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Sarma Trading Company Indranagar Growth Bodhjung NagarAgartala, West Tripura, Pin-790014
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Report Contents
1 INTRODUCTION TO................................................................................................................................. .
1.1 About Sarma Trading Company……………………………………………………………………..1.2 Mission……………………………………………………………………………………………… 1.3 Project Background………………………………………………………………………………… 1.4 Promoter,s Background………………………………………………………………………………1.5 Present domestic Industry status in Tripura…………………………………………………………..
2 PROJECT PROFILE..............................................................................................................................
2.1 Product& By product…………………………………………………………………………………2.2 Industrial use of product and by-product,……………………………………………………………2.3 Growth in Wheat Flour cultivation in Tripura Nutritionals facts………………………………….2.4 Storage Facilities in Tripura………………………………………………………………………..2.5 Price of Wheat……………………………………………………………………………………..2.6 Source of Wheat …………………………………………………………………………………….
3 .Project Brief...............................................................................................................................
3.1. Project Description3.2 Project location.................................................................................................................................3.3 Comparative advantage in Tripura................................................................................,,,,,,,,,,,,,,,,,,,,,,,3.4 Requirement of utilities..........................................................................................................................3.5 Nutritional facts.....................................................................................................................................3.6 Benefits of Wheat Flour........................................................................................................................3.7 Profitability analysis of the project………………………………………………………………….3.8 Process flow for Wheat Flour chips…………………………………………………………………3.9 Process & Technology……………………………………………………………………………….3.10 Suppliers of plant, machinery & technology (indigenous & import)………………………………3.11 Capacity of the Plant……………………………………………………………………………….3.12 Key Success Factors / Practical Tips for Success................................................................................4 Project Investment Cost & Financial Analysis......................................................................................
4.1 Land Cost ……………………………………………………………………………………………. 4.2 Factory & Building cost ........................................................................................................................ 4.3 Plant & Machinery Cost………………………………………………………………………………
4-Market Analysis .............................................................................................................
4.1 Market Information............................................................................................................................... 4.2 Market Overview & Demand ..................................................................................................................4.3 Demand and supply gap............................................................................................................................4.4 Target Customers .................................................................................................................................... 4.5 Raw Material Requirement...................................................................................................................... 4.6 International Scenario ...............................................................................................................................4.7 Wheat Production i n India .......................................................................................................................4.9 Private Sector involved in Wheat Market .............................................................................................. 5-MACHINERY REQUIREMENT........................................................................................................................
5.1 Machinery Cost...................................................................................................................................... 5.2 Other fixed assets requirement .............................................................................................................
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5.3 Utilities Requirement.......................................................................................................................... …5.4 Vehicle requirement.........................................................................................................................7- Project Implementation Schedule............................................................................................ ..
7.1 Project Implementation Schedule chart.......................................................................................... 7.2 Implementation Schedule Timeline…………………………………………………………………8- Operation & Management of the Project......................................................................................... 8.1 Project Management........................................................................................................................... 8.2 Manpower Requirement………………………………………………………………………………9 .Regulation Requirements &Govt. Support………………………………………………………… 9.1 Regulation Food Laws, Environment……………………………………………………………….. 9.2 Compliance with norms of Tripura Pollution Control Board (PCB)……………………………………10 Details Civil Engineering……………………………………………………………………………. 10.1 Plan & Design………………………………………………………………………………………… 10.2 Estimation……………………………………………………………………………………11. Details Machanical Engineering…………………………………………………………………… 11.1 Plant layout………………………………………………………………………………………… 11.2 Plant & Machinery Details………………………………………………………………………….12 Details Electrical Engineering…………………………………………………………………….. 12.1 Design of Electrical Connection…………………………………………………………………… 12.2 Phase Details Voltage Generation…………………………………………………………………
13-ANNEXURE- 1 FINANCIAL STATEMENTS..............................................................................
1. ANNEXURE- II LAND DOCUMENT ................................................................................ 2. ANNEXURE- III PROMOTER DOCUMENT .................................................................... 3. ANNEXURE- IV QUOTATION DOCUMENT ................................................................................
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Application form for scheme of Technology Up-gradation /Establishment /Modernization of FoodS.No. Particulars Details
A. Promoters 1.
Name & Address of the Promoter including telephone, fax, e-mail etc.
Mr. Amitabha SarmaMr. Asit Chandra SarmVill - AraliaP.O- Aralia , Agartala,P.S-West Agartala,Dist: West Tripura, Pin-799004.
2. Type of organization like Govt. Institution / organization, Industry Association, University, NGO, Co-operative, others etc.
Sarma Trading Company , Partnerships
3. Background/credentials of applicant organization 5 years Experience of own Business of Grocery shop
4. Financial Status Financial Sound persons
5. Existing Industry if any NoB. Project Description6. Name of the project MANUFACTURING UNIT 0F MODERN
Flour Mill PROCESSING UNIT7. Location/Area of the project Industrial Growth Centr , Agartala , Sadar ,
West Tripura 8. Products/By Products Wheat Chips9. Process with complete flow chart Enclosed with Details Report10. Technology (Indigenous/important) Enclosed with Details Report11. Capacity of the plant/Unit Production target Initially 15 MT/day
Max capacity of product 25mt /day Double Roller Machine
12. In case of expansion/modernization of existing facilities/unit( details of existing capacity and proposed capacity after expansion & along with capacity utilization)
No
C. Project Cost (including proposed cost, appraised cost separately)13. Capital Investment (Fixed Capacity)
i. Land Area Costii. Building iii. Civil Works iv. Technical civil Works
Enclosed with (Proposed Estimation)
14. Plant & Machinery (Indigenous)(Capacity /Specification/Cost)
Cost Of Project Rs. Lakhs
Fixed CapitalLand and Site development 8.10 Civil Work 36.56Plant and Machinery 83.97Electrical & other 10.45Office equipments 0.75
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Pre operative expense 1.00 Total 140.92 Working Capital(Two Month) Manpower Cost 2,552Raw Materials 14.50Electricity 1.06Contingency .86
Total
18.97
Total Cost of Project 151.8915. Important Machinery
(Capacity/Specification/Cost)83.97 lakhs
16. Pre-operative expenses 1.00 lakhs17. Working capital 18.9718. Raw Materials/Packaging
(Source/Quantity/Cost) 14.50
19. Labour (Quantity/Cost)
Direct
20. Effluent disposal Self septic TankD. Means of Finance( including proposed & appraised means of finance, separately)
21. Means of Financing a) Equity Promoter/Foreign/Other)b) Loan (term/w3orking capital)c) Grant in aid under NMFPd) Other sources
Enclosed with
22. Financial Benchmarks a) Cash Flowb) Break Even pointc) Internal Rate of Returnd) Debt Enquiry Ratioe) Debt Service Coverage Ratio
a. Enclosed with DPRb.
23. In cash of expansion/modernization all the above benchmarks to be given separately-existing we well as projected
NO
24. In cash of expansion/modernization proposals Audited Balance sheet of last three years to be enclosed.
NO
E. Marketing 25. Marketing
a) Existing Marketb) Future Demandc) Marketing Strategy d) Linkage to farm/backward linkagese) Forward market linkages
a. National Market -Tripura , North East India
b. Foreign Market- Bangladeshc. Others Information Enclosed
with DPRF. Implementation Schedule 26. Item of work Date of implementation Work starting Target Date: May2015
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(Bar charts/Milestone Charts may be enclosed)
Production Target Date : Nov 2015
G. Personnel 27. Details of technical & Managerial personnel
(Operation, Maintenance, managerial, finance, marketing etc) required & available.
Enclosed with DPR
H. employment Generation-Direct/Indirect 28. a) Direct
b) IndirectDirect
Date:
Signature
Place: Name and Designation
Seal of the organization
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INTRODUCTION
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1. INTRODUCTION.
There are 2012 roller flour mills in our country producing approximate2100 million tons, of milled cereal products worth Rs. 18000 crores. Flour Mills can be installed with minimum capacity of 30 TPD of raw material crushing capacity per day to maximum 1000 TPD. The capacity suggested in this report is for mini flour mill i.e. 47tons of raw material crushing capacity per day. As per CII mckinsey survey it is estimated that during 2013 the market for branded Atta has grown to Rs. 15000 crore.
1.1 About Sharma Trading Company
Sharma Trading Company will be set up under the Ministry of company affairs, Govt. of India & SSI unit, Tripura, at 2015 with an aim of producing premium quality flour for the banking industry. Its main objective is to produce premium quality wheat Products such as Flour (Maida), Resultant flour (Atta), Bran, and Dalia (cattle feed). The company is going to start its production with an installed capacity of 450 MT per month. Our main aim is to serve our domestic and international customers by supplying their desired wheat flour consistently.1.2 Mission
SARMA Mills is committed to leading India’s food grain industry by supplying fine quality, nutritious wheat products that adhere to the strictest controls on quality, and by forging new links with companies eager to provide Indians with healthy and wholesome food.
1.3 Project Background 1.3.1 Socio-Economic Benefits of the Project
Agro-processing is now regarded as the sunrise sector of the Indian economy in view of its large potential for growth and socio economic impact specifically on employment and income generation. Some estimates suggest that in developed countries, up to 14 per cent of the total work force is engaged in agro-processing sector directly or indirectly. However, in India, only about 3 per cent of the work force finds employment in this sector revealing its underdeveloped state and vast untapped potential for employment. Properly developed, agro-processing sector can make India a major player at the global level for marketing and supply of processed food, feed and a wide range of other plant and animal products. The project will have few positive impacts which are highlighted below:
EconomyThe project will introduce a small amount of money into the economy directly and much more indirectly over time which will increase capital flow in the economy. In effect, this will support economic empowerment, domestic investment and poverty alleviation to some extent.
Employment The project will create employment in small number directly and an indirectly in the operation and decommissioning phases. The ripple effect will mean a few number will improve their social status and living conditions and that of their dependents.
Market Availability
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The proposed development is meant to bring about a source of market to the area’s local resources. The new development is meant to provide a new source for locally produced goods.
1.4 Promoter’s Background
NAME Mr. Amitabha SarmaFather’s Name Mr. Asit Chandra SarmaCommunication Address :- Vill – Aralia, P.O- Aralia , Agartala,
P.S-West Agartala,Dist: West Tripura, Pin-799004.
Date of birth 11-11-1974Nationality Indian by birth.
Caste UREducation Qualification MA (MUSIC)
Experience
Language Known Bengali, English, Hindi.
Computer Knowledge Yes.
NAME Mr. Abhijit SarmaFather’s Name Mr. Asit Chandra SarmaCommunication Address :- Vill – Aralia, P.O- Aralia , Agartala, P.S-West
Agartala, Dist: West Tripura, Pin-799004.
Date of birth 06-07-1980
Nationality Indian by birth.
Caste UREducation Qualification
Experience In business
Language Known Bengali, English, Hindi.
Computer Knowledge Yes.
NAME Mr. Arunabha Sarma
Father’s Name Mr. Asit Chandra SarmaCommunication Address :- Vill – Aralia, P.O- Aralia , Agartala,
P.S-West Agartala, Dist: West Tripura, Pin-799004.
Date of birth 06-07-1980
Nationality Indian by birth.
Caste UREducation Qualification M> Music
Experience In business
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Language Known Bengali, English, Hindi.
Computer Knowledge Yes.
PROJECT PROFILE
o Product& By producto Industrial use of product and by-product,o Growth in cultivation in Tripura Nutritionals factso Storage Facilities in Tripurao Price of Wheato Source of Wheat
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2.1 Products & By-products
Wheat: Ranked next to maize in terms of consumption, wheat has been playing an important role in leveraging the agrarian scenario of India. The annual production of wheat in India stands at 65-75 million tons, thereby making India its second largest producer in the world after China. People in India consume 70-72 million tons of wheat on an average. In India, it is commonly known as 'atta' and is eaten mostly in the form of rotis, chapattis, etc. There are about 200 flour mills operating in India having a capacity to produce about 15 million tons of wheat.Wheat is defined as a cultivated grass which is grown primarily for its nutritional grains. It grows anywhere between 2 and 4 feet. The scientific name of wheat is ‘Gramineae’ and belongs to the genus 'Triticum'. There is a wide variety of wheat that can grow in different climatic conditions, whether it's cold, hot or dry. It is an annual crop that grows once a year, and thus, at the end of each year, the fields must be plowed and prepared to enable the grass to grow. It can be planted to some extent as a forage crop for the livestock, whereas the straw of the wheat can be used to make roof thatching or as fodder for animals.
Today, India is exporting sufficient quantities of all types of wheat and extensive research efforts are underway for improving its cereals and grain output in the years to come. Wheat cultivation has traditionally been dominated by the northern region of India. The northern states of Punjab and Haryana Plains in India have been prolific wheat producers.. With a production reaching ten times in past five years, India is today the second largest wheat producer in the whole world. Various studies and researches show that wheat and wheat flour play an increasingly important role in the management of India’s food economy.
TypesofWheatA wide variety of wheat is grown in today's times. However, the three principal types of wheat that are produced in India comprise of:
Hard Red winter wheat: It produces good quality flour used primarily in making bread, burgers, biscuits, etc. It has a high protein content of 10-14%, because of which it has a high amount of gluten in it
Soft Wheat: Products like cakes, doughnuts, cookies, pastries, etc. are best made with soft wheat as it does not require the same amount of leavening as yeast bread. It contains about 6-10% protein.
Durum: Durum has a very hard texture and has a high protein and gluten content in it. It contains semolina, a course, golden amber product, which, when mixed with water, forms a dough. It's this dough that is largely used in making pasta products like noodles, spaghetti, etc.
White Wheat: It has a soft texture and is used in making cereals, cakes, biscuits, etc.
2.2 By Products:-
Atta: Atta is the flour used to make most South Asian flatbreads, such as chapatti, roti, naan and puri. Most Atta is milled from the semi-hard wheat varieties, also known as durum wheat that comprises 90% of the Indian wheat crop, and is more precisely called durum atta.Maida: Whole meal flour made from soft wheat similar in texture to cake flour. In reality, it resembles more to the Pastry flour being Whole meal flour (higher protein)
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Bran: Bran, also known as miller's bran is the hard outer layers of cereal grain. It consists of the combined aleurone and pericarp.Bran is particularly rich in dietary fiber and essential fatty acids and contains significant quantities of starch, protein, vitamins, dietary and phytic acid, which is an antinutrient that prevents nutrient absorption. The bran itself can be heat-treated to increase its longevity.
Dalia: Dalia, also known as miller's bran is the hard outer layers of cereal grain. It consists of the combined aleurone and pericarp.Bran is particularly rich in dietary fiber and essential fatty acids and contains significant quantities of starch, protein, vitamins, dietary and phytic acid, which is an antinutrient that prevents nutrient absorption. The bran itself can be heat-treated to increase its longevity.2.3 Price of wheat:
Minimum Support Price (MSP) The MSP of Wheat for the last 5 years is as under:
Prices in Rs/QuintalWS Year 2010-10 2011-12 2012-13 2013-14 2014-15Wheat 1100 1120 1285 1350 1400Source: CACP
Major Mundis arrivals (domestic) (in tons)
Name of market
Arrivals August,2014
Arrivals July,2014
Arrivals August,2013
% Change(Over Previous Month)
% Change(Over Previous Year)
Kanpur 13465 36680 15280 -63.29 -11.88 Mathura 4255 15330 7593 -72.24 -43.96 Bhopal 2349.33 2668.8 1294.6 -11.97 81.47 Indore 5956.5 14267.82 9600.1 -58.25 -37.95 Khanna 48.8 87.5 13.2 -44.23 269.70 Mumbai 10939.2 15308.1 1349.2 -28.54 710.79 Jalana 300 46.6 4.9 543.78 6022.45 Source: AGMARKNET and Agriwatch, *Agriwatch price
Major mudis prices (domestic) ( in Rs/ quintal )
Name of market
Prices August,2014
Prices July,2014
Prices August,2013
% Change(Over Previous Month)
% Change(Over Previous Year)
Kanpur 1430.64 1420.85 1406.34 2.11 2.82 Mathura 1444.97 1447.2 1445.2 -0.15 -0.02 Bhopal 1643.12 1734.11 1656.58 -5.25 -0.81 Indore 1516.37 1500.97 1593.85 1.03 -4.86 Amritsar 1455 1416 1465 2.75 -0.68 Khanna 1427.5 1429.12 1458.41 -0.11 -2.12 Mumbai 2434.5 2649.28 2200 -8.11 10.66 Jalana 1602.31 1557.8 1712.82 2.86 -6.45 Source: AGMARKNET and Agriwatch ,
2.4 Future price (market servey) (Unit in USD/Ton)
Source: Chicago Board of Trade (CBOT) CBOT Wheat has fallen considerably from last year owing to higher production globally.
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12.0 Trade Policy.
2.5 Export Policy: Export of wheat is free.
2.6 Source of wheat:Wheat will be imported from Bihar and Uttar Pradesh,Siliguri,Gwahati.
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Contract Month
03.09.2014
Week Ago(28.08.2014)
Month Ago(04.08.2014
3 Month Ago (04.06.2014)
6 Month Ago(04.03.2014)
1 Year Ago(04.09.2013)
% Change over previous year
Sep 2014
192.33 204.46 199.87 229.63 240.46 245.79 -21.75
Dec, 2014
196.83 210.06 207.4 237.52 244.96 250.29 -21.36
Mar 2015
204.46 217.23 214.38 243.95 247.44 253.14 -19.23
May 2015
209.33 220.72 218.88 247.54 248.18 254.15 -17.64
Jul 2015
212.36 222.37 221.91 249.46 244.23 252.77 -15.99
Sep 2015
216.21 225.4 226.04 252.31 245.61 253.23 -14.62
PROJECT BRIEF
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3.1 Name of the project: SARMA TRADING C0MPANY PVT LTD
3.2 Project Location: Bodhjung Nagar, Agartala, West Tripura
3.3 Comparative Advantage in Tripura
In the long run, wheat will behave like a typical Agro-commodity. The prices will depend upon the cost of raw material, storage etc. Therefore, the success of the project would hinge on basics of business i.e. efficiency in purchase of raw material, processing and marketing efficiency. In this regard Tripura has many advantages as given below.
Proximity to International Land ports:-The land ports like Bangladesh Exports (Akhaura, Sonamura, Belonia, Sabroom, and Srinagar) are close to the proposed location of the project which will offer a comparative advantage for the export markets.
Availability of Social and Industrial Infrastructure: - Tripura can boast of excellent industrial infrastructure and social amenities which is attracting investment in all the sectors. There is good availability of required power, water, manpower, etc for the industry.
3.4 Requirement of Utilities:-
The plant requires supply of fresh water for washing, cold water of drinking quality and compressed air for control equipment and for pneumatically movement, besides electricity supply for running all the process and utility equipments.
Steam: - The requirement of steam is about 5000 kg / hour out of which 80% is of 13 bar pressure.
Power Requirement: - The total electrical load requirement is estimated at 150 KVA. Since, it is a continuous process and the supply of uninterrupted supply is desirable it is planned to have a Generator set of 150 KVA capacities.
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Water:-The requirement of water will be 2,000 litres/ hour for processing and boiler. Water can be re-circulated. Besides, water would be required for cleaning of the plant and workers use. The daily requirement for water would depend upon treatment of the waste water and recirculation of the same however, a minimum quantity of 2, 00,000 would be required and it is planned to set up and water tanks of 2 lakhs litres /day capacity.
Transportation Facilities: - Transportation will be facilitated through road and railways.
3.5 Nutritional FactsWheat is rich in manganese, phosphorus, magnesium, and selenium. It is also a good source of zinc, copper, iron, and potassium. Furthermore, calcium is found in wheat in small quantities.
Vitamin Content of Wheat: Wheat is rich in vitamin B6, niacin, thiamin, folate, riboflavin, and pantothenic acid. Vitamin E and K are also present in smaller, but still significant amounts.
Caloric Content of Wheat: Wheat has a calorific value of 339.0 calories per 100 grams. Being a grain, it has a satisfactory amount of calories, therefore acting as a valuable dietary food source.
Health Benefits of Wheat: Consumption of whole wheat is necessary for a healthy metabolism, as it prevents breast cancer, gallstones, childhood asthma, and heart disease. It is definitely an essential food for women to consume for gastro-intestinal health, and it also reduces the risk of high blood pressure, diabetes, and high cholesterol. On top of all of that, it also has phytonutrients, which promote better health through maintaining high blood cell counts and protecting against cancer.
Nutritional Facts of Wheat flour products
Amount per 100 gmCalories 339Total Fat 2.5 g 3%Saturated fat 0.5 g 2%Polyunsaturated fat 1 gMonounsaturated fat 0.3 g
Cholesterol 0 mg 0%Sodium 2 mg 0%Potassium 431 mg 12%Total Carbohydrate 71 g 23%Protein 14 g 28%Vitamin A 0%Calcium 3%Vitamin D 0%Vitamin B-12 0%Vitamin C 0%
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Iron 19%Vitamin B-6 20%Magnesium 36%
Nutritional Facts of Bran
Amount per 100 gmCalories 224Total Fat 0.9 g 1%Saturated fat 0.1 g 0%Polyunsaturated fat 0.4 gMonounsaturated fat 0.2 gCholesterol 0 mg 0%Sodium 7 mg 0%Potassium 44 mg 1%Total Carbohydrate 86 g 28%Dietary fiber 79 g 316%Sugar 0 gProtein 8 g 16%Vitamin A 1%Calcium 4%Vitamin D 0%Vitamin B-12 0%Vitamin C 0%Iron 15%Vitamin B-6 10%Magnesium 16%
3.6 Benefits of wheat and its product
Studies show that eating wheat lowers the risk of many chronic diseases.
The benefits of wheat most documented by repeated studies include:
stroke risk reduced 30-36% type 2 diabetes risk reduced 21-30% heart disease risk reduced 25-28% better weight maintenance
Other benefits indicated by recent studies include:
reduced risk of asthma healthier carotid arteries reduction of inflammatory disease risk lower risk of colorectal cancer healthier blood pressure levels less gum disease and tooth loss
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3.7 By Product Details & usage
Whole wheat flour: It contains the finely ground bran, germ and endosperm of the whole kernel. Whole wheat products have a distinctive flavor and coarser texture than those made from white flour.Maida: The bran and germ are separated in making white flour or maida. Maida bakes more uniformly into a loaf of a greater volume and it is more bland in taste and more easily digested. It can be stored in an air-tight container in a refrigerator Semolina: It is coarsely ground endosperm and its chemical composition is similar to that of white flour. It is used in the manufacture of macaroni products. It is roasted before storing to save it from insects and worms. Macaroni products: These products are also called pasta or alimentary pastes. These products include macaroni, spaghetti, vermicelli and noodles. Wheat germ: Wheat germ is about 2-3 per cent of wheat grain. It has a high nutritional quality, comparable to animal proteins. Wheat bran: It increases the stool weight by increasing the water holding capacity of the bran. Wheat bran prevents constipation and may lower the risk of colon cancer. By-Products:Wheat by-products are useful in
(1) Geotextiles, (2) Filters, (3) Sorbents, (4) Structural composites, (5) Non-structural composites, (6) Molded products, (7) Packaging
3.8 Profitability Analysis of the Project
A detailed profitability analysis of the project has been done for a period of 6 years. The major assumptions underlying profitability analysis are given here under:
Projected sales estimated on the basis of growth, locational advantage for domestic and export markets as per the details are given in Details in market Analysis Chapter
Input Output ratio of raw material and finished good considered 10:9.5
Market price of bran, dahlia, wheat, maida is at 19/kg,14/kg,14.50/kg & 14.50/kg respectively. Price of B2B sales is assumed as 60 %( retailer, bulk buyer & FCI), 20% (export) & 20% wastage and market return.
Salary as per table- estimated manpower requirement with 15% annual increase.
Electricity consumption as per use of the installed capacity of motors and electricity installations. Electricity rate Rs. 7.34 /unit.
Insurance of fixed asset and stock @ of 0.35% /year.
Interest rate & financial terms: - Working capital interest has been considered at 14.5%
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3.9 Process flow for wheat
Wheat:Wheat is first cleaned thoroughly to remove dust, stone and other foreign matters clean wheat is tempered before grinding by treating with water so that the bran is separated from the endosperm. The tempered wheat is crushed between corrugated rollers (Break rolls). The first break rolls are set relatively far apart to grind the wheat lightly, while successive break yield finer and finer products. The first break is separated by sieving or bolting in to very fine particles (flour), intermediate particles (middlings) and coarse particles (stock). The stock is then sent to second break rolls. This process may continue through 5 to 6 breaks. The stock contains pieces of endosperm and bran and the stock from the last break is principally bran. The middlings contain endosperm, bran and germ which are then successively classified and some of the bran removed are sent to reduction rollers. These are smooth rollers, but like the break rolls they are graduated so that successive reduction becomes finer and finer. After each reduction, sifters separate the flour, middling and stock, this process is continued until most of the endosperm has been removed as flour and most of the bran has been separated in the sifters.2. Power requirement of the unit is 300 HP.
3. There are no pollution problems for unit except dust which may damage the plant and machinery and adversely affect the health of workers also, for this cyclones may be used to separate dust.
4. The Miller should be made aware about the energy requirement of the milling system and for this selection of motors should be proper. 3.9.1 Process Description for wheat Milling
The plant of a flour mill has four main functions:
1. To store a reserve of wheat.2. To remove all the impurities from the wheat and prepare it for milling.3. To mill the wheat and separate flour from the bran and skins of the wheat.4. To store the milled products before dispatch
Preparing the wheat – The wheat is first weighed, inspected and graded.
Cleaning – Impurities like stones, dirt, metals and other seeds are removed in this process.
Tempering – During this stage the wheat is soaked in water to make it easier to remove the outer bran layer.
Milling – Involves a number of repeated steps.
The wheat is ground by a machine equipped with rollers that break it into pieces.Then it is put through sifters. The resulting meal starts out coarse and with repeated grinding and sifting becomes fine white flour, wheat bran and wheat germ. The milling process can either produce distinct products-wheat bran, refined white flour, wheat germ—that can be packaged and sold separately, milled together to produce a whole grain flour, or blended to form different flours.
Blending – Different components are blended back together to form different flours.
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3.10 Process Flow diagram
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3.11 Capacity of the Plant
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The proposed project will have the total output capacity of 5200 MT per year; in its first year of operation the unit will produce flour assuming 80%.
Capacity of the plant worked out on the basis of drying capacity of 2 rollers –
PRODUCTION CAPACITY (P.A.)Sl.no Item Quantity.(MT)1 Atta 30002 Maida 12003 Dalia 20004 Bran 1600
3.12 Quality Parameters Table: Quality parameters for different wheat products.
Wheat Product Grain Texture Protein (%) Gluten StrengthBread WheatChapati Hard Medium to high (10-13) Medium and extensible
Bread Hard High (> 13) Strong and extensible
Biscuit/Cake Soft Low (8-10) Weak and extensible
Durum WheatPasta Very hard High (> 13) Strong
Source- http://www.krishisewa.com
Tables 4: Quality standards of Indian wheat.
Quality Parameter Agro-climatic zone NHZ NWPZ NEPZ CZ PZ Country
AverageProtein (%) 10.04 11.19 11.13 11.62 12.56 11.3Moisture (%) 11.71 10.65 10.89 9.90 11.03 10.9Test Weight 79.50 78.70 79.00 81.40 80.50 79.82Sedimentation value (cc)
34 40 45 43 41 40.6
Hardness 5.1 5.4 5.5 5.6 6.7 5.66Extraction rate (%) 68.2 69.4 70.4 69.8 69.6 69.48Total defects (%) 7.14 8.56 9.62 6.57 6.53 7.68Chapati quality (Max. score 10)
6.63 6.52 6.87 7.11 6.48 6.72
Bread loaf volume (cc)
510 529 565 507 568 536
Bread quality (Max. score 10)
6.58 7.00 7.87 6.41 8.13 7.2
Biscuit spread factor
8.00 6.75 6.45 6.50 6.11 6.76
NWPZ : North Western Plains Zone; NEPZ : North Eastern Plains Zone; CZ : Central Zone; PZ :
Peninsular Zone; NHZ : Northern Hills Zone
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Source- http://www.krishisewa.com Particular Maida Atta Bran Soji Daimond Brand 2450/Q 2400/Q 2050/ Q 2450/ Q Nature care Brand 2360/Q 233o/Q 2050/Q 2560/Q
Ganesh Brand 2360/Q 2330/Q 2050/ QSarma (Proposad ) 2250/q 2300/Q 2000/Q 2380/Q
Survey Date -20/03/2015 Source:Pradeep Dey ( whole sales traders) Maharaj ganj Bazar, agartala, West Tripura
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CAPITAL INVESTMENT
3.1 Capital Investment3.1.1 Land Area Cost3.1.2 Building Cost3.1.3 Civil works3.1.4 Technical Civil works3.2.1 Plant & Machinery (Indigenous plant)3.2.1.1 Capacity3.2.1.2 Specification3.2.1.3 Cost3.2.2 Plant & Machinery (Imported Machinery)3.2.2.1 Capacity3.2.2.2 Specification3.2.2.3 Cost3.3 Pre-operative expenses3.4 Working Capital3.4.1 Raw Material & Packaging3.4.2 Labour3.4.3 Effluent Disposal
3.1 Capital Investment4.1 Estimation of Capital Cost for all Project Components
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4.1.11 Project Cost Summary
Cost Of Project Rs. Lakhs Fixed CapitalLand and Site development 8.10 Civil Work 36.56Plant and Machinery 75,43Electrical & other 10.45Office equipments 0.75
Pre operative expense 1.00 Total 132.2 Working Capital(Two Month) Manpower Cost 2.55Raw Materials 14.50Electricity 1.06Contingency .86
Total 1Total Cost of Project 151.26
4.1.1 Land & Site Development
The developed piece of land will be provided by owner; however, the cost for the same has been budgeted as per the details given in table-5 below
Table-5 Cost budget
~ 26 ~
Project Cost outlay
Total Cost of the ProjectTotal Capital cost
Rs. LakhsPromoter Contribution 32.26 Bank loan 120.00Total 151.26
Land & Site Development Areain sq.mts
Unit cost(per sq.mtr)
Total
1 Land 3,50,000.002 Site Developments 20,0003 Compound Wall 80,0004 Internal Road (7 Mtr wide ) 60,0005 Storm water drains (CC drain with
cover slab, recharging wells, across drainage of storm water drain tank)
80,000
6 Landscaping 007 Signage 008 Deep tube well 1,20,0009 Security Cabin/Time office 1,00,0000Sub total 8,10,000
9.1.3 Civil Cost
The rate of construction is considered as per prevailing market rate and similar project. The details on working areas have been provided by supplier of plant & machineries and consultant’s knowledge of similar project in India. The estimates of civil cost are given in table-
Table - Civil Works Cost Factory Shed(Proposed)
Particular Area in sq.mtr Rate / sq.mtr Rs. Lakhs1 Factory 2007400.002 Office, Laboratory & Store 7,50,000.004 Workers amenities 1,28000.005 Toilet block and septic tank 1,76000.006 Boiler room 2,45000.007 Generator room 175000.00TOTAL 36,56,000.00
9.1.4 Plant and Machinery Cost Machinery & Equipments. Cleaning Section Sl
No Particular Qty Rate Amount1 Intake hoper items 1 10000 100002 Separator 2 85000 1700003 Scourer 1 90000 900004 Dry -de –stoner 1 165000 1650005 Wet Scourer 1 90000 900006 Bruch Machine 1 95000 950007 Meganetic Separator 3 7000 210008 Fan For Cleaning Section 3 30000 900009 Fan for Dry -de –stoner 1 45000 45000
10 Cyclone Dust Controller 4 35000 14000011 Package & Erision Cost 45800
Total 961800
Milling Section 1 Roller Mill With Rolls 2 560000 11200002 Planshifter 1 375000 3750003 Purifier 2 160000 3200004 Bran Finisher 2 55000 1100005 Magnetic Separator 2 7000 140006 Fan for Purifier 1 30000 300007 Cyclone Dust Collector 1 35000 350008 Dust Collector 1 50000 500009 Package & Erision Cost 102700
Total 2156700 Conveying System
1 Elevator 7 75000 525000
~ 27 ~
2 Worm Conveyor 8 55000 4400003 Pneumatic Conveying system 5000004 Impact Detactor 2 120000 2400005 Disc Mills 1 100000 100000
90250
Total 1895250 Estimated cost of Buyer,s Contribution
1 Belt , Buckets, V Pully , V Belt, GG Gear Box 500000 2 Vibration Pad, nail , Cotton, tape etc 650000
3 Electrical Motor 600004 Tools & Tackls 2500005 Gravity Pipe , Y ,device 2700006 Air Ducting 400000
7 Installation 106500
Total 2236500 1 Grant Total 6905000 2 Tax 2% 131800 3 Transporation 500000 4 Overall total 7543100 Overall total(say) 7543000
Pre Expensive Cost : 100000.00
(In Rupees.)
WORKING CAPITAL4.1.7 Raw Material
Sl.no Particulars Amt. Rs Amt. Rs (inlakh)
1 Wheat blended of different category 750 MT @ Rs.1100/-ton 82,50,000 82.5
2 Gunny Bags 8200 No. @ Rs. 15/- each. 1,23,000 1.232 Packaging Materials 60tons@ Rs 5600.00 112000 1.233 Chemicals and Reagents etc. (L.S) 1,56,000 1.564 Mis Expense 50000 .50
TOTAL 87,02,000 87.02
~ 28 ~
Sl No
Particular Qty Total
Utilities Equipments1 Steam boiler and Chimney 2 1,10,0003 Air compressors 1 50,0004 Water storage tank 1 50,0006 Installation and Misc. 40,000
Total Utilities Equipments A 2,50,000Electrical Equipments
1 PLC, Instrumentation Cables fittings, external lighting etc 2,75,0002 Gen-set- 300HP-20 KW 5,20,000
Total Electrical Equipments B 7,95,000Total Utilities & Electrical Equipments (A+B) 10,45,000.00
PER MONTH =7.25
4.1.8 Salary & Wages
Sl.No. Manpower Cost No. of employee
Per Month salary TotalSalaries
1 Manager –cum-Chemist 1 10,000/- 10,000/-2 Plant Foreman 3 8000/- 24000/-3 Electrician 1 5000/- 5000/-4 Operator 3 6000/- 18000/-5 Un-Skilled Workers. 6 4000/- 24000/-6 Accountant 1 8000/- 8000/-7 Clerk / Store keeper 2 4000/- 8000/-8 Sales Supervisor 2 6000/- 12000/-9 Peon 1 3000/- 3000/-10 Security Personal 1 4000/- 4000/-11 Total 116000/-12 Add Pre-requisites @ 10% of salary. 11600/-Total 127600/-
4.1.9 Utilities (per month)
1. Power : 300 HP X 16 X300 X 80 % = 107424 KWH Rs 7.34 /unit = 5,63,976.00/12= 46998.00= 47000(say)4.1.10 ContingencyTable-10. Contingencies per month
1 Postage and Stationery. 1,000/-2 Telephone Charges 1,000/-3 Consumable Stores 2,000/-4 Repair & Maintenance. 2,000/-5 Advertisement & publicity. 4,000/-6 Transport Charges. 20, 000/-7 Other Miscellaneous Expenses. 1,000/-8 Electrical Security 12000/-
Total 43,000/-
(G) FINANCIAL ANALYSIS.
1. Cost of Production (per year).
4. Depreciation on furniture and others fixed asset @ 20% 30,000/-
~ 29 ~
Cost of Production (Rupees.)
1. Total recurring cost per year. 7,91,92,512
2. Depreciation on building @ 10% per annum. 265600
3. Depreciation on machinery @ 10% p.a. 4,74,000
5. Interest on total investment @ 14.5% per annum 1632700/-
Total Rs. 8 1594812/- 2. Turnover (per year).
Item Value (Rs.)Atta 3000MT @ Rs. 14,500 / MT 43500000/-Dalia 2000 MT @ Rs. 10,500 / MT 210,00,000Maida1200 MT @ Rs. 13,500 / MT 162,00,000/-Bran 1600 MT @ Rs. 9,500 / MT 15200,000/-Total Rs. 95900000/-
3 Net Profit per year (before Income tax)( Figures in Rs. Lac.)Profit = Sale - Production Cost.= 95900000/-- 81594812=7955188
+
6. Break Even Point.Fixed Cost (per year). (RUPEES.)
1. Depreciation on Building@ 10% p.a 265600
Depreciation on machinery @ 10% p.a 4,74,0002. Depreciation on furniture & other fixed assets. 30,000/-
3. Interest on total investment. 1632700/-
4. 40% of salary & wages. 612480/-
5. 40% of other expenses. 650000/
Total Fixed Cost. 2032,080
BEP = Fixed Cost x 100Fixed cost + Profit
=2032,080 x 1002032,080+ 7955188
= 20.34%
~ 30 ~
= 7955188x 100 = 8.88% 95900000
4. Net Profit Ratio
= Net Profit x 100Turn over per year 5. Rate of return
Total Investment= 7955188 X 100 15989000
= 70.48 %
~ 31 ~
MEANS OF FINANCE & FINANCIAL BENCHMARKS
4.1.1 Equity4.1.2 Loan4.2 Financial Benchmarka) Cash flowb) Break Even Pointc) IRR
5.1 Means of Finance
Table -11 – Means of Finance
4.1.11 Project Cost Summary
Cost Of Project Rs. Lakhs Fixed CapitalLand and Site development Rs. Lakhs Civil WorkPlant and Machinery 8.10Electrical & other 36.56Office equipments 83.97Pre operative expense 10.45 Total 0.75 Working Capital(Two Month) 1.00
~ 32 ~
Project Cost outlay
Total Cost of the ProjectTotal Capital cost
Promoter Contribution Bank loanTotal
Manpower Cost 140.92Raw MaterialsElectricity 2,552Contingency 14.50 Total 1.06Total Cost of Project 159.89
5.2 Financial IndicesThe Project will be highly profitable as can be seen from the following financial indices
Projected Profitability Statement :BasisBasis Annual growth in business 10%Annual increase in expenses 5%Rate of interest on loan 15%
1st Year 2nd Year 3rd Year 4th Year 5th Year 6thYearCapacity Utilisation [%]
60.00 65.00 70.00 75.00 80.00 85.00
Annual sale[Estimated][Rs.]
1200.00 4,68.00 5,04.00 5,40.00 5,76.00 6,12.00
Less: Cost of RM 87.02 95.00 ,100.00 110.00 124.00 132.00Gross profit 2,5.00 2,730.00 2,940.00 3,150.00 3,360.00 3,570.00Less:Salary
564.00 592.20 621.81 652.90 685.55 719.82
Other Rec. expenses
264.00 277.20 291.06 305.61 320.89 336.94
Profit before Dep., Int.& Tax
1,692.00 1,860.60 2,027.13 2,191.49 2,353.56 2,513.24
Less: Depreciation 219.95 219.95 219.95 219.95 219.95 219.95P.B.I.T 1,472.05 1,640.65 1,807.18 1,971.54 2,133.61 2,293.29Interest payable 356.11 296.76 237.41 178.05 118.70 59.35Pre-tax profit 1,115.54 1,343.89 1,569.78 1,793.48 2,014.91 2,233.94Tax payable (say 10%)
95.59 118.39 140.98 163.35 185.49 207.39
Net profit after Tax 1,020.35 1,225.50 1,428.80 1,630.13 1,829.42 2,026.54Profit on Sales (%) 23.62 26.19 28.35 30.19 31.76 33.11Cumulated Net Profit:
1,020.35 2,245.85 3,674.65 5,304.78 7,134.20 9,160.75
Pay-back period: 6 th years
Proposed repayment period 6 years including Monatorium Period 0 years
Proposed repayment schedule1st year 2nd year 3rd year 4th year 5th year 6th year
Loan at beginning of year
2,374.05 1,978.38 1,582.70 1,187.03 791.35 395.68
Proposed repayment
395.68 395.68 395.68 395.68 395.68 395.68
Loan at end of year 1,978.38 1,582.70 1,187.03 791.35 395.68 -
Projected cash flow statement1st year 2nd year 3rd year 4th year 5th year 5th year
Sources of fund:Equity 124.95Loan 2,374.05
~ 33 ~
PBIT 1,472.05 1,640.65 1,807.18 1,971.54 2,133.61 2,293.29Cum. Dep.added back
219.95 219.95 219.95 219.95 219.95 219.95
Total: 4,191.00 1,860.60 2,027.13
2,191.49 2,353.56 2,513.24
Uses of fund:Increase in FC 2,130.00Increase in WC 369.00Decrease in Loan 395.68 395.68 395.68 395.68 395.68 395.68Interest payable 356.11 296.76 237.41 178.05 118.70 59.35Tax payable 118.39 140.98 163.35 185.49 207.39Total: 3,346.38 810.82 774.06 737.08 699.87 662.42Opening Balance - 844.62 1,894.40 3,147.48 4,601.88 6,255.5
8Surplus generated 844.62 1,041.78 1,253.07 1,454.41 1,653.69 1,850.8
2Closing Balance 844.62 1,894.40 3,147.48 4,601.88 6,055.58 8,106.4
0
Projected Balance Sheet `At the end of 1st year 2nd year 3rd year 4th year 5th year 6th year Liabilities:Equity 124.95 124.95 124.95 124.95 124.95 124.95Loan 1,978.3
81,582.70 1,187.0
3791.35 395.68 -
Cumulated Profit earned
1,020.35 2,245.85 3,674.65 5,304.78 7,134.20 9,160.75
Total: 3,123.67
3,953.50 4,986.63
6,221.08 7,654.83 9,285.70
Assets:Gross Block 2,130.00 1,910.05 1,690.10 1,470.15 1,250.20 1,030.2
5Less: Depreciation 219.95 219.95 219.95 219.95 219.95 219.95Net Block 1,910.05 1,690.10 1,470.15 1,250.20 1,030.25 810.30Working capirtal 369.00 369.00 369.00 369.00 369.00 369.00Cash Balance 844.62 1,894.40 3,147.48 4,601.88 6,255.58 8,106.4
0Total: 3,123.6
73,953.50 4,986.6
36,221.08 7,654.83 9,285.7
0
Calculation of BEPComponent of Fixed CostInterest (100%) 356.11 296.76 237.41 178.05 18.70 59.35Depreciation (100%)
219.95 219.95 219.95 219.95 219.95 219.95
Salary & Off. Exp (40%)
331.20 347.76 365.15 383.41 402.58 422.70
907.26 864.47 822.50 781.41 741.23 702.01BEP[100 X F.C / (F.C+N.P)]
47.07 41.36 36.53 32.40 28.83 25.03
Calculation of DSCRTotal Fund for Debt-Service [N/P+Dep. + Int.
1,596.41
1,886.15 2,028.14 2,168.07 2,305.85
~ 34 ~
paid]
Total Debt-Service [Repayment + Int.]
751.78 692.43 633.08 573.73 14.38 455.03
Debt-Service Coverage Ratio:
2.12 2.52 2.98 3.54 4.21 5.07
Cash Flow of Working Capital
The working capital will be arranged by POP and the margin money for the same has not been included in the project cost however, for understanding the requirement of working capital the details have been worked out and presented in Table-12 Particulars 2015 2016 2017 2018 2019 2020Development of Backward Linkages 1.00 1.20 1.25 1.31 1.64 1.95Repair & Maintains 6.63 8.29 9.12 10.13 10.13 11.77Misc. Manufacturing Cost 5.00 5.50 6.05 6.66 7.33 8.06Interest on working capital 8.81 9.36 10.62 11.88 12.17 13.36Cost of production (b) 450.64 460.00 470.00 500.64 550.64 650.64Contribution 24.00 28.00 34.00 44.00 48.00 64.00Insurance 1.24 1.27 1.30 1.4 1.51 1.62Depreciation 5.41 5.41 5.41 5.41 5.41 5.41Amortization 1.77 1.77 1.77 1.77 1.77 1.77Profit before Taxation 15.14 18.24 19.14 19.42 20.08 21.40Provision for Taxation 0.00 0.00 0.00 0.00 0.00 0.00Net profit after tax 6.81 7.00 7.10 7.12 7.23 7.33
Every cost of lakhs Cash Flow Table:
A:sources of found 2015 2016 2017 2018 2019 2020PAT 54.14 82.24 91.14 95.42 201.08 130.93Depreciation/o of POP exp 89.18 89.18 89.18 89.18 89.18 89.18
Increase in Bank Borrowing
65.54 13.38 9.66 9.76 9.88 1.47
Increase in Creditors 35.78 4.05 4.05 4.05 4.05 4.05414.64 288.85 294.03 298.41 304.19 224.08
B: disposition of founds 0.00 0.00 0.00 0.00 0.00 0.00Increase in current Assets 223.08 25.82 20.09 20.21 20.40 7.02
Increase in Non C. Assets 0.00 0.00 0.00 0.00 0.00 0.00
223.08 125.82 70.09 120.21 20.40 7.02C: Opening Balance 0.00 191.56 354.59 578.53 565.73 1040.52D: Net Surplus(a-b) 191.56 163.03 223.94 178.20 283.79 217.06E: Closing Balance 195.08 354.59 578.53 756.73 1040.52 1257.58IRR 29.45 %BEP
BEP at Installed capacity – Payback period Eight years
~ 35 ~
~ 36 ~
MARKET ANALYSIS
4.1 Market Information…………………………………………………………………………….4.2 Market Overview & Demand …………………………………………………………………..4.3 Demand and supply gap…………………………………………………………………………4.4 Target Customers ……………………………………………………………………………….4.5 Raw Material Requirement……………………………………………………………………….4.6 International Scenario ……………………………………………………………………………4.7 Wheat Production in India……………………………………………………………………….. 4.7.1 Government wheat policy........................................................................................................... 4.8 Public Sectors Involved in Wheat Market.....................................................................................4.9 Private Sector involved in Wheat Market
6.1 Existing market Information
Whole wheat flour is used in making Chapaties, Puries, Parotha and other roasted cereal based products. Wheat flour or Maida is a basic raw material for making Bread, Biscuits Cakes and other bakery products. Atta , maida , Cattle Feed are Bran, Daliya is used in many sweetmeat products. Bran separated on milling is used as cattle feed. The products sold under brand names are very few. The concept for branded cereal flour products is now increasing 6.2 Market Overview & Demand
The demand for Flour Mill is rising in accordance with the increase in population. The number of existing Mills is not at par to meet the growing demand. However, this industry has not yet been developed to any sizeable extent in the country and as such it is not capable enough to meet the demand of the
growing population.
~ 37 ~
Year Export Import 2009-10 0 0.16 2010-11 0 0.18 2011-12 0.74 0 2012-13 6.51 0 2013-14 5.56 0.01 2014-15(Apr-July) 2.14 0
Source: Depart. Of Commerce, 2013 (Unit in million MT)
6.3 Future Demand
MARKET Year Production Unit of Measure Growth Rate
2009 80680 (1000 MT) 2.69 %
2010 80800 (1000 MT) 0.15 %
2011 86870 (1000 MT) 7.51 %
2012 94880 (1000 MT) 9.22 %
2013 93510 (1000 MT) -1.44 %
2014 95910 (1000 MT) 2.57 %
Assumption of Climate &ICAR.
2015 97923 (1000 MT) 3.45%
2016 98454 (1000 MT) 3.45%
2017 103455 (1000 MT) 4,12%
2018 112345 (1000 MT) 5.60%
2019 115000 (1000 MT) 5.76%
2020 175680 (1000 MT) 5.90% Source: Depart. Of Commerce, 2013
6.4 Demand and supply gap
The wheat flour produced in Tripura & north east is known as Atta. This is the Hindi word for wheat flour commonly used in South Asian cooking. Wheats are mainly eaten in Tripura & north east as chapati and roti. Wheat based products are a major part of the diet in Tripura & north east. A typical meal would consist of daal, bread (roti) and tea or a soft drink. The upper and middle classes eat quite differently, but Roti is an essential item on the table to be baked fresh and eaten hot. There is huge demand of flour within Tripura & north east but statistically the demand of the flour in Tripura & north easti market can be characterized by the daily protein & carbohydrates requirement of person against the protein & carbohydrates provided by flour.A comparison of estimated supply and projected demand of wheat flour in Tripura & north east is given below:.Year Flour Demand Surplus/Deficit
7,766,223 9,097,830 (1,331,607)7,119,005 9,000,180 (1,881,175)7,079,831 9,195,480 (2,115,649)7,947,493 9,388,890 (1,441,397)
~ 38 ~
9,057,774 9,479,610 (421,836)9,531,099 9,699,480 (501,126)9,531,099 10,080,000 (548,901)
Source: USAID & Competitive support fund
6.5 Target Customers
The major target market of the project consists of commercial suppliers, whole sellers & retailers, confectionary producers and households.
6.6 Export of wheat by Neighboring Countries.
Wheat production in the world has been increasing dramatically fast due to the massive demand and increase in population. As per statistics provided by FAO in 2012/2013, the world’s total wheat output was estimated at 17,782,000 million tons. Table 3 describes the statistics on world wheat Production, Consumption, Trade & Supply as below. An analysis of the potential to this market is presented in the Table- 5. Table- Potential Export Market
Bangladesh
2015 2016 2017 2018 2019
1200 MT 1250 MT 1300 MT 1400 MT 1550MT
Statistical Reports of markets. Source: International Grains Council (IGC)
6.7 World wheat estimates (2013-14) (in Million MT)
Source: International Grains Council (IGC)
Source: DGCI &India’s main wheat destinations are Bangladesh, South Korea, UAE & Indonesia.
~ 39 ~
2012-13 2013-14 14-150(Forecast)Production 655 710 699
Trade 140 152 144Consumption 675 690 697
Carry Over Stock 172 194 194
6.8 Trade data (India) for last 5 years
Year Export Import 2009-10 0 0.16 2010-11 0 0.18 2011-12 0.74 0 2012-13 6.51 0 2013-14 5.56 0.01 2014-15(Apr-July) 2.14 0
Source: Depart. Of Commerce
6.9 Import Policy:Import of seeds is restricted. Whereas, import of wheat for human consumption is permitted through State Trading Enterprises
HS code Item description Import policy Standard Duty
Bound Duty Customs duty
10011100 Durum wheat: Of seed quality
Restricted 100 100 100%
10011900 Other Durum wheat
State Trading Enterprises
100 100 0% since 09.09.06
10019100 Other: Wheat of seed quality
Restricted 100 100 100%
10019910 Other wheat State Trading Enterprises
100 100 0% since 09.09.06
10019920 Meslin State Trading Enterprises
100 100 100
Source: DGFT, D/o Revenue, WTO
6.10 Domestic v/s International prices
~ 40 ~
Source: Domestic Price: Agmark, Intl Prices: FAO Prices
Domestic prices were higher than International prices during June - Aug, 2013, Nov 2013- Feb 2014 and May to August 2014.
Source: Domestic Price: Agmark, Intl Prices: FAO Prices
~ 41 ~
6.11 Marketing Strategy
Wheat products are more or less sold in bulk on the consideration of price and quality. The export is entirely dependent upon International prices and India’s competitiveness as such India’s quality is acceptable in foreign markets now. The marketing channels for the wheat product are as follows:
a) Exports in Bangladesh & North East - Direct export or through merchant exporters. The present share of this category is estimated at around 10%of the production sales at Bangladesh & 20% North East States.
b) Domestic Bulk users/processors – The major bulk users of wheat flour product various grocery shop, restaurant, Hotels etc. We have an aim to direct sales about 65%-70% of States’s Consumption of wheat products.
c) Wholesale trade – Some companies have also appointed state level wholesalers/traders for catering to needs of QSRs, Small Food Processing Units, Caterers, Restaurants and other end users. The present share of this channel is estimated at 5%-10%.
d) Retail market – . The product is distributed like FMCG by appointing distributor network and also through organised retail. At present the share of this segment hardly 15% but holds lot of potential .Looking at the above it is very clear that the product can be sold through close interaction with the bulk users and keeping in view their quality needs and commercial consideration .However, as a long term strategy manufacturing of value added consumer products and promoting a brand would also be desirable.
6.12 Price of wheat product
The prices of wheat products are also quite volatile due to linkage of price with the fresh wheat flour product price. It has been observed from the market that there are four price points in the domestic industry as explained below.
Bulk Buyers:-
The prices for Bulk Buyers per metric ton are given below for bulk packs depending upon payment terms.
PRODUCTION CAPACITY (P.A.)Sl.no Item Rate Per MT 1 Atta 140002 Maida 140003 Dalia 135004 Bran 18500
Small Buyers: - There are a numbers of small buyers who are not sure of their annual requirement and are not in a position to stock high quantities and buy month to month basis on prevailing market prices. These buyers buy directly from the manufacturers or their sales agents.
Retail Buyers: - Sharma flour mill aims at introducing a new brand whose packs are 50kg, 20kg, 10kg, 5kg & 2kg
Export Buyers: - The export price for merchant exporters or direct export by the manufacturers will be in a suitable range. The commission will be provided depending upon the payment terms and quantity.
~ 42 ~
Bulk Buyers Small Buyers Retail Buyers Export Buyers0
1
2
3
4
5
6
7
8
201520162017
6.13 Backward linkage
Collection Centres Raw Material Standardization
6.14 Forward Market linkages
Emergence of Cold Chains: - With increasing availability of market chains and their reach to small town has made distribution of products easy in India and there are many success story.
Product Innovation: - Wheat products will have many advantages like convenience, consistency in quality, easy availability and cost efficiency.
List of Exporters
Prabhat IndustriesDeals in: wheat flour, semolina, broken wheatBusiness Type: Manufacturer / Exporters / Wholesale SuppliersAddress: Near Ekta Sarovar, Behind Roadways Bus Stand, Pilibhit, Uttar Pradesh IndiaPrimary Number: 08042756237Govinda EnterprisesDeals in: fine wheat, wheat, spices, flour, pulses. Business Type: Manufacturer / Exporters / ImporterAddress: 7/22, Tilak Nagar, Kanpur, Uttar Pradesh IndiaPhone(s): 91-44-42664404Mobile: +91-9884070041Agarwal Seeds & Chemical ProductsDeals in: Agro wheat seeds, fresh wheat seeds, agro seeds, wheat seeds, agricultural wheat seeds. Business Type: Manufacturer / Exporters / Wholesale SuppliersAddress: Naintal Road, Bilaspur, Rampur, Uttar Pradesh, IndiaMobile: 9897168150M.k.industriesDeals in wheat, pulses, rice, rice branBusiness Type: Exporters / Wholesale SuppliersAddress: Naya Bazar Dalpatti Lakhisarai - 811311 Bihar, IndiaLaxmi Oil & Flour MillDeals in: wheat, wheat flourBusiness Type: Manufacturer / Wholesale Suppliers
~ 43 ~
Address: Village Dhurve near Food Corporation of India Katari Hill Road Gaya - 823001 Bihar, India Eastern Agro Marketing AgenciesDeals in: wheat, wheat flour, wheat seeds.Business Type: Manufacturer / Wholesale SuppliersAddress: 257, Sreemanta Market, A.T. Road,Guwahati-781008, Assam, India
List of Importers
Moon Tsn InternationalAddress: Moon Tsn International, 952/b Osman Manzil (1st Floor) Asadgonj , Bangladesh
Jalal TradersAddress: Sherpur Road, Colony ,bogra. , Bangladesh
M/s. Masud IncorporationAddress: 273/a, Musa Market, 1st Floor, New Chaktai. , Bangladesh
SacoAddress: 64, Baitul Mukarram , , Bangladesh
A. Growth in wholesale market:
Growth in Quick Service Restaurants:-. A fast growth in expected in fast food chains, hotel, catering in trains, railway station and air ports in Tripura which is expected to increase in future. The projective growth of Quick Service Restaurant and hotel is given in
Table-6 Quick Service Restaurants (QSRs) per month
QSR Outlets/KG (approx) Expansion/KG (approx)
Momo n more 1000 1200
Rajarshee 2000 2500
Ashoka 2000 2500
Green chilly 1000 1200
Abhishek 1200 1500
Invitation 1500 2000
Source : Market survey*The amount provided are based on market survey
B. Growth in wholesale market:
Table- Growth in wholesale market (per month) in Tripura
Wholesale distributor / stockist Outlets/Quintal (approx) Expansion/KG (approx)
Ghar sangshar 10 15
M/S Madan Mohan Saha 18 30
Gitanjali Traders 30 50
~ 44 ~
JAY S ree Laxmi Bhander 12 20
Saha Traders 20 30
M/S Joy Usha Trading Co 10 30
Vikash Trading Company 30 40
Source: Market survey*The amount provided are based on market survey
~ 45 ~
POJECT IMPLEMENTATION SCHEDULE
~ 46 ~
6.1 Project Implementation Schedule
Activities Starts from Feb `2014’ 1 2 3 4 5 6 7 8 9 10
11 12
1 Submission of DPR
2 Approval by DPR
3 Process of ROC
4 Land and its development
5 Detailed Engineering
6 Negotiation and selection of Vendors
7 Award of ` Turn Key` Contract
8 Securing temporally power supply
9 Civil works
10 Order of Imported Machinery
11 Order of Indian Machinery
12 Installment of Machinery
13 Recruitment of key staff
14 Regulatory compliance
15 Commissioning trials
16 Procurements Activities
17 Market Dev. Activities
6.2 Implementation schedule timeline.The approximate time required for various activities is given below. However, it may vary from place to place depending upon the local circumstance:-
1 Feasilbity Study 1 Month/.2 SSI Registration . 7 Days
3 Project Report Preparation. 1 Month4 Availability of Finance 2 Month
5 Machinery Procurement, Erection, Commissioning & Trial Run, etc.
8th months onward.
~ 47 ~
OPERATI0N & MANAGEMENT OF THE PROJECT
7.1 Project Management
The project will be implemented by Mr Amitabha Sarma & his two brothers.
~ 48 ~
The main features of the management will include:- Developing a management system. Make a system systematic. Maintaining bakery in a cost effective and easy way. Keeping every record and data for future. Giving good delivery support to customer. Keeping every track record. Ensuring quality and security.
3
7.2Key Success Factors:
The commercial viability of the proposed Flour Mill depends on the following Factors:Utmost care should be taken while selecting wheat. Only the best quality wheat should be used. Waste Production should be kept at minimum and production process need to be monitored very carefully. Advance sale orders can ensure the success of the business. It is recommended to estimate the wheat requirements for the year and this should be contracted for in advance with the suppliers to secure the drastic fluctuations in the prices of wheat. Quality maintenance will play an important role as it is evident from the behaviour of the general consumers that they are more specific towards health issues than ever before. Cost Accounting system should be strengthened so as to monitor the entire process and determine the reasons for major variances in the process such as Material, Labour and Factory Overhead Variances. Location of the project is of prime importance. Selection of technical / skilled staff would be very crucial decision to be made by the management. Continuous efforts should be made for up-gradation of the technology.
7.2 Manpower RequirementSuccess of any project also depends upon the quality of manpower employed. No difficulty is envisaged in recruitment of the experienced staff. The services of the suppliers of process equipment will be utilized in training of key personnel of production and maintenance departments. Considering nature of the business and requirement of the manufacturing unit the man power requirement has been worked out as per the Table-13below.
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Table 13 - Man power requirement for Wheat product unit
Sl.No. Manpower Cost No. of employee
Per Month salary TotalSalaries
1 Manager –cum-Chemist 1 10,000/- 10,000/-2 Plant Foreman 3 8000/- 24000/-3 Electrician 1 5000/- 5000/-4 Operator 3 6000/- 18000/-5 Un-Skilled Workers. 6 4000/- 24000/-6 Accountant 1 8000/- 8000/-7 Clerk / Store keeper 2 4000/- 8000/-8 Sales Supervisor 2 6000/- 12000/-9 Peon 1 3000/- 3000/-10 Security Personal 1 4000/- 4000/-11 Total 116000/-12 Add Pre-requisites @ 10% of
salary.11600/-
Total 127600/-
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REGULATORY REQUIREMENTS & GOVT.SUPPORT
8 .Regulatory Requirements & Govt. Support
8.1 Regulations -Food Laws, Environment
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The following commercial approvals / registration are required to obtained..Registration with District Industries Centre
Registration under Factories Act.
Factories Act & Rules
The Factories Act , 1948
The Tripura Factories Rules , 2007 a) Tripura Factories (First Amendment) Rules, 2008b) Tripura Factories (Second Amendment) Rules, 2013c) Tripura Factories (Third Amendment) Rules, 2014
The Factories (Safety Officers) Rules, 1984. (State Rules)
The Factories Welfare Officers (Duties, Qualification and conditions of service)Rules,1986 .
Tripura Major Accident Hazard Control Rules, 2001.
Other Acts & Rules
The Organisation is responsible for enforcement of 19 central Acts & Rules as mentioned below.
The Indian Boilers Act, 1923.
Boiler Catagories:
1 Horizontal, Multitubular, Wet back, Smoke Tube, Husk Fired Boiler
107 sq. mtr. M/s Veesons Energy System Pvt Ltd,
Tirichirapalli
Sarvasiddhi Agrotech Pvt. Ltd. Bodhjungnagar
Bodhjungnagar Industrial Growth Centre, Agartala
2 Horizontal, Shell Type, Smoke Tube,
Wet back, Multitubular, Husk
Fired Boiler
69.7 sq. mtr.
Thermax Ltd,
Pune
Joy Ram Rice Mill, Brajanagar
Ranirbazar,West Tripura
The Workmen's Compensation Act, 1923.
The Payment of Wages Act, 1936.
The Cotton Ginning & Pressing Factories Act, 1923 .
The Dangerous Machines (Regulation) Act, 1986 .
The Maternity Benefits Act, 1961.
The Indian Boilers Regulation, 1950.
The Tripura Boilers Rules, 1983 .
The Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989.(Central Rules).
The Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996, (Central Rules).
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The Tripura Factories Rules, 1952 .
The Workmen's Compensation Rules, 1952 .
The Tripura Payment of Wages Rules, 1952.
The Tripura Maternity Benefits Rules, 1971 ..
Registration for VAT&CST
Trader’s Licence from APMC
Import -Export License
NOC from the state pollution control board.
REQUIREMENT FOR OBTAINING FRESH CONSENT CERTIFICATE/RENEWAL OF CONSENT
/ Following documents should be submitted along with Application Forms Site Plan of the Industry No Objection Certificate from neighbors and land owner Project Report with details of manufacturing process Documents of land Photocopy of money receipt
Consent Fees
REQUIREMENT FOR RENEWAL OF CONSENT CERTIFICATE
Following documents should be submitted along with Application Forms
Last year's Consent Certificate Documents of land Photocopy of money receipt Consent Fees
AIR POLLUTION:Air pollution source & control system:
In the wheat flour mills, the cleaning process is somewhat similar to that followed in the pulse mills. However, the number of stages of cleaning are generally two or three stages (more compared to that of pulse mills) to ensure thorough cleaning of the wheat. Sources of emission are similar as discussed in the pulse mills section. In general, single cyclone or a series of two or three cyclones are commonly installed as dust collection devices for the cleaning section in the wheat mills. A schematic presentation of the process flow diagram showing the points of dust generation in is shown at Figure 4.2, 4.3 & 4.4 for dry type wheat flour mill, wet type wheat flour mill & wheat processing (roasting) mills respectively. In the milling section, the outer shell is separately collected through a combination of cyclones. The fine powder emissions from subsequent milling stages is primarily the product in terms of wheat, flour or maida which is carefully collected using high efficiency multiple cyclones and bag filter house. In wheat flour mill, dust is generated at various points in the cleaning and milling sections and is detailed below. Sources of Dust Emissions:
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Cleaning section:
• While unloading the wheat • At different stages of lifting and discharging of wheat through bucket elevator and screw conveyor • At Reel machine • During vibrating screening • At De-stoner machines • At Scourers machine • At Aspirator machine • At Magnetic separator • At Toggle Cylinder
Milling Section
• At bucket elevator discharge points • At Grinding mill discharge. • At Purifier machine • At Plansifter machine
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WATER POLLUTION:
In dry type wheat flour mills, there is no wastewater generation from process.
NOISE POLLUTION:
Noise is generated from various material handling and process equipments, which are highlighted below: Typical Noise Pollution Sources in Wheat:
Wheat
Cleaning
Separator Scourer Vibratory screen Reel machine Cleaning DestonePacking machine Roller Mill Purifier
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Milling Planshifter Blower Bran Finisher Milling Fan Wheat Milling ID Fan
Noise prevention measures:
For noise generating sources, such as rotary/vibratory screen, bucket elevators, screw conveyors and grinders, motors etc, following noise prevention cum control measures are recommended. • Providing Vibration dampening pads to prevent noise generated due to vibration • To provide rigid enclosure for rotary/vibratory screens • Bucket elevator transfer points to be covered with rigid enclosures • Ear plugs, ear muffs may be provided to workers exposed to higher noise levels.
Industry information:
Scale :
Large/Medium/ Small No. of staff :
Working Season:
Gross capital investment in Rs. :
[land, building, plant, machineryexcluding capital investment onpollution control system](supported by affidavit/ certificate from Chartered Accountant /Annual report)
Proposed date of commissioning:Full address of the proposed factory (mentioning Post Office, Police Station, Urban Local body/Panchayet with Ward No. etc.):..............................................................................……………….............…………………
..............................................................................……………….............…………………
..............................................................................……………….............…………………
Telephone ………………………………… Fax ………………………………… Mobile
No………………e-mail……………………………….website…………………………
Police Station…………………..……………………. P.O…………………….. Pin Code
…..……………………………Urban Local Body/ Panchayet…………………………………
……...………..……………………………………………Ward No…………………………
Mouza. No & Sheet No…………..……………………………………… ………………
Plot No./Dag No…………………………………………………………………………………
Subdivision………………………………District………………………………………………
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Raw material(s) : (attach additional sheet if required) Quantity / day : (attach additional sheet if required)
Products(s) : (attach additional sheet if required) Quantity / day : (attach additional sheet if required)
Water consumption (K L D)
Industrial-
Domestic
Wastewater quantity (KLD)
Industrial-
Domestic-
Waste water discharged through sewage treatmentplant / septic tank to: (Name of place of discharge)
Municipal Drain / River / Water Body / Wetland / Others(tick the appropriate discharge places alongwith name of River/Water body/Wetland/Drain/Others
Wastewater treatment facility, if any(attach additional sheet if required)
Final discharge to
Solid waste : Nature Quantity / day :
Air emission sources : (attach additional sheet if required)
Air pollution control devices: (attach additional sheet if required)
Number and Capacity (KVA) of Diesel Generator (DG) Sets
Appropriate acoustic enclosure and stack with specified chimney height will be installed for the proposed DG set(s) as prescribed in the Gazette Notifications of Ministry of Environment and Forest, Government of India dated 17 May, 2002 and 25 September, 2000.
I hereby declare that all information provided herewith are true and the gross capital investment mentioned are based on Detailed Project Report / Certificate of a Chartered Accountant and I shall be solely responsible for submission of duly filled in and signed hard copies of the application form and all related documents .
Name of applicant :
Seal of the company Signature of the applicantDesignation(Proprietor/Partner/Managing Director/ Authorised Representative):Permanent Residential Address of applicant : Tel. no.
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Mobile no.
Office Address of the Unit: Tel. no
Fax No
Correspondence Address of the unit: Tel No.
Fax No.
Check-list of accompaniments : [Please put tick mark (√ ) as applicable]
1. Detailed Project Report including details of Raw Materials and Fuel use, details of Process
Description, Specification and details of Plants and Machineries, Cost Analysis Data.
2. Undertaking/Affidavit/Annual Report/ Certificate from a Chartered Accountant
3. Site Plan
4. Additional sheet against Raw material and Quantity (If required)
5. Additional sheet against Product and Quantity (If required)
6. Additional sheet against Wastewater treatment facility (If required)
7. Additional sheet against Air emission sources (If required)
8. Additional sheet against Air pollution control devices (If required)
9. Land and Building Valuation Certificate/Documents
10.Agreement Copy of rent/lease between the owner of the unit & the land owner if the
land /building is rented/leased.
11. No objection Certificates from surrounding neighbours of the unit.
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PLANT & MACHINERY
8.1 Process Flow of Flourmill
Following is the process flow of flourmill:Intake hopper is made up of concrete, steel and cement. A pit is dig in the soil below the ground level about 2 to 2.5 meters depth. It is covered with a net of 10 mm round steel duly welded with 5 mm round at a particular distance. Around 5,000 Kg. weights can be placed in this pit at a time.
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There is a controlled mechanical system for opening the gate of Intake Hopper to 1st Elevator. 1st single Bucket Elevator lifts the grain vertically and feeds it in Drum Sieve machine. It is a rotary drum type sieving machine which can separate out the fine dust by aspiration system developed by negative pressure whereas thrash, jute sutli, lumps etc. are separated out by sieving.After sieving through the Drum Sieve, the grain will feed in vibro-type Seed Cleaner by gravity. The impurities, which are bigger or smaller than the size of grain, is separated out by sieving with the help of different size sieves and the light impurities will be separated out by Aspiration System. These light impurities will be collected in the Dust Cyclone.After sieving the material from Seed/Grain cleaner, the raw wheat will go into the 2nd single Bucket Elevator by gravity. This Elevator will lift the material vertically and feed it in the Worm Conveyor, which is fitted on the top of 1st & 2nd Concrete Bins. The cleaned material will go into 1st & 2nd Bins. These bins are designed for multiple hoppers from the bottom side. The output flow of the material can be controlled with variable pocket feeder and the wheat can be put in the Worm Conveyor. The Worm Conveyor takes the wheat from 1st & 2nd Bins to feed it to Elevator No. 3 by gravity. Elevator No. 3 lifts the material vertically and feeds it to the Gravity Separator Cum Destoningmachine. In this machine we can separate out heavy metals, stones, glass pieces and also the light impurities from the wheat. Thereafter, the wheat will go to scouring machine by gravity. In the scouring machine dust is removed from the upper layer of wheat by friction. Dust and some part of bran are separated out from the wheat by sieving. Aspiration channel is also provided with Scouring machine for further cleaning of the wheat by negative pressure of air stream.From the Scourer Aspiration channel the wheat goes to Intensive Dampner through Bucket Dampner by gravity system with the help of Bucket Dampner where measured quantity of water will be added in the wheat. Water will be mixed immediately with the help of Intensive Dampner. From Intensive Dampner wheat will go to single BucketElevator No. E1- 4 by gravity.Elevator No. 4 lifts the material vertically and feeds it into Worm conveyor No. W3 and feeds the wheat in Bin No. III, IV, V & VI for conditioning. The wheat is kept in the conditioning for 16-24 hours depending upon the variety of wheat and atmospheric temperature.After conditioning, the wheat is taken out from the multiple hoppers. This wheat is feeded in the Elevator No.E1-5 through Worm Conveyor W4. Elevator E1-5 lifts the material vertically and puts it in the second Intensive Dampner through Bucket Dampner. Desired moisture is added here and the material is put in Bin No. VII & VIII for about 4 to 6 hours.Material is taken out from the Bin No. VII & VIII through the conveyor and is feeded into the Elevator E1-6 by gravity.Elevator E1-6 lifts the material vertically and feeds it into the Scouring/Brush Machine, so that the bran could be removed from the upper layer of wheat. This bran is separated by sieving and aspiration channel. Then this material goes to final Seed cleaner by gravity. The Seed cleaner finally performs the cleaning of the seed and keeps the material in Worm conveyor and then it goes to Elevator E1-7.Bucket Elevator E1-7 lifts the material vertically and feeds it into Milling Bin. From Milling Bin it goes to 1st break of Roller Mill. In Roller Mill material is grind with the help of Chilled Cast Iron Rolls. After grinding, the material is lifted vertically by pneumatic conveying system and feeded into the Plan Sifter through Pneumatic cyclone and air Lock.In the Plan Sifter (sieve) we can sieve the material into many segments. The final product goes to Worm conveyor and then packed. Intermediate product goes to Purifier machine for further purification. Desired quantity of Sujji is taken out for packing and the remaining material goes to Roller Mill for further grinding and sieving. Coarse material also goes to further grinding and sieving. This process is continued in sequence up-todesired product.In the whole process we grind the wheat in grooved rolls softly, so that purest form of Bran can be obtained. In this process by separating the bran we can get Samolina, Sujji in the purest form. In the intermediate product where we cannot separate out the bran from Semoline, the Semoline obtained at this stage is called ‘Atta’.
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~ 61 ~
~ 62 ~
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DETAILED ESTIMATION
~ 70 ~
DETAILED ESTIMATE FOR CIVIL WORK1) PROPOSED ABSTRACT OF COST :-
Particular Area in sq.mtr
Rate / sq.mtr Rs. Lakhs
1 Factory 1007400.002 Office, Laboratory &
Store7,50,000.00
4 Workers amenities 1,28000.005 Toilet block and septic
tank1,76000.00
6 Boiler room 2,45000.007 Generator room 175000.00TOTAL 26,56,000.00
~ 71 ~
DETAILED ELECTRICAL ENGINEERING
~ 72 ~
1. Introduction Grinding of cereal seeds is due to the mechanical action of several forces: compression,
shearing, crushing, cutting, friction and collision, to which seeds are subjected, depending on the design if
the mill used for grinding (roller mill, hammer mill, stones mill or ball mill). By applying these forces,
when the mechanical resistance of the particles is exceeded, their division happens in a number of smaller
particles of different sizes, geometric shapes, masses and volumes.
An industrial wheat mill has several technological phases, starting with coarse grinding of seeds to fine
grinding of the resulted milling products, after their sorting in fractions of different sizes. The first
technological phase of grinding process, in wheat mills, is gristing or coarse grinding phase, which also
consists of several technological passages.
A technological passage consists of a grinding machine (roller mill), a machine for sifting and sorting of
the resulted milling fractions (plansifter compartment) and, eventually, a machine for the conditioning of
semi-final product (semolina machine or bran finisher). In a technological passage, intermediate fractions
are obtained, which, by a new grinding, lead to the obtaining of high-qualityflour at milling passages (fine
grinding).
Wheat processing requires a long and gradual transformation into flour. This process takes place after a
gradual crushing schedule, from fine to finer, from machine to machine, of wheat seed, respectively of the
crushed particles resulting from it. Each grinding operation is immediately followed by a sorting operation
by sifting (fig.1) because during grinding, a wide variety of grinded seed particles is obtained.
FIGURE 1.
Schematic diagram of a grinding passage
Before the grinding process is started, grains must undergo the cleansing process. This is followed by a
conditioning process that ensures a uniform moisture content for the entire lot of grains, helping endosperm
softening and cover harshening, which improves the separation process.
~ 73 ~
One of the fractions resulting from a plansifter compartment is composed of flour particles (with sizes
under 160 μm), in a higher or lower percentage of the total flour that can be withdrawn in the industrial
mill. To extract the full amount of flour from the wheat berries, multiple passes (passages) are required.
Some passages are part of coarse grinding phase (gristing), where the milling rollers have fluted surface,
while other passages are part of milling phase (fine grinding), where the milling rollers have smooth
surface.
Intermediate milling products are, mainly, grists (seed particles with various sizes), semolina (large,
average and small) and dunsts (harsh and smooth). They all return in the grinding process for flour
extraction, but the grists are grinded by mills with fluted rollers (gristing passages), while semolina and
dunsts are grinded by mills with smooth rollers (milling passages). Semolina and dunsts, as intermediate
milling products, are particles of clean endosperm or with a small percentage of cohesive coat.
Particles obtained by grinding have sizes in a fairly wide range (1200-160 μm, within the mentioned
fractions), average size of the particles of resulted fraction being determined by granulometric analysis
using sieve classifier.
In roller mills, wheat seeds are grinded in the gristing phase by pairs of fluted rollers, thus being obtained a
wide range of particles with sizes from < 200 µm to > 2000 µm, [1], consisting in coat particles (of larger
sizes) and endosperm particles (of smaller sizes), to be further separated with plansifters. The milling
process aims to grind the endosperm into finer particles of flour and semolina, while the coating and the
seed particles must remain in large sizes to be separated by sifting, [2]. In gristing passages, milling rollers
with fluted surface are used, and in milling passages, rollers with smooth surface are used. The quality of
wheat milling process is influenced by the physical and mechanical properties of seeds and of the
intermediate products (size distribution, seeds hardness, moisture content) and by the design and functional
parameters of the roller mill (mutual arrangement of the rollers, differential speed, distance between the
rollers, flutes profile, mutual position of the flutes), [3,4]. Effects of these factors are manifested in the size
distribution of material particles, compositional distribution of the material, wear degree of the rollers,
energy consumed for grinding, [4].
Fang, Campbell et al. (2002) showed that if the distance between rollers increases from 0.3 mm to 0.7 mm,
wheat seeds breakage in the gristing phase has a lower intensity, resulting in more particles of large sizes
and less particles of smaller sizes. Distance between rollers indirectly influences the specific surface and
energy consumption per mass unit and directly influences the specific energy, [5]. Different flutes
arrangements on the rollers lead to the obtaining of different size distributions. If the roller flutes are
arranged in blade/blade position results in a relatively uniform size distribution, and back to back
arrangement lead to a deep parabolic distribution, [1].
~ 74 ~
Differential speed of milling rollers has a significant effect on the grinding of semolina, flour and wheat
bran. With the increase of differential speed of rollers, it also increases the amount of semolina and
decreases the amount of flour and wheat bran, [6]. This is due to the difference between shearing and
compression forces which are applied on the particles.
It is very important to know the size distribution of the material subjected to grinding, as well of the grist,
so that appropriate adjustments can be made to roller mills, and also to choose the fabrics for the sieving
frames of plansift compartments. Particles size distribution of the granular material can be determined
using superposed sieve classifiers (sieve shakers), with different sizes of sieve holes. This can be assessed
by various mathematical functions, from which, most used is the Rosin-Rammler function.
Experiments were performed on the material subjected to grinding (before and after grinding) and
cumulative distribution curves were drawn for the sieved material, by computer aided regression analysis
of the experimental data with Rosin-Rammler function. Based on the data obtained from particle size
distribution were also determined other physical characteristics of the analyzed material: average particle
size, grist modulus, specific surface of the granular material, surface increasement resulted from grinding
within a passage (break), bulk density and specific mass.
Within this chapter are presented the flow diagrams for two wheat mills of different capacities, one of 100
tons / 24 hours and one of 220 tons / 24 hours, from which it can be estimated the movement of products
within the mill.
There are also presented the experimental results obtained from the particles size distribution of the
material subjected to grinding and of the resulted grist, in both technological phases, for the two mills, as
well as particles size distribution of the material for various grinding machines of the analyzed mills.
Knowing of the mechanical characteristics of wheat seeds and of the grist particles, and also their size
characteristics, volume and mass of the wheat seeds, is useful for estimating the energy required for
crushing.
For this purpose, in this paper are presented the results of some experimental research on the behaviour of
wheat seeds in uniaxial compression tests between parallel plates. There are also presented the curves of
variation for the crushing force and energy absorbed until the crushing point of seeds.
The results presented and the obtained data are of real interest for the designers of roller mills, as well as
for the manufacturers and users of such machines.
2. Technological diagrams for wheat grindingThe technological passage consists of one or two pairs of milling rollers, both processing the same product,
combined with one or more plansifter compartments for sieving.
Gristing is the technological phase aiming to fragment the wheat seed in particles of different sizes and to
remove the endosperm from the coating. Particles resulted from first, second and third grinding phase vary
~ 75 ~
in size, from breakages like half seeds to flour particles with very fine granulometry. As gristing is
repeated, particles will get increasingly finer, the amount of white flour decreases, and seeds coating
reaches the penultimate and last phase as fine dust, [7]. Thus, grist is the intermediate product obtained in
the milling industry, by grinding grains by mean of roller mills with fluted surface.
Fig. 2 presents the technological diagram of gristing phase of the wheat in an industrial mill with the
capacity of 220 t/24 h.
Milling unit consists of 9 double roller mills, of which the first processes, in both sections, the same
material (whole seeds), two plansifters, together amounting 14 compartments, three double semolina
machines and five brushes and bran finishers. The three phases of the process (gristing, milling, sorting)
can be observed in fig.3 – fig.5.
Gristing phase consists of six simple mills with fluted rollers, four full and two half’s of plansifter
compartments and four bran finishers which process the coatings resulted from multiple grinding
operations. The seeds are processed in a mill with double rollers placed in horizontal plane, noted by B1–
B2.
The first grist is processed in passage B3, and the fractions obtained here will follow different routes, to the
milling passages, or to the semolina machines or bran finishers, passages B4gr and B5f being responsible
for the processing of material particles with high coating content, and passage B4f processes the second
refuse from gristing passage B3, with fractions having the same characteristics processed in plansifter
compartments. The development of gristing phase in directly connected to the type of meal and the degree
of flour extraction. Products resulted from gristing are named intermediate products and they consist of:
big grist, fine grist, big semolina, middle semolina, fine semolina, big dunst, soft dunst, flour and bran, [7].
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FIGURE 2.
Technological diagram of gristing phase for a Buhler mill with capacity of 220 t / 24 h, [8]
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FIGURE 3.
Technological diagram for sorting of big semolina in Bühler mill, [7]
Particles size of these components, resulted from sieving process, is determined by the size of the sieve
holes used in sieving compartments. Depending on the particles size, semolina and dunsts can be classified
as: big semolina with average size of 1200-630 μm; middle semolina 630–400 μm; fine semolina 400–310
μm; big dunsts 310–245 μm; soft dunsts 245–160 μm. Semolina sorting is dome in sorting phase (fig.2. ) A
clear delineation between soft dunsts and flour can not be practically achieved, and therefore, are cases
when soft dunsts (dm = 220 μm) are considered to be flour (flours granulosity is given by the sieves, with
mean equivalent size of the particles below 160 μm).
Particles of intermediate products can be highlited not only by their size, but also by shape, volume,
specific mass, aerodynamic properties. Particles with rich coating have irregular shape in the form of foils
with rolled or folded edges. Particles of clean endosperm have polyhedral shape with sharp edges and
convex lateral surfaces.
Semolina is an intermediate product obtained in percentage of 25…30% in industrial wheat milling, is
found as small granules and after cleaning is further milled to obtain flour or a food product known as
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”kitchen semolina”. This is obtained in percentage of 2...3 % at wheat milling and it is cleaned in special
semolina machines in order to remove coating particles by the combined action of sieving and airflows.
Dunst is a fine semolina obtained as intermediate product from the grinding of wheat or semolina.
After gristing phase it is important to sort the milling products using a wide range of sizes for sieve holes
(1000...224 μm), followed by the cleaning of semolina and dunsts, the phase of semolina opening being no
longer necessary, since most coating was already removed in the gristing phase (fig.3).
The unit is fully automated, all mill equipments starting and stopping from the computer, starting with the
equipments from the final technological phases (bagging, flour homogenization, sieving with plansifters,
semolina cleaning, bran finishers, etc.) from the circuit of flour or intermediate products, while stopping
begins with the first pair of rollers, i.e. reverse of start up.
FIGURE 4.
Technological flow of semolina grinding phase in wheat mill, capacity of 100 t/24 h, [11]
Apart from the 12 technological passages, each consisting in a pair of roller mills and one plansifter
compartment, the mill also has a double machine for semolina, three bran finishers and other auxiliary
equipments (detachers, wheat brushes, filters and cleaning cyclones, etc.), as well as the proper elements
for the pneumatic transport system from one equipment to another, according to the technological flow.
In breakage phase the technological diagram of mill contains five pairs of rolls, filled with one
compartment of plane sieve, two semolina machines and three wheat bran finishers. The technological
~ 79 ~
breakage phase is completed with one compartment of plane sieve without grinding machine, in which the
material is sorted by fractions of different sizes as well as the other compartments of plane sieve.
The first grist, obtained from seeds processing with the pair of fluted rollers Sr.1, is processed in passage
Sr.2, and from here the fractions follow various routes, to grinding passages, to semolina machines to
wheat bran finishers. The sifting material from the second and the last set of gristing passage Sr.1, is send
to a plansifter compartment for division in fractions (Div.1), which next reach the MG1 and MG2 semolina
machines. The refuse from the last set of frames in the first passage is then sent to the M2 grinding
passage.
The circulation of grist intermediate products in the technological diagram is shown in fig.4 and fig.5.
In the grinding phase (fig.5), the technological diagram of milling unit consists of seven simple roller mills,
each fitted with one plansifter compartment for sorting in fractions of the grinded products and the
extraction of flour from these products.
FIGURE 5.
Technological flow of the semolina grinding phase in a wheat mill with 100 t/24 h, [9]
All roller mills of both technological phases have the length of 1000 mm and diameter of 250 mm, with
fluted surface, in the gristing phase, respectively smooth surface without flutes in the grinding phase. In the
gristing phase, the ratio of the tangential speeds of fluted rollers is k=2.54, and in the grinding phase, for
five pairs of rollers, k=2.54, and for two pairs of rollers k=1.5.
As shown in fig.5, the products to be grinded into the grinding phase are products arriving from gristing
phase (or breakage phase), inclusive from grists (Sr.1-6) or from semolina machines and bran finishers.
The siftings from MG1 and MG2 semolina machines, which are semolinas with sizes below 0.8-1.0 mm,
are grinded in the first technological passages M1A and M1B, while the siftings from FT1 and FT3 bran
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finishers go to the last two grinders M4 and M5, which processed products with higher content of bran. In
diagram, the first refusal from M1A and M1B grinders is led to M3 grinder, working with half
compartment of plane sieve. It is noted that to grinders which grinded smaller particles of endosperm
(about 0.40 mm), after the mill rollers in technological flow are placed detached of material, due to
agglomerations arising from the compression of smaller particles of endosperm in the action zone of
grinding rolls.
In fig.6 is shown the arrangement of rollers to a mill with 100 t /24 h capacity, where the samples for our
determinations were collected.
FIGURE 6.
Arrangement of roller mills for the mill with capacity of 100 t /24 h
Plans ifters are driven by electric motors of 4 kW, cos φ = 0,81 and speed of 960 rot/min.
Double machine for semolina is driven by two moto-vibrators of 400 W and speed of 960 rpm.
Characteristics of driving motors for mill rollers are given in table 1.
P
as
sa
ge
I (A)
P,
k
W
n,
rp
m
co
s
φ
Pass
age
I (A)
P,
k
W
n,
rp
m
c
o
s
φ
N Lo N Lo
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o-
lo
ad
ad
o-
lo
ad
ad
Sr
.
1
1
945
3
0
9
6
0
0.
83
M1
B10 15
1
1
9
6
0
0
.
7
9
Sr
.
2
2
137
2
2
9
6
0
0.
83M2
11
,916
1
1
9
6
0
0
.
7
9
Sr
.
3
2
332
1
8
9
7
5
0.
82M3
10
,918
7,
5
9
6
0
0
.
7
6
Sr
.
4
1
330
1
5
9
7
0
0.
81M4
10
,915
1
1
9
6
0
0
.
7
9
Sr
.
5
1
317
1
1
9
6
0
0.
79M5 12 16
1
1
9
6
0
0
.
7
9
M
1
A
1
015
1
1
9
6
0
0.
79M6 12 17
1
1
9
6
0
0
.
7
9
TABLE 1.
~ 82 ~
Characteristics of electric motors for the drive of mill rollers, for wheat mill with capacity of 100 t/24 h [9]
According to relevant regulations, on the technological diagram (fig.4 or fig.5) should be written the
characteristics of grinding rollers: length, diameter (ex.1000x250, in mm), number of flutes and their
inclination (ex.7/cm, I=8%), flute angles (ex.35/65), mutual arrangement of the flutes (ex.S/S), speed ratio
(ex.k=2.5), and the characteristics of fabrics used in plansifter frames (ex.3x46 – 3 frames with 46 wires
per inch or 3xX for flour frames), at semolina machines (ex.42, which represents the number of wires per
inch or 1000-500, which is frame size) or at bran finishers (ex.0.5 – size of fabric hole).
Sieve frames from top of compartments are fitted with metal mesh as they separate seed brokens of
relatively large sizes (which would wear quite quickly the textile fabrics), while flour frames from the
lower set are fitted with frames with plastic or textile fabrics.
Lately, textile fabrics have been replaced with sieve frames with meshes of plastic fabric. According to
literature, fot the technological diagram of the analyzed mill, the equivalence between the sieve number
and the size of its holes, as they are specified in the diagram, is shown in table 2.
Sieve
no.
1
8
2
0
2
6
3
6
4
0
4
6
4
8
5
0
5
4
5
6
6
0
V
I
I
I
I
XX
Hole
size
(µm)
1
1
7
0
1
0
5
0
7
8
0
5
2
0
4
7
0
3
9
0
3
7
0
3
5
0
3
2
0
3
1
0
2
8
0
1
8
0
1
7
0
1
5
0
TABLE 2.
Equivalence between sieve number and hole sizes
3. Physical and granulometric characteristics of seeds and grinding productsIn the grinding process is necessary to know the physico-mechanical characteristics of the material at the
entry and exit from a processing machine, in this case, roller mills.
Main factors influencing the process of grain grinding are the physico-mechanical properties of seeds and
of the grinding products, the constructive and functional characteristics of the grinding machines as well as
the technological regime, most of those factors having a random character.
As a result of grinding it is obtained a mass of particles with various smaller sizes and different geometrical
shapes (grist).
~ 83 ~
Granulometric distribution of the grinded material and of the material leaving the grinding process can be
assessed by the cumulative weight (%) of material passing through the sieve holes of classifier T(x) or
which are refused by its sieves R(x), calculated on base of mass weight (%) of the fractions from the sieve.
(R(x)+T(x)=100). The mathematical expression of granulometric distribution in case of grinded biological
materials, is based on laws of mathematical statistical method of small particles, [11-14].
There will be defined three usual types of laws of cumulative granulometric distribution.
The Rosin-Rammler distribution, for material particles with larger sizes than sieve holes, is expressed
by the relation:
R(x)=100 e⋅ −bxn
(1
)
Options
where: R(x) is the mass percentage weight of fraction with larger particles than x (which remained on the
sieve with meshes with size x); x – is the sieves meshes size by which the particles rest; b and n are the
own coefficients of grinding material.
The Schuhman distribution is defined by the relation:
R(x)=100 {1−(x/k)⋅ a}(2
)
Options
where: R(x) and x have the significance from to relationship (1), k - the module product particles size (the
size of sieve mesh through which, theoretical, pass all the sample particles (100%)), a - the distribution
module.
The logistics type distribution with two parameters is defined by the relation:
R(x)=100 e⋅ α+βx1+eα+βx(3
)
Options
where: R(x) and x have the significance from relationships (1-3) α and β are logistical constants.
Of these characteristics are important: the bulk density, ρv (kg/m3), of the material to be processed, the
density of the material, ρ (kg/m3); the equivalent sizes of material particle at entry and exit of the grinding
machine, dm (mm); angle of internal friction of particles appreciated by natural slope angle, ψ (o); angle of
material friction with the surfaces working components, φ (o); material porosity, ε (%) and others.
Of particular importance is the equivalent size of seeds subjected to grinding in the first technological
passage.
~ 84 ~
The density is the ratio between the sample mass and the volume of the particle in it. To determine the
densities of wheat seeds, respectively the grinding products, the pycnometrical method was used (xylene
0.8254 kg/cm3).
The porosity is the property of granular materials, respectively of the grains, to not occupy the entire
volume of storage, with an intergranular space. Knowing the values of bulk density and material density,
the porosity was evaluated using the following relation, [15]:
ε(%)=(1−ρv/ρ) 100⋅ (%)(4
)
Options
The static friction coefficient. The most common method for determining the coefficient of static friction is
inclined plane method which was used in this paper. It was used a device with adjustable incline plane,
[15]. Two sets of determinations were realized on three types of surfaces: glossy fiberglass, steel sheet and
cotton canvas.
Assessing parameters of the grinding process are: grinding degree, grinding finesse and specific energy
consumption at grinding.
Grinding degree and grinding finesse are determined by granulometric analysis, using a sieve overlay
classifier with oscillatory movement.
Grinding degree is defined by the λ index and represents the ratio between equivalent sizes of particles
before and after grinding, De, respectively dm, or the ratio between the outer surface of the particles
resulted in the grinding process and the initial surface of the particle subjected to grinding, Sf,
respectively Si:
λ=De/dm=Sf/Si(5)
OptionsAbsolute value of the increase of particles outer surface in the grinding process ΔS, is given by:
ΔS=Sf−Si=Si(λ−1)(6)
OptionsThe grinding finesse has been appreciated by the geometric mean diameter dm of the grinding particles which was determined by the size distribution analysis, using the relation of weighted average:
dm=(1/100).∑ni=0pidi, (7)
~ 85 ~
where: pi is mass weight of fraction remaining on the sieve i of the classifier, di, is diameter (average value)
of fractions particle on the sieve i, considered the arithmetic average of the sieves holes size that contain
fraction i.
The surface area and the surface increase. Knowing the mean diameter of particles of a granular mixture,
their specific surface Se.m is determined with the relation, [10,15]:
Se.m.=6/ρ d⋅ m(m2/kg),(8
)
Options
where: ρ is the density of the particles.
There are presented the results of some experimental research on the physical characteristics of grinding
products on the technological flow of gristing phase of wheat from a mill with capacity of 100 t / 24 h (SC
Spicul Rosiori de Vede, Teleorman, Romania).
The material tested in the experiments was taken from the entry, respectively from the exit of each pair of
milling rollers (from the five pairs of the phase).
The experimental data characterizing the physical properties of the grist obtained are shown in table 3.
Also, in table 4 and table 5 are presented the results of size distribution analysis on mixtures of material
entering and leaving the rolls placed in the technological grinding phase.
Break
Static friction coefficient µ
Natural slope angle ψ
Cotton canvas Glossy fiberglass Steel sheet
M1A E 1.74 - >1.76 68,7 0.61 – 0.85 39,43
M1B I 1.24 – 1.82 56,4 0.45 – 0.67 30,19
M2 I >1.76 61 0.6 – 0.86 43,97
M3 E >1.76 72,4 0.58 – 0.82 38,35
M4 E >1.76 67,5 0.58 – 0.73 41,96
M5 I >1.76 64,3 0.60 – 0.88 46,62
M6 E >1.76 69,5 0.54 – 0.71 40,17
TABLE 3.
~ 86 ~
The values of static friction coefficient and natural slope angles [15]
From table 3 it is noted that the static coefficient values, on the glossy fiberglass and metal are within the
limits set in various specialized papers, while the values obtained in the experiments on cotton canvas fall
in broad limits, probably due to material fractions moisture, but also because of its granularity, this
phenomenon is observed, especially, to flours and relatively small particle fractions of endosperm.
li
(m
m)
M1A - I M1A – E
li
(m
m)
M1B – I M1B - E
p
i(%
)
T
i(%)
p
i(%
)
T
i(%)
p
i(%
)
T
i(%)
p
i(%
)
T
i(%)
0,0
0
0,9
0
0,0
0
34,
40
0,0
0
0,0
0
0,4
0
0,0
0
7,7
0
0,0
0
0,1
8
1,0
0
0,9
0
16,
30
34,
40
0,1
3
0,6
0
0,4
0
8,0
0
7,7
0
0,2
5
3,7
0
1,9
0
10,
30
50,
70
0,1
8
3,9
0
1,0
0
23,
80
15,
70
0,3
2
33,
30
5,6
0
15,
80
61,
00
0,2
5
22,
10
4,9
0
35,
60
39,
50
0,5
0
49,
10
38,
90
12,
50
76,
80
0,3
2
48,
90
27,
00
21,
90
75,
10
0,7
1
12,
00
88,
00
10,
70
89,
30
0,4
0
24,
10
75,
90
3,0
0
97,
00
dM1AI = 0,55 dM1AE = 0,33 dM1BI = 0,36 dM1BE = 0,26
TABLE 4.
The ponder values (pi) of the fractions from the sieving machine classifier sieves and of the cumulative
weights Ti(%) for the collected gritting, at entrance “I” and exit “E” from the mentioned rolls (only M1A,
and M1B), [9]
~ 87 ~
Bre
ak
Equival
ent
size(I/E
)
Grindi
ng
degree
Bulk
dens
ity
True
densi
ty
Specifi
c
surface
Surface
increas
e
Poros
ity
mm λg/
dm3
g/
dm3
x1
03m2/kg
x1
03m2/kg%
M1
A
0,55-
0,331,68
560,
0-
389,
5
1344,
9-
1247,
1
8,13-
14,726,595
58,3-
68,7
M1
B
0,36-
0,261,385
583,
5-
499,
0
1338,
7-
1372,
0
12,34-
16,724,38
56,4-
63,6
M20,19-
0,171,113
480,
5-
437,
5
1233,
3-
1313,
4
26,04-
27,551,513
61-
66,7
M30,35-
0,450,788
363,
5-
308,
5
1252,
9-
1119,
8
13,55-
11,95-1,605*
71-
72,4
M40,22-
0,240,940
452,
5-
419,
5
1290,
6-
1290,
6
21,02-
19,76-1,252*
64,9-
67,5
M5 0,22- 0,924 430, 1205, 22,74- -1,854* 64,3-
~ 88 ~
0,24
5-
419,
5
4-
1210,
2
20,89 65,3
M60,24-
0,270,903
416,
0-
373,
0
1274,
4-
1224,
5
19,40-
18,23-1,164*
67,4-
69,5
TABLE 5.
The values of grinding degree, specific surface, surface increase and porosity
[i] - The sign * in table 3, for negative values of specific surface increases, means that at the passage
through milling rollers with smooth surface, agglomeration of gritting particles occurs.
Based on the data obtained from the experiments and presented in table 6, were mapped graphics, using
MS Excel version 7.0 program (fig.6), the variations of mean diameter and bulk density to technological
breakage passage of milling unit.
Physical
characterist
ic
Sr
.1
-I
Sr
.1
-E
Sr.
2-I
Sr.
2-E
Sr.
3-I
Sr.
3-E
Sr.
4-I
Sr.
4-E
Sr.
5-I
Sr.
5-E
Bulk
density,
ρv (kg/m3)
7
1
3.
0
38
1.
5
482
.0
346
.5
267
.8
292
.0
255
.0
257
.0
269
.0
266
.0
Density, ρ
(kg/m3)
1
2
3
9
12
50
121
9
120
0
110
0
106
3
101
6
113
0
110
0
119
1
Equivalent
size, (mm)
3.
7
6
2.
13
2.2
3
1.2
2
1.5
1
0.9
0
1.0
6
0.8
4
0.6
5
0.6
3
~ 89 ~
Grinding
degree, λ1.76 1.83 1.67 1.26 1.03
Specific
surface,
(m2/kg)
1.
2
9
2.
25
2.2
1
4.1
0
3.6
1
6.2
7
5.5
7
6.3
2
8.3
9
8.0
0*
Surface
increase,
ΔS (m2/kg)
0.96 1.89 2.66 0.75 –0.39*
Natural
slope
angle, ψ
(gr.)
2
1.
8
37
.8
37.
1
37.
5
44.
6
39.
0
41.
1
39.
2
42.
6
44.
4
Porosity, ε
(%)
4
2.
5
69
.5
60.
5
71.
1
75.
7
72.
5
74.
9
77.
3
75.
5
77.
7
TABLE 6.
Physico-mechanical characteristics of grinding products at gristing passages of wheat, from the mill with
capacity of 100 t / 24 h, [10]
Correlation between individual volume of the seeds, calculated with the relation:V=(1/6)πlwt(where: l, w, t represent the measured length, width, and thickness of each seed, and the seeds are assimilated with ellipsoid geometrical bodies) and their weight is presented in fig.7.
~ 90 ~
FIGURE 7.
Variation of mean diameter and bulk density of grinding intermediate products on the grinding
technological flow with grinding rollers [15]
Sieves used in granulometric analysis with sieve classifier and the results obtained by analysis are given
in table 7, for each of the five technological passages, at the entry end exit from the respective mill rollers.
l
i(
m
m
)
Sr.1 - E
l
i(
m
m
)
Sr.2 - I Sr.2 - E
l
i(
m
m
)
Sr.3 - I Sr.3 - E
p
i(
%
)
R
i
(
%
)
p
i(
%
)
R
i
(
%
)
p
i(
%
)
R
i
(
%
)
p
i(
%
)
R
i
(
%
)
p
i(
%
)
R
i
(
%
)
0.
00
2
4.
2
0
0.
0
0
0.
00
2.
0
0
0.
0
0
3
4.
7
0
0.
0
0
0.
00
1
3.
4
0
0.
0
0
4
3.
1
0
0
.
0
0
1.
00
8.
4
0
2
4.
2
0
0.
71
6.
0
0
2.
0
0
1
1.
5
0
3
4.
7
0
0.
71
2
2.
5
0
1
3.
4
0
2
0.
6
0
4
3
.
1
0
1.
40
1
5.
1
0
3
2.
6
0
1.
00
1
9.
2
0
8.
0
0
2
2.
2
0
4
6.
2
0
1.
00
2
2.
8
0
3
5.
9
0
2
3.
0
0
6
3
.
7
0
2.
00
2
0.
1
4
7.
7
1.
40
1
3.
9
2
7.
2
1
1.
5
6
8.
4
1.
40
1
2.
0
5
8.
7
5.
1
0
8
6
.
~ 91 ~
0 0 0 0 0 0 0 07
0
2.
80
2
7.
0
0
6
7.
8
0
2.
00
2
9.
5
0
4
1.
1
0
1
4.
9
0
7
9.
9
0
2.
00
2
0.
1
0
7
0.
7
0
7.
2
0
9
1
.
8
0
4.
00
5.
2
0
9
4.
8
0
2.
80
2
9.
4
0
7
0.
6
0
5.
2
0
9
4.
8
0
2.
80
9.
2
0
9
0.
8
0
1.
0
0
9
9
.
0
0
d1E = 2.13 mm d2I = 2.23 mmd2E = 1.22
mmd3I = 1.51 mm
d2E = 0.90
mm
l
i(
m
m
)
Sr.4 - I Sr.4 - E
l
i(
m
m
)
Sr.5 - I Sr.5 - E
p
i(
%
)
R
i
(
%
)
p
i(
%
)
R
i
(
%
)
p
i(
%
)
R
i
(
%
)
p
i(
%
)
R
i
(
%
)
0.
00
2
6.
0
0
0.
0
0
4
2.
6
0
0.
0
0
0.
00
5.
2
0
0.
0
0
5.
8
0
0
.
0
0
0.
71
2
5.
2
6.
2
7.
4
2.
0.
25
3.
9
5.
2
3.
9
5
.
~ 92 ~
2
0
0
0
5
0
6
00 0 0
8
0
1.
00
2
8.
3
0
5
1.
2
0
2
0.
7
0
7
0.
1
0
0.
32
2
1.
1
0
9.
1
0
2
2.
6
0
9
.
7
0
1.
40
1
1.
9
0
7
9.
5
0
3.
6
0
9
0.
8
0
0.
50
2
8.
2
0
3
0.
2
0
2
9.
7
0
3
2
.
3
0
2.
00
7.
8
0
9
1.
4
0
5.
0
0
9
4.
4
0
0.
71
3
5.
3
0
5
8.
4
0
3
2.
7
0
6
2
.
0
0
2.
80
0.
8
0
9
9.
2
0
0.
6
0
9
9.
4
0
1.
00
6.
3
0
9
3.
7
0
5.
3
0
9
4
.
7
0
d4I = 1.06 mmd4E = 0.84
mmd5I = 0.65 mm
d5E = 0.63
mm
TABLE 7.Values of weights (%) pi for the fractions on the shaker sieves of the sifter machine and of the cumulative
percentages Ri (%) for the collected grinded products, at entry “I” and exit “E” from pairs of mentioned
rollers (Sr.1…Sr.5), [10]
Based on the results obtained by granulometric analysis with the sieve classifier were tested by nonlinear
regression analysis, the three laws of cumulative distribution for the refuse of the sieves R(x) (Rosin-
Rammler function, Schuhman function and two parameters logistical function), for products entering the
~ 93 ~
process, and for the products leaving the pairs of rollers, in the gristing phase of the grinding process.
Experimental points and the curves of cumulative distribution for the refuse of the sieves (R(x)), using the
three functions (eq.1, eq.2, eq.3), for some grinding products are presented infig.8.
FIGURE 8.
Correlation between volume and the mass of wheat seeds in an technological mixture (before grinding)
The coefficient values k, a, b, n, α and β, from the cumulative distribution relations Rosin–Rammler,
Schuhman and the two parameters logistical function, as well as the R2 correlation coefficient values
(which verifies the distribution adequacy degree expressed through the (1), (2), (3) relations),
correspondent for the nine analyzed probes (from the five roll pairs) are presented in table 8.
From the analysis and interpretation of the obtained data for the 9 probes, which come from the mill rolls
with rifles (for the coarse gritting in the breaking passages) (fig.9), following conclusions were found:
For the vast analyzed material probes, from the mills flux, the best law of cumulative distribution is
the Rosin-Rammler (1) with a correlation coefficient R2≥0.982, time in which the Schuhman type
distribution law with a correlation coefficient R2≥0.933 (usually R2≥0.956) can be used with
satisfactory results, in these cases;
For the two parameter distribution law, the R2 correlation coefficient presents close values from the
ones obtained through the Rosin-Rammler function, R2≥0,963, at half the probes being very close;
The total grinding degree of the wheat breakage phase at the analyzed mill is approximately λ = 7,
correspondent to a coarse gritting (crushing);
It is appreciated that, in all cases, at seeds wheat grinding in the complex roller mills, we can consider
that the best law of distribution is the Rosin-Rammler (1), (R2≥0,982), but the other methods,
Schuhman and two parameter logistic, also can be used with satisfactory results.
~ 94 ~
FIGURE 9.
The curves described by the cumulative distribution laws (1), (2), (3) towards the experimental points
R(%) for the gritting product from the five roll pairs (Sr.2…Sr.5) [10]; (I-entrance; E-exit); Rosin-
Rammler; - - - - Schuman; ― ‧ ― ‧ logistical function)
Law
type
Co
eff.
Sr.
1-
E
Sr.
2-I
Sr.
2-
E
Sr.
3-I
Sr.
3-
E
Sr.
4-I
Sr.
4-
E
Sr.
5-I
Sr.
5-
E
~ 95 ~
Rosin-
Ramm
ler
(eq.1)
b0.2
24
0.1
14
0.6
65
0.4
11
1.0
25
0.7
01
1.1
69
2.4
72
2.6
52
n1.6
59
2.3
02
1.3
82
1.7
47
1.6
82
2.2
20
2.0
93
2.8
52
2.8
17
R20,9
88
0,9
87
0,9
96
0,9
82
0,9
96
0,9
96
0,9
96
0,9
98
0,9
99
Schuh
man
(eq.2)
k4.2
01
3.3
98
2.8
93
2.9
66
2.5
31
2.5
32
2.4
31
1.0
25
1.0
16
a0.9
96
17
23
0.6
74
0.9
60
0.4
95
0.7
11
0.4
64
1.7
10
1.6
39
R20,9
99
0,9
81
0,9
85
0,9
56
0,9
58
0,9
33
0.9
40
0,9
91
0.9
87
Logist
ic with
two
param
eters
(eq.3)
α2.5
73
3.7
01
2.2
43
2.7
44
2.7
60
3.3
97
3.2
16
4.3
47
4.3
03
β
-
1.2
45
-
1.6
66
-
2.0
53
-
1.9
81
-
3.3
45
-
3.3
80
-
4.0
56
-
6.7
39
-
6.8
78
R20.9
84
0,9
74
0.9
72
0.9
63
0.9
88
0.9
95
0.9
94
0.9
97
09
97
TABLE 8.
The coefficient values a, k, b, n, α and β and of the R2 correlation coefficients, for the three size distribution
laws tested, for the gritted products from the „I” entry to the „E” exit between the mentioned roll pairs
(Sr.1...Sr.5), [10]
In plansifter compartments, material fractions are separated and sorted, as any granular material is made of
particles with sizes between a minimum and a maximum value, in the interior of the mixture the size
distribution being characterised by various distribution laws.
~ 96 ~
It must be mentioned that material particles, being extracted from various areas of the seed (from exterior
to interior) have different mechanical characteristics and composition. This, and the different sizes of
particles gives a different behaviour of the particles during grinding.
Thus is important to study and to know the size distribution of the particles of each fraction obtained in
each frame set of the six plansifter compartments.
Size of sieve holes used for the experiments and the amount of material fractions on each sieve (individual
and cumulative) for the separated material are presented in table 9.
l
C1
Entra
nce li
(
m
m
)
C
1
B
r
e
a
k
2
li
(
m
m
)
C1
DIV1
’
l
C
1
Fli
(
m
m
)
C
1
D
I
V
1
”
li
(
m
m
)
C1
M2
p
T
i
(
%
)
p T
p
i
(
%
)
T p T p T
p
i
(
%
)
T
0 2
0
.
0
0
0
.
0
0
0
1 0
0
.
0
0
0
1
.
1
0
0 0 4 0
0
.
0
0
0
6 0
0
.
0
0
0
0
.
6
0
0
1 8 2
4
.
2
1
.
0
0
2 1 0
.
1
8
2
.
3
0
1 0 4 4 0
.
1
2
8 6 0
.
0
9
1
.
9
0
0
~ 97 ~
0 0 0 5 0
1 1
3
2
.
4
0
1
.
4
0
0
1 3
0
.
2
5
0
5
.
0
0
3 0 2 4
0
.
1
8
0
1 1
0
.
1
2
5
4
1
.
5
0
2
2 2
4
7
.
5
0
2
.
0
0
0
2 4
0
.
4
0
0
5
1
.
7
0
8 0 1 7
0
.
2
5
0
2 2
0
.
1
8
0
1
5
.
0
0
4
2 2
6
7
.
7
0
2
.
5
0
0
2 6
0
.
6
3
0
2
8
.
6
0
6 0 6 9
0
.
3
1
5
3 5
0
.
2
0
0
3
0
.
1
0
5
4 5
9
4
.
8
0
4
.
0
0
0
1 8
0
.
7
1
0
1
1
.
3
0
8 0 1 9
0
.
4
0
0
1 8
0
.
2
5
0
1
0
.
9
0
8
d1E = 2.13
mm
d1Break2 =
2.27 mm
d1DIV1’ = 0.58
mm
d1F =
0.08
mm
d1DIV1” =
0.31 mmd1M2 = 0.19 mm
l C2
Entra
nce
l C2
Break
3
l C2 DIV1’ l C2 F l C2
M2
li
(
m
m
C
2
D
~ 98 ~
)
I
V
1
”
p
i
(
%
)
T
p
i
(
%
)
T
p
i
(
%
)
T
i
(
%
)
p
T
i
(
%
)
p
T
i
(
%
)
p T
0
3
4
.
4
0
0 0
2
3
.
5
0
0 0
5
.
6
0
0
.
0
0
0 1
0
.
0
0
0 1
0
.
0
0
0
.
0
0
0
0 0
0
1
1
.
5
0
3 1
3
0
.
1
0
2 0
4
.
0
0
5
.
6
0
0 3
1
9
.
1
0
0 9
1
7
.
7
0
0
.
1
2
5
1 0
1
2
2
.
2
0
4 1
1
3
.
5
0
5 0
7
.
7
0
9
.
6
0
0 2
5
4
.
0
0
0 2
2
7
.
1
0
0
.
1
8
0
5 1
1
1
1
.
6
0
6 2
1
7
.
6
0
6 0
2
6
.
1
0
1
7
.
3
0
0 1
7
5
.
6
0
0 9
4
9
.
4
0
0
.
2
5
0
1 7
~ 99 ~
2
1
5
.
0
0
7 2
1
2
.
4
0
8 0
4
9
.
2
0
4
3
.
7
0
0 6
9
1
.
7
0
0 2
5
9
.
0
0
0
.
3
1
5
4 2
2
5
.
3
0
9 3
2
.
9
0
9 0
7
.
4
0
9
2
.
6
0
0 1
9
8
.
4
0
0 1
8
4
.
1
0
0
.
4
0
0
2 7
d2E = 1.22
mm
d2Break3 =
1.56 mm
d2DIV1’ = 0.52
mm
d2F = 0.07
mm
d2M2 =
0.17 mm
d2DIV1” =
0.37 mm
TABLE 9.
Values of weights pi(%) of sieved fractions and of the cumulative weights Ti (%) for products collected at
the entrance, respectively exit of plansifter compartments, C1 and C2
In every fraction there is a percentage of material with sizes smaller than the size of the sieve hole, which
means that sieving is incomplete, even if the number of frames is quite high. However, the average particle
size of fraction C1–Break 2 is 2.27 mm, much larger than the opening of sieve holes of the package (1.05
mm). This shows that here are obtained the parts of seed with quite large sizes, which must be reintroduced
in the grinding process at the passage Break 2.
At the second set of sieving frames of plansifter compartment C1, the opening of fabric holes is 470 µm
(no. 40), but mean size of particles of fraction C1-DIV1’ is 0.58 mm, slightly larger than the opening of the
holes. It is noticed (Table 9) that there are particles with sizes smaller than the size of holes which remain
unseparated (at least 8.4%). This phenomenon is valid for all sets of sieves in the plansifter with six
compartments, as can be seen from the analysis of the results presented in table 9.
Composition of fraction C1-DIV1” of plansifter compartment C1 consists of the refuse of sieve frames no.
56 (with holes opening 0.31 mm), after the sieved of the second set, consisting of particles that passes
through sieve no. 40 (with holes opening 0.47 mm) was extracted flour F (mean size of particles 0.08 mm).
This fraction with fraction C1-DIV1’ and with the two fractions C2-DIV1 of the second plansifter
compartment are directed to the sorting-dividing compartment DIV1 (compartment C5). Mean particle
~ 100 ~
sizes of fraction DIV1”, from compartment C1, are 0.31 mm (equal to the opening of sieve holes which
refused them, proving that here also the sieving is incomplete).
The last components of plansifter compartments in gristing passage shave higher content of coating
particles which are found in the upper layers of material on the frames, thus being recommended that they
do not separate through the holes, even if their sizes are about the size of endosperm particles, to be further
removed in semolina machines (sieving motion leads to the layering of mixture components by density).
Flour particles have mean sizes under 0.18 mm in all plansifter compartments, while particles of last refuse
from the five passages fitted with pairs of rollers have mean sizes over 0.37 mm (see Table 9). Values of
coefficients b and n in the equation of relationship Rosin–Rammler cumulative distribution law (eq.1), for
the material which passed through sieve holes in granulometric analysis, and the correlation coefficients
R2 and χ2 have high values which show the adequacy degree of the given function with the experimental
data. In all cases, for all fractions obtained during gristing phase of wheat in the studied mill, the
correlation is very good, appreciated by values of coefficient R2≥ 0.926.
As it can be noticed from fig.10, there are fractions having most particles of sizes close to the minim value
of sieve classifier holes, but there are also components with particles with sizes from the mean size to the
maximum size of the sieve holes used for granulometric analysis.
However, most components show mean profile (with central inflection point) of the separation curves
which demonstrates the correct choosing of sieve classifier sizes (made from a set of 30 sieves by trying to
take into consideration the arrangement in geometric distribution with holes ratio of2√).
From the analysis of coefficients b and n from Rosin–Rammler law (eq.1) it is noticed that values of
coefficient b are 0.2–1.5 103 for most analyzed fractions, generally with high values, for the small size
components of the particles (flour or dunsts), 1 106 – 5 107, giving the size characteristics of such particles
(Table 10).
Plansifter
compartm
ent
b nR
²χ²
Plansifter
compartm
ent
b nR
²
χ
²
C
1
C
1
E
nt
ra
0.
2
2
2
1
.
6
6
3
0
.
9
8
8
1
7.
0
3
9
C
4
C
4
E
nt
ra
0.
62
1
1
.
9
5
8
0
.
9
8
8
2
1
.
9
1
~ 101 ~
nc
e
nc
e4
C
1
Br
ea
k
2
0.
1
6
9
1
.
9
6
4
0
.
9
8
7
1
8.
8
9
0
C
4
F
2.
06
·1
03
5
.
6
6
5
0
.
9
9
7
1
.
1
4
4
C
1
D
I
V
1”
3
7.
8
1
2
3
.
4
1
2
0
.
9
9
3
9.
1
4
7
C
4
M
4
1.
15
1⋅
03
3
.
9
6
7
0
.
9
7
6
3
6
.
4
1
4
C
1
D
I
V
1’
1
5.
7
8
2
6
.
0
3
3
0
.
9
9
7
6.
2
4
5
C
4
F
T
2
0.
02
7
4
.
5
5
7
0
.
9
9
6
9
.
0
7
1
C
1
F
2.
2·
1
03
3
.
0
5
1
0
.
9
3
8
1
4
2.
8
2
7
C
4
Br
ea
k
5
2.
59
0
2
.
9
8
3
0
.
9
9
9
1
.
0
9
1
C
1
M
2.
8
6·
5
.
0
0
.
9
2
0.
4
C
4
M
1.
6·
10
6
.
0
0
.
9
3
.
3
~ 102 ~
21
03
2
8
8
8
4
05 3
5
4
9
9
7
0
TABLE 10.
Values of coefficients b and n and correlation coefficient R2 for Rosin – Rammler granulometric
distribution, for the granulometric distribution law for fractions of the two plansifter compartments
Values of exponent n indicate the uniformity or the irregularity degree of particles from the analyzed
fractions.
The analysis of this exponent values for the fractions of each plansifter compartment (Table 9) shows that
they have a wide range of values, even for the same type of grinding product (for example flour – F),
which shows the irregularity of particles, both for a given fraction and between fractions.
FIGURE 10.
Curves of granulometric distribution given by eq. (1) in correlation with experimental data for grinding
fractions in plansifter compartments during gristing phase of wheat in a mill with capacity of 100 t /24 h
4. Some mechanical characteristics of wheat seeds in uniaxial compression testsMain stress to which seeds are subjected, while passing through mill rollers, is given by the type of rollers
surface, namely smooth or fluted. Regardless the surface type, one of the main stress during grinding is
compression (or crushing), especially if the mill rollers have smooth surface. To estimate the behaviour of
seeds while passing through the rollers, experimental research is required on the compression stress of
~ 103 ~
seeds from various wheat varieties, knowing that not all varieties have similar mechanical characteristics.
Even seeds from the same variety have different behaviour, due to the irregular development stage in the
ear, and also from one ear to another.
The compression of wheat seeds is performed in three different stages: the first stage is elastically
deformation, characterized by the proportionality between the compression force and the deformation; the
second stage is plastic deformation, characterized by large increases of seed deformation at small increases
of compression force; the last stage consists in cracking or rupture, being characterized by seed crushing
when reaching a certain value of compression force, [17-20].
Compression test is an objective method for determining the mechanical properties of cereal seeds and also
one of the best techniques for determining the modulus of elasticity by the study of their behaviour at
compression stress, using force-deformation curve, [21,22].
By performing uniaxial compression tests on wheat seeds, force-deformation curve is obtained, giving the
possibility to determine hardness, apparent modulus of elasticity, crushing resistance, force and
deformation and energy consumption in various specific points of the curve (i.e. rupture point) and
maximum stress in the material, [21,23].
Cereal seeds have a different behaviour under the action of compression forces, depending on their
moisture content, [17,20], variety, development stage, geometric sizes, individual mass, glassiness, (soft
cereals and hard cereals) etc.
In fig.1 is presented a typical force-deformation curve for compressed Flamura wheat seed.
The bioyield point is the point on the force – deformation curve at which the force decreases or remains
constant with increasing deformation. Force in the rupture point (rupture force) is the minimum required
force for the wheat seed to break (rupture). Deformation at bioyield and rupture points is the deformation at
loading direction, [24,25]. Values of force and deformation to bioyield and rupture points are directly read
from force-deformation curve and recorded by machine used for compression test, [21].
Energy absorbed in bioyield and rupture points could be determined from the area under the force-
deformation curve between the initial point and the bioyield and rupture point, respectively, using equation
[24,25]:
W=FD2(mJ)(9
)
Options
where: W is energy absorbed (mJ), F is force in bioyield or rupture point (N), D is deformation in bioyield
or rupture point (mm), (see fig.11).
~ 104 ~
FIGURE 11.
A typical force –deformation curve of wheat grain (type Flamura), [20]
Based on a standard method (ASAE 2008, [21]), for a seed placed between two parallel plates, the modulus
of elasticity could be calculated with following equation, [20,2 1 ,21]:
E=0.338k3/2uF(1−μ2)D3/2[1R'+1R1']1/2(10
)
Options
where: E – modulus of elasticity for cereal seeds, (MPa); ku – coefficient which depends on the geometrical
properties of wheat seeds (ku = 1,303 - adapted from calculus tables of Kozma and Cunningham,
1962); F – compression force, (N); D – seed deformation (m); µ - Poisson ratio, (µ = 0,3 for wheat
seeds); R' and R'1 – small and large radius of the curvature of convex surface seed in contact with the flat
surface, (m), (see fig.12, left).
FIGURE 12.
Estimation of curvature radius and force-deformation curve of wheat seed, (adapted from [25,26]) PL –
proportional limit; PI – point of inflection; Pc – point of calculation
According to the standard method (ASAE 2008, [21]), also presented by Mohsenin in [25,26], curvature
radius of convex surface, R' and R'1 (fig.12) can be calculated using relations (11) and (12):
~ 105 ~
R1' H+L≅ 2/42H
R' H2≅
(1
1)
where: H is seed thickness, (m), and L is seed length, (m), in undistorted state.
This method was used by many researchers to determine the modulus of elasticity for different agricultural
products, [27-30].
According to the standard method (ASAE 2008), values of force F and deformation D, from equation
(2) are calculated for the proportionality area of force-deformation curve in the point of
calculation Pc(fig.12). The position of this point is estimated visually, as the point is located halfway
between curve origin and proportionality limit PL (fig.12, right). It was found that the point of
calculation Pc is located lower than the point of inflection, also established visually, [21].
To determine the variation of mechanical resistance characteristics of wheat seeds from the same variety,
compression tests were performed for sets of 100 seeds of three varieties of Romanian wheat (Flamura,
Glosa and Trivale – soft wheat), using Hounsfield mechanical testing machine, at a constant speed of the
crushing device of 5 mm min-1, using a force cell of 1000 N. Were graphically plotted the force-
deformation curves for each seed, and from each diagram were collected data about: force, deformation
and energy absorbed in the bioyield point (F1, ε1, W1), respectively in the final point (rupture), (F2, ε2, W2).
The analysis of measured data showed that the seeds of Flamura variety were larger than Trivale variety,
for all three main sizes, and for their volume. The same goes for seeds mass. Flamura variety seeds were
more uniform as size and mass. Regarding the mechanical characteristics of wheat seeds, it was found that
compression forces, for bioyield point and for final seeds crushing, were smaller for Trivale variety than
Flamura. The same goes for energy absorbed to the bioyield point, respectively to crushing. Since the sizes
of Trivale seeds were smaller than Flamura seeds, the deformations carried to the bioyield point,
respectively to crushing, were smaller for Trivale than Flamura, but the standard deviation of the values
was smaller for Flamura for deformations, showing that Flamura seeds were more regular in terms of
deformations (until crushing).
In fig.13 are presented two examples of force-deformation curves for two varieties of wheat, and
infig.14 are presented the histograms of bioyield force and energy absorbed for seed crushing.
FIGURE 13.
Examples of force-deformation curves for the two wheat varieties, [23]
On the histograms were traced the variation curves for the analyzed parameters by regression analysis of
the values given by the histogram, using the normal function presented in equation (13), [23]:
~ 106 ~
px=100a12π−−√be−12(x−cb)2(13
)
Options
where: px(%) is the percentage weight of each class interval (number of seeds with values in the considered
class interval); a – class interval for each analyzed parameter; b and c are regression coefficients of the
analyzed function (b is the standard deviation, c is the values mean).
Values of coefficients for the regression function used in statistical analysis and values of correlation
coefficient R2 for data given by histograms are presented in
Measured
parameter
s of wheat
seeds
Flamura wheat variety Trivale wheat variety
a b c R2 a b c R2
Length l,
(mm)
0.2
0
0.40
46.443
0.98
9
0.2
0
0.50
16.186
0.97
1
Width w,
(mm)
0.1
0
0.20
23.429
0.97
4
0.2
0
0.28
42.994
0.98
1
Thickness
t, (mm)
0.2
0
0.24
83.058
0.97
5
0.2
0
0.31
52.664
0.98
3
Mass m,
(g)
0.0
1
0.00
80.051
0.98
8
0.0
1
0.00
90.037
0.98
1
Volume
V, (mm3)
5.0
0
5.87
035.57
0.96
8
5.0
0
6.20
726.23
0.98
5
Bioyield
force F1,
(N)
20.
0
41.3
6
122.6
4
0.92
1
20.
0
39.4
8
104.7
0
0.88
8
Bioyield
energy
0.0
1
0.02
4
0.036 0.92
3
0.0
1
0.01
7
0.026 0.88
4
~ 107 ~
W1, (J)
TABLE 11.
Values of coefficients for regression equation (eq.13) and its correlation with experimental data [20]
FIGURE 14.
Histograms and variation curves for the force in bioyeld point and the energy consumption in rupture point
for wheat seeds
Analysis of histograms and variation curves, as well as of data in table 11, shows that all analyzed
parameters have almost normal distribution, assessed by values of correlation coefficient R2.
Using standard method (ASAE 2008, [21]) and equations (10), (11) and (12) were determined the values of
modululs of elasticity for wheat seeds of Flamura, Trivale and Glosa varieties, in this paper being
presented their mean values, (table 12).
Fig.15 shows the machine used for uniaxial compression tests between parallel plates of weat seeds and
their position.
From the sample of 100 determinations for each variety of wheat, were selected the 50 most representative
determinations, being kept the values found for force and absolute deformation of the seed.
Force-deformation curves, for each of the 50 determinations (of a variety) were processed so that each has
the same origin (same starting point), and the intervals of reading (recorded) to be the same. Values for the
parameter on the ordinate (forces in the mentioned points) were averaged (arithmetic average for the 50
determinations was calculated) for the same value of deformation (parameter on the abscissa), and these
values were used to retrace the force-deformation curve, which respresents the curve of mean values of
compression force (fig.16). Using the approximately normal distribution, were statistically estimated the
~ 108 ~
limits within which the mean force-deformation curve is found, for a confidence interval of 95%. For
normal distribution, the confidence interval corresponding to 95% confidence level ranges between +/-
1,96, considered standard deviations. Thus, the confidence interval of mean curve was calculated using the
following equation:
μ=m±1.96σn−−√(14
)
Options
where: μ is the confidence interval, and m is the mean value of the analyzed parameter (in this case, the
compression force) andσ/n−−√=Sm
is the standard error of the mean, σ – standard deviation, and n–number of seeds from each variety of wheat (in this paper, n = 50).
On the curve of mean values (fig.16), were determined the values of mechanical characteristics mentioned
before (forces and deformations in the characteristic points) and it was calculated the value of modulus of
elasticity using the standard method (ASAE 2008, [21]), for mean curve (for the three varieties of wheat).
FIGURE 15.
Hounsfield - Mechanical testing machine used in compression test [20]
Knowing the forces and deformations in the points of bioyield and rupture, from the area under the force-
deformation curve between the initial point and the bioyield and rupture point, respectively, using equation
(1), energy absorbed in bioyield and rupture point was determined.
Measured parameters of
wheat seeds
Mean of parameters valuesValues of parameters read from
the mean curve
Flamu
ra
Triva
le
Glo
sa
Flamu
ra
Triva
le
Glo
sa
Bioyield force Fb, (N) 93.2 83.1 98. 98.4 81.1 94.
~ 109 ~
0 0
Bioyield energy Wb, (J) - - - 0.0280.01
8
0.0
16
Rupture force Fr, (N) 107.8 90.5103
.6104.2 83.2
94.
7
Rupture energy Wr, (J) - - - 0.0380.01
8
0.0
16
Bioyield
deformati
on
Relative
deformati
on, δb
0.1380.09
2
0.0
77- - -
Absolute
deformati
on,
Db (mm)
0.3040.26
7
0.2
600.464
0.34
8
0.2
92
Rupture
deformati
on
Relative
deformati
on, δr
0.0990.10
9
0.0
86- - -
Absolute
deformati
on,
Dr (mm)
0.4190.32
0
0.2
900.576
0.40
0
0.3
60
Modulus of elasticity,
(MPa)313 364 486 298 369 468
TABLE 12.
Values of measured and determined parameters in uniaxial compression test [20]
~ 110 ~
Analysis of data presented in table 12 showed that the values of bioyield force, respectively values of the
force in the point of rupture of wheat seeds, determined from the mean curve are very close to the values of
these forces obtained from the force-deformation curves for each particular seed.
FIGURE 16.
Mean curves force-deformation for three wheat varieties and 95 % confidence interval, [20]
Analysis of curves presented in figure 15 shows that they have similar shapes for the three varieties of
wheat, and also within each of them and the force-deformation curves for each individual seed analyzed
from each variety of wheat.
As absolute values of the force in the bioyield point, respectively in the rupture point, they are found in
between 83.1 N for Trivale variety and 98.0 N for Glosa variety regarding the bioyield force, respectively
90.5 N for Trivale and 107.8 N for Flamura (values calculated with arithmetic average of the 50
determinations). These values are very close to the values presented in literature [31], where is stated that
crushing force (rupture) of wheat seeds is of approximately 100 N.
On the relative deformation of seeds, during the compression tests, for the force in the bioyield point
(bioyield force), respectively rupture, data in table 12 also show relatively close values for the wheat seeds
of the three varieties.
5. ConclusionsDevelopment of technological gristing process of the wheat in a mill is very important for the entire
technological flow of the mill, having a great influence on the degree of flour extraction, without excessive
grinding of seed coating.
Based on material samples taken from the entrance and exit of each pair of milling rollers it can be
determined, by laboratory analysis, the equivalent average sizes of the material, grinding degree in the
passage, and the specific surface of material particles.
~ 111 ~
Granulometric analysis of the material to be grinded or of the grinded material at mill rollers, and of the
sorted fractions in plansifter compartments show a distribution after multiple known laws, from which
most used is Rosin-Rammler distribution function, with high correlation coefficient R2.
However, it is shown that there can also be used with good results the Schuhman and logistical two
parameters distribution laws, the finding suggest that the type of granulometric distribution law which best
describes the size of grinded biological materials depends on material nature and the place and role of
roller mill used for grinding in the general technological flow. Knowledge of adequate mathematical
models describing the size distribution of grinded materials is useful in all engineering activities related to
the processes on the flow of complex roller mills of last generation.
Values of mechanical characteristics of wheat seeds (regardless the variety) are necessary to estimate the
energy consumed for their grinding in grain mills. A great influence on the grinding energy is given by the
crushing force and their relative and absolute deformation, determined by experimental research of uniaxial
compression.
For some wheat varieties presented in this chapter, compression force in the rupture point, determined from
force-deformation curves has values of 100-110 N, for seed moisture content of about 12%.
Crushing energy has values of 0.02-0.04 J, for each wheat seed, but it is influenced by the moisture of
seeds and by seed arrangement during compression: on width ”sideways” or on thickness ”laying flat”.
Regarding the modulus of elasticity, its values are between 313-487 MPa, being greater as moisture is
lower. It was found that lower moisture content resulted in higher values of modulus of elasticity and to
lower values of rupture energy, which confirm that wetter seeds have greater plasticity than dry seeds, so
they have higher energy consumption.
~ 112 ~
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