RICE MILLING
Milling Process
Cleaning - removing foreign materials such as rice
straws, stones, seeds, etc. from the paddy.
Dehusking and Husk Separation - removing the husk
from the paddy with a minimum damage to the grain,
and separating the husk from paddy.
Paddy Separation - separating dehusked paddy from
the remaining grains. Most dehusker removes about
90% of the husk.
Bran Removal - removing all or part of the bran layer
from the grain to produced polished rice.
Grading - separating or grading broken grains from
unbroken rice. Broken are separated into different sizes.
Two General Types of Mill
Small-capacity single machine - usually operated at the village level for
custom milling, e.g. steel huller, single pass rubber roll rice mill either
stationary and travelling models. Capacity ranged from 45 to 270 k.
paddy per hour.
Large-capacity multiple machine - used for commercial milling.
Sizes varies from 2 to 4 tons of paddy per hour. It consists of several
stages of milling machines that dehusk rough rice, separates brown
rice, and for removing bran. Equipment are used to move paddy
and its by-product into various machineries.
Dehusking Equipment
Steel hullers - It combines the dehusking and polishing process in
one operation. Husking is accomplished due to friction between
grains and steel parts of the huller which cause the husk and bran to
be scraped off. This machine has lower head rice recovery and high
power requirement. Steel huller operates at 800-900 rpm for smaller
mill and 600-800 rpm for larger mill.
Disk huller speed 14 m/sec
Rubber Roll Paddy Husker
Consist of two rubber rolls rotating opposite in direction at different speed. One
roll moves slower than the other by 25%. The difference in the peripheral speed
causes the shearing action which dehusked the grains. Faster rubber rolls worn
out quicker than the other. Wearing out rubber roll reduces the diameter and
capacity of the huller. The advantages is the high milling recovery while the
disadvantage is the cost of replacement of the rubber roller. The average
capacity of the pair of rubber is 100-200 tons paddy per pair. The optimum age
of rubber begins 2-3 months after manufacture and decreases rapidly when the
rubber is 6-9 months old.
Paddy Separation Equipment
Compartment-Type Paddy Separator – It is made of steel or wood
consisting of number of compartments in one or more decks. The
number of compartments determine the capacity. Each
compartment has a capacity of 40 kg brown rice per hour for long
grains and 60 kg/hr for short grains.
Tray Separator
It consist of several indented trays mounted one above the other about 5 cm
apart all attached to an oscillating frame. Tray moves up and forward causing
the brown rice and paddy to be separated. Capacity ranges from 1.2 to 9.5 tons
per hour.
Bran Removal
Vertical Abrasive Whitener - dehusked paddy enters the top center and moves
outward by centrifugal force to the edge of metal cone. The cone has abrasive
surface and turn inside a cylinder covered with screen. Clearance between the
cone and screen is adjusted at 10 mm by raising and lowering the cone. Vertical
rubber brakes (30 to 50 mm wide) is placed at an interval around the cone.
Abrasive action takes place on brown rice as it moves down between the cone
and the screen. Peripheral speed of the cone is about 13 m/sec. Air aspiration
through the whitener reduces breakage caused by heating and keep the dust out
of the mill.
Rice Polishers
These are sometimes called pearlers or refiners to make the rice more glossy
and highly polished. They are made of vertical or horizontal abrasive whitener
wherein the cone are covered with leather strips and operated at lower rpm.
The leather strips rolls the whitened rice against the screen which make the
remaining bran to removed and rice become shinier and glossier. The machine
produces few broken grains and power consumption is less than by 30-40% of
the whitener.
Rice Milling Efficiency
Rice milling accounts for the largest share in the loss of rice grain.
These losses are either on the quantity or on the quality of the rice
produced in milling. The quantity of milled rice produced is
dependent on the milling recovery of the paddy while its quality
depends on the extent or amount of head rice or broken rice.
In general, the quality of paddy brought to the mill for milling can
hardly be controlled. However, the milling recovery as well as the
degree of head grain in milled rice can best achieved by proper
selection of the type of machine used, proper adjustment and
proper combination of equipment in the milling system.
Indices of Efficient Milling
The quality and quantity of milled rice from paddy are affected by
the following:
– grain factors
– mechanical factors
– operational factors
Generally, grain factors include production and postproduction field
operations such as harvesting, drying, storage and handling, and
varietal characteristics like length and thickness of grains, amount of
chalky or immature kernels, hull thickness, and protein content, etc.
On the other hand, mechanical and operational factors include the
type of machine used, machine adjustments, the system used and
their operation.
Grain Factors
The moisture content of paddy at harvest affects head rice recovery.
Maximum head rice recovery obtained when the paddy harvested
has 20% moisture content. When the grains are milled at high
moisture levels, head rice recovery decreases because wet grains are
soft and susceptible to deterioration. Drying the grains removes the
moisture and induces hardening of the kernels. Apparently, total
milling yield and head grain recovery is higher in hard (dry) grains
than soft (wet) grains.
Paddy grains are normally dried to about 14% moisture content
to obtain optimum milling results. Controlled frying using artificial
dryers is preferred over sun drying method in reducing the
moisture content of the grains. In artificial dryers, sun cracking in
the grains is greatly reduced thereby minimizing breakage during
milling. The air temperature for drying is found optimum at 43.33
°C (110 °F)
Mechanical and Operational Factors
Hulling and whitening operations are major causes of grain
breakage during milling. In these operations, grains are subjected to
severe pressure and friction unlike in the other auxiliary operations.
Proper selection, adjustments and operation of the equipment in
these operations are therefore critical for optimum results.
Sanitation
Sanitation of rice mills, especially those where no separate buildings
are provided for storing paddy and milled rice should be observed.
Dust in rice mill is almost non-preventable but can be minimized by
installing simple aspiration systems. Mills should be free from health
hazards to the mill technicians.
Safety Precaution During Operation
The safe operation of mills requires the adoption of the guarded
pulley systems. Many rice mills operated by the single shaft drive
have unguarded pulley and belt system. This is dangerous and must
be remedied. The use of individual electric motor to drive every
component is advisable especially where investment is not a
constant.
Auxiliary equipment required, such as fans and cyclone separators
for dust control.
Location and size of elevator pits if required, height and location of
elevators, gravity flow for grain sprouting, and grain valves.
Operational requirements such as loading, emptying bags, bagging
by-products and rice, electric controls, and safety features.
Alternative layouts, cost differences, advantages, and
disadvantages.
References
Belonio, A.T. 2014. Refrigeration and Cold Storage. Lecture Notes, Central Luzon State
University
Camacho, I. R. Rice Milling Systems. Ag. Engineering Training Program. The International Rice
Research Institute. Los Baños, Laguna. 29pp.
NAPHIRE. Improving Rice Milling Efficiency. pp.101-117
RNAM. Test Code and Procedure for Rice Mills. ESCAP/RNAM. c/o UNDP, PO Box 7285. Domestic
Airport Office Lock Box. 1300 Domestic Road, Pasay City, metro Manila. 56pp. October 1990.
The Rice Postproduction Operations Committee. The Philippines Recommends for Rice Postproduction
Operations, Los Baños, Laguna: PCARRD; NAPHIRE, 1987. 130p. (PCARRD Technical Bulletin Series No. 63).
130pp
Wimberly, J.E. 1983. Technical Handbook for the Paddy Rice Postharvest Industry in Developing Countries.
The International Rice Research Institute. Los Baños, Laguna, Philippines. 188pp.