Latest Technology Development for Cutting Turmeric Rhizomes

8/14/2019 Latest Technology Development for Cutting Turmeric Rhizomes

1/29

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

C.O.E. & T.,Akola


2/29


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.

C.O.E. & T.,Akola


3/29


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.

C.O.E. & T.,Akola


4/29


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.

C.O.E. & T.,Akola


5/29


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.

C.O.E. & T.,Akola


6/29


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

C.O.E. & T.,Akola


7/29


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

C.O.E. & T.,Akola


8/29


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

C.O.E. & T.,Akola


9/29


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

C.O.E. & T.,Akola


10/29


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.

C.O.E. & T.,Akola


11/29


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.

C.O.E. & T.,Akola


12/29


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.

C.O.E. & T.,Akola


13/29


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

C.O.E. & T.,Akola


14/29


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

C.O.E. & T.,Akola


15/29


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.

C.O.E. & T.,Akola


16/29


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

C.O.E. & T.,Akola


17/29


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

C.O.E. & T.,Akola


18/29


= 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.

C.O.E. & T.,Akola


19/29


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

C.O.E. & T.,Akola


20/29


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

C.O.E. & T.,Akola


21/29


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

C.O.E. & T.,Akola


22/29


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.

C.O.E. & T.,Akola


23/29


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

C.O.E. & T.,Akola


24/29


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

C.O.E. & T.,Akola


25/29


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)

C.O.E. & T.,Akola


26/29


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

C.O.E. & T.,Akola


27/29


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

C.O.E. & T.,Akola


28/29


Types of Chutes

a) Ordinary straight b) Roller straight c) Spiral d) Oval e) Coil f) Arched g) Cascade

C.O.E. & T.,Akola


29/29


Types of Loading Facilities

Documents

Latest Technology Development for Cutting Turmeric Rhizomes