Punjab Seed Corporation Sahiwal 3.51

PLANT MACHINERY


Year of import = 1978-79

Year of installation = 1987-88

Cost of plant = 24.22 Million Rupees

Make = German.

Supplier. = August Harbermann.

Capacity = 36 tons per hour (Pre-cleaning section)

= 20 tons per hour (Main plant section)

Cost of civil work including colony = 33.50 Millions Rupees
Total Project Cost = 57.72 Million Rupees
• Machinery imported directly by the Govt. of Pakistan with collaboration of World Bank. Erection carried out by supplier. During trial they declared that construction of Plant building is not on specific standard, as it vibrate, then again Plant re-installed on 1987-88 at re-constructed building.
STEPS INVOLVED DURING PROCESSING.

(i) Intake.
(ii) Aspiration.
(iii) M-1 (Scalper) = 38 Mt. per hour.
(iv) M-2 (Combinent)
(v) Selectors =04 set (20 Mt. per hour)
(vi) Indent cylinder =04 set (20 Mt. per hour)
(vii) Calibrator =02 set (03 Mt. per hour)
(viii) Gravity separator =02 set (5-6 Mt. per hour)
(ix) Treator. =10 Mt. per hour
(x) Weighing, Packing & Labeling. =07 Mt. per hour(50 kg bags)
(xi) Storage.

1. Intake.

Filled bags are cut on it and poured for pre-cleaning.
2. Aspiration.

Dust is removed at this step.
3. M-1 (Scalper).

De-stoning, De-threading, Removal of Tags, Mud stone and long piece of wheat straw Carried out at this step.

4. M-2 (Combinent)

Dust, wheat straw & shriveled grains eliminated at this step.

5. SELECTOR.

Light weight (shriveled), small size seed, wheat chaff, weeds, & dust removed at this step.
Presently we have 04 Nos. set of selector at Plant site.
6. INDENT CYLINDER.

Broken seed, weeds, oversize seed and Barley eliminated at this step.
04 Nos. set of cylinder are working presently.



7. Calibrator.
Broken/half cut grains, shriveled/under size grains are removed, 02 Nos. set of calibrators are working presently.
8.GRAVITY SEPARATOR.

Used for grading & sizing of grains.
Two gravity separators are installed at Plant but not being used due to un-balance in capacity performance.
9.TREATOR.

Seed is treated with fungicide & dye (Rodhamin-B) under instruction of PSC HQ (As and when required).

10.Weighing, Packing & Labeling.
Final process seed is weighed, packed and labeled in desired seed bags.
11.Storage.
Finally packed seed is stored in main store, after that it will dispatch to different station for sale.



COB DRYER SECTION.

• COB DRYER CHAMBER = 12 NOS. (10 MT. per chamber
capacity)
• COB DRYER STORAGE CAPACITY = 120 MT. (COBS)
• MAIZE COBS SHELLER CAPACITY = 20 MT. PER HOUR.
• AIR CAPACITY = 1,40,000 cbm. Per Hours.

Note: -
Only 06 Nos. Chambers are in operation.




STEPS INVOLVED DURING DRYING/PROCESSING OF COB SECTION.


1. Feeding & Sorting in to bin
2. Storage in bin for drying
3. Shelling
4. Processing
5. Grading
6. Treating
7. Drying after treator
8. Weighing, Packing & labeling
9. Storage.



1. Feeding & Sorting.
Bags of cobs cut in hopper & sorting is carried out at feeding conveyor belt & then feeded in to bin for drying.
2. Storage in bin for drying.
Cobs remain in bins for 72 to 96 hours for drying depending upon the moisture content of cobs, moisture is down to about 12%.
3. Shelling.
Cobs dried at 12% moisture, are shelled through sheller (Shelling capacity 20 MT. per ton).
4. Processing.
A). Grains received after shelling are firstly cleaned through selectors. Big pieces of pith, broken and under size seed are removed.
B). Cleaned grains received through selectors, secondly passed through indent cylinders & trash, minute pieces of pith and broken grains are removed.


5. Grading.
Grains received after indent cylinder, are graded through grader into three categories i.e. small, flate (medium + large) & round (medium + large) in shapes.
6. Treating.
Flate & round shape grains are treated separately with fungicide & dye with Rodhamin-B colour.
7. Drying after treator.
The moisture added during treatment is dried through dry conveyor belt to bring the moisture contents of seed at 12%.
8. Weighing, Packing & labeling
Final processed & treated seed is weighed, packed and labeled in desired seed bags according to shapes of grains separately i.e. flate & round. .
9. Storage.
Final packed seed is stored in Oil seed stores, after that it will dispatch to different station for sale.

Total Plant Area.

15 Acres 650486.50 Sft.



STORE SPACE AVAILABILITY.


Two types of storage space is available at this Plant
1. Silos 2. Main Store.
SILOS.
58 Nos. silos are available at Plant site. (52 Nos. are used for storage each having capacity 1100 bags per 100 kg approximately. 06 Nos. are not use for storage till the Ist day of Plant operation due their un-fit location).
Main Store.
= 56 Shells = 74700 Sqft (52 Nos. shells are used for storage of seed and 04 Nos. shells are used for final packing operation.
Pre Store.
= 04 Nos. = 16200 Sqft. (These stores are used for storage of Farm produce, minor crop seed & packing material etc.


LAST THREE YEAR EXPENDITURE FOR REPAIR AND MAINTENANCE OF PLANT MACHINARY.
Years. Amount.
2006-2007 Rs.1225881.00
2007-2008 Rs. 998173.00
2008-2009 Rs. 930375.00
2009-2010 Rs. 273913.00
2010-2011 Rs. 488606.00



PROCESSING ACCOUNTS.
2007.
Crop. Procurement. Processing. Invisible Losses. % Age.
Wheat 164904 (100 kg) 288267 (50 kg) 78049 (Excess) -
Paddy 37158 (60 kg) 106135 (20 kg) 54341 kg 2.41 %
Maize (Autumn) 651 (100 kg) 1185 (50 kg) 1160 kg 1.72 %
Maize (Spring) 400 (100 kg) 847 (50 kg) 619 kg 1.57 %
2008.
Crop. Procurement. Processing. Invisible Losses. % Age.
Wheat 144114 (100 kg) 6170 (100 kg)
253215.5 (50 kg) 142605 kg (Excess) -
Paddy 43338 (60 kg) 117875(20 kg)
802 (60 kg) 50953 kg 2.00 %
Peas 157 (100 kg) 277 (50 kg) 963 kg (Seed losses) 6.5 %
Maize (Spring) 816.5 (100 kg) 1896 (50 kg) 801 kg 1.02 %
2009.

Crop. Procurement. Processing. Invisible Losses. % Age.
Wheat 233901 (100 kg) 405856 (50 kg) 57250 kg 0.25 %
Paddy 31588 (60 kg) 90452(20 kg) 28740 kg 1.51%
Peas 466(100 kg) 855 (50 kg) 1555 kg 3.35 %
Hybrid Maize 4815 (50-60 kg) 5677 (10 kg) 114809 kg 41.96 %
2010.

Crop. Procurement. Processing. Invisible Losses. % Age.
Wheat 276190 (100 kg) 405532(50 kg) Nil
168119 kg (Excess) 0.74%
Paddy 33134 (60 kg) 57390(20 kg) 23459 kg 1.17%
Peas 1672(100 kg) 2836 (50 kg) 2196 kg 1.40 %
Hybrid Maize 282 (50 kg) 343 (10 kg) 6004 kg 42.72 %




• Quality Control.
All this processing operation is controlled by the internal Quality control analysis Laboratory. Some briefs related the QA/QC System is narrated as below: -
GATE TEST .
o Drawing of sample from consignment at gate.
o Maintaining record of gate sampling.
o Preparation of working sample.
o Entries in analysis register.
o Analysis of sample.
o Acceptance/Rejection of sample.
o If accepted refer to plant site for unloading.
o If rejected informing to concerned officer for rejection.
o Keeping the samples record till the completion of processing.
ROUTINE TEST/STACK SAMPLING.
o Drawing of sample from the four sides of reserve/ basic stack.
o Analysis of samples.
o Informing to store section about the status of stack.
DURING PROCESSING SAMPLING.
o Drawing of sample from hopper on an hourly basis.
o Entry in lab. shift record register during processing.
o Preparation of working sample.
o Analysis of sample.
o Writing of results in lab shift register.
o Informing to processing staff about the processing deficiencies for improvement.