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Rice milling is the process of removing the hull, bran and germ from the rice paddy (rough rice) to produce edible white rice. Rice milling machinery Japan is typically classified into two types: pre-milling and milling equipment.
Pre-Milling Equipment
Pre-milling machinery prepares paddy rice for the actual milling process. They help ensure a more efficient and uniform milling of the rice. Key features include better rice yield and enhanced quality.
Typical features of pre-milling equipment include: better milling results, higher rice yield, and improved quality and increased milling efficiency.
The main types of rice pre-milling equipment include:
Paddy Separator
The paddy separator is an important machine in the rice milling process. It is used to separate unbroken rice grains from paddy rice (rice still in its original state, including hull and bran). The paddy separator works on the basis of the difference in size, shape, and weight between paddy rice and brown rice.
Dehusking/ Husking Machine
The dehusking or husking machine is critical in rice milling. Its primary function is to remove the outer husk layer from paddy rice. This process exposes the bran layer and the polished white rice interior.
Initial Whitening Machine
The initial whitening machine is a crucial component in the rice milling process. After dehusking, the underlying bran layer may still be partially intact. The primary whitening machine aims to remove this outer layer and reveal the polished white rice within.
Milling Equipment
The actual rice milling machinery comes in different types, each specifically designed for certain milling stages. They vary in how much of the rice grain they process, how efficient they are, and how high a percentage of whole grains they produce.
Details of rice milling equipment include:
Whitening Rice Mill
The whitening rice mill, also known as a rice whitener, is a crucial piece of equipment in the rice milling process. After the husk is removed from the paddy rice, the rice grains still have a bran layer that needs to be eliminated to reveal the polished white rice underneath. This inner layer is what consumers typically look for when purchasing rice for cooking and consumption.
The primary purpose of the whitening rice mill is to remove this bran layer and produce polished white rice. The whiteners work by grinding the rice grains using abrasive elements or emery wheels. These elements gently scrape off the bran layer, which can impart a slightly cloudy appearance to the rice.
Length Grader
A length grader is essential after the whitening process. It serves to categorize the rice grains based on their length. Typically, this machine utilizes a combination of sieves and air classification to distinguish between whole rice grains, broken rice grains, and other by-products.
The classification is usually based on size differences, and it is a critical step in ensuring that the final rice product meets specific quality standards. Moreover, the process is vital for maximizing rice yield, as it allows millers to identify and separate different rice grain fractions for further processing or commercial use.
Polisher
Rice polishing machines are critical in the rice milling process. As the name suggests, their primary purpose is to polish rice grains after the whitening process. Polishing not only enhances the visual appeal of the rice by giving it a shiny and lustrous surface but also improves its texture and cooking characteristics.
Moreover, rice polishing machines play a vital role in reducing the amount of bran that is often recovered during the milling process. This is because the polishing process removes the bran residue clinging to the rice grains. As a result, polished rice typically fetches higher market value than unpolished or semi-polished rice.
Capacity:
The capacity of rice milling machinery is typically expressed in terms of rice paddy input per hour or per day. The capacity of rice milling machines varies according to the model and size, as follows:
Small-scale rice milling machines may handle between 100 kg and 500 kg of rice paddy per hour.
Medium-scale rice milling machines generally have a processing capacity of between 500 kg and 2,000 kg per hour.
Large-scale rice milling plants have a much higher processing capacity, typically between 2,000 kg and 10,000 kg per hour or more, depending on the number of machines and production lines.
Operating environment:
For safety and proper functioning, it is essential to pay attention to the operating environment of the rice mill. Choose a dry, ventilated, clean, and sanitary place with abundant rice stores. The working temperature will be high if the sun is strong, which may exceed 40 degrees. Please use proper equipment to improve the cooling effect. Keeping the milling area away from the source of fire and electricity is also essential for safety.
Power source:
Small-scale rice milling machines are usually powered by electricity. Standalone machines are typically 220V/380V three-phase motor power. Medium to large-scale rice milling plants generally use 380V three-phase power. Diesel generators or solar-powered systems can be used in remote areas without access to the electricity grid.
Large-scale rice milling plants usually use three-phase power at 380V or higher, depending on the motor's capacity, which is usually between 45 kW and several hundreds of kW.
Core accessories:
The core components of rice milling machines include rice hulling machines, rice polishing machines, rotary sieves, rice dedusting machines, rice debranning machines, classifiers, and packing machines.
All the core components of rice milling machines are designed and manufactured with advanced technology to be easily replaced and easy to maintain and adjust, ensuring that the entire rice milling production line works smoothly and efficiently.
Regular maintenance of rice milling machinery is essential to ensure its efficient operation and extend its service life. The following are some maintenance methods and tips for rice milling machinery:
Regular cleaning:
Clean the rice milling equipment regularly to remove rice flour, husks, and other debris. This will improve the equipment's milling efficiency and product quality. Use clean water to wash the machine parts and then dry them with a clean cloth, avoiding the use of corrosive cleaners.
Lubrication:
Regular lubrication of moving parts of rice milling machines, such as bearings, gears, and chains, helps reduce friction and wear and ensure smooth operation. Use the appropriate lubricant for each component and regularly inspect and replenish it.
Scheduled inspections and repairs:
Develop a scheduled maintenance plan based on the frequency of use and the manufacturer's advice. Regularly inspect the entire rice milling equipment, including the electric motor, transmission system, and milling components, to ensure they are in good working condition. Repair or replace the parts as needed to avoid breakdowns.
Agriculture industry
Rice milling machinery plays a vital role in the agriculture industry as it processes harvested rice into consumable products. Agricultural cooperatives and farmhouses use rice milling machines to transform their rice crops into marketable products for sale.
Commercial rice production
Commercial rice producers and small-scale rice farmers depend heavily on rice milling equipment. This equipment allows them to efficiently and quickly process a large amount of rice in order to satisfy the rising demand of consumers.
Food processing industry
The food processing sector relies heavily on rice milling machines. The purpose of these machines is to produce various processed rice products such as flour, noodles, and cereals. The completed processed rice products are crucial ingredients for manufacturers to create other food items.
Restaurants and catering services
Rice milling machinery is used by restaurants and catering companies to produce rice products such as rice noodles, rice flour, and other items. These companies are then able to offer a greater variety of meals and services to their clientele.
Export trade
The purpose of rice milling machines is to prepare rice grains for export. Countries that produce rice in large quantities rely heavily on rice milling machinery as it is an essential piece of equipment needed to process the rice and package it for exportation.
Public institutions
Public institutions such as schools, hospitals and welfare facilities make use of rice milling machines in order to produce rice supplies to meet their own internal demands. Additionally, some of these public institutions may also serve as food processing centers open to the general public.
Production Demand:
Consider the amount of rice one's business typically processes and the desired output per hour. If looking for small-scale milling machinery, a compact 20-ton-a-day rice milling machine would suffice, but larger businesses that have a high demand for rice might benefit from a more extensive milling line with a higher processing capacity.
Quality of Final Product:
It's vital to consider the type of rice one's business typically processes and the desired quality. For example, if one's business mainly processes premium rice, investing in advanced milling machinery that can produce rice with high yield and quality is worth it.
Budget:
When choosing rice milling machinery, consider the initial cost of the machine and additional expenses, such as installation, training, maintenance, and spare parts.
Energy Efficiency:
Milling rice consumes a lot of energy, but rice milling machines' energy-efficient models help reduce electricity expenses and environmental impact.
Automation:
Consider whether an automated or semi-automated milling machine is preferable. Fully automated machines offer higher productivity but at a higher cost.
Spaerts and Servies:
When deciding on a Japanese rice milling machine manufacturer or supplier, it's crucial to consider the availability of spare parts and the quality of after-sales services provided. Ensure that the supplier can provide essential spare parts quickly and that their customer support team is responsive and helpful.
Q1: What are the trending features of rice milling machines in 2023?
A1: The Japanese rice milling machine has a modern design that includes energy-saving features like eco-friendly motors and variable frequency drives. There is real-time monitoring and automated controls that have touch-screen interfaces, cloud connectivity, and AI-driven optimization. Cloud connectivity lets remote access for data analysis and process optimization. Safety is a huge consideration in modern rice mill design, so newly improved machines have safety enclosures, emergency shut-off systems, and anti-overload mechanisms. Some machines also have noise and vibration reduction technology to make rice milling a more peaceful and less disruptive process. Smart technology rice mills also come with customizable milling options to meet diverse customer preferences and product demands.
Q2: What is the future of rice milling machine technology?
A2: The future of the rice milling machine is smart technology, which will have automation, efficiency, eco-friendliness, security, and dependability. The industry will no longer be entirely dependent on human knowledge and talent, and there will be uniformity, as all machines will be intelligent and connected. The machine will do everything goal-oriented and data-driven. Japan is probably the leader in developing intelligent rice mill machines that will have cloud connectivity and remote monitoring. Other features will be energy-saving, automated processing, noise reduction, and security systems that will make the machine more user-friendly and long-lasting.
Q3: How many steps are there in the rice milling process?
A3: There are five basic steps in the rice milling process. First, paddy separation is done, then the paddy is de-husked, the paddy is separated from the husk, the paddy is boiled in a boiler to become milled rice, and finally, polished rice is obtained.
Q4: What kinds of rice milling machines are popular in Japan?
A4: In Japan, the combined rice milling machine is popular because it separates, de-husks, mills, and polishes in one step. It is efficient, space-saving, and reduces rice yield loss. Another popular rice milling machine is the dai-gohan seizo ki, which is a large rice mill used for commercial purposes.
