CHAPTER ONE

INTRODUCTION

1.0 BACKGROUND TO THE STUDY

Sugarcane is the common name of a species of herb belonging to the grass
family. There are three major categorical species of sugarcane found in
Nigeria, and these are Saccharin officinarum, S. incense, and S. Spontaneum.
It is of six perennial grasses species, in the tribe And ropogoneae of the
Graminea (Purse glove, 1988). It grows up to heights of 2 to 7 meters having
clumped up, jointed, cylindrical, stout stalks; of diameter 1.25cm to 7.25cm
(Munoz et al, 2007). Several different horticultural varieties are known, and
they differ by their stem colour and length (Anonymous, 1998). Sugarcane
has been cultivated since ancient times. The most widely used cultivation
technique is by stem cuttings, since many varieties do not produce fertile
seeds (Microsoft, 1994).
Sugarcane was one of the first "cash crops" of early colonial America.
Bowel (1939) emphasized that this is one of the many species of plants that
depend on human intervention for proper survival. It is a very easy, and
profitable plant to grow, but does not naturally reproduce very effectively. It
grew plentifully in the southern states, and was a major source of income for
many plantations. The areas where it is readily grown in the United States
are Hawaii, Louisiana, Florida and Puerto Rico. The countries in the world
that produce the largest amounts of sugarcane are Brazil, Cuba, Kazakhstan,
Mexico, India, and Australia (Microsoft, 1994).For centuries it has been
harvested by hand, because sugarcane was not easily harvested by machine.
It was formerly, mainly, harvested using large machete like blades. For this

1
reason sugarcane fields have very large amounts of farm hands, and are a
major source of employment throughout South America, Central America,
and even the Caribbean (Wikipedia, 2010). In early America, when the plant
was readily harvested, it was a major source of slavery in the south, but the
elimination of slave practices demanded the uprising of mechanical
techniques to the harvesting of sugarcane. Wikipedia (2010) states that
mechanical harvesting uses a combine, or chopper harvester. Other
companies such as Cameco or John Deere have copied the original modern
harvester design: the Austoft 7000 series. The machine cuts the cane at the
base of the stalk, strips the leaves, and deposits the cane into a transporter,
while blowing the thrash back onto the field; having the ability to harvest
100 long tons (100 t) each hour. It is noteworthy that machine-harvested
cane must be rapidly processed. Once cut, sugarcane begins to lose its sugar
content, and damage to the cane during mechanical harvesting accelerates
this decline. Sugarcane, is highly adequate in the provision of energy for the
nutritional requirement of both livestock and humans. Based on its land use
factor, its value of calories per unit area is highest for any plant
(Heiser,1981). Furthermore, due to the content of sugarcane - 70% water,
14% fibre, 13.3% saccharose ( about 10 -15% sucrose), and 2.7% soluble
impurities – it provides 60% of the world’s sugar production while the rest is
provided by sugar beet (World Bank, 1998).
The juice within the sugarcane and the remnant of the extraction process are
very important to manufacture numerous useful substances and materials in
the community. For this purpose the industrialization of the extraction
process to cater for a very large amount of sugarcane, by way of maximizing
its usefulness is economically significant. Also, smaller technological

2
 breakthroughs such as the sugarcane juice extraction machine for the cottage
industry have been made to cater for small scale sugarcane processing.

1.1 STATEMENT OF THE PROBLEMS

Sugarcane juice, over the years, has been successfully used in the production
and manufacturing of the edible refined sugar; using machines which were
fabricated and constructed to large scale production, industrialization and
large capital requirements. This makes the extraction of sugarcane juice a
fantasy to local or small-scale industrial establishments. Thus, this
amputates the involvement of small-scale farmers in the business of
sugarcane juice extraction and refined sugar production; at large. In Nigeria,
it is quite remote for those who are subsistent in agricultural practices to take
part in sugar production practices in the scope of their practice. Furthermore,
the major way by which the suckle in sugarcane has been enjoyed over the
years has been by the employment of the teeth in biting off the rind and
chewing up the internal tissues. When this is achieved, the juice would then
be extracted and sucked in the mouth.
After this the bagasse is spat out. The grossness of this procedure tends to:
• Put the human teeth in duress; imagine if the amount to be consumed is
large.
• Possibly soil the hands and clothing of the consumer.
• Classify the consumption of sugarcane as raze and rural, causing a
reduction in the widespread acceptance of the crop for consumption.
At present, the construction of the cottage industry sugarcane juice extractor
has been facilitated to cushion these problems so far. The important step of
producing sugar from the extracted juice by the machine would be enhanced
also; because, aside from consumption, sugarcane cultivation in the world is
3
 targeted towards the production of sugar, ethanol, and many more. The
aggregate of the various cottage industry extraction activity, would sum up
to meeting the global requirement for the numerous sugarcane products; but
what state the machine puts the extracted juice in, is another thing to
consider.
In this light, one should not, for the purpose of solving a problem, create
another problem. The incursion of rust and surrounding debris into the
extraction process of the fabricated machine has been an issue to which one
needs to proffer solution to. These numerous contaminants when introduced
into the desired substance get to mix-up with it and when consumed, they
tend to reside in the body and accumulate until its adverse effect would be
prominent. For any consumer, the knowledge of such a technology would
make them find satisfaction in retaining backward and archaic techniques
such as’ buccal’ juice extraction.

1.2 AIMS AND OBJECTIVE OF WORK

The study is aimed at improving the previously constructed sugarcane juice
extractor for the cottage industry.
Other objectives of this work include:
i. To improve the aesthetics of the constructed machine.
ii. Identify and construct the missing components of the sugar cane
extractor; especially the casing, hopper and chutes. The casing of the
operating chamber would in turn help improve the enclosure of the
extraction process, minimizing the interaction of the surrounding with
the process.

4
 iii. The reduction of machine use hazard. This is achieved by ensuring
that the various joints are well secured; and covering most moving
parts.
iv. The improvement of the separation of the juice from bagasse; and the
collection.
v. Testing of the machine. This is subjecting the machine to tests under
laboratory conditions.
vi. Evaluate the performance of the machine.

1.3 JUSTIFICATION

The use of non-reactive metallic materials for the fabrication would also go
a long in segregating the frame-metal, which is stainless steel, from having
contact with the juice. This would also help improve, by way of reduction,
the introduction of rust into the extracted juice. Since juice is liquid in
nature, it has a good amount of moisture in it; which would enhance the
corrosion of the stainless steel frame. The construction of the casing for the
operating chamber would help shield off the intrusion of rust in the extracted
juice.
Furthermore, the casing would improve the safety of the operator. This is
ensured by the covering of the moving parts: such as the gears. Also the
aesthetics of the machine construction would be upgrade. This would not
interfere with the steady operation of the machine, but this would improve
the people appreciation of the machine.
In closing, when the status of fabrication of this machine is upgraded it
would go a long way in improving the losses in the extraction process; such
5
 as time losses and good product losses. Also the hygiene of the machine
would be better since the presence of contaminants such as rust would be
curbed. Then, due to the adoption of the hopper section the quantity of
sugarcane pieces and cutting that can be handled at the same time would be
more thus saving time losses and the activity of the employed labour.

1.4 SCOPE AND LIMITATION OF THE STUDY

The scope of study consists of:
i. Develop the juice extraction mechanisms for the sugar cane juice
extraction.
ii. Develop a cleaning system.
iii. Set up the bagasse cutter and collector.
iv. Set up filler for sugar cane juice.

6
 CHAPTER TWO
LITERATURE REVIEW

2.1 HISTORICAL BACKGROUND OF SUGARCANE

EXTRACTOR
Sugarcane is any of six to thirty-seven species (depending on taxonomic
system) of tall perennial grasses (Naturland, 2000). Sugarcane is a tropical
grass belonging to the same family as sorghum, Johnson-grass, and corn –
also known as maize (Midwest Research Institute, 1997). It is of the
kingdom Plantae, phylum Magnoliophyta (Monocots, Commelinids), order
Poales, family Poaceae and genus Saccharum L. Sugarcane only rarely
produces seeds capable of germination. Most of the several hundred usable
clones are cross-fertilizations’ between S. officinarum (high sugar content),
S.sinensis (adaptable), S. spontaneum and S. robustum (disease resistant).
The most common clones are octaploid (eight corresponding, similar in
position, structure, function or characteristics sets of chromosomes in a cell),
and are propagated vegetatively (Naturland, 2000).
Sugarcane is indigenous to tropical South Asia and Southeast Asia. Different
species likely originated in different locations with S. barberi originating in
India and S. Edule and Sugar cane juice extractor coming from New Guinea.
Crystallized sugar was reported 5,000 years ago in India. Around the eighth
century A.D., Arabs introduced Table top Sugarcane juice machine to the
Mediterranean, Mesopotamia, Egypt, North Africa, and Andalusia. By the
tenth century, sources state, there was no village in Mesopotamia that did
not grow sugar cane. It was among the early crops brought to the Americas

7
by the Andalusia’s (from their fields in the Canary Islands), and the
Portuguese "Boiling houses" in the 17th through 19th centuries converted
sugarcane juice into Commercial sugarcane juicer machine. These houses
were attached to sugar plantations in the western colonies.
Slaves often ran the boiling process, under very poor conditions. Made of
cut stone, rectangular boxes of brick or stone served as furnaces with an
opening at the bottom to stoke the fire and remove ashes. At the top of each
furnace were up to seven copper kettles or boilers, each one smaller and
hotter than the previous one. The Cane juicer machine began in the largest
kettle. The juice was then heated and lime added to remove impurities. The
juice was skimmed, and then channeled to successively smaller kettles. The
last kettle, which was called the automatic sugarcane juice machine, was
where the cane juice became syrup. The next step was a cooling trough,
where the sugar cane machine, hardened around a sticky core of molasses.
This raw sugar was then shoveled from the cooling trough into sugarcane
juice crusher (wooden barrels), and from there into the curing house.
A sugar plantation on the island of Réunion in the late 1900s Sugarcane is
still extensively grown in the Caribbean. Christopher Columbus first brought
it during his second voyage to the Americas, initially to the island of
Hispaniola (modern day Haiti and the Dominican Republic). In colonial
times, sugar formed one side of the triangular trade of New World raw
materials, European Commercial sugarcane extractor manufactures, and
African slaves. France found its sugarcane islands so valuable, it effectively
traded its portion of Canada, famously dubbed "a few acres of snow," to
Britain for their return of Guadeloupe, Martinique and St. Lucia at the end of
the Seven Years' War. The Dutch similarly kept Suriname, a sugar colony in
South America, instead of seeking the return of the New Netherlands (New
8
York). Cuban sugarcane produced sugar that received price supports from
and a guaranteed market in the USSR; the dissolution of that country forced
the closure of most of Cuba's sugar industry. Sugarcane remains an
important part of the economy of Guyana, Belize, Barbados, Haiti, along
with the Dominican Republic, Guadeloupe, Jamaica, and other islands.
Manual sugarcane crusher production greatly influenced many tropical
Pacific Islands, including Okinawa and, most particularly, Hawai’i and Fiji.
In these islands, sugarcane came to dominate the economic and political
landscape after the arrival of powerful European and American agricultural
businesses, which promoted immigration of workers from various Asian
countries to tend and harvest the crop. Sugar was the dominant factor in
diversifying the islands' ethnic makeup, profoundly affecting their politics
and society. Brazil is the biggest grower of sugarcane, which goes for sugar
and sugar cane Juice extractor for gasoline-ethanol blends (gasohol) for
transportation fuel. In India, sugarcane is sold as jiggery, and also refined
into sugar, primarily for consumption in tea and sweets, and for the
sugarcane juice crusher production of alcoholic beverages. Sugar cane field
on Madeira
Sugarcane cultivation requires a tropical or temperate climate, with a
minimum of 60 centimeters (24 in) of annual moisture. It is one of the most
efficient photosynthesizes Table top Sugarcane juice crusher in the plant
kingdom. It is a C-4 plant, able to convert up to 2 percent of incident solar
energy into biomass. In prime growing regions, such as India, Pakistan,
Peru, Brazil, Bolivia, Colombia, Australia, Ecuador, Cuba, the Philippines,
El Salvador and Hawaii, sugarcane can produce 20 lb (9 kg) for each square
meter exposed to the sun. Although sugarcanes produce seeds, modern stem
cutting has become the most common reproduction method. Each automatic
9
cane juice crusher cutting must contain at least one bud and the cuttings are
sometimes hand-planted. In more technologically advanced countries like
the United States and Australia, Industrial sugar cane juicer machine is
common. Billets harvested from a mechanical harvester are planted by a
machine which opens and re closes the ground. Once planted, a stand can be
harvested several times; after each harvest, the cane sends up new stalks,
called ratoons. Successive harvests give decreasing yields, eventually
justifying replanting. Two to ten harvests may be possible between
plantings.
Sugarcane mechanical harvest in Jaboticabal, São Paulo, Brazil Sugarcane is
harvested by hand and automatic sugar cane juice machine mechanically.
Hand harvesting accounts for more than half of production, and is dominant
in the developing world. In hand harvesting the field is first set on fire. The
fire burns dry leaves, and kills any lurking venomous snakes, Table top cane
extractor without harming the water-rich stalks and roots. Harvesters then
cut the cane just above ground-level using cane knives or machetes. A
skilled harvester can cut 500 kilograms (1,100 lb) of sugarcane per hour.
Sugarcane exhibit at Louisiana State Exhibit Museum in Shreveport shows
importance of the crop to south Louisiana from earliest times.
Mechanical harvesting uses a combine, or chopper harvester. The Fresh
sugarcane juicer machine series was the original modern harvester design
that has now been copied by other companies including Cameco John Deere.
The machine cuts the cane at the base of the stalk, strips the leaves, and
deposits the cane into a transporter, while Commercial sugar cane extractors
blowing the thrash back onto the field. Such automatic sugar cane juice
crusher can harvest 100 long tons (100 t) each hour, but machine-harvested
cane must be rapidly processed. Once cut, sugarcane begins to lose its sugar
10
content, and damage to the cane during mechanical harvesting accelerates
this decline.
Sugarcane is still extensively grown in the Caribbean. Christopher
Columbus first brought it during his second voyage to the Americas, initially
to the island of Hispaniola (modern day Haiti and the Dominican Republic).
Sugarcane appliance machine In colonial times, sugar formed one side of the
triangular trade of New World raw materials, European Large sugarcane
Juice Presser manufactures, and African slaves. France found its sugarcane
islands so valuable, it effectively traded its portion of Canada, famously
dubbed "a few acres of snow," to Britain for their return of Manual hand
sugarcane juice crusher Guadeloupe, Martinique and Stainless steel
sugarcane machine at the end of the Seven Years' War. The Dutch similarly
kept Suriname, a sugar colony in South America, instead of seeking the
return of the New Netherlands (New York). Cane juicer instrument Cuban
sugarcane produced sugar that received price supports from and a
guaranteed market in the USSR; the dissolution of that country forced the
closure of most of Cuba's sugar industry. Stainless Steel Manual sugar cane
crusher remains an important part of the economy of Guyana, Belize,
Barbados, Haiti, along with the Dominican Republic, Guadeloupe, Jamaica,
and other islands.
Sugarcane production greatly influenced many tropical Pacific Islands,
including Okinawa and, most particularly, Hawaii and Fiji. In these islands,
Table top sugar cane juicer machine came to dominate the economic and
political landscape after the arrival of powerful European and American
agricultural businesses, which promoted immigration of workers from
various Sugar cane standard juicer crusher Asian countries to tend and
harvest the crop. Sugar was the dominant factor in diversifying the islands'
11
 ethnic makeup, profoundly affecting their politics and Sugar cane standard
machine in the society. Brazil is the biggest grower of sugarcane, Domestic
sugarcane Juicer extractor which goes for sugar and Sugar cane Stainless
Steel Manual squeezer for gasoline-ethanol blends (gasohol) for
transportation fuel. In India, sugarcane is sold as jiggery, and also refined
into sugar, primarily for consumption in tea and sweets, and for the Heavy
duty cane crusher production of alcoholic beverages.

2.2 FACTORS TO BE CONSIDERED IN THE DESIGN OF

SUGARCANE EXTRACTION
i. The type of material that are to be used: when designing a sugarcane
extractor the material that are going to be used should be considered
because the juice that are going to be produced by the extractor
machine is drinkable so we need to consider the type of material being
used in the design of the sugar cane extractor machine because of rust
and deformation of the material used in the designing of the material
so we consider using stainless steel as the best material in designing
the sugarcane extractor because of it durability, it keep the physical
condition of the machine at high level, it resist corrosion, it does not
readily corrode, rust, or stain with water as ordinary steel does.
ii. Clearance in-between the two gears of the extractor machine: the
clearance in between the two gears are to be considered because when
there isn’t an adequate clearance in between the two gears of the
extractor machine the gears can crush each other and can easily lost it
original shape.

12
 iii. The sugarcane extractor should be easily moveable from one point to
another without stress and time wastage i.e. considering the use of
tires.
iv. The sugarcane extractor machine should have a safety interlock i.e. to
prevent dust.

2.3 EXISTING TYPES OF SUGARCANE EXTRACTORS

The modern sugar cane juicer has come a long way from the trapiche, the
old traditional wooden roller press, used by the indigenous people of
countries such as Panama and Columbia. A commercial sugar cane juice
extractor is quite expensive. When looking for a household model, this may
also prove difficult. These are hard to find and may require placing an order
from another country, such as Malaysia, Singapore, and India, which offers a
sugar cane press for the tabletop (Rika, 2010). Some health food merchants
in the United States have turned to an extractor for sugar cane so that they
can tap into the organic juice market. Some extractors have the capacity to
process around 170 canes in an hour, while others boast an easy filtration
system. By Rika (2010), the prices also vary for the sort of extractor. A less
expensive model may be found around $200 in a high-powered juice and
vegetable extractor, where true sugarcane extractors could be as much as
$3000 for large, industrial-size selections.

2.3.1 THE TRAPICHE

The trapiche which is a Spanish word meaning ‘sugarcane crusher’- when used in
terms of the machine, or ‘sugarcane mill’ - when used for the location, is a
traditional wooden roller press, used by the people of Panama and Columbia to
extract sugarcane juice (Riza, 2010). This machine which is of varying sizes is

13
basically made from wood. It has two vertical rollers for crushing the sugarcane.
These rollers are held in place by a wooden frame, while one of the rollers receives
and transmits, by a longitudinal twist grove, the rotary motion to the second roller
for crushing. It is powered manually or by animal draught (mostly for the larger
and static ones found in the mill), to perform the juice extraction.
Plate 1: The Trapiche

2.3.2 ZAMA COMPANY JUICERS

The Sugar Cane Juice Extractor is a countertop model. It has a stainless steel body,
and powered by 1 hp motor, having a productivity of 250kg/hr. For easy cleaning,
the front cover can be removed. The maximum insertion size of the sugar cane
must be 57.15 mm in diameter, and adequately crushes the sugarcane with one
insertion. It has a dimension of 450mm × 450 mm × 480 mm and is easy to operate
(Zama, 2010). Plate 2: The ZAMA Sugarcane Juicer The Zama Enterprise
Company offers many other models in their product line. For example,

14
their industrial strength model can accommodate 6-7 cane sticks at one time. A 5
hp motor runs this high volume option. The machine weighs 136.078 kg compared
to other models that weigh around 45.36 kg and accept sugarcane with a diameter
of 50.8 mm or less.

2.3.3 THE MCI MODELS

One of the options currently on the market is a sugar cane juicer called the MCI-
170 that comes with the usual commercial-juicer price-tag. This is an extractor
with a stainless steel cabinet, body and juice drum. The unit also has a drink tap.
The juicer can go through around 170 canes per hour. The power input is 1.5 hp
and machine speed is 35 rpm. The dimensions (l*b*h) of the MCI-170 are 457.2
15
mm x 406.4 mm x 533.4 mm. This is quite a hefty machine by juicing standards, as
it weighs in at around 86.18 kg. A gas version is also available. A slightly more
manageable version is the MCI-60, which dispatches with 60 canes per hour. It
comes with the same stainless steel construction, standard drive container and filter
with drink tap. The 3/4 hp motor that powers the machine creates a machine speed
of 25 rpm. This is a slightly svelte model with dimensions (l*b*h) of 457.2 mm x
330.2 mm x 457.2 mm. This heavy contraption weigh 45.36 kg.

2.3.5 JINSHUI SUGARCANE JUICE EXTRACTOR

This juicer originated from Jinshui road, China, and it has found its market in
places like North America, South America, Southeast Asia, Africa, Eastern Asia,
Western Europe, etc. It is a desktop, vertical Juicer which uses belts and gear
rotation, with high efficiency, low power consumption and low noise level. Model
Power Voltage Speed Capacity Frequency Size (l*b*h) Weight SXZ-60 370w
220v 25r/min 280kg/h 50Hz 540*440*960mm 75KG Contacts inside the machine
where the local use of fresh sugar cane pieces or stainless steel plating, meet the
health requirements. It is used in hotels, restaurants and eateries collective

16
canteens.
Furthermore, it has a good appearance, structurally compact, simple to operation
and easy to clean. It ensures hygiene due to its anti-corrosion and anti-rust stainless
steel. The machine can be also be used to squeeze ginger, garlic, etc. The
availability of sugarcane juice extraction machines in Nigeria is achieved by the
Dangote Sugar Refinery, majority-owned by Nigeria's leading private
conglomerate, Dangote Group, which is the main sugar plant in Nigeria; after the
fall of the Bacita Sugar Company of Nigeria. It has a production capacity of 1.44
million MT per annum, making it the largest sugar refinery in sub Saharan Africa
and second largest in the world (Dangote Sugar, 2011). In all the scale of
production of the machines available in the country are majorly for large scale
production requirements. This has helped Nigeria awake from the slump in its
sugar production.
Finally, the Department of Agricultural Engineering, University of Agriculture,
Abeokuta, has also constructed a sugarcane juice extractor (Soetan, 2008). This
machine for the cottage industry is fabricated to cater for the juice extraction
requirement for the small-scale sugarcane farmer. This juicer which weighs about
100 kg is a 2-rollers crusher with a gear transmission system. It is powered
mechanically and it is the focus of this project work.
Plate 6: The existing sugarcane juice extraction machine

17
2.3,6 CONVENTIONAL SUGAR CANE JUICE EXTRACTION
MACHINE
Conventional sugar cane juice extraction machine were used for a long time
because it is cheap and last longer. Conventional machine is a simple machine
which consists of several gears, rollers and lever attached on a cast iron chassis
body. Most conventional machine are made up cast iron material which is strong
18
and durable. These machine were made by simply mechanism of rolling and
crushing (Kulkami, 2005). Human force is required to extract the juice using this
machine. A lever is attached on a set of gear, when the lever is spin manually by
hand, both roller will spin to crush the sugar cane. This process requires lot of
energy because sugar cane is hard to crush and sugar cane is needed to be crushed
repeatedly. Most conventional machine consist of only a set of roller.
Conventional machine operates on exposed extraction mechanism which is not
hygienic for food and beverages standards. Besides that, rust on the surface of the
roller also may affect the quality of the juice and contaminate the juice.

19
2.4 PRODUCTS OF SUGARCANE
Sugar cane products include table sugar, Falernum, molasses, rum, cachucha (the
national spirit of Brazil), and ethanol; amongst others. The bagasse that remains
after sugar cane crushing may be burned to provide heat and electricity. It may
also, be because of its high cellulose content, serve as raw material for paper,
cardboard, and eating utensils that, because they are by-products, may be branded
as "environmentally friendly". generally highlights that in most countries where
sugarcane is cultivated; there are several foods and popular dishes derived directly
from it, such as:
a. Raw sugarcane: chewed to extract the juice.
b. Sugarcane juice: a combination of fresh juice, extracted by hand or small mills,
with a touch of lemon and ice to make a popular drink, known variously as ganne
ka rass, guarab, guarapa, guarapo, papelón, aseer asab, Ganna sharbat, mosto and
caldo de cana.
c. Cachucha: a liquor made of the distillation of sugarcane and it is the most
popular
distilled alcoholic beverage in Brazil.
d. Jaggery: a solidified molasses, known as Gur or Gud in India, traditionally
produced
by evaporating juice to make a thick sludge and then cooling and molding it in
buckets. Modern production partially freeze dries the juice to reduce
caramelization and lighten its color. It is used as sweetener in cooking traditional
entrees, sweets and desserts.
e. Panela: solid pieces of sucrose and fructose obtained from the boiling and
evaporation of sugarcane juice; a food staple in Colombia and other countries in

20
South and Central America.
f. Molasses: used as a sweetener and a syrup accompanying other foods, such as
cheese or cookies.
g. Rapadura: a sweet flour which is one of the simplest refining of sugarcane juice.
h. Rum: especially in the Caribbean. It is a strong alcoholic drink, mostly with a
dark brown colour.
i. Falernum: a sweet, and lightly alcoholic drink made from sugar cane juice.
j. Syrup: a traditional sweetener in soft drinks, now largely supplanted (in the US
at least) by high-fructose corn syrup, which is less expensive because of subsidies.
k. Rock candy: crystallized cane juice.
l. Sayur Nganten : name of Indonesian soup made of trubuk stem (Saccharum
edule).
m.Ethanol fuel: Ethanol is generally available as a by-product of sugar production.
It can be used as a bio-fuel alternative to gasoline, and is widely used in cars in
Brazil. It is a promising alternative to gasoline, and may become the primary
product of sugarcane processing, rather than sugar. In summary, the fibrous and
woody residue, bagasse, is useful in boilers as fuel, production of chemicals,
papers, particleboards and farmland mulching, amongst others. Supplies for
fertilizers, sugarcane wax and animal feed supplements, can be provided by the
dried filter cake, while the molasses provides an inedible form known as blackstrap
(further processed into animal feeds, ethanol, yeast, etc.) and the edible syrup
(MRI, 1997).

2.5 STORAGE
Whole cane sugar is very hygroscopic (draws water), and it should be stored air-
tight in a dry place. When the product is incorrectly stored, yeasts may begin a

21
fermentation process. Under ideal storage conditions (dry, dark and no smells),
whole cane sugar can be stored for 12-18 months (Naturland, 2000).

2.6 GLOBAL DISTRIBUTION AND PRODUCTION OF

SUGARCANE

Table 1: Top ten sugarcane producers (FAO, 2008)

Figure 1: Global distribution and production
of sugarcane (FAO, 2008) Originally, people chewed sugarcane raw to extract its
sweetness, but with time, Indians
discovered how to crystallize sugar during the Gupta dynasty, around 350 AD.
Sugarcane was
originally from tropical South Asia and Southeast Asia, but it is conceived that
different
species likely originated in different locations with S. barberi originating in India
and S. edule
and S. officinarum coming from New Guinea (Yamada et al., 1998).
Around the eighth century A.D., Indian traders introduced sugar to the
Mediterranean,
Mesopotamia, Egypt, North Africa, and Andalusia. By the tenth century, sources
state, there
was no village in Mesopotamia that did not grow sugar cane. Watson stated that it
was among
the early crops brought to the Americas by the Andalusia’s (from their fields in the
Canary
Islands), and the Portuguese.

22
Sugarcane is grown in over 110 countries (FAO, 2008). In 2008 an estimated 1,743
million
metric tons were produced worldwide, with about 50 percent of production
occurring in Brazil
and India (FAO, 2008).
Statistically, Brazil is the biggest grower of sugarcane, which goes for sugar and
ethanol for
gasoline-ethanol blends (gasohol) for transportation fuel. In India, sugarcane is
sold as
jaggery, and also refined into sugar, primarily for consumption in tea and sweets,
and for the
production of alcoholic beverages.
From Table 1, it is evident that African countries have not found their place in the
chart for
production of sugarcane in the world. Although in Nigeria there was a sugarcane
processing
factory in Bacita in the 20th century, it has found itself diminish and fizzled out.
Formerly,
countries like the United States were prominent in sugarcane production but later
lost their
verve after the eradication of slavery and the advent of the war crisis they
experienced. India
which is one of the primary traced sources for the sugarcane crop, alongside New
Guinea, has
not held on to leading in the production of sugarcane. areas in Africa are found to
have an average output of about 500kg/ha; unlike
areas in South America and Asia which have output as high as 4000kg/ha. In India,
23
the states
of Uttar Pradesh (38.57 %), Maharashtra (17.76 %) and Karnataka (12.20 %) lead
the nation
in sugarcane production.

In the United States, sugar cane is grown commercially in Florida, Hawaii,

Louisiana, and Texas
(IPM, 2008).

24
CHAPTER THREE
DESIGN ANALYSIS
3.0 DESIGN OF COMPONENTS
Each component of the sugarcane extractor has being designed to withstand,
compressive stress, rust and corrosion. This was achieved by selecting appropriate
type of materials for each part with thickness that can easily be welded, machine
and fitted.
3.1 SELECTION OF MATERIALS
Stainless steel was selected for the design of the sugarcane extractor
machine because it certain desirable characteristics needed in the device.
These include:
i. It resists corrosion and rust.
ii. It has remarkable strength and ductility.
iii. It is easy to machine, weld, and forge.
iv. The material is affordable and available.
v. It does not stain with water as ordinary steel does.
3.2 DESIGN OF SUGARCANE EXTRACTOR TANK
To make the sugarcane extractor tank, a 1.2mm stainless steel sheet of about
1070mm long by 330mm wide is needed. Two side A and B were marked out. Side
A and B were cut round to the diameter of 330mm and height 330mm. The
sugarcane extractor tank is to be mounted on an angle bar.
3.3 SELECTION OF THE ROLLER SHAFT
The 2 roller is made up of stainless steel of about 30mm long and 510mm wide
and grooved with 10 teeth each.
3.4 SELECTION OF GEAR
25
The gear is made up of mild steel of different shape 2 driver and 2driven the
driver has 30 teeth and the driven 45teeth the smaller gear has 30teeth the diameter
of the idler gear is 45 teeth
3.5 SELECTION OF CASTOR WHEEL TYRE
The tyre is of about 180mm and it is made up of rubber. It was carefully selected to
move the extractor machine from one point to another without and means of
disturbance
3.6 SELECTION OF ANGLE BAR
The angle bar is 5mm thick made up of mild steel it is used to make the sugarcane
extractor in an upright manner the length is 3700mm by 4600mm and height of
8400mm.
3.7 REQUIRED IMPROVEMENT ON THE JUICE EXTRACTOR
The major purpose of this project work is to work on the casing of the sugarcane
juice extractor which was formerly constructed. This casing is to isolate the
operating chamber, which includes the crushing drums performing the juice
extraction, from its surrounding.
As shown in Plates 3a and 3b, the machine is rusty and dirty. The gears are packed
with bad grease and the machine requires maintenance. The machine frame which
is made of mild steel
has lost its glow, and some of the welded joints are weak.
Therefore, the moving parts such as the gears will be attended to for the safety of
the operator
who would be manning the machine for any required extraction process. This
would also add to
the beauty of the machine along with the cleaning and painting of the corroded
machine parts.

26
3.7.1MATERIALS
1. Steel plate. The plate thickness used is 1.2 mm and a purchase dimension of 4ft
by 2ft span.
2. Cutting disc and grinding disc. These are attached to the angle grinder to power
its operation. The cutting disc when attached is used to cut the plate metal to the
desired shape and orientation, while the grinding disc was used to smoothed the
roughness on the cut detail.
3. Welding electrode. The oerlikon welding electrode was purchased and used.
Details which need to be permanently held together are joined through welding
process.
4. Non-polar solvent. This was chosen based on market availability. The purpose
of the solvent is to wash and clean the metal parts which have been packed with
dust and debris. The choice of solvent was one of the petroleum hydrocarbon
products e.g. petrol, kerosene.
5. Iron Wire brush. It was used to brush off the corroded surfaces and rust on the
previously existing sugarcane juice extractor. This would prepare the surface for
painting.

3.8 DESCRIPTION OF IMPROVED MACHINE

After the completion of the construction of the various component sections for the
framework casing, the machine is assembled and the machine is seen to be in the
form depicted by the Plate. The well washed gear components and fasteners are
fitted back to place. The keys for
Fulcrum
the key ways required in the assemblage of the component parts to the shafts were

27
replaced with new ones, before the running of the machine. The casing of the
machine was carried out successfully and the various sections were assembled to
the existing machine after all the gears and bearings were thoroughly washed and
cleaned.
3.8.1 HIGHLIGHTS OF IMPROVEMENT
1. The parts in contact with the sugarcane are made of stainless steel; which is
corrosion, rust and heat resistant, and does not contaminate the processed agro-
material.
2. Operation of the machine would be relatively easy, having simple operating
mechanisms running the extraction process.
3. Labour for machine operation would be minimal and learning how to operate the
machine would be easy.
4. The base stand for the power source is reinforced.
5. The power requirement of the machine was moderately low, yet efficient.
6. The aesthetics of the machine was upgraded.

3.8.2 FUNCTIONALITY DESCRIPTION

1. The machine noise level would be low.
2. The flexibility of the rollers combination to sugarcane of any diameter would be
possible.
3. Machine handling of split and whole canes would be feasible; relatively with the
same extraction efficiency.
4. The sugarcane-rollers friction needed to facilitate the crushing when the
sugarcane is feed into the operating chamber, and hence juice extraction, would be
adequately present.
5. The heat generated would not be adverse to the operation of the machine.

28
3.9 TEST PARAMETERS AND PROCEDURE
After the machine has been improved check was carried out to ascertain the
efficiency of the machine, so as to know if the modification is adverse to the
machine or beneficial to its operation.
3.9.1 TEST PROCEDURE
For the test, the following equipment’s and materials were used.
1. Lengths of harvested sugarcane.
2. The sugarcane juice extractor.
3. Venire caliper for measuring diameter.
4. A measuring tape for measuring the sugarcane length.
5. A container for collecting the extracted juice.
After the purchase of the sugarcane species, Saccharum officinarum, from the
market, they were cleaned before major dimensional quantities such as the average
diameter, length and weights were obtained and recorded. Furthermore, the
sugarcane was separated into specimens and labeled A to J. Progressively,
preliminary testing was done on the machine with specimens A, B and C, while
specimens D to J were used for the main final test. All the specimens were fed in
by hand, horizontally between the rollers in the operating chamber, and then the
extruded bagasse were collected and re-fed in through the hopper in form of
pieces. For each specimen’s extraction, the calculations to check the performance
of the machine was done; to determine machine efficiency using the following
formulae.
3.8.2 TEST FROMULAE AND PARAMETERS
In testing the sugarcane juice extractor, the following parameters and formulae are
useful for and applicable to this project work (Soetan, 2008).

29
 A. AVERAGE DIAMETER (DM)
This parameter is expressed in millimeter and it is the mean of the three diameter
values obtained from the sugarcane specimen. The head and tail diameters are the
measured diameters at the two extremes of the specimen length, while the middle
diameter is the diameter measured at midlength the sugarcane specimen. Thus,
DM = Head diameter + Middle diameter + Tail diameter
____________________________________
3 ... (1)
B. EXTRACTION EFFICIENCY (ɳp) FOR
PRELIMINARY TEST
This is an estimated value expressed below as
ɳp = Weight of juice extracted in grams
85% initial weight of specimen in grams ... (2)
C. JUICE EXTRACTION EFFICIENCY (ɳj)
This is the ratio of the amount of juice extracted to that
contained in the sugarcane. This is given by the below
expression and mostly taken to be in percentage, %.
ɳj = Juice extracted (j e)
Amount of juice contained in sugarcane (j c) ... (3)
The amount of juice contained in the sugarcane is the value
obtained from the difference between the initial weight and
the bone-dry weight, that is, the weight after drying.
D. MEAN OR AVERAGE EXTRACTION EFFICIENCY
ɳa = Summation of juice extraction efficiencies, Ʃ(ɳj)
7 ... (4)

30
E. STANDARD DEVIATION (δ)
This is the square root of the ratio of the summation of the squared absolute value
of the difference of the extraction efficiency (ɳj) of a specimen and the mean (ɳa),
to the frequency of treated values (N). Mathematically,
(
√ )
δ= Ʃ ɳj −ɳa 2 ….(5)
¿¿ N

F. RATE OF JUICE EXTRACTION (ɳr)

In this case there is a function of time involved in the calculation. This is taken as
the weight in
kilograms of juice extracted per hour. This quantity is expressed in percentage, %.
ɳr = Weight of juice extracted (wj)
Time taken for the extraction (tj) ... (6)

CHAPTER FOUR
31
DEVELOPMENT AND ASSEMBLY PROCEDURE
4.0 CONSTRUCTION PROCEDURE
After designing and selection of various component parts, it is important to
carryout construction and assembly of the whole arrangement and testing, to
enable one to know if it satisfies the set down objectives and qualities required,
such tht the efficiency of the equipment can be determined.
4.1 EQUIPMENT AND TOOLS
The equipment can be conveniently manufactured in any well-equipped workshop.
The following list of item/equipment with trained operatives are needed for the
construction
OPERATION TOOLS/ USES
EQUIPMENT
Measurement Measuring tape (7.5mm) It is used to measure out
the corresponding length
of the desired
requirement.
Marking out Marking out table, straight It is used to mark out
edge ruler, try square, etc desired specification of
selected materials.
Cutting Hack saw, cutting disc. It is used to cut out the
mark out length of the
selected materials.
Welding Arc welding machine, It is used to join the
Stainless electrode. stainless materials cut
out to become a unit.
Grinding Grinding disc It is used to smoothing

32
 the surface of the welded
joint.

4.2 CONSTRUCTION
S/N PARTS OPERATION TOOLS/EQUIPMENT
1 CASING 1.2mm thick stainless Measuring tape
steel plate measured to
required length. The
measured length were
marked out
grind off the carbons at hand grinding machine with
the edges of the a grinding disc.
stainless steel plate.
Joining of the cut Electric arc welding
stainless steel plate machine with stainless
together. electrode
Smoothing of the Hand grinding machine
welded surface. with grinding disc.
2 STAND Angle iron was Measuring tape
measured to the
required length.
The measured length Try square, scriber mark
was marked out. out table
Cut the required length Hack saw
into plates
Joining the cut length Electricity welding machine

33
 to the casing. with gauge 12 electrode

4.3 ASSEMBLY PROCEDURE

When the construction of the component part had been successfully carried out, it
is necessary to assemble the parts to form a unit (equipment) readily for operation
use so as to fulfill the purpose of design and suitable for recommendation, also for
general acceptability. The construction parts for the casings were welded together,
also welded the stands to the casing for more rigidity. The two gears were
connected and the tire were fixed to the stand to make it mobilable to move from
one point to another without time wastage after all this have being done the welded
part of the machine were smoothed with the grinding disc.
4.4 MAINTAINANCE
Maintenance is an important practices that must ensured for good functioning of
the device.
The following are some checks on the machine.it is proper to always check that:
i. All part joint are tightly fitted.
ii. The sugarcane extractor machine should be clean after used.
iii. Always check for leakage on the sugarcane extractor machine when in
used.
iv. Proper control of the machine must be ensured.
4.5 PROCEDURE OF CASING FABRICATION
After the purchase of the materials from the market at owode-onirin, development
diagram for the respective sections was made. The steel plate material was then cut
to obtain the details as represented in the following figures. The required drilling
was also done on them before the major joining and assembling processes
commenced. When the cut out details are all obtained, they are folded along the

34
dash lines to take the form required for the casing. The casing work done on the
existing sugarcane juice extractor is made up of four (4) major components. These
are:
a. The top cover
b. The hopper
c. The side plate
d. The base tray

4.6 MATERIAL COST ESTIMATE

S/N COMPONENT QTY UNIT TOTAL
PRICE ₦ PRICE ₦
1 STAINLESS STEEL 1 12500 12500
SHEET (1.2mm)
2 STAINLESS STEEL 1 19500 19500
SHEET (5mm)
2 TIRE 4 1500 6000

3 2” ANGLE BAR 3 2000 6000

4 3” STAINLESS PIPE 1 1800 1800

5 STAINLESS 10 DOZEN 700 7000

ELECTRODE
6 IRON ELECTRODE 6 DOZEN 300 1800

7 CUTTER 7 900 6300

8 GRINDER 5 500 2500

9 INCHIES & LOCKER 1 PAIR 500 1000

35
10 TRANSPORT 3500 3500

11 PAINTS

TOTAL 67900

CHAPTER FIVE
CONCLUSION AND RECOMENDATIONS
36
5.0 CONCLUSION
The sugarcane juice extraction machine constructed in the Department of
Mechanical Engineering, Lagos State Polytechnic, Ikorodu, has gone through a
process of improvement from its previous state, to a better and improved state.
All the improvement on the machine is not only to enhance its aesthetic
characteristic, but also enhancement of the extraction efficiencies. Due to its
flexibility of power source, it is adaptable to the end users capability; making it a
suitable machine for its target audience – the cottage industry. To a large extent,
the work done has helped in projecting the machine once again and increasing the
attention from its observers. The machine now looks more attractive and catchy,
thereby achieving the goal of advertising this technological creativity from within
the department. With the provided isolation of the extraction process from the
surrounding, the interaction of contaminants with the extracted juice is observed to
be negligible. The crushing drum worked without getting stuck irrespective of the
casing fabrication done in the improvement of the machine.
Furthermore, with a juice extraction efficiency and rate of juice extraction values
of 65 -76% and 0.0156 l/s respectively, the machine would provide the mobile
satisfaction it is fabricated for. The improvement on the hygiene property of the
machine would go a long way in preserving the quality of the extracted juice. The
completion of this project work, which is focused on the improvement of the
machine, brings a sigh of satisfactory relief, both to the fabricator and the end user.
5.2 RECOMMENDATIONS FOR FURTHER IMPROVEMENTS
If further work is to be done on the machine, I would like to recommend the
following upgrades and adjustments to the fabricated machine.
1. Stainless steel can be used for fabricating the machine. This would help increase
the hygiene of the machine.

37
2. A sieve can be incorporated to collect small bagasse particles that make their
way out, through the juice chute or outlet, with the extracted juice.
3. Incorporate some travel wheel to aid the mobility of the machine from one area
or point to another.
4. A knifing section to cater form cutting and breaking the sugarcane before juice
extraction can be constructed.
5. the crushing drums can be made adjustable to vary the gap between the crushing
drum; i.e. varying crushing and juice extraction for various diameters of the
sugarcane being crushed.

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38
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40