K.t.c. Foods Private Limited

Nissing, Karnal, Haryana

The factory of K.T.C. Foods Private Limited is located in the green, pollution-free area, near Karnal in Haryana in North India. This unit is equipped with the latest technology in the world for every aspect of processing of paddy-right from cleaning, de-stoning, drying, de-husking, bran-removal, polishing and finally sorting. Although the plant is fully automatic but supervisors keep a close watch on the whole process. The final product is tested here before it goes into the market. The various processes involved in the making of product are as follows, Procurement :The basmati paddy is procured from the region where the soil composition is rich and unique with the climate especially conducive. This gives basmati delicate texture, flavor and aroma. The purchased paddy is sampled and checked repeatedly to ensure 100% purity level. No compromise is made on purity at any cost. Cleaning :

• Paddy Cleaning : The accepted paddy from mandis first goes through a cleaning process. The cleaners thoroughly dry rinse the paddy for any kind of farm trash in it. The rejections from cleaners are carefully examined for any kind of material loss. The in-process quality control ensures that no farm trash is found in the output
• De Stoning : Immediately after the cleaning process, the paddy passes on to de-stoning Process. In this, the stones, which cannot be removed by cleaners, are removed by specific gravity differentiators.
• Magnetic Separation : Any surface adherents or external ferrous material is removed from the paddy by electromagnetic separators drum. Paddy is evenly spread out in a thin layer over a magnetic drum resulting in ferrous material separation.
• Paddy Separation : The lighter paddy varieties are separated from each other by specific gravity differentiation principle. Very slowly and gently, the output of the de-husker is fed into this machine. A unique eccentric vibration of the table afloats the lighter paddy over heavier rice and broken paddy being rougher travels in the opposite direction against slope resulting in a very efficient separation. The paddy from this machine goes back for re-husking.
• De - Moisturising : Paddy is uniformly dried and processed through dryer to reduce moisture content and then stored in warehouses for maturing. Paddy arrivals from the farm may have moisture content upto 20%. The paddy storage or drying takes place at 15% moisture content. For drying, the paddy is fed from the top of the dryer and hot air is passed into the dryer in a cross flow. The hot air slowly and uniformly caresses the paddy till it attains the requisite moisture content. During paddy drying, care is taken to ensure smooth and uniform drying without damaging the paddy kernel or causing the formation of external fissures. Depending upon the amount of moisture that needs to be removed, the paddy may have to pass through the dryers once or twice.

Storage :

• Storage for long terms : The paddy is stored for a minimum of 6-7 months before milling. During this time, it should be carefully preserved to retain its unique physiochemical characteristics. Our strong team of storage technologists ensure that the paddy doesn't get infested and guard it from any kind of deterioration.
• Dehusking : It is a process to remove the non edible husk of the paddy to get brown rice. Husk is removed by shearing force which is created by the relative speed of two rubber rolls revolving in opposite direction. Deliberately low de-husking efficiency is maintained for achieving the lowest possible breakage from this machine. This process leaves behind some paddy in the output of this machine, which is removed in the paddy separation process. To husk the paddy delicately, very soft rubber rolls create a shearing force that is just sufficient for the process.
• Polishing : Utmost care is taken for consistent whiteness at all the stages of polishing. This makes sure that the endosperm of the rice kernel is still intact with a very strong and thin bran layer. This bran layer retains maximum amount of aroma evolving compounds in it. It also gives extra protection to the rice kernel to prevent breaking during cooking. Moreover this polishing process is designed in such a way that rice kernel's delicate tip (nakka) remains intact even if rice passes through abrasion or friction. Maximum amount of care and effort goes in to this process as it is the stage in which the rice quality is defined.