BLOG

Production feasibility for paddy processing plant

03 September 202219 min reading

The following article explains the production information of ‘Paddy Processing Facilities’, which is provided by Yasar Makine Metal with the use of the latest technology, which is the result of more than 52 years of experiment, research and development and observations.

INTRODUCTION

Yasar Makine Metal has been established in 1969, with the mission of enterprising service policy in the manufacturing sector. Yasar Group has a 60.000 square meters closed area and 90.000 square meters open area. Yasar Group serves to paddy and rice processing machine sector, hazelnut machine sector, and on–vehicle equipment sector with more than 250 experienced employees.

Nowadays Yasar Makine Metal; is proud of becoming one of the leading exporter companies of the developing industry city of Samsun and the Black Sea region. Our company exports European standards machines to more than 60 countries in Asia, North America, Europe, Africa, and Latin America.

Since its establishment, Yasar Makine Metal has been developing its production lines constantly with enriched computer-controlled production lines and remote-control systems. By standard or special process is applied for the best yield of the final product, after the quality of the product has been tested. With continuing investments in the R&D department, new projects are being held by Yasar Makine Metal. In order to manufacture the best quality rice, a new paddy and rice processing factory has been established at Edirne – Ipsala by our company where we can test and observe the performance and capacity of the machines, the yields of the machines, and the life duration of the machines in a real continuous production flow.

The machines that are manufactured by Yasar Makine Metal are made with strong body structures, continuous production features, and advanced technology applications. The employees of Yasar Makine Metal, who are specialized and professional in their fields of activity, focused on customer satisfaction and after-sales services. Our quality of products and services are proven by the most important certification institutions.

The machines that are manufactured by Yasar Makine Metal, are certified ISO-9001-2000 quality management certification, CE Branding Rights and GHOST- R certification given by TSE. With respect to these quality certification, Yasar Group is always focused on working for all solutions for customer.

Yasar Makine Metal offers complete solutions for its customers at the design, production and application stages on a turn-key basis. Since its establishment, Yasar Group has completed successfully on-time project applications and after-sales services to the customer.

All machines on the production lines have their own standardization, therefore all body structures and machining processes are operated by computer-controlled production lines.

Our valuable business partners; our company gives all efforts to be worthy of your confidence in our company, with expanding our enthusiasm as the first day of our establishment and our degree of responsibility plays an important role in holding our efforts at the highest point. The growing support of business partners Yasar Group’s efforts to improve the quality of manufacturing and services will continue to increase day by day. We thank our business partners, and we wish to bring the kindness of humanity to the country through the investments we’ve made.

MAIN SECTIONS IN PADDY PROCESSING PLANT

As seen below; we have divided the factory plan into 6 main sections.

1. Paddy Mill Section ( Husk and Paddy )

2. Whitener Section and Polisher Section ( Rice)

3. Classification Sections ( Rice)

4. Storage and Packing ( Rice )

5. Bran Systems

6. Air ( Compressor )

7. Flow System

8. Result

1. Paddy Mill Section

In this section; paddy cleaning from garbage, millet, powder and stones then first peeling process doing by the Paddy Husker after that Paddy Separator, send back to the paddy peeler which unpeeled products. The Paddy Separator transfers the peeled rice to the next machine.

ELEVATOR TREMI PIT (POST PIT)

It is generally used in food products; it is manufactured as standard or custom according to the area of usage in the plant. It is used to transport the product to the machines or be processed or to be stored. In this project; it is used to provide access to the system of the ready-to-processing paddy.

Elevator

The elevators are used with the aim of carrying the products such as paddy vertically in the product processing plants. Elevator is a system which provides the motor with reducer, which is assembled on the elevator belt that is stretched with surrounding around two spaced tambours, to be turned with being driven and that enters the sub-elevator and carried until the top-elevator with being brandished and spilled to the exit point during the turning around the driven drum.

1.1.PADDY CLEANER

Although the grain cleaning machine is generally designed for paddy, it can be used in other pulses machines by changing the sieve numbers. Paddy, rice and so on. cleaning of legumes, separation of foreign materials (garbage, millet, powder straw, etc.) The machine cleans the fine products in the product with air aspirator. It can produce two sizes of sieve. The machine can be used for pre-cleaning of dry or wet grain products.

The product poured into the feed bunker of the machine is transferred to the next stage with flow pipes after cleaning. The product starts to be scattered by means of vibration method on the sieve. Garbage and dusts that are lighter than paddy are separated from the paddy by the aspirator.

According to the size of the sieve pre-installed on the machine, the product passes under the sieve and starts sieving from the bottom sieve. If it is thinner than paddy under the bottom sieve, small and heavy particles fall off. The product remaining on the lower layer is poured into the second sieve table to be separated again. At the same time, the light items which are left in three of the products are sucked and cleaned to separate them again with the aspirator. On the second sieve plate, the product passes over again. The separated product is dispatched from the clean product outlet bin.

1.2 DESTONER

Destoner machine; It is used for cleaning from stones, sand and soil inside dry granular agricultural products such as rice and paddy.  The product entering the entrance of the stone separator is poured into the sieve of the machine. The vibration created by the eccentric system and the product air are floated on the sieve with the effect of air from below and vacuum air from above. Heavy materials (stone, soil, sand, etc.) are scratched upwards on the sieve with the vibration of the sieve table. The product we want to break down goes down because it is lighter. Through this process, stone, soil, sand, it is separated from the materials. 

1.3 PADDY PEELER

It was developed for the ones who desire a combined machine which has got high capacity in the paddy processing plants. The paddy husker and the husk aspirator which are combined have got a very important place about the plants to modernize themselves with more production capacity, less place covering, less electric consume and low care expenses. Glume aspirator with paddy husker is a machine which husks the cover of the paddy and separate the glume and the rice from each other’s in the paddy processing plants.

It husks the cover of the glume aspirator with paddy husker while it moves among the mangles which are covered with rubber turning in different circuits from each other in opposite sides. The husked mixture (paddy, rice, dandruff and glume) are powered on an eccentric system. The distinguished mixture on the sieve enters into the aspirator reservoir of the machine and distinguished from each other’s in the air channels and exists from the machine beside being transported to different flows. The feeding bunker has sensor, when bunker is full with product machine start to work.When feeding bunker becomes to empty machine stop.

When the machine starts; it distributes the paddy which is on the electromagnetic vibro product distributor to the husking mangles. The paddy which moves through the mangles are husked and they are poured on the eccentric system sieve as 3 different products which are rice, paddy and glume. The mixture which is distinguished on the sieve is poured into the aspirator part in order the rice and the glume to be separated from each other’s. The aspirator system; provides the mixture (paddy, rice, dandruff, glume and raw piece) to be distinguished with the help of the aspirator that it provided itself. The products which are distinguished (rice, dandruff and glume) are transported to out of the machine from different exit ways.

1.4 PADDY SEPARATOR

Working at high capacity and consuming low energy in paddy milling facilities, the paddy separator separates the rice and the paddy from the peeled mix once the paddy is peeled. The machinery separating the paddy and the rice using the notched sieves on the machine is automated and equipped with a sensor system that shuts down the machine automatically once the grains in the feed bunker are finished, and starts up the machine automatically once the bunker is refilled.


The machine is developed for users requiring a combined machine and the features such as high production capacity, small footprint, lower energy consumption and lower maintenance costs are significant for modernizing the facilities.

It separates the unpeeled paddy inside the rice and forwards to the peeler for re-peeling. The unpeeled paddy and the peeled rice exiting from the peeler roll enter the filling control sensor-fitted reservoir of the paddy separator mixed. Consisting of two main bodies on a single chassis and individually adjustable bodies activated by the same drive gear, the paddy separator enables the plant capacity to be increased and maintaining the energy consumption at minimum level. Thanks to the control sensors fitted at minimum and maximum levels of the intake reservoir, the machine automatically stops when the grain is insufficient as per the machine capacity and saves on energy consumption. The machine is re-started when the sensors detect that there is grain and the reservoir is full. The grain received in the machine reservoir is flowed to the separately operating proper machine proportionally. Thanks to the specially designed successive multiple sieve system manufactured from chrome material, the separation operation is performed by utilizing the difference in the surface of the paddy and the rice.

The machine has three outputs. Only rice comes out of one outlet. Forwarded to the next machinery for processing. The second output is rice and paddy which cannot be separated by the machine. This grain is returned to the paddy separator via return elevator for re-separation. And the paddy exits from the third outlet. The paddy is forwarded to the peeling unit for re-peeling.

2. WHITENER AND POLISHER SECTION

At this section; by taking the bran and foreign substances on the surface of the rice, it takes its final form.

2.1. WHITENER

Whitener machine is a machine which sandpapering and bleaching the integument and bran on the surface of the rice; stone system which is ranged vertical in the machine.

The rice which enters the machine; is poured into the pusher helix in a flow system which is programmed in advance and in control. The result of the helix to push the rice into the product process cage with a circular movement; the rice is again scattered to forward in a circle shape. During this scattering; with the friction that the rice encounters during its passing in the product slowing set; with the sandpaper stones and with the abrasion devoted to crashing to bleach sieve surfaces; its bleach is provided with being separated from the natural-colored bran part.


During these bleaching studies, the stresses in the product slowing set, sandpaper stones and the frictions to the sieve system and during the frictions in the circular turnings; the emerged heating is prevented with the produced air via the pressing air fan, blowing into the bleaching system thanks to the air pipe; the cooled rice in the temperature of its natural heat; is controlled with the observation made by the processed rice control cover; and the product is taken from the exit.

If the product is not bleached as wanted; the bleaching setting arm is turned and bleaching level setting mechanism is moved, product slowing sets are approached to the sand paper stones and the rice to be bleached as wanted is provided. Also, the bran product which emerged during bleaching moment; exits out of cage from the assembled sieve pores thanks to the pressure air. All of the bran which is taken in empty in the system, fills into the machine bran reservoir and it is sucked with a sucking fan which is connected from outside to the system.Bran from this machine is used in animal feed industry.

2.2. WATER POLISHER

The water polishing machine is installed according to the processing order of the milling machine and it’s used in the polishing process of rice. The machine enhances the quality by polishing by means of the pieces in the pie. It is pushed towards the machine's product handling cage by the pusher coil located in the brass machine entering into the product entry bin of the machine. The brass pushed by the spiral gathers a brilliant appearance by rubbing the curtains in the machine with the striking lantern sweeping. The bran coming out during the friction is conveyed out of the sieve pores by the compressed air system. The shining brass is shipped from the rice outlet bin.


The brass print cover on the machine's brass outlet reservoir is used to shine the rice on the desired calf. Brightness adjustment is performed by moving the cover back and forth. As the print lid is tightened, the brightness of the rice grain increases. As loosened, the grain brightness decreases. As the moisture content of the processed product changes, it is also necessary to control the machine's pressure lid adjustment and bring the appropriate setting.

3. CLASSIFICCATION SECTIONS

This section is the place where it is separated according to its aspect ratio and good - bad condition.

3.1. RICE PLANSIFTER

Rice Plansifter; using in rice mill plant, rice powder, soil, powder broken, zero broken, broken, and rice is the machine that provides classification.

The Plaster Rice Sieve is processed in rice processing plants by separating the brass from the crumb and polishing it after it is polished. 


The brass product entering the Plaster Rice Sieve product entry bin is distributed in both directions in a balanced manner through the distribution box. Rice floated on the sieves with vibratory circular shakes of the machine are classified according to the sizes of the sieved sieves used. The rice remaining on the sieve moves towards the outlet chamber through the product outlet paths in the sieve. The rice falling down the sieve pores starts to be sifted in the second sieve. In the same way, the product which is sifted in the second sieve and left on the sieve is conveyed to the product outlet by the product outlet routes in the sieve. Once the brass has entered the machine, it is sifted in five sieve systems. As a result, rice; from the outlet of the rice outlet, from the broken rice outlet, from the outlet of the broken rice, and from the broken outlet of zero. If desired, the machine can be separated from the soil by inserting a sieve into the sieve vessel

3.2. RAW GRAIN TRIEUR

Raw Grain Trieur machine is a machine that picks up the ripen rice and sifts it apart. The Raw Grain Trieur, which is set up during the procedure, is used to separate immature raw materials from the rice. As shown in the picture above, the raw material drops from the holes and is separated from the brass by the rotation of the brass elephant which is stuffed into the sieve from the product input bin. Remove rice; the raw materials falling from the holes of the brass outlet are transported in the raw material discharge chamber by the hammer-pushing coil.


3.3. BROKEN TRIEUR

The broken trieur is used in the fracture removal process, through the complete, intact piece of the rice in the mill. Due to the difference in the printing properties of the sieve system, the broken pearl separates from the full pearl. The machine is manufactured as single floor and two floor.

The plant is used to separate broken rice from the product after the rice has been destroyed. As shown in the picture above, the machine falls into the broken trowel when it is attached to the special printed rice paddle in the special rice paddle in the paddy and the broken drum and when the paddle approaches the peak at the rotating drum. The attached rice drops earlier than the elbow and is pushed towards the rice outlet chamber by the rice pushing coil. The fractures falling into the pan are likewise pushed towards the fracture outlet chamber by the broken pusher coil.

3.4. COLOR SORTER

Tanem Color Sorter sorting with three times.

1- Bad rices sorting from good rice and goes to the 2. step. Good rice goes to the next process.

2- Inside bad rice sorting good rice and goes to the 3. step. Bad rice goes to the sack or bag.

3- Inside good rice sorting bad rice and goest to the sack or bag. Good rice goes to the next step.


Good Rice; desired rice.

Bad Rice; rice to be separated.

The camera is equipped with super high resolution 5400 CCD sensor and LED light source. Reduces the cost of LED light and sensor operation and ensures long-term operation stability. Embedded design and touch screen operation.

3.5. LUBRICATION DRUM

Oil hoop machines provide the products’ process in the paddy process plants to be finished in whole and before they are stocked; for the rice to be seen bright 0,36% oil is used and oiling process is carried out. Also longer shelf life is provided for the rice.

The rice which is processed in paddy processing plants; provides all of the surface to be oiled in the oil hoop machine with mixing 0,36% oil. The machine,as seen in the picture; the product enters from the product entry reservoir and provides combination with the oil which comes from the oil hoop in the hoop which turns 32 d/d in a minute. The rice which is oiled thanks to the turning in the machine; exits from the product exit reservoir.

4. Storage and Packing

Storages are used to store processed products in food processing plants. Storages which are generally used to store or rest food products can be made standard or custom depending on the area to be installed in.

Storages are standard made of 2,5mm 430 chrome materials can be laser cut and used to manufacture according to requirement. The automatic bagging system is used in sewing the package mouth of the weighed and filled product. The machine which is usually used with granular food products can also be used to weigh and package any kind of grain products.

5. Bran Systems

The bran aspirators are used in the aspiration of various machines in the processing plants such as paddy, wheat, semolina etc. products. The bran aspirators are used in sucking and transporting the materials such as dust, bran etc. as the result of processing the product in the machines and the dust in the environment. The bran aspirators according to their features, have coupled system and easy installing feature. It is assembled with various angles is available but it is the most ideal to be installed towards the weather turning side.

Devoted to using the equipments which make cost necessary such as band, tambour was not used.

The bran aspirators which are used in the aspiration of the different machine groups in the plant; are generally used in distinguishing the dust generated in the machines from the light foreign materials from the raw-materials.

Thanks to the fan wings which are stated in the body of the aspirators that are in cylinder shape and which work with an electric motor; vacuum is made on a side and on the other side the air pressure is provided. While air vacuum is provided from the bran aspirators’ bodies; the air to be separated from the dust is provided with giving to out of system, filters and dust cyclones.

6. Air Systems

It is a system which produces the pressed air which is needed by the machines which work with pneumatic (air) system in the plant.

7. Flow Systems

It is used for providing the product flow among the machines.  It is used for the output and input of every machine.

Flow pipes will be in Ø 120 and Ø 150 mm diameters and they will be produced from DKP Steel tinplate. Dandruff air channels will be manufactured from DKP tinplate in 200x200x2 dimensions.

8. Result

Our machines; the product operates with maximum capacity and minimum loss. We are preferred all over the world because our productivity is very high.

Note : Experiments vary according to region products. However, we guarantee maximum efficiency.

Articles in Cover Story Category
11 February 20224 min reading

Smart solution: Emulsifier replacement with enzymes

13 September 20161 min reading

GRAIN CLEANING PROCESS BEFORE GRINDING

Wheat, which is one of staple foods of mankind, is facing many contaminants in growing, harvesting,...