INTRODUCTION:

Rice is the staple food for 65% of the population in India. It is the largest consumed calorie source among the food grains. India is the second largest producer of rice in the world next to China. West Bengal is the leading producer of paddy in the country. It accounts for 16.39% of the total production, and the other leading states are Uttar Pradesh (13.38%), Andhra Pradesh (12.24%), Punjab (9.47%), Orissa (7.68%) and Tamil Nadu (7.38%); the remaining states account for 33.45% of the production.

Indian Basmati Rice has been a favorite among international rice buyers. Indian rice will is highly competitive and has been identified as one of the major commodities for export. This provides us with ample opportunity for development of rice based valueadded products for earning more foreign exchange. Modern rice mills are having high capacity and are capital intensive, although efficient have been developed for obtaining rice by processing the Paddy from its raw form are playing the significant role in the development of agro processing industries.

INDUSTRY PROFILE Paddy in its raw form cannot be consumed by human beings. It needs to be suitably processed for obtaining rice. Rice milling is the process which helps in removal of hulls and barns from paddy grains to produce polished rice. Rice forms the basic primary processed product obtained from paddy and this is further processed for obtaining various secondary and tertiary products. Status of Rice Milling Units in India Rice milling is the oldest and the largest agro processing industry of the country. At present it has a turnover of more than 25,500/- crore per annum. It processes about 85 million tonnes of paddy per year and provides staple food grain and other valuable products required by over 60% of the population. Paddy grain is milled either in raw condition or after par-boiling, mostly by single hullers of which over 82,000 are

registered in the country. Apart from it there are also a large number of unregistered single hulling units in the country. A good number (60 %) of these are also linked with par-boiling units and sun -drying yards. Most of the tiny hullers of about 250-300 kg/hr capacities are employed for custom milling of paddy. Apart from it double hulling units number over 2,600 units, under run disc shellers cum cone polishers numbering 5,000 units and rubber roll shellers cum friction polishers numbering over 10,000 units are also present in the country.

Further over the years there has been a steady growth of improved rice mills in the country. Most of these have capacities ranging from 2 tonnes /hr to 10 tonnes/ hr. THE HISTORY OF RICE According to the Microsoft Encarta Dictionary (2004) and the Chambers Dictionary of Etymology (1988), the word 'rice' has an Indo-Iranian origin. It came to English from Greek Oryaz, via Latin Oriza, Italian riso and finally Old French Ris the same as present day French riz. It has been speculated that the Indo-Iranian vrihi itself is borrowed from a Dravidian vari. Vari, in Telugu Warinci or the Tamil arisi, from which the Arabic Ar-ruzz, from which the Portuguese and Spanish word Arroz originated. Rice is a grain belonging to the grass family. The plant, which needs both warmth and moisture to grow, measures 2-6 feet tall and has long, flat, pointy leaves and stalkbearing flowers which produce the grain known as rice. Rice is consumed by nearly one-half the entire world population and many countries, like Asia, are completely dependent on rice as a staple food. Rice is one of the few foods in the world which is entirely non-allergenic and glutenfree. There are many unproven mythological tales as to how rice came to be, though historians hold little or no stock in any. Most believe the roots of rice come from 3000 BC India, where natives discovered the plant growing in the wild and began to experiment with it. Cultivation and cooking methods are thought to have spread to

the west rapidly and by medieval times, southern Europe saw the introduction of rice as a hearty grain. The first cultivators of rice in America did so by accident after a storm damaged ship docked in the Charleston South Carolina harbor. The captain of the ship handed over a small bag of rice to a local planter as a gift, and by 1726, Charleston was exporting more than 4,000 tons of rice a year. TODAY Today, rice is grown and harvested on every continent except Antarctica, where conditions make its growth impossible. The majority of all rice produced comes from India, China, Japan, Indonesia, Thailand, Burma, and Bangladesh. Asian farmers still account for 92-percent of the world's total rice production. More than 550 million tons of rice is produced annually around the globe. In the United States, farmers have been successfully harvesting rice for more than 300 years. There are thousands of strains of rice today, including those grown in the wild and those which are cultivated as a crop. NUTRITIONAL INFORMATION Rice remains a staple food for the majority of the world's population. More than twothirds of the world relies on the nutritional benefits of rice. Rice is naturally fat, cholesterol and sodium free. It is a complex carbohydrate containing only 103 calories per one-half-cup serving.

PRODUCT PROFILE OF THE COMPANY The Products to be obtained through paddy from the Rice Milling plant are as follows: Sl.no. 1. 2. 3. 4. Particulars Rice Broken Rice Husk Bran

Paddy when milled usually yields apart from marketable rice (head rice, medium and big broken rice) about 22% husk and 9% bran. The economic utilization of the byproducts is essential for proper viability of the industry.

RICE The product of Sri Sai Rice Industry remains only the rice, but it has the following different and good varieties of rice available at reasonable prices on the basis of needs, wants and demands of the customers; HMT sona Sona masoori Emergency BT IR64 Swarna Husk Husk is not edible, even by animals. Husk has many possible uses. But the most practical, profitable use is as fuel, particularly in the rice mill. Parboiling and drying of paddy needs heat energy. Husk is used as fuel in boilers to produce steam and hot air required for the purpose. Husk has Colorific value of about 3000 kcal/kg (nearly one third of that of mineral oil and half that of coal). The other uses of husk are loose particle boards and insulating material in building and cold storages, in shipping and packing material etc. Fully burnt white ash of husk can be used for manufacturing Sodium silicate, silica gel, insulating bricks and also used as diluents in manure etc.

Bran Rice bran is the most valuable by product of rice milling industry. It contains 12% to 15% protein, 14% to 20% of oil and is rich source of vitamin B. Bran is utilized in several ways. It is used as feed for animals. It is used as a more valuable source of vegetable oil and should be first solvent extracted to recover the oil. The extracted bran is used as animal feed. Broken Rice The medium and large broken rice is mixed with the head rice depending on the marketing requirements. The small broken rice that is separated during grading of milled rice is sold as such or used for rice flour making. PRODUCT
Marketers in a business must ensure that a business sells products that meet customer needs and wants. The role of Production and Operations is to ensure that the business actually makes the required products in accordance with the plan. The role of PRODUCT in POM therefore concerns areas such as:

- Performance - Aesthetics - Quality - Reliability - Quantity - Production costs - Delivery dates

PLANT To make PRODUCT, PLANT of some kind is needed. This will comprise the bulk of the fixed assets of the business. In determining which PLANT to use, management must consider areas such as: - Future demand (volume, timing) - Design and layout of factory, equipment, offices

- Productivity and reliability of equipment - Need for (and costs of) maintenance - Heath and safety (particularly the operation of equipment) - Environmental issues (e.g. creation of waste products) PROCESSES There are many different ways of producing a product. Management must choose the best process, or series of processes. They will consider: - Available capacity - Available skills - Type of production - Layout of plant and equipment - Safety - Production costs - Maintenance requirements

PROGRAMMES The production PROGRAMME concerns the dates and times of the products that are to be produced and supplied to customers. The decisions made about programme will be influenced by factors such as: - Purchasing patterns (e.g. lead time) - Cash flow - Need for / availability of storage - Transportation

PEOPLE

Production depends on PEOPLE, whose skills, experience and motivation vary. Key people-related decisions will consider the following areas:
Wages and salaries - Safety and training - Work conditions - Leadership and motivation - Unionisation - Communication

PRODUCTION PROCESS The production process in brief includes the following Paddy Pre-Processing Milling of Rice Cleaning Dehusking Husk Separation Paddy Separation Compartment Type Separator Polishing Grading Color Sorter Weighing and Packing.

A detailed process of the above steps is explained as below Paddy Pre- processing
A. Paddy Cleaning Paddy after harvesting and thrashing contains some foreign matter depending upon harvesting, thrashing and handling methods. The foreign matter may be other seeds, straw, chaff, sand; stones, dust, soil and iron particles. Paddy received in the mill must be first cleaned to remove these foreign matters before it can be properly stored. Otherwise they may cause deterioration of the paddy during storage or may damage or

obstruct the conveying and milling machinery. The first cleaning operation of paddy after thrashing is called 'Scalping'. It removed the bulk of the foreign matter. But the paddy is not completely cleaned. The small amounts of impurities that still remain are later removed during the next cleaning operation during the rice milling process. Scalper cleaners use both sieves and aspirators.

B. Paddy Drying Intake paddy also generally contains more moisture than is safe for storage and has to be dried. Freshly harvested paddy normally has moisture content of 18% to 25%. This moisture must be brought down by drying to ensure a good storage quality. A moisture content of 14% is considered safe for short periods of storage. For long

storage, the grain should be dried to 13% moisture or less. During the process of drying, cracking of paddy may occur if drying is not proper. This will lead to breakage of rice during milling. Therefore, drying process must be so adjusted that cracks to not develop in the grains. The high moisture gradient between the grain center and the surface causes cracking. Drying should not be continuous, but in stages, with the rest periods between drying stages. These periods are called tempering. This avoids cracking of paddy while drying. It is said that not more than 2 to 4% moisture should be removed in one drying stage in the case of mechanical drying with hot air. Paddy may be dried for, say half an hour then tempered for 6 hours, then dried again. This cycle is followed till the paddy is dried to required moisture. Several methods of drying are adopted viz., Sun Drying, Mechanical Drying, Batch dryers or continuous flow dryers. Paddy husk is the most common fuel used for drying paddy.

C Paddy Storage Paddy is harvested twice or thrice in a year. But rice is consumed throughout the year. Therefore, paddy is stored to meet the need between harvests. Storage must keep the paddy safe and also maintain its quality. It should provide protection against weather,

insects, pests, birds, micro organisms, moisture and any type of contamination. Care should also be taken to store different types of paddy

separately to avoid mix up. Paddy dried to a moisture level (less than 14%) should be maintained dry and cool during storage. Paddy can be stored in bags or in bulk. The choice between the two systems depends on a number of local factors including cost of local construction, bags, operating and handling equipment, transport system, labour and investments. Either method can provide safe storage as long as scientific storage practices are observed. Storage bins can be either of steel or concrete.

Milling of Rice Unlike other food grains, rice is mostly cooked and consumed in whole form. Hence the milling operation should provide maximum out turn of milled rice and with a minimum of brokens. Before the paddy is kept ready for milling operation, it is necessary to bring all the grains, preferably to a uniform moisture content level which may vary from 10% to 14% for optimal milling yields and avoid excessive breakage. The different kinds of milling are hand pounding, huller, sheller cum huller.

The operations of a Modern Rice Mill are Cleaning: Removing foreign matter such as sand, stones, straw, seeds etc. Dehusking: Removes husk from paddy with minimum of damage to the grain. Husk separation: Removes the husk from the mixture obtained after dehusking. Paddy separation: Separates dehusked brown rice from remaining unhusked paddy, the paddy being returned for dehusiing

Polishing: Removes all or part of the bran layer from the brown rice to produce polished rice Grading: Separates brokens from unbroken rice. The brokens are separated into different sizes. Apart from the above, the mill also use color sorters and length graders.

A. Cleaning Cleaning is the first step in rice milling. It enables the production of clean rice and provides protection to other milling machinery, thereby increasing milling capacity. Impurities that are lighter than paddy are removed by an aspirator. Metallic (ironimpurities) are removed by the use of a magnet. Impurities larger or smaller in size but heavier than paddy are removed by sieves. Vibrating sieves are used. Impurities that have the same size as paddy but are heavier than paddy are removed by specific gravity separator namely destoners. Intake paddy is often subjected to a preliminary partial cleaning prior to storage and prior to the main cleaning in the mill.

B. Dehusking A rubber- roll sheller consist of two rubber roller rotating in opposite direction at different speeds, both rollers have the same diameter, but one roll rotates about 25% faster than the other. The differences in peripheral speed subject the paddy grains falling between the roll to a shearing action that strip of the husk. One roller is fixed in position and the other is adjustable laterally in order to increasing or decreasing the clearance between the two rolls. Rolls are cooled by blowing air on the roll surface. The shelling i.e., dehusking rate is generally maintained at about 85%, compared to the disc shelling. Some breakage invariably occurs and the fine brokers may be blown off along with the husk. The degree of Shelling with the rubber roll can be raised to about 85% without much of grain breakage, whereas the disk sheller can be operated at not more than 6070% degree of shelling, to keep breakage at a low level. However, rubber roll wear out fast and have to be replaced often. This, though a disadvantage, is offset by the reduction in breakage and increase in total rice outturn. C. Husk Separation

A mixture of dehusked rice (brown rice), remaining unshelled paddy, some broken rice and husk that has been split off the paddy comes out of the sheller. This mixture is subjected to sieving cum aspiration to separate brokens and husk. Sieving prior to aspiration helps in separating and recovering the small brokens formed during shelling. Light weight paddy husk is separated from the heavier paddy and rice by aspiration.

D. Paddy Separation Shelling is not possible to a level of 100%. The grains differ in size due to which some grains remain unshelled. Therefore, a paddy separator is used to separate the remaining unhusked paddy from husked brown rice. The unhusked paddy is returned to the dehusker while the brown rice is carried forward to the polisher. The separation is accomplished in the separator by taking advantage of the difference in physical density (heaviness), size and surface smootheness (or toughness) of paddy and brown rice. Paddy collected from the separator is called return paddy, for it has to be returned to the sheller: The return paddy grains are shorter or thinner than normal paddy. Hence

it is preferable to collect the return paddy in a bin and shell it at the end with closer clearances between the rolls. Alternatively, the return paddy can be shelled in a separate small sheller. This will increase the efficiency of the plant. If return paddy is returned to the original sheller with same setting, it will simply go on circulating, thus lowering the capacity.

E. Compartment Type Separator The oscillating table is-divided into zigzag channels and is inclined from one side to the other along the zigzag channels. The surface of the table is of smooth steel. The table oscillates cross wise, i.e. perpendicular to the direction of the grain flow. The mixture of paddy and brown rice is fed from the hopper to the center of the channels. The impact of

the grains on the sides of each channel causes the unhusked paddy grains to move up the inclined slope toward high side of the table. The dehusked brown rice slides down the slope to the lower side of the table. The slope and stroke of the table are adjusted to meet the needs of paddy of different size or condition, to ensure complete separation. Usually there are several decks one above the other to increase capacity. Paddy collected from the separator is called return paddy, for it has to be returned to the sheller. The return paddy grains are shorter or thinner than normally paddy.

Hence, it is preferable to collect the return paddy in a bin and shell it at the end with closer clearances between the rolls. Alternatively the paddy can be shelled in a separate, small sheller. This will increase the efficiency of the plant. If return paddy is returned to the original Sheller with same setting, it will simply go on circulating, thus lowering the capacity.

F. Polishing The brown rice is next polished to remove bran layers. Some amount of polishing is essential for easy cooking and storage, although excessive polishing reduces the nutritive value of rice. There are three whiteners, one glaze master and one silky polisher in the unit for effective polishing of brown rice.

G. Grading After the polishing operation, the milled rice contains, in addition to white grains, broken grains of different sizes as well as some bran and dust. Separation of these materials must be done. Bran and dust particles are removed by aspiration. Broken rice may be separated either by a Plan sifter or by a Trieur.

Color Sorter

Color sorter is used for sorting out discolored grains from the lot. Optical sensors are adopted here to compare the color of the Individual grains. The discolored grains are blown out of the main stream. Weighing and Packing This can be manual or automatic. An automatic intake weigher receives rice in a continuous flow and releases it in exact predetermined quantities by weight. At the

same time, the number of weighments made is recorded by an automatic counter, thus giving an accurate record of the total weight of material processed in the mill. The automatic bagging scale ensures dust free bagging of the finished products and records the number of weighments made, by an automatic counter.

THE PROCESS FLOW CHART

Paddy PreProcessing

Milling of Rice

Cleaning

Dehusking

Husk Separation Paddy Separation Compartment Type Separator

Polishing

Grading

Color Sorter

Weighing and Packing

Market: Global rice production in 2008-09 is 460 million tons while consumption stood around 446 million tons. Andhra Pradesh is one of the major paddy cultivated state in India with 39.78 lakh hectares with an output of 118 lakh tonnes. In Andhra Pradesh rice is grown in 22 districts of which 18 districts are under high

productivity group, with an yield of more than 2500 kg/ha. Production of Rice in India: India produced 95.68 mn tonnes in the year 2007-08 of which most of the production is available during Kharif season by almost 86.5%. The year wise rice production is given in the table below: Product/Rice Khariff Rabi Total 2003-04 78.62 9.91 88.53 2004-05 72.23 10.90 85.3 2005-06 78.27 13.52 91.79 2006-07 80.17 13.18 93.35 2007-08 82.78 12.90 95.68

Indian sales are primarily categorized as FCI sales and local market sales. FCI (Food Corporation of India) is a major purchaser of rice and Government suggests minimum support price for paddy and FCI purchases 20-25% of total rice production in the country as levy.
Indias Rice Production in Global Context:

2012-13*(Proj.) 2011-12 2010-11 2009-10 2008-09 2007-08 2006-07 2005-06 2004-05 2003-04 2002-03 2001-02 0

22.25 22.88 21.38 19.49 21.61 22.08 21.86 21.7 20.53 22.7 18.9 23.39 50 Indias share (In %)

103 104.32 95.98 89.09 99.18 96.69 93.35 91.79 83.13 88.53 71.82 93.34 100 150 200 250 300 350

463 456 449 457 459 438 427 423 405 390 380 399 400 450 500

Indian Production in million MT

World Production in million MT

Production of rice in major rice producing countries is as follows (Source: USDA):

Qty in thousand MT
Countries China India Indonesia Others Bangladesh Vietnam Thailand Burma Philippines Brazil Japan Pakistan United States Korea South Egypt Cambodia Nepal World Total 2008/09 134330 99180 38310 33080 31200 24393 19850 11200 10755 8570 8029 6900 6546 4843 4673 3992 2850 448701 2009/10 136570 89090 36370 35303 31000 24993 20260 11642 9772 7929 7711 6800 7100 4961 4564 4056 3013 441134 2010/11 137000 95980 35500 37290 31700 26371 20262 10528 10539 9300 7720 5000 7593 4295 3100 4233 2680 449091 2011/12 140700 104320 36500 37144 33700 27075 20460 10816 10700 7888 7646 6500 5866 4224 4250 4268 2970 465027 2012/13Jan 143000 99000 36900 38001 33800 27710 20500 10750 10990 8160 7751 6800 6356 4006 4700 4225 2900 465549 2012/13Feb 143000 99000 36900 37955 34000 27710 20500 10750 10990 8160 7756 6800 6356 4006 4700 4225 3000 465808