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DESIGNING A PINEAPPLE MACHINE
7ULKURNAIN BIN SALIM
This project is submitted in partial fulfillment of the requirements for the degree of Bachelor of Engineering with Honours
(Mechanical Engineering and Manufacturing Systems)
Faculty of Engineering UNIVERSITI MALAYSIA SARAWAK
2004
ACKNOWLEDGEMENTS
Alhamdulillah, Thank God for all His blessing and permission I was able to
complete this Final Year Project. First and foremost I would like to take this
opportunity to thank my supervisors, En. Rash Muslimen and Dr. Ghazali Tambi for
their valuable advices, their patience and willingness to assist me completes this
report. Without their support, the work is never have been finished. I would like to
mention my special thanks to my mother and my father, my parents for their
continuous encouragement and support in my life. I am forever grateful to them for
that.
I would like to thank Mr Masri and Mr Rhyier and other lab technicians for
their technical advice and information. They have always been exceptionally helpful
whenever I faced any problem in developing the idea for this project.
i
Designing A Pineapple Machine
Zulkurnain bin Salim
ABSTRACT
The purpose of this study is to learn about the operation of pineapple machine and
redesigned the new machine. To do this project, a few pineapple machines are
studied to learn the main process of pineapple machine. From this information, new
machine will be redesigned to fulfill the user needs. The existing machines are too
complicated in term of operation and not efficient. So, for the redesigned machine,
the improvement is made so that it is easy to use and at the same time improved the
whole operation of the machine. Besides redesigning, analysis is made to determine
its capability to operate in a desired condition. As a result of this study, an improved
pineapple machine which performs the operation of slicing and coring has been
designed.
11
Merekabentuk Mesin Nanas
Zulkurnain bin Salim
Abstrak
Projek ini adalah bertujuan untuk mengkaji operasi beberapa jenis mesin nanas dan
merekabentuk semula sebuah mesin baru. Bagi melaksanakan projek ini, beberapa
mesin nanas dikaji untuk mengetahui proses utama bagi mesin nanas. Daripada
maklumat yang tersebut, mesin yang baru direkabentuk untuk memperbaiki mesin
yang sedia ada untuk memenuhi kehendak pengguna. Mesin yang sedia ada terlalu
komplikateddari segi operasi dan tidak cukup efisyen. Oleh itu, bagi mesin yang
direkabentuk semula ini perlu dibuat supaya senang digunakan dan pada masa yang
sama memperbaiki operasi keseluruhan mesin. Selain merekabentuk, analisis dibuat
untuk menentukan keupayaannya untuk beroperasi dalam keadaan yang diingini.
Hasil rekabentuk yang diperolehi ialah mesin nanas yang dapat melakukan proses
menghiris dan mengupas.
111
Table of Contents
Contents
ACKNOWLEDGEMENTS
ABSTRACT
ABSTRAK
CONTENTS
LIST OF FIGURE
LIST OF TABLE
INTRODUCTION
1.1. Introduction
1.2. Problem statement
1.3. Aims and Objectives
1.4. Scope
1.5. Summary
2. LITERATURE REVIEW
2.1. Overview of Pineapple Machine
2.2. Pineapple Processing
2.3. Pineapple Description
2.4. Samarahan Pineapple
2.5. Review on Ginaca Machine
2.5.1. The Synchronization of Ginaca machine
Page
1
11
iii
iv
vi
viii
1
1
2
3
3
4
5
5
6
7
9
10
11
iv
2.6. Pineapple Machines Today
2.7. Pineapple Machine In Samarahan
2.8. Summary
3. METHODOLOGY
3.1. Basic Step In designing
3.1.1. Study on relevant subject
3.1.2. Design The Machine
3.1.3. Design Analysis
3.1.4. Material Selection
3.2. Summary
4. DISCUSSION
4.1. Pineapple Parameter
4.2. Existing Machine
4.3. Concept Generation
4.4. Evaluation of Concept
4.5. Redesigned Machine
4.6. Design Analysis
4.7. Comparison of the existing machine (improved features)
4.8. Summary
5. CONCLUSION AND RECOMMENDATION
6. REFERENCES
7. APPENDICES
13
17
19
20
21
21
22
29
40
41
43
43
45
51
58
60
65
76
76
77
79
82
V
LIST OF FIGURE
FIGURE
NUMBER
Figure 1.1
Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4
Figure 2.5
Figure 2.6
Figure 2.7
Figure 2.8
Figure 2.9
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4
Figure 3.5
Figure 3.6
Figure 4.1
Figure 4.2
Figure 4.3
Figure 4.4
PAGE
An officer of IADP Samarahan
Smooth Cayenne pineapple
Basic model of Ginaca machine
1919 model Ginaca
1925 Ginaca machine
ELLIOT HAND-OPERATED SLICER
SINGLE KNIFE PINEAPPLE SLICER
FILTER CENTRIFUGES
Squeezer machine that is used to produce pineapple cordial
Some part in squeezer machine
Basic steps in design
Example of contradiction table
Example of comparison table
Shaft parameters
Portion of double-strand roller chain
General properties of steel
Pineapple parameter
Elliot Hand-operated slicer
Explosive diagram of Elliot hand-operated slicer
Concept I
3
8
11
12
12
14
15
16
17
18
20
27
28
30
32
41
44
45
46
54
V1
Figure 4.5 Concept 2
Figure 4.6 Concept 3
Figure 4.7 Redesigned machine
Figure 4.8 Explosive diagram of redesigned machine
Figure 4.9 Physical decomposition
55
56
60
61
62
vii
LIST OF TABLE
TABLE PAGE
NUMBER
Table 2.1: The characteristics of pineapple variety in Samarahan 9
Table 3.1: Basic design considerations 22
Table 3.2: Design considerations 23
Table 3.3: PREFERENCE RATING TABLE 28
Table 3.4: Service factor for bending 30
Table 3.5: Service factor for difference conditions 34
Table 3.6: Horsepower table 36
Table 3.7: Values of K 38
Table 3.8: Slow speed factor 39
Table 3.9 Design Considerations 42
Table 4.1: Specifications of Elliot hand-operated slicer 47
Table 4.2: Part by part Elliot hand-operated slicer 47
Table 4.3: Contradiction table 53
Table 4.4: PREFERENCE RATING TABLE 58
Table 4.5: The Criterion Comparison Table for AHP 58
Table 4.6: The Completed. Criterion Weights 59
Table 4.7: Redesigned machine specifications 62
Table 4.8: Part by part features of redesigned machine 63
Table 4.9: Recommended shaft diameters 66
V111
Table 4.10: Types of chains 71
Table 4.11: Types of bearing 75
ix
Df: 51G\ING A PINFAPPLF MACFiINF.
CHAPTER 1
INTRODUCTION
This chapter described the whole project. First, it describes the area of the study.
Then, a few problems are identified from the existing machines. From the problems
identified, we will bound the scope of the project to be focused on. In addition, the
aim and objectives of the project will be determined.
1.1 Introduction
Pineapple processing in a large quantity is quite a challenge in manufacturing
industry. But it can be done by using large machine with complex system. This
machine cost a lot of money and this why pineapple processing usually involves big
company with sophisticated machine to perform processes such as peeling, slicing
and coring.
In this project, a new machine that are capable to process pineapple with low
cost and suitable to process pineapple in Kota Samarahan will be designed. The
focus is on how we can process pineapple in a large quantity with low cost, with
simple manual to operate the machine so that the pineapple can be marketed for
small industry in Kota Samarahan area.
The machine that is going to be designed must be simple enough to meet the
requirement for Kota Samarahan. In addition, the machine must be flexible to cope
with the unplanned pineapple planting in Samarahan. For those reasons, the suitable
process are coring and slicing. Coring process involves the process of cutting out the
skin of pineapple. Slicing is the process of cutting the pineapples into slices. Both of
1
DENIGN ING A P1NI=, -IPPLE=. I\1 A('I[iN E:
the processes can be combined in one machine so that the final product is the
pineapple that has been cored and sliced.
Basically, pineapples in Samarahan are planted not for commercialized purpose.
Most of the farmers in Kota Samarahan are prefer to sell them directly to customers
or sell them to the wholesalers. Because of that, pineapples in Samarahan are planted
in small scale with the unplanned schedule. It is meant that pineapples plant in
Samarahan are depend on the farmers themselves. It causes the unbalanced supply
for pineapples in Samarahan because of the unsynchronized planting.
1.2 Problem Statements
The main purpose in this project is to design new machine for Samarahan area.
This is due to the need for suitable machine in processing pineapple in Samarahan.
Accordings to En. Esuwandi Seruji , the existing machine in market does not fulfill
the requirement for Samarahan area in term of capacity of pineapple that can be
supplied by farmers monthly. Most of the machines are large scale machine that
require about 1000 pineapples every month. This capacity is out of capability of the
farmers in Samarahan. So, it is a requirement to design new machine for small scale
to process pineapple in Samarahan.
According to En. Esuwandi Seruji, an officer at Samarahan IADP , most of the
farmers in Samarahan are practicing traditional ways to plant pineapple. The
plantation of pineapples in Samarahan are unscheduled and the capacity of the
pineapple can not be maintained. Samarahan area need for new machine which are
lower in cost and can be flexible with the capacity of pineapple in Samarahan.
2
pESIGNTNGA P(NI:. A('PLEM. ACHINI
Figure 1.1 : En. Esuwandi Seruji, an officer at IADP Samarahan who is
responsible for pineapple plantation in Kota Samarahan
1.3 Aims and Objectives
The aim of this project is to design a machine that capable to perform the
process of slicing and coring for Kota Samarahan area for the purpose of small and
medium industry. The objectives of this project are :
" Learn how the pineapple can be processed by slicing and coring.
" Find the way or methods to reduce the cost of the machine so that it can be
used in small and medium industry.
" Learn the process of designing.
" Design pineapple machine for slicing and coring.
1.4 Scope
This project is focus on designing for a new pineapple machine to fulfill the
requirement in Samarahan. This machine is designed for the application of farmers in
Kota Samarahan. The criteria that should be considered are the capability of the
3
DESIGNING A PINEAPPLE MACHINE
farmer in Kota Samarahan to use the machine, cost of the machine and the flexibility
to cope with the capacity.
The machine should suitable with the pineapples in Kota Samarahan in term of
sizes and weight so that suitable system can be applied to the machine. The machine
should also be suitable for the variety of the pineapple in Kota Samarahan.
1.5 Summary
In this chapter, the purpose of the project is clearly defined to redesigned new
pineapple machine to improve the existing machine. A few considerations are taken
into account in order to improve the machine. The considerations are based on the
problem statements which determine the scope of the project.
4
DESIGNING A PINEAPPLE MACHINE
CHAPTER 2
LITERATURE REVIEW
The purpose of this chapter is to study the parameters that are involved in this
project. The scope of the project based on the objectives that are stated in the first
chapter. The relevant subjects are studied to be used as a guide for this project. The
first subject is the pineapple itself that is to be processed. This chapter is also focus
on the principle operation of pineapple machine. For this purpose, a few examples of
existing pineapple machines are studied to realize the new pineapple machine that is
going to redesign.
2.1 Overview of Pineapple Machine
Usually pineapple processing machine involves the process of peeling, slicing
and coring. Each of the process needs for a sophisticated machine to perform the
process. Processing pineapple in large quantity usually involves big company for
heavy industry which required high capital cost. One of the most popular machines
to process pineapple is GINACA machine. This machine was revolutionized by
Henry Ginaca in 1911 [The American Society of Mechanical Engineers, 1993]. The
revolution of Ginaca machine bring to the increasing of production volume to more
than triple compared by using manual method that fully depend on the labor.
Ginaca machine was then implemented by DOLE company which is one of the
largest company that produce product based on pineapple. Until now, Ginaca
machine is widely used around the world after the great revolution in 1911 and many
5
DESIGNTNG A PINEAPPLE MACHINE
improvements have been achieved so that it can be applied for heavy industry. Most
of the machines are fully automated or semi-automated and used in big factory [The
American Society of Mechanical Engineers, 1993].
2.2 Pineapple Processing
The production of pineapples in industry began in Hawaii because of its natural
condition that has basaltic soil with hilly terrain (good drainage). Other factor is
because of the cheap labors. It produced sugar, a primary ingredient for syrup in
early pineapple packs. Canned pineapple began to be commercialized in 1890. All
the processes utilize hand labor include the processes of peeling, coring and filling
the can. These early factory production rate are about 15 pineapples/minute. The
using of machine to process pineapple was started by James D. Dole when he hired
Henry G. Ginaca (1876 - 1918) to design a machine to peel and core pineapples. As a
result, the machine that had been developed (called Ginaca machine until now) had
tripled the production rate and decrease the direct depend on labor. Current Ginaca
machines run at speeds around 100 pineapples/minutes and big canners utilize about
20 machines/factory. [Mitsui, 2004]
The procedures that had been developed based on classifying the fruit into a
number of grades by diameter centering the pineapple on the core axis and cutting
fruit cylinders to provide slices to fit the No. 1,2 and 2-1/2 can sizes [The American
Society of Mechanical Engineers, 1993].
The basic process in pineapple processing involves the process of coring, peeling
and slicing. Coring is done to center the pineapple so that the next process can be
done easily, while the process of peeling is done to cut out the skin and unused part
6
DESIGNING A PINEAPPLE MACHINE
from the pineapples. More important process is slicing where the pineapples are cut
into pieces depend on the way of packaging.
2.3 Pineapple Description
Pineapple is the family member of Bromeliad which embraces about 2,000
species. It is also known as Ananas comosus Men. (syns. A. sativus Schult. f.,
Ananassa sativa Lindl., Bromelia ananas L., B. comosa L. ). Usually, pineapple plant
can achieve high around 2 2.5 to 5 ft (0.75-1.5 m). The leaves spread about 3 to 4 ft
(0.9-1.2 m). The leaves is green in color or striped with red , yellow or ivory. It
plants from flower that joint together forming cone shaped, compound, juicy, fleshy
fruit to 12 in (30 cm) or more in height. Pineapple is a tropical plant which can grow
in temperature range of 65°-95°F (18.33-45°C). The rainfall that suitable for
pineapple planting is about 45 in (1,143 mm). [Morton, 1987]
Pineapple can be grouped into four main classes according to the international
trade. There are ̀ Smooth Cayenne', ̀ Red Spanish', ̀ Queen' and ̀ Abacaxi'. Type of
pineapple that can be found in India, Sri Lanka, Malaysia and Thailand is variety of
`Smooth Cayenne'. This pineapple can achieve weight from 1.8- 4.5 kg. Other
variants of `Smooth Cayenne' are Hilo (Hawai), St. Michael (Azores) and Esmeralda
(Mexico). `Smooth Cayenne' is planted because it is suitable for canning, can be
sliced and has great flavor. [Morton, 1987]
The most famous pineapple in West Indies, Venezuela and Mexico is from class
`Red Spanish'. This pineapple is approved more dependable than other class of
pineapple in that area. The most important thing is this pineapple is suitable for
7
DESIGNING A PINEAPPLE MACHINE
canning because it is more or less round, orange-red in colour with weight around 3
to 6 1bs (1.36- 2.7 kg). [Morton, 1987]
Figure 2.1 : Smooth Cayenne pineapple [Morton, 1987].
`Mauritius' is a variant of pineapple that can be found easily in Malaysia. It is also
known as `Malacca Queen, `Red Ceylon' and `red Malacca'. This pineapple is quiet
small with the weight around 3 to 5 lbs (1.36-2.25 kg) and its external colour is
yellow.
The second place is taken by `Singapore Red' which also known as `Singapore
Queen'. It's leave is usually all-green in colour and sometimes have a reddish stripe.
The fruit is also quiet small about 3.5 to 5 lbs (1.6-2.25 kg) in weight [Morton,
1987].
Another variant of pineapple that can be found in Malaysia is `Green Selangor'
which also known as `Green Spanish' and `Selassie'. With all-green leaves, it has
golden-yellow flesh with dots and suitable for canning [Morton, 1987].
8
DESIGNING A PINEAPPLE MACHINE
2.4 Samarahan Pineapple
There are several variety for Samarahan pineapple. The varieties are Morris,
Josapine, N36, Gandul, Sarawak pineapple and Sawit. Therefore, the most
common pineapple in Samarahan is Morris pineapple.
Variety Weight
(kg)
Stem
(mm)
Amount of
solidity
(%)
Acid (%) Quality of
storage
Morris 1.0 24 15.9 0.49 ***
Josapine 1.3 28 16.8 0.63 *****
Sarawak 2.2 28 13.7 0.61 ***
Table 2.1 : The characteristics of pineapple variety in Samarahan.
[MARDI, 1998]
Key : ***** = very good
*= bad
Most of the pineapples in Samarahan are sold directly to the customer. There is no
industry to commercialize the pineapple in Samarahan. But when there are surplus of
pineapples, they are processed to produce cordial using the machine that is supplied
by IADP Samarahan. It is depends on the farmers themselves whether to process the
pineapple to produce cordial or not.
9
DESIGNING A PINEAPPLE MACHINE
2.5 Review on Ginaca machine
The production of pineapple for commercialized was started about 1890 in Hawai.
The process is fully man-power which was needed for high labor. It becomes change
when the pineapple machine is introduced into the industry which strongly increases
the production rate. But, the requirement for the high labor was still the issue. This
issue needed for automated pineapple machine as a solution.
The operation of Ginaca machine is basically involves the process to center the
pineapple on the core ; cut out a fruit cylinder ; eradicate the crush and juice material
; cut off the end ; and remove the central fibrous core. In early when the machine was
innovated, it can process 50 pineapples per minute manually and needed for high
labor.
Ginaca is a combination of separated devices. First part is consisted of a chain
provided with pusher, a centering head and a stationary sizing knife. Second part
consisted of a six-pocket turret mechanism. Third part consisted of a skin eradicator
to remove the juice material.
After the innovation of basic Ginaca machine in 1911, there were some
improvement that were achieved to increase the capacity of the machine and decrease
the needed for high labor. The important achievement were happened on 1919., 1925
and after world war. The improvements were included the addition parts of Ginaca
machine like stationary curved tube and vertical turret mechanism [The American
Society of Mechanical Engineers, 1993].
10
DESIGN ING A PINEAPPLE.. MACHINE
Figure 2.2: Basic model of Ginaca machine [The American Society of
Mechanical Engineers, 19931
2.4.1 The synchronization of Ginaca machine
1919 model Ginaca
The development of pineapple machine brings to the new model of Ginaca in
1919. The totally different are the using of inclined sizing knife and vertical turret
compared between the models before it. The maximum speed of this machine can
produce 65 pineapples per minute.
11
DESIGNING A PINEAPPLE MACHINE
Figure 2.3: 1919 model Ginaca [The American Society of Mechanical
Engineers, 1993]
1925 Ginaca machine
This model has a capability to process from 90- 100 pineapples per minute. 1925
model was developed by aligning the turret with the sizing knife. The improvement
had hardly improves the eradicators, feeds, auxiliary drives and construction.
Figure 2.4: 1925 Ginaca machine [The American Society of Mechanical
Engineers, 1993]
12
DESIGNING A PINEAPPLE MACHINE
Post-world war designs
After world war, there were a few attempts to improve the basic design of Ginaca
machine. The improvement was involved the combination of gravity force. The
improvement was also included the using of `jet transfer' ;a method which used
resulting pressure between the free cylinder into the turret to replace the gravity force
so that the process can be made horizontal. Most of the attempts to improve the
machine were fail to achieve their objectives due to the complexity of the machine
and failure to operate as an expected. But, the improvement that had been achieved
has increase the capacity up to 100 pineapples per minute. It was also had been
approved that basic Ginaca machine which operate base on gravity transfer are more
efficient.
2.6 Pineapple Machines Today
Nowdays, there are various types of pineapple machine that perform various types
of processes like coring, peeling and slicing. The examples of these machines are
FCPM-80 pineapple peeler, Elliot hand-operated slicer and single knife pineapple
slicer. These machines meet their requirement when applied for heavy industry. But,
they are not efficient to be applied for Samarahan area which is not large in scale for
heavy production. Other factors are the high cost for the machine and the limited
capability of the farmers in Samarahan area to operate the sophisticated machines.
13
DESIGNING A PINEAPPLE MACHINE
ELLIOT HAND-OPERATED SLICER
This slices pineapple into a hollow cylinder shape for canning. The cored pineapple
fruits are fed by hand to a V-block, located underneath the cutting assembly. When
the pineapple fruit rests on the knife assembly, it passes through a series of slots
which cut the pineapple cylinder into slices. Throughput: 600-720 pineapple fruits
per hour. Dimensions: 91 x 61 x 168cm [FMC CORPORATION, 1999]
Figure 2.5: ELLIOT HAND-OPERATED
SLICER (FMC CORPORATION, 19991
14