GEM system: Parboiling and flour production equipment for rice

Reduce milling losses, enhance nutritional and organoleptic quality

The "GEM parboiling and flour production for rice" technology is an improved system designed to enhance the parboiling process for rice. This technology introduces a new, advanced design for parboiling equipment, replacing the traditional cast iron drum method that typically exposes processors to harmful emissions, such as carbon monoxide and fine particulate matter. The GEM system utilizes a stainless steel parboiler tank and an enhanced stove design to efficiently steam rice, improving the overall process performance and product quality. It's specifically tailored for small to medium-scale processors in rice-growing regions of Sub-Saharan Africa, where energy and market infrastructures are often underdeveloped. The system's structure and components are easily accessible and can be constructed in remote communities. It significantly reduces the time required for steaming rice compared to conventional methods, achieving substantial improvements in grain quality and efficiency.

This technology is TAAT1 validated.

9•9

Scaling readiness: idea maturity 9/9; level of use 9/9

Cost: $$$ 500 USD

Equipment

ROI: $$$ 70 %

Internal rate of return for a GEM parboiling system

0.64 USD

firewood per 100kg of rice

IP

Open source / open access

Problem

High milling losses.
Decreased nutritional quality of the rice.
Undesirable texture, aroma, and appearance of the rice.
Significant time and effort required for the process.

Solution

Improved and Safer Design: The GEM parboiling system significantly reduces the steaming time to 20-25 minutes, which enhances efficiency and minimizes exposure to harmful emissions.
Quality Enhancement: The GEM system brings improvements in the parboiling process, increasing grain translucency, reducing chalkiness, and enhancing the overall nutritional quality of the rice, making it more appealing to consumers.
Health and Nutritional Benefits: Parboiled rice offers health benefits such as a low glycemic index, increased fiber content, and higher availability of vitamin B compared to non-parboiled rice.
Economic aspect: Compared to the traditional system, GEM allows women in Benin to gain an additional 140 kg of milled rice per tonne of paddy and 73 USD per tonne.
Adaptability and Accessibility: The GEM technology is made from simple, locally available materials, such as stainless steel and fire bricks, and is designed to be easily built and scaled in remote communities. The technology comes in different sizes, allowing processors to align it with their financial resources and production needs.

Key points to design your business plan

For Manufacturers

Manufacturing the parboiling technology streamline rice processing, reduce emissions, and optimize resource utilization.

To successfully navigate this market, you need to know where to source the raw material for making the equipment, identify efficient transportation methods, and explore suitable storage facilities.

Your potential customers are : wholesale distributors of input to retailers, and to development projects, government agencies, and NGOs.

Building strong partnerships with wholesale distributor networks is key to the success of your business.

For Resellers

Selling the parboiling technology not only provides a valuable product but also fosters closer engagement with users while simultaneously reducing the significant harvest losses often recorded

To successfully navigate this market, you need to know where to source this equipment (Benin, Cameroon, Ghana and Nigeria), identify efficient transportation methods, and explore suitable storage facilities.

The cost varies depending on the size of the technology. The main expense of the GEM parboiling technology is the installation of a gasification stove, which costs around USD 500. Include the cost of transport and any import duties and taxes.

Your potential customer base is: Farmers, development projects, and farmers cooperatives or associations.

For Users

Using parboiling systems enhance productivity, improve product quality, and contribute to environmental sustainability. Additionally, integrating parboiling technology can lead to cost savings, efficiency gains, and increased market competitiveness in the rice industry.

As key partners you need sellers or fleet managers.

As for the structure of cost : The GEM parboiling technology drastically cuts firewood expenses. Traditional methods cost USD 1.83 per 100 kilograms of rice, while GEM reduces it to just USD 0.64. Installing a gasification stove, costing around USD 500, almost eliminates fuel costs by using rice husk waste for heat generation.

Adults 18 and over: Positive high

It increases income and productivity, especially for women, by allowing them to process more rice and earn higher profits.

The poor: Positive medium

Reduces the cost of producing rice, making it more affordable and accessible, contributing to food security among low-income households.

Under 18: Positive medium

It improves nutrition by enhancing the nutritional quality of rice.

Women: Positive high

Strengthens women’s technical and business skills, making them more competitive in the rice market and improving their livelihoods.

Climate adaptability: Highly adaptable

The system's energy efficiency makes it more adaptable to regions facing climate stress, reducing reliance on traditional fuel sources.

Farmer climate change readiness: Significant improvement

It increases rice quality while reducing costs

Carbon footprint: A bit less carbon released

The system lowers greenhouse gas emissions by using less energy and reducing reliance on wood or charcoal.

Water use: A bit less water used

The improved technology optimizes water usage during the parboiling process, reducing water wastage.

Countries with a green colour: Tested & adopted
Countries with a bright green colour: Adopted
Countries with a yellow colour: Tested

Countries where the technology has been tested and adopted
Country	Tested	Adopted
Benin	Tested	Adopted
Cameroon	Tested	Adopted
Ghana	Tested	Adopted
Nigeria	Tested	Adopted

This technology can be used in the colored agro-ecological zones. Any zones shown in white are not suitable for this technology.

Agro-ecological zones where this technology can be used
AEZ	Subtropic - warm	Subtropic - cool	Tropic - warm	Tropic - cool
Arid
Semiarid
Subhumid
Humid

Source: HarvestChoice/IFPRI 2009

The United Nations Sustainable Development Goals that are applicable to this technology.

Goal 1: no poverty

By increasing rice output and profits for women, the GEM system boosts income and improves livelihoods

Goal 8: decent work and economic growth

GEM creates better job opportunities for women and youth in the rice sector, contributing to economic growth and more sustainable livelihoods.

Goal 5: gender equality

GEM empowers women economically by increasing their productivity and income, and providing skills training, which enhances their participation in decision-making and economic activities.

Goal 13: climate action

It reduces carbon emissions through more efficient energy use and decreasing reliance on firewood.

Cleaning and Washing Rough Rice: Clean rough rice with hulls using a winnower and wash it with water. Remove floating grains with fissures and transfer the remaining rice into a clean container, ensuring no sand or gravel from the bottom is included.
Soaking Process: Add 2 parts of water per part of rice by weight. Heat the rice and water mixture to 80°C. Let the mixture sit at ambient temperature for 16 hours.
Steaming the Soaked Rice: Place the soaked rice into a steaming vessel. Position the steaming vessel atop a tank filled with boiling water for 20-25 minutes to allow the vapor to pass through the rice.
Drying Parboiled Rough Rice: Dry the parboiled rice with hulls in the sun until it reaches 18% moisture content. Further dry the rice in the shade until it reaches 14% moisture content. Use a tarpaulin on a cemented surface raised from the ground to dry the rice.
Dehusking and Polishing: Dehusk the parboiled rice using a huller. Polish the rice using a roll mill.
Processing into Flour: Crush and grind the polished grains into a fine powder using a dry rice flour mill.
Packaging: Package the rice flour using paper or plastic bags.