Mixed-Flow Drying System: Safeguarding Food Security for Wilmar Tanzania
Key Highlights
Wilmar Rice Tanzania Limited (formerly Murzah Wilmar Rice Millers Ltd), operating a strategic rice processing complex in Morogoro, Tanzania, required a modern automated grain drying system to replace traditional open-air sun drying. The goal was to eliminate grain mold, reduce post-harvest losses and strengthen food security across East Africa.
GSS supplied a full automated grain dryer and bulk handling package custom-engineered for paddy and wheat for this site. The equipment package centered on a GSS high-efficiency mixed-flow process dryer, an eco-friendly biomass rice husk furnace system, a heavy-duty bucket elevator, screw conveyors, and a dual environmental dust collection package integrating process dust extraction and flue gas scrubbing.
GSS continuous mixed-flow process dryer eliminated grain mold in the humid climatic conditions of East Africa. Biomass rice husk heating system reused agricultural waste to drastically cut fuel costs. The dual dust extraction setup met strict environmental standards, providing a green, standardized solution for regional agricultural industrialization.
Client Profile: A Core Food Security Hub in East Africa
Located in the Kihonda Industrial Zone of Morogoro, Wilmar Rice Tanzania Limited (a major subsidiary under Wilmar Group) is a flagship agricultural processing base in East Africa. As a vital infrastructure to safeguard Tanzania’s national food security, the complex integrates paddy receiving, modern drying, silo storage, and advanced rice milling. It serves as a regional benchmark for agricultural modernization.
Goals & Challenges: Overcoming Tropical Grain Mold & Biomass Energy Transition
As a premier agricultural processing complex in East Africa, the facility faced several universal industry challenges during grain post-harvest management:
- High Post-Harvest Losses from Traditional Sun Drying : In East Africa’s hot and humid climate, traditional open-air sun drying caused large moisture fluctuations, severe grain cracking, mold degradation, and massive post-harvest losses. A continuous mechanical drying system was urgently needed.
- Eco-Friendly Biomass Utilization of Rice Husks : Rice milling generated large quantities of rice husks. Converting these agricultural by-products into renewable fuel was critical to replace costly diesel and gas, cut operational energy costs, and achieve low-carbon production.
- Dust & Flue Gas Emission Control : High-speed grain drying generated process dust, while rice husk combustion generated flue gas. Complete dust extraction and flue gas scrubbing were mandatory to comply with international environmental regulations.
Customized Solution: Integrated Mixed-Flow Drying & Biomass Energy Package
To meet Wilmar Group’s global manufacturing and environmental standards, GSS delivered a custom one-stop bulk handling and drying solution for paddy and wheat :
- GSS Mixed-Flow Process Dryer : GSS deployed one high-efficiency Mixed-Flow Process Dryer using continuous, constant-temperature drying to ensure even moisture removal. It accurately controlled final moisture, eliminated mold risk and protected grain quality & milling yield.
- Biomass Rice Husk Thermal Energy System: One heavy-duty biomass rice husk furnace system was integrated, equipped with husk conveying fans and air supply fans. By burning rice husks obtained from milling, the system provided steady hot air for the dryer while drastically reducing operational fuel expenses.
- Closed-Loop Material Handling System : One heavy-duty bucket elevator (16m lift height) and three screw conveyors were deployed to handle raw grain intake, elevator feeding, and dried grain discharge, ensuring high dust-tightness and minimal grain damage.
- Dual Environmental Dust Collection Package: This dual environmental dust collection package incorporated one GSS insertable dust collector for collecting grain dust from the dryer and one flue gas scrubber system with an induced draft fan to clean combustion emissions, ensuring zero dust escape and compliant stack emissions.
Project Value:Post-Harvest Loss Reduction, Circular Economy, and Overseas Standardization
Grain Mold Prevention
The GSS continuous mixed-flow drying system overcome the bottlenecks of open-air drying. It ensured stable 24/7 moisture removal during humid harvest seasons and prevented massive post-harvest grain deterioration.
Biomass Heating Enables Circular Economy
Utilizing rice husks as clean biomass fuel reduced reliance on fossil energy, greatly cutting drying expenses while achieving zero-carbon thermal energy utilization.
Agricultural Processing Standards
The high automation and integrated dust control of GSS equipment provided solid technical support for Wilmar Group’s global management standards and accelerated regional industrial upgrading in East Africa.
"Operating a modern rice complex in East Africa requires drying technology that can mitigate mold risks while operating cost-effectively in local conditions. The complete continuous drying and biomass heating package provided by GSS has delivered exceptional results in our Morogoro facility. The mixed-flow dryer handles high-moisture paddy effortlessly with uniform results, while the rice husk furnace utilizes our agricultural waste to cut fuel expenses drastically. GSS has provided outstanding equipment backing for our national food security initiative."
