Nkiwane

DEDICATION
i
Redesign and Manufacture of a Chilli Grinding Machine
ACKNOWLEDGEMENT
ii
ABSTRACT
This project is focused on designing and manufacturing of aChilli grinding machine. Thisis a
post-harvest technological device which crushes raw, dry chilli into powder.The idea of
conducting this design is based on improving the livelihoods and for value addition on chilli
for chilli farmers in Inyanga. The simplicity of the technique and low investment cost will
play an integral role in small scale farmers operations by increasing productivity of chilli
output since there will be a technological and economic way of producing it hence improving
the quality of social and economic living conditions of this farmers.The design specifications
were gathered from the farmers and transformed into a workable solution by the researcher
with the aid of the academic knowledge acquired during the course of study. The main
components of this machine are electric motor, pulleys and belt, casing which contains
crushing blades, shaft, machine guards and supporting frame. The chilli is loaded from top
hopper and the grinding takes place in the casing that contains blades that runs centrifugally
crushing chilli going through the sieves and collected through the outlet hopper. For
manufacturing the Chilli grinding machine, the processes included are milling, turning,
drilling, grinding, welding, cutting, rolling as well as painting. Therefore the required
machinery for these operations should be used.
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Table of Tables
Table 1: Possible Solution Analysis.........................................................................................47
Table 2: Scoring Matrix for Possible Solution.........................................................................49
Table 3: Part List of the Chilli Grinding Machine...................................................................60
Table 4: Manufacturing Process Table....................................................................................61
Table 5: Estimated Total Production Time of Chilli Grinding Machine.................................62
Table 6: Maintenance Schedule of the Chilli Grinding Machine......................................65
Table 7: Total Material Used and its Cost...............................................................................66
Table 8: Expertise Cost............................................................................................................67
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Table of Figures
Figure 1: Raw Granite Pestle and Wood (Source: Nazlina Hussin for pickles and spices.com)
..................................................................................................................................................15
Figure 2: Raw Granite Pestle and Mortar (Source: nazlina hussin for pickles and spices.com)
..................................................................................................................................................15
Figure 3: Grinding Stones (Source: nazlina hussin for pickles and spices.com).....................16
Figure 4: Cam Operated Grinding Machine (Source: ijrtitcc.org)...........................................17
Figure 5: Electrically Operated Machine (Source: indiamart intermeshltd )...........................17
Figure 6: Manual Grinding Machine (Source: Christian Council of Tanzania, 1980)............18
Figure 7: Flow Chart for Chilli Line........................................................................................20
Figure8: Blades on a Grinding Casing (Source:
http://www.zepter.com/MainMenu/Products/HomeArt/MasterpieceCookware/Mixsy.aspx).22
Figure 9: Belt Drive System (Source: https://en.wikipedia.org/wiki/beltdrive)......................26
Figure 10: Flat Belt on a Pulley (Source: http//eh.wikipedi.org/wiki/pulley)..........................28
Figure 11: Fillet Welds.............................................................................................................34
Figure 12: Butt or Groove Welds.............................................................................................35
Figure 13: Butt Weld................................................................................................................36
Figure 14: Power Determination Graph...................................................................................42
Figure 15: Possible Solution 1.................................................................................................44
Figure 18: Bending Moment Diagram.....................................................................................53
Figure 19: Bending Moment and Shear Force Diagram..........................................................54
v
Table of Contents
DEDICATION...........................................................................................................................2
ACKNOWLEDGEMENT.........................................................................................................3
ABSTRACT...............................................................................................................................4
Table of Figures.........................................................................................................................5
Table of Tables...........................................................................................................................6
Table of Contents.......................................................................................................................7
CHAPTER 1: INTRODUCTORY...........................................................................................12
1.1 Introduction....................................................................................................................12
1.2 Statement of the problem................................................................................................12
1.3 Problem Background......................................................................................................12
1.4 Aim.................................................................................................................................12
1.5 Objectives..................................................................................................................13
 To design a grinding and sieving system that should produce powdered chilli ranging
from 12µm to 20µm.............................................................................................................13
1.6 Justifications:..................................................................................................................13
1.7 Limitation.......................................................................................................................13
1.8 Delimitations..................................................................................................................13
1.9 Conclusion......................................................................................................................14
CHAPTER 2: LITERATURE REVIEW.................................................................................15
2.1 Introduction....................................................................................................................15
2.2 Existing designs..............................................................................................................15
2.2.1 Traditional methods of chilli processing.................................................................15
Among the existing designs there are two groups which are the traditional methods and
the modern methods. The figures below show the traditional methods of grinding chilli.
Figure 1 shows the pestle and the wood and the Figure 2 shows the pestle and the mortar
and the last figure shows the grinding stones...................................................................15
2.2.2 Modern methods......................................................................................................17
2.2.2.2 Chilli grinding machine electrically operated..............................................................18
2.3 Automated Chilli Processing Line..................................................................................19
2.3.1 Destoning and Leaf Remover..................................................................................19
2.3.2 Dry Cleaner..............................................................................................................20
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2.3.3 Stem Cutting............................................................................................................20

2.3.4 Crushing...................................................................................................................20
2.3.5 Milling.....................................................................................................................20
2.3.6 Sterilizing.................................................................................................................21
2.3.7 Oil Mixer..................................................................................................................21
2.3.8 Sieving.....................................................................................................................21
2.3.9 Vacuum Conveyor...................................................................................................21
2.4 Sieving............................................................................................................................22
2.4.1 Sieve catalogue........................................................................................................22
2.5 Beaters and Blades.........................................................................................................22
2.5.1 Moisture Content.....................................................................................................23
2.6 Drive System selection...................................................................................................24
2.6.1 Belt Drives...............................................................................................................24
2.6.2 Types of Belt Drives................................................................................................24
2.6.3 Types of Belts..........................................................................................................25
2.6.4 PULLEY..................................................................................................................28
2.7 SHAFT DESIGN............................................................................................................29
2.7.1 CLASSIFICATION OF SHAFTS...............................................................................29
2.7.1.1 Transmission shafts...............................................................................................29
2.7.2 DETERMINATION OF SHAFT SIZES ON THE BASIS OF STRENGTH.........31
2.8 Bearing selection............................................................................................................31
2.9 Limits and Fits................................................................................................................32
2.10 STRENGTH OF RECTANGULAR (SQUARE OR FLAT) KEYS............................32
2.10.1Types of keys..........................................................................................................32
2.11 Joints.............................................................................................................................33
2.12 Fatigue Analysis...........................................................................................................34
2.12 Factor of safety.............................................................................................................34
2.13 Welding of components................................................................................................34
2.13.1 Advantages of welding..........................................................................................34
2.13.2 Types of welds.......................................................................................................35
2.14 Criteria or characteristics of an effective guard...........................................................37
2.15 Electric Motor Analysis................................................................................................38
2.15.1 Types of AC Motors..............................................................................................38
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2.15.2 Basic Electric Motors.............................................................................................39

2.15.3 Selection of motors................................................................................................40
2.15.4 Classification of motors.........................................................................................40
2.15.5 Speed of AC Motors..............................................................................................41
2.15.6 AC Motor Performance.........................................................................................42
2.16 Conclusion....................................................................................................................43
CHAPTER 3: DESIGN SOLUTION, ANALYSIS AND SYNTHESIS.................................44
3.1 Introduction....................................................................................................................44
3.2 Research design..............................................................................................................44
3.3 Interviews.......................................................................................................................44
3.4 Observations...................................................................................................................44
3.4.1 Data collections techniques used in this project include.........................................44
3.5 GENERATING POSSIBLE SOLUTIONS....................................................................45
3.5.1 POSSIBLE SOLUTION 1.......................................................................................45
3.3.3.1 Manually operated piston crushers.......................................................................46
3.4 ANALYSIS OF POSSIBLE SOLUTIONS....................................................................47
3.4.1 Solution screening and scoring................................................................................48
3.4.2 SOLUTION SCORING MATRIX..........................................................................48
The scoring matrix below shows the overall percentage of every possible solution. The
sub criteria consists, for example cost operation, affordability, maintenance, availability
of materials, rate of production, manufacturability and the total rank.............................48
3.4.3 DESIGN SOLUTION SELECTED.........................................................................49
3.5 CONCLUSION..............................................................................................................49
CHAPTER 4: DESIGN MANUFACTURE, ASSEMLY AND MAINTENANCE................50
4.1 Introduction....................................................................................................................50
4.1.1 Design calculations..................................................................................................50
4.2 PART LIST FOR A CHILLI GRINDING MACHINE.................................................58
4.3 MANUFACTURING PROCESS OF THE CHILLI GRINDING MACHINE.............60
4.4 Estimated total production time......................................................................................62
4.4.1 Estimated total production Time..............................................................................62
4.5 Safety..............................................................................................................................63
4.5.1 Safety instructions....................................................................................................63
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4.6 MAINTENANCE...........................................................................................................63
4.6.1 Advantages...............................................................................................................64
4.6.2 Disadvantages..........................................................................................................64
4.6.3 Maintenance schedule table.....................................................................................65
CHAPTER 5: PROJECT EVALUATION...............................................................................66
5.1 Introduction....................................................................................................................66
5.2 Total cost of manufacturing the chilli grinding machine...............................................67
5.3 Labour Costs...................................................................................................................67
5.4 Fixed Costs.....................................................................................................................69
5.5 Overhead Costs...............................................................................................................69
5.6 Material costs..................................................................................................................69
5.7 Total Selling Cost...........................................................................................................70
5.8 Testing the prototype......................................................................................................70
5.9 Conclusion......................................................................................................................70
CHAPTER 6: RECOMMENDATIONS, FURTHER WORK AND CONCLUSION............71
6.1 Introduction....................................................................................................................71
6.2 Recommendations and Further work..............................................................................71
6.3 Constrains.......................................................................................................................71
6.4 Conclusion......................................................................................................................71
REFERENCE...........................................................................................................................72
APPENDICES..........................................................................................................................74
APPENDIX 1: Table showing Kb and Kt factors: For rotating shafts:................................74
(Source -http://www.engineeringtoolbox.com).....................................................................74
APPENDIX 3: Table showing Keyways standard sizes......................................................76
(Source -http://www.engineeringtoolbox.com).....................................................................76
ix
CHAPTER 1: INTRODUCTORY
1.1 Introduction
This chapter looks at the problem and its setting. The statement of the problem will be given
as well as the background to the problem. It lays down the aim as well as the objectives to
this research. Justifications to this study will be explored, the scope outlined and lastly the
conclusion to the chapter will be made.
1.2 Statement of the problem

There is a post-harvest technological gap in the chilli value addition processes resulting in
low market prices as well as losses due to decay.
1.3 Problem Background

Chillies cultivation is one of the developing export segments in Zimbabwe.Howevera case
study that the researcher conducted in Manicaland mainly Inyanga reviewed that the
producers of chillies are economically and socially weaker people facing various problems,
chief to them being the technological gap in chilli processing. Due to ignorance in processing
methods and financial weakness, the farmers possess a weak bargaining power and on the
other hand, the traders (middleman) take the advantage of the farmers‟ weakness” because
they are generally well informed, well organized, financially sound and very tactful in their
dealings.
The majority of farmers are marginal, small scale, scattered, and unorganized. They do not
have sufficient knowledge and skills for the scientific marketing of their produce. Some of
the chillies rot and decay since green chilli needs to be stored at about 8℃ .Keeping this in
mind, the researcher ought to redesign and manufacture a chilli grinding mill so as to curb the
technological gap.
1.4 Aim
To add value to chilli by redesigning and manufacturing a chilli grinding machine for small
scale farmers in Nyanga.
10
1.5 Objectives
 To design a grinding and sieving system that should produce powdered chilli ranging
from 12µm to 20µm
 To design a drive mechanism capable of transmitting a torque to exert a force ranging
from 80N to 150N
 To design a machine that is capable of grinding 20kg per hour
1.6Justifications:
Value addition in terms of prices and revenue to farmers, the prices to be offered are
relatively lower for the farmer in comparison to the costs or loss of profit margins, if their
chilli is sold to a third party. This project will also improve the quality of finished product
due to use of standard sieves for example the grade of chilli is going to be finer as the design
done will utilise a sieve that only allows smaller, finer particles to pass through. Need for
mechanisation, since other farmers do the grinding in a manual way, which takes way longer
to accumulate a sizeable quantity of chilli particles in the air. Chilli pepper contains
impressive list of derived chemical compounds that are known to have disease preventing and
health promoting properties vitamin C, which is seven times higher than an orange, also a
sizeable amount of iron, potassium and magnesium is found in the chilli, hence having,
disease preventing and health promoting properties. Embarking on this project will reduce
severe muscular and skeletal disorders due to repeated work such as manual grinding and
pounding the user is spared muscle aches.
1.7 Limitation
The major limitation of this project is communication to gather the first hand information
hence the researcher rely on phoning, which is the hearsay information which is a secondary
information.
1.8 Delimitations
The project will focus on manufacturing a chilli grinding machine for the farmers particularly
in Inyanga, Manicaland. The project will be done at Harare Polytechnic, within the
Mechanical and Production Engineering Division
11
1.9Conclusion
Having looked at the problem and its setting, a statement of the problem was given as well as
the background to the problem. The chapter laid down the aim as well as the objectives to this
research. Justifications to this study were explored, the scope outlined and lastly the
conclusion to the chapter was made. The next chapter will review the related literature to this
study
12
CHAPTER 2: LITERATURE REVIEW
2.1 Introduction
The chapter mainly focused on Literature related to the study. The main reasons for
reviewing the literature were to further define the research problem, then expand upon the
context and background of the study, to identify and examine previous research studies
,dealing with each of the variables in the study to provide insight into methods, measures
,subjects and approaches used by other researchers and also to find out what other researchers
have said about the present area of the study, whether there are constant findings or that past
studies disagree. The literature was also reviewed to justify the present study, Bell E
(2007).The discussion was only subdivided along the following subtopics; Automated chilli
processing line, existing designs, design calculations. A summary was given at the end of the
chapter
2.2 Existing designs
2.2.1 Traditional methods of chilli processing
Among the existing designs there are two groups which are the traditional methods and the
modern methods. The figures below show the traditional methods of grinding chilli. Figure 1
shows the pestle and the wood and the Figure 2 shows the pestle and the mortar and the last
figure shows the grinding stones.
2.2.1.1 Raw Granite Pestle
As of today, in the rural household, throughout the country the rural people use pounding
method of crushing .In this traditional method a wooden mortar having one or more shallow
pockets for keeping the paddy and one or two rural women folk pound the paddy by means of
round long wooden log of 5ft-6ft called pestle .In this traditional method the mortar is made
of stones as well. The diagram below (fig 1) explains further.
13
Figure 1: Raw Granite Pestle and Wood (Source: Nazlina Hussin for pickles and
spices.com)
Raw Granite Pestle and Mortar
This method was mainly used in India to crush chilli, whereby a large granite mortar was
used in conjunction with a pestle hand lifted by a person. The weight of the pestle would
crush the chilli as shown on the diagram. The above method is similar to the Zimbabwean
scenario where a wooden pestle and motor is also used. The diagram (fig 2) below illustrates
the concept.
Figure 2: Raw Granite Pestle and Mortar (Source: nazlina hussin for pickles and
spices.com)
2.2.1.2 Grinding stones
14
The old day’s methods of grinding spices are different. Before electric blenders, the spices
were painstakingly ground manually. Every house had their own grinding stones made of
undressed granite. This was used for grinding small quantities of spices. The methods are
common also in Zimbabwe. The main disadvantage is that small quantities can only be
produced. For commercial reasons, the methods are outdated. The diagram in fig 3 explains
the concept.
Figure 3: Grinding Stones (Source: nazlina hussin for pickles and spices.com)
2.2.2 Modern methods
2.2.2.1 Chilli grinding machine manually operated
The manual crushing machine works with mechanism of 2 grinding stones ( fixed and
rotating). The pulley is provided to transmit motion between 2 grinding stones. As the
rotating gear is rotating towards the fixed grinding stones the powder, that comes from the
pod goes out through the outlet named product output. As we motion with the help of paddle.
A chain socket arrangements which is mounted on the shaft will rotate and because of that
motion our gear shaft will also rotate in clockwise direction which is connected to shaft 1. As
the Gear 1 rotates in clockwise direction, the Gear 2 which is attached to the shaft 02 will
also rotates in anticlockwise direction with respect to that our flywheel and Gear 3 will also
rotates in same direction, as Gear4 which is completely meshed will rotate in clockwise
direction which is attached to the shaft S3. As the shaft 3 rotates in clockwise direction with
15
respect to that CAM will also rotates we had provided CAM and follower arrangements for
lifting for punching rod. It converts rotary motion into reciprocating motion as shown below
in fig 4.
Figure 4:Cam Operated Grinding Machine (Source: ijrtitcc.org)
2.2.2.2Chilli grinding machine electrically operated
Figure 5: Electrically Operated Machine (Source: indiamart intermeshltd )
2.2.2.2.1 Working principle
Raw material keeps being stricken by high speed spinning tooth then turn to powder. It uses a
screen of different size mesh to control the size of powder. As illustrated above fig 5.
16
2.2.2.3 Chilli grinding machine
Figure 6: Manual Grinding Machine (Source: Christian Council of Tanzania, 1980)
The manual grinding machine works with mechnism of 2 grinding stones (fixed and rotating).
The pulley is provided to transmit motion between 2 grinding stones.As the rotating gear is
rotating towards the fixed grinding stones the powder thats comes from the pod goes out
through the outlet named product output as shown in fig 6.
2.3 Automated Chilli Processing Line

Chilli powder making machine used to produce chilli powder as a product by processing the
whole dry chilly. This is fully automatic line. By just feeding the chilli into the hopper, the
whole process is done automatically.
It includes the number of processes:
2.3.1 Destoning and Leaf Remover
This machine consists of two parts
1. Vibrator with sieve that removes sand, small stones and seeds.
17
2. Air blower that helps in removing the leaves which are blown out of it using high
pressured air
2.3.2 Dry Cleaner
After removing the unwanted contaminants, dry cleaning is done to completely clean the
chilli. It contains a number of brushes working in sequence; the chilli is passed through these
brushes so it gets cleaned completely. And then the chilli is passed to stem cutter.
2.3.3 Stem Cutting
The stem cutting system contains rollers and blades. Using this machine, the chilly stem is
removed and gets separated from chilli. The chilli is fed into the rollers, the roller number of
holes at the surface so chilli stem get stuck into these holes. The cutters are place outside the
roller, the roller rotates and the cutters keep cutting the stem. Using this process, the chilli
remains inside the roller and the stem remains outside and gets separated.
Now the chilli is ready to be crushed and is passed to the crusher.
We cannot grind the chilly in one go because grinding process produces heat and the
chemical properties of product gets changed so it is done in two steps, first is crushing and
then milling.
2.3.4 Crushing
The crusher contains two rotary blades that rotates in opposite directions, the chilly is fed
between the blades and cut into small pieces.
2.3.5 Milling
Milling or grinding is done using pin mill.
Pin Mill reduces the average sized material to fine powder and maintains the quality of
material. It uses air cooling to maintain the temperature of the final product. There are two
rotating disks with pins/knifes, the substance that is to be grinded, is fed into the space
between disks and through the grinding motion of the disks the material is converted into
powder.
2.3.6 Sterilizing
18
Chilli powder is then sent for sterilization. The sterilizer contains layers of conveyor belts;
the product is passed through the UV rays to make sure that it is not contaminated with
bacteria.
2.3.7 Oil Mixer
Oil is mixed in the chilli powder to give it flavours, the oil mixer mixes the oil with powder
2.3.8 Sieving
A sieve is used for sifting the powder to make sure there are no lumps and to get desired
mesh size.
2.3.9 Vacuum Conveyor
Vacuum Conveyor is used to pull the powder from sieve so there is no risk of spreading the
chilli powder in the air.
The vacuum conveyor passes the powder to packing machines.
2.3.1 FLOWCHART FOR CHILLI LINE
Figure 7: Flow Chart for Chilli Line
2.4Sieving
A sieve, or sifter, is a device for separating wanted elements from unwanted material or for
characterizing the particle size distribution of a sample, typically using a woven screen such
as a mesh or net or metal. The word "sift" derives from "sieve". In cooking, a sifter is used to
separate and break up clumps in dry ingredients such as flour as well as to aerate and
combine them. A strainer is a form of sieve used to separate solids from liquid.
19
Sieving is a simple technique for separating particles of different sizes. A sieve such as used
for sifting flour has very small holes. Coarse particles are separated or broken up by grinding
against one-another and screen openings. Depending upon the types of particles to be
separated, sieves with different types of holes are used. Sieves are also used to separate
stones from sand. Sieving plays an important role in food industries where sieves (often
vibrating) are used to prevent the contamination of the product by foreign bodies.
2.4.1Sieve catalogue
For sieve specification and standards, reference to appendix 4 was made. A catalogue was
used.
2.5 Beaters and Blades

The Beater Blade is used for the grinding of products with a high fat content e.g. Cocoa nibs
and Hazelnuts. Product is fed into the grinding chamber at a controlled rate, by means of a
dosing screw. High speed rotating blades break the product down to the required particle size
and the high fat content ensures conversion into a pumpable mass with optimal flow
properties. The fineness of the finished product is deter-mined by the mesh size of an
integral, annular sieve, through which the mass flows on its way to the exit of the mill. The
shell and base of the grinding chamber are jacketed to facilitate the processing of product
under controlled conditions. The concept of blade mechanism on a casing is shown on a
casing shown below
20
Figure 8: Blades on a Grinding Casing (Source:

http://www.zepter.com/MainMenu/Products/HomeArt/MasterpieceCookware/Mixsy.as
px)
2.5.1Moisture Content
Traditionally chilli is dried directly under the sun. The other method is solar drying which
saves up about 48% of drying time and yields more in terms of quality without contamination
of chilli with insects as what happens with sun drying in an open space. The other method of
is drying them in an air oven for three days at 55degrees Celsius. Moisture content of the
pods is obtained by toluene method using Dean starck trap in the laboratory to determine the
optimum moisture content of chilli peppers and the atmospheric humidity that will produce
this moisture content. Moisture content analysed in chilli ranges from 9,1-19.8% with a mean
value of 11.4 ± 2.4% .it is important to use properly dried chillies with low moisture content
that has less than 10% to minimise health hazards.
21
2.6Drive System selection
2.6.1Belt Drives
A belt is defined by Shigley as a looped strip of flexible material used to transmit power from
one shaft to another by means of pulleys which rotate at the same speed or at different speeds.
It is a flexible power transmission element that seats tightly on a set of pulleys or sheaves.
Belts primarily are used for speed reduction; the smaller sheave is mounted on the high-speed
shaft, such as the shaft of an electric motor. The tensile force in the belt exerts a tangential
force on the driven sheave, and thus a torque is applied to the driven shaft. When transmitting
power, friction causes the belt to grip the driving sheave, increasing the tension on one side,
called the “tight side,” of the drive.
2.6.2Types of Belt Drives
The belt drives are usually classified into the following three groups:
1. Light drives - These are used to transmit small powers at belt speeds up to about 10 m/s as
in agricultural machines and small machine tools.
2. Medium drives - These are used to transmit medium powers at belt speeds over 10 m/s but
up to 22 m/s, as in machine tools.
3. Heavy drives -These are used to transmit large powers at belt speeds above 22 m/s as in
compressors and generators.
2.6.2.1 Advantages of belt drives
 Belt drives are simple and economical (cheap in terms of cost)

 They allow misalignment(they don’t require parallel shafts only)
 Protects the system from overloads (they are provided with overload ad jam
protection)
 Noise and vibration are damped out. Machinery life is increased because load
fluctuations are shock-absorbed.
 They are lubrication-free. They require less maintenance cost.
 Belt drives are highly efficient in use (between 90% and 98%)
2.6.2.2 Disadvantages of belt drives
 Speed ratio is not constant (slipping and stretching)
22
 There is heat accumulation

 Speed is limited
 Power is limited to 700KW
2.6.3 Types of Belts
1. Flat belt - The flat belt is mostly used in the factories and workshops where a moderate
amount of power is to be transmitted, from one pulley to another when the two pulleys are
not more than 8 metres apart.
2. V- belt - The v belt is mostly used in the factories and workshops where a great amount of
power is to be transmitted from one pulley to another, when the two pulleys are very near to
each other.
3. Circular belt - The circular belt is mostly used in the factories and workshops, where a
great amount of power is to be transmitted from one pulley to another when the two pulleys
are more than 8 metres apart.
2.6.3.1Selection of belt drives
Following are the various important factors upon which the selection of belt drive depends:
 Speed reduction ratio

 Speed of the driving and driven shaft
 Power to be transmitted
 Centre distances between the shafts
 Positive drive requirements
 Shaft layout
 Space available
 Service conditions
2.6.3.2 Belt Mass
17mm belt section has a mass of 0.183 kg/m, Maximum load is 13.472 kg.
22 mm belt section has a mass of 0.34 kg /m, Maximum load is 22.77 kg.
2.6.3.3 Belt length
23
The relation between centre distance and belt pitch length is given by the following
formula
( D−d )2
L = 2C + 1.57(D + d) + 4C ……eqn1
Where C = centre distance
D = pitch diameter of large sheave
d = pitch diameter of smaller sheave
L = pitch effective length of belt
2.6.3.4 Belt Torque
Torque of a belt drive, torque is found from
T or Mt = (T1 – T2 …eqn2
Where r = radius of pulley in metres
T1 and T2 = Tensions in the tight side and slack side of the belt respectively in
Newton
2.6.3.5 Centrifugal Tensions, Tc
The belt is having some mass, and as it passes over a pulley around a circular path, it is
subjected to centrifugal force. The effect of this is to increase the tensions on both the tight
and the slack side. The tension where θ1 is the angle of contact caused by centrifugal forces is
called centrifugal tension. It becomes more significant and should be considered in the
design.
Tc = mv2 ……eqn3
Where m = mass of belt / unit length, kg/m,
V = velocity of belt in m/s
2.6.3.6 The angle of contact
24
These angles are important because commercially available belts are rated with an assumed
contact angle of 1800. This will occur only if the drive is 1 (no speed change). The angle of
contact on the smaller of the two sheaves will always be less than 180 0, requiring a lower
rating.
Figure 9: Belt Drive System (Source: https://en.wikipedia.org/wiki/beltdrive)
The angle of contact of the belt on each sheave is
Θ1 = 1800 – 2Sin-1[D – d / 2C] ………...eqn4
Θ2 = 1800 + 2Sin-1[D – d / 2C] …………eqn5
Where θ1 of the smaller pulley and θ2is the angle of contact of the bigger pulley.
…………eqn6
These angles are important because commercially available belts are rated with an
assumed contact angle of 1800. This will occur only if the drive is 1 (no speed change).
The angle of contact on the smaller of the two sheaves will always be less than 180 0,
requiring a lower rating.
25
The Power transmitted by a belt is a function of the belt tensions and belt speed;
Let T1 and T2 = Tensions in the tight side and slack side of the belt respectively in
Newton
r1 and r2 = Radii of the driving and driven pulleys respectively in metre and
ν = Velocity of the belt in m/s ¿ ωr=2 πNr /60 …eqn7
The effective turning (driving) force at the circumference of the driven pulley or
follower is the difference between the two tensions (i.e. T1 – T2)
Therefore, Work done per second = (T1 – T2) ν N-m/s
Power transmitted =Tω……eqn 8

Torque exerted on the driving pulley
¿ T 1 – T 2 ¿ r 1. … . eqn 9
Similarly, the torque exerted on the driven pulley
¿(T 1 – T 2)r 2 .… … … . eqn 10
2.6.4 PULLEY
A pulley is a on an axle or shaft that is designed to support movement and change of

direction of a taut cable or belt, or transfer of power between the shaft and cable or belt. In
the case of a pulley supported by a frame or shell that does not transfer power to a shaft, but
is used to guide the cable or exert a force, the supporting shell is called a block, and the
pulley may be called a sheave.
A pulley may have groove or grooves between flanges around its circumference to locate the
cable or belt. The drive element of a pulley system can be a rope, cable, belt, or chain.
26
Figure 10: Flat Belt on a Pulley (Source: http//eh.wikipedi.org/wiki/pulley)
2.7 SHAFT DESIGN

Hearn (1997) concurs that the term “shaft” refers to a rotating machine element which is used
to transmit power from one position to another through various members such as gears and
pulleys mounted on the shaft by means of keys or splines. The most common shafting
material used is mild-steel because of its machinability, good wear resistance, high strength
and good heat treatment properties hence shafts made from alloy steel such as nickel, nickel-
chromium or chrome-vanadium steel, low-carbon steel are used. Shaft sizes are determined
on the basis of strength or both strength and rigidity.
2.7.1 CLASSIFICATION OF SHAFTS
2.7.1.1 Transmission shafts
They are used to transmit power between source and the machines using power. They include
line shaft, jack shaft and counter shafts
 Line shaft is a long continuous shaft which receives power from the source and
distribute to different machines.
 Jackshaft is directly connected to the source of power and from which other shafts are
driven
 Counter shafts receive power from line shaft and transmit to a machine
2.7.1.2 Machine shafts
They are incorporated within the machines, such as the crank shafts
27
2.7.1.3 Design consideration of shafts
Shafts are designed on the basis of strength, rigidity and stiffness
In the designing shafts on the basis of strength, the following cases may be considered:
 Shafts subjected to twisting moment or torque only

 Shafts subjected to bending moment only
 Shafts combined to twisting and bending moment only
 Shafts subjected to axial loads in addition to combined torsion and bending loads
From the Torsion theory:
τ Gθ T
= …. eqn11
R L J
Where,
T- Torque,
τ – Shear stress,
G- Modulus of rigidity,
θ−angle of twist , in radians
J- Polar second moment of area of the shaft cross section, R- radius and
L- Length of shaft
The angle of twist is obtained from:
TL
θ=
GJ ,
Hence the twist should not exceed 0,250/m for machine tools and 30/m for line shafts.
Maximum permissible shear stress adopted from American Society of Mechanical

Engineer (ASME) – (Khurmi, 2005) may be taken as:
a) 56Mpa for shafts without allowance for keyway

b) 42Mpa for shafts with allowance for keyway
28
2.7.2DETERMINATION OF SHAFT SIZES ON THE BASIS OF STRENGTH
The action of forces on a shaft is generally one of the following: (torsion, bending or torsion
combined)
2.7.2.1 TORSION
For a twisting moment, Mt on a solid circular shaft of diameter, d, the
Working shear stress will be given by;
… … .. eqn 12
For solid shafts the polar section modulus is given by;
π D4
J= … … eqn13
32
And for hollow shafts;
π (D 4 −d 4 )
J= … … eqn14
32
. .. eqn15
2.8Bearing selection
A bearing is a device used to support and guide a rotating, oscillating, or sliding shaft,
Hannah and Stephens, (1972). Whenever a shaft rotates, it needs a bearing for smooth and
effective operation. It is designed to reduce friction, support a load, and guide moving parts
such as wheels, shafts, and pivots.
The common type of bearing used is the ball or roller bearing. The ball bearings are used for
light loads and the roller bearings are used for heavier loads. During use, they are lubricated
for the following purposes:
I. To reduce friction and wear between the sliding parts of the bearing.
II. To prevent rusting or corrosion of the bearing surfaces
III. To prevent the bearing surfaces from water, dirt etc
IV. To dissipate heat
29
2.9 Limits and Fits

Carvill (1993) posits that limits are stated maximum and minimum dimensions of a part. Fits
measure the clearance between the hole and the shaft. A tolerance is the difference between
maximum and minimum dimensions of a component, that is, between upper limit and lower
limit. Allowance it is the difference of dimension between two mating parts. Depending on
the type of application, the permissible variation of dimension is set as per available standard
grades. In other words, allowance is the margin of error that is allowable to accommodate
reasonable inaccuracies in manufacturing. It is a measure of the amount of deviation from the
basic size of a part or the measure of the difference between maximum limit and minimum
limit.
2.10 STRENGTH OF RECTANGULAR (SQUARE OR FLAT) KEYS

A key is a piece of mild steel inserted between the shafts and hub or boss of the pulley to
connect those together in order to prevent relative motion between them. It is always inserted
parallel to the axis of the shaft. Key are used as temporary fastening and are subjected to
considerable crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of
hub of the pulley to accommodate a key. According to Ryder (1969), a key is a wedge-like
steel fastening that is inserted within two machine or structural parts to prevent them from
having relative motion with respect to each other. This causes the two members to act as a
unit or single part. These can be saddles, flat, square, pin etc.
2.10.1Types of keys
 Sunk keys
 Saddle keys
 Round keys
 Splines
 Flat
 Square
P t=T /r . … … eqn 17
But this tangential force is a shearing load on the key over its rectangular area bl,
parallel to the direction if the load.
Hence the shear stress on key will be;
30
Pt
τ sk = ≤[ τ sk ]
bl …eqn18
The same load is resisted by the area ½ (tl) perpendicular to the direction of this load
which tends to compress or crush this area of the key against the shaft hence,
… … eqn 19
2.10.1.1Key Design Assumptions
The width of key (b) =1/4 d . .. eqn20

The minimum length of key (l)  1.5d ..eqn19
2.11 Joints
Every machine is made up of a number of parts which may be manufactured separately and
joined together to perform the duties of the machine.
Joints can be classified as;
a) Detachable joints: These allow for disassembling without destroying the connecting
components or the fastened elements hence replacements, repair, transportation, etc. are
made easier.
Examples are threaded, keyed and pined cotter joints.
b) Permanent joints: These cannot be disassembled without destroying the connecting

components.
Examples are welded, brazed, soldered, adhesive, riveted and interference fit joints.
2.12 Fatigue Analysis

Fatigue is the failure of a material under fluctuating stresses. The fatigue limit of a particular
material is the maximum stress, which can be applied for an unlimited number of times
without causing failure. If the applied stress exceeds the fatigue limit, then the component can
only be limited to a number of cycles before failure occurs. If the applied stress is kept below
the fatigue limit then the component could be expected to have longer life span.
2.12 Factor of safety
Factor of Safety (FOS), also known as Safety Factor (SF) is a term describing the capacity of
a system beyond expected loads or actual loads. Essentially, the factor of safety is how much
31
stronger the system is than it usually needs to be for intended load. The ratio of the Ultimate
Tensile Stress (UTS) to the working stress is called the factor of safety thus mathematically,
UTS
FOS= STRESS ….. eqn20
WORKING
Shaft safety factor is considered to be 3.Factor of safety is multiplied by torque when

calculating diameter of shaft (Khurmi, 2005).
2.13Welding of components
Welding is a process of joining metals in which the parent metals are fused together to form a
single piece. Welding is normally used where:
 Strength is required
 As a substitute for forgings and castings
 As a fabrication medium to join parts permanently.
 As a medium to replace fasteners such as rivets and bolts.
 As a repair medium to replace broken and worn out sections of a member.
2.13.1 Advantages of welding
 Welding is stronger compared to rivets as there is no weakening of section due to

drilling or punching.
 Less labour as number of operations such as drilling or punching are replaced by a
single weld.
 Welding is light since the straps and rivets are eliminated
 Welded joints can be made more than 100% strong i.e. the joint will never fail,
 Is no need of patterns, moulds etc. with the adoption of welding,
 Lighter construction and material saving during fabrication by welding,
 With the modern welding techniques it is possible to add the specific material with
desired characteristics to any portion of the machine part.
2.13.2 Types of welds
For general machine elements most welds are fillet welds, though butt welds are used a great
deal in designing pressure vessels.
32
Figure 11: Fillet Welds
BUTT OR GROOVE WELDS
Figure 12: Butt or Groove Welds
Special butt or groove welds can also be T joint for thick plates, U and V welds for thick
plates, corner weld and edge welds for sheet metal.
During the welding process the generated heat may cause metallurgical changes in the parent
metal in the vicinity of the weld. Residual stresses may also be introduced because of
clamping or holding. These may be corrected by a light heat treatment after welding.
2.13.2.1 Design of butt and fillet welds

33
The strength of a welded joint depends on:
 The skill of the operator

 The type loading- (steady or fatigue)
 Whether shielded or unshielded welding is done
 The type of the joint
 The type of stress existing within the joint.
2.13.2.2 BUTT WELD
Figure 13: Butt Weld
Shown in the diagram is a single V butt weld loaded by a tensile force F. For either
tension or compression the normal stress will be given by;
F

hl
Where
h- Weld throat
t- length of the weld
NOTE:
The weld throat h does not include the reinforcement which is desirable in order to
compensate for flows. If there are fatigue loads it is good practice to grind or machine off the
reinforcement.
34
2.14 Criteria or characteristics of an effective guard

The safeguard must:
 Prevent contact -the safeguard must prevent hands, arms, or any part of a worker's body or
clothing from making contact with dangerous moving parts. A good safeguarding system
eliminates the possibility of the operator or other workers placing any part of their bodies
near hazardous moving parts.
 Secured & well-constructed -workers should not be able to easily remove ortamper with the
safeguard, because a safeguard that can easily be made ineffective is no safeguard at all. They
must be firmly secured to the machine. Guards should be made of durable material that will
withstand the conditions of normal use. They may be constructed of sheet metal, screen, wire
cloth, bars, plastic, or any other material that is substantial enough to withstand whatever
impact it may receive and to endure prolonged use.
 Protect from falling objects/contain the hazard -The safeguard should ensure that no
objects can fall into moving parts. A small tool which is dropped into a cycling machine
could easily become a projectile that could strike and injure someone.
 Create no new hazards -A safeguard defeats its own purpose if it creates a hazard of its
own such as a shear point, a jagged edge, or an unfinished surface which can cause a
laceration or creates a pinch point between the guard and moving machine parts. The edges of
guards, for instance should be rounded in such a way that they eliminate sharp edges.
 Create no interference -any safeguard which impedes a worker from performing the job
quickly and comfortably might soon be overridden or disregarded. Proper safeguarding can
actually enhance efficiency since it can relieve the worker's apprehensions about injury.
 Allow safe lubrication - if possible, one should be able to lubricate the machine without
removing the safeguards. Locating oil reservoirs outside the guard, with a line leading to the
lubrication point, will reduce the need for the operator or maintenance worker to enter the
hazardous area.
2.15 Electric Motor Analysis

An Electric motor is a machine which converts electric energy into mechanical energy.
Its action is based on the principle that when a current carrying conductor is placed in a
35
magnetic field, it experiences a mechanical force whose direction is given by Fleming’s

Left hand Rule and whose magnitude is given by F = Bill Newton
2.15.1 Types of AC Motors
Classification Based On Principle of Operation:

(a) Synchronous Motors.
1. Plain
2. Super
(b) Asynchronous Motors.
1. Induction Motors:
(a) Squirrel Cage
(b) Slip Ring (External resistance).
2. Commutator Motors:
(a) Series
(b) Compensated
(c) Shunt
(d) Repulsion
(e) Repulsion start induction
(f) Repulsion induction Classification Based on Type of Current:
1. Single Phase
2. Three Phase
Classification Based On Speed of Operation:
1. Constant Speed.
2. Variable Speed.
3. Adjustable Speed.
Classification Based On Structural Features:
1. Open
2. Enclosed
3. Semi enclosed
4. Ventilated
2.15.2Basic Electric Motors
Motors are used to create rotary motion and drive components that need to be turned.
They power compressor, pumps, fans, timers and any other devices that must be driven
36
within a rotating motion. An electric motor changes electrical energy into mechanical
energy by magnetism which causes the motor to turn. The method by which magnetism
cause motors to rotate uses the principles that like poles of magnets repel and unlike
poles attract. A rotating magnetic field which is produced by the reversal of poles in the
rotor or stator makes an electric motor move continuously. An alternating current of 60
HZ changes direction 120 times per second, there for, the current would change the
polarity of the stator poles on each reversal of current. If alternating current changes
direction causing a polarity change 120 times seconds, then the motion will turn into a
continuous motion because the poles of the stator will be continuously repelling and
attracting the permanent poles of the rotor.
2.15.3 Selection of motors
 The conditions prevailing at the point of installation with respect to ambient

temperature and to the presence of dust, moisture or explosive material
 The starting energy requirement (loaded or unloaded)
 Starting current limitations
 Single or multi speed operation
 Continuous or intermittent operation
 Efficiency and power factor
All motors generate a certain amount of heat due to power losses in the windings
If the heat is not dissipated to the surrounding, the motor temperature will become
excessive and breakdown of the winding insulation will result
2.15.4Classification of motors
1. Synchronous Motors & its Uses: Because its speed remains constant under varying loads, it
is used for driving continuously operating equipment at constant speed. These motors have
the rotor (which is connected to the load) rotating at the same speed as the speed of rotation
of the stator current. In other words, we can say these motors don't have slip with respect to
the stator current. They are sometimes used no to drive the load but instead act as
"synchronous condenser", to improve the power factor of the local grid to which it is
connected to.
37
These kinds of motors are used even in high precision positioning devices like modern
robots, ammonia and air compressors, motor generator sets, continuous rolling mills, paper
and cement industries. They can also act as stepper motors.
2. Asynchronous Motors & it's Uses: The most common form of motor which is used in
everyday life from pumping water up the overhead tank to power plant boiler feed pumps,
these kind of motors rule. These motors are very flexible to use and matches the load demand
almost for everything. The most widely used Induction Motors are very important for many
industries due to their load bearing capacity and flexibility. These motors, unlike synchronous
motors, slip when compared to the stator current field. They are generally used for various
types of pumps, compressors and acts as prime movers for many types of machinery.
3. Single & Three Phase Motors and their Uses: The A.C. Motors can find their usage
in 2 forms based on their power supply. The single phase motors are generally found
their use in low power requirements/domestic appliances like ceiling fans, mixer
grinders, portable power tools etc. The three phase motors are generally found for high
power requirements like power drives for compressors, hydraulic pumps, air
conditioning compressors, irrigation pumps and many more.
4. Constant, Variable & Adjustable Speed Motors: As already said, A.C. Motors are
highly flexible in many ways including their speed control. There are motors which
should be run at a constant speed for air compressors. Certain cooling water pumps
driven by A.C. motors can be run at two or three speeds by just switching the number
of poles used. If the number of poles is changed then the speed also changes. These
serve best for sea water cooling pumps in marine engine room applications & many
power plants. The speed of the motors can also be varied continuously by some
electronic arrangements thus this can be suited for certain applications like a ship's
cargo pump, whose discharge rate has to lowered as per the terminals requirement.
5. Varied Structure Motors: These types of motors have different outer cage
arrangements, depending upon the usage or any special industrial requirement. For
motors used in gas and oil terminals, the casing must be of intrinsically safe, thus it
may either have a enclosed casing or a pipe ventilated arrangement such that the sparks
produced inside the motor does not cause a fire outside it. Also many motors are totally
enclosed as it may be open to weather like those used in hydroelectric power plants
38
2.15.5Speed of AC Motors
An AC motor at zero load would tend to operate at or near a synchronous speed, in

which are related to the frequency, of the AC power and the number of electrical pole p
wound into the motor, according to the equation
2.15.6AC Motor Performance
The performance of electric motor is usually displaced on graph of speed versus torque
as shown below the vertical axis is the rotational speed of the motor as percentage of
synchronous speed the horizontal axis is the torque developed by the motor as a
percentage of the full load or rated torque. When exerting its full load torque the motor
operates at its full speed and delivers the rated power. The torque at the bottom where
the speed is zero is called the starting torque or locked down rotor. It is the torque
available to initially get the load moving and begin its acceleration. This is one of the
important selection parameters for motors as will be discussed in the description of the
individual type of motors. The knee of the curve called the breakdown torque is the
maximum torque developed by the motor during acceleration. The slope of the speed
/torque curve in the vicinity of the full load operating point is an indication of speed
regulations. A flat curve (a low slope indicates good speed regulations) with little
variation in speed as load varies. Conversely a steep curve (a high slope) indicates per
speed regulations, and the motor will exhit wide swings in speed in speed as load
varies. Such motors produce a soft acceleration of a la which may be an advantage in
some application. But where fairly constant speed is desired, a motor with good speed
regulation should be selected
39
Figure 14: Power Determination Graph
For electric motors, we use Power =Tω
2.16 Conclusion
In this chapter relevant information pertaining to the process of chilli and methods of
grinding chilli at standard percentage of moisture content was gathered and this shaped the
way forward and managed to help mold the new ideas and thesis in the manufacturing of a
new design. Relevant formulae’s that helps in design calculations and parameters of the chilli
grinding machine where compiled and these gives a lee-way to the analysis and synthesis of
the design process hence giving birth to the possible solutions.
40
CHAPTER 3: DESIGN SOLUTION, ANALYSIS AND

SYNTHESIS
3.1 Introduction
According to The Web Centre for Social Research Methods, research design is the structure
of research. It is further defined as the “glue” that holds all the elements in a research project
together. This chapter dealt with design and methodology. It identified, described and
discussed the design and methodology for the present study. It went on to explain procedures
for data analysis, presentation and interpretation. At the end a summary was given.
3.2 Research design

Speaking, there are two major types of research models. A combination of these two
approaches was used in this research project as explained below. For concept selection,
method used was the weighted objectives method.
3.3 Interviews
Interviews enable face to face discussion with human subjects. Visits were made to Mbare
Musika
3.4 Observations
3.4.1 Data collections techniques used in this project include
1. Direct observations – primary data was collected through direct observation to the small
scale farmers using the manual methods already discussed in the previous chapter. It was
observed that the current manual methods are labour intensive, cumbersome and inefficient.
2. Desktop research – the internet has proved to be a vital tool of modern day information
source and could not be left out, related journals and books were also used to obtain
information on best practices, available chilli grinding machines with their capabilities and
efficiencies.
3. Interview – face to face interviews were conducted with small scale farmers using our
native language in order to get paramount information from horse’s mouth. Telephone
interview were also conducted and enough data was gathered
41
3.5 GENERATING POSSIBLE SOLUTIONS

The designs will start as conceptual until a detailed design is developed and drawings are
produced. In this particular project, only three concepts will be reviewed and the chosen one
is developed. A selection criterion using the tabulated format will be adopted to separate the
solutions so as to bring the one that best fits the working conditions of these small scale
farmers.
3.5.1POSSIBLE SOLUTION 1
3.5.1.1 The working principle of possible solution 1
The process of the chilli powder machine works as follows; dried chilli is fed in through top
hopper and it enters into a casing that has threshers which has blades that run centrifugal,
turning the chilli into powder. The powder is obtained from the continuous crushing of the
pod. During the continuous crushing of the pod, powder is collected into the sieve. The chilli
powder goes via the outlet hopper and collected through sealable bags to keep the chilli
powder fresh. The mechanism is motor driven has 2 pulleys and a belt as shown below
Figure 15: Possible Solution 1
42
3.3.2.1 Working principle of possible solution
Dry chilli is fed through the feeding hopper, which has to be controlled in order to avoid over
loading the machine. Beaters rapidly crush chilli into powder using centrifugal motion. The
beaters are made of rust –free material and are fixed radically on the plate that is fixed to the
rotor shaft. The ground chilli passes through sieves and the powder is collected into sealable
bags through the outlet hopper. The main prime mover here is a diesel engine unlike in the
first scenario
3.3.3.1 Manually operated piston crushers
The figure shown below is a hand operated grinding machine which uses a cam, follower and
piston mechanism. As the crank is rotated, the cam and follower enables the pistons to
reciprocate and pound the dried chilli into powder. The ground chilli passes through sieves
and the powder is collected into sealable bags through the outlet hopper.
43
3.4ANALYSIS OF POSSIBLE SOLUTIONS

Table 1: Possible Solution Analysis
3.4.1 Solution screening and scoring
Operation conditions
 Should be user friendly to operate.
44
 Dust should not affect the operator

 Operator safe from traversing parts
Design easiness and simplicity
 Accessibility of the inside parts

 easiness of assembly and disassembly
 simple prime mover mechanism
 easiness of manufacture of machine parts and components
Affordability
 locally available parts and materials

 Materials available at low and economical prices
 Low tolerance
Key
 · Excellent - 5
 · Good -4
 · Fair- 3
 Average-2
 Poor-1
 · Unsatisfactory 0
3.4.2 SOLUTION SCORING MATRIX
The scoring matrix below shows the overall percentage of every possible solution. The sub
criteria consists, for example cost operation, affordability, maintenance, availability of
materials, rate of production, manufacturability and the total rank
45
Table 2: Scoring Matrix for Possible Solution
3.4.3 DESIGN SOLUTION SELECTED
After a critical analysis, solution 1 has proved to be the best for the desired application.
The design can be manufactured at reasonable cost. There are no complicated
manufacturing methods required for this design. From the functionality point of view,
the design has all the necessary features to carry out the desired tasks. This design is
easy to use and can be maintained without difficulties.
3.5 CONCLUSION
This chapter led to the selection of the best possible solution through various stages of
analysis. So the next part of the chapter will then focus on the design calculations of the
selected design solution
46
CHAPTER 4: DESIGN MANUFACTURE, ASSEMLY AND

MAINTENANCE
4.1 Introduction
This chapter focuses mainly on the design and manufacture of the main component which is
possible solution 1 selected in chapter 3. The manufacture and assembly of the chilli grinding
machine will be done after the designing and sizing of the component. Manufacturing process
materials selection as well as standards and non-standards are laid down. Furthermore, this
chapter will present information about maintenance requirements of the machine before,
during and after the usage.
4.1.1 Design calculations
4.1.1.1 Belt drive calculations
Determination of the belt contact angles
Considering the centre distance (C) as 500 between two pulleys then the angle of contact of
the belt on each sheave is
θ1 = 1800 – 2Sin-1[D – d / 2C] …..eqn4

= 1800 – 2Sin-1[100 – 40/ 2 x 500]
θ1= 173,120
θ2= 1800 + 2Sin-1[D – d / 2C] …..eqn5
= 1800 + 2Sin-1[100 – 40/ 2 x 450]
θ2 = 186, 870
Where θ1 is the angle of the smaller pulley on the electric motor and θ2 is the angle of
contact of the bigger pulley
4.1.1.2 Determination of the length of the belt
The belt length is determined using the formula below:
47
( D−d )2
Length of belt (L) = 2C + 1.57(D + d) + 4C ……eqn1
¿ 2(500)+1.57 ( 100+40 ) +¿
= 1000 + 219, 8+ 1,8
L =1221,6mm
µθ
The pulley which governs the design is the one with the smaller value of e . Therefore the
smaller pulley governs the design.
T 1−mv2
µθ
Hence, e = ……eqn6
T 2−mv2
µθ
0.3 (173,12
180 )
π
e =e
= 2, 475
m= 0,22kg/m maximum load for an A –section V belt is 18,75kg=(183,9N)
V= w ×r
……..eqn7
Where w=2πn/60
=2π(1440)/60
=150,8 rad/sec
r = 0.02m ( since the shaft diameter is 40mm
V = 150,8 ×0,02
T 1 −m v 2
3m/s Therefore 2.475=
( T 2 −m v 2 )
2.475=183,9−0.22 ¿ ¿
181,92
2 . 475=
T 2−1,98
181,92
T2 = −1,98
2,475
T2 = 71,52N
Therefore T1 = 183,9 N and T2 = 71,52N
48
4.1.1.3 Centrifugal Tension Effect
Centrifugal Tension effect is caused by belt mass and belt velocity. When diameter D of the
bigger pulley is 250mm, speed of the pulley N2 being 403,2 rpm
Then,T c =mv2 ………e qn3
πDNr
But, v=ώ r =
60
π x 0.250 x 403,2
v= x 0.02
60
¿ 0.1056 /s
T c =0.22 x 0.10562
Therefore T c =0.0232 N
Torque
Assuming that a one horse power is to be used
Then power =1×745,7
=745.47W
Where 745.7W is equivalent to 1HP
But Power = Tw ……..eqn8
=T (2πNr/60
T =P×60/2πNr
=745.7(60)/2π1440
Torque =4,945Nm
Therefore twisting moment = 4,945Nm
4.1.1.4 Shaft designing
Mass of chilli fed into the casing = 2.7kgs
Therefore, Weight of the chilli = Mass × Gravity (mg)
= 2.7 x 9.81
= 26.5N
49
Calculating weight of blades
Mass=density x volume
Volume of tooth
=100×6×137
= 82200mm
Volume of teeth
82200×6=493200mm
Volume of the casing = Area x height
= πr 2h
= 3,142x 0,1602x 0.315
= 0,025333803m3
Then, Mass of the casing = Density x Volume
= 7800 x 0,039584067
=197,6036646kgs
Therefore, Weight = Mass × Gravity (mg)
= 197,6036646 x 9.81
=19535N
Combining the weight of the chilli and the weight of the casing = 1953,5N +26,5N
= 1980N
This force 1980 is acting at the centre of the span 150mm from the end as shown in the force
diagram below.
Mass of the bigger pulley = 1kg
Then weight of bigger pulley = Mass × Gravity (mg)
= 1 x 9.81
=9,81N
50
Figure 18: Bending Moment Diagram
Finding reactions at the supports (RA and RB)
Taking moments about A
Total Clockwise moments = Total Anticlockwise moments
RA (0,25) =9,81(0,3) +1980(0.150)
RA =9,81(0,3) + 1980(0.150) ÷ 0.25
RA =1199,772
Using Total Upward forces = Total Downward forces
RA + RB= 9,81 + 1980
1199,772- RB = 1989.81
RB= 1989.81 -1199.772
RB =790,035
Therefore the reactions of the supports points are RA 1199,772N and RB 790.035N
Shear Force (SF) diagram calculations
SF at D = -9,81
SF at A= --9,81 + 1199.772 =1189,962N
SF at C= 1189,962 - 1980 =790.035
SF at B =790,035- 790,035=0
Bending Moment (BM) diagram calculations
BMD at D=0
BMD at A=9,81×0,5= 0,5N
BMD at C= -9,81×0,150+ 1189,962 ×0,1 =118N
51
BMD at B =0
Figure 19: Bending Moment and Shear Force Diagram
4.1.1.4.1 Shaft Diameter

Determining the diameter of shaft, d
16 2 2
τ max =
πd 3
√( K b Mb ) +(K t M t )
………eqn 14
52
Where Kb is the combined shock and fatigue factor applied to bending moment
Mb is the maximum bending moment
Kt is combined shock and fatigue factor applied to Twisting moment
Mt is Twisting moment
τmax is allowable shear stress
dis the diameter of the shaft
For gradually applied loads Kb= 1.5 and Kt = 1.0
Therefore making shaft diameter, d,
16
d 3=
π ×¿ ¿
d 3=¿ 1,2126 x 10−7 x 513,346
d 3= 0,00006225
d=∛ 0,00006225
d = 0,03963 m
d=39,6 mm
The designed minimum shaft diameter is 39,6mm, therefore for safety of operation the
designer selects 40mm diameter shaft to be accommodated in the self-aligning Plummer
block bearings.
4.1.1.4.2 Determination of the shaft speed

When a motor pulley (driver) diameter (d) is70mm,driven pulley (D) 250mm and speed (N1)
of the electric motor to be 1440 rpm, speed (N2) of the output shaft is determined as follows:
N1 D
Speed ratio= =
N2 d
53
1440 250
=
N2 70
70 x 1440
N 2=
250
N2 = 403.2 rpm
4.1.1.5 Key design
The width of key (b) = ¼ (d) ……eqn19
Where d is the diameter of the shaft
b =40/4
=10mm
Length of the key = 1,5(d) …..eqn18
=1,5(40)
= 40mm
Therefore key dimensions is {40mmx10mm}
Shear stress (λsk) on the key =shearing load on the key {Pt) /breath of the key
(b) x length of key(l)
But Pt = T/r …..eqn15
Where T = Torque (Nm) and r =radius (m) of the shaft
For a 40mm shaft Pt = 4,9 ÷ (0,02)
Pt = 245N
But this tangential force is a shearing load on the key over its rectangular area bl,
parallel to the direction of the load. Hence the shear stress induced on the key will be;
Pt
τ sk = ≤[ τ sk ]
bl …..eqn16
54
τsk = 245 ÷(0,01 x 0,06)
τsk= 245 ÷ 0, 0006 Nm-2
τsk = 408 333, 3Nm-2
The key shearing stress is safe given that for steel shaft with keyways, the allowable
shear stress = 42 MN/m2
The same load Pt is resisted by the area 1/2 (tl) of the key perpendicular to the direction
of this load which tends to compress or crush this area of the key against the shaft.
2 Pt
σc = ≤[ σ ck ]
k tl ……….eqn17
σck= 2 x 245 ÷ (0.008 x 0.06)
σck= 490 ÷ 0,00048 Nm-2
σck= 1 020 833 Nm-2
σck= 1, 02 MNm-2
4.2 PART LIST FOR A CHILLI GRINDING MACHINE

The below table shows all parts that make up the grinding machine. Some components are
bought whilst most are manufactured in the workshop
Notation
G.C – Grinding chamber
MF – Main Frame
B- Bearings
S.A - Shaft Assembly
PDA- Pulley Drive Assembly
EM- Electric motor
T P- Top Hopper
OT – Outlet Hopper
55
C - Casing
BN - Bolts and Nuts
VB-V Belts
B - Buy
M- Manufacture
Table 3: Part List of the Chilli Grinding Machine
56
4.3 MANUFACTURING PROCESS OF THE CHILLI GRINDING

MACHINE
The manufacturing process on the table 4 below shows the manufacturing table which
contains detailed information of every part of the chilli grinding machine of how it is
measured and marked
Table 4: Manufacturing Process Table
Assembly Assembly Sub components Material Manufacturing requirements

number lot name requirements
1 Grinding Grinding chamber Mild steel shaft Machine the shaft to the
chamber consists of shafts Ø40×181mm, required diameter on the lathe,
with blades, 6mm stainless steel mark and mill the keyway on
thresher and a plate 2×320mm, the milling machine. Fabricate
sieves. The 1,6mm plate the blades and weld them right
grinding chamber stainless steel round the shaft. And then cut 2
is joined together 539× 474mm round plates to make up a
with a top hopper casing for the grinding
chamber and then weld
together with a 1,6 mm plate
that is rolled on a rolling
machine Develop a pattern for
the top hopper using
triangulation method and weld
it to the grinding chamber
2 Outlet Side plate, base 1,6 mild steel plate Mark off, cut to size bend the
hopper plates plate to the required
measurements. Weld the tray,
assembly the tray on the main
frame at the side bottom of the
grinding chamber
340 Main Supporting frame, 40×40×5L Mark, and cut the angle iron
frame bearing into the required dimensions
and fabricate the
required frame design using
AC welding ,machine mark off
the 10mm base plates and cut
them to size 3.Attach the base
plates to the supporting frame
using AC welding
4 Pulley Electric motor , Stainless steel Insert the cast iron pulleys of
drive rotating shaft, v- Ø40mm, the correct measurements
assembly belt 35mm thick rubber, together with the v-belts onto
Cast iron Ø 40 the desired spacing on the
mm×35 thick shafts of the barrel
5 Machine 1,5 mild mild steel Mark off, cut the size roll the
57
guard plate plate into the required shape

according to dimensions and
weld it to the frame by arc
welding as it covers the pulley
system
4.4 Estimated total production time

The estimated total production time is shown on the table below. The manufacturing
operations are a result of work measurement using analytical and some practical experience
of producing similar part
4.4.1 Estimated total production Time
Table 5: Estimated Total Production Time of Chilli Grinding Machine
Node Activity Duration [Hrs]
1 Marking off, cutting, rolling 1hrs

the grinding chamber
2 Marking, cutting and welding 1hr
the angle irons for the
supporting frame to size and
fabricate it
3 Marking off, developing the 2hrs
feed hopper
4 Mark off, machine the shaft 2 hrs

Ø40 to the correct lengths, and
cutting keyways
5 Mark off, cut and fabricate 2 hrs

the blades and then weld them
to the bush
6 Lock the bush to the shaft and 1hrs

place the shaft on its position
on the grinding chamber
7 Mark off, cutting, and welding 1hr
of the outlet hopper to the
casing
8 Welding the grinding chamber 1/2 hrs
9 Weld the top hopper to the 1 hrs
58
casing
10 Assembly the casing to the 1hrs
main frame
11 Insert the bearing to the 2 hrs
appropriate positions on the
shafts and assemble to the
frame as well as fastening the
bolts on the casing
12 Assemble motor and the 2hrs
pulley drive to their respective
positions
13 Fabricate and assembling the 2hrs
guard
14 Test run 1/2 hrs
15 Paint the prototype 1hr
4.5 Safety
The first safety priority is given to the operator hence on this design at all components in
rotary motion there is a safety guard
To increase the life expectancy of the machine, the operator must be firstly taught each and
every operation of the machine so that he or she may have vast knowledge of the machine
way of operation. The operator must strictly adhere to all safety regulations required by the
designer for the machine to run correctly
4.5.1 Safety instructions
 The machine must be operated by someone who is not under the influence of alcohol
 The operator must not over feed the grinding chamber with chilli beyond the written
capacity of the chamber
 The machine guard should be kept in its respective position of design to protect the
operators.
 Long and loose clothing should be avoided in the vicinity of machine so as to
minimize chances of accidents.
 Only those with a knowhow of operating this machine should be allowed access to
machine
 Bearings should be greased at regular intervals
59
4.6MAINTENANCE
In all the machines there is need for maintenance at a certain instance since some machines
elements have the tendency of wearing out
Maintenance is divided into, breakdown maintenance, preventive maintenance, scheduled

maintenance and planned maintenance. But in this case the designer has chosen the
preventive maintenance the best maintenance technique to be used
Preventive maintenance can be defined as follows: a method of maintaining the machine

elements before a breakdown has occurred or before some parts are worn out or can be
defined as actions performed on a time- or machine-run-based schedule that detect, preclude,
or mitigate degradation of a component or system with the aim of sustaining or extending its
useful life through controlling degradation to an acceptable level. This type of maintenance
should be done periodically
4.6.1 Advantages
• Cost effective in many capital-intensive processes.
• Flexibility allows for the adjustment of maintenance periodicity.
• Increased component life cycle.
• Energy savings.
• Reduced equipment or process failure.
4.6.2 Disadvantages
• Catastrophic failures still likely to occur.
• Labour intensive.
• Includes performance of unneeded maintenance.
• Potential for incidental damage to components in conducting unneeded maintenance.
60
4.6.3Maintenance schedule table
Table 6: Maintenance Schedule of the Chilli Grinding Machine
Area to be maintenance Frequency

Adjusting bolt Generally tighten all bolts and loose
connections before the use of machine.
Bearings They have to be checked before use if there
are no any cracks and must be replaced
before they reach their design life span.
Also grease them frequently.
Belt Check the tensions and conditions of the
belt before switching on the machine
Pulleys They must be checked often times for
cracks and must be replaced
Shaft and electric motor Check for shaft alignment before starting
the machine. Also run the machine to check
for unusual sounds.
4.7 Conclusion
This chapter is a descriptive of the design manufacturing process, which gives the insight on
the procedure and steps taken to come up with the prototype, it gave the maintenance
schedule that has to be followed to ensure smooth flow and running of the machine. The
chapter gives way for the project evaluation that follows.
61
CHAPTER 5: PROJECT EVALUATION
5.1 Introduction
This chapter focuses on project evaluation. The thrust of project evaluation is to highlight and
enumerate the project costs which include cost of material, labour, fixed as well as overheads.
The overall results of the project parameters are the presented in cost benefit analysis. Also
included in this chapter is testing of the prototype.
Table 7: Total Material Used and its Cost
5.2 Total cost of manufacturing the chilli grinding machine

The total cost of manufacturing the machine was broken down as follows:
62
 Cost of Material– this is the cost of raw materials used on the chilli grinding machine.
 Labour cost – this is the cost of skilled, semi-skilled labour and the technical
expertise.
 Fixed costs – workshop rentals, electricity and water bills.
 Overhead costs – costs related to administration work (transport and miscellaneous
cost
5.3 Labour Costs

The total labour hours required for manufacturing until completion of the project was broken
as shown on table below comprising of the specialisation areas and hourly rates of
manpower.
Table 8: Expertise Cost
The project expected completion period is 2 days to be achieved in 8 hour working day which
translated to 16 manpower hours of work for the team. The time frame is inclusive of set up
time during the 2 day period within which the project is expected to be completed.
Project expenditure considering labour was as follows:
Costs associated with 2 artisans = 2 x hourly rate
= 2 x $2.50
= $ 5.00 / hr.
Costs associated with metal fabricator for a 2 day period
= 1 x hourly rate x total number of hours

63
= 1x $2.50 x16
= $40.00
Costs associated with turner machinist for a 2 hours of the day
= 1 x hourly rate x total number of hours
= 1 x $2.50 x 2
= $5.00
Therefore total costs associated with two artisans = $40.00 + $5.00
= $ 45.00
Costs associated with 1 Assistant= 1 x hourly rate
= 1 x $2.00
= $ 2/hour
Costs associated with 1 assistant for a 2-day period = 1 x hourly rate x total number of hours
= 1 x $2.00 x 16
= $32, 00
Then the total cost of direct labour on this project = $45.00+ $32.00
=$77.00
Project Supervisor = $ 3.00 x 2 hours x 30 days
= $ 3.00 x 2 x 30
= $ 180
Now, adding supervisor’s work and total direct labour cost= overall labour related costs. That
is
Overall labour related costs = $77.00 + $180.00
= $257.00
64
5.4 Fixed Costs

Fixed costs were estimated at $45 based on prevailing industrial rental rates for a general
engineering workshop.
Rental rates = $20
Electricity = $20
Water charges = $5
5.5 Overhead Costs

These costs were charged at 25% of direct labour costs, deriving from the current industrial
practice:
Overhead costs = (25 / 100) x $257, 00
=$64.25
5.6 Material costs

Material cost of $272,00determined from table above.
Therefore manufacturing cost of the chilli grinding machine
=$272.00 + $257, 00 + $45.00 + $64,25
= $638, 25
Value Added Tax (VAT) = 15% of manufacturing cost.
= 0.15 x $638, 25
=$95, 70
Therefore: Total manufacturing cost = manufacturing cost + value added tax of the
manufacturing cost
= $638,25+ 95,70
= $733, 95
5.7 Total Selling Cost

Then allowing 14% profit, selling price = 14% of the total manufacturing cost
65
= 1.14 x $733,95
= $836.70
5.8 Testing the prototype

Soon after completion of manufacturing, the chilli grinding machine was tested for
functionality in the workshop to check if it is fulfilled its principle of operation. The grinding
machine managed to perform as per design specifications and its performance is applicable
5.9 Conclusion
This chapter managed to sum up all the costs incurred during the manufacturing of the chilli
grinding machine from inception to complete manufacture. The selling price of the gadget
has been determined as $836, 70. In the next chapter, the designer recommends further work
to be carried out on the project.
66
CHAPTER 6: RECOMMENDATIONS,
FURTHERWORKAND CONCLUSION
6.1 Introduction
This chapter serves to conclude the whole designing, developing and manufacture of the
project. It looked at constraints, recommendations, and at last a conclusion was made.
6.2 Recommendations and Further work

 Blades design should not be rigidly fixed on the rotating shaft. The designer sights
that further work should be done so as to make them have pin- joints that allow the
blocks to swing thus attaining more thrust to hit the dried chilli into powder.
 The main objective was to produce fine powder from 12µm to 20µm. However sieves
of this capacity could not be accessed. The machine ground but not to these
specifications
 There is need for dust filter bags so as to extract the choking dust released during
grinding which might be harmful to the user of the machine.
6.3 Constrains
The researcher faced a number of factors that affected the design and manufacture of the
chilli grinding machine from reaching the peak of its development and the advancements
within its potential. These factors are as follows:
a) Availability of appropriate information, since some crucial information and other

relevant information that was not readily available was basing on information
obtained via the phone, since l couldn’t travel to Inyanga.
b) Cost of components, since the researcher is a fulltime student and due to price hiking
the materials required for the project for example stainless steel could not be
afforded. The researcher was restricted to using cheap and low cost components.
6.4 Conclusion
This entire document has managed to give an overview of the design and manufacture of a
chilli grinding machine for small scale farmers. The project design calculations and
specifications made the project to meet the set objectives. In general, the main objective was
full filled; hence it is safe to say the project was a success.
67
REFERENCE
Bryman, A. and Bell, E. (2007). Research Methods. NewYork: Oxford University Press.
Cohen, L., and Manion, L. (2000). Research Methods in Education. (5th Edition). London:
Carvill. J. (1993). Mechanical Engineer’s Data Handbook. British Library Cataloguing.
Joseph. E. Shigley,(1996). Standard Handbook of Machine Design. (3rd Edition), McGraw
Kurmi. R. S and Gupta J. K. (2005). A text book of Machine Design. Uurasia Publishing
Hannah. J. and Stephens. R. C. (1972 ). Mechanics of Machines. (1st Edition), London.
Hearn E., J. (1977). Mechanics of Materials 1. British Library Cataloguing.
Timing R.L. (1992) Manufacturing technology Vol 1 2nd Ed
Groover M.P (1987) Automation, Production Systems and Computer Integrated

Manufacturing
Websites-
http://www.engineeringtoolbox.com 19/10/18
http://www.zepter.com/MainMenu/Products/HomeArt/MasterpieceCookware/Mixsy.as
px 12/09/18
Christian Council of Tanzania: Manually-operated grinding mills: An evaluation (Dar-

es-Salaam, Department for Development Services, 17/03/18
http//eh.wikipedi.org/wiki/pulley 22/05/18
copyright nazlina hussin for pickles and – spices .com 10/10/18
http://.wikihow.com/rewind-an-electric-motor#/image:rewind-an-electric-motor
15/10/18
http://.wikipedia.org/ existing designs 08/07/18
http://en.wikipedia.org 05/010/18
https://en.wikipedia.org/wiki/beltdrive 19/05/18
68
69
APPENDICES
APPENDIX 1: Table showing Kb and Kt factors: For rotating shafts:
Rotating shaft: Kb kt
Load applied gradually 1.5 1.0
Steady load 1.5 1.0
Load applied suddenly, minor shocks 1.5 – 2.0 1.0 – 1.5
Load applied suddenly, heavy shocks 2.0 – 3.0 1.5 – 3.0
(Source -http://www.engineeringtoolbox.com)
70
APPENDIX 2: Table showing typical Mechanical and Physical properties for

Engineering Metals(source : Courtesy of E.J. HEARN: - Mechanics of Materials)
Young Shear Shear yield Ultimate strength Density

Modulus modulus G strength in shear (MN/m2) (kg /m3)
MATERIAL
of elasticity (GN/m2) (MN/m2)
E(GN/m2)
Aluminium alloy 69 26 - 240 2770
Brass 102 38 - -- 8350
Bronze 115 45 - - 7650
Cast iron: Grey 90 41 - -
Malleable - 330
170 83 166 7640
Low carbon 207 80 175 350 7800
(mild) steel
Nickel-chrome 208 82 650 950 7800
steel
Titanium 107 40 - - 4507
71
APPENDIX 3: Table showing Keyways standard sizes

Shaft Ø up-to and including (mm) Width (w) mm Thickness (h) mm
17 6 6
22 8 7
30 10 8
38 12 8
44 14 9
(Source -http://www.engineeringtoolbox.com)
72

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DEDICATION

2.3.3 Stem Cutting............................................................................................................20

2.15.2 Basic Electric Motors.............................................................................................39

1.2 Statement of the problem

1.3 Problem Background

CHAPTER 2: LITERATURE REVIEW

2.2 Existing designs

2.2.1 Traditional methods of chilli processing

2.2.1.1 Raw Granite Pestle

Raw Granite Pestle and Mortar

2.2.1.2 Grinding stones

2.2.2 Modern methods

2.2.2.1 Chilli grinding machine manually operated

Figure 4:Cam Operated Grinding Machine (Source: ijrtitcc.org)

2.2.2.2Chilli grinding machine electrically operated

Figure 5: Electrically Operated Machine (Source: indiamart intermeshltd )

2.2.2.2.1 Working principle

2.2.2.3 Chilli grinding machine

Figure 6: Manual Grinding Machine (Source: Christian Council of Tanzania, 1980)

2.3 Automated Chilli Processing Line

It includes the number of processes:

2.3.1 Destoning and Leaf Remover

This machine consists of two parts

2.3.2 Dry Cleaner

2.3.3 Stem Cutting

Now the chilli is ready to be crushed and is passed to the crusher.

Milling or grinding is done using pin mill.

2.3.7 Oil Mixer

2.3.9 Vacuum Conveyor

The vacuum conveyor passes the powder to packing machines.

2.3.1 FLOWCHART FOR CHILLI LINE

Figure 7: Flow Chart for Chilli Line

2.5 Beaters and Blades

Figure 8: Blades on a Grinding Casing (Source:

2.6Drive System selection

2.6.2Types of Belt Drives

2.6.2.1 Advantages of belt drives

 Belt drives are simple and economical (cheap in terms of cost)

2.6.2.2 Disadvantages of belt drives

 Speed ratio is not constant (slipping and stretching)

 There is heat accumulation

2.6.3 Types of Belts

2.6.3.1Selection of belt drives

 Speed reduction ratio

2.6.3.2 Belt Mass

2.6.3.3 Belt length

Where C = centre distance

D = pitch diameter of large sheave

d = pitch diameter of smaller sheave

L = pitch effective length of belt

2.6.3.4 Belt Torque

Torque of a belt drive, torque is found from

Where r = radius of pulley in metres

2.6.3.5 Centrifugal Tensions, Tc

Where m = mass of belt / unit length, kg/m,

V = velocity of belt in m/s

2.6.3.6 The angle of contact

Figure 9: Belt Drive System (Source: https://en.wikipedia.org/wiki/beltdrive)

The angle of contact of the belt on each sheave is

Θ1 = 1800 – 2Sin-1[D – d / 2C] ………...eqn4

Θ2 = 1800 + 2Sin-1[D – d / 2C] …………eqn5

Power transmitted =Tω……eqn 8

A pulley is a on an axle or shaft that is designed to support movement and change of