Jas Mini Dal (pulse) Mill

The structure of our nation  is agricultural based. Maximum population of our country live on its agro based nature. From times immemorial pulses (Dal) have formed part of daily Indian menu. In India only 6.25 million tons of pulses which are roughly 50% of total annual Indian production are processed mainly in the rural areas by the old traditional system of either pounding those mortars or by grinding in village flour mills (Chakkies), which do not yield desired results even after putting in tremendous hard labors.

            Remaining 50% of the pulses are mainly being processed in big Dal mills in the country satisfactory results.

            As considerations of the factors in above, the Jas Enterprises AHMEDABAD, have made revolutionary developments in the pulse processing industries by designing the JAS brand Mini Dal Mill consisting the followings in single units: -

  Cleaning and grading Pitting Pretreatment with Oil Conditioning   De-husking and Splitting Polishing

            Hand operated pulses de-husking machine are becoming fastest popular in the country because they yield excellent result and so are ideal replacement of village Chakkies as shall from the comparatives chart shown here under:-

Comparison of performance of   Jas Mini Dal Mill with Village Flour Mill (Chakkies)

Process
            Process of dehiscing is done in two major steps. In the first step the cleaned and size graded grain are scarified followed by oil addition and sun/mechanical drying. In the second step the removal of husk and splitting into two cotyledons is done by passing the material through versatile pulse de-husker. This de-husker gives 2-4% higher yield of good quality Dal, than the traditional Dal mill.

            This method developed by Jas Enterprises is less laborious, requires less time and reduces losses during de-husking.   

            One of these methods developed and ready for commercialization is 'MINI DAL MILL'. The technical up gradation & cost economics of the 'MINI DAL MILL’ combined with facilities of Grader cum Cleaner can prove to be a boon to the farmers. This unit can be installed near the farm itself.   

The advantages of this unit will be:-   

1.                   Value addition of the product.

2.                   Cost of transportation saved.

3.                   Additional income through sale of seed coats as cattle feed. 

4.                   Improved yield of 'Dal' due to use of improved milling technology. 

5.                   Easier operation & less maintenance cost.

Suitable Motor for Dal mill:   

            The motor is provided with a pulley and is mounted at the bottom of the stand with V-belt to drive it. The motor requirement is of 2 HP single / three phases.   

Process on Dal mill

Cleaning and grading:

This unit consists of a vibratory inclined sieve, hopper, grain collector, waste collector and motor. The vibratory sieves are provided with different size holes to match the requirements of the type of Dal being processed. The vibrations are induced by a cam operated link which is mounted on a motor driven shaft.

  Pitting

An emery roller machine is used to obtain cracking and scratching of clean pulses passing through it. For loosening the husk to facilitate the subsequent oil penetration this is required. Gradually the clearance between the emery roller and cage (housing) is narrowed from inlet to outlet. Cracking and scratching of husk takes place mainly by friction between pulses and emery as the material is passed through the narrowing clearance. During the operation some of the pulses are de-husked and split which are separated by sieving.

   Pretreatment with Oil:

A screw conveyor allows passing the scratched or pitted material through it and mixing of some edible oil like linseed oil is completed. The linseed oil is used at the rate of 1.5 to 2.5 kg/tones of pulses. These are kept on floors for about 12 hours to diffuse the oil.

    Conditioning

Pulses are conditioned by alternate wetting and drying. Moisture (3.5%) is added to the pulses after sun drying for a certain period and tempering is done for about eight hours. The grain is dried in the sun again. By allowing water to drop from an overhead tank on the pulses which are passed through the screw conveyor addition of moisture to the pulses are achieved. Until all pulses are sufficiently conditioned the whole process of alternate wetting and drying is continued for two to four days. Pulses are finally dried to about 10 to 12% moisture content.

      De-husking and Splitting:

For De-husking of conditioned pulses emery rollers called as Gota machine are used. In one pass or single operation about 50% of pulses are de-husked. De-husked pulses are split into two parts. De-husked split pulses are separated by sieving and the husk is aspirated off. Un-split de-husked pulses and tail pulses are again de-husked and milled in a similar way. Till the running pulses are de-husked and split of the whole process is repeated tow or three times.

 Polishing:

Polishing is completely by treating de-husked and split pulses with a small quantity of oil and/or water.   

   Pre-Milling of Pulses:-

            To obtain best results during de-husking and splitting of pulses in the pulse de husking machine in Jas brand mini Dal mills, latest model improved version, pre milling including grading of pulses size wise is very essential.

Basically the raw pulses are first cleaned of dust, chaff, stones and other extraneous materials.Cleaned pulses are graded by sieves or pulses graded and soaked in water in cement’s tanks having 6” depth. Height of pulses soaked be 5” and the water level should be1” above the pulses.

            Soaked pulses are taken out of the water after specific time and put on the sieve. Swollen pulses which do not pass through sieve (from which un-swollen pulses earlier passed through the same) are ready for heaping in shade whereas the pulses which pass through the same sieves. Then these pulses are ready for heaping in shade. Degree of happing of swollen pulses in shade should be 30 to 40. This process should be continued till the pulses are swollen to the desired extent.

            There after the pulses are in thin layers in the open sun drying. Duration of sun drying of pulses vary according to weather condition prevailing at the time of processing.

            After sun drying the pulses are again heaped in shade so moisture contents in the pulses may become uniform as need in them for de-husking.

            Then the pulse are graded again fed in to the pulse de husking machine in Jas Mini Dal Mill  in graded lots to achieve he best results with minimum brokenness.

            For the guidance of the entrepreneurs, the process of details of pre-milling of pulses after proper cleaning is shown here after in a tabulated chart.

Note: -

      Period of soaking in water will very according to weather condition and quality of pulses.

      Duration of sun drying will vary according to weather condition.

      Pulses should not be warm at the time of De-husking/splitting.

      Pulses should be de-husked and split in graded lots only.

      Pulses shown at 1 & 2 must be dried within 3 days to get better results. Their processing in

      ainy season should be avoided.

      The de-husked pulses mixed with the un-husked pulses and the husks are again de-husked in the Jas brand mini Dal mill as usual. In second pass all the pulses are de-husked.

PROCESS DETAILS OF PRE MILLING OF PULSES