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UDP PROJECT REPORT

DESIGN & FABRICATION OF SUGARCANE JUICER MACHINE

By

PATEL KALPITKUMAR KAMLESHBHAI

CHARADVA HARDIK NILESHBHAI

PARMAR KETAN DHIRUBHAI

POKAR DHAVAL JENTIBHAI

Under the guidance of

PROF. PARAG PAIJA

(M.TECH)

A project report submitted to

Gujarat Technological University in

Partial Fulfillment of Requirements for the

Degree of Bachelor of Engineering in

           Department of MECHANICAL ENGINEERING

SEPTEMBER 2016

CERTIFICATE

This is to certify that research work embodied in this thesis entitled“DESIGN & FABRICATION OF SUGARCANE JUICER MACHINE”was carried out by KALPITKUMAR KAMLESHBHAI PATEL (130040119541) at B.H.GARDI COLLEGE OF ENGINEERING & TECHNOLOGYfor partial fulfilment of Bachelor of Engineering degree to be awarded by Gujarat Technological University. This research work has been carried out under my supervision and is to my satisfaction.

Date:/    / 2016

Place: Rajkot

Internal guide H.O.D.

PROF. PARAG G PAIJA Dr. AMIT V  SATA

SIGN:

SIGN:

CANDIDATE DECLARATION

I declare that the dissertation report presented here for Bachler of Engineering. (Mechanical) entitled “DESIGN & FABRICATION OF SUGARCANE JUICER MACHINE”is my own work conducted under the guidance of PROF. PARAG G PAIJA

I further declare that to the best of my knowledge, this dissertation report does not contain any part of work, which has been submitted for the award of any degree either in this university or in other university/ deemed university without proper citation.

Signature of Student:

Name of Student: PATEL KALPIT K

Enrollment No: 130040119541

Name of Guide: PROF. PARAG G PAIJA

Signature of Guide:

Department of MechanicalEngineering

B.H.GARDI COLLEGE OF ENGINEERING & TECHNOLOGY

ACKNOWLEDGEMENT

We express our sincere gratitude to B. H. Gardi College of Engineering& Technology Rajkot for giving us an Opportunity to done Project.

We would like to express our sincere gratitude to our guide Prof Parag Paija for his perseverance, persuasion, encouragement and guidance during the Project Work.

We would like to Thanks Mr.Ambrish Nashit for Their Suggestions and guidance.

We special thanks for all teachers who directly or indirectly help us

KALPIT K PATEL

DATE:___/___/2016 NAME & SIGN OF STUDENT

TABLE OF CONTENTS

CERTIFICATE 1

CANDIDATE DECLARATION .2

ACKNOWLEDGEMENT 3

LIST OF FIGURE 6

ABSTRACT 7

CHAPTER 1 : INTRODUCTION...............................................................................8

1.1 History......................................................................................................................8

1.2 Project summary......................................................................................................10

1.3 Objective of work....................................................................................................11

1.4 Literature Review....................................................................................................12

CHAPTER2......................................................................................................................14

2.1 Canvas..........................................................................................................................14

2.1.1 Observation Matrix Canvas........................................................................................15

2.1.2AEIOU Summary.........................................................................................................15

2.1.3 Ideation canvas………………………………………………………………………17

2.1.4 Product Development Canvas....................................................................................18

2.2 Block diagram……………………………………………………………….…….21

CHAPTER 3………………………………………………………………………….22

3.1Implementation.........................................................................................................22

3.2 Specification of sugarcane juice machine Motor…………………………………24

3.3 Spur gear design…………..………………………………………………………24

3.4 Gearbox design……………………....……………………………………………27

3.5 Future work………………………………………………………………...……32

3.6 Conclusion……………………………………………………………………….32

REFERENCES.......................................................................................33

LIST OF FIGURE

Figure 1. Simple sugarcane crusher.............................................16

Figure 2. Sugarcane juice exactor..........................................17

Figure3. Sugarcane juice exactor with more hezardness....................................18

Figure4.Morden sugarcane juice exactor without hazardness...............................19

Figure 5.Observation Matrix........................................19

Figure 6AEIOU Summary

Figure 7 Ideation Canvas

Figure 8 Product Development Canvas

Figure 9 cad model of sugarcane juice exactor

Figure 10 cad model of sugarcane juice exactor

Figure 11 rollers mechanism

Figure 12 chain-sprocket assembly

ABSTRACT

Our main objective in past sugarcane juicer machine we get juice extraction efficiency nearly about 75% but improvement and modification in which we can include that the maintenance and cleaning of the machine parts, identification of the required improvements, casing of the machine operating chamber for the juice extraction, and aesthetic improvement, and testing the machine performance. According to experimentally work done an improved sugarcane juice extractor has removable crushing rollers previously problem faced to housing with a juice extracting compartment so in improved sugarcane juice extractor we try to preferably a housing with juice extracting compartment. By providing casing surrounding the rollers try to control/reduce the diseases which are caused while fly and mosquito are on the rollers or surrounding the rollers.By including medium size rollers due to which it is not difficult to introduce various ingredients. The various scouted challenges to reduce the hazardness of the machine, improvement of the separation of the juice from baggage’s and collection. Evaluate & improve the performance of the machine.

Key words:- Three roller sugarcane machine, Casing, Reduce hazardness, Time reducing ,More efficient

CHAPTER-1 INTRODUCTION

1.1 History

Sugarcane majorly found in Nigeria, in these are Saccharum officinarum, S. sinense, and S. Spontaneum. Since the many years the extraction of juice was already done which also give juice extraction efficiency nearly about 75% but there are some improvements required in sugarcane crusher machines.

According to shown in figure.1 it is old type sugarcane juicer machine which is time consuming and in which more work is required, more energy utilized.

Figure 1 simple sugarcane crusher

According to shown in figure.2 in which the problems are related to illness due to fly, bees and mosquitos are moving surrounding the rollers or due to on the rollers. Due to this problem many diseases are assures to people.  

Figure 2: sugarcane juice exactor

As shown in figure.3 in which the problems are also can consider related to less efficiency and more energy utilized and also considering problem of more hardness.

Figure 3: sugarcane juice exactor with more hezardness

According to shown in figure.4 which is semi-automatic sugarcane crusher machine. In which by improving in rolling mechanism such that by putting more than two rollers. Due to which try to extract the juice in once a time. Due to which improve the performance of the machine and also in improvement of the separation of juice from bagages and collection.

Figure 4: Morden sugarcane juice exactor without hazardness

1.2 Problem Summary

Sugarcane juice, over the years, has been successfully used in the production and manufacturing of the edible refined sugar; using machines which were fabricated and constructed to large scale production, industrialization and large capital requirements. This makes the extraction of sugarcane juice a fantasy to local or small-scale industrial establishments. Thus, this amputates the involvement of small-scale farmers in the business of sugarcane juice extraction and refined sugar production; at large. In Nigeria, it is quite remote for those who are subsistent in agricultural practices to take part in sugar production practices in the scope of their practice.

Furthermore, the major way by which the suckle in sugarcane has been enjoyed over the years has been by the employment of the teeth in biting off the rind and chewing up the internal tissues. When this is achieved, the juice would then be extracted and sucked in the mouth. After this the bagasse is spat out. The grossness of this procedure tends to:

Put the human teeth in duress; imagine if the amount to be consumed is large

Possibly soil the hands and clothing of the consumer.

Classify the consumption of sugarcane as raze and rural, causing a reduction in the widespread acceptance of the crop for consumption.

At present, the construction of the cottage industry sugarcane juice extractor has been facilitated to cushion these problems so far. The important step of producing sugar from the extracted juice by the machine would be enhanced also; because, aside from consumption, sugarcane cultivation in the world is targeted towards the production of sugar, ethanol, and many more. The aggregate of the various cottage industry extraction activity, would sum up to meeting the global requirement for the numerous sugarcane products; but what state the machine puts the extracted juice in, is another thing to consider.

In this light, one should not, for the purpose of solving a problem, create another problem. The incursion of rust and surrounding debris into the extraction process of the fabricated machine has been an issue to which one needs to proffer solution to. These numerous contaminants when introduced into the desired substance get to mix-up with it and when consumed, they tend to reside in the body and accumulate until its adverse effect would be prominent. For any consumer, the knowledge of such a technology would make them find satisfaction in retaining backward and archaic techniques such as’ buccal’ juice extraction.

1.3 OBJECTIVE OF WORK

The improvement of the previously constructed sugarcane juice extractor for the cottage industry is the main objective of this project work. The scheduled improvement is to cater for the under listed purposes.

Maintenance of the sugarcane juice extractor machine.

To improve the aesthetics of the constructed machine.

Identify and construct the missing components of the sugar cane extractor; especially the casing, hopper and chutes. The casing of the operating chamber would in turn help improve the enclosure of the extraction process, minimizing the interaction of the surrounding with the process.

The reduction of machine use hazard. This is achieved by ensuring that the various joints are well secured; and covering most moving parts.

The improvement of the separation of the juice from bagasse; and the collection.

Testing of the machine. This is subjecting the machine to tests under laboratory conditions.

Evaluate the performance of the machine.

1.4 LITERATURE REVIEW

Syed Altaf Hussain, K. PalaniKumar, V. Pandurangadu, V.Siva Prasad [2]

The review mainly focuses on replacement of cast iron spur gears with Nylon spur gear in the application of sugarcane juice machine.

In this study they have performed a theoretical analysis of a procedure to determine the Lewis factor and also performed the contact analysis of spur gears to find the stress distribution between gear teeth.

Michael T. Adamolekun, Robinson Akinnusi, Kehinde A. Adewole, [3]

The review mainly focuses on design, load analysis and testing of machine for sugarcane juice extractor for small scale industries. Thereafter, 1 kg of unshrouded sugarcane was first weighed and fed into the machine. The time for crushing and squeezing was noted. This was repeated for different weight of 2kg,3kg, 4kg and 5kg respectively. From the data obtained, the efficiency of the machine was calculated.

Olaoye. J.O [1]

In this research paper first design, calculation and construction of sugarcane juice extractor machine components with help of power, force and RPM. After machine testing and with help of data calculated efficiency of machine.

Syndey e tilby [5]

In this review mainly focuses that improved sugarcane separation equipment having movable carriages adjacent to the tower-like central unit, such carriages being movable toward and away from such central unit and having removal apparatus thereon.

 Secondary carriage provide additional downstream functions or earlier diversion of the product streams.

Mr.Patil, Mr.Talashkar S.P Mr.Tagare [4]

The review mainly focuses on that constructed machine prototype going through dangerous procedure. Other problems associated that skilled labour are required and considerable amount of time that the trimming procedure takes.

Rafael E. Snachez, Alfredo J.  Sanchez [6]

The review mainly focuses on that an improved sugarcane juice extractor has removable crushing rollers.The juice extractor includes a housing with a juice extracting compartment and closure for a accessing the compartment. The closure is such that which permits viewing of the compartment during operation. A waste channel is also provided for the exit of the crushed cane pulp.

Jorge E.  Gonzales [8]

The review mainly focuses on that extracting and processing sugarcane juice from sugarcane sticks to produce a natural juice product. This includes sugarcane sticks with high sucrose level, extracting sugarcane juice using roller mill apparatus, filtering juice through a screen filter and stabilize the pH of the juice in a non-acidic solution.

Mysore Nagarajarao Ramesh, Bashyam Raghavan [7]

The review mainly focuses on that providing a method wherein the flavoured sugarcane juice containing 18-20% soluble solids and can be preserved after suitable dilution in aseptic unit packs.

 The following steps are: Sugarcane cleaning, Pre-treatment, washing, crushing the sugarcane up to 50-60%, Filtration, maintain the pH 3.5-4.0.

CHAPTER: 2

CANVAS

2.1.1 Observation Matrix

Observation

Time Consuming

More energy utilized

Less efficiency

Problem of illness

Generally available machines have more hazardness

Scouted challenges

To reduce the hazardness of the machine

To improve the aesthetics of the constructed machine.

Improvement of the separation of the juice from bagasse and the collection.

Evaluate & improve the performance of the machine.

Top five problems on the basis of Desirability, Feasibility, and viability

Use of the non-reactive metallic material for the fabrication which is mild steel having contact with the juice.

To boost the production of sugarcane juice & its products.

The casing would improve the safety of the operator.

Due to the adoption of the hopper section which will be saving the time losses & activity at employed labour.

The reduction of machine hazardness which is achieved by ensure that various joints are well secured.

Final problem Select 1 from Top 5

To boost the production of sugarcane juice & its products.

Figure 5: observation Matrix

AEIOU Summary

Environment

From the Sugarcane farm get idea related to juice extractor.

Improvement in available sugarcane juice extractors.

Try to reducing the noise problem

Separation of juice from bagasse.

Interactions

Farmer

Industry

Juice shopper  

Objects

Reducing hazardness of machine

Minimizing the interaction of surrounding

Economical Significant

Improvement in aesthetics look

Activities

For the extraction of juice

Home Purpose application

Industrial purpose application

Jaggery

Sugar

Separation of bagasse and its collection

Users

Jaggery making industry

Juice maker

Worker

Khandsari / sugar making industry

Figure 6: AEIOU Summary

2.1.3 Ideation Canvas

People

Jaggery making industry

Khandsari / sugar making industry

Juice maker

Worker

Activities

For the extraction of juice

Home purpose application

Industrial purpose application

Jaggery

Sugar

Separation of bagasse and its collection

Situation/context/Location

Industrial location

Juice shop

Home purpose

Props/Possible solutions

Reducing hazardness of machine

Economical significant

Improvement in juice separation

Minimizing the interaction of the surrounding

Improvement in aesthetics look

Figure 7: Ideation Canvas

2.1.4 Product Development Canvas

Purpose

Reduce the hazardness

Improve the performance of machine

Improve the aesthetics of the machine.

Maintenance of sugarcane juicer.

Juice separation improve from bagasse

People

Worker

Jaggery industry

Juice maker

Sugar industry

Home purpose

Product Experience

More efficient

Reduce hazardness

Cost  reduction

Flexibility

Time reducing

Product Functions

Separation of juice by passing sugarcane through one time pilling

Reduce human efforts

Reduce the illness

Product Features

Reduce the noise pollution

High efficiency

Compact in size

High Flexibility

Easy in maintenance

Components

Gear box

Roller

Bearing

Chain and sprocket

Spur gear

Strainer

Motor

Casing

Customer Revalidation

Provide a better safety

Pure juice extraction

Improve aesthetic of constructed Machine

Noise reduction

Reject, Redesign, Retain

Redesign

Figure 8: Product Development Canvas

2.2 Block Diagram

CHAPTER 3

3.1 Implementation:

Figure 9: cad model of sugarcane juice exactor

Figure 10: cad model of sugarcane juice exactor

Figure 11: Roller mechanism

Figure 12: chain-sprocket assembly

[1] Motor

[2,3,5] Spur gear

[4] Roller

[6] Chain

[7] Sprocket

3.2 Specifications of sugarcane juice machine motor [9]

Power (P) = 0.74 kW = 740 watt

Horsepower= 1 HP

Speed (N) = 500 RPM

Power (P) = 2πNT/60

740 = (2×π×500×T)/60

Torque (T) = ((740×60))/((2×π×500))

T= 14.2 Nm

T= 14200 N-mm

3.3 Spur Gear design [9]

Trial 1:

m=7             

Y=0.289          

N=30 rpm

Cs=1.75

Z=15 teeth      

P=0.74 kW          

Sut=300N/mm²

Mt=(60×'〖'10'〗'^6 (kW))/2πN

= (60×'〖'10'〗'^6×0.74)/(2×π×30)

d=m×Z

   =(7×15)   =105mm

b=10m=10*7=70 mm

Check for design: [9]

Pt=(2×Mt)/d

= (2×235549.31)/105

= 4486.65 N

V=πdn/(60×'〖'10'〗'^3 )

  = (π×105×30)/(60×'〖'10'〗'^3 )

= 0.1649 m/s

Cv=3/((3+v))

= 3/((3+0.1649))

   = 0.9478

Peff =(Cs×Pt)/Cv

= (1.75×4486.65)/0.9478

= 8283.30 N

Sb =m×σb×Y

 =7×70×100×0.289

 =14161 N

Fs=Sb/Peff

=1.71

So design is safe.

Specification of spur gear:-[9]

Number of teeth on gear=15

Module=7 mm

Face width=70 mm

Pitch circle diameter=105 mm

Addendum=7 mm

Dedendum=8.75 mm

Clearance=1.099 mm

Tooth thickness =10.99 mm

Fillet radius=27.3 mm

3.4 Gearbox design: [9]

i\'=Angular velocity first driving gear/Angular velocity last driven gear

  =500/30

  =16

i=√i\'= √16=4

20° pressure angle

Zp=15

Zg=iZp=4×15

    = 60

Z1=Z3=15

Z2=Z4=60

The speed of the shaft are as follow.

Na=500 rpm

Nb=Na(Z1/Z2)

=500×(15/60)

=125 rpm

Nc= Nb×(Z3/Z4)

=125×(15/60)

=31.25 mm

Assume velocity 5 m/s

Cv = 3/(3+V)

=  3/'█'([email protected])

=3/8

m = [(60×'〖'10'〗'^6)/π {(kW)×Cs×fs/z3×n3×Cv×(b/m)×(Sut/3)×y} ]

  =[(60×'〖'10'〗'^6)/π {(0.74)×1.75×(1.5/15)×125×(3/8)×10×(300/3)×0.289}

m= 5 mm

Gear dimensions:

D3= mZ3=5×15=75 mm

D4=5×60=300 mm

B=10m=50 mm

Beam strength

Sb=m×b×σb×Y

=5×50×100×0.289

=7225 N

Static load

Mt=(60×'〖'10'〗'^6 )kW/2πNb

    = ((60×'〖'10'〗'^6 )×0.74)/(2π(125))

    = 56531.83 N-mm

Pt=(2Mt/d3)

= (2×56531.83)/75

=1507.51 N

V=(π×d3×n3)/(60×'〖'10'〗'^3 )

    = (π×75×125)/(60×'〖'10'〗'^3 )

 =0.49087 m/s

Cv=3/( (3+v))

=3/((3+0.49087))

=0.859

Effective load

Peff=(Cs×Pt)/Cv

        = (1.75×1507.51)/0.859

=3069.80 N

Fs=Sb/Peff

=7225/3069.80

=2.35

So design is safe.

Gear dimension:

Gear (1) and (3) dimension

Module=5 mm

Face width=50 mm

Addendum==5 mm

Dedendum=6.25 mm

Tooth thickness=7.855 mm

Filet radius=19.5 mm

Pitch circle diameter=75 mm

Addendum circle diameter=85 mm

Dedendum circle diameter=62.5 mm

Number of teeth =18

Clearance=0.65 mm

Figure 13: Gearbox

Gear (2) and (4) dimension

Module=5 mm

Face width=50 mm

Addendum==5 mm

Dedendum=6.25 mm

Tooth thickness=7.855 mm

Filet radius=19.5 mm

Pitch circle diameter=300 mm

Addendum circle diameter=310 mm

Dedendum circle diameter=287.5 mm

Number of teeth =60

Clearance=0.196 mm

3.5 Future work

Up to this semester we complete work up to select the gear, select the economical suitable material and design and in next semester we will make a prototype of three roller type sugarcane juicer machine.

3.6 Conclusion

By selecting this project we conclude that we observed many problems in previous available machines. The problems were related to more hazardness, more energy utilized, problem of illness, less efficiency, juice separation from bagasse. And in our project we introduce three roller type sugarcane juicer machine with casing and also consider about material and use corrosion less material which is economical suitable for people.

References

Journal of Agricultural Technology 2011 Vol. 7(4): 931-944 ISSN 1686-9141, Development of a sugarcane juice extractor for small scale industries by Olaoye, J. O.*

International Journal of Modern Engineering Research (IJMER)    Vol.2, Issue.4, July-Aug 2012 pp-2862-2866      ISSN: 2249-6645 , Modelling and Analysis of Spur Gear for Sugarcane Juice Machine under Static Load Condition by Using FEA by V. Siva Prasad, Syed Altaf Hussain,V.Pandurangadu, K.PalaniKumar.

Journal of Multidisciplinary Engineering Science and Technology (JMEST) ISSN: 3159-0040 Vol. 2 Issue 5, May – 2015, Development of a Sugarcane Juice Extractor for Small Scale Industries Kehinde A. Adewole, Michael T. Adamolekun, RobinsonAkinnusi. Department of Mechanical Engineering, the Federal University of Technology.

International journal of advanced scientific and technical research,  Issue 3 volume 3, May-June 2013,ISSN 2249-9954, Design and manufacturing of sugar cane peeling machine  (1)Mr. Tagare V.S, (2)Mr. Patil V.B ,(3)Mr. Talaskar S.P, 4Mr. Wadar S.D studied at tatyasaheb kore instistute of engineering and technology Warananagar.

Sugarcane separation configuration by Syndey e tilby, us patent, patent no-5116422.

Sugarcane juice extractor by Rafael E. Snachez, Alfredo J.  Sanchez U.S. Patent No.5, 320,035.

Flavoured sugarcane juice in aseptic unit packs, Mysore Nagarajarao Ramesh, Bashyam Raghavan U.S. Patent No.2006/0083835 A1.

Method for producing sugarcane juice by Jorge E.  Gonzales U.S.Patent No.6,245,153 B1

Books of machine design by V.B.Bhandari.

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