DEHUSKING RUBBER ROLLER FOR RICE MILL
[CODE NO.3437]
Rubber Roller is a rubber or an elastic material covering the core of metal or other material. Rice Dehusking Rubber Roll are precisely made and fitted with the fresh CI drums and aluminium drums. These rolls are specifically used for dehusking of raw rice. Due to the use of these rolls, raw rice get perfectly polished and whiten.
Rice (Oryza sativa L.) has been the staple food for more than half of the humanity in the world or two-third of the World’s population. Rice is the seed or kernel of paddy, which is covered by two different layers, namely- bran (inner layer) and husk (outer layer). Literally, paddy becomes rice only when the two layers are removed properly through different milling processes. In the first step, brown rice is extracted by removing hull/husk from the paddy, which contains bran layer still intact around the kernel. In the second step, the bran layer is removed by polishing machine that rubs the grains together under pressure, and the output is the polished white kernel or fine rice, which is ready for cooking. The former process is known as hulling and the latter is known as milling of paddy. But, in short, it is the conversion ratio from paddy to rice, or one can term it as hulling and milling ratio. Therefore, the two terms-1) hulling and milling ratio; 2) conversion ratio, will be used interchangeably throughout this paper.
In term of production, India has become the second largest producer of rice in the world (21 per cent of global rice production), next to China. As on 2009, rough total production of paddy was 14, 8260 thousand MT in the country, but, as estimated by USDA, it was 13, 2013 thousand MT. On the demand side, India’s domestic consumption was, on an average, 95% of what it produced and was still the third largest exporter of rice, after Thailand and Vietnam, with about 20% of the world’s total rice exports in 2006-07. In the recent years, with the growth of population, more pressure on the arable land has been made and this in turn, the need for higher productivity of crops was felt in the country. At the same time, large quantity of foodgrain was reported to be lost due to inefficient milling processes in the country. Therefore, it calls for a better processing technique of rice to prevent processing loss.
Generally, rice kernels are often susceptible to breakage due to inefficient milling processes. Therefore, more efficient milling processes are highly recommended for better recovery ratio and quality rice kernel production. It is also identified as one of the most important remedies for preventing post-harvest loss and an issue that is widely recognized around the world.
COST ESTIMATION
Plant Capacity : 20.00 Pairs/day
land & Building (700 Sq.mt) : Rs. 94.00 Lacs
Plant & Machinery : Rs. 53.00 Lacs
Working Capital for 1 Month : Rs. 20.21 Lacs
Total Capital Investment : Rs. 1.79 Cr
Rate of Return : 26%
Break Even Point : 67%
INTRODUCTION
CHARACTERISTICS OF RUBBER ROLLERS
CHARACTERISTICS OF RUBBER USED IN RUBBER ROLLER
B.I.S. SPECIFICATION
MARKET SURVEY
RICE PRODUCTION BY STATES (MILLION TONS)
EXPORT DATA OF RICE RUBBER ROLL
IMPORT DATA OF RICE RUBBER ROLL
OVERVIEW OF RUBBER ROLLER INDUSTRY
REDUCING RUBBER CONSUMPTION AND COSTS
REDUCING ‘OVERBUILD’ AND MATERIAL FLOW
REDUCING REJECTION RATE
IMPROVED RUBBER USAGE
RUBBER COST SAVINGS
BENEFITING FROM AUTOMATION
CORE PREPARATION
MANUFACTURERS/SUPPLIERS OF RUBBER ROLLER FOR RICE
FORMULATION OF DEHUSKING RUBBER ROLLER FOR RICE MILL
MANUFACTURING PROCESS OF DEHUSKING
RUBBER ROLLER FOR RICE MILL
CORES:
BONDING METHODS:
BUILDING:
CURING:
FINISHING
COMPOUNDING
RICE MILL ROLLERS:
PROCESS FLOW DIAGRAM
PROCESSING STEP IN RUBBER ROLLER
PROCESS DESCRIPTION OF MIXING PROCESS ON KNEADER MACHINE
DIFFERENT METHOD
FOR RUBBER ROLLER MANUFACTURE
STRUCTURE OR ROLLER CORE & MATERIALS
ROLLER CORE MATERIALS
ROLLER BALANCE
OTHER POINTS TO NOTE
NUMBER OF ROTATIONS OF THE ROLLER ･DESIRED BALANCE WEIGHT (G)
DETAILS OF RUBBER ROLLER MANUFACTURE
CROWN PROCESSING
1. CROWN TYPES
2. CROWN PRECISION
6. RUBBER HARDNESS
1. HARDNESS TESTER
2. DUROMETER SPRING TYPE HARDNESS TESTER
HARDNESS CORRECTION VALUES DEPENDS ON THE THICKNESS
OF THE TEST PIECE
3. INFLUENCE OF TEMPERATURE ON RUBBER HARDNESS
4. MEASUREMENT VARIATIONS
7. BONDING BETWEEN CORE AND RUBBER
8. SPECIAL SURFACE GROOVING
THE STANDARD SHAPES ARE SHOWN IN THE DIAGRAM BELOW.
9. RUBBER ROLLER PRECISION
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED
IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
RUBBER CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
RUBBER MIXING MILL
BABY BOILER
LATHE MACHINE
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET