Plant, Machinery, Processing & Capacities Specifications!

Plant Specifications

Our Plant is equipped with state-of-the-art technology and high-tech machinery. The plant is based on production line equipped with Buhler and Satake machinery including Color Sortex (Z+-series) by sortex England, evidently making us distinctive from the rest of the units in pakistan. The plant is located on 5 acres of land with milling capacity of 5 Metric tons per hour and stocking capacity of 10000 Matric tons.

The atmosphere in the premises is hygienic and conducive for the food products. The premise is dust and bacteria-free and hygienically treated on monthly basis. All the machines, conveyers, bins and hoppers are equipped with a generously sized aspiration system; keeping the entire building dust-free. The system is highly automated and the only rice touched by human hands is the samples mechanically drawn by the miller to verify the milling degree and quality.

Combi Cleaner:

The rice is first fed to the Combi Cleaner where all the foreign matters such as stones, tree stumps, hey are removed from the rice. The principle of working is associated with oscillating double screen bed supported by aspiration system. The upper screen is scalper that let through the grain while retains the straw, tree stumps and hey etc. The second screen retains the grains while let through the broken grains, tips, hazardous stones and weed seed etc. Qualitatively, Pre-cleaner installed in Atlas Foods operates at production capacity of 5MT/Hour. The quality of product before pre-cleaning and after pre-cleaning is monitored in order to check the efficiency of Pre-Cleaner to produce the quality product. 

De-Stoner:

The De-Stoner removes all the stones from the rice. The de-stoner is a simple vibrating deck and air blower that suspends the grain from the stones. The stones are thrown off in one end and the brown rice in the other end.  It is operated at production capacity of 5MT/Hour. Destoning is considered as CCP (Critical Control Point) and always be monitored on hourly basis in terms of product quality.

Paddy-Seperator:

It removes all the paddy mixed in the rice. The paddy is reprocessed to the husking units.  Atlas Foods is having shaking tray type separators, which operate at the principle based on differences in specific gravity of rice and paddy (e.g. Rice is heavier than Paddy). The Paddy separator is composed of several rectangular trays with dimples stacked one above the other that are angled forward and sideways from the horizontal plane. The trays are oscillated from side to side. On the trays, paddy gathers on the lower end, and brown rice on the upper side, with mixtures in between. Paddy separators beds in at Atlas foods have the production capacity of 5 MT/hour (each with 2.50 MT/Hour).

Polishing:

Polishing is an essential step in the plant which increases the smoothness and brightness of the rice and gives it a sparkling touch. Rice is allowed to pass through mist polishers which impart an extremely clean and glossy white appearance to the kernels, a distinct advantage over traditional milling methods. The result is a sparkling grain with creamy smoothing touch. This is essential for easy cooking and also enhances aroma.

The abrasive whitener is composed of a horizontal cylinder coated with an abrasive material (carborundum).  The carborundum peels off the bran layers from the brown rice. The cylinder rotates inside a perforated steel plate cylinder. The coarse bran drops through the perforations in the plate. Generally, the abrasive whitener works with lower milling chamber pressure than the friction-type whiteners and is therefore suitable for Super Basmati Rice and other long grain varieties.

The grain is further processed in a friction whitener. The friction-type whitener is composed of a ribbed steel cylinder rotating inside a perforated steel plate cylinder, and resembles the Engleberg system. The ribs force the grains to rub against each other and against the steel cylinder. The forces of attrition remove the remaining bran layers left by the abrasive whitener, which generates heat and stress in the kernel. Therefore, The quality conscious, Atlas Foods (Pvt.) Limited uses two friction whiteners in series to reduce the stresses on the grain.

Atlas Foods is export quality rice oriented entrepreneur therefore a mist polisher is employed to brush off remaining bran dust and to create a characteristic gloss on the milled rice.  In mist polishers, a controlled amount of water mist is injected, resulting in highly polished grain.  Mist polishing improves the storability of milled rice because of the complete removal of the bran. Atlas Foods is lined with SM-18, NF-14 and mist polisher with result oriented production capacity of 5MT/Hour. The milling degree is measured to save the nutritional value of rice with world's renowned apparatus called "Kett Whiteness Meter".

 Size-Grading:

After polishing, the milled rice is separated on the basis of grain size & thickness. The Rotary sieve, length graders and thickness graders performs both thickness and length grading where the broken and shriveled rice is separated from head rice to a very high percentage of accuracy and the result is the product of long uniform length rice available to be fed the color sorter.

The length graders used in Atlas Foods (Pvt.) limited are the indented cylinder, also referred to as truer.  It consists of a rotating cylinder with cavities (i.e. indents) inside and a catch trough with a screw conveyor.  As the indented cylinder rotates, grains are caught in the indents and lifted. Head rice falls on while broken grains are elevated to the catch trough. The screw conveyor will convey the broken outside the cylinder. The entire cylinder is set at a slight angle. Length graders are usually used in series, with indents of various sizes used for each grading step keeping in view the given specifications.

Color-Sorting:

The latest state-of-the-art laser color sorter (Z+ Series – Buhler England) removes the defected rice such as discolored, immature (green), chalky, red rice etc. Color sorting is an intricate computer-controlled process where CCD technology is used for performing high-resolution-optical inspection of each and every kernel. It removes the high concentration of predominantly chalky and discolored kernels to give final product a uniform appearance and charismatic look.

Packing:

Latest Electronic weighing scales with high level of sensitivity ensure precise degree of accuracy in weighing. The rice is packed in bags of high quality made of Jute, Cotton, Paper and Polyethylene ranging from 1 kg to 100 kg. The High quality packing material preserves natural aroma & taste.

All this process is carefully executed to increase the shelf life of our products. The administration operates with a very effective and well-coordinated transportation system both inland and outward. The company deals with major shipping lines to ensure safe transportation of cargo to the destination within stipulated time. Special packing can be supplied on particular demand from the client.

List of Machinery and Capacity

Following list of our Plant installed Machinery and their Capacity.