Dar Es Salaam Institute of Technology: June, 2017

DAR ES SALAAM INSTITUTE OF TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT
BACHELOR OF MECHANICAL ENGINEERING
NTA LEVEL 8
SENIOR PROJECT-II
PROJECT TITLE : DESIGN AND MANUFACTURE OF SPICE

MILLING MACHINE
PROJECT TYPE : PROBLEM SOLVING
STUDENT NAME : STELLA MWENDWA
ADMISSION No : 130545491358
CLASS : B.ENG 14 ME
June, 2017
Certification
CERTIFICATION
The undersigned certify that she has read the project titled: Design and manufacturing
of spice milling machine. In the fulfillment of the requirements for the Bachelor of
Engineering degree in Mechanical Engineering at Dar es salaam Institute of
Technology.
……………………………
Eng. Dunstan Mbunga.
(Project supervisor)
i
Declaration
DECLARATION
I declare that this project titled Design and manufacture of spice milling machine is
submitted to Department of Mechanical Engineering of Dar es Salaam Institute of
Technology in Partial fulfillment of the Bachelor Degree in Mechanical
Engineering.This is my work was not submitted elsewhere for the award of any other
degree.
……………………..
STELLA MWENDWA
(Student Name)
ii
Acknowlegment
ACKNOWLEDGEMENT
I would like to express my sincere gratitude to all people whom in one way or another
they have contributed upon doing this project. I feel obliged to some of them whose
help was most appreciated. It is not possible to mention every one in this report due to
limited space, so I extend my thanks to the following;
Firstly I would like to acknowledge helpful discussion I have had with my supervisor
Eng Dustan Mbuga,a lecturer at Mechanical Engineering Department at D.I.T who has
has helped in many and various ways.
Secondly I would like to express my sincere thanks to Eng.Sanga.a lecturer and Head
of Mechanical Engineering Department at D.I.T for his lectures on how to underdo
project findings and writing project report and Dr Malifeza(Departmenr Project
Coordinator) for his valuable directives and advise that helps me during preparation of
this proect.
I also express grateful thanks to all academic staff of Mechanical Engineering
Department at Dar es Salaam Institute of Technology for their technical advice,
supervision and encouragement to fulfill my project.
In addition to that I would like to my Husband Mashaka.E.Mahande for his assistance,
support and encouragement while undergoing this project.
Lastly, I would like to acknowledge all worthwhile contributions from people,
Institutions and firms for supplying of the information which has become very helpful
in preparation of this project report.
iii
Dedication
DEDICATION
I would like to dedicate this project to my family Mashaka.E.Mahande (husband) &

Janeth Mahande (baby) and Melkiad Mwendwa(father). I do appreciate their efforts.
May God Bless them.
iv
Abstract
ABSTRACT
Spices is among the dominant crops in Tanzania which enables most smollholder
farmers earn income . Economy of Tanzania is mostly based on agriculture, which
account for more than half of the GDP, provide 85%(approximately) of exports, and
employs approximately 80% 0f the work force.About 80% of the population in
Tanzania lives in rural areas and are in some way or another depending on agriculture.
This project work is on the design and fabrication of a spice milling machine. It is
aimed at providing a base for the commercial production of a portable spice milling
machine,using available raw material at relative low cost. The successful fabrication
of a spice milling macine is one of the major, if not the challenge in spice processing .
This work is intended to help solve some of the problems heading a successful design
and fabricaton of spice milling machine.
Through Literature, the Mortar and pestle, Hammer Mill, Ball Mill, Wood Pellet Mill,
Pellet Mill, Grist Mill (flour mill) methods of milling spices and effects of various
methods of spicing were reviewed for obtaining the optimal design and manufacture
the prototype, clearance between the grinding discs, Hummer and betwee top milling
chamber and bottom milling chamber were reviewed.
Using the above, various methods of forces application for the milling of spices had
been consided and preliminary designs made. The development of the machine will
bring to an end the local methods of milling process which is a limitation on the large
scale production of processed spices(flour of spices) It will revolution spices
cultivation, production and product.
v
Contents
CONTENTS
CERTIFICATION...........................................................................................................i
DECLARATION............................................................................................................ii
ACKNOWLEDGEMENT............................................................................................iii
DEDICATION..............................................................................................................iv
ABSTRACT...................................................................................................................v
LIST OF FIGURES........................................................................................................x
LIST OF TABLES........................................................................................................xi
CHAPTER ONE.............................................................................................................1
INTRODUCTION..........................................................................................................1
1.1 Background...........................................................................................................1
1.2 Problem statement................................................................................................2
1.3 Project objectives..................................................................................................3
1.3.1 Main objectives..............................................................................................3
1.3.2 Specific objectives.........................................................................................3
1.4 Significance of the project....................................................................................3
1.5 Limitation.............................................................................................................4
CHAPTER TWO............................................................................................................5
LITERATURE REVIEW...............................................................................................5
2.1 Introduction..........................................................................................................5
2.2 Spice.....................................................................................................................5
2.2.1 Forms of Spices.............................................................................................5
2.2.2 Types of spices..............................................................................................6
2.2.3 Application of spices.....................................................................................6
2.4 Handling spices.....................................................................................................6
2.5 Mill (grinding)......................................................................................................7
vi
Project Work for Bachelor of Mechanical Engineering Students, DIT
2.6 The Principle of Grinding Mill.............................................................................7
2.6.1 Types of grinding mills..................................................................................8
2.7 Mortar and pestle..................................................................................................8
2.7.1 How to use a mortar and pestle.....................................................................9
2.8 Hammer Mill......................................................................................................10
2.8.1 Advantages..................................................................................................11
2.8.2 Disadvantages..............................................................................................11
2.8.3 General Design............................................................................................12
2.8.4 Feeder Design..............................................................................................12
2.8.5 Hammer design and configuration..............................................................13
2.8.6 Screen Design..............................................................................................13
2.8.7 Hammer mill perforated screens..................................................................14
2.8.8 Mills Hammers............................................................................................14
2.8.9 Dimension of a hammer..............................................................................14
2.9 Ball Mill..............................................................................................................15
2.9.1 Description...................................................................................................15
2.9.2 Ball mill working principle..........................................................................16
2.9.3 Ball mill application....................................................................................16
2.10 S.A.G Mill........................................................................................................16
2.10.1 S.A.G Mill principle operation..................................................................17
2.11 Pellet Mill.........................................................................................................17
2.11.1 Wood Pellet Mill.......................................................................................18
2.12 Grist Mill (flour mill).......................................................................................19
2.12.1 Early History..............................................................................................19
2.13 Pulverizers.......................................................................................................20
2.13.1 Mono pulverizer........................................................................................20
2.13.2 Min Pulverizer...........................................................................................20
vii
Contents
CHAPTER THREE......................................................................................................22
METHODOLOGY.......................................................................................................22
3.1 Introduction........................................................................................................22
3.2 Literature Review...............................................................................................22
3.3 Data collection....................................................................................................22
3.4 Consultation........................................................................................................22
3.5 Observation.........................................................................................................22
3.6 Data analysis.......................................................................................................22
3.7 Analyzing the probable solution.........................................................................23
3.8.Determinations of machine parameters..............................................................23
3.9 Drawings.............................................................................................................23
3.10 Prototype manufacturing..................................................................................23
3.11 Report writing...................................................................................................23
CHAPTER FOUR........................................................................................................24
DATA COLLECTION.................................................................................................24
4.1 Data collection....................................................................................................24
4.1.1 Types of Spices............................................................................................24
4.1.2 Properties of Spices....................................................................................24
4.1.3 Moisture Content.........................................................................................24
4.1.4 Size and shape Spices..................................................................................25
4.1.5 Selection of the appropriate materials.........................................................26
CHAPTER FIVE..........................................................................................................27
DATA ANALYSIS......................................................................................................27
5.1 Design of Spice milling machine........................................................................27
5.1.1 Design parameters.......................................................................................27
5.1.2 Generation and evaluation of alternatives...................................................28
5.1.3 Alternative design type A............................................................................28
viii
5.1.4 Alternative design type B............................................................................30
5.1.5 Alternative design type C............................................................................32
5.1.6 Selection of suitable design.........................................................................34
5.1.7 Determination of the weighing factor..........................................................34
5.1.8 Ranking the altenative design......................................................................35
5.2 Design the best alternative..................................................................................35
5.2.1 Belt selection...............................................................................................37
5.2.2 Key design...................................................................................................52
5.2.3 Pulley design................................................................................................56
5.2.4 Milling chamber..........................................................................................58
5.2.5 Hummer design............................................................................................58
5.2.6 sieve design..................................................................................................58
5.2.7 Hopper design..............................................................................................59
5.2.8 frame design................................................................................................59
5.2.9 Spice milling machine safe working procedure..........................................59
5.2.10 Manufacturing process..............................................................................60
CHAPTER SIX.............................................................................................................64
CONCLUSION AND RECOMMENDATION...........................................................64
6.1 Conclusion..........................................................................................................64
6.2 Recommendations..............................................................................................64
REFERENCES.............................................................................................................65
APPENDICES..............................................................................................................66
ix
List of Figures
LIST OF FIGURES
Figure 1.1: women grindind spices using manual operated machine............................3

Figure 2.1: A Mortar and pestle (Source: ukerewe village)...........................................8
Figure 2.2: Cross section view of a hammer mill.........................................................11
Figure 2.3: Major components of hammer mill............................................................12
Figure 2.4: Hammer Mills Screen................................................................................14
Figure 2.5: Hummer mill dimension.............................................................................14
Figure 2.6: Ball Mill.....................................................................................................15
Figure 2.7: S.A.G Mill...................................................................................................17
Figure 2.8: Wood Pellet Mill........................................................................................19
Figure 5.1: Design alternative A...................................................................................29
Figure 5.2: Design alternative B...................................................................................31
Figure 5.3: Design alternative C..................................................................................33
Figure 5.4: Show center distance..................................................................................38
Figure 5.5: Free body diagram (b) Shearing force diagram (c) Bending moment
diagram.........................................................................................................................46
Figure 5.6: bearing.......................................................................................................52
Figure 5.7: forces acting on the key..............................................................................53
Figure 5.8:sketch of the key dimension.........................................................................55
Figure 5.9: sketch section of driven pulley...................................................................57
x
List of Tables
LIST OF TABLES
Table 2.1: Technical specification of wood pellet mill.................................................18

Table 2.2: Technical specification for mono pulverizer...............................................20
Table 2.3: Technical specification for min pulverizer..................................................21
Table 4.1: Data from SIDO..........................................................................................26
Table 5.1: Morphological chart for milling machine...................................................28
Table 5.2: Design alternative for spice milling machine..............................................28
Table 5.3: Marks and average for an Alternative A.....................................................30
Table 5.4: Marks and average for an Alternative B.....................................................32
Table 5.5: Marks and average for an Alternative C.....................................................33
Table 5.6: Determination of the weighing factor.........................................................34
Table 5.7: Weighting factors, weight and score...........................................................35
Table 5.8: Procedure used to manufacture the prototype............................................60
Chapter One
CHAPTER ONE
INTRODUCTION
1.1 Background
Agriculture is the foundation of Tanzanian economy. It accounts about a half of the
national income, three quarters of merchandise export and is the source of food and it
provides employment opportunities to about 80% percent of Tanzanians. It has
linkages with the non-farm sector through forward linkages to agro-processing,
consumption and export, provides raw materials to industries and market for
manufactured goods.
Agriculture in Tanzania is dominated by smallholder farmers (peasants) cultivating an
average farm size between 0.9 hectares and 3.0 hectares each. About 70 percent of
Tanzania’s crop area is cultivated by hand hoe, 20 percent by ox plough and 10
percent tractor. It is rain fed agriculture. Food crop production dominates the
agriculture economy 5.1 million hectors are cultivated annually, of which 85 percent
is under food crops. Women constitute the main part of labor force. The major
constraint facing the agriculture sector is the falling labor and land productivity due to
application of poor technology, dependence on unreliable and irregular weather
conditions. Both crops and livestock are adversely affected by periodical droughts.
Irrigation holds the key of stabilizing agricultural production in Tanzania to improve
food security, increase farmers’ productivity and incomes, and also to produce higher
valued crops such as vegetables and even flowers. Agricultural GDP has grown at 3.3
percent per year since 1985, the main food crops at 3.5 percent and export crops at 5.4
percent per year. Considering that the overall GDP growth target for having poverty in
the range of 6-7 percent. The micro economic reforms have and continue to have had
significant impact on the agricultural sector. The economic reforms have lead to the
opening up of the sector to private sector investment in production and processing,
input importation and distribution and agricultural marketing. Most of production and
processing and marketing functions have been assigned to the private sector. The
government has retained regulatory and public support functions or facilitation role.
Farmers are free to sell their crops to cooperatives or private traders. Due to
competition, normal producer prices for food and export crops have increased as such
farmers can now sell their
produce much faster. Farmers are no longer confined to a single source for their
essential inputs for crops and livestock.
Urban agriculture has flourished as a household-level initiative to cope with economic

hardships encountered as a result of raising cost of living. Urban agriculture that
consists of raising and growing of vegetable and food crops is found in Tanzanian
towns and cities where the ready markets for agricultural products are found.
Producers are vegetables, milk, broilers’ meat and eggs sell to private households and
to school, hotels, bars, cafeterias and restaurants.
Our country is situated along the tropic zone where various types of spices such as
pepper, ginger, dry tomatoes etc, are cultivated. Over 80% of spices used in this
country are cultivated by Tanzanian peasant in various regions such as Mtwara, Lindi,
Mbeya, Morogoro, Tanga, Uguja and Pemba etc.
Apart from being used as spices in our country, they are also exported to foreign
country as a business product. Since these products are seasonal, they are processed
and stored for future use. Various spices are milled for preservation purpose, adding
its value in the market and simplification of packaging and storage.
Different ways have been used to mill these spices depending on environment and
availability of facilities. The peasants in our villages do mill these spices by pounding
manually using pestle and mortar, the process which is very tiresome and powdered
product obtained is poor and small.
By designing the spices milling machine will have the capacity of milling up to 20
kilogram per hour at high quality compared to manually pound. : [ CITATION
Agr98 \l 1033 ]
1.2 Problem statement

Milling of spices has been a serious problem due to the following ambiguities:
i. Traditional methods take about 1hour to mill 3kg of spices.
ii. The value of spices which is not milled is low at the same time packaging and
storage is difficult.
iii. There is no simple and low cost machine of milling spices.
iv. Inhaled spices powder causes, sneezing, coughing and lung diseas
2
Chapter One
Figure 1.1: women grindind spices using manual operated machine

(At Ukerewe District)
1.3 Project objectives

1.3.1 Main objectives
The main objectives of this project is to design the spice mill machine that will be
cheaper ergonomic to peasants.
1.3.2 Specific objectives

The following is the specific objectives of the project;
i) To study the existing methods that is used to mill spices.
ii) To design the machine parts with specification required and estimate the cost
involved.
iii) To design and manufacture of spices milling machine.
1.4 Significance of the project

The design of spice milling machine are aimed to replace the existing manual milling
process, the following advantages is expected:
i) High working capacity-the machine will mill from 3kg/hr to 20kg/hr of spices.
ii) To have a low cost machine that is affordable to peasants
iii) The peasants will earn more income in their sells by adding value to the
product
iv) The safe working condition of the machine that will ensure life of personnel
and time saving.
1.5 Limitation
The project is focusing to small and medium scale farmers in Tanzania. The machine
will be capable of milling various spices are recommended and also maize, sorghum
etc. small modification to the machine such as to change the sieve and the rotational
speed in the milling chamber
4
Chapter Two
CHAPTER TWO
LITERATURE REVIEW
2.1 Introduction
In literature review the technical information has been obtain from different sources.
The information collected is those having an influence of knowing the various type of
spices and their properties and also the different process used to mill the spices and
their design procedures. These will also give determination activities in an excellent
manner. All technical related topic which seem to have assistance in accomplishing of
the project will be included in this section
2.2 Spice
A spice is a dried seed, fruit, root, bark, vegetable substance used in nutritionally in
significant quantities as a food additive for the purpose flavor, color or as a
preservative that kills harmful bacteria or prevent their growth.
Spice is a vegetable product that made from plant, especially in the form of powder,
which is used for giving the test to other food. It is strongly flavored and aromatic part
of a plant used in a small quantity as either a preservative or flavor in cooking. Spice
are generally the dried part of the plant, i.e. bark, root, stem of plant.
2.2.1 Forms of Spices

i) Whole spice: These spice are used in their original form after being thoroughly
cleaned. These spice are used both garnishing as well as flavoring .e.g. cloves,
cinnamon, black pepper.
ii) Ground Spices: Grinded spices are used as their deriver flavor quickly and also
they blend easily into a product; this is so because grinding a spice break down
into protective cell structure.
Whole spices can be grouped further into the following classification.

i) Dried fruits or seeds, such as fennel ,mustard, and black pepper
ii) Dried buds such as cloves
iii) Roots and rhizomes, such as turmeric, ginger and galingale
5
2.2.2 Types of spices

There are different types of spices being produced for their culinary, medicinal use.
Spices are essentially the flavored or aroma part of a plant used as a preservative or
food flavoring. These spices are cultivated and grown in different parts of the world
depending on climatic conditions, soil required etc.
Spices can be grouped as:
i) Dried fruits or seeds, such as fennel, mustard, and black pepper
ii) Arils, such as mace
iii) Barks, such as cinnamon and cassia
iv) Berries, such as Black pepper and chili
v) Kernel, such as Nutmeg.
vi) Dried buds, such as cloves.
vii) Stigmas, such as saffron
viii) Roots and rhizomes, such as turmeric, ginger and galingale.
ix) Leaf such as Basil, Bay Leaf, Marjoram, Sage, Curry Leaf
x) Resins, such as foetida
xi) Herbs such as bay, basil and thyme are not, strictly speaking, spices, although
they have similar uses in flavoring food. The same can be said of vegetable
such as onion and garlic.
2.2.3 Application of spices

Spices is used mainly for food flavoring and preservation. However, spices have
been used for medicinal, aromatic properties that also make them useful in a
number of industries including:
i) Perfumes
ii) Cosmetics
iii) Medicine
iv) Beverage
2.4 Handling spices

A spice may be available in several forms: fresh, whole dried, or pre-ground dried
generally, spices are dried. A whole dried spice has the longest shelf life so can be
purchased and stored in larger amounts, making it cheaper on a pre-serving basis.
Some spices are rarely available either fresh or whole, for example turmeric, and must
6
Chapter Two
be purchased in ground form, small seeds, such as fennel and mustard seeds, are used
both whole and in powder form.
The flavor of a spice is derived in part from compounds that oxidize or evaporate
when exposed to air. Grinding a spice greatly increase its surface area and so increase
the rates of oxidation and evaporation. Thus, flavor is maximized by storing a spice
whole and grinding when needed.
2.5 Mill (grinding)

A grinding mill is a unit operation designed to break a solid material into smaller
pieces. There are many different types of grinding mills and many types of material
processed in them. Historically mills were powered by hand (mortar and pestle),
working animal, wind (windmill) or water (watermill). Today they are also powered
by electricity.
The grinding of solid matters occurs under exposure of mechanical forces that trench
the structure by overcoming of the interior bounding forces. After the grinding the
state of the solid is changed: the grain size disposition and the grain shape.
Grinding may serve the following purposes in engineering shape:
i) increase of surface area of a solid
ii) manufacturing of a solid with a desired grain size
iii) pulping of resource
2.6 The Principle of Grinding Mill

A grinding mill crushes material between two closely placed, heavy objects like
stones. They are rotating with respect to one another so the material gets crushed like
in a mortar and pestle. Observation and research finding indicate that earliest type of
grinding mill is called a quern stone, which consists of the two heavy stones which fit
together. The top rotates and the corn is trapped between the stones. The faces usually
have small groves carved into then, and these function a lot like the teeth on the file.
The corn gets “stuck” and other sides rotates, and files away the free surface of the
stuck again.
If the grain are approximately a sphere (but isn’t) and isn’t perfectly spread over the
grinding faces. The upper stone will be supported by thin layer of grain which works a
little bit like ball bearings. But because the grains aren’t perfect spheres, when they
rotate a few will rotate and try to raise the upper stone, increasing the pressure on the
7
grain to such an extent that the husk is likely to crack. If the upper stone is being
turned fairly fast, the pressure gets bigger.
2.6.1 Types of grinding mills

There are various types of grinding mill such as follows
i. Mortar and pestle
ii. Hammer mill
iii. Ball mill
iv. SAG mill
v. Pellet mill
vi. Grist mill also called flour mill or corn mill
vii. pulverizer
2.7 Mortar and pestle

A mortar and pestle is a tool used to crush, grind, and mix substances. The pestle is a
heavy bat shaped stick whose end used for pounding and grinding, and the mortar is a
bowl, typically made of hard wood, marble, clay or stone. The substance is a ground
between the pestle and the mortar. This method provide a traditional means of milling
spices, from engineering point of view it is time consuming and arduous.
In case of Tanzania, still we use this tradition method to mill spices in a mortar and
pestle. At most tradition process techniques are laborious, monotonous and carried out
by the hand whereby women and children are responsible. The time required milling
spices depends on the skill of operator and the variety. Typical times for milling
spices are approximately one hour to mill 3 kilograms of spices.
Figure 2.2: A Mortar and pestle (Source: ukerewe village)
8
Chapter Two
Mortar used pulverize plant material

Mortars are also used in cooking to prepare ingredients such as guacamole and pesto
(which derive its name from the pestle pounding), as well as grinding spices into
powder.
Good pestle and mortar making materials must be hard enough to crush the substance
rather than be own away by it. They cannot be too brittle either, or they will break
during the pounding and grinding. The material should also be cohesive, so that small
bits of the mortar or pestle do not get mixed in with the ingredients. Smooth and non-
porous materials are chosen that will not absorb or trap the substances being ground.
In food preparation, a rough or absorbent material may cause the strong flavor of a
past ingredient to be tasted in food prepared later. Also the food particles left in the
mortar and on the pestle may support the growth of microorganisms. When dealing
with medications, the previous prepared drugs may interact or mix, contaminating the
currently used ingredients.
Rough ceramic mortar and pestle sets can be used to reduce substances to very fine
powders, but stain easily and are brittle. Porcelain mortars are sometimes conditioned
for use by grinding some and to give them a rougher surface which helps to reduce the
particle size. Glass mortars and pestles are fragile, but stain resistant and suitable for
use with liquids. However, like the porcelain type, they do not grind as finely as the
ceramic type. Other materials used include marble, stone, wood (highly absorbent),
bamboo, iron, steel, brass, and basalt. Mortar and pestle sets made from the wood of
old grape vines have proved reliable for grinding salt and pepper at the dinner table.
Uncooked rice is sometimes ground in mortars to clean them. This process must be
repeated until the rice comes out completely white.
2.7.1 How to use a mortar and pestle

Place the food in the mortar (bowl) in small quantities.
Use some downward pressure over the food with the pestle (pounder). With hard
foodstuffs, like peppercorns and even pills, move the pestle back and forth over it with
some pressure until it breaks up. Turn the pestle in a circular motion around the
mortar, maneuvering it back and forth with a bit of pressure over still unbroken pieces.
It doesn’t take long to get used to using a mortar and pestle. Whether it’s to grind
some peppercorns, or your coffee beans, or avocadoes for guacamole, a mortar and
pestle set can be a handy non- electric kitchen tool.
9
2.8 Hammer Mill

A hammer mill is a machine whose purpose is to shred material into the fine particles.
They have many sorts of applications in many industries, including:
i. Ethanol plants
ii. Grinding used shipping pallets for mulch.
iii. Sawmills ( size reduction of trim scrap and planer shavings into boiler fuel or
mulch )
iv. A farm machine, which mills grain into coarse flour to be fed to livestock.
Shredding paper
v. Milling grain.
vi. Shredding scrap automobiles.
vii. In waste management.
The concept is fairly straightforward. A hammer mill is essentially a steel drum
containing a vertical or horizontal cross-shaped rotor on which pivoting hammers are
mounted. The hammers are free to swing on the ends of the cross. The rotor is spun at
a high speed inside the drum while material is fed into a feed hopper. The material is
impacted by the hammers on the ends of rotating across and thereby is shredded and
expelled through screens in the drum.
Slow speed horizontal pallet grinders mall grain hammer mills can be operated on
household current. Large automobiles shredders can use one or more 1.5 MW diesel
engines to power the hammer mill.
The material is beaten until it is small enough to fall through the screen which forms
the lower portion of the casing. Since the hammer bars are hinged, the presence of any
hard material does not cause damage to the equipment. The bars are readily replaced
when they are worn out. The machine is suitable for the crushing of both brittle and
fibrous materials, and, in the latter case, it is usual to employ a screen with cutting
edges. The hammer mill is suitable for hard materials although, since a large amount
of fines is produced, it is advisable to employ positive pressure lubrication to the
bearings in order to prevent the entry of dust. The size of the product is regulated by
the size of the screen and the speed of rotation.
A number of similar machines are available, and in some the hammer bars are rigidly
fixed in position. Since a large current of air is produced, the dust must be separated in
a Clone separator or bag filter.
10
Chapter Two
Figure 2.3: Cross section view of a hammer mill

Source: (www.feedmachinery.com)
2.8.1 Advantages
i. Are able to produce a wide range of particle size
ii. Work with any friable material and fibres
iii. Ease of use
iv. Lower initial investment when compared with roller mill
v. Minimum maintenance is needed
vi. Particle produced with hammer mill will generally be spherical with a
surface that appears polished
2.8.2 Disadvantages
i. Less energy efficiency when compared to roller mill
ii. May generate heat (source of energy loss)
iii. Produce greater particle size variability (less uniform)
iv. Hammer mill are noisy and can generate dust pollution
11
Figure 2.4: Major components of hammer mill

Source: (www.feedmachinery.com/hammer_mill.php)
2.8.3 General Design

The major component of these hammer mills, shown in the picture, include: a delivery
device used to introduce the material to be ground into the path of the hammers. A
rotor comprises a series of machined disk mounted on the horizontal shaft perform
this task. Free swinging hammers that are suspended from rod running parallel to the
shaft and through the rotor disk. The hammer carrey out the function of smashing the
ingredients in order to reduce the particle size. A performed screen and either gravity-
or air –resisted removal of ground product. Act to screen the particle size of the
hammer mill to ensure the particles meet a specified mesh size.
2.8.4 Feeder Design

Materials are introduced into the hammer by variable speed vein feeder. This type of
feeder can have its motor slaved by a programmable controller to the main drive
motor of the hammer mill. The operational speed of the feeder is controlled to
maintain optimum amperage loading of the main motor.
12
Chapter Two
2.8.5 Hammer design and configuration

The design placement of the hammer is determined by operating parameter such as
rotor speed, motor kilowatt and open area in the screen. Optimal hammer design and
placement will provide maximum with feed ingredients. Hammer mills in which the
rotor speed is approximately 1800rpm, should be using hammer which are around
250mm long, 63.5mmwide and 6.4mm thick. For a rotor speed of of about 3600rpm,
hammer should be 150 to 200mm long, 50mm wide and 6.4 mm thick. The number of
hammer used for hammer mills of 1800rpm, should be 1 for every 1, 86 to 2.6
kilowatt, and for 3,600 rpm, one for every 0.75 to 1.5 kilowatt. Hammers should be
balanced and arranged on the rods so that they do not trail one another. The distance
between hammer and the screen should be 12 to 14 mm for size reduction of cereal
grains. The velocity or tip speed of the hammers is critical for proper size reduction.
Tip speed is the speed of hammer at its tip or edge furthest away from the rotor, and is
calculated by multiplying the rotational speed of the drive source (shaft rpm) by the
circumference of the hammer tip arc.
A common range of tip speeds in hammer mill is commonly in the range between
5,000 and 7,000 m/ min. when the tip speed exceed 15, 000 meter per minute, careful
consideration must be given to the design of hammer mill, the material used in its
construction and the fabrication of all the components .Anything which increases the
chance of collision between hammer and a target ; increase the magnitude of
collision ; or improves material take away provides an advantage in particle size
reduction. The magnitude of the collisions can be escalated by increasing speed of the
hammers.
2.8.6 Screen Design

The amount of open area in a hammer mill screen determines the particle size and
grinding efficiency. The screen must be designed to maintain its integrity and provide
the greatest amount of open area. Screen openings (holes) that are aligned in a 60-
degree staggered pattern optimize open area while maintaining screen strength. This
method will result in a 40 percent open area using 3.2 mm holes aligned on 4.8 mm
centers. Feed producers need to pay particular attention to the ratio of open screen
area to horsepower. Recommended ratio for grains would beb55 cm2 per horsepower
(Bliss, 1990).
13
2.8.7 Hammer mill perforated screens

Hammer mills screens are used inside a hammer mill to separate particle size. Particle
of small enough diameter that has been successfully grained by the hammer mill
passes though the screen and leaves the hammer mill with the aid of pneumatic
system.
Figure 2.5: Hammer Mills Screen

Sources: http://www.feedmachinery.com/glossary/hammer mill.php
2.8.8 Mills Hammers

Hammers are used inside the hammer mill to impact smash ingredients up into small
particles, make it more suitable for uniform mixing and usage in field. Hammers are
available in huge range of configuration, shapes, facing and material. Hammer s are
available as a single holed or with two holes, with two holes allowing the hammers to
be used twice as a wear is done to one end of the hammer; the hammer can be rotated
and used a second time. The hole fits onto a rod inside the hammer mill and swings to
hit the material.[ CITATION Mar00 \l 1033 ]
Figure 2.6: Hummer mill dimension
2.8.9 Dimension of a hammer

A: Thickness
B: Width
C: Diameter to fit rod size
D: Swing less
E: Total length
14
Chapter Two
2.9 Ball Mill

A ball mill is a type of grinder used to grid materials into extremely fine powder for
use in mineral dressing process, paints, pyrotechnics, and ceramics.
Figure 2.7: Ball Mill

Source: http: //en.Wikipedia.Org/wiki/File: Ball mill
2.9.1 Description
A ball mill, a type of grinder, is cylindrical device used in grinding (or mixing)
materials like ores, chemicals, ceramic raw materials and paints. Ball mills rotate
around a horizontal axis partially filled with the material to be ground plus the
grinding medium. Different materials are used as media, including ceramic balls, flint
pebbles and stainless steel balls.
An internal cascading effect reduces the material to a fine powder. Industrial balls
mills can operate continuously fed at one end and discharged at the other end. Large to
medium – sized ball mills are mechanically rotated on their axis, but small ones
normally consists of a cylindrical capped container that sits on two drive
shafts(pulleys and belts are used to transmit rotary motion). A rock tumbler functions
on the same principle. Ball mills are also used in pyrotechnic mixtures such as flash
powder because of their sensitivity to impact.
High –ball mills are potentially expensive and can grind mixture particles to a small as
5 mm, enormously increasing surface area and reaction rates. The grinding works on
15
principle of critical speed. The critical speed can be understood as that speed after
which is steel balls (which are responsible for the grinding of particles) start rotating
along the direction of the cylindrical device ; thus causing no further grinding.
There are many types of grinding media suitable for use in a ball mill, each material
having its own specific properties and advantages. Common in some applications are
stainless steel balls. While usually very effective due to their density and low
contamination of the material being processed, stainless steel balls are unsuitable for
some applications, including:
i) Black powder and other flammable materials require non sparking lead,
antimony, brass, or bronze grinding media.
ii) Contamination by iron of sensitive substances such as ceramic raw materials.
In this application ceramic or flint grinding media is used.
iii) Ceramic media are also very resistant to corrosive materials.
2.9.2 Ball mill working principle

This ball mill is horizontal type tubular running device, has two warehouses. This
machine grid type and its outside run along gear. The material enters spirally and
evenly the first warehouse of the milling machine along the input material hollow axis
by input material device. In this warehouse, there is a ladder scale board, and different
specification steel balls are installed on the scale board, when the barrel body rotates
and then produces centrifugal force, at this time, the steel ball is carried twosome
height and falls to make the material grinding and striking. After grinded coarsely in
the first warehouse, the material then enters on the second warehouse for regrinding
with the steel ball and scale board. In the end, the power is discharged by the output
material board and the end products are completed.
2.9.3 Ball mill application

The ball mill is the key equipment for regrinding. It is widely used for the cement, the
silicate product, new type building material, fire-proof material, chemical fertilizer,
black and non-ferrous metal, glass ceramics and etc., ball mill can grind core or other
materials that can be grinded either by wet process or by the dry process
2.10 S.A.G Mill

S.A.G is an acronym for semi-autogenously grinding, which means that it utilizes
steel balls in addition to large rocks for grinding. The SAG mills use a minimal ball
16
Chapter Two
charge of 6 to 15%. It has a large diameter and short length. It rotates, tumbling its
contents, causing a breaking action. The liner is made of wear resistant steel and fitted
with lifters, which assist in raising the load as the mill rotates. The load consists of a
dry ore, steel balls and water, which occupies 30% of the volume. 8% of this volume
is steel balls.
The mill chute is continuously fresh ore and crushed until it is small enough to pass
through the discharge grates, the feed rate of the mill depends on the horsepower
available to turn the mill and how much weight the mill shell can withstand, which is
dependent on the support provided by the hydrostatic trunnion bearings.
Figure 2.8: S.A.G Mill

[ CITATION mil00 \l 1033 ]
2.10.1 S.A.G Mill principle operation

A rotating drum throws large rocks and steel balls in a attracting motion which causes
impact breakage of larger rocks and compressive grinding of finer particles. Attrition
in the charge causes grinding of finer particles. SAG mills are characterized by their
large diameter and short length. The inside of the mill is lined with lifting plates to lift
the material inside up and around the inside of the mill, where it then falls off the
plates and falls back down. SAG mills are primarily used in the gold, copper and
platinum industries with applications also in the lead, zinc, silver, alumina and nickel
industries.
2.11 Pellet Mill

Pellets create cylindrical pellet from a mixture of dry powder feedstock, such as flour.
Saw dust, or grass, and wet ingredients, such as molasses or steam. The pellet is made
by compacting the mash or mill into many small holes in a die. The die is usually
round and the die is pushed from the inside out. Pellet mills are used in the production
17
of animal feed, and of wood and grass fuel pellet for use in a pellet stove. Pellet mills
are unlike grinding mills, in that they combine small materials into larger,
homogeneous mass, rather than break larger materials into smaller pieces. In this way
pellet mills are similar to extruders. Feed stock of pellet mills can sometimes break
down and then re- form, or polymerase, under the extreme heat and pressure of the
pellet mill. Pressure in the die can reach up to 25,000psi.
2.11.1 Wood Pellet Mill

The process of pelleting consists of forcing of a soft material through holes in a metal
die plate to form compacted pellets which are then cut to a pre-determined size. The
wood pellet mills china which has been developed for this purpose in now very
diverse in design and there is much controversy between different equipment
manufactures as to which type is the most effective. Most pellet mills now have one or
more conditioning units mounted above them where liquids such as water can be
added to improve pellet ability. The water is sometimes added in the form of usually
the die plate itself rotates, and on its outer-side stationary knives cut the pellets to a
pre-set length. From there, they are transferred to a cooler/drier to remove the heat
which is generated during the pelleting process or is often added during steam
conditioning. The moisture content of the pellets also needed to be reduced for proper
storage. http://en.wikpedia.org/wiki
Table 2.1: Technical specification of wood pellet mill
model Capacity Power Net weight Outside

dimension
GC-9PK-200 80-120kg/h 7.5kw 250kg 100x43x95cm
GC-9PK-260 80-120kg/h 7.5kw 330kg 120x50x107cm
GC-9PK-300 150-200kg/h 22kw 410kg 127x52x107cm
GC-9PK-400 250-350kg/h 30kw 550kg 147x60x115cm
18
Chapter Two
Figure 2.9: Wood Pellet Mill

[ CITATION mil13 \l 1033 ]
2.12 Grist Mill (flour mill)

Flour milling is a mechanical manufacturing process which produces flour from which
wheat through comprehensive stages of grinding and separation.
A flour mill predates agricultural production; its evolution from a tedious manual
chore to a highly automated, efficient and exact industrial process reflects many social
changes and significant technological developments.
Flour is a powder made of cereal grains, other seeds or roots.
The production of flour has also historically driven technological development, as
attempts to make gristmills more productive and less labor-intensive led to the
watermills and windmill, terms now applied more broadly to uses of water and wind
power for purposes other than milling.
2.12.1 Early History

The first water-powered mill commenced operation in 1607 at PORT-ROYAL. Many
of the early wind –and driven mills has been preserved and may be seen in Ontario,
Quebec and Maritimes. Pair of circular m ill stones was used for grinding the grain.
The best millstones, made of burr, a hard silicate found in France Seine River valley,
were constructed in segments, cemented together and bound with heavy iron bands.
Both milling face of the stone were grooved. The miller’s skill lay in maintaining the
grinding faces of the stones, since the precision of millstone dressing determined the
fines of the grist. Stones were dressed with a chisel faced hammer called a mill-bill A
flour miller also required a true –steel, a bar scale for weight and a slate for tallying
the incoming grain and the outgoing grist.
19
2.13 Pulverizers
Pulverizer machines are used to smash materials into tiny shards or granules.
Pulverizer machines can crush all types of items, including plastics, glass, aluminum,
concrete, coal, rock, resin, tires, and medical waste. Pulverzer machines come in a
number of different forms. Hammer mills, ring mills, double roll crushers, granulators,
impactors, and shredders are all forms of pulverzer machines.
2.13.1 Mono pulverizer

Mono pulverizers is used for grinding different types of spices, salt, coffee, sugar,
fresh fruits, vegetables, herbs, tobacco, leaves, oil cake, cattle and poultry feeds and
other food products. These mono pulverizers are widely demanded by clients and have
a superior characteristics that includes;
i. Compact size
ii. Dust free operation
iii. Ideal for dry as well as wet-pulpy crushing
iv. Highly effective as well as non-stop continuous crushing
v. Single pieces crushing chamber with no separate joints of fabrication for outlet
vi. Increased production leading to faster return on its achievements
vii. No wastage of product
viii. Causes no pollution
Table 2.2: Technical specification for mono pulverizer
Model Tw-1 Tw-2
Chamber size 152mmx76mm 203mmx50mm
DIA X WIDTH 152mmx75mm 200mmx50mm
Motor (kW) 1.1 1.1
Grinding speed (RPM) 2880 2880
2.13.2 Min Pulverizer

Min pulverizers are the machine that is designed to offer effective and continuous
grinding. These products are applicable for various spices, fresh fruits, garlic, coffee,
sugar, fruit pulp, herbs, vegetables, poultry feeds, custard powder, icing sugar, instant
20
Chapter Two
food and various other allied foods. These mini pulverzers are known for their
superior features that are:
i. Increased production
ii. No wastage of product
iii. Single pieces grinding chamber no separate joints of fabrication for out late
iv. Rotating parts are balanced for reducing friction loss and noise
v. Four members beaters are from special steel and single piece (without joints)
are hardened
vi. Dust free production
vii. No pollution hazards
Table 2.3: Technical specification for min pulverizer
Model TW-4 TW-5 TW-6
DIA XWIDTH 203mmx76mm 254mmx101mm 304mmx101mm
DIA XWIDTH 200mmx75mm 250mmx100mm 300mmx100mm
Motor(Kw) 1.5 to 2 3.5 to 5.5 5.5 to 7.5
Grinding 5000 5000 5000

Speed(RPM)
21
Chapter Three
CHAPTER THREE
METHODOLOGY
In order to achieve the objectives of this project, the following methods have been
used as the basis for analysis.
3.1 Introduction
This section involves the background of the project, problem statement, project
objectives, significance and feasibility of the project.
It also displays the general overview on what is to be done in the entire project.
3.2 Literature Review

In this part, it involves the study of related topics which assist in providing knowledge
that help in fulfilling the demand of the project.
The knowledge about the procedures to be followed in machine design and the study
on some existing grinding machines.
3.3 Data collection

This section involves the important information seem to contribute ideas in designing
the appropriate spice milling machine in order to fulfill the main objective of the
project.
Both primary and secondary data was collected through visiting, interviews,
observations and consultation while others are extracted from written documents.
3.4 Consultation
Different qualified persons such as peasants, engineers, supervisors and other experts
have been consulted to contribute their ideas.
3.5 Observation.
Through observation, I visited those three firms and watch a real situation by
obtaining the information (such as local method of milling spices) through my own
eyes without conducting an interview.
3.6 Data analysis

The analysis of the data collected has been done in order to reach the optimum
required design of machine. This involves the following;
22
3.7 Analyzing the probable solution.

Evaluation and selection of the best alternatives were made including driving power;
driving mechanism, position of machine, size of machine etc. these were done in
consideration with rate and quality of production, safety, ergonomics and aesthetics of
the machine.
3.8.Determinations of machine parameters

The calculation of size and capacity of different parts of machine have been
determined. This includes shafts, pulley, hopper and key, bearings, milling hammers,
housing unit, belt and frame. Also speed and torque have been determined so as to
reach optimum design of spices milling machine.
3.9 Drawings
The drawings in the form of assembly and details have been made to assist the
manufacturing of machine to the required shape and size.
3.10 Prototype manufacturing

After have drawings and specifications of the materials, the prototype was
manufactured so as to verify the function ability of the designed machine.
3.11 Report writing

The compiling of the general work of the project performed from the beginning up to
the general design was made including conclusion and recommendation.
23
Chapter Four
CHAPTER FOUR
DATA COLLECTION
4.1 Data collection

In to go further with the design, the following preliminary data have been collected;
i. Types of the spices
ii. Size of spices available
iii. Properties of spices
iv. Moisture content of spices
v. Main parts of machine to be designed and the material to be used to each
component part
4.1.1 Types of Spices

Spices can be grouped into two forms as:
i) Whole spices: these spices are used in their original form after being
thoroughly cleaned. These spices are used in both for garnishing as well as
flavoring.
ii) Ground spices: grinded spices are used as they deliver flavor quickly and also
they blend easily into a product; this is so, because grinding a spice breaks
down the protective cell structure,
Whole spices can be grouped further into the following classifications

i. Dried fruits or seeds, such as fennel, mustard, white and black pepper
ii. Dried buds, such as cloves,
iii. Roots and rhizomes, such as turmeric, ginger and galingale.
4.1.2 Properties of Spices

The properties of different spices are shown in the table 02 at the Appendix B.
The quality specifications of spices are shown in the table 03 at the Appendix C.
4.1.3 Moisture Content

i. Moisture content of spices was determined using the procedure detailed by
Henderson et al.,(1977).The spices sample were dried at 1300C for 18 hours
(ASAE,2000
24
The average bulk density of spice group of root and rhizomes at the moisture content
of 78%(db) is found to be 183kg/m 3.After the spice are dried to the final moisture
content of 64% (db.), the average bulk density is found to be 73kg/m3.
The weight loss of the samples was recorded and the moisture determined in
percentage. This was replicated three times. The moisture content was calculated
as:
MCwb= (Wi-Wd)/wd× 100
Where
MCwb= Moisture content, wet basis, %
Wi= Initial weight of sample, kg
Wd= Dried weight of sample, kg
This is in order to know the percentage of the dryness required for milling. Thus from
this test the conclusion was that the spices in the form of grains of about 8.89%= wb,
moisture content can be milled to give the desired output.
4.1.4 Size and shape Spices

The shape of spices in the group of roots and rhizomes is measured and due to its
irregularity but the observed average raw spices are in between 35mm to 70 mm long
and 20mm to 60mm wide.
Micrometer screw gauge with least solution count 0.71mm was used to determine the
diameter of the spices in the group of dried seeds or fruits and dried.
Three groups of 50 spices grains samples were drawn randomly from each moisture
content level. From each group, 20 spice grains were picked randomly and were
thoroughly mixed together from which 30 spice grains were randomly selected.
The diameter of each individual spice grain was measured triaxially along the
principal axis, major ( L1), intermediate (L2) and minor ( L3) . Its equivalent diameter
De was calculated using the using equation 2.2 given by Ciro, 1997.
(Reported by Aseogwu, et al, 2006)
De= F1+F2+F3
3
Where
L1=L 2=L 3
F1= Arithmetic mean diameter=
3
25
Chapter Four
F2= Geometric mean diameter= (L1L2L3) 1/3, mm

F3 =Square mean diameter= (LIL2+L2L3+L3L2) I/2 , mm
From this research the result is in table below which presents the mean values and
standard errors of the axial dimensions of the spice grain at different moisture
contents. The table also contains the arithmetic mean, geometric mean and the
equivalent diameters of the spice grain.
Data collected at SIDO and proposed materials
Table 4.4: Data from SIDO
S/No Parts Materials Propossed

dimension(Parameter)
1 Hopper Stanless steel
2 Shaft Medium caron steel
3 Belt Rubber V-Belt
4 Pulley Mild steel V -Belt
5 Motor Single phase 1Hp
6 Frame Mild steel
7 Sieve Mild steel Dia 0.075mm
8 Bearing Stainless steel
9 Milling Chamber Mild steel 200mmx370mm
4.1.5 Selection of the appropriate materials

In order to come out with a reliable, available, and affordable spice milling machine;
the best selection of the material is most important. This help to know the mechanical
properties, the resistance from corrosion. This gives assistance understanding the
material which will be required to manufacture all the parts of the machine. The
materials are shown on table 04 on Appendix D which shows the grades of carbon
steel and their application. Also the mechanical properties of plain carbon steel as
shown at a table 05 an appendix E
26
Chapter Five
CHAPTER FIVE
DATA ANALYSIS
5.1 Design of Spice milling machine

After being done the literature review, methodology and data collection, here is
another step of design that is selecting best alternative solution to meet the set specific
objectives.
Before doing analysis different alternatives are generated in order to have a wide
range of choice. In generating the solution, different alternatives is discussed in this
section. The number of functions are identified and the means of achieving them. To
identify the novel combinations of elements or components the morphological chart
method is used. This chart sets out the complete range of elements, components and
sub-solution that can be combined together to make a solution. The feasible solution is
selected considering cost, performance, maintainability, power, safety and ergonomics
and those which are known to be efficient and practical and affordable for small and
medium scale farmers.
5.1.1 Design parameters

This design must have the following features;
1. Means of milling
i. Cylinder with rods/pins
ii. Roller with fins
iii. Shaft with round bars
2. Means of feeding
i. Manually
ii. By gravity
Means of transmission
i. Gear with sprocket
ii. Belt
iii. Chain
4 . Source of power
i. Electric motor
ii. Diesel engine
27
5.1.2 Generation and evaluation of alternatives

In generating alternatives the morphological chart below describe the possible
combination of features and the means of achieving them.
Table 5.5: Morphological chart for milling machine
FEATURES MEANS
Feeding Manual By gravity
Transmission Belt with pulley Gear Chain sprocket
Source of Power Electric motor Diesel engine
Means of Milling Cylinder with Shaft with round Roller with fins
rod/pin bar
Three alternative to be considered .These are:
Table 5.6: Design alternative for spice milling machine
S/No. ALTERNATIVE DESIGN TYPE
1 Spice milling machine with A

round bar welded on the
shaft
2 B
Spice milling with drum
Jaws driven by pullet and
belt
3 C
Spice milling with round
bar welded on shaft.
5.1.3 Alternative design type A

Spice milling machine with round bar welded on shaft
This method requires two sprockets and a chain around the two sprockets. One
sprocket is driver, is connected to the motor shaft. The second sprocket is driven
sprocket which connected to the driven shaft of the machine. The spices are feed into
28
Chapter Five
the hopper by means of gravity. The means of milling is by using round bar welded to
the shaft.
Advantage of design alternative A

i. As no slip takes place during chain drive, hence perfect velocity ratio is
obtained.
ii. Since the chains are made of metal, therefore they occupy less space in width.
iii. It may be used for both long as well as short distances.
iv. It gives less loads on the shaft.
v. It has the ability to transmit to several shafts one chain only.
vi. Simple in manufacturing
vii. Simple in feeding spices into the hopper.
Disadvantages of alternative design A

i. The production cost of chain is relatively high
ii. The chain drive needs accurate mounting and careful maintenance, particularly
lubrication and slack adjustment
iii. The chain drive has velocity fluctuations especially when unduly stretched.
iv. Diesel is expensive.
Figure 5.10: Design alternative A
29
Table 5.7: Marks and average for an Alternative A

Judges Productio Durabilit Capacit Maintenabilit Efficienc Ergonomic Safet
n cost y y y y s y
1 5 2 3 4 3 4 4
2 5 3 4 5 2 5 5
3 4 4 3 4 3 4 5
4 4 3 3 3 2 4 5
5 5 3 2 4 4 4 4
Averag 4.6 3 3 4 2.8 4.2 4.6

e
5.1.4 Alternative design type B

Spice milling machine with flat plate direct plate drive though coupling
This method requires a coupling as the machine element that is used to connect two
shaft of the transmission system and transmit torque without change their magnitude
and direction.
Principle of operation
The machine has simple structure which consist the feeding unit (Hopper feeder) to
which the dry spice are feed in a milling chamber where the milling process is done.
The driving mechanism between the motor shaft and the shaft of rotating flat plate is
performed by direct drive with coupling. The milling process is accomplished by
rotating flat plate fixed on the rotating shaft .As the process goes on ,the under siz
glass particles fall down through the sieve while over size remain in the milling
chamber for further crushing again into small particle required to pass into the sieve
hole up to the outlet chute.
This mechanism is characterized into the following factors:

i. It is relative cheap because only coupling is required to transmit motion from
one shaft and other
ii. It is safe because the moving part are guarded
30
Chapter Five
iii. It is good in performance but there is no chance of varying the speed of driven
shaft
iv. It is high efficiency
v. Coupling are ready made at different size ,hence can be easily purchased
vi. It require little service and carefully maintenance on alignment shaft
vii. It is simple in fabricating because of the few machine member
Figure 5.11: Design alternative B

KEY:
1. Feed hopper
2. Nut 9.Bearing
3. Milling chamber 10. Coupling bolts
4. Rotating Shaft 11.Motor
5. Bearing 12. Coupling
6. Frame
7. Sieve plate
8. Hummer
31
Table 5.8: Marks and average for an Alternative B

Judges Productio Durabilit Capacit Maintainabili Efficienc Ergonomi Safet
n cost y y ty y cs y
1 4 5 4 5 5 5 4
2 5 3 5 5 4 5 5
3 4 5 3 3 5 4 5
4 4 4 5 5 4 5 4
5 5 3 5 4 3 4 4
Averag 4.4 4 4.4 4.4 4.2 4.6 4.4
e
5.1.5 Alternative design type C

Spice milling machine with hummers driven by pulleys and belt
This type of driven contains belt and pulleys. One pulley is driver, the second being
the driven. The dry spices are fed manually into the hopper then pushed into the
milling chamber. As the milling hammers rotate with its shaft the spices get milled by
beaten inside the milling chamber.
Principle of operation
The machine has simple structure with consists the feeding unit (hopper feeder) to
which the dry spices are fed and the milling process is performed by the rotation of
hammers mounted on the rotating shaft. As the process goes on, the undersize glass
particles fall down through the sieve while the oversize remains in the crushing
chamber for further milling again into small particles required to pass into the sieves
holes up to the outlet chute.
Advantages:
i. It is smooth and quite in operation
ii. It is relatively cheap and easy to maintain.
iii. Transmit power at constant angular velocity.
iv. Eliminates the restriction on speed.
v. It uses hammers to crush the defective glass bottles.
Disadvantages
32
Chapter Five
i. It requires grooved pulleys, thus increase the manufacturing process.

ii. Tensioning the belt is required to avoid slip
iii. There is possibility of power loss due to slippage of the belt.
Figure 5.12: Design alternative C

KEY:
1. Hopper Feeder 6. Hummer

2. Top part 7 .Top milling chamber
3. Bottom milling chanber 8. Shaft
4. Sieve
5. Pulley
Table 5.9: Marks and average for an Alternative C
Judge Producti Durabil Capac Maintainab Efficien Ergonom Safe

s on cost ity ity ility cy ics ty
1 5 3 3 3 3 4 2
2 5 3 4 5 2 3 4
3 4 4 2 3 4 3 4
4 4 4 4 5 2 4 2
5 5 3 5 4 3 3 3
Avera 4.6 3.4 3.6 4 2.8 3.4 3
ge
5.1.6 Selection of suitable design

In order to get the best alternative of the design, the following are some factors that
put into consideration and the ranking technique is used;
i. Cost relative to productivity
33
ii. Safety and aesthetics

iii. Durability
iv. Capacity
v. Maintainability
vi. Locally manufacturability
vii. Performance.
5.1.7 Determination of the weighing factor

The designers, users or people who are familiar with the product/process/services can
rank the design considering features starting NO. 1 as the best, continuing in this
manner to the last number depending on the number of features to be considered.
Ranking can be summarized as shown in table 5.5
Table 5.10: Determination of the weighing factor
Judges Producti Durabili Capacit Judge Producti Durabili Capacit

on cost ty y s on cost ty y
1 5 4 4 4 3 4 5
2 5 5 4 3 3 4 4
3 3 4 5 4 4 3 4
4 4 3 5 5 4 3 5
5 3 3 5 4 3 3 4
Sum of 20 19 23 20 17 17 22
Ranks(R ∑ Ri=138
j)
Weighti 0.145 0.138 0.167 0.145 0.123 0.159 ∑Ri = 1
ng
Factor
F=Ri/∑
Ri
5.1.8 Ranking the altenative design

Table below, shows the weighting factors, weight and score of each alternative
according to the five judges as indicated in each table of the three Alternatives.
Table 5.11: Weighting factors, weight and score
34
Chapter Five
Production cost
Capacity
Safety
Total score
Rank order
Durability
Maintainability
Efficiency
Alternatives
Ergonomics
Weighting 0.145 0.138 0.167 0.145 0.123 0.123 0.159
Factors
A Score 4.6 3.4 3.6 4 2.8 4.2 4.6 2
Weight 0.667 0.414 0.501 0.58 0.3444 0.5166 0.7314 3.577
B Score 4.4 4 4.4 4.4 4.2 4.6 4.4 1
Weight 0.638 0.552 0.7348 0.638 0.5166 0.5412 0.6996 4.3202
C Score 4.6 3.4 3.6 4 2.8 3.4 3 3
Weight 0.667 0.4692 0.6012 0.58 0.3444 0.4182 0.477 3.7544
Note: Weight = Score x Weighting factor
5.2 Design the best alternative

Having selected best alternative it necessary to perform design calculation for proper
of the size of various components of this machine.
Since the machine is designed to be domestic users the following are parameters of the
desired machine.
During the process of design, some of the parameters are to be assumed and others are
estimated and other are estimated.
Since the selection of motor depends on the work to be performed in the intended
machine.
Capacity required=800kg/hr.
Motor specifications,
Single phase, 220V
The capacity of motor=3HP=2.2371Kw
The speed of the motor, N1=1470rpm
The speed of the machine, N2=2940rpm
35
N 1 1470
Speed ratio= = ………………………………………………………(5.1)
N 2 2940
Speed ratio=1:2
Drive V-Belt
Capacity of the machine 800kg/hr.=13.333kg/min
Machine Capacity
Shaft speed ¿ ……………..……..………………………(5.2)
Feed per cycle
13.333
Feed per cycle¿
1470
Feed/cycle=0.544kg/rev
Determination of angular velocity for motor
2 πN
ω 1= …………………………………………………….………………(5.3)
60
2 π ×1470
.ω 1=
60
ω 1=153.938 Rad /sec
Torque transmitted by motor
Power
T m= …………………………………………...….……………….…..(5.4)
ω1
2.2371=Tm ×153.938
2.2371× 1000
T m=
153.938
Tm=14.5325Nm2
Torque = Force x Radius ………………………………………………………(5.5)
14.5325Nm=Force x 0.1m
14.5325 Nm
Force=
0.1m
Force=145.325N
Determination of angular velocity for driven pulley
2π N2
ω 2= ………………………………………………………..…………(5.6)
60
2 π ×2940
ω 2=
60
36
Chapter Five
ω 2=307.876 Rad/ sec
Determination of the speed ratio
ω1
r= ……………………………………………………….……….….……(5.7)
ω2
153.938
r=
307.876
r =1:2
5.2.1 Belt selection

From the table 05 on Appendix F we have choose the type of belt and smaller sheave
diameter diameter, D1 considering the torque of 14.5325Nm and extend the service
life of the belt, D 1 <dmin. Thus the belt type is A and smaller shieve diameter is
90mm.
From the standard series of diameter , then the smaller shieve diameter is choosen to
be D1=100mm
Belt type is to be selected as Normal Selection belt type A.
Computation of the belt speed
D1 ×ω
V= 1
2 ×1000
200 ×153.938
V=
2 ×1000
V =15.3938 m/ sec
37
Specify tentatively the center distance considering the following
Figure 5.13: Show center distance

Determination of the centre distance between the driver and driven pulley
C min =(D1 + D 2)+ h………………………………………………………(5.8)
Where
D1=Diameter of drive pulley
D2=Diameter of driven pulley
h=is the belt Thickness
For belt type A, h=8mm
Cmin=0.55(100+200)+8
Cmin= 173mm
And
Cmax=2(100+200)
Cmax=600mm
Determination of the belt length
π ( D + D1 )2
Ld =2C min + (D 1+ D2)+ 2 ……………………....……………………(5.9)
2 4 × C Min
2
π (100+200)
Ld =2× 173+ (200+100)+
2 4 × 173
Ld =831.69 mm
The nearest design standard length of the V belt Ais taken as Ld=900mm
38
Chapter Five
Determination of the final (new) center distance

2
π π
[ ]√
C=0.25 L D− ( D 1 + D 2 ) + {L D− ( D 1 + D 2 ) } −8 ¿ ¿ ¿
2 2
2
π π
[ )]
√
C=0.25 900− ( 200+100 + {900− ( 200+100 ) } −8 ¿¿ ¿
2 2
C=512 mm
The center distance will be C=512mm
Calculation of the number of the ribs for the V belt
Depending on the section, the initial power (P0) transmitted by the one belt is to be
selected from the table and this will be used for determining the allowable power P
Determine the number of the belt required
From the formula

P0
Z= ………………………………………….……………………(5.10)
[P ]
Where
P=C α × C S
P0= Power transmitted by one belt under standard condition

P=Allowable power per one belt
C α- Coefficient account for the effect angle of contact at the smaller pulley
Cs- Service factor that takes care of the type of drive, type of driven mechanism
and operation
Now
P0- is selected depending on the type of belt, velocity of the belt and smaller sheave
diameter such that,
v=¿19.62m/s which is found between 15-20 m/s
Po-is selected from the table 07
15m/sec 19.62 20m/sec
2.39 Po 2.74
By interpolation
Then
39
19.62−15
PO =2.39+(2.74−2.39)( )
20−15
PO =2.39+0.35 ×0.94
PO =2.39+0.329
Po = 2.719kW
From the table 08 Appendix G the service factor C2 that takes care the type of drive,
the type of driven mechanism and operation.
For impact machine, Hammer crusher Cs=0.7
Angle of wrap
Angle of contact between pulley and belt
0 (D 1−D 2 )
∝=180 −2 arcsin ……………………………………………………………
2C
…......(5.11)
(255−100)
∝=1800 −2 arcsin
2× 743.59
∝=¿1680
Now from the table 08 on the Appendix Hthe coeffient C ∝ is found in between 1600
and 1700
By interpolation
160 168 170

0.9 C∝ 0.97
168 0−1600
C ∝=0.94+(0.97−0.94)( )
170 0−1600
C ∝=0.960
Now
P=P 0 ×C s ×C ∝
P=2.719 × 0.7 ×0.964
P=¿1.789
Then
40
Chapter Five
2.417566
Z=
2.1021
Z=1.1497
Z=1 Belt
The number of belt Z=1
Initial tension of the V—belt
From the equation below the initial tension of the belt can be calculated
780 × P
Z= +q+ v 2………………………………….............……..…(5.12)
C ∝ ×C s ×× v × Z
Where
P-Moderate power
q-Mass per runoff the belt
v-Speed of the belt
Z-Number of the belt
Now
780× 2.1027
T i= + 1.05× 15.392
0.9× 0.95 ×1 ×15.39
T i=147.348 N
Force acting on the shaft
Consider the equation below

α
F s=2 T i × Z × sin …………..............
2
…………………………………………………………(5.13)
Where
T i=The initial Tension of the belt
Z=Number of the belt
α= Angle of Wrap
41
Now
168.80
F s=2 ×147.348 ×1 ×sin
2
F s=293.293 N
Consider the following Equation

Total force acting on belt =Total Tension on the belt F s=T i +T 0
…………………………………………………………………………...…….(5.14)
Where
T i−¿Initial tension of the belt (Tight side)

T 0−¿Tension in the slack side of the belt
Now
293.293=147.348+ T 0
T 0=145.945 N
Shaft design
The material used for the shaft should have the following properties;
i. It should have high strength
ii. It should have good machinability
iii. It should have good low notch sensitivity factor
iv. It should have good heat treatment properties
v. It should have high wear resistance properties
A selected material for this design is Carbon Steel 40C8

For Shaft purchased under definite physical condition specifications the permissible
shear stress may taken as 30 percent of the elastic limit in tension (Syt) but not more 18
percent of the ultimate tensile strength (Sut). In other word, the permissible shear stress
is τ max=0.3 S yt or τ max=0.18 Sut which is less
From the material;
Ultimate tensile strength¿)
Yield strength¿)
Now
τ max=0.3× 320=96 N / mm2
42
Chapter Five
Orτ max=0.18× 560=100.8 N /mm2
Since shaft is keyed shaft the value above is reduce by 25%

As the less value is to considered
τ max=0.75× 96=72 N /mm 2
72 N
The maximum shear strength will be τ max=
mm 2
According to the A.S.M.E code, the bending and torsion moments are to be multiplied
by factors Kb and Kt to account for the shock and fatigue in operating conditions
Where
Kb – Is the combined shock and fatigue factor applied to bending moment

Kt -Is the combined shock and fatigue factor applied to torsion moment.
Since the load to shaft will be applied gradually from the table Kb and Kt are selected
as 1.5 and 1.0 respectively. For shaft dimensions see Appendix I
By considering the following parameters
Diameter of the large pulley (sheave)=200mm
Note
The means of disc, Hammer and spacer are estimated as follows
i. The weight of spices to be milled is neglected.
ii. The weight of shaft is neglected
iii. No slippage between the pulley and the belt .
iv. The shaft will carry six discs, twenty hammers and twenty specers.
Mass of each disc is estimated as 4kg

Mass of each spacer is estimated as 1kg
Mass of each Hammer is estimated as 0.25kg
Now
The total mass acting on the shaft =mass of discs + Mass of spacer + mass of Hammer
Tm=4x3+1x2+0.25x20
Tm=19kg
The weight acting on the shaft=Mass x Acceleration
W t =19 ×10
43
W t =190 N
Since this weight will be equal distribution on the shaft on the length of 250mm, then
the total weight will be 190N/mm or 0.9KN/length of the shaft
W t =0.19 ×0.25=0.0475 kN
Resolve Forces Vertically
V . F=293.2935 × sin30 0
V . F=146.64675
Resolve forces horizontally
H . F=293.2935 × cos 300
H . F=253.9995 ≈ 254 N
SHAFT REACTIONS FORCES ACTING ON THE SHAFT.
Total weight acting on the shaft

Single pointing load = The weight acting on the shaft +the force acting on the shaft
Single point load = 190x 0.25+145.325
Single pointing load=192.825N
Considering the vertically forces
Taking moment about point A
146.64675 ×85+250 × R B =192.825× 125

R B=46.55 N
Since,∑ (Upward force)=∑ ( Downward force )
44
Chapter Five
(146.6467+192.82−46.55)
R A =292.92 N
Shear force calculations;
F D =−146.64 N
F A=−146.64675+ 292.92=146.273 N
F C =137.47−192.825=−46.55 N
F B=46.55 N
Bending moment
At D;MD=0
A ; M A=292.92× 85=19888.4 Nmm
C ; M C =46.55 ×125=5818.75 Nmm
B ; M B=0
To get maximum bending moment and maximum shear force, we draw the bending
moment and the shear force diagrams using the force analysis
45
Figure 5.14: Free body diagram (b) Shearing force diagram (c) Bending moment
diagram
46
Chapter Five
Considering horizontally force;
Taking moment about point A
254 × 95+250 × R B=192.825 ×125

R B=10.052
Since,∑ (Upward force)=∑ ( Downward force )
R A =284.12+192.825−10.052
R A =436.77 N
Shear force calculation
F D =−254 N
F A=−284.12+ 436.77=182.77 N
F C =182.77−192.825=−10.052 N
F B=−10.052 N
Bending moments
At D ; M D =0
A ; M A=436.77 ×85=37125.45 Nmm
C ; M C =10.055 ×125=1256.87 Nmm
B ; M B=0
Resultant bending moment;
At D; M B =0
A ; M b= √ ¿ ¿
M b=44704.4474 Nmm
C ; M b= √ ¿ ¿
M b=5945.067 Nmm
C ; M b=0
The maximum bending moment, M b=44701.447 Nmm
47
Considering equivalent twisting moment

T e =√( M b × K b )2+(T × K t )2
T e =√(44701.4477 × 1.5)2 +( 14532.5× 1)2

T e =68608.9 Nmm
From
π × τ × d3
T e= ……………………………………………..……………...
16
………………(5.12)
68608. ×10.055
d 3=
π ×72
d=14.5mm
Considering equivalent bending moment
1
M e= [ M b + √( M 2 +T e2 ) ]…………………………......……………….
2
……………………..(5.13)
M b +T e
M e=
2
44701.447+68608.9
M e=
2
M e =56655.1735 Nmm
π × σ × d3
M e=
32
8015.067 ×32
d 3=
π ×72
d=22.03 mm
By taking the larger of two values, =22mm
The standard diameter size for transmission shaft starts with 25mm to 30mm and
above. Therefore the shaft diameter is taken as 30mm [Nagpal, 1991]. The detail
drawing of the shaft is shown in the appendix 1.
48
Chapter Five
Selection of bearing
A bearing is a machine element whose function is to support a moving element and to

guide or confine its motion, while preventing motion in the direction of applied load.
Due to relative motion the contact between surfaces, a certain amount of power is
wasted in overcoming the friction resistance and if the rubbing surfaces are in direct
contact, there is a rapid wear. So in order to avoid wear, lubricants are applied in
between the contact surfaces. But in the food processing machine, the contamination
of the oil and grease is strictly prohibited, so unlubricating bearing is to be selected.
Determination of radial and axial forces acting on a bearing

The equivalent dynamic load is expressed as
P= XF R +YF A P ………………………………........……………………...........(5.14)
Where:
P ¿ Equivalent dynamic load ( N)
F R =¿Radial load (N)
F A=¿ Axial thrust load (N)
X =¿Radial factor
Y ¿Thrust factor
From the previously calculations on bearing:
R B=F RB
RC =F RC
Since there is no axial load, F a=0
Radial force acting on the bearing
The Radial force acting on the bearing is the resultant reaction at the bearing,
therefore at point A:
R A =√ R2AH + R 2AV …..................………………………………………………….(5.15)
R A =√ 292.922+10.055 2
R A =293.093 N
At point B;
49
R B=√ R2BH + R2BV ……………………………………………………............................

(5.16)
R B=√ 436.77 2+ 46.552
R B=439.24 N
Since there is no axial load, f a=0
Therefore;
Radio load at bearing A=293.093 N
Radio load at bearing B=439.24 N
Determination of the value of radial factor from manufacture catalogue was found that
for single row deep groove ball bearing , X =1∧Y =0
From the equation
The equivalent dynamic load at A is
P A =XF RA (Since F a =0);
P A =1 x 293.093 N
P A =293.093 N
The equivalent dynamic load at B is;
PB =XF RB
PB =1 x 439.24 N
PB =439.24 N
Calculation of the expected bearing life

Machine used for short period or immediately and whose break down would not have
series consequence eg. Hand tool, lifting tackle in workshops and operated machines,
agriculture machines, cranes in erecting shops, Domestic machine. Life of bearing is
between 4000 and 8000 hours (Kurmi and Gupta, 2002)
By assuming that, the machine is working for 8hours of service per day:
Assume L H =5000 Hours
Bearing life is expected as:
60 N 2 Lh
L=
10 6
Where:
L=¿Bearing life (¿ million revolution)
N 2=¿ Speed of rotation (rpm ¿
50
Chapter Five
Lh=¿ Bearing life(hours )

60 x 2940 x 5000
L= L=882million revolutions
106
Dynamic load capacity:
From Load Life relationship as expressed below:

L=¿..................................................................................................................(5.16)
Where
C ¿ Dynamic load capacity( N )
P=¿ Equivalent dynamic load( N )
j=¿3 (For ball bearings)
1
Therefore, C=PL j xLoad factor
Let load factor for belt drive be 2.5

For bearing A,
1
C=P A L j x 2.5
Then,
1
C=293.093 X 88 2 3 X 2.5
Since, C=7026.97 N
For bearing B,
1
C=PB xL j xLoad factor
Then;
1
3
C=439.24 X 882 X 2.5
Since;
C=10530.88 N
From the catalogue of bearing selection under Y bearing is selected since it is used in
a wide variety application, they are simple in design, non-separable, capable of
operating at high speed, require little attention or maintenance in service. From
calculations, the shaft diameter is 30mm, and it is found from the catalogue that the
dynamic load capacity equivalent to the values obtained above is 10800 Nand bearing
designation is SKF YAR 206,[SKFElectronic catalogue,1995]
Shaft diameter = Internal diameter of the bearing
51
Figure 5.15: bearing
Principle dimensions (mm)

Inner diameter of the bearing,d=30
Nominal diameterd 1=¿ 33.7
Outer diameter of the bearing, D=52
The axial width of the bearing, B=34.1
Basic load rating ( N )
Dynamic load, C=10800
Static loadC o=7800
Fatigue load limit, Pu=¿ 232
Mass = 0.17kg
Designation =SKF YAR 206(SKF Electronic hand book, 1999), From Appendix J
5.2.2 Key design

A Key is a machine element which is inserted between the shaft and the hub or boss of
the pulleys gears, wheels sprockets to connect these together in order to prevent
relative motion between them .It is always inserted between the parallel to the axis of
the shaft. Even though pulleys, gears and sprockets are assembled with interference fit
it with desirable to use a key to transmit the torque.
Keys can be used as a temporary or permanent fastening and are subjected to
considerable crushing and shearing stresses.
A keyway is a slot recessing a shaft and hub of the pulley to accommodate a key.
The materials for the key were selected to be mild steel.
52
Chapter Five
Considering the figure below:
Figure 5.16: forces acting on the key

Types of key common in use are:
i. Sunk key
ii. Saddle key
iii. Round key
iv. Splines
Sunk key
The sunk keys are provided half in the keyway of the shaft and half of the key way of
the pulley, wheel, gear or sprocket.
The sunk keys are of the following type
i. Rectangular sunk key
ii. Squire sunk key
iii. Parallel sunk key
iv. Gib head key
v. Feather key
Design of the rectangular key

A rectangular key it is selected because it has more stability compare to others.
The design of rectangular key is subjected on two criteria failure due to their
i. Shearing stress
ii. Compression stress
Let F C =¿force due to compression
F S=shearing force due to torque
Key failure due to force
T 2T
F S= =
d d …………………………………....................................…………….2.17
2
53
Where
T =Torque transmitted by shaft ¿)
D=Diameter of shaft ¿)
F S=Tangential force( N )
The shear will occur in plane AB and the shear stress is given by:
FC
shear stress= …………………....................................…………………2.18
bx l k
Where:
b ¿Width of key
l k ¿ length of the key
2 xT
Shear stress , τ= …………………………….........…………………….2.19
bxdxl
Key failure due to compression or bearing stress
But F S=F C
2 xF s
Then,σ c =
h xl
We have from the shaft design, the maximum allowable stress of the shaft equals to
72 N /mm2. Therefore, for safe design the stress due to the key should be less than the
maximum allowable key stress.[Khurmi& Gupta,2002]
Key Dimension
The type of key dimension is a rectangular sunk key
Consider the sketch below
54
Chapter Five
Figure 5.17:sketch of the key dimension
Length of key,l k
l k =1.5 d
l k =1.5 x 30
l k =45 mm
Width of key, b
d
b=
4
24
b=
4
b=6.25
Thickness of the key, h
d
h=
6
30
h=
6
h=5 mm
From the standard, the dimension of the key is given as b=8 mm , h=7 mm ,and l k
ranges between 20 and 80 for the shaft with diameter between 22mm to 30mm
Therefore the dimension was taken as;
l k =40 mm
b=8 mm
h=7 mm
Check for induced shear stress
55
2 xT
τ s=
dxbxl
2 x 14532.5
τ s=
30 x 8 x 40
τ s=3.633 N /mm2
Fromτ max >τ s
since ,72 N /mm2 >3.633 N /mm2
(Hence the design is safe)
Check for the induced crashing stress.
4 xT
σC =
bxdxl
4 x 14532.5
σC =
24 x 7 x 40
σ C =8.3 N /mm2
From;
σ max >σ c
Since; 72 N /mm2 >8.3 N /mm2
(Hence the design is safe)
5.2.3 Pulley design

A pulley is a machine element which is used to transmit motion of one shaft to another
by means of flat belts-belt or ropers. Since the velocity ratio is the inverse ratio of the
diameters of driving and driven pulleys, therefore the pulley diameter should be
carefully selected in order to have a desired velocity ratio. The pulleys must be in
perfect alignment order to allow the belt to travel in a line normal to the pulley
surfaces.
The pulley may be made of cast iron, cast steel or pressed steel, wood and paper. The
pulley made of pressed steel are lighter than cast pulleys, but in many cases they have
lower friction and may produce excess wear.
The material selected for design of spice milling machine pulleys is cast iron
Types of pulleys
i. Cast iron pulleys
ii. Steel pulleys
56
Chapter Five
iii. Wooden pulleys

iv. Paper pulleys
v. Fast and loose pulleys
The cast iron pulleys have the following characteristics
i. Their cost is very low and the rim is held in place and the rim is held in place
by the web from the central boss or by arm or spokes. The arm may be straight
or curved and the cross section is usually elliptical
ii. The cast iron pulleys are generally made with rounded rims. This convexity is
known as crowing. The crowing tends to keep the belt in center on a pulley rim
while in motion.
iii. When the cast iron pulley contract in mold, the arm are in the state of stress
and very reliable to break. The curved arm tend to yield rather than to break.
The arm sare near the hub.
iv. The cast iron pulley may be solid or split type
The following procedures may be adopted for the design of cast iron pulleys
1. Dimension of the pulley
2. Dimension of the arms
3. Dimension of the hub
The figure below were considered
Figure 5.18: sketch section of driven pulley

The hub
The outer diameter of the hub,d h
d h=2d
d h=2 x 28
57
d h=56 mm .
Length of the hub,l b
l b=1.5 d
l b=1.5 x 28
l b=42 mm
The thickness of the rim, t p
D
t p= +3
255
200
t p= +3
200
t p=4 mm
Design of the milling parameters
The design of the milling machine parameter includes the following:
Hopper, hammer, sieve, milling chamber and frame
5.2.4 Milling chamber

This is the chamber welded to the driven shaft,it consist disk plate separated by
spacer. It has the same revolution as that of the shaft. The spices are to be milled
inside this milling chamber by means of hammers. Its dimension is 210mmx390mm.
All this are made from mild steel in order to void contaminations with the grains.
Appendix M.
5.2.5 Hummer design

Hammer operate on the principle of most materials will grind, mill or crush upon
impact with the hammers. The materials are fed into the hammer mills from the top by
the gravity fall into the milling chamber. The materials are contacted with a series of
hundred rotating hammers. The materials are grounded by repeated contact with these
hammers, contact with wall of the milling chamber and particle to particle contact. the
materials remain in a milling chamber until it is suitably sized to pass through the
perforated screen that cover the bottom half of the milling chamber .the output of the
rate of production of the hammer milling depend up on the screen size, shaft speed
which is typically from 1800 – 3600rpm,and the configuration of the hammers
For further dimension of the hammer design see Appendix N
58
Chapter Five
5.2.6 sieve design

The sieve is the one which determine the final size of the product since it helps to
winnowing. i.e. To separate the final product from the course. The sieve oscillation is
ranging from 5-12 mm oscillations per second.Since the hole of the sieve are in
standard the diameter ranging from 2 to 7 mm depending upon the nature of the
substance to be ground and the desired output. See Appendix O.
5.2.7 Hopper design
For the dry spice to flow free in the hopper, the slope of the hopper is mostly
considered. The hopper will be made of steel.The inclination angle is recommended
not below than twenty degree will be satisfied for the free flow of the dry spices once
allowed. The flapper will be pushed into the block the flow and pulled out to allow the
flow of the spacer inside of the milling chamber. The dimensions are on the detail
drawing of the hopper. See Appendix P.
5.2.8 frame design

The frame is design strong enough so as to withstand all weight of the assembled
machine and that of the spices inside of the milling chamber and inside of the hopper.
The frame is made of mild steel materials. Its structure is shown at the detail drawing.
See Appendix Q.
5.2.9 Spice milling machine safe working procedure

Before starting the machine make sure that the safety precaution are read and clearly
understood by the operator, this will ensure the safety of the operator and machine is
not endangered.in order to operate the designed spice milling machine in a safety
manner ,firstly the condition of the spice should be dry, make sure that all parties and
mounting are properly fastened and the belt is not loose and is well secured with a
belt guard.by doing so the machine will produce the output at the rate and quality as it
was intended.
Operation
i. Start the machine by switching on the motor
ii. The spices are poured into the feeder hopper.
iii. The spices are manually fed by gravity from the hopper to the milling chamber
iv. Control the throughput by using the throughput control
59
v. Daily services such as inspection, greasing, checking belt tension are to be done
by the operator.
vi. The major maintenance of the machine such as inspecting the milling chamber,
greasing the hammers, changing the sieve, bearing replacement should be done
by qualified personnel.
vii. Shut down the machine whatever you heard any abnormal sound from the motor,
milling chamber and call expert for further inspection of the machine.
viii. The machine should be operated to the recommended time.
ix. The machine operating rate should be within the recommended rate.
x. In case of any fault of the machine, it should be reported immediately.
5.2.10 Manufacturing process

Below are the procedures used during the manufacturing of Spice milling machine
prototype. Each part of this machine had its own tools and equipment required, but
there were some common tools and equipment which were used in almost each
procedure, as they are listed below:
i. Personal protective equipment i.e. boots, overall, glass/goggles, gloves and
helmets.
ii. Tape measure, and
iii. Scriber
Table 5.12: Procedure used to manufacture the prototype
S/No NAME OPERATION TOOLS/EQUIPMENT

USED
1 SHAFT i)A mild steel shaft of Ø32x600mm i.Taper measure
length was measured, marked and ii.Scriber
clamped to a power hacksaw iii.Lathe machine, drill
clamp, and cut to Ø32×365mm. bit M12
ii)A Ø32×365mm was then iv.Power hacksaw, and
clamped to a lathe machine, where coolant.
it was faced both sides to length of v.File
787.4mm. vi.Shaper machine
iii)Steps of Ø30mm were turned ,
from both ends of the shaft to
distances of 125mm and then
60
Chapter Five
40mm from either end.

iv)A shaft was then moved to a
shaper machine, where a key way
of 10mm×8mm×5mm was cut
from the 177.8 mm end.
i. Clamp and cut the workpiece

2 SPACER ᴓ40x91mm on the power hacksaw i. Power hacksaw
machine. machine.
ii. Clamp the workpiece on the
ii. Tape measure
lathe machine and face it on both
sides/faces. iii. lathe machine
iii. Bore the centre hole of iv. Facing tool.

ᴓ33x91mm
v. Drill bit
starting with small diameter bit to
the ᴓ33mm.Remember to use the vi. Boring tool
coolant.
iv. Release the workpiece from the
jaw chuck and clean the machine.
i. From mild steel plate of 4mm

3 TOP thick measure two equal plate of i. Tape measure
MILLING dimension ii. scriber
CHAMBER 390mmx200mmx380mm on top at iii. Welding machine,
acentre of this plate produce halfe tong, wire brush and
circle of R15.5mm electrodes
ii. Cut a one plate of 204mm x iv)Grinding machine
90mm
iii. Cut anaother plate for bottom of
the dimension 390mmx204mm
i. Cut two plate of equal dimension

4 BOTTOM of the dimension 390mmx180mm
i. Tape measure
MILLING and the one end on length 180mm
61
CHAMBER reduce by 102mm ii. scriber

ii. Cut the cover with the patition iii. Welding machine,
of 102mm x 103mm x 301mm and tong, wire brush and
then join with the two plate. electrodes
iii. On the flate area at the center iv. Grinding machine
produce the half circle which when
assemble with bottom to produce
the full diameter of dia 31mm
i. Cut the Plate of 300mm length x

5 INLET
210mmx290mm
HOPPER
ii. Measure and cut the two plate of i. Scriber
300mm lenth x 90mm x 150mm ii. Steel rule
iii. Measure the cut plate of
iii. Wood hummer
290mmx 90mm
iv. Work bench
i. Collect the mild steel sheet of
6 DISCHARG
2mm thick, mark and cut to
E
dimensions as shown on the detail i. Scriber
HOPPER
drawing ii. Steel rule
ii. Join the pieces by arc welding to
iii. Work bench
make the desired shape of
discharge Hopper. iv. Cutting grinder
iii. Clean and remove sharp edges.
v. Welding machine.
i. Four angle iron of equal vi. Wire brush

7
600mmlength x50x50x4mm thick
STAND i. Hacksaw
(Vertical)
ii. Four angle iron of equal length ii. Tape measure
200mm length x 50mm iii. scriber
x50mmx2mmthick
iv. Welding machine,
iii. Join it with it with four vertical
tong, wire brush and
angle iron
62
Chapter Five
electrodes
8 v. Grinding machine
ASSEMBLY i. Place the frame/stand on the vi. File
suitable area
ii. Mount Mount the bottom
i. Box spper
milling chamber
ii. Welding machine
iii. Mount the assembled shaft with
iii. combination spanner
the bearing, discs spacer, hummer
iv. Hammer
on the bottom milling chamber.
iii. Mount the top milling chamber
on the bottom milling chamber by
using M16 Bolt
iv. Mount the feeding hopper on
the top milling chamber.
v. Assembly pulley on the driven
shaft
vi. Inset the electrick motor on the
stand and then the belt.
63
Chapter Six
CHAPTER SIX
CONCLUSION AND RECOMMENDATION
6.1 Conclusion
The design and manufacture of Spice milling machine has involved various
procedures which result to feasibility of this project. Literature review and data
collection shows the existing method of milling the spices. Data arecollected through
observation and interview from different people and small scale farmers. These data
were very useful during the development of the best alternative. During designing of
this machine, different factors such as production cost, durability, capacity, efficiency,
ergonomics and safety were critically analyzed from which the optimum design was
selected. Different parts were designed involving calculations and other parts were
designed on the basis of shape and size of machine so as to reach the optimal design
of the machine.
The manufacture of Spice milling machine have been successfully done up to the
point of producing a spices flours. The machine is tested by mixing black pepper,
cloves and cinnamon and quality was good and found to operate as per design
parameters.The grinding capacity is 800kg of spices per hour. Hence a complete
development of the design of the spice milling machine was achieved according to the
preset objectives
6.2 Recommendations
The design and manufacture of spice milling machine is recommended to used
commercially according to the grinding capacity.it is recommended that the machine
should be constructed using stainless steel material and also the machine operation
switch should be mounted on the frame where operator can access operation easily.
64
References
REFERENCES
(n.d.). Retrieved from http://www.feedmachinery.com/glossary/hammer mill.php
(n.d.).
(n.d.). http://www.feedmachinery.com/glossary/hammer mill.php.
Agriculture product. (1998).
John, M. (2000). hammer mill. cambridge: hammer sake.
milling hammer machine. (2000). http://www.feedmachinery.com/glossary/hammer

mill.php.
milling machine. (2013). http://www.feedmachinery.com/glossary/hammer mill.php.

Khurm, R.S & Gupta, J.K.2005. Machine Design. “Engineering materials and their
Properties”. New Delhi.
65
Appendices
APPENDICES
APPENDIX A
ENERGY MANAGEMENT OPPORTUNITY
In order to save energy the following Energy management opportunity are available
i. Reduce the motor speed to suit optimum system flow with balancing damper
in the maximum position for the balance air distribution
ii. Replace the out dated equipment with new unit sized at optimum efficiency
iii. Use energy efficiency motors
(SADC Industrial Energy Management Project, 2000; Module9)
COST ESTIMATION FOR THE PROJECT
The types of costs that have been considered are;
i. Material cost
ii. Labour cost
iii. Total cost
The labor Cost
The cost of labour for this project is calculated using the formula below;
Material cost
The considered cost in this project is roughly estimated based on the construction of
the whole machine. The parts like belt, motor, bearing, bolts and nuts pulleys, and
angle iron should be purchased from dealers and manufacturers according to design
specifications (refer table 5.3)
Table 1: Project cost estimation sheet

S/N Description Quantity Price each Subtotal
1 Angle Iron,40 x 40 x 4mm 2 25000/= 50000/=
2 Ms sheet( 2400 x 1200 x 4mm) 1 80000/= 80000/=
3 Driver pulley 180mm 1 15000/= 15000/=
4 Driven pulley 90mm 1 25000/= 25000/=
5 Shaft(ϴ 30mm x 600mm) 1 50000/= 50000/=
6 V- Belt 1 5000/= 5000/=
7 Electric geared motor, 2.2kW,1 1 240000/= 240000/=
phase
8 Bearing ( Plummer block) 2 18000/= 18000/=
9 Bolt,Washer and nuts M 19 10 1000/= 10000/=
66
Project Work for Bachelor of Mechanical Engineering Student, DIT
10 Bolt, Washer and nuts M 17 4 300/= 1200/=

11 Key 1 500/= 500/=
12 Spacer 3 5000/= 5000/=
13 Disc Plate 3 5000 15000/=
11 Cutting disc 2 5000/= 10000/=
12 Welding rod, 5kg 1 11000/= 11000/=
13 Grinding disc 1 5000/= 5000/=
Total 540,700/=
Labour cost = 30% of the material cost
30× 540700
Labour cost = = Tshs 162,210/=
100
The labour cost will be Tshs 162,210/=
Total cost
The total cost of peanut butter machine is the summation of material cost, labor cost,
and machining cost.
Total cost = Material cost + labor cost
=540,700/= + 162,210/=
Total cost = Tshs 865,80/=
67
Appendices
APPENDIX B
Table 2 Properties of Spices
Spices Properties
Black Pepper Black has a sharp, penetrating aroma and acharacteristic piney
flavor. It is hot and biting to the taste
Clove Flavour of cloves is strong, fruity, and sweet almost hot, clove are
available both whole and ground. Used for to add test to many
dishes such as meats, vegetables and curries
Garlic( powder It has strong, pungent green flavor and is the one of the popular
salt) seasonings used today. Garlic can be conveniently purchase as
fresh bulbs, dehadrated powder,minced flakes, and blends with
salt. It add flavor to the fish
Ginger The flavor of ginger is pungent, lemon/citrus, warm, and sweet.
Ginger is available ground , whole (gingerroot), and crystallized.
Used to add zest to many dishe such as gingersnap
Cinnamon Cinnamon has a characteristic wood, musty, earth and sweet
flavor. It is warming to taste. It is available whole as ground.
Used in spiced vegetable dishes, almost in sweet dishes such as
banking, pies and meat
68
APPENDIX C
Table 3 Quality specification for spices
Spice Extraneous Moisture % Total Ashes% Acid insoluble
matter % wt wt wt Ash % wt
Ginger 1.0 12.0 6.0 1.0
Chill 0.8 7.5 10.0 1.2
Coriander 2.0 10.0 8.0 2.0

Fenugreek 2.0 6.0 6.0 1.0
69
Appendices
APPENDIX D
Table 04 Grade of carbon steel and their application
TYPE OF CARBON USES

STEEL PERCENT
Dead Mild 0.0 to 0.1 Rolled steels for cold working and for
Tinplate.Solid drawn tube and
wires.Good welded properties
Mild 0.1 to 0.33 Rolled sections for structural work.
Plates or ship building etc. Very good
machining properties, bright drawn bars
used extensively in general engineering
work of all kinds. Good welded
properties
Medium carbon 0.34 to 0.6 Drop forgings, axes, crank shaft and
other stressed components.High tensile
wires, springs for forging dies, hammers
and other tool
High Carbon 0.6 to 0.9 Springs, punches, dies, drills, shears
chisels and cutting tool
Table 5 Mechanical Properties of plain Carbon Steel Appendix E
GRADE Sut(N/mm2) Syt(N/mm2) HARDNESS

7C4 320 - -
10C8 340 - -
30C8 500 400 179
40C8 540 380 217
APPENDIX E
Table 6.Type of belt
70
71
Appendices
APPENDIX F
Table 7. Present sieve standard
Standard Particle Geometry
4mm Irregular
3mm Irregular
2.5mm Irregular
2mm Irregular
1.5mm Irregular
1mm Irregular
0.75mm Semi powder
0.5mm Semi powder
0.25mm Semi powder
0075mm powder
SHEAVE DIAMETER SERIES

63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 224, 250, 280, 315, 355, 400,
450, 500, 560, 630, 710, 800, 900, 1000, 1120, 1250, 1400, 1400, 1600, 1800, 2000.
3150, 4000.
72
APPENDIX G
Table 07: The coefficient of account for the effect of angle of contact at
smaller pulley
The value of Cα
α1 180 170 160 150 140

Cα 1 0.97 0.94 0.91 0.88
Table 08: The service factor CS that takes care of the type of the drive
Operation Types of machines Cα

For steady operation Belt conveyor, lathes and 1
grinding machines
Moderate vibration Milling machines, chain 0.9
conveyor.
Considerable vibrations Flight conveyors, planning 0.8
machines.
Impact machines Breakers, crushers, hammers 0.7
73
Appendices
APPENDIX H
Table 09: Y – bearings, series YAR2, YAJ2
Basic load Fatigu Mas Designati

Principle dimensions ratings e load s on
limit
dynam Stati Selected
ic c bearing
d d1 D B C s r 1,2 C co Pu
m N N Kg
m
12 24.2 40 27.4 1 11. 0. 7350 4750 140 0.11 SKF YAR
2 5 3 203/12
15 24.2 40 27.4 1 11. 0. 7350 4750 140 0.09 SKF YAR
2 5 3 9 203/15
17 24.2 40 27.4 1 11. 0. 7350 4750 140 0.08 SKF YAR
2 5 3 8 203
20 24.2 47 31.0 1 12. 0. 9800 6550 196 0.14 SKF YAR
4 7 6 204
25 28.2 52 32.1 1 14. 0. 10800 7800 232 0.17 SKF YAR
5 3 6 205
30 33.7 62 38.1 1 15. 0. 15000 1120 355 0.28 SKF YAR
8 9 6 0 206
35 39.7 72 49.2 1 17. 1. 19600 1530 455 0.41 SKF YAR
9 5 0 0 207
40 46.1 80 49.2 2 19. 1. 23600 1900 560 0.55 SKF YAR
2 0 0 0 208
45 51.8 85 49.2 2 19. 1. 25500 2160 640 0.60 SKF YAR
2 0 0 0 209
50 56.8 90 51.6 2 19. 1. 27000 2320 695 0.69 SKF YAR
2 0 0 0 210
55 62.5 10 55.6 2 22. 1. 33500 2900 865 0.94 SKF YAR
0 5 5 0 0 211
60 69.1 11 65.1 2 25. 1. 40500 3600 1060 1.30 SKF YAR
0 6 4 5 0 212
65 75.6 12 68.3 2 25. 1. 44000 4000 1180 1.65 SKF YAR
0 7 4 5 0 213
70 82.5 12 74.6 2 30. 1. 46500 4500 1320 1.90 SKF YAR
5 8 2 5 0 214
74
80 87.1 14 82.6 3 33. 2. 54000 5500 1530 2.80 SKF YAR

0 0 3 0 0 216
90 101. 16 96.0 3 39. 2. 73500 7350 1960 4.10 SKF YAR
4 0 6 7 0 0 218
10 112. 16 108. 4 42. 2. 95000 9300 2320 5.65 SKF YAR
0 5 0 0 0 0 0 0 220
75
Appendices
APPENDIX I
76
Appendices
APPENDIX R
84
APPENDIX K
77
Appendices
78
Appendices
APPENDIX L
78
APPENDIX M
79
Appendices
APPENDIX N
80
Appendices
81
APPENDIX O
81
Appendices
APPENDIX P
82
APPENDIX Q
83
APPENDICES
APPENDIX S
85

Dar Es Salaam Institute of Technology: June, 2017

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Dar Es Salaam Institute of Technology: June, 2017

Uploaded by

Copyright:

Available Formats

DAR ES SALAAM INSTITUTE OF TECHNOLOGY

MECHANICAL ENGINEERING DEPARTMENT

BACHELOR OF MECHANICAL ENGINEERING

PROJECT TITLE : DESIGN AND MANUFACTURE OF SPICE

PROJECT TYPE : PROBLEM SOLVING

STUDENT NAME : STELLA MWENDWA

Eng. Dunstan Mbunga.

I would like to dedicate this project to my family Mashaka.E.Mahande (husband) &

1.2 Problem statement................................................................................................2

1.3 Project objectives..................................................................................................3

1.3.1 Main objectives..............................................................................................3

1.3.2 Specific objectives.........................................................................................3

1.4 Significance of the project....................................................................................3

2.2.1 Forms of Spices.............................................................................................5

2.2.2 Types of spices..............................................................................................6

2.2.3 Application of spices.....................................................................................6

2.4 Handling spices.....................................................................................................6

2.5 Mill (grinding)......................................................................................................7

2.6 The Principle of Grinding Mill.............................................................................7

2.6.1 Types of grinding mills..................................................................................8

2.7 Mortar and pestle..................................................................................................8

2.7.1 How to use a mortar and pestle.....................................................................9

2.8 Hammer Mill......................................................................................................10

2.8.3 General Design............................................................................................12

2.8.4 Feeder Design..............................................................................................12

2.8.5 Hammer design and configuration..............................................................13

2.8.6 Screen Design..............................................................................................13

2.8.7 Hammer mill perforated screens..................................................................14

2.8.8 Mills Hammers............................................................................................14

2.8.9 Dimension of a hammer..............................................................................14

2.9 Ball Mill..............................................................................................................15

2.9.2 Ball mill working principle..........................................................................16

2.9.3 Ball mill application....................................................................................16

2.10 S.A.G Mill........................................................................................................16

2.10.1 S.A.G Mill principle operation..................................................................17

2.11 Pellet Mill.........................................................................................................17

2.11.1 Wood Pellet Mill.......................................................................................18

2.12 Grist Mill (flour mill).......................................................................................19

2.12.1 Early History..............................................................................................19

2.13.1 Mono pulverizer........................................................................................20

2.13.2 Min Pulverizer...........................................................................................20

3.2 Literature Review...............................................................................................22

3.3 Data collection....................................................................................................22

3.6 Data analysis.......................................................................................................22

3.7 Analyzing the probable solution.........................................................................23

3.8.Determinations of machine parameters..............................................................23

3.10 Prototype manufacturing..................................................................................23

3.11 Report writing...................................................................................................23

4.1 Data collection....................................................................................................24

4.1.1 Types of Spices............................................................................................24

4.1.2 Properties of Spices....................................................................................24

4.1.3 Moisture Content.........................................................................................24

4.1.4 Size and shape Spices..................................................................................25

4.1.5 Selection of the appropriate materials.........................................................26

5.1 Design of Spice milling machine........................................................................27

5.1.1 Design parameters.......................................................................................27

5.1.2 Generation and evaluation of alternatives...................................................28

5.1.3 Alternative design type A............................................................................28

5.1.4 Alternative design type B............................................................................30

5.1.5 Alternative design type C............................................................................32

5.1.6 Selection of suitable design.........................................................................34

5.1.7 Determination of the weighing factor..........................................................34

5.1.8 Ranking the altenative design......................................................................35