The operation of the parboiling system starts with a feeding elevator.
The feeding elevator carries the completely cleaned raw paddy to the chain conveyor, which transports the paddy to the search bin.
At the end of the conveyor the buckets are emptied by gravity into the discharge section. The system feeding elevator is designed for its higher efficiency of bunk’d material handling and is updated with the latest technologies like speed monitor, belt slack monitor, energy meter, information receiving and sending station.
Feeding elevator transfers the paddy to the chain conveyor. The system chain conveyors are best performing machines which receives raw paddy from feeding elevators and distributes the paddy to multiple numbers of search bins.
Feeding elevators and chain conveyors are built with a link test technology like chain conveyor distribution mechanism, having pneumatics live gates with manual override.
Search bins are fabricated for sufficient storage of raw paddy.
Our entire search bins are equipped with level monitoring sensors. These sensors stop the filling when it reaches a definite maximum level and then the paddy is fed to the PHS tank.
Here is the first phase of our boiling infrastructure scientifically known as the rehydration process.
The system rehydration machine has a cylindrical top with conical bottom and a scientifically designed steam sparger system which takes care of treating each and every grain properly. The running capacity of the PHS machine is multi times the holding capacity of the hydration tank.
After filling of the paddy, heat load by esteem is enforced with a low medium pressure through the branched spudger system.
After filling up the paddy, in the PHS machine, first volume of the paddy will be given thermal treatment. This thermal treatment is completely dependent upon three parameters: latent heat, sensible temperature, time of thermal treatment. Thermal treatment mainly ensures uniformly distributed heat load to every grain.
Free hydration process of the paddy results in filling up of cracks and fissures in paddy and increases the porosity of the husk resulting in increasing the absorption rate of water that helps to reduce soaking time or hydration time. When thermal treatment coefficient reaches equilibrium then the rotary discharge valves start to open. From that point the entire process will be carried out on the basis of first come, first treat and first out.
The machine dehydration can be carried out by two ways: paddy first crosses and water first crosses.
In most of the cases, generally paddy first process will be carried out.
The machine dehydration or soaking infrastructure consists of auto hydro feeding mechanism, auto hydro circulation mechanism, auto static hydro thermal temperature maintaining system, auto hydro draining system and discharge mechanism, auto or manual.
The hydration process is a very important process in parboiling. In this process the crane has to achieve maximum gelatinization. In gelatinization deformation of starch granules occurs. The machine ensures that each and every grain will undergo a uniform gelatinization process in order to get the desired result in terms of color and hardness.
Hydration process. Hydration process is carried out in several steps: dwell or thermal seasoning, water feeding, water circulation, drain and discharge.
Dwell or thermal seasoning. After the PHS process there is a process called dwell or thermal seasoning. After thermal treatment at PHS the hydration tank receives the paddy. After coming to the hydration tank the paddy will be conditioned or thermally seasoned for the prescribed time based on the consumer color preference.
Dwell or thermal seasoning is done for base color application and that is mainly dependent on the age of the paddy.
This system has auto water feeding mechanisms. The required quantum of water will be fed into the hydration tank and it will be monitored regulated and controlled by PLC.
Before water feeding, the Pro system will decide the temperature of the feeding water based on the following parameters: consumer color preferences or process color acquisition, GT aged moisture and possible process color acquisition.
Temperature of the soaking water plays a very critical role in the hydration or soaking time.
To ensure uniform gelatinization, this system has the most effective aqua circulation system.
Circulation system has two components: total number of circulations per cycle and circulation pitch.
Once the paddy reaches the saturation in water intake then the hydration process will be concluded.
At the end of the hydration we obtain gelatinized paddy.
During the process of gelatinization starch granules get deformed and due to which the grain swell by approximately 14 to 18 percent and the nutrients are diffused from the brand to the endosperm.
After this process, surplus water will be drained with our ADS or Auto Drain System with the help of our to be patented QAD valves.
After hydration the moisture content of the discharged paddy kernel will increase up to 28 percent to 30 percent approximately. Then after that the gelatinized paddy is discharged to the belt conveyor and it is taken to the next valve chain of the parboiling ecosystem.
Completely gelatinized paddy will discharge to the belt conveyor which in turn feeds to the elevator of the next level process.
The next level process we call it as gel cook, cooking of gelatinized paddy is termed as gel cook.
The system general cook station is known as Bhatta gel cook station.
The gel cook station assists to achieve the best degree of starch gelatinization and uniform gel consistency which ensures homogeneous parboiling results in best characteristics of color, texture, gel consistency, shelf-life and other best qualities of milled rice.
Search bin feeds the gelatinized paddy to the gel cook. Once the paddy is filled up to the holding capacity, pneumatic slide gates will close and heat load in the form of latent heat of steam will be given to well gelatinized paddy.
The uniform heat load spreads across all the zones. Gel cook station is a unique concept that consists of three alternate dynamic thermal treatment stations and three dynamic seasoning stations.
These stations have a unique geometrical shape arranged vertically with increasing intensity of heat load to give the best quality parboil rice.
The intensity of the heat load is directly proportional to the amount of sensible heat load in each zone which further depends on the size of the heat load distributor pipes.
The most important aspects of gel cooking are: the branched spudger system. Each dynamic thermal treatment zone has a branched steam distribution sparger system which provides effective distribution of heat load through each and every grain.
In the gel cook process nutrients are pressed into deformed starch granules.
Calcium, thiamine, folate, niacin, iron, sodium, potassium, calcium, magnesium, phosphorus, dietary fiber and carbohydrates are completely locked into the endosperm.
After that the structure of the starch gets reformed and the grain becomes harder.
Hardness of the grain is controlled by varying the DSG or degree of starch gelatinization. Paddy is discharged from the high-intensity zone when desired DSG or degree of starch gelatinization is reached. The discharge is done through the rotary discharge gates.