Rice Processing Plant (32 TPH)
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RICE PROCESSING PLANT (32 TPH)
[EIRI/EDPR/4630] J.C.: 2847XL
INTRODUCTION
Rice is two species in the Poaceae ("true grass") family, Oryza sativa and Oryza glaberrima. These plants are native to tropical and subtropical southern and southeastern Asia and in Africa. Rice provides more than one fifth of the calories consumed by humans in their global diets. Rice is a monocarpic annual plant, growing to 1–1.8 m tall, occasionally more depending on the variety and soil fertility. The grass has long, slender leaves 50–100 cm long and 2–2.5 cm broad. The small wind-pollinated flowers are produced in a branched arching to pendulous inflorescence 30–50 cm long. The seed is a grain (caryopsis) 5–12 mm long and 2–3 mm thick.
COST ESTIMATION
Plant Capacity 640 MT/Day
Land & Building (15 Acres) Rs. 27.59 Cr
Plant & Machinery Rs. 101.16 Cr
Working Capital for 2 Months Rs. 75.48 Cr
Total Capital Investment Rs. 210.15 Cr
Rate of Return 28%
Break Even Point 50%
CONTENTS
INTRODUCTION
ABOUT RICE
PADDY CULTIVATION GLOBALLY
TABLE 1: MAJOR RICE PRODUCING COUNTRIES IN THE WORLD (MILLED PRODUCTION IN MILLION TONS)
TABLE 2: INTERNATIONAL GRAIN COUNCIL’S WORLD RICE PROJECTIONS (IN MILLION METRIC TONS)
TABLE 3: DOMESTIC BALANCE SHEET (IN MMT)
TABLE 4: AVERAGE PRICE OF PADDY COMMON AT MAJOR STATES IN INDIA MAY, 2023
TABLE 5: STATE WISE AREA UNDER PADDY IN INDIA
RICE PRODUCTION IN INDIA: 2019-20
PRODUCTION VOLUME OF RICE IN INDIA FROM FINANCIAL YEAR 2010 TO 2022, WITH ESTIMATES FOR 2023
MARKET ASSESSMENT
INDIAN RICE MARKET
PRODUCTION SCENARIO
THE PRODUCTION OF RICE DURING FY 2019-20 AND FY 2020-21 IS GIVEN IN THE TABLE:
EXPORTS
THE EXPORT OF NON-BASMATI RICE FROM INDIA TO TOP 10 COUNTRIES DURING THE YEAR 2020-21 IS SHOWN HEREUNDER:
THE GRAPH SHOWING THE EXPORT VALUE OF NON-BASMATI RICE TO THE ABOVE LISTED COUNTRIES FOR THE 2020-21 IS SHOWN HEREUNDER:
CONSUMPTION
EXISTING GAPS IN RICE MILL INDUSTRY
PROFIT GAPS DUE TO POST-HARVEST LOSSES
MARKET ASPECTS
RICE MILLING PRODUCTS
RICE BRAN
BROKEN RICE
RICE HUSK
APPLICATIONS OF HUSK
LAND
LAND UTILIZATION PLAN
PLANT AND MACHINERY
POST-HARVEST DRYER
TECHNICAL OPERATIONS
SILO STORAGE SYSTEM
SCADA SYSTEM
REAL TIME CONTROL AND MONITORING SYSTEM
SCADA IS A SYSTEM OF SOFTWARE AND HARDWARE ELEMENTS THAT ALLOWS RICE MILL TO:
SCADA BASED CENTRALIZED CONTROL SYSTEM
* MOTOR CONTROL CENTRE
* HUMAN MACHINE INTERFACE (HMI)
* PROGRAMMABLE LOGIC CONTROLLERS (PLC)
BENEFITS OF SCADA
PRODUCTS AND BY-PRODUCTS
PROCESS AND TECHNOLOGY
* PADDY STORAGE
* PADDY PRE-CLEANING
* POST-HARVEST DRYER
* SOAKING & STEAMING
* DRYING
* CLEANING
* DE-HUSKING
* PADDY SEPARATOR
* WHITENING
* GRADING
* PACKING/STORAGE
THE PROCESS FLOW CHART FOR THE PRODUCTION OF PARBOILED RICE IS GIVEN HEREUNDER:
PROCESS FLOW FOR PRODUCTION OF PARBOILED RICE
CONSUMABLES
WATER REQUIREMENT FOR A 640 TPD MILL
EFFLUENT TREATMENT PLANT
CHARACTERISTICS OF THE RAW EFFLUENT AND TREATED WATER PARAMETERS
INSTALLED CAPACITY OF THE RICE MILL
RAW MATERIAL
CONSUMABLES
STEAM & FUEL
THE STEAM REQUIREMENT FOR EACH SECTION IS ENVISAGED AS UNDER:
THE IN-HOUSE GENERATION OF HUSK PER DAY FROM THE MILL IS AS BELOW:
POWER
WATER
EFFLUENT TREATMENT PLANT
STATUTORY COMPLIANCES
POLLUTION CONTROL MEASURES
THE SPECIFICATIONS PRESCRIBED BY GOVERNMENT OF INDIA FOR THE PROCUREMENT OF PADDY IS GIVEN BELOW:
ENVIRONMENTAL IMPACT ASSESSMENT
SOLID WASTE DISPOSAL AND MANAGEMENT
RICE HUSK IN MILL HOUSE
MITIGATION MEASURES
WATER EFFLUENT AND MANAGEMENT
WASTE WATER AFTER PARBOILING PROCESS
CHARACTERISTICS OF WASTE WATER
MITIGATION MEASURES
AIR POLLUTION AND MANAGEMENT
THE EMISSION STANDARDS SET BY TNPCB FOR BOILERS IS AS FOLLOWS:
THE EMISSION STANDARDS SET BY TNPCB FOR RISE HUSK BOILERS IS AS FOLLOWS:
MITIGATION MEASURES
PROCESSING
PARBOILING
ADVANTAGES OF PARBOILING
DISADVANTAGES
MILLING OF PADDY
QUICK FACTS ABOUT PARBOILED RICE
TECHNOLOGY & MACHINERY PROVIDER
AGRI PROCESS INNOVATIONS TECHNOLOGIES LLP
STAGE ONE: PRE-HYDRATION
STAGE TWO: HYDRATION
STAGE THREE: GEL COOK
CONTINUOUS PARBOILING
THE RATE OF DRYING DEPENDS ON
DURING THE SECOND PHASE, THE DRYING RATE DEPENDS ON:
ACCELERATED AGED RICE
OUTCOMES OF AGEING
ADVANTAGES OF AGEING
WHY IS THE AGEING OF RICE ACCELERATED?
SALIENT FEATURES
LIST OF MACHINERY & EQUIPMENTS
MILLING SEPARATOR
DESTONER
PADDY HUSKER
PADDY SEPARATOR
RICE WHITENER
RICE POLISHER
ROTARY SIFTER
THICKNESS/WIDTH SEPARATOR
LENGTH GRADER
LICENSES REQUIRED
LIST OF DOCUMENTS:
OTHER LICENSES REQUIRED FOR THE SETUP:
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
DEPRECIATION:
FIXED ASSETS:
WORKING CAPITAL:
BREAK-EVEN POINT:
OTHER FIXED EXPENSES:
MARGIN MONEY:
TERM LOANS:
TOTAL LOAD:
LAND AREA/MAN POWER RATIO:
LIST OF MANUFACTURERS
CONVEYOR BELT
BUCKET ELEVATORS
WEIGHING MACHINES
BAG SEALING MACHINE
D.G. SET
LABORATORY TESTING EQUIPMENTS
EFFLUENT TREATMENT AND DISPOSAL
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
ANAEROBIC TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
EQUIPMENT REQUIREMENTS
MANPOWER
GENERAL
BASIS OF ESTIMATION
UTILITIES
UTILITIES
WATER
STEAM
UTILITIES (EQUIPMENTS)
WATER TREATMENT PLANT
STEAM GENERATING SYSTEM
REFRIGERATION SYSTEM:
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
METHOD OF PADDY AND RICE QUALITY ANALYSIS
DIFINITION OF QUALITY COMPONENT
PADDY GRAIN QUALITY
RICE QUALITY
COMPONENT OF PADDY GRAIN QUALITY
CALCULATION:
COMPONENT OF RICE QUALITY
STANDARD OF PADDY AND RICE QUALITY
SHAPE AND SIZE FOR RICE
MACHINERY PHOTOGRAPHS
RAW & FINAL PRODUCTS PHOTOGRAPHS
FINAL PRODUCTS PHOTOGRAPHS
SWOL ANALYSIS
STRENGTHS:
AVAILABILITY OF RAW MATERIAL:
DEMAND FOR THE OUTPUT:
WEAKNESS:
OPPORTUNITIES:
THREATS:
TECHNOLOGY:
COUNTER THE COMPETITION:
ORGANIZATION CHART
PLANT LATOUT
CONSULTANT
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
IMPLEMENTATION SCHEDULE
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)
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