Departamento de Investigación y DesarrolloCarlos Castro V.

Barney Jacome S.Marcelo Quintana G.

Carlos Jr. Castro V.Danilo Vera C. June 2019

Comparison between parboiled and aged rice and advances with the automation of aging rice by

using INDUHORST technology

JATUN HUAYRA MEPHISTO MCM

Outline

✓ Fundaments of aging rice

✓ Parboiled rice:

✓ Main characteristics

✓ Procedures to obtain parboiled rice

✓ Aged rice:

✓ Main characteristics

✓ Procedures to obtain aged rice

✓ Differences between parboiled and aged rice

✓ Advances in the automation of Induhorst EVA-7000 and EVA-14800 aged rice machines

Fundaments of aging rice

✓ Fresh rice contains around 80% of starch

✓ Starch: Different contents of amylose and amylopectin

✓ Large chains of starch cause undesirable conditions in cooked rice.

✓ Large chains of starch should be destroyed:➢ Traditional: 5 to 15 months of storage➢Artificial way :

✓ Parboiled (36 to 55 hours)✓ Aging using Induhorst technology (24-36

hours)

Comparison between traditional aging, induced aging and parboiled rice

CharacteristicsTraditional

AgingInduced

agingParboiled

Processing time

1 – 3 years ~32 hours ~ 55 hours

Maintenance risk

High risk Low risk Low risk

Amylosecontent

Increase Increase Increase

Grain breakdown

Low risk Low risk Very low risk

Color change whiteness loss (2 points)

whiteness loss (2 points)

Cream color

What is parboiled rice?

Is a hydrothermal process in which the crystalline form ofstarch present in the paddy rice is changed as a result of theirreversible swelling and fusion of starch (Kasasian 1982)

Importance of parboiled rice

✓Is staple food in Bangladesh, Sri Lanka

✓Accounts for more than half of the rough rice produced in India and Nepal and large proportion in Pakistan.

✓Its popular in parts of Africa and Asia.

✓Its stimated that about one fifth of the world’s rice is parboiled (Gariboldi, 1984)

(Bhattacharya 1985; Pillaiyar 1988, 1990)

✓ Consists of steeping rough rice in ambient temperaturewater for a few days followed by steaming or boiling at1000C and sun-drying

✓ Pressure-parboiled rice requires a longer cooking timeand cook harder than traditional parboiled rice whichundergoes aging of storage changes.

✓ Amylose content seems to be the most dominant qualityas in raw rice quality (Biswas & Juliano, 1988)

Main characteristics of parboiling rice

The major objectives of parboiling are to:

✓ Increase the total and head yield of the paddy

✓ Prevent the loss of nutrients during milling

✓ Salvage wet or damaged paddy

✓ Prepare the rice according to the requirements of consumers

Aged Rice.- Main Characteristics

✓ It is an spontaneous and natural phenomenon.

✓ Rice grain with long term storage that had undergoeschanges in its physical properties and chemicalcomposition.

✓ Cause important effects on rice cooking and eatingquality.

Why is important to consume aged rice

✓ Facilitate the cooking: higher volume expansion and water absorption upon cooking.

✓ Less sticky cooked rice

✓ Improve digestion: due to starch transformation ( amylopectin to amylose)

….Aged rice: Main characteristics

✓Volume expansion/water absorption

✓Consistency

✓Fluffier

✓Palatability

✓Other: Flavor

Main concerns with traditional rice aging method

✓ Time consumed ( From 1 to- 3 years)

✓ Use of space for storage (use of rough rice)

✓ Maintenance risk (pest attack, over heating, natural disaster ( flooding, changes in temperature)

✓ Higher costs/ Investment

✓ Lower return rate/low benefits

Parboiled rice vs induced aging of rice

Characteristic Parboiled Aging Induced aging

Process steps 1) Soaking 1)Milled

2) Cooking 2)Induhorst machine

3) Drying 3)Unloaded/storage

4) Milled

5)Stored

Process time 42 – 65 hours 24-36 hours

Parboiled rice vs induced aging of rice

Characteristic Parboiled Aging Induced aging

Grain Maintenance risk Low risk Low risk

Amylose content Increased Increased

Grain breakdown Reduced Low risk

Color change Color change, from white to white brown

whiteness loss (2 points)

Advantages in the automation of Induhorstaging rice machine

2001- Manual (no automation)- Many commander buttons- High risk of grain damage/by

operator errors- High rice color variation

2006- Manual (no automation)- Many commander buttons- Medium risk of grain damage/by

operator errors- Medium variation color in

processed rice

2019- Last Generation Programmable

Logic Control (PLC)- Higher memory capacity (recipe storage)- Digital operation (no buttons)- Very low risk of grain damage- Low risk of lost programming

2012- Programmable Logic Control (PLC)- Many commander buttons- Low risk of grain damage/by

operator errors- Low variation color in processed rice

EVA-14700 Aged Machine

3D design aged rice machine line

Description EVA 7000 EVA 14800

Capacity ~7000 kg/process ~14800 kg/process

Installed Power/hour 65 kW/86.9 HP 110 kW/147.5 HP

Process power/h. 40 kW 75 kW

Dimension (L – W - H) 4.1 x 2.1 x 4.2 (m) 4.1 x 2.1 x 6.7 (m)

Installation Voltage 220-380-440V (3ph) 220-380-440V (3ph)

Frequency 50-60 Hz 50-60 Hz

Weight without load 6900 kg 12500 kg

Weight with load ~13900 kg ~27200 kg

Resistance 18 units 30 units

Technical Information of EVA-7000 and EVA-14800

maquina con características de funcionamiento

Processing characteristics

Action EVA 7000 EVA 14700

Process capacity/batch ~7000 kg (154 qq) ~14800 kg (326 qq)

Operational hand labor 1 operator 1 operator

Rice type Husked rice Husked rice

Loading time 45 min 45 min

Process time 18 - 32 hours 18 - 32 hours

Cooling time* 6 – 10 hours 6 – 10 hours

Unloading time 45 min 45 min

Humidity lose/process ± 1% ± 1%

*For unloading, the grain temperature do not should exceed the 10oC respect the external temperature

maquina con características de funcionamiento

EVA 7000 and EVA14700 power consumption characteristics

Action EVA 7000 EVA 14700

Power consumption/process*

600 kW 1130 kW

Total power used for Fresh rice*

3.87 kW/qq($ 0,43 /qq)

3.48 kW/qq($ 0.38 /qq)

Total power used for Pre-stored rice (4 – 6 months)**

2.79 kW/qq($ 0.31/qq)

2.51 kW/qq($ 0.28/qq)

* Based on real 25 hour process. Data from Processing plant in Perú

** Based on real 18 hour process. Data from Processing plant in Perú

Experiences of Induhorst aged rice machine in different countries

Production Line in Lambayeque - Peru

Photos courtesy: Barney Jacome S.

Photos courtesy: Carlos Castro. Photos courtesy: Barney Jacome S.

Production Line Guayas Province- Ecuador

Achievements

✓ The increase of processing capacity

✓Reduction of processing costs

✓ Use of last Generation Programmable Logic Control (PLC)➢ Wireless remote control ➢ Higer level of operational control➢ Record of time processing, temperature used, loading

and unloading time, etc➢ Adjustment to the differents specifications of the

demandent.

Grainy rice test