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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
Development and Performance Evaluation of an
Optimized Screw type Domestic Oil Expeller
Naquib Mahmud Chowdhury and Faisal Mahmud
Department of Industrial and Production Engineering
Bangladesh University of Engineering and Technology
Dhaka-1000, Bangladesh
[email protected], [email protected]
Abstract
Domestic extraction of oil from different types of seeds and agricultural products is a common practice in many agricultural countries. Consumers depend mostly on local mills to extract the desired oil from different agricultural
products in those countries which involves few difficulties and limitations. Consumer surveys were conducted locally
to identify the related difficulties associated with the oil extraction processes. From consumer surveys, it was identified
that, poor oil extraction efficiency, high power consumption, large space requirements, high purchasing cost and lack
of portability due to increased weight are the most common problems in locally available oil expeller machines. Since
these problems are highly prominent in those available machines, an improved screw type oil expeller machine was
designed for domestic uses considering the consumer requirements. Focusing on the improvement of oil extraction
efficiency (OEE) and elimination of those existing difficulties, few necessary modifications were done while
designing the product using Taguchi design methodology and design of experiments (DOE). Consequently, structural
analysis for different parts of the product based on its operating conditions were performed using ANSYSTM before
developing the product. Finally, the conclusion and scope of improvements are presented.
Keywords Screw Oil Expeller, Oil Extraction Efficiency, Quality Function Deployment, Design Analysis, Design of Experiments
1. Introduction
Oil extraction from different plant sources is a common practice in agricultural countries. There is a wide variety of
oils extracted from different plant sources such as olive oil, palm oil, soybean oil, mustard seed oil, corn oil, peanut
oil and other vegetable oils are used for different purposes in these countries. There is not any convenient and cheaper
solution for the domestic consumers to extract the oil from these sources. As a result, domestic consumers depend
mostly on local mills to extract the oil from their desired sources. For industrial oil extraction, screw oil expeller is
the most widely used machine. Screw oil expeller is a mechanical device which can generate pressure from rotation
of feed to expeller screw manually or automatically. Screw press method for oil extraction is a mechanical method for
extracting oil from raw materials. Extracted oil from screw pressing are used either as a food product or as an industrial
product.
To develop a modified and improved screw oil expeller, we initiated with a customer survey to identify the customer
needs, requirements and drawbacks of existing products in the market. Some major drawbacks of available screw
press expeller were identified from this customer survey which includes poor oil extraction efficiency, heavyweight,
high purchasing cost, difficulties in maintenance and cleaning mechanism etc. After that, quality function deployment
or, QFD analysis was performed to convert those customer needs into technical requirements and prioritization was done accordingly. A functional decomposition using the black-box model was performed subsequently. Both
quantitative and qualitative analysis were accomplished for the selection of material, manufacturing and joining
process followed by the CAD design. In this developed screw expeller, seeds are confined in barrel through a hopper
and extraction of the oil is accomplished by exerting sufficient force on confined seed. The residue of the material
from which oil has been expressed exits from the unit and is known as the cake. The seeds are continuously fed to the
expeller screw which grinds, crushes and presses the oil out as it passes through the machine. A strip heater is
incorporated with the barrel for heating of seeds for better oil extraction efficiency. A design of experiment was
implemented while fabrication to identify the potential factors affecting oil extraction efficiency. By implementing
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
structural design simulation, verification of parts used in screw expeller were performed and helped in increasing
overall performance efficiency. Screw shaft is the most vital element of screw expeller as it provides the required
amount of pressure for extracting oil from the raw materials. It is evident from this study that, the failure of screw shaft will result into extra costs which is undesirable. In addition, excess stress, bending, displacement may cause
major overhaul of the press. So, to increase the life of screw press and efficiency of oil extraction, it is necessary to
find exact stress and bending of the screw shafts. The research design and simulation were performed by SolidWorksTM
and FEA (Finite Element Analysis) with ANSYSTM software.
2. Literature Review
Homburg et al. (2015) defined product design as a set of constitutive elements of a product that consumers perceive
and organize as a multidimensional construct comprising the three dimensions of aesthetics, functionality, and
symbolism. Alsyouf et al. (2015) investigated how to assess and improve the performance of products. According to
this study, the main objectives were to assess the products flaws and their causes, analyzed the most critical problems,
suggested and chose the best solution. The main contribution of this paper is to introduce a verified procedure that
combines a variety of tools and methods from different disciplines used in a new context in product design. The paper
suggested four steps in improving product design such as: assess the current performance using fishbone diagram,
Pareto analysis, FTA, RBD, FMECA; identify the stakeholders needs through customer survey; establish target
specification performing QFD and HOQ to translate the stakeholders’ requirements into product technical specification (TS) and testing and final specifications using design of experiments through analysis of variance tool
ANOVA. Many studies have been carried out in mechanical expression of oil from screw based oil expeller.
Srikantha (1980) estimated that, nearly 90% of the total oilseeds produced in India are crushed using mechanical
expression. In that study, mechanical screw presses (oil expellers) used in India had been stated as inefficient since they leave 8 to 14 % of the residual oil in the cake and thus, a large quantity of precious edible oil (about 0.6 million
tons) goes with the cake. Merrikin and Ward (1981) performed a comparison analysis of the commercial and small-
scale expeller units for processing sunflower seeds. They developed hypothetical curves of radial and axial pressure
inside small expellers. Mrema and McNulty (1985) stated mechanical expression of oil from vegetable oilseeds as the
most widely used method for oil extraction. The conventional theory of mechanical oil expression suggests that the
oilseed cells must be ruptured by a combination of physical (crushing) and thermal (cooking) pretreatments before
substantial oil expression can occur. Rosenthal et al. (1996) also stated mechanical screw pressing as the most popular
method of oil separation from vegetable oilseeds in the world. Ali and Watson (2014) performed a comparative
analysis between improved expeller and standard expeller and revealed that optimal operation of the expeller was not
achieved. He also noted that:
The driving mechanism needed improvement as the small worm frequently broke down into pieces.
Energy consumption of the modified expeller was higher when compared to the standard improved expeller.
Absence of any standard specification while manufacturing, were producing substandard oil expellers.
Isobe et al. (1992) developed a screw press based on twin screws and reported an oil recovery of over 93% from
untreated and raw sunflower seed. Singh and Bargale (2000) designed and developed a modified oil expeller based on
a novel principle of single feed, double stage compression to improve the efficiency of oil recovery. Bamgboye and
Adejumo (2008) also developed and modified a screw press for sunflower oil expeller. Modh and Mevada (2011)
designed and made improvement in some components of oil expeller machine and also carried out the thrust ball
bearing analysis and results to compare with analytical results. Deli et al. (2011) studied the effects of physical parameters of a screw press machine on oil yield of N. sativa seeds using a KOMET Screw Oil Expeller. Different
nozzle size, extraction speed and diameter of shaft screw were applied in their study. From their study, they found that
different nozzle size, diameter of shaft screw and rotational speed effects the percentage of oil yield. Moses (2014)
conducted a performance evaluation test to investigate efficiency of oil expeller machine, the effect of kneading
temperature on the oil yield and the extraction losses of the machine. Fakayode and Ajav (2019) developed and
evaluated a screw press moringa oil expeller in terms of oil expression efficiency (OEE), material balance efficiency
(MBE) and expression loss (EL). Four different models were fitted to the output variables.
3. Methodology
Khoo and Ho (1996) defined quality function deployment (QFD) as a planning methodology for translating customer
needs into appropriate product features. In QFD operation, relationship matrices are used to describe the relations
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
between different customer needs and design requirements. The best way to transform customer needs into engineering
characteristics for a product or service is quality function deployment (QFD). For obtaining QFD, we identified our
target market those are rural farmers and urban domestic users. We performed a survey on 89 potential consumers for developing consumer needs for our domestic oil expeller through direct questionnaires, online surveys, and interviews.
The customer needs can be summarized into three different categories which is showed by the following table:
Table 1: Customer requirements with preference
High Preference
High oil extraction efficiency
Low power consumption
High durability
Lightweight
Moderate Preference
Easy cleaning mechanism
Easy maintenance
Flexibility
Low Preference
After sales service
Compact design
Touch control mechanism
Converting this customer requirements to design requirements, in order to perform QFD:
Figure 1: House of quality for domestic oil expeller
From house of quality, screw specification, motor specification and material are identified as the three most important
technical requirements for this product. After this, function decomposition was performed followed by black box
analysis and component hierarchy. Feng and Zhang (1999) defined functional decomposition of a product, device or
system as a process of making a complex function simpler by segmenting into parts. Kurtoglu et al. (2008) explained
black box analysis as a method of testing that examines the functionality of a product without peering into its internal
structures or workings.
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
Figure 2: Black box analysis for domestic oil expeller
The component hierarchy of domestic oil expeller is given below according to the consisting units for the product:
Figure 3: Component hierarchy for domestic oil expeller
Functional decomposition was carried out for individual units of the product. Functional decomposition for heating
unit of domestic oil expeller is given below:
Figure 4: Functional decomposition for heating unit of domestic oil expeller
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
A design of experiment was carried out while fabricating the product. Zhang et al. (2007) defined Taguchi design
technique as a powerful tool for improving productivity during research and development, so that high quality products
can be produced quickly and at low cost. It is applied to plan the experiments. For the improvement of oil extraction efficiency of domestic oil expeller, design of experiment analysis was performed. In depth investigation into the
problem primarily identified four potential factors responsible for lower oil extraction efficiency. The following table
shows the current levels (-) and experimental target levels (+), which are assured to affect oil extraction efficiency.
Table 2: Two levels of four factors
Factors Levels (- or +)
Current value (-) Experimental value (+)
(T) Heating temperature 700 C 900 C
(S) Rotational speed 90 rpm 75 rpm
(P) Pitch diameter 1.8 cm 2.2 cm
(L) Length of screw shaft 36 cm 38 cm
Several experiments with the above four factors, each with two levels, were performed and oil extraction efficiency
were calculated accordingly, as shown in the combinatorial matrix given in the following figure.
Figure 5: Combinatorial matrix for four factors of domestic oil expeller
Once, all the 16 combinations of experiments (or cells) are executed and scores/defects are recorded, column-wise
and row-wise total scores are calculated. For instance, S- column has a total score of 247.1, obtained by adding all the
average readings in that column. The contribution of individual factors are calculated subsequently for performance
evaluation. From the contribution matrix, we have identified the relation between oil extraction efficiency with
individual factors. The contribution matrix for the domestic oil expeller is given below:
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
Figure 6: Contribution of individual factors
A full factorial ANOVA for the domestic oil expeller has been performed to identify the main effects and interaction
effects between the design variables.
Table 3: Full factorial ANOVA table
Though, there is not any significant interaction effects between the design parameters, but the main effects of the
design parameters are statistically significant. From analysis, it was found that heating temperature, screw pitch and
rotational speed of the screw shaft have a positive relation with oil extraction efficiency (OEE). The oil extraction
efficiency increases with the increase in heating temperature, screw pitch and rotational speed of screw shaft. On the
other hand, oil extraction efficiency has negative relationship with pitch diameter and decreases with the increase in
pitch diameter.
4 factors
interactions
T S P L TS TP SP TL SL PL TSP TSL TPL SPL TSPL
1 - - - - + + + + + + - - - - + 56.1
2 + - - - - - + - + + + + + - - 61.2
3 - + - - - + - + - + + + - + - 63.7
4 + + - - + - - - - + - - + + + 66.9
5 - - + - + - - + + - + - + + - 64
6 + - + - - + - - + - - + - + + 68.8
7 - + + - - - + + - - - + + - + 70.1
8 + + + - + + + - - - + - - - - 71
9 - - - + + + + - - - - + + + - 61.1
10 + - - + - - + + - - + - - + + 65.9
11 - + - + - + - - + - + - + - + 67.8
12 + + - + + - - + + - - + - - - 72.3
13 - - + + + - - - - + + + - - + 65.9
14 + - + + - + - + - + - - + - - 73.8
15 - + + + - - + - + + - - - + - 71.8
16 + + + + + + + + + + + + + + + 75.5Main and
interaction
contribution
34.9 42.3 45.9 32.3 -10.3 -0.3 -11 6.9 -0.9 -6 -5.9 1.3 4.9 -0.5 -1.9
Cell
Group
Factors 2 factors interacions 3 factors interactionsOutput
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
The interaction effects between the parameters for the domestic oil expeller is shown in the figure below:
Figure 7: Interaction effects between parameters for the domestic oil expeller and ANOVA table
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
The F value, P value and signal to noise ratios were also calculated subsequently for each individual parameters and
their interactions for performing analysis of variance. While designing the product, these main and interaction effects
between the design parameters were studied with utmost importance. As the interaction effects had not been found as statistically significant, only the main effects for the parameters were considered in designing the final product with
appropriate dimensions and measurements.
The CAD design using SolidWorksTM for individual parts and components of domestic oil expeller are given below:
Table 4: CAD design of different components of domestic oil expeller
Part CAD Design Part CAD Design
Hopper
Material Flow Channel
Valve
Motor
Gear 1
Gear 2
Cage Barrel
Shaft Screw
Choke
Strip Heater
Box Cover
Stand
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
Gear, Screw Shaft and
Motor Sub-Assembly
Final CAD Assembly
The structural analysis using ANSYSTM for different components of domestic oil expeller has been carried out for
identifying the critical stress areas.
Figure 8: Stress analysis for screw shaft
Figure 9: Stress Analysis for gear and screw shaft assembly
Figure 10: Stress analysis for cage barrel
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
Table 5: Performance analysis of domestic oil expeller
Parameter Conventional oil expeller Modified domestic oil expeller
Average power consumption/1kg seed 900W 660W
Availability of usage versatility Yes Yes
Oil extraction efficiency(Rapeseed) 73% 75.5%
Oil residue in cake/wastage(Rapeseed) 27% 24.5%
Average weight 35 kg 10.5 kg
Average dimension 1.6m*0.9m*1.2m 0.5m*0.25m*0.35m
Design flexibility No Yes
Portability No Yes
4. Conclusion
The scarcity of cost effective and efficient options for domestic oil extraction is very prominent in agricultural
countries. Modified domestic oil expeller offers a perfect solution for this specific problems. The steps of product design from customer surveys to the manufacturing processes were strictly followed. Design of experiment analysis
using Taguchi design method was performed for improving design parameters. Subsequently, the domestic oil expeller
was tested against different parameters and it was observed through the results that screw shaft length, pitch diameter,
heating temperature and rotational speed have a significant impact oil extraction efficiency. However, the design is
effective for only domestic uses. It needs to be refined and amended to increase its output for usage in industrial
sectors effectively. We can also explore the quality (e.g. density, viscosity etc.) of extracted oil and perform
comparative analysis. These can be scopes of future studies in this field. So, by removing existing limitations, domestic
oil expeller can be an attractive and efficient solution for domestic customers of all sectors inhabiting in both urban
and rural areas.
Acknowledgements
This study has been done under fully cooperation and resources of Department of Industrial and Production
Engineering, Bangladesh University of Engineering and Technology (BUET). The authors express gratitude for all
the efforts and cooperation to complete the research.
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Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,
Detroit, Michigan, USA, August 10 - 14, 2020
© IEOM Society International
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Biographies
Naquib Mahmud Chowdhury is a novice researcher and a final year undergraduate student from the Department of
Industrial & Production Engineering of Bangladesh University of Engineering and Technology. His research interest
includes manufacturing process, supply chain management, total quality management, artificial intelligence and
machine learning.
Faisal Mahmud is a novice researcher. He is currently a final year undergraduate student from the Department of
Industrial and Production Engineering of Bangladesh University of Engineering and Technology (BUET). He is
interested in research topics like uncertainty modeling, reliability analysis, stochastic process, supply chain
management etc. He has published one conference paper on a case study of maintenance availability of pharmaceutical
industry.
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