logo...indian food industries, dholka, gujarat location 128 tpb parboiling and 32 x 5 tpb dryer apit...

All our projects are driven to ensure

time, cost and quality goals are

achieved.

Complete Design, Engineering,

Manufacturing, Erection and

commissioning are executed by

our skilled and resourceful

Professionals.

APIT - Indo US Joint venture is the

World’s Best Paddy Process

Specialists known for its Process,

Innovations, and Technologies.

We are committed towards

Hygienic Process, Nutrition

Preservation and Environment

friendly Products.

INTRODUCTION

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2 4

3

I N F R A S T R U C T U R E

Our USA office located at Stuttgart,

Arkansas since from 1997.

We are setting up world class Works

Infra, at KIADB Industrial Area,

Doddaballapur.

Our Works is located at Machohalli,

Magadi Road, Bangalore where our

Process, Electrical, Engineering,

Production, SCM team works.

Our Corporate office is in Solus JainHeights, J. C. Road, Bangalore where ourMarketing and Project team works

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EXPERTISE SOLUTIONS

Ageing of Paddy

JOHN WAYNE

President

ManagerManager

ALLAN DAY

ManagerManager

SANDY LUNA

Manager

Automation System

Parboiled Paddy

Harvested Paddy

Cleaning and Drying systems Vertical

Batch wise and continuous

parboiling systems along with dryers

Accelerated aged rice solution

Recipe intelligence process automation

system

PRODUCT PORTFOLIO

1 Indigo Batch wise Parboiling and DryingSystem

2 BRIS Continuous Parboiling System

3 Bhatta Gel Cook Station

4 Indigo Steam Curing System (Accelerated Aged Rice System)

5 Indigo Mixed Flow Recirculation LSU Dryers

6 Automation (Rice Intelligence Process System)

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Vaishnavi Rice Industries(Accelerated Aged Rice)

Mandapeta, Andhra

Pradesh

64 TPB Steam Curing

and 32 x 2 TPB Dryer

1

2

3

4

Bidhatha Agro Industries(Parboiled)

Malda, West Bengal

64 TPB Parboiling

and 32 x 2 TPB Dryer

Indian Food Industries(Parboiled)

Dholka, Gujarat

128 TPB Parboiling and

32 x 5 TPB Dryer

Salam Auto Rice Mill(Parboiled)

Kushtia, Bangladesh

96 TPB Parboiling and 32

x 3 TPB Dryer

TRADEMARK PROJECTS

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PARBOILING PROCESS DESIGN AND APPLICATION VIDEO

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Parboiled Process-

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INDIAN FOOD INDUSTRIES

• IR64

• Basmati Long Grain

Variety

• Parimal

• Katarni

Raw materials to be Processed

Indian Food Industries,

Dholka, Gujarat

Location

128 TPB Parboiling and

32 x 5 TPB Dryer

APIT Infrastructure

12 TPH

Project Size

Satake India

Engineering Pvt. Ltd.

Milling Partners

13

Vision

Our Mission

• to overcome challenges

• For least cost of operation

• For cost effective process and

• to achieve complete control on process

MISSION,

VISION &

VALUES

M I S S I O N & V I S I O N

To extensively study and analyze the raw

material, to design most accurate process and

to achieve most desired result

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Quality consistency in every batch.

Uniform color consistency.

Low Cooking quality

1

YOUR TITLE

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5

C H A L L E N G E SF o r P a r b o i l i n g

4High Process

Brokens

3Difficulty in

achieving Golden Yellow Color

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C U S TO M E R R E Q U I R E M E N T S

0%

20%

40%

60%

SUPER WHITE WHITE CREAM GOLDEN YELLOW

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M E T H O D O L O G Y

1) Designing the Process:

The Process is designed based on the customer’s

process requirements (SW/W/C/GY).

• Super White(SW)

• White(W)

• Cream(C)

• Golden Yellow(GY)

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Infrastructure USP Reason

Pre-Hydration System (8 Nos.)

1. Branched Sparger System.

2. Temperature maintaining system

1. Uniform Colour Consistency.

2. Perforations in the branched

sparger system ensures uniform

exposure of steam to each

grain.

S E L E C T I O N O F S T R U C T U R E

F O R P A R B O I L I N G P L A N T

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Hydration System (32 Nos.)

1) Water feeding mechanism

2) Constanttemperature maintaining mechanism

3) Circulation automation

1) Uniform Colour Consistency.

2) Good cooking results.

3) Quality consistency in every batch.

4) Reduction in process brokens.

Bhatta Gel Cook Station (4 Nos.)

1) Branched Sparger System

2) Alternate steaming and tempering zones


2) Perforations in the branched sparger system ensures uniform

exposure of steam to each grain.

3) Highest degree of starch gelatinization that ensures complete

and homogeneous parboiling, to ensure uniformity in colour,

texture and quality of rice.

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InfrastructureMode of

OperationUSP Reason

LSU Dryer (5 Nos.)AUTO

1. V-Port chamber

2. 45 deg inclined Blower

3. Temperature monitoring and maintaining system

1. Facilitates more drying space

2. Uniform drying of grains and reduces steam loss.

3. Monitors drying temperature throughout the process which in turn reduces process broken.

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SL. NO PROCESS PROCESS MODE

1Pre-Hydration System AUTO

2Water feeding, Circulation, drain AUTO

3Bhatta Gel cook process AUTO

4Dryer rotor VFD control

5Dryer (Temperature control) AUTO

M O D E O F O P E R AT I O N

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Super White

PHS

Steam Pressure 3.5 bar

Temperature 100-110 deg

Rotor speed 12-20 rpm

Paddy filling time to hydration tank 15 mins

HS


Soaking Time 10-12 hrs

Resting Time 0 hrPump lps avg. 12-18

GC

Pressure 1.5-2 bar



Dryer

Pressure 5-8 bar


Drying time 8 hrs


Process Parameters

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Process Parameters:

White

PHS

Steam Pressure 3.5 bar




HS

Temperature 40-50 degSoaking Time 5 hrsResting Time 0 hrPump lps avg. 12-18

GCPressure 1.5-2 barTemperature 95-100 degRotor speed 8-16 rpm

Dryer

Pressure 5-8 barTemperature 140-70 degDrying time 8 hrsRotor speed 1350-1400 rpm

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Cream

PHSSteam Pressure 3.5 bar

Temperature 100-110 degRotor speed 12-20 rpm


HS

Resting time 20 minsSoaking Time 5 hrsTemperature 55-65 degPump lps avg. 12-18

GCPressure 1.5-2 barTemperature 98-102 degRotor speed 8-16 rpm

Dryer

Pressure 5-8 barTemperature 140-70 degDrying time 8 hrsRotor speed 1350-1400 rpm

Process Parameters:

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Golden Yellow

PHSSteam Pressure 3.5 bar

Temperature 100-110 degRotor speed 12-20 rpm


HS

Resting time 5-6 hrsSoaking Time 6 hrsTemperature 60-80 deg

Pump lps avg. 12-18

GC Pressure 1.5-2 barTemperature 102-108 degRotor speed 8-12 rpm

Dryer Pressure 5-8 barTemperature 140-70 degDrying time 8 hrsRotor speed 1350-1400 rpm

Process Parameters:

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FINDINGS

• Maximum Head Rice Yield (% Out Put Moisture)

• Least Process Brokens

• Best Cooking results

• Increased Water Uptake Ratio

• Volume Expansion Ratio

(In Comparision with Exisiting System)

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Increased water uptake can be achieved by our APIT’S NEW PARBOILING AND DRYING SYSTEM along with automation .The APIT system has 3 stage infrastructure for 3 stage process :

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COOKING RESULTS

12 % Extra water uptake with APIT ‘S New Parboiling and Drying system

Existing system (80% water uptake by paddy )

APIT system (92 % water uptake by paddy )

Water uptake ratio: Water uptake or absorption rate is the increase in volume (w/w) of the kernels after cooking. The weight of rice increases after cooking is due to water absorption by it during cooking process

WATER UPTAKE RATIO : Weight of cooked rice /weight of uncooked rice

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COOKING RESULTS

Quantum of paddy Paddy/Water ratio Cooking yield @Existing system (80% water uptake )

Cooking yield @APIT System (92% water uptake )

Extra yield

1 Kg 1:2 1.6 Kg 1.8 Kg 0.2 Kg

1 Kg 1:2.5 2 Kg 2.3 Kg 0.3 Kg

1 Kg 1:3 2.4 Kg 2.7 Kg 0.3 Kg

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COOKING RESULTS

BENEFITS OF APIT’S PARBOILING AND DRYING SYSTEM

• Increased cooking yield

• Optimum cooking time

• Strengthening of kernel(cooked) integrity

•Increase in elongation ratio

• Reduced percentage soluble leached material

•Increased volume expansion ratio

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With the help of our APIT’S New Parboiling and Drying system Indian Food Industries achieved 6 COLORS OF RICE

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OUTPUT RESULT(BROKEN PERCENTAGE )

0%

2%

4%

6%

8%

10%

12%

14%

16%

18%

20%

EXISTINGPLANT

APIT

NO OF BROKENS( BASMATI VARIETY )

EXISTING PLANT

APIT

With APIT new Parboiling and Drying system

there is reduction of 2

% process

broken

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Accelerated Aged Rice

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VAISHNAVI RICE INDUSTRIES

• Jaya

• Surekha

Raw materials to be Processed

Mandapeta, Andhra

Pradesh

Location

64 TPB Steam Curing and 32

x 2 TPB Dryer

APIT Infrastructure

8 TPH

Project Size • Buhler India Pvt. Ltd.

• Milltec Machinery Pvt. Ltd.

• Satake India Engineering Pvt.

Ltd.

Milling Partners

44

Vision

Our Mission

• to overcome challenges

• For least cost of operation

• For cost effective process and

• to achieve complete control on process

MISSION,

VISION &

VALUES

M I S S I O N & V I S I O N

To extensively study and analyze the raw

material, to design most accurate process

and to achieve most desired result

45

Process Brokens

Uniform color consistency.

Chalkiness in grains

1

YOUR TITLE

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5

C H A L L E N G E S

4Increased Rejection

Percentage

3 Blast Grains

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C U S TO M E R R E Q U I R E M E N T S

0%

10%

20%

30%

40%

50%

60%

70%

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M E T H O D O L O G Y

1) Designing the Process:

The Process is designed based on the customer’s

process requirements (SW/W/C/GY).

• Super White(SW)

• White(W)

• Cream(C)

• Golden Yellow(GY)

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S E L E C T I O N O F S T R U C T U R E

For Steam Curing Plant


Bhatta Gel Cook (2 Nos.)

Branched Sparger System


2) Perforations in the branched sparger system

ensures uniform exposure of steam to each and

every grain.

3) Highest degree of Thermal treatment that

ensures complete and homogeneous Ageing, to

ensure uniformity in colour, texture and quality of

rice.

Tempering Bins (4 Nos.)

- 1) To achieve the desired output colour which depends on the age of the paddy.

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MODE OF OPERATION

SL. NO. PROCESS PROCESS MODE

1 Bhatta Gel Cook process Complete Auto

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Process Parameters:

1 FIFO Time 8/10/12 mins

2 Thermal Seasoning time 30/45/60/90/120 mins

AGEING TABLE

Age of paddy 0 1 2 3

APIT steam curing system

12.5% 12.5% 13% 13.5 % Optimum ageing moisture

Existing system 9.5 % 10% 10.5 % 11% Optimum ageing moisture

Moisturedifference (%)

3 % 2.5 % 3.5 % 2.5 % Optimum ageing moisture

FINDINGS

logo...indian food industries, dholka, gujarat location 128 tpb parboiling and 32 x 5 tpb dryer apit...

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