Being a deficit State in the production of paddy and rice, the most modern concepts of rice processing and milling has become highly inevitable to increase the productivity. Lack of modern rice processing and milling techniques has resulted in low out turn and losses due to pests, animals, insects and pilferage are also seen very high.

As a result, the millers with the encouragement from the Government have turned up their minds to seek improved methods of milling to avoid the drawbacks of traditional milling. The quality of the rice produced in modern rice mills is marvelous and will be free from dust, mud balls, immature black rice and other foreign materials.

The next advantage, which adds to the feasibility of the modern rice-milling concept, is that it can operate during any season. Both the consumers and the entrepreneurs are benefited with the introduction of modern rice mills. The former is benefited with the availability of fresh products throughout the year and the latter is benefited because they will be able to derive income throughout the year. The traditional par boilers cannot operate during the rainy season and the promoters of modern rice mills are benefited.

The manufacture of rice starts with the procurement of paddy either from the farmers or from the dealers. We try to procure paddy mostly from the farmers directly during the harvesting season. The harvesting season may vary from place to place. The promoters take keen interest to procure the best quality paddy, which will only give good quality rice. Paddy is also procured from the dealers both from the State of Kerala and other States like Tamilnadu, Pondicherry, Karnataka, Andra Pradesh and Madhya Pradesh.


Since Kalady is the main centre for the marketing of both paddy and rice, the paddy produced in the different States will reach the market at Kalady to cater the various rice milling units located in Kalady area and it's suburbs. The paddy procured is kept in the godown according to their quality and the consumption is made according to the requirement of the consumers.

PLANT, MACHINERY AND MANUFACTURING PROCESS OF RICE


The manufacture of rice from paddy is done in three stages, the par boiling, drying and milling of paddy to make rice and rice bran.

The first part of the machines consists of the raw paddy cleaners, destoner and dust blowers. The raw paddy is taken to the first paddy cleaner machine and destoner machine through the dust blower, where the dust, stones and immature paddy is removed.

This is then taken to the paddy cleaner machine, where the dust, mud balls and immature paddy is also removed. This is again cleaned to make it completely free from the above foreign materials. Unless the paddy is cleaned well, the rice produced out of such paddy will be of inferior quality. The cleaned paddy is taken to the paddy storage tanks through an elevator, where it is soaked in water to remove the immature paddy completely. The soaked paddy is then taken to the par boiling tanks through a metal chute.

The paddy is boiled to the required level in the par boiling tank using the steam produced by the boiler machine. The boiler machine is fired using the paddy husk produced during the production process. The boiled product is then taken to the paddy drier machine through a conveyor system, where it is dried using the hot air produced by the boiler machine. We take utmost care in maintaining the quality of the products manufactured by us. For the above, we give maximum care to maintain the hygienic conditions both inside and outside the factory premises and in every stage of production for ensuing the quality of the products manufactured.

The second part of the machinery is the drier machine, which consists of the drying plant, heat exchanger and blower. The steam produced by the boiler machine is used for drying the paddy in the drier machine. Steam consists of both water content and heat content. The water content in the steam is separated using a heat exchanger machine, and the heat content is transferred to the paddy drier machine, where the paddy is dried to the required level in eight hours time.

The boiled paddy is taken to the drying part of the machine through an elevator attached to the drier machine. The flow of paddy in the drying part of the machine is controlled by a filtrol, which gets direct drive from an electrical motor through a gear box. 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, which consists of a paddy cleaner, rubber sheller, three cone polishers, bran blower and separator, a destoner machine and a vibrator machine. The paddy is being cleaned and the impurities are removed even while the drying process is going on in the drier machine.

The dry paddy is then taken to the paddy cleaner machine, through an elevator, where it is cleaned once again. The cleaned paddy is taken to the rubber sheller machine through another elevator , where the paddy husk is removed. The paddy husk is collected in a separate room and this is used as the fuel for firing the boiler machine. Normally the paddy husk produced during the production process will be sufficient as fuel for the process of manufacturing.
The shelled paddy will go to the paddy separator machine, which will separate the unshelled paddy and the rice. The unshelled paddy will go back to the rubber sheller machine once again and the shelled paddy is taken to the first cone polisher machine, where the rice bran is also removed from the rice. This will go to the bran blower and separator machine, 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 polisher machines for polishing the rice with rice bran. This will give the product more vitamin contents. After polishing, the rice will go to the destoner machine and vibrator machine, where the stones and broken rice are completely removed from the product to make it superior in quality.



The final product is collected at the end of the milling section and this will go to the rice colour sorter machine for removing the black and immature rice completely. Thus the production of rice is subjected to strict quality control right from procurement of paddy to all the different stages of production for maintaining our brand name in the market. We believe that consumers are the best advertisers of any product and we have experienced the same since the beginning.

The colour sorter machine is newly introduced in the rice mill industry in the State of Kerala. This machine is directly imported from Italy. The rice collected at the end of the milling section reaches the colour sorter machine through an elevator and is allowed to pass through the machine , which completely remove the black grains present in the rice and only good rice is collected as the end product. These are packed in gunny bags, weighed, stitched and taken to the market for human consumption. The rice colour sorter machine is to be kept in a cool place for which a fully air conditioned factory building is constructed for the industry.


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