Birbhum PDF

NEED ASSESSMENT SURVEY REPORT-2012
RICE MILL CLUSTER,

BIRBHUM, WEST BENGAL
DCS MSME SCHEME
DESIGNER : KAUSTAV RAY MANDAL
Need Assessment Survey, Rice Mill Cluster, Birbhum, West Bengal Page 1
CONTENTS :
1. Acknowledgement
2. Introduction
3. General information
4. Documentation overview
5. Cluster level
5.1. Cluster level information
5.2. Cluster product and by products
5.3. Raw material
5.4. Existing machineries and equipments
5.5. Manufacturing process
5.6. Packaging exhibition
5.7. Problems faced at cluster level
5.7.1. Heterogeneity
5.7.2. Technical
5.8. Proposals
5.8.1. Assumptions
5.8.2. Model characteristics
5.8.3. Performance characteristics
6. Design audit unit base
6.1. List of units
6.2. Individual unit audit report
6.3. Problems faced as unit basis
6.3.1. Poor quality of paddy
6.3.2. Rice brand testing lab
6.3.3. Environmental problems
6.4. Opportunities areas for design interventions
6.5. Technical problems
7. Analysis and recommendation
7.1. Technical analysis
7.1.1. Parboiling
7.1.1.1. Performance analysis of boiler
7.1.1.2. Par-boiling system
7.1.2. Pre-cleaning
7.1.3. Removing the husk
7.1.4. Paddy separator
7.1.5. Polisher/whitener
7.1.6. Separation of white rice
7.2. Rice husk technology
7.2.1. Rice quality an overview
7.2.1.1. Quality characteristics of paddy
7.2.1.2. Quality characteristics of milled rice
7.2.1.3. Paddy quality determination
7.2.1.4. Procedures for measuring quality of paddy grain
7.2.1.5. Procedures for measuring quality of milled rice
7.2.1.6. Standards and grades of milled rice
7.2.1.7. Comparison of rice mill output
7.2.1.8. Testing of a rice mill performance and quality
7.2.2. Insects and rodents
7.2.3. Husk problem
7.2.3.1. Green technology
7.2.3.2. Feedstock
7.2.3.3. Preparation of feed stock
7.2.3.4. Rice husk processing plant
7.2.3.5. Combustion and power generation unit
7.2.3.6. Liquid sodium silicate and activated carbon production
7.2.3.7. Precipitated silica production
7.2.3.8. Main applications of products
7.3. Water re-utilisation
7.3.1. Boilers/boiler-house
7.3.2. Cooling towers
7.3.3. Drinking water
7.3.4. Water recycling
7.3.5. Water treatment in rice mill
8. Optimal design of a rice mill utility system with rice husk logistic network
8.1. Introduction
8.2. Problem statement
8.3. Problem formulation
8.4. Model formulation
8.5. Conclusion
9. Conclusion
1. ACKNOWLEDGEMENT
I would like to thank Birbhum Rice Mill Association and entire team for
organizing the Design Clinic Scheme Program and showing me their work
also letting me be part of their work-life to accomplish the program.
I would also thank “Design Clinic Scheme;National Institute of Design ”,

who has given me an opportunity to accumulate an intensive report after
realizing my strength, potential and past experiences.
My special thanks to each individual unit member of Birbhum Rice Mill

Association and Mr. Dipak Pramanik, the chairman of Birbhum Rice Mill
Association, who have given me their great support during the design
audit. Without their kind involvement and assistance I would have not
been able to accomplish the Need Assessment Survey on rice mill cluster in
Birbhum district.
2. Introduction :
India is the second biggest rice producing country in the world after China.
It contributes about 20 percent of the world output of rice. Paddy being the
major cereal crop of India covers an area of more than 42.8 million hectares,
the largest under any single crop. West Bengal is the highest rice producing
state in India and Birbhum district plays a vital role in rice producing.
Being a designer as well as an engineer I always like to observe and
analyze objects or system with economical benefits.
Birbhum Rice Mill Cluster is running under several problems. During my
Need Assessment Survey in this cluster as well as unit basis audit I have
tried to figure out the flaws in an interactive way with mill-owners and
workers and to provide them some spot solutions. And most importantly I
have tried to spot out certain innovation and design area that would help
for better growth of product and running a unit well.
3. General Information :
Birbhum is situated in the west part Thermal Power Plant, though northern
of West Bengal. Its neighbor districts region is powered by Farakka Power
are Murshidabad, covering its east Plant. At Bakreswar India’s largest
and partially north border, and rice mill presents.
Burdwan, covering its south border.
West and rest part of north border is
in touch with Bihar.
The zilla sadar of Bhirbhum is Suri.
Another towns are Sainthia, Sukhna,
Bolpur, Dubrajpur, Nolhati,
Bakreswar etc. Suri is well
communiacated with state capital
Kolkata by railway and highways.
Here is present Shantiniketan at
Bolpur. Soil nature is red in color.
The famous Baulgaan continues its
tradition over the years.
The rice mills are situated at different
parts of the district. Murakshi river
flows across the middle of the district
dividing it into two parts. The main
towns are powered by Bakreswar
West Bengal ↑
4. Documentation Over View :
Interviewee : nineteen rice mills which are selected

by Birbhum Rice Mill Association at
1. Dipak Pramanik different part of Birbhum.
2. Goutam Chhajer The purpose of the survey was to
3. Surendra Coher collect detailed information by
4. Prem Chhajer observing the process of manufacture,
by meeting and interviewing different
5. Falguni Laha
people involved in this profession and
6. Jagadish Ch. Jash to identify the problem areas. All the
7. Dipak Kr. Agarwala. findings were recorded using notes
8. Lalit Kr. Agarwala and photographs.
9. Rahul Khaitan Views of various parties were taken
10. Dip Chand Khaitan into account to get a better
11. Chandra Nath Mondal understanding of the scenario. I was
provided with a co-ordinator from the
12. Dilip Pal
association to help me to visit
13. Bijoy Choudhury different unit during the survey. I was
14. Mukesh Kr. Choudhury welcomed with different type of
15. Purushottam Choudhury reactions. Few of the people were
16. Vivek Choudhury very friendly and over enthusiastic to
17. Karan Choudhury share their view and information of
18. Biswa Bijoy Ghosh the material and process and some
welcome me with susceptive eye (I
19. Narottam Kr.Sarda.
was asked questions like “Are you
from income tax department?”). But
over all I got a friendly environment
The field work of the Need and immense cooperation from the
Assessment Survey was conducted owners of the rice mills.
from June 4, 2012 to June 8, 2012 in
5. Cluster Level :
5.1. Cluster Information :
Rice mill cluster in Birbhum has near about ninety three units in different
part of the district. The owners of all the rice mills have formed Birbhum
Rice Mill Association. The chairman and vice-chairman of the association
are Mr. Dipak Pramanik and Mr. Narottam Kr. Sarda respectively. The
President of this association is Mr. Biswa Bijoy Ghosh. The association has
certain norms which have been decided by the mill owners collectively and
all the rice mills have to follow the norms. The relationship between the
mill owners is very friendly. India’s largest rice mill belongs to this cluster.
5.2. Cluster product and by products :
Rice is the product
and husk and ash are obtained as byproducts.
5.3. Raw Materials :
Paddy is the only one raw material in this cluster.
5.4. Existing machineries and equipments :
The units under the cluster use more or less same type of technical machineries and
equipments. Some units, though few in number, have machineries and equipments
of higher degree of technical facility and production rate. And the rests have
mediocore technical equipments.
5.5. Manufacturing Process :
The manufacturing process employed in the clusters is continuous and

fully automated or semi automated , consisting of Paddy Cleaning, Par
Boiling, Drying, Milling, Sorting 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. The next stage is a pre-milling process
called Parboiling, which is the partial cooking of the grain with husk, done
to impart the required hardness to paddy grains so as to withstand the
pressure exerted during the Milling process. The parboiled paddy is taken
to the Drying section which consists of the Drying plant, Heat exchanger
and Blower.
The steam produced by the boiler is used for drying the paddy in the drier.
The drying time can be altered by adjusting the temperature of the drier.
When the paddy is sufficiently dry, it is taken to the Milling section.
Milling is the process of removing husk from paddy by application of force
through a rubber roller. Milling section consists of a Rubber Sheller, Cone
Polishers, Bran Blower and Separator, De-stoner and a Vibrator machine.
The paddy is collected in a separate room and is used as the fuel for firing
the boiler, or sold for making cattle feed, manure, etc.
The shelled paddy is then directed to the Paddy Separator, which will
separate the unshelled paddy and the rice. The unshelled paddy will again
go back to the Rubber Sheller and the shelled paddy is taken to the first
Cone Polisher, where the rice bran is also removed from rice. This will then
go to the Bran Blower and Separator, which will completely remove the
bran from the product. The bran will be collected in a separate room and
will be sold to the consumers directly. The hulled paddy is again taken to
the second and third Cone Polishers for polishing the rice. After polishing,
the rice will move to the de-stoner and vibrator, where stones and broken
rice are completely removed from the product to make it superior in
quality. The rice collected at the end of the milling section then moves to
the Color Sorter for removing the black and immature rice completely. The
product is then moved to the Packing Section for packing in different sizes
of polythene and gunny bags, weighed, stitched and taken to the store
room for dispatch.
The flow-chart of the manufacturing process can be shown as follow:
The milling machines are controlled by a central control panel. A huller, a

whitener, a colour sorter, and a packer can be also controlled locally. All
the machines are sequentially operated, while the machines are conversely
stopped if an overload is detected. The main silos such as paddy silo,
brown rice silo and polished rice silo are very large, compared with the
auxiliary hoppers for each machine which can be used as buffer hoppers.
Their levels can be detected by proximity sensors (switches) attached to the
main silos and auxiliary hoppers. So, the exit gates of silos or hoppers are
automatically controlled by the signals from the proximity sensors. The
amount of materials in the main silos is automatically measured by the
load cells installed at the bottom of the main silo legs.
The manufacturing process can also be divided in two stages for better
understanding.
These are
1. RAW RICE /PARBOILED RICE PROCESSING FLOW CHART
2. PROCESS FLOW CHART FOR SUPER POLISHING/ REFINING FOR
CUSTOMIZED OR EXPORT MARKET
1. RAW RICE /PARBOILED RICE PROCESSING FLOW CHART
2. PROCESS FLOW CHART FOR SUPER POLISHING/ REFINING
FOR CUSTOMIZED OR EXPORT MARKET
5.6. Packaging Exhibition :
The final product is now packaged and exhibited.
5.7. Problems faced by the cluster :
5.7.1. Heterogeneity : The major problem faced by the cluster is

heterogeneity in the composition of rice milling industry. Large
variations are found in type, capacity, location, services
rendered as well as in ownership of different processing units.
Consequently investment requirement, cost and return also
vary over a wide range. Heterogeneity in rice mill cluster arises
mainly from the widely varying economic activities made
available to private rice mill in different areas and sectors of the
district.
5.7.2. Technical : Another common feature of rice milling industry is

considered that its technical potential capacity is not fully
utilized and this is because of the seasonal concentration and
spatial spread of paddy production coupled with the existence
of a number of diverse processing units competing with one
another in supplying facilities. As these small mills generally
do not purchase and store paddy on their own, their operations
tend to be restricted to the paddy season, and their installed
capacity remained unutilized/underutilized during the rest of
the period of the year.
5.8. Proposal :
A simulation model for system evaluation of a rice mill plant is developed

with SLAM (simulation language for alternative modelling).
5.8.1. Assumtions :
The assumptions used in the model were the following:
a. The intake period of materials is T1 h in the morning and T2 h in the
afternoon with T3 h for lunch break, but the milling operation was carried
out continuously.
b. The weight of an entity in the simulation is assumed to be M kg.
c. The conveying time for chutes is included in the conveying time of the
bucket elevator.
d. No machine breakdown is occurred.
e. The duration time of each process is determined on the basis of actual
data with a normal distribution and a standard deviation of 5%.
f. The materials separated from each machine does not include other
foreign materials.
g. The capacity of the processes is taken as
intake X t/h,
hulling Y t/h,
milling Z t/h,
and packing P t/h.
The unit of simulation time in the model is minute.
5.8.2. Model characteristics :
The model is consisted of a network model and an user insert model. The
main milling process controlled by a programmable logic controller is
expressed with the network model, while the duration time of each process
and the control on the materials intake process are expressed with the user
insert model.
The automatic operation of each machine and the hopper exit gates are
considered as nodes of SLAM. The network model consists of the main
network for the automated basic milling process, sub-network for the
creation of entities according to time, and control network. The automated
basic milling process is modelled in the main network, and the creation of
entities according to time is modelled in the sub-network. The intake time
of materials is modelled with GATE , OPEN and CLOSE nodes. The signals
for the control of each machine and exit gates of hoppers is described in the
control network. The levels inside the hoppers are described with a
DETECT node, and exit gates of hoppers are automatically operated with
OPEN and CLOSE nodes and ALTER node according to the signals of
DETECT nodes. The duration time of each process is modelled in the user
insert model. Also, the amount of intake materials is controlled in the user
insert model using SUBROUTINE EVENT.
5.8.3. Performance characteristics :
The main performance characteristics of the model to be analysed are
i. Hulling efficiency, milling efficiency and milled rice recovery

ii. The amount of foreign materials discharged from each machines
iii. Flow restriction in process
iv. Stopping the individual machines
v. Capacity of individual machines.
6. Design Audit Unit Wise :
6.1. The units which have been audited during Need Assessment
Survey are :
LIST OF RICE MILLS WITH TELEPHONE NUMBERS & ADDRESS
Sl. Name of Rice Mill ADDRESS Mobile No. Contact Person

No
.
1 R.K. Rice Mill Sukhna 9434001447 Dipak Pramanik
2 Birbhum Agro Product (P)Ltd. Sainthia 9434004537 Goutam Chhajer
3 Sree Kocher Rice Mill ,, 9434021119 Surendra Kocher
4 Chhajer Rice Mill (P)Ltd. ,, 9434017971 Prem Chhajer
5 Kushal Rice Mill ,, 9434021119 Surendra Kocher
6 Swastidipa Rice Mill Angargoria 9434007835 Falguni Laha
7 Bharat tirth Rice Mill Deocha 9434032518 Jagadish Ch. Jash
8 Ma Shanti Agro Food (P)Ltd., Mollarpur 9434003588 Dilip Kr. Agarwala
9 Jay Baba Bakerswar Rice Mill (P)Ltd. ,, 9732009854 Rahul Khaitan
10 Khaitan Rice Mill " 9434001484 Dip Chand Khaitan
11 Suri Rice Mill Suri 9434004059 Chandra Nath Mondal
12 Amarduty Agro Tech (P) ltd " 9434006048 Dilip Pal
13 Jai Balaji Rice Mill ,, 9434000097 Bijoy Choudhury
14 Daulat Ram Industries Dubrajpur 9434032880 Mukesh Kr. Choudhury
15 Bharat Mata Rice Mill " 9434007592 Purushottam Choudhury
16 Birbhum Rice & Gl. Mills ,, 9434014664 Karan Choudhury
17 Satyanarayan Rice Mill Bolpur 9434019171 Biswa Bijoy Ghosh
Ahmodpu
18 Sarbottam Rice Mill r 9434013800 Narottam Kumar Sarda
6.2. Individual Unit Audit Report :
6.2.1. R. K. Rice Mill, Sukhna.
Sl.No. Problems Type of problem Remarks/Solution

1. Technical No serious machinery Highly equipped, software oriented and has its
problem own technician. Regular monitoring is done.
2. Labour Available Lack of skilled workers.
3. Power Sudden break down Needs steady, uniform and continuous power
and low quality of supply.
power.
4. Water Available
5. Water re- Govt. permissible limit Compromise between permissible limit and
utilisation owner’s profit without polluting nature.
6. Drainage No such problem. Ok.
problem
7. Rice brand Does not know what Needs a Rice Brand Test Lab in the district.
testing degree of quality of
rice they are
producing.
8. Paddy Impure paddy. Needs a Paddy Quality Test Lab in the district.
Quality Testing is done by visual identity.
testing
9. Ash disposal No place to dispose If an ash handling plant, such as fertilizer plant,
ash as it is highly can be set up in any remote area in the district,
pollutant. ash will be used as a raw material in that
plant.
10. Supply chain Almost regular.
11. Packaging No such problem. Good.
and branding
12. Inspection Regular basis. Good.
13. Marketing Brokers. Needs corporate houses as their regular
customers.
14. Banking No such problem. Satisfactory.
15. Ergonomic No such problem. Ok.
16. Govt. Policy Power subsidy
Oppertunities area for design and development :
1. Training and skill upgradation

2. Environmental factors
Strength :
Highly equipped machineries, Good packaging and branding, organized unite.
Expected Yearly Turn Over : Satisfactory.
6.2.2. Bhirbhum Agro Product (P) Ltd., Sainthia.

1. Technical Frequently happens. Lack of good technicians, electricians.
2. Labour Non-availablility Lack of skilled workers. Unit is run by semi-
skilled workers.
power.
4. Water Available
5. Water re- Govt. permissible limit. Compromise between permissible limit and
problem
rice they are producing.
8. Paddy Impure paddy. Needs a Paddy Quality Test Lab in the
Quality district.
testing
9. Ash disposal No place to dispose ash If an ash handling plant, such as fertilizer
as it is highly pollutant. plant, can be set up in any remote area in the
district, ash will be used as a raw material in
that plant.
10. Supply chain Almost regular. Good.
11. Packaging Not so sophisticated. Some amount of product is damaged and
and branding wasted.
customers.
14. Banking High interest. Satisfactory.
15. Ergonomic Closed working Breathing problem of workers.
environment.
16. Govt. Policy Power subsidy Intensive is needed.
1. Technology, modernization
2. Training and skill upgradetion
3. Ergonomic and environmental factors
Strength :
Family business, market demand.
Expected Yearly Turn Over : Under-achievement.
6.2.3. Sree Kocher Rice Mill, Sainthia.

1. Technical Medeicore equipments. Lack of good technicians, electricians.
2. Labour Non-availablility. Lack of skilled and fresh workers. Unit is run
by semi- skilled workers.
3. Power Almost desirable. Seasonally affected.
4. Water Seasonally available. Seasonally affected.
6. Drainage Insufficient passage Poor.
problem and space of wasted
water.
Quality district.
testing
that plant.
10. Supply chain Almost regular. Good.
and branding wasted. Help of corporate house is needed.
12. Inspection Regular Basis. Good.
customers.
environment.
16. Govt. Policy Power subsidy Intensive is needed.
1. Technology modernization
2. Training and skill upgredation
3. Packaging and branding
Strength : Eager interest, family business, market demand.
Expected Yearly Turn Over : Fluctuation occurs due to seasonal effect.
6.2.4. Chhajer Rice Mill (P) Ltd., Sainthia.

1. Technical Medeicore equipments. Lack of good technicians.
2. Labour Available. Has skilled workers.
3. Power Low quality of power. Supply is continuous, but fluctuations beyond
range.
6. Drainage Insufficient passage Very poor.
water.
Quality district.
testing
that plant.
10. Supply chain Irregular. Seasonally affected.
customers.
environment.
16. Govt. Policy Power subsidy. Intensive is needed.
4. Marketing
Strength : family business, local consumer.
Expected Yearly Turn Over : Under achievement.
6.2.5. Swastidipa Rice Mill, Angargoria.

Problem in feed pump.
2. Labour Non-availability. Lack of skilled workers.
range.
water.
Quality district.
testing
Chimney blockage district, ash will be used as a raw material in
often occurs. that plant.
13. Marketing Brokers. Needs corporate houses as their regular and
direct customers.
environment.
Strength : Worker, labour, management.
Expected Yearly Turn Over : under achievement.
6.2.6. Bharat Tirth Rice Mill, Deocha.

1. Technical Semi sophisticated. Good.
3. Power Low quality of power. Supply is continuous, but fluctuations
beyond range.
4. Water Available. Good.
5. Water re- Govt. permissible limit. Compromise between permissible limit
utilisation and owner’s profit without polluting
nature.
6. Drainage No such problem. Good.
problem
7. Rice brand Does not know what degree Needs a Rice Brand Test Lab in the
testing of quality of rice they are district.
producing.
8. Paddy Quality Impure paddy. Needs a Paddy Quality Test Lab in the
testing district.
9. Ash disposal No such problem. It is situated in a remote area.
10. Supply chain Regular. Good.
11. Packaging and No such problem. Good.
branding
13. Marketing Brokers. Needs corporate houses as their
regular and direct customers.
14. Banking High interest.
15. Ergonomic Closed working environment. Breathing problem of workers.
1. Training and skill upgradetion

2. Ergonomic
Strength : Management.
Expected Yearly Turn Over : Fluctuating.
6.2.7. Ma Shanti Agro Product (P) Ltd., Mollarpur.

range.
water.
Quality district.
testing
that plant.
customers.
environment.
1. Technical ,modernization
3. Marketing
Strength : Local consumers, quality of product.
Expected Yearly Turn Over : Under achievement.
6.2.8. Jay Baba Bakreswar Rice Mill (P) Ltd., Mollarpur.

1. Technical Highly sophisticated. Has its own Technicians.
3. Power No such Problem. Continuous and Quality power supply.
4. Water Aavailable. Good.
6. Drainage No such Problem. `Good.
problem
rice they are
producing.
8. Paddy Quality Impure paddy. Needs a Paddy Quality Test Lab in the
testing district.
9. Ash disposal No place to dispose If an ash handling plant, such as fertilizer
ash as it is highly plant, can be set up in any remote area in
pollutant. the district, ash will be used as a raw
material in that plant.
11. Packaging No such problem. Has its own packaging and branding unit.
and branding
13. Marketing No such problems. But needs corporate houses as their regular
customers.
15. Ergonomic No such problem. Good.
16. Market and No such problem. Has its own marketing dept.
competition
study
Strength : Highly equipped, marketing strategy, quality of product.
Expected Yearly Turn Over : More or less achieved.
6.2.9. Suri Rice Mill, Suri.
Problems Type of problem Remarks/Solution

Sl.No.
1. Technical Medeicore equipments. Good.
2. Labour Not available. Lack of skilled and fresh workers.
3. Power No such problem. Continuous, steady and uniform power supply.
4. Water Crysis.
water.
Quality district.
testing
that plant.
customers.
environment.
1. Technical, modernisation
4. Marketing
Strength : Local consumers and local suppliers.
Expected Yearly Turn Over : Fluctuates.
6.2.10. Jai Balaji Rice Mill, Suri.

3. Power Average. Steady and uniform, but discontinuous power
supply.
4. Water No such problem. Good.
problem
Quality district.
testing
that plant.
10. Supply chain Irregular. Shortage.
customers.
4. Marketing
Strength : Quality of product.
Expected Yearly Turn Over : New unit, running three months only.
6.2.11. Amarduty Agro Tech. (P) Ltd., Suri.

3. Power Sudden break down Needs steady and uniform power supply.
and low quality of
power.
4. Water No such problem. Good.
problem
Quality district.
testing
that plant.
10. Supply chain Regular. Surplus.
customers.
4. Marketing
Strength : Local consumers and suppliers.
Expected Yearly Turn Over : Under achieved.
6.2.12. Daulat Ram Industries, Dubrajpur.

1. Technical No serious machinery Has own technicians
problem.
power.
4. Water Available Ok.
problem
rice they are
producing.
testing
ash as it is highly plant, can be set up in any remote area in the
pollutant. district, ash will be used as a raw material in
that plant.
11. Packaging Own. Some % of product is wasted.
and branding
customers.
14. Banking Comparing it with Bank should consider this industry at a
other industry. different angle at it deals with aagricultural
product.
4. Marketing
Strength : Local consumers.
6.2.13. Bharat Mata Rice Mill, Dubrajpur.

problem.
power.
problem
rice they are
producing.
testing
that plant.
and branding
customers.
product.
4. Marketing
Strength : Local consumers.
6.2.14. Sarbottam Rice Mill, Ahmodpur.

problem.
2. Labour Non-availability of
skilled and fresh labour.
3. Power Sudden break down and Needs steady, uniform and continuous power
low quality of power. supply.
4. Water Not available through
out the year.
problem
testing degree of quality of rice
they are producing.
Quality district.
testing Testing is done by visual identity.
as it is highly pollutant. plant, can be set up in any remote area in
the district, ash will be used as a raw
material in that plant.
10. Supply chain In-adequate supply. Seasonally affected.
and branding
customers.
14. Banking Comparing it with other Bank should consider this industry at a
industry. different angle at it deals with aagricultural
product.
17. Ownership Fragmentation.

Strength : Organised planning, technical knowledge, huge experience,

quality of product.
Expected Yearly Turn Over : Fluctuating.
6.2.15. Satyanarayan Rice Mill, Bolpur.

problem.
3. Power Reasonable. Has substitute arrangement.
problem
rice they are
producing.
testing
that plant.
and branding
customers.
product.

Strength : Bank independency, family business.
6.3. Problems faced as unit basis :
The problems in the units of Rice Mill Cluster, Birbhum, West Bengal are
almost homogeneous in nature. The main three problems in this cluster are
1. Poor quality of paddy

2. No Rice Brand Testing Lab
3. Environmental problems such as ash disposal, water re-utilisation.
4.
6.3.1. Poor quality of paddy :
The impurity in paddy here is 10-12% where as in Panjab and Hariyana it is

merely 1-2%.
It is estimated about 10 percent of paddy/rice is damaged and/or lost in
processing, storage and transport with the present methods and
machinery. Sixty to eighty percent head yield is obtained with 10-25 broken
and admixture of bran and husk whereas with modern techniques, 68-72
percent head rice with 5-7 percent broken and better utilizable by-products.
Since paddy is the staple food of practically all paddy growers and also it is
seasonal with one harvest per year, there should be some facility in storage
which can be protected from various hazards like damage caused due to
spontaneous heating, damage by birds, rodents and insects.
6.3.2. Rice Brand Testing Lab :
There is no Rice Brand Testing Lab in the district. They have to go

Burdwan to test the rice brand. If such lab be set up with the help of Govt.
this problem can be solved permanently.
6.3.3. Environmental Problems :
Bran obtained in milling is a part of the rice kernel and as such is quite rich
in fat.
Polished rice contains 0.3 percent fat whereas brown rice contains about 2.2
percent fat on a moisture free basis. Rice bran contains 20 percent
extractible but the bran produced in commercial mills usually contains 13-
18 percent extractible. The quantity of bran if totally extracted for the oil in
it, is capable of producing 7.17 lacs tones of edible rice bran oil. Thus, if this
total potential is exploited, enough oil would be available to curtail a major
portion of the import of edible oils required to fill up the ever widening
gap between the demand and supply of edible oils in the country.
Rice husk is the largest by-product of rice milling industry which amounts
to 22-24 percent of the total paddy. The heating value of husk has been
reported to be 3000-3500 Kcal/kg. Thus, husk can be used for generating
steam for parboiling paddy and as heat source mechanical dryers. Twenty
kg of husk can generate 60,000-70,000 Kcal which would be enough to
reduce the moisture content of one tones of paddy from 20 to 14 percent. It
can be used as fuel in domestic stoves and as a soil conditioner or a
diluents component in commercial mixed fertilizers. It can also be used as
an abrasive material because of its high silica content. Husk ash is used in
glass industry for polishing. Rice husk can be directly used as a loose
insulating material in building and cold storage facilities. Success has been
achieved in the use of husk ash for manufacturing cement.
Pure silicon which is used for making semiconductors is a very costly
material that can be obtained from rice husk. Boards and briquettes can
also be produced from rice husk.
6.4. Oppertunities areas for design interventions :
The areas where interventions are required are listed below:

1) Technology,
2) Marketing
3) Entrepreneurship & Management
4) Human Resource & Training
5) Finance
6) Infrastructural facilities
7) Govt. Policy
6.5. Technical Problems :
Parboiling of paddy, a process of partial boiling or cooking prior to milling

which imparts an extra strength to the rice kernel so that it could withstand
the milling stress and result in higher head yield. This significant increase
in the hardness of the kernel results due to gelatinization of the starch
during parboiling and the disrupted protein which expanded and occupied
all the air spaces in the endosperm.
Research on food value of rice has shown that parboiled rice has more
nutritive value than the raw rice because of the migration of vitamins from
outer layers of the rice kernel into the inner starchy endosperm due to
moisture heat treatment. Moreover, due to better milling quality, the losses
of broken and fines into the bran are reduced considerably in the milling
process of parboiled rice, and hence, total rice outturn of 72-73 percent (2-8
percent more than the raw rice) and whole rice outturn of 60-65 percent
(20-30 percent more than raw rice) are obtained. This is perhaps the easiest
and cheapest method of attaining the self-sufficiency in meeting the
growing demand for rice.
Loss of rice due to inefficient drying method is also not insignificant. Sun
drying is the most popular and traditional method of drying. This method
is completely dependent upon weather and it needs specially constructed
large floor area that restricts the capacity of a mill to a certain extent.
Excessive losses will occur due to scattering, birds, rodents etc. This can be
improved by drying paddy in a mechanical dryer using husk as burning
fuel.
7. Analysis and Recommendation :
One whole at the present scenario, the cluster has no homogeneity up to

the mark; design intervention is required in training and skill upgradation
of workers, packaging and branding, marketing, technology. It has a high
income discrepancy between the worker and the unit owner.
7.1. Technical Analysis :
A schematic diagram of a milling system is as follow :
1- Rice tank; 8- Tank;

2- Paddy sort-out sieve; 9- Whitening machine;
3- Tank; 10- Polishing machine;
4- Husking machine with cylindered 11- Whitened rice classifying drum.
rubber; E1, E2, E3, E4, E5, E6, and E7: convey
5- Tank; buckets.
6- Rice sort-out sieve; X1, X2: Cyclones for collecting bran.
7- Grit collector; F1,F2,F3: separation fans.
In the previous diagram the convey buckets can be replaced by ducts which are
used with forced draft fens or blowers. The separating fans are powered by
individual servo motors that its speed can be controlled individually according to
will.
7.1.1. Parboiling :
Parboiling of paddy is a hydrothermal process that may be defined as

gelatinization of starch within the rice grain. During the parboiling process
the starch and protein expand and fill the internal air space which creates
strong cohesion between them. Both fissures and cracks present in the
endosperm are sealed and tough enough to withstand milling stresses
which increases the total yield of edible rice and minimizes the broken rice
quantity.
The fuel used in the boiler is generally a bio-mass. Among the Asian
countries India has the highest total use of biomass mainly as wood
whereas, Bangladesh has the high proportional use of non-wood biomass.
This biomass is derived from rice husk, cow-dung rice straw and lesser
amounts of jute stick, fire wood, twigs, leaves and other waste materials.
A schematic diagram of existing par-boiling system is shown below :
The energy flow through the existing furnace can be shown as
7.1.1.1. Performance analysis of boiler :
7.1.1.1.1. Determination of inside volume of boiler :
The length, diameter and wall thickness of steam vessel are measured. The
presence of steam generator safety measures like safety valve, pressure-
gauge, temperature meter, chimney etc are observed and are recorded. The
volume of cylindrical steam generator is calculated using the equation (1).
V =1000*(M D2/4)*L ---------(1)
Where, V = Volume of steam generator, litre
D = Diameter of steam generator, m
L = Length of steam generator, m
The semi-cylindrical was in irregular shape. Therefore, the cross-sectional
area was divided into a number of trapezoids i.e., the boundaries between
the extremities of the ordinates are assumed to be straight lines. The
following equation (2) of trapezoidal rule is generally used to calculate the
cross-sectional area.
A = d/2 (O0+ 2O1 + 2O2+..................+ 2On-1 + On)................... (2)
Where , A = X-sectional area of steam generator, m2
d = common distance between ordinates, m
O = ordinates at each point f division, m
The cross-section was multiplied by the length of steam generator to
calculate the volume of steam generator (equation 3).
V = 1000 × A × L --------- (3)
Where, V = Volume of steam generator, litre
A = X-sectional area of steam generator, m2
L = Length of steam generator, m
7.1.1.1.2. Determination of Initial, final and evaporated water (steam)

volume for different boiler :
a. Horizontal :
CASE I : both the initial and final level more than half full:
Initial Volume, Vi = [ MR2 – R2(θ – sinθ)/2]*xL------------------ (4)

Final volume, Vf = = [ MR2 – R2(Φ – sinΦ)/2]*xL----------------- (5)
Where, Vi= Initial water volume, m3
Vf= Final water volume, m3
R = Radius of steam generator, m
θ = 2 cos-1(a/R) ------------ (6)
a = Hi - R
Hi = Initial water level, m
ϕ = 2 cos-1 (b/R) ------------ (7)
b = Hf - R
Hf = Final water level, m
L = Length of steam generator
CASE II : initial level more than half full and final level less than half full
Initial Volume, Vi = [ MR2 – R2(θ – sinθ)/2]*xL---------- (8)

Final volume, , Vf = = [R2(Φ – sinΦ)/2]*xL -------------- (9)
Where,Vi= Initial water volume, m3
Vf = Final water volume, m3
θ = 2 cos-1(a/R) ------------ (10)
a = Hi - R
ϕ = 2 cos-1 (b/R) ------------ (11)
b = R - Hf
CASE III : initial and final level less than half full:
Initial Volume, Vi = [ R2(θ – sinθ)/2]*xL------------------- (12)
Final volume, Vf = = [R2(Φ – sinΦ)/2]*xL--------------- (13)
Where, Vi= Initial water volume, m3
Vf = Final water volume, m3
θ = 2 cos-1(a/R) ----------------- (14)
a = Hi - R
ϕ = 2 cos-1 (b/R) ----------------- (15)
b = R – Hf
b. Semi-cylindrical :
Initial volume of water

Vi = Initial wetted X-sectional area × Length of steam generator -------(16)
Final volume of water
Vf = Final wetted X-sectional area × Length of steam generator ---------(17)
Weight of feed water, kg
Wfeed =Volume of feed water (m3) × specific weight of water (kg/m3) × Sp.
gravity--------(18)
Weight of final water, kg
Wfinal =Volume of final water (m3) × specific weight of water (kg/m3) × Sp.
gravity-------(19)
Weight of evaporated water (kg), Wsteam= Wfeed - Wfinal -------------- (20)
7.1.1.1.3. Efficiency of boiler :
Sensible heat in feed water, kJ/kg

hfeed = Wfeed × Cpw × tfeed --------------------------------------------------------- (21)
where,
hfeed = heat content in feed water, kJ/kg
Wfeed = weight of feed water, kg
Cpw = 4.1868 kJ/kg-K
tfeed = temperature of water, °C
Heat addition to steam, kJ/kg

q1 = hf + xhfg – hfeed -------------------------------------------------------------- (22)
where,
q1 = heat addition to steam, kJ/kg
hf = sensible heat in hot water, kJ/kg
x = 0.95, quality of steam
hfg = latent heat of vaporization, kJ/kg
hfeed = sensible heat in feed water, kJ/kg
Heat addition to remaining hot water in the steam vessel, kJ/kg

hrw = hf – hfeed ---------------------------------------------------------------- (23)
Total heat addition into vessel/boiler, kJ
Eout = q1 × Wsteam + hrw × (Wfeed – Wsteam) -------------------------------------- (24)
Total energy supplied, kJ
Ein = Whusk × Chusk ---------------------------------------------------------------- (25)
where, Ein = Energy input, kJ
Whusk = weight of husk, kg
Chusk= calorific value of rice husk, kJ/kg
Thermal Efficiency of steam vessel,

η effi. = (Eout / Ein) × 100 % ----------------------------------------------------- (26)
7.1.1.2. Par-boiling system :
The parboiling system consists mainly of two parts one is the steam
generation unit (steam vessel and furnace) and other part is steaming bin
for parboiling paddy. Steaming bin is connected with the steam generator
with a steam pipe. The steam is produced at a very low pressure in
traditional rice parboiling systems in Birbhum. However, some rice miller
uses high pressure and high temperature steam for producing special
quality of parboiled rice.
A schematic diagram of improved per-boiling system is shown below:
7.1.2. Pre-cleaning :
When paddy comes into the mill it contains foreign material such as straw,
weed seeds, soil and other inert material. If this is not removed prior to
hulling the efficiency of the huller and the milling recovery are reduced.
Most pre-cleaners separate three groups of materials:
• The first separation is done by scalping or removing the objects that
are larger than the grain. Either a flat oscillating screen or a rotary
drum screen that allows the grain to pass through but retains straw
can do this.
• The second separation retains the grains but allows broken grains,
small stones and weed seeds to pass through. An air aspirator may
also be incorporated to remove the dust and the light empty grains
The capacity of the paddy pre-cleaner is usually based on the capacity of

the rice mill. A pre-cleaner for a 3 t/h rice mill would normally have a 5
t/h cleaning capacity.
Types of pre-cleaner :
Grain pre-cleaners can be classified according to their cleaning mechanism.

These are:
1. Oscillating Sieve type

Oscillating sieve pre-cleaners are simple and often made locally. The
machine consists of two sieves of different sizes depending on the size and
shape of the grain. The top sieve has a slotted profile larger than the
bottom and both screens can be changed to suit the grain size or crop type.
action of this machine is similar to
the sieve oscillation cleaner. Some
3. Aspiration cum Oscillation cleaners are also equipped with
Type magnets to remove ironic
The aspirator grain cleaner particles. Aspiration style cleaners
removes lighter impurities such as can have either single or double
dust, dirt, chaff and straw by action aspiration.
blowing or sucking air through
the mass of falling grain and
removing these light impurities in
the air stream. Impurities that are
not removed by the air are then
separated from the grain using
oscillating sieves. The sieving
3. Rotary Cleaner
This machine consists of one or two drums; each drum is fitted with mesh
of different sized hexagonal or square perforation and an oscillating sieve.
Foreign matter larger than the grain is removed as the paddy or rice passes
through the drums. Paddy then flows onto the oscillating sieve to separate
heavier impurities such as stone.
There are two types of rotary cleaner:
Single drum with aspirator and oscillation sieve. The single drum aspirator
utilizes a single drum to separate large, light and heavy impurities. Lighter
impurities are separated by suction aspiration and the oscillation sieves
separate heavier impurities such as sand.
Double drums with aspirator. This machine has two rotation drums with each
drum having a different size hole on the wire mesh. It utilizes an aspirator
to separate light impurities. This machine is typically used for cleaning
freshly harvest paddy.
4. De- stoner with aspiration

This machine is the same as a single drum with aspiration and oscillating
sieves but has an additional special arrangement for separating stones that
have the same physical dimensions as paddy. Of particular importance is
the direction of flow of the paddy compared to the direction of movement
of the stones.
7.1.3. Removing the husk :
The husk layer is removed from the paddy by friction and the process is
called either de-husking or de-hulling. De-husking was traditionally done
using mortar and pestles but, in modern rice mills, it is done by passing the
paddy grains between two abrasive surfaces that are moving at different
speeds. After separating the husk and paddy, the husk is removed by
suction (aspirated) and then transported to a storage dump outside the
milling plant. The percentage of paddy that is de-hulled to produce brown
rice during this process is called the hulling efficiency An efficient husker
will remove 90% of the husk in a single pass. After the husk has been
removed the brown rice goes to a paddy separator. The kernels that were
not de-husked in the first pass will be separated and then returned to the
de-husker..
Types of Husking machines
1. Steel Huller
The steel huller removes the husks and whitens the rice in one pass. Paddy
rice is fed into the machine and passes between a revolving steel shaft and
a cylindrical shaped mesh screen. These machines are normally powered
by a 15 to 20 hp engine and are very simple to operate. They are relatively
cheap.
Advantage Disadvantage
• Very compact • Low milling efficiency.
• Easy to operate. • Produces high amount of
• Low cost and easy to cracked and broken rice.
maintain. • By-products - husk, bran and
• Can mill small amount of very small broken are often
paddy for individual farmers. mixed
• Low cost of milling
(handling and conveying
equipment is minimal).
3. Under runner disc sheller
The under-runner husker is very common in Asia. This machine has two
steel discs, which have an emery coating. The upper disc is stationary and
fixed to the cast iron housing. Paddy flows from a centrally located hopper
between the abrasive surfaces of the revolving lower disc and the
stationary upper disc. Resistance between the emery surface on the discs
and the paddy grains removes the husk leaving the brown rice kernel.
Brown rice and husks are then discharged circumferentially over the
revolving disc and exit through an outlet. This machine is very economical
to run, produces a moderate amount of cracked or broken grain, and has a
hulling efficiency of about 85-90%.
• Capacity is higher than steel • Machine is very heavy and
huller type. requires a moderate size
• Cracked and broken grain is operating space.
less than steel huller type. • This process scratches the rice
• More power efficient than kernel.
steel huller type. • As the abrasive stone wears,
• Easy to operate. sand and silicon dislodges and
• Low operation cost. mixes with rice and bran.
• Machine is very durable. • Rice recovery less than the
• It is nearly comparable to rubber rolls huller.
rubber rolls huller • Huller efficiency in this
machine is 85-90%
3. Rubber roller huller
The rubber-roller huller is the most efficient hulling machine. As the name
suggests two rubber rollers of the same diameter are operated at different
speeds to remove the husk from the paddy. One roller has a fixed position
and the other is adjustable to meet the desired clearance. The adjustable
roller rotates slightly slower than the fixed roller. Rubber-roll hullers have
an aspirator in the base of the machine to separate the hulls from the brown
rice. The roll diameter varies from 150 to 250 mm and the roller width from
60 to 250 mm. The correct clearance is dependent on the varietal
characteristics and the width and length of paddy. This method of hulling
can achieve hulling efficiencies of 85% to 90% with minimum broken or
cracked grain. This type of machine is now widely used in developed
countries.
• Reduce breakage of • Cost to purchase
milled kernels. • Cost of rubber rollers
• High hulling efficiency.
• By-products are free
from sand and silicon.
• Bran also in higher
quantities compared to
disc huller
• Very compact in
comparison to disc huller.
• Less vibration
7.1.4. Paddy separator :
The output from the huller is a mixture of paddy rice, brown rice, husk,
broken paddy, and sometimes bran. The huller aspirator removes the
lighter material such as husk, bran and very small brokens. The remainder
passes onto the paddy separator where the unhulled paddy rice is
separated from the brown rice. The amount of paddy present depends on
the efficiency of the husker, and should not be more 10%. Paddy separators
work by making use of the differences in specific gravity, buoyancy and
size between paddy and brown rice. Paddy rice has a lower specific
gravity, higher buoyancy, and is physically bigger, longer and wider than
brown rice.
There are two types of paddy separator -
1. Compartment Separator
The compartment type of paddy separator is dependent on the
separator uses the difference in compartment area. For a 2-ton/hr
specific gravity and the buoyancy capacity rice mill, a 45-
to separate paddy and brown rice. compartment separator made up
When paddy and brown rice of 15 compartments on each of
move over an inclined plane, they three decks is used.
move at different speeds
depending on their specific
gravity, their shape and contact
area, smoothness of inclined
surface and the co-efficient of
sliding friction. Brown grains are
smaller, heavier, rounder and
smoother and will slide faster than
paddy grains. The processing
capacity of the compartment
2. Tray Separator
The tray separator uses the consumes less power than the
differences in specific gravity compartment type separator.
grain length and the co-efficient of
friction to separate paddy and
brown rice. The oscillation and
slope of the tray forces the brown
rice to move up the slope and the
paddy to slide down. The
separation performance of this
type of paddy separator is very
good. This machine is very
compact, easy to adjust, and
Separation principle
Hulling Efficiency
In principle, the huller can efficiently remove between 80 and 95% of the
husk from the paddy in one pass. When setting up a rubber huller it is
normal to have 10% of the paddy returned for a second hulling. If
efficiencies higher than these are attempted the level of grain breakages
will increases.
7.1.5. Whitener or polisher :
White rice is produced from brown rice by removing the bran layer and the
germ. The bran layer is removed from the kernel by applying friction to the
grain surface either by rubbing the grains against an abrasive surface or
against each other. The amount of bran removed is normally between 8-
10% of the total paddy weight but this will vary according whiteness
required.
The process used to polish brown rice can be classified as abrasive or
friction.
Abrasive: In this process the grain vertical or horizontal in design.
is whitened by the abrasive action Thevertical cone whitener is very
of the rice kernel passing between common in many Asian countries.
a moving abrasive surface and
stationary screen. The hard rough
surface is usually stone or a
carborundum type material. The
abrasive process applies less
pressure on the grain and is better
suited for long grain varieties.
Abrasive polishers can be either
Friction: In the friction whitener more pressure on the grain than

the grain kernels are forced an abrasive whitener.
against each other and a metal
screen by a steel-ribbed cylinder
rotating inside a metal-plated
cylinder. The frictional forces
created between individual rice
grains and between the grains and
the metal screen surface remove
the bran layer from the grain.
Friction polishers are always
horizontal in design and apply
The whitening process applies pressure to the grain, which generates heat
and causes cracking and breakage of somekernels. To reduce the number of
broken grains and the grain temperature during the whitening process, rice
is normally passed through two to four whitening and polishing machines
connected in series. Rice temperatures should not exceed 43-440C during
any process. The arrangement of machines to process the rice during rice
whitening is dependent on the physical characteristics rice grains. Proper
sequencing of the machines will help reduce the amount of broken kernels
during whitening and polishing. The normal arrangement of whitening
and polishing long and short grain rice as follows :
Short grain:
Long grain :
7.1.6. Separation of white rice :
After polishing, the white rice is separated into head rice and, large and
small broken rice by a sifter. Head rice is normally classified as kernels,
which are 75-80% or more of a whole kernel. The sifter is made up of a
series of oscillating screens through which the rice passes. The output from
the bottom screen is the very fine broken tips and is called the brewers.
To attain a higher degree of precision for grading and separation, a length
or indent grader is also used. This machine is made up of 1-3 rotating
indented cylinders. The broken and smaller rice pieces fall into the indents
on the rotating roller surface and are removed leaving the whole rice
kernels or head rice.
Different indent sizes are used according to the grain.
7.2. Rice husk technology :
7.2.1. Rice quality-an overview :

This skills section examines the different factors that affect grain quality,
and explains how to measure grain quality characteristics for both paddy
and milled rice.
Quality of rice is not always easy to define as it depends on the consumer
and the intended end use for the grain. All consumers want the best quality
that they can afford. As countries reach self-sufficiency in rice production,
the demand by the consumer for better quality rice has increased.
Traditionally, plant breeders concentrated on breeding for high yields and
pest resistance. Recently the trend has changed to incorporate preferred
quality characteristics that increase the total economic value of rice. Grain
quality is not just dependent on the variety of rice, but quality also depends
on the crop production environment, harvesting, processing and milling.
The quality characteristics of paddy and milled rice can be considered
separately.
7.2.1.1. Quality characteristics of paddy :

A number of interrelated features determine the quality of paddy. These
are:
• Moisture content of paddy,
• Purity degree,
• Varietal purity,
• Cracked grains,
• Immature grains,
• Discoloured/fermented grains and damaged grains.
These characteristics are determined by the environmental weather

conditions during production, crop production practices, soil conditions,
harvesting, and post harvest practices.
Moisture content
Moisture content has a marked influence on all aspects of paddy and rice
quality and it is essential that paddy be milled at the proper moisture
content to obtain the highest head rice yield. Paddy is at its optimum
milling potential at moisture content of 14% wet weight basis. Grains with
high moisture content are too soft to withstand hulling pressure which
results in grain breakage and possibly pulverization of the grain. Grain that
is too dry becomes brittle and has greater breakage. Moisture content and
temperature during the drying process is also critical as it determines
whether small fissures and/or full cracks are introduced into the grain
structure.
Degree of purity
Purity is related to the presence of dockage in the grain. Dockage refers to
material other than paddy and includes chaff, stones, weed seeds, soil, rice
straw, stalks, etc. These impurities generally come from the field or from
the drying floor. Unclean paddy increases the time taken to clean and
process the grain. Foreign matter in the grain reduces milling recoveries
and the quality of rice and increases the wear and tear on milling
machinery.
Varietal Purity
A mixture of varieties causes difficulties at milling and usually results in
reduced capacity, excessive breakage, lower milled rice recovery and
reduced head rice. Different sizes and shaped grains make it more difficult
to adjust hullers, whiteners and polishers to produce whole grains. This
results in low initial husking efficiencies, a higher percentage of re-
circulated paddy, non-uniform whitening, and lower grade of milled rice.
Grain dimensions
Grain size and shape (length-width ratio) is a varietal property. Long
slender grains normally have greater breakage than short, bold grains and
consequently have a lower milled rice for recovery. The grain dimensions
also dictate to some degree the type of milling equipment needed. For
instance, the Japanese designed milling equipment may be better suited to
short-bold, japonica grains whereas Thai made equipment will be more
suitable for longer, slender grain types.
Cracked grains
Overexposure of mature paddy to fluctuating temperature and moisture
conditions leads to development of fissures and cracks in individual kernel.
Cracks in the kernel are the most important factor contributing to rice
breakage during milling. This results in reduces milled rice recovery and
head rice yields.
Immature grains
The amount of immature paddy grains in a sample has a major affect on
head rice yield and quality. The immature rice kernels are very slender and
chalky and this results in excessive production of bran, broken grains and
brewer’s rice. The optimal stage to harvest grain is at about 20-24% grain
moisture or about 30 days after flowering. If the harvest is too late, many
grains are lost through shattering or dry out and are cracked during
threshing, which causes grain breakage during milling
Damaged grains
Paddy deteriorates through biochemical change in the grain, the
development of off-odours and changes in physical appearance. These
types of damage are caused from water, insects, and heat exposure.
Yellowing
Yellowing is caused by over-exposure of paddy to wet environmental
conditions before it is dried. This results in a combination of
microbiological and chemical activity that overheats the grain. These
fermented grains frequently possess partly gelatinized starch cells and
generally resist the pressures applied during grain milling. While the
presence of fermented grain does not affect milling yields it does
downgrade the quality of the milled rice because of the unattractive
appearance.
Insect- or mould-damaged grains can be distinguished by the presence of

black spots around the germ end of the brown rice kernel which are caused
by the microorganisms, insects, or a combination. Mould damage in
particular is increased by unfavourable weather conditions. In the process
of milling, these black spots are only partly removed which consequently
increases the presence of damaged grains.
7.2.1.2. Quality characteristics of milled rice :
The quality characteristics of milled rice are classified both physically, and
chemically.
Review the following terms before reading about physical and chemical
characteristics of milled rice:
• Paddy or rough rice = similar term for paddy, or rice retaining its husk
after threshing
• Brown rice or husked rice = paddy from which the husk has been
removed
• Milled rice = rice after milling which includes removing all or part of the
bran and germ from the husked rice
• Head rice = milled rice with length greater or equal to three quarters of
the average length of the whole kernel
• Large brokens = milled rice with length less than three quarters but more
than one quarter of the average length of the whole kernel
• Small brokens or "brewers rice" = milled rice with length less than one
quarter of the average length of the whole kernel
• Whole kernel = milled rice grain without any broken parts
• Milling recovery = percentage of milled rice (including brokens) obtained
from a sample of paddy.
• Head rice recovery = percentage of head rice (excluding brokens)
obtained from a sample of paddy.
Physical Characteristics :
Milling degree
The degree of milling is a measure of the percent bran removed from the
brown rice kernel. Milling degree affects milling recovery and influences
consumer acceptance. Apart from the amount of white rice recovered,
milling degree influences the colour and also the cooking behaviour of rice.
Un-milled brown rice absorbs water poorly and does not cook as quickly as
milled rice. The water absorption rate improves progressively up to about
25% milling degree after which, there is very little effect.
Head rice
“Head rice” or head rice percentage is the weight of head grain or whole
kernels in the rice lot. Head rice normally includes broken kernels that are
75-80% of the whole kernel. High head rice yield is one of the most
important criteria for measuring milled rice quality. Broken grain has
normally only half of the value of head rice. The actual head rice
percentage in a sample of milled rice will depend on both varietal
characteristics (i.e. the potential head rice yield), production factors, and
harvesting, drying and milling process. In general harvesting, drying, and
milling can be responsible for some losses and damage to the grain.
Whiteness
Whiteness is a combination of varietal physical characteristics and the
degree of milling. In milling, the whitening and polishing greatly affect the
whiteness of the grain. During whitening, the silver skin and the bran layer
of the brown rice is removed. Polishing after whitening is carried out to
improve the appearance of the white rice. During polishing some of the
bran particles stick to the surface of the rice which polishes and gives a
shinier appearance.
Chalkiness
If part of the milled rice kernel is opaque rather than translucent, it is often
characterized as “chalky”. Chalkiness disappears upon cooking and has no
effect on taste or aroma, however it downgrades milled rice. Excessive
chalkiness is caused by interruption during the final stages of grain filling.
Though chalkiness disappears upon cooking and has no direct effect on
cooking and eating qualities, excessive chalkiness downgrades the quality
and reduces milling recovery.
Chemical characteristics :
Gelatinization temperature
The time required for cooking milled rice is determined by gelatinization
temperature or GT. Environmental conditions, such as temperature during
ripening, influence GT. A high ambient temperature during development
results in starch with a higher GT. GT of milled rice is evaluate by
determining the Alkali spreading value. In many rice-growing countries,
there is a distinct preference for rice with intermediate gelatinization
temperature.
Amylose content
Starch makes up about 90% of the dry matter content of milled rice. Starch
is a polymer of glucose and amylose is a linear polymer of glucose. The
amylose content of starches usually ranges from 15 to 35%. High amylose
content rice shows high volume expansion (not necessarily elongation) and
high degree of flakiness. High amylose grains cook dry, are less tender, and
become hard upon cooling. In contrast, low-amylose rice cooks moist and
sticky. Intermediate amylose rice are preferred in most rice-growing areas
of the world, except where low-amylose japonicas are grown.
Based on amylose content, milled rice is classified in “amylose groups”, as
follows:
• waxy (1-2% amylose),
• very low amylose content (2-9% amylose),
• low amylose content (10-20% amylose),
• intermediate amylose content (20-25% amylose) and
• high amylose content (25-33% amylose).
Amylose content of milled rice is determined by using the colorimetric
iodine assay index method.
Gel consistency
Gel consistency measures the tendency of the cooked rice to harden after
cooling. Within the same amylose group, varieties with a softer gel
consistency are preferred, and the cooked rice has a higher degree of
tenderness. Harder gel consistency is associated with harder cooked rice
and this feature is particularly evident in high-amylose rice. Hard cooked
rice also tends to be less sticky. Gel consistency is determined by heating a
small quantity of rice in a dilute alkali.
7.2.1.3. Paddy quality determination :
Collect two samples of approximately 500 grams of fresh paddy, and

determine the following characteristics by following the procedures as
outlines above. Use the sheet to record your findings
• Moisture content (oven method, and moisture meter)
• Grain dimensions (L/W ratio)
• Dockage-weeds
• Dockage-inert matter
• Insects (dead, alive)
• Cracked grains
• Unfilled or immature grains
• Discoloured and damaged grains
• 1000 kernel weight
Sheet exercise: Quality of paddy or rough rice
7.2.1.4. Procedures for measuring quality of paddy grain :
Crack Detector
Using the Paddy Crack Detector, count the numbers of cracked grains in a
100 grain sample then compute the % cracked grains using the equation:
Grain Dimensions
Using a calliper or photographic enlarger, collect 20 paddy samples at
random from each replicate and measure the dimensions to obtain the
average length and width of the paddy grains. To obtain the paddy shape,
the following equation can be used:
Immature Grains
Select a 25 gm grain sample and select, segregate and weigh the immature
grains in sample. Calculate the percentage immature grains in the sample
using the formula:
Dockage in Paddy
Remove light foreign matter, stones, weed and seeds from a 100gm sample.
Obtain the total weight then compute the dockage percentage as follows:
1000 Kernel Weight

Determined by counting and weigh 1,000 grains (paddy).
7.2.1.5. Procedures for measuring quality of milled rice :
Milling degree
Milling degree is computed based on the amount of bran removed from the
brown rice. To obtain the weight of brown rice, de-hull the paddy samples
using the Laboratory Huller. Estimate the percent milling degree using the
following equation:
Milling recovery
Using the Abrasive Whitener, mill the de-hulled samples. Compute milling
recovery by dividing the weight of milled rice recovered by the weight of
the paddy sample, as follows:
Dockage in Milled Rice

Select, segregate and weigh the foreign matter. Record the number of un-
hulled grains collected from the sample. Determine the percentage of
dockage of milled rice using the equation:
Broken grain
Using the Grain Grader, separate the broken grain from the whole grains.
Compute the percentage of the head rice and brokens using the following
equations:
Chalkiness
A visual rating of the chalky proportion of the grain is used to measure
chalkiness based on the standard Evaluation System SES scale presented
below:
Select, segregate and weigh the chalky grains (SES Scale 9). Determine the
% chalky grain using the equation:
Whiteness
Measure the grain whiteness using the Whiteness Meter. Separate and
weigh yellow-fermented grains. Calculate the percentage of
yellow/fermented grains using the formula:
Grain Shape
Follow the procedure of determining grain shape of paddy. Based on the
length to width ratio, theshape of the milled rice will be determined. L/W
ration is given by:
The ISO Classification is as follows:
1000 grain weight

Count and weigh 1,000 whole grains.
Amylose content
Select twenty grains and ground them in a Cyclone Mill. Amylose content
is analyzed using the simplified iodine colorimetric procedure. Samples are
categorized into low, intermediate and high based on the following
grouping:
Gelatinization temperature (GT)

GT is measured by determining the alkali-spreading value for which the
alkali digestibility test is employed. Grains are soaked in 1.7% KOH and
incubated in a 30 0C oven for 23 hours. Measurement ranges are based on
the following: Gelatinization temperature is estimated by the extent of
alkali spreading and clearing of milled rice soaked in 1.7% KOH at room
temperature or at 39 0C for 23 hours. The degree of spreading is measured
using a seven-point scale as follows:
1. grain not affected
2. grain swollen,
3. grain swollen, collar incomplete and narrow,
4. grain swollen, collar complete and wide,
5. grain split or segmented, collar complete and wide,
6. grain dispersed, merging with collar, and
7. grain completely dispersed and intermingled.
Gel consistency
Select from two to 10 grains and ground separately in the Wig-L Bug. Gel
consistency is measured by the cold gel in a horizontally-held test tube, for
one hour. Measurement ranges and category are as follows:
7.2.1.6. Standards and grades for milled rice :
Standards can be defined as a quantitative way by which we measure and

compare certain quality characteristics. This measured comparison of
recognizable quality characteristics can be described as ‘grading’.
To date, there are few universally accepted international standards for

paddy and milled rice. This is primarily due to a difference in emphasis on
the importance of grading paddy and milled rice quality among countries.
However, national standards exist and are being used as a marketing basis.
In general, grading factors for paddy are (1) purity, (2) foreign matter, (3)
defectives and (4) moisture content.
For milled rice, the characteristics considered for grading are (1) head rice,
brokens and brewers percentages (2)defects, (3) foreign matter, (4) presence
of paddy and (5) moisture content.
Objectives of establishing standards and grades

1. to ensure only edible rice reaches the consumer;
2. to improve postharvest practices so as to eliminate or reduce waste;
3. to improve agronomic practices to increase farm yields;
4. to improve processing practices for better milling recoveries and for
market expansion and
5. to protect consumers from price/quality manipulation.
In relation to the first objective, the characteristics such as moisture content,

foreign material, seeds and discoloured (damaged) grains are important
considerations in assuring that only edible rice reaches the consumers. By
setting standards for degree of milling, broken rice content, moisture and
damaged grains, the second objective is addressed. Better threshing and
drying, and improved storage facilities are expected to emerge to meet the
required standard. The third objective provides incentives to the
farmer/agricultural scientist to optimize production by considering
standards for chalkiness, varietal purity, foreign seeds, immature grains
and red rice. The fourth objective provides a measure of the miller’s success
in delivering high milling recovery and allowing the market expansion.
Characteristics considered are standards for degree of milling, broken rice,
paddy kernels and foreign matters. Finally, standards which clearly
identify to consumers the true value of their purchases will provide the
protection required against the possibility of unfair trading practices.
7.2.1.7. Comparison of rice mill output :
Select a homogenous sample of paddy and run trials with different

husking/whitening/polishing equipments.
Input results using the sheet. Make a comparative analysis of the results
obtained.
• Moisture content
• Head rice percentage
• Brokens
• Chalkiness
• Whiteness
• Milling degree
• Heat damaged/discoloured grains.
Quality of milled rice
Grade the milled rice samples based on the National standards of milled
rice in the Philippines. Take recommendations on improving the paddy
and rice grade.
7.2.1.8. Testing of a rice mill for performance and quality :
Visit a rice mill and sample the paddy before milling, brown rice after
husking and the milled grain after processing. At the same time, monitor
the performance of the rice mill by collecting the outputs from all of the
outlets from the mill over a given time period.
The following samples need to be collected and weighed at the rice mill
• Head rice
• Course brokens
• Fine brokens
• Brewers rice
• Course bran
• Fine bran (“meal”)
• Husk.
Time
Samples will be collected for 10 minutes from each outlet. An open woven
bag will be necessary to collect the husk.
Weighing
Use the miller’s scales.
Sub-sampling
Sub samples will be taken from each of the outlets so that they can be
analyzed in the laboratory.
Sampling times
Sampling times will depend on the capacity of the mill. A good benchmark
is to collect from each outlet for at least 10 minutes.
Expected outputs
A good quality mill will produce 55% head rice, 15% brokens, 10% bran
and 20% husk, all on % paddy weight basis
Sampling outputs
Collect a grain sample from the paddy, brown rice and from all stages of
the process.
Check the list.
Make an assessment of where in the rice mill improvements could be made

to improve the milling output.
7.2.2. Insects & Rodents :
A. Insects :
Insects in stored rice can be classified into three groups according to their
feeding habits namely internal feeders, external feeders and scavengers.
i. Internal Feeders
These are insects whose larvae feed entirely within the kernels of the grain.
These include rice weevil, angoumois grain moth and lesser grain borer.
Rice Weevil (Sitophilos oryzae (Linnaeus)): Adults and larvae feed on a wide
variety of grains. Female deposits a single egg in the grain by boring a hole
inside. The egg stays in the grain until it becomes an adult thus making the
grain completely damaged.
Angoumois Grain Moth (Sitatroga cerealella (Olivier)): Eggs are laid on or

near grain. The white larvae bore into the kernels of the grain and feed on
the inside. When mature, the larvae eat its way to the outer portion of the
grain, leaving only a thin layer of the outer seed coat intact. Pupation takes
place just under the seed coat. When the adult emerges from the grain, it
pushes aside the thin layer of seed coat leaving a small trap door covering
its exit point from the kernel. They infest only the surface layer of bulk-
stored grain, adults are unable to penetrate deeply.
Lesser Grain Borer (Rhyzopertha dominica (Fabricus)): The eggs are laid in
the grain mass and larvae may enter the kernels and develop within or,
they may feed externally in the flour-like dust that accumulates from the
feeding of the adults and their fellow larvae.
ii. External Feeders

External feeders are insects that feed from the outside of the grain even
though they may chew through the outer coat and devour the inside.
Cigarette or Tobacco Beetle (Lasioderma serricorne (Fabricius)): Feeds on

books, flax tow, cottonseed meal, rice, ginger, pepper, dried fish, crude
drugs, seeds, pyrethrum powder, and dried plants.
Flat Grain Beetle (Cryptolestes pusillus (Schonherr)): The female places her
eggs loosely in the grain mass. The larvae and adults are able to penetrate
the seed coat of the undamaged grain.
iii. Scavengers
Scavengers feed on the grain only after the seed coat has been broken either
mechanically or by some other insect.
Saw-toothed Grain Beetle (Oryzaephilus surinamensis (Linnaeus)): Eggs are

usually laid, either singly or in small masses, in a crevice in the food supply
but in items like flour, they are laid freely.
B. Rodents :
Rodents are characterised by their teeth. They have a pair of incisor teeth in
the upper and lower jaws. The incisors are curved inwards and have an
extremely hard anterior coating. The softer inside layer is worn down
much more rapidly than the hard, outer layer. This means that the teeth are
continually kept sharp, enabling them to damage even materials such as
masonry and electric cables. The incisors do not stop growing. This means
that the animals are forced to gnaw steadily in order to wear them down.
The three most important rodent species are:

• Black rat or House rat (Rattus rattus)
• Common rat (Rattus norvegicus)
• House mouse (Mus musculus).
Storage Hygiene and Technical Measures
• Keep the store absolutely clean. Remove any spilt grain immediately as it
attracts rodents.
• Store bags in tidy stacks set up on pallets, ensuring that there is a space of
all round the stack.
• Store any empty or old bags and fumigation sheets on pallets, and if
possible in separate stores.
• Keep the store free of rubbish in order not to provide the animals with
any places to hide or nest. Bum or bury it.
• Keep the area surrounding the store free of tall weeds so as not to give
the animals any cover. They have an aversion to crossing open spaces.
• Keep the area in the vicinity of the store free of any stagnant water and
ensure that rainwater is drained away, as it can be used as source of
drinking water.
7.2.3. Husk problem :
All over the world the discharge of the husk accruing in the numerous rice
mills causes a serious environmental problem. This agricultural waste
however has a significant calorific value and a high percentage of
amorphous silica.
With an innovative technology these favourable characteristics of rice husk
will be used for solving the environmental problems and at the same time
producing electricity and high value industrial products.
7.2.3.1. Green technology :
A new processing technology for production of silica using as feedstock

rice husk from rice milling process is developed.
Processing technology consists of a rice husk fired power plant and a

chemical plant, producing from the rice husk ash high value industrial
substances, namely liquid sodium silicate, precipitated silica and activated
carbon.
7.2.3.2. Feedstock :
Rice husks makes up about 20% of the rice (paddy) weight. The rice millers
world-wide therefore should generate more than 100 million tons of rice
husks. Nowadays almost 70% of the rice husks are not commercially used.
Using one of the world´s major agriculture products - rice - as primary
feedstock and avoiding disposal of either
• rice husks which are difficultly biodegradable or
• ash from combustion of rice husks
makes the Technology “Green” and is able to solve a huge environmental
problem in the cluster as well as all over the world.
According to international estimates the rice demand by 2020 will growth
to 780 million tons. Because the rice growing areas can’t be dramatically
extended the rice harvest from one hectare shall increase from actual 5 tons
to 12 tons by means of new improved rice seeds.
7.2.3.3. Preparation of feed stock :
• During rice milling approximately 70% of the raw rice is processed to

“white” rice.
• Rice husks which are about 20% of raw rice are shelled, separated and
stored in storage silos.
• The bran from rice polishing, which is about10 % of the raw rice is
separated and most commonly used for animal feed.
All these processing steps are executed in classic rice mills all over the
world.
7.2.3.4. Rice husk processing plant :
Now the rice husks from various

rice mills are collected and will be
transported to the Rice husk
processing plant.
Unloading will be done
pneumatically or with gravity
flow and excavators to
intermediate silos. Before entering
the silos impurities are separated
by means of a riddle screen.
Afterwards the husks are ground
and fed to storage silos.
The caloric value of about 14
MJ/kg of the rice husks represents
about 35% of the caloric value of
diesel or bunker oil with a caloric
value of 40.5 MJ/kg.
7.2.3.5. Combustion and power generation unit :
A special rice husk combustion

unit generates steam and the rice
husk ash is separated in hoppers.
The main part of the steam is feed
into a steam turbine-generator set
which generates electric energy.
Electric energy is either partly

used for the rice mill if it is located
nearby and for the rice husk
processing plant. The main part of
electric energy is sold to the public
grid and is a valuable product of
the plant.
Depending on the combustion technology and process parameter rice husk

ash with more or less carbon content (5% - 40 %) can be produced. The
other components of the ash are amorphous silica and a small amount of
crystalline silica as well as some inerts.
The ash is collected from the several hoppers and the flue gas filters of the
combustion unit and is stored in storage silos.
The lay-out of such unit is shown below :
7.2.3.6. Liquid Sodium Silicate and Activated Carbon Production
Rice husk ash is first digested with caustic soda and then filtered. In the
filter diluted liquid sodium silicate is separated from unwashed carbon
filter cake.
The diluted liquid sodium silicate is fed to storage tanks while the carbon
cake in the filter is washed and chemically cleaned before dried in the
drying section.
The special serial dryers allow the
production of powdered activated
carbon with a residual water
content of about 8%. The
powdered activated carbon is
screened and stored in storage
silos. For distribution of activated
carbon packing in bags of various
sizes is executed in the packing
unit. The liquid sodium silicate
(~24% silicate) can be sold as
commodity chemical in tank-
tainers or trucks.
7.2.3.7. Precipitated Silica Production :
Liquid sodium silicate is processed with acid and filtered. The filter
separates a diluted sodium sulphate (Glauber’s salt solution) and the wet
silica product. The salt solution can be evaporated or fed to a reverse
osmosis and solid salt is produced as valuable by-product.
The wet filter cake is finally washed and fed to the drying unit. With
special dryers a precipitated silica product with about 8% water content is
produced.
The precipitated amorphous silica powder is screened and stored in
storage silos. For distribution of silica products packaging in bags of
various sizes is executed in the packing unit.
7.2.3.8. Main Applications of the Products :
Precipitated Silica:
Typical properties of our products:
BET surface area 205-290 m2/g (gas adsorption), DBP oil absorption
170-240 ml/100g
• Rubber reinforcement
• Solar panels
• Plastic reinforcement
• Agriculture (animal food)
• Food, healthcare, cosmetics
• Catalyst; Coatings
• Pulp and Paper processing
• Detergents and soaps
• Adsorbents
• Anticaking agent for packing
Activated carbon:
• Food and beverages (decolouring)
• Pharmaceuticals
• Water purification
• Sweetener
• Solvent recovery
• Air purification
Liquid Sodium Silicates:

Weight ratios of SiO2 to Na2O from 1.6 to 3.3
• Detergents and cleaning compounds
• Adhesives & cements
• Paints& coatings
• Pulp & Paper processing
• Ceramics & binders
• Water treatment
• Textile processing
• Mining & mineral processing
• Petrochemical processing
7.3. Water re-utilisation :
7.3.1. Boilers/boiler house :
Problem areas: Solutions :

i. Reverse osmosis/de
i. Scaling and corrosion mineralization
ii. Bio-fouling ii. Softening & filtration
iii. High operation cost iii. Recycling water
iv. High maintenance cost iv. Chemical dosing & pH
v. Reduced equipment life controllers
vi. High water consumption.
7.3.2. Cooling towers :
Problem areas: Solutions :

i. Reverse osmosis/de
i. Scaling and corrosion mineralization
ii. Bio-fouling ii. Softening & filtration
iii. High operation cost iii. Recycling water
iv. High maintenance cost iv. Chemical dosing & pH
v. Reduced equipment life controllers
vi. High water consumption.
7.3.3. Drinking water :
Problem areas :
Solutions :
i. Foul taste & odour
ii. Dissolved salts i. Reverse osmosis
iii. Microbiological ii. UV systems
contamination iii. Filtration
iv. Chlorine levels iv. Ultra-filtration
v. Organic contaminants v. Pressure boosting
vi. Low water pressure
7.3.4. Water recycling :
Problem areas :
Solutions :
i. Waste water from back-
wash of boilers i. Re-cycling water
ii. Waste water from backwash
of boiler-house ii. Sewage treatment plant
iii. Waste water from par-
boiling iii. Effluent treatment plant
iv. Softener backwash
7.3.5. Water treatment in rice mill :
A model set-up of a rice mill having water recovery and re=cycling system
is shown here :
8. Optimal Design of a Rice Mill Utility System with Rice Husk
Logistic Network :
Abstract :
Thermal energy for drying and electricity for milling operations typically
comprise a significant 55% of a rice mill operating cost. Optimal design of
rice mill utility system that efficiently utilizes rice husk biomass has
potential to increase profitability of rice milling industry. This paper
presents a mathematical approach for simultaneous optimal planning of
rice husk logistic network as well as optimal design of a rice mill utility
system that efficiently utilizes rice husk supplied from various locations in
order to satisfy the electricity and drying requirements of the rice mill
throughout the year. A mixed integer linear programming (MILP) problem
was formulated to determine: (1) the optimal logistic network for the rice
husk supply, (2) the economic scale of the rice husk cogeneration system,
and (3) an optimal utility supply network for a series of dryers consisting
of a combination of cyclonic husk furnace (CHF) and cogeneration systems.
NOMENCLATURE :
Subset :
b = biomass boiler and turbine with different performance parameter

capacity
c = CHF with different performance parameter and capacity
i = inclined bed dryer i
j = rice husk from internal rice mill j
k = rice husk from external rice mill k
f = fluidized bed dryer f
t = period
Variable :
ACCOSTBb = annualized capital cost of biomass boiler b (RM/year)

ACCOSTCc = annualized capital cost of CHF c (RM/year)
ACRHJj = annual transportation of rice husk from internal rice mill j (t/yr)
ACRHKk = annual transportation of rice husk from external rice mill k
(t/yr)
AElecO = annual electricity required from outsources (MWh)
ElecGBbt = electricity generated from condensing extraction turbine b at
period t (MWh)
ElecDt = electricity demand at period t (MWh)
ElecGt = electricity generated at period t (MWh)
ElecOt = electricity required from outsources at period t (MWh)
HPbt = HP steam from boiler b to condensing extraction turbine b at period
t (t/h)
HEATCFcft = heat supplied by CHFc to FBDf at period t (MJ/h)
HEATCHFct = heat supplied by CHFc at period t (MJ/h)
HEATCIcit = heat supplied by CHFc to IBDi at period t (MJ/h)
HEATLPIit = heat supplied by LP stream at period t (MJ/h)
HEATMPFmt = heat supplied by MP stream at period t (MJ/h)
LPbt = LP saturated steam extracted from condensing extraction turbine b
period t (t/h)
LPCt = LP saturated steam extracted from condensing extraction turbine b
to cooling tower at period t (t/h)
LPIit = LP saturated steam extracted from condensing extraction
turbine b to IBD coil at period t (t/h)
MPbt = MP saturated steam extracted from condensing extraction turbine b
at period t (t/h)
MPDt = MP saturated steam extracted from condensing extraction turbine
b to d internalstream process at period t (t/h)
MPFft = MP saturated steam extracted from condensing extraction turbine
b to FBD coil at period t (t/h)
RHt = amount of rice husk consumed at period t (t/h)
RHBbt = amount of biomass feed into boiler b at period t (t/h)
RHCct = amount of rice husk feed into CHF c at period t (t/h)
RHJjt = amount of rice husk transfer from internal rice mill j at period t
(t/h)
RHKkt = amount of rice husk transfer from external rice mill k at period t
(t/h)
Binary variables :
YOBbt = binary variable in operating biomass boiler b at period t

YOCct = binary variable in operating CHF c at period t
YPBb = binary variable in purchasing biomass boiler b
YPCc = binary variable in purchasing CHFc
Parameter :
AARHJi = annual available RH at internal rice mill j (t/yr)

AARHKk = annual available RH from external rice mill k (t/yr)
BElecDt = basic electricity demand of drying equipment and office
accessories at period t (kWh)
CCOST = capital cost of equipment (RM)
CCRH = calorific value of rice husk (MJ/t)
EFFFC = efficiency of FBD coil
EFFIC = efficiency of IBD coil
ElecBBbt = electricity requirement of biomass boiler and turbine b at period
t (kWh)
ElecCHFct = electricity requirement of CHF c at period t (kWh)
ElecFft = electricity requirement of FBD at period t (kWh)
ElecIit = electricity requirement of IBD at period t (kWh)
Electariff = electricity tariff (RM/MWh)
ENBBb = enthalpy change across biomass boiler (MJ/t)
ENLPb = enthalpy change between HP and LP across condensing
extraction turbine b (MJ/t)
ENMPb = enthalpy change between HP and MP across condensing
extraction turbine b (MJ/t)
ENFBD = enthalpy change of MP across FBD (MJ/t)
ENIBD = enthalpy change of LP across IBD (MJ/t)
HEATFft = required heat of FBD at period t (t/h)
HEATIit = required heat of IBD at period t (t/h)
LWBBb = lower bound of biomass boiler b (t/h)
LWCHFc = lower bound of CHFc (t/h)
LWLPb = minimum extraction rate of LP stream at turbine b (t/h)
LWMPb = minimum extraction rate of MP stream at turbine b (t/h)
n = life span of equipment (year)
PCRHKk = purchase cost of rice husk from external rice mill k (RM/t)
Periodt = duration of period t (h)
r = interest rate
TCRHJj = transportation cost of rice husk from internal rice mill j (RM/t)
TCRHKk = transportation cost of rice husk from external rice mill k (RM/t)
UPBBb = upper bound of biomass boiler b (t/h)
UPCHFc = upper bound of CHF c (t/h)
Year = operating hours in a year (h)
ηBBb = efficiency of biomass boiler
ηCHFc = efficiency of CHF
ηTURBb = efficiency of condensing extraction turbine b
9.1. Introduction :
Rice milling companies often operate at marginal profit due to energy-

intensive drying and milling operations that contribute to the high
operating costs of rice processing. Thermal energy for drying and
electricity for milling operations typically comprise a significant 55% of a
rice mill operating cost. To effectively reduce operating costs and increase
profitability while satisfying the electricity and drying needs of a rice mill
at appropriate times of the year, it is vital to design an optimal rice mill
utility system that efficiently utilizes rice husk as the main by product of
rice milling and an important source of renewable energy.
Rice husk typically amounts to between 22 and 24 wt % of the total paddy

input. Its moderate heating value between 3000 and 3500 kcal/kg allows
rice husk to be utilized in rice mill for power generation, for cogeneration
system, and most extensively, for paddy drying. For the latter, rice husk is
typically combusted in a cyclonic husk furnace (CHF) to produce hot gas
for paddy dryers. It was reported that 20 kg of husk can generate 60 000 -
70 000 kcal heat, enough to reduce the moisture content of 1 ton of paddy
from 20 - 14%.
Rice husk has also been widely used as a fuel for cogeneration system,
which must be designed with the flexibility to supply electricity for rice
milling operations throughout the year, and heat for dryers during
harvesting seasons (peak drying period). During the peak drying period, a
cogeneration system should generate electricity for rice mill operations and
provide extensive amount of thermal heat to dry paddy within 72 h of
harvesting in order to preserve its quality. At other times of the year after
the paddy drying season (i.e., during off-peak season), cogeneration should
maximize electricity generation for rice milling.
To date, many studies on optimization of rice processing revolve around

rice milling operations, particularly drying. A few other studies focus on
synthesis and optimization of rice processing plants excluding the utility
system.5 Note that most studies on modelling and optimization of
biomass-based cogeneration system have not considered rice husk logistic
network. Arivalagan et al. made an early attempt to formulate an
integrated energy optimization problem for a cogeneration system. They
present an MILP model to determine the economic optimum energy-mix
for a process plant. Uran modelled a cogeneration system for a wood
processing plant into a multi period problem and identified the lowest heat
capacity and the payback period for the system. Gamou et al. determined
the optimal cogeneration system size to match the energy demand. Their
work however, do not consider biomass logistic network. Caputo et al.9
considered logistic variables in formulating a model to evaluate the
economics of biomass utilization in combustion and gasification plants.
However, the model was not formulated into an optimization problem.
An optimal combination of rice husk-based cogeneration and CHF systems

can offer ample cost-saving opportunities for a rice mill to meet its
electricity and drying demands. However, to maximize the economic
impact of the cogeneration and CHF systems, the following constraints
need to be considered:
(a). Variation of Heat and Power Demands during Different

Periods of the Year
The energy profile of a rice mill with a drying facility varies throughout the
year. During harvesting period which typically last for 30 days in a paddy
growing season, the harvested paddy will be dried to reduce its moisture
content to a level that allows its quality to be preserved for storage, within
72 h of harvesting. This narrow time frame where predominantly thermal
energy is being consumed in dryers is known as the peak drying period.
During this period, electricity is also consumed to operate the rice mill’s
machinery and appliances. The off-peak drying period covers the
remaining duration of paddy growing season outside the 30-day paddy
harvesting and drying periods. During the off-peak season when the
dryers are not operating, energy is mainly consumed in the form of
electricity. A detailed assessment must therefore be made to economically
exploit the marked difference in heat and energy demands during the peak
and off-peak drying periods for the proposed utility system.
(b). Energy Supply Options
Several options can be considered in order to meet the heat and power
demands of an integrated rice mill and drying facility. The heat demand
can be fulfilled by a combination of cogeneration and CHF systems which
utilize rice husk as a source of fuel. From the point of view of thermal
energy requirement, CHF is an attractive option as the large amount of
calorific value available from rice husk combustion can be used to satisfy
the huge quantity of heat required during peak drying season. On the other
hand, cogeneration can supply bulk of the electricity requirement for rice
milling during off-peak season, and supply heat, as well as electricity for
drying and milling operations during peak season. Without a cogeneration
system, the rice mill electricity demand has to be supplied from the
national grid. The efficiency and cost-effectiveness of the various energy
options are vital to consider for an optimal utility systems design.
(c). Rice Husk Supply Limitation.
Rice husk as the main by product of rice milling is an important and easily
accessible source of renewable energy for a rice mill. However, the amount
of rice husk from a given rice mill is typically limited and may not be able
to sustain the heat and power demands of energy intensive milling and
drying operations. Hence, there is a need to transport and purchase rice
husk from other rice mills. The limited amount of rice husk and the
required transportation as well as purchasing costs are key factors to
consider in the design of a rice mill utility system.
Limited supply of rice husk, the rice husk cost as well as logistic cost,
varying heat and power demands during different periods of the year, and
various energy supply options are the key factors influencing the optimal
design of a rice mill utility system. To date, no study has simultaneously
explored all these factors. There is a need to develop a new systematic tool
for the optimal planning and design of a utility system configuration
comprising of cogeneration and CHF systems that considers the logistic
network.
This portion presents a mathematical approach for simultaneous optimal
planning of rice husk logistic network, as well as design of a rice mill utility
system that efficiently utilizes rice husk from various locations to satisfy
the electricity and drying requirements of the rice mill at appropriate times
of the year. To address this problem, here is formulated an integrated
superstructure that consists of all logistics and utility system configurations
of practical interest , transform the superstructure as a mixed integer linear
programming (MILP) problem, and develop an optimal solution
methodology.
9.2. Problem statement :
A rice producing company has planned to install a cogeneration system

within its centralized drying facility which is located in one of its rice mills.
The proposed drying facility is aimed to dry approximately 100 000 tons of
paddy annually. A combination of CHF and cogeneration system shall be
designed to meet the heating requirements of the drying facility and also to
generate power in order to meet some (if not all) of the mill’s electricity
demand. This setup which includes a proper coordination for the rice husk
logistic network is expected to provide ample cost-savings opportunity for
the rice producing company.
As mentioned earlier, the ratio between paddy to be dried (to reduce

moisture content from 20% to 14%) and the required ice husk is around 50:
1. However, the moisture content of paddy collected from the field in a
humid area like Birbhum can reach up to 25%. It is therefore estimated that
4,000 tons of rice husks are required to dry 100,000 tons of paddy, to give a
ratio of 25: 1 between paddy to be dried and the required rice husk in the
case of Birbhum. More rice husks are therefore required to be purchased
and transported from other mills make up for the limited amount of rice
husk being produced by a single rice mill.
Given the different heating and electricity requirements during peak and
off-peak drying seasons for a rice mill, a cogeneration system in operating
conditions, capital cost for various sizes of cogeneration system, distance
between rice husk supply locations and utility system and transportation
cost, the problem consists of simultaneously determining:
(1) The optimal logistic network for rice husk supply
(2) The economic scale of rice husk-based cogeneration system
(3) The optimal utility network configuration
The relevant variables to be determined are the rice husk logistic network
(rice husk transported from other rice mill locations), the cogeneration
system design parameters (size, rice husk consumption, steam flow rate,
electricity generation) and the utility system configuration which consists
of cogeneration and CHF (steam flow rate from cogeneration system and
hot gas from selected CHF units). The proposed utility system’s design
takes into account typical heat losses of operating equipment to the
ambient. The objective is to achieve the required heat and electricity
demands at the minimum total annualized cost of equipment, utilities, and
logistic costs.
9.3. Problem formulation :
Superstructure :
This figure shows a schematic of a rice mill utility system that utilises
rice husk as a fuel. The CHF supplies heat to a dryer system which may
consist of a combination of commonly used dryers including fluidized bed
dryer (FBD) and inclined bed dryer (IBD). Electricity is supplied by the
national grid.
This figure illustrates the proposed superstructure that consists of two

substructures, namely rice husk logistic network and utility system
network. Rice husk is transported from internal rice mills (represented by
subset j) and external rice mills (represented by subset k). The cogeneration
system, CHF, IBD and FBD are represented by b, c, i, and f respectively.
The details for each substructure are explained below:
(a). Rice Husk Logistic Network. Rice husk supply comes from internal
rice mills j, or external rice mills k at various locations. The distance
between rice husk supply locations and the cogeneration facility affects the
transportation cost. The internal rice mills are the rice mills owned by the
company which also operates the cogeneration facility. Hence, the rice
husks from the internal rice mills are free of charge. For the external rice
mill, the rice husk cost must be added on top of the transportation cost.
(b). Utility System. Utility system includes a cogeneration system
(consisting of a boiler and a turbine), a CHF system and electricity grid.
The utility system configuration highly depends on the rice mills heat as
well as electricity demands within a fixed period t. High pressure steam
generated in the boiler is used to drive steam turbine and convert
mechanical energy to electricity. During peak drying period, the exhaust
medium pressure (MP) and low pressure (LP) saturated steams from
turbine are utilized to satisfy the dryers’ heating requirements. However,
during off-peak drying period where there is no heat demand for dryers,
cogeneration can maximize its power output and be the main source of
electricity supply for the rice mill.
9.4. Model formulation :
The proposed linear model is formulated with the following assumptions:
a. Electricity load factor variation is not considered since the machines

and equipment are assumed to operate at full load.
b. The heat loads of the dryers are fixed, by assuming:
i. Moisture content of collected paddy and the targeted moisture
contents are constant.
ii. The dryers operate at full load throughout the peak drying
period.
iii. Temperatures of the dryers are uniform throughout the drying
process.
c. Piping cost for the steam distribution system is assumed negligible in
comparison to equipment cost.
d. No binary variables have been defined for the rice mill locations for
the following reasons:
i. No limit has been imposed on the number of rice mills selected.
ii. Unlike machines or equipments that need to be purchased or
installed, no cost is involved in selecting rice mills. The cost of
rice husk actually depends on the transportation as well as
purchased cost.
9.4.1. Objective function :
The objective of this study is to simultaneously synthesize an optimal

structure of rice husk logistic network, as well as a rice mill utility system,
which includes a cogeneration system and CHF units, aimed at meeting the
rice mill heat and power demands at minimum cost. The minimum total
annual cost function consists of the capital costs for cogeneration system
and for CHF, and the operating costs comprising of electricity,
transportation, and rice husk costs.
f(x) = ΣYPBb(ACCOSTBb)+ΣYPCc(ACCOSTKc)+AElecO(Electariff)+
ΣACRHJj(TCRHJj) + ΣACRHKk(TCRHKk+PCRHk) (1)
1st term : capital cost for cogeneration system.

2nd term : capital cost for CHF.
3rd term : electricity cost.
4th term : rice husk cost from internal rice mill.
5th term : rice husk cost from external rice mill.
The annualized capital cost of equipment is given by
9.4.2. Rice husk demand and supply :
Equation 3 describes the relationship between rice husk demand and

supply. The left hand side of eq 3 states that rice husk supply comes from
internal rice mills (j), as well as external rice mills (k). The right-hand side
of the equation states that rice husk’s demand comprises of CHF and
cogeneration system, which provide the rice mill heat and power demands
within a given period t.
9.4.3. Steam generation from rice husk :
HP steam is
generated when rice husk is burnt as fuel in the boiler. The
amount of HP steam generated depends on the amount of rice
husk burnt, its calorific value, the boiler efficiency and the
enthalpy change across boiler as given by eq 4.
9.4.4. Turbine work output :

The HP steam produced by the
boiler is then extracted as MP and LP steam, as given by eq 5.
The ideal work done by the turbine is the total enthalpy change of
MP and LP steam across the extraction- condensing turbine.
Considering the turbine efficiency (ηTURBb), electricity produced
by the turbine is given by eq 6.
9.4.5. Steam Generation for FBD or Cooling Water :
Equations 7 and 8 show how the MP and LP steam are utilized. The
MP steam extracted from turbine is directed to heat exchanger
coils at the FBD to heat up the dryer air.
The LP steam is directed to IBD heat exchanger coils or to cooling water
system.
The heat supplied to FBD coil by MP steam is dependent on the flow rate
of MP steam, the heat transfer efficiency of FBD coil and the enthalpy
change across FBD coil.
The flow rate of LP steam, the heat transfer efficiency at IBD coil and the
enthalpy change across IBD coil influence the heat supply to IBD coil by LP
steam.
9.4.6. CHF heat balance :
The heat produced by CHF depends on the amount of rice husk fed into it,
the rice husk calorific value and the efficiency of the CHF, as given by eq
11.
The heat produced by CHF is utilized to heat up FBD and IBD dryer air.
The dryer heat requirement of FBD is supplemented by MP steam
extracted from turbine and CHF units.
The IBD heat demand is satisfied by LP steam extracted from turbine and
CHF units.
Electricity is generated by cogeneration system.
Equation 16 is used to calculate the total electricity demand for the rice mill
and drying facilities.
If electricity produced by cogeneration system is insufficient to meet

electricity demand, the additional electricity requirement will be
outsourced from the national grid. Electricity produced from cogeneration
system is related to outsource electricity as follows:
Equation 18 is used to annualize the seasonal requirement of rice husk.
9.4.7. Rice husk availability :
The total annual rice husk transported from each rice mill to the drying
facility must not exceed the annual rice husk availability. This limitation is
described by eq 19.
The following constraints ensure that rice husk transported from each
external rice mill to the drying facility does not exceed the specified annual
rice husk availability.
In the rice processing industry, one season comprises of the peak period
(involve drying) and off-peak period. Equation 21 represents the amount of
annual rice husk transported from internal and external rice mills during
both periods.
9.4.8. Selection of cogeneration system :
An integer variable is assigned to ensure only one biomass boiler is

purchased throughout the periods, as described in eq 22.
9.4.9. Design constraint for cogeneration system :
The hourly steam generated is governed by the boiler capacity, or the

upper bound for boiler steam generation. To ensure boiler operability, a
boiler must be operated above the boiler turndown ratio, which is typically
50% of the boiler maximum capacity. In eq 23, an Integer variable, YPBb is
assigned to design constraints, to ensure the capacity constraint is observed
for the selected boiler.
Equations 24 and 25 ensure that the MP and LP steam from the extraction-
condensing turbine b are bounded by the given minimum extraction rates.
The CHF will only be purchased if only it operates at period t. Note that
there is no limit on the number of CHF to be purchased. This constraint is
formulated as eq 26.
The rice husk consumption in a CHF is bounded by the given minimum
and maximum values for the respective CHF unit, as described in eq 27.
9.5. Conclusion :
The design of an optimal rice mill utility system configuration with

consideration of rice husk biomass logistic network is a complex problem
that involves the trade-offs between various capital and operating costs for
the overall rice mill utility system and its biomass fuel logistic network. By
combining the economics and process data, optimization offers a
comprehensive solution for the plant management to address this complex
problem.
A mathematical approach has been developed for simultaneous optimal

planning of rice husk logistic network, as well as optimal design of a rice
mill utility system that efficiently utilized rice husk from various locations,
to satisfy the electricity and drying requirements of the rice mill at
appropriate times of the year. A mixed integer linear programming (MILP)
problem was formulated to determine the optimum cogeneration system
size, the optimal rice husk logistic network as well as the optimal utility
supply network. Solution to the MILP problem yielded an optimal utility
system configuration consisting of a specified network of rice husk logistic
network, a 15 tons boiler and 8 units of CHFs to satisfy the rice mill heat
and power requirements.
9. Conclusion :
An ideal cluster should be a centre of better eco-friendly environment,

quality production, user friendly workstation and tools with sustainable
practices and processes in the place.
Therefore, there is an urgent need of modernizing the methods and

machinery by new innovations and popularizing the new innovations and
the new techniques of paddy processing such as parboiling, drying,
milling, handling, storage, transport and byproduct utilization to reduce
the substantial losses.

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NEED ASSESSMENT SURVEY REPORT-2012

RICE MILL CLUSTER,

DCS MSME SCHEME

DESIGNER : KAUSTAV RAY MANDAL

I would also thank “Design Clinic Scheme;National Institute of Design ”,

My special thanks to each individual unit member of Birbhum Rice Mill

Interviewee : nineteen rice mills which are selected

5.1. Cluster Information :

Rice is the product

and husk and ash are obtained as byproducts.

Paddy is the only one raw material in this cluster.

The manufacturing process employed in the clusters is continuous and

The milling machines are controlled by a central control panel. A huller, a

The final product is now packaged and exhibited.

5.7.1. Heterogeneity : The major problem faced by the cluster is

5.7.2. Technical : Another common feature of rice milling industry is

A simulation model for system evaluation of a rice mill plant is developed

5.8.2. Model characteristics :

5.8.3. Performance characteristics :

The main performance characteristics of the model to be analysed are

i. Hulling efficiency, milling efficiency and milled rice recovery

Sl. Name of Rice Mill ADDRESS Mobile No. Contact Person

1 R.K. Rice Mill Sukhna 9434001447 Dipak Pramanik

2 Birbhum Agro Product (P)Ltd. Sainthia 9434004537 Goutam Chhajer

3 Sree Kocher Rice Mill ,, 9434021119 Surendra Kocher

4 Chhajer Rice Mill (P)Ltd. ,, 9434017971 Prem Chhajer

5 Kushal Rice Mill ,, 9434021119 Surendra Kocher

6 Swastidipa Rice Mill Angargoria 9434007835 Falguni Laha

7 Bharat tirth Rice Mill Deocha 9434032518 Jagadish Ch. Jash

8 Ma Shanti Agro Food (P)Ltd., Mollarpur 9434003588 Dilip Kr. Agarwala

9 Jay Baba Bakerswar Rice Mill (P)Ltd. ,, 9732009854 Rahul Khaitan

10 Khaitan Rice Mill " 9434001484 Dip Chand Khaitan

11 Suri Rice Mill Suri 9434004059 Chandra Nath Mondal

12 Amarduty Agro Tech (P) ltd " 9434006048 Dilip Pal

13 Jai Balaji Rice Mill ,, 9434000097 Bijoy Choudhury

14 Daulat Ram Industries Dubrajpur 9434032880 Mukesh Kr. Choudhury

15 Bharat Mata Rice Mill " 9434007592 Purushottam Choudhury

16 Birbhum Rice & Gl. Mills ,, 9434014664 Karan Choudhury

17 Satyanarayan Rice Mill Bolpur 9434019171 Biswa Bijoy Ghosh

6.2.1. R. K. Rice Mill, Sukhna.

Sl.No. Problems Type of problem Remarks/Solution

1. Training and skill upgradation

Highly equipped machineries, Good packaging and branding, organized unite.

Expected Yearly Turn Over : Satisfactory.

Sl.No. Problems Type of problem Remarks/Solution

Family business, market demand.

Expected Yearly Turn Over : Under-achievement.

Sl.No. Problems Type of problem Remarks/Solution

Strength : Eager interest, family business, market demand.

Expected Yearly Turn Over : Fluctuation occurs due to seasonal effect.

Sl.No. Problems Type of problem Remarks/Solution

Strength : family business, local consumer.

Expected Yearly Turn Over : Under achievement.

Sl.No. Problems Type of problem Remarks/Solution

Strength : Worker, labour, management.

Expected Yearly Turn Over : under achievement.

Sl.No. Problems Type of problem Remarks/Solution

1. Training and skill upgradetion