Pemrosesan beras, Konstruksi produksi dan produksi tepung

Sebagai dua makanan pokok paling dasar di atas meja, the processing of rice and flour embodies the precision and efficiency of modern industry, from raw material to finished product. From harvesting rice and wheat in the fields to final packaging as finished grains, the entire process relies on specialized equipment and a strict quality control system. This article will focus on the basic processes used today to transform these two raw materials into finished products.

Rice processing line: the transformation from paddy to white rice

Paddy rice, the raw material for rice, undergoes seven major steps: cleaning, husking, separating the rice from the husks, milling, grading, polishing, and color sorting before it becomes the rice we eat every day.

1. Cleaning:

Freshly harvested rice undergoes a four-stage purification process: primary cleaning, penyaringan, stone removal, and magnetic separation, gradually removing various types of impurities.

Primary cleaning: Vibrating screens are commonly used, optionally in conjunction with air separators. The purpose of primary cleaning is to remove bulky impurities such as straw and flakes. With the addition of an air separator, lighter impurities such as grass seeds and chaff can also be removed.

Screening: Available equipment includes flat rotary screens, which are used to remove impurities of similar weight but different particle sizes, such as pebbles and broken rice grains, to ensure uniform rice particle size.

Stone removal: A stone remover is typically used. The rice is passed over an inclined screen surface and airflow to remove stones of similar particle size, further improving the rice’s purity.

Magnetic separation: As the final cleaning step, it removes unremoved metal impurities from the rice before it enters other equipment to prevent metal impurities from scratching the rice huller and mill.

2. Hulling:

The purpose of hulling is to remove the husks from the rice grains, effectively husking the rice without damaging the unhusked rice.

The primary equipment for hulling rice is the rice husker. To prevent damage to the unhusked rice, hullers typically use rubber rollers. These rollers rotate in opposite directions, squeezing and rubbing the rice grains between them, ultimately removing the husks.

Pada saat yang sama, a husk separator removes the husks, preventing them from mixing with the unhusked rice and facilitating subsequent processing.

3. Pemisahan:

After hulling, some of the brown rice still has hulls that haven’t been completely removed. This step separates these unhulled rice from the brown rice, allowing the unhulled rice to be returned to the huller for a second hulling.

Separation primarily involves the separator utilizing the density difference between the brown and unhulled rice. Vibration and airflow create separate layers on an inclined screen.

The brown rice, with its higher density, moves forward along the screen and is discharged through one outlet. The unhulled rice, with its lower density, moves toward the other side of the screen and is discharged through another outlet, achieving precise separation.

4. Rice Milling:

Brown rice is coated with a layer of bran, giving it a rough texture and making it prone to spoilage. Karena itu, this step removes the bran to produce pure white rice.

A rice mill uses high-speed grinding rollers to grind away the bran on the surface of the brown rice.

A sprayer can also be installed to blow away the bran and lower the temperature of the white rice, reducing the risk of broken rice and preserving its integrity.

5. Grading:

This primarily separates broken rice from whole rice, which is produced during the rice milling process, and sorts the rice by particle size.

Grading is performed using grading screens. Whole rice particles with larger sizes are discharged from the upper screen, while broken rice particles with smaller sizes are discharged from the lower screen. This achieves particle size classification and increases the commercial value of the finished product.

6. Polishing:

Although the graded white rice is ready for sale, a small amount of rice bran may remain on the surface, making it appear less shiny. Polishing is performed to achieve a whiter, smoother surface.

A common polishing machine is a vertical iron roller polisher. During operation, a power-driven servo motor drives the first peeling roller at high speed, which in turn drives the second peeling roller to create a squeeze and friction effect.

The rice rubs against the roller surface, removing the bran, making the rice more lustrous and more commercially valuable.

7. Color Sorting:

This is a crucial step in obtaining high-quality rice. Because white rice may contain yellow grains, diseased grains, or grains infested with insects, these “bad grains” must be removed to ensure the rice has a uniform color and is safe for consumption.

Once the color sorter detects grains of unusual color, it immediately issues a command to blow these “bad grains” away with a high-pressure airflow, leaving only the acceptable white rice.

Wheat processing lines: From grains to energy for thousands of households

Flour processing involves separating the wheat bran, kuman, and endosperm, leaving only the endosperm for grinding into flour. Depending on the degree of processing precision, different grades of flour can be obtained.

The entire process consists of five key steps, each centered around separating impurities and purifying the endosperm.

1. Cleaning:

Raw wheat contains many impurities, requiring further processing to obtain pure wheat for subsequent production line processing.

The initial steps are similar to the rice cleaning process, using equipment such as vibrating screens, rotary screens, and stoners to clean the raw material. Namun, wheat undergoes an additional step: a wheat washer removes dust and pesticide residue from the surface of the wheat, ensuring that the wheat is clean and harmless.

2. Tempering:

Before milling, the wheat must be tempered. Only wheat with sufficient moisture or humidity will produce higher-quality flour. This step primarily involves adding water to the wheat to soften and strengthen the bran, making the endosperm easier to grind.

This process requires minimal equipment and can be performed without machinery; simply ensure that the wheat is in sufficient contact with water before tempering.

3. Grinding:

The core step in flour processing involves multiple grinding steps to break the wheat into pieces, separating the bran, kuman, and endosperm, and finally grinding the endosperm into flour.

The equipment typically used is a flour mill. The flour milling process consists of three steps: bran milling, heart milling, and slag milling. These steps, respectively, separate the bran from the endosperm, further separate the bran, and grind the endosperm into flour.

4. Sieving:

The flour, slag, core, and bran from the endosperm particles are separated through sieving, allowing the flour to be collected as the finished product.

A flat rotary sieve, a device with multiple layers of screens of varying apertures, removes the smallest flour particles from the bottom. Other impurities are removed through the outlets of the other screens above.

5. Packaging:

Unlike rice, which can be stored directly, the collected flour must be promptly bagged and sealed to prevent moisture, oxidation, and deterioration, while facilitating storage and distribution.

Automatic packaging machines are commonly used for packaging. The weight of each bag is set, and the flour is automatically loaded into the packaging machine. After loading, the flour is sealed and finally conveyed via a conveyor belt to a storage silo or transported elsewhere.

Professional manufacturer service: help you solve all processing problems

As a professional manufacturer with nearly 20 years of experience in food processing, we can confidently provide you with a perfect production line solution.

Whether you’re a small start-up or a large enterprise looking to upgrade your equipment, we can provide you with a comprehensive solution.

1. Equipment:

We offer different solutions based on your production scale. If your production site is small, we can provide you with an integrated processing line, which takes up minimal space, offers low investment costs, and offers a quick return on investment.

If you’re a large enterprise, we can also offer a more fully automated, intelligent production line to reduce labor costs and enhance the market competitiveness of your products.

2. Value-Added Services:

We provide free site planning and layout tailored to your site size, providing a fully customized processing solution.

During the production line installation, we will arrange a professional team to visit you for on-site installation and commissioning to ensure stable operation. If operator training is required, we also provide free training to help your staff master equipment operation and routine maintenance.

Our production lines can operate for over five years, assuming no operational errors or external damage. We offer a three-year free replacement period for all but the core equipment components.

If you are interested in our production line or you are planning to invest in the construction of a related production line, please contact us. We will provide you with the most suitable solution and provide you with the best service.