The turnkey project (EPC+O&M) covers a rice processing capacity of 30-300 t/day, and can produce rice protein powder with a protein content of ≥ 80% and by-product rice starch syrup. The entire set complies with EU CE and FDA food grade specifications.
1、 Core processes and equipment
a. Raw material receiving and flexible rice brushing
-Vacuum grain suction device+500 ton vertical silo, low-temperature circulation (<14 ℃) insect proof; The bottom of the warehouse is converted into meters, and the flow rate is automatically matched with the later stage.
-Flexible rice brushing machine (rubber+nylon composite roller), with a crushing rate of<0.5% and a surface bran layer removal rate of ≥ 95%, reducing the burden for subsequent color selection.
b. Intelligent rice matching and vacuum jet conveying
-A four channel color sorter (0.1 mm CCD) is used to remove lesion particles; PLC automatically adjusts the proportion of different varieties according to the protein content target, with an accuracy of ± 0.3%.
-Vacuum+jet (Venturi) combined transportation, with a pipeline wind speed of 18 m/s and a 30% reduction in fragmentation rate, while achieving multi-point entry and exit to reduce bucket residue.
c. Drainage crushing&ultrafine crushing
-The three-axis drain machine reduces the surface moisture content to 12%; Vertical impact mill (160 kW) with a single fineness of 120 mesh; The ultra-fine crusher is equipped with a grading wheel, D90=45 µ m, providing a larger specific surface area for enzymatic hydrolysis.
d. Screening, enzymatic hydrolysis, and dehydration separation
-High amplitude screening removes>80 µ m coarse fibers; Continuous jet liquefier (α - amylase, 105 ℃/8 min) DE 12-15.
-Three phase spiral centrifugation: heavy phase fiber, light phase glucose syrup, medium phase protein slurry (12% dry matter); The protein recovery rate is ≥ 92%.
e. Diaphragm pressure filtration&airflow drying
-A high-pressure diaphragm filter press (1.6 MPa) is used to press the protein slurry into a filter cake with a water content of 45%; Pulse airflow drying tower (inlet air 160 ℃/outlet air 75 ℃) instantly dehydrates to ≤ 7%, retaining whiteness L * ≥ 88.
f. Screening, powder blending, and online removal
-Ultrasonic vibrating screen (80-120 mesh optional) → Weight loss scale for batch addition of vitamins and minerals; Metal detector+magnetic grid combination, completely eliminating Fe with a diameter of ≥ 0.3 mm.
g. Packaging and storage
-Fully automatic FFS machine: 25 kg valve pocket 600 bag/h; Robot palletizing (5-axis)+high-level forklift are sent into the three-dimensional warehouse, and inventory management is integrated with ERP.
2、 Intelligent Control and Data
-DCS+cloud SCADA, 5000+I/O points; AI algorithm predicts cleaning nodes, reducing CIP water consumption by 28%.
-Online NIR detects protein, moisture, and whiteness every 5 seconds, automatically adjusts filter pressure and drying temperature to ensure batch CV<1%.
3、 Main performance indicators
-Rice → protein powder yield 7% (protein 80%), glucose syrup yield 18%;
-Steam 1.6 t/t powder, electricity consumption 580 kWh/t powder, comprehensive energy consumption reduced by 20% compared to traditional batch production;
-Dust emissions<10 mg/m ³, noise<75 dB (A), in compliance with Thailand and Vietnam Green Factory 4.0 standards.
4、 Turnkey scope
Process design → equipment manufacturing → installation and commissioning → personnel training → certification (HALAL/BRC/organic) → operation and maintenance management; The construction period is 10-12 months, and the investment recovery is about 3.5 years.
5、 Conclusion
This fully automated production line is based on six core technologies: flexible rice brushing, vacuum jet, ultrafine grinding, three-phase centrifugation, diaphragm pressure filtration, and airflow drying. It achieves a fully enclosed, continuous, and intelligent process from raw rice to protein powder tanks, providing a high-value, replicable, and scalable turnkey solution for deep processing of rice.
