DECLARATION

We declare that we have personally undertaken the project reported herein under

supervision.

DATE NAME SIGNATURE

KARIMU ABDULAI

ALHASSAN INUSAH

BAWA AZUMAH
ABUBAKARI JALEEL

ZIBLIM HUDU
SULEMAN MUSILIU

HADRAT M. HARUNA
NORBERT J.

AMOANAB

JONATHAN AKPALU

AYELIYA A. DANIEL

I declare that I have supervised the students in undertaking the project reported herein

and confirms that the students have my permission to present it for assessment.

DATE …………………………………DR P.Y. ANDOH

(SUPERVISOR)

i
 ABSTRACT
Gari is a product from processed cassava (Manihotesculenta) .Cassava is one of the
major important food crops in Ghana which contributes to the nation’s economic
growth. In processing gari, the fresh cassava tuber is peeled, washed, grated,
pressed/fermented, and pulverized/sifted and fried. The existing processing techniques
used in the production of gari in small scale is time consuming, much human involving
and labour intensive which leads to inefficient production of gari in terms of quality and
quantity.
This project is a developed alternative continues flow integrated single unit gari

processing machine that addresses these inefficiencies. Analyses were performed for

the determination of sizes and also material selection for each part of the machine. The

system was fabricated using local materials and tested for its functionality, durability

and reliability.

An industrial process in gari production by the proposed project considers alternative

modified conceptual designs to eliminate the human element and improve productivity.

Hence, this project is to design, manufacture and test a single unit continues flow gari

processing machine.

ii
 DEDICATION

This project is dedicated to the Almighty Allah who has been our strength and source of

knowledge throughout the whole process. We also dedicate this project to our parents

who have made our dreams come true.

iii
 ACKNOWLEDGEMENT

As authors of this project work, we wish to acknowledge the support of all who in

diverse ways contributed to the success of this project. We thank the Almighty God

with whose divine protection and guidance has seen us through to the successful

completion of this project work. We also acknowledge the immense contribution,

guidance and support received from the following personalities throughout the project

work,

DR P.Y. ANDOH (MAIN SUPERVISOR)

MR. P.O. TAWIAH (SECOND SUPERVISOR)

MR. KWESI KISSIEDU (T. A. TO DR. P.Y ANDOR)

EUGENE BORQUAYE (T. A. TO DR. P.Y ANDOR)

Our acknowledgement also goes to the following Institutions for permitting us to use

their Institutions for our research: Council for Scientific and Industrial Research

(CSIR), Savanna Agricultural Research Institute (SARI)-Nyankpala, Bontanga cassava

Irrigation Project.

iv
 TABLE OF CONTENT

DECLARATION ............................................................................................................... i

ABSTRACT ...................................................................................................................... ii

DEDICATION .................................................................................................................iii

ACKNOWLEDGEMENT ............................................................................................... iv

TABLE OF CONTENT .................................................................................................... v

LIST OF FIGURES ......................................................................................................... ix

LIST OF TABLES ............................................................................................................ x

CHAPTER ONE ............................................................................................................. 1

INTRODUCTION ............................................................................................................ 1

1.1 BACKGROUND INFORMATION ........................................................................... 1

1.2 REVIEW OF GARI PROCESSING ........................................................................... 3

1.3 PROBLEM STATEMENT ......................................................................................... 3

1.4 OBJECTIVES OF THIS PROJECT ........................................................................... 4

1.5 ORGANISATION AND STRUCTURE OF THE REPORT ..................................... 5

CHAPTER TWO ............................................................................................................ 6

LITERATURE REVIEW............................................................................................... 6

2.1 HISTORY OF GARI PROCESSING ......................................................................... 6

2.2 GARI PROCESSING (SMALL-SCALE) .................................................................. 6

2.3 FLOW CHART FORGARI PROCESSING OPERATIONS ................................... 11

2.4 EXISTING GARI PROCESSING MACHINES ...................................................... 12

2.4.1 THE CASSAVA GRATER.............................................................................. 12

2.4.2 THE PRESS ...................................................................................................... 13

v
 2.4.3 SIFTER.............................................................................................................. 14

2.4.4 FRYER/ROASTER .......................................................................................... 15

CHAPTER THREE ...................................................................................................... 16

METHODOLOGY........................................................................................................ 16

3.1. MATERIAL AND METHOD ................................................................................. 16

3.2. DEVELOPMENT OF CONCEPTUAL DESIGNS ................................................. 21

3.2.1. CONCEPTUAL DESIGN 1 PROCESS LAYOUT .......................................... 21

3.2.1.1. GRATER ........................................................................................................ 23

3.2.1.2 THE PRESS .................................................................................................... 24

3.2.1.3 THE SIFTER. .................................................................................................. 25

3.2.1.4 FRYER ............................................................................................................ 26

3.2.2. CONCEPTUAL DESIGN 2 PROCESS LAYOUT .......................................... 27

3.2.2.1 GRATER ......................................................................................................... 29

3.2.2.2 PRESS ............................................................................................................. 30

3.2.2.3 SIFTER ............................................................................................................ 31

3.2.2.4 FRYER ............................................................................................................ 32

3.2.3. CONCEPTUAL DESIGN 3 PROCESS LAYOUT ....................................... 33

3.2.3.1 GRATER ......................................................................................................... 35

3.2.3.2PRESS .............................................................................................................. 36

3.2.3.3 SIFTER ............................................................................................................ 37

3.2.3.4 FRYER ............................................................................................................ 38

3.3 CONCEPT EVALUATION ..................................................................................... 39

3.4 THE FINAL DESIGN............................................................................................... 42

vi
CHAPTER FOUR ......................................................................................................... 48

DESIGN SPECIFICATIONS ...................................................................................... 48

4.1 THE MAIN FRAME ................................................................................................ 48

4.2 DESIGN ANALYSIS OF THE GRATER ............................................................... 48

4.2.1 THE HOPPER .................................................................................................... 49

4.2.2 THE GRATING UNIT:...................................................................................... 50

4.2.3 Weight of the Grating Drum............................................................................... 51

4.2.4 The Discharge Unit: ........................................................................................... 52

4.2.5 THE PRIME MOVER........................................................................................ 52

4.2.6 SHAFT DESIGN ................................................................................................ 52

4.2.7 BELT DESIGN .................................................................................................. 59

4.2.8 KEY DESIGN .................................................................................................... 60

4.2.9 BEARING SELECTION ................................................................................... 63

4.3 DESIGN ANALYSIS OF THE PRESS.................................................................... 64

4.3.1 DESCRIPTION OF THE PRESS AND WORKING PRINCIPLES ................. 64

4.3.2 DESIGN CONSIDERATIONS AND CALCULATION PROCEDUERS ........ 65

4.3.3 DESIGN OF THE SCREW THREAD .............................................................. 66

4.3.4 THE DESIGN OF THE CHAIN DRIVE ........................................................... 71

4.4 DESIGN ANALYSIS OF THE SIFTER .................................................................. 74

4.4.1 HOPPER ................................................................................................................ 75

4.4.2 WEIGHT OF SIFTING BAR............................................................................. 75

4.4.3 DETERMINATION OF SIFTING TORQUE ................................................... 76

4.4.4 POWER REQUIREMENTS .............................................................................. 77

4.4 .5 SELECTION OF CHAIN AND SPROCKET .................................................. 77

4.4.6 SHAFT DESIGN ................................................................................................ 79

4.4.7 KEY DESIGN .................................................................................................... 80

vii
 4.4.8 BEARING SELECTION ................................................................................... 81

4.4.9 DESIGN ANALYSIS OF THE FRYER ............................................................ 82

4.4.10 THE HOPPER .................................................................................................. 83

4.4.11 THE FRYING CYLINDER ............................................................................. 84

4.4.12 THE HEATING CHAMBER ........................................................................... 86

4.4.13 THE CONVEYOR ........................................................................................... 89

4.4.14 CHAIN DRIVE ................................................................................................ 93

CHAPTER FIVE ........................................................................................................... 96

FABRICATION AND ASSEMBLY............................................................................ 96

5.1. INTRODUCTION ................................................................................................... 96

5.2. FABRICATION OF THE SUPPORTING STAND ................................................ 97

5.3 THE GRATER .......................................................................................................... 99

5.4 THE PRESS ............................................................................................................ 103

5.5 THE SIFTER ........................................................................................................... 106

5.6 THE FRYER ........................................................................................................... 111

CHAPTER SIX .......................................................................................................... 116

CONCLUSION ............................................................................................................. 116

6.1. CONCLUDING REMARKS ................................................................................. 116

6.2. RECOMENDATIONS........................................................................................... 116

REFERENCES ............................................................................................................ 117

APPENDIX A .............................................................................................................. 118

APPENDIX B ............................................................................................................... 124

viii
 LIST OF FIGURES

Figure 3.1 concept 1 isometric view .............................................................................. 21

Figure 3.2 concept 1 orthographic views ....................................................................... 22

Figure 3.3 Exploded view of concept 1grater ................................................................ 23

Figure 3.4 Exploded view of concept 1press ................................................................. 24

Figure 3. 5 Exploded view of concept 1sifiter ................................................................ 25

Figure 3.6 Exploded view of concept 1fryer .................................................................. 26

Figure 3.7 Isometric view of concept 2 .......................................................................... 27

Figure 3.8 Orthographic views of concept 2 .................................................................. 28

Figure 3.9 Exploded view of concept 2 grater ............................................................... 29

Figure 3.10 Exploded view of concept 2 press ............................................................... 30

Figure 3.11 Exploded view of concept 2 sifter .............................................................. 31

Figure 3.12 Exploded view of concept 2 fryer ............................................................... 32

Figure 3.13 Isometric view of concept 3 ......................................................................... 33

Figure 3.14 Orthographic views of concept 3 ................................................................. 34

Figure 3. 15 Exploded view of concept 3 grater ............................................................. 35

Figure 3.16 Exploded view of concept 3 press ............................................................... 36

Figure 3.17 Exploded view of concept 3 sifter .............................................................. 37

Figure 3.18 Exploded view of concept 3 fryer ............................................................... 38

Figure 3.19 Isometric view of the final design .............................................................. 42

Figure 3. 20 Orthographic views of the final design ...................................................... 43

ix
 LIST OF TABLES

Table 3. 1 CRITERIA FOR GRATER .......................................................................... 17

Table 3. 2 CRITERIA FOR PRESS............................................................................... 18

Table 3. 3 CRITERIA FOR SIFTER .............................................................................. 19

Table: 3.4 CRITERIA FOR FRYER ............................................................................. 20

Table 3. 5 SELECTED CONCEPTS ............................................................................. 39

Table 3. 6 DECISION MATRIX FOR GRATER .......................................................... 44

Table 3.7 DECISION MATRIX FOR PRESS .............................................................. 45

Table 3.8 DECISION MATRIX FOR SIFTER ............................................................. 46

Table 3.9 DECISION MATRIX FOR FRYER............................................................... 47

x
 CHAPTER ONE

INTRODUCTION

This chapter introduces the need for a single unit gari processing machine. It includes

the background information, problem statement, project objectives, and structure of the

report and the significance of the research.

1.1 BACKGROUND INFORMATION

Gari is a pre-cooked food obtained by processing cassava (Manihotesculenta) and is

consumed in Ghana and other African states such as Nigeria, Togo, Benin, etc. It is a

fine grain and can be made into breads, crackers and pancakes.. Average area cropped

per year between 1999 and 2004 was about 750,000 hectares, with the primary

producers being the Eastern, Brong-Ahafo, and Ashanti regions. Total annual output of

cassava during the same period was about 10 million metric tons.(MOFA).The cassava

has an economic life of 8months -10 years,( K. E. Kolabi, 2010), but can be harvested

8months after planting. The average urban consumer prefers gari because it is a pre-

cooked food product. It serves us a source of food for almost all students in the boarding

schools. Due to its high consumption rate, the traditional methods employed to process

it does not meet the market demand.figure1.1 below shows pictures of fresh cassava

tubers.

Cassava tubers (Abubakari Garden, Bole)

1
Table 1: Typical composition of a cassava tuber

Constituent Percentage

Moisture ………............ 70 %

Starch …………………… 24 %

Fiber……………………… 2 %

Protein …………………..1 %

Other ……………………..3 %

Source: www.csir.org.gh

The traditional method of producing gari is that; fresh cassava is peeled, wash and cut

into small pieces. It is then grated and collected into sacks and press to drain the liquid.

It is allowed to ferment for two to three days. The fermented grated cassava is then

pulverized (sifted). The fine grated cassava which is still in the moist state is then fried

and dried to obtained gari.(pictures of gari are shown in below)

Gari (Mandari Women group gari processing centre, Bole District)

2
1.2 REVIEW OF GARI PROCESSING

The peeling of cassava, the first stage in cassava processing in general, remains a bottle

neck. Hand-peeling is slow and labour-intensive though it yields the best results.

Attempts made to mechanize cassava peeling as a means to increase the production rate

and minimize labour intensity have met only with marginal success (Ayernor, 1981).

The existing methods of grating cassava include manual, mechanized wooden and steel

framed graters. The grating process is far from standardized. It is the step that

establishes the granulation and the particular nature of the gari products;. Industrial

processes need to standardize this mechanical operation to ensure particulate uniformity

of the product. The existing methods of pressing involve the use of weights such as

stones, logs, metals, and screwed presses. The existing frying includes the use of frying

pan and rotating drum roasters. Traditionally gari is fried by women in shallow

earthenware of cast iron pans over a wood fire. This manual method of processing gari

is time-consuming, inefficient, unhygienic and labour intensive.

1.3 PROBLEM STATEMENT

The demand for small-scale gari processing machines has developed from the use of

manual methods to the use of stand-alone machines which has serious challenges. Even

though modern and advance technologies have gone into gari processing machines,

much attention has not been given to making the processes involve in gari processing

continuous through integration of the machines. Environmental influence on the

traditional method of gari processing, presents organizational, hygienic, quality and

safety challenges to the country (Ghana) and Africa as a whole. Existing technologies

have developed unit machines for unit operations. Therefore challenges associated with

3
the handling of the gari through the processes are extant. These challenges include; too

much human involvement, delays in processes, and high cost of stand-alone machines.

In view of the set objectives of this project and the inherent problems associated with

the existing methods of gari processing, there is therefore the need to designed and

manufacture a single unit gari processing machine that incorporates all the separate

processes.

1.4 OBJECTIVES OF THIS PROJECT

The general objective of this project is to analyze the existing gari processing machine

designs and come out with an integrated continuous flow gari processing machine.

The main objective of this project is to produce a detailed description of the various

processes involve in the existing processing methods , the type of machinery and

equipment required and their performance and energy consumption.

The specific objectives are:

 To produce conceptual designs for the grater, press, sifter, and fryer/roaster.

 To provide design analysis for the grater, sifter and fryer/roaster for small scale

gari processing plant

 To construct and test the all-in-one gari processing machine to effectively

processed an average of 1,000 – 1,600kg of gari per hour.

4
1.5 ORGANISATION AND STRUCTURE OF THE REPORT

This project is structured to consider various concepts of gari processing machines

evaluate them and come out with the best workable concept. Literature researches based

on books red, the internet and as well as visits to small- scale gari processing centers are

captured in the literature review. Analysis and design specifications are also considered

as well as fabrication and testing of prototype. Most tables and production drawings are

captured in the appendices but these includes references for further research.

Chapter one presents the general introduction, problem statement, objectives and

organization of the report. Chapter two reviews existing literature that absolutely deals

with discussions and review of related literature. The third chapter presents the

methodology. It contains the material and method, development of conceptual designs,

evaluation and selection of final design.

Chapter four composes of the design analysis and cost estimation of materials used in

the construction of the design. Chapter five presents the various techniques of

fabrication employed in the construction of the various components of the final design.

The sixth chapter presents the conclusion and recommendations of the final design.

5
 CHAPTER TWO

LITERATURE REVIEW

This chapter reviews the previous attempts to unify the separate machines for gari

processing including how the processing industry has come so far. It includes proposed

modifications to the present day design with regard to the present situation in Ghana.

2.1 HISTORY OF GARI PROCESSING

Gari is a product from processed cassava (manihotesculenta). Cassava is perhaps the

most important food crop in Ghana. The cassava tuber is produced in all regions, except

for two in the northern part of the country. Average area cropped per year between 1999

and 2004 was about 750,000 hectares, with the primary producers being the Eastern,

Brong-Ahafo, and Ashanti regions. Total annual output of cassava during the same

period was about 10 million metric tons, (MOFA). The cassava crop is perceived to

generate extensive farm and non-farm linkages for rural development, being utilized in

various forms. Apart from cooking the fresh root, it can be processed into gari

(fermented cassava dough), tapioca (toasted starch), and cassava flour (crude and

refined). All these products are used for human consumption.(Accessed 30th January,

2008, Nweke, 2004a).

2.2 GARI PROCESSING (SMALL-SCALE)

The results of research and modifications in many industrial disciplines and the

availability of raw material, which provided the opportunity for small-scale fully

mechanized processing evolved a sequence of processing steps designed to process

cassava in to an acceptable quality gari for domestic use and for the local markets. Gari
6
processing starts with fresh cassava from farm where it is carried to the processing

centre.The cassava tuber is then peeled, washed, grated, pressed/fermented,

pulverized/sifted and fried.

Fresh cassava tubers (Iddrisu farm, Mandari –Bole)

Peeling

Peeling is done using a traditional method, a simple knife or machete is used to peel the

cassava, a new skill is exhibited in the process of peeling, there is always caution in the

entire peeling process. The style of peeling aids in removing the cassava covering and

not the edible part of the tuber. The advantage is that washing the peeled tubers requires

limited use of water before grating is done.

Traditional way of peeling cassava (source: Nantegari processing centre, 2010).

7
Washing

The peeled cassava is placed in large basins and then washed with water. This is

thoroughly done to remove traces of dirt before grating. The washing of the peeled

cassava is expected to clean the dirt and reduce the possible infestation of pathogens

comprising of fungal, viral, and bacterial pathogens, insects, and nematodes. The

washed cassava is then ready for grating using various methods from traditional to

modern rural and appropriate technologies available. Figure 2.3 shows the local means

of washing peeled cassava tubers before grating.

Traditional method of washing cassava (mandarin women cassava processing centre,

Bole District)

Grating

Traditionally the cassava grater was made by perforating any metal-like tin to grate the

peeled cassava. This applies force and friction in the process to grate the cassava as

shown in Fig 2.4a. However, with the advent of intermediate technologies, various

methods have been improved and used by processors at the household level. The mobile

and stationery-grating unit have taking over the grating of peeled cassava at this level.

Grating is done by powering the grater with a horsepower diesel or petrol engine, which

8
is controlled by a steering wheel at the right side of the grater by turning to push the

cassava tuber in the hopper (as shown below)

Traditional means of grating cassava Improved grating method

Pressing (Draining of water from grated dough)

The grated dough is put in sacks and tightened hard. It is then squeezed underweights

such as stones and logs or a specially made press. The aim is to squeeze and drain liquid

matter in the dough. To be able to drain the water, the press is periodically tightened as

and when the water is reduced. It could take an average of three days to dry and finish

pressing the cassava dough. This depended on the type of press being used by the client.

Cassava starch is the starting point for so many important industrial products such as

dextrin, glucose syrup, etc. Cassava starch is preferred amongst other types because of

its good gelling property.

Traditionally, cassava starch is produced by first washing the peeled root manually and

then grating to produce starch milk from which the fiber is separated through special

strainers or sieved through muslin cloth and washed thoroughly and the starch will then

collect and settle down.

9
 Local way of pressing Improved pressing method

.(Jekayinfa And Olajide, 2007).

Sifting (sieving dried dough)

After the water has been pressed out and the dough squeezed, it becomes compact or

hard. The compact matter is then sifted by the use of a sieve that is made of palm

branches or metal that is perforated. This is done when a fire shed was ready and large

frying pans, which could be clay made or metal prepared for frying the cassava

granules.

Sifting ( Ayishatu, Damango)

10
Frying (Gari making)

The sifted cassava dough is the ready for drying through a frying/roasting process that

could take thirty minutes to two hours (even more time) depending on the hotness of the

frying pans, the quantity of the dried cassava being fried, the skills and techniques being

used.

Local way of frying (Yagbon Women group, Damango)

2.3 FLOW CHART FORGARI PROCESSING OPERATIONS

The flow chart indicates the flow of cassava tuber through the various processing units

to the last processor to obtain gari. It consist of the fresh cassava tubers, manual peeling

of the cassava, grating of the peeled cassava, pressing the dough, sifting the squeezed

dough, frying and drying of the sifted cassava.

Fresh cassava
tubers
Grating Pressing Sifting Frying

Peeling
Peelingand
washing
Sieving

11
2.4 EXISTING GARI PROCESSING MACHINES

Several attempts to improving gari production have resulted into the manufacture of

separate mechanized machines for the various processes involved in the gari production.

2.4.1 THE CASSAVA GRATER

The current design consists basically of 3 units: the hopper unit, the grating drum and

the delivery channel. All these components are mounted on an angle iron frame. The

machine assembly is powered mechanically. It can be use in rural settlements where

electricity supply might not be in existence. Apart from faster grating rate, it required

less human involvement. The grating drum is made of metallic pipe that carries a

perforated plate which served as the grater. This overcomes the problem faced in the

wooden grating drum. (mohammed B. Ndaliman).

Conventional type Mobile type

Cassava grater

(GERALD KOJO AHORBO IFAD, CONSULTANT, SEPTEMBER 2008)

12
2.4.2 THE PRESS

The cassava presses are equipment used to de-water the grated cassava. There are two

main types of cassava presses: the single screw press and the double screw press. The

double screw press is found with most of the users because of the capacity(350kg/batch)

and its suitability for pressing three to four big bags of grated cassava at a time. They

are robust and manually operated. The single screw press requires one person to operate

while the double screw press requires two persons to operate.

Single screw press double screw press

Screw press

(GERALD KOJO AHORBO IFAD, CONSULTANT, SEPTEMBER 2008)

13
2.4.3 SIFTER

The gari sifter is a vibrating sieve that separates the gari through one discharge spout

and the roughage through another spout. It is powered by a 5.5HP motor and operated

by one person. It is fabricated from mild and stainless steel and has a capacity of

1000kg/hr. The cassava dough/gari sifter sieves disintegrated cassava dough or gari by

the shaking (or oscillating) action of a wooden box sieve filled with the material to be

sifted. It has a capacity of 250kg/hr and operated manually by a person.

Gari sifter Cassava dough/gari sifter

(GERALD KOJO AHORBO IFAD, CONSULTANT, SEPTEMBER 2008)

14
2.4.4 FRYER/ROASTER

Roasting and drying are combined in the “frying” of the gari. At village level, gari is

fried in shallow cast-iron pans, or in the more traditional areas in earthenware pans, over

an open wood fire. The sieved cassava mash is spread thinly in the pan in 2-3kg batches.

A piece of calabash is often used to press the mash against the hot surface of the pan but

scraped quickly and stirred constantly to keep the material moving to prevent it from

burning until frying is completed when it reaches a temperature of 80° to 85°C. The

rapid heating partially gelatinizes the gari which is dried during the operation of frying.

The process takes 30-35 minutes, with the moisture content of the final product reduced

to about 18%.

Fryers in a traditional mode in Nigear

We have observed that, the various processes and machines in the production of gari

need to be reconsidered and restructured by making the process continuous, eliminating

human factors and replacing with a machine that incorporates all the various processes

to meet the growing demand for the commodity in Ghana and beyond.

15
 CHAPTER THREE

METHODOLOGY

This chapter talks about the proposed conceptual designs and how the final design was

selected.

3.1. MATERIAL AND METHOD

The main methods used for this project are literature review of the internet and library

on gari processing, consultations and interactions with local gari producers and group

brainstorming to arrive at conceptual designs, and the evaluation of the conceptual

designs for the selection of one for further analysis.

Reading of text books and other related literature from the internet revealed the

application of basic principles of science on many processes and equipment. The use of

friction in grating the cassava, application of pressure to dewater the dough, the use of

vibration to disintegrate the compacted dough and heat at high temperature to fry the

gari.

The conceptual designs of the various processing machines were evaluated based on

general evaluation criteria such as cost, safety, maintenance and accessibility, and

specific criteria related to a particular machine. The evaluation criteria for selection are

as follows:

16
 Table 3.1 CRITERIA FOR GRATER

PARAMETE NUMBER TYPES OF SHAPES NUMBER OF EASE OF

RS OF PARTS FASTENERS ASSEMBLY

MAGNI S MAGNITUDE S MAGNIT S MAGNITU S

TUDE C C UDE C DE C
O O O O
R R R R
E E E E
1– 10 5 CYLIDRICAL 5 1-10 5 VERY 5
EASY

11-20 4 RECTANGUL 4 11-20 4 EASY 4

AR

21-30 3 HEMISPHERI 3 21-30 3 FAIRLY 3

CAL EASY
/
CYLINDRICA
L
31-40 2 CONICAL 2 31-40 2 DIFFICUL 2
T

41 & 1 SPHERICAL 1 41 & 1 VERY 1

ABOVE ABOVE DIFFICUL
T

17
 Table: 2.3 CRITERIA FOR PRESS

PARAM NUMBER OF TYPES OF NUMBER OF EASE OF

ETERS PARTS SHAPES FASTENERS ASSEMBLY

MAGNITUDE S MAGNITUDE S MAGNITUDE S MAGNITUDE S

C C C C
O O O O
R R R R
E E E E
1– 10 5 CYLIDRICAL 5 1-10 5 VERY EASY 5

11-20 4 RECTANGUL 4 11-20 4 EASY 4

AR

21-30 3 HEMISPHERI 3 21-30 3 FAIRLY 3

CAL EASY
/
CYLINDRICA
L
31-40 2 CONICAL 2 31-40 2 DIFFICULT 2

41 & ABOVE 1 SPHERICAL 1 41 & ABOVE 1 VERY 1

DIFFICULT

18
Table 3Table:3. 3 CRITERIA FOR SIFTER

PARAM NUMBER OF TYPES OF NUMBER OF EASE OF

ETERS PARTS SHAPES FASTENERS ASSEMBLY

MAGNITU S MAGNITUD S MAGNITUD S MAGNITU S

DE C E C E C DE C
O O O O
R R R R
E E E E
1- 10 5 CYLIDRICA 5 1-10 5 VERY 5
L EASY

11-20 4 RECTANGU 4 11-20 4 EASY 4

LAR

21-30 3 PYRAMID 3 21-30 3 FAIRLY 3

EASY

31-40 2 CONICAL 2 31-40 2 DIFFICUL 2

T

41 & 1 SPHERICAL 1 41 & 1 VERY 1

ABOVE ABOVE DIFFICUL
T

19
 Table 4Table: 3.4 CRITERIA FOR FRYER

PARAME NUMBER OF TYPES OF NUMBER OF EASE OF

TERS PARTS SHAPES FASTENERS ASSEMBLY

MAGNITU S MAGNITUDE S MAGNITU S MAGNITUD S

DE C C DE C E C
O O O O
R R R R
E E E E
1- 10 5 CYLIDRICAL 5 1-10 5 VERY 5
EASY

11-20 4 RECTANGUL 4 11-20 4 EASY 4

AR

21-30 3 HEMISPHERI 3 21-30 3 FAIRLY 3

CAL EASY
/
CYLINDRICA
L
31-40 2 CONICAL 2 31-40 2 DIFFICULT 2

41 & 1 SPHERICAL 1 41 & 1 VERY 1

ABOVE ABOVE DIFFICULT

After the consideration and selection of the final design based on the evaluation criteria,

the selected machine components were designed using Microsoft word and AutoCAD.

20
3.2. DEVELOPMENT OF CONCEPTUAL DESIGNS

Conceptual designs were established for the facility layout and associated machines.

These machines include the grater, press, sifter and fryer. In all, three concepts were

generated based on their construction, orientation and the type of drive.

3.2.1. CONCEPTUAL DESIGN 1 PROCESS LAYOUT

Figure : 3.1. Concept 1 isometric view

21
Figure: 3. 2 concept 1 orthographic views

22
3.2.1.1. GRATER

This design consist ot a rectangular hopper partly covered at the top, which houses the

grating drum. The grating drum is made of a cylindrical wooden drum with saw teeth

grating blades mounted on the surface. The grating drum is provided with a horizontal

shaft rotating on two pillow bearings mounted on an angle iron framed table. The

throughput is 900kg of cassava per hour.

Figure: 3. 3 Exploded view of concept 1grater

23
3.2.1.2 THE PRESS

The screw press consists of the following:

Hopper, conveyor screw, cylindrical net, shaft spring, spring guide (stopper), bearing

and rectangular plate. The press is powered by a prime mover, which causes the

horizontal screw to turn at the range of 6 to 30 rpm. The screw is designed so that it

squeezes the dough that is dropped into the screw press, the length of the conveyor

screw is surrounded by a cylindrical net and the water is squeezed out of the cassava

dough by the screw press through the drain. The residual fiber (dough), which are called

the press cake are pushed to the far end of the machine by the screw, forcing the spring

to give way for the dough to come out through the delivery chute.

Figure: 3. 4Exploded view of concept 1press

24
3.2.1.3 THE SIFTER.

The sifter comprises of the following:

The housing, the beater, the bearing, the delivery chute. The sifter is been driven by a

prime mover which cause the horizontal rotating beater to disintegrate the pressed

cassava dough into a granular form, and forces it through the delivery chute as the result

of rotation of the shaft.

Figure: 3.5 Exploded view of concept 1sifiter

25
3.2.1.4 FRYER

This consists of three units; these include conveyor, the heating chamber, and the frying

cylinder. The conveying of sifted cassava from the entrance through the frying to the

exit point is achieved by an arrangement of conveyor blades and scooping blades

oppositely fixed on the circumference of the conveyor’s shaft. The heating consist of

three burners in a specified rectangular container whose sides are air tight to ensure no

leakage of flame. The burner has a regulator. This is expected to heat the frying cylinder

up to about 690c. heat is allowed to heat to heat up the cylinder from it. The top of the

cylinder has rectangular opening to allow for ventilation and inspection during frying.

There is an opening at the bottom end of the heating part of the cylinder for discharge of

dry gari into basin.

Figure: 3.6 Exploded view of concept 1fryer

26
3.2.2. CONCEPTUAL DESIGN 2 PROCESS LAYOUT

Figure:3.7 . Isometric view of concept 2

27
Figure: 3.8Orthographic views of concept 2

28
3.2.2.1 GRATER

The grating drum (ф10cmx30cm long) is made of cylindrical mild steel pipe

wrapped with a grating plate, which is a perforated flat metal galvanized or

stainless steel sheet. The grating drum is mounted on a horizontal shaft which

connects it to the prime- mover by a V-belt drive. A feed hopper with a cover is

mounted on top of the grating drum and cassava tubers are fed at a regular rate

and in the process of the grater rotating the cassava is grated. The grated cassava

is collected below the grating unit. The throughput is 1tonne of cassava per hour.

Figure: 3.9Exploded view of concept 2 grater

29
3.2.2.2 PRESS

The press is made up of a tapered screw conveyor which is place inside a perforated

cylindrical mesh with uniform diameter. As the grated cassava is conveyed along the

length of the conveyor, it is squeezed against the mesh forming a compacted mass at the

tail end of the conveyor. This mass is delivered through the opening at the end. The

conveyor and the mesh arrangement is housed between the top cover which has a

hopper at the top to receive grated cassava and the base which has an opening at the

extreme end which serves as drainage for squeezed liquid. The conveyor runs on two

pillow bearings mounted at each end of the shaft.

Figure: 3.10 Exploded view of concept 2 press

30
3.2.2.3 SIFTER

The design is based on the concept that sifting is by rubbing the cassava mash on two

surfaces .the design of the concave canopy is such that there is decreasing gap exist

between the brushes and the concave canopy with a maximum clearance of 75mm at the

top. This allows the mash fed into the hopper flows down the sifting chamber. The

clearance decrease as the sifting unit moves to the concave canopy. It then increases

gradually to a clearance of 1.5mm at the bottom where the sifting unit (brushes) rubs the

mash against the sieve, thus effecting sifting. The particle of the sifted mash that are the

same sizes as the sieve passes through while the bigger ones which are the ungraded

cassava roots parts and fibers are retained and conveyed to the residue collecting trough

by the sifting unit which also serves as auger

Figure: 3.11 Exploded view of concept 2 sifter

31
3.2.2.4 FRYER

The fryer consists of two bevel gears that are meshed to transmit drive from driver shaft

which has a pulley and driven shaft which has a stirrer blade attached at the lower end.

The stirrer unit is enclosed in a cylindrical housing which has a thick circular plate

welded circumferentially onto the housing just underneath the stirrer blade.

The thick plate separates the frying chamber from the heating chamber. The frying

chamber has a discharge gate to discharge fried gari.

The heating chamber also has an opening for the supply of heat. The horizontal shaft is

driven by a motor which in turn is transferred to the vertical shaft through the gearing

arrangement. The horizontal shaft (driver) runs on a pillow bearing whiles the vertical

shaft (driven) runs on thrust bearing.

Figure: 3. 12 Exploded view of concept 2 fryer

32
3.2.3. CONCEPTUAL DESIGN 3 PROCESS LAYOUT

Figure: 3. 13 Isometric view of concept 3

33
Figure: 3. 14 Orthographic views of concept 3

34
3.2.3.1 GRATER

This design consists of circular hopper housing the grating unit. The grating is done by a

disc the surface of which has its surface covered with pointed projections (teeth) . The

disc is rotating on a vertical shaft driven by a belt drive. The peeled cassava is fed

through the hopper into the grater. The cassava is self-fed under gravity onto the grating

disc. And the grated cassava exits at the outlet. The throughput is 800kg of cassava per

hour.

Figure: 3.15 Exploded view of concept 3 grater

35
3.2.3.2PRESS

This consists of a rotating drum made of steel cylinder suspended on two roller

bearings. It is enclosed by a steel plate housing perforated right beneath the rotating

drum. The perforation is to allow for drainage of the liquid.

The grated cassava enters the press at the top opening. The rotating drum then presses it

against the inclined wall of the housing. The liquid escapes through the holes under the

drum. As the drum rotates it pushes the pressed cassava dough through the outlet.

Figure: 3.16 Exploded view of concept 3 press

36
3.2.3.3 SIFTER

This comprises of a sieve and a cam shaft mounted horizontally on two bearings. The

cam shaft converts a rotary motion from a prime mover, into a reciprocating motion of

the hinged sieve. This to and fro movement of the sieve causes the pressed cassava to

disintegrate and fall through its holes into the fryer chute.

Figure: 3. 17 Exploded view of concept 3 sifter

37
3.2.3.4 FRYER

This consists of a collector, frying unit and an outlet. The frying comprises of a

cylindrical unit with a coiled path inside it, and then a heating coil.

The sifted cassava dough enters the fryer through the collector. The coiled path carries

the dough round while it is being fried. Before it gets to the outlet, it is completely fried

into gari.

Figure: 3. 18 Exploded view of concept 3 fryer

38
3.3 CONCEPT EVALUATION

The concepts were evaluated on the criteria of manufacturability, weight, ease

assembly, and source of energy. These criteria (objectives) for evaluation are ranked

equally and hence have equal weight with the each other objective.

The final concept was chosen based on the evaluation and analysis of the concepts.

Table: 3. 5 SELECTED CONCEPTS

COMPONENT CHOSEN REMARKS

CONCEPT

Chosen base on design: simplicity and highest score.

Grater 2
A throughput of 50 to 60kg/h
Optimum is met.
The press by its tapered screw Conveyor design

conveys the grated cassava as well as squeezes it

Press 2 along the length of the conveyor , forming

Compacted mass at the tail end, making the process

continuous and smooth compared to other concepts

Sifting is done using friction and by the process a

Sifter 1 very fine particles are sieved out.

Also base on highest score

The heat supplied for frying needs to be regulated

Fryer 1 and this concept gives efficient heat regulation and

scores higher compared with other concepts.

39
Grater

Press

40
Sifter

Fryer

41
3.4 THE FINAL DESIGN

Based on the scores awarded in the evaluation of the various units, the grating unit, the

press and the sifter of conceptual design 2 were selected. While the fryer selected from

conceptual design 1. Putting these selected units together, the final design is as follows.

Figure: 3.19 Isometric view of the final design

42
Figure: 3.20 Orthographic views of the final design

43
 Table 6Table:3. 6 DECISION MATRIX FOR GRATER

OBJECTIVE INITIAL EASE EASE OF EASE OF TOT

COST MANUFACTURE MAINTENANCE ASSEMBLY AL
WEIGHT 0.25 0.25 0.25 0.25 SCO
PARAMETE NUMBER OF TYPE OF SHAPES NUMBER OF EASE OF RE
RS PARTS FASTENERS ASSEMBLY
MA S V MAGNIT S VA MAG SC VA MAG SC VAL
GNI C AL UDE C LU NITU OR LU NITU OR UE
TU O UE O E DE E E DE E
DE R R
E E
CONCEPT 1 22 3 0.7 RECTAN 4 1.0 14 4 1.0 FAIL 3 1.00 3.75
5 GULAR 0 0 Y
EASY
CONCEPT 2 14 4 1.0 RECTAN 4 1.0 10 5 1.2 EASY 4 1.00 4.25
0 GULAR 0 5
CONCEPT 3 9 5 1.2 CONICA 3 0.7 5 5 1.2 VERY 5 1.25 4.50
5 L 5 5 EASY
/
CYLIND
RICAL

44
 Table 7Table: 3.7 DECISION MATRIX FOR PRESS

OBJECTIVE INITIAL EASE EASE OF EASE OF TOTA

COST MANUFACTU MAINTENAN ASSEMBLY L
RE CE SCOR
WEIG 0.25 0.25 0.25 0.25 E
HT
PARAMETER NUMBER OF TYPE OF NUMBER OF EASE OF
S PARTS SHAPES FATENERS ASSEMBLY

M S VAL MAGN S VA MA S VA MAGN S VAL

A C UE ITUDE C LU GNI C LU ITUDE C UE
G O OE TUD O E O
N R R E R R
I E E E E
T
U
D
E
CONCEPT 1 1 4 1.00 CYLIN 5 1.2 10 5 1.2 FAIRL 3 0.75 4.25
3 DRICA 5 5 Y
L EASY
CONCEPT 2 1 5 1.25 CYLIN 5 1.2 10 5 1.2 EASY 4 1.00 4.75
0 DRICA 5 5
L
CONCEPT 3 7 5 1.25 RECT 4 1.0 4 5 1.0 VERY 5 1.25 4.50
ANGU 0 0 EASY
LAAR

45
 Table 8Table: 3.8 DECISION MATRIX FOR SIFTER

WEIG 0.25 0.25 0.25 0.25 TOTAL

HT SCORE
PARA NUMBER OF TYPE OF NUMBER OF EASE OF
METE PARTS SHAPES FATENERS ASSEMBLY
RS
M S VALU M S VA M S VAL MAG S VALU
A C E A C LUE A C UE NITU C E
G O G O G O DE O
NI R N R N R R
TU E I E I E E
DE T T
U U
D D
E E
CONC 10 5 1.25 C 5 1.25 8 5 1.25 VERY 5 1.25 5.00
EPT 1 Y EASY
L
I
N
D
R
I
C
A
L
CONC 10 5 1.25 C 5 1.25 1 5 1.25 VERY 5 1.25 5.00
EPT 2 Y 0 EASY
L
I
N
D
R
I
C
A
L
CONC 12 4 1.00 P 3 0.75 1 4 1.00 FAIR 3 0.75 3.50
EPT 3 Y 2 LY
R EASY
A
M
I
D

46
 Table 9Table:3.9 DECISION MATRIX FOR FRYER

OBJE INITIAL COST EASE EASE OF EASE OF TO

CTIV MANUFACTU MAINTENANC ASSEMBLT TA
E RE E L
WEIG 0.25 0.25 0.25 0.25 SC
HT OR
PARA NUMBER OF TYPE OF NUMBER OF EASE OF E
METE PARTS SHAPES FATENERS ASSEMBLY
RS
MAG S VAL MAG S VA MA SC VA MA SC VAL
NITU C UE NITU C LU GNI O LU GNI O UE
DE O DE O E TUD RE E TUD RE
R R E E
E E
CON 11 4 1.00 REC 4 1.00 6 5 1.25 EAS 4 1.00 4.25
CEPT TAN Y
1 GUL
AR
CON 12 4 1.00 CYLI 5 1.25 6 5 1.25 FAI 3 0.75 4.25
CEPT NDRI RLY
2 CAL EAS
Y
CON 5 5 1.25 CYLI 5 1.25 4 5 1.25 VER 5 1.25 5.00
CEPT NDRI Y
3 CAL EAS
Y

47
 CHAPTER FOUR

DESIGN SPECIFICATIONS

This chapter summarizes the design of the critical components of the chosen grater,

press, sifter and fryer concepts with their stress analysis and the specification of the

non-critical components.

4.1 THE MAIN FRAME

The main frame supports the entire weight of the machine. The two design factors

considered in determining the material required for the frame are weight and strength.

The main frame is constructed with 1½ ″ by 1½ ″ angle iron. The angle irons are welded

together to form the frame work. The welding provides very rigid joints. This is in line

with the modern trend of providing rigid frames. This provides the strength and rigidity

for the overall machine.

4.2 DESIGN ANALYSIS OF THE GRATER

In the design of the grater, the following were considered;

I. Sizing of the shaft

II. Design of the pulley and determination of transmitted speed

III. Specification of prime mover (driver)

IV. Selection of bearings

V. Choice of belt

VI. Capacity of hopper (Inlet chute)

48
VII. Volume of the cylindrical pipe

VIII. Force needed for grating

IX. Process capacity

X. Shear force and bending moment on the shaft

XI. Selection of materials for the various components of the machine.

4.2.1 THE HOPPER

The hopper is designed to be fed in a vertical position only. The material used for the

construction is mild steel (AISI 1020 CD, Syt of 352 MPa) sheet metal, which is readily

available in the market and relatively affordable. The hopper has the shape of a

hexagonal pyramid
W
L

Volume of hopper (V h )

Vh = 1/3 xAbxH ------------------------------------------------------------------- (4.1 )

Where Ab = base area

49
 H = height

From appendix B the volume of hopper is 0.006m3

4.2.2 THE GRATING UNIT:

This unit consists of the shaft, perforated mesh, rolled sheet, circular discs and rivet

pins. The grating drum will be formed by the shaft passing through the rolled cylindrical

sheet and it will be welded in place by circular discs. This drum is then wrapped with

the perforated mesh by riveting.

Weight of Pulley:

The weight of pulley on a shaft can be determined as follows:

Weight of pulley, Wp=mg, with

Where;

V=A x LP= [ ] x LP

m=ρ x [ ] x LP

Therefore, WP= ρ x= [ ] x LP x g

Where LP= Length of pulley

The resulting weight of the pulley from computation is FEY= 81.863N which is exerted

vertically. Horizontal weight on the pulley; FEX= .=0.1425KN

The Pacific Journal of Science and Technology –124–

http://www.akamaiuniversity.us/PJST.htm Volume 12. Number 2. November 2011

(Fall)
50
4.2.3 Weight of the Grating Drum

The grating drum is modeled as a hollow cylindrical drum. The material to be used for

the production of the drum is the mild steel with a density of 7860kg/m3 and the

perforated mesh is stainless steel with a density of 7930kg/m3 .

Weight of Drum is given as,

Wd =m g, ………………………………………………………(4.2)

where

m= ρ V,

ρ = Density of the Material

For Stainless steel, 7930kg/m3

For Mild steel, 7860kg/m3

g= Acceleration due to gravity

V= [Volume of The two Circular plates + Volume of the Rolled Steel Sheet +
Volume of Perforated Mesh]

Volume of pipe, Vp = πΔr2h

Volume of Circular Disc, Vd = πΔr2h

The resulting weight of the drum from appendix B is 1.174N. This weight acts at the

centre of the grater shaft.

The cassava weight under consideration to be grated at a time is of equivalent mass of

10 kg and a weight of 100 N.

The total weight (WT) is therefore 101.174 N (0.101174kN).

51
 4.2.4 The Discharge Unit:
The discharge unit is connected at the lower end of the hopper. It directs the flow of the
grated cassava to the press.

4.2.5 THE PRIME MOVER

A 5.0hp petrol engine is used to power the machine. A pulley is used to transmit power

to the grater’s drum at reduced speed and increased torque. This enables the drum to

exhibit rotary motion thereby grating the cassava.

4.2.6 SHAFT DESIGN

Shaft design consists primarily of the determination of the correct shaft diameter to

ensure satisfactory strength and rigidity when the shaft is transmitting power under

various operating and loading conditions. Shafts are either solid or hollow. The

following presentation is based on shafts of ductile materials and circular cross-section.

The length of the shaft has been pre-determined at 400mm.

PULLEY
SPROCKET BEARING GRATING DRUM BEARING

Y RBY
WTY
RBX
A RDY
WTX
B FEX
RDX
FAX C
FAY
D
FEY

E
100mm
100mm
100mm
100mm
52
Properties of the selected material

The properties of the steel are: Sy = 572 MPa, Su = 813 MPa and the percent elongation

is 19%.

Assumptions

Since the material has a good ductility, estimate the Sn = 290 MPa. Although we do not

know the actual size at this time, we might select Cs = 0.80. For this problem, lets

design for a reliability of 0.99 and use CR = 0.81. The design factor is taken to be N = 3.

The endurance strength is then computed as:

S‫׳‬n= SnCsCR ……………………………………………………….(4.3)

From appendix B, the endurance strength is 187.92MPa

Computation for the torque in the shaft: T= ………………………..(4.4)

From appendix B, the torque in the shaft 0.03562kN.m

53
Forces:

Forces due to Chain and Sprocket:

FA= ………………………………………………………………..(4.5)

F =F CosӨ
AX C

F =F SinӨ
AY C

The torque is computed as and the torque is determined as

0.035619 KN.m. The equivalent forces are determined as FA=0.7124kN,

FAX=0.3085kN, and FAY=0.617kN

54
 Reactions at the Bearings Due to Vertical Loading(yz):

Below is represented the expected free body diagram of vertical forces acting on the
FAY FEY
shaft;

0.1m 0.1m 0.1m 0.1m

WTY RDY
RBY
To obtain the reactions at each bearing, we will have to take moment about the two

expected bearing points independently.

For YZ plane, ∑MD =0; [- 0.617( 0.3)+0.2RBY -0.1012(0.1) +0.0819(0.1)]=0

Therefore, RBY=0.9352KN;

Also ∑FY=0; [-0.617+0.9352-0.1012+RDY-0.0819] =0; RDY=-0.1351KN

Reaction at the Bearings Due to Horizontal Loading

Below is represented the expected free body diagram of horizontal forces acting on the

shaft
FEX
FAX
0.1m 0.2m 0.1m

RBX RDX

55
 Using the FEX and FAX horizontal forces, we then obtained the horizontal reactions at the

bearings by taking the moments about the two bearing points independently.

For YZ plane, ∑MD=0; [-0.3085(0.3)+0.2RBX+0.1425(0.1)]=0; RBX=0.3915KN

∑FX=0; [-0.3085+0.3915+RDX-0.1425]; RDX=0.0595KN

0.3085KN 0.1425KN 0.617KN 0.1012KN0.1351KN 0.0819KN

0.1m 0.2m 0.1m 0.1m 0.1m 0.1m 0.1m

0.9352KN
0.3915KN 0.0595KN

-0.03085KN
0.0617KN
0.0082KN
0.01425KN 0.0299KN

XZ PLANE YZ PLANE

Bending Moment and Shear force diagrams of the grater shaft in the xz and yz plan

56
SIZING THE SHAFT

From the shear force and bending moment diagrams the maximum moment that induces

stress and bending in the shaft is 0.016445 KNm. The diameter of the shaft can be

determined by:

D= [ √ ( ) ]

The stress concentration factor for a well-rounded fillet is 1.0 with a safety factor of 3.0.

By substitution, the shaft’s diameter is determined as 25.0 mm

Deflection of the Shaft

The angle of twist was computed from the relation;

Ø= ……………………………………………………………….(4.7)

Where:

T- is the torque subjected on the shaft?

J- polar moment of inertia

G -Youngs Modulus of rigidity

57
Speed Transmission

The transmission system consists of a pulley system reducing the motor speed by a

Note: Dr = Diameter of the driver pulley = 100mm

Dd = Diameter of the driven pulley =250mm

Therefore speed ratio is 1:2.5

In determining the horse power, a motor speed of 1000rpm was selected.

Power Transmission

The velocities ratio of the motor pulley/driver pulley and the drum pulley/ driven pulley

is calculated mathematically, as shown below:

Let Nr = Speed of the driver in r.p.m. =2500 rpm

Nd = Speed of the driven in r.p.m. = 1000rpm

Length of the belt that passes over the driver, in one minute = π DrNr

=785.4m

Similarly, length of the belt that passes over the follower, in one minute

= π Dd Nd

58
= 785.4m

Since the length of belt that passes over the driver in one minute is equal to the length of

belt that passes over the follower in one minute, therefore

Dr Nr = ɳ Dd Nd …………………………………………………………(4.8)

Where ɳ=1

4.2.7 BELT DESIGN

Dr Dd

Determination of Centre Distance (C)

Rubber Manufacturing Association(RMA) recommended that the centre distance is

dictated by other considerations as follows:

For speed ratios less than three:

……………………………………………………………..(4.9)

From appendix B, C= 275mm

For speed ratios of 3 or more, C = D

59
Length of Belt

In order to compute the length of the belt required, we use the formula below

…………………………………………….(4.10)

C = Distance between the center of the two pulleys

L = Length of Belt Required

From appendix B, the length of the belt is1120mm

Angle of Contact on Driver Belt Sheave

This is the lap angle of the belt over the motor’s pulley:

……………………………………………….(4.11)

Where;

( )

4.2.8 KEY DESIGN

The function of a key is to prevent relative rotation of a shaft and the member to which

it is connected. Different types of keys are available, the choice of which is dependent

on power requirements, tightness of fit, stability of connection and cost. A flat

rectangular key was adopted, as this is used where added stability is desired.

For a good result, the width of a key is made one-quarter the diameter of the shaft. The

thickness of a key for equal strength of the key in failure by shearing of the key, and

60
compression on the key may be determined by the corresponding allowable stresses in

shear and compressions.

The length of the key can be calculated as;

……………………………………………………….(4.12)

This length is less than the width of the hub of the sprocket and pulley. The design of the

shaft includes retaining rings on both sides of the sprocket. It is desirable to keep the

key-seat well clear of the ring grooves. Therefore, a specified length of 12mm key is

specified.

The forces on the top and bottom of the key resist tipping of the key, and the force, F,

between the side of the key and the key way in the hub is due to the resisting torque,

Where:

T '= resisting torque; F = resisting force;

d = diameter of shaft; L = length of key.

From standard tables, for a 25mm diameter shaft, the key dimension is given as;

width (W), 6.25 mm. For a torque of 0.035619K Nm, a factor of safety of 3 and yield

strength of 352MPa, the length of the key is determined as 12mm. In summary, the key

has the following characteristics:

61
 w  31.5.25
mm
mm… 3812mm
.1mm

……… 76 mm
20mm
…. 31 . 75 x 31 . 75 x 38 . 1 key
.25× .25×12 key

 mm
6.25mm
3.125mm

 mm
21.875m


m
Details of the completed design

Material: AISI 1020 CD steel

Width: 6.25 mm

Height 6.25 mm

Length 12 mm

62
4.2.9 BEARING SELECTION

The bearing was selected based on its load carrying capacity, life expectancy and

reliability. The relationship between the basic rating life, the basic dynamic rating and

the bearing load is:

P………………………………………………………(4.13)

But , therefore,

Where:

L10 = life of bearing for 90% survival at one million revolutions;

L = required life of bearing in million revolutions; n = rotational speed (rev/min);

C = basic dynamic load rating (N); P = equivalent dynamic bearing load (N);

K = exponent for life equation with: K = 3 for ball bearing;

K = 10/3 for roller bearing.

The bearing selected for the grater is the roller bearing.

63
Summary of Bearing Selection

Bearing Number: 6205

Bearing Series Number: 6200

Basic dynamic load rating (C): 10.81 kN

Bearing Weight: 1.29 N

Bearing bore: 25mm

4.3 DESIGN ANALYSIS OF THE PRESS

4.3.1 DESCRIPTION OF THE PRESS AND WORKING PRINCIPLES

The screw press consists of the following:

The hopper, tapped conveyor screw, cylindrical net, bearing and cylindrical housing

with a chute and drain. The press is powered by a prime mover, which causes the

horizontal tapped conveyor screw to turn at the range of 6 to 30 rpm. The screw is

designed so that it squeezes the dough that is dropped into the screw press, the length

of the conveyor screw is surrounded by a cylindrical net and the water is squeezed out of

the cassava dough by the screw press through the drain. The residual fibers (dough),

which are called the press cake, are pushed to the far end of the press by the worm shaft,

forcing the dough to come out through the delivery chute.

64
 4.3.2 DESIGN CONSIDERATIONS AND CALCULATION PROCEDUERS

Design considerations

In designing the machine the following where considered: high extraction of water, high

extraction efficiency of about 84% lower extraction of about 70%,compartability of

cassava dough, quality of cake, availability and cost of construction materials. Other

factors included the desire to design the cylindrical barrel to accommodate the required

quantity of dough, the design of the tapped worm shaft to ensure maximum conveyance

and efficient pressing of dough, and the design of main frame must be structurally

strong and stable to support the machine.

Design calculations

SCREW PRESS DESIGN

Known factors

1. Shaft diameter, ds =25mm

2. Shaft speed, N= 20rpm

3. common difference between next successive screw depth d = -2.5mm

4. screw depth at the feed end a =25mm

5. number of screw turns n = 9

6. Screw pitch, Ps = 50mm

7. Diameter of screw thread, Ds = 100mm

The tapered worm shaft is the main component of the press which is being driven by the

grater as a result the dough is being processed. In operation the worm shaft Conveys and

65
pressed the dough from the inlet as it rotates and in the process squeezed it through the

outlet chute. Therefore, in order to safe guide against bending and torsional stresses, the

diameter of the shaft was pre-determined and the torque is calculated as

4.3.3 DESIGN OF THE SCREW THREAD

The worm shaft is basically a tapered screw conveyor with the volumetric displacement

being decreased from the feed end of the housing to discharge end. This subjected the

dough to pressure as the shaft rotates forward by the screwing process. The worm

threading system was designed as a step up shaft diameter and decreasing screw depth

using the expression in Eqn. 2.

Un= a + (n-1) d …………………………………………………………..(4.14)

Where:

Un =screw depth at discharge end

a = screw depth at the feed end

n = number of screw turns

d = common difference between next successive screw depth.

Substituting in the values in to equation 4.15 gives the screw depth at the discharge

end as 5mm.

Determination of theoretical screw volume per pitch

The theoretical screw volume is given by

66
Vs= area x pitch …………………………………………………. ( 4.15)

Where D1=inside diameter of housing, D2outside diameter of housing and S = screw

pitch

From appendix B, the theoretical screw volume is 7.85 x 10-5m3

Determination of mass flow rate

mass flow rate is dependent on product density, theoretical screw volume per pitch, and

speed of screw and filling

ṁ= Vs ……………………………………………………………………………………….. (4.16)

where Vs= theoretical screw volume, n= speed, = density of cassava mash, =filling

ratio of screw.

From appendix B, the mass flow rate is calculated to be 1.06kg/s

Determination of drive power

this is dependent on flow rate, gravity, displacement, length, resistance.

Neglecting gravitational effects, the drive power is calculated from the formula,

Drive power = ṁ x L x fi/ɳ …………………………………….. ( 4.17)

Where L= Length, fi= displacement factor, ɳ = worm/screw efficiency

From tables, fi =1.9, ɳ =0.79

From appendix B the drive power is calculated as 1.27kW

67
Worm shaft power

The worm shaft is given by the formula

Ps= ɳ …………………………………………………………………… ( 4.18 )

From appendix B the worm shaft will transmit 1.61kW of power

The worm shaft will transmit 1.61kW of power

Torque

The torque is calculated as

T= ……………………………………………………………….(4.19)

T= =768.72Nm

The load that can be lifted by worm shaft

The load that can be lifted by the worm shaft was determined from the equation given

by Hall et al (1961) as :

We = T ………………………………………………………. (4.20)

Where:

Ws = the load that can be lifted by the worm shaft

T = torque transmitted by the worm shaft

Dm = the mean thread diameter

68
 Of friction

But

Where n = the thread angle = tapering angle

= 14.98

Substituting in the values in equation (4.19) gives

We = 768.72 x

= 37.8KN

From appendix B the load that can be lifted by the worm shaft is calculated as 37.8KN

The pressure developed by the worm shaft

The pressure and the pressing area developed by the worm shaft where determine by

Hall et al, 1961 as

Pr = ………………………………………………………….. (4.21)

AP = m nh

Where:

Pr = the pressure developed by the worm thread

AP = the pressing area

h = the worm depth at the maximum pressure (at the discharge end)

69
n = number of worms

AP = = 10602.88mm2

Substituting in the values into equation (4.21) gives

Pr = = 3.57N/mm2

From appendix B the pressure developed by the worm shaft is 3.57N/mm2

Pressure of the housing

The pressure that can withstand by the housing was determined by the equation given by

Ryder (1984) and Khurmi and Gupta (2008) as

Pb = ……………………………………………………………. (4.22)

Where:

Ph = the pressure to be withstand by the housing

t = the thickness of the housing =5mm

a= the allowable stress = 0.27x yield stress of mild steel (200N/mm2) = 54N/mm2

Di =inside diameter of housing

Substituting the values into equation (4.23) gives

Pb = = 5.4N/mm2 or 5.4 MPa

From appendix B the pressure to withstand the housing is 5.4 MPa

70
The capacity of the press

The theoretical capacity of the press was determined using a modified of the equation

given by Onwualu et al.(2006) as:

Qp = 60 - ps NS ………………………………………………(4.23)

Where:

Qp = the theoretical capacity of the shaft

Ds = the diameter of the worm thread

ds = the base diameter the worm shaft

ps = the worm pitch

Ns = the rotational speed of the worm shaft

= the filling factor

the bulk density of cassava dough

From appendix B the capacity of the press is 122.36kg/h

4.3.4 THE DESIGN OF THE CHAIN DRIVE

The drive system consists of design specification of the chain number, lubrication type

and the sprocket diameter to ensure optimum power and transmission. We specify a

service factor of 1.4 with the drive been mechanical drive of an internal combustion

engine and under a moderate shock. The shaft requires 880.54kw (1.18hp). The design

power is given as:

71
Design power =service factor the required of the shaft ……………………(4.24)

The desired speed ratio is given as,

Speed Ratio = …………………………………………………………..(4.25)

Where = input speed, = output speed

From appendix B, the Speed ratio is calculated to be 2.0

From tables of design power and speed, a single strand roller, no. 40 chain with pitch

12.7mm standard chain seems best for the drive. A 15-toothsprocket rated 0.07hp at

10rpm is selected since there is no power column for 20rpm. At this speed, type II

lubrication (oil bath) is recommended.

The required number of teeth on the large sprocket N2 is calculated to be 30 teeth in

appendix B by the relation

N2=speed ratio x N1 ………………………………………………..(4.26)

The actual expected output speed is calculated to be 20rpm in appendix B by the

relation = …………………………………………………(4.27)

The pitch diameter of the small sprocket is calculated to be 61.1mm in appendix B by

the relation

D1 = ………….……………………………………….(4.28)

72
The pitch diameter of the large sprocket is calculated to be 121.5mm in appendix B by

the relation

D2 = ……………………………………………………(4.29)

For the nominal centre distance, 40 pitches, which is the middle of the recommended

range, is selected.

The required chain length in pitches is given as

L =[ ⁄ ] ……………………(4.30)

From appendix B, L is calculated to be 102.6 pitches, and 102 pitches, which is an even

number, is selected.

The actual theoretical centre distance is calculated as

C= [ √[ ] ] …(4.31)

And found to be 39.7 pitches (504.2mm)

73
 Summary of the design

Pitch P: 12.7mm

Length L: 102 pitches = 1295.4mm

Single strand sprockets

Lubrication: Type I
504.2mm
m

Input speed: 40rpm Output speed: 20rpm

No. of teeth N1 = 15 teeth No. of teeth N2 = 30 teeth
Pitch diameter D1 = 61.1mm Pitch diameter D2 = 121.5mm

4.4 DESIGN ANALYSIS OF THE SIFTER

Assumptions

1. It is assume that the shaft is uniform throughout.

The major components the sifter includes the hopper, sifting drum, sifting unit (shaft

and brushes), sieve, find granules outlet and ungraded outlet. In the design of the sifter

the following are considered;

1. Volume of hopper

2. Sizing of the shaft

3. Weight of the sifting brushes

4. Selection of chain and sprocket

5. Bending and shearing force on the shaft

74
4.4.1 HOPPER

The hopper feed pressed cassava mash into the sifter. The shape of the hopper is like a

truncated rectangular pyramid. Stainless steel plate is recommended for its construction.

Stainless is more hygienic and resist corrosion hence its selection. The hopper is attach

to the top of the sifting cylinder. The pressed cassava mash feeds into the sifting

cylinder by gravity. W
L

Volume of hopper (V h )

Vh = 1/3 xAbxH ------------------------------------------------------------ (4.32 )

Where Ab = base area

H = height

From appendix B the volume of hopper is 0.003m3

4.4.2 WEIGHT OF SIFTING BAR

The sifting bar is cylindrical in shape. The material to use in its production is mild steel

AISI 1020 CD with sy of 352Mpa.

75
Weight of the sifting is giving by

W = mg ……………………………………………………………(4.33)

Where m = mass of sifting bar

g = acceleration due to gravity.

The mass of the bar is giving by m = ρ x v

The volume of the sifting bar is giving by

V = π ( ro ─ ri) x L. …………………………………………………..(4.34)

Where ro = outer radius

ri = internal radius.

From appendix B the weight of sifting bar is 398.5N.Tthis weight acts at the centroid

of the sifter shaft.

4.4.3 DETERMINATION OF SIFTING TORQUE

The torque T is giving by ;

T = F x r ………………………………………………………….(4.35)

Where F = force available on the sifting bar

r = sifting bar radius

from appendix B the sifting torque is 10.62Nm

76
4.4.4 POWER REQUIREMENTS

The sifter receives drive from the grater. The power required by the sifting shaft is

giving by;

P = F x V ----------------------------------------------------------------------- (4.36 )

Where F = sifting force

V = velocity

From appendix B the power required by the grater is 445.38w (0.6hp)

4.4 .5 SELECTION OF CHAIN AND SPROCKET

The drive system consist of the design specifications of the chain number lubrication

type and sprocket diameter to ensure optimum power, torque and transmission. We

specify a service factor of 1.4 with the being a petrol engine and under moderate shock.

The shaft requires 0.445kw (0.6hp). The design power is giving as ;

Design power = factor of safety x power required by shaft.

From appendix B the design power is 1335W or 1.3KW

The speed ratio is computed from the relation ;

Speed ratio = driver speed/driven speed --------------------------------- (4.37)

From appendix B the desired ratio is 2.5

77
From tables of designed power and speed, the standard chain that fit the drive is selected

as a no 40; 127cm pitch standard single- strand roller with 13teeth (N1) and type II

lubrication. The required no of teeth on the larger sprocket, N2 is computed using N2 =

speed ratio x N1 -------------------------------- (4.38)

The actual expected output speed of the sifter is n2 = n1 (N1/N2) --------- (4.39 )

From appendix B the actual expected output speed is 406rpm

The pitch diameter of the smaller sprocket is computed as ;

D1 = p/sin(180/N1) ---------------------------------------------------------- (4.40 )

From appendix B the pitch diameter of the smaller sprocket is 53mm

Where p = pitch

The pitch diameter of the larger sprocket is computed as ;

D2 = p/ sin(180/N2) -------------------------------------------------------- (4.41)

From appendix B the pitch diameter of the larger sprocket is 129.5mm

The normal center distance between the sprockets is 40 pitches(508mm) by

specification.

The length L, of the belt using the center distance is computed from the formular

L = [2C + ½(N2 + N1) + (N2 ─ N1)2/4π2C] pitches ----------------------(4.42)

From appendix B the length of the belt is 102.7 pitches

An integral no of pitches of 102 is selected.

78
Summary of the design

Pitch P : 12.7mm

Length L : 102 pitches = 1295mm

Single strand sprockets

Lubrication: Type

508mm

Input speed: 1000rpm Output speed: 40rpm

No. of teeth N1 = 13 teeth No. of teeth N2 = 32 teeth
Pitch diameter D1 = 53mm Pitch diameter D2 = 129.5mm

4.4.6 SHAFT DESIGN

Shaft design consist primarily of the determination of the correct shaft diameter to

ensure satisfactory strength and rigidity when the shaft is transmitting power under

various operating and loading conditions. Shafts are either solid or hollow. The

following presentation is based on shafts ductile materials and circular cross-sections.

The length of the shaft is predetermined at 600.0mm.

The diameter of the shaft is computed as

d = 36.59(p/τsN)0.33mm…………………………………………………..(4.43)
Where p = power
τ = shear stress
N = speed

79
Table: shows allowable shear stress for shafts

Service condition τs (Mpa)

Heavily loaded short shaft carrying no axial load 48-106
Multiple bearing long shaft s carrying no axial load 13-22
Axially loaded shafts (bevel gear drive or helical 8-10
gear drive)
Shafts working under heavy overloads(stone crushes, 4.5-5.3
etc).
The material from which the shaft will be machined, selected from standard table is

AISI 1020 with tensile yield strength of 352Mpa cold drawn and ultimate tensile

strength 470Mpa and hardness Brinell of 122 and 15% elongation(ductile).the stress

concentration factor for a well rounded fillet is 1.5 with a safety factor of 3.0.The shaft

diameter is given by d= 36.5(P/τN)0.33. From appendix B the shaft diameter is 25.0mm

4.4.7 KEY DESIGN

The function of a key is to prevent relative rotation of shaft and the member to which it

is connected.

Different types of keys are available , the choice of which is dependent on power

requirements , tightness of fit stability of connection and cost. A flat rectangular key was

adopted, as this is used where added stability is desired. For a good results , the width of

a key is made one quarter the diameter of the shaft. The thigkness of a key for equal

strength of the key in failure by shearing of the key , and compression on the key may

be determined by the corresponding allowable stress in shear and compression.

The length of the key can be calculated as L = 4TN/DWSy--------------- (4.44)

80
Where T = toque

N = speed

D = diameter

W = width

Sy = yield stregth

The forces on the top and bottom of the key resist tipping off the key, and the force F,

between the side of the key and keyway in the hub is due to the resisting torque T,

T = Fd/2 = 10.62Nm

From standard tables , for 25mm diameter shaft, the key dimension is giving as;

width(W), 6.35mm. for a torque of 10.62Nm, a factor of safety of 2.5 and yield strength

of 352Mpa, the length of the key is determined as L = 4 x 10.62 x 4oo/0.025 x0.006

x352

4.4.8 BEARING SELECTION

The bearing is selected based on its load carrying capacity, life expectancy and

reliability. The relationship between the basic rating life, the basic dynamic rating and

the bearing load is;

C = (L/L10)1/kP ------------------------------------------------------------- (4.45)

(C/P)k = L/L10

But L = 60n/106million revolutions,

81
Therefore L10 = (106/60n) x (C/P)k

Where C = basic dynamic load rating (N)

L10= life of bearing for 90% survival at one million revolutions

L = required life of bearing in million revolution

N = rotational speed(rev/min)

K = exponent for life equation with

K = 3 for ball bearings and

K = 10/3 for roller bearings

The bearing selected for the sifter is the single –row , deep groove Conrad –type ball
bearing with a bore of 25mm.

Summary of bearing selection

Bearing No-6205

Bearing bore- 40mm

Basic dynamic load rating(C): 10.81kN

Bearing weight 1.29N

4.4.9 DESIGN ANALYSIS OF THE FRYER

The major components of the fryer concept chosen includes; the hopper, frame support,

sprocket and drain, spiral conveyor Shaft, heating chamber, Frying cylinder, discharge

funnel, Bearings, Thermometer, gas cylinder, control valve and knob, and then hose.

In the design of the fryer, the following were considered

82
1. Capacity of hopper

2. Volume of the frying cylinder

3. Heat needed for the frying

4. Force needed to convey the sifted cassava granules

5. Determination of speed and horse power required

6. Design of the screw shaft Conveyor

7. Design of the chain drive

8. Selection of Materials for the various components

4.4.10 THE HOPPER

The function of the hopper is to feed sifted cassava granules into the fryer. The shape of

the hopper is like a truncated rectangular pyramid. Stainless steel plate is recommended

for its construction to prevent rusting due to the acid contained in the cassava juice.

The hopper is welded on top of the frying cylinder so that gravitational force can act on

the sifted cassava. The hopper uses a cam and follower mechanism to close and open the

passage per cycle of operation.

Hopper volume
Volume of 0.0126m3 Cassava mash is needed to pass through the hopper in 5 times.

The Volume of the hopper is given as,

Vh = ⁄ x Ab x H……………………………………………………………….(4.46)

Where, Ab = Base area, H = vertical height

83
 W

But Base area,

Ab = L x W

Where L = Base length and W = Base width

From Appendix B the volume of the hopper is 0.00253m3

Number of times the mass passes through the hopper, N is given as

N= ………………………………………………… (4.47)

4.4.11 THE FRYING CYLINDER

The frying cylinder is where the frying of the gari takes place. Stainless steel is

recommended for its construction in order to preset rust due to the acid in the cassava

Juice, and also to make the gari more hygienic.

The cylinder is heated from underneath to a temperature of 60 by heat generated from

the heating chamber.

84
The top of the cylinder has rectangular openings for ventilation inspection of gari during

frying.

Size of the frying cylinder

The cylinder is sized based on the assumption that necessary evaporation space is

required above the mash in the cylinder.

The volume of the cylinder, (Vc) is determined as follows.

Vc = 2
………………………………………………………………………………(4.48)
h

Where r = radius of the cylinder h = length of the cylinder

From Appendix B, the volume of the frying cylinder is 0.05m3

The Area of cylinder, Ac is given as;

Ac = 2 rh+ 2 r2 ………………………………………………………………..(4.49)

From Appendix B the area of the frying cylinder is found to be 1.01m2

85
Volume of cassava mash in the cylinder

It is assumed that the cassava mash in the cylinder is 1/3 the volume of the cylinder.

Thus:

Volume of mash,

Vm = ⁄ Vc …………………………………………………….…………………(4.50)

From Appendix B, Vm is 0. 017m3

The density of cassava mash ( increases from 1239 to 1509kgm3 when it is

dehydrated from 51.8 to 6.0(wet basis)

Mass of the cassava mash

The mass of the cassava mash m is given as;

m= v ………………………………………………………………………………(4.51)

From Appendix B the mass is 25.65kg

4.4.12 THE HEATING CHAMBER

The heating chamber is to generate the heat required by the frying cylinder (60 ) for

frying. The heating chamber comprises of three the temp burners fixed in a rectangular

container with control valve for regulating. The walls of the container are lagged to

reduce the amount heat loss.

86
Heat Required For the Frying

Quantity of heat required, Q is given as;

Q =mc T …………………………………………………………………….(4.52)

where m= mass of cassava mash in the cylinder

c= specific heat capacity of the mash

T = temperature range

Given specific heat capacity of the mash (1. 59J/kg ), the quantity of heat required is

calculated to be 2447.01 W in Appendix B.

Time required for the frying

Rate of transfer of Heat is given as;

………………………………………………………………(4.53)

where K = thermal conductivity of the mash

Ac = Surface area of the cylinder

T2 = cylinder temperature

T1 = ambient temperature

L = thickness of the mash in the cylinder

87
From Appendix B, the time required for the frying is 20 seconds

Force required in conveying the mash

Fx = ………………………………………………………………….. (4.54)

Where m = mass of the mash

= angular velocity of the mash being conveyed

But =

Where = speed of the shaft in revolutions per minute

Linear velocity is given as

V = ……………………………………………………………………………..(4.55)

Where x is the distance travelled by the mash.

From Appendix B, the sifted mash is conveyed by a force of at a velocity of 0.

075m/s.

Frictional force is given as

Fr = N …………………………………………………………………………(4.56)

Where = Co-efficient of friction of the mash

N = Normal force acting on the mash

88
From Appendix B, the Frictional force is 120.56N

The total force in the cylinder is found as

∑ = Fx + Fr ………………………………………………………………………(4.56)

From Appendix B, the total force is 127.76N

Power required

The power required to drive the fryer is given as

P= …………………………………………………………………………………(4.57)

Where W = Work done t= time taken

and

W= ∑ .X………………………………………………………………………………..(4.58)

Where X is the distance covered by the mash.

From Appendix B, the Work done in conveying the mash over the length of the frying

cylinder is 207.21Nm and the power required is 9.582W or 0.013hp.

4.4.13 THE CONVEYOR

The spiral conveyor shaft conveys the sifted granules from the entrance, through the

frying cylinder to the discharge point. There are ten scooping blades oppositely fixed in

the conveying screw on the circumference of the shaft.

89
 Screw
Pitch
Worm diameter

Shaft diameter

Scoopers
Known factors

1. Material to be conveyed is cassava mash

2. Maximum size of hard lumps is 35mm

3. Angle of screw conveyor with the horizontal=50

Diameter of the shaft

The diameter of the shaft is given as

……………………………………………………..(4.59)

Where P=power=, n= shaft speed = allowable shear stress for shaft

From appendix B, the diameter of the shaft calculated to be 19mm

The Size Of The Screw Conveyor

The size of the screw conveyor depends on two factors

1. The capacity of the conveyor

2. The lump size of the material to be conveyed (maximum dimensions of the particle).

90
The allowable size of a lump in a screw conveyor is a function of the radial clearance

between the outside diameter of central pipe and the radius of the inside of the screw

trough, as well as the proportion of the lumps in the mixture

The lump size of the material affects the selection of the screw diameter which should

be at least 12 times larger than the lump size of a sized material and 4 times larger than

the largest lump of an un-sized material.

In the situation at hand, we are considering a mixture of lumps and fines in which not

more than 10% are lumps ranging from maximum size to one-half of the maximum, and

90% are lumps smaller than one-half of the maximum size.

A maximum lump size of35mm will therefore give us a screw diameter of 140mm.

The screw pitch

Normally standard screw pitch is taken equal to the diameter of the screw, D. however;

it may range from 0.75 to 1.0 times the diameter of the screw.

In this case we select a pitch equal to the screw diameter which is 140mm.

Speed of the Screw conveyor:

The usual range of speed of screw conveyor is 10 to 165rpm. It depends on the diameter

of screw and the type of material.

91
Considering the screw diameter of 140mm, and the material, a speed of16rpm will be

appropriate.

The loading efficiency

The value of loading efficiency should be taken large for materials which are free

flowing and non abrasive, while for materials which are not free flowing and or abrasive

in nature, the value should be taken low:

Ψ = 0.12 to 0.15 for abrasive material

= 0.25 to 0.3 for mildly abrasive material

= 0.4 to 0.45 for non abrasive free flowing materials

For the situation at hand, the materials are non abrasive free flowing in which case the

maximum value of loading efficiency is 45.

Inclination Factor:

The inclination factor C is determined by the angle of screw conveyor with the

horizontal. From tables, an angle of 50 corresponds to inclination factor of 0.9

0° 5° 10° 15° 20°

Angle of screw with the horizontal

Value of factor C 1 0.9 0.8 0.7 0.65

92
 Summary of the design

 Speed, n=16rpm

 Screw diameter, D=150mm

 Screw Pitch, p=140mm

 Conveyor screw length, L=500mm

 loading efficiency, Ψ=0.4 to 0.45 for non abrasive free flowing materials

 Inclination factor = 0.9

4.4.14 CHAIN DRIVE

The drive system consists of the design of specification of the chain number, lubrication

type, and sprocket diameter to ensure optimum power, torque and transmission. We

specify a service factor of 1.4 with the drive been a petrol engine and under a moderate

shock. The shaft requires 0.013hp. The design power is given as;

Design / maximum power = service factor x power required

Design / maximum power = 1.4 x 0.013 = 0.018 hp

The power that can drive the fryer shaft without failure is

The desired speed ratio is given as,

Speed Ratio =

Where = input speed, = output speed

From appendix B, the Speed ratio is calculated to be 1.25

93
From tables of design power and speed, a single strand roller, no. 40 chain with pitch

12.7mm standard chain seems best for the drive. A 15-toothsprocket rated 0.07hp at

10rpm is selected since there is no power column for 16rpm. At this speed, type II

lubrication (oil bath) is recommended.

The required number of teeth on the large sprocket N2 is calculated to be 20 teeth in

appendix B by the relation N2=speed ratio x N1

The actual expected output speed is calculated to be 15rpm in appendix B by the relation

The pitch diameter of the small sprocket is calculated to be 61.1mm in appendix B by

the relation

D1 = …………………………………………………….(4.60)

The pitch diameter of the large sprocket is calculated to be 81.2mm in appendix B by

the relation

D2 = ……………………………………………………(4.61)

For the nominal centre distance, 40 pitches, which is the middle of the recommended
range, is selected.

The required chain length in pitches is given as

L =[ ⁄ ] ………………………(4.62)

94
From appendix B, L is calculated to be 57.52 pitches, and 58 pitches, which is an even

number, is selected.

The actual theoretical centre distance is calculated as

C= [ √[ ] ] ….(4.63)

And found to be 20.4 pitches (259.1mm)

Summary of the design

Pitch P : 12.7mm

Length L : 58 pitches = 736.6mm

Single strand sprockets

Lubrication: Type I

508mm

Input speed: 20rpm Output speed: 16rpm

No. of teeth N1 = 15 teeth No. of teeth N2 = 20 teeth
Pitch diameter D1 = 61.1mm Pitch diameter D2 = 81.2mm

95
 CHAPTER FIVE

FABRICATION AND ASSEMBLY

This chapter presents a summary of the fabrication and assembly of a prototype of the

grater, the press, the sifter and the fryer.

5.1. INTRODUCTION

In design and manufacture, it is worthy to have a prototype of the design. This is where

the proposed designs are checked to see if they can be manufactured with the available

technology and changes made to suit the manufacturing process. The ideal design

proposed in chapter 4 is modified as seen fit during the manufacturing process to save

time, money and as well make use of available technology. The fabrication was divided

into five sections namely: supporting stand, the grater assembly, the press assembly,

sifter assembly, and fryer assembly. Actual production drawings can be found in

Appendix C.

96
5.2. FABRICATION OF THE SUPPORTING STAND

NO. OPERATION QTY MATERIAL PART TOOLS/EQUIPMENT

1. Mark and cut a 4 38.1mm legs Tape measure, power
length of 1200mm angle iron hacksaw
2. Mark and cut a 3 “ “ “
length of 950mm
3 Mark and cut a 2 “ “ “
length of 700mm
4 Mark and cut a 3 “ “ “
length of 500mm
5 Mark and cut a 2 “ Top brace “
length of 700mm (lateral)
6 Mark and cut a 2 “ “ ”
length of 260mm
7 Mark and cut a 4 “ “ “
length of 350mm
8 Mark and cut a 2 “ Top brace “
length of 300mm (traverse)
9 Mark and cut a 1 “ “ “
length of 380mm
10 Mark and cut a 3 “ “ “
length of 620mm
11 Mark and cut a 2 “ “ “
length of 1600mm
12 Mark and cut a 4 “ Diagonal “
length of 1200mm Brace
13 Mark and cut a 2 “ Middle “
length of 254mm brace
(lateral)
14 Mark and cut a 4 “ “ “

97
 length of 344mm
15 Mark and cut a 2 “ Middle “
length of 294mm brace
(traverse)
16 Mark and cut a 2 “ “ “
length of 614mm
17 Mark and cut a 1 “ “ “
length of 154mm
18 Assemble the parts Mild steel Support Arc Welding machine,
into electrode stand sub- Chipping hammer
Four units by assemblies Try square
welding
19 Assemble the four 1 Bolt and nuts Complete spanners
units by bolt and support
nuts stand

98
5.3 THE GRATER

PART LIST FOR GRATER

PART NAME DIMENSION(MM) QTY MATERIAL

Hopper 200X300X300 1 Mild Steel

Shaft 1 Mild Steel

Drum 1 Stainless Steel

Pulley 1 Cast Iron

Bearings 2 Cast Iron

Perforated Mesh 1 Stainless Steel

OPERATION SEQUENCE FOR GRATER

NO. OPERATION QTY MATERIAL PART TOOLS/EQUIPMENT

1. Mark and cut a 2 2mm mild Hopper Steel rule, hand shears,
trapezoidal shape steel plate plates scriber
of opposing
lengths 300mm
and 200mm at
400mm apart
2. Mark and cut a 2 “ “ “
trapezoidal shape
of opposing
lengths 200mm
and 100mm at
400mm apart
3 Mark and cut a 2 “ Grating “

99
 length of 200mm x chamber
100mm plates
4 Mark and cut a 2 “ “ “
length of 100mm x
100mm
5 Mark and cut a slot 2 “ “ Steel rule, scriber,
of 28mm x 50mm chisel, hammer
in the 100 x100mm
plates
6 Assemble the 1 Mild steel Hopper Arc Welding machine,
hopper plates by electrode sub- Chipping hammer
0
welding at 90 to assembly Try square
each other
7 Assemble the 1 Mild steel Grating Arc Welding machine,
grating chamber electrode unit sub- Chipping hammer
plates by welding assembly Try square
at 900 to each other
8 Weld the grating 1 Mild steel Hopper Arc Welding machine,
chamber sub- electrode Chipping hammer
assembly to the
bottom of the
hopper sub-
assembly
9 Mark and cut a 1 2mm Mild Grating Tape measure, hand
length of 314.2mm steel plate drum plate shears, scriber
x 190mm
10 Roll and weld the 1 “ Drum pipe Rolling machine, Arc
plate along the Welding machine,
314.2mm to form a Chipping hammer
perfect cylinder
11 Mark and Cut a 2 “ Drum pipe Dividers, Chisel,

100
 circular plate of end covers hammer
diameter 100mm
12 Drill a 25mm 2 “ “ Pillar drilling machine,
diameter hole at 25mm Drill bit
the Centre of the
plate
13 Weld the circular 2 “ Grating Welding machine,
plates at the ends drum Chipping hammer
of the drum pipe
14 Obtain and 1 Grater Centre lathe, vernier
machine a shaft shaft calipers, tape measure
shaft down to
x 400mm
15 Insert the shaft into 1 Mild steel Drum arc welding machine,
the grating drum electrode assembly chipping hammer,
such that it over steel rule
laps 105mm at
both ends and weld
it to the end plates
16 Mark and cut a 1 Stainless Grating Hand shears
length 314.2mm steel plate
x190mm and
perforate it to
obtain a rough
surface at one side
17 Wrap the grating 1 Riveting Grating Hand drill, riveting
plate around the pins drum machine, bench vice
grating drum with
the rough surface
on top and rivet it
to the drum

101
18 Mount the grating 2 Pillow Grating Spanners, grease gun
drum shaft onto the bearings, unit Spirit level.
support stand with size 13 bolt
no. 6205 pillow and nuts
bearings
19 Cover the grating 1 size 13 bolt “ Spanners
drum with the and nuts
hopper and fasten
it to the support
stand
20 Obtain and mount 1 Drive Hammer, spirit level
a
sprocket and
pulley at
the opposite ends
of the shaft.

102
5.4 THE PRESS

Table PART LIST FOR THE PRESS

PART NAME DIMENSION(MM) QTY MATERIAL

1
Hopper 280x180x200 Mild steel
1
Tapered conveyor Stainless steel
screw
1
Cylindrical net 205; L=500 Stainless steel
2
Bearing Cast iron
1
Cylindrical housing 212; L=500 Stainless steel
1
Shaft ; L=800 mild steel

OPERATION SEQUENCE FOR PRESS

NO. OPERATION QTY MATERIAL PART TOOLS/EQUIPMENT

1. Mark and cut a 2 2mm mild Hopper Steel rule, hand shears,
trapezoidal shape steel plate plates scriber
of opposing
lengths 200mm
and 100mm at
240mm apart
2. Mark and cut a 2 “ “ “
trapezoidal shape
of opposing
lengths 120mm
and 80mm at
240mm apart
3 Assemble the 1 Mild steel Hopper Arc Welding machine,
hopper plates by electrode Chipping hammer
welding at 900 to Try square

103
 each other
4 Mark and cut a 1 2mm Mild Cylindrical Tape measure, hand
length of steel plate housing plate shears, scriber
383.4.0mm x
500mm
5 Roll and weld the 1 “ Cylindrical Rolling machine, Arc
plate along the housing Welding machine,
383.4mm to form Chipping hammer
a cylindrical
shape
6 Mark and cut a 1 2mm Mild Cylindrical Tape measure, hand
length of steel plate net plate shears, scriber
373.4.0mm x
500mm
7 Mark and Drill 1 “ “ Electric hand drill,
holes at drill bit, steel
5mm intervals rule scriber
over the entire
surface of the
plate
8 Roll and weld the 1 “ Cylindrical Rolling machine, Arc
plate along the net Welding machine,
373.4mm to form Chipping hammer
a cylindrical
shape
9 Suspend the net 2mm Mild Cylindrical Spanners
in the cylindrical steel plate, housing and
housing with 3 size 10mm net
flanges bolt and nuts
10 Mark and Cut a 2 “ Housing end Dividers, Chisel,
circular plate of covers hammer

104
 diameter 122mm
11 Drill a 25mm 2 “ “ Pillar drilling machine,
diameter hole at 25mm Drill bit
the Centre of the
plate
12 Obtain and 1 press shaft Centre lathe, vernier
machine a shaft calipers, tape measure
shaft
down to
x 800mm
13 Mark and Cut a 1 2mm mild Worm/screw Tape measure, hand
rectangular plate steel plate plate shears, scriber
of height 100mm
14 Coil the 100mm 1 “ Worm/screw Arc Welding machine,
high plate around shaft Chipping hammer,
the shaft to form Tape measure
a helix of pitch
50mm over a
length of
500mm. leaving
a length of
150mm at each
end of the shaft
15 Fix the circular
plates at the ends
of the screw on
the shaft
16 Weld the circular 2 “ Pressing unit Welding machine,
plates at the ends Chipping hammer
of the Cylindrical
housing

105
17 Mount the Size 13 bolt “ Spanners, spirit level
pressing unit on and nut,
the support stand pillow
using no. 6205 bearings
pillow bearings
18 Obtain and fix a 1 key Drive system Hammer, spirit level
15teeth sprocket
with
on one end of the
shaft
19 Obtain and fix a 1 key Drive system Hammer, spirit level
30teeth sprocket
with
on the other end
of the shaft

5.5 THE SIFTER

PART LIST FOR SIFTER

PART NAME DIMENSION(MM) QTY MATERIAL

Hopper 250 x180 x200 1 Stainless steel

Sifting bar 5 x 50 x 40 Mild steel

Sifting shaft Ø25, L = 100 1 Mild steel

Sifting drum Do = 212; Di = 210 1 Mild steel

Sifting mesh Do = 200; Di = 196 1 Mild steel

Fine grain outlet 700 x200 x 100 1 Mild steel

106
Ungraded outlet 170 x 150 x 80 1 Mild steel

bearing Ø25 2 Chromium steel

Sprocket(small) Ø

Sprocket(large) Ø

chain

OPERATION SEQUENCE FOR SIFTER

NO. OPERATION QTY MATERIAL PART TOOLS/EQUIPMENT

1. Mark and cut a 2 2mm mild Hopper Steel rule, hand shears,
trapezoidal shape steel plate plates scriber
of opposing lengths
200mm and
100mm at 240mm
apart
2. Mark and cut a 2 “ “ “
trapezoidal shape
of opposing lengths
120mm and 80mm
at 240mm apart
3 Assemble the 1 Mild steel Hopper Arc Welding machine,
hopper plates by electrode Chipping hammer
welding at 900 to Try square
each other
4 Mark and cut a 1 2mm Mild Sifting Tape measure, hand
length of 666.0mm steel plate drum plate shears, scriber
x 500mm
5 Roll and weld the 1 “ Sifting Rolling machine, Arc

107
 plate along the drum Welding machine,
666mm to form a Chipping hammer
Sifting drum plate
6 Mark and cut a 1 2mm Mild Sifting Tape measure, hand
length of 656.0mm steel plate mesh shears, scriber
x 500mm
7 Mark and Drill 1 “ “ Electric hand drill,
holes at drill bit, steel
5mm intervals over rule scriber
the entire surface
of the plate
8 Roll and weld the 1 “ “ Rolling machine, Arc
plate along the Welding machine,
656mm to form a Chipping hammer
cylindrical shape
9 Suspend the net in 2mm Mild Sifting Spanners
the cylindrical steel plate, cylinder,
housing with 3 size 10mm and mesh
flanges bolt and nuts
10 Mark and Cut a 2 “ Housing Dividers, Chisel,
circular plate of end covers hammer
diameter 212mm
11 Drill a 25mm 2 “ “ Pillar drilling machine,
diameter hole at 25mm Drill bit
the Centre of the
plate
12 Obtain and 1 Sifting Centre lathe, vernier
machine a shaft shaft calipers, tape measure
shaft down to
x 800mm
13 Obtain, mark and 10 2x50mm flat Sifting Steel rule, hand shears,

108
 cut 5 x 50 x 40mm bar bars scriber
14 Weld the sifting electrode Sifting Arc Welding machine,
bars onto the shaft shaft with Chipping hammer,
in a spiral form bars Tape measure
over a length of
500mm, leaving a
length of 200mm at
one end and
100mm at the other
end
15 Fix the circular
plates at the ends
of the sifting bars
on the sifting shaft
16 Weld the circular 2 “ Sifting unit Welding machine,
plates at the ends Chipping hammer
of the sifting drum
17 Mount the Sifting Size 13 bolt “ Spanners, spirit level
unit on the support and nut,
stand using no. pillow
6205 pillow bearings
bearings
18 Mark and cut a 1 2mm mild Fine grains Tape measure, hand
trapezoidal shape steel plate outlet plate shears, scriber
of opposing lengths
700mm and
200mm at 200mm
apart
19 Bend 100mm from 1 “ Fine grains Bending machine,
each end from the outlet Steel rule
700mm length at

109
 900
20 Attach the Fine Mild steel “ Welding machine,
grains outlet to the electrode Chipping hammer
front end of sifting
unit
21 Mark and cut a 1 2mm mild Un-grated Tape measure, hand
trapezoidal shape steel plate cassava shears, scriber
of opposing lengths outlet plate
270mm and 80mm
at 150mm apart
22 Bend 50mm from 1 “ Un-grated Bending machine,
each end from the cassava Steel rule
270mm length at outlet plate
900
23 Attach the Un- Mild steel Un-grated Welding machine,
grated cassava electrode cassava Chipping hammer
outlet plate to the outlet
left end of sifting
unit
24 Obtain and fix a key Drive Hammer, spirit level
13teeth sprocket system
with on
the free end of the
grating shaft
25 Obtain and fix a key Drive Hammer, spirit level
32teeth sprocket system
with
at the end of the
sifting shaft

110
5.6 THE FRYER

PART LIST FOR FRYER

PART NAME DIAMENTION(MM) QTY MATERIAL

Hopper 200 x 190 x200 1 Stainless steel plate

Frying cylinder Ø200 x 1500 1 Mild steel

Conveyor screw shaft Ø19 x 800 1 Mild steel

Conveyor screw Pitch=150; ø150 x 500 1 Mild steel

Bearings Ø25 2 chromium-steel

Gas burner Ø100 x 20 3 Aluminium

Gas cylinder

Hose Ø 15 x 3000 1 Plastic

Heating chamber 200 x 150 x 1500 1 Mild steel

Sprocket(small) Ø61 ; 15teeth 1

Sprocket(large) Ø81.2; 20teeth 1

Chain Pitch 12.7 length 736.6 1

111
OPERATION SEQUENCE FOR FRYER

NO. OPERATION QTY MATERIAL PART TOOLS/EQUIPMENT

1. Mark and cut a 2 2mm mild Hopper Steel rule, hand shears,
trapezoidal shape steel plate plates scriber
of opposing
lengths 200mm
and 80mm at
200mm apart
2. Mark and cut a 2 “ “ “
trapezoidal shape
of opposing
lengths 190mm
and 80mm at
200mm apart
3 Assemble the 1 Mild steel Hopper Arc Welding machine,
hopper plates by electrode Chipping hammer
0
welding at 90 to Try square
each other
4 Mark and cut a 1 2mm Mild Frying Tape measure, hand
length of 628.4mm steel plate cylinder shears, scriber
x 1500mm plate
5 Roll and weld the 1 “ Frying Rolling machine, Arc
plate along the cylinder Welding machine,
628.4mm to form Chipping hammer
a Sifting drum
plate
6 Mark and Cut a 2 “ Frying Dividers, Chisel,
circular plate of cylinder hammer
diameter 200mm end covers
7 Drill a 25mm 2 “ “ Pillar drilling machine,

112
 diameter hole at 25mm Drill bit
the Centre of the
plate
8 Obtain and 1 Fryer shaft Centre lathe, vernier
machine a shaft calipers, tape measure
shaft
down to x
1650mm
9 Mark and Cut a 1 2mm mild conveyor Tape measure, hand
rectangular plate steel plate screw plate shears, scriber
of height 92mm
10 Coil the 92mm 1 “ conveyor Arc Welding machine,
high plate around screw Chipping hammer,
the shaft to form a Tape measure
helix of pitch
50mm over a
length of 1500mm.
leaving a length of
100mm at one end
and 50mm at the
other end of the
shaft
11 Fix the circular
plates at the ends
of the conveyor
screw on the fryer
shaft
12 Weld the circular 2 “ Frying Welding machine,
plates at the ends cylinder Chipping hammer
of the frying sub-
cylinder assembly

113
13 Mark and Cut a 1 2mm mild Heating Tape measure, hand
rectangular plate steel plate chamber shears, scriber
of length 200 x base plate
1500mm
14 Mark and Cut a 2 2mm mild Heating Tape measure, hand
rectangular plate steel plate chamber shears, scriber
of length 150 x side plates
1500mm
15 Assemble the Heating Welding machine,
plates at 900 by arc chamber Chipping hammer
welding to form Try square
the heating
chamber
16 Obtain and fix 3 Ø100 x Heating Gas welding
three pieces of 20mm Gas chamber equipment, steel rule
Ø100 x 20mm gas burners,
burners, with their brass
regulators, in the electrode
middle of the
heating chamber at
an interval of
300mm
17 Weld the Frying Mild steel Frying unit Welding machine,
cylinder sub- electrode Chipping hammer
assembly on top of Try square
the Heating
chamber
18 Bore a Ø36mm Discharge Ø36mm drill bit, pillar
hole through the hole drilling machine,
bottom of the left centre punch, hammer.
end of the heating

114
 chamber to the
frying cylinder
19 Mark and cut a galvanize Outlet Steel rule, hacksaw,
length of 200mm pipe chute scriber, vernier
from a Ø38.1 x calipers
6000mm galvanize
pipe
20 Pass the pipe Mild steel Outlet Welding machine,
through the electrode chute Chipping hammer
heating chamber Try square
and Weld it to the
frying cylinder
21 Mount the frying Size 13 bolt “ Spanners, spirit level
unit shaf on the and nut,
support stand pillow
using no. 6205 bearings
pillow bearings
22 Obtain and fix a key Drive Hammer, spirit level
15teeth sprocket system
with on
free end of the
press shaft
23 Obtain and fix a key Drive Hammer, spirit level
20teeth sprocket system
with on
the right end of the
fryer shaft
24 Connect the 1 chain Drive unit A pair of pliers
sprockets with a
12.7mm pitch no.
40 standard chain,
736.6mm long

115
 CHAPTER SIX

CONCLUSION

This chapter summarizes the design of the grater, press, sifter, fryer and construction of

the prototype of the continues gari processing plant with recommendations.

6.1. CONCLUDING REMARKS

The designs of the grater, press, screw conveyor, sifter, and the fryer were a success

since the primary objective of providing all design drawings was accomplished. Also

analysis for the grater, the press, the sifter and the fryer was fully completed.

The secondary objective of constructing and testing the continues flow gari processing

plant is to effectively process an average quantity of fresh cassava of about 150kg

producing 60-70kg of gari per 1 hour was partially successful.

6.2. RECOMENDATIONS

The design and construction of the continues flow gari processing plant was no

exception to the eminent challenges faced by many design and construction centers. The

major setback however, was the absence of a1:10 reduction gear box which was needed

to reduce the speed of the sifter before transmitting it to the press. This resulted in

higher speeds of the press and fryer shafts causing inadequate pressing and

frying/drying. Another setback was the sifting of wet cassava immediately after

pressing, it is not easily disintegrated. Bole Rural Technology Facility was where the

construction and testing was carried out. We will therefore recommend that in order to

achieve a satisfactory functioning the reduction gear be incorporated.

116
 REFERENCES

1. O. R. adetunji & A. H. Quadri, “design and fabrication of an improved cassava grater”,

the pacific journal of science and technology, Volume 12, number 2. November 2011.

2. Gbasouzor Austin Ikechukwu, A. I. V. Maduabum, “improved Mechanized Gari frying

Technology”, International Multi-conference of engineers and computer scientists

(IMECS) 2012 vol. II.

3. Kudabo, E. A; Onipede, E. A. Adegbenro, “Design, fabrication and performance

evaluation of an improved cassava mash sifter”, Journal of Agriculture and veterinary

sciences, Vol. 4, March 2012.

4. Vincent Corporation, “screw press operation hints”, September 2009 international citrus

and beverage.

5. Adesoji M. Olaniyan1*, Kamaldeen A. Yusuf2, Adebayo L. Wahab3 and Kunle O.

Afolayan4, “Design, Development and Testing of a screw press expeller”, department of

agricultural and bio systems engineering, faculty of engineering and technology.

6. P. Y. Andoh, “Machine design I & II”, Mechanical Engineering IDL 2011.

7. Wilhemina Quaye, J. Gayin, I. Yawson, W. A. Blahar, “characteristics of various

cassava processing methods”, Journal of root crops, 2009, vol. 35 no. 1, pp 59-68.

8. Gerald Kojo Ahorbo, “Data-base on cassava equipment and cassava equipment

prototypes in Ghana”, final report IFAD consultant September 2008.

117
 APPENDIX A

COST ESTIMATION OF THE PLANT

PART QTY UNIT COST AMOUNT (GH₵)

(GH₵)

SHEET METAL (2mm 2 120 240.00

Plate)

1.5 INCH ANGLE IRON 2 40 80.00

SHAFT (Ø30mmx6000) 1 400 400.00

BOLTS (size 13) 24 0.3 7.20

BOLTS (size 12) 6 0.2 1.20

BELT/SHEAVE 1 20 20.00

CHAIN/SPROKETS 3 50 150.00

PILOW BEARING 10 15 150.00

HINGES 2 2 2.00

WELDING 600.00

SPRAYING 100.00

5.5HP PETROL ENGINE 1 300 300.00

TRANSPORTATION 300

Total 2,350.4

118
Table 10: Key Size versus Shaft Diameter

119
Table 11: Performance Parameters for Bearing Materials in Boundary Lubrication

Table 12: Bearing Materials Properties

120
 Table 13: Bearing Materials Properties

Table 14: Comparison of Bearing Types

Table 15: Radial and Thrust Factor for Single-Row Deep-Groove Ball Bearing

121
Table 16: Recommended Design Life for Bearings

122
123
APPENDIX B-CALCULATIONS

Design Equation for the Grater

Weight of pulley:

Vertical weight of pulley, WPy= mg,

with Where; V= A x LP = x LP

Therefore

WPy = ρ LP x g

Where g=9.81m/s2, d=0.25m, LP=0.025m, ρ=6800kg/m3

WPy=

= 81.863N =0.081863KN

Horizontal weight of pulley,Wpx= KN

TORQUE ,T= =0.03562kN.m

., D=0.25m

124
Weight of the Grating Drum

Weight of Drum, Wd =m g, where

m= ρ V,

ρ = Density of the Material

For Stainless, 7930kg/m3

For Mild steel, 7860kg/m3

g=9.81m/s2

V= [Volume of The two Circular plates + Volume of the Rolled Steel Sheet +

Volume of Perforated Mesh]

Volume of pipe,Vp = πΔr2h =7.501 x 10-6 m3

Volume of Circular Disc,Vd =1.57 x10-5m3

Therefore, Weight of Drum, Wd =ρ V g

Wd = 9.81[({vp + vd} x7860) + (7930 x Vp)]

= 9.81[(0.7501+1.57) 7860 +(7930 0.7501)] 10-5

=1.174N

125
Forces due to Chain and Sprocket:

Fc = KN

AX CCosӨ =0.7124 x Cos 60=0.3562KN

F =F

AY CSinӨ=0.7124 x Sin 60=0.3085KN

F =F

Reactions at the Bearings Due to Vertical Loading(yz):

For YZ plane, ∑MD =0; [- 0.617( 0.3)+0.2RBY -0.1012(0.1) +0.0819(0.1)]=0

Therefore, RBY=0.9352KN;

Also ∑FY=0; [-0.617+0.9352-0.1012+RDY-0.0819] =0;

RDY=0.1426KN

Reaction at the Bearings Due to Horizontal Loading

For YZ plane, ∑MD=0; [-0.0356(0.3)+0.2RBX+0.1425(0.1)]=0; RBX=-0.0179KN

∑FX=0; [-0.0356-0.0179+RDX-0.1425]; RDX=0.196KN

MAXIMUM BENDING MOMENT

M=√ =√ =0.06898KN

126
SIZING THE SHAFT

The diameter of the shaft can be determined by:

D= [ √ ( ) ]

Where D=? , N=3, K=1.0, S’n=187.92MPa, T=0.03562KN, Sy=572MPa

⁄
Therefore D=[ √ ] =22.5mm

A design shaft of diameter 25mm was specified.

Length of Belt

Trial centre distance. Dd C 3 .In the interest of conserving space, let’s try C

= 610mm. The required belt length is computed from

( ) ⁄ ]
[

=[ ⁄ ]=1779mm

From tables, the nearest standard length is 1803mm. Then,

= =5014

[ √ ]/16=622mm

127
The angle of wrap of the belt on the small sheave

[ ⁄ ]=1 -2 [ ⁄ ]=

KEY DESIGN

The length of the key can be calculated as;

T=0.035619K Nm, D=25mm, N=3, W=6.25 mm, Sy=352MPa

Therefore L= =7.772

A key length of 12mm was specified.

CALCULATIONS FOR THE PRESS DESIGN

Determination of theoretical screw volume per pitch

Vs= area x pitch …………………………………………………. ( 4.15)

Where D1=inside diameter of housing, D2outside diameter of housing and S = screw

pitch

=7.85 x 10-5m3

128
Determination of mass flow rate

ṁ= Vs ……………………………………………………………………………………….. (4.16)

where Vs= theoretical screw volume, n= speed, = density of cassava mash, =filling

ratio of screw.

ṁ= 7.85 x 10-5x 20 x 1509 x 0.45= 1.06kg/s

Determination of drive power

Drive power = ṁ x L x fi/ɳ

Drive power = 1.06x 0.5 x 1.9/0.79 = 1.27kW

Worm shaft power

Ps= ɳ

Ps = = 1.61kW

Torque

T=

T= =768.72Nm

The load that can be lifted by worm shaft

Ws = T

129
But

= 14.98

Ws = 768.72 x

= 37.8KN

The pressure developed by the worm shaft

Pr =

AP = m nh

AP = = 10602.88mm2

Pr = = 3.57N/mm2

Pressure of the housing

Pb =

Pb = = 5.4N/mm2 or 5.4 MPa

The capacity of the press

The theoretical capacity of the press was determined using a modified of the equation

given by Onwualu et al.(2006) as:

Qp = 60 - ps NS =

Where:

130
Qp = the theoretical capacity of the shaft

Ds = the diameter of the worm thread

ds = the base diameter the worm shaft

ps = the worm pitch

Ns = the rotational speed of the worm shaft

= the filling factor

the bulk density of cassava dough

Qp = 60 – x 0.05 x 20 x 0.45 x 1509 = 122.36kg/h

DESIGN CALCULATIONS FOR THE SIFTER

4.3.1 hopper

Volume of hopper (V h )

Vh = 1/3 xAbxH)

Where Ab = base area

H = height

Ab = L x W;

L = length = 250mm(0.25m); W = width = 180mm(0.18m); H = 200mm(0.2m)

Ab = 0.25m x 0.18m = 0.045m2

Therefore the volume of hopper is

Vh = 1/3 x0.045 x 0.2 = 0.003m3

131
4.3.3 Weight of sifting brushes Weight of the sifting bar

Weight of the sifting is giving by W = mg

Where m = mass of sifting bar

g = acceleration due to gravity.

The mass of the bar is giving by m = ρ x v

The volume of the sifting bar is giving by V = π ( ro ─ ri) x l.

Where ro = outer radius

ri = internal radius.

The resulting mass of the bar from appendix B 387.75N.Tthis weight acts at the

centroid of the sifter shaft.

Density of steel = 7750kg/m3

Volume of sifting bar = π(0.1 ─ 0.096) x 0.4 = 0.005m3

Mass = ρ x v

7750 x 0.005 = 38.75kg

Therefore the weight W = mg

= 38.75 x 10 =387.5N

The mash cassava weight to be sifted perminute is 1.2kg and a weight of 12N.

The total weight is therefore (387.5 + 12) = 398.5N

132
Determination of sifting Torque

The torque T is giving by ;

T=Fxr

Where F = force available on the sifting bar

r = sifting bar radius

but F = mω2r

where ω = angular velocity

m = 7750 x 0.005 = 38.75kg

ω = 2πN/60

= 2π x 400/60 = 41.89rad/sec

r = 0.0125m

F = 38.75 x (41.89)2 x 0.0125 = 849.97N

Therefore the torque is T = 849.97 x 0.0125 = 10.62Nm

POWER REQUIREMENTS

The power required by the sifting shaft is giving by;

P=FxV

Where F = sifting force

V = velocity

The force required to sift the mash is F = mω2r =849.97N

V = rω = 0.0125 x 41.89 = 0.524m/s.

The power is therefore is P = 849.97 x 0.524 = 445.38W = 0.6hp

133
4.3 .4 Selection of chain and sprocket

Design power = factor of safety x power required by shaft. Using factor of safety of 3

Design power = 3 x 0.445kw = 1335w or 1.3kw

The speed ratio is computed from the relation ;

Speed ratio = driver speed/driven speed = 1000rpm/400rpm = 2.5

From which the desired ratio is 2.5.

From tables of designed power and speed, the standard chain that fit the drive is selected

as a no 40; 127cm pitch standard single- strand roller with 13teeth(N1) and type II

lubrication. The required no of teeth on the larger sprocket, N2 is computed using N2 =

speed ratio x N1 --------------------------------- ( )

The actual expected output speed of the sifter is n2 = n1 (N1/N2) ------------------------ ( )

= 1000(13/32) = 406rpm

The pitch diameter of the smaller sprocket is computed as ;

D1 = p/sin(180/N1) ----------------------------------------------------------------------- ( )

= 12.7/sin(180/13) = 53mm

The pitch diameter of the larger sprocket is computed as ;

D2 = p/ sin(180/N2)

= 12.7/sin(180/32) = 129.5mm

134
The normal center distance between the sprockets is 40pitches(508mm) by specification.

The length of the belt using the center distance is computed from the formular

L = [2C + ½(N2 + N1) + (N2 ─ N1)2/4π2C] pitches --------------------------------------- ( )

= [ 2(40) + ½( 32 +13) +(32 ─13)2/4π2 x 40] = 102.7 pitches.

An integral no of pitches of 102 is selected.

Summary of the design

SHAFT DESIGN

The length of the shaft is predetermined at 600.0mm.

The diameter of the shaft is computed as d = 36.59(p/τsN)0.33mm

Where p =power

τ = shear stress

N = speed

d = 36.59(445.38/4.5 x 400)0.33mm = 23.0mm.

Diameter 25mm is selected

KEY DESIGN

The length of the key can be calculated as L = 4TN/DWSy---------------------------- ( )

135
Where T = toque

N = speed

D = diameter

W = width

Sy = yield stregth

The forces on the top and bottom of the key resist tipping off the key, and the force F,

between the side of the key and keyway in the hub is due to the resisting torque T,

T = Fd/2

= 849.97 x 0.025/2 = 10.62Nm

From standard tables , for 25mm diameter shaft, the key dimention is giving as;

width(W), 6.35mm. for a torque of 10.62Nm, a factor of safety of 2.5 and yield strength

of 352Mpa, the length of the key is determined as

L = 4 x 10.62 x 4oo/0.025 x0.006 x352

BEARING SELECTION

The relationship between the basic rating life, the basic dynamic rating and the bearing

load is;

136
C = (L/L10)1/kP ------------------------------------------------------------------------------ ( )

(C/P)k = L/L10

But L = 60n/106million revolutions,

Therefore L10 = (106/60n) x (C/P)k

Where C = basic dynamic load rating (N)

L10= life of bearing for 90% survival at one million revolutions

L = required life of bearing in million revolution

N = rotational speed(rev/min)

K = exponent for life equation with

K = 3 for ball bearings and

K = 10/3 for roller bearings

The bearing selected for the sifter is the single –row, deep groove Conrad –type ball
bearing with a bore of 25mm.

Summary of bearing selection

Bearing No-6205

Bearing series No

Bearing bore- 40mm

Basic dynamic load rating(C): 10.81kN

Bearing weight: 1.29

137
 THE FRYER CALCULATIONS

HOPPER DESIGN

Assumptions Used in the Calculations

i. The hopper shape and size are not necessary to be larger than the cylinder

ii. Volume of 0.0126m3 Cassava mash is needed to pass through the hopper in 5 times.

The Volume of the hopper is given by

Vh = ⁄ x Ab x H

Where, H = vertical height = 0.2m

Ab = Base area = L x W = 0.2 x 0.19 = 0.038m2

Substituting in the values of Ab and H gives

Vh = ⁄ x 0.038 x 0.2 = 0.00253m3

Number of times the mass passes through the hopper, N is given by

138
 N=

Substituting in the values of V and Vb gives

N= = 4.98 5 times

CYLINDER DESIGN

Assumptions Used in the Calculations

i. Necessary space is required above the mash in the for evaporation

ii. Space necessary to demonstrate frying process and

iii. Length that loud the mash within a specified time.

The volume of the cylinder (Vc) is determined as follows:

Vc = r2h
h

Using a cylinder of radius, r = 0. 1m and length, h = 1.5m

Vc = 3.142 x 0.12 x 1.5= 0.05m3

Area of cylinder:

139
Ac = 2 rh+ 2 r2

Ac = (2x x 0.1x1.5)+2 (0.1)2

= 1.01m2

Volume of cassava mash in the cylinder:

Assuming the cassava mash in the cylinder is 1/3 the volume of the cylinder, then

Volume of mash, V =1/3 V

= 1/3 x 0.05= 0. 017m3

The density of cassava mash increases from 1239 to 1509kgm2 when it is dehydrated
from51.8 to 6.0(wet basis)

Takes density of cassava mash, =1509kg/m3

The mass of the cassava mash can be calculated using the relation

M= v =1509 x 0.017 = 25.65kg

HEAT REQUIRED FOR THE FRYING

Quantity of heat required, Q is given as

Q =mc T

Where M= mass of cassava mash in cylinder =25.65kg

C= specific heat capacity of the mash = 1. 59J/kg

T = temperature range =60

140
Substituting in the values gives,

Q = 25.65 x 1.59 x 60 = 2,447.01 W

Time required for the frying

Rate of transfer of Heat is given as

where K = thermal conductivity of the mash = 0. 2

Ac = Surface area of the cylinder = 1.01m2

T2 = 60 (cylinder temperature)

T1 = 30 (25 ambient temperature)

L = 0. 05m (thickness of the mash in the cylinder)

Substituting in the values gives,

= =1121.2W/S

= (but Q is calculated as 2,447.01 W)

= = 20.19s 20 seconds

141
POWER REQUIRED

Velocity of the mash along the cylinder.

V = x distance covered by the mass = length of the cylinder = 1.50m

V= = 0. 075m/s

Force, Fx =

Where N = speed of fryer shaft = 16rpm

Fx= 25.65 x

The force causing the mash to move is

Frictional force Fr = N Where

= Co-efficient of friction of the mash =0.47

N = Normal force acting on the mash

N= mg = 25.65 x 10 =256.50

Where g = acceleration due to gravity = 10m/s2

Fr = 0.47 x 256.50 =120.56N

∑ = Fx + Fr = +120.56 =127.76N

142
Work done, W= ∑ x distance covered(X)= 127.76 x 1.50 = 191.64Nm

Power,P = = = 9.582W

But 746 watt = 1 hp

9.582W =x

x= =0.013hp

the power required to covey the cassava mash is 0.013hp

the torque of the shaft is calculated as

T= ………………………………………………………………………………()

Where p= power=9.582W, N=speed of the shaft = 16rpm

Therefore T = = 5.72Nm

THE CONVEYOR

Diameter of the shaft

The diameter of the shaft is given as

( )

Where P=power=9.582w, n= shaft speed=16rpm

143
From tables, 4.5MPa is the value selected for the allowable shear stress,

Substituting in the values gives

= 19mm

CHAIN DRIVE

The Design/ Maximum Power

This is the power that can drive the fryer without failure.

And it is given as,

Design power = service factor x power required

Design power = 1.4 x 0.013 = 0.02hp

The desired speed ratio is given as,

Speed Ratio =

Where = input speed, = output speed

Speed ratio = = 1.25

From tables in appendix ….,

144
A single strand no. 40 chain with pitch 12.7mm seems best. A 15-toothsprocket rated at

0.07hp at 10rpm is selected since there is no power column for 16rpm. At this speed,

type II lubrication (oil bath) is recommended.

The required number of teeth on the large sprocket N2 is given as

N2=speed ratio x N1

= 1.25 x 16 = 20 teeth

The actual expected output speed is given as

= 20 = 15rpm

The pitch diameter of the small sprocket is given as

D1 =

= = 61.1mm

The pitch diameter of the large sprocket is given as

D2 =

= = 81.2mm

For the nominal centre distance, 40 pitches, which is the middle of the recommended
range, is selected.

145
The required chain length in pitches is given as

L =[ ⁄ ]

=[ ⁄ ] = 57.52 pitches

The 58 pitches, which is an even number, is selected.

The actual theoretical centre distance is calculated as

C= [ √[ ] ]

C= [ √[ ] ]

C = 20.4 pitches = 259.1mm

Summary of the design

Pitch P : 12.7mm

Length L : 58 pitches = 736.6mm

Single strand sprockets

Lubrication: Type I

508mm

Input speed: 20rpm Output speed: 16rpm

No. of teeth N1 = 15 teeth No. of teeth N2 = 20 teeth
Pitch diameter D1 = 61.1mm Pitch diameter D2 = 81.2mm

146
APPENDIX C-ASSEMBLY DRAWINGS

ISOMETRIC VIEW OF THE PLANT

147
ORTHOGRAPHIC VIEWS OF THE PLANT

148
 2 1

EXPLODED VIEW OF THE GRATING UNIT

PART NO. QTY NAME MATERIAL

1 1 Hopper Mild steel

2 1 Grating drum Mild steel

3 1 Grater Shaft Mild steel

4 2 Bearing Chromium steel

5 1 Pulley Mild steel

6 1 Sprocket Plain carbon steel

149
 1

EXPLODED VIEW OF THE PRESSING UNIT

PART NO. QTY NAME MATERIAL

1 1 Press cylinder Mild steel

2 1 Press net Mild steel

3 1 Conveyor Shaft Mild steel

4 2 Sprocket Plain carbon steel

5 2 Bearing Chromium steel

6 1 Outlet Mild steel

150
 1
3

6
5

EXPLODED VIEW OF THE SIFTING UNIT

PART NO. QTY NAME MATERIAL

1 1 Sifting cylinder Mild steel

2 1 Fine granules outlet Mild steel

3 1 Ungraded cassava outlet Mild steel

4 2 Sprocket Plain carbon steel

5 2 Bearing Chromium steel

6 1 Sifting net Mild steel

7 1 Sifting shaft Mild steel

151
 7

3
5

EXPLODED VIEW OF THE FRYING UNIT

PART NO. QTY NAME MATERIAL

1 1 frying cylinder Mild steel

2 1 Conveyor shaft Mild steel

3 1 Heating chamber Mild steel

4 2 regulators Brass

5 2 Burners Aluminium

6 1 Hose plastic

7 1 Gas Cylinder

152
APPENDIX D – WORKING DRAWINGS

200mm

100mm

Grating chamber plates

300mm 200mm

400mm 400mm
200mm

100mm
Hopper plates

314.2mm

190mm

GRATING DRUM PLATE

153
100mm 100mm

GRATING
CYLINDER

400mm

GRATER SHAFT

50mm

186mm

1500mm

CONVERYOR SHAFT

154
APPENDIX E - PROJECT PICTURES

Picture 1: preparing plate for marking out

155
Picture 2: perforation of grating plate

Riveting of Grating plate to drum

156
Picture 3: welding of hopper

157
Picture 4: machining of shaft

Picture 5: grating unit assembly

158
Picture 6: Assembling of grating and pressing units

159