Detailed Project Report (DPR) on dehusking rubber roller for rice mill

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