One of Gujarat’s most dynamic companies integrates multiple production processes as part of a major business development plan11/10/2014 Bühler automated system improves productivity, quality and efficiency for Indian pulse processor. The Bühler Group, the world’s leading provider of rice and pulse processing solutions, today announced the installation of a fully automated pulse processing plant, at Shivam Proteins in Gujarat, India, enabling the company to meet increasing customer demand, while also delivering improved energy efficiency, better product quality and faster throughput.
The highly integrated solution, which produces hulled and split pigeon peas for the domestic market, was designed and installed by The Bühler Group. With a capacity of two tonnes per hour, the automated plant saves labour costs while ensuring consistent product quality and hygienic operation. It has been designed to be capable of processing locally grown pigeon peas as well as all major imported varieties to the highest quality premium products.
Shivam Protein, a wholesaler and retailer of pulses and grains, is based in Dabhoi, Gujarat, one of the main centres of the Indian pulse processing industries. The company started as a trading organisation over 60 years ago and moved into processing so that it could guarantee its products.
To ensure excellence within its production operations, Shivam opted for high-technology equipment and so began its long-standing relationship with Buhler. This is a new and growing approach in India, where manual labour still dominates. This can lead to low productivity, inconsistent product quality and compromised hygiene standards.
Shivam’s adoption of leading edge technologies has proved to be a trendsetter and has had a positive response from the market, which is now increasing its demand for a greater range of cleaner and safer products, including pulses, grains and rice.
The new plant was commissioned from Buhler as a complete project, which included design, installation and full testing before handover. The plant integrates all the key processes of pigeon pea production. As well as cleaning, it also grades and dries the peas, then dehulls, splits, optically sorts and polishes them before the final packaging stage.
The plant ensures high throughput, which helps lower the cost of production. It also guarantees key criteria such as product quality and hygienic processing, which are essential for market growth.
Since the plant was commissioned, Shivam has reported complete satisfaction with the new integrated plant. Yield has increased by 2%, when compared to the existing mill, whilst labour and power costs per tonne of output have been reduced significantly, due to the automated processes.
Mr. Ashok Jethwani, Owner of Shivam Proteins, says: “The Buhler dryer is the latest innovation in pulse processing. As well as improving the drying of the raw materials, it has helped to increased splitting efficiency by 25 per cent. De-hulling has also become more effective, while the even drying in turn helps lead to a more natural colour, resulting in an increased production of premium product.”
Buhler is committed to innovations in pulses processing, to deliver increases in yield, better safety and hygiene, and to meet the ever growing expectations of consumers. The automation and technical excellence Bühler brings to pulse processing helps reduce damage, provides far more efficient separation of impurities and much greater recovery of valuable product, such as lighter grains, which would otherwise be rejected into the waste stream.
The elevated hygiene standards in Buhler plants have been successfully promoted to Shivam’s customers. The performance of the Buhler plant, particularly its contribution to product appearance and hygiene, has been welcomed by Shivam’s customers and is allowing the company to develop plans for retail packaging and supply, with a view to quickly attaining consumer market leadership for pigeon peas daal.
Surojit Basu, Bühler’s Global Product Manager for Pulses, Spices & Sesame says Shivam placed a lot of trust in Buhler throughout this project: “Mr. Jethwani’s trust in our abilities has been a result of our long term relationship. He has been in the industry for a long time, so is well aware of needs of the consumers and also of the issues of the industry, which is why he appreciated and supported our breakthrough innovations in pulses processing. The success of this project means he is keen to continue the relationship and support to our continued innovations in pulse processing.”
This project further acknowledges Bühler’s reputation as the leading provider of hygienic, high capacity and cost effective solutions for pulse and rice processors. The company’s dedication to investing in research and development coupled with its engineering expertise gained over 150 years means it is well positioned to continue to deliver innovative solutions to increase yield and ensure a more profitable product, consistently.