latest technology development for cutting turmeric rhizomes
TRANSCRIPT
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Latest Technology Development for Cutting Turmeric Rhizomes
INTRODUCTION
Turmeric is one of the important spice and cash crop in Indian. India is
leading country and ranking first in respect of production and export of turmeric, it
is about 80% and remaining 20% is shared by Chaina and Pakistan. The present
traditional method of turmeric processing is uncontrolled processing technique.
The recovery of the turmeric powder obtained has ranged between 12 to 15%
maximum and there was possibility of the deteriorating quality in respect of
curcumin content of the powder due to uncontrolled and excess heating during
cooking.
Entire process took about 20 to 25 days for obtaining final product i.e.
turmeric powder, Recently the machinery developed for processing of turmeric
made it possible to process turmeric rhizomes with in 24hrs by vacuum
evaporation technique. The recent developed process & machinery had some
limitations like the excessive process cycle time 24 hr. secondly the cutting of
rhizomes into 1cm length pieces is performed manually, manual controlling of
critical parameters, excessive time required for drying the tray type drier. This was
right time to incorporate some new technique and automation to increase
productivity, qualitative and quantitative improvement in final output i.e. turmeric
- powder for value addition. The new technique of cutting rhizomes and drying
and automation in plant made it possible to reduce process cycle time of 24 hrs to
2 hrs. this has miraculously increased the demand of auto machine by the private
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processor of turmeric because this new machinery really helped processor in
getting more recovery & getting more prices to their final produce in the market.
Economical standard of farmers can be improved by providing good price to their
agro produce in the market. The value addition in the agro produce is possible by
introducing this new technique of agro produce processing.
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Latest Technology Development for Cutting Turmeric Rhizomes
AIM :
Development of machinery for cutting Turmeric Rhizomes. This unit has
made it possible to reduce process cycle time from 24 hr to 2 hr. Control of all
parameters effectively due to automation, which ultimately improves the nutritive
value of turmeric powder. The three areas where new system needs to be designed
and incorporated are auto-cutting unit of rhizomes, automatic orientation of
rhizomes & auto-cutting in 1 cm pieces. This reduces cutting time and makes the
process online.
Objectives:
Development of machinery for cutting turmeric Rhizomes to reduce time of
cutting, labour required and to increase production lot of work had been carried
out in respect of crop improvement for better quality and yielding potential but not
much emphasis has been given on the turmeric processing in respect improvement
in quality as well as increasing the recovery of concentrated powder. The present
traditional method of turmeric processing consist of
1. Cooking of rhizomes in open pan (Uncontrolled cooking)
2. Sun-drying on open hard surface (for about 10 to 15 days).
3. Polishing by rubbing on hard surface or in rotating drum.
4. Grinding dried rhizomes to powder.
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Latest Technology Development for Cutting Turmeric Rhizomes
In this uncontrolled processing technique many times due to excess heating
temperature there was a formation of blackish hard turmeric rhizomes popularly
known as 'Lokhadi Halad'.
The entire process took about 20 to 25 days for obtaining final product i.e.
turmeric powder as well as labour requirement is more during the sun drying
depending on the bright sunny days and cloudy weather conditions. And due to
this tidies and uncontrolled processing technique and as the prices was governed
by middleman, the farmers are not preferring to cultivate this precious turmeric
crop.
Looking towards the urgent need of controlled processing technology, it is
suggested to develop the technology for cutting of turmeric rhizomes with in 2 hrs
for 50 kg.
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Latest Technology Development for Cutting Turmeric Rhizomes
TRADITIONAL METHODOLOGY
The present traditional method used in India for processing turmeric is
crude uncontrolled method and require 25 days for processing. This method
consist of
Cooking of rhizomes in open pan (uncontrolled cooling)
Sun drying on open hard surface (for @ 10 to 15 days)
Grinding dried rhizomes in powder.
The recent method & machinery developed needs 24 hrs for processing
turmeric this method keeps the "curcumin" content intact, which is very
important. This method consist of
Washing of rhizomes in Rhizomer washing m/c.
Cutting of rhizomes in 1 cm pieces, (this operation is not fully automatic
hence time consuming).
Vacuum evaporation in the vessel made from grade steel.
Cooling of rhizomes at room temperature by spreading over the clean floor.
Cabinet air blower drier for drying the rhizomes.
Grinding
Packing in desired quantity.
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Process flow chart for preparation of powder from fresh turmeric rhizomes.
(Traditional Method)
Farm fresh turmeric Rhizomes
Washing and Cutting
0.2% preservative / additive to avoidchanges in colour, flavour etc. during the
processing.
Vacuum evaporation at 25 in. Hg for 60 min
Cooling down the rhizomes at room
temperature by spreading over the clean
floor.
Vacuum evaporating for 20 min.
Drying in the hot air oven for about 18 to 22
hrs at 600C temperature
Pulverizing / grinding and packaging
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Process flow chart for preparation of powder from fresh turmeric rhizomes.
(New Method)
Farm fresh turmeric Rhizomes
Auto washing & cutting
On line addition of 0.2% preservatives to avoid
changes in color, flavour during the process
Vacuum evaporation at 25 in Hg.
Installed online cooling unit where forced cool air isblown on the rhizomes in rotary chamber
Vacuum evaporation
Introduced rotary drier with high capacity hot airgenerator unit
Pulverizing / grinding and packaging
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Comparison between recent machinery and improved automated plant with
addition of some new techniques (Batch size 50 kg.)
Recent machinery developed Time Improved automated plant with new
techniques introduced in the process
Time
Raw Material - Raw Material -
Farm fresh turmeric
rhizomes
Farm fresh turmeric rhizomes
Washing & cutting 2.5 hr. Auto washing & cutting 15 min.
0.2% preservatives to avoid
changes in color, flavour
during the process
- On line addition of 0.2%
preservatives to avoid changes in
color, flavour during the process
--
Vacuum evaporation at 25
in Hg.
1 hr. Vacuum evaporation at 25 in Hg. 1 Hr.
Cooling down the rhizomes
at room temp. by spreading
over the clean floor.
1 hr. Installed online cooling unit where
forced cool air is blown on the
rhizomes in rotary chamber
10 min
Vacuum evaporation 20 min Vacuum evaporation 20 min.
Drying in the hot air 18-22
hr.
Introduced rotary drier with high
capacity hot air generator unit
45 min.
Pulverizing / grinding and
packaging
30 min Pulverizing / grinding and packaging 30 min.
Process time 24 Hr. Process time 3 hr. 15
min
BENEFITS OF AUTOCUTTING OVER MANUAL CUTTING
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Sr.
No.
Factors Manual
Cutting
Auto cutting Benefits
1 Time 2.5 hrs 15 min Saving of 2
hrs 15 min
2 Labour cost Rs. 400
(4 Labour)
Nil Rs. 400 saving
3 Production per hr. 25 kg 50 kg Productivity is
doubled
DETAILS OF VARIOUS SYSTEMS USED IN THE CUTTING UNIT
An automatic loading and unloading device is a set of mechanisms which
automatically transfer parts from the storage to the operative zone of the machine
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and remove the processed part semi-product again to the place of storage after the
machining process is over.
Loading and unloading facilities for piece parts are made in the form of
independent units of a machine, units integrally linked with a machine or units of
machine fixtures. Despite the extremely important role they play in automatic
machines such facilities belong to the group of auxiliary mechanisms because they
do not participate directly in the process of machining assembly, i.e., in the
process which change the state of the object of labour. The facilities include a
magazine or bunker containing a store of parts, and the functional mechanisms:
orientation device, blank, cutting off device, feeder, device for pushing blanks in
and out, agitating member, unloaded, reception chute and drive.
The design and principal of operation of loading and unloading facilities
depend on the type of parts, kind of machining and the features of the work space
of a machine (automatic transfer machine ) on which the device is mounted. By
the mode of concentrating a store of piece parts the loading facilities are
subdivided into magazines, bunker-magazines and bunkers.
In the bunker-magazine loading facilities the store of blanks is placed in the
bunker in several rows and a definite orientation is imparted to each part manually
or by a special mechanism independent of the loading facility. The receiver is
designed as a chute whose width is limited by the length of the part. The parts are
transferred to the work area by a feeder.
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CHUTES
The nature of motion of parts subdivides all chutes into rolling chutes and
sliding chutes, the form of longitudinal profile into ordinary straight, roller
straight, curved, screw-type, zigzag and special.
The form of cross-sectional area distinguishes opened and closed chutes.
Closed types are employed for the vertical arrangement, when the chute in
inclined at an angle greater then 100, for long blanks, and irrespective of the length
for parts made in the form of caps, stepped and tapered shafts because they tend to
be mis-aligned. Inspection holes are provided in the walls of closed chutes to
observe the motion and prevent the seizure of the parts. The chutes are calculated
to determine the dimensions in cross and longitudinal cross sections, the
inclination of the chute and the speeds with which the blanks move.
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BUNKERS
The most popular bunkers for the orientation mechanisms with movable
gripping members are illustrated. In design, the bunkers are made cylindrical,
conical and bucket type. They are manufactured either with one container to
accumulate and select the parts or with two inter linked containers. In the later
case one container, bunker 1, is employed to accumulate the main store of parts,
and the other, bunker 2, to select them. The parts move from bunker 1 into bunker
2 gradually under the action of the forces of gravity. Sometime bunker 1 is
designed separately and can be arranged vertically.
The first group of bunkers is applied on a broad scale but has a number of
shortcomings: intensive agitation of parts by the moving gripping member which
causes dents and scratches on the surface of the parts, many parts accumulated in
the bunker and a resulting high pressure exerted by the upper layers on the
lowermost ones, which makes, it difficult to prepare the parts for gripping and
reduces the efficiency of the loading device.
The second group is free from the shortcomings inherent in the bunkers of
the first group and may be recommended as the basic one for loading facilities.
The bunkers are made in cast and welded designs. The most popular are
welder bunkers. The volume of a bunker (work space) depends on the necessary
store of part which should be accommodated to ensure an uninterrupted operation
of the loader during the rated period of time.
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WHY DISC POCKET TYPE ORIENTATION MECHANISM IS USED ?
Are intended to grip parts from the bunker and orient them in space but not
in time. In this way the part emerge from the mechanism in a definite position
(oriented), but at various intervals of time. The parts are oriented in time by the
feeder of the loading device. They are arranged in the bunker in haphazard manner
and for this reason the process of orientation with the delivery in the pre-assigned
position to the bank is in many respects random and should be considered from the
viewpoint of the theory of probability.
The orientation mechanism yields parts unevenly, i.e., at various time
intervals, but for all that the capacity of the mechanism may be assumed about the
same and equal to Qav at certain period of time. The parts should be delivered into
the feeder and hence, to the operative mechanism of the machine uniformly in
quantities denoted by Qf. Since the efficiency of the orientation mechanism is
affected by the factors sometimes out of control, this mechanism is designed for
operation with an "overfilling", i.e., Qav >Qf.. Depending on the type of device, the
conditions of its operation and the shape of the parts being fed in, the excess of Qav
over Qf. ranges from 10 to 35 per cent.
Since at various intervals of time the parts can fill the reception
mechanisms (banks) the orientation mechanism should be provided with a safety
device automatically disengaging the gripping member and also automatically
engaging it as soon as it is possible to receive new parts. In a number of cases the
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safety mechanism is substituted by devices to reject extra parts into a special
container.
All these mechanisms will be discussed below in the description of specific
designs of orientation mechanisms. The number of designs of such mechanisms
available today is large indeed, but they can be united in two classes: (a)
orientation mechanisms with grips performing rotary, oscillatory or reciprocating
motion and (b) mechanisms with vibrating gripping and orienting members or, as
they are commonly called, vibrobunkers.
By the mode of feeding parts into the bank, orientation mechanisms of the
first class are subdivided into mechanisms with the delivery of parts piece by
piece, with the delivery of parts in batches following one another continuously,
and with the delivery of parts in a continuous flow. The orientation mechanisms of
the second class feed the parts into the bank only in a continuous flow.
Distinctions made between pocket mechanism in which the slots are
arranged along the chord of the working disk perpendicularly to its plane, and
along the disk radius. Apart from the gripping method, these mechanisms are
distinguished by the method of delivery. Stationary disk 1 of the mechanism is
mounted on the housing of worm reduction gear 5. Movable (working) disk 2 is
secured on shaft 3 of the worm reduction gear. Pockets P are provided over the
circumference of disk 2, and vanes 6 used to fill better the pockets with parts are
attached to the surface of the disk. Bunker 4 is secure on stationary disk 1. The
orientation mechanism is installed at an angle of 35-450 to the horizontal, and
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operates as follows. The parts are loaded into the bunker onto the surface of
working disk 2. As the disk rotates, the parts drop into the pockets P, are carried to
the reception port of the stationary disk and go further to the bank. The method of
delivery of parts into the bank depends on the design of the reception part of the
bank. In the receiver the parts can be turned from a horizontal position, i.e., fed
into the bank in the direction of part axis, or retain their horizontal position.
In our design the parts are gripped and oriented during one operation. If a
part has to be oriented in two operations as is the case when asymmetric parts, for
example, caps with a displaced gravity centre, are fed in, use is made of
orientation mechanisms with double pockets or a device for secondary orientation
mounted in the receiver of the bank.
When the parts are delivered from the working disk of a pocket-type
orientation mechanism directly into the receiver, calculation is extended to the
dimensions of the pockets, the inlet portion of the receiver, speed of rotation of the
working disk and, hence, the efficiency of the orientation mechanism. The method
of gripping the part affects the efficiency of the orientation mechanism, since the
speed of the working disk and the coefficient of gripping probability are dependent
on it. The efficiency of pocket-type orientation mechanisms can be improved by a
more intensive agitation of the parts.
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DESIGN PROCEDURE
Basic Parameters
We have length of turmeric rhizome (l) = 9 cm
Diameter of turmeric rhizome = 2 cm
a) Design of pocket.
m - Pitch
l - Length of Rhizome
d - thickness of partition
D1 - Clearance between part and pocket wall
m = L + d + D1
= 9 + 2.5 + 0.5
m = 12 cm
Width L = 1 + 0.5 d
= 9 + 1
= 10 cm
Depth of pocket
b = 1.5 d
b = 3 cm
Thickness of working disk
S = 0.9 d
S = 0.9 x 2
= 1.8 cm ~ 2 cm
Diameter of diskD = 10 - 1
= 90 cm
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No. of Pockets
180Z = -------------------------------------------------------------
1.5 + 2.5d 1 + 0.5arc sin ( ----------------) + arc sin ( ------------------)
D DZ = 8
The No. of pockets are 8
Size of receiver port
12 + d2
B = n1 ------------1 + f
92 + 22
B = 1.5 ------------
1 + 0.7
B = 75 cm = 8.66 cm
Now
2dB = 1 + V ---------
G
2 x 28.66 = 1 + V ---------
9.81
V = 1033 cm / min
= radius of part inertia w.r.t. axis passing through pt. of contact of partwith be receiver edge.
12 + 15 (d/2)2 = ----------------------12
102 + 15 (2/2)2 = ----------------------12
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= 2.28 ~ 3 cm
Now, - inclination of rotations diskwe take = 350
Now, Vmax - max. peripheral velocity at the disk
g(cos - f sin )Vmax = (B - d/2) ----------------------
2(d/2 - s1)
980 (cos 35 - 0.7 sin 35)= (75 - 1) ------------------------------
2 (1 - 0.5)
Vmax = 1335 cm / min
As Vmax > V
Hence design is safe.
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b) DESIGN OF BUNKER
Batch size = 50 kg
Time period = 2 hrs.
We have to determine its volume
We have,
Length of Rhizome = 9 cm
Diameter of Rhizome = 2 cm
Volume of each rhizome= / 4 x d2 x 1= 29 cm3
~ 30 cm3
Volume of 50 kg rhizomes = 1,50,000 cm3
Qav - Avg. efficiency of loader in pcs / min.
Qav = KZn
K = Coefficient of probability
= 0.6
Z = No. of pockets
Z = 8
n = Rate of rotation
n = 12 r.p.m.
Qav= 57.6 pcs / min
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Volume of bunker :-
Vp . T. X QavgVbunk= ----------------------
q
Vp - Volume of rhizome
T - Time period of operation
Qav - average of efficiency of operation
q - Coefficient of filling
30 x 120 x 57. 6Vbunk= ----------------------------
0.6
Vbunk= 3,45,600 cm3
As volume of bunker >> Volume of 50 kg rhizome
Hence bunker is capable of fulfilling whole volume of 50 kg rhizome.
Hence design is safe.
c) Design of receiver chute
We choose close type chute for this purpose.
Height of chute :-
H = D + D - dia. of rhizome
= clearance = 1 cmH = 2 + 1
= 3 cm
B = L + = 9 + 1
B = 10 cm
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ACHIEVEMENTS OF THE PROJECT
Successfully designed and fabricated Rhizome cutting machine with
capacity of 50 kg/hr. The challenge to develop the machine was accepted by us
and ultimately achieved the different benefits of the units is explained below.
Table 1
Costing comparative statement :
Particular Recent
Machinery
Improved Auto-
Machinery
Cost Saving
Power Nearly double (35
H.P.)
Nearly half (18
H.P.)
Process cost saved
is Rs. 7.75 per kg.
of Rhizomes
proceed
Labour 8 Labours 2 persons 1
Operator &
Inspector
Processing Time 24 hr. (3 batches
are possible
overlapping cycle)
1 hr. (in
overlapping cycle
it comes to 2 hr.)
Total Processing
cost per Kg of
rhizomes
Rs. 10 / kg. Rs. 2.25/kg
Production / day 50 kg./ batch X 3
batches = 150 kg.
50 kg. / batch x 24
= 1200 kg.
Increase in
production by
1050 kg.
Table No. 2
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Quantitative benefits : (Considering machinery of the capacity 50 kg / batch)
Production
Increase
Recent Machinery Improved Auto
machinery
Benefits
Value Addition Say Rs. 2 x / kg.
Cost of raw material
say Rs. X)
Cost will be 1.25
X/Kg.
25% value
addition
Export Market
to final produce
Inferior qualities Quality of turmeric
powder is excellent as
the parameters are
auto controlled.
Nutritive value
is more
Export market to
machinery
M/c is manually
controlled hence no
export potential
Export potential to the
machinery
Revenue
Generation of
Indian Govt.
SOCIO ECONOMIC BENEFITS
In present method the cutting of rhizomes is carried out manually which is
very tedious job, it require more time for cutting and more number of labour.
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i) This plant causes the value addition to the agro produce.
ii) Because of value addition to agro produce the basic turnover
increases . Which causes the improved standard of living.
iii) Productivity increases.
iv) This plant can be installed at rural area also.
v) By this plant technical manpower employment is possible.
Table : 3
Other Benefits :-
Nutritive value Loss of nutritive value Nutritive value is intact
Curcumin percentage Less percentage More percentage
RESULT AND DISCUSSION
From costing comparative statement it is seen that increase in production per day
per machine = 1050 Kg. Hence in a season of 4 months the increase in production
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by one machine (considering 26 working days per months) = 1050 x 26 x 4 =
1,09,200 kg. = 109 tons.
Process cost saved per Kg. of rhizomes processed = Rs. 7.5
Total production per season by one machine = 1200 x 26 x 4 = 124800 Kg. = 125
tons. Hence processing cost saved per / machine = 1,24,8000 x 7.75 = Rs.
9,67,200/-
Cost involved in Automation and upgradation of units is tentatively Rs. 7 to 8
lacs. This cost can be recovered within one season.
The above explained automation has been reached to it's final stage only
because of development of Rhizome cutting machine. This cutting Process was the
only bottleneck. All other equipments used in this automated plant are available in
the market. Only one operation i.e. cutting operation had no other option than
manual cutting.
Our project has given revolutionary break and successfully developed the
machine.
CONCLUSION
India is a country having agro base economy. Maximum Indian population
is involved in agro-based activities. It is the need of time to make available the
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technologies to the farmer, which can given value addition to agro produce. As
Indian is leading producer of turmeric this technology developed for getting
qualitative turmeric output will definitely give benefit to the farmer due to value
addition. The cost involved in automation and introducing new technique is
approximately Rs. 7 to 8 lacs, which can be recovered in one season by one
machine. The cost of cutting machine is just 10,000 /- for 50 kg capacity. But this
given revolutionary break to the total process.
To see India as a super power unto 2020 it is the prime responsibility of
technocrats to work for developing machinery that can relieve stressful work of
farmers and give benefit to them by improving quality of their produce. There is a
tremendous scope to work on such project.
REFERENCES
1) Industrial Automotion by Turgen (Mir Publication, Moscow)
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2) Principles of Automation by Malav (Mir Publication, Moscow)
3) Mechatronics by H.M.T. (Tata Mac Graw Hill Publication)
CONTENTS
Sr.
No. Particulars
Page
No.
1 INTRODUCTION 1
2 AIM AND OBJECTIVE 3
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3 TRADITIONAL METHODOLOGY 5
4 BENEFITS OF AUTOCUTTING OVER MANUAL CUTTING 9
5 DETAILS OF VARIOUS SYSTEMS USED IN THE CUTTING
UNIT
5.1 Chutes
5.2 Bunkers
5.3 Disc pocket type orientation mechanism
10
6 DESIGN PROCEDURE 15
7 ACHIEVEMENTS OF THE PROJECT 21
8 RESULT AND DISCUSSION 23
9 CONCLUSION 24
10 REFERENCES 25
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Types of Chutes
a) Ordinary straight b) Roller straight c) Spiral d) Oval e) Coil f) Arched g) Cascade
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Types of Loading Facilities