INTERNSHIP REPORT ON WHEAT

PROCESSING AT NAGA LTD.

SUBMITTED BY :
LOGESH.D

Indian Institute of Food Processing Technology,

Ministry of Food Processing Industries, GoI
Thanjavur - 613005

2019

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 ACKNOWLEDGEMENT

We would like to express our deep sense of gratitude to our institute INDIAN
INSTITUTE OF FOOD PROCESSING TECHNOLOGY, Thanjavur

for encouraging and permitting us for engaging ourselves in this internship at

Naga Ltd.

We are also grateful to the Mr. Sriram Prasad, Head of R&D for permitting us to
utilize all the facilities available in the industry.

We also thank Mr. Prabagran, Mr. Bhuvaneswaran, Ms. Abhinaya ,Ms.

Keerthana and other staff members of the industry for their guidance in our

effective learning.

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WHEAT
Wheat, any of several species of cereal grasses of the genus Triticum (family
Poaceae) and their edible grains. Wheat is one of the oldest and most important
of the cereal crops. Of the thousands of varieties known, the most important are
common wheat (Triticum aestivum), used to make bread; durum wheat (T.
durum), used in making pasta (alimentary pastes) such as spaghetti and
macaroni; and club wheat (T. compactum), a softer type, used for cake, crackers,
cookies, pastries, and flours.

STRUCTURE OF WHEAT:

The endosperm is the potential white flour within the centre of the wheat grain.
When milled, the endosperm fractures along the cell walls, and separates from
the bran layers. The ease of separating the endosperm from the bran layers is
determined by the wheat's characteristics. Hard wheat (used for bread making)
will allow easy separation, whilst the endosperm of soft wheat (used for biscuit
flours) does not separate as cleanly from the bran layers.

The bran layers of the wheat grain consist of four separate layers: the pericarp,
Testa,

nu cellar layers and aleurone cells. Bran is nutritionally rich in protein and is
used in the production of brown and wholemeal flours. The wheat germ is the
embryo that would eventually develop into the wheat plant. It is rich in certain
vitamins, protein and oil. Consequently, it is often used in health foods, such as
fortified bread and wholemeal flour.

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NUTRITIONAL COMPOSITION:

The nutritional composition of the wheat grain varies somewhat with

differences in climate and soil.

CONTENTS PERCENTAGE
Water 12
Carbohydrates 70
Protein 12
Fat 2
Minerals 1.8
Crude fibres 2.2
Thiamin, riboflavin, niacin, and small amounts of vitamin A are present,
but the milling processes removes most of those nutrients with the bran and
germ.

PRODUCTS

 Wheat Atta

 Wheat Maida

 Rava

 Flakes

 Wheat Bran

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WHEAT STORAGE
The flow of resource between the point of origin and the point of consumption of
the grains are done in an orderly manner by the logistics division of Naga ltd.,in
order to ensure a timely production and good yield .

Wheat storage is done in silos. Naga Limited has a capacity of 64,000

(8*8000tonnes) for storage of wheat in Trichy road, Dindigul,which is the largest
in India with increasing efficiency in wheat handling .

This division of Naga is for receiving wheat from different parts,storing and
dispatching to the milling unit.

It receives wheat from different parts of the world through different modes of
transportation . Container vessels from ships are one of the transportation mode
for import of wheat from other countries like Australia. Wheat is also brought
from Northern parts of India through racks from trains . Roadway transportation
is also a mode of transport used here . Trucks such as trippers,tankers brings
wheat from harbours, stations and other parts to the storing unit .

The truck bringing wheat is first weighed in the weighing bridge .Wheat is then
unloaded to the hopper on the ground surface .Using chain conveyors , the wheat
is transported through the tunnels under the ground . Bucket elevator are used to
rise the wheat to the higher altitude for the further processing.

Cleaning is an essential step in every processing plant of wheat . It is to optimize

the storage life of the grains and to improve the quality of the product . This step
is to prevent diseases , improves the process flow , remove unwanted materials
and enhance production reliability .

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[Process type I]

The grains which is to be dispatched earlier are cleaned by the universal cleaning
machine-TAS. It has the multiple cleaning and separating action.

TAS uses:

[1] Electro magnetic flux for the removal of magnetic particles.

[2] Jet filters for aspiration for the removal of dust and light particles.

[3] Destoner for the removal of stones by the reciprocating action of the sieve.

Then filled in gunny bags and stored in godowns or dispatched to the mills.

Process type [II]

The grains to be stored are sent for the pre-cleaning setup which consists of
various separators,cleaner, sieves, sifters, aspirators. Then taken to the
distribution channel on the top using bucket elevators which then fed into the silo
based on the specific variety by batch wise chain conveyor.

The storage period of the grains in the silo highly depends on the demands faced
in the market and in milling unit. Long time storage of grains posses great threats
to the quality of grain which may be degraded by pest or fungal growth. In
order to overcome the above mentioned challenge fumigation is done in discreate
time period. Aluminium phosphate which is majorly used as the reagent in
fumigation.

As the rate of respiration of wheat increases the temperature of the grains inside
silo goes up which degrades the grain quality. Thus frequent decor-ring
[recyclation] of grains are done.

At the time of dispatch , the grains are transferred to baby silos(4*) and then
loaded to the trucks.

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QUALITY CHECK
Quality control of raw wheat which are bought and stored is a crucial part of
wheat processing. The quality tests of wheat is done at three different points :

1. Samples taken from racks when bought (before storage)

2.Samples taken as lots (during storage for long periods)

3.Samples taken during dispatch (after storage)

Once the wheat is bought ,they are are classified into different varieties based
on zones from where they are grown and based on its gluten content (an
important property of wheat). Sample from each variety is taken for quality tests.
After grading based on size ,cleaning is done. Based on refraction, sound wheats,
strivelled wheat, broken wheat, sticks, stones are separated. During test
experiments the quantity of impurities are taken in count and the sound wheat is
further taken for analysing the various parameters.

TESTING OF WHEAT IS OF THREE PHASES:

[1] AS A WHOLE GRAIN

[SEPARATOR & CLEANER]

Separation takes place on the basis of shape,size and density.It separates

strivelled wheat,broken,dust and sticks. And amount of each outlet is calculated.

[HECTOLITRE]

Hectolitre weight (or weight per unit volume) is the weight of 100 litres of wheat
and is the simplest criteria of wheat quality. The factors affecting the hectolitre

weight are kernel shape and uniformity of kernel size, orientation of kernels in
container when it is filled, density of the grain influenced by structure of grain
and its chemical composition. It is determined to asses the quality of wheat grain.

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[1000 KERNEL WEIGHT]

Sound or good grains has higher weights whereas unsound wheat have lower
weights and hence 1000grain weight is calculated.

[2] AFTER FIRST BREAK

Grains are allowed to be milled in a roller mill and samples are taken and tested
after first break and after complete milling.

[MOISTURE]

It is an indicator of grain storability. Wheat or flour with high moisture content

may attract mold,bacteria, and insects and all of which can cause deterioration
during storage.

[ASH]

Ash is primarily concentrated in the bran,hence ash content indicates milling

performance indirectly by revealing the amount of bran contamination in flour.

[3] AFTER COMPLETE MILLING

Sound wheats are milled in a multi-stage hammer mill and the flour produced are
analysed for further properties gluten content and sedimentation value.

[GLUTEN CONTENT]

The wet gluten provides information on the quantity and estimates the quality of
gluten in wheat or flour samples .Gluten is responsibility for the elasticity and
extensibility characteristics of flour dough. Wet gluten reflects protein content
and is common flour specification required by end-user in the industry.

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MILLING
NAGA flour mills have an effective layout machinery in order to produce high-
quality finished products and to ensure consistent finished product quality with
maximum yield. The machine work 24 hrs a day, with an average output of 800-
900T/D. The raw wheat are processed cleaned, conditioned ,and milled in to a
finished product such as Maida, Atta, Sooji and Bran as bi-product. Plant is built
in a 7 storey building and equiped with Bhuler machineries.

PROCESSES INVOLVED IN MILLING:

[1]Intake & Pre-cleaning

[2]Cleaning & Conditioning

[3]Milling

[1] INTAKE &PRE-CLEANING

[HOPPER]

Grain is usually supplied to the industry by the help of trucks, trains, ships.

Its further dipped in the hopper located on the ground. Unloaded in the rate of 15
tones per truck.

[ELEVATOR]

Material is then transported for further processing through elevator to the higher
altitude in to the production unit.

[PADDLE CONVEYORS]

Paddle designed chain conveyors are used where loading angles are too steep.
the paddles are fitted at regular intervals along the length of the shaft and it
completes the work at much faster rates.

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PRE CLEANING:

In order to remove impurities and foreign materials that have entered the product
in the field or during harvesting and transportation and to assure a safe
production process, as well as improved storage life and higher end product
quality. Also preliminary cleaning of grain reduces the wear and tear on the
downstream equipment in the production process.

[DRUM SEPARATOR]

The drum separator also called drum sieve is installed in grain receiving lines,
which serves to separate course impurities contained in cereals during the pre-
cleaning phase such as straw particle, string, paper, pieces of wood, maize leaves
and cobs etc. It runs round and round in the machine, the stream of material
flows in and goes through the sieve while the coarse are separated as over tails.
Grain and offal are collected and sent to different outlets.
[ASPIRATOR CHANNEL]

Lighter particles such as straw, dust, or hull fragments are separated according to
specific gravity from the heavier grains.

When the grain stream sheet is fed into the inlet of the channel and flowing
down, the air suction goes through the grain sheet, the hulls, small straws,
shrunken grain, or other slight offal are brought away. The volume of the air
suction is adjustable according to the grain kinds and the capacity of the flow.

[NIR]

Online testing of moisture, protein, and ash contents of raw material and final
products
[BINS]

Through elevators materials are stored in a temporary bins based on the varieties
until further processing.

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[BLENDING]

Different varieties of wheat from respective bins are blended in this unit, in a
required ratio needed for the specific recipe through an automated volumetric
feeder.

[2] CLEANING AND CONDITIONING

CLEANING:

It consists of two consecutive cleaning, namely first and second cleaning

Contaminants such as foreign seeds, stones, ferrous metals, bits of wood, straw
and dust are identified and removed based on deviations in size, weight, colour
or magnetic properties.

After the first cleaning section, water is added to the grain, conditioning it for
optimal separation in the subsequent milling process.. After conditioning, the
grain enters the second cleaning section in which the kernel’s surface impurities
are removed.

[DE STONER]

Is employed for the efficient removal of stones, glass and other high-density
matter from the grain stream.

The principle of operation is to separate grain and gravel by vibrating motion,

adjusting air flow and adjusting the inclination of the screen surface.

[SCOURER]

Removes impurities such as dust, sand, clods of soil etc. that adhere to the grain,
thus providing ideal preparation for grinding. It also significantly improves
product hygiene by reducing microbial count on the skin of the wheat. It is
mainly used to clear away the clods on the surface and hence increases water
penetration into the wheat.

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[COLOUR SORTER]

They separate items by their colours, detecting the colours of things that pass
before them, and using mechanical or pneumatic ejection devices to divert items
whose colours do not fall within the acceptable range or which are desired to
form a separate group from the rest.

It consists of five chambers for the flow of grains at a rate of 12 tonnes per hour,
the first three is for input and separates based on the colour and the rest for the
recycling .

[COCKLE CYLINDER]

Cockle cylinder machine consists of steel drum into which thousands of small
indents are pressed. It is made in such a shape of indents as to trap only
particular size seed. Drum rotates slowly and grain to be graded is feed inside.
Paddles are fitted to spread the grains over a wide area. The entrapped grains
broken, cockles are separated and discharged by a screw conveyor and machine
guarantees total separation of broken grains and cockle.

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CONDITIONING

[DAMPNER]

During dampening, the grain enters the dampener through the front-end inlet.
Together with the separately added water, the grain undergoes an intensive
intermixing and water penetration by the bi-rotor whirling system. The
thoroughly dampened grain is discharged from the machine through the
tangential outlet to the tempering bins.

Dampening helps :

 Make the bran tough and elastic

 Mellow the endosperm

 Achieve the correct flour moisture content

 Maintain constant grinding conditions

The dampener enables moisture addition rates of up to 7% in a single pass for

12.5t/hr of wheat flow.

In the first conditioning ,the moisture is raised up to 15% in 24hours (12hours

process and 12hours resting time) .

The second dampening process is to bring the moisture content up to 16% where
0.5% is set as offset moisture done in 12hours. The moisture content is brought
to16% so that the final moisture of the product is 14% which is lost due to heat
generated during milling.

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[3] MILLING

MAJOR PROCESSES:

[1]GRINDING – [i]BREAK ROLLS

[ii]REDUCTION ROLLS

[2]PURIFIER

[3]SHIFTER

In the milling section, the endosperm is separated from the hull and
germ and processed into flour. The wheat is ground on multiple consecutive
roller mills, which are often called the heart of a flour mill. After each roller mill,
the different parts of the kernel are separated by sifters. Numerous sieves utilize a
circular motion to divide the different products by size. Additionally, bran
finishers and purifiers optimize the separation process. The grinding and sifting
process is repeated multiple times to maximize the separation, improving the
quality and yield of the finished products. The results are flours of various
qualities, bran and, if required, germ .

[BREAK ROLL]

This breaking open of the wheat and releasing of the endosperm from the bran
gradually is a mechanical process achieved by passing the wheat between rolls
that are grooved; these flutes being cut in a linear, and the two rolls running at
different speeds to produce a cutting or shearing action.

The extent that the endosperm must be scraped off the bran skin depends on the
flour extraction required. Also the extent to which the endosperm can be scraped
off the bran skins depends on many items such as the condition of the wheat
used, the design of the fluting on the rolls and the roll gap adjustment itself. As
the break increases, the grooves in the rolls are closer and gap between the rolls
are also made closer.

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Fourth and fifth break normally set to clean out the bran with as little bran
powder production as possible.

[PURIFIERS]

Purification is any process that separates bran particles and germ from
endosperm. In particular, it is the gradual reduction of middlings to reduce
endosperm and flatten the germ and bran particles so that they can be removed in
the sifter.

Then directed to the head reduction roller mills while the composite particles of
endosperm and bran stock is directed to the lower reduction or recovery roller
mills. Purifiers are to be set in such a manner to ensure that the stocks are
thoroughly separated and that there is not contamination in the separations.

[SIFTERS]

Sifters are used to separate small granules & powder impurities with the help of
various sizes of sieves. The principle of working is based on the vibratory motion
produced by a high power motor. Every outlet of break rolls are led into the
sifters and further sieved and classified according to the particle size and led as
input to the consecutive break roll and a specific reduction roll.

[REDUCTION ROLLS]

Reduction roller mill rolls are straight roller mill rolls. The task of reduction
roller is gradually to convert semolina obtained in the crushing system into the
flour and to make flake by crushing bran and germ particles. They make the
compress, crushing and shredding tasks. Expansion occurs at the edges because
of heat released due to compression and crushing in these rolls

[BRAN DUSTER]

It removes flour particles still adhering to the bran, reducing to a minimum the
residual starch content of the bran.

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They are horizontally oriented, with a high-speed shaft with paddles inside
perforated sheet metal cylinder. A horizontal bran duster has the inlet at the end
of the machine along the top and an outlet hopper positioned under the perforated
sheet metal screen collecting the through stock and the discharge at the opposite
end of the machine for the over tail of the perforated sheet metal screen.

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