Potato Grader CIGR2019
Potato Grader CIGR2019
4 107
Md. Nazmul Huda, Md. Kamal Uddin Sarker*, Md. Abdul Munnaf
(Department of Agricultural and Industrial Engineering, Faculty of Engineering, Hajee Mohammad Danesh Science and
Technology University, Dinajpur 5200, Bangladesh)
Abstract: Grading potatoes by size is an important operation for preparing tubers for seed and for commercial purposes. If
potatoes were sold after grading, this would be beneficial to both producers and consumers. Since mechanical graders are not
locally available, potatoes are graded, when necessary, by hand. This is a time consuming, costly, and inefficient method.
This work concerns the development of a potato-grading machine for small-scale farmers. The grader consisted of a hopper,
grading unit, prime mover and catchment tray fitted on a frame. The grading unit was made up of plastic oil container, hopper
and catchment tray made up of mild steel sheet and the frame was made up of mild steel angle bar. A 0.56 kW, single phase
electric motor was used as a prime mover with a gear box (30:1) for reducing the rotational speed. Machine parameters for the
evaluation included the speed of the grading unit (RPM) and inclination of the grading unit (degree). These were tested on
potato tubers taking note their influence on grading system efficiency, capacity, damaged tubers and power consumption as
independent variables. Data were analyzed and the results indicated that optimum set-up of the grader was at 6 RPM speed of
the grading unit, inclination of 30 giving a system efficiency of 91.57%, capacity 420.10 kg hr-1, damaged tubers of 1.17% and
low power consumption of 9.30 W-hr. The cost of the grader was estimated to be US$434 (1US$ equals 84.25 BDT) with a
break-even quantity of 29 tons of tubers in one year.
Keywords: potato grader, capacity, power consumption, efficiency, damage tubers, break event point
Citation: Huda, Md. N., Md. K. U. Sarker, and Md. A. Munnaf. 2019. Design, fabrication and performance evaluation of drum
type potato grader. Agricultural Engineering International: CIGR Journal, 21(4): 107–114.
products of the rated size of the prime mover of the took to grade the samples were also recorded.
grader and the time of operation. In this study 0.56 kW Number of correctly graded small tubers
eff S = (5)
motor was used. Power consumption is related by Total number of small tubers in the sample
Equation (3) (Valentin et al., 2016). Number of correctly graded medium tubers
eff M = (6)
Power consumption = kilowatts×t, W-hr (3) Total number of medium tubers in the sample
where, t is the time of operation in hours. Number of correctly graded large tubers
eff L = (7)
Injury was accounted as those tubers with abrasion Total number of large tubers in the sample
after the grading operation. The percentage of injured 2.4.6 Cost analysis of the potato grader
tubers was taken by considering the total number of A Simple cost analysis was done for the potato grader.
tubers with abrasion after the operation against the total The analysis included the actual cost of the device, annual
number of tubers prior to the operation. Abrasion was fixed cost and variable cost. The annual fixed cost
visually inspected and those tubers with abrasion of 5% included depreciation, interest and shelter cost. Variable
higher than the surface area were considered damaged as cost included repair and maintenance cost, labor cost and
shown in Equation (4) (Valentin et al., 2016). electricity cost. Assumption was made as interest 13%,
Total number of tubers with abrasion shelter 0.01% per year; repair and maintenance cost
Injury,% = × 100
Total number of tubers in the sample 0.01% per hr, operation per day 8 hrs, annual use 250 hrs
(4) and estimated life span 7 yrs of the machine.
2.4.3 Sample preparation for performance test The cost was calculated using following formulas:
A quantity of 200 kg of Potato tubers for the chosen The annual depreciation was calculated as
variety (Cardinal) were procured from the market in D = P – S/L (8)
August 15, 2017. Tubers with initial damages such as where, D is the depreciation; P is the purchase price of
scratches, abrasion, decay and greening were not the machine; S is the salvage or selling price and L is the
considered in the sample. Thus, there was no initial time between buying and selling.
damage during the testing of the device. The samples Interest on investment was calculated as
were divided into 27 groups with 7 kg each containing I = [P + S/2]×i (9)
small, medium and large. On the average, each group had where, I is the interest on investment; P is the purchase
50% small, 30% medium and 20% large-sized tubers. price of the machine; S is the salvage or selling price; i is
Each tuber was manually measured with slide caliper to the current interest rate.
determine the size and was given a label to easily Total cost per year calculated as
distinguish after grading. The samples were prepared by Total cost = Annual fixed cost + Variable cost (10)
following Valentin et al. (2016). Break-even point of the device was considered in this
2.4.4 Test run study which is expressed in terms of the amount of tubers
A two factor completely randomized design test runs needed to grade per year. Break even cost of the device is
of 27 were used in the study with 9 treatment given by Equation (11) (Valentin et al., 2016).
combination and 3 replications. Each replication used AFC
BEP = (11)
7 kg of potato tubers as initially prepared. CR − VC
2.4.5 Evaluation procedure where, CR is the custom rate; AFC is the annual fixed
As initially prepared, each 7 kg of potato tubers were cost and VC is the variable cost.
loaded into the hopper while the grading unit was rotating.
3 Results and discussion
After the grading operation, tubers that dropped on the
appropriate region and number of damaged tubers were 3.1 Physical properties of potato tubers
counted and recorded. This was to determine the grading The mean, standard deviation, maximum, and
efficiency of each region as shown in Equations (4), (5), minimum, coefficient of variation, quartile and percentile
(6) and (7) (Valentin et al., 2016). The time, in seconds, it (33, 66 percent) of physical properties (mass and
December, 2019 Design, fabrication and performance evaluation of drum type potato grader Vol. 21, No. 4 111
diameter) of the Cardinal and Granola (oval shape) potato 40.36 g. Diameter ranges of product separation were
varieties are shown in the Table 2. under 40, 40-55 and above 55 mm selected according to
Results in the Table 2 indicated that the maximum the percentiles. The relationship between mass and
and minimum diameters of the selected potato variety diameter of measured potatoes could be expressed by the
were 108 mm and 22.20 mm. The mean diameter was equation,
48.91 mm. Also the maximum and minimum mass of the Y = 10.986X0.4179 (R2= 0.89)
potato tubers were 194.10 g and 6.10 g with a mean of where, Y= Mass, g and X= Diameter, mm.
Table 2 The physical characteristics of the potatoes
Percentiles
Properties Maximum Minimum Mean Standard deviation Coefficient of Variance
33 66
3.2 Specifications of the potato grader 3.3.1 Combined effect of speed and inclination angle on
The fabricated machine tested in the study was a the performance
drum type potato grader which had the following Table 4 shows the summary of the results on the
components: hopper, grading unit, receiving tray and performance evaluation of the device.
power transmission system. Table 3 presents the final Table 4 Interaction effect of the speed and inclination of
specifications of the device after fabrication. potato grader
Table 3 Specifications of the drum type potato grader Angle GSE Capacity Injured Power Consumption
RPM
(degree) (%) (kg hr-1) (%) W-hr/sample
Item Specification
-1 3 91.57a 420.10i 1.17a 9.30a
A. Capacity, kg hr 420.10
b h ab
6 6 85.50 494.20 0.92 7.13c
B. Grading Efficiency, % 91.57
d g abc
9 77.76 586.52 0.67 6.20d
C. Injury,% 2.22
b f abc
3 84.40 547.71 0.83 7.91b
D. Main structure c e abc
Overall Dimensions 9 6 80.13 600.17 0.67 6.51d
Length, mm 3031 9 67.40e 741.34d 0.58bc 5.43e
Width, mm 610 d c abc
Height, mm 1676 3 77.57 630.00 0.67 6.67cd
e b bc
12 6 66.17 720.60 0.58 5.22e
E. Grading unit assembly
f a c
9 60.77 900.53 0.33 4.39f
Length, mm 2286
Note: * Means separation in column followed by the same letter (s) are not
Diameter, mm 584
significantly different at P=0.05.
F. Feeding mechanism type Manual feeding, hopper type
G. Prime mover
220 V, 0.56 kW single phase, The Table 4 shows that the maximum capacity of the
capacitor type electric motor
grader was found to be 900.53 kg hr-1 at 12 rpm and 90 of
H. Gear box 30:1
I. Transmission system Open drive belt and pulley combination inclination angle. But at the same time the grading system
Pulley 1 38.1 mm efficiency was very low (60.77%). At the same time the
Pulley 2 101.6 mm
percentages of injured tubers were low (0.33%) and
Pulley 3 50.8 mm, 76.2 mm, 101.6 mm
Pulley 4 152.4 mm power consumption also low (4.39 W-hr/sample). On the
Belt type V-belt, A-36, A-64,A-65, A-66 other hand, the grading system efficiency was high
3.3 Performance evaluation of the grader (91.57%) at 6 rpm and 30 inclinations angle with the
The overall performance of the grader was lowest capacity (420.10 kg hr-1). At the same time the
determined by measuring different parameters considered percentage of injured tubers were high (1.17%) and
in the study. The grading capacity, grading system power consumption also high (9.30 W-hr/sample). It
efficiency (GSE), injury percentage and power shows from the table that there are variations of grading
consumption of the grader as affected by speed and capacity, efficiency, damaged tubers and power
inclination angle of the grading cylinder were computed consumption with variations of RPM and angle of
and analyzed. inclination.
112 December, 2019 AgricEngInt: CIGR Journal Open access at http://www.cigrjournal.org Vol. 21, No. 4
Table 4 shows that minimal injured tubers were found Capacity (kg hr-1) 532.60c 605.00b 742.80a
a ab
Injured (%) 0.89 0.72 0.53b
when the grader was operated at 12 RPM and 9 degree
Power Consumption (W-hr) 7.96a 6.29b 5.34c
inclination with a value of 0.33%. Highest injured tubers Note: *Means separation in raw followed by the same letter (s) are not
were found when grader was operated at 6 RPM and significantly different at P=0.05.
3 degree inclination. Percentage of tuber injured The capacity of the grader using speed of 9 and
increased with decreasing the speed and inclination of the 12 RPM is significantly higher than using a speed of
grading unit. Slow speed and small inclination angle 6 RPM. High speed (12 RPM) induces more velocity to
caused accumulation of the tuber in the grading unit that the tubers causing them to travel along the unit at a faster
induced greater impact as result of their weight which rate. Conversely, lowest speed (6 RPM) resulted to slow
increased the percentages of injured tubers. material flow through the grading unit resulting to longer
December, 2019 Design, fabrication and performance evaluation of drum type potato grader Vol. 21, No. 4 113
time of operation that caused lower capacity. amount of tubers in the grading unit along with very high
Power consumption was lowest at 12 RPM. The RPM. The large number of tubers in the grading unit
grader operated at a faster rate causing shorter time of tends to create a heavier impact among each other during
operation. Lowest speed (6 RPM) resulted to more power the rotation of the grader. For the inclination of the grader,
consumption. Tubers stayed at a longer time in the unit it was observed that at very low inclination which is 3
causing more power inputs. Although power consumption degrees, there were more number of tubers injured which
is very minimal, the differences on the mean values are is almost 0.91% of the total samples as shown in Table 6.
significant. 3.4 Cost analysis of the potato grader
Injured tubers were found to be minimal at a speed of 3.4.1 Cost estimation
12 RPM. Highest injury of 0.89% at 6 RPM could be due The present potato grader was designed and
to large accumulation of tubers in the unit creating fabricated in such a way as to keep its cost low. Table 7
significant impacts as a result of weight of the large shows the cost factors and items of the potato grader.
quantity of tubers. Abrasion of tubers resulted not only From the table, it can be seen that the cost of grading with
with the high RPM of the grader but also due to large the present grader was only Taka 0.28 per kilogram.
quantity of tubers. The combined effect of the speed of Table 7 Cost factors and items of the potato grader
the grading unit and the heavy weight of tubers causes Cost factors/items Unit Amount
greater impact to the tubers. A. Cost of the grader US$/Unit
Materials US$ 261.14
3.3.3 Influence of Inclination Gear box US$ 83
Table 6 shows the mean values for the machine Electrical motor US$ 47.5
Construction cost US$ 142.4
parameters as affected by the inclination of the grading Total Cost US$ 534
unit. Highest grading system efficiency of 84.94% was B. Life of the grader Year 7
C. Annual use Hrs 250
observed at an inclination of 3 degrees whereas; lowest
D. Annual fixed cost
efficiency was obtained at an inclination of 9 degrees. a. Depreciation US$/yr 68.67
b. Interest (13%) US$/yr 38.19
Extremely high inclination caused fast transfer of tubers c. Shelter(0.01% of P) US$/yr 0.05
Total US$/yr 106.91
to the next region as caused by gravity plus the effect of Total US$/hr 0.43
the rotation of the grading unit. This also reduces the time E. Variable Cost
a. Repair and maintenance (0.01% of P) US$/hr 0.05
of operation causing significantly high capacity of b. Labour (two labours, 3.5 US$/day) US$/hr 0.88
c. Electricity US$/hr 0.04
750.38 kg hr-1 and lower power 5.43 W-hr. Tubers in this Total US$/hr 0.97
scenario especially the smaller ones at the first region F. Total cost US$/hr 1.4
move to the next selection region without passing to the G. Cost of grading (assuming 420.10 kg/hr) US$/kg 0.003
Table 6 Effect of inclination on efficiency, capacity, injury From Table 7 shows that the device has an initial cost
and power consumption of potato grader of US$534 with an estimated life span of 7 years. With
Inclination (degrees) basic assumptions and current market practice the annual
Machine Parameters
3 6 9 fixed cost of operating the device is US$ 106.91.
GSE (%) 84.94a 77.31b 68.17c Assumptions include: interest, 13%, shelter 0.01% per yr,
-1 c b a
Capacity (kg hr ) 500.27 629.74 750.38 repair and maintenance 0.01% per hr, operation per day
Injured (%) 0.91a 0.69ab 0.53b
8 hr, annual use 250 hr and custom rate US$ 0.006 kg-1.
Power Consumption (W-hr) 7.54a 6.62b 5.43c
Note: * Means separation in raw followed by the same letter (s) are not The grader needs to grade a quantity of 29 tons of potato
significantly different at P=0.05. tubers in one year to break-even the cost of fabrication.
Injured tubers as influenced by the inclination of the Figure 3 shows the cost curve emphasizing the
grader were observed to decrease with higher inclination break-even quantity. If available quantity of tubers is
as shown in Table 6. As shown earlier in Table 5, injured greater than the break-even quantity, the use of the grader
tubers were observed to be influenced by the large will result to profit. Otherwise, the machine is expensive
114 December, 2019 AgricEngInt: CIGR Journal Open access at http://www.cigrjournal.org Vol. 21, No. 4
to use when available quantity is less than the break-even graded by the device in one year to break-even the cost.
quantity. Grading by using this machine will cost US$0.003 kg-1.
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