RICE MILL OPERATING SYSTEM

FOR HASHINI FACTORY

CHAPTER TWO

N.ABILASHINI
Registration Number: SEU/IS/13/MIT/043

FACULTY OF MANAGEMENT AND COMMERCE

SOUTH EASTERN UNIVERSITY OF SRI LANKA
Table of Contents
2 CHAPTER TWO BACKGROUND ANALYSIS ................................................. 2

2.1 Introduction ..................................................................................................... 2

2.2 Details and Review of Previously Developed System .................................... 2

2.3 Background Analysis for the Rice mill operating system ............................... 4

2.4 Brief introduction of the Rice mill operating system .................................... 35

2.5 Conclusion..................................................................................................... 39

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 2 CHAPTER TWO
BACKGROUND ANALYSIS

2.1 Introduction
This chapter describes the details and review of previously developed system,
background analysis of the Rice mill operating system. Also it comprised the
functions of the Rice mill operating system under the background analysis and
provides the solution to overcome the problems in the manual system. The new
system will enhance the effectiveness of the manual system. It broadly will consider
about technology environment of new system and what are the advantages of Rice
mill operating system or Hashini Factory.
The Rice milling is the process that helps in removal of hulls and bran’s from
paddy grains to produce polished rice. Rice is rich in genetic diversity with
thousands of varieties grown throughout the world. Rice has been one of man's
most important foods. Today, this unique grain helps sustain two-thirds of the
world's population. It is life for thousands of millions of people. It is deeply
embedded in the cultural heritage of their societies. About four-fifths of the world's
rice are produced by small-scale farmers and are consumed locally. Milling is the
process wherein the rice grain is transformed into a form suitable for human
consumption, therefore, has to be done with utmost care to prevent breakage of
the kernel and improve the recovery.

2.2 Details and Review of Previously Developed System

Nowadays people are interacting with the ICT devices in their day to day life. Thus
they cannot engage with the physical reading materials, such as printed papers,
weighted books and so on. And, the long processes and physical activities of current
existing manual systems are wasting the peoples’ valuable time and days. [Harvey
Dietel, P. (n.d.). C# 2010]

Further, some of the drawbacks being faced in manual system are as follows: Quick
searching and browsing features are not available, Lack of user feedbacks and

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comments, Unable to preview the required materials, Record keeping is difficult,
Backup data can be hard to generated, Lack of proper communication with the
business dealers.

The system that is going to be developed is Rice mill operating system. This is
desktop application system. This project intends to computerize the Rice Mill
Operating System in For Hashini Factory in order to improve the record management
efficiency due to the grown size of records of data. During analysis, data collected on
the various files, decision points and transactions handled by the present system.

The commonly used tools in the system are Data Flow Diagram, interviews, etc.
Training, experience and common sense are required for collection of relevant
information needed to develop the system.
The success of the system depends largely on how clearly the problem is defined,
thoroughly investigated and properly carried out through the choice of solution. A
good analysis model should provide not only the mechanisms of problem
understanding but also the frame work of the solution.
Thus it should be studied thoroughly by collecting data about the system. Then the
Rice mill operating system should be analyzed thoroughly in accordance with the
needs. System analysis can be categorized into four parts. System planning and initial
investigation.

Information Gathering

Applying analysis tools for structured analysis

Feasibility study

Cost/ Benefit analysis.

In existing system all the transaction done manually, so taking more time for a
transaction like getting information and also for searching of recodes. Currently it is
doing as a one-day process for verifying all records. So after conducting the
feasibility study we decided to make the manual Rice Mill Operating System to be
computerized.
Drawbacks and Functions of the current system are listed below.
 Inconsistency in data entry errors, miscuing information.

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  Large ongoing staff training cost.
 System is dependent on good individuals.
 Reduction in sharing information and customer services.
 Time consuming and costly to produce reports.
 Lack of security.
 Duplication of data entry.
 Vulnerability to Human Error: Every system humans work with is vulnerable
to errors made by a distracted, fatigued or incompetent team member.
Automated systems still require human interaction, but reduce the number of
decisions or operations a human must perform.

 Searches Take Longer and are Less Efficient: Searching for a specific
business recodes very difficult.

These are the various work that need to be done in Rice Mill Operating System. All
these works are done on papers. So it is very slow to do the all the works by manual
system. All the records are entered and maintained in separate files. So, to search a
single data of users maintaining processes has to go through every file. It will increase
the work load of the members. There is no enough security in manual system in
maintaining data. [Thomas Connolly and Carolyn].

The manual data handling is relatively inefficient in both processing and reporting.
Report generating process in the existing system is consuming lot of time, because to
generate a report they have to go through every file. So this system going to propose
Rice mill operating system For Hashini Factory to do all these works and activities.

2.3 Background Analysis for the Rice mill operating system

A rice grain is made up of an outside husk layer, a bran layer, and the endosperm, see
The husk layer (lemma and palea) accounts for 20% of the weight of paddy and helps
protect the grain kernel from insect and fungal attack. When the husk is removed, the
rice is called brown rice. Brown rice contains the bran layer and the endosperm. The
bran layer is made up of the pericarp and testa, the aluerone layer and the embryo.
The degree to which this bran layer is removed is known as the milling degree. The

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desired amount of bran removed depends on the country. In sri lamka, the aluerone
layer is often not removed however in many other countries all bran layers are
removed to give very highly polished rice. The storage life of milled rice is improved
when all of the bran layers are removed.

Table 1: Physical characteristics of paddy rice

Physical characteristic Percentage

Paddy 100
Husk 20
Brown rice 80
Meal 8-10
Pericarp and testa (5-
6%) Aluerone (1%)
Embryo (3%)
White rice 70-72

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Location

The establishment shall be located in an area with no adverse impact to the communities.
Effective preventive measures against pollution caused by noise, dust and smoke, generated
during the production operations of rice mill shall be in place. A new rice mill establishment
shall be located away from the community.The establishment shall not be located in an area
that may cause contamination to rice products, such as waste disposal dump sites. If it is
unavoidable, effective preventive measures against the contamination caused by disease
carrier animals and other contaminants that may adversely affect to the quality of rice products
shall be in place.The establishment should be located in an area not subject to flooding. The
location area should be stable without crack or shrinkage which may result in the ground
breaking or sinking.The selected area should have sufficient open spaces to provide areas
for operation separated from office space, accommodation, parking area, waste water
treatment system and other necessary facilities.The location shall be in an area that is
easy to transport and access. Adequate infrastructures shall be available.

A.1.2 Building and operating areas

Drying area

Floor shall be made of smooth concrete, clean, no water logging, and free of rubbish.
In case the floor is not concrete, it shall be covered with materials that are able to prevent
contamination and moisture absorbance from the ground.

The drying area shall be protected from the entry of pets and disease carrier animals,
and/or installed with fences.

Soaking and steaming areas

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Building structure shall be made of strong and durable materials, easy to clean and
maintain.(1) Wall, partition and floor shall be water-proof, non-absorbent, and made of non-
toxic materials suitable for its intended use.

(2) Wall, partition and floor should have smooth surfaces.

(3) Floors should be designed for good drainage and no water-logging.

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Storage areas for paddy, rice products and by-products

A.1.2.3.1 For normal storage with no control of temperature and relative humidity, the paddy
arrangements can be categorized into two methods, bulk and bag storage, such as gunny bags
or plastic bags etc. Such area shall have the following characteristics:

(1) Designated areas for each product shall be provided separately in order to prevent the mix-ups
and contamination, and to allow piles of paddy, rice products and by-product to be arranged
according to types.

(2) Building structure shall be made of durable materials, strong, water-proof, with smooth
surface and non-toxic, and easy to clean and maintain.

(3) Storage areas shall be able to prevent the entry of pests and disease carrier animals, such
as rodents and birds.

(4) Storage areas shall be able to protect against moisture.

(5) Adequate ventilation shall be provided to remove heat and moisture out of piles of
products in order to minimize the damage caused by fungi and storage pests.

A.1.2.3.2 For silo storage, at present, there are three types of silo; (1) single control of
temperature, (2) single control of relative humidity, (3) combination of temperature and
relative humidity controls. Good design of silo shall be as follows:

(1) Silo shall be able to allow effective circulation of paddy or rice products by the basis of
first-in and first-out system without any leftover. In addition, silo and its surrounding area
shall be clean, dry, no drains or any outlet that be able to allow an access of pests and disease
carrier animals, such as rodents.

(2) Silo structure shall be strong and easy to clean and maintain.

(3) Silo shall be able to prevent the entry of pests and disease carrier animals.
(4) Silo shall be able to protect against moisture.

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(5) Silo shall have adequate ventilation, or ambient temperature and relative humidity control
systems in order to prevent the accumulation of heat and moisture affecting the damage to
rice, including the formation of mold and the growth of microorganisms as well as to prevent
the breeding ground of rice pests.

A.1.2.4 Areas assigned for paddy cleaning, dehusking, polishing, grading and rice
product packing

A.1.2.4.1 Areas shall be designed to have adequate operational working spaces and clearly
separated in a logical order corresponding to the sequence of operations in order to facilitate
the operations and provide effective protection against the contamination from pests and
disease carrier animals. Particularly, a separate area for packing of rice products shall be
provided in a closed system as much as practicable so as to minimize the potential risk of
contamination of rice products since the contamination cannot be eliminated after this stage.

A.1.2.4.2 Building structure shall be strong and made of durable and non-toxic materials,
smooth, easy to clean and maintain.

A.1.2.4.3 Adequate areas assigned for paddy receiving and temporary storage of bags
containing polished rice for transport should be at least five times larger than the packing
area being used currently.

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A.1.2.4.4 In case a rice product packing room is constructed, the followings should be taken
into account:

(1) The packing room shall be a closed system.

(2) The building structure shall be durable and strong. Floor and wall shall be strong, smooth
without cracks, made of non-toxic materials, easy to clean and maintain.

(3) The packing room shall be clean. Effective cleaning programme shall be provided.
Personal hygiene shall be controlled.

(4) Effective preventive measures against moisture, dust, pests and disease carrier animals
shall be established and implemented.

(5) Adequate lighting shall be provided in proper positions and installed with protection
covers so as to prevent the contamination of glass debris.

A.1.3 Equipment, machinery and utensils

A.1.3.1 Equipment, machinery and utensils appropriate for production capacity shall be
designed and installed by selecting accurate specifications, types and sizes corresponding to
each production stage with sufficient numbers for operation, and ready for use. In addition,
they should be installed in the positions convenient for operations, cleaning and maintenance,
by taking into account the potential risk of causing contamination.

A.1.3.2 All equipment, machinery and utensils used in the production shall be strong, durable
and made of materials appropriate for operations in each stage of production processes,
provided that they do not cause contamination harmful to the consumer and shed any
particulate matter such as metal and stone particles, paints or lubricant by which the rice
products can be contaminated.

A.1.3.3 All equipment, machinery and utensils used in the production shall be regularly
cleaned and maintained in order to ensure their readiness for use

A.1.2.3 Storage areas for paddy, rice products and by-products

A.1.2.3.1 For normal storage with no control of temperature and relative humidity, the paddy
arrangements can be categorized into two methods, bulk and bag storage, such as gunny bags
or plastic bags etc. Such area shall have the following characteristics:
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(1) Designated areas for each product shall be provided separately in order to prevent the mix-ups
and contamination, and to allow piles of paddy, rice products and by-product to be arranged
according to types.

(2) Building structure shall be made of durable materials, strong, water-proof, with smooth
surface and non-toxic, and easy to clean and maintain.

(3) Storage areas shall be able to prevent the entry of pests and disease carrier animals, such
as rodents and birds.

(4) Storage areas shall be able to protect against moisture.

(5) Adequate ventilation shall be provided to remove heat and moisture out of piles of
products in order to minimize the damage caused by fungi and storage pests.

A.1.2.3.2 For silo storage, at present, there are three types of silo; (1) single control of
temperature, (2) single control of relative humidity, (3) combination of temperature and
relative humidity controls. Good design of silo shall be as follows:

(1) Silo shall be able to allow effective circulation of paddy or rice products by the basis of
first-in and first-out system without any leftover. In addition, silo and its surrounding area
shall be clean, dry, no drains or any outlet that be able to allow an access of pests and disease
carrier animals, such as rodents.

(2) Silo structure shall be strong and easy to clean and maintain.

(3) Silo shall be able to prevent the entry of pests and disease carrier animals.
(4) Silo shall be able to protect against moisture.
(5) Silo shall have adequate ventilation, or ambient temperature and relative humidity control
systems in order to prevent the accumulation of heat and moisture affecting the damage to
rice, including the formation of mold and the growth of microorganisms as well as to prevent
the breeding ground of rice pests.

A.1.2.4 Areas assigned for paddy cleaning, dehusking, polishing, grading and rice
product packing

A.1.2.4.1 Areas shall be designed to have adequate operational working spaces and clearly
separated in a logical order corresponding to the sequence of operations in order to facilitate
the operations and provide effective protection against the contamination from pests and
11
disease carrier animals. Particularly, a separate area for packing of rice products shall be
provided in a closed system as much as practicable so as to minimize the potential risk of
contamination of rice products since the contamination cannot be eliminated after this stage.

A.1.2.4.2 Building structure shall be strong and made of durable and non-toxic materials,
smooth, easy to clean and maintain.

A.1.2.4.3 Adequate areas assigned for paddy receiving and temporary storage of bags
containing polished rice for transport should be at least five times larger than the packing
area being used currently.

A.1.2.4.4 In case a rice product packing room is constructed, the followings should be taken
into account:

(1) The packing room shall be a closed system.

(2) The building structure shall be durable and strong. Floor and wall shall be strong, smooth
without cracks, made of non-toxic materials, easy to clean and maintain.

(3) The packing room shall be clean. Effective cleaning programme shall be provided.
Personal hygiene shall be controlled.

(4) Effective preventive measures against moisture, dust, pests and disease carrier animals
shall be established and implemented.

(5) Adequate lighting shall be provided in proper positions and installed with protection
covers so as to prevent the contamination of glass debris.

A.1.3 Equipment, machinery and utensils

A.1.3.1 Equipment, machinery and utensils appropriate for production capacity shall be
designed and installed by selecting accurate specifications, types and sizes corresponding to
each production stage with sufficient numbers for operation, and ready for use. In addition,
they should be installed in the positions convenient for operations, cleaning and maintenance,
by taking into account the potential risk of causing contamination.

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 1. All equipment, machinery and utensils used in the production shall be strong, durable and
made of materials appropriate for operations in each stage of production processes, provided
that they do not cause contamination harmful to the consumer and shed any particulate matter
such as metal and stone particles, paints or lubricant by which the rice products can be
contaminated.

2. All equipment, machinery and utensils used in the production shall be regularly cleaned and
maintained in order to ensure their readiness for use.

3. The equipment, machinery and utensils shall be checked for accuracy before use, especially
moisture meters, mechanical driers, silos used for paddy and rice storage, stone and metal
particle separators, colour sorters and rice packing machines in order to ensure that they can
perform correctly and effectively.
2.4 Brief introduction of the Rice mill operating system

Paddy or rice grain consists of husk and brown rice. Brown rice, in turn, con tains bran
which comprises the
outer layer and the edible portion. Rice milling is removal or separation of husk (dehusking)
and bran to obtain the edible portion for consumption. The process has to be accomplished
with care to prevent excessive breakage of the kernel and improve recovery of paddy or rice.
The extent of recovery during milling depends on many factors like variety of paddy, degree
of milling required, the quality of equipments used, the operators, etc. Milling is the process
wherein the rice grain is transformed into a form suitable for human consumption,
therefore, has to be done with utmost care to prevent breakage of the kernel and improve the
recovery.Brown rice is milled further to create a more visually appealing white rice.After
harvesting and drying, the paddy is subjected to the primary milling operation which
includes de-husking as well as the removal of bran layers (polishing) before it is consumed.
In this process the rice which is obtained after milling is called raw rice.An other process
through which rice is obtained after milling is called "Parboiling Rice." Nearly 60% of the
total rice produced in India is subjected to parboiling.Rice milling losses may be qualitative or
quantitative in nature. Quantitative or physical losses are manifested by low milling
recovery while low head rice recovery or high percentage of broken kernel reflects the
qualitative loss in rice grains.
 II.METHOD OF MILLLING
2.1) Traditional Method:Before the advent of mechanical milling, hand-pounding
traditional method of rice milling was in practice. In fact, hand-pounding rice has got more
nutritive value as compared to machine milling
rice. In hand-pounding, a variety of implements is used such as :Mortor and Pestle, Hand Stone
(Chakki)etc
2.2) Mechanical Method:With the introduction of mechanized mills, hand-pounding method
has steadily decreased because it could not compete with machine mills. The conventional
mills in use can be categorized into three main types :
• Huller mills
• Sheller-Huller mills
• Sheller-Cone Polisher mills.

III.IMPORTANCE OF MILLING
Milling is a crucial step in post-production of rice. The basic objective of a rice milling system
is to remove the
husk and the bran layers, and produce an edible, white rice kernel that is sufficiently
milled and fr ee of impurities. Depending on the requirements of the customer, the rice should
have a minimum of broken kernels.

IV.THE RICE KERNEL COMPOSITION

Most rice varieties are composed of roughly 20% rice hull or husk, 11% bran layers,
and 69% starchy
endosperm, also referred to as the total milled rice. Total milled rice contains whole
grains or head rice, and brokens. The by-products in rice milling are rice hull, rice germ and
bran layers, and fine brokens.

V.MILLING SYSTEMS
A rice milling system can be a simple one or two step process, or a multi stage
process. In a one step
milling process, husk and bran removal are done in one pass and milled or white rice is
produced directly out of paddy. In a two step process, removing husk and removing bran
are done separately, and brown rice
produced as an intermediate product. In multistage milling, rice will undergo a
number of different processing steps. Depending on whether the the paddy is milled
in the village for local consumption or for the marketing rice milling systems can be
classified into the categories village rice mills and commercial mills.

VI.COMMERCIAL MILLING
Commercial milling systems mill the paddy in stages, and hence are called
multi-stage or multi-pass
rice mills. The objective of commercial rice milling is to reduce mechanical
stresses and heat buildup in the grain, thereby minimizing grain breakage and
producing uniformly polished grain. Compared to village-level systems, the
commercial milling system is a more sophisticated system configured to maximize
the process of producing well-milled, whole grains.
The rice milling facility comes in various configurations, and the milling
components vary in design and performance. “Configuration” refers to how the
components are sequenced. The flow diagram below shows a modern commercial
mill catering to the higher end market.

The new computerized system has been designed and created in a manner to solve all
the problems the For Hashini Factory is currently facing. Using the System, we can
get the following solutions for the current manual system problems. This Rice mill
operating system effective and efficient way to handle the Business.


Prompt updating of information: In the Rice mill operating system, the
information will always remain up to date as the updating will be prompt and
without any efforts.

Fast computation of information: The computation of information will be
quite fast in the Rice mill operating system.

Generation of managerial and strategic reports: The new system would
provide for regular generation of reports which would help the management in
decisions making work and in controlling the over-all working of the
organization.

The new system has to decrease the time and workload, which existing when
done manually, this new system has to lead to less paper works.

Electronic process faster and accurate than traditional paper.

New system has separate options to add, delete and modify the information.

Computer printed reports are clearer than handwritten paper.

To make the system easy to use.

Administrator can search a member record by his/her name.

The system is password protected and the users have to enter a password to
log into the system. This prevents unauthorized users logging into the system.
And it also provides security for the payment options.

Immediate storage of information: In the Rice mill operating system, it will be
easy to store information at any given time at the correct places.
 Accuracy: The level of accuracy in the new Rice mill operating system would
be higher. All operations and computations would be done correctly and this
will ensure that whatever information is coming from the center.

Reliability: The reliability of the Rice mill operating system would be high
due to the above stated reasons. The reason for the increased reliability of the
system is that now there would be proper storage of information, its
maintenance would be well managed and retrieval would be possible in the
desired manner.

Non Redundant Information: In the new system mostly care be taken that no
information is repeated, any usage of storage or otherwise. This would assure
economic usage of storage or space and consistency in the data stored.
reducing paperwork by eliminating the need for hand written records

Staff’s satisfaction: The new system provides faster access to the system and
new features to make work easier. So the work load of the members is
reduced.

Reduced overhead cost: The Rice mill operating system also helps to reduce
the extra cost incurred. The manual system requires lot of paper work and
maintaining.

Reduce work load: Through the automated data handling and user friendly
environment the Rice mill operating system facilitates to reduce the work load
of Hashini Factory.
 
Result generating process and managing books in the existing system is
consuming lot of time, because to provide borrow and rendering facility to
each and every user. The new system provides functionalities to make this
process easier and quickly.

Conclusion

This chapter defines Background Analysis of the system. It includes details of

previously developed system, background analysis for the Rice mill operating system,
and brief introduction of the Rice mill operating system/solution. That mean mainly
identifies the current manual system and their problems and it define how to develop
the new system to removing drawbacks in current system and what are the solutions
provided by the Rice mill operating system to overcome the manual system problems.
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[2]. Harvey Dietel, P. (n.d.). C# 2010 for programmers. Dietel Developer Series.

[3]. Greene, A.S. (Second Edition). Head First C#.

[4]. Sharp, J. (March 2010). Microsoft Visual C# Step by Step. Microsoft Press.

[5]. Simon Bennet, S.M (2nd Edition). Object-Oriented System Analysis and Design.

[6]. Skinner, K.W. (Second Edition). Beginning Visual C#.

[7]. Thomas Connolly and Carolyn E.Begg,Database Solutions, Second

Edition:England:Pearson Education Limited,2004,PP1-98

[8]. Sharp, J. (March 2010). Microsoft Visual C# Step by Step. Microsoft Press.