Claims:WE CLAIM:
1. A system (100) for gel cooking of paddy, wherein the system (100) comprises:
a control module;
a surge bin (102), wherein the surge bin (102) is configured to receive a hydrated paddy from a hydration tank;
an inlet hopper (105), wherein the inlet hopper (105) is configured to receive the hydrated paddy from the surge bin (102) via a spouting pipe (111);
an alternate arrangement of a plurality of a dynamic steaming chamber (106a, 106b, 106c) and a plurality of a dynamic resting chamber (107a, 107b, 107c) which forms a vertical channel with inlet hopper (105) at inlet end to receive the hydrated paddy and a discharge mechanism (109) at outlet end to discharge the processed paddy, wherein the dynamic steaming chamber (300a) of the plurality of the dynamic steaming chamber (106a, 106b, 106c) consist of two truncated cones with varying curvature angle are joined at the centre, wherein a branched sparger system (300b) is placed at centre of the dynamic steaming chamber (300a) in order to provide uniform steaming to the hydrated paddy, wherein the dynamic resting chamber (400) of the plurality of the dynamic resting chamber (107a, 107b, 107c) consist of cylindrical chamber with truncated cones with shell attachment on the top and bottom to form a cylindrical assembly, wherein the contour shape formed due to the alternate arrangement of the plurality of the dynamic steaming chamber (106a, 106b, 106c) and the dynamic resting chamber (107a, 107b, 107c) enables tumbling of the paddy while traveling down from the inlet end towards the outlet end, thereby getting the uniform steaming for all the paddy grains.
2. The system (100) as claimed in claim 1, wherein a high level sensor (101) and a low level sensor (103) mounted on the surge bin (102) are configured to monitor and control the level of the hydrated paddy in the surge bin (102) using the control module.

3. The system (100) as claimed in claim 1, wherein a Resistance Temperature Detector (RTD) sensor from a set of Resistance Temperature Detector (RTD) sensor (108a, 108b) is mounted on the first and third dynamic resting chamber of the plurality of the dynamic resting chamber (107a, 107b, 107c).

4. The system (100) as claimed in claim 1, wherein the surge bin (102) comprising a slide gate (104) configured for immediate discharge or as an emergency shut off gates to stop the hydrated paddy surges.

5. The system (100) as claimed in claim 4, wherein the slide gate (104) comprising a manual slide and a pneumatic operated slide gate, wherein the pneumatic operated slide gate is controlled by the control module.

6. The system (100) as claimed in claim 1, wherein the inlet hopper (105) comprising a shape of a truncated cone consisting of a perforated stainless-steel sheet with flange on the top and with a shell sheet at the base to facilitate a contour shape.

7. The system (100) as claimed in claim 1, wherein the branch sparger system (300b) comprising a series of horizontal slits arranged zigzag in tetrad pipes (300e) emerging from a central vertical steaming line.

8. The system (100) as claimed in claim 1, wherein the control module comprises a Programmable Logic Controller (PLC).

9. The system (100) as claimed in claim 1, wherein the discharge mechanism (109) comprises rotary discharge gate (RDG), wherein the Programmable Logic Controller (PLC) is configured to receive the signal from the set of Resistance Temperature Detector (RTD) sensor (108a, 108b) to control the rotary discharge gate (RDG).

10. A method (500) for gel cooking of paddy, wherein the method (500) comprising a step of:
Receiving (501) hydrated paddy at a surge bin (101), wherein the surge bin (102) is configured to receive a hydrated paddy from a hydration tank;
Receiving (502) hydrated paddy at an inlet hopper (105), wherein the inlet hopper (105) is configured to receive the hydrated paddy from the surge bin (102) via a spouting pipe (111);
Receiving (503) hydrated paddy from the inlet hopper (105) at a plurality of a dynamic steaming chamber (106a, 106b, 106c) and a plurality of a dynamic resting chamber (107a, 107b, 107c), wherein the plurality of a dynamic steaming chamber (106a, 106b, 106c) and the plurality of a dynamic resting chamber (107a, 107b, 107c) are arranged alternatively in order to form a vertical channel with inlet hopper (105) at inlet end to receive the hydrated paddy and a discharge mechanism (109) at outlet end to discharge the processed paddy, wherein the dynamic steaming chamber (300a) of the plurality of the dynamic steaming chamber (106a, 106b, 106c) consist of two truncated cones with varying curvature angle are joined at the centre,
Providing (504) uniform steaming to the hydrated paddy via a branched sparger system (300b), wherein the branched sparger system (300b) is placed at centre of the dynamic steaming chamber (300a), wherein the dynamic resting chamber (400) of the plurality of the dynamic resting chamber (107a, 107b, 107c) consist of cylindrical chamber with truncated cones with shell attachment on the top and bottom to form a cylindrical assembly, wherein the contour shape formed due to the alternate arrangement of the plurality of the dynamic steaming chamber (106a, 106b, 106c) and the dynamic resting chamber (107a, 107b, 107c) enables tumbling of the paddy while traveling down from the inlet end towards the outlet end, thereby getting the uniform steaming for all the paddy grains;
discharging (505) the processed paddy via the discharge mechanism (109) at outlet end.

Dated this 06th Day of September 2021
 
Priyank Gupta
Agent for the Applicant
IN/PA-1454
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
A SYSTEM AND A METHOD FOR GEL COOKING OF PADDY

APPLICANT:
AGRI PROCESS INNOVATIONS TECHNOLOGIES LLP
An Indian Entity having address as:
No.164 & 165,
KIADB, Obedenahalli Industrial Area,
3rd Phase, Doddaballapur,
Bangalore – 560125 Karnataka. India

The following specification describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application does not claim priority from any other patent application.

TECHNICAL FIELD
The present subject matter described herein, in general, relates to a field of an agriculture processing. More particularly, the present subject matter relates to a system and a method for Gel Cooking of paddy.

BACKGROUND
The concept of conversion of a paddy to a rice is known as the paddy processing. The paddy processing comprising a parboiling system. Further, the parboiling comprises three stages namely a pre hydration (pre steaming), a hydration (soaking) and a post hydration (post steaming / gel cook). The third stage of the post steaming is configured to receive a hydrated paddy from second stage of the hydration. In a conventional system, a batch wise post steaming of paddy decreases the productivity of a paddy processing system. The batch wise post steaming also results in non-uniform quality between the batches. Further, the conventional system of the post steaming is dependent on operator’s skill which will turn into the human errors and non-uniformity. Further, the conventional system of the post steaming did not ensure the uniform thermal treatment, uniform starch gelatinization to each grain of the paddy. Further, non-optimum use of a steam increases the operational cost in the conventional system of the post steaming. Furthermore, a cylindrical or other conventional shape chambers in the conventional system for the post steaming facilitate the steady flow of paddy grains (without tumbling) that will increases non uniform quality of an output paddy grains.
Thus, there is a long-standing need of a system and a method for post steaming / gel cooking of paddy which solves above mentioned problems.
SUMMARY

This summary is provided to introduce the concepts related to a system for post steaming / gel cooking of paddy and the concepts are further described in the detail description. This summary is not intended to identify essential features of the claimed subject matter, nor it is intended to use in determining or limiting the scope of claimed subject matter.

In one implementation, a system for gel cooking of paddy is disclosed. The system may comprise a control module, a surge bin, an inlet hopper, an alternate arrangement of a plurality of a dynamic steaming chamber and a plurality of a dynamic resting chamber. The surge bin may be configured to receive a hydrated paddy from a hydration tank. The inlet hopper may be configured to receive the hydrated paddy from the surge bin via a spouting pipe. The alternate arrangement of the plurality of the dynamic steaming chamber and the plurality of the dynamic resting chamber which forms a vertical channel with inlet hopper. Further, the vertical channel may comprise inlet end to receive the hydrated paddy and a discharge mechanism at outlet end to discharge the processed paddy. Further, the dynamic steaming chamber of the plurality of the dynamic steaming chamber may consist of two truncated cones with varying curvature angle are joined at the centre. Further, a branched sparger system may be placed at centre of the dynamic steaming chamber in order to provide uniform steaming to the hydrated paddy. Further, the dynamic resting chamber of the plurality of the dynamic resting chamber may consist of cylindrical chamber with truncated cones with shell attachment on the top and bottom to form a cylindrical assembly. Further, the contour shape may be formed due to the alternate arrangement of the plurality of the dynamic steaming chamber and the dynamic resting chamber enables tumbling of the paddy while traveling down from the inlet end towards the outlet end, thereby getting the uniform steaming for all the paddy grains.
In another implementation, a method for gel cooking of paddy is disclosed. The method may comprise step for receiving hydrated paddy at a surge bin, wherein the surge bin is configured to receive a hydrated paddy from a hydration tank. The method may further comprise step for receiving hydrated paddy at an inlet hopper, wherein the inlet hopper is configured to receive the hydrated paddy from the surge bin via a spouting pipe. The method may further comprise step for receiving hydrated paddy from the inlet hopper at a plurality of a dynamic steaming chamber and a plurality of a dynamic resting chamber, wherein the plurality of a dynamic steaming chamber and the plurality of a dynamic resting chamber are arranged alternatively in order to form a vertical channel with inlet hopper at inlet end to receive the hydrated paddy and a discharge mechanism at outlet end to discharge the processed paddy, wherein the dynamic steaming chamber of the plurality of the dynamic steaming chamber consist of two truncated cones with varying curvature angle are joined at the centre. The method may further comprise step for providing uniform steaming to the hydrated paddy via a branched sparger system, wherein the branched sparger system is placed at centre of the dynamic steaming chamber, wherein the dynamic resting chamber of the plurality of the dynamic resting chamber consist of cylindrical chamber with truncated cones with shell attachment on the top and bottom to form a cylindrical assembly, wherein the contour shape formed due to the alternate arrangement of the plurality of the dynamic steaming chamber and the dynamic resting chamber enables tumbling of the paddy while traveling down from the inlet end towards the outlet end, thereby getting the uniform steaming for all the paddy grains. The method may further comprise step for discharging the processed paddy via the discharge mechanism at outlet end.

BRIEF DESCRIPTION OF DRAWINGS

The detailed description is described with reference to the accompanying figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

Figure 1 illustrates a system (100) for gel cooking of paddy, in accordance with an embodiment of a present subject matter.
Figure 2 illustrates an inlet hopper (200) of the system, in accordance with an embodiment of a present subject matter.
Figure 3a, 3b, 3c and 3d illustrates a dynamic steaming chamber unit (300a), a branched sparger system (300b), a transverse view of tetrad pipe arrangement (300c), and a tetrad pipe perforation arrangement (300d) respectively, in accordance with an embodiment of a present subject matter.
Figure 4 illustrates a dynamic resting chamber unit (400), in accordance with an embodiment of a present subject matter.
Figure 5 illustrates a method (500) for gel cooking of paddy, in accordance with an embodiment of a present subject matter.

DETAILED DESCRIPTION

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

The present disclosure relates to a system (100) for gel cooking of paddy. In one embodiment, referring to figure 1, the system (100) for gel cooking of paddy may comprise a control module, a surge bin (102), an inlet hopper (105), an alternate arrangement of a plurality of a dynamic steaming chamber (106a, 106b, 106c) and a plurality of a dynamic resting chamber (107a, 107b, 107c). The surge bin (102) may be configured to receive a hydrated paddy from a hydration tank. Further, the surge bin (102) may a buffer bin to feed paddy to the system (100) for gel cooking of paddy continuously. Since there is wet paddy to be handled, the surge bin (102) may be made of stainless steel in construction of grade (202). Further, the feed for the surge bin (102) comes from the hydration tanks (not shown in figure 1), wherein the paddy may be hydrated for a specific duration, based on several factors. Further, a high level sensor (101) and a low level sensor (103) mounted on the surge bin (102) are configured to monitor and control the level of the hydrated paddy in the surge bin (102) using the control module. Further, the signals from the high level sensor (101) and the low level sensor (103) are linked with the control module for maintaining the paddy for continuous gel cooking process. Further, the surge bin (102) comprising a slide gate (104) configured for immediate discharge or as an emergency shut off gates to stop the hydrated paddy surges. Further, the slide gate (104) comprising a manual slide and a pneumatic operated slide gate. The pneumatic operated slide gate is controlled by the control module. Further, the slide gate (104) may be activated or deactivated by the compressed air of an air compressor. Further, compact and economical design of the pneumatic slide gates (104) serves a wide application involving as intermediate discharges, or as cut off valves or as emergency shut off gates to stop material surges. Further, the pneumatic slide gates (104) may consist of a heavy-duty slide plate made of stainless steel having thickness ranging from 3/16" up to 1/2". Further, the corner design of the slide gate prevents the slide plate from binding up while actuating open or closed of the slide gate (104). Further, the alternate arrangement of the plurality of the dynamic steaming chamber (106a, 106b, 106c) and a plurality of a dynamic resting chamber (107a, 107b, 107c) forms a vertical channel. The vertical channel comprises an inlet hopper (105) at inlet end to receive the hydrated paddy and a discharge mechanism (109) at outlet end to discharge the processed paddy. Further, the control module comprises a Programmable Logic Controller (PLC). Further, the discharge mechanism (109) comprises rotary discharge gate (RDG). Furthermore, the Programmable Logic Controller (PLC) is configured to receive the signal from the set of Resistance Temperature Detector (RTD) sensor (108a, 108b) to control the rotary discharge gate (RDG).

Now referring to Figure 2, the inlet hopper (200) is illustrated, in accordance with an embodiment of the present subject matter. The inlet hopper (200) may be configured to receive the hydrated paddy from the surge bin (102) via a spouting pipe (201). Further, the spouting pipe (201) may comprise standard stainless-steel pipes of 200NB which are used for connecting the outlet of various equipment to the subsequent element inlet. Further, the inlet hopper (200) may comprise a truncated cone (202) consisting of a perforated stainless-steel sheet with flange on the top and with a shell sheet at the base. In one exemplary embodiment, the total height of the inlet hopper (200) is 968 mm and the diameter is 677 mm. Further, a slope angle of the inlet hopper at the upper and lower truncated cone is 70 and 110 degrees, respectively. Further, the inlet hopper (200) may attach to the first dynamic steaming chamber of the plurality of a dynamic steaming chamber (106a, 106b, 106c).

Now referring to figure 3a, the dynamic steaming chamber unit (300a) of the plurality of a dynamic steaming chamber (106a, 106b, 106c) is illustrated, in accordance with the embodiment of the present subject matter. Further, the dynamic steaming chamber (300a) of the plurality of the dynamic steaming chamber (106a, 106b, 106c) consist of two truncated cones with varying curvature angle are joined at the centre. In one exemplary embodiment, the system (100) for gel cooking of paddy may consist of three dynamic steaming chambers (106a, 106b, 106c) arranged in odd numbers. Further, the dynamic steaming chamber unit (300a) of the plurality of a dynamic steaming chamber (106a, 106b, 106c) may comprise unique geometrical shape form by attaching two stainless steel truncated cones. Further, the two truncated cones with varying curvature angle of 65 and 70 degree are joined at the centre to form the dynamic steaming chamber (300a). Further, two cones of the dynamic steaming chamber (300a) may comprise height of 366 and 468 mm respectively. Further, the dynamic steaming chamber (300a) may comprise a total diameter at the centre is 760 mm. Further, the dynamic steaming chamber (300a) may comprise total length of 1090 mm. Further, the plurality of the dynamic steaming chamber (106a, 106b, 106c) may anchored vertically to form an assembly by the help of the shell rings at the top and base of each dynamic steaming chamber. Further, the dynamic steaming chamber may comprise an access door (302) for maintenance placed at the upper cone. Further, the steam may be introduced through a stainless-steel inlet pipe (301) attached to the upper shell area of the dynamic steaming chamber (300a).

Now referring to figure 3b, the branch sparger system (300b) is illustrated, in accordance with the embodiment of the present subject matter. In one embodiment, the branched sparger system (300b) is placed at centre of the dynamic steaming chamber (300a) in order to provide uniform steaming to the hydrated paddy. Further, the steam may introduce through the sparger system comprising of a series of horizontal slits arranged in tetrad pipes emerging from a central vertical steaming line. The slits may be designed at varying degrees located at the two sides. The perforations may made at under surface and at end of the tetrad pipes. Further, sparger system (300b) may comprise of three level arrangement of horizontal pipes. Further, each level may distinctly arrange in cross to the other.

Now referring to figure 3c, a transverse view of tetrad pipe arrangement (300c) is illustrated, in accordance with the embodiment of the present disclosure. Further, the branching pipes may comprise slope at an angle of 30 degree corresponding to the subsequent tetrad unit in such a way to cover the total area across the central axis.

Now referring to figure 3d, a tetrad pipe perforation arrangement (300d) is illustrated, in accordance with the embodiment of the present disclosure. Further, the tetrad pipes cover a diameter of 315.5 mm inside the chamber. The zig zag arrangement of spargers facilitates equal distribution of the steam for the paddy fed within the chamber. Further, the outer dimension of the central axis pipe and the branching tetrad pipes is 33.31 mm diameter. The main inlet steam pipe may be connected to the three steaming chambers through an 88.9 mm outer diameter line. Further, the tetrad branched pipes have three rows of perforations (two sides and one bottom), wherein each row of perforation measuring 0.8 x 1.6 mm slit width and length which is of 2:1 ratio respectively. Further, the perforation slit at the sides are distinct form the lower side by a linear fashion with an inclination angle of 25 degree. Further, the lower perforation slit is in the curved shape in comparison to the side slit. Further, the distance between each adjacent sets of perforations gradually decrease towards the centre. Further, the inclinations of pipes and the perforation arrangements may deduce after a series of trails which meet the requirements with maximum efficiency. Further, this design facilitates three-dimensional thermal treatment and equal distribution of low-pressure steam across the chamber for uniform quality of paddy. Further, the steam consumption of this steaming chamber may about 600- 650 kg/hr and the pressure varies between 0.8 to 1.5 bar. Further, the output capacity of gel cooking system may be between 6 (for hydrated paddy) - 12 tph (For dry process). Further, the soaked paddy moves by the influence of gravity and the hexagonal design brings about 360-degree rotation of the paddy.

Now referring to figure 4, the dynamic resting chamber unit (400) is illustrated, in accordance with the embodiment of the present subject matter. Further, the dynamic resting chamber (400) of the plurality of the dynamic resting chamber (107a, 107b, 107c) consist of cylindrical chamber with truncated cones with shell attachment on the top and bottom to form a cylindrical assembly. Further, after completion of each steaming cycle the paddy enters a dynamic resting chamber for resting process for a brief period. Further, the plurality of the dynamic resting chamber (107a, 107b, 107c) follow the plurality of the dynamic steaming chamber (106a, 106b, 106c). Further, the dynamic resting chamber (400) of the plurality of the dynamic resting chamber (107a, 107b, 107c) may consists of a cylindrical stainless-steel chamber with truncated cones with shell attachment on the top and bottom (401, 403) forming a cylindrical assembly. Further, the dynamic resting chamber (400) may comprise a height of 1349 mm and the diameter at the centre 844mm. Further, the upper and lower truncated cones may be attached to the central cylinder at a curvature angle of 52 and 54 degrees. Further, the dynamic resting chamber (400) may be equipped with a Resistance Temperature Detector (RTD) sensor (402) at the first and third the dynamic resting chamber (400) of the plurality of the dynamic resting chamber (107a, 107b, 107c). The two RTD sensors (402) may be mounted on the first and third resting zones ensure the required set temperature to be provided to the grain. Further, this plays a crucial role in regulating the rotary discharge gate (RDG) for sample discharge controlled by the control module. Further, the speed of the emerging paddy is regulated by RDG which varies between 6 to 10 rpm depends on process and the paddy variety.

Now referring to figure 5, a method (500) for gel cooking of paddy is illustrated, in accordance with the embodiment of the present subject matter.

At step (501), the system may be configured for receiving hydrated paddy at a surge bin (101). The surge bin (102) may be configured to receive a hydrated paddy from a hydration tank.
At step (502), the system is configured for receiving hydrated paddy at the inlet hopper (105). In one embodiment, the inlet hopper (105) is configured to receive the hydrated paddy from the surge bin (102) via the spouting pipe (111).
At step (503), the system may be configured for receiving hydrated paddy from the inlet hopper (105) at a plurality of a dynamic steaming chamber (106a, 106b, 106c) and a plurality of a dynamic resting chamber (107a, 107b, 107c). The plurality of a dynamic steaming chamber (106a, 106b, 106c) and the plurality of a dynamic resting chamber (107a, 107b, 107c) may be arranged alternatively, in order to form a vertical channel with inlet hopper (105) at inlet end to receive the hydrated paddy and a discharge mechanism (109) at outlet end to discharge the processed paddy. The dynamic steaming chamber (300a) of the plurality of the dynamic steaming chamber (106a, 106b, 106c) may consist of two truncated cones with varying curvature angle are joined at the centre.
At step (504), the system is configured for providing uniform steaming to the hydrated paddy via a branched sparger system (300b). In one embodiment, the branched sparger system (300b) is placed at centre of the dynamic steaming chamber (300a). The dynamic resting chamber (400) of the plurality of the dynamic resting chamber (107a, 107b, 107c) consist of cylindrical chamber with truncated cones with shell attachment on the top and bottom to form a cylindrical assembly. Further, the contour shape formed due to the alternate arrangement of the plurality of the dynamic steaming chamber (106a, 106b, 106c) and the dynamic resting chamber (107a, 107b, 107c) enables tumbling of the paddy while traveling down from the inlet end towards the outlet end, thereby getting the uniform steaming for all the paddy grains.
At step (505), the system may be configured for discharging the processed paddy via the discharge mechanism (109) at outlet end.
The embodiments illustrated above, especially related to the system for gel cooking of paddy provide following advantages:
• The system for gel cooking of paddy is equipped with continues steaming mechanism for soaked paddy which brings about uniform product with high quality which directly influences high-market value.
• This continuous and special contoured system eliminates the grain-to-grain nonuniformity in comparison to other continuous process and the batch process systems.
• Each paddy grain receives uniform steaming at a uniform rate by the involvement of the branched sparger system which covers the entire spatial area of the steaming chamber.
• Further, the system for gel cooking of paddy is intact with no moving parts with no adjustments and control by virtue of fully automatic sensors and valves to control both paddy and steam. This reduces the human interference and brings about consistent and quality results of the output paddy.

Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure.

The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.