VISVESVARAYA TECHNOLOGICAL UNIVERSITY Jnana Sangama, Belagavi-590018 A KSCST (41 st series) Sponsored Project report on “DESIGN AND FABRICATION OF TENDER COCONUT AND MATURED COCONUT PROCESSING UNIT” In partial fulfilment of the requirement for the award of degree of BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING Submitted by RANGEGOWDA N G 1KI14ME082 SIDDESH S 1KI14ME096 SRINIVASA K M 1KI14ME099 PRAVEEN K S 1KI14ME078 Under the guidance of Mr. Manjunath Channappagoudra M.Tech Assistant Professor Dept. of Mechanical Engineering KIT, Tiptur DEPARTMENT OF MECHANICAL ENGINEERING KALPATARU INSTITUTE OF TECHNOLOGY TIPTUR-572202 2017-2018 KALPATARU INSTITUTE OF TECHNOLOGY TIPTUR-572202 DEPARTMENT OF MECHANICAL ENGINEERING
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VISVESVARAYA TECHNOLOGICAL UNIVERSITY
Jnana Sangama, Belagavi-590018
A KSCST (41st series) Sponsored Project report
on
“DESIGN AND FABRICATION OF TENDER COCONUT AND
MATURED COCONUT PROCESSING UNIT”
In partial fulfilment of the requirement for the award of degree of
BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING
Submitted by
RANGEGOWDA N G 1KI14ME082
SIDDESH S 1KI14ME096
SRINIVASA K M 1KI14ME099
PRAVEEN K S 1KI14ME078
Under the guidance of
Mr. Manjunath Channappagoudra M.Tech
Assistant Professor
Dept. of Mechanical Engineering
KIT, Tiptur
DEPARTMENT OF MECHANICAL ENGINEERING
KALPATARU INSTITUTE OF TECHNOLOGY
TIPTUR-572202
2017-2018
KALPATARU INSTITUTE OF TECHNOLOGY
TIPTUR-572202
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the project report on “DESIGN AND FABRICATION OF
TENDER COCONUT AND MATURED COCONUT PROCESSING UNIT” has
been successfully carried out by RANGEGOWDA N G (1KI14ME082), SIDDESH S
(1KI14ME096), SRINIVASA K M (1KI14ME099),PRAVEEN K S (1KI14ME078),
at KIT, Tiptur in partial fulfilment of the requirement for the award of BACHELOR
OF ENGINEERING, IN MECHANICAL ENGINEERING during the academic year
2017-2018. It is certified that all corrections suggested have been incorporated in the
report.
Signature of Guide Signature of HOD
……………………… ………………………
Mr. Manjunath Channappagoudra. M.Tech Dr. Viswanatha B.M. M Tech, Ph..D
Assistant professor Professor and HOD
Dept. of Mechanical Engg. Dept. of Mechanical Engg.
K.I.T, Tiptur. K.I.T, Tiptur
Principal
………………………
Dr. Nandeeshaiah. ME, Ph.D
Principal
K.I.T, Tiptur
i
ACKNOWLEDGEMENT
We consider this a privilege to express a few words of gratitude to all those who guided
and inspired us for the successful completion of our project work.
Our delightful thank to our guide Mr. Manjunath Channappagoudra, Assistant
Professor for his excellent guidance throughout our project and for his valuable
suggestions.
We also extend immense thanks to our Head of the Department, Dr. Viswanatha B.M. for
extending all facilities throughout our project work.
We would like to thank Dr. Nandeeshaiah, Principal of KIT, Tiptur, for providing an
excellent academic environment in this institution.
We express our deep sense of gratitude to Kalpataru Institute of Technology, Tiptur that
has provided us an opportunity in ful-filing our most cherished desire of reaching our
goal.
We express our deep sense of gratitude to Karnataka State Council for Science and
Technology (KSCST), Indian Institute of Science, Bangalore for selecting our project
under Student Project Programme (SPP) – 41st series and providing financial support to
complete our project work.
Project Associates:
Praveen K S 1KI14ME078
Rangegowda N G 1KI14ME082
Siddesh S 1KI14ME096
Srinivasa K M 1KI14ME099
ii
ABSTRACT
The world is presently confronted with a lot of health issues even having modern
sophisticated technologies. Blood pressure, Kidney stones, Mal nourishment, Gallbladder
diseases are the major and unavoidable health issues as on today irrespective of age
group. In this regard there is a lot of scope to search for solutions which are feasible and
promising better health. In this view organic coconut products namely Virgin coconut oil,
Tender coconut mint cooler, Tender coconut green chilly cooler and Tender coconut tea
will give the harmonic health benefits for the human being. From the exhaustive literature
associated with human health issues it has given constructive hopes to have healthier life
with inventing identical solution. Hence the project is aimed to design, development and
fabrication of machine to resolve the health issues with some extent. The new approach
with sincere effort may give positive signs towards healthier life for human kind. The
defined objectives of the project are not only for health aspects, it will also encourage the
coconut formers, unskilled people and unemployed people to have their own jobs with
good profit in turn their annual economy.
iii
CONTENTS
Particulars Page no.
Acknowledgement i
Abstract ii
List of figures vi
List of table viii
Acronyms and abbreviations ix
Chapter 1 Introduction 1
1.1 History of coconut tree 2
1.2 Importance of coconut tree and its products 4
1.2.1 Health benefits of VCO 4
1.2.2 VCO as a versatile product 5
1.2.3 Nutritional benefits of TCW 6
1.3 Problem identification and definition 8
Chapter 2 Literature Review 10
2.1 Objectives of project work 14
Chapter 3 Materials and Methodology 15
3.1 Materials 15
3.1.1 SS 304(Food grade) 15
3.1.2 Hydraulic jack 15
3.1.3 Steel vacuum base coconut scrapper 16
3.1.4 Food thermometer 17
iv
3.1.5 Instant cooler 17
3.2 Methodology 18
Chapter 4 VCO Production Process 21
4.1 Pre-processing stage 21
4.1.1 Selection/Harvesting 21
4.1.2 Husking 23
4.2 Processing stage 23
4.2.1 Handling coconut water 23
4.2.2 Selection of coconut kernels for processing 25
4.2.3 Removal of the coconut kernel 25
4.2.4 Drying of freshly comminuted kernel 27
4.2.5 Virgin coconut oil extraction 28
Chapter 5 Design Details and Fabrication 29
5.1 Design drawing details of parts 29
5.2 Assembly views 32
5.3 Fabricated model 34
Chapter 6 Outcomes of the Project work 36
6.1 Comparisons of conventional method versus
our fabricated machine 36
6.2 Tender coconut products 36
6.2.1 Tender coconut mint cooler 36
6.2.2 Tender coconut green chilly cooler 38
6.2.3 Tender coconut mango flavoured 39
6.2.4 Tender coconut orange flavoured 41
v
6.2.5 Average profit forecasting of TCW products 41
6.3 Calculations for VCO 42
6.4 Cost of the project 43
Chapter 7 Conclusion 44
References 45
vi
LIST OF FIGURES
Fig. No. Description Page no.
1 Coconut tree 3
2 Problem identification and solutions 8
3 Hydraulic jack 15
4 Steel vacuum base coconut scrapper 15
5 Food thermometer 16
6 Instant cooler 17
7 Method of extracting TCW 18
8 Method of extracting VCO 18
9 Process flow 19
10 Good, mature coconuts 20
11 Over mature coconuts with germination growth 21
12 Husked coconuts with the eye still covered by
a portion of husk 22
13 Splitting of coconuts 23
14 Left, good coconut kernel for processing. Middle,
discoulred kernel for rejection. Right, kernel with
haustorium. 24
15 Grating of coconut kernel 25
16 Process flow of VCO extraction 27
17 a- i Design drawings of the parts 30
18 a-d Assembly view of TCW extracting machine 31
vii
19 a-d Assembly view of VCO extracting machine 32
20 a-b Fabricated model of TCW extracting machine 34
21 a-b Fabricated model of VCO extracting machine 35
22 Packed tender coconut mint cooler 37
23 Packed tender coconut green chilly cooler 38
24 Packed tender coconut mango flavoured 40
25 Packed tender coconut orange flavoured 41
viii
LIST OF TABLE
Table no. Description Page no.
1 Comparisons of conventional method versus our
fabricated machine 36
2 Ingredients for tender coconut mint cooler 37
3 Ingredients for tender coconut green chilly cooler 38
4 Ingredients for tender coconut mango flavoured 39
5 Ingredients for tender coconut orange flavoured 41
6 Cost of the project 43
ix
ABBREVIATIONS
ASTM American society for testing and materials
DCN Desiccated coconut
Ltr Litre
Rs Rupees
SS Stainless steel
TCW Tender coconut water
VCO Virgin coconut oil
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 1
Chapter 1
INTRODUCTION
The tender coconut water(TCW) and virgin coconut oil(VCO) are recommendable
to the people of almost every age. They have high nutritional value and most of the
doctors recommend both tender coconut water and virgin coconut oil to their patients.
The calorie and the sugar content of tender coconut water is also very low. So it does not
have any bad effect on human health. It acts as tonic that reduces the fatigue in an instant.
The tender coconut water is considered as the healthiest drink because of its high vitamin
and protein content. VCO is also considered unique in the sense that it is the only oil with
multi-functional uses: It is the only oil which one can eat as a food supplement or
functional food, use for cooking, apply to the hair and skin as a moisturizer and
conditioner, and use as a major ingredient in skin care products or as carrier oil in
aromatherapy and massage oils.
On an average, street hawker sells at about 100 green coconuts per day. The
conventional way of cutting the coconut is done by the sharp knife and the task is done by
the expertise and anybody cannot do it. In the conventional way, cutting the top portion of
the coconut and the time required for the operation is more than 1 Minute. Hence the
waiting time for the customer is more and attraction of the customer is less. Now a day
the process of chopping the green coconut is very tedious and chances of causing the
accident are more. Utmost care and skill is required to chop the coconut in traditional
way. To compare “our invention” with traditional method, ours is safest.
Today the industrial sector in India is hit badly due to lack of power and improper
management in small scale production. This is the basic reason for the developing a
virgin coconut oil extraction machine. Extraction machine refers both to manual and
economically as a mode of daily commuting aspects as well as the use of virgin oil in a
commercial activity, which is the natural oil obtained from fresh coconut by various
extraction methods as well as being efficient in operation and durable. In this project
fabrication of virgin oil extraction machine using simple designs and mechanism is
carried out.
Our main objective is to fabricate a low-cost hydraulic coconut punching and
shearing machine for tender coconut in which we punch the hole and cut the coconut into
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 2
two halves and ready to sell the coconut to customer and anyone can chop and have a sip
of coconut water and with the same machine we can also extract the virgin coconut
oil(VCO) from the matured coconut.
1.1 History of coconut tree
Coconut palm (Cocos nucifera) can be found throughout the tropics and in many
islands in the Pacific as it is the tropics most common plant. Its history is complex and
has played a major role in both human and ecological survival. The origins and its
dissemination have undergone much debate and there are many theories as to how
coconuts arrived to the Pacific but what becomes clear is the capacity for coconuts to
survive and colonize new areas. It starts from the beginning of the nut whose resiliency
has the strength to withstand some of the world’s worst case scenarios and the palms
ability to adapt to many different environments. Humans have also played a major role in
cocos dispersal because of its ability to provide many different resources like food and
water. It has often been referred to as the “tree of life” or the “tree of heaven”.
During the Ice Ages, between 8,000 and 14,000 years ago, an extensive land area
now known as Malesia, was inundated by rising sea levels. As the shallow continental
shelf between the present-day Malay Peninsula, Sumatra, Borneo and Mindanao was
submerged, drinking water sources would have been contaminated and the cultivation of
crops in low-lying areas forced to higher ground. Among those the coconut palm was one
of the few plants that could tolerate a degree of salinity, and tender-nuts became a source
of pure, sweet drinking water for the human beings in the area. Selection for increased
water content, early germination and other characteristics that are now recognized as
signs of domestication was consistently applied for a long time, over a large area and on
each generation of coconut palms by every generation of people.
According to Western records Cocos nucifera was first reported in 545 AD by an
Egyptian, Cosmos, who saw them in Sri Lanka and India. Marco Polo had also seen them
in 1280 in Indonesia. Vasco de Gamma travelled the route around the tip of Africa to
India in 1498 and only reported seeing “coquos” when he visited Malindi in Kenya.
Christopher Columbus incorrectly identified coconut palms while visiting the Caribbean
in the 1490s. McCormack (2005) states that in 1549 Diego Corenco evidently introduced
the first coconut palm into Puerto Rico. Recent studies of early Spanish records indicate
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 3
that coconut palm naturally travelled to the America by ancient voyagers or by floating
across the ocean by strong currents.
Cocos nucifera, also known as coconut palm, comes from the family Arecaceae
(palm) which consists of 4000 species of large monocotyledonous plants. The plant has
many has many uses and has been a common resource for food crops and ornamental
aesthetics. Coconut palms are pan tropical, meaning they can be found in most tropical
and sub-tropical regions. Most palms have a single segmented flexible trunk with an
average height of 65-72 feet but can reach up to 100 ft. while cultivated plants generally
extend to about 20-50ft. During the first 40 years palms can grow about 12-20 inches a
year. The trunk is anchored by many roots which prefer loose sandy soils, yet are very
resilient to strong winds of cyclonic strength. Palms have one of the largest leaves,
fronds, which are pinnately compound that sprout spirally from the apex of the trunk.
There can be up to 30 leaves on one tree, each frond averages at about 20 ft long, leaves
produce about 200 leaflet per year, the average lifespan of one frond is up to 3 years.
Typically, one frond is lost and formed every month developing about 12-14 fronds per
year. Coconut palms do not begin to produce fruit until they reach about five years old
and can continue to produce for about 50 years.
India has emerged as the largest producer of coconut in the world with a production
of 15729.75 million nuts per annum and accounts to 26.9 per cent of the world’s
production. In India 90 per cent of the production comes from southern states, of which
the major contribution from Kerala (45%), Tamil Nadu (28%), Karnataka (11%) and
Andhra Pradesh (9%). Coconut is used in the preparation of beverages, desserts, sweets
and commonly used in most of the Indian culinary preparations. At national level, the
consumption of coconut as tender coconut is less than 10 per cent of the total production.
Coconut production is 1635 million nuts in Karnataka (Kretchmer and Bose, 2009). [19]
Fig.1 shows the picture of coconut tree.
Fig.1 Coconut tree
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 4
1.2 Importance of coconut tree and its products
The coconut palm (Cocos nucifera) is a tropical tree species which once was the first
major estate crop, extending over large uniform areas, but is now mainly grown and
harvested by small farmers. In addition to the production of vegetable oil for industrial
uses from cosmetics and explosives to bio-fuels and health and wellness products, it is
also a fiber crop, a food and beverage crop, and a visual amenity palm for tourist hotels,
golf courses and city parks and village gardens throughout the tropics. From its natural
habitat on the shoreline of uninhabited oceanic islands to inland locations on the fringes
of deserts and the foothills of mountain ranges, it can provide every necessity for survival
of castaways, subsistence consumption, local markets and international trade.
The coconut has provided critical sustenance for countless tropical coast-dwellers
over many millennia before becoming, during more than a century, the primary source of
vegetable oil in many temperate industrial countries. The remarkable diversity of its
products, derived from coconut fruit, i.e. juice, edible kernel, oil, shell, fiber and peaty
cortex; plus, building material from the frond and trunk; edible "heart-of-palm" from the
growing point; sap (toddy) to drink and provide sugar, and fuel from the bunch stalks, all
of these provide the rationale for the title “The Tree of Life” respectfully bestowed upon
this palm. Industrial uses further include the separation of glycerin and fatty acids, the
production of soaps, detergents and bio-diesel, and coco methyl ester (CME) for mixture
with regular diesel.
1.2.1 Health benefits of VCO
Virgin coconut oil is considered a nutraceutical, i.e. a substance that nourishes and
also protects and heals. Studies have suggested the following.
The medium chain (C8 –C12) fats in coconut oil are similar in structure to the fats
in mother’s milk that gives babies immunity from disease and have similar effects
(Kabara 2000).
Coconut oil possesses anti-inflammatory, anti-microbial and antioxidant
properties that work together to protect the arteries from atherosclerosis and the
heart from cardiovascular disease (Fife 2004).
It is cholesterol-free, trans-fat free and heart-healthy (Verallo-Rowell 2005).
It boosts the immune system (Dayrit 2005).
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 5
It protects against heart disease by increasing high density lipoprotein which
collects the excess or unused cholesterol in the body for excretion in the liver
(Blackburn et al. 1989 cited in Dayrit 2005).
Monolaurin, which is formed by the body when coconut oil is ingested, provides
protection against infectious diseases caused by lipid-coated microorganisms
(Kabara 2000). Diseases caused by such pathogens are not ordinarily cured by
known antibiotics.
It is digested easily without the need for bile and goes direct to the liver for
conversion into energy (Dayrit 2005).
It stimulates metabolism, boosts energy and prevents deposition of fats, thereby
helping to prevent obesity (Dayrit 2003).
It improves the nutritional value of food by increasing the absorption of vitamins,
minerals and amino acids (Fife 2004).
It inhibits the action of cancer-forming substances (Lim-Syliangco 1987).
1.2.2 VCO as a versatile product
VCO is a unique and versatile coconut product for the reasons given below.
a) It has multi-functional uses as discussed above, thereby providing flexibility in
marketing.
b) Technologies are available for it to be processed at different scales of operation.
VCO can be produced at home even without any specialized equipment or it can
be produced in large-scale commercial plant operations.
c) Other functional food products can be processed together with it, depending on
the type of technology applied, thereby maximizing the utilization of coconut
kernel and increasing the economic viability of the operation. For the dry process
of VCO manufacture, high dietary fiber coconut flour can be produced as a co-
product. For the wet process (coconut milk route), low fat desiccated coconut
(DCN) or another type of VCO and coconut flour can be produced as co-products.
d) With minimal additional investment, VCO production can easily be integrated
with an existing coconut milk or desiccated coconut processing plant. Production
of VCO can be integrated with an existing DCN plant with just the addition of a
high pressure expeller and filter press. It can also be integrated with an existing
coconut milk plant with the addition of fermentation equipment (modified natural
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 6
fermentation process) or the addition of a three phase centrifuge (centrifuge
process).
e) Lower quality VCO can still be used for processing other downstream products
such as bath soaps and massage oils, thereby preventing any waste.
f) It is one of the highest valued coconut products in the world market.
1.2.3 Nutritional benefits of tender coconut water
The water of fresh tender coconut which is the liquid endosperm is the most
nutritious wholesome beverage that the nature has provided for the people of the tropics
to fight the sultry heat. According to Ayurveda "It is unctuous, sweet, increasing semen,
promoting digestion and clearing the urinary path."
Some of the medicinal properties of T.C.W. reported are:
Makes an excellent oral rehydration sports beverage - replaces electrolytes from
exercise, heat stress and illness
Aids in exercise performance
Natural isotonic beverage – contains the same level of electrolytes found in human
blood
Has 15 times the amount of potassium as most sports and energy drinks (264 mg vs
12.5 mg /100 ml)
Reduces problems for infants suffering from intestinal disturbances
Cardio protective: helps regular blood pressure (due to high potassium); improves
circulation
Reduces swelling in hands and feet
Prevents abnormal blood clotting
Aids in kidney function including those with kidney stones; Nutritional support for
those with urinary tract/bladder problems
Helps balance blood sugar in diabetics
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 7
Improves digestion
Reported by some people to reverse cataracts
Contains nutrients that feed friendly gut bacteria
Helps relieve constipation or diarrhea
Possesses anti-aging properties
Nutritional support for healthy skin: restores strength and elasticity to skin; reduces
age spots; reduces wrinkles and sagging
Regulates the functioning of the intestine which promotes smoother, more hydrated
skin
Enhances healing of wounds and lesions
Supports good vision and provides nutritional support in those who have a tendency
towards glaucoma
Contains potent antioxidants
Nutritionally supports immune function
Provides nutrients important in preventing osteoporosis
1.3 Problem identification and definition
The world is presently confronted with a lot of health issues even having modern
sophisticated technologies. Blood pressure, Kidney stones, Mal nourishment, Gallbladder
diseases are the major and unavoidable health issues as on today irrespective of age
group. In this regard there is a lot of scope to search for solutions which are feasible and
promising better health. In this view organic coconut products namely Virgin coconut oil,
Tender coconut mint cooler, Tender coconut green chilly cooler and Tender coconut tea
will give the harmonic health benefits for the human being. From the exhaustive
literature associated with human health issues had given constructive hopes to have
healthier life with inventing identical solution. Hence project aimed to design,
development and fabrication of machine to resolve the health issues with some extent.
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 8
Almost every TCW seller uses the traditional way to extract coconut water. They use
a sharp knife to make a hole at top of tender coconut. This requires a skill and lot of
efforts to make the hole. As it requires lots of efforts, it reduces the efficiency. It also
causes the shoulder pain to the seller. To overcome this problem, we have designed a
machine which will easily extract the coconut water with less human efforts. The machine
will be level operated and it does not require any kind of special skills. It can also be used
to cut off the coconut into two halves. The virgin coconut oil is also extracted from the
same set up by changing the adjustments in the machine. In this work hydraulic jack is
used as intermediate power source between human and work process. The Fig.2 shows
the flow chart of problem identification and solution.
Fig.2 Problem identification and solutions
Problem identification and solution
Design and fabrication of tender coconut and matured coconut processing unit 2017-18
Department of Mechanical engineering, KIT, Tiptur-572201. Page 9
Chapter 2
LITERATURE REVIEW
Manisha DebMandal, Shyamapada Mandal [1] The coconut palm (cocos nucifera) is
found all over the globe, where it has minglade into the lives of local people. It provides
almost all the requirements of humans such as food, drink, firewood, medicines, domestic
utensils etc. Because of these reasons, it has been called the “Tree of heaven” and “Tree
of Life”.
Edward Chan and Craig Elevitch [2] The coconut is native to coastal areas of South East Asian
countries such as Malaysia, Indonesia, Philippines and Westward towards the Coastal India, Sri
Lanka, East Africa and tropical islands such as Seychelles, Andaman and Mauritius. In their
regions, the palms were able to establish themselves on sandy and coralline coasts. Coconut palm
can either be an introduction or even possibly a native to Pacific coasts of Central America.
T. Roshni et al., [3] A power operated coconut punch-cum-splitter was developed for
extracting coconut water and coconut meat. The equipment mainly consists of screw rod,