logo...indian food industries, dholka, gujarat location 128 tpb parboiling and 32 x 5 tpb dryer apit...
TRANSCRIPT
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LOGO
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All our projects are driven to ensure
time, cost and quality goals are
achieved.
Complete Design, Engineering,
Manufacturing, Erection and
commissioning are executed by
our skilled and resourceful
Professionals.
APIT - Indo US Joint venture is the
World’s Best Paddy Process
Specialists known for its Process,
Innovations, and Technologies.
We are committed towards
Hygienic Process, Nutrition
Preservation and Environment
friendly Products.
INTRODUCTION
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2 4
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I N F R A S T R U C T U R E
Our USA office located at Stuttgart,
Arkansas since from 1997.
We are setting up world class Works
Infra, at KIADB Industrial Area,
Doddaballapur.
Our Works is located at Machohalli,
Magadi Road, Bangalore where our
Process, Electrical, Engineering,
Production, SCM team works.
Our Corporate office is in Solus JainHeights, J. C. Road, Bangalore where ourMarketing and Project team works
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EXPERTISE SOLUTIONS
Ageing of Paddy
JOHN WAYNE
President
ManagerManager
ALLAN DAY
ManagerManager
SANDY LUNA
Manager
Automation System
Parboiled Paddy
Harvested Paddy
Cleaning and Drying systems Vertical
Batch wise and continuous
parboiling systems along with dryers
Accelerated aged rice solution
Recipe intelligence process automation
system
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PRODUCT PORTFOLIO
1 Indigo Batch wise Parboiling and DryingSystem
2 BRIS Continuous Parboiling System
3 Bhatta Gel Cook Station
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4 Indigo Steam Curing System (Accelerated Aged Rice System)
5 Indigo Mixed Flow Recirculation LSU Dryers
6 Automation (Rice Intelligence Process System)
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Vaishnavi Rice Industries(Accelerated Aged Rice)
Mandapeta, Andhra
Pradesh
64 TPB Steam Curing
and 32 x 2 TPB Dryer
1
2
3
4
Bidhatha Agro Industries(Parboiled)
Malda, West Bengal
64 TPB Parboiling
and 32 x 2 TPB Dryer
Indian Food Industries(Parboiled)
Dholka, Gujarat
128 TPB Parboiling and
32 x 5 TPB Dryer
Salam Auto Rice Mill(Parboiled)
Kushtia, Bangladesh
96 TPB Parboiling and 32
x 3 TPB Dryer
TRADEMARK PROJECTS
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PARBOILING PROCESS DESIGN AND APPLICATION VIDEO
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Parboiled Process-
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INDIAN FOOD INDUSTRIES
• IR64
• Basmati Long Grain
Variety
• Parimal
• Katarni
Raw materials to be Processed
Indian Food Industries,
Dholka, Gujarat
Location
128 TPB Parboiling and
32 x 5 TPB Dryer
APIT Infrastructure
12 TPH
Project Size
Satake India
Engineering Pvt. Ltd.
Milling Partners
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Vision
Our Mission
• to overcome challenges
• For least cost of operation
• For cost effective process and
• to achieve complete control on process
MISSION,
VISION &
VALUES
M I S S I O N & V I S I O N
To extensively study and analyze the raw
material, to design most accurate process and
to achieve most desired result
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Quality consistency in every batch.
Uniform color consistency.
Low Cooking quality
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YOUR TITLE
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C H A L L E N G E SF o r P a r b o i l i n g
4High Process
Brokens
3Difficulty in
achieving Golden Yellow Color
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C U S TO M E R R E Q U I R E M E N T S
0%
20%
40%
60%
SUPER WHITE WHITE CREAM GOLDEN YELLOW
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M E T H O D O L O G Y
1) Designing the Process:
The Process is designed based on the customer’s
process requirements (SW/W/C/GY).
• Super White(SW)
• White(W)
• Cream(C)
• Golden Yellow(GY)
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Infrastructure USP Reason
Pre-Hydration System (8 Nos.)
1. Branched Sparger System.
2. Temperature maintaining system
1. Uniform Colour Consistency.
2. Perforations in the branched
sparger system ensures uniform
exposure of steam to each
grain.
S E L E C T I O N O F S T R U C T U R E
F O R P A R B O I L I N G P L A N T
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Infrastructure USP Reason
Hydration System (32 Nos.)
1) Water feeding mechanism
2) Constanttemperature maintaining mechanism
3) Circulation automation
1) Uniform Colour Consistency.
2) Good cooking results.
3) Quality consistency in every batch.
4) Reduction in process brokens.
Bhatta Gel Cook Station (4 Nos.)
1) Branched Sparger System
2) Alternate steaming and tempering zones
1) Uniform Colour Consistency.
2) Perforations in the branched sparger system ensures uniform
exposure of steam to each grain.
3) Highest degree of starch gelatinization that ensures complete
and homogeneous parboiling, to ensure uniformity in colour,
texture and quality of rice.
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InfrastructureMode of
OperationUSP Reason
LSU Dryer (5 Nos.)AUTO
1. V-Port chamber
2. 45 deg inclined Blower
3. Temperature monitoring and maintaining system
1. Facilitates more drying space
2. Uniform drying of grains and reduces steam loss.
3. Monitors drying temperature throughout the process which in turn reduces process broken.
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SL. NO PROCESS PROCESS MODE
1Pre-Hydration System AUTO
2Water feeding, Circulation, drain AUTO
3Bhatta Gel cook process AUTO
4Dryer rotor VFD control
5Dryer (Temperature control) AUTO
M O D E O F O P E R AT I O N
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Super White
PHS
Steam Pressure 3.5 bar
Temperature 100-110 deg
Rotor speed 12-20 rpm
Paddy filling time to hydration tank 15 mins
HS
Temperature 35-40 deg
Soaking Time 10-12 hrs
Resting Time 0 hrPump lps avg. 12-18
GC
Pressure 1.5-2 bar
Temperature 95-100 deg
Rotor speed 8-16 rpm
Dryer
Pressure 5-8 bar
Temperature 140-70 deg
Drying time 8 hrs
Rotor speed 1350-1400 rpm
Process Parameters
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Process Parameters:
White
PHS
Steam Pressure 3.5 bar
Temperature 100-110 deg
Rotor speed 12-20 rpm
Paddy filling time to hydration tank 15 mins
HS
Temperature 40-50 degSoaking Time 5 hrsResting Time 0 hrPump lps avg. 12-18
GCPressure 1.5-2 barTemperature 95-100 degRotor speed 8-16 rpm
Dryer
Pressure 5-8 barTemperature 140-70 degDrying time 8 hrsRotor speed 1350-1400 rpm
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Cream
PHSSteam Pressure 3.5 bar
Temperature 100-110 degRotor speed 12-20 rpm
Paddy filling time to hydration tank 15 mins
HS
Resting time 20 minsSoaking Time 5 hrsTemperature 55-65 degPump lps avg. 12-18
GCPressure 1.5-2 barTemperature 98-102 degRotor speed 8-16 rpm
Dryer
Pressure 5-8 barTemperature 140-70 degDrying time 8 hrsRotor speed 1350-1400 rpm
Process Parameters:
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Golden Yellow
PHSSteam Pressure 3.5 bar
Temperature 100-110 degRotor speed 12-20 rpm
Paddy filling time to hydration tank 20 mins
HS
Resting time 5-6 hrsSoaking Time 6 hrsTemperature 60-80 deg
Pump lps avg. 12-18
GC Pressure 1.5-2 barTemperature 102-108 degRotor speed 8-12 rpm
Dryer Pressure 5-8 barTemperature 140-70 degDrying time 8 hrsRotor speed 1350-1400 rpm
Process Parameters:
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FINDINGS
• Maximum Head Rice Yield (% Out Put Moisture)
• Least Process Brokens
• Best Cooking results
• Increased Water Uptake Ratio
• Volume Expansion Ratio
(In Comparision with Exisiting System)
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Increased water uptake can be achieved by our APIT’S NEW PARBOILING AND DRYING SYSTEM along with automation .The APIT system has 3 stage infrastructure for 3 stage process :
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COOKING RESULTS
12 % Extra water uptake with APIT ‘S New Parboiling and Drying system
Existing system (80% water uptake by paddy )
APIT system (92 % water uptake by paddy )
Water uptake ratio: Water uptake or absorption rate is the increase in volume (w/w) of the kernels after cooking. The weight of rice increases after cooking is due to water absorption by it during cooking process
WATER UPTAKE RATIO : Weight of cooked rice /weight of uncooked rice
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COOKING RESULTS
Quantum of paddy Paddy/Water ratio Cooking yield @Existing system (80% water uptake )
Cooking yield @APIT System (92% water uptake )
Extra yield
1 Kg 1:2 1.6 Kg 1.8 Kg 0.2 Kg
1 Kg 1:2.5 2 Kg 2.3 Kg 0.3 Kg
1 Kg 1:3 2.4 Kg 2.7 Kg 0.3 Kg
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COOKING RESULTS
BENEFITS OF APIT’S PARBOILING AND DRYING SYSTEM
• Increased cooking yield
• Optimum cooking time
• Strengthening of kernel(cooked) integrity
•Increase in elongation ratio
• Reduced percentage soluble leached material
•Increased volume expansion ratio
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With the help of our APIT’S New Parboiling and Drying system Indian Food Industries achieved 6 COLORS OF RICE
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OUTPUT RESULT(BROKEN PERCENTAGE )
0%
2%
4%
6%
8%
10%
12%
14%
16%
18%
20%
EXISTINGPLANT
APIT
NO OF BROKENS( BASMATI VARIETY )
EXISTING PLANT
APIT
With APIT new Parboiling and Drying system
there is reduction of 2
% process
broken
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Accelerated Aged Rice
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VAISHNAVI RICE INDUSTRIES
• Jaya
• Surekha
Raw materials to be Processed
Mandapeta, Andhra
Pradesh
Location
64 TPB Steam Curing and 32
x 2 TPB Dryer
APIT Infrastructure
8 TPH
Project Size • Buhler India Pvt. Ltd.
• Milltec Machinery Pvt. Ltd.
• Satake India Engineering Pvt.
Ltd.
Milling Partners
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Vision
Our Mission
• to overcome challenges
• For least cost of operation
• For cost effective process and
• to achieve complete control on process
MISSION,
VISION &
VALUES
M I S S I O N & V I S I O N
To extensively study and analyze the raw
material, to design most accurate process
and to achieve most desired result
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Process Brokens
Uniform color consistency.
Chalkiness in grains
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C H A L L E N G E S
4Increased Rejection
Percentage
3 Blast Grains
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C U S TO M E R R E Q U I R E M E N T S
0%
10%
20%
30%
40%
50%
60%
70%
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M E T H O D O L O G Y
1) Designing the Process:
The Process is designed based on the customer’s
process requirements (SW/W/C/GY).
• Super White(SW)
• White(W)
• Cream(C)
• Golden Yellow(GY)
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S E L E C T I O N O F S T R U C T U R E
For Steam Curing Plant
Infrastructure USP Reason
Bhatta Gel Cook (2 Nos.)
Branched Sparger System
1) Uniform Colour Consistency.
2) Perforations in the branched sparger system
ensures uniform exposure of steam to each and
every grain.
3) Highest degree of Thermal treatment that
ensures complete and homogeneous Ageing, to
ensure uniformity in colour, texture and quality of
rice.
Tempering Bins (4 Nos.)
- 1) To achieve the desired output colour which depends on the age of the paddy.
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MODE OF OPERATION
SL. NO. PROCESS PROCESS MODE
1 Bhatta Gel Cook process Complete Auto
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Process Parameters:
1 FIFO Time 8/10/12 mins
2 Thermal Seasoning time 30/45/60/90/120 mins
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AGEING TABLE
Age of paddy 0 1 2 3
APIT steam curing system
12.5% 12.5% 13% 13.5 % Optimum ageing moisture
Existing system 9.5 % 10% 10.5 % 11% Optimum ageing moisture
Moisturedifference (%)
3 % 2.5 % 3.5 % 2.5 % Optimum ageing moisture
FINDINGS
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