REI Agro, Haryana

Customer Name: REI Agro, Haryana

Project : Turnkey Solution for a 1200 TPD Rice Mill including Design & Consultancy, Engineering, Supply of PCCs, MCC, Cable Laying & Erection, Automation and MIS Reporting.
Customer : REI AGRO, Bawal, Haryana, India
Capacity : 2 X 25 TPH
End Product : Basmati Rice

Customer Pains:

• Revamping of existing 2X 12 TPH lines to 2 X 25 TPH lines at the same premises using the same space along with 48 Silos both for Paddy and Head Rice
• Efficient design to utilize the space available – Electrical and Material Flow
• Minimize the time in Integration between electrical and Control equipment
• Reduce time to market as the complete Electrical and Automation erection, installation and commissioning takes minimum 6 months as there are more than 800 feeders
• Increase throughput from 60% to 80%
• Real time availability of data to decision maker
• Reduce the no. of operators
• Reduce breakage and improve Product quality& consistency
• Increase Energy efficiency

Results delivered:

• The overall scope delivered in 158 days resulting in 22 additional days of production @ 50 TPH for 528 hrs resulting in additional revenues of INR 30 M against an order of INR 50 M on Dyanamic Engineers – Use of LOGIX to reduce engineering time
• The overall efficiency of the plant achieved at 84% against the target of 80% from original efficieny of manual plant at 60%
• Reduction in manpower by 60%
• Line balancing leading to NIL Nuisance tripping because of Jamming and starvation
• Increased product quality and consistency due to reduction in grain breakage resulting in fetching higher market price
• Reduced downtine with fault indication software and enhanced troubleshooting
• Real time Production reports available on decision maker’s mobile phone
• Achieved SILO temperature control through ROD Type temp. sensors
• Accurate loss analysis using online Weighers and Flow Meters
• Compact design resulted in accomodating 2X25 TPH along with 48 SILOS lines in place of 2X12TPH lines in the same space
• Energy consumption reduced by 18% by use of VFDs and NIL machine idling
• Unexpected shutdowns due to Power outages reduced to almost zero due to selection given in each MCC to select source as TG or GRID/ DG

System Configuration: