Storage

They are stored in a separate room as per the needs. Then the main production process starts.

2.1Pulverization
The grain form of the urad dal is put through the pulverizer and converted into fine urad flour. This process is also used for surati dal in case of surati papad. This process takes round about 30 mins for 50 kgs of grains.

2.2 Hing And Papad Khar
Hing and papad khar which come in the form of cubes are converted into powder manually.

2.3 Purification of Miri (black pepper)
Miri comes in the form of small round hard balls. But in papad it is required in the form of small particles(which is the actual miri ball inside the miri).

This miri is not pure as it has dust and stones which have to be removed. The next machine removes the dust particles from the out let shown on the left side.
The stones are removed by the same machine from the outlet at the back shown in the second picture

For this a machine called blower is used. In this process miri is put in the blower which crushes it in 3 DIFFERENT FORMS from 3 different sides as shown in the picture below

1) Cuts it into half as shown below
2) Actual miri balls that come out which are used to make papad
3) Miri Powder

The half miri that comes out is again put in the small machine shown below to remove the actual miri ball from it.

The last and the final process is when the actual miri balls are put in the machine shown below to remove the powder or the half miri balls left from the actual miri balls that are used in the actual papad making.
As shown in the picture behind the miri is collected in the box s and this purified miri is put in the dough.

2.4 Making of the dough
The dough is made in a machine called the dough maker. First the urad flour is put in the required quantity followed by a mixture of miri hing and papad Khar. After this a mixture of cold water and salt is put in it. Then the machine is switched on and within a time of four minutes the dough is ready.


2.5 Flattening of the Dough
After the dough is ready it is sent to the flattening area in the plant(own sheds)where a supervisor takes care of the whole process and the women with the help of marble tops and rolling pins flatten it. In this process a bit of oil is used for lubrication of the dough which makes the process much easier. The broken and spoiled papads if any are kept aside.

2.6 Drying
After the dough is flattened it is kept in an open area for drying with the help of natural sunlight. This process takes around one day. After this process the papads are ready to be sent for packaging. The broken and spoiled papads if any are kept aside.

2.7 Packaging
In this process papads are manually packed in plastic bags and are sealed with the help of sealing machines. The broken and spoiled papads if any are kept aside. Then this packets are stored as mentioned above.

Company tried to have an automatic production process but it dint work

3.1 Fully Automatic Machine
The whole machine and the process is broken up as shown in the snaps 1 - 4

1) The dough is made In a separate machine as shown in the snaps 1 and 2 above and below
2) This is the continued part of the machine above
The dough is made smooth when it comes out of the same machine.
3) Then the dough is rolled in such a manner as shown below
4) The left over goes from the from one side to the other and is rolled into papad again

The Automatic machine dint work because
The cost goes up as the machine itself costs Rs15-20lakhs,and the cost to buy the pulverizer, dough maker and blower also remains.
Although the quality of raw materials remains the same, when papad are kept in the machine to dry due to the heat the actual taste of black pepper(miri) and urad dal changes. There is a big difference in the taste.