
IN THE FIFTIES MECHANISM CAME INTO THIS INDUSTRY AND HULLERS
WERE INTRODUCED. WHILE POLISHEDRICE COULD BE BPRODUCED BY
REMOVING THE BRAN COATING BUT BRAN COULD NOT SAVE ON THIS
PROCESS. BROKEN RICE PERCENTTAGE WAS ALSO HIGH AND OVERALL
RECOVERY PERCENTAGE WAS LOW.
THERE WAS TECHNOLOGICAL ADVANCE AND RUBBER ROLLER WERE
USED FOR MILLING PADDY AND BRAN COULD BE RECOVERED
SEPARATELY , BESIDES INCREASE IN RECOVERY PERCENTAGE .
PARBOILING AND DRIER SYSTEM WERE DEVELOPED WHICH SAVED THE
COST OF PRODUCTION AND ENABLED TO THE MILLS TO RUN 300 DAYS IN
A YEAR.
IN WEST BENGAL RICE MILLING INDUSTRY HAD A CHECKERED HISTORY .
IN WEST BENGAL MAZOR RICE MILL HAVE BEEN SET UP IN THE BURDWAN
DISTRICT . AS THIS DISTRICT HAS A WIDE FERTILE LAND SUITABLE FOR
PADDY PRODUCTION.
PROMOTERS OF THE EXISTING RICE MILL ARE THE LEADING BUSINESS
MEN OF THE LOCALITY AND SUCCESSSFULLY RUNNING THE EXISTING
UNIT SINCE BEGINNING. THEY HAVE DECIDED TO EXPAND AND UPGRADE
THE EXISTING UNIT WITH MODERN MACHINERIES TO GET THE EXPORT
QUALITY OF RICE AT A LOW PRODUCTION COST.
MARKETABILITY
MANUFACTURING PROCESS
THE PRODUCTS
POWER
THE EXISTING POWER IS AVAILABLE FOR 450K.V.A W.B.S.E.D.C.L POWER
CONNECTION .THERE IS ALSO TWO NUMBER 500 KVA D.G SET AND ONE
NUMBER 365 K.V.A D.G SET. FOR THE EXPANDED UNIT POWER
CONNECTION WILL BE EXTENDED FROM 450 K.V.A TO 700 K.V.A AND AS
STAND BY ONE 600 K.V.A D.G SET WILL BE INSTALLED.
WATER
THE REQUIRED WATER IS AVAILABLE. THE SUBMERSIBLE WATER PUMP
ALREADY EXISTS WITHIN FACTORY PREMISES.
STEAM
THE PRESENT REQUIRMENT OF THE STEAM GENERATION CAPACITY
LANKSHIRE BOILER.THE UNIT HAS INSTALLED ONE 4M.T/ HOUR STEAM
GENERATION CAPACITY HUSK FIRED WATER TUBE BOILLER OF PRESSEL
MAKE
DEPRECIATION
DEPRICIATION ON FIXED ASSET P.A. HAS BEEN CHARGED AS UNDER
BUILDING & SHED@ 10%
PLANT & MACHINERY@ 10%
MICS.FIXED ASSEST 10%
CAR @ 15%
TECHNICAL KNOW-HOW
NO SOPHISTICATED TECHONOLOGY IS REQUIRED FOR RICE MILL
INDUSTRY.THE OWNERS ARE EXPERINCED IN THIS ACTIVITY. SKILLED
WORKERS ARE ALREADY ENGAGED FOR SMOOTH OPERATION. AS A
RESULT THE UNIT IS NOT FACING ANY TECHNICLE PROBLEM.
EFFLUENT DISPOSAL
UNIT DOES NOT USE OR DISCHERGE ANY HARMFUL AND/OR DAMAGING
CHEMICAL WHICH MAY DAMAGE THE CROP FIELD AND WATER
RESORVOIR IN ANY WAY. REGRADING GASEOUS EFFLUENT THE SMOKE
COMES OUT IS VENTED THROUGH 110 FT . HEIGHT CHIMNEY . HOWEVER .
THE UNIT HAS ALREADY OBTAINED CLEARENCE CERTIFICATE FROM
POLLUTION CONTROL BOARD.
MANPOWER
THE UNIT HAS FULL IMPLEMENTATION OF 35 EMPLOYEES WHICH ARE
GIVEN HERE UNDER:
SL CATEGORY NO RATE(P.M) RS. IN LAKH
NO
TOTAL 17.78
SCHEDULE OF INTEREST
RATE OF INTEREST ON TERM LOAN HAS BEEN CONSIDER @ 6% P.A. AND
ON WORKINGCAPITAL LOAN@6%P.A.
PROCESS DEFINITION
INTRODUCTION
There are around 35000 rice mills in India. Most of the rice mills are small and
use very low cost low efficiency equipments.
However, for a majority of these Indian Rice mills, the connected load is less than
or around 500 KW and steam demand is lower than 3- 4 TPH.
PROCESS
RICE has to be processed in mill for removing their husk before it can be
consumed. There are two types of processing- RAW RICE PROCESSING and
PARBOILED RICE PROCESSING. Here, PARBOILED RICE PROCESSING is
carried out.
Drying 12
Soaking 10
- 5 10 15 20 25
Pre-Steaming: Raw paddy is fed into handies where it is steamed for 15-20
minutes. This is done to raise temperature of paddy initially before soaking in hot
water at about 800 C. This helps produce high quality rice. In some rice mills
(especially mills catering to export market), small handies are specially installed
for this purpose above the main handies.
Soaking: After direct steaming, hot water at 800 C is circulated into the handies
through pumps for 15 minutes to make temperature uniform throughout the tank.
This is followed by soaking the paddy in handies for about 4 hours. Water
temperature during the entire period is not allowed to fall below 60 0 C. If the
temperature of water falls, a small amount of water is drained and fresh hot water
is circulated to raise the temperature in the handies.
Freshly harvested paddy has a lower rate of water absorption than stored paddy
and the rate of moisture absorption increases with increasing temperature.
Soaking temperature of 700 C represents the transition point, below which paddy
absorbs water at a slow rate and above which the rate increases sharply and
progressively.
Depending on paddy variety, optimal soaking time varies between 7.5 & 9.5
hours for a soaking temperature of 500 C, from 5 to 6 hrs for a soaking
temperature of 600 C and from 2.75 to 4 hours for a soaking temperature of 700
C.
Energy Saving Opportunity: The hot water after soaking may be
wasted as a drain that represents enthalpy loss.
Steaming: After soaking the paddy, water is drained out through discharge drain.
Hot & soaked paddy is steamed in the same handies for 15-20 minutes. In some
rice mills (especially mills catering to export market), small handies are specially
installed for this purpose below the main handies.
At 50 1
Dryer Air Temp, deg C
60 - 50 1
85 - 60 3
110 - 85 5
0 1 2 3 4 5 6
Hrs
Rapid drying with hot air leads to heavy breakage during milling as the damage
to milling quality starts at 15% moisture level of paddy and increases sharply with
further drying. So, most convenient way of drying lightly parboiled paddy would
be to dry in two passes with tempering in moisture range of 15-19%, followed by
conditioning after final drying.
Tempering also increases drying rate, so that in-dryer drying time can be
reduced. Tempering below critical moisture level is advantageous only if it is
done at elevated temperatures but not at room temperature. For example, with a
drying air temperature of 800 C and dried to a moisture content of 14 %, minimum
breakage of 0.9% on milling will occur if the paddy, during drying, is conditioned
at 500 C. Again, with a drying air temperature of 60 0C and dried to a moisture
content of 13.5 %, minimum breakage of 0.6 % on milling will occur if paddy,
during drying, is conditioned at 500 C. In both cases, however, a reduction in
mentioned moisture content will require paddy to be conditioned at a higher
temperature (not above the drying temp) to achieve minimum breakage on
milling.
Dried Paddy is then taken to de-stoner & pre-cleaner for separating out any
foreign material, dust, dirt, etc. Associated with the pre-cleaner & de-husker are
their individual blowers that blow away the foreign matter.
Clean paddy is then taken to de-huskers where milling of paddy is done. Here,
husk is removed by blowing compressed air. After de-husking, dust & husk are
separated out and screening of rice (using magnetic separators) is done to
separate out brown rice and other varieties of rice. Major % of brown rice is again
sent for screening and small % is directly sent in brown rice graders (depending
upon order booking & demand).
Polished (white) rice is sent to graders where grading of rice is done, depending
on grain size. After final screening and quality checks, rice is packed in bags and
dispatched.
Energy Saving Opportunity: The polishers are big rated motors. A motor load
survey should be carried out. Also associated with these polishers are their
POLLUTION CONTROL
THERE IS NO MAJOR POLLUTION PROBLEM ASSOCIATED WITH THIS
INDUSTRY EXCEPT FOR DISPOSAL OF WASTE WHICH SHOULD BE
MANAGED APPROPRIATELY. THE ENTREPRENEURS ARE HAVING "NO
OBJECTION CERTIFICATE" FROM THE STATE POLLUTION CONTROL
BOARD.
ENERGY CONSERVATION
ONLY ELECTRICITY IS USED AS A SOURCE OF ENERGY.
HP V d in a
flashi yer
ng aw
Paddy soaking
en
recovery
dr
essel
Dryer Blowers
Cond
e
re
Can b
system
captu
efficiency study
Paddy drying Pre-cleaner
blower system
study
iciency study
system eff
blower
De-stoner Paddy de-stoning
Paddy de-husking
study
efficiency
drop &
silencer pr er Powder & Bran removal
Compressed air &
w
Powder blo
motor load survey
Polishing
Compressed air
system
Grading & Sorting
ANNEXURE
THE MILL OWNERS AND THE MANAGERS WERE NOT OPEN IN PROVIDING
INFORMATION ON PURCHASE AND SALE PRICES AND OR OTHER
RELEVANT DATA.