DESIGN AND DEVELOPMENT OF COCONUT HUSK PALLET

MAKING MACHINE
This Project report is submitted to
Yeshwantrao Chavan College of Engineering
(An Autonomous Institution Affiliated to Rashtrasant Tukdoji Maharaj Nagpur University)
In partial fulfillment of the
requirement for the award of
the degree

Of

Bachelor of Engineering in Mechanical Engineering

By
Amit Khapekar, Vaibhao Surpam
Riya Chavhan, Akash Rathod

Under the guidance of

Prof. G. H. Waghmare

DEPARTMENT OF MECHANICAL ENGINEERING

Nagar Yuwak Shikshan Santa’s

YESHWANTRAO CHAVAN COLLEGE OF ENGINEERING
(An autonomous institution affiliated to Rashtrasant Tukadoji Maharaj Nagpur University, Nagpur)
NAGPUR – 441110
2021-22

i
Nagar Yuwak Shikshan Santa’s

YESHWANTRAO CHAVAN COLLEGE OF ENGINEERING

 (An autonomous institution affiliated to Rashtrasant Tukadoji Maharaj Nagpur University,Nagpur)
NAGPUR – 441110
2021-22

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE OF APPROVAL
Certified that the Mini-Project report entitled
“DESIGN AND DEVELOPMENT OF COCONUT HUSK PALLET MAKING
MACHINE”
has been successfully completed by
S. No. Roll No. Registration No. Name of Student
1 102 18010115 Amit Khapekar
2 168 17010276 Vaibhao Surpam
3 210 19030060 Riya Chavhan
4 227 19030111 Akash Rathod

under the guidance of

Prof. G.H. Waghmare

in recognition to the partial fulfillment for the award of the degree of

Bachelor of Engineering in Mechanical Engineering,
Yeshwantrao Chavan College of Engineering
(An Autonomous Institution Affiliated to Rashtrasant Tukdoji Maharaj Nagpur University)

Prof. G. H. WAGHMARE
(Guide)

Prof. V. M. KORDE Dr. J. P. GIRI

(Coordinator) (HOD, ME Dept.)

Signature of External Examiner:

Name:
Date:

DECLARATION
iii
I/We Certify that

a. The work contained in this project has been done by me under the guidance of my supervisor(s).
b. The work has not been submitted to any other Institute for any degree or diploma.
c. I have followed the guidelines provided by the Institute in preparing the project report.
d. I have conformed to the norms and guidelines given in the Ethical Code of Conduct of the Institute.
e. Whenever I have used materials (data, theoretical analysis, figures, and text) from other sources, I have
given due credit to them by citing them in the text of the report and giving their details in the references.
Further, I have taken permission from the copyright owners of the sources, whenever necessary.

Signature of students:

AMIT HARISH KHAPEKAR VAIBHAO OMPRAKASH SURPAM

RIYA VIJAY CHAVHAN AKASH BHIMRAO RATHOD

iv
 ACKNOWLEDGEMENT

The project would not have come to a definite completion without the help of many people. It becomes an
obligation on our part to acknowledge their efforts and to thank them.

We would like to thank our guide Prof. G. H. Waghmare, professor, Mechanical Engineering Department,
YCCE for thorough guidance in the project. We are extremely grateful and indebted to them for their expert,
sincere, valuable guidance, practical suggestions and encouragement which was of immense help to us.

We would like to express our sincere gratitude to Dr J.P. Giri, Head of Department of Mechanical
Engineering, YCCE for his constant encouragement towards the successful completion of our work.

We wish to express our sincere thanks to Dr U.P. Waghe, Principal, YCCE for providing us with all the
necessary facilities and the infrastructure without which we would not have been able to complete our project
successfully.

We would also like to thank our Project Coordinator Prof. V. M. Korde, YCCE for their continuous
guidance owing to which the project could take shape.

Last, but not the least, we would like to thank all the faculty members and non-teaching staff members who
helped us despite of their busy schedule.

v
 TABLE OF CONTENTS

CONTENTS PAGE NO.

Title Page i.
Certificate of Approval ii.
Declaration iii.
Acknowledgement iv.
Table of Contents v.
List of Figures vii.
List of Tables viii.
Abstract ix.

CHAPTER 1 INTRODUCTION

1.1 About Pallets 2

1.2 Overview 3
1.3 Coconut Husk 5
1.4 Problem Statement 6
1.5 Aims and Objective 6
1.6 Thesis Contribution 7

CHAPTER 2 REVIEW OF LITERATURE

2.1 Overview 9

CHAPTER 3 WORK DONE

3.1 Construction 12
3.2 Working 16
3.3 Calculation 19
3.4 Analysis 24

CHAPTER 4 RESULT AND DISCUSSION

4.1 Comparison between Wooden Pallets and Coconut Pallets 27
4.2 Claims 28

vi
CHAPTER 5 SUMMARY AND CONCLUSION
5.1 Conclusion 30
5.2 Summary 31

CHAPTER 6 LITERATURE CITED

6.1 Literature Cited 33
6.2 References 34
6.3 List of Publishing 35

vii
 LIST OF FIGURES

Figure Number Name of figure Page no.

1.1 Wooden Pallet 2

1.2 Coconut Pallet 2

1.3 Pallet 3

1.4 Coconut Husk 5

3.1 Hydraulic Cylinder 12

3.2 Open Centre 13

3.3 Closed Centre 13

3.4 Pressure Centre 13

3.5 Base Plate 15

3.6 Top Plate 15

3.7 Functioning Principle of Hydraulic Cylinder 17

3.8 Hydraulic Press Machine 20

3.9 Piston Rod 23

3.10 Stress in Column 24

3.11 Total Deformation in the column 24

3.12 Stresses in movable plate 24

3.13 Deformation in movable plate 24

3.14 Typical flow diagram of fully automatic compressed 25

pallet production plant

viii
 LIST OF TABLES

Table Number Table Name Page no.

3.1 Material Selection 19

Dimensions of Hydraulic
3.2 Press Machine 19

Comparison between
4.1 Wooden Pallets and 27
Coconut Pallets

6.1 Literature Cited 33

6.3 List of Publishing 35

ix
 ABSTRACT

A Coconut pallet can be defined as a type of pallet which is made of waste coconut husk and used in
transporting heavy materials and also it helps companies for one ways export pallets from Asia. Coconut pallets
are widely used for transport materials and keeping heavy materials in the industries such as iron, copper, tin.
However, the design of coconut pallet and hydraulic press machine is complicated by the large number of
geometries. According to Michiel Vos, coconut pallet is natural and bio degradable and recycled which can be
used for transporting material instead of using wooden pallets. In this study, the focus is on the research and
study of pallets of coconut and wooden especially waste coconut husk. For this purpose, the simulation Solid
Work is used. The results show that the Coconut pallet is the best performing pallet that can be used in
companies.

KEYWORDS - Coconut Husk, Wood, Pallets, Hydraulic press machine, Coconut pallet

x
 CHAPTER 1

INTRODUCTION

1
CHAPTER 1:
INTRODUCTION

1.1 ABOUT PALLET

A pallet is an equipment or a type of storing container which is used for storing heavy
materials such as iron, rod, copper. It is a facility used for heavy materials in Industries. It is
made of waste coconut husk. They are the integral part of coconut, used to support pallets
which provide the services such as shipping, storing. To minimise the need of wooden
pallets, coconut pallets are the key for the sustainable transporting material.
In the existing world of increasing mobility and growing trade, material and commodities
need to be transported safely across various actors of the economy: from suppliers to
manufacturers, from manufacturers to warehouses, from warehouses to retailers, and finally
to consumers.
Coco Pallets are fully bio-based and they contain natural fibres and lignin, while
ordinary pressed wood pallets, in addition to being more expensive, contain synthetic resins.
They also don’t require any glue because the coconut husk has its own natural glue called
lignin. This natural glue is activated when they grind the coconut husk and press them
together at high temperatures.
Coco Pallets have important advantages for the transport of goods because they are
stronger and lighter, they are fire retardant, and thanks to an adjusted design, also easier to
stack, so they take up less space. Above all, they are cheaper, and a lower price is always the
best sales argument for a sustainable product.

Fig 1.1 Wooden Pallet Fig 1.2 Coconut pallet

2
1.2 OVERVIEW
Over 1.7 billion pallets are used to transport goods from Asia to the rest of the
world every year. Almost 170 million trees are felled to make these single-use or one-way
export pallets. Meanwhile, 7.4 billion coconuts have been harvested all over the world. The
undesired hairy coconut shells are either burned or tossed in the ocean after consumption,
resulting in approximately 60 billion Kg of garbage every year. By turning waste coconut
husks into shipping pallets, SURFACES REPORTER (SR) introduces a unique eco-friendly
approach to put them to new use and benefit us both economically and environmentally.

While the Indian coir sector has been using leftover coconut husks for some time, it
barely accounts for 28.41% of their overall production. A novel product with significant
benefits for both goods transportation and the environment. The husk, the outer hairy
component of the coconut waste stream, is used to create the new material. Only 15% of the
waste from coconut production is utilised nowadays, leaving the other 85% to be burned,
landfilled, or left to rot.

Pallets are made near to the coco husk supply, providing additional money to local
farmers. Furthermore, farmers can cease burning coconut husks, reducing pollution in the air.
CocoPallets are completely biodegradable because they only include natural fibres and lignin,
whereas typical pressed wood pallets contain synthetic resins in addition to being more
expensive. They also don't require any glue because the coconut husk's natural glue is
sufficient.

Fig 1.3 : Pallet

3
The company says that these coco pallets are far more durable, cost-effective, and
environmentally friendly than hardwood or plastic pallets. Furthermore, they anticipate that
the project will be sufficient to prevent the loss of nearly 200 million trees. Coco pallets,
unlike wooden pallets, do not contain synthetic binding agents. They're also completely
biodegradable. These can also be ground down into mulch and used as a substitute for a high-
quality, natural soil improver at the end of their useful life.

From a distance, the company's coco pallets have numerous advantages: they are termite,
moisture, and fire resistant, can easily carry 2000 kg static weight and 1000 kg dynamic load,
are ISPM15 compatible, nestable, and economically priced. These pallets are made in a
factory.

Why is it recommended that a similar initiative be taken in India? India is now the world's
third largest producer of coconut. Kerala, India's southernmost state, produces around 45
percent of the country's coconuts, with the remaining 92 percent going to Kerala's neighbours
and other Southern Indian states.

INVENTION BACKGROUND

Coir, also known as coconut fibre, is a natural fibre derived from the husk of a coconut that is
used in products such as floor mats, doormats, brushes, and mattresses.

Coconut Shells as a Wood Substitute?

Pallets for shipping are strewn throughout the place. These pallets represent a significant
investment in trees, even if they are utilised until they disintegrate. Coconut shells, of all
things, can be used to construct durable, reusable, fire-resistant pallets.

What's more, coconut shells are currently classified as a waste product. To keep them from
stacking up in large regions of Asia, they're simply left to rot or burn. By converting these
shells into a viable product, a large number of trees can be spared from logging. Additionally,
the coconut shells.

4
1.3 COCONUT HUSK

The entire fibrous substance encircling the fruit, including both the inner endocarp
(liquid and solid food part) and the outer mesocarp (fibrous part), is referred to as coconut
husk.

The mesocarp cements the fibre materials scattered throughout the mass, which is made up of
fibres and elastic cellular cork like parenchymatous cells. The leathery exocarp (thin outer
slippery layer) of this substance separates from the spongy fibrous mesocarp after resting in
water. The fibrous threads are made up of a lignified form of cellulose that is harsh and rigid.

Fig 1.4: Coconut Husk

Coconut fibre is produced from the husk of the coconut fruit and is one of the natural fibres
plentiful in tropical climates. Coir fibre is another name for it. The outer shell of a coconut is
used to obtain coconut fibre. Respectively. According to the official website of the
International Year for Natural Fibres 2009, around 500 000 tonnes of coconut fibres are
produced annually worldwide, with the majority of production occurring in India and Sri
Lanka. It is estimated to be worth $100 million in total. Thailand, Vietnam, the Philippines,
and Indonesia are the top exporters, followed by India and Sri Lanka. Approximately half of
the coconut fibre produced is exported as raw fibre.

5
1.4 PROBLEM STATEMENT

Coco Pallets are long-lasting, high-quality transport pallets constructed from abundantly
available trash from the coconut industry. There will be no need for synthetic resin because
the lignin in the coconut husks will act as a binder.

The pallets will address two major issues.

● Wood scarcity/deforestation: China, Japan, and most Asian countries lack sufficient
wood resources to meet their own demands. To make one-way pallets for exporting
goods, massive volumes of lumber must be imported from New Zealand, the
Americas, Siberia, and the Baltic states. This results in wasteful tree cutting and
transportation, which has a significant environmental impact.
● To destroy pests on wooden pallets, no fumigation (methyl bromide) or heat treatment
is required.

1.5 AIMS AND OBJECTIVE

● To develop a transporting pallet model which can easily carry weight up to 3000 tones
and can be easily carried with less effort.

● To reduce the transportation and storage cost of coconut pallets, pallets should be
manufactured with waste material of coconut husks.

● To reduce the cost and difficulty of handling wooden pallets and make use of coconut
pallets.

● To transport heavy materials, moving, conveying, sorting, and storing goods and
materials.

6
1.6 THESIS CONTRIBUTION

The first part of the thesis consists of a literature review of important background
knowledge for pallets design and development of pallets and hydraulic machines. The paper
presented by many authors on coconut and coconut waste helps in understanding of the
project. Chapter 1 introduces the need for change of pallet use from wooden to coconut pallet
and provides an overview of the project. Chapter 2 explains review of literature. Chapter 3
includes the methodology used in designing the hydraulic machine used for making coconut
husk pallets, their construction and working. In Chapter 4, results obtained from analysis
performed are represented and discussed. It also includes a summary of the project and
conclusion. Finally literature is cited in Chapter 6.

7
 CHAPTER 2

REVIEW OF LITERATURE

8
CHAPTER 2 :
REVIEW OF LITERATURE

2.1 Overview

1) Published by : Edwin Keijsers on March 10, 2016 at Wageningen, Netherland, “The

use of coconut pallets help reduce deforestation.”

It is a new type of pressed pallet machine whereas hot press technology is used; in this
machine workers can reuse the waste materials such as coconut husk, waste wood to gain
more benefits. Single mould pressed machine can widely use a variety of materials to make
pallets, such as waste wood pallets, wood chips, waste coconut, tree branches, and other
materials which contain long fibres.

In this machine materials containing rich fibre also can be used to produce the pallets such as
bamboo, palm trees, coconut, softwood, wheat straw, waste wood. And the production
process of the pressed pallet machine is the same as the hydraulic press.

1) Coconut waste 2) Chipping

3) Crushing 4) Glue mixing

5) Drying 6) Hot pressing

2) Published by : Axel Barrette on October 16, 2019 at Wageningen, Netherland,

“Coconut husks are the best alternatives to wood.”

This paper proposes an Environmental and 100 % bio-based durable transportation pallet
made from recycled coconut husk waste. Entrepreneur Michiel Vos, Co-founder of the
company Cocopallet BV, used the Wageningen technique in his company to press the
coconut husks not to make board but to make pallets. Cocopallet are sustainable, affordable,
bio-based, biodegradable, 100% wood free export pallets, nestable as they fit into each other,
reducing cost and lowering the carbon footprints of transportation.

9
 3) Published by : Michiel Vos on March 3, 2010 at Wageningen, Netherland, “Coco
pallets made from coconut waste to replace timber pallets and saving trees.”

This paper proposes around 5 billion timber pallets are produced annually, causing the
deforestation of 500 million trees per year. Most of those trees are cut down far away in
places like Canada and New Zealand because there is a shortage of timber in Southeast Asia.
As we know each year some 7.4 billion coconuts are harvested worldwide, and most of the
value of the coconut is to be found inside. Around 85% of the unwanted hairy husk is either
being burned, thrown in the ocean, or piled up to create giant biohazards.

4) Published by : Fino Menezes on December 10, 2019 at Wageningen, Netherland,

“How coconut waste can contribute to a circular economy.”

This paper proposes about shells, it takes between 60 and 70 shells to make a pallet and they
are just as strong as wooden and plastic pallets and saving upto 70% warehouse space on
traditional pallets.

5) Published by : Tejas Patel, Saurin Sheth in April 2015 at Vallabh Vidyanagar India,
“Design of Semi-automatic Hydraulic Blanking Machine using PLC”.

This paper proposes Hydraulic blanking machines controlled by PLC having advantage over
the conventional blanking machine.

10
CHAPTER 3

WORK DONE

11
CHAPTER 3:
WORK DONE

3.1 CONSTRUCTION

1] Hydraulic Cylinder

A hydraulic press is a mechanical machine used for lifting or compressing various

parts and components. The force is generated by the use of hydraulic fluids to increase the
pressure inside the cylinder. The hydraulic press machine works on Pascal's
principle.Hydraulic cylinders can be used for any application where a strong push or pull
force is required. Hydraulic press machine consists of basic components used in a hydraulic
system that includes a hydraulic cylinder, piston, ram, pipelines for fluid flow, oil reservoir
and a controller. The piston inside the cylinder is pushed by hydraulic fluid, which
causes the movement of the piston. A ram connected with a piston, then compresses the
material. Incompressible fluid such as oil with proper density and viscosity is used as a link
for transmitting hydraulic pressure.

Fig 3.1 : Hydraulic Cylinder

12
2] Piston Rod
Bar is straight and it is of homogeneous material.
Rod is continuous and no changes occur.
Line of force acting coincides with the axis of ram/rod.

3] Piston
The piston is a short, cylinder-shaped metal component that separates the two sides of the
cylinder barrel internally. The piston is usually machined with grooves to fit elastomeric or
metal seals. These seals are often O-rings, U-cups or cast iron rings. They prevent the
pressurised hydraulic oil from passing by the piston to the chamber on the opposite side. This
difference in pressure between the two sides of the piston causes the cylinder to extend and
retract. Piston seals vary in design and material according to the pressure and temperature
requirements that the hydraulic cylinder will see in service

4] Direction Control Valve

Directional control valves perform only three functions:

● stop fluid flow

● allow fluid flow, and
● change direction of fluid

We have used a 5/3 spool type directional control valve which has 5 ports with 3
following conditions.

Fig 3.2 : Open Centre Fig 3.3: Closed centre Fig 3.4: Pressure centre

13
 ➔ Open centre
➔ Closed centre
➔ Pressure centre

5. Pressure Control Valve

Pressure control valves limit the system pressure to protect the system components. There are
four types of pressure control valve:

1. Pressure Relief Valve - They are designed to protect hydraulic systems when pressure
in the system increases beyond the specified design pressure or maximum working
pressure. They are normally closed and it opens when the pressure exceeds a specified
maximum value and diverts the pump flow back to reservoir or tank internally. They
are located near a hydraulic pump.
2. Pressure Reducing Valve - They are designed to limit and maintain outlet pressure.
They are normally open and closed if the pressure exceeds specified design pressure
at the outlet. They are located near hydraulic actuators.
3. Sequence Valve - The sequence valve is used to ensure that a certain pressure level is
achieved in one branch of the circuit before a second branch is activated.

6] Flow Control Valves

A flow control valve is used for adjusting the flow rate of a fluid in a
pipeline. The valve contains a flow passage or a port whose area can be varied.
Flow control valves (Throttle valves) influence the volumetric of compressed air, in both
directions. Flow control valves with constant restriction. Here, the length of the throttling
section is greater than its diameter. Flow control valves with adjustable restriction.

14
7] Base Plate
Base plate with slots is used here which is in 350x 400 mm size.

Fig 3.5 : Base Plate

8] Top Plate
This plate is connected with the piston rod and will carry some amount of force at that time.

Fig 3.6 : Top Plate

15
3.2 WORKING

The working principle is that the Hydraulic cylinder provides high pressure and pushes the
piston to Extrude and mould the material. The heating of a heating plate at high temperature
promotes the solidification and moulding of urea-formaldehyde glue and thus to increase the
strength of the pallet.

1. Crushing process in coconut shell pellet line.

Due to the quite hardness of the coconut shell, the coconut shell needs to be crushed from big
chunks to small pieces by a special coconut shell crusher.

2. Drying process in coconut shell pallet processing line.

For containing certain moisture, crushed coconut shells enter the drying machine through a
conveyor and feeding machine. The coconut shell dryer can dry off the excess moisture to
improve the pallet strength after palletizing.

3. Second crushing process in coconut shell pallet making line.

After drying, the coconut shell pieces need to be crushed again into small fibrous pieces for
better palletizing.

4. Mixing of glue
Synthetic glue is used for mixing and for absorbing in Husk. It is used to improve the strength
of the pallet.

5. Hydraulic Press
Here we have a Direction Control Valve[DCV] where we have to control the lever
position manually .When the lever is at position one the higher pressure fluid passing through
dcv actuates the piston of cylinder from top position to bottom and when lever is shifted to
second position, the dcv changes the input ports connection to the output port and by this
piston moves from bottom position to top position.
So firstly ,we have to place the mixed material over the top of the bottom plate.After which
the DCV lever is operated to first position due to which the piston will move down, resulting
the Top plate moving in downward direction and pressing the material with some force acting

16
on it. After exerting some pressure on the material to form a Pallet, we have to change the
lever position. Changing the lever position will result in upward movement of the top plate
and thus we are done with the work.

The functioning principle of a Hydraulic cylinder

A double acting hydraulic cylinder is a cylinder that contains two ports through which
hydraulic fluid can pass.Double acting hydraulic cylinder, as name indicates, will be operated
hydraulically in both direction i.e. forward direction and return direction.
Double acting hydraulic cylinder will have one piston within a cylindrical housing. When
hydraulic oil will be supplied to its cap end port, hydraulic pressure force will be applied over
the piston or plunger and hence the piston will be extended and this stroke of the cylinder will
be termed as forward stroke. During extension of the cylinder piston or plunger, hydraulic oil
at the rod end side will be pushed out and will be directed towards the reservoir.

Fig 3.7 : Functioning principle of Hydraulic Cylinder

17
6. Cooling and packing process in coconut shell pellet plant
Palletized coconut shell has a certain temperature, so it needs to be cooled by a coconut shell
pallet cooling machine after being conveyed by a belt conveyor. After cooling, the high-
quality biomass pellet is packed by the automatic packing machine. All the above processes
are equipped with a dust collector, which makes the whole coconut shell pallet manufacturing
process no dust pollution.

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3.3 CALCULATION
Designing of 4 column type hydraulic press
Design Prerequisites: Hydraulic press system is to be designed according to the requisites of
following.
1. 5 ton operating force.
2. 350 bar cylinder pressure.
3. Stroke length 300 mm.

Table 3.1 Material Selection

Sr. Parts Material Young’s Modulus Tensile Strength Poisson’s

no (Gpa) (Mpa) Ratio

1 Cylinder & Pillar ST-42-S 210 412 0.3

2 Piston with rod, EN8 200 541 0.3

base, nuts, & bolts

3 Platens and Bolster EN24 207 800 0.29

➢ Dimensions of Hydraulic press machine

Table 3.2 Dimensions of Hydraulic Press Machine

Stroke Length 300 mm

Steady Plate size 350 mm * 400 mm

Movable Plate size 350 mm * 400 mm

Bore internal diameter 65 mm

Bore outer diameter 70 mm

Diameter of Pillar 20 mm

19
 Fig 3.8: HYDRAULIC PRESS MACHINE

Cylinder body design since we are designing for 5-ton capacity,

the force is 5000 kg = 49032.5
3.1 a) Internal Bore diameter(Di):
Formula for applying pressure
P = F/A ------------------- (1)
Where, pressure is in N/mm2
F = Force in N
A = Area in mm2
Therefore,
35 = 49032.5 / (π / 4 x Di2)
Di = 65 mm
Since ASTM A106-B Standard Bore from catalogue manual is 63 mm Therefore Bore
diameter Di = 63 mm.

b) To find the thickness of the press cylinder.

Material for tube: St-42 Structural steel hollow tube
Tensile strength = 42 kgf/mm2
= 412.02 N/mm2
For hydraulic press machines where loading is uncertain in design Application, hence FOS is
chosen is 4.

20
The FOS chosen is on the higher side because this is the equipment for checking valves.
Normally a FOS of around
2.5 to 3 is chosen since testing equipment should be more accurate and long lasting therefore
a FOS of 4 is
chosen.
Ft = σt = 412.02/4 = 103.00 N/mm2

c) Clavarino’s equation for closed cylinder

t = (Di / 2) {√ [(Ft + (1-2μ) P / (Ft - (1-μ) P)] - 1} ------------
---------------------- (2)
Where, t = Cylinder thickness
Di = Inner diameter of the cylinder body = 63mm
P = Working pressure = 35 N/mm2
μ = Poisson's ratio = 0.3
t = (Di/2) [√ {(Ft + (1-2μ) P / (Ft - (1-μ) P)} -1]
t = 13.433=13.5 mm
OD of cylinder
D0= Di + (2 x t) --------------------------------------------------------------(3)
D0= 63 + (2 x 13.5)
D0 = 90 mm.
Standard D0 = 100 mm.

d) Piston rod design

Material: Steel, EN–8
Assumptions made
1) Bar is straight and homogenous material.
2) Rod is continuous and no abrupt changes occur.
3) Line of force acting coincides with the axis of ram/rod.
For pressure of 350 bar
Load F = A * P= {𝜋4x (63)2} x 35 = 49032.5 N
Force = Area x stress
F = A x σt
For EN-8 material tensile strength is 541.985 N /mm2

21
For FOS of 4, then
σt = 541.985 / 4 = 135.5 N /mm2
49032.5 = { 𝜋4x (dp)2 x 135.5}
(dp)2 = (49032.5∗ 4)/(π∗ 135.5 )
dp = 460.73 mm.

e) Design of pillar(column)
Material: Structural steel St-42
Force acting on each pillar= 49032.5/4 = 12258.125 N
Working stress= Ft= σt= 412.02/4 = 103.00 N/mm2
σt = F / A, F= σt.A
Standard d= 30 mm
103x (Π/4) xd2 = 12258.125
d=19.07 (minimum diameter of pillar)

f) Stresses acting on the pillar(column)

σt = F / A = 49032.5/706.85= 69.367 N/mm2
σt= 69.367 N/mm2
F= force acting on pillar
L= length of pillar
A= C/S Area of pillar
E= Young's modulus
Deformation of pillar
δ=(FL)/(AE) ---------------------------------------------------------- (4)
δ= 0.109 mm

22
g) Design of platen
Material: EN-24
Tensile strength= 800 N/mm2
Working stress= σt= 800/4 = N/mm2
To find thickness of platen [19]
t1=k3√a.b. F/σt(a2+b2) ------------------------------
------------------------------------ (5)
a= length= 420 mm
b= width= 420 mm
K= coefficient of material= 3 (steel)
F=force acting= 49032.5 N
t1 = 51.46
Standard thickness is 52 mm.

Figure 3.9 : Piston Rod

23
3.4 ANALYSIS

➢ Analysis of column pillar

Stress of 43.68 MPa is generated in the column due to applied load as shown in figure 1.
Total deformation of
0.052 mm is found due to the applied load on the column as shown in the figure 2.

Fig 3.10: Stresses in the column Fig 3.11: Total Deformation in the column

Analysis on Movable Plate

➢ Stress and Deformation in the movable platen
Stress of 57.15 MPa is generated in the movable platen due to applied load as shown in figure
3. Total deformation of 0.09 mm is found due to the applied load on the movable platen as
shown in the figure 4.

Fig 3.12: Stresses in the movable platen Fig 3.13: Deformation in movable plate

24
Figure 3.14: Typical flow diagram of fully automatic compressed pallet production plant.

25
 CHAPTER 4

RESULTS AND DISCUSSION

26
CHAPTER 4 :
RESULTS AND DISCUSSION

4.1 Comparison between Wooden Pallets and Coconut Pallets

Wooden Pallets Coconut Pallets

1. Rising pallet life costs due to wood 1. Produced with heat and high
shortages, potential delays at port of pressure. 100% Wood free.
destination and end-of-life disposal.

2. Bulky design leads to inefficient, 2. 100% natural and biodegradable

pollutive shipping and storage. Free of any synthetic resins.

3. Use of nails and chemical 3. Fully circular Valuable as soil

fumigation Landfill or burning at end- improver at the end of the
of-life. supply chain.

4. Unsustainable one-time use of wood 4. Nestable design saves 70%

pollutive and better suited for long- shipping and storing space
term applications (furniture, building,
etc

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4.2 CLAIMS

We Claim,
This comprises of :
1. Crushing section of coconut husk which is done on a crusher machine.
2. Drying section in which we dry off moisture to improve the strength of the pallet.
3. Mixing section consists of a mixing of crushed particles of husk with synthetic glue.
4. Hydraulic press where the material is pressed with some specific pressure.
5. The quality of compost obtained by using this apparatus and method will be of better
nutritional quality
6. The overall time required for formation of compost will be reduced.

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 CHAPTER 5

SUMMARY AND CONCLUSION

29
CHAPTER 5:
SUMMARY AND CONCLUSION

5.1 CONCLUSION

In this work the 4 - column hydraulic press is designed and analysed with standard.
The maximum stresses induced in the 4 column hydraulic press machine is less than
permissible stress of the material. This machine is used for compressive pressing operation
in sheet metal industries where the deformation of the press should be permissible.
Pressing accuracy plays an important role to maintain the close tolerance and to increase
productivity. As analysis shows maximum deformation found is lesser than 1 mm which is
tolerable for such hydraulic pressing operations. It is a multi-purpose machine which is used
for performing pressing and forging tasks. By changing the die, different operations like
blanking, sheet metal and bending etc. can be performed on a hydraulic press machine by
varying input to the cylinder which is restricted by the output of the pump. It ought to be
permissible. Pressing precision is critical for maintaining tight tolerances and increasing
production. The highest distortion detected, according to the analysis, is less than 1 mm,
which is acceptable for hydraulic pressing activities.

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5.2 SUMMARY

The present invention introduces the field of coconut pallet making machine which plays a
major part. As well as includes the study of coconut pallets and the difference between them
and wooden pallets. The hydraulic coconut pallet making machine mechanisation will
improve the overall quantity of pallets and make them cheaper and have more strength as
compared to wooden pallets.
It specifically focuses on
1. Making of Coconut Pallet
2. Design and Develop a Hydraulic machine for making coconut pallets
3. Less manual use
4. Build a strong and having good strength coconut pallet

This machine is going through the design development process from data comparison to
product fabrication. The detailed design development process ensures that the final result of
the machine is achieving the objective to reduce and eliminate repetitive tasks performed by
human resources. The machine is controlled by the new concept of the controller with an
open-source controller that makes the machine more flexible and easier to handle. The
machine is tested for machining tolerance to ensure the machine provides high accuracy
results. Although the machine 'Still limited to perform the heavy-duty process, this machine
can help the small and medium enterprise industry increase productivity by eliminating and
reducing human error.

Coconut husks are the rough exterior shells of the coconut and have been used in the
production of higher products such as coco peat, coco husk chips, coco crush and coir fibre. It
is not used as an alternative of food but can be useful in developing a potting plant to grow
plants and flowers. Coconut husk offers an effective solution for greenhouse production as a
raw material of soil and has an excellent capacity to absorb the nutrition and transfer it to the
plants. It is capable of retaining the moisture inside for a longer period of time, which helps
to grow plants healthier.

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 CHAPTER 6

LITERATURE CITED

32
CHAPTER 6
LITERATURE CITED

6.1 LITERATURE CITED

Sr. no Authors Title of Paper Place and date of

publication

1 Michiel Vos Coco pallets made from Wageningen,

coconut waste to replace Netherlands on March 2,
timber pallets and saving 2010.
trees.

2 Edwin Keijsers The use of coconut pallets Wageningen,

help reduce deforestation. Netherlands on March
10, 2016.

3 Axel Barrett Coconut husks are the best Wageningen,

alternatives to wood. Netherlands on October
16, 2019

4 Fino Menezes How coconut waste can Wageningen,

contribute to a circular Netherlands on
economy. December 10, 2019

5 Tejas Patel Design of Semi-automatic Vallabh, Vidya nagar

Hydraulic Blanking Machine India on April 2015
using PLC

33
6.2 REFERENCES

Textbooks:-
1. Dynamic Behaviour of the Hydraulic Press for Free Forging, Karel Raz, Vaclav
Kubec, and Milan Cechura, 2014.
2. Computer Aided Design and Analysis of Power, D. Ravi, Power Press, 2014.
3. Bent Hollow Channel Punching Using Hydraulic Compact Press, S. Ajaya Kumar and
K. Gopi Krishna, 2016.
4. Stress analysis of a Frame of a Bush pressing Machine for pumps AMIT KALEKAR
2015.

Internet Links:-
1. https://www.cocopallet.com
2. https://www.ideassonline.org/public/pdf/CocoPallet-ENG.pdf
3. https://www.wageningenur.nl/en/biobased-economy
4. https://www.bioplasticnews.com
5. http://www.arsinmachine.com/wp-content/uploads/Hydraulic-Press-tonnage-
calculation.pdf

34
6.3 LIST OF PUBLISHING

Sr. Authors Title of Paper Name of International Place and Date of

no Journals/ International Publication with
Conference Citation Index

Amit Khapekar
Design and Recent Advances in At YCCE, Nagpur
Vaibhao Surpam Development of Materials, on
1 Coconut Husk Pallet Manufacturing and 26th -27th April
Riya Chavhan Making Machine Machine Learning 2022
(RAMMML - 2022)
Akash Rathod

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