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A study on existing rice processing system and drier performance in selected

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Thesis · November 2007

DOI: 10.13140/RG.2.2.15883.54561

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A STUDY ON EXISTING RICE PROCESSING
SYSTEM AND DRIER PERFORMANCE
IN SELECTED AUTO RICE MILLS

A PROJECT REPORT
by

KOWSHIK KUMAR SAHA

ID NO.-0503039
REG. NO.-29777
SESSION-2002-03

and

MUHAMMAD SHAHINUR ALAM

ID NO.-0503051
REG. NO.-29789
SESSION-2002-03

Submitted to the

Department of Farm Power and Machinery

Faculty of Agricultural Engineering and Technology
Bangladesh Agricultural University, Mymensingh

in partial fulfillment of the requirement

for the degree of

BACHELOR OF SCIENCE
IN
AGRICULTURAL ENGINEERING

November 2007

1
A STUDY ON EXISTING RICE PROCESSING
SYSTEM AND DRIER PERFORMANCE
IN SELECTED AUTO RICE MILLS

A PROJECT REPORT
by

KOWSHIK KUMAR SAHA

ID NO.-0503039
REG. NO.-29777
SESSION-2002-03

and

MUHAMMAD SHAHINUR ALAM

ID NO.-0503051
REG. NO.-29789
SESSION-2002-03

Approved as to style and content by

Supervisor
(Dr. Md. Ashraful Haque)

Chairman, Examination Committee

and
Head
Department of Farm Power and Machinery
Faculty of Agricultural Engineering and Technology
Bangladesh Agricultural University, Mymensingh

2
 DEDICATED
TO OUR
BELOVED PARENTS

3
 ABSTRACT

The study was conducted during the period from August 2006 to July 2007. The whole
processing system was observed in two auto rice mills in Mymensingh sadar upazilla. But
the detailed experimental study was done in Progoti Auto Rice Mill at Gopalpur,
Mymensingh. The mills process both parboiled and unparboiled rice and all available
local variety. This study dealt with the processing of parboiled rice and the rice variety
was BRRI-14 (Gazi). The initial moisture content of the paddy was 17.5% (wb). After
preliminary steaming the paddy was soaked in water at normal temperature for 6 hours.
Then it was again steamed with steam of temperature 105°C for 12 minutes. After
steaming the moisture content of the paddy increased to 29.5% wb. The materials were
then dried in a continuous flow re-circulating type mechanical drier for 7 hours and 10
minutes. The capacity of the drier was 11000 kg (M.C = 17.5% wb). Total weight of
water removed by the drier was 2090.88 kg from the dried material. The amount of
energy required to remove this water was 3763.58 MJ. The energy supplied from various
sources was 4439.54 MJ. The calculated efficiency of the drier was 84.77%. The drying
rate constant was found 0.35 per hour. After drying the average percentage of cracked or
fissured rice was found to be 5.2%. A rubber roll huller and three disc type polishers were
in operation in this rice mill. The milling recovery and head rice yield for mechanically
dried paddy were 71.5% and 70% respectively while for sun dried paddy these were 68%
and 65% respectively. The quality parameters of head rice like color, odor and head rice
recovery were observed as satisfactory.

4
 ACKNOWLEDGEMENT
All praise to acknowledge immeasurable grace and profound kindness of Almighty Allah, the
supreme Ruler of the Universe, who enabled to the author to discover the smallest fraction of his
significance of creation through this work.

The authors deem it a proud privilege and great pleasure to express their indebtedness, deepest
sense of gratitude, sincere appreciation and profound regards to their beloved and reverend
teacher and supervisor Dr. Md. Ashraful Haque, Associate Professor & Head, Department of
Farm Power & Machinery, Bangladesh Agricultural University, Mymensingh, for his kind
advice, scholastic constructive criticisms during entire study and in the preparation of the
project report manuscript.

They would like to extend of their heartfelt appreciation and thankfulness to Professor Dr. Bilash
Kanti Bala, Department of Farm Power & Machinery, Bangladesh Agricultural University,
Mymensingh for providing necessary practical facilities and helpful suggestions during the
course of the study.

They feel happy to express their cordial respect and profound gratitude to MR. AKM Saiful
Islam, scientific officer, Farm Machinery and Postharvest Technology Division, BRRI, Gazipur
and MR. Ashik-E-Rabbani, Assistance Professor, Department of Farm Power & Machinery,
Bangladesh Agricultural University, Mymensingh for their valuable suggestions.

They wish to convey their sincere gratitude and indebtedness to all the respected teachers of the
Department of Farm Power and Machinery, Bangladesh Agricultural University, Mymensingh,
for their kind help, co-operation and valuable suggestions.

They are very grateful to Mr. Abdul Quddus, proprietor, Mr. Shariful Islam, manager and all
labors of Progoti Auto Rice Mill, Gopalpur, for their help and assistance during this study. They
are thankful to Mr. Saiful Islam, rice mill technician for his assistance.

They would also like to acknowledge the support given us by our parents, brothers & sisters in
completing this project report.

THE AUTHORS

5
 CONTENTS

Chapter Page
REPORT APPROVAL ii

DEDICATION iii

ABSTRACT iv

ACKNOWLEDGEMENT v

LIST OF CONTENTS vi

LIST OF TABLES ix
LIST OF FIGURES x

LIST OF APENDICES xi

I INTRODUCTION 1
II REVIEW OF LITERATURE 4

III METHODOLOGY 7

3.1 Period of data collection 7

3.2 Site and mill selection 7

3.3 Data collection 7

3.3.1 Measurement of initial condition of input paddy 8

3.3.2 Soaking and steaming parameter 8

3.3.3 Ambient air condition and air flow rate 8

3.3.4 Psychrometric properties of drying air 9

3..3.5 Energy consumed by the drier 9

3.3.6 The energy actually utilized by the drier 9

3.3.7 Drying efficiency 9

3.3.8 Changes in moisture content of paddy during drying 10

6
 CONTENTS (continued)

Chapter Page
3.3.9 Drying rate constant 10

3.3.10 Percentage of fissure after drying 11

3.3.11 Milling recovery and different fractions 11

3.4 Measuring instruments 11

3.5 Description of the optical box 12

IV TERMINOLOGY 13

V PROCESSING OF PARBOILED RICE IN SELECTED RICE

MILLS 15

5.1 Parboiled and unparboiled rice 15

5.2 The processing steps 15

5.2.1 Collecting paddy 15

5.2.2 Cleaning 17

5.2.3 Soaking and Steaming 17

5.2.4 Drying 18

5.2.5 Dehusking and separation of husk 19

5.2.6 Polishing 19

5.2.7 Marketing and Supply 20

VI RESULTS AND DISCUSSION 21

6.1 Physical dimension of paddy 21

6.2 Pre-steaming and soaking 22

6.3 Steaming 22

6.4 Drying 22

6.4.1 Air flow rate 27

7
 CONTENTS (continued)

Chapter Page
6.4.2 Performance of the drier 27

6.4.3 Drying rate constant 28

6.5 Percentage of fissured grain 28

6.6 Milling recovery and head rice yield 30

VII CONCLUSION ANS RECOMMENDATIONS 32

7.1 Conclusion 32
7.2 Recommendations 33
VIII REFFERENCES 34
IX APPENDICES 37

8
 LIST OF TABLE

Table No. Title Page

6.1 Physical parameters of rough and milled rice 21

6.2 Air flow in the drier 27

6.3 Performance of the drier 28

6.4 The percentage fissured kernel 30

6.5 Milling recovery for mechanically dried and sun dried parboiled 30
paddy

9
 LIST OF FIGURES

Figure Title Page

No.
3.1 Psychrometric properties measurement points 9

3.2 Optical box 12

5.1 Rice milling system flow chart in auto rice mill 16

5.2 Boiler used in the rice mill 17

5.3 Soaking and steaming chamber 18

5.4 Cross flow type mechanical drier 18

5.5 Close view of a rubber roll huller 19

5.6 Three disc polishers working in series 20

6.1 Change of moisture content of paddy in drier with time for 1 st run 23

6.2 Variation of drying rate with moisture content during drying of paddy 24
for 1st run
6.3 Change of moisture content of paddy in drier with time for 2nd run 25

6.4 Variation of drying rate with moisture content during drying of paddy 26
for 2nd run
6.5 Moisture ratio versus time of drying 29

10
 LIST OF APPENDICES

Page

Appendix-A 37

Appendix-B 39

Appendix-C 42

Appendix-D 44

11
 CHAPTER-I
INTRODUCTION

Bangladesh is an agricultural country whose economy is largely dependent on agriculture.

Among the various crops produced in the country rice is the major one. Moreover rice is the
staple food of the population of this country. Majority of the rural population are involved in
production, processing and marketing of rice. But the rice processing technology followed by the
mill owners are either completely traditional or a combination of modern and traditional method.
The government of Bangladesh has not yet prescribed any standard for rice processing
technology. The millers are processing rice at their own convenience using partial mechanization
in combination with some obsolete techniques (Sarkar, 2001).

A rice kernel is covered by two layers. The outer layer is called the husk or hull and the inner
layer is the bran. The whole rice kernel, including these two layers, is called paddy (rough rice).
Husk is not edible and bran reduces the rice luster; therefore, they must be removed from the
paddy. The husk is not tightly attached to the kernel and is easily removed. When this layer is
removed, the kernel is called brown rice. The bran is more difficult to remove because it is
tightly attached to the kernel. The process of removing the bran is called whitening or Pearling.
During this process, rice kernels are subjected to intensive mechanical and thermal stresses
which might damage or break some of the kernels. Some parameters such as the type of
whitening machine, the paddy characteristics, and the environmental factors affect the rice kernel
damage and breakage during the milling process (S. Afzalinia et al, 2004).

Since the early 1970s, there has been a growing emphasis on rice post harvest technology and its
transfer to farmers and end-users. In Asia and the pacific region, post harvest losses of paddy
(rough or unhulled rice) due to delayed or improper drying or lack of drying facilities are high
especially when harvesting coincides with the monsoon or rainy season. Premature germination,
spoilage and damage due to fungi or insects are common losses incurred because of high grain
moisture content prior to milling.

12
Poor or defective drying facilities or incorrect drying procedures may result in very fast drying
rates, incomplete drying, moisture re-absorption, absence of tempering process and uneven
moisture distribution within the grain mass. Improper drying results in high cost, low
efficiencies, high milling losses and poor quality of milled rice. Deterioration of paddy is
accelerated when it is stored with high grain moisture content or is exposed to wet or high
relative humidity conditions. Unless the grain is dried immediately and properly stored after
harvest losses are likely to be incurred at the pre-milling and milling stages. A grain drier can be
evaluated properly only after reliable tests have been performed (RNAM, 1995).

At this stage, production and processing of quality rice for internal consumption and export can
be the means of augmenting farmers as well as national income. Since 1960’s, the production of
rice has been increased many fold but the matter of product quality is still neglected. The
physical dimensions of rice kernels are of vital importance to those engaged in the rice industry
and trading in international market. Rice varieties may be classified based on two physical
parameters i.e. length and shape. A good number of fine and coarse rice varieties are being
produced in the country. But they are grown and marketed in limited quantities. Coarse varieties
are rated best in quality and produce much higher return than high quality non-coarse rice in
international market. Appearance of milled rice is an important consideration to the consumer.
Appearance also depends upon the size and shape of the rice kernel, translucency and chalkiness
of the grain. The appearances of most Bangladeshi coarse and fine rice are good looking, white,
translucent and soft after boiling (BRRI, 2000).

Parboiled paddy should be dried to 12-14% moisture for safe storage or milling (Bala, 1997).
Parboiled paddy is more difficult to dry and requires more energy than none-parboiled paddy
because its moisture content is much higher. However; higher air temperatures help to reduce the
drying time. If drying is done too fast, internal stresses develop in the grain and cause breakage
during milling. After drying is completed, the paddy should be allowed to stand for at least
several hours preferably for 1 or 2 days to equalize moisture content (Vhutto, 2004).

Drying temperatures between 35˚C and 45˚C showed less fissuring effect depending on varieties
(Islam et al, 2003). In the field alternate drying and wetting due to sun and rain induce cracks in

13
the matured grains. Cracks are induced in the rice kernel if the cut crops are left in the field for
drying. The cracks are developed in the kernel because they were subjected to hydrothermal
stress. In the day time, the paddy temperature increased substantially, however, at night become
moisture due to dew, which produces hydrothermal stress in the grain enhance full cracks inside
the kernel (Mahadevapa et al, 1969; Mathews and Sapadaro, 1976).

In the old milling plants, a friction type whitener is often used in such a way that brown rice is
whitened by passing it through this whitener without using a polisher. In some cases, these
whiteners are used in series. In the modern milling plants, a set of three or four vertical abrasive
whiteners in series is used as whitener with a friction whitener as a polisher.

The quality of milled rice is greatly influenced by the whole processing system. But in our
country the processing system of rice is not technically developed yet. To develop this sector it is
primarily necessary to asses the existing processing system. So considerable amount of research
work is necessary in this sector.

The specific objectives of this study are as follows:

1. To study the existing processing system thoroughly in the selected auto rice mills.
2. To evaluate the drier performance in a selected auto rice mill and
3. To asses the quality of final product.

14
 CHAPTER-II
REVIEW OF LITERATURE

This chapter is devoted to a brief review of the results of some of the previous studies which are
related to present research work. It is always beneficial for research to consult available literature
to asses the stock of knowledge and re3cieve guidelines for conducting further research in the
particular area.

The factors responsible for grain loss during milling are fissures in the grains, type of the milling
equipment, degree of bran removed, physical dimension of the grains and content of immature
grain in the lot. Araullo et al. (1976) reported that the milling recovery of rice is 63% and 70%
from Engel burg type disc huller and rubber-roll huller, respectively.

Chavan and Magar (1977) reported that the length and breadth of 11 selected varieties of paddy
ranged from 7.2 to 9.4 mm and 2.2 to 3.4 mm respectively.
Sananyak and Weijerante (1990) observed the range of L/B ratio from 2.87 to 4.16 in 5 selected
rice varieties.

Sarker(1985) worked on three large rice mills located at different places and the average rice loss
of 3.66 kg of milled rice per 100 kg of rough rice due to breakage in milling. Individual grain
loss may be as high as about 25 of its head rice weight, if broken during milling and grain
breakage percentage was found to exceed the percentage of the cracked grains in the sample.

Rahman et al. (1996) discussed the advantages and disadvantages of different rice processing
units and concluded that rubber huller should be used in Bangladesh for better milling output and
quality of rice.

Wimberly (1972) reported that modern mills using rubber-roll hullers combined with abrasive
and friction whiteners gave an average overall increase in total rice recovery of 2.5% over a disc-
huller and 6.6% over the Engle berg huller with polisher on rural areas and modern automatic

15
rice mills in the commercial areas are essential. These types of mills can produce uniform quality
of rice.
Toquero (1977) conducted commercial milling / husking test in Philippines and found that
rubber-roll huller gave the highest husking/ milling recovery. Stone disc cone and steel huller
(Engle berg) followed in that order.

Arora (1985) carried out a study on different types of floors namely concrete, kacha, black
polythene, white polythene and canvass. Result of drying studies, milling test and cost analysis
for different floors revealed that black polythene is the best surface for sun drying of paddy.

Farouk (1994) discussed about the processing technology and management system for rice mills
in Bangladesh in his unpublished report. This report was studied and the processing technology
and management system for semi-automatic rice mills was known.

Araullo (1976) reported that the milling recovery of rice is 63%, 67% and 70% from Engel berg,
disc huller and rubber-roll huller rice mills respectively.

Mazed and Akhter (1996) observed that the milling recovery and quality of milled rice depends
on the milling machinery, pre-milling treatments and the paddy variety. Milling losses are very
high due to the use of inefficient steel huller for husking and polishing.

Choudhury (1984) mentioned from the preliminary results that the farm level rice post-harvest
losses from harvest to milling operations did not exceeds 15%.

BRRI and FAO (1985) reported the total paddy losses from harvest to milling were about 13%
and the parboiling drying and milling losses were reported to be 2.16%, 2.22% and 2.78%
respectively. The parboiling loss was due to improper parboiling, incomplete soaking and drying.
The milling loss was due to over polishing and breakage.

Haque and Quasem (1997) reported that the total paddy losses in Bangladesh from parboiling to
milling were 5.7, 7.7 and 6.7% for the aman, boro and aus seasons respectively with the

16
weighted average loss of 6.7%. Parboiling loss was high due to domestic animals and birds
feeding during drying and also scattering. Milling loss was 3.8%. Raw paddy milling produced
higher broken compared with parboiled paddy due to soft kernels.

Sarkar and Faruk (1989) reported that among all operations performed in harvesting and post
harvest processing of rice, major losses occur during milling (6%). The observed that inadequate
parboiling treatment, development of fissure in the grains and nature of milling equipments used
were some important factors responsible for losses during milling. The concluded that a set of
standards regarding the degree of milling and the selection of parboiling and milling equipment
are necessary for improving the performances of the rice processing industry in Bangladesh.

Duma (1990) studied the field performance of the UPBL-improved village rice mill, which
utilized a traditional steel huller in the Philippines. Milling recovery and head rice yield were 3-
8% higher than that of a traditional mill.

Jayasena and Han Gantilike (1986) studied commercial rice mills of Sri Lanka and found that
the total output of the modern mill was 69.2% and that of semi-modern and traditional huller
mills were 68.8% and 67.5%. The modern rice mill gave the highest head rice yield of 66.1%
and traditional huller mill gave the lowest of 60.3% and impurities were 0.3%, 0.5% and 0.7%
for modern, semi modern and traditional mill. The quality of bran received from the traditional
huller mill was high but low in quantity.

Kabir (1989) studied the milling quality of rice produced by local rice mills and found 85.38%
head rice yield, 14.17% broken rice and 0.28% impurities. The average moisture content of
milled rice was 14.99%.

Ahmed et al. (1996) in a study found that the post-harvest activities in Bangladesh were
traditional and labor intensive. The main activities were manual harvesting, manual threshing,
sun drying, winnowing, traditional parboiling and milling by huller mills or traditional devices.
Many of the post-harvest activities in the rural areas were done by women.

17
 CHAPTER-III
METHODOLOGY

The methodology followed in this study is described bellow.

3.1 Period of data collection

This study was conducted during the period from August 2006 to July 2007. We have done
the research study at the weekend or during off day along with our course study during this
period. We have made a presentation about this study during the last March 2007.

3.2 Site and mill selection

The Alalpur, Gopalpur and Shamvugonj union under Mymensingh sadar upazila were
selected as study area. These sites were selected because of their easy transportation facilities
and a large number of auto and semi-auto rice mills were densely located in this area. Nipa auto
rice mill, Alalpur and Millers auto rice mill, Gopalpur were selected for studying the processing
system and Progoti auto rice mill, Gopalpur was selected for detailed experimental study because
we have resource and time constraints to travel to a long distance on the other hand there exists a
congenial environment and we have friendly relationship with the working people. The selected
rice mills were fully automatic with the provisions of large drying yard for sun drying .The mills
process both parboiled and unparboiled rice and all the available local varieties. But this study
covers only the parboiled rice processing system and the studied rice variety was BRRI-
14(Gazi).

3.3 Data collection

In addition to the collection of information on processes, methods and equipment used for
processing of rice, following data were collected by direct measurement during operation of the
selected rice mill.
1. Initial condition of the input paddy
2. Soaking and steaming parameters

18
 3. Ambient air condition and air flow rate
4. Psychrometric properties of drying air
5. Energy consumed by the drier
6. The energy actually utilized by the drier
7. Drying efficiency
8. Moisture content changes of the paddy during drying
9. Drying rate constant
10. Percentage of fissure in kernel after drying
11. Milling recovery and different fractions

3.3.1 Measurement of initial condition of input paddy

Initially the physical dimensions and the moisture content of input paddy were measured. Several
kernels were taken randomly from different bag and their length and breadth were then measured
with the help of slide calipers. The length and breadth were determined for at least five kernels
and then average dimension was calculated. The breadth was measured at the middle and on two
sides of each kernel. The initial moisture content was also measured by the moisture meter taking
sample randomly from different locations of a bag and also from several bags. The average value
was then calculated for at least five samples.

3.3.2 Soaking and steaming parameter

After cleaning the paddy was soaked and partially boiled by passing steam inside the soaking or
steaming chamber. The condition of soaking water and the duration of soaking were measured.
The steam temperature, duration of pre-steaming and steaming were also measured by using stop
watch and digital thermometer.

3.3.3 Ambient air condition and air flow rate

The ambient air temperature and relative humidity were measured by using thermocouple at a
location just behind the blower inlet. The air velocity through the blower was measured by using
both digital and mechanical anemometer at the suction point of the blower. The inlet area of the
blower was measured and then air flow rate was calculated.

19
3.3.4 Psychrometric properties of drying air
From the temperature and the relative humidity of drying air other psychrometric properties were
read from the psychrometric chart. These properties were measured at three locations (shown in
Fig. 3.1) such as ambient condition, after passing the heat exchanger and finally after leaving the
drier.

Ambient Heat Dryer

condition exchanger
Point-1 Point-2 Point-3

Fig. 3.1: Psychrometric properties measurement points.

3.3.5 Energy consumed by the drier

The energy consumed by the drier was supplied from three sources. These were heat exchanger,
blower motor and conveyor motor. The energy supplied by the heat exchanger was measured
from the enthalpy difference of drying air before and after passing the heat exchanger and the
energy supplied by motors connected to the blower as well as the conveyor were taken directly
from their rated power.

3.3.6 The energy actually utilized by the drier

This is the amount of energy that is actually required to remove the moisture from the paddy to
dry it to desired level and it was measured by calculating the amount of moisture removed from
the paddy. The removed moisture was calculated from the initial and final moisture content and
total mass of paddy dried at a time.

3.3.7 Drying efficiency

While energy consumed by the drier that is energy input and the energy actually utilized by the
drier that is the energy output was measured than the drier efficiency was calculated as follows:

20
 Energyoutp ut
Efficiency   100
Energyinpu t

3.3.8 Changes in moisture content of paddy during drying

The sample of paddy was collected at 15 to 20 min interval and moisture content was measured
by using a moisture meter (Kett Electronic Co., special PB 210/6 No. 121469) following the
standard procedure.
Drying rate is the difference of two consecutive moisture contents of a drying material divided
by the average time interval. Mathematically the drying rate is expressed by the following
equation:

dm/dt= - (m2-m1)/Δt
Where,
dm/dt = drying rate, hr‫־‬¹
m2-m1 = difference of moisture contents of grain at time interval Δt
Δt = time in hour

3.3.9 Drying rate constant

Drying rate constant was calculated by graphical method using single exponential equation.
M Me
= ae  kt ............................................(3.1)
M Me
Which can be written as,
M Me
ln ﴾ ﴿= ln (a) kt
M Me
This is of the form
y=mx+c
Where
M Me
y = ln ﴾ ﴿
M Me
x=t

21
 m = -k
c = ln (a)
When the equation (3.1) is plotted on a semi-log paper, it will give a straight line with a negative
slop of
y2  y1
= (0.4343) (k) (f)
x2  x1
Where
f = scale factor
k can be determined graphically by drawing a straight line and determining the slope of the
straight line.

3.3.10 Percentage of fissure after drying

The percentage fissure of the kernel was measured by randomly taking samples of 50 kernels.
The husk of the dried paddy was first removed carefully by the forceps. Then the dehusked
kernels were observed by an optical box and the fissured kernels were counted to calculate
percentage of fissured kernels.

3.3.11 Milling recovery and different fractions

Data of milling performance were collected from the mill owner by asking him about the
quantity of head rice, broken rice, husk and bran obtained from 40 kg of paddy. The each milling
output was converted into percentage.

3.4 Measuring instruments

The following instruments were used to measure the required data:
1. Digital moisture meter (Kett, special PB 210/6 No. 121469).
2. Digital thermometer to measure grain and air temperature.
3. Digital hygrometer to measure relative humidity of air.
4. Digital and mechanical anemometer to measure the air flow rate.
5. Scale and calipers to measure length and breadth of rice kernel.
6. Optical box to measure fissure of rice kernel.

22
3.5 Description of the optical box
An optical box was fabricated for the purpose of identifying fissured rice kernel (illustrated in
Fig. 3.2). It is made of wood and the outside dimensions are 5˝x 5˝x 4.25˝. The box is fabricated
with the facility to provide an electric bulb (5 watt) inside the box. It consist a glass sheet of
diameter 2.5˝ on the top side. An extra cover is provided to protect the glass. 50 kernels can be
examined at a time.

Fig. 3.2: The optical box.

23
 CHAPTER-IV
TERMINOLOGY

The most important terminologies related to this study are defined below as per RNAM:

RICE:
Generally refers to the grain of Oryza sativa to distinguish it from other species of grain or
crop. Rice also refers to the kernel without the husk or hull or bran, i.e. milled rice. Unless
otherwise indicated, paddy or rice is referred to as grain.
PADDY OR ROUGH RICE:
Rice with hull or husk still intact with the grain; test paddy refers to the paddy being dried on
test the drier.
HUSK OR HULL:
The outermost rough covering of the paddy grain consisting of empty glumes and awn.
RICE DRIER:
A device for removing excess moisture in the grain, generally by forced convection with or
without addition of heat in drying air.
DRIED GRAIN:
Grain which have undergone a full cycle of drying and in which the level of moisture content
is considered appropriate for optimum milling and safe storage.
Grain which has been dried by means of the test driers called machine dried grain and which has
been died by means of laboratory drier is called laboratory dried grain.
BROWN RICE:
Rice kernel, the hull or husk of which have been removed, usually by a huller or a husker.
MILLED RICE:
Rice kernel, the hull or husk and bran of which have been removed.
HEAD RICE:
A whole grain of milled rice; also a broken milled rice grain with length equal to or greater
than 3/4 of the average length of a whole grain.

24
BROKEN RICE:
Brown or milled rice grain which is less than 3/4 of the original length of the grain.
PERCENTAGE CRACKED BROWN RICE:
The number of grains showing cracks or fissures per 100 grains of hand husked paddy.
Cracked grain index is the ratio of the percentage cracked brown rice from the machine dried
grain to that from the laboratory dried grain.
PERCENTAGE BROKEN RICE:
The percentage of broken rice recovered from the mass of the corresponding input paddy to
rice husker then to the whitener. Broken rice index is the ratio of the percentage broken rice from
the machine dried grain to that from the laboratory dried grain.
HEAD RICE RECOVERY:
The mass of head rice recovery from the mass of the corresponding input paddy to the rice
whitener. Head rice recovery index is the ratio of head rice recovery of the machine dried grain
to that of the laboratory dried grain.
TOTAL MILLING RECOVERY:
The percentage total mass of milled rice (head and broken rice) recovered from the mass of the
corresponding input paddy to the rice mill (husker or huller and whitener). Total milling
recovery index is the ratio of the total milling recovery of machine dried grain to that of the
laboratory dried grain.
PERCENTAGE HEAT DAMAGED GRAIN:
The number of grains showing thermal injuries, such as gelatinization, scorched portions,
deformation discoloration, per 100 grains. Heat damaged grain index is the ratio of the
percentage heat damaged grain from the machine drier to that from the laboratory drier.

25
 CHAPTER-V
PROCESSING OF PARBOILED RICE IN SELECTED
RICE MILLS

Processing of parboiled rice by the millers were observed and studied thoroughly including the
process involved, methods followed and equipment used. Information was collected without
disturbing the normal processing work done by the rice mill workers. These information are
presented in this chapter and the whole processing system is also shown in a flow chart in Fig.
5.1.

5.1 Parboiled and unparboiled rice

Major portion of the Bangladeshi people like parboiled rice. Parboiling involves soaking of
paddy either in hot or normal water followed by steaming. Parboiling is done to reduce breakage
in milling and to lengthen the storage life of rice. Soaking and steaming gelatinize the kernels
preventing development of fissures inside the kernels. Sometimes steaming of paddy is done
twice – once before soaking called pre-steaming and once after soaking; that is required for
complete gelatinization of the rice kernels. Soaking and steaming is omitted to produce
unperboiled rice. It is generally believed that unperboiled rice is more susceptible to breakage
and recovery of head rice is less than the parboiled rice.

5.2 The processing steps

Processing of parboiled rice involves a number of steps that required to be completed in
sequence, different methods are followed and different equipment is used. The processing system
of the mills under study is described below.

5.2.1 Collecting paddy

Generally the mill owner acts as a middlemen; that is buying and selling of rice is done by other
traders, millers only done the processing work and charge for processing per ton basis.
Sometimes the mill manager purchases paddy directly from the farmers.

26
 Paddy feeding Husk

Cleaning Burnt in burner

Impurity
Ground
Heated air into the boiler water in
Clean paddy Tank

Steam from boiler

Soaking/steaming chamber Ground
water lifting

Pre-steaming (5 min)

Heat exchanger Ambient air

Soaking (6 hrs)

Hot air
Steaming (12 min)

Drying (7.5 hrs)

Rubber roll huller Rough rice Broken rice HEAD RICE

Brown rice + Rough rice Separator

Rough
rice

Brown rice separator (petty separator) Polisher (3 stages)

Brown rice Bran

Fig. 5.1: Rice milling system flow chart in auto rice mill.

27
5.2.2 Cleaning
Cleaning is the removal of foreign materials such as particles of sand, stones, straw, seeds etc.
from the paddy. The input paddy contains a lot of impurities. These impurities were removed by
using a two stage sieve along with air blasting before entering the soaking chamber. In the first
stage, light impurities like chaff and dust were removed. And second stages, the heavier
impurities like stone and brick part were removed.

5.2.3 Soaking and Steaming

Soaking is the primary stage of parboiling. Quality of milled rice in terms of head rice recovery,
test, odour, hardness etc. depends on soaking process. Soaking was done to bring the moisture
content of rice to about 30% (w.b.). For better gelatinization and to reduce soaking duration pre-
steaming was done. Fresh ground water was used for this purpose. After soaking, steam was
passed through the soaking chamber for complete gelatinization of paddy.

Fig. 5.2: Boiler used in the rice mill.

28
 Fig. 5.3: Soaking and steaming chamber.
5.2.4 Drying
A continuous flow re-circulating type mechanical drier (Fig. 5.4) was used to dry the parboiled
paddy. The gelatinized paddies were conveyed into the drier by using an automatic belt
conveyor.

Fig. 5.4: Cross flow type mechanical drier.

29
The paddy re-circulated in the drier and hot air was passed through the drier as cross-flow. The
ambient air was heated by a heat exchanger.

5.2.5 Dehusking and separation of husk

It is the removal of the husk from the paddy with a minimum damage to the grain, and separating
the husk from the paddy. The husking was done by a rubber-roll huller. The husks, brown rice
and unhusked rice were separated by a tray-type paddy separator. Then unhusked rice was
returned to the huller.

Fig. 5.5: Close view of a rubber roll huller.

5.2.6 Polishing
The process of removing the outer and sometimes inner bran layer is most commonly referred to
as whitening. Sometimes it is termed polishing or milling. Polishing, however, refers to the
process of removing small bran particles that stick to the rice surface after whitening and gives
the rice grains shiny appearance. The two processes used to remove the bran from the grain are
abrasion and friction. The brown rice was polished in a abrasion type polisher. There were three
polishers coupled with sieves arranged in series. After polishing the head rice, bran and broken
rice were delivered through different outlets.

30
 Fig. 5.6: Three disc polishers working in series.

5.2.7 Marketing and Supply

The final product is packed in bags and supplied to the market by truck or other vehicle. The
bran and broken rice are also supplied separately to the market. The husk was used in the mill as
fuel to produce steam in the boiler.

31
 CHAPTER-VI
RESULTS AND DISCUSSION

Rice processing system in several auto rice mills were observed but detailed study was
conducted in Progoti Auto rice mill. Data on the following topics were collected by direct
observation and measurement during operation of the selected auto rice mills.
BRRI-14 (Gazi) rice was processed in the mill; initial moisture content of the rice was 17.5%
(w.b.). The following data were measured during processing.

6.1 Physical dimension of paddy

The average length and breadth of the rough rice (BRRI-14) processed in the mill were 8.24 mm
and 3.32 mm respectively. And the average length and breadth of milled rice were 5.38 mm and
2.4 mm respectively.
Table 6.1: Physical parameters of rough and milled rice
Rice Length Average Breadth Average L/B
kernel (L) mm Length (B) mm Breadth Ratio
type (L) mm (B) mm
8.4 3.2
8.1 8.24 3.4 3.32 2.48
Rough
8.0 (sd=0.1816) 3.3 (sd=0.1303)
8.3 3.2
8.4 3.5
5.1 2.1
5.4 5.38 2.3 2.4 2.24
Milled
5.6 (sd=0.1923) 2.5 (sd=0.2)

5.3 2.5
5.5 2.6

32
The FAO recommended that the length more than 7 mm is extra long, 6 to 7 mm is long, 5.5 to
5.9 mm is medium and less than 5.5 mm is short. The FAO also classified the shape of rice by
the length-breadth ratio; more than 3.0 is slender, 2.4 to 3.0 is medium, 2.0 to 2.39 is bold
(coarse) and less than 2.0 is round. According to this grading, the rice variety falls in short size
(length less than 5.5 mm) and in bold (length/breadth ratio .0 to 2.392).

6.2 Pre-steaming and soaking

Soaking was done at normal temperature with fresh ground water. The duration of soaking was 6
hours. Before soaking, pre-steaming was done for 5 mins to shorten the soaking period. In the
soaking process, the voids in the hull and rice kernel are filled with moisture and then swell,
which causes an increase in the volume of the grains. Soaking is necessary to increase the
moisture level of grain for complete gelatinization during steaming. After full soaking moisture
content of grain was 29.7 % (w.b.).

6.3 Steaming
After soaking the steam was passed through the grains for 12 mins. The steam temperature was
105°C. The parboiled paddy was then unloaded from the steaming vessel and loaded into the
drier conveyor.

6.4 Drying
Drying was done in a continuous flow re-circulating type drier. The capacity of the drier was
11000 kg per batch. During drying the moisture content of paddy in drier was measured for two
different runs and graphs of time versus moisture content are plotted and presented in Fig. 6.1
and Fig. 6.3. The drying rate versus moisture content is also presented in Fig. 6.2 and Fig. 6.4 for
these runs. From Fig. 6.1 and Fig. 6.3 it is evident that the moisture content initially reduced
rapidly but later it changed slowly, because of high resistance to move moisture from inside to
outer surface of the kernel. The drying rate versus moisture content graphs, show that the drying
rate reduced with the reduction of moisture and the trend could be explained by a straight line for
the range of moisture content shown in the graphs.

33
 1st run

40 Average %wb
35
30
Moisture content (%wb)

25
20
15
10
5
0
PM :5
0 05 20 40 00 20 55 15 35 55 15 35 55 15 45 05 25 45 05 30 45
5 12 1: 1: 1: 2: 2: 2: 3: 3: 3: 4: 4: 4: 5: 5: 6: 6: 6: 7: 7: 7:
:3
12
Time

Fig. 6.1: Change of moisture content of paddy in drier with time for 1st run.

34
 Drying rate vs moisture content
8 (1st run)

6
Drying rate %/h

0
15.8 15.6 16 16.1 17 17.5 17.2 17.4 17.9 19.8 19.6 19.2 20.2 21.3 22.4 24.6 24.4 28 27.1 28.4 29.4 29.5

Moisture content % (wb)

Fig. 6.2: Variation of drying rate with moisture content during drying of paddy for 1st run.

35
 Moisture content (%wb)

0
5
10
15
20
25
30
35
40
8:
05
am

8:
20

8:
35

8:
50

9:
10

9:
30

9:
50

10
:2
5
10
:4
5
11
:0
5
11
:2
5

36
11
:4
5

Tim e
2nd run

12
:0
5
12
:2
5
12
:4
5
1:
15
pm

1:
35

1:
55

2:
15
Fig. 6.3: Change of moisture content of paddy in drier with time for 2nd run.

2:
35

3:
00
Average %wb

3:
25
 Drying rate vs Moisture content
(2nd run)
6

4
Drying rate %/h

0
14.9 15.1 15.4 15.8 16.3 16.9 17.3 18.1 18.9 19.1 19.2 20.9 22.4 23.1 25 26.1 26.8 26.9 28.3 29.3 29.4
Moisture content % (wb)

Fig. 6.4: Variation of drying rate with moisture content during drying of paddy for 2nd run.

37
6.4.1 Air flow rate
The air flow rate was found 11.58 m3/s and that is 13.4 kg/s (at ambient condition specific
volume of air is 0.865 m3/kg, Appendix-B). The velocity was measured by both mechanical and
digital anemometer. The calculations are shown in Table 6.3.

Table 6.2: Air flow rate in the drier

Measuring Distance Time Velocity Average Inlet Air flow rate
instrument (m) (s) ( m/s) Velocity area of
( m3/s ) ( kg/s )
( m/s ) the
blower
( m2 )
Mechanical 433.53 90 4.81
Anemometer 567.98 130 4.36
403.04 90 4.47
Digital _ _ 4.87 4.745 2.44 11.58 13.4
Anemometer _ _ 5.01
_ _ 4.95

6.4.2 Performance of the drier

Table 6.3 shows the amount of energy supplied to the drier from different components of it. The
total energy input to the drier was 4439.54 MJ and the energy utilized was 3763.584 MJ. The
efficiency of the drier was found 84.77 %. This performance of drier is satisfactory. Due to some
limitations the boiler efficiency and fuel burning efficiency was not considered in this case. The
energy supplied by the heat exchanger and the total energy output was determined by
psychrometric analysis of drying air. The detailed calculation is given in Appendix-A and
Appendix-B.

38
 Table 6.3: Performance of the drier
Component Supplied Total Moisture Energy Drier
energy Energy removed actually efficiency
( MJ ) input ( kg ) utilized (%)
( MJ ) ( MJ )

Heat exchanger 3477.2

Blower motor 4439.54 2090.88 3763.584 84.77
577.404
Conveyor motor 384.936

6.4.3 Drying rate constant

The experimental data were plotted in a semi-log paper in the form of equation (3.1) as shown in
Fig. 6.5.
1.15  60
The drying rate constant, k =
3  0.4343 150
= 0.35 h 1
In the study drying rate constant was not very high. So the drying rate constant we found is very
low.

6.5 Percentage of fissured grain

After drying the percentage of fissured kernel was calculated and it was found 5.2 %. The drying
air temperature and drying rate have a great influence on fissuring of rice kernel. In this study the
drying air temperature was found 40.3˚C which is in the range recommended by Islam et al,
2003. The observed percentage fissured kernel was within the reasonable limit. Higher
percentage of head rice recovery was obtained from this result.

39
 1.00

1.15

3.0
Moisture ratio

0.10

0.01
0 60 120 180 240 300 360 420 480 540
f
Time, min

Fig. 6.5: Moisture ratio versus time of drying

40
 Table 6.4: The percentage fissured kernel
No. of No. of grain per Fissured Percentage Average percentage
observation sample found fissured kernel fissured kernel
1 50 3 6
2 50 2 4
3 50 4 8 5.2

4 50 3 6
5 50 1 2

6.6 Milling recovery and head rice yield

The average percentage of head rice, broken rice, husk and bran recovery were 70.0, 1.5, 16.0
and 5.5 in mechanical drier. On the other hand for sun dried paddy these recovery percentages
were 65.0, 3.0, 16.0, 6.0 and 10.0 (Table 6.5). The final moisture content of mechanically dried
and sun dried paddy was 14.6 % (wb) and 14.0 % (wb) respectively.

Table 6.5: Milling recovery for mechanically dried and sun dried parboiled paddy
Item Dried in mechanical drier Sun dried paddy

Weight % Weight %
( kg ) ( kg )
Paddy 40 100 40 100
Head rice 28.0 70.0 26.0 65.0

Broken rice 0.60 1.50 1.20 3.0

Husk 6.40 16.0 6.40 16.0

Bran 2.20 5.50 2.40 6.0

Weight Loss 2.80 7.0 4.00 10.0

41
From this comparative data it is clear that mechanical drier results better milling yield than sun
drying. This is because; in mechanical drier the parboiled rice dried uniformly and at a moderate
drying air temperature range. On the other hand sun dried parboiled rice undergoes a
hydrothermal stress which produce full cracks inside the kernel. In sun drying, the intensity of
sun light varies throughout the day and temperature does not remain uniform in different layers
of paddy. Moreover, at night, temperature falls and the grain adsorbs moisture from atmosphere.
All these reasons might have influenced to induce fissure in the sun dried kernels.

42
 CHAPTER-VII
CONCLUSION AND RECOMMENDATIONS

From this study, the following conclusion and recommendations can be made.

7.1 CONCLUSION
The mills under study process all available local varieties. They practice pre-steaming before
soaking. The soaking operation was done for 6 hours with fresh ground water. The moisture
content of the paddy after soaking was found 29.7 % (w.b.). The steaming temperature was
105˚C and duration was 12 min for parboiling. All the mills under study used rubber-roll huller
and mechanical drier but they have yard for sun drying also. The whole rice processing system is
highly technical, which requires skilled labor and technicians. It was observed that, the mills do
not have sufficient skilled labor and technicians. Most of the mill operators are untrained and
they operate mills with indigenous knowledge. The boiler used in the mills has not any standard
for steam pressure and temperature. Operating this boiler is very risky. Breakage of any parts of
the mill during operation causes a serious loss of time and profit because the millers has not
proper link with local workshop.

In this study the drying air temperature was 40.3˚C, resulting a drying rate which was not very
high. The drier efficiency found in this study was 84.77 %. The drying rate constant was found to
be 0.35 per hour, which is very low and indicates that the drying rate was not very high.
Percentage of fissured kernel was observed to be 5.2 % after drying, which is reasonable. This
might be attributed to low drying rate. Generally fissure results from high drying air temperature
and high drying rate. The milling recovery and head rice yield was found 71.5 % and 70 %,
respectively for mechanically dried paddy and those for sun dried paddy were 68 % and 65 %,
respectively.

43
7.2 RECOMMENDATIONS
For better output the moisture content after soaking should be more than 30 % (w.b.). The
moisture content of the paddy can be increased by using hot water for soaking. Fresh ground
water should be used to avoid any odor in the final product. There should have standard steam
pressure and temperature value and proper safety protection for safe operation of the boiler the
air flow rate should be controlled so that it can efficiently remove the moisture from the paddy to
get high drier efficiency. This efficiency can be improved by using the blower and conveyor
motors of appropriate horse power. The air flow rate should be such that it becomes fully
saturated after passing the drier. Mechanical drier results higher milling recovery and better
quality products than sun drying. So sun drying should be avoided. There should have
appropriate communication and agreement with the local workshops to repair the component
very quickly to minimize the loss of time and benefit due to breakage of any component of the
mill.. A good managerial skill is also necessary to increase the profit of the mill. Financial and
technical support from GOs and NGOs can improve existing condition of rice mills.
Considerable amount of research work is also necessary to improve the existing rice processing
system for quality rice production.

44
 CHAPTER-VIII
REFERENCES

Abedin, M.J. (2002). Experimental investigation on Solar Tunnel Drier for Drying of Jack Fruit
Leather. M.S. Thesis Dept. Farm Power and Machinery. Bangladesh Agricultural
University, Mymensingh.

Alam, M.M. (2004). Technical and Economic Performance of Some Selected Rice Mills of
Bangladesh. M.S. Thesis Dept. Farm Power and Machinery. Bangladesh Agricultural
University, Mymensingh.

Altaf, H.M. and Ashrafuzzaman, M. (2004). A Study On Recovery of Rice And By-products
From Various Mill Categories. A project report Dept. Farm Power and Machinery.
Bangladesh Agricultural University, Mymensingh.

Bala, B.K. (1997). Drying and Storage of Cereal Grains

Duma, R.C. (1999). Technical Evaluation of The UPLB Improved Village Rice Mill In Laguna.
Agricultural Mechanization Development Programme, University of Philippines. Los
Banos. Philippines.

Farouk, S.N.and Islam, M.R. (1994). Study of Processing Technology And Management
Systems For Rice Mills In Bangladesh. Bangladesh Agricultural University Research
Project.

Hoque, M.Z. (1975). Influence of cultural practices on the yield and performance of high
yielding varieties of rice. Workshop on experience with high yielding varieties of rice
cultivation in Bangladesh. BRRI.

Hussein, M.S. and S. Furuchi (1977). Effect of soaking time and temperature on the yield of

45
 parboiled rice. Joint International Conference on Agricultural Engineering and
Technology Exhibition, Dhaka.

Islam, A. (1997). Performance Study on Various Rice Husking Processes In Bangladesh. M.S.
Thesis Dept. Farm Power and Machinery. Bangladesh Agricultural University,
Mymensingh.

Kabir, H.M. (1989) Study of factors affecting parameters in in existing rice processing mills. A
project report, Dept.of Farm Power and Machinery. Bangladesh Agricultural University,
Mymensingh.

Kabir, U. (1997) A study on marketing of Boro paddy in some selected areas of co-operation and
marketing, Bangladesh Agricultural University, Mymensingh.

Kamal, S.M.K. (1998). Marketing cpnsumption patternof finding rice in some selected areas of
Dhaka and Gazipur district. Bangabandhu Sheikh Mujibur Rahman Agricultural
University, Salna, Gazipur,1703.

Khatun, F. and Akter, U.S. (2002). A study on Energy And Lobour Utilization In Village Rice
Processing Mills. A project report Dept. Farm Power and Machinery. Bangladesh
Agricultural University, Mymensingh.

Rahman, M.M. and Sarkar, S. (2002). A Study on The Milling Performance And By-Product
Utilization of Some Selected Semi Auto Rice Mills In Mymensingh And Jamalpur. A
project report Dept. Farm Power and Machinery. Bangladesh Agricultural University,
Mymensingh.

RNAM Test Codes and Procedures for Farm Machinery. Technical series No. 12.

Sarkar, N.N.and Farouk, S.M. (1989). Some Factors Causing Rice Milling Loss In Bangladesh.
Agricultural Mechanization In Asia, Africa And Latin America. Vol. 20. No.2 pp. 49-52.

46
Sarkar, N.N. (1985). Milling Performance of Some Rice Mills In The Mymensingh District. A
project report Dept. of Farm Power and Machinery. Bangladesh Agricultural University,
Mymensingh.

Singha, A.K. (2005). Grading And Quality of The Popular Rice Varieties Sold In Selected Local
Markets of Bangladesh. M.S. Thesis Dept. Farm Power and Machinery. Bangladesh
Agricultural University, Mymensingh.

Singhal, O.P. and Samuel, D.V.K. (2003). Engineering Properties of Biological Materials.

Vhutto, M.Z.A. (2004). Study of Coarse Rice Processing In Commercial Rice Mills in
Chapainawabgonj District. M.S. Thesis Dept. Farm Power and Machinery. Bangladesh
Agricultural University, Mymensingh.

47
 APPENDIX-A

Ambient Heat Dryer

condition exchanger
Point-1 Point-2 Point-3

Fig. A-1: Psychrometric properties measurement points.

h1= 96 kJ/kg
RH= 82%

M. C. = 0.0252 kg/kg of air

Point-1
wb1= 29.1ºC

db1= 32 ºC

Fig. A-2: Ambient air at point-1.

48
 h2= 106 kJ/kg

RH= 54%

M. C. = 0.0252 kg/kg of air

wb2=31.1ºC

Point-1

Point-2

db2 = 40.3 ºC

Fig. A-3: Point-1 to point-2 sensible heating.

h3= 106 kJ/kg

Point-3
M. C. = 0.0292 kg/kg of air

RH=100%

Point-1 Point-2

db3 = 31 ˚C

Fig. A-4: Point-2 to point-3 after passing the dryer.

49
 APPENDIX-B

Detail calculation of drier performance:

The average air velocity = 4.75 m/sec
Air velocity was measured at the inlet of the blower by both mechanical and digital
anemometers. And finally the average air velocity was considered.
Inlet area of the blower, A= length x breadth
=160.00 cm x 152.4 cm
=24384 cm 2
=2.44 m 2
Air flow rate, Q= A x V= 2.44 m 2 x 4.75 m/s
= 11.59 m 3 /s
From psychrometric chart, at ambient temperature 32°C and RH= 82%,
Specific volume of air = 0.865 m 3 /kg
3
1.59 m
Mass flow rate M= s = 13.4 kg/s
3
0.865 m
kg

Quantity of rice dried in each batch, ( ww1 + wd1 ) = 11000 kg

(With initial moisture content, m w1

= 17.5 % (w.b.)

Now weight of water at this condition,

w w1
 (ww1  wd 1)  mw1

= 11000 x 0.175
= 1925 kg
So weight of bone dry material,

w d1
= (11000-1925) kg

=9075 kg
In the drier at time t = 0, moisture content, m w2
= 29.5 % ( wb)

m d2
= 41.08 % (db)

50
 Weight of water contained, w w2
= w m
d1 d2

= 9075 x 0.418
= 3793.35 kg

m = 15.8 %( wb)
After drying final moisture content, w3

m = 18.76 %( db)
d3

Weight of water remaining, w = w m

w3 d1 d3

= 9075 x 0.1876
= 1702.47 kg
Weight of water removed during drying,

w w
 (ww2  ww3) kg

= (3793.35-1702.47) kg
= 2090.88 kg

Since 1800 KJ energy is required to remove 1 kg of water from paddy (Bala, 1997), the
amount of energy required to remove 2090.88 kg of water is,
E = 1800 KJ/kg x 2090.88 kg
= 3763584 KJ
= 3763.584 MJ
i.e. drier output energy is 3763.584 MJ
Dry bulb temperature of the ambient air T 1 = 32°C and relative humidity RH= 82%.
From psychrometric chart, enthalpy of the ambient air 96 KJ/kg
After passing the heat exchanger, the temperature became T 2 = 40.3°C and relative humidity
RH= 54%
From psychrometric chart enthalpy of this air, h 2 = 106 KJ/kg
Air flow rate is 13.40 kg/s
Total drying time = 430 mins
Total energy added by heating,
E 1 = (106-96) KJ/kg x 13.40 kg/s x 430 mins x 60 s/1 min
= 3477200 KJ

51
 = 3477.2 MJ
Rated power of blower motor = 30 hp
= 30 hp x 746 W/1hp
= 22380 W (J/s)
Power input to blower motor,
E 2 = 22380 J/s x 430 mins x 60s/1 min x 1 KJ/1000J
= 577404 KJ
= 577.404 MJ
Rated power of the conveyor motor = 20 hp
= 20 hp x 746 W/1hp
= 14920 W (J/s)
Power input to the conveyor motor,
E 3 = 14920 J/s x 430 mins x 60s/1 min x 1 KJ/1000J

= 384936 KJ
=384.936 MJ
Total energy input, E 1 +E 2 +E 3 = 3477.2 + 577.404 + 384.936

= 4439.540 MJ
Output 3763.584
Drier efficiency = =  100 = 84.77%.
Input 4439.540

52
Table C-1:
Data table for 1st run (Progoti auto rice mill)
Date: 03-05-2007

Time Cumulative Reading-1 Reading-2 Reading-3 Reading-4 Average Drying

Time interval time %wb %wb %wb %wb %wb rate
12:35
PM 0 30.1 29.4 29.6 28.8 29.5
12:50 15 15 29.1 30.2 30.3 28 29.4
1:05 15 30 29.2 28.6 28.3 27.6 28.4 4
1:20 15 45 27.8 25.9 27.5 27.2 27.1 5.2
2.7

APPENDIX-C
1:40 20 65 26.3 29.2 27.8 28.7 28
2:00 20 85 23.1 25.3 24.7 24.5 24.4 7
2:20 20 105 25.2 23.4 26.1 23.7 24.6
2:55 35 140 23 22.1 22.5 22.1 22.4 3.77
3:15 20 160 22.5 22.2 20.1 20.3 21.3 3.33
3:35 20 180 20.9 20.1 19.7 19.9 20.2 3.3
3:55 20 200 18.6 19.8 19.3 19.1 19.2 3
4:15 20 220 20 19.1 20.1 19.2 19.6
4:35 20 240 20.6 19.7 19.3 19.5 19.8
4:55 20 260 17.9 17.2 17.8 18.5 17.9 5.7
5:15 20 280 17.3 17.1 17.8 17.3 17.4 1.5
5:45 30 310 17.7 17.3 16.8 16.9 17.2 0.4
6:05 20 330 17.8 17.4 17.2 17.6 17.5
6:25 20 350 16.6 17.1 17.4 16.9 17 1.5
6:45 20 370 16.1 15.9 16.5 16 16.1 2.7
7:05 20 390 16.3 16.2 15.7 15.8 16 0.3
7:30 25 415 15.2 15.9 15.5 15.8 15.6 0.96
7:45 15 430 16.3 15.9 15.5 15.3 15.8 0.8

53
Table C-2:
Data table for 2nd run (Progoti auto rice mill)
Date: 17-05-2007

Time Cumulative Reading-1 Reading-2 Reading-3 Reading-4 Average Drying

Time interval time %wb %wb %wb %wb %wb rate
8:05am 0 30.1 29.2 29.5 28.9 29.4
8:20 15 15 30.2 29.4 29.9 28.5 29.3 0.4
8:35 15 30 28.7 28.5 27.9 28.2 28.3 4
8:50 15 45 25.8 27.1 27.5 27.2 26.9 5.6
9:10 20 65 26.1 27.2 26.8 27.5 26.8 0.3
9:30 20 85 25.9 26.2 26.4 25.8 26.1 2.1
9:50 20 105 25.8 23.9 25.6 24.6 25 3.3
10:25 35 140 23 23.4 22.8 23.1 23.1 3.26
10:45 20 160 22.6 22.1 22.7 22.3 22.4 2.1
11:05 20 180 21.5 20.6 21.3 20.2 20.9 4.5
11:25 20 200 19.6 19.2 19.1 18.7 19.2 5.1
11:45 20 220 19.3 19.5 18.6 18.9 19.1 0.3
12:05 20 240 18.7 19.1 18.87 19.3 18.9 0.6
12:25 20 260 18.1 17.9 18.5 17.8 18.1 2.4
12:45 20 280 17.2 17.3 17.5 17.1 17.3 2.4
1:15pm 30 310 16.9 17.2 16.8 16.5 16.9 0.8
1:35 20 330 15.7 15.5 16.9 17.2 16.3 1.8
1:55 20 350 15.9 15.6 15.1 16.5 15.8 1.5
2:15 20 370 15.2 15.3 15.5 15.7 15.4 1.2
2:35 20 390 14.9 14.8 15.5 15.2 15.1 0.9
3:00 25 415 14.7 14.6 15.3 15 14.9 0.48
3:25 25 440 14.4 14.3 15 14.9 14.6 0.72

54
 APPENDIX-D

Calculation of drying rate constant

Table D-1:
Drying rate constant for 2nd run
Date: 17-05-2007

Time Cumulative Average

Time interval time %wb Average % d.b. Moisture ratio
8:05am 0 29.4 0.416 1
8:20 15 15 29.3 0.414 0.99
8:35 15 30 28.3 0.394 0.92
8:50 15 45 26.9 0.367 0.84
9:10 20 65 26.8 0.366 0.83
9:30 20 85 26.1 0.353 0.79
9:50 20 105 25 0.333 0.72
10:25 35 140 23.1 0.3 0.61
10:45 20 160 22.4 0.288 0.57
11:05 20 180 20.9 0.264 0.49
11:25 20 200 19.2 0.237 0.4
11:45 20 220 19.1 0.236 0.4
12:05 20 240 18.9 0.233 0.39
12:25 20 260 18.1 0.221 0.35
12:45 20 280 17.3 0.209 0.31
1:15pm 30 310 16.9 0.203 0.29
1:35 20 330 16.3 0.194 0.26
1:55 20 350 15.8 0.187 0.23
2:15 20 370 15.4 0.182 0.22
2:35 20 390 15.1 0.177 0.2
3:00 25 415 14.9 0.175 0.19
3:25 25 440 14.6 0.171 0.18

55

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