Journal of Agricultural Engineering Vol.

48(3): July-September, 2011

Design, Development and Evaluation of Barnyard Millet Dehuller

K.P. Singh1, H.N. Mishra2 and S. Saha3
Manuscript received: February, 2011 Acceptance of revised manuscript: June, 2011

ABSTRACT

Barnyard millet (Echinochloa frumentacea L.), is presently dehulled manually. A 40-50 kg/h capacity dehuller
driven by a 3.7 PS electric motor was designed, developed and optimized for process and machine parameters.
The dehulling efficiency of 88.3±2.8% with 6.1±1.1% broken grain were obtained at optimized machine parameters
(9 canvas strips over periphery of impeller and over hanging 3 mm width of canvas strip) and process parameters
(8.6 m/s peripheral speed; 5 passes and 8.4% db moisture content).

Barnyard millet (Echinochloa frumentacea L.) is a 50 kg/h capacity dehuller for barnyard millet was designed
commonly grown millet crop in the arid and semiarid region and developed, at Vivekananda Institute of Hill Agriculture,
of the world. It contains 5–8.5% protein, 3.5–4.6 % fat, Almora, India, for better dehulling performance.
57– 66% carbohydrates, 2.5-4.0% ash and 6.4-12.2 %
fibre at moisture content of 0.25-0.05 kg.kg–1 dry matter. MATERIALS AND METHODS
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The presence of all the required nutrients makes the

barnyard millet suitable for large scale utilization in the Raw Material
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manufacture of baby food, snack foods, dietary food, etc. Barnyard millet (CV. VL–172) grain sample was obtained,
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from grain, kernel and flour (Subramannian and for the experiments, from the experimental farm of
Viswanathan, 2007). Barnyard millet is a small grain (Singh Vivekananda Institute of Hill Agriculture (ICAR), Almora.
et al., 2010) containing large proportion (40–45%) of husk Barnyard seed were graded to obtain two grades namely,
and bran, and requires proper processing prior to A–grade (size >1.75 mm) and B–grade (size < 1.75 mm).
consumption. The removal of hull from seed greatly The size of barnyard millet seed varied between 1.2 and
improves the appearance of the product (Deshpande et 2 mm.
al., 1982) and enhances the digestibility. Dehulling of
barnyard millet is difficult, as the small size grains are held Design and Development of Dehuller
firmly in the glumes, requiring considerable shear force The dehuller of 40–50 kg/h capacity was designed and
coupled with repetitive impact (Singh et al., 2003). The developed for dehulling barnyard millet using a 3.7 PS
cells of inner epidermis are closely compressed against electric power source. The dehulling drum was fitted with
those of the outer part. Barnyard millet has an aleuronic a canvas strip as a cutting device, to provide gentle impact
layer reported to contain strongly cutinized cell walls (Zee and shear on the grain. The dehulling chamber was fitted
and O’ Brein, 1971). Barnyard millet is dehulled with a sliding sieve, which allowed repetitive impact and
conventionally by arduous process of manual pounding shear to detach the husk from the grain. The friction force
which needs one-hour effort for dehulling of 2%2.5 kg between canvas strip and barnyard millet grain provided
grain (Pushpamma, 1989). the required force on grain for detaching the hulls from the
grains (Fig. 1).
Various dehulling methods based on working principles of
impact or abrasion suitable for small-scale abrasive milling The development and testing of the prototype unit provided
systems (Reichert and Youngs, 1976; Reichert et al., 1984) important information about the basic dehulling operation,
were employed, in preliminary trials, for dehulling of which is required to design commercial scale-dehulling units
barnyard millet but for the poor performance. In abrasive (Sanders, 1996). The mathematical design (discussed
methods of dehulling, abrasions and attrition forces crush below) of dehulling impeller (length=396 mm; diameter=330
the seed causing a high proportion of dehulling losses (Gupta mm; shaft diameter=30 mm), concave (surface
and Das, 1999). Taking the above facts in view and area=1,29,600 mm2; spacing of round bars=8 mm; number
employing a combination of impact as well as shear, a 40– of round bar needed for fabrication of concave=36), sieves
1
Central Institute of Agricultural Engineering, Bhopal– 462038, email:kpsingh123@rediffmail.com; 2Indian Institute of Technology,
Kharagpur - 721 302; 3Vivekananda Institute of Hill Agriculture (ICAR), Almora - 263 601, Uttarakhand
July - September, 2011 Design, Development and Evaluation of Barnyard Millet Dehuller

3 3 2 3
Y = a0 + ∑ ai xi + ∑ aii xi + ∑ ∑a x x
2
ij i j …(1)
i =0 i =1 i =1 j = i +1

Where,
aii= Quadratic regression coefficient,
xi = Coded values of independent variables, and
Y = Predicted value of responses.

Five levels of overhanging width of canvas strip were

obtained by changing the position of the hole in canvas
strip for fitting with mild steel flat. The independent variables
were fixed at 5 levels as per CCRD, and a total number of
13 experiments were carried out, in which 5 were repeated
Fig. 1: Impact and shear principle for dehulling of barnyard at central point.
millet grain
CCRD for optimization of process parameters
(length=800 mm; width=400 mm, blower (surface area Trials were conducted as per CCRD with three independent
of blower fins=56000 mm2; length of fins=467 mm; width variables viz., peripheral speed (Vp), number of passes (ηp)
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of the fins=120 mm) and feeding hopper (top length=300 and moisture content (θ). The five required levels of drum
mm; top width=240 mm; side slope=70°; height=561.5 speed were obtained by using suitable combination of
pulleys on motor and impeller shafts. Non-linear second
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mm) were carried out. The three dimensional model of

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impeller and hopper were developed using ProE-wildfire order regression equations of the form (equation 1) were
3.0 CAD software. developed for the responses as function of coded value of
the independent parameters and optimized for maximizing
Experimental Design the dehulling efficiency (DE) and minimizing the broken
Preliminary trials were conducted with five independent grain (BG).
variables viz., peripheral speed, number of passes, moisture
Optimization Procedure
content, and number of canvas strip over periphery of
dehulling drum and overhanging width of canvas strip and The response surface methodology (RSM) (Khuri and
was found to greatly affect (10-15%) the dehulling efficiency Cornell, 1987) was used as statistical method for analyzing
and capacity of the dehuller as compared to other independent the experimental data and solving the multivariate equations.
parameters. Two set of experiments were conducted, based The RSM is one of the most effective methods for
on preliminary trials, using Central Composite Rotatable optimization of parameters and many food scientists have
experimental Design (CCRD) (Lorezen and Anderson, 1993; frequently used it (Nath and Chattopadhyay, 2007). In RSM,
Rastogi et al., 1998). First set of CCRD experiment was less number of trials was needed, compared to factorial
conducted with two machine parameters (keeping other three experiment, to evaluate the multiple parameters and their
parameters constant), and second set of CCRD experiment interactions. In the study, the optimization was carried out
with three process parameters and optimized values of two using Design Expert 7.0.0 software, which gave optimum
machine parameters. values based on assigned criteria and experimented results.

CCRD for optimization of machine parameters RESULTS AND DISCUSSION

Trials were conducted with two independent machine Optimization of Machine Parameters
parameters viz., number of canvas strip over periphery of
dehulling drum (ηCS) and over hanging width of canvas The process variables were fixed (peripheral speed 8 m/s,
strip (Boh). The coded values of independent variables viz., number of passes 7 and moisture content 7.5%) on the
x1 and x2 were converted into their real form as ηCS and Boh, basis of preliminary trials for optimization of machine
respectively (Singh et al., 2008). parameters. Two machine parameters, number of canvas
strips over periphery of dehulling impeller (ηcs) and over-
Non-linear second order regression equations were hanging width of canvas strip (B oh), were taken as
developed as: independent variables. Throughput (TU), dehulling

18
K.P.Singh, H.N.Mishra and S.Saha JAE : 48 (3)

efficiency (DE) and specific energy consumption (SEC) were Table 2. Analysis of variance (ANOVA) data for the
taken as dependent variables. A centrally composite RSM design throughput (TU), dehulling efficiency (DE) and
(Table 1) was used to show interactions of number of canvas specific energy consumption (SEC)
strip over periphery of impeller and over hanging width of
canvas strip on the responses of the dehulling in 13 runs (Table Source F-values for responses
TU DE SEC
1), of which 5 were for the centre point, and 8 were for non-
*** ***
centre point (Montgomery, 2001). Model 20.7 96.8 88.9***
ηcs 40.9*** 282.9*** 168.3***
Machine Throughput
Boh 51.6*** 17.1** 160.4***
The ANOVA of machine throughput (TU) shows (Table 2) ηcs × Boh ns 7.0* ns
high model F value (20.7), suggesting that the quadratic
model can be successfully used to fit the experimental data ηcs 2
ns 176.4 ***
6.2*
(p<0.001). Boh 2 6.6* ns 9.1*
Lack of Fit ns ns ns
Both linear terms had significant effect on the model ***, **, *
=Significant at p<.001, p<.01 and p<.05 respectively
(p<0.001). The square term of Boh was significant (p<0.05),
whereas ηcs was not. The cross products and the lack of The three-dimensional graphs with two variables (Fig. 2a)
fit were non- significant. The developed relation with actual depict the combined effects of TU at different Boh, and
values (neglecting the high error generating terms, p-value could be concluded that increase in ηCS had almost similar
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> 0.05) has been given in equation 2. effect as Boh on TU values. The increase in TU with increase
of ηCS was seen, and might be due to increase of repeated
TU = +1.53+ 4.05ηcs + 4.91Boh −1.07Boh
2
(R 2 = 0.94) …(2)
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shear force on grain samples.

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Where,
Boh = Over hanging width of canvas strip, mm, Boh increased to 35 kg.h-1 at 3.38 mm from initial TU of 24
kg.h-1 at 0.73 mm. The increase in throughput (TU) might
ηcs = Number of canvas strip over periphery, and be due to the increase in width of canvas (up to some
TU = Throughput, kg.h–1. extent, before bending) strip over periphery could provide
ηcs) and over hanging width (Boh) on throughput (TU), dehulling efficiency (DE) and
Table 1. Effect of number of canvas strip (η
specific energy consumption (SEC)

Run Number of canvas Over hanging width Throughput, Dehulling Specific energy
strip of canvas strip, mm kg.h-1 efficiency, % consumption,
kWh.kg-1 grain
η cs Boh TU DE SEC
*
1 4 (–1.414 ) 3 (0) 26.3 96.0 0.025
2 11 (+1) 4 (+1) 51.3 98.8 0.085
3 11 (+1) 1 (–1) 30.5 98.1 0.051
4 12 (+1.414) 3 (0) 52.7 98.4 0.071
5 8 (0) 0 (–1.414) 21.1 98.0 0.022
6 5 (–1) 4 (+1) 32.2 97.0 0.043
7 8 (0) 3 (0) 42.0 98.3 0.041
8 8 (0) 3 (0) 37.0 98.5 0.037
9 8 (0) 5 (+1.414) 50.5 98.6 0.077
10 8 (0) 3 (0) 43.0 98.6 0.041
11 5 (–1) 1 (–1) 24.8 97.0 0.020
12 8 (0) 3 (0) 42.4 98.7 0.045
13 8 (0) 3 (0) 40.6 98.5 0.043
Note: Values shown in brackets are coded values of respective independent variables

19
July - September, 2011 Design, Development and Evaluation of Barnyard Millet Dehuller

more abrasive force to the husk of the grain. The TU and ηCS of 8. For all ηCS, throughput achieved maxima at
became almost constant beyond 3.4 mm Boh. The transfer more than 97 per cent.
of impact and shear force reduced with increase of over
hanging width of canvas strip due to increase of flexibility Specific Energy Consumption
in strip. The continuous, but gentle increase in TU was The ANOVA (Table 2) of specific energy consumption
observed with increase of ηCS from 5 to 9. The rate of (SEC), shows very high model F value (68.9) suggesting
increase in TU became constant beyond 9. that the quadratic model could be successfully used to fit
the experimental data (p<0.001). As per F–values, both of
Dehulling Efficiency the linear terms Boh and ηCS had high influence on specific
The ANOVA of dehulling efficiency (DE) (Table 2) shows energy consumption (p<0.001). The quadratic terms of
very high model F value (96.8), suggesting the usefulness both parameters moderately affected (p<0.05) the specific
of quadratic model to fit the experimental data (p<0.001). energy consumption during dehulling of barnyard millet.
Linear and quadratic terms of ηCS had highly significant No significant effect was observed at interaction(s) level.
effect on threshing efficiency (p<0.001), where as the linear The numerical presentation in variation of specific energy
term of the Boh had moderate effect (p<0.01). The effect consumption (SEC, kW.h.kg-1) with different variables viz.,
of interaction term on DE was also observed (p<0.05). number of canvas strip (ηCS) and over hanging width of
The quadratic term of Boh and the lack of fit were non- canvas strip (Boh, mm) could be fitted well in quadratic
significant. The regression analysis of the response of equation 4.
dehulling efficiency (DE) versus two independent variables
SEC = 0.017–0.002 ηCS–0.002Boh+0.0004 ηCS2+0.0014Boh2
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(actual values), neglecting the high error generating terms,

fitted well in the second order polynomial (eq. 3). + 0.0006 ηCS× Boh (R2=0.98) … (4)
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DE=91.2+1.5 η cs +0.02 B oh –0.08 η cs 2+0.05 η cs ×B oh Where,

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(R2 = 0.99) … (3) SEC = Specific energy consumption, kW.h.kg-1,

Where, Boh = Over hanging width of canvas strip, mm, and
DE = Dehulling efficiency, %, ηcs = Number of canvas strip over periphery.
Boh = Over hanging width of canvas strip, mm, and
It could be observed (Fig. 2c) that the specific energy
ηcs = Number of canvas strip over periphery.
consumption increased with increase in both Boh and ηCS.
It can be observed (Fig. 2b) that the dehulling efficiency
Optimization of Machine Parameters
(DE, %) increased with η CS up to 8 and reduced
thereafter at all Boh achieving maxima more than 98%. Firstly, the range of optimized responses was achieved
Very slow linear increase in DE with increase of Boh was (using Design Expert- 7.0.0 software) numerically by
observed at fixed value of η CS. Thus, the dehulling putting the values of process variables and responses at
efficiency was found to be maximum at Boh of 3.38 mm

Fig. 2a: Effect of number of canvas strip and over hanging Fig. 2b: Effect of number of canvas strip and over hanging
width of canvas strip on throughput width of canvas strip on dehulling efficiency

20
K.P.Singh, H.N.Mishra and S.Saha JAE : 48 (3)

Optimization of process and material parameters at

fixed machine parameters
CCRD and RSM has been successfully applied to optimize
process parameters (Mangaraj and Singh, 2011; Singh et
al., 2008) and is advantageous over single factor study.
.
Twenty trials were carried out (Table 3) according to CCRD
and their combined effects were studied. The optimized
machine parameters i.e. number of canvas strip over
periphery of impeller (9) and over hanging width of canvas
(3 mm) were used for this study for optimization of process
parameters viz., peripheral speed (Vp), number of passes
(ηp) and moisture content (θ).
Fig. 2c: Effect of number of canvas strip and over hanging
width of canvas strip on specific energy consumption
Dehulling Efficiency
The ANOVA of dehulling efficiency (DE) shows (Table 4)
optimization criteria (to maximize the throughput and very high model F value (24.7) indicating that the quadratic
dehulling efficiency as also minimize the specific energy model could be successfully used to fit the experimental
consumption). In numerical optimization, one solution was data (p<.001). F–values show that the linear terms of
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obtained as number of canvas strip (9) and over hanging independent variables peripheral speed, number of passes
width (3mm). The corresponding responses for and moisture content significantly affected the DE (p<.001).
throughput, dehulling efficiency and specific energy
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However, the quadratic terms of peripheral speed affected

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consumption were 46.5 kg.h-1, 98.8% and 0.054 kW.h.kg-1, the DE at 5% level of significance (p<.05). No significant
respectively. effect was observed in interaction terms of all variables as
well as quadratic term of number of passes and moisture
Similar results were obtained from graphical optimization,
content. The nonlinear second order regression equation
using Design Expert 7.0.0 (Fig. 3). In order to verify the
(eq. 5) was developed as a function of real values of
optimum conditions, an experiment was conducted at these
independent variables viz., Vp, ηp and θ for the dependent
conditions. The actual TU, DE and SEC obtained, with
variables dehulling efficiency.
optimum process variables, were 51.2±3.6 kg.h-1, 97±1.4%
and 0.052±0.011 kW.h.kg-1, respectively. DE = −189.0 + 34.5V p + 26.1η p + 9.24θ − 2.06η p2 ...(5)
Where,
DE = Dehulling efficiency, %,
Vp = Peripheral speed, m.s-1,
θ = Moisture content, %, and
ηp = Number of passes.

Response surface plots and contours for dehulling

Fig.3: Superimposed contours for throughput (TU),
dehulling efficiency (DE) and specific energy
consumption (SEC) of dehuller at varying over
hanging width (Boh)and number of strips (η ηcs). O1
is the optimal point with Boh= 3 mm and ηcs=9
efficiency of barnyard millet as function of impeller
peripheral speed, number of passes and moisture content
(Fig. 4 a, b) show gradual increase in dehulling efficiency
with increase in number of passes as well as the impeller
peripheral speed. Dehulling efficiency decreased with
decrease in moisture content from 9 to 7.22%, and the
rate of decrease was rapid thereafter. Low dehulling
efficiency at higher moisture content might be due to excess
deformation of seeds, which withstood the impact force
given by canvas strip on it, without splitting the hulls. Similar
dehulling trends with moisture content was also reported
for melon seed (Makanjuola, 1972), pumpkin seed (Joshi,

21
July - September, 2011 Design, Development and Evaluation of Barnyard Millet Dehuller

Table 3. Effect of peripheral speed (Vp), number of passes (ηp) and moisture content (θ) on dehulling efficiency (DE) and
broken grain (BG) of barnyard millet

Expt. Peripheral Number of Moisture Dehulling Broken

No Speed, m.s-1 passes Content, % (db) efficiency, % %
Vp ηp θ DE BG
1 10.17(+1*) 4 (–1) 7.22 (–1) 92.00 8.60
2 7.34 (–1) 4 (–1) 7.22 (–1) 75.00 6.30
3 8.76 (0) 3 (–1.682) 9.00 (0) 61.00 2.70
4 8.76 (0) 5 (0) 9.00 (0) 88.00 5.30
5 10.17 (+1) 4 (–1) 10.78 (+1) 71.00 6.70
6 10.17 (+1) 6 (+1) 10.78 (+1) 81.00 9.10
7 7.34 (–1) 6 (+1) 7.22 (–1) 84.00 6.00
8 8.76 (0) 5 (0) 9.00 (0) 85.00 5.00
9 7.34 (–1) 6 (+1) 10.78 (–1) 73.00 4.80
10 8.76 (0) 5 (0) 6.00 (–1.682) 93.00 8.80
11 10.17 (+1) 6 (+1) 7.22 (–1) 96.00 12.20
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12 8.76 (0) 5 (0) 12.00 (+1.682) 67.00 4.30

13 8.76 (0) 5 (0) 9.00 (0) 84.00 5.90
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14 8.76 (0) 7 (+1.682) 9.00 (0) 93.00 9.40

15 11.14 (+1.682) 5 (0) 9.00 (0) 91.00 10.90
16 7.34 (–1) 4 (–1) 10.78 (+1) 63.00 4.10
17 8.76 (0) 5 (0) 9.00 (0) 86.00 5.60
18 6.37 (–1.682) 5 (0) 9.00 (0) 65.00 5.50
19 8.76 (0) 5 (0) 9.00 (0) 83.00 6.20
20 8.76 (0) 5 (0) 9.00 (0) 87.00 6.70
*
Values shown in brackets are coded values of respective independent variables

Fig. 4: Response surface showing the effect of (a) number of passes and peripheral speed, and (b) moisture content and
number of passes on dehulling efficiency

22
K.P.Singh, H.N.Mishra and S.Saha JAE : 48 (3)

1993) and sunflower seed (Gupta and Das, 1999). Around Table 4. Analysis of variance showing the effect of peripheral
4–6% grains remained unhulled even after six passes of speed, number of passes and moisture content on
repeated dehulling, possibly due to the presence of immature dehulling efficiency (DE) and breakage (BG)
grains in the lot. Maximum (96%) dehulling efficiency was
observed at peripheral speed of 10.2 m.s-1, six numbers of Source F-values for responses
DE BG
passes and moisture content of 7.2% db (Table 3).
Model 24.7*** 17.9***
Broken Grain
Vp 59.4*** 68.5***
It is clear from the ANOVA (Table 4) for quadratic model
that broken grain (BG) content was significantly affected ηp 60.6*** 38.2***
(p<0.001) by linear terms of independent variables. θ 79.6*** 29.1***
However, no significant effect of quadratic terms of number
of passes and moisture content was observed on BG. The Vp × ηp ns 6.1*
BG was significantly affected by the quadratic term of Vp × θ ns ns
peripheral speed at 5% level of significance. Interaction
terms between peripheral speed and number of passes were ηp × θ ns ns
significantly affected the BG at 1% level of significance Vp 2
ns 18.2**
(p<0.01). Other interaction terms were not significant
(p>0.05). The second order regression equation was ηp 2 11.4** ns
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developed as a function of actual values of independent θ2 ns ns

variables Vp, ηp and θ for the dependent variable BG. The
Lack of Fit ns ns
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developed relation (eq. 6) with actual values (neglecting

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the non-significant terms) is given as: ***, **, *

= Significant at p<.001, p<.01 and p<.05 respectively

BG = 5.79 + 6.50V p + 7.21η p − 7.52θ + 0.91η + 0.74η p ×V p 2

p ( R = 0.94)
2

(Fig. 5 a and b) that the dehulling losses increased with

… (6)
increases in peripheral speed and number of passes.
Where,
BG = Broken grain, %, It can, thus be concluded that the high peripheral
(>8 m s –1) speed of impeller might produce higher
Vp = Peripheral speed, m.s-1,
centrifugal force on grain kernel and thereby more dehulling
θ = Moisture content, % (db), and loss (8–12%). Similar results were reported by Jain (1980)
ηp = Number of passes. for paddy seed and Joshi (1993) for pumpkin seed. In the
present study, gradual decrease in dehulling loss was
It is evident from the response surface contours and plots observed with increase in moisture content. Minimum

Fig. 5: Response surface showing the effect of (a) number of passes and peripheral speed, and (b) moisture content and
peripheral speed on broken grain

23
July - September, 2011 Design, Development and Evaluation of Barnyard Millet Dehuller

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Fig. 6: Superimposed contours for dehulling efficiency (DE) and broken grain (BG) of dehuller at varying (a) number of
ηp) and peripheral speed (Vp), ((b) moisture content (θ ) and peripheral speed (Vp)
passes (η
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dehulling loss (2.7%) was observed at peripheral speed of the optimization of machine and process parameter indicated
8.76 m.s-1, 3 number of passes and moisture content of that the number of canvas strip over periphery (ηs), over
9% db. hanging width of canvas strip applied on impeller (Boh),
peripheral speed of impeller (Vp), moisture content of grain
Optimization of Process Variables (m) and number of passes (ηp) of the grain significantly
The graphical optimization of process variables was done affected the performance of the dehuller. The dehuller
using Design Expert 7.0.0 (Anon, 2002) software. Firstly, worked more efficiently and resulted in low broken grain
the range of optimized responses was achieved numerically and specific energy consumption when operated at optimum
by putting the values of process variables within the parameters for machine (ηcs=9; Boh =3 mm) and process
experimental range and following the optimization criteria (Vp=8.6 m.s-1; ηp =5; θ =8.4% db). The developed dehuller
(to maximize the dehulling efficiency and minimize the can be promoted as a small-scale unit for income and
broken percentage). With numerical optimization, the employment generation.
optimised peripheral speed, number of passes and moisture
content were 8.6 m.s-1, 5 and 8.4% (db), respectively, with ACKNOWLEDGEMENT
corresponding responses for dehulling efficiency and
dehulling loss as 87.4 and 6.2%, respectively. Almost similar The financial assistance provided by the All India Co-
results were obtained from graphical optimization (Fig. 6 a coordinated Research Project on Post Harvest Technology,
and b). (ICAR), New Delhi to carry out the work is duly
acknowledged.
In order to verify the optimum conditions an experiment
was conducted at these conditions. The actual dehulling REFERENCES
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