Innovative Technology for Sustainable Food Production(Post Harvest Technology) - AARDO Presentation

Dr. Shankar Krishnapillai (DPhil. Oxon)Professor and Head of Machine Design SectionDepartment of Mechanical EngineeringIIT MadrasChennai 600 036

Email: skris@iitm.ac.in

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Brief Background:

Bachelors Degree in Mechanical Engineering – University of Kerala, India.Doctorate (DPhil) - University of Oxford, 1996

Thereafter Worked at NASA-JSC, National University of Singapore.

Joined IIT Madras in 2003.

Became Professor in 2013.

Areas of Interest:Mechanical Design, Optimization, Computer-aided Design.Applications to Rural Technology.

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Machine Design Section is a part of Mechanical Engineering Department.The other sections are Thermal and Manufacturing sections.

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Machine Design Section is well equipped with excellent Computer aidedDesign Labs

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Research Laboratories

• Advanced Materials and Product Design Group• Center for non-destructive evaluation • Computational Materials and Mechanics Group • Computational Mechanics Laboratory• Fatigue, Fracture and Small Specimen Testing• Integated Modeling and Simulation Lab• Mechanics of Time Dependent Materials

Laboratory• R2D2 Lab• Stimuli-Responsive Systems Laboratory• Tribology Laboratory• Optimization Lab• Dynamics Laboratory

We have a large number of research laboratories working in hardcore engineeringareas. In addition to this, we also work in areas like Rural Technology.

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TECHNOLOGIES TO BE DISCUSSED TODAY:

1.A PORTABLE CABLE WAY FOR POST HARVEST RESOURCE COLLECTION

2.MONORAIL BASED AGRICULTURAL TRANSPORTATION DEVICE FOR POST HARVEST RESOURCE COLLECTION

3.HOUSEHOLD COLD PRESS OIL EXPELLER

4.LOW BED TRACTOR TRAILER FOR AGRICULTURAL POST HARVEST APPLICATIONS

5.TECHNOLOGIES FOR COIR INDUSTRY:(A)TABLE TOP COIR ROPE MACHINE (B)INDUSTRIAL MACHINE IMPROVEMENT AND AUTOMATION

THESE TECHNOLOGIES HAVE BEEN DEVELOPED USING FUNDS FROM

(A)CORPORATE SOCIAL RESPONSIBILITY FUNDS – FROM INDUSTRY(B)RURAL TECHNOLOGY CELL FUNDS – IITM(C)SOCIALLY RELEVANT TECHNOLOGY FUNDS - IITM

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1. A PORTABLE CABLE WAY FOR POST HARVEST RESOURCE COLLECTION

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A simple, economical, compact portable cableway has been developed, fabricated and tested for transportation of any produce loads from farm to collection point.

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Background :

India is one of the largest sugar producers in the world. It is produced from sugarcane.

Sugar can be produced from various crops: sugarcane, sugar beet, palm jaggery etc.

The immediate reason for this project is the problems faced by Sugarcane Farmersin Karur District of Tamilnadu. It is typical of other farmers also.

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Background :

India is one of the largest sugar producers in the world. It is produced from sugarcane.

Sugar can be produced from various crops: sugarcane, sugar beet, palm jaggery etc.

The immediate reason for this project is the problems faced by SugarcaneFarmers in Karur District of Tamilnadu.

1. There is a significant shortage of labour in the Indian farming sector. All sorts of agricultural activities are thus affected.

2. Especially affected is post harvest resource collection (most labour intensive).

4. Due to small size of Indian farms (Land Ceiling Act) western type of large-scale mechanisation is not possible.

5. Wetland fields (surrounded by ditches, canals) make vehicle entry difficult into some farms.

6. Damages of fruit like bananas during manual transportation.

Cable way is a preferred option here.10

One headload of sugarcane25-30kg

Wetland fields, difficult for vehiclesto enter.

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Edward S Neumann et.al, “Modern Material Ropeway Capabilities and Characteristics”,Journal of Transportation Eng, Vol(111),1985.

Some advantage of cable ways:

1.One of the most economical means of material handling (minimum energy consumption & labour requirement).

2.Moves material in a straight line.

3. Can cover rough terrain because doesn’t touch the ground.

4. Minimum ecological impact.

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Example: Cable way used by Hindustan Copper Ltd, Madhya Pradesh

Source: www.hindustancopper.com

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Various Types of Cable Ways:

1. Self Propelled

2. Hauled by rope

3. Gravity

Mono-cable way and Bi-cable way:

Mono: One cable way only for onward and return.Bi-cable way Separate cable-ways for onward and return.

Edward S Neumann, Sam Bonasso, Abel D.I.Dede, “Modern Material Ropeway Capabilities and Characteristics”, Journal of Transportation Eng, 111,651-653,1985

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Objectives of Portable Cable way:

1.Simple and economical. Use readily available parts.

2.Easily erectable in the field. After use, can be removed and shifted to another field.

3. Continuously transport loads of 25-30kg over distance of several hundred metres.

4.Prevents damage and bruising of agricultural products during handling (banana/tapioca).

5.Reduces labour cost. Gives value addition due to above causes.

6. Avoids spinal injury in the long term.

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Cableway – Schematic diagram

Loaded trolley

Top cable

Bottom cable

anchor

anchor

Tightening device

Portable post

Portable post

Loaded trolley

Empty trolley

Recirculating rope

Motor and Winch – 2HP

Span 5-7m

openable

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Clamp

1.8m

2.3m

Tie rods

Top Cableway

Bottom cableway

2.2 m

0.83 m

400

A portable post

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2.3m

450

50kg

Cable Tensions:With a single concentrated load of 50kgf, there will be forces as shown below.

7m span and 3% sag

300kgf(endpost)

1. Thus 4 or 5 concentrated loads of 50kg may cause a cable tension of 2 tonnes.

2. A 12mm dia cable (8 tonne load capacity) was adequate,

3. End post have to be very sturdy to withstand the compressive loads.

300kgf(endpost)

Tension=420kgf

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2.3m

1.8m

A cableway post is assembled

Top cableway riding on swivel arm

Bottom cableway swivel arm (V groove)

10 cm

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Simple trolley with sling:It is designed to move on the steel cable on two nylon wheels (less friction). The circulating rope pulls the trolley when it is clamped to the trolley.

Load is carried in a sling under the trolley.

cable

sling

Trolley with nylon wheels

rope

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Winch and Motor:

1. The recirculating rope is pulled by a winch powered by a 2HP, 1500rpm electric motor and a gear box.2. Winch drum is about 0.3 m dia and surface is corrugated for better grip.3. Rope is 8mm dia nylon rope, with one twist around the winch drum.

Winch unit with 2 HP motor& reduction gear.

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Cable Tensioning device: (this is for removing the sag)

1.The cable is tightened with 2 tonne chain pulley block.2.One end of chain pulley is anchored 1.5m under the ground. 3.The cable is tightened easily by pulling the side chain of the pulley block.

Chain pulley block to tensionthe cable.

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Testing of prototype

Cable way was tested over distances of 25m, 75m and 100m.

It worked satisfactorily.

Sugarcane loads (upto 5 trolleys at a time) were hauled continuously at speed of 0.3m/sec without break. Every 16s a load can be attached.

Photos and Videos

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Economic aspects of cable way:

1. Cost of cable way with generator is Rs 2.5 lakhs (USD 3500)

2. It needs 4 people half-a-day to install the cable way.

3. A longer cableway does not require proportionately more effort.

4. Once a cable way is installed, it may need 3-4 people to run it (1 at either end) irrespective of distance or terrain.

5. Manual labour can be saved depending on the distance covered.

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2. MONORAIL BASED AGRICULTURAL TRANSPORTATION DEVICE

Such monorail conveyors are used in factories for production lines.

We have adapted the concept for cheap, agricultural transportation useover very large distances.

As used in factories

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Advantages of monorail(in many ways similar to cable way)

1. Economical means of material handling (minimum energy consumption & labour requirement).

2. Can cover rough terrain.

3. Minimum ecological impact.

Better than cable way in some respects:

1.Can carry heavier loads. No problem of sagging, tensioning the cable.2.Can have curved paths.3.Easy to extend by adding more rails.4.Only one operator used at either end.

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Schematic diagram of Agricultural transportation system

(a) Traction unit with scooter engine (b) Several trolleys carrying loads of 45 kg (c) Support posts (d) Overhead rail (box section) (e) Foundation (concrete/steel shoes)(All are commonly available in local workshop, economical, no expertise needed)

Foundation Foundation

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6m (one span)

100x50x3mm box sectionMild steel.From Bus body workshop.

45kg

45kg

45kg45kg

45kg

rail

Design of the rail

Only 10mm sag is noticed when loadedwith 5 trolleys in one span. So the rails arevery rigid.post

post

sag

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Trolley Design

Trolley is 1m long, and with 2cast iron grooved wheels,rotating in bearings.

It takes very liitle effort to pusha trolley.

Hooks for slings

Dummy ironload

rail

trolley

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Traction unit with 9Hp scooter engine

Initial model without self starter orforward/reverse.

Final model with self starter,forward/reverse.

Gear box to reduce engine at 4000rpmto trolley wheel at 50rpm.

Speeds of 0.6m/s and above are usedwith gears.

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Design of the monorail posts:

Monorail posts must be sturdy, easily available, easily transportable, quickly erectable. They have to support the load from the rails and trolleys.

This post with C shape with steel shoe can be used for portable application

For permanent posts, concrete base/foundationcan be used.

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How are two rails joined together?

A smaller box section is used as an insert to connect two rails together.This is an easy method. It is possible to add rails one after the other and extend.

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Trials of the monorail was done over short distances (5-6 spans) andfound to be reliable and workable.

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Final implementation in agricultural field (July 2020)

Distance of 220m. Cost of items Rs 8 lakhs (USD 10,000)

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Seven or eight trolleys were used, each with a load of 40-45kg.Only 2 operators are needed. The speed of trolleys can be adjustedwith gear and accelerator combination. The best speed is little more thanwalking speed for easy loading/unloading of trolleys.

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3. COLD PRESS OIL EXPELLER

1. Based on feedback obtained from many sources it would be very useful for Indian rural farmers to have a compact oil expeller in their farm to extract good quality oil which can be an additional income for them.

2. Oil cake (the waste material) is a nutritious animal feed. 3. Wide range of domestic seeds need to be crushed. (groundnut/sesame/copra. etc)

4. The current oil expellers in the market are either very expensive (large scale) or not satisfactory in performance. The small table top models, which are usually imported, are not suitable for local conditions or seeds.

5. There is an increasing demand for cold pressed oils in the Indian/Global market for edible oils/cosmetics.

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Hot press

Oil is compressed with a screw or any device, which is heated from 100-200Oc.

The cell walls rupture and oil is easily extracted. Higher productivity (40-45 % of seed weight)

The high temperatures change the chemical structure of oils

A lot of important substances like vitamin E, sterols, and carotenoids are lost.

Chemicals are added to retain the smell/taste of original oil.

Cold press

Oil is compressed at room temperature. Below 50Oc

More compression effort. Lesser productivity (30% of seed weight).

Cold pressed oil retains most of its natural physiological and chemical properties and most importantly its original taste.

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Type of cold press oil devices used in India:

1.Cattle driven oil-Mill (Ghani of Chakku or Sekku)Lining of the pit (mortar) is made of hardwood.Pestle is either stone or hardwood.About 10-15kg/hr of seed.

2.Motorized Ghani (steel, no wood). About 5-10 Hp motor.Higher productivity. Costs – Rs 2,50,000 (USD 3500)But oil comes out at higher temperature due to steel friction.Not exactly cold-pressed.

3.Solvent based extractions: For coconuts, the coconut milk can be subjected to heating and centrifuging and enzymic action to separate oil.Other seeds may require artificial solvents like hexane to dissolve andlater distil the oil.

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Oil seeds

High Torque

Oil seeds movement

shell

Screw type oil press: Can generate high pressures to extract oil.

Screw has a reducing depth to compress and crush the seeds.

However this is not enough to pressure to make cold pressed oil.

oil oil

Hopper

Screw (with reducing depth)

Oil cake

Oil cake

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Tapered screw type press:

This is a novel concept which gives higher compressions due to dual effect.Can produce cold press oil in table top models.

Compression occurs due to reducing diameter as well as reducing depth.

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Screw and Shell – made of rust proof material.

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½ HP electric motor

Speed of screw – 33 rpm(reduction gear is needed) forhigh torque.

Total cost Rs 27,000(USD 300)

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Sesame seed:

Seed input: 6.00 kg/hrOil weight: 1.73 kg/hrPercentage of oil by weight: 28.8%Oil cake: 4.27 kg/hrOil temp: 360C

Groundnut seed:Seed input: 3.00 kg/hrOil weight: 0.90 kg/hrPercentage of oil by weight: 30.0%Oil cake: 2.1 kg/hrOil temp: 360C

Copra (dried coconut): Has to be cut into small pieces first.Seed input: 5.00 kg/hrOil weight: 1.90 kg/hrPercentage of oil by weight: 38.0%Oil cake: 3.1 kg/hrOil temp: 360C

Performance of cold press oil expeller:

Sesame oil cake

Groundnut oil cake

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Improved cold press oil expeller:To improve the productivity of the oil expeller, 1 HP motor and larger screw is used.The input opening and hopper size is increased.Now the productivity was increased by 50%. Oil of same quality was obtained.The current machine is undergoing trials for extended use.

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4. LOW BED TRACTOR TRAILER FOR AGRICULTURAL POST HARVEST APPLICATIONS

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Existing trailers in India are overloaded, upto 4 times the height of side walls.(upto loads of 20t). It is used in the post harvest time.

The C.G is high and they overturn at moderate speeds and curves. Many fatalaccidents occur.

The braking is also poor, mechanical brakes are used.

A new design is needed with low CG to prevent toppling and also increase the load carrying capacity and maximum allowable speed and safety. 51

Low bed Tractor Trailer IS: 8213-1987(Agricultural Trailer) standards:Max Length =7.5m, Width=2.4m, Min clearance from ground=0.5mWe have to stay within these limits, and still produce a strong trailer capable of 20t load.

Initial design 6m long and 2.3m widewith 0.5m min clearance.

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Strong I-sections and C-sectionsteel beams are used to make theZ shaped corners.

These are cut and welded togetherusing special techniques.

1. A triangular piece is cut

2. The I section is bent

3. The cut section is inserted 4. Extra reinforcement steel plate 5. Extra reinforcement side plate

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Stress analysis for extreme loading of 20t + 7t trailer weight for various cases.

Front wheel hits a bump

Rear wheel falls into a ditch

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Parameter Old Design New design

Length of the trailer 4.80 m 6.00 m

Width 2.30 m 2.30 m

Clearance above the ground 1.20 m 0.50 m

C.G from groundfor loading 20t

3.07 m 2.00 m

Max. speed 20.0 kmph 35.0 kmph

Comparison between old and new designs of trailer

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The final fabrication of tractor trailer included (a) lengthening to 7.5m (b) real 2 axles instead of 1 (b) air brakes powered by tractor (c) a turntable. All are made in local workshop.

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5. TECHNOLOGIES FOR COIR INDUSTRY

TABLE TOP MACHINEINDUSTRIAL SCALE MACHINE

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• Manufacture of coir fibre, yarn and coir based products are important traditional industries of Kerala. Coir Industry is of great importance to Kerala where it is second only to agricultural source of employment.

• Coconut fibre from the husk is either discarded as waste or used as a fuel, and it is processed into products only in a few countries like India and Sri Lanka. It is a significant value addition.

• Coir industry is concentrated in Alleppey District providing employment to 400,000 persons out of which 330,000 are women. This sector exports coir products of around 100,000 MT worth Rs. 4000 million a year (USD 50 million).

• Among the coir products, high quality coir rope is the most important product. This rope is also used for carpets, mats, flooring etc (for export).

• There is a need to upgrade the technology and productivity from traditional ways:• (a) Avoid drudgery/hand injury/scarring.

(b) Uniform quality.(c) Larger outputs for export markets.

• Now the coir ropes have to follow industrial standards IS 14596:1998 i.e specified twist per metre, runnage (i.e., metres/kg) for different ropes.

TABLE TOP MACHINE - motivation

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In many parts of Kerala the rope is made in traditional way, using a manually turned wheel.Recently, motorized wheels have been used.

The most popular rope produced here is “Vykom rope”: 50 twist/metre, 235m/kg, 2 strand

• Walking to and fro from several km’s per day.• Bleeding aberrations in palm and fingers resulting in scars in hand• Uneven twist.• Length of rope 10-12m have to be spliced together.

Women have to walk backwards 10-12 metres feeding the rope.

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Purpose of the Machine:

The machine makes excellent Vykom rope as per IS 14596:1998

50 twists per metre, dia 4.5mm, 235 m/kg.Productivity of 6.5 metres/minute with ½ HP motor.(Double that of manual method)

Does not require Nylon core.

The machine is envisaged to be semi-automatic. It requires an operatorto feed the coir yarn.

It is envisaged for home based use.

This machine is already in service in Alleppey.

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Sl No Type Runnage (mtr/kg)

1 Arattupuzha 200-220

2 Anchuthengu 240-270

3 Mangadu 140-160

4 Vaikkom 180-200

Popular type of ropes in Kerala

Used for binding nativecanoes

Used for mats/carpets

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Input twister 1

Input twister 2

Static roller(guide/holder)

Final pulling-cumtwisting mechanism

Yarn- strand1

Yarn- strand2

50o

Drum(passivelyrotateson a shaft)

34.5cm

Machine axis

16 cm

RotatingArm Rope

After a lot of studies, and trials the following arrangement was designed to make Vykom rope (other ropes can also be made by changing the speed of rollers).

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Test Bed

Variablespeed

Variable anglebetween yarn

Variablespeed

Variable distance

All important parameters were varied using two speed control motorsMany different ropes can be obtained wth different speed combinations.

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Computer model was made before fabrication

Parameter

Input feed Rollers (rpm)

Twisting Mechanism (rpm)

Low Productivity 540 140

Medium productivity

640 140

High productivity

640 180

Different productivity rates was obtainedusing different speeds.

By changing the belts and pulleys differentproductivity can be obtained.

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Prototype machine with ½ HP motor.The drum assembly can wind 500m rope in one go before change.

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With inexpert workers from outside Kerala, 2 workers are needed to feed the rope

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Expert women workers from Kerala can operate this machine easily and comfortably.

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Completed machine with safety features delivered to women workers in Alleppey.With this machine they can make double or triple the amount of rope per day ofbetter and uniform quality.

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Finished mats made with rope from this machine, is better than manually made mats.

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Improvement and Automation of an industrial type of coir machine (ASM)

(project in Progress)

Automatic Spinning Machine (ASM) made by KSCMMC, Kerala Government.Automatically makes rope when fibres are fed into it from the right.

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Has 2 drums: : Produces 40 metres/min (80kg per shift)Drum Speed : 424rpm; Twister speed : 1502rpmCoir type : Non-standard type. Uses a nylon core.Power : 1.5HPCost : Rs 2,30,000 (USD 3000)Only 1 person needed to feed the machine with coir yarn.

Two drums of ropeare produced

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• Kerala State Coir Machinery Manufacturing Company (KSCMMC) is a Kerala Government initiative which is committed for ensuring development & growth of coir based industries in Kerala. It is established in Alleppey town, Kerala.

• KSCMMC focus upon the development of coir manufacturing equipments & machineries in order to boost the growth of coir industry in India.

• They have a wide ranging collaboration with IIT Madras foe design improvements.

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Worker loadscoir yarn Willowing drums (2)

(drums with spikes for combing)

Drums for final rope

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A common shaft drives everything

Problem:(1) A common shaft attached toa single motor drives all thecomponents viz drum, willowingunit, twisters. It is not possible to obtain relative change inrpms to obtain different types of rope.

(2) The rope obtained now isnon-standard. It has to fallinto certain standard categories.For that the correct relative speeds need to be found out.

(3) Increase productivity.

Solution:(1) Provide separate motor drivesfor all components. (2) Provide separate speed controlfor these motors.(3) Find right speed combinationfor making different ropes.

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Sl No Type Runnage (mtr/kg)

1 Arattupuzha 200-220

2 Anchuthengu 240-270

3 Mangadu 140-160

4 Vaikkom 180-200

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All these ropes can be made by changing the speeds between thedifferent motors. But detailed experimentation is required.

Five different motors (M1-M5) are provided, for separate control of each part.

Willowing drum

conveyor

Willowing drum

conveyor

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Motor Motor Type Location/ Purpose Drive/Control Type

M1 1HP 3Phase Induction Motor

Head Drive VFD (Variable Frequency Drive)Driven with Feedback control

M2 0.5HP 3Phase Induction Motor

Feeder Differential Speed VFD Driven with Feedback control

M3 0.5HP 3Phase Induction Motor

Nozzle VFD Driven

M4 0.5HP 3Phase Induction Motor (Geared)

Conveyor VFD Driven

M5 0.5HP 3Phase Induction Motor

Combing wheel Without VFD

The addition of these motors increased the price Rs 100,000 (i.e. USD 1200),but it was essential to provide value to the customer.

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Current status of the project:

•5 Motors and their electronic speed controls have been added.•Testing is underway to determine which speed combinations give which types of ropes.

•How much productivity can be increased by using higher power motors is being investigated.

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Summary:

Application of technology can improve the problems faced by small and mediumfarmers of developing countries. It can improve productivity, quality, avoid drudgery,and improve safety etc.

There is a reluctance in farmers to accept new technology.

Technology must be cost effective for small farmers.

Although the problems appear simple, the engineering may be complicated.

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END

Thank You!!