3×2000Ton Storage System for Rice Mill Plant — Bolivia

Project Summary

The challenge: A leading Bolivian rice processing enterprise, operating a modern rice milling facility, faced critical bottlenecks as production capacity outpaced raw grain storage infrastructure. During peak harvest season, the facility could only store approximately 800 tonnes of paddy rice on-site, forcing the plant to either turn away incoming deliveries or rely on expensive third-party warehousing located up to 15 kilometers away. This created significant logistical delays, increased transportation costs by an estimated 30%, and exposed the raw rice to moisture reabsorption and contamination during transit and temporary outdoor staging. The existing flat-storage configuration required a crew of 12 workers per shift for manual loading, unloading, and material repositioning, driving labor costs to unsustainable levels while introducing inconsistency in feed rate to the milling line, which reduced overall milling efficiency by approximately 18%. Furthermore, the lack of temperature and humidity monitoring in the existing storage area led to periodic hot spots and localized mold growth, resulting in an average post-harvest loss rate of 3.5% annually. The client urgently needed a storage solution that could accommodate the full harvest intake window of 60 days, maintain grain quality through Bolivia's variable tropical climate conditions, and integrate seamlessly with the existing rice processing line to ensure uninterrupted production throughout the year.

Our solution: Manxing's engineering team conducted a comprehensive site assessment and developed a fully integrated grain storage and handling system centered on three galvanized corrugated steel silos, each with a 2,000-tonne capacity for paddy rice, delivering a total system capacity of 6,000 tonnes. Each silo features a 25-meter diameter and 18-meter eave height, constructed from high-tensile galvanized steel sheets with a zinc coating of 350 g/m², engineered to withstand Bolivia's high-humidity tropical environment and seismic conditions. The receiving system incorporates a high-capacity bucket elevator rated at 50 tonnes per hour for vertical lifting, paired with a belt conveyor network spanning over 120 meters of horizontal transport, and a chain conveyor distribution system with automated slide gates that direct grain to any of the three silos based on real-time fill-level data. Before storage, all incoming paddy passes through a dedicated grain cleaning unit equipped with dual-deck vibrating screens and aspiration channels, removing impurities, chaff, and broken kernels to ensure only clean, uniform grain enters the silos. Each silo is fitted with a comprehensive temperature monitoring system using thermocouple cables at 12 vertical levels, combined with ambient and grain moisture sensors that feed data to a centralized PLC control panel. The PLC system manages automated aeration fans that activate when temperature differentials exceed 5°C, maintaining uniform grain temperature below 25°C to prevent insect proliferation and moisture migration. A dust collection system with pulse-jet bag filters is integrated at all transfer points, maintaining airborne dust levels below 10 mg/m³ and ensuring compliance with occupational safety standards. The entire system is designed for modular expansion, with structural and mechanical provisions pre-engineered to allow future addition of up to two additional silos without disrupting ongoing operations.

The outcome: The completed 6,000-tonne storage system has enabled the client to receive and store the entire harvest intake within the 60-day window, eliminating reliance on third-party warehousing and saving an estimated $180,000 annually in external storage and transportation fees. Continuous, automated feeding to the rice milling line has increased overall plant throughput by 22%, with the mill now operating at a consistent 8-tonnes-per-hour capacity across all shifts year-round, including non-harvest periods when raw grain is drawn from silo storage. The intelligent PLC-controlled system reduced the material handling workforce from 12 to 3 operators per shift, cutting labor costs by 75% while improving workplace safety by minimizing manual grain handling. Temperature-controlled aeration and real-time monitoring have reduced post-harvest grain losses from 3.5% to below 0.8%, preserving an estimated 162 tonnes of paddy rice annually that would otherwise have been lost to spoilage. The modular design has already allowed the client to begin planning a Phase 2 expansion, with Manxing's pre-engineered provisions ensuring that additional capacity can be added with minimal downtime. The facility now operates as one of the most advanced rice storage installations in Bolivia, with full traceability from intake to discharge and grain quality consistently meeting export-grade specifications.

Project at a Glance

Equipment Provided

Grain Bins

Handling Equipment

Grain Cleaning & Grading

Aeration & Monitoring

Project Gallery

Project Timeline

Results

• ✓ The completed 6,000-tonne storage system has enabled the client to receive and store the entire harvest intake within the 60-day window, eliminating reliance on third-party warehousing and saving an estimated $180,000 annually in external storage and transportation fees. Continuous, automated feeding to the rice milling line has increased overall plant throughput by 22%, with the mill now operating at a consistent 8-tonnes-per-hour capacity across all shifts year-round, including non-harvest periods when raw grain is drawn from silo storage. The intelligent PLC-controlled system reduced the material handling workforce from 12 to 3 operators per shift, cutting labor costs by 75% while improving workplace safety by minimizing manual grain handling. Temperature-controlled aeration and real-time monitoring have reduced post-harvest grain losses from 3.5% to below 0.8%, preserving an estimated 162 tonnes of paddy rice annually that would otherwise have been lost to spoilage. The modular design has already allowed the client to begin planning a Phase 2 expansion, with Manxing's pre-engineered provisions ensuring that additional capacity can be added with minimal downtime. The facility now operates as one of the most advanced rice storage installations in Bolivia, with full traceability from intake to discharge and grain quality consistently meeting export-grade specifications.
• ✓ Delivered on schedule with full commissioning
• ✓ 6,000 tonnes total storage capacity

"ManXing's storage system integrated seamlessly with our rice milling operation. The automated receiving-to-storage-to-production flow has significantly reduced labor and improved grain quality consistency. We can now plan production with confidence year-round."

Production Manager — Bolivian Rice Processing Enterprise

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