American Journal of Engineering Research (AJER) 2019

American Journal of Engineering Research (AJER)

e-ISSN: 2320-0847 p-ISSN : 2320-0936
Volume-8, Issue-6, pp-118-123
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Research Paper
Open Access

Design Parameters for a Sugar Cane Extractor

Rachel Ugye and Oladele Ayodeji Kolade

Department of Mechanical Engineering, Kaduna polytechnic, Kaduna..

Corresponding Author: Rachel Ugye

ABSTRACT: This paper Discussed the design and constructing a portable and cost effective juice extraction
machine to expand sugarcane production in Nigeria. It will help to reduce the total cost of sugarcane
production process and to avail farmers the opportunity of sugarcane business and to increase local production
of sugar,.The design procedures is carefully described. The need for this design became necessary because the
currently available sugarcane juice extractors
require high energy and sophisticated mills, driven mechanically. These are out of the reach of
small scale and rural farmers that are presently involved in processing of cane juice into
ethanol, brown sugar and other related products in Nigeria.
KEYWORDS: Sugar cane, Juice, extraction,farmers.
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Date of Submission: 26-05-2019 Date of acceptance: 08-06-2019
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I. INTRODUCTION
In recent times, many tones of fruits have been wasted in the past and many more are likely to be
wasted if unchecked, the need for producingmachine that is capable of extracting juice from fruits without
wastage and maintaining the quality and colour of juice is very obvious.(Rein, R.Wer al( 2007.)
Juice extracted from fruits can be used as flavorings agents in other manufacturing industries. Some of
the products used are cake, yoghurt, sweets; tea etc, a wide range of juice drink can be produced from fruits
when the juice extracted from the fruit is mixed with sugar syrup and other ingredients.
The currently available sugarcane juice extractors require high energy and are application of more
sophisticated mill driven mechanically (Muchow et al. 2000, Ou et al., 2002). Some of the available cane
crushers are of high capacity mainly for industrial applications. These are out of reach of small scale and rural
farmers that are presently involved in processingof cane juice into ethanol, brown sugar and other related
products at small scale level. The problems associated with processing of sugarcane include small size of farms
and farm fragmentation as a result of land ownership by inheritance. Poor storage facilities and practices to
preserve harvested canes or extracted juice from being refined to sugar (Mello and Harris, 2000; Wegener,
1996). In addition to the above problems using the same carriage capacity/medium, it will further reduce
production cost to transport extracted sugarcane juice from the farm to the factory for refining into sugar than
transporting harvested sugarcane to the factory for processing. This is because the extracted juice from a trailer
load of sugarcane many not be up to 30% of a trailer load of juice.
It was clearly indicated that processing of sugarcane starts with the extraction of juice from sugarcane
stalk. Several methods of juice extraction were in used. These methods included boiling the cane to extract the
juice, use of wooden presses and application of moresophisticated mills driven mechanically or by bullocks
(Okogie, 1980). The high power requirements during processing of sugarcane constitute the major constrain in
the development of small scale sugar processing plants. This also explains why natural sugar juice is not
generally available. The recent upsurge of interest in generation of biofuels from plant material has necessitated
current waves of interest in the partial mechanization of cane juice extraction and coupled with the production of
bio ethanol for domestic and
industrial application (Galitsky et al., 2007). The development of a small scale sugarcane juice
extractor was therefore to meet the needs of the small scale farmers who cannot avoid high capacity and

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American Journal of Engineering Research (AJER) 2019
complex cane crushers. The main objectives of this study were to design and construct a simple mechanical
device for extraction of sugarcane juice. The functional performance and economics of operation of the machine
were evaluated.
1.1 Significance Of The Study
Sugarcane juice crusher has been an important machine in our generation today and it plays a vital role
in the sugar industries. Theproduction of crushers that can be affordable to individual and local industries can go
a long way in satisfying the needs of the masses.

1.2 Scopeofthestudy
This design is aimed at constructing a portable and a cost free sugarcane juice extractor that can be
affordable to both farmer individuals and local industries. The machine has an approximate height of 805mm,
the length of 511.3mm and a breath of 459.96mm. The efficiency of the machine depends on clearance feeding
rate and speed of rotation when feeding is more.

1.3 Sugarcane Juice

Juice from sugarcane is extracted by crushing the sugarcane between two rollers and one feeding
crusher (gear) after they have been stripped of leaves and cut into suitable length. By this means, most of the
juice is extract. The residual then passes through a collector and is further compressed by presser to remove the
remaining juice. The juice extracted from the plant contain about 75% water 2O% sucrose, 4 organic matter and
l% mineral matter. This crude juice is collected and freed from organic andnitrogeneous matter by heating and
treating with lime which precipitates phosphoric acid as flocculent calcium phosphate, this absorbs the organic
content. Another method is by treatment with sulphurdioxide which precipitates calcium sulphide. The cleaned
juice is concentrated by evaporation at reduced pressure and then allowed to crystallize

1.4 Traditional Crusher

The earliest mills were probably malter and pestle arrangement operation press by human power, then
by animals or water power, and screw press. These were widely used for juice extraction until it was taken over
by roller mills which were invented by a cane grower in Sicily in 1449.

1.5 Capacity Of Equipment

Many factory influence the selection of adequate equipments in the sugarcane factory. These factors
includes: local conditions, the variety and readiness of the cane, the type of process, the desired quality of the
output and many other considerations affect the sizeand capacity of the equipment at various stages of
production in the different stations.

1.6 Juice Extraction

The common products from sugarcane extraction includes sugar, syrup and edible molasses, by-
products extracted from juice also include black strap molasses, bagasses or stalk residue filter press cake and
bagasses ashes, black strap molasses is largely used for the production of alcohol and for livestock feed.
The fibre from bagasses is used for manufacturing paper, hand board and insulation wallboard. Filter
press cake has a fertilizer value equal to farm yard manure. Most of the surge used for syrup is milled on three
roll mills operated by motor power.

1.7 Effect Of Compression On Cane

Crushers or compressive machine are heavy equipment and are used extensively in the food industry.
In jaw crushers, the materials are fed in between two heavy jaws, one fixed and the other reciprocating so as to
work the materials down in a narrow space, crushing it as it goes. The gyratory crusher consist of truncated
conical crusher inside which its crushing head rotate eccentrically, the crushing head is shaped as an inverted
cone and the material being crushed is trapped between the fixed point and the inner
gyrating cones and it is again forced into a narrower space as a result of which it is crushed. Crushing
roll consist of two heavy cylinders mounted parallel to each other. They rotate in opposite direction and the
material to be crushed is trapped, ripped and crushedbetween them as it passes through.

1.8 Juice Clarification

This is the treatment of the juice after collection to kill and destroy the action of germs and bacteria in the juice
and to clear the juice from dirt, stalk etc.
1.9 Parts Selection

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American Journal of Engineering Research (AJER) 2019
Machine part must meet the conditions for reliability i.e. the capacity to do their specified job, retaining
all of their service indices during their predetermined service life and the condition of the economy i.e. cost, the
least amount in manufacturing and operation.
1.10 The Basic Criteria:
i. Strength: The ability of a material to be tough and ductile.
ii. Rigidity: The capacity of component to resist changes in shape when subjected to forces
iii. Wear resistance: The ability to resist gradual reduction of the size of parts and a change in the shape of the
machine along with various surfaces due to friction
iv. Heat resistance: The ability to resist heat due to friction.
v. Vibration stability: Is the ability of the machine to operate in the required range of duty without
inadmissible vibration

1.12 Components Of The Machine

(i) Hopper: Is made of galvanize mild steel, it has an area of 240 X 210 (mm) at the top and 200mm.
(ii) Rotating shaft (rollers): These are the rotation element, made of mild steal. Design to rotate by the
transmitted power from the wheel through the electric motor to the gears and finally the rotating shaft and
rollers which tears the can into shreds but extract no juice.
(iii) Bearing: The bearings are used to provide bearing surfaces for rotating parts.
(iv) The stand: The stand is meant to provide a support for the machine (gears, rollers, hopper, bearings and
side plats), It has an approximate height of 505mm. The rest include side plats and rods which serve as
supports to the rollers, gears and bearings and side bar.

II. DETAIL DESIGN OF SUGARCANE CRUSHING MACHINE

The design detail includes the following: actual crushing force (strength), Crusher diameter, length and actual
power selected for the electric motor etc.

I Estimating Crushing Strength

An experiment was performed to estimate the crushing force. The test was conducted weighing three
different samples of sugar cane that were labeled A, B and C., each of the samples were divided into four parts
with two of the parts skinned and the other two parts remained unskined.
The diameter of the samples are: A= 35mm
B = 31mm
C = 21.39m

The above result are further explain in the table below. Table 5
A B C
s/no Weight (a) Force of Weight failure Force of failure Weight (g) Force of
failure (b) (N) failure (N)
(N)
1 79 42 37 46 20 30
2 61 35 30 33 19 27
3 52 25 26 30 18 20
4 53 27 20 27 17 15

From the experimental analysis, the maximum value of force of failure is used as the crushing force as seen
from table (4i) above the crushing force value is 46 Newton.
Hence crushing force = Fs
Fs = force of failure * Factor of safety
= 46 * 1.5 = 69N
The maximum value of force of failure is obtained at a certain mass of the sugarcane from table (4i), this mass is
obtained as 37g
37
M = mass =
1000
= 0.037kg
Design of shaft:
Using the relation
Fs = M*W

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American Journal of Engineering Research (AJER) 2019
Where Fs = Crushing force N
M - Mass of sugarcane kg
W -Angular speed red/sec
R - Radius of shaft mm
However
2N
Wm =
60
Where the value for 1800 r.p.m from table (4.ii) so as to achieve finer
crushing sugarcane.

Table 6
Standard horse power speeds frame numbers and polyphase. Squirrel cage induction motor, types A and B
(National Electric motors Association) rating 1985.
HP O. E4 1800 rpm 1420 rpm 900 rpm Size A1 U
0.5 - - - - 143 143 7
0.75 - - - 143 145 145 7 0.75
1 - - 143 145 182 182 9 0.76
1.5 143 143 145 182 184 184 9 0.88
2 145 145 145 184 213 213 10.5 0.88
3 186 182 182 213 215 215 10.5 1.1
5 182 184 184 215 254 254 12.5 1.1
7.5 184 213 213 254 256 256 12.5 1.4
10 213 215 216 256 284 284 14 1.6

2N
From Wm =
60
Substituting the value, gives:
2 1800
Wm =
60
= 188.5 rad/sec.

Substituting the value of w into equation

Fs = Mw2r
69 = 0.37 188.5 2r
r = 69 1314.69
r = 0.0525m
= 52.5mm

Diameter crusher, d = 2 * radius (r)

= (2 x 52.5) = 105mm

Ii Power Selected From A.C Motor

2NT
Motor power, Pm =
60
Where T- Torque
N - Speed = chosen as 1800 rpm
Torque = force of shaft x radius of shaft
T = f* r
= 69 X 52.5 = 3097.5N
Substituting in
2 3622.51800
Pm =
60
Pm = 682825 watts (w)
= 682.825kw

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American Journal of Engineering Research (AJER) 2019

682.825 *103
Horse power H.P =
746.58 *103
= 0.9147H.P
Hence, a 1 hp motor of 1800 r.p,m is selected

Iii Design Of The Crusher Length

Since length is a function of the angle of twist t, then the length can be obtained from
584MtL

Gd 4
Where θ = angle of twist deg.
L = Length of the shaft. M
Mt = Torsional moment Nm
G = Torsional modulus of elasticity
d = shaft diameter, m
The amount of twist permissible depends on the particular application, and varies about 0.3deg/m for machine
tools shafts to about 3 deg/m.
Torsional moment is
9550 Kw
Mt = Nm
rev
min
From equation Pm = 0.682825kw

9550 * 0.682825
Mt =
1800
= 3.62277kNm
Also
G = 80 *109 N/m (for steel)
d = 0.105m
584 * L
Hence, θ =
80 *109 * 0.1054
And L=4.596
So  increase as length increases
  L
Assuming a machine tool shaft
when = 0.3 degree
L = 4.596 * 0.3
L = 1.3788m
When  = 0.6
L = 4.596 X 0.6

L = 2.757m

Substituting the value of L and θ in

 0.3
K= = at θ = 0.3 deg.
L 1.3788
Assuming a length of 300mm (0.3m) in the design of the sugarcane crushing machine we have
 = 0.2176 X 0.3
= 0.6528 (Maximum torsional deflection) for axial deflection,
Fs L
6=
AE m
Where  = axial deflection m

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American Journal of Engineering Research (AJER) 2019

Em = modulus of elasticity, 207 x 109 N/rn

Fs = 69N (crushing force)
 0.1052 Nm
A = Area of the crusher
4
L = Length of the crusher = 0.3m

69 * 0.3
б=
 40.1052 * 207 *109
6 = 1.15 * 10-8m

2.1 Materials Selection

The materials used in the construction of the construction of the machine are as follows
(i) Mild steel (low carbon steel)-because of its malleability, ductility and plasticity properties.
(ii) Stainless steel-Used as bearing material because of its ductility .
(iii) Cast iron is used for the manufacture of the pulley, since it can be machined and for it’s cheapness.

III. CONCLUSION
The design parameters for the fabrication of a juice extractor have discussed in this paper, The output
capacities of 10.50, 12.00 and 14.25 kg/ hr can be maintained at operating speeds of 0.25, 0.3 and 0.36 m/s,
respectively. The extraction efficiencies will ranged between 40 and 61 % at operating speed of 0.25 and 0.36
m/s. It wasobserved that in most juice extracting machines the optimum performance cannot be sustained over a
longprocessing period because of the observed bluntness in the perforated gratingdrum over time of use and this
reduces the extraction efficiency of the machine.Further work would be carried out on the arrangement of the
grating drum,crushing chamber and effects of some processing factors on expression of juicefrom cane fibre in a
compression chamber.

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Rachel Ugye " Design Parameters for a Sugar Cane Extractor" American Journal of Engineering
Research (AJER), vol.8, no.06, 2019, pp.118-123
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