Processing

Rice Processing

The journey to promote the finest basmati rice commences with the careful selection of seeds. Each year, Najah Foods distributes meticulously chosen, healthy, and pure seeds to farmers at no cost. A robust network is maintained throughout the season to engage with farmers, guiding them from seedling to the harvest stage. Experts from Najah Foods visit farmers, offering assistance in soil preparation, proper use of fertilizers, pest control techniques, and overall crop care.

The critical step in ensuring the best quality basmati rice lies in the selection and purchase of pure, healthy, and top-grade paddy. The company goes beyond market prices, offering premiums to attract farmers with the best produce, prioritizing quality over cost. Simultaneously, NAJAH FOOD ensures that a significant portion of the profit reaches the hardworking farmers. NAJAH FOOD’s strategically places its purchase point in Gujrat, the heart of the basmati growing area, where farmers bring their produce at the onset of the paddy season.

Paddy selection is a meticulous process that demands a rice mill’s utmost dedication, expertise, and time. The quality of the final product is heavily reliant on the procured paddy. While some rice mills opt for the easier route of purchasing semi-processed rice from brokers instead of directly from farmers, NAJAH FOODS takes a different approach. Paddy is acquired at the beginning of the rice season, eliminating the possibility of mixing inferior varieties. This strategic move capitalizes on the fact that paddy from different rice varieties matures at different times, preventing any inadvertent mixing. In contrast, semi-processed rice available with brokers throughout the rest of the year remains susceptible to mixing, often challenging to detect.

HUSKING

The chosen paddy undergoes a gradual moisture reduction process using both traditional and modern techniques until it reaches the optimal moisture content for husking. This gradual drying method prevents thermal cracks in the rice grain that could lead to breakage later on.

At NAJAH FOOD’s Sheller in Gujrat, brown rice is produced through a series of processes, including cleaning, dehusking, and grading. During this stage, only the outer husk is removed, leaving the germ and bran layer intact. To ensure the delicate rice grains don’t develop cracks or broken tips during husking, NAJAH FOOD has installed a high-quality Japanese Husker from Stake. The bran layer, rich in minerals and vitamins, is retained through minimal processing, resulting in healthier rice. Following grading, the brown rice is transported to NAJAH FOOD’s warehouses in different cities.

WEARHOUSING

For Basmati to achieve superior cooking characteristics and a robust aroma, it needs to mature for nine months to a year.

NAJAH FOODS adheres to a strict policy of building up stocks during harvest and carrying out the maturation process under expert control, avoiding reliance on market purchases on an order-to-order basis. Stocks are stored in spacious and well-ventilated godown in Gujrat and Islamabad. Regular inspections and fumigation are conducted under expert supervision to protect against infestation by organisms during the maturing period.

CLEANING

In the initial stage, multiple cleaning steps ensure that the rice remains hygienic, free from foreign materials like straw, mud balls, threads, stones, and paddy.

Rigorous measures are in place to prevent contamination during processing, with all machines, conveyors, bins, and hoppers equipped with a generously sized aspiration system to keep the entire facility dust-free. The company follows HACCP-compliant standards for hygienic processing and provides suitable sanitation facilities.

WHITENING & POLISHING

The second stage involves removing bran layers through whitening and polishing machines to give the rice a pearl-white appearance.

This process is carried out gradually in several passes to preserve kernels from breaking. Mist polishers at NAJAH contribute to an exceptionally clean and glossy appearance, offering a distinct advantage over traditional milling methods. Some machines at the plant, introduced for the first time by Buhler GmbH, further enhance NAJAH FOOD’s capabilities.

COLOR SORTING & RICE GRADING

Prior to packaging, the rice undergoes a color-sorting process to eliminate discolored grains, ensuring a final product with uniformity in all aspects. Color sorting is a computer-controlled procedure utilizing CCD technology for high-resolution optical inspection of each kernel. This method removes predominantly chalky and discolored kernels from healthy ones.

NAJAH FOOD’s advanced Z-series color sorter is equipped with state-of-the-art cameras that detect even the subtlest colors and defects smaller than 0.3mm. It incorporates innovative sorting algorithms that efficiently identify spot or color defects, enhancing yield. The equipment features a product tracking and automatic calibration mechanism for consistent sorting efficiency. The feeding system, with an advanced chute design, ensures precise product presentation. Basmati rice designated as brown rice or cargo rice undergoes proper fumigation, cleaning, and grading before packing.

PACKAGING & SHIPPING

The packaging process is meticulously designed to extend the shelf life of products and facilitate easy handling until consumption. Additionally, recognizing the importance of presentation in the market, NAJAH FOODS goes the extra mile to showcase its products in beautifully designed, eye-catching packaging. A dedicated team of designers and printers collaborates to create packaging tailored to meet customer requirements.