ARC 4401: ARCHITECTURAL DESIGN IV
LEVEL FOUR, 1ST SEMESTER PROECT
RICE MILLING PLANT DESIGN
SITE REPORT
CASE STUDIES FOR RICE MILLING PLANT DESIGN
GERAWA AND FURSA RICE MILLING PLANTS
MUHAMMAD MODIBBO EES/19/ARC/00279
Faculty of Earth & Environmental Science
BAYERO UNIVERSITY, KANO
1 INTRODUCTION
In architecture, conducting case studies is an essential process that precedes the
design phase of a building, particularly for complex and large-scale projects like the
1000 TPD rice mill we are tasked with designing. Case studies allow architects to
draw valuable insights from existing projects, enabling them to understand how
similar structures have been successfully executed. By analyzing these projects,
architects can identify best practices in site selection, spatial organization, material
usage, and the integration of technology, ensuring that the new design is both
functional and innovative.
For our project, we visited one of the largest rice mills in West Africa as part of our
case studies. This experience provided us with a firsthand understanding of the
intricacies involved in rice milling facilities, from the layout of production lines to
the integration of industrial machinery. These observations will be instrumental in
informing our design decisions, ensuring that our 1000 TPD rice mill meets industry
standards while also pushing the boundaries of contemporary architectural practice.
2 GERAWA RICE MILLING PLANT, KANO
NAME: Gerawa Rice Mill
LOCATION: Tsamiya Babba, Hadeja – Kano Road, Kano, Nigeria.
FUNCTION: Rice Milling and Distribution
STRUCTURE: Industrial Scale Rice Mill Using Imported Industrial Scale Machines
2.1 Background
Gerawa Rice Mill, located in Kano, Nigeria, is one of the largest rice mills in West
Africa. Established by Alhaji Isa Gerawa, a prominent businessman. The mill began
operations in 2017, processing about 400 metric tons of rice per day. As demand
increased, they expanded in 2022 and added a second, newer and state of the art Rice
Mill with a capacity of about 650 TPD. The complete rice parboiling and milling
plant produces 1040 tons per day. The milling site is fully maximized with fully
equipped infrastructures including a water treatment plant that is presently
undergoing expansion to help meet the capacity of the 2nd Rice Mill.
2.2 Facilities
The Gerawa Rice Mill is fully equipped with different facilities that ensure it carries
out its whole rice milling processing. This includes supporting facilities to make sure
the company reaches maximum capacity.
Gate House
Kitchen
Admin Block
Intake Area
Finished Goods Storage
Rice Mill 1
Storage Area 1
Rice Mill 2
Storage Area 2
Quality Control Room
Powerhouse
Control Room
Water Treatment House
Maintenance Unit
2.3 Layout and Building Materials
The plant's layout begins with a weighbridge and adjacent office, where trucks
carrying paddy or finished rice are weighed. The layout is designed to optimize
workflow, starting from the intake area, where paddy is separated from larger foreign
materials and transported via elevators to the cleaning, parboiling, and drying areas.
The production hall, constructed with a steel frame and sandcrete block walls,
features terrazzo flooring (1200 x 1200mm), likely chosen for its durability ease of
cleaning, and resistance to heavy loads.
The main production hall is constructed with a steel frame, with sandcrete block
walls forming the partitions. The roof structure features steel members such as
C-section purlins, along with translucent roofing sheets placed at intervals to allow
natural light in, and whirlybirds for ventilation. The older production hall is
complemented by a newer facility that houses state-of-the-art milling machinery.
The newer hall features longer vertical windows instead of skylights, providing an
alternative method of achieving adequate lighting and ventilation.
Architectural Variable Description
Dominant Building Materials Reinforced concrete, sandcrete block walls,
steel, and aluminum partitioning
Main Structural System Steel Portal Frames for the Production Halls and
reinforced concrete columns and beams for
other supporting facilities
Spatial Organization Machines are arranged in a U-shaped and
L-shaped production line
Environmental Feature Though there was sufficient space in the inside
for tucks to turn, with exception of the truck
yard on the outside, the surrounding was not
maximized to its full potential. There was
inadequate landscaping and greenery
2.4 Production Process and Machinery
The Gerawa plant has two production halls: the older one, with a capacity of 400
TPD, and a newer one that can produce between 600-650 TPD. The production lines
are organized in L-shaped and U-shaped configurations, optimizing space and
workflow. A notable design feature is that the milling machines are elevated on a
platform made of concrete and finished with tiles (first-floor), supported by steel
columns encased in concrete, which allows for better control, monitoring and
circulation around the machines, below the platform.
The older production hall uses traditional skylights and whirlybirds to manage
lighting and ventilation, while the newer hall achieves these functions through longer
vertical windows, eliminating the need for skylights. This newer design also
incorporates improvements in the milling process, such as switching the positions of
the color sorter and length graders, which has resulted in increased production
efficiency and capacity.
OLD PARBOILING/DRYING AREA & RICE MILL
NEW PARBOILING/DRYING AREA & RICE MILL
MACHINES
3 FURSA CROWN RICE MILL, KANO
NAME: Fursa Rice Mill
LOCATION: Designer Street, Kofar Gadon Kaya, Kano, Nigeria
FUNCTION: Rice Milling and Distribution
STRUCTURE: Medium Scale Rice Mill Using Imported Machines
3.1 Background
Over the years, Fursa Crown Rice Mill has built a reputation for producing quality
rice through traditional milling techniques. Unlike newer facilities that utilize
modern technology, Fursa Crown relies on more conventional methods, including
the use of wood-fired boilers for steam generation during the parboiling process. As
a result, this mill only produces 140 TPD of rice. The mill's operations are centered
on a compact facility, which includes storage areas for paddy rice, a parboiling
section, and the main milling hall. Despite facing challenges such as outdated
equipment and space constraints, Fursa Crown Rice Mill continues to serve as a key
player in the local rice industry, providing employment opportunities and
contributing to the food security of the region.
3.2 Facilities
Gate House
Mosque
Power House
Admin Block
Flour Mill
Rice Mill
Storage Silos
3.3 Layout and Building Materials
The Fursa plant features a steel frame structure with sandcrete block walls. However,
a significant design flaw was observed in the production hall, where the rice milling
machines reach almost to the roof's top, indicating a lack of proper space analysis
during the design phase. The flooring is made of concrete, and the roof features
skylights and whirlybirds for ventilation. Despite these features, the hall remains
stuffy, likely due to insufficient headroom and inadequate circulation pathways for
hot air to escape.
Also, it is worth noting that the machinery in the production hall was also elevated
onto a first floor platform. However, this uses exposed steel columns to hold up the
deck, which is useful for easy dismantling. Moreover, the platform is made of steel
plate, which may not be ideal in terms of noise due to vibration of the machines and
heat retention as steel has a lower thermal mass than concrete. Meaning it cannot
absorb and store large amounts of heat. In the case of concrete, this can help stabilize
the temperature in a production hall by reducing temperature fluctuations, which is
beneficial in environments where consistent temperatures are crucial.
Moreover, the site layout at Fursa is tight. There is not enough room for trucks to
turn as the buildings seem to be jam-packed into a site that is not ideal, in terms of
size, for a rice mill of Fursa’s scale.
Architectural Variable Description
Dominant Building Materials Reinforced concrete, sandcrete block walls,
steel, and aluminum partitioning
Main Structural System Steel Portal Frames for the Production Halls and
reinforced concrete columns and beams for
other supporting facilities
Spatial Organization Machines are arranged in a U-shaped production
line
Environmental Feature There is not enough space in the site for turning
radius of trucks. This is evident as the Bus we
took to the site had to back out of the gate. The
design of the site also lacks good landscaping
features.
3.4 Production Process and Machinery
Fursa’s production process is more traditional, with older machinery and a less
efficient workflow. The lack of modern technology and poor spatial planning
contribute to the plant’s lower production capacity (just 140 TPD) and less favorable
working conditions compared to Gerawa.
4.0 KEY TAKEAWAYS
4.1 Structural System
Both plants employ steel frame structures with sandcrete block walls. The use of
steel provides the necessary strength to support the large spans required in
production halls, while sandcrete blocks are utilized for partitioning and exterior
walls.
4.2 Spatial Organization
The Gerawa plant's spatial organization is superior, with a clear layout that
facilitates the smooth movement of materials and personnel. The newer production
hall’s U-shaped layout is particularly effective in optimizing space and workflow.
In contrast, the Fursa plant suffers from poor spatial organization, with insufficient
headroom and poorly planned machinery placement.
4.3 Environmental Considerations
Gerawa's newer production hall addresses environmental concerns by eliminating
skylights and whirlybirds in favor of vertical windows, which provide natural
lighting and ventilation. However, Fursa's facility, despite having skylights and
whirlybirds, remains poorly ventilated, likely due to inadequate headroom and
airflow management. Landscaping also needs to be paid close attention to as it is a
means of improving the micro-climate on the site and increasing working
productivity.
Hard and soft landscapes will be provided along with sceanic relaxation gardens
and areas no not just improve employee productivity and satisfaction but also to
improve the air quality of the site with trees converting the harmful CO2 back into
essential Oxygen
5 Design Considerations and Recommendations
The insights gained from these case studies highlight the importance of proper
space planning, material selection, and the integration of modern technology in the
design of a rice milling plant. The design of a 1000 TPD rice milling facility
should incorporate lessons from Gerawa’s successful layout and machinery
optimization while avoiding the pitfalls observed at Fursa, such as inadequate
ventilation and poor space utilization.
Key design considerations for the new plant include the use of durable materials
like terrazzo for flooring, steel for structural members, and thoughtful spatial
organization to ensure efficient workflow and optimal working conditions. The
integration of modern machinery and energy-efficient systems will be crucial in
achieving high production capacity and sustainability.
6 Conclusion
The case studies of the Gerawa and Fursa rice milling plants provided valuable
insights into the architectural and operational requirements of a modern rice
milling facility. The lessons learned from these visits will be instrumental in
designing a 1000 TPD rice milling plant that is efficient, sustainable, and capable
of meeting Nigeria’s growing demand for locally produced rice.