A
PROJECT WORK ON THE
IMPROVEMENT OF THE FABRICATION AND TESTING OF A SUGARCANE JUICE EXTRACTOR FOR THE COTTAGE INDUSTRY BY
MAKINDE-OJO, AYOOLA MacJAY (formerly: OLUWAMAKINDE AYOOLA S.)
MATRICULATION NUMBER 2005/0203 A PROJECT THESIS SUBMITTED TO THE
DEPARTMENT OF AGRICULTURAL ENGINEERING COLLEGE OF ENGINEERING UNIVERSITY OF AGRICULTURE ABEOKUTA IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR A BACHELORS IN ENGINEERING
NOVEMBER 2010 1
ABSTRACT Over the years, sugarcane production in Nigeria has been championed by small-scale farmer who end up terminating the juice extraction at the consumption level using the teeth to bite off the rind and chewing on the internal tissue to suck up the juice. To boost the production of sugarcane and its products, Dr. Ukatu A. C. (Late) and Mr. Soetan A. C., created a sugarcane juice extraction machine fabricated and constructed in the Agricultural Engineering department of the University of Agriculture, Abeokuta. This juice extraction machine, constructed over two year ago, has a juice extraction efficiency of 70 – 77% and a rate of juice extraction of 60 – 65%. To this end, the required improvement and modification for the machine is to be carried out in the course of this project work. This includes the maintenance and cleaning of the machine parts, identification of the required improvements, casing of the machine operating chamber for the juice extraction, painting and aesthetic improvement, and testing the machine performance. To achieve this, the appropriate materials were purchased from a Gate market in the city of Ibadan, Oyo state, while the sugarcane specimens of the Saccharum officinarum species, were purchased from Eleweran market, Abeokuta, Ogun state. The purchased materials for the machine improvement work were fashioned into the required form and installed, while the purchased sugarcane was used in testing the improved machine. Finally, aside the obvious upgrade in the aesthetics of the machine, the improved sugarcane juice extraction machine for the cottage industry was tested and the extraction efficiency was obtained as a range of 65% – 76%, while the rate of juice extraction is 56.19kg/hr.
2
DEDICATION The work is dedicated to the Late Dr. Ukatu, hoping in the course of this project work I did not disappoint him. It is also dedicated to everyone who has lost somebody significant and dear to them.
May the tears we have sown in pain for all our losses, Bring us a bountiful harvest of gain and satisfying pluses.
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ACKNOWLEDGEMENT I acknowledge God for His mercy and grace; seeing me through tertiary tutelage. Next is my memorable family and its members; for being the condiments that define me, and life; for being the furnace that forged me. Personally and officially, as my project supervisor, I would never forget Prof. Adewunmi B. A. for his steady hand. Also I wish to say a big thank you to the Vice chancellor, Prof. Balogun O. O., my dean, Prof. Ajisegiri E. S. A., head of department, Prof. Adewumi B. A. The technical staff of the workshop: Mr. Rasaki M. A., Mr. Shonde A. O., Mr. Olukan N. A., Mr. Taiwo A. A., Mr. Oyekunle T. O., Mr. Ojelade A. O., and all the unmentioned, yet, wonderful staff of the college of engineering, and the university, for the scholarly and administrative network that fashioned my academic framework. Unforgettably, I appreciate my colleagues and friends: Adiyeloja Ibrahim T., Lawal Abimbola, Salako Sola P., for lending me a hand in the course of the testing activity. Banuso Omotayo, Bolarinwa Oluwafunmilola, Sulaiman Ifeloluwa, all my level mates, you and even my enemies.
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CERTIFICATION This is to hereby certify that Makinde-Ojo Ayoola MacJay Samuel Olubanjo (formerly Oluwamakinde Ayoola Sunday) with matriculation number 2005/0203 of the department of Agricultural Engineering, College of Enginerring in the Universty of Agriculture Abeokuta, undertook his final year project work for the 2009/2010 session, satisfactorily, under the supervision of Prof. B. A. Adewumi.
_________________________ Prof. Adewumi B. A.: Supervisor
_________________________ Prof. Adewumi B. A.: Head of Department
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TABLE OF CONTENT
page
Title page Abstract
i
Dedication
ii
Acknowledgement
iii
Certification
iv
List of plates
viii
List of figures
ix
List if tables
x
CHAPTER ONE: INTRODUCTION
1
1.1 BACKGROUND INFORMATION
1
1.2 PROBLEM STATEMENT
2
1.3 OBJECTIVE OF WORK
3
1.4 JUSTIFICATION
3
CHAPTER TWO: LITERATURE REVIEW
5
2.1 SUGARCANE
5
2.1.1 SUGARCANE VARIETIES
5
2.1.2 PRODUCTS OF SUGARCANE
5
2.1.3 STORAGE
7
2.2 GLOBAL DISTRIBUTION AND PRODUCTION OF SUGARCANE
7
2.3 PROCESSING OF SUGARCANE
8
2.3.1 HARVESTING
11
2.3.2 SUGARCANE TRANSPORT
11 6
2.3.3 MILLING AND JUICE EXTRACTION
11
2.3.4 HIGHLIGHT OF FURTHER PROCESSING
12
2.4 EXISTING SUGARCANE EXTRACTORS
12
2.4.1 THE TRAPICHE
13
2.4.2 ZAMA COMPANY JUICERS
13
2.4.3 TU-100
13
2.4.3 THE MCI MODELS
15
2.4.4 THE ABAMASTER JUICER
15
2.4.5 JINSHUI SUGARCANE JUICE EXTRACTOR
15
CHAPTER THREE: MATERIALS AND METHOD
18
3.1 DESCRIPTION OF THE EXISTING EXTRACTION MACHINE
18
3.1.1 THE CRUSHING UNIT/ ROLLER
19
3.1.2 THE SHAFT
19
3.1.3 GEARS
19
3.1.4 BELT AND PULLEY
20
3.1.5 POWER SOURCE
20
3.1.6 THE MACHINE FRAME
20
3.2 REQUIRED IMPROVEMENT ON THE JUICE EXTRACTOR
20
3.2.1 MATERIALS
20
3.2.2 PROCEDURE OF CASING FABRICATION
21
3.3 DESCRIPTION OF IMPROVED MACHINE
28
3.3.1 DESIGN DESCRIPTION
28
3.3.2 FUNCTIONAL DESCRIPTION
29
3.4 TEST PARAMETERS AND PROCEDURE 7
30
3.4.1 TEST PROCEDURE
30
3.4.2 TEST FROMULAE AND PARAMETERS
31
CHAPTER FOUR: RESULT AND DISCUSSION
33
4.1 DIMENSIONS OF SUGARCANE SPECIMEN
33
4.2 EFFICIENCIES OF JUICE EXTRACTION
33
4.3 JUICE EXTRACTION EFFICIENCY
35
4.4 THE RATE OF JUICE EXTRACTION
36
CHAPTER FIVE: SUMMARY AND RECOMMENDATION
37
5.1 SUMMARY
37
5.2 RECOMMENDATION
37
REFERENCE
39
8
LIST OF FIGURES
page
Figure 1: Global distribution and production of sugarcane (FAO, 2008)
8
Figure 2: The flowchart of sugarcane juice extraction process
10
Figure 3: Development of top cover section
22
Figure 4: Development of hopper section
24
Figure 5a: Development of side plate
26
Figure 5b: Development of base tray (chute)
26
9
LIST OF PLATES
page
Plate 1: The Trapiche
13
Plate 2: The ZAMA Sugarcane Juicer
14
Plate 3: The Abamaster SCJE 2000
14
Plate 4a: The MCI 60
14
Plate 4b: The MCI 170
14
Plate 5: The SXZ-60 Jinshui Sugarcane Juice Extractor (Rika, 2010)
16
Plate 6: The existing sugarcane juice extraction machine
17
Plate 7a: The front view of the existing sugarcane juice extraction machine
18
Plate 7b: Rear view of the existing sugarcane juice extraction machine
18
Plate 8: The top cover after construction
23
Plate 9a: Folded cut out detail of hopper
25
Plate 9b: Hopper detail with attached tray
25
Plate 9c: The hopper section when assembled to the machine
25
Plate 10a: The constructed side plate
27
Plate 10b: The machine frame with the side plate in place
27
Plate 11a: Construction of base tray
28
Plate 11b: Base view of assembled machine with base tray in place
28
Plate 12a: Previous state of the machine
29
Plate 12b: Present state of the machine
29
10
LIST OF TABLES
page
Table 1: Top ten sugarcane producers (FAO, 2008)
8
Table 2: Features of the Jinshui Sugarcane Juice Extractor
15
Table 3: Dimensions and weights of the sugarcane specimens
33
Table 4: Result of the preliminary test
34
Table 5: Result of performance test
34
Table 6: Parameter for rate of juice extraction calculation
36
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CHAPTER ONE: INTRODUCTION 1.1 BACKGROUND INFORMATION Sugarcane is the common name of a species of herb belonging to the grass family. There are three major categoric species of sugarcane found in Nigeria, and these are Saccharum officinarum, S. sinense, and S. Spontaneum. It is of six perennial grasses species, in the tribe Andropogoneae of the Graminea (Purseglove, 1988). It grows up to heights of 2 to 7 meters having clumped up, jointed, cylindrical, stout stalks; of diameter 1.25cm to 7.25cm (Munoz et al, 2007). Several different horticultural varieties are known, and they differ by their stem colour and length (Anonymous, 1998). Sugarcane has been cultivated since ancient times. The most widely used cultivation technique is by stem cuttings, since many varieties do not produce fertile seeds (Microsoft, 1994). Sugarcane was one of the first "cash crops" of early colonial America. Boyel (1939) emphasized that this is one of the many species of plants that depend on human intervention for proper survival. It is a very easy, and profitable plant to grow, but does not naturally reproduce very effectively. It grew plentifully in the southern states, and was a major source of income for many plantations. The areas where it is readily grown in the United States are Hawaii, Louisiana, Florida and Puerto Rico. The countries in the world that produce the largest amounts of sugarcane are Brazil, Cuba, Kazakhstan, Mexico, India, and Australia (Microsoft, 1994). For centuries it has been harvested by hand, because sugarcane was not easily harvested by machine. It was formerly, mainly, harvested using large machete like blades. For this reason sugarcane fields have very large amounts of farm hands, and are a major source of employment throughout South America, Central America, and even the Caribbean (Wikipedia, 2010). In early America, when the plant was readily harvested, it was a major source of slavery in the south, but the elimination of slave practices demanded the uprising of mechanical techniques to the harvesting of sugarcane. Wikipedia (2010) states that mechanical harvesting uses a combine, or chopper harvester. Other companies such as Cameco or John Deere have copied the original modern harvester design: the Austoft 7000 series. The machine cuts the cane at the base of the stalk, strips the leaves, and deposits the cane into a transporter, while blowing the thrash back onto the field; having the ability to harvest 100 long tons (100 t) each hour. It is noteworthy that machineharvested cane must be rapidly processed. Once cut, sugarcane begins to lose its sugar content, and damage to the cane during mechanical harvesting accelerates this decline. 12
Sugarcane, is highly adequate in the provision of energy for the nutritional requirement of both livestock and humans. Based on its land use factor, its value of calories per unit area is highest for any plant (Heiser,1981). Furthermore, due to the content of sugarcane - 70% water, 14% fibre, 13.3% saccharose ( about 10 -15% sucrose), and 2.7% soluble impurities – it provides 60% of the world’s sugar production while the rest is provided by sugar beet (World Bank, 1998). The juice within the sugarcane and the remnant of the extraction process are very important to manufacture numerous useful substances and materials in the community. For this purpose the industrialization of the extraction process to cater for a very large amount of sugarcane, by way of maximizing its usefulness is economically significant. Also, smaller technological breakthroughs such as the sugarcane juice extraction machine for the cottage industry have been made to cater for small scale sugarcane processing. 1.2 PROBLEM STATEMENT Sugarcane juice, over the years, has been successfully used in the production and manufacturing of the edible refined sugar; using machines which were fabricated and constructed to large scale production, industrialization and large capital requirements. This makes the extraction of sugarcane juice a fantasy to local or small-scale industrial establishments. Thus, this amputates the involvement of small-scale farmers in the business of sugarcane juice extraction and refined sugar production; at large. In Nigeria, it is quite remote for those who are subsistent in agricultural practices to take part in sugar production practices in the scope of their practice. Furthermore, the major way by which the suckle in sugarcane has been enjoyed over the years has been by the employment of the teeth in biting off the rind and chewing up the internal tissues. When this is achieved, the juice would then be extracted and sucked in the mouth. After this the bagasse is spat out. The grossness of this procedure tends to: •
Put the human teeth in duress; imagine if the amount to be consumed is large.
•
Possibly soil the hands and clothing of the consumer.
•
Classify the consumption of sugarcane as raze and rural, causing a reduction in the widespread acceptance of the crop for consumption.
At present, the construction of the cottage industry sugarcane juice extractor has been facilitated to cushion these problems so far. The important step of producing sugar from the extracted juice by the machine would be enhanced also; because, aside from consumption, 13
sugarcane cultivation in the world is targeted towards the production of sugar, ethanol, and many more. The aggregate of the various cottage industry extraction activity, would sum up to meeting the global requirement for the numerous sugarcane products; but what state the machine puts the extracted juice in, is another thing to consider. In this light, one should not, for the purpose of solving a problem, create another problem. The incursion of rust and surrounding debris into the extraction process of the fabricated machine has been an issue to which one needs to proffer solution to. These numerous contaminants when introduced into the desired substance get to mix-up with it and when consumed, they tend to reside in the body and accumulate until its adverse effect would be prominent. For any consumer, the knowledge of such a technology would make them find satisfaction in retaining backward and archaic techniques such as’ buccal’ juice extraction. 1.3 OBJECTIVE OF WORK The improvement of the previously constructed sugarcane juice extractor for the cottage industry is the main objective of this project work. The scheduled improvement is to cater for the under listed purposes. i.
Maintenance of the sugarcane juice extractor machine.
ii.
To improve the aesthetics of the constructed machine.
iii.
Identify and construct the missing components of the sugar cane extractor; especially the casing, hopper and chutes. The casing of the operating chamber would in turn help improve the enclosure of the extraction process, minimizing the interaction of the surrounding with the process.
iv.
The reduction of machine use hazard. This is achieved by ensuring that the various joints are well secured; and covering most moving parts.
v.
The improvement of the separation of the juice from bagasse; and the collection.
vi.
Testing of the machine. This is subjecting the machine to tests under laboratory conditions.
vii.
Evaluate the performance of the machine.
1.4 JUSTIFICATION The use of non-reactive metallic materials for the fabrication would also go a long in segregating the frame-metal, which is mild steel, from having contact with the juice. This would also help improve, by way of reduction, the introduction of rust into the extracted juice. 14
Since juice is liquid in nature, it has a good amount of moisture in it; which would enhance the corrosion of the mild steel frame. The construction of the casing for the operating chamber would help shield off the intrusion of rust in the extracted juice. Furthermore, the casing would improve the safety of the operator. This is ensured by the covering of the moving parts: such as the gears. Also the aesthetics of the machine construction would be upgrade. This would not interfere with the steady operation of the machine, but this would improve the people appreciation of the machine. In closing, when the status of fabrication of this machine is upgraded it would go a long way in improving the losses in the extraction process; such as time losses and good product losses. Also the hygiene of the machine would be better since the presence of contaminants such as rust would be curbed. Then, due to the adoption of the hopper section the quantity of sugarcane pieces and cutting that can be handled at the same time would be more thus saving time losses and the activity of the employed labour.
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CHAPTER TWO: LITERATURE REVIEW 2.1 SUGARCANE Sugarcane is any of six to thirty-seven species (depending on taxonomic system) of tall perennial grasses (Naturland, 2000). Sugarcane is a tropical grass belonging to the same family as sorghum, Johnsongrass, and corn – also known as maize (Midwest Research Institute, 1997). It is of the kingdom Plantea, phylum Magnoliophyta (Monocots, Commelinids), order Poales, family Poaceae and genus Saccharum L. Sugarcane only rarely produces seeds capable of germination. Most of the several hundred usable clones are cross-fertilisations between S. officinarum (high sugar content), S.sinensis (adaptable), S. spontaneum and S. robustum (disease resistant). The most common clones are octaploid (eight corresponding, similar in position, structure, function or characteristics sets of chromosomes in a cell), and are propagated vegetatively (Naturland, 2000). 2.1.1 SUGARCANE VARIETIES Native to warm temperate to tropical regions of Asia, they have stout, jointed, fibrous stalks that are rich in sugar, and measure two to six meters (six to nineteen feet) tall. All sugar cane species interbreed, and the major commercial cultivars are complex hybrids. Some of such species
are:
•
Saccharum arundinaceum
•
Saccharum procerum
•
Saccharum bengalense
•
Saccharum ravennae
•
Saccharum edule
•
Saccharum robustum
•
Saccharum munja
•
Saccharum sinense
•
Saccharum officinarum
•
Saccharum spontaneum
In the diversity of the species of sugarcane, the unifying factor for them all is the similitude of the products and uses that sugarcane bears. 2.1.2 PRODUCTS OF SUGARCANE Sugar cane products include table sugar, Falernum, molasses, rum, cachaça (the national spirit of Brazil), and ethanol; amongst others. The bagasse that remains after sugar cane crushing may be burned to provide heat and electricity (Wikipedia, 2010). It may also, because of its high cellulose content, serve as raw material for paper, cardboard, and eating utensils that, because they are by-products, may be branded as "environmentally friendly". 16
Wikipedia (2010) generally highlights that in most countries where sugarcane is cultivated; there are several foods and popular dishes derived directly from it, such as:
a. Raw sugarcane: chewed to extract the juice. b. Sugarcane juice: a combination of fresh juice, extracted by hand or small mills, with a touch of lemon and ice to make a popular drink, known variously as ganne ka rass, guarab, guarapa, guarapo, papelón, aseer asab, Ganna sharbat, mosto and caldo de cana. c. Cachaça: a liquor made of the distillation of sugarcane and it is the most popular distilled alcoholic beverage in Brazil. d. Jaggery: a solidified molasses, known as Gur or Gud in India, traditionally produced by evaporating juice to make a thick sludge and then cooling and molding it in buckets. Modern production partially freeze dries the juice to reduce caramelization and lighten its color. It is used as sweetener in cooking traditional entrees, sweets and desserts. e. Panela: solid pieces of sucrose and fructose obtained from the boiling and evaporation of sugarcane juice; a food staple in Colombia and other countries in South and Central America. f. Molasses: used as a sweetener and a syrup accompanying other foods, such as cheese or cookies. g. Rapadura: a sweet flour which is one of the simplest refinings of sugarcane juice. h. Rum: especially in the Caribbean. It is a strong alcoholic drink, mostly with a dark brown colour. i. Falernum: a sweet, and lightly alcoholic drink made from sugar cane juice. j. Syrup: a traditional sweetener in soft drinks, now largely supplanted (in the US at least) by high-fructose corn syrup, which is less expensive because of subsidies. k. Rock candy: crystallized cane juice. l. Sayur Nganten : name of Indonesian soup made of trubuk stem (Saccharum edule). m. Ethanol fuel: Ethanol is generally available as a by-product of sugar production. It can be used as a bio-fuel alternative to gasoline, and is widely used in cars in Brazil. It is a promising alternative to gasoline, and may become the primary product of sugarcane processing, rather than sugar.
17
In summary, the fibrous and woody residue, bagasse, is useful in boilers as fuel, production of chemicals, papers, particleboards and farmland mulching, amongst others. Supplies for fertilizers, sugarcane wax and animal feed supplements, can be provided by the dried filtercake, while the molasses provides an inedible form known as blackstrap (further processed into animal feeds, ethanol, yeast, etc.) and the edible syrup (MRI, 1997).
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2.1.3 STORAGE Whole cane sugar is very hygroscopic (draws water), and it should be stored air-tight in a dry place. When the product is incorrectly stored, yeasts may begin a fermentation process. Under ideal storage conditions (dry, dark and no smells), whole cane sugar can be stored for 12-18 months (Naturland, 2000). 2.2 GLOBAL DISTRIBUTION AND PRODUCTION OF SUGARCANE Originally, people chewed sugarcane raw to extract its sweetness, but with time, Indians discovered how to crystallize sugar during the Gupta dynasty, around 350 AD. Sugarcane was originally from tropical South Asia and Southeast Asia, but it is conceived that different species likely originated in different locations with S. barberi originating in India and S. edule and S. officinarum coming from New Guinea (Yamada et al., 1998). Around the eighth century A.D., Indian traders introduced sugar to the Mediterranean, Mesopotamia, Egypt, North Africa, and Andalusia. By the tenth century, sources state, there was no village in Mesopotamia that did not grow sugar cane. Watson stated that it was among the early crops brought to the Americas by the Andalusians (from their fields in the Canary Islands), and the Portuguese. Sugarcane is grown in over 110 countries (FAO, 2008). In 2008 an estimated 1,743 million metric tons were produced worldwide, with about 50 percent of production occurring in Brazil and India (FAO, 2008). Statistically, Brazil is the biggest grower of sugarcane, which goes for sugar and ethanol for gasoline-ethanol blends (gasohol) for transportation fuel. In India, sugarcane is sold as jaggery, and also refined into sugar, primarily for consumption in tea and sweets, and for the production of alcoholic beverages. From Table 1, it is evident that African countries have not found their place in the chart for production of sugarcane in the world. Although in Nigeria there was a sugarcane processing factory in Bacita in the 20th century, it has found itself diminish and fizzled out. Formerly, countries like the United States were prominent in sugarcane production but later lost their verve after the eradication of slavery and the advent of the war crisis they experienced. India which is one of the primary traced sources for the sugarcane crop, alongside New Guinea, has not held on to leading in the production of sugarcane. 19
From Figure 1, areas in Africa are found to have an average output of about 500kg/ha; unlike areas in South America and Asia which have output as high as 4000kg/ha. In India, the states of Uttar Pradesh (38.57 %), Maharashtra (17.76 %) and Karnataka (12.20 %) lead the nation in sugarcane production.
Table 1: Top ten sugarcane producers (FAO, 2008)
Figure 1: Global distribution and production of sugarcane (FAO, 2008) In the United States, sugar cane is grown commercially in Florida, Hawaii, Louisiana, and Texas (IPM, 2008).
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2.3 PROCESSING OF SUGARCANE After the farmer plants the perennial sugarcane plant on the farmland, it would grow up to harvest quality before adequate primary processing procedure, up to raw juice extraction, would be carried out. As represented as a flow chart in Figure 2, from the sugarcane planting, the mature crop land would be subjected to pre-harvesting land burning to cater for venomous snakes that habit the sugarcane plantation. The burning would also help eliminate excess and unwanted crop trash such as the leaves and stalks; to an extent it would help reduce the moisture of the crop thereby increasing the transported quantity. When it is delivered to the factory it is cleaned to remove debris, dirt and the remaining trash before it is being broken or cut up, manually or mechanically, then subjected to milling (with addition of some water) for juice extraction. When this is achieve the raw juice can then be subjected to further processing after strainers are used to sieve the unwanted juice particles and the bagasse is collected at another end (Midwest Research Institute,1997). The highly useful bagasse would also be processed to derive the desired advantageous and lucrative products it provides.
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Sugarcane planting
Pre-harvesting land burning
trash removal
Harvesting
Cane loader and transporting
Factory unloader
Cleaning
debris removal
Breaking and cutting
Addition of water
Cane milling
Raw juice
Bagasse and residue
Strainer
Further processing
Refining and further processing
22
Figure 2: The flowchart of sugarcane juice extraction process Traditionally, sugarcane processing requires two stages. Mills extract raw sugar from freshly harvested cane, and sometimes bleach it to make "mill white" sugar for local consumption. Refineries, often located nearer to consumers in North America, Europe, and Japan, then produce refined white sugar, which is 99% sucrose. These two stages are slowly merging. Increasing affluence in the sugar-producing tropics increased demand for refined sugar products, driving a trend toward combined milling and refining into sugarcane processing. 2.3.1 HARVESTING Sugarcane stems are collected from the field during harvest. At harvest, minimum trash is collected from the farmland, along with the desired sugarcane to the mills (Naturland, 2000). Mostly before harvesting, the farmland is set on fire to consume all the dry leaves and dangerous creatures habiting the crop area. Further removal of the top and leaves is done manually by hand trimming, then cutting of the sugarcane into bits; loaded into the trailer of cart and immediately taken to the mill to be processed. The cut up sugarcane has to be processed immediately, because it quickly deteriorates once cut; due to rapid enzymic and microbial processes taking place. Thus harvested sugarcane is not stored for later processing. 2.3.2 SUGARCANE TRANSPORT The harvested crop is to be moved or relocated from the farm area to the respective mill for further processes. The use of manual labour to carry the crop into the vehicle or mechanical crane loader is selected. After this, the vehicle is used to cart the crop to the mill. The content of the vehicle is also carried off by manual or mechanical unloading techniques. The sugarcane is transferred for cleaning before crushing. 2.3.3 MILLING AND JUICE EXTRACTION Once the harvested sugarcane is received in the mill, it is first cleaned and washed free of dirt. They are then broken before being feed into the roller mills, of a fabricated roller number (2 – 18 roller combinations), for extraction. The sugarcane juice extractor machine would be suitable for the design and functional requirements of the mill. The collected juices contain 10–15 percent sucrose, and the remaining fibrous solids, called bagasse, are burned for fuel. Bagasse makes sugar mills energy self-sufficient. Surplus bagasse is used as animal feed, in paper manufacture, or to generate electricity for sale.
23
The cane juice is next mixed with lime to adjust its pH to 7. This mixing arrests sucrose's decay into glucose and fructose, and precipitates some impurities. The mixture then sediments, allowing the lime and other suspended solids to settle. The clarified juice is concentrated in a multiple-effect evaporator to form syrup about 60 percent sucrose by weight. This syrup is further concentrated under vacuum until it becomes supersaturated, and crystalline sugar is added to the syrup to activate crystallization of the syrup-like sugar. On cooling, more sugar crystallizes from the syrup. A centrifuge separates the sugar from the molasses. Additional crystallizations extract more sugar; the final residue is called blackstrap. 2.3.4 HIGHLIGHT OF FURTHER PROCESSING Raw sugar is yellow to brown in colour. Bubbling sulfur dioxide through the cane juice before evaporation bleaches many colour-forming impurities into colourless ones. This sulfation produces sugar known as "mill white", "plantation white", and "crystal sugar". Such sugar is the most commonly consumed in sugarcane-producing countries. The processing of sugarcane is targeted on the production of cane sugar, yet other products which include bagasse, molasses and filtercake are also very useful and are not readily discarded. 2.4 EXISTING SUGARCANE EXTRACTORS The modern sugar cane juicer has come a long way from the trapiche, the old traditional wooden roller press, used by the indigenous people of countries such as Panama and Columbia. A commercial sugar cane juice extractor is quite expensive. When looking for a household model, this may also prove difficult. These are hard to find and may require placing an order from another country, such as Malaysia, Singapore, and India, which offers a sugar cane press for the tabletop (Rika, 2010). Some health food merchants in the United States have turned to an extractor for sugar cane so that they can tap into the organic juice market. Some extractors have the capacity to process around 170 canes in an hour, while others boast an easy filtration system. By Rika (2010), the prices also vary for the sort of extractor. A less expensive model may be found around $200 in a high-powered juice and vegetable extractor, where true sugarcane extractors could be as much as $3000 for large, industrial-size selections.
24
2.4.1 THE TRAPICHE The trapiche which is a Spanish word meaning ‘sugarcane crusher’- when used in terms of the machine, or ‘sugarcane mill’ - when used for the location, is a traditional wooden roller press, used by the people of Panama and Columbia to extract sugarcane juice (Riza, 2010). This machine which is of varying sizes is basically made from wood. It has two vertical rollers for crushing the sugarcane. These rollers are held in place by a wooden frame, while one of the rollers receives and transmits, by a longitudinal twist grove, the rotary motion to the second roller for crushing. It is powered manually or by animal draught (mostly for the larger and static ones found in the mill), to perform the juice extraction.
Plate 1: The Trapiche 2.4.2 ZAMA COMPANY JUICERS The Sugar Cane Juice Extractor is a countertop model. It has a stainless steel body, and powered by 1 hp motor, having a productivity of 250kg/hr. For easy cleaning, the front cover can be removed. The maximum insertion size of the sugar cane must be 57.15 mm in diameter, and adequately crushes the sugarcane with one insertion. It has a dimension of 450mm × 450 mm × 480 mm and is easy to operate (Zama, 2010).
25
Plate 2: The ZAMA Sugarcane Juicer
Plate 3: The Abamaster SCJE 2000
Plate 4a: The MCI 60
Plate
26
4b:
The
MCI
170
The Zama Enterprise Company offers many other models in their product line. For example, their industrial strength model can accommodate 6-7 cane sticks at one time. A 5 hp motor runs this high volume option. The machine weighs 136.078 kg compared to other models that weigh around 45.36 kg and accept sugarcane with a diameter of 50.8 mm or less. 2.4.3 THE MCI MODELS One of the options currently on the market is a sugar cane juicer called the MCI-170 that comes with the usual commercial-juicer price-tag. This is an extractor with a stainless steel cabinet, body and juice drum. The unit also has a drink tap. The juicer can go through around 170 canes per hour. The power input is 1.5 hp and machine speed is 35 rpm. The dimensions (l*b*h) of the MCI-170 are 457.2 mm x 406.4 mm x 533.4 mm. This is quite a hefty machine by juicing standards, as it weighs in at around 86.18 kg. A gas version is also available. A slightly more manageable version is the MCI-60, which dispatches with 60 canes per hour. It comes with the same stainless steel construction, standard drive container and filter with drink tap. The 3/4 hp motor that powers the machine creates a machine speed of 25 rpm. This is a slightly svelte model with dimensions (l*b*h) of 457.2 mm x 330.2 mm x 457.2 mm. This heavy contraption weighs of 45.36 kg. 2.4.4 THE ABAMASTER JUICER The Abamaster Sugar Cane Juicer, SCJE 2000, has a powerful 1/2 hp motor. This durable machine is easy to use, has a stainless steel body and drums, and a reduced gear design for maximum torque. It accommodates sugarcane diameter of up to 57.15 mm. The equipment dimension (l*b*h) is 279.4 mm x 304.8 mm x 406.4 mm, while the crate dimension is 533.4 mm x 533.4 mm x 609.6 mm. It has a speed of 30 rpm and a forward- reverse switch system operating the crushing rollers (Abamaster, 2010). 2.4.5 JINSHUI SUGARCANE JUICE EXTRACTOR This juicer originated from Jinshui road, China, and it has found its market in places like North America, South America, Southeast Asia, Africa, Eastern Asia, Western Europe, etc. It is a desktop, vertical Juicer which uses belts and gear rotation, with high efficiency, low power consumption and low noise level.
27
Table 2: Features of the Jinshui Sugarcane Juice Extractor (Rika, 2010) Model SXZ-60
Power 370w
Voltage 220v
Speed 25r/min
Capacity 280kg/h
Frequency Size (l*b*h) Weight 50Hz 540*440*960mm 75KG
Contacts inside the machine where the local use of fresh sugar cane pieces or stainless steel plating, meet the health requirements. It is used in hotels, restaurants and eateries collective canteens. Furthermore, it has a good appearance, structurally compact, simple to operation and easy to clean. It ensures hygiene due to its anti-corrosion and anti-rust stainless steel. The machine can be also be used to squeeze ginger, garlic, etc.
Plate 5: The SXZ-60 Jinshui Sugarcane Juice Extractor (Source: Rika, 2010) The availability of sugarcane juice extraction machines in Nigeria is achieved by the Dangote Sugar Refinery, majority-owned by Nigeria's leading private conglomerate, Dangote Group, which is the main sugar plant in Nigeria; after the fall of the Bacita Sugar Company of Nigeria. It has a production capacity of 1.44 million MT per annum, making it the largest sugar refinery in sub Saharan Africa and second largest in the world (Dangote Sugar, 2011). In all the scale of
28
production of the machines available in the country are majorly for large scale production requirements. This has helped Nigeria awake from the slump in its sugar production. Finally, the Department of Agricultural Engineering, University of Agriculture, Abeokuta, has also constructed a sugarcane juice extractor (Soetan, 2008). This machine for the cottage industry is fabricated to cater for the juice extraction requirement for the small-scale sugarcane farmer. This juicer which weighs about 100 kg is a 2-rollers crusher with a gear transmission system. It is powered mechanically and it is the focus of this project work.
Plate 6: The existing sugarcane juice extraction machine
29
CHAPTER THREE: MATERIALS AND METHOD 3.1 DESCRIPTION OF THE EXISTING EXTRACTION MACHINE After the fabrication for over two (2) years most of the machine components are still intact and in good states. The machine is a combination of shafts, gears of varying sizes, pulley, crushing rollers, bearings, fasteners, the metal framework and prime mover or power source (Soetan, 2008).
Plate 7a: The front view of the existing sugarcane juice extraction machine
30
Plate 7b: Rear view of the existing sugarcane juice extraction machine The various parts that make up the existing sugarcane juice extractor for the cottage industry are described below. 3.1.1 THE CRUSHING UNIT/ ROLLER The crushing unit is made of two 2.5 mm thick, 380 mm long hollow stainless steel cylinders and stainless steel rods of 16mm diameter. Each stainless steel hollow cylinder has 18 of such stainless steel rods welded longitudinally round the cylinder surface, and equidistant from adjacent rods. These rollers were made from stainless steel because of their ability to handle food materials without getting them contaminated. Stainless steel does not rust or corrode and this makes them ideal for food handling and thereby sugarcane juice handling. The stainless steel rods, which were indented with a metal hand-grinding machine to form a riblike structure and make it aggressive, have within them a spacing of 5mm. These arrangements ensure that slip that would occur with sugarcane during feeding in the case of plain crushing rollers is reduced to minimum if not eliminated (Soetan, 2008). 3.1.2 THE SHAFT Basically four shafts were used in the construction of the machine. Each of the crushing rollers is carried by a shaft having a diameter of 40 mm, with the upper shaft having a length of 700 mm and the lower shaft, 573 mm. 3.1.3 GEARS The top crushing roller shaft carries one gear on each end, while the bottom roller shaft carries only one gear, and on one end. The gears used on the left of the upper shaft and the left side of the lower shaft have 17 teeth each and are in mesh, meaning that both rollers are dependent on each other. When one of the rollers shaft is driven, the other roller also moves with the same speed. The top roller is driven by the gear on its right side and this motion is transmitted through the shaft to the left gears and thereby the bottom shaft also moves.
31
The gear on the right side of the upper shaft has 68 teeth and it is driven by a small pinion of 18 teeth. This is shown in the diagram below. The 68 teeth gear serves to reduce the transmission speed reaching the crushing rollers and thereby increase transmission torque on each roller and therefore, the crushing force on the surface of the rollers. The 18 teeth gear that drives the 68 teeth gear is connected to a shaft of diameter 38 mm that is driven through another system of gear and pulley – the drives input. 3.1.4 BELT AND PULLEY They are used in transmitting motion from the motor to the drive shaft. Just like gears, they transmit motion, but unlike gears, they are flexible, meaning the center distance between the driving and driven member can be changed conveniently, therefore, pulleys can transmit motion over distances. 3.1.5 POWER SOURCE This is a 5.5 hp electric motor. The input is applied by means of the V-belt and pulley described earlier. The speed from the engine is reduced by the pulley. The pulley now transmits this reduced speed and increase torque from the engine by means of a shaft to the 17 teeth gear explained in the gear section which is in mesh with the 75 teeth gear. For this power source, the machine speed is 30 rpm. 3.1.6 THE MACHINE FRAME This part is mainly made with the mild steel and angle bars. The mild steel is used to make two ‘h’ shaped flat profiles. This is set up on a stand made of angle bars; upon which the motor is placed. 3.2 REQUIRED IMPROVEMENT ON THE JUICE EXTRACTOR The major purpose of this project work is to work on the casing of the sugarcane juice extractor which was formerly constructed. This casing is to isolate the operating chamber, which includes the crushing drums performing the juice extraction, from its surrounding. As shown in Plates 3a and 3b, the machine is rusty and dirty. The gears are packed with bad grease and the machine requires maintenance. The machine frame which is made of mild steel has lost its glow, and some of the welded joints are weak.
32
Therefore, the moving parts such as the gears will be attended to for the safety of the operator who would be manning the machine for any required extraction process. This would also add to the beauty of the machine along with the cleaning and painting of the corroded machine parts. 3.2.1 MATERIALS 1. Steel plate. The galvanized steel plate is used. The plate thickness used is 1.5 mm and a purchase dimension of 1219.2 mm by 2438.4 mm span. 2. Bolt and nut. For coupling the cut out details together, selecting bolts and nuts having a threading diameter of 10mm. 3. Cutting disc and grinding disc. These are attached to the angle grinder to power its operation. The cutting disc when attached is used to cut the plate metal to the desired shape and orientation, while the grinding disc was used to smoothed the roughness on the cut detail. 4. Gasket. This is used to seal up the opening through which leakage may occur. 5. Welding electrode. The oerlikon welding electrode was purchased and used. Details which need to be permanently held together are joined through welding process. 6. Non-polar solvent. This was chosen based on market availability. The purpose of the solvent is to wash and clean the metal parts which have been packed with dust and debris. The choice of solvent was one of the petroleum hydrocarbon products e.g. petrol, kerosene. 7. Iron Wire brush. It was used to brush off the corroded surfaces and rust on the previously existing sugarcane juice extractor. This would prepare the surface for painting. 8. Paint. Silver-colour paint was used to coat, protect and add lustre to the extractor. 9. Painting brush. This is used in paint application to the machine surfaces. 3.2.2 PROCEDURE OF CASING FABRICATION After the purchase of the materials from the market at Ibadan, development diagram for the respective sections was made. The steel plate material was then cut to obtain the details as represented in the following figures. The required drilling was also done on them before the major joining and assembling processes commenced. When the cut out details are all obtained, they are folded along the dash lines to take the form required for the casing.
33
The casing work done on the existing sugarcane juice extractor is made up of four (4) major components. These are: a. The top cover b. The hopper c. The side plate d. The base tray
34
INSERT FIGURE 3 HERE
35
THE TOP COVER This is the largest detail for the casing work done on the existing sugarcane juice extractor. As shown in the Figure 3, it has a maximum span of 900mm by 500mm. When the detail is cut according to the development shown in Figure 3, it is then folded along the broken lines. Also the required holes of diameter 5mm are drilled at the designated points, while the section subtending an angle 50⁰ is welded to the side of the plate with which it subtends the angle. At the end of the construction of the top cover, it is seen to take the form shown in Plate 8 below.
Plate 8: The top cover after construction
36
INSERT FIGURE 4 HERE
37
THE HOPPER As shown in the development in Figure 4, it is made to be the front section of the machine and would also have an opening as shown to allow for horizontal feeding of the sugarcane. When the sugarcane has been extracted over and over again, the bagasse can further be poured in through the hopper to subject it to further extraction. When the detail is cut out, it is folded along the broken lines and the bolt holes are drilled to the shape shown in Plate 5a, then the hopper tray is constructed and screwed to the detail shown in Plate 9a to take the form shown in Plate 9b before the opening is finally cut out.
Plate 9a: Folded cut out detail of hopper
Plate 9b: Hopper detail with attached tray
38
Plate 9c: The hopper section when assembled to the machine
39
INSERT FIGURE 5a AND 5b HERE
40
THE SIDE PLATE This detail was obtained from the development in Figure 5a, and it is the most tasking detail to obtain. It demanded the drilling of 50mm diameter holes for the shaft passage, 10mm diameter holes for the bearing bolt passage and the 5mm diameter hole for the hopper fastening bolt passage. Finally, the bending of the edges as represented in Figure 5a gives the required side plate shown in Plate 10a and Plate 10b.
Plate 10a: The constructed side plate
Plate 10b: The machine frame with the
side plate in place
41
THE BASE TRAY (CHUTE) This detail as shown in Figure 5b is meant to serve as the conveyor of the juice through one side and the bagasse through another side. The fulcrum of the two outlet sides which measure up to 100mm connects the two sides which are bent to suit the direction of flow of the outlets as shown in Plate 11a; having the shorter side for the juice chute and the longer side for the bagasse chute. The side of the fulcrum are welded up to seal up the sides and bear the side plates which will be fitted on it, when the machine is assembled. In the assembling of the machine, the base tray can only be seen by a shot from the base of the machine as seen in Plate 11b, yet it is very vital in the separation for the extraction process.
42
Fulcrum
Plate 11a: Construction of base tray
Plate 11b: Base view of assembled machine with base tray in place
3.3 DESCRIPTION OF IMPROVED MACHINE After the completion of the construction of the various component sections for the framework casing, the machine is assembled and the machine is seen to be in the form depicted by the Plate 12b below. The well washed gear components and fasteners are fitted back to place. The keys for
43
the key ways required in the assemblage of the component parts to the shafts were replaced with new ones, before the running of the machine. The casing of the machine was carried out successfully and the various sections were assembled to the existing machine after all the gears and bearings were thoroughly washed and cleaned. 3.3.1 HIGHLIGHTS OF IMPROVEMENT 1. The parts in contact with the sugarcane are made of galvanized steel; which is corrosion, rust and heat resistant, and does not contaminate the processed agro-material. 2. Operation of the machine would be relatively easy, having simple operating mechanisms running the extraction process. 3. Labour for machine operation would be minimal and learning how to operate the machine would be easy. 4. The base stand for the power source is reinforced. 5. The power requirement of the machine was moderately low, yet efficient. 6. The aesthetics of the machine was upgraded.
44
Improvement
45
Plate 12a: Previous state of the machine
Plate 12b: Present state of the machine
3.3.2 FUNCTIONALITY DESCRIPTION 1. The machine noise level would be low. 2. The flexibility of the rollers combination to sugarcane of any diameter would be possible. 3. Machine handling of split and whole canes would be feasible; relatively with the same extraction efficiency. 4. The sugarcane-rollers friction needed to facilitate the crushing when the sugarcane is feed into the operating chamber, and hence juice extraction, would be adequately present. 5. There would be no interaction of the lubricants from the transmission system to the operating chamber. 6. The heat generated would not be adverse to the operation of the machine. 3.4 TEST PARAMETERS AND PROCEDURE After the machine has been improved check was carried out to ascertain the efficiency of the machine, so as to know if the modification is adverse to the machine or beneficial to its operation. 3.4.1 TEST PROCEDURE For the test, the following equipments and materials were used. 1. Lengths of harvested sugarcane. 2. The sugarcane juice extractor. 3. A 5.5 hp electric motor. 4. A weighing balance for weighing the sugarcane, juice or bagasse. 5. Vernier calliper for measuring diameter. 6. A measuring tape for measuring the sugarcane length. 7. A container for collecting the extracted juice. 8. An oven or solar radiation for drying the bagasse. 9. Polythene bags for bagging the specimens used. 10. A stopwatch. 11. Calculator.
46
After the purchase of the sugarcane species, Saccharum officinarum, from the market, they were cleaned before major dimensional quantities such as the average diameter, length and weights were obtained and recorded as shown in Table 3. Furthermore, the sugarcane was separated into specimens and labelled A to J. The engine is left on to warm for about 10 minutes before engaging the sugarcane juice extractor. Progressively, preliminary testing was done on the machine with specimens A, B and C, while specimens D to J were used for the main final test. All the specimens were fed in by hand, horizontally between the rollers in the operating chamber, and then the extruded bagasse were collected and re-fed in through the hopper in form of pieces. For each specimen’s extraction, the stopwatch is activated from the start off and stopped at the end of the extraction process. After subjecting each sugarcane specimen to 5 times of extractions rounds, the bagasse was collected into a labelled polythene bag and its weight was recorded, before they are sun/oven dried at a temperature of 105⁰C, for a period of 24 hours to dry to bone dry weight. When the proceed reading are taken, the calculations to check the performance of the machine was done; to determine machine efficiency using the following formulae. 3.4.2 TEST FROMULAE AND PARAMETERS In testing the sugarcane juice extractor, the following parameters and formulae are useful for and applicable to this project work (Soetan, 2008). A. AVERAGE DIAMETER (DM) This parameter is expressed in millimetre and it is the mean of the three diameter values obtained from the sugarcane specimen. The head and tail diameters are the measured diameters at the two extremes of the specimen length, while the middle diameter is the diameter measured at midlength the sugarcane specimen. Thus, DM = Head diameter + Middle diameter + Tail diameter
3
B. EXTRACTION EFFICIENCY (ɳp) FOR PRELIMINARY TEST This is an estimated value expressed below as
47
... (1)
ɳp = Weight of juice extracted in grams
85% initial weight of specimen in grams
... (2)
C. JUICE EXTRACTION EFFICIENCY (ɳj) This is the ratio of the amount of juice extracted to that contained in the sugarcane. This is given by the below expression and mostly taken to be in percentage, %.
ɳj = Juice extracted (je)
Amount of juice contained in sugarcane (jc)
... (3)
The amount of juice contained in the sugarcane is the value obtained from the difference between the initial weight and the bone-dry weight, that is, the weight after drying.
D. MEAN OR AVERAGE EXTRACTION EFFICIENCY
ɳa = Summation of juice extraction efficiencies, Ʃ(ɳj) 7
... (4)
E. STANDARD DEVIATION (δ) This is the square root of the ratio of the summation of the squared absolute value of the difference of the extraction efficiency (ɳj) of a specimen and the mean (ɳa), to the frequency of treated values (N). Mathematically,
δ=
Ʃ (ɳj - ɳa) 2 N
... (5)
F. RATE OF JUICE EXTRACTION (ɳr) 48
In this case there is a function of time involved in the calculation. This is taken as the weight in kilograms of juice extracted per hour. This quantity is expressed in percentage, %.
ɳr = Weight of juice extracted (wj)
Time taken for the extraction (tj)
49
... (6)
CHAPTER FOUR: RESULT AND DISCUSSION 4.1 DIMENSIONS OF SUGARCANE SPECIMEN As highlighted in the previous chapter, the values of the dimensional characteristics of the purchased sugarcane specimen, from a market at Eleweran in Abeokuta, Ogun state, are shown in the Table 3. Table 3: Dimensions and weight of the sugarcane specimens
700
Middle diameter (mm) 38
Tail diameter (mm) 42
B
690
31
34
35
33.3
802.6
C
670
32
37
41
36.7
796.2
D
710
33
36
40
36.3
1116.7
E
780
31
35
37
34.3
876.5
F
680
36
40
43
39.7
1301.3
G
700
30
33
38
33.7
725.6
H
600
32
34
36
34.0
958.1
I
540
35
39
41
38.3
1010.4
J
750
34
36
39
36.3
1005.2
Length (mm)
A
Average diameter (mm) 38.0
Weight (g)
Head diameter (mm) 34
Sugarcane specimen
990.7
After the measurements were taken, the specimens A, B and C were used for preliminary testing of the machine, as stated in the previous chapter, while specimens D to J were used for the final testing of the improved machine. 4.2 EFFICIENCIES OF JUICE EXTRACTION Estimating and assuming the maximum juice release of the sugarcane as 85% of its initial weight (Soetan, 2008), the values and result of the preliminary test carried out to first test-run the machine are shown in Table 4. The main test for the machine is then carried out and shown in Table 5. All the formulae are used as appropriate to obtain the results for the machine efficiency.
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Table 4: Result of the preliminary test Specimen
Length (mm)
Initial weight (g)
Bagasse weight (g)
Weight of juice extracted (g)
85% of initial weight (g)
Preliminary Extraction efficiency (%)
A
700
990.7
524.2
466.5
842.1
55.4
B
690
802.6
449.2
353.4
682.2
51.8
C
670
796.2
402.3
393.9
676.8
58.2
Mean/Average
55.1
Standard deviation
2.62
The main test which is the performance test is carried out using the specimens D to J and the obtained values were tabulated below. Also to carry out the project experiment work, I take into consideration the activity of sun-drying to obtain the dry weight of the bagasse. Also the lost juice weight is gotten as the difference of final and dry weights. At the end of the experimental activity and computation of readings, I performed further calculations required. Table 5: Result of performance test Sugarcane specimen
Length (mm)
D
710
E
Initial weight (g)
Bagasse weight (g)
Juice extracted (g)
Dry bagasse weight (g)
Lost juice (g)
1116.7
510.3
606.4
223.3
287.0
Juice extraction efficiency (%) 68
780
876.5
373.9
502.6
178.4
195.5
72
F
680
1301.3
549.5
751.8
227.3
322.2
70
G
700
725.6
351.1
374.5
174.9
176.2
68
H
600
958.1
422.3
535.8
181.6
240.7
69
I
540
1010.4
410.6
599.8
199.8
210.8
74
J
750
1005.2
411.8
593.4
192.3
219.5
73
51
Mean/Average
70.6
Standard deviation
2.26
4.3 JUICE EXTRACTION EFFICIENCY For the improved sugarcane juice extraction machine, using Table 5 above, the average of values of juice extraction efficiency is obtained to be
ɳa
=
summation of juice extraction efficiencies, Ʃ(ɳj)
7 =
68 + 72 + 70 + 68 + 69 + 74 + 73
=
70.6%
7 Since the value of the average juice extraction efficiency of the machine has been obtained, maintaining a confidence level of 95%, as used by Soetan (2008), the confidence interval, I, also will be gotten from Confidence interval Where,
=
ɳa + Z.Sd
ɳa
= 70.6% or 0.706
Z
= distribution table equivalent for confidence level of 95% = 1.96 (Mann,
Sd
= deviation range value =
n
= number of test specimen = 7
Sd
= 0.706(1 – 0.706) ÷ 7
1992)
Thus,
ɳa (1- ɳa ) ÷ n
= 0.0297 Then,
I
= 0.706 + (1.96 × 0.0297)
= 0.706 + 0.0583
Therefore, it is acceptable to state that the extraction efficiency of the machine ranges from approximately 65% to 76%.
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In comparing the efficiency range obtained for this machine in its improved state to its previous state, there has been a drop in the efficiency range. The former range had a minimum of 70% and a maximum of 77%, still the machine in its improved state is still appreciably efficient. It is relieving to know that similar existing sugarcane juice extraction machines in countries like India and Brazil have their juice extraction efficiency value ranging from 60 – 65% (DEP Agro Machineries, 2007). Therefore for a juice extraction efficiency range of 65 – 76%, the improvement did maintain a good machine efficiency value. 4.4 THE RATE OF JUICE EXTRACTION To obtain the rate of juice extraction of the machine, the total weight of the extracted sugarcane juice (wj) is measured and found to be 3964.3g, and the overall time taken to carry out the extraction process (tj) is measure to be 254seconds. The parameters shown in Table 6 are obtained from only Table 5 above. Table 6: Parameters for rate of juice extraction calculation Sugarcane specimen
Total length (mm)
Total initial weight (g)
Total bagasse weight (g)
Total juice extracted (g)
Total time taken (s)
Rate of juice extraction (g/s)
D to J
4760
6993.8
3029.5
3964.3
254
15.61
Thus, the rate of extraction
(Rate of extraction in litres)
ɳr =
3964.3 254
= 15.61g/s or 56.19kg/hr
= 0.0156 l/s or 0.0562 l/hr
Based on the number of times the sugarcane was passed through the machine, which was 3 times per sugarcane, it is still satisfactory to obtain a juice extraction rate of approximately 56%. This value is still close to that of similar existing sugarcane juice extraction machines, which according to DEP Agro Machineries (2007) is 60kg/hr.
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CHAPTER FIVE: SUMMARY AND RECOMMENDATION 5.1 SUMMARY The sugarcane juice extraction machine constructed in the Department of Agricultural Engineering, University of Agriculture, Abeokuta, has gone through a process of improvement from its previous state, as shown in Plate 8a, to a better and improved state, as shown in Plate 8b. All the improvement on the machine is not only to enhance its aesthetic characteristic, but also enhancement of the extraction efficiencies. Due to its flexibility of power source, it is adaptable to the end users capability; making it a suitable machine for its target audience – the cottage industry. To a large extent, the work done has helped in projecting the machine once again and increasing the attention from its observers. The machine now looks more attractive and catchy, thereby achieving the goal of advertising this technological creativity from within the department. With the provided isolation of the extraction process from the surrounding, the interaction of contaminants with the extracted juice is observed to be negligible. The crushing drum worked without getting stuck irrespective of the casing fabrication done in the improvement of the machine. Furthermore, with a juice extraction efficiency and rate of juice extraction values of 65 -76% and 0.0156 l/s respectively, the machine would provide the industrial satisfaction it is fabricated for. The improvement on the hygiene property of the machine would go a long way in preserving the quality of the extracted juice. The completion of this project work, which is focused on the improvement of the machine, brings a sigh of satisfactory relief, both to the fabricator and the end user. 5.2 RECOMMENDATIONS FOR FURTHER IMPROVEMENTS If further work is to be done on the machine, I would like to recommend the following upgrades and adjustments to the fabricated machine. 1. Stainless steel can be used for fabricating the machine if it is to be used industrially. This would help increase the hygiene of the machine.
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2. A sieve can be incorporated to collect small bagasse particles that make their way out, through the juice chute or outlet, with the extracted juice. 3. Incorporate some travel wheel to aid the mobility of the machine from one area or point to another. 4. A knifing section to cater form cutting and breaking the sugarcane before juice extraction can be constructed and attached to the machine to complement its operation. 5. If it is feasible, the crushing drums can be made adjustable to vary the gap between the crushing drum; thereby varying crushing and juice extraction for various diameters and girth of the sugarcane being crushed.
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REFERENCES Anonymous (1998), Sugarcane Bulgaras. Florida State University Publication. Abamaster Incorporated (2010), Counter top Sugarcane Juice Extractor. www.abamaster.com/productSpecWeb.php?modelId=2000 Boyel, H. (1939), Distribution of Sugar Cane Production in Cuba. Economic Geography 15 (3):311. Dangote Sugar (2011), About us. www.dangote-sugar.com/about.php DEP Agro Machineries Private Limited, (2007). Sugarcane Crushers. www.depagro.com FAO (2008). Crop production. The United Nations. June 2010. Heiser, C. B. (1981), Seed to Civilization: The Story of food. Second ed. W. H. Freeman and Co., San Francisco. 254pp. IPM (2008), Meagher: Sugarcane IPM. www.ipmworld.umn.edu.April 2008 Mann, H. (1992). Introductory Statistics. Longman Group Limited, London Microsoft Encarta Encyclopedia (1994). Sugarcane. Microsoft Network, United States of America. Midwest Research Institute (1997), Sugarcane Processing. Emission Factor Documentation for AP-42, Section 9.10.1.1; final report. June 1997. Munoz, R. A., Suchman, E. A., Baztarria, J. M., Lehtola, C. J. (2007). Sugarcane Cultivation and Processing. www.ilo.org/encyclopedia. Naturland (2000), Organic Farming in the Tropics and Subtropics: Sugarcane, First Edition.www.naturland.de 56
Purseglove, J. W. (1988), Tropical Crops: Monocotyledons. Longman Group Ltd., London. 607pp. Rika Susan (2010), Article: A Household Sugarcane Juicer Only a Sweet Dream? www.ezinearticles.com/?expert=Rika_Susan. Soetan, C. A. (2008). The Development of a Sugarcane Juice Extractor for the Cottage Industry. B. Eng. Project Requirement. Department of Agricultural Engineering, University of Agriculture, Abeokuta, Nigeria. Timothy Braun (1999), Ethnobotanical Leaflets. www.siu.edu/~ebl/. World Bank Group (1998), Pollution Prevention and Abatement Handbook. World Bank: National Development and Reform Commission, P.R. China. Wikipedia (2010), Sugarcane. http://en.wikipedia.org/wiki/Sugarcane Yamada, Y., Hoshino, K. & Ishikawa, T. (1998). "Gluconacetobacter corrigendum” [sic]. In Validation of Publication of New Names and New Combinations Previously Effectively Published Outside the I.J.S.B. List no. 64; 48:327–328 Zama Enterprise (2010), Sugarcane Juicer Machine Presser. www.zamaenterprise.com/products/Sugar-Cane-Juicer-Machines-Presser-Counter-Top-model%2C-1HP.html
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