For every Indian, pulses form an integral part of diet; consumed almost daily. Pulses are the major source of protein and in the form of dall-roti or dall-chawal are non substitutable staple food in all geographical regions, all religions, and all income and social categories. Let it be home-made food, hotel food, ready to eat food or any kind of snack food; one will definitely find some kind of pulses in it.
India is world’s largest producer and consumer of pulses. Out of total pulses that are consumed in India; more than 75% are consumed after converting them into 'dall'. Conversion of pulses into 'dall' is the third largest food processing industry in the country.
It involves two main operations, viz. 1) Removal of the husk and 2) Splitting it into cotyledons (two parts). Removal of husk (seed coat) reduces roughage; improves storability, cooking quality, palatability and digestibility.
Dehusking & splitting may appear to be a very simple job; like just scrapping away the husk by an abrasive device and split the two cotyledons inside by applying as high impact as may be required. But it is well known that it is not so simple. The bondage of husk with cotyledons is strong and the strength of bondage varies in each variety of pulses.
Forced dehusking and splitting causes heavy processing losses. Outermost 5% layer of dall contains 40% of total protein. A sizable part from this high value protein concentrated area of cotyledons is converted into powder and broken.
It goes with husk powder (chuni), which is used as cattle feed, so human being is deprived of the product to such an extent. This also creates the problem of acute dust pollution. On account of this, the economic viability for dall miller also changes unfavorable and the pulse grower (farmer) also gets less value for his produce.
Girish Maheshwari (Director) from BhagyaRekha Enterprises narrates the success story of the new technology introduced by their company in dall milling.
Scenario of technology available for dall milling industry :
Unlike paddy (rice), wheat and oil-seed processing industries - which have industry proven modern techniques and state of art processing plants running worldwide; dall milling industry by large is centered in India only.
This industry don't have a big brother in foreign to look upon for any technological help. This suggests that importing technological skills for improvement of this industry is a very remote possibility.
Even the solutions and machines available in India, which are specifically meant and made for particular industries such as wheat, rice, coffee, spices, etc. are not perfectly suitable for dall milling. As the characteristics of pulses and the process to convert them into dall is different. It needs individualistic approach for each variety.
On account of non availability of new technology, same set of old, outdated machines and equipment are used, in the industry.
About the new technology :
We took this as a challenge and converted the obstacle into an opportunity. With years of intense R&D, prototypes and successful trials, we can proudly claim to be the pioneer in developing and perfecting a technology for the dall milling industry.
This is resulting in higher yield, shorter process time and reduction in processing expenses. Not only this but the dall obtained by this process system is better in protein value, appearance, cooking quality and shelf life.
Irrespective of external climatic conditions, the quality of dall is consistent round the year. No chemical is been used and the process is fully automated and totally hygienic. The area required for land and building is also lesser. Rotation of capital invested in raw material is faster and the miller is relieved from the tension of protecting the extra stock in process from fluctuations in rates (teji-mandi).
With higher yield, shorter process time and reduced processing expenses, the payback period on investment in plant and machine is also very short.
Benefits of new process system :
● Increased output of dall.
Output of dall is increased by 3 to 5%. Thus generating more dall for our pulses deficient country and increasing the profitability of the dall miller and pulse grower (farmer).
● Retaining maximum protein contents in dall.
The protein rich 1st quality dall (phatka) is increased upto 78%, up by 20% from the current 55-58%. Thus, providing more nutritious dall for consumption.
● Reducing process time from 5-7 days to 2 days.
At present, conversion of raw pulses (toor, moong, urad, masoor etc.) into dall takes around 5-7 days. Now this process time is reduced to 2 days. Thus by saving on valuable capital, space and fluctuations in the rate (teji-mandi)
● Reducing consumption of oil by 60-80%.
For processing raw pulses into dall, millers use edible oil, which is a commodity in shortage. With new process system there is a 60-80% reduction in the consumption of oil.
● Reducing energy (electricity and burning fuel) consumption.
By using the new process system, burning fuel and electricity consumption is reduced by 35 - 50%.
● Reducing dust pollution.
Completely dehusked grain (gota) is attained in 'single' post oil rolling operation. By eliminating repetitive rolling (scrubbing/scratching) process, dust pollution is minimised and is almost nill.
● Better quality of finished product.
The dall obtained by this process system is very superior on all aspects; such as sharp edges, colour, shining, appearance, cooking quality and protein value.
● Non dependability on weather.
The quality and finishing of dall is consistent throughout the year irrespective of external climatic conditions.
● Eliminating the need for sun drying.
As the complete process is automated there is no need for sun drying. The plant can be run 12 months of the year without worrying for rain or thundershowers.