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

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.

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 project

The Parboiling Systems technology addresses workload issues in rice production, simultaneously reducing emissions and improving resource efficiency. It enhances food security and advances environmental sustainability, in line with critical Sustainable Development Goals including Zero Hunger, Gender Equality, and Climate Action.

To incorporate this technology into your project and specify the essential tasks and conditions, follow these steps:

Conduct awareness campaigns targeting processors and consumers to educate them about the advantages of GEM parboiling systems.
Assist processors in selecting the optimal size and configuration of parboiling systems to suit their specific needs and capacity.
Establish mechanisms for ensuring a consistent supply of high-quality rice grain to support the parboiling process.
Develop strategies for local and regional marketing of rice flour and other food products derived from the parboiled rice, promoting their benefits and encouraging consumption.

The main expense of the GEM parboiling technology is the installation of a gasification stove, which costs around USD 500. Assess the product amount required for your project, considering the technology cost.

As the technology is available in Benin, Cameroon, Ghana, Cote d'Ivoire, Mali, Niger, Senegal, Togo, Nigeria, Ethiopia, Maddagascar and Mozambique include the delivery cost to the project site, accounting for potential import clearance and duties. A group of trainers could offer training and assistance during project setup. Add the cost for training and after-training support for using the technology.

Communication support for the technology should be developed (flyers, videos, radio broadcasts, etc.)

To implement the technology in your country, you could collaborate with agricultural development institutes and agro-dealers.

For a better optimization of fleet management, you should associate Improved rice varieties for Africa (NERICA and ARICA lines), Deep urea placement (nitrogen management), Foliar micronutrient addition, Engineered irrigation surfacing (and water lifting), Motorized weeders (cut and bury paddy weeds), RiceAdvice digital support.

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

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.