ACKNOWLEDGEMENT

All praise is due to Allah the custodian of the universe and hereafter, for preserving our soul
alive to this day and making this work a success. May his mercy and blessing be upon his servant
and Messenger Muhammad (S.A.W), his family, companion and all those who follow his
guidance till the last day.
I am highly thankful and grateful to almighty y Allah for providing me with the life, health and
knowledge enough to complete these pieces of work. Many thanks also to my parent and siblings
for their words of encouragement and moral support.
To my supervisor Malam Nura Abdullahi, I am very grateful for supervision and guidance
during the course of my studies. Special thanks to Engr. Usman Shafiu personal manager and
Engr. Sagir production manager Al-Hamsad golden rice mill for the constant position criticism
and guiding to make me a better experience and .research student.
My profound gratitude is due to my respective lectures and then entire staff of the department of
food science and technology and my colleagues in the department.
I am greatly indebted to all my friends and family who remained supporting especially during the
difficult period of this training Adamu Ado Adamu And many more that space will not allow
me to mentioned their names. I THANK YOU ALL.

1
 DEDICATION
This pieces of work is whole dedicated to almighty Allah (S.A.W) For His guidance and my First
beloved (Nafisat Adamu)

2
Content

DEDICATION………………………………………………………………………..……………………………………………………………………I

ACKNOWLEDGEMENT……………………………………………………………………………………………………………………………..II

CHAPTER ONE..............................................................................................................................................1
1.0 INTRODUCTION...........................................................................................................................1
1.2. A BRIEF HISTORY OF THE SIWES, AIMS AND OBJECTIVES................................................1
1.3. AIMS AND OBJECTIVES OF SIWES...........................................................................................1
CHAPTER TWO.........................................................................................................................................2
2.1 BRIEF HISYTORY OF THE COMPANY.......................................................................................2
2.2.ORGANIZATIONAL SET-UP.........................................................................................................3
CHAPTER THREE.....................................................................................................................................4
3.0.THEORITICAL ASPECT OF THE PROGRAMME........................................................................4
3.1. INTRODUCTION:...........................................................................................................................4
3.2.DIFFERENT SECTIONS IN RICE PROCESSING INDUSTRY.....................................................4
3.2.1.RAW MATERIAL WAREHOUSE................................................................................................4
3.2.1.1.Method Of Preventing Raw Material From Spoilage In The Warehouse.....................................4
3.2.1.2. Function of The Raw Material Warehouse.................................................................................5
3.3. LIFTING AND TRANSPORTING EQUIPMENT..........................................................................5
3.3.1. BUCKET ELEVATOR.................................................................................................................5
3.3.2. CHAIN CONVEYOR...................................................................................................................6
3.3.3. BELT CONVEYOR......................................................................................................................6
3.3.4.SCREW CONVAYOR...................................................................................................................7
3.4. TERMINOLOGIES IN RICE PROCESSING..................................................................................7
.................................................................................................................................................................9
3.5.2. INTAKE POINT..........................................................................................................................10
3.5.3.PRE-CLEANING SECTION........................................................................................................10

3
3.5.3.1. CLEANING..............................................................................................................................10
3.5.3.2. PADDY VIBRATING-CLEANER..........................................................................................11
3.5.3.5. DE-STONER............................................................................................................................12
3.5.4. PARBOILING SECTION...........................................................................................................13
3.5.4.1. CHANGES AFTERPARBOILING
............................................................................................................................13
3.5.4.2. ADVANTAGES OF PARBOILING........................................................................................14
3.5.4.3DISADVANTAGE OF PARBOILING......................................................................................14
3.5.4.4. MAJOR STAGES OF PARBOILING PROCESS....................................................................15
3.5.4.5. SOAKING................................................................................................................................15
3.5.4.6. OBJECTIVES OF SOAKING..................................................................................................16
3.5.4.7. STEAMING.............................................................................................................................17
3.5.4.8. SOME ADVANTAGES OF STEAMING................................................................................18
3.5.4.9. DRYING...................................................................................................................................18
3.5.4.10. TRADITIONAL DRYING METHOD:..................................................................................18
3.5.4.11. Mechanical drying method:....................................................................................................18
3.5.5. MILLING SECTION...................................................................................................................20
3.5.5.0. MILLING OPERATION OF PADDY.....................................................................................20
3.5.5.1 FLOW CHART.........................................................................................................................20
PARBOILED PADDY........................................................................................................................20
3.5.5.2. VIBRATING-CLEANER.........................................................................................................21
3.5.5.3. DE-STONING ............................................................................................................................22
3.5.5.4. DE-HUSKING..........................................................................................................................22
3.5.5.5. DOUBLE BODY PADDY SEPERATOR................................................................................24
3.5.5.6. WHITENING...........................................................................................................................26
3.5.5.7. POLISHING.............................................................................................................................26
3.5.5.8. MULTIPLE GRADER.............................................................................................................27
3.5.5.9. LENGTH GRADER.................................................................................................................28
3.5.5.10. RICE COLOR SORTER.........................................................................................................29
3.5.5.11. Working principle:..................................................................................................................30
3.5.5.12. Difference By-Product Of The Rice Mill Industry..................................................................31
3.5.5.13. Difference Between Brown Rice And White Rice..................................................................31
3.5.5.14. ImportantFunctions Of Brown Rice Over a White Rice..........................................................32

4
 1. Brown Rice is Rich in Selenium......................................................................................................32
2. Brown Rice is Very High in Manganese..........................................................................................32
3. Brown Rice Holds Naturally Occurring Oils....................................................................................32
4. Brown Rice Promotes Weight Loss................................................................................................32
5. Brown Rice Has Antioxidants.........................................................................................................32
6. Brown Rice is Very High in Fiber....................................................................................................32
7. Brown Rice is a Slow-Release Sugar...............................................................................................33
3.5.6. LABORATORY ANALYSIS.....................................................................................................33
3.5.6.1. Analysis of paddy base on characterized grades.......................................................................33
3.5.6.2. Analysis of paddy at the drying stage base on average moisture level for milling....................33
3.5.6.3. Analysis of milled Rice.............................................................................................................33
3.5.6.4. Discussion.................................................................................................................................34
3.5.7.1. PACKAGING...........................................................................................................................34
3.5.7.2. FINAL PRODUCT WAREHOUSE/STORAGE......................................................................35
3.8.0. STEAM SOURCE.......................................................................................................................35
3.8.1. BOILER.......................................................................................................................................35
4.0 CHAPTER FOUR....................................................................................................................................36
4.1. PROBLEMS ENCOUNTERED.............................................................................................................36
CHAPTER FIVE............................................................................................................................................37
5.1. SUMMARY...................................................................................................................................37
5.2 CONCLUSION...................................................................................................................................37

5
6
 CHAPTER ONE
1.0 INTRODUCTION
The student industrial training is the training programm which forms part of the academic
standard in the various degree programme for all Nigeria Tertiary Institutions. It seeks to bridge
the gap existing between technology and other professional education programmes in Nigerian
Tertiary Institutions.

1.2. A BRIEF HISTORY OF THE SIWES, AIMS AND OBJECTIVES

Student industrial work experience scheme (SIWES) is an accepted skills program which forms
part of the approved academic standards in the degree program for Nigerian universities. In
1974, the federal government of Nigeria introduced the national policy on industrial training,
called the student industrial work experience scheme (SIWES). This program is under the
umbrella of the Ministry of Education through the Industrial Training Fund (ITF), was designed
to help students acquire the necessary practical education/experience in their fields of study and
other related professions.

This is an effort which was created in order to bridge the existing gap between the theory taught
in the classroom and practice of science, agriculture, medicine, engineering, technology and
other professional programs in the Nigerian tertiary institutions. This program is aimed at
exposing the students to the use of various machines and equipment’s, professional work
methods and ways of safeguarding the work areas in organizations and parastatals. The program
was established basically to impact elaborate practical understanding the students with respect to
their various disciplines. It is also intended that the student through a process relation to
academic knowledge and practical industrial application would understand the underlying
principles acquire the practical applications towards excellence in his or her discipline.

The Students Industrial Work Experience Scheme (SIWES) program involves the student,
Universities and the industries. This training is funded by the Federal Government of Nigeria and
jointly coordinated by the Industrial Training Fund (ITF) and the National Universities
Commission (NUC).

7
1.3. AIMS AND OBJECTIVES OF SIWES

i. To prepare students for the work situation they are likely to meet after graduation.
ii. To expose students to work methods and techniques in handling equipment and
machinery that may not be available in the university / institute.
iii. Provide a student an opportunity to apply their bridging the gap between higher
education and actual practice.
iv. Enlist and strengthen employer’s involvement in the entire educational process of
preparing university graduates for employment in industry.
v. To provide an avenue for students in the university to acquire industrial skills and
experience in their course of study
vi. Make transition from the university to the world of work easier and thus enhance
students contact for late job placement after graduation.

8
 CHAPTER TWO
2.1 BRIEF HISYTORY OF THE COMPANY
A Brief History of Al-hamsad Golden Rice Mill Limited (Rice Mill).Al-hamsad Golden Rice
Mill is located at Plot 129 kundila bompai , Industrial Estate, Nasarawa local government ,kano
Nigeria. Al-hamsad rice mill is owned by Alhaji Dalhatu Abubakar.

Few years back, starting from the year 2015, when there was a change of Government from the
hands of Former president Goodluck Ebele jonathan, lot of government policies where changed
part of which was diversification of economy into Agricultural sector which also leads to the
restriction of the importation of most food stuffs item including foreign Rice.

This leads to emergence of new companies moving into the domestic production and Milling of
Nigeria local Rice.

This was one of the Encouraging reasons which brought about the establishment of Al-Hamsad
rice mill ltd.

The need to develop the economy by establishing home made rice milling company crossed the
mind of the chairman Al-Hamsad groups in person of Ah Dalhatu Abubakar and the process
commenced immediately starting from the year 2016.

By the year 2017, the processes needed for the establishment has already been accomplished of
which production successfully commenced by march 2017 producing at lower capacity of about
50 bags a day after training of staffs who are going to be operating the milling machines were
done before such period. The process was on the positive side, as the staffs were trying their
possible best to understand how the machines operate and meets up with the customers demands.

By the end of 2017, the company was stable enough as its number of customers were even
beyond its capacity.

This brought about the need to expand the factory, which was immediately commenced at that
period by the chairman, moving up from about 50 bags per day to about 600 bags per day, and
the process was completed around ending of 2017 to early 2018. The company has a staff
capacity of about 100 staffs including both the admin and factory staffs, who are tirelessly

9
 working for the success and up growing of the business. And the company is currently the best
White rice producing company in Kano, and in Nigeria as a whole in high competition to win the
market shares in the production of parboiled Rice.

After the expansion to about 600 bags in 2017 ending towards early 2018, the customer base also
increased, and such capacity can’t also satisfy the customer base, a further expansion is also on
the process with the hope of completing such the expansion in April 2019, and by the time such
is completed, the company will be producing about 2,400 bags per day.In conclusion Al-hamsad
rice mill is having a vision to be the best Rice milling company not only in Nigeria but in AfrIca

2.2.ORGANIZATIONAL SET-UP
CHAIRMAN

MANAGING DIRECTOR & CHIEF

EXECUTIVE OFFICER

GENERAL MANAGER PRODUCTION MANAGER

ADMIN ACCOUNTAN SALES/MKT CHIEF FLOOR/FACTORY QUALITY

MANAGER T ING MGR. SECURITY MANAGER CONTROL MGR

ADMIN ACCOUNT SALES/MKT SECURITY MACHINE MACHINE

OFFICER OFFICER ING OFFICER GUARD OPERATOR MAINTENANCE

10
 CHAPTER THREE
3.0.THEORITICAL ASPECT OF THE PROGRAMME
3.1. INTRODUCTION:
Rice (Oryza sativa L.) is the staple food for nearly two-thirds of the world’s population. It has been
reported that as much as 75% of the daily calorie intake of the people in some Asian countries is derived
from rice. It is reported that the world's stocks of stored rice grain have been falling relative to each
year's use, because the consumption surpasses the production. The deficiency of food production not
different social and economic unrest. Researchers have also predicted that the global warming will make
rice crops less production and it could threaten to erase the hard-won productivity gains that have so far
kept the rice harvest in step with population growth. Rice processing is a combination of several
operations to convert paddy into well milled silky-white rice, which has superior cooking quality
attributes. The majority of consumers prefer well milled rice (WMR) with little or no bran remaining on
instance, the Japanese like well milled sticky rice, but Americans prefer semi-milled long grain or even
Rice properties are known to be dependent on the variety of rice, methods of cultivation, processing

3.2.DIFFERENT SECTIONS IN RICE PROCESSING INDUSTRY

3.2.1.RAW MATERIAL WAREHOUSE
Raw material warehouse is the storage area where the raw rice can be stored for a long period of
time which gives prevention to the raw material product from attack of rodents, insects, and
direct sunlight before the production take place.

3.2.1.1.Method Of Preventing Raw Material From Spoilage In The Warehouse

1. The raw material warehouse should be arranged with palates or canvas to avoid
an attack from rodent and any other insect.
2. The raw material of paddy rice should be arrange accordingly due to some that
were not dried to the average moisture content safe for storage (11-15%) which
will be prevented from darkness or germination.
3. Distance from roofing to the raw material arrangement should be provided to
avoid warmth from sunlight.

11
3.2.1.2. Function of The Raw Material Warehouse
The main function of the raw material warehouse is to provide maximum prevention to the raw
material product from different attack that may lead to spoilage. Raw material warehouse have
also another importance which preventthe raw material from direct sunlight, which may lead to
the reduction of the nutritional values of some food products.

3.3. LIFTING AND TRANSPORTING EQUIPMENT

3.3.1. BUCKET ELEVATOR
Elevator is any type of conveyor device that lift and transport the material in a continuous
stream in to bins. Elevators are generally powered by electric motors that either drive traction
cables and counterweight systems like a hoist, or pump hydraulic fluid to raise a cylindrical
piston like a jack.

Outlet Outlet

Inlet Inlet

Bucket elevator

12
3.3.2.BELT CONVEYOR
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor). A belt conveyor system is one of many types of conveyor systems. A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums), with an endless loop of
carrying medium—the conveyor belt—that rotates about them. One or both of the pulleys are
powered, moving the belt and the material on the belt forward. The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley. There are two main industrial
classes of belt conveyors; those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials, such asgrain , salt , coal , ore , sand , overburden and more.

Belt conveyor

3.3.3.SCREW CONVAYOR

A screw conveyor Is a machine that uses a rotating helical screw blade,called a ‘’flighting ‘’,usually
within a tube, to move liquid or granular materials, They are used in many bulk handling industries.

13
 Conveyor Screw

3.4. TERMINOLOGIES IN RICE PROCESSING

To understand the different objectives of rice milling, one should know the following terms:

Rough RICE: Also called paddy rice. Rice as it comes from the field. Rice kernels are still
encased in their inedible, protective hull.

Paddy rice

Brown RICE: Brown rice is the hole grain with just the first outer layer (husk or hull) removed
through milling

14
 Brown rice

White RICE: This is the brown rice after whitening and polishing which include the removal of bran and
layer the bran of the brown rice.

White rice

Milling Recovery: Total milled rice obtained out of paddy; this is expressed as weight
percentage of milled rice (including broken) obtained from a sample of paddy. The maximum
milling recovery is 69-70% depending on rice variety, but because of grain imperfections and the
presence of unfilled grains, commercial millers are happy when they achieve 65% milling
recovery. Some village type rice mills have 55% or lower milling recovery.
Milling Degree: This is a measure of the amount of bran removed from the brown rice.
Head Rice: Milled rice with length greater or equal to three quarters of the average length of the
whole kernel. It is often expressed on a % paddy or rough rice basis (on 14% Moisture content
basis).
Head Rice Recovery: Weight percentage of head rice (excluding broken) obtained from sample
of paddy. Under controlled conditions head rice recovery can be as high as 82% of the total
milled rice or 56% of the paddy weight. Commercial rice mills turn out 53% head rice on
average, whereas head rice recovery of local processed is in the order of 30%.
Whole Grain: This is a milled rice grain without any broken part.
Impurities: This refers to the materials in the rice that are not part of the milled rice kernel. It
may include stones, husk, bran , chaff and weed seeds, etc.
Blower: The blower can simply be described as a mechanical device (high speed far) which
directs streams of air through a pipe network at a very high pressure and it is used to transport
15
products from one place to another. The major component which make up the blower are: the fan
blade (made from lighter-material such as aluminium) an electric motor which provide power for
the high speed rotation of the fan blade. During operation, the design of the fan blade (blending
outward) produces spray of air forward which are directed through conveyor pipe network for
pneumatic operation.
Compressor:

3.5.0.RICE PRODUCTION PROCESS

3.5.1. FLOW CHART

INTAKE

ELEVATOR

PRE CLEANING

ELEVATOR

SILOR

SORKING TANKS

BELT CONVERYOR
MACHANICAL DRYER
AUTOMATIC DRYER
BURNER
3.5.2 INTAKE POINT

Intake point is the area where the raw paddy is collected and been subjected to the pre-cleaning
section. Intake point has a slopping structure that the sacks are opened manually by the workers
where the paddy are poured in the intake channel through a metal grid and been transported to
the pre-cleaning section by means of bucket elevator.

16
3.5.3.PRE-CLEANING SECTION
3.5.3.1PRE-CLEANING
After harvesting and threshing rice, it is transferred to the processing plant where foreign objects
are removed. Pre-cleaning is the removal of foreign material such as sand, stones, straw, metal
particles, and other seeds from the paddy. Pre-cleaning is the first step in modern rice milling.
Cleaning not only produces clean rice but also protects the other milling machinery and increases
milling capacity.

Pre-cleaning section comprised of two cleaning machine.

1. Paddy pre-cleaner machine
i. Drum sieve
ii. Separator
2. De-stoner machine

3.5.3.2. PADDY VIBRATING-CLEANER

Vibrating cleaner, is also called vibrating cleaning sieve, can be widely used in initial of
paddy rice and other food. It is generally erected in paddy cleaning procedure to remove large,
small and light impurities. By equipped with different sieve with different meshes, the vibrating
cleaner can classified the paddy according to it size and then we can get product with different
size.

The vibrating cleaner has a two tier screen surface, sealing well. As a result of the vibrating
motor drive, the size of excitation force, vibrating direction and screen body angle can be
adjusted, vibrating cleaner is characterize by the high removing impurity efficiency, stable
performance smooth operation low power consumption.

17
Drum sieve: This is a cleaning apparatus which is used for the removal of any large impurities,
large stones, sand and immature paddy. Sand and immature are discharge by means of screen
conveyor.

Motor Large particles

Drum sieve

18
Separator: This is also another cleaning apparatus attached by paddy pre-cleaner which are used
for the removal of small impurities, where sand and immature paddy are sucked out by means of
blower as the paddy is transported to the des-toner machine for further operation

3.5.4. PARBOILING SECTION

Parboiling is a hydrothermal treatment of rough rice (paddy) prior to milling. Parboiling affect
the milling stage cooking and ultimately consumers preference of rice.

Parboiling process of paddy intended to improve nutrition content and reduce glycemic index of
rice, therefore it suitable for diabetics and diet purpose.

3.5.4.1. CHANGES AFTERPARBOILING

Rice goes through some major changes after parboil process. Most of the changes regard to its
nutrition levels and quality. As a result of the changes, some people dislike it but most like it.

Some major changes are:

 Milling – Milling becomes easier as the hull becomes easy to remove. However, bran
removal becomes a more difficult to task.
 Starch Gelatinization – The starch present gelatinizes which makes the grain hard,
translucent and tough.
Breakage during milling decreases as total yields increase compared to white rice.
 Texture and Taste – The whole process affects the coarseness of the grain. It becomes
hard and at the same time smooth. This directly influences the taste. Some people find
ultimate satisfaction in the taste while for some it’s not so heavenly.
 Inactivation of Enzymes – The remaining enzymes inactivate during the process which
halts fungus growth and biological processes.

19
3.5.4.2. ADVANTAGE OF PARBOILING

There are great overall advantages of parboiling.

 Due to hardening of the grain, insect find it more difficult to infect (bite).
 Total yield after milling increases by 3 – 4% when compared to regular rice as the
breakage reduces.
 It’s rich in minerals as it contains 3% of calcium, potassium, zinc, iron and magnesium
which if consumed on a daily basis is very beneficial for the body.
 It loses less starch during cooking. Once cooked, it stands for long time and stay fluffy.
 High blood sugar levels of body are well-managed because of sufficient carbohydrate
presence.
 Being rich in vitamin B & niacin it helps in producing neurotransmitters and helps our
body metabolize food into energy.
 Parboiled rice rich is heaven for diabetics as it has low glycemic index meaning the food
gets converted to sugar very low.
 Cooking quality differs from normal rich as it’s non-glutinous and non-sticky.

3.5.4.3 DISADVANTAGE OF PARBOILING

 Parboiled rice it almost doubles the total processing cost as bran removal is more difficult
which costs more.
 Longer cooking times means more usage of fuel.
 It develops darker color compared to white rice.
 It has more changes of developing rancidity because of the loss of natural antioxidants
during parboiling. Due to long soaking in traditional processing, some mycotoxinsmay
develop and cause health hazards.

3.5.4.4. MAJOR STAGES OF PARBOILING PROCESS

i. Soaking
ii. Steaming
iii. Drying

20
3.5.4.5. SOAKING
Soaking is a process or method use to soak the raw rice (paddy) in a soaking tank with hot or
cold water in order to increase its moisture content prior to steaming process.

Paddy soaked in water at ambient temperature (20-30 oC) will take 36 to 48 hours to reach 30%
moisture content. In hot water (65-70oC) at hot season for 7 to 8 hours while at cold season the
temperature of (75-80oc) for 9 to 10 hours is preparable. If soaking time is too long, part of the
rice dissolves in the water, the seed begin to germinate, and starch fermentation occurs.

Water temperature and length of soaking time affect the solublization of substances in the rice as
well as color, smell, and taste. The minerals content, sulfides, and PH of the soaking water also
affect the results of the process. During cold soaking, starch fermentation occurs because of
respiration of paddy grains and the release of carbon dioxide. Fermentation can cause an off-
flavor and can lead to excessive development of fungi and other microorganisms in the paddy.
Aflatoxins may also develop beyond permissible limits. Therefore avoid soaking paddy in cold
water.

During hot water soaking, the grain absorbs moisture faster and reaches a moisture level of (25-
30%) in 7 to 8 hours depending on the variety. Respiration and fermentation are restricted.

The shortest period of soaking time is achieved by maintaining a constant water temperature.
This requires continuous recirculation and reaching of the water. Hot soaking keeps the grain at
higher temperature which will reduce the steaming time needed to complete the process

After soaking is completed, the water is drained and moisture level should be 30% for either cold
or hot soaked paddy and being transferred the soaked paddy to the steaming tank/online cooker
by the means of belt conveyor to the down of elevator.

3.5.4.6. OBJECTIVES OF SOAKING

 The main objectives of soaking is to achieve quick and uniform water absorption. The
lower the water temperature the slower the soaking process. However, temperature
should not exceed the gelatinization temperature or the paddy will be cooked.
Gelatinization is the process by which starch granules change to a gelatinous or jelly
form, filling the voids and cementing the fissures in the grain. Soaking time can be

21
 reduced by first subjecting the paddy to a vacuum for a few minutes or by soaking it
under pressure in hot water.
 Soaking will minimize the steaming time needed to complete the process.
 Soaking with hot water will also help in transferring some vitamins contain in husk to the
germ layer such as thiamin, riboflavin, and niacin.

Soaking tank, clean rough paddy silos, bucket elevator and belt conveyor are attached

22
3.5.4.7. STEAMING
Steaming is a process whereby the paddy will be cook in an online cooker with steam as it
generated from the boiler, is pumped through the steam pipeline to the online cooker containing
steamed paddy at the steam pressure of (75 – 100psi) for 8 to 10 minute depending on the quality
of paddy, or if the pressure of steam is less as (50 – 75), the time will be 5 to 8 minutes.

3.5.4.8. SOME ADVANTAGES OF STEAMING

 Its high heat can be applied at a constant temperature,

 It is relatively easy to handle,

 It gives relatively high degree of control of the paddy temperature,

 It can be stopped instantly,

 It has a higher heat transfer rate than other media (such as hot water).
3.5.4.9. DRYING
Drying is a process whereby paddy is exposed to heat or hot air to remove the excessive amount
of moisture content to a moisture level safe for milling i.e. (11 -12%).

The drying process involves different methods. Each method has its own elementary advantages
and disadvantages.

3.5.4.10. TRADITIONAL DRYING METHOD:

1. Sun Drying: It is still a preferred technique in many parts of the world mainly because of
its low cost.

This method, however, is labor-intensive and should not be adopted if you plan to mill the
grains.

1. Field Drying: This involves cutting rice panicles in the fields and stacking them into
racks and piles. This method sometimes causes a massive heat build-up within the stacks
and deteriorates the grains rapidly.
2. In-Store Drying: Grains with the moisture content below 18% are dried slowly inside
storage bins. These bins are equipped with aeration components and pre-heated air. It
controls the humidity level of the air. It is a slow and gentle drying process and takes
from days to weeks.

23
3.5.4.11. Mechanical drying method:
1. Heated Air Drying: This technique involves high temperatures to rapidly dry the
grains. It can be stalled whenever the desired moisture content is achieved. It can be further
ramified into 3 categories:

i. Batch Dryer: Used by farmers and small rice millers, this is a labor intensive
method and leads to uneven drying.
ii. Re-Circulating Batch Dryer: This is put to use by commercial rice millers and
cooperatives. It requires moderate capital investment.
iii. Continuous Flow Dryer : Generally used by large commercial facilities.

But in Al-hamsad rice, usually mechanical drying method is achieved. Because the traditional
drying method like sun drying has some effect to the products.

In mechanical drying method, Re-circulating batch dryer that was use in Al-hamsad rice. The
drying time is 8-10 hours in cold season but when during hot season can be 7-8 hours depending
on the temperature of steam.

Immediately after drying, the paddy is been unloaded and been transferred to the silos for further
operation.

24
 MECHANICAL DRYER

3.5.5. MILLING SECTION

In milling unit, there also another cleaning operation i.e. secondary cleaning operation whereby
when the paddy is being transferred from silos to the milling unit, the separator will remove all
the cores particle and dust, then the de-stoner will also remove all the stones and make paddy
free from any other impurities.

3.5.5.0. MILLING OPERATION OF PADDY

3.5.5.1 FLOW CHART

PARBOILED PADDY

PRE-CLEANING

DE-STONING

25
 DE-HUSKING

SEPARATOR (WHOLE RICE AND HUSKS)

WHITENING

MULTIPLE GRADING

LENGTH GRADER

WATER POLISHING

SORTING

WEIGHING/SCALING

PACKAGING

3.5.5.2. VIBRATING-CLEANER
Vibrating cleaner, is also called vibrating cleaning sieve, can be widely used in initial of
paddy rice and other food. It is generally erected in paddy cleaning procedure to remove large,
small and light impurities. By equipped with different sieve with different meshes, the vibrating
cleaner can classified the paddy according to it size and then we can get product with different
size.

26
The vibrating cleaner has a two tier screen surface, sealing well. As a result of the vibrating
motor drive, the size of excitation force, vibrating direction and screen body angle can be
adjusted, vibrating cleaner is characterize by the high removing impurity efficiency, stable
performance smooth operation low power consumption.

VIBRATING CLEANER

3.5.5.3. DE-STONING .
De-stoner is a cleaning machine which is used for the removal of stones and remaining other
impurities such as sand and immature paddy are sucked out by blower.

De-stoner are powered by two vibrio motor with the help of aspiration blower which is work in
the principle of vibration.

The clean paddy is immediately been transported to the silos for further operation by means of
elevator.

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Rough paddy in Blower

Stones Dust Clean paddy

De-stoner Machine

3.5.5.4. DE-HUSKING
Husker is a first operating machine in a milling unit after secondary cleaning operation, which is
the process whereby the paddy is been de-husk removed to the husk and produce a brown rice.
This operation undergo by the use of rubber roll husker which is compressed to scrubbed the
paddy by the help of air compressor.

Rubber Roll Huller

The rubber roll huller is by far the most important technology used today for hulling rough rice.
The rubber roll paddy husker, often referred to as a huller or Sheller (Fig. 16), consists of two
rubber rolls rotating in opposite directions at different speeds (Fig. 17). One roll moves about
25%; faster than the other. The difference in peripheral speeds subjects the paddy grains falling

28
between the rolls to a shearing action that strips off the husk. The clearance between the rolls is
adjustable and is kept at less than the thickness of the grain.

Husker machine attached with rubber roll huller

husk + brown rice

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 Rubber roll huller

3.5.5.5. DOUBLE BODY PADDY SEPERATOR

Double body paddy separator is a machine which is the process whereby the paddy rice is
separated from brown rice and the separated paddy rice will then be removed. At the mill, it is
commonly called “rice residue”. The paddy separator functions based on the following five
principles:

1. Suitable speed

2. Holes on the tray

3. Different surface of rice -paddy rice is velutinous while brown rice is glossy

4. Slope of the tray

5. Flowing rate of the rice into the separator

All five principles must be balanced to ensure the most efficient separation. Rice coming out of
the paddy separator can be one of these:

 Pure brown rice that is ready for following processes.

 Brown rice with some paddy rice that is sent to the inlet deck for the second round of
separation.
 Paddy rice with some brown rice that moves down to the bucket elevator and back to the
container for another round of husking.

The key function is to remove paddy from rice. If rice contaminated with paddy, the consumer
can get a negative impression that the rice is not clean.

After the separation, brown rice is sent along the conveyor chain and down to the bucket elevator
which shifts rice to a container above a polisher. When the polishing step begins, rice can be
released to the machine immediately.

Brown rice with

some paddy

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 Paddy Brown rice + paddy

Brown rice Double body paddy separator

3.5.5.6. WHITENING
Whitening is the process which removes the bran from the de-husked brown rice. The forces
utilized are abrasion and frictional forces. Abrasion occurs during high speed and low pressure
conditions and friction occurs at low speed and high pressure conditions.

There are three kinds of whitening machines employed in the rice processing industry

1. Vertical abrasive whitening cone

2. Horizontal abrasive whitening cone

3. Horizontal Jet peeler Machine

Function of the whitening machine

The main function of the whitener machine is to remove the bran from the brown rice to produce
a white kernel (white rice).

31
Brown rice in

White rice o ut

Whitening machine

3.5.5.7. POLISHING
A rice polisher is a machine for buffing (or "polishing") kernels of rice to change their
appearance, taste, and texture. Water Jet (Silky) Polisher machine is used for polishing the rice
surface by spraying water through the mixing chamber and by creating friction among rice grains
using milling rollers. The weight controlled outlet of the polisher controls the retaining time of
kernels inside the milling chamber. The water Jet (Silky) polisher produces rice grains with a
shiny surface finish.

White rice in

32
Polished rice

Polishing machine

3.5.5.8. MULTIPLE GRADER

Multiple grader is a machine used for grading the rice based on size. Multiple grader used to
grade more than two different size of the rice, small broken rice, good quality rice, mix of
somewhole grains with big broken rice, and mix of some whole grains with unwanted particles
i.e. weed seed.

Rice coming out of the grader one can be one of this:

 All the whole grain will sent to the sortex machine for further operation.
 The mix of good quality with some big broken will sent to the length grader for following
process.
 The mix of some whole grains with unwanted particles i.e. weed seed will move down
and send back for another round of grading, while

33
  The pure small broken will directly sent to the packaging unit.

Multiple grader machine

3.5.5.9. LENGTH GRADER

The Length Grader uses an indented cylinder to separate one or two kinds of broken or shorter
grains from whole grain by length. Length graders are indispensable for producing high quality
products in rice milling and seed cleaning plants, since the broken or shorter grains that are more
than half the length of whole grain are difficult to separate through sieving or thickness / width
grading.

The grains which are longer in length drop out of the indents before they reach the catch trough.
The grains which remain in the indents are thrown into the catch trough.

Features:

1. Easy assembly and disassembly operations are ensured through its compact design, a light
body and its simple construction.

2. The transition pipes are equipped with sampling outlets so that grain can be sampled at each
stage.

3. The degrees of separation of grain can be observed through the inspection windows.

34
4. Lower maintenance is ensured through the use of direct—coupled motors rather than belt or
chain drive systems.

5. More than 10 types of screens of different configuration are available for separating various
types of grains.

Big broken rice out

Whole rice out

Length grader machine

3.5.5.10. RICE COLOR SORTER

A Rice color sorting machine, also named Rice colour sorter, or Rice Color Sorter, which is used
to separates rice grains according to color differences in raw rice arising from anomalies like bits
of stone, bad rice, black rice, half-husked rice, etc. A high-resolution CCD optical sensor drives a
mechanical sorter to separate different granular materials, automatically sorting heterochromatic
particles out of the batch of raw rice; removing such impurities in this process improves the
quality of the rice.

3.5.5.11. Working principle:

Rice processing begins in a milling plant, where the harvested grains run through a production
line where the rice is boiled, dried, de-stoned, husked, hulled and shelled. It then is taken to the
color sorter machine. At this point, the rice mixture will travel by elevator belt into a hopper on

35
top of the machine, from which it will flow down along chutes in the colour sorter, streamlining
their flow to so that they may be scanned by CCD sensors. The moment the camera detects any
color defects, the camera instructs ejectors fitted in the machine to open the nozzle. The nozzle is
connected to valves containing compressed air. This air is then used to shoot out the color
defected material from the input rice. The types of defects in rice include black tipped, chalky,
and yellow, mouse droppings, immature grain, etc.

Vibrio

Rice color sorter

Discolored White sorted

COLOR SORTER

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 Example of sorting

3.5.5.12. Different Types of By-Products Of The Rice Mill Industry

 Broken rice
 Reject rice (Discolored)
 Bran
 Husk

3.5.5.13. Difference Between Brown Rice And White Rice

Brown rice is the whole grain with just the first outer layer (husk or hull) removed through
milling. It retains its fiber and germ which contains vital nutrients, while

White rice is brown rice that has been milled to remove the bran and much of the germ, reducing
fiber and nutrient content drastically. The grain is further polished to take away the remaining
layer of germ (called the aleurone layer) which contains essential oils.

White rice Brown rice

37
 Example difference between brown rice and white rice

3.5.5.14. Important Functions of Brown Rice Over a White Rice

1. Brown Rice is Rich in Selenium
Extremely high in selenium, an important trace mineral known to drastically reduce our chances
of developing certain forms of cancer, as well as heart disease, inflammatory conditions and
rheumatoid arthritis.

2. Brown Rice is Very High in Manganese

One cup of brown rice gives us over 80% of our daily manganese requirements. This mineral
helps the human body create the important fatty acids that make healthy forms of cholesterol. It
is also beneficial to the health of our nervous and reproductive systems.

3. Brown Rice Holds Naturally Occurring Oils

These heart-healthy oils are naturally found in brown rice and can help the body reduce LDL
forms of cholesterol.

4. Brown Rice Promotes Weight Loss

Because of its fiber-richness and ability to keep healthy bowel function, brown rice “keeps things
moving” in a way that promotes weight-loss and metabolic function. Brown rice makes you feel
fuller on less food.

5. Brown Rice Has Antioxidants

Most people associate antioxidants with blueberries and green tea, but many are unaware that
brown rice is also a source of antioxidants.

6. Brown Rice is Very High in Fiber

Studies have correlated the high use of whole grains like brown rice with lowered levels of colon
cancer. This may be related to its high fiber content. Studies show that fiber actually attaches to
cancer-causing substances and toxins, helping to eliminate them from the body, and keeping
them from attaching to the cells in our colon. Brown rice also contains the necessary components
to stabilize digestion, prevent/relieve constipation and promote proper elimination/bowel
function.

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7. Brown Rice is a Slow-Release Sugar
Unlike stripped rice, brown rice can help keep blood sugar stabilized, as it releases sugars slowly
and in a sustained fashion. This makes it a better option for diabetics, as compared to white rice.
While studies in Asia have shown a link between the consumption of white rice and risk of type-
2 diabetes, new research shows that individuals who eat at least two servings of brown rice
weekly can reduce their chances of developing diabetes 2 by up to 11 percent.

3.5.6. LABORATORY ANALYSIS

3.5.6.1. Analysis of paddy base on characterized grades
In Al-hamsad rice mill, the paddy is characterized in to three different grades such as grade A,
grade B and grade C.

Grade A - this grade is characterized as long once which has a best quality and desired for the
customer preference, which is not broken as easy during milling and even so. This grade is best
prefer in the Al-hamsad rice and most of the industry.

Grade B- (L.G) this grade is characterized as short and flat rice that has a low quality which is
easy broken during milling and is not prefer for some of the industries and is desired for the
customers and consumer preference.

Grade C - this grade is also characterized as very short rice that has very low quality and easy to
broken during milling, which is not accepting by many industries.

3.5.6.2. Analysis of paddy at the drying stage base on average moisture level for milling
The average moisture level of paddy safe for milling is been tested by the moisture tester to
determine its average level when drying, when the paddy is getting to the more than half of its
average moisture level, it has to be tested severally to avoid over drying which may lead to the
high percentage of broken during milling.

3.5.6.3. Analysis of milled Rice

In this process, percent of husk (WH) and percent of whole rice after de-husking (%WW) was
calculated following blow mentioned formulae. Similarly, %Broken after de-husking (%WB),
Total yield (%TY), %broken after final polishing (%WB1), %Average length (%WL), Head

39
yield (%HY) and %Average length (%WL) was also calculated as described in the following
section.

% Husk (WH) = WH/Wx100

Where, WH is husk weight in grams. W is total parboiled paddy taken for the milling in grams.
Here is 250g for each sample.

% whole rice after de-husking (%WW) = WW/WB x 100

Total yield (%TY) = WP/Wx 100

Where, WP is the total weight of polished rice in grams (head and broken rice).

% broken after final polishing (%WB1) = WB1/WP x 100

Where, WB1 is the weight of the broken after polishing.

% Head yield (%HY) = WH/W x 100

Where, WH is the total head yield obtained.

% Average length (%WL) = WL/WH x 100

Where, WL is the average length of head yield.

3.5.6.4. Discussion
Parboiling process for paddy was developed to reduce the amount of breakage grains, to retain
the nutritional quality in the paddy such as, mineral content, vitamin content in the grains etc.and
this process also aided in raising the long life of the polished final product and helped in long
time storage before retail selling in the market.

3.5.7.1. PACKAGING
Packaging is the process whereby the finish product will be package in a packaging material that
avoid from spoilage.

In the rice processing packaging unit, the measuring scale and sticking machine are provided
whereby the measuring scale can be set base on the preparable Net-weight were applicable to the

40
industry and been move to the sticking machine by means of chain conveyor. But at Al-hamsad
rice mill are used to package on 10kg, 25kg and 50kg depending on the customer’s choice.

3.5.7.2. FINAL PRODUCT WAREHOUSE/STORAGE

Finish product warehouse is a storage place where the final product can be stored to avoid cross-
contamination that may lead to spoilage.

The warehouse of the finish product can be design and arrange with palates that prevent from
moisture absorption which may lead to spoilage.

Usage of Parboiled Rice

The uses of rice worldwide is great; principal among them include; staple food (Nutrition) both
human and animals. Countries also benefit from rice production by getting foreign exchange, and
above all medicine. The grain products of rice, include: flakes, rice flour, starch, rice milk, rice
cakes, and the extended uses of rice include: rice husk for fuel, rice bran for oil and animals feed,
reject (i.e. discolored) for animal feed also, broken rice used as snacks, rice flour and rice
beverage.

3.8.0. STEAM SOURCE

3.8.1. BOILER
Boiler is a closed vessel in which a liquid, typically water, has heat energy applied to create steam. Old
boiler of the nineteenth century were typically made of very expensive high quality wrought-iron, but
most modern boilers are made of steel or steel alloys due to high-temperature characteristics and better
strength-to-weight ratios.

Heat energy is provided to the boiler chamber by burners fueled by natural gas, oil, coal, or by electric
heaters, but in Al-hamsad rice mill use husk as a fuel.
While boiler are widely used in many industries, some typical applications for industrial boiler are:
 Steam power generators
 Hot water applications
 Food preparation,
 Water sanitation purposes

41
 4.0 CHAPTER FOUR
4.1. PROBLEMS ENCOUNTERED
Inadequate power supply to aid efficient working condition
Inadequate skilled personnel
Inadequate safety equipment
Inadequate spare parts of equipment
 Financially, I was way behind. Unlike my school where I walk to lectures every day, here
I have to take public transportation to my place of work five times a week for twenty-
weeks. This was a very big challenge for me because no financial assistance was
rendered to me either by the ITF or the organization where I was attached.












 CHAPTER FIVE

42
5.1. SUMMARY
The six months Students Industrial Work Experience Scheme (SIWES) program, where I was
attached in the Al-hamsad Golden Rice; Ltd. (Rice mill) has been worthwhile. I was posted to
the Production Department of the Company and that afford me the opportunity to experience
other sections of the company such as Purchasing, Sales and Administration Department.
The processes of milling parboiled rice using commercial milling machine by analyzing the
relationship between processing conditions (soaking, steaming, drying and milling) and
properties of milled rice were part of the training I acquired. I came in contact with various
equipment and machines in the period of the SIWES program, most of which I had no chance of
using prior to this period. The application of concepts in theoretical Food Science and
Technology was understood, since I was involved in the processing. I was given series of
assignments by my industrial based Supervisors. The programmed gave me the opportunity to
learn much practical method and improved my interpersonal relationship with people from
different background. It has also integrated my mind as to worth the working environment.


5.2 CONCLUSION
This SIWES attachment was a privilege and I never regretted exploring it because of the
massive practical knowledge I tapped. To me, it was not just another academic
requirement, I viewed it as a job and I have to work hard to contribute to my
organization’s success and most importantly, my success. I was able to acquire practical
knowledge in the following field:

. Boiling section
 Paddy cleaning
 Parboiling
 Milling and
 Packaging

RECOMMENDATION
Government should provide steady power supply to reduce cost of fueling.

43
  The company should employ more skilled personnel.
 The company should re-strategies on their marketing system by taking advantage of the
available media houses and opening up of new sales outlets of the company.
 The company should provide adequate safety equipment (First Aid Box, Protective wears
such as clothes, goggle, hand gloves etc. Fire extinguisher) to avert inherent danger.
 There should be regular disbursement or payment of the student’s allowances to enable
more students’ to participate effectively in all the activities of SIWES.

5.4. REFERENCES
1. Central Food Technological Research Institute (CFTRI).

44
Parboiling of Paddy; Project Circular 7 (revised); Central Food Technological Research Institute:
Mysore, India, 1969. [GoogleScholar]

2.Fhttp://faostat.fao.org/site/567/default.aspx#ancor (accessed on 27 January 2010. [Google

Scholar].

3. Roberts, LR. Composition and taste evaluation of rice milled to different degrees.

J. Food Sci. 1979, 44, 127–129. [GoogleScholar]

4. FAO. International year of rice. Proceedings of International Year of Rice: Twenty fourth
FAO Regional Conference for Europe, Montpellier, France, 5–7 May 2004.

5. Marshall, WE. Effect of degree of milling of brown rice ad particle size of milled rice on
starch gelatinization. Cereal Chem

1992,69, 632–636. [GoogleScholar]

6. Islam, R; Shimizu, N; Kimura, T. Effect of processing conditions on thermal properties of

parboiled rice. Food Sci. Technol. Res 2002, 8, 131–136. [GoogleScholar]

7. Islam, R; Shimizu, N; Kimura, T. Quality evaluation of parboiled rice with physical

properties.

Food Sci. Technol. Res 2001,7, 57–63. [GoogleScholar]

8. International Rice Research Institute (IRRI).

Main Milling Practices; International Rice Research Institute (IRRI): Manila, Philippines, 2003.
Available online: http://www.knowledgebank.irri.org/troprice/Main-Milling-Practices.htm
(accessed on 12 November 2003). AO. Production. FAO Statistical Database. 2010. Available
online:

9. FAO. Production. FAO Statistical Database. 2010. Available online:

http://faostat.fao.org/site/567/default.aspx#ancor (accessed on 27 January 2010. [Google
Scholar].

45
10.FAO.Undernourishment around the worid.FAO Statistical Database.2006.Available online:
http://apps fao.org/page/collection subset=agriculture(access on 4 octorber 2008)[Google Scholar

11. My industrial supervisor (Engr Usman Shafiu Personal Manager Al-hamsad rice mill ).

12.My industrial supervisor 2(Engr Sageer production manager Al-hamsad rice mill)

13 I my-self Student Trainee (Adamu Ado Adamu).

14. Wikipedia

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