Detailed Project Report (DPR) on Rice Sheller

RICE SHELLER

[EIRI/EDPR/1359] J.C.129

INTRODUCTION

Rice sheller is the process that helps in removal of hulls and bran from Paddy grains to produce polished rice. The objective of rice milling is to get whole grain rice and preserve most of the rice kernel, in their approximate original shape.

In order to improve nutritional and cooking quality of rice, a pre-treatment is given to paddy and the rice so obtained by milling the pretreated paddy is known as parboiled rice. The rice obtained from milling untreated rice is known as raw rice or white rice.

Primary milling of rice is an important activity in food grains. Rice is used in almost all parts of India. Few decades ago, rice grains were processed at family level before cooking. Today, due to Industrialization and global competitive market trend, it has emerged as one of the major industrial activity in tiny, small, medium and large scale sector to cater to the needs of increasing population. Large number of mills engaged in processing/milling of rice are spread over in almost all states across the country. Due to increasing demand the number of rice mills will continue to increase throughout the country.

The input to the Rice mill is paddy whereas the output is parboiled rice and raw /white rice depending upon whether the pretreatment is given to paddy or not. The objective of milling is to get whole grain rice and preserve most of the rice kernels in their original shape. The technologies used for rice milling in tiny and small mills are mostly conventional in nature and are not oriented towards minimizing pollution by incorporation of in plant pollution prevention cum control measures. These units generate substantial amount of pollution, especially air pollution as a result of fugitive emissions from various operations.

The pollution is particularly high in cleaning of paddy, parboiling of paddy and milling of rice. Primary and secondary cleaning of paddy gives rise to solid waste and fugitive emission in the work environment. The coal or husk fired boiler generates fly ash, suspended particulate matter, smoke, and oxides of carbon. Residents of nearby towns suffer due to pollution generated by rice mills. Though some of changes are being brought in production processes to improve the efficiency and lowering the cost of production etc., as regards to pollution abatement & control it remains mostly unsatisfactory. A Civil Writ came up for hearing before the Punjab and Haryana High Court recently and during hearing, the Hon’ble Court had passed an interim order-“It be made known as to why rice husk etc. cannot mandatory be required to be stored, after expulsion by the machine, directly into an enclosed area, so that it does not in any way get out of the factory premises on to the crops/passing vehicles/any residence made in open fields/on farm workers, at all.” In compliance of the orders passed by the court, Punjab Pollution Control Board carried out a study so that some immediate action could be taken to prevent air pollution in the surrounding areas by following enclosed storage practices. 

The study included inspection of shellers of different capacities, measures taken by these shellers to store the Rice Husk in an environmentally sound manner, adequacy of the enclosure provided around the rice husk storage area, etc. After going through recommendations of the study, court expressed that problem of spillage of Rice Husk could not be solved without providing air tight enclosures. The court also expressed that loading/handling of Rice Husk should be inside the air tight enclosure, so as to rule out any possibility of rice husk particles becoming air borne. The handling and proper disposal of Rice Husk Ash is also a big problem. The ash deposited in the nearby areas is causing health impacts to humans as well as plants.

Keeping in view the orders passed by the court and the gravity of air pollution caused by this sector, Central Pollution Control Board entrusted a project on ‘framing the guidelines for sitting of rice shellers/mills; handling and storage of rice husk and handling; storage and disposal of ash generated in boiler using rice husk as fuel’ to Federation of Indian Chambers for Commerce and Industry, so as to improve the environmental performance of the rice mills.

COST ESTIMATION

Plant Capacity            40 MT/Day

Land & Building (1.5 Acre)    Rs. 3.35 Cr

Plant & Machinery                    Rs. 2.23 Cr

Working Capital for 3 Months    Rs. 5.07 Cr

Total Capital Investment          Rs. 10.97 Cr

Rate of Return                          41%

Break Even Point                      40%

CONTENTS

INTRODUCTION

OVER VIEW OF RICE SHELLER

USES AND APPLICATION

B.I.S. SPECIFICATION

MARKET SURVEY

INSTALLED CAPACITY, PRODUCTION AND CAPACITY UTILIZATION OF RICE

APPARENT CONSUMPTION OF RICE

ESTIMATED DEMAND

DEMAND SUPPLY GAP

MANUFACTURING PROCESS OF RICE SHELLER

PROCESS FLOW DIAGRAM FOR RICE SHELLER

AVERAGE YIELD OF RICE FROM PADDY

MANUFACTURING PROCESS OF WHITE RICE (RAW)

PROCESS FLOW SHEET OF WHITE RICE (RAW)

EMISSION ASSESSMENT IN RICE SHELLER

SELECTION OF RICE PROCESSING UNIT FOR STUDY

HANDLING AND STORAGE OF RICE HUSK AND DISPOSABLE OF BOILER ASH

EMISSION AND ENVIRONMENTAL ASPECTS

SOURCES OF FUGITIVE EMISSIONS IN RICE MILLS

EMISSION CONTROL SYSTEM ADOPTED BY RICE PROCESSING UNIT

CONTROL SYSTEMS ADOPTED

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERIES

ADDRESSES OF FOREIGN MACHINERIES SUPPLIERS FOR RICE SHELLER

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)