INDUSTRIAL RICE PRODUCTION: PROCESS FLOW

AND OPERATIONS

STANDARDISATION ASSIGNMENT

BY
MBANISI UGWUMDINACHI DANIEL
20CK027540

MCE528: PRODUCTION ENGINEERING II

2024/2025 SESSION

April 2025
1. Introduction

Rice is one of the most important staple foods globally, especially in Asia. To ensure its
quality, safety, and availability, rice must undergo a series of well-structured processes from
its raw form (paddy) to the final consumable product (white rice). This report outlines the
production process carried out in a rice production plant, detailing each stage involved in
converting harvested paddy into market-ready rice.

2. Objective

 Highlight the significance of modern machinery and automation in streamlining rice

production.
 Demonstrate how waste reduction and resource optimization are achieved at various
stages of processing.
 Provide insights into optional processes like parboiling and fortification, which
enhance nutritional value and cater to specific market demands.
 Serve as an informative reference for students, professionals, and stakeholders interested
in agricultural engineering, food processing, or supply chain management.

3. Production Process Overview

I. Paddy Reception and Storage

The production process begins once the paddy is harvested from the field. Upon arrival at the
rice mill, the paddy undergoes an initial inspection and is stored in large silos to ensure its
preservation until ready for processing. Efficient storage management is essential for
maintaining the quality of the paddy before milling.

II. Cleaning

The first step in milling involves the removal of impurities such as dirt, stones, and foreign
materials from the paddy. Pre-cleaning machines, equipped with sieves and air blowers,
perform this task. This step ensures that the milling process is smooth and that the final rice
product is free from contaminants.

III. Drying

Paddy is often harvested with varying moisture content, and if the moisture content is too high,
drying is necessary to ensure proper milling. The drying process involves using either heated
air or mechanical dryers to reduce the moisture content to an optimal level (14-15%). Proper
drying prevents mold growth and ensures efficient milling.

IV. Milling Process

Milling is the central operation in rice production. This phase involves multiple steps:

a) Hulling (Dehusking): The outer husk is removed using a dehusker or hulling

machine, leaving behind brown rice.
b) Polishing: The brown rice undergoes polishing to remove the bran layer, resulting
in white rice. Further polishing can be done to improve the rice’s appearance.
c) Whitening: The rice is whitened to enhance its appearance and texture, ensuring it
meets market standards.
V. Sorting and Grading

After milling, rice is sorted based on size and quality. Various sorting machines, including
screens and color sorters, separate the rice into different categories, such as long grain,
medium grain, and short grain. Grading ensures that the rice meets the required specifications
for consumer use.

VI. Packaging

The sorted and graded rice is then packaged for distribution. Modern packaging machines
ensure that the rice is packed hygienically and accurately, with proper weight and packaging
to prevent contamination and degradation during storage.

VII. Storage and Distribution

Once packaged, rice is stored in warehouses or distribution centers, awaiting transportation to

retailers or directly to consumers. Proper storage conditions are necessary to prevent exposure
to moisture and pests, ensuring the rice remains of high quality until it reaches the market.
4. Workflow Diagram
5. Quality Control and Storage

4.1 Quality Control

Throughout the rice production process, quality control is essential to ensure the final product
meets the desired standards. Samples of rice are often taken at different stages to check for
moisture content, size, and purity. The rice may also be tested for chemical residues, foreign
particles, and the presence of any defects or damage.

4.2 Storage

Rice is stored in climate-controlled facilities to maintain its quality. Proper storage conditions
include temperature and humidity control to prevent spoilage. Long-term storage may require
the use of fumigation or pest control measures to avoid contamination by insects or rodents.

6. By-products and Waste Management

In industrial rice production, various by-products are generated, including rice husks, bran,
and broken rice. These by-products have alternative uses:

 Rice husks are often used as fuel for boilers in rice mills, or they can be used in the
production of biofuels or animal feed.
 Rice bran is a valuable by-product, often used to produce rice bran oil or as animal feed.
 Broken rice is typically used for making rice flour or can be sold at a lower price for use
in food products.

Waste management practices, such as recycling husks and using organic waste for
composting, are commonly implemented to minimize the environmental impact of rice
production.

7. Standards and Specifications

Category Standards/Specifications

Codex Alimentarius: Food safety, pesticide

International Standards
residues, food additives.

ISO Standards: Rice processing equipment (ISO

7301), grading of rice (ISO 7971), and sampling
(ISO 24333).

USDA Grading Standards (USA): Classification of

National Standards rice by quality (Grade 1, 2, 3, 4), broken rice, whole
grain.

FSSAI Standards (India): Moisture content

(≤14%), permissible broken rice (≤25%), pesticide
 Category Standards/Specifications

residue limits.

EU Regulations (Europe): Classification, grading,

and pesticide residue limits.

Moisture Content: 12-14% for proper storage and

Quality Specifications
shelf life.

Grain Size and Shape: Long, medium, or short

grain rice.

Purity: Limited admixture of foreign materials (dust,

stones).

Defects: Maximum allowable physical defects

(discoloration, insect damage).

Pesticide Residues: Maximum Residue Levels

Safety Standards
(MRLs) for safe consumption.

Mycotoxins: Limits on aflatoxins and other mold-

produced toxins.

Heavy Metals: Limits on arsenic, lead, cadmium in

rice.

Material: Food-grade, non-toxic packaging materials

Packaging Standards
(plastic, woven sacks).

Labeling: Must include origin, production date, best-

before date, rice grade, and nutritional info.

Environmental/Sustainability Water Management: Efficient irrigation techniques,

like drip irrigation.
Carbon Footprint: Reducing greenhouse gas
emissions in rice cultivation.

Waste Management: Recycling and reusing by-

products (rice husks, bran).
8. Resource & Component Breakdown

Infrastructure

 Borehole or Water Source System: Water supply for irrigation and processing.
 Milling Plant: Facility where rice is processed, including dehusking, polishing,
and grading.
 Storage Warehouses: Climate-controlled facilities for storing raw and processed
rice.
 Quality Control Laboratory: Space for testing rice for moisture content,
impurities, and pesticide residues.

Equipment

 Combine Harvesters: Machines for harvesting rice from the field.

 Dehuskers: Machines to remove the husk from rice.
 Dryers: Equipment for reducing moisture content in harvested rice.
 Milling Machines: Equipment for polishing and whitening rice.
 Grading and Sorting Machines: Equipment for sorting rice by size and quality.
 Packaging Machines: For sealing rice in bags or containers.

Documentation

 Standard Operating Procedures (SOPs): Guidelines for all production and

milling processes.
 Harvesting and Processing Logs: Daily logs for tracking rice harvests,
processing times, and equipment usage.
 Quality Control Test Reports: Records of testing rice quality, including
moisture levels and impurities.
 Compliance Documents: Government or industry certifications for rice quality
and food safety.
 Maintenance Records: Documentation of regular maintenance performed on
machines and equipment.
 Training Manuals: Guides for training workers on rice processing and safety
procedures.
Personnel

 Agronomists: Experts who monitor rice cultivation practices and ensure healthy
crops.
 Milling Technicians: Skilled workers operating dehuskers, polishers, and
grading equipment.
 Quality Assurance Officer: Ensures that the processed rice meets safety and
quality standards.
 Maintenance Engineers: Responsible for maintaining and repairing milling and
processing equipment.
 Warehouse and Distribution Supervisors: Oversee storage and transportation
of processed rice.

Supplies

 Fertilizers and Pesticides: Chemicals used for rice cultivation to promote

growth and protect against pests.
 Rice Packaging Materials: Bags, woven sacks, and vacuum-sealed packaging
materials for storing and distributing rice.
 Rice Grading Tools: Instruments for assessing the size and quality of rice.
 Cleaning Agents: Used for maintaining cleanliness in rice processing and
packaging areas.