Detailed Project Report on PARBOILED RICE PROCESSING PLANT (CAP: 6 TPH)

Rice is two species in the Poaceae ("true grass") family, Oryza sativa and Oryza glaberrima. These plants are native to tropical and subtropical southern and southeastern Asia and in Africa. Rice provides more than one fifth of the calories consumed by humans in their global diets. Rice is a monocarpic annual plant, growing to 1–1.8 m tall, occasionally more depending on the variety and soil fertility. The grass has long, slender leaves 50–100 cm long and 2–2.5 cm broad. The small wind-pollinated flowers are produced in a branched arching to pendulous inflorescence 30–50 cm long. The seed is a grain (caryopsis) 5–12 mm long and 2–3 mm thick.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



PARBOILED RICE PROCESSING PLANT (CAP: 6
TPH)
[EIRI/EDPR/4749] J.C.: 2969XL


Rice is two species in the Poaceae ("true grass") family, Oryza sativa and Oryza
glaberrima. These plants are native to tropical and subtropical southern and
southeastern Asia and in Africa. Rice provides more than one fifth of the calories
consumed by humans in their global diets. Rice is a monocarpic annual plant,
growing to 1–1.8 m tall, occasionally more depending on the variety and soil
fertility. The grass has long, slender leaves 50–100 cm long and 2–2.5 cm broad.
The small wind-pollinated flowers are produced in a branched arching to
pendulous inflorescence 30–50 cm long. The seed is a grain (caryopsis) 5–12 mm
long and 2–3 mm thick.

Rice is a staple food for a large part of the world's human population, especially in
East and Southeast Asia, making it the most consumed cereal grain. It is the
world's largest crop (700 million metric tons in 2005), with maize ("corn") (692
million metric tons in 2005) and wheat (626 million metric tons in 2005) behind it.
Rice cultivation is well-suited to countries and regions with low labour costs and
high rainfall, as it is very labour-intensive to cultivate and requires plenty of water
for irrigation, much like the licorice crops found in Eastern Europe. Rice can be
grown practically anywhere, even on steep hillsides. Although its species are
native to South Asia and certain parts of Africa, centuries of trade and exportation
have made it commonplace in many cultures.

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CONTENTS

INTRODUCTION

ABOUT RICE

PADDY CULTIVATION GLOBALLY

TABLE 1: MAJOR RICE PRODUCING COUNTRIES IN THE WORLD (MILLED
PRODUCTION IN MILLION TONS)

TABLE 2: INTERNATIONAL GRAIN COUNCIL’S WORLD RICE PROJECTIONS (IN
MILLION METRIC TONS)

TABLE 3: DOMESTIC BALANCE SHEET (IN MMT)

TABLE 4: AVERAGE PRICE OF PADDY COMMON AT MAJOR STATES IN INDIA
MAY, 2023

TABLE 5: STATE WISE AREA UNDER PADDY IN INDIA

RICE PRODUCTION IN INDIA: 2019-20

MARKET ASSESSMENT

INDIAN RICE MARKET

PRODUCTION SCENARIO

THE PRODUCTION OF RICE DURING FY 2019-20 AND FY 2020-21 IS GIVEN IN
THE TABLE:

EXPORTS

THE EXPORT OF NON-BASMATI RICE FROM INDIA TO TOP 10 COUNTRIES
DURING THE YEAR 2020-21 IS SHOWN HEREUNDER:

THE GRAPH SHOWING THE EXPORT VALUE OF NON-BASMATI RICE TO THE
ABOVE LISTED COUNTRIES FOR THE 2020-21 IS SHOWN HEREUNDER:

CONSUMPTION

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EXISTING GAPS IN RICE MILL INDUSTRY

PROFIT GAPS DUE TO POST -HARVEST LOSSES

INDUSTRY OVERVIEW

GLOBAL ECONOMY

EMERGING MARKET AND DEVELOPING ECONOMIES

OVERVIEW OF THE INDIAN ECONOMY

ROAD AHEAD

INDIAN FMCG INDUSTRY

INDIAN FOOD PROCESSING INDUSTRY

EXPORT OF PROCESSED FOOD AND RELATED PRODUCTS

FOOD PROCESSING SEGMENTS AND PRIVATE PLAYERS

STRATEGIES ADOPTED

RISING BUSINESS AND PRODUCT INNOVATION

RESEARCH

LOW-COST PRICE STRATEGY

GROWTH DRIVERS OF INDIAN AGRICULTURE

DEMAND-SIDE DRIVERS

SUPPLY-SIDE DRIVERS

POLICY SUPPORT

INSTITUTIONAL CREDIT AND INVESTMENTS ON A RISE

RISING INCOME AND GROWING MIDDLE CLASS TO DRIVE DEMAND FOR
PROCESSED FOOD

FAVOURABLE POLICIES ARE SUPPORTING THE SECTOR GROWTH

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HIGHLIGHTS OF UNION BUDGET 2023-24

KEY INDUSTRIAL REGULATIONS AND POLICIES

A. INDUSTRY RELATED LAWS AND REGULATIONS

THE FOOD SAFETY AND STANDARDS ACT, 2006 (“FSS ACT”)

THE INDIAN BOILERS ACT, 1923 (“BOILERS ACT”) AND THE INDIAN BOILER
REGULATIONS, 1950 (“BOILERS REGULATIONS”)

THE LEGAL METROLOGY ACT, 2009 (“LEGAL METROLOGY ACT”) AND LEGAL
METROLOGY (PACKAGED COMMODITIES) RULES, 2011

CONSUMER PROTECTION ACT, 2019 (“COPRA, 2019”)

ELECTRICITY ACT, 2003

SHOPS AND ESTABLISHMENTS LEGISLATIONS

MUNICIPALITY LAWS

PROFESSIONAL TAX

TRANSFER OF PROPERTY ACT, 1882

SALE OF GOODS ACT, 1930

THE REGISTRATION ACT, 1908

INDIAN STAMP ACT, 1899

A. TAX RELATED LAWS

B. FOREIGN INVESTMENT RELATED LAWS AND REGULATIONS

OVERSEAS DIRECT INVESTMENT (“ODI”)

INTELLECTUAL PROPERTY LAWS INFORMATION TECHNOLOGY

A. ACT, 2000

INDIAN PATENTS ACT, 1970

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TRADE MARKS ACT, 1999

A. EMPLOYMENT RELATED LAWS

THE CODE ON WAGES, 2019

THE OCCUPATIONAL SAFETY, HEALTH AND WORKING CONDITIONS CODE,
2020

THE INDUSTRIAL RELATIONS CODE, 2020

THE CODE ON SOCIAL SECURITY, 2020

FACTORIES ACT, 1948

INDUSTRIES (DEVELOPMENT AND REGULATION) ACT, 1951

INDUSTRIAL EMPLOYMENT (STANDING ORDERS) ACT, 1946

CONTRACT LABOUR (REGULATION AND ABOLITION) ACT, 1970, AS AMENDED
(THE “CLRA ACT”)

EMPLOYEES STATE INSURANCE ACT, 1948, AS AMENDED (THE “ESIC ACT”)

THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION,
PROHIBITION AND REDRESSAL) ACT, 2013

GENERAL CORPORATE AND OTHER ALLIED LAWS

MARKET ASPECTS

RICE MILLING PRODUCTS

RICE BRAN

BROKEN RICE

RICE HUSK

APPLICATIONS OF HUSK

LAND

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LAND UTILIZATION PLAN

PLANT AND MACHINERY

POST-HARVEST DRYER

TECHNICAL OPERATIONS

SILO STORAGE SYSTEM

SCADA SYSTEM

REAL TIME CONTROL AND MONITORING SYSTEM

SCADA IS A SYSTEM OF SOFTWARE AND HARDWARE ELEMENTS THAT
ALLOWS RICE MILL TO:

SCADA BASED CENTRALIZED CONTROL SYSTEM

MOTOR CONTROL CENT RE

HUMAN MACHINE INTERFACE (HMI)

PROGRAMMABLE LOGIC CONTROLLERS (PLC)

BENEFITS OF SCADA

PRODUCTS AND BY -PRODUCTS

PROCESS AND TECHNOLOGY

PADDY STORAGE

PADDY PRE-CLEANING

POST-HARVEST DRYER

SOAKING & STEAMING

DRYING

CLEANING

DE-HUSKING

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PADDY SEPARATOR

WHITENING

GRADING

PACKING/STORAGE

THE PROCESS FLOW CHART FOR THE PRODUCTION OF PARBOILED RICE IS
GIVEN HEREUNDER:

PROCESS FLOW FOR PRODUCTION OF PARBOILED RICE

CONSUMABLES

WATER REQUIREMENT FOR A 640 TPD MILL

EFFLUENT TREATMENT PLANT

CHARACTERISTICS OF THE RAW EFFLUENT AND TREATED WATER
PARAMETERS

INSTALLED CAPACITY OF THE RICE MILL

RAW MATERIAL

CONSUMABLES

STEAM & FUEL

POWER

WATER

EFFLUENT TREATMENT PLANT

STATUTORY COMPLIANCES

THE FOLLOWING STATUTORY APPROVALS ARE REQUIRED FOR THE
PROPOSED RICE MILL:

POLLUTION CONTROL MEASURES

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THE SPECIFICATIONS PRESCRIBED BY GOVERNMENT OF INDIA FOR THE
PROCUREMENT OF PADDY IS GIVEN BELOW:

ENVIRONMENTAL IMPACT ASSESSMENT

RICE MILL EFFLUENTS

SOLID WASTE DISPOSAL AND MANAGEMENT

RICE HUSK IN MILL HOUSE

MITIGATION MEASURES

WATER EFFLUENT AND MANAGEMENT

WASTE WATER AFTER PARBOILING PROCESS

CHARACTERISTICS OF WASTE WATER

MITIGATION MEASURES

AIR POLLUTION AND MANAGEMENT

THE EMISSION STANDARDS SET BY TNPCB FOR BOILERS IS AS FOLLOWS:

THE EMISSION STANDARDS SET BY TNPCB FOR RISE HUSK BOILERS IS AS
FOLLOWS:

MITIGATION MEASURES

PROCESSING

PARBOILING

IMPROVED PARBOILING METHOD OF CFTRI, MYSORE, INDIA (BATCH)

ADVANTAGES OF PARBOILING

DISADVANTAGES

MILLING OF PADDY

QUICK FACTS ABOUT PARBOILED RICE

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TECHNOLOGY & MACHINERY PROVIDER

AGRI PROCESS INNOVATIONS TECHNOLOGIES LLP

STAGE ONE: PRE-HYDRATION

STAGE TWO: HYDRATION

STAGE THREE: GEL COOK

CONTINUOUS PARBOILING

THE RATE OF DRYING DEPENDS ON

DURING THE SECOND PHASE, THE DRYING RATE DEPENDS ON:

ACCELERATED AGED RICE

OUTCOMES OF AGEING

ADVANTAGES OF AGEING

WHY IS THE AGEING OF RICE ACCELERATED?

SALIENT FEATURES

LIST OF MACHINERY & EQUIPMENTS

MILLING SEPARATOR

DESTONER

PADDY HUSKER

PADDY SEPARATOR

RICE WHITENER

RICE POLISHER

ROTARY SIFTER

THICKNESS/WIDTH SEPARATOR

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LENGTH GRADER

LICENSES REQUIRED

LIST OF DOCUMENTS:

OTHER LICENSES REQUIRED FOR THE SETUP:

PRINCIPLES OF PLANT LAYOUT

SOME OF THE FACTORS IN RAIL-TRACK PLANNING ARE:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

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13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

DEPRECIATION:

FIXED ASSETS:

WORKING CAPITAL:

BREAK-EVEN POINT:

OTHER FIXED EXPENSES:

MARGIN MONEY:

TERM LOANS:

TOTAL LOAD:

LAND AREA/MAN POWER RATIO:

LIST OF MANUFACTURERS

CONVEYOR BELT

BUCKET ELEVATORS

WEIGHING MACHINES

BAG SEALING MACHINE

D.G. SET

LABORATORY TESTING EQUIPMENTS

EFFLUENT TREATMENT AND DISPOSAL

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

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WASTE TREATMENT

PRIMARY TREATMENT

ANAEROBIC TREATMENT

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

EQUIPMENT REQUIREMENTS

MANPOWER

GENERAL

BASIS OF ESTIMATION

UTILITIES

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

STEAM

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

METHOD OF PADDY AND RICE QUALITY ANALYSIS

DIFINITION OF QUALITY COMPONENT

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PADDY GRAIN QUALITY

RICE QUALITY

COMPONENT OF PADDY GRAIN QUALITY

COMPONENT OF RICE QUALITY

1. MEASURING THE DEGREE OF POLISHED

STANDARD OF PADDY AND RICE QUALITY

SHAPE AND SIZE FOR RICE

MACHINERY PHOTOGRTAPHS

RAW & FINAL PRODUCTS PHOTOGRAPHS

FINAL PRODUCTS PHOTOGRAPHS

QUALITY CONTROL

QUALITY CONTROL PROCEDURE/ PARAMETERS

PHYSICAL EXAMINATION

DETERMINATION OF MOISTURE CONTENT

PROCEDURE

CALCULATION

DETERMINATION OF SOLUBLE SOLIDS

APPARATUS

SWOL ANALYSIS

STRENGTHS:

AVAILABILITY OF RAW MATERIAL:

DEMAND FOR THE OUTPUT:

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WEAKNESS:

OPPORTUNITIES:

THREATS:

TECHNOLOGY:

COUNTER THE COMPETITION:

ORGANIZATION CHART

PLANT LAYOUT

CONSULTANT

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

IMPLEMENTATION SCHEDULE


APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

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11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 144 MT/Day

Land & Building (6 Acres) Rs. 3.76 Cr

Plant & Machinery Rs. 4.39 Cr

Working Capital for 3 Months Rs. 25.80 Cr

Total Capital Investment Rs. 34.25 Cr

Rate of Return 26%

Break Even Point 50%