Description:FIELD OF INVENTION
[0001] Embodiments of the present disclosure relate to the field of gelatinization of paddy, and more particularly, a system and a method for paddy processing based on feedback from sensors.
BACKGROUND
[0002] Paddy parboiling is a post-harvest processing operation that has been practiced for centuries in the Indian subcontinent. Freshly harvested paddy is pre-steamed in large vessels known as "Handi" over a wood or coal fire. However, the paddy has a non-uniform dark yellow coloration, takes a longer time to cook, and has a typical steeping smell. As a result, commercial acceptance of parboiled rice has been limited to rural consumption.
[0003] Direct steam heating from process boilers replaced the conductive fire heating. Steel cylindrical vessels with conical hoppers were built with an internal network of perforated pipes. Steam is fed into the strainer and spreads throughout the tank. The cylindrical vessel was used for all three steps of parboiling: pre-steaming (Kacchi), steeping, and final steaming (Pakki). Among rice millers, this was known as the "One Handi System." All three processes had strict time constraints and required advanced operational skills. Any time lag tends to result in discoloration and batch non-uniformity. As a result, the batch size was limited to 2 tons.
[0004] With automation, time sequencing and with the help of pneumatic Steam flow valves, the process of parboiling was further automated. However, the system was unable to be upgraded from batch to continuous process. Minor improvements were made to split the operation processes into two stages, from "One Handi System" to "Kacchi & Pakki System," to achieve larger soaking batch sizes. There were minor color improvements, and soaking batch sizes were increased from 2 to 6 tons.
[0005] Kachhi system "Final Steaming" was made to be a continuous process by a system called Online-Cooker (OLC) in a recent technological advancement. The Pakki tank was upgraded to a narrow cylinder with a central steam strainer and peripheral perforation at intervals, with provision for steaming and discharge automation. The system though could achieve continuity in the process but had the following issues: non-uniform cooking, dark yellow colorization, and water condensation in the system. However, there is a lack of a such system that reduces dark yellow colorization, non-uniform cooking, and removal of water condensate in the system.
[0006] Hence, there is a need for an improved system and method for paddy processing based on feedback from sensors which addresses the aforementioned issue(s).
BRIEF DESCRIPTION
[0007] In accordance with an embodiment of the present disclosure, a system for paddy processing based on feedback from sensors is provided. The system includes a steaming assembly comprising a plurality of steaming chambers wherein the plurality of steaming chambers is configured to cook paddy uniformly and remove condensed vapor from the paddy throughout the steaming chambers wherein the steaming assembly comprises a top steaming chamber, a middle steaming chamber and a bottom steaming chamber. The top steaming chamber comprising a cylindrical inlet port arranged on a top section of the top steaming chamber and a frustum-shaped outlet port arranged on a bottom section of the bottom steaming chamber wherein the cylindrical inlet port receives the paddy through a pneumatic slide gate wherein the pneumatic slide gate is positioned above the top steaming chamber. The middle steaming chamber comprising a frustum-shaped inlet port arranged on the top section of the middle steaming chamber and the frustum-shaped outlet port arranged on the bottom section of the middle steaming chamber and the bottom steaming chamber comprising the frustum-shaped inlet port arranged on the top section of the bottom steaming chamber and a cylindrical output port arranged on the bottom section of the bottom steaming chamber wherein the cylindrical output port discharges the paddy through a rotary airlock valve wherein the rotary airlock valve is positioned below the bottom steaming chamber wherein the wherein the top steaming chamber, the middle steaming chamber, and the bottom steaming chamber comprises a plurality of strainers wherein each of the plurality of strainers is positioned one above the other at regular intervals extended to an opposite face of the top steaming chamber, the middle steaming chamber and the bottom steaming chamber wherein the plurality of strainers is operatively coupled to an inverted plate positioned at a pre-defined angle between opposite sides of the top steaming chamber, the middle steaming chamber and the bottom steaming chamber wherein the inverted plate prevents overcooking of the paddy and prevents direct contact between the paddy and the plurality of strainers. The system further includes the tempering assembly operatively coupled to the steaming assembly comprising a first tempering chamber and a second tempering chamber wherein the first tempering chamber is positioned between the top steaming chamber and the middle steaming chamber and the second tempering chamber is positioned between the middle steaming chamber and the bottom steaming chamber thereby establishing a consecutive arrangement wherein the tempering assembly is adapted to remove liquid condensate and vapor condensate from the paddy wherein the tempering assembly comprises the first tempering chamber and the second tempering chamber. The first tempering chamber comprising the frustum-shaped inlet port arranged on the top section of the first tempering chamber and the frustum-shaped outlet port arranged on the bottom section of the first tempering chamber and the second tempering chamber comprising the frustum-shaped inlet port arranged on the top section of the second tempering chamber and the frustum-shaped outlet port arranged on the bottom section of the second tempering chamber and the tempering assembly is configured to achieve uniform on-line gelatinization of starch in the paddy. Further, the system includes the rotary airlock valve operatively coupled to the bottom steaming chamber of the steaming assembly wherein the rotary airlock valve provides a required output of the paddy based on a pre-set rotation per minute wherein the rotary airlock valve is operated based on a required temperature of the paddy in the bottom steaming chamber. Further, the system also includes a cooling unit comprising a cooler and a blower operatively coupled to the rotary airlock valve wherein the cooler and the blower comprises a plurality of perforated ports wherein the plurality of perforated ports allows the paddy to pass through and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice. The system includes a processing subsystem hosted on a server. The processing subsystem hosted on a server wherein the processing subsystem is configured to execute on a network to control bidirectional communications among a plurality of modules. The processing subsystem includes a control system module operatively coupled to the steaming assembly, the tempering assembly, the rotary airlock valve, the cooler with the bowler, a pressure regulation valve, and a pneumatic slide gate wherein the control system is configured to automatically control the processing of paddy based on a feedback from a sensor wherein the control system is configured to couple the rotation per minute of the rotary airlock valve based on the feedback from the sensors and control the pneumatic slide gate at an intake, and the pressure regulation valve based on the feedback from the sensors. Furthermore, the system includes a pressure regulation valve operatively coupled to the corresponding steaming assembly wherein the pressure regulation valve set the steam pressure to a predetermined value.
[0008] In accordance with another embodiment of the present disclosure, a method for paddy processing based on feedback from sensors is provided is provided. The method includes receiving, by the cylindrical inlet port of a steaming assembly, the paddy through a pneumatic gate wherein the pneumatic gate is positioned above the top steaming chamber. The method also includes cooking, by a steaming assembly, paddy uniformly and removing condensed vapour from the paddy, upon receiving the paddy, wherein the paddy passes through the steaming assembly with varying steam temperature to ensure the uniform cooking. The method further includes preventing, by an inverted plate operatively coupled to a plurality of strainers in the steaming assembly, overcooking of the paddy and preventing direct contact between the paddy and the plurality of strainers. Further, the method includes removing, by a tempering assembly, liquid condensate and vapor condensate from the paddy to achieve uniform on-line gelatinization of starch in the paddy. The method also includes discharging, by a cylindrical output port of a steaming assembly, the paddy through a rotary airlock valve wherein the rotary airlock valve is positioned below the bottom steaming chamber. The method further includes providing, by a rotary airlock valve of a bottom steaming chamber of the steaming assembly, required output of the paddy based on a pre-set rotation per minute wherein the rotary airlock valve is operated based on a required temperature of the paddy in the bottom steaming chamber. Further, the method includes allowing, by a cooling unit of the rotary airlock valve, the paddy to pass through plurality of perforated ports and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice. The method also includes coupling, by a control system of a processing subsystem, the rotation per minute of the rotary airlock valve based on the feedback from the sensors. Further, the method includes controlling, by a control system of the processing subsystem, the pneumatic slide gate at an intake, and the pressure regulation valve based on the feedback from the sensors. Furthermore, the method includes setting, by a pressure regulation valve of a steaming assembly, the steam pressure to a predetermined value.
[0009] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0011] FIG. 1 is a block diagram representation of a system for paddy processing based on feedback from sensors in accordance with an embodiment of the present disclosure;
[0012] FIG. 2a and FIG.2b are schematic representations of a side view and a front view of a steaming assembly and a tempering assembly arrangement respectively in accordance with an embodiment of the present disclosure;
[0013] FIG. 3 is a schematic representation of a pressure regulation station supplying pressure to the steaming assembly in accordance with an embodiment of the present disclosure;
[0014] FIG. 4 illustrates exemplary dimensions of the system described in FIG.1 in accordance with an embodiment of the present disclosure;
[0015] FIG. 5 is a block diagram of a computer or a server in accordance with an embodiment of the present disclosure;
[0016] FIG. 6(a) illustrates a flow chart representing the steps involved in a method for paddy processing based on feedback from sensors in accordance with an embodiment of the present disclosure; and
[0017] FIG. 6(b) illustrates continued steps of the method of FIG. 6 (a) in accordance with an embodiment of the present disclosure.
[0018] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0019] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0020] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0022] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0023] In accordance with an embodiment of the present disclosure, a system for paddy processing based on feedback from sensors is provided. The system includes a steaming assembly comprising a plurality of steaming chambers wherein the plurality of steaming chambers is configured to cook paddy uniformly and remove condensed vapor from the paddy throughout the steaming chambers wherein the steaming assembly comprises a top steaming chamber, a middle steaming chamber and a bottom steaming chamber. The top steaming chamber comprising a cylindrical inlet port arranged on a top section of the top steaming chamber and a frustum-shaped outlet port arranged on a bottom section of the bottom steaming chamber wherein the cylindrical inlet port receives the paddy through a pneumatic slide gate wherein the pneumatic slide gate is positioned above the top steaming chamber. The middle steaming chamber comprising a frustum-shaped inlet port arranged on the top section of the middle steaming chamber and the frustum-shaped outlet port arranged on the bottom section of the middle steaming chamber and the bottom steaming chamber comprising the frustum-shaped inlet port arranged on the top section of the bottom steaming chamber and a cylindrical output port arranged on the bottom section of the bottom steaming chamber wherein the cylindrical output port discharges the paddy through a rotary airlock valve wherein the rotary airlock valve is positioned below the bottom steaming chamber wherein the wherein the top steaming chamber, the middle steaming chamber, and the bottom steaming chamber comprises a plurality of strainers wherein each of the plurality of strainers is positioned one above the other at regular intervals extended to an opposite face of the top steaming chamber, the middle steaming chamber and the bottom steaming chamber wherein the plurality of strainers is operatively coupled to an inverted plate positioned at a pre-defined angle between opposite sides of the top steaming chamber, the middle steaming chamber and the bottom steaming chamber wherein the inverted plate prevents overcooking of the paddy and prevents direct contact between the paddy and the plurality of strainers. The system further includes the tempering assembly operatively coupled to the steaming assembly comprising a first tempering chamber and a second tempering chamber wherein the first tempering chamber is positioned between the top steaming chamber and the middle steaming chamber and the second tempering chamber is positioned between the middle steaming chamber and the bottom steaming chamber thereby establishing a consecutive arrangement wherein the tempering assembly is adapted to remove liquid condensate and vapor condensate from the paddy wherein the tempering assembly comprises the first tempering chamber and the second tempering chamber. The first tempering chamber comprising the frustum-shaped inlet port arranged on the top section of the first tempering chamber and the frustum-shaped outlet port arranged on the bottom section of the first tempering chamber and the second tempering chamber comprising the frustum-shaped inlet port arranged on the top section of the second tempering chamber and the frustum-shaped outlet port arranged on the bottom section of the second tempering chamber and the tempering assembly is configured to achieve uniform on-line gelatinization of starch in the paddy. Further, the system includes the rotary airlock valve operatively coupled to the bottom steaming chamber of the steaming assembly wherein the rotary airlock valve provides a required output of the paddy based on a pre-set rotation per minute wherein the rotary airlock valve is operated based on a required temperature of the paddy in the bottom steaming chamber. Further, the system also includes a cooling unit comprising a cooler and a blower operatively coupled to the rotary airlock valve wherein the cooler and the blower comprises a plurality of perforated ports wherein the plurality of perforated ports allows the paddy to pass through and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice. The system includes a processing subsystem hosted on a server. The processing subsystem hosted on a server wherein the processing subsystem is configured to execute on a network to control bidirectional communications among a plurality of modules. The processing subsystem includes a control system module operatively coupled to the steaming assembly, the tempering assembly, the rotary airlock valve, the cooler with the bowler, a pressure regulation valve, and a pneumatic slide gate wherein the control system is configured to automatically control the processing of paddy based on a feedback from a sensor wherein the control system is configured to couple the rotation per minute of the rotary airlock valve based on the feedback from the sensors and control the pneumatic slide gate at an intake, and the pressure regulation valve based on the feedback from the sensors. Furthermore, the system includes a pressure regulation valve operatively coupled to the corresponding steaming assembly wherein the pressure regulation valve set the steam pressure to a predetermined value.
[0024] It must be noted that the system described herein is referred to ‘Complete Gelatinization by Peripheral Steaming System (CGPS)’.
[0025] FIG. 1 is a block diagram of a system for paddy processing based on feedback from sensors in accordance with an embodiment of the present disclosure. The system (100) includes a steaming assembly (110) comprising a plurality of steaming chambers. The plurality of steaming chambers is configured to cook paddy uniformly and remove condensed vapor from the paddy throughout the steaming chambers. The steaming assembly (110) comprises a top steaming chamber (115), a middle steaming (120), and a bottom steaming chamber (125). The top steaming chamber (115) comprises a cylindrical inlet port arranged on a top section of the top steaming chamber (115) and a frustum-shaped outlet port arranged on a bottom section of the top steaming chamber (115). The cylindrical inlet port receives the paddy through a pneumatic slide gate. The pneumatic slide gate (not shown in FIG.1) is positioned above the top steaming chamber (115). The middle steaming chamber (120) comprises a frustum-shaped inlet port arranged on the top section of the middle steaming chamber (120) and the frustum-shaped outlet port arranged on the bottom section of the middle steaming chamber (120). The bottom steaming chamber (125) comprises the frustum-shaped inlet port arranged on the top section of the bottom steaming chamber (125) and a cylindrical output port arranged on the bottom section of the bottom steaming chamber (125).
[0026] The cylindrical output port of the bottom steaming chamber (125) discharges the paddy through a rotary airlock valve (145). The rotary airlock valve (145) is positioned below the bottom steaming chamber (125). The top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125) comprises a plurality of strainers (not shown in FIG.1) wherein each of the plurality of strainers is positioned one above the other at regular intervals extended to an opposite face of the top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125). The plurality of strainers (not shown in FIG.1) is operatively coupled to an inverted plate (not shown in FIG.1) positioned at a pre-defined angle between opposite sides of the top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125). In one embodiment, the inverted plate is in the shape of letter ‘V’. The inverted plate with 65 degree internal angle is placed above each strainer to ensure mixing of paddy and preventing direct contact of paddy with the strainer. The inverted plate prevents overcooking of the paddy and prevents direct contact between the paddy and the plurality of strainers.
[0027] Typically, the plurality of steaming chambers are octagonal in shape and identical to one another, with the only difference being their inlet and outlet depending on their position in the system. In one embodiment, the steaming chamber is connected with four peripheral steam strainers one above the other at regular intervals extended to the opposite face of the steaming chamber.
[0028] The system (100) also includes the tempering assembly (130) operatively coupled to the steaming assembly (110) comprising a first tempering chamber (135) and a second tempering chamber (140). The first tempering chamber (135) is positioned between the top steaming chamber (115) and the middle steaming chamber (120) and the second tempering chamber (140) is positioned between the middle steaming chamber (120) and the bottom steaming chamber (125) thereby establishing a consecutive arrangement. The tempering assembly (130) is adapted to remove liquid condensate and vapor condensate from the paddy. Further, the first tempering chamber (135) comprises a frustum-shaped inlet port arranged on the top section of the first tempering chamber (135) and a frustum-shaped outlet port arranged on the bottom section of the first tempering chamber (135). Likewise, the second tempering chamber (140) comprises a frustum-shaped inlet port arranged on the top section of the second tempering chamber (140) and the frustum-shaped outlet port arranged on the bottom section of the second tempering chamber (140) and the tempering assembly (130) is configured to achieve uniform on-line gelatinization of starch in the paddy. Typically, the tempering assembly (130) allows internal steam exchange hence helping in the optimal usage of steam. The tempering assembly (130) also provides a natural passage of vapor condensate out of the steaming assembly (110) hence taking away the excess heat and allowing control over non-enzymatic Millard browning and the tempering assembly (130) drains out liquid condensate with excess condensate removal subsequent stage steaming uniformly.
[0029] It must be noted that the steaming chambers and tempering chambers are constructed in a polygonal shape. However, it will be appreciated to those skilled in the art that the steaming chambers and tempering chambers may accommodate any other suitable shape to perform the method disclosed here.
[0030] The system (100) further includes the rotary airlock valve (145) operatively coupled to the bottom steaming chamber (125) of the steaming assembly (110). The rotary airlock valve (145) provides a required output of the paddy based on a pre-set rotation per minute. The rotary airlock valve (145) is operated based on the required temperature of the paddy in the bottom steaming chamber (125). Typically, the rotary airlock valve (145) is a one-way regulated flow discharge unit attached to a chain sprocket drive system driven by a geared motor. The rotation per minute (RPM) geared motor is controlled by a variable frequency drive. Depending on the final temperature of the paddy in the bottom steaming chamber (125), the rotary airlock valve (145) is operated.
[0031] Further, the system (100) includes a cooling unit (150) comprising a cooler and a blower operatively coupled to the rotary airlock valve (145). The cooler and the blower comprises a plurality of perforated ports (not shown in FIG.1). The plurality of perforated ports (not shown in FIG.1) allows the paddy to pass through and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice. Typically, the plurality of perforated ports is “V” in shape to bifurcate the paddy into two halves.
[0032] Further, the system (100) includes a processing subsystem (105) hosted on a server (108). In one embodiment, the server (108) may include a cloud-based server. In another embodiment, parts of the server (108) may be a local server coupled to a user device (not shown in FIG.1). The processing subsystem (105) is configured to execute on a network (115) to control bidirectional communications among a plurality of modules. In one example, the network (115) may be a private or public local area network (LAN) or Wide Area Network (WAN), such as the Internet. In another embodiment, the network (115) may include both wired and wireless communications according to one or more standards and/or via one or more transport mediums. In one example, the network (115) may include wireless communications according to one of the 802.11 or Bluetooth specification sets, or another standard or proprietary wireless communication protocol. In yet another embodiment, the network (115) may also include communications over a terrestrial cellular network, including, a global system for mobile communications (GSM), code division multiple access (CDMA), and/or enhanced data for global evolution (EDGE) network.
[0033] Further, the processing subsystem (105) includes a control system module (160) operatively coupled to the steaming assembly (110), the tempering assembly (130), the rotary airlock valve (145), the cooling unit (150), a pressure regulation valve (not shown in FIG.1), and a pneumatic slide gate (not shown in FIG.1). The control system module (160) is configured to automatically control the processing of paddy based on feedback from a sensor. The control system module (160) is configured to couple the rotation per minute of the rotary airlock valve (145) based on the feedback from the sensors and control the pneumatic slide gate (not shown in FIG.1) at an intake, and the pressure regulation valve (not shown in FIG.1) based on the feedback from the sensors. Typically, the control system comprises a plurality of sensors. The plurality of sensors comprises a temperature sensor, a steam pressure sensor, and a proximity sensor. The temperature sensor measures the temperature of the paddy loaded from the steaming assembly (110). The steam pressure sensor measures the amount of steam required for each steaming chamber and the proximity sensor is positioned at the pneumatic slide gate (not shown in FIG.1) to sense the presence of the paddy.
[0034] Furthermore, the system includes a pressure regulation valve (not shown in FIG.1) operatively coupled to the corresponding steaming assembly. The pressure regulation valve (not shown in FIG.1) set the steam pressure to a predetermined value. Typically, a pressure regulation station (not shown in FIG.1) receives steam from a process boiler (not shown in FIG.1).
[0035] FIG. 2a and FIG. 2b are schematic representations of a side view and a top view of a system arrangement respectively in accordance with an embodiment of the present disclosure. The system (100) includes the top steaming chamber (115), the first tempering chamber (135), the middle steaming chamber (120), the second tempering chamber (140), the bottom steaming chamber (125), the rotary airlock valve (145), and the cooling unit (150). Typically, the cooling unit (150) comprises a cooler and a bowler wherein the excess condensate vapor is blown out. The top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125) comprise a plurality of strainers (240). The first tempering chamber (135) and the second tempering chamber (140) are connected with peripheral perforated condensate removal ports (250) that opens to the atmosphere. Typically, the rotary airlock valve (145) is a one-way regulated flow discharge unit connected to chain sprocket drive system driven by a geared motor. The rotary airlock valve (145) is operated based on the final temperature of the paddy in the bottom steaming chamber (125).
[0036] It must be noted that FIG. 2a and FIG.2b illustrates the consecutive arrangement of the steaming assembly and tempering assembly (130) in the system (100). This consecutive arrangement enclosed three steaming chambers and two tempering chambers. It will be appreciated to those skilled in the art that the system performs best with the said number of steaming chambers and tempering chambers but should not be limited to the said number. In one embodiment, the consecutive arrangement may be flexible to accommodate any number of steaming chambers and tempering chambers.
[0037] FIG. 3 is a schematic representation of a pressure regulation station connected to the steaming assembly in accordance with an embodiment of the present disclosure. The system (100) includes the pressure regulation station (270) that receives steam from a process boiler (275). Typically, the process boiler is one that is operated at a pressure or temperature that uses more than 10% of its capacity for direct steam humidification. Further, the steam pressure is set to a predetermined value with the aid of a pressure regulation valve (265). Three branches of a steam pipeline (260) are branched with pipes (280) that are connected to the perforated strainers in the top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125).
[0038] FIG. 4 illustrates exemplary dimensions of the system described in FIG.1 in accordance with an embodiment of the present disclosure. The system (100) includes a first tempering chamber (135), a top steaming chamber (115), a middle steaming chamber (120), a bottom steaming chamber (125), a cooling unit (150), and a rotary airlock valve (145). It must be noted that the exemplary dimensions are expressed in millimeters (mm).
[0039] FIG. 5 is a block diagram of a computer or a server in accordance with an embodiment of the present disclosure. The server (200) includes processor(s) (315), and memory (305) operatively coupled to the bus (310). The processor(s) (315), as used herein, means any type of computational circuit, such as, but not limited to, a microprocessor, a microcontroller, a complex instruction set computing microprocessor, a reduced instruction set computing microprocessor, a very long instruction word microprocessor, an explicitly parallel instruction computing microprocessor, a digital signal processor, or any other type of processing circuit, or a combination thereof.
[0040] The memory (305) includes several subsystems stored in the form of executable program which instructs the processor (315) to perform the method steps. The memory (305) includes a processing subsystem (105). The processing subsystem (105) further has a control system module (160). The control system module (160) is configured to automatically control the processing of paddy based on feedback from a sensor. The control system module (160) is configured to couple the rotation per minute of the rotary airlock valve (145) based on the feedback from the sensors and control the pneumatic slide gate (not shown in FIG.4) at an intake, and the pressure regulation valve (not shown in FIG.4) based on the feedback from the sensors. Typically, the feedback from the sensors is integrated to a programmable logic circuit that automatically controls the pneumatic slide gate at intake, pressure regulation valve, and rotation per minute of the rotary airlock valve (145) through a variable frequency for blower.
[0041] In accordance with an embodiment of the present disclosure, a system for paddy processing based on feedback from sensors is provided. The system includes a steaming assembly (110) comprising a plurality of steaming chambers wherein the plurality of steaming chambers is configured to cook paddy uniformly and remove condensed vapor from the paddy throughout the steaming chambers wherein the steaming assembly (110) comprises a top steaming chamber (115), a middle steaming chamber (120) and a bottom steaming chamber (125). The top steaming chamber (115) comprising a cylindrical inlet port arranged on a top section of the top steaming chamber (115) and a frustum-shaped outlet port arranged on a bottom section of the top steaming chamber (115) wherein the cylindrical inlet port receives the paddy through a pneumatic slide gate wherein the pneumatic slide gate is positioned above the top steaming chamber (115). The middle steaming chamber (120) comprising a frustum-shaped inlet port arranged on the top section of the middle steaming chamber (120) and the frustum-shaped outlet port arranged on the bottom section of the middle steaming chamber (120) and the bottom steaming chamber (125) comprising the frustum-shaped inlet port arranged on the top section of the bottom steaming chamber (125) and a cylindrical output port arranged on the bottom section of the bottom steaming chamber (125) wherein the cylindrical output port discharges the paddy through a rotary airlock valve (145) wherein the rotary airlock valve (145) is positioned below the bottom steaming chamber (125) wherein the wherein the top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125) comprises a plurality of strainers wherein each of the plurality of strainers is positioned one above the other at regular intervals extended to an opposite face of the top steaming chamber (115), the middle steaming chamber (120) and the bottom steaming chamber (125) wherein the plurality of strainers is operatively coupled to an inverted plate positioned at a pre-defined angle between opposite sides of the top steaming chamber (115), the middle steaming chamber (120) and the bottom steaming chamber (125) wherein the inverted plate prevents overcooking of the paddy and prevents direct contact between the paddy and the plurality of strainers. The system further includes the tempering assembly (130) operatively coupled to the steaming assembly (110) comprising a first tempering chamber (135) and a second tempering chamber (140) wherein the first tempering chamber (135) is positioned between the top steaming chamber (115) and the middle steaming chamber (120) and the second tempering chamber (140) is positioned between the middle steaming chamber (120) and the bottom steaming chamber (125) thereby establishing a consecutive arrangement wherein the tempering assembly (130) is adapted to remove liquid condensate and vapor condensate from the paddy wherein the tempering assembly (130) comprises the first tempering chamber (135) and the second tempering chamber (140). The first tempering chamber (135) comprising the frustum-shaped inlet port arranged on the top section of the first tempering chamber (135) and the frustum-shaped outlet port arranged on the bottom section of the first tempering chamber (135) and the second tempering chamber (140) comprising the frustum-shaped inlet port arranged on the top section of the second tempering chamber (140) and the frustum-shaped outlet port arranged on the bottom section of the second tempering chamber (140) and the tempering assembly (130) is configured to achieve uniform on-line gelatinization of starch in the paddy. Further, the system includes the rotary airlock valve (145) operatively coupled to the bottom steaming chamber (125) of the steaming assembly (110) wherein the rotary airlock valve (145) provides a required output of the paddy based on a pre-set rotation per minute wherein the rotary airlock valve (145) is operated based on a required temperature of the paddy in the bottom steaming chamber (125). Further, the system also includes a cooling unit (150) comprising a cooler and a blower operatively coupled to the rotary airlock valve (145) wherein the cooler and the blower comprises a plurality of perforated ports wherein the plurality of perforated ports allows the paddy to pass through and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice. The system includes a processing subsystem hosted on a server. The processing subsystem hosted on a server wherein the processing subsystem is configured to execute on a network to control bidirectional communications among a plurality of modules. The processing subsystem includes a control system module (160) operatively coupled to the steaming assembly (110), the tempering assembly (130), the rotary airlock valve (145), the cooler with the bowler, a pressure regulation valve (155), and a pneumatic slide gate wherein the control system is configured to automatically control the processing of paddy based on a feedback from a sensor wherein the control system is configured to couple the rotation per minute of the rotary airlock valve (145) based on the feedback from the sensors and control the pneumatic slide gate at an intake, and the pressure regulation valve (155) based on the feedback from the sensors. Furthermore, the system includes a pressure regulation valve (155) operatively coupled to the corresponding steaming assembly (110) wherein the pressure regulation valve (155) set the steam pressure to a predetermined value.
[0042] The bus (220) as used herein refers to internal memory channels or computer network that is used to connect computer components and transfer data between them. The bus (220) includes a serial bus or a parallel bus, wherein the serial bus transmits data in bit-serial format and the parallel bus transmits data across multiple wires. The bus (220) used herein may include but not limited to, a system bus, an internal bus, an external bus, an expansion bus, a frontside bus, a backside bus and the like.
[0043] FIG. 6 (a) illustrates a flow chart representing the steps involved in a method (300) for paddy processing based on control system feedback in accordance with an embodiment of the present disclosure. FIG. 6 (b) illustrates continued steps of the method (300) of FIG. 6 (a) in accordance with an embodiment of the present disclosure. The method (300) includes receiving, by the cylindrical inlet port of a steaming assembly, the paddy through a pneumatic slide gate wherein the pneumatic slide gate is positioned above the top steaming chamber in step 305. Typically, the pneumatic slide gate operates based on a proximity sensor. The proximity sensor detects the presence of the paddy before it enters a steaming assembly.
[0044] The method (300) also includes cooking, by the steaming assembly, paddy uniformly and removing condensed vapour from the paddy, upon receiving the paddy, wherein the paddy passes through the steaming assembly with varying steam temperature to ensure the uniform cooking in step 310. Typically, for uniform cooking of paddy, the temperature varies from one steaming chamber to another steaming chamber.
[0045] The steaming assembly comprises a top steaming chamber, a middle steaming chamber and a bottom steaming chamber.
[0046] Further, the method (300) includes preventing, by an inverted plate operatively coupled to a plurality of strainers in the steaming assembly, overcooking of the paddy and preventing direct contact between the paddy and the plurality of strainers in step 315.
[0047] Further, the method (300) also includes removing, by a tempering assembly, liquid condensate and vapor condensate from the paddy to achieve uniform on-line gelatinization of starch in the paddy in step 320.
[0048] Typically, when paddy is cooked, the starch granules absorb water and expand like a balloon. As the temperature rises, the granules absorb more water until they reach their maximum volume, which is termed as the gelatinization temperature.
[0049] Furthermore, the method (300) includes discharging, by a cylindrical output port of a steaming assembly, the paddy through a rotary airlock valve wherein the rotary airlock valve is positioned below the bottom steaming chamber in step 325. Typically, the RPM of the rotary airlock valve is regulated as per requirement from 5 to 15.
[0050] The method (300) includes providing, by a rotary airlock valve of a bottom steaming chamber of the steaming assembly, required output of the paddy based on a pre-set rotation per minute wherein the rotary airlock valve is operated based on a required temperature of the paddy in the bottom steaming chamber in step 330.
[0051] The method (300) further includes allowing, by a cooling unit of the rotary airlock valve, the paddy to pass through plurality of perforated ports and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice in step 335. Typically, the paddy is then sent to a drier where it is dried to a moisture of 11 to 12% and then taken for milling.
[0052] Furthermore, the method (300) includes coupling, by a control system of a processing subsystem, the rotation per minute of the rotary airlock valve based on the feedback from the sensors in step 340. Typically, the control system comprises various sensors which indirectly control the processing flow of paddy.
[0053] The method (300) includes controlling, by a control system of the processing subsystem, the pneumatic slide gate at an intake, and the pressure regulation valve based on the feedback from the sensors in step 345.
[0054] The method (300) also includes setting, by a pressure regulation valve of a steaming assembly, the steam pressure to a predetermined value in step 350.
[0055] Typically, the pressure regulation station receives steam from the process boilers wherein the pressure regulation valve sets the steam pressure to a predetermined value. Typically, any vessel in which steam is generated or superheated under pressure or vacuum by direct or indirect heat application is referred to as the process boiler.
[0056] Various embodiments of the system and method for paddy processing based on feedback from sensors described above enable various advantages. The method achieves uniform gelatinization of paddy by removing excess condensate vapor and water in the steaming chamber. Further, with the automatic and recipe-based operation, the color of the paddy improves resulting in less steam consumption and wastage. Furthermore, the dry parboiled paddy reduces the drying time. Moreover, the system includes the control system module which automatically controls the flow of the paddy. The system also enables easy installation.
[0057] The techniques described in this disclosure may be implemented, at least in part, in hardware, software, firmware, or any combination thereof. For example, various aspects of the described techniques may be implemented within one or more processors, including one or more microprocessors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or any other equivalent integrated or discrete logic circuitry, as well as any combinations of such components. The term “processor” or “processing subsystem” may generally refer to any of the foregoing logic circuitry, alone or in combination with other logic circuitry, or any other equivalent circuitry. A control unit including hardware may also perform one or more of the techniques of this disclosure.
[0058] Such hardware, software, and firmware may be implemented within the same device or within separate devices to support the various techniques described in this disclosure. In addition, any of the described units, modules, or components may be implemented together or separately as discrete but interoperable logic devices. Depiction of different features as modules or units is intended to highlight different functional aspects and does not necessarily imply that such modules or units must be realized by separate hardware, firmware, or software components. Rather, functionality associated with one or more modules or units may be performed by separate hardware, firmware, or software components, or integrated within common or separate hardware, firmware, or software components.
[0059] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[0060] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[0061] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. , Claims:1. A system (100) for paddy processing based on feedback from sensors comprising:
a steaming assembly (110) comprising a plurality of steaming chambers wherein the plurality of steaming chambers is configured to cook paddy uniformly and remove condensed vapor from the paddy throughout the steaming chambers wherein the steaming assembly (110) comprises:
a top steaming chamber (115) comprising a cylindrical inlet port arranged on a top section of the top steaming chamber (115) and a frustum-shaped outlet port arranged on a bottom section of the top steaming chamber (115) wherein the cylindrical inlet port receives the paddy through a pneumatic slide gate wherein the pneumatic slide gate is positioned above the top steaming chamber (115);
a middle steaming chamber (120) comprising a frustum-shaped inlet port arranged on the top section of the middle steaming chamber (120) and the frustum- shaped outlet port arranged on the bottom section of the middle steaming chamber (120);
a bottom steaming chamber (125) comprising the frustum-shaped inlet port arranged on the top section of the bottom steaming chamber (125) and a cylindrical output port arranged on the bottom section of the bottom steaming chamber (125) wherein the cylindrical output port discharges the paddy through a rotary airlock valve (145) wherein the rotary airlock valve (145) is positioned below the bottom steaming chamber (125); and
wherein the top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125) comprises a plurality of strainers (240) wherein each of the plurality of strainers (240) is positioned one above the other at regular intervals extended to an opposite face of the top steaming chamber (115), the middle steaming chamber (120) and the bottom steaming chamber (125) wherein the plurality of strainers (240) is operatively coupled to an inverted plate positioned at a pre-defined angle between opposite sides of the top steaming chamber (115), the middle steaming chamber (120) and the bottom steaming chamber (125) wherein the inverted plate prevents overcooking of the paddy and prevents direct contact between the paddy and the plurality of strainers (240);
a tempering assembly (130) operatively coupled to the steaming assembly (110) comprising a first tempering chamber (135) and a second tempering chamber (140) wherein the first tempering chamber (135) is positioned between the top steaming chamber (115) and the middle steaming chamber (120) and the second tempering chamber (140) is positioned between the middle steaming chamber (120) and the bottom steaming chamber (125) thereby establishing a consecutive arrangement wherein the tempering assembly (130) is adapted to remove liquid condensate and vapor condensate from the paddy wherein the tempering assembly (130) comprises:
the first tempering chamber (135) comprising the frustum-shaped inlet port arranged on the top section of the first tempering chamber (135) and the frustum- shaped outlet port arranged on the bottom section of the first tempering chamber (135);
the second tempering chamber (140) comprising the frustum-shaped inlet port arranged on the top section of the second tempering chamber (140) and the frustum-shaped outlet port arranged on the bottom section of the second tempering chamber (140);
wherein the tempering assembly (130) is configured to achieve uniform on-line gelatinization of starch in the paddy;
the rotary airlock valve (145) operatively coupled to the bottom steaming chamber (125) of the steaming assembly (110) wherein the rotary airlock valve (145) provides a required output of the paddy based on a pre-set rotation per minute wherein the rotary airlock valve (145) is operated based on a required temperature of the paddy in the bottom steaming chamber (125);

a cooling unit (150) comprising a cooler and a blower operatively coupled to the rotary airlock valve (145) wherein the cooler and the blower comprises a plurality of perforated ports (250) wherein the plurality of perforated ports (250) allows the paddy to pass through and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice;
a processing subsystem (105) hosted on a server wherein the processing subsystem (105) is configured to execute on a network to control bidirectional communications among a plurality of modules comprising:
a control system module (160) operatively coupled to the steaming assembly (110), the tempering assembly (130), the rotary airlock valve (145), the cooling unit (150), a pressure regulation valve (155), and a pneumatic slide gate wherein the control system module (160) is configured to automatically control the processing of paddy based on feedback from a sensor wherein the control system module (160) is configured to:
couple the rotation per minute of the rotary airlock valve (145) based on the feedback from the sensors; and
control the pneumatic slide gate at an intake, and the pressure regulation valve (155) based on the feedback from the sensors;
a pressure regulation valve (155) operatively coupled to the corresponding steaming assembly (110) wherein the pressure regulation valve (155) set the steam pressure to a predetermined value.

2. The system as claimed in claim 1 wherein the control system module (160) comprises a plurality of sensors wherein the plurality of sensors comprises a temperature sensor, a steam pressure sensor, and a proximity sensor wherein the temperature sensor measures the temperature of the paddy loaded from the steaming assembly (110) wherein the steam pressure sensor measures the amount of steam required for each steaming chamber wherein the proximity sensor is positioned at the pneumatic slide gate to sense the presence of the paddy.

3. The system as claimed in claim 1 wherein the feedback from the control system module (160) is transmitted into a programmable logic circuit that automatically controls the pneumatic slide gate at intake, the pressure regulation valve (155), and the rotation per minute of airlock valve through a variable frequency blower.

4. The system as claimed in claim 1 wherein the top steaming chamber (115), the middle steaming chamber (120), and the bottom steaming chamber (125) is internally similar wherein the steam temperature of each steaming chamber varies.

5. The system as claimed in claim 1 wherein the rotary airlock valve (145) is a one-way regulated flow discharge unit driven by a geared motor wherein the rotation per minute geared motor is controlled by a variable frequency drive.

6. The system as claimed in claim 1 wherein the pressure regulation station (270) receives steam from a process boiler (275) wherein the pressure regulation valve (265) sets the steam pressure to a predetermined value.

7. A method (300) for paddy processing based on control system feedback comprising:
receiving, by the cylindrical inlet port of a steaming assembly, the paddy through a pneumatic slide gate wherein the pneumatic slide gate is positioned above the top steaming chamber; (305)
cooking, by a steaming assembly, paddy uniformly and removing condensed vapour from the paddy, upon receiving the paddy, wherein the paddy passes through the steaming assembly with varying steam temperature to ensure the uniform cooking; (310)
preventing, by an inverted plate operatively coupled to a plurality of strainers in the steaming assembly, overcooking of the paddy and preventing direct contact between the paddy and the plurality of strainers; (315)
removing, by a tempering assembly, liquid condensate and vapor condensate from the paddy to achieve uniform on-line gelatinization of starch in the paddy; (320)
discharging, by a cylindrical output port of a steaming assembly, the paddy through a rotary airlock valve wherein the rotary airlock valve is positioned below the bottom steaming chamber; (325)
providing, by a rotary airlock valve of a bottom steaming chamber of the steaming assembly, required output of the paddy based on a pre-set rotation per minute wherein the rotary airlock valve is operated based on a required temperature of the paddy in the bottom steaming chamber; (330)
allowing, by a cooling unit of the rotary airlock valve, the paddy to pass through plurality of perforated ports and the excess condensate vapor is blown out through an exhaust fan and makes the paddy cool, dry and results in whiter milled rice; (335)
coupling, by a control system module of a processing subsystem, the rotation per minute of the rotary airlock valve based on the feedback from the sensors; (340)
controlling, by a control system module of the processing subsystem, the pneumatic slide gate at an intake, and the pressure regulation valve based on the feedback from the sensors; (345) and
setting, by a pressure regulation valve of a steaming assembly, the steam pressure to a predetermined value. (350)
Dated this 06th day of January 2023
Signature

Jinsu Abraham
Patent Agent (IN/PA-3267)
Agent for the Applicant