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ISSN 2229-5518
Abstract- In fish farming, the consumption of feeds in pellet form aids the total consumption of the ingredientsby
fishes. Nevertheless, some local farmers in Nigeria are using pelletized feeds in their various farms because of the
reduced cost. However, some readily identifiable disadvantages of such pelletized feeds exist. As such extruded feeds
have recently become appealing to local famers and those who use the extruded feeds rely heavily on importation.
The aim of this project is to design and fabricate a fish feed extruder with improved qualities and affordable cost using
locally sourced materials to aid the production of extruded feeds by local small scale farmers.The design was carried
out using engineering principles with due consideration to cost, ease of operation, serviceability, durability and
performance. Based on these, an extruder using 5HP, 3- phase electric motor with a production capacity of 300kg/hr
was designed and fabricated using locally sourced mild steel materials. It consists of hopper, screw, barrel, die, drive
system and heater.An element of 1000W was attached to the barrel surface so as to ensure cooking of resin pellet.
The cylindrical pellets size produced was in the range 3– 5mm diameter suitable for fish and poultry. Based on this
evaluation, there was a drastic improvement in the quality of locally processed pellets. The designed and fabricated
extruder performed smoothly as a fish feed extruder.
Index Terms- Extruded feeds, Pelletized feeds, Pellets, Fish feeds, Extruder.
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more expensive and more difficult to maintain observed that the nutritive value of most grains is
than pellet mills, but are capable of operating enhanced, at least for some animals, when their
under a much wider range of conditions. The high starch component is gelatinized.
heat treatment which can be applied in pressure It has been discovered by researchers that the
extruders can make the pellets more palatable and consumption of feed in pellet form helps to aid the
also inactivate some undesirable factors found in total consumption of the ingredients by fishes
oil meals and other ingredients. Extruders can also without selectively discarding the less palatable
deliver firmer pellets; provide many different sizes ingredients thus improving the nutritional value
and shapes of pellets, and process mixtures which consumed. It is apparent that local fish farmers in
cannot be satisfactorily handled by the pellet mill. Nigeria are mostly using pelletized feed for their
Extruders can perform a cooking function, which fishes because of the reduced cost. This pelletized
does significantly improve the nutritive value of feed is not properly processed during its
many raw materials, as they are concerned. production thereby reduces growth inhibition in
Moscicki and van Zuilichem, (1984) reported that the fishes, causes water pollution and promote
average value for energy consumption of a harmful organisms and defectives enzymes in fish
pelletizer making ruminant feed pellets is 8 to 13 feeds. Therefore, there is need for development of
kWh per ton whereas an average single-screw machinery to produce and meet local demand.
extruder requires about 90 to 180 kWh for well The research is aimed in designing, fabricating and
gelatinized feeds. For twin-screw extruders, the evaluating a fish feed extruder using locally
power requirement would be much less, however, sourced materials capable of producing high
on the order of 9 to 14 kWh per ton. It has been quality feed pellets.
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2. MATERIALS AND METHOD The table below is a summary of design criteria
Material Selection and Production Planning and the materials used in the fabrication of the
machine components.
TABLE 1
MACHINE PARTS SPECIFICATIONS
Component Part Dimension Material Used Quantity
Hopper ø 300 x 435 mm Mild steel plate 1
Barrel ø 133 x 800 mm Mild steel (aco pipe) 1
Screw conveyor ø 50 x 1000 mm (inner shaft), High carbon steel 1
ø 125 x 800 mm (sleeve pipe) Mild steel
Die head plate ø 135 x 10 mm Mild steel plate 1
Frame 2mm x 2mm Angle iron 5
Pulley ø 250 mm Mild steel 1
Fasteners (bolts and nuts) ø 15 x 50mm (for tightening), Mild steel bold and 8
ø 10 x 50mm (for barrel casing) nuts 20
Finishing and coating - Chemical (paint) -
Pillow bearing ø 50 mm - 2
Flat bar ø 40 mm x 800mm Mild steel 1
Mild steel welding Gauge 10 and 12 - 2 packets
electrode
Grinding disk - - 2
Electric motor 5 horse power - 1
V- belt 12 mm thickness Rubber 2
After procurement of the parts, each component include, lathe machine, drilling machine, welding
was examined to locate points where alterations machine, sniper, hammer and block, hacksaw vise
would be carried out most easily. This information and electrodes.
was used to carry out production planning and
assembly planning. The machine tools and the Machine Design
major tools used in the fabrication of the extruder
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The design was carried out using principles of performance. The design of this machine was
engineering design with due consideration to cost, separated into two distinct phases:
ease of operation, serviceability, durability and
(1) Design of Machine Components:This was thespecific calculations affecting the machine being
divided into fundamentals and basics. The designed. The components include the hopper,
fundamentals refer to the principles governing barrel, screw conveyor, die and frames.
each component while the basics deals with
(2) Design ofDrive System: This includes the
speed reduction unit specification (motor-screw
reduction phase) and the belt/pulley design
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Where
Step 2: Determination of Conical Hopper
Volume of cone with a top (frustum) ⇒
πh
Outlet Diameter
[(R₁2 + R₁r₁ + r₁²) − The opening of the diameter for conical hoppers is
3
R₂²+R₂r₂+r₂² (2) given by (Jenike, 1964)
Where (R₁2 + R₁r₁ + r₁²) − (R₂² + R₂r₂ + r₂²) is CAS
D = H(θ) (5)
wall thickness of frustum ρg/gc
θ
Let h be the height, R the radius of the upper base, H (θ) = 2 + (6)
60
and r the radius of the lower base of the frustum. Where gc is gravity constant conversion factors to
Generally, volume, V, for a hollow cylinder is convert the result from units of mass to units of
given by: 1kgm
force 2 . Typical value for H is about 2.4 (Jenike,
Ns
V = Area x height = π(r₁2 − r²₂)h (3) 1964). Therefore θ semi included angle of the
Thickness of the cylindrical wall, t:
materials from equation (5) is 24°.
t = r₁- r₂
Hence
As commonly practiced, the coefficient of friction friction, the flow factor (ff) can be determined from
is expressed as the angle of wall friction given by ∅ the Jenike published charts for conical hopers.
as; σc
For flow: > 𝜎𝜎𝜎𝜎 (8)
∅ = arc tan(µ) (7) ff
With known values of semi included angleθ, wall Assuming σy and σc are related by the material flow
friction ∅ and the effective angle of internal function
σy = σc1.34
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Thus, the criterion for flow becomes V = Linear velocity of the shaft in meters/seconds
But F = ma (15)
σy1/1.34
[ ] >σ y M = Mass of rotating shaft in kilogram (kg)
ff
And so the critical value of unconfined yield stress a = Angular acceleration of the motor in
σ crit is found when
R
radian/seconds square (rad/s2)
a = w²r (16)
[
σy1/1.34
] = σ y(9) w = angular velocity of the motor in
ff radian/seconds
ff = 1.54from the Jenike published chart for conical
w = v/r
hoppers. The angle θ was reduced by 3° as a Therefore v = wr (17)
margin of safety (1964). Therefore θ used was 21° By putting equation (16) into (15)
throughout. Hence solving for σy from equation (1)
gives σ crit
R
F = mw2 r (18)
By putting (18) and (17) into (14)
By applying law of indices we have, P = mw²r x wr (19)
2πN
σ y (-0.34/1.34)= 1.54 But w = (20)
60
Putting (20) into (19)
Therefore σy equals to σcrit is 0.1823 kN/m2
R R
πN 3
P = 8M � � r 2 (21)
2.4 x 0.1823 x 1000 60
D =
900 x 9.81
Step 5: Determination of Screw Conveyor
Minimum diameter of circular outlet D is 0.0495
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Diameter and Power to Drive Conveyor
The diameter and power of the screw conveyor
Step 3: Determination of Mass Flow Rate of required for conveying material at a rate of
Conical Hopper 500kg/hr for the capacity of continuous screw
The mass flow rate or discharge rate of a conical conveyors was calculated from the expression
hopper was determined by the equation (Jenike, given by (Spirakorshy and Dyachkov, 1967).
1964): 4Q
Dg D² = (22)
ṁ=ρ°A√ (10) 60πSnφρc
2(m+1)Tan θ
πD²
Where, Q = capacity of screw conveyor,
Where A = (11) S = screw pitch
4
For conical hopper m = 1 n = speed of convey = loading efficiency
The stress action on the hopper wall is given by: p = free bulk density of the material,
ρ°gB 4zμK c = loading factor depending on the inclined angle
Pv = �1 − exp �− �� (12)
4μKgc D to the horizontal
Where B is the hopper maximum diameter and z is The recommended values by Spirakorshy and
the cylinder height Dyachkov, (1967) for slow flowing abrasive material
To estimate the normal stress on the hopper wall are
Jassen’s assumption was applied S = 0.8D, φ = 0.125 and c = 1 for inclination angle b0
Pw = KPv (13) = 0.
The material that can withstand the maximum The recommended minimum a maximum speed of
stress acting on the wall of the hoppers should be conveyor is between 24 – 150 rpm.
selected. 2000
D² =
60x3.142x0.8Dx120x0.125x900x1
Step 4: Capacity Design for a Given Electric
Motor Rating 2000
D= � � 0.3
The design for motor output power enables 2036016
appropriate selection of a motor with enough
Therefore, the diameter of the screw conveyor is
power to start and run the machine at full load.
Power = F x V (14) 0.125m.
QL
Where Pr = (ωo + sin β°) (23)
P = Power in watts 367
Where ωo is 4.0 for slow – flowing abrasive material,
F = Rotational force acting on the shaft in Newton
R
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𝐷𝐷𝑒𝑒𝑁𝑁𝑒𝑒 = 𝐷𝐷𝑠𝑠𝑁𝑁𝑠𝑠 (24) α₂ = 1800 + 2sin − 1 ( ) = 198.26°
0.630
Where, De and Ne are the diameter and speed of
Step 11: Determination of Tension in the Belt
driving pulley. Also, Ds and Ns are the diameter
Tension T 1 acting on the tight side of the belt and
and speed of driven pulley. For a driving pulley of
the tension T 2 acting on the slack side of the belt
50mm diameter, the driven pulley diameter was
are calculated using the equation at Hall et al
calculated from the above at 250mm (0.250m) and
(1982) by Fadare, (2004).
the input ratio is 1:5.
T₁ − mV² fα
= ℯ (29)
Step 8: Determination of Belt Length T₂ − mV² sin 0.5θ
With known pitch diameters of pulleys
Where m = mass of a unit length of the belt
Ds = 250mm, De = 50mm and center distance
v = Linear velocity of belt;
between motor/shaft pulley, C = 630mm.
α = Angle of wrap on pulley (rad)
The length of belt required is calculated using the
f = Coefficient of friction between belt & pulley.
(Fenner, 1994) by (Fadare, 2004) equation below:
T 1 = Tension in the tight side of belt (N)
Ds − De T 2 = Tension in the slack side of (N)
L = 2C + ( ) + 1.57 (Ds + De) (25) θ = Groove angle for v – belt (degree).
4C
The maximum tension in the tight side of the belt
L = 2(0.630) + (
0.250 − 0.050
) + 1.57 (0.250 + 0.050) depends on the allowable stress of the material.
4(0.630) For a B section belt the following parameters are
Therefore the length of the belt require = given:
1,812.5mm. T 1 = allowable tension = 900N (Hall et al, 1982),
From the catalogue the nearest B section belt to θ = 38 ± 0.50 (Fenner, 1994), f = 0.2 (Tangka,
1812.5mm length is 1819mm. Hence, B 1810 belt
P
1995)
was selected. The linear velocity V is given by
π x Ds x Ns
Step 9: Center To Center Distance Design V = (30)
60
The minimum distance between driving and 3.142 x 0.250 x 120
driven pulleys for appropriate belt tension is V= = 1.571m/s
60
obtained below
1 The right side of the equation [29] was determined
C = (D₁ + D₂) + D₂ (26)
2 for both small and large pulleys as follows:
For small pulley
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equation (Hall et al, 1982) by (Fadare 2004).
of material conveyed by the feed screw. The die
P = (T₁ − T₂) V (31)
was made using two layers of 3mm thickness mild
P = (900 − 162.84)1.571
steel plates which was welded together into
Hence the power capacity per belt equals 1.158Q
appropriate dimension. It has a diameter of 136mm
(1.158kW)
and is removable. Finally sixty (60) numbers of
holes were drilled around the surface of the die
Fish Feed Extruder Construction
plate to make way for the resin pellets to pass
Barrel Design and Construction: The barrel through. The drilled holes are 3-5 mm in diameter.
was constructed by machining a purchased round
hollow mild steel pipe into appropriate length of Hopper Design and Construction:This was
800mm. it has an outer diameter of 133mm and designed and constructed locally. The construction
inner diameter of 130mm with a thickness of about was separated into two sections; the cylindrical
3mm. After the barrel was halved, four flat bars and conical sections. The two shapes were
were welded to the edges. These flat bars were achieved with the aid of a roller after cutting to the
drilled into 10 holes each. The upper and the lower required dimension. The hopper outlet is 50mm
part were held together with the aid of 20 pieces of and maximum diameter of 300 mm. Hopper
M12 bolts and nuts. This was done for the ease of heights is 425mm and a thickness of 2mm.
maintenance and assembly of the inner Extruder assembling: After the construction of each
components (i.e. screw and bearing replacement part of the extruder had being completed, the
and adjustment). Furthermore, a circular opening various parts of the extruder were coupled as
of 30mm diameter was created a few meters away follows: firstly the upper and the lower barrel were
from the die plate. This serves as a vent to reduce held together by the 20 bolts and nuts. After the
overheating of resin pellets during the extrusion screw conveyor was placed into the barrel from the
process. A U-shape element of 1000W was fixed at front side. The inner bearing was attached to the
the bottom of the barrel surface to ensure thermo- shaft and the back casing which has a drilled hole
mechanical cooking of the resin pellets. The at the center was welded to barrel. Immediately
element is mounted on the barrel by two insulators the second bearing was also attached to the back of
(clay and mild steel plate of 6mm thickness). This the casing along the drive system. The welding
mild steel insulator was machined to size by an gauge was used to create a hole of about 50 mm on
oxy- acetylene gas because of its high thickness. the barrel surface. The hopper was welded on this
The stopped the heat from escaping to the hole which was at a small distance from where the
surroundings other than the barrel alone. screw starts. This whole work was now welded on
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two supports at the two ends of the barrel before extrusion begins. The heat sink is air. This heat
finally welded on the constructed frame. The facilitates more melting of resins. A test was
material used for the frame was angle iron. The carried out on the coupled extruder using fish feed
larger pulley was fixed and the electric motor to purchased. Before the extrusion process mixing
which the smaller pulley was adapted was sitting and milling were carried out on the feed from a
firmly on the frame. A belt was fixed to the grinding machine to ensure homogeneity of the
grooves of the pulleys giving a V shape belt. A fish pellets. The feed ingredients were propelled
guide which had being constructed with a mild along the barrel of the extruder by the screw
steel place initially was mounted to the frame with conveyor which rotates in the anticlockwise
bolts and nuts. At the end, a ring was that was also direction at a speed of 120rpm. The mechanical
halved was welded to the edge of the barrel. This screw action and the friction it created sheared,
ring was drilled and threaded with six holes on the blended and cooked the resins. During the
face. The die plate was also drilled and threaded at extrusion process, the heater helped in cooking the
the circumference which made it possible to screw starch in the resins completely and also served as a
the die with the ring on the edge of the barrel. drier to remove excess moisture from the pellets.
Because of the pressure found inside and outside
the barrel, the resins expanded and according to
Working Principle of the Extruder and Test the die shape (with several drilled holes) it created
In this system, the screw conveyor is used to
pellets in the range of 3- 5mm sizes. A multi meter
convey raw materials to the melt zone at a steady scale was used to detect the temperature of heat
rate. A three phase 5hp electric motor is used loss to the surrounding during this test. Heat loss
rotate the shaft. During the journey, resin pellets was due to conduction and convention. Heat was
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encounter friction from feed screw surfaces and
lost through the extruder from the barrel surface,
barrel surface and each other. Prior to the hopper outlet and vent. The total heat loss was
production, the heater which is attached to the calculated as 110kW. Heat loss due to conduction
outside surface of the barrel will be switched on to was negligible in the calculation.
get hot to a maximum temperature so as to heat
the thick wall of the barrel properly before
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3 4
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7 8
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9 100
5. CONCLUSION
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The selection, design, construction and testing of
the fish feed extruder for a fish farm were
undertaken. The extruder was tested and it worked
smoothly by producing pellets in the range 3- 5mm
11
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