Design, Construction and Performance Evaluation of A Bush Mango Juice and Seed Extractor

Design, Construction and Performance Evaluation of A Bush Mango Juice and Seed Extractor

Gbabo Agidi1, J. T Liberty2 and A. S Akingbala1

Department of Agricultural and Bioresources Engineering, 1Federal University of Technology, Minna, Niger State Department of Agricultural and Bioresources Engineering, 2University of Nigeria, Nsukka, Enugu State, Nigeria

Abstract This work aimed at the design and construction of a bush mango juice and seed extractor. The extractor consists of hopper, beating chamber, extractor chamber which consists of a bottom perforated cylinder and a decreasing pitch screw conveyor (auger), and a lower semi-cylindrical juice collector. The upper shaft to which the beaters are welded has a speed of 250rpm, while the auger has a speed of 98rpm. Bush mango were fed into the beating chamber through the hopper and the beaters beat and conveyed the fruits into the extraction chamber where the juice is then extracted with the help of the decreasing pitch screw conveyor. The extracted juice then flows through the perforations into the lower semi-cylindrical juice collector. The extractor has extraction efficiency of 66%, juice recovery rate of 69%, and capable of extracting bush mango juice without crushing the seeds. The machine has low maintenance cost and replacement of parts can be done with ease because the machine was made from locally available materials. Machine of this nature can be employed to increase the production of bush mango juice locally.

Keywords Bush mango, extraction chamber, perforated cylinder, seed extractor

1. INTRODUCTION

   Bush mango (Irvingiagabonensisis) commonly refer to as Ogbono, African mango, Iba-tree, wild mango, Dikanut or odikabread tree are economically important fruit tree native to moist lowland tropical forest in Central and West Africa, constitute an important part of rural diet in Nigeria (Mollet et al., 1995; Harris, 1996). The tree is a hardwood and the fruit is a fleshy, fibrous drupe, but it is the seeds that are used for weight loss. Traditionally, these are dried in the sun, ground to paste or powder and used to thicken certain Nigerian and Cameroonian soups. The bush-mango-seed extract used for weight loss is rich in proteins, fiber and antioxidants. Research on Bush mango shows beneficial effects for diabetes and obesity, as well as analgesic, antimicrobial, antioxidant, and gastrointestinal activity. (Oben et al., 2008).

   Ethnomedicinal treatments utilize the bark, kernels, leaves, or roots for a variety of ailments .The bark is mixed with palm oil for treating diarrhea and for reducing the breast-feeding period. The shavings of the stem bark are consumed by mouth to treat hernias, yellow fever, and dysentery, and to reduce the effects of poison in French Equatorial Africa (George and Zhao, 2007). The antibiotic properties of the bark help heal scabby skin, and

   the boiled bark relieves tooth pain (Ainge and Brown, 2001). The Mende tribe in Sierra Leone grinds the bark into a paste with water and applies the product to the skin for pain relief. (George and Zhao, 2007; Okolo et al., 1995) In certain parts of Africa, the bark extract is ingested to produce an analgesic effect (Okolo et al., 1995). The powdered kernels act as an astringent and are also applied to burns (George and Zhao, 2007).The stems of the tree have been used as chewing sticks to help clean teeth (Ainge and Brown, 2001).

   African bush mango juice produces a quality wine at 8% alcohol content after 28 days of fermentation that in 1 study was comparable in color, flavor, sweetness, and acceptability to a German reference wine (Akubor, 1996; Leekey, 1999).

   However, unprocessed bush mango spoils easily, compared to the processed ones (i.e in juice form) and extraction of bush mango juice by squeezing with hand is time consuming, laborious and inefficient. Therefore, this study is aimed to:

   1. Design and construct a bush mango juice extractor

   2. Extract bush mango juice without damaging or crushing the bush mango seed and

   3. Also to increase the production of local species mango juice

2. MATERIALS AND METHODS

   The following properties were considered in selecting the materials needed for the construction of the extractor:

   • Physical properties such as size, shape, density etc.

   • Mechanical properties which include; strength, toughness, stiffness, fatigue, hardness and wear resistance

   • Chemical properties: this includes resistance to oxidation and all forms of corrosion since the machine is to be used in processing food.

   • Material availability: the materials used were selected based on their availability such that they can be obtained from the market with ease.

   • Cost of materials: materials used can be made available at a cheaper price to peasant farmers

   • Cost of maintenance: replaceable parts were not welded to the machine frame in order to allow for easy replacement of parts.

   • Strength of material: to avoid operational failure, the strength of the materials used was ascertained. These were determined by establishing data and formulae. Based on the data and formulae applied, the strength and size of parts such as central shaft, power of electric motor required, size of bearing and thickness of the sieve materials were determined.

   • Durability and Hygiene: the machine will come in contact with easily oxidized food (liquid substance). It is therefore necessary to ensure all these parts coming in contact with the juice be made of stainless steel of appropriate strength. The use of stainless steel material for constructing the auger, shaft, perforated drum and collector will enhance the durability of the machine because of its corrosive resistance. However, for construction of the proto-type, ordinary, mild steel was used but painted to reduce corrosion.

   Fig1: Isometric view of the bush mango fruit juice & seed extractor

   Fig 2: Orthographic view of the bush mango fruit juice & seed extractor

   1. Machine Description

      The components of the bush mango juice extractor include the following:

      1. Hopper: the fruits are fed into the beating chamber through the hopper. It is trapezoidal in shape with inlet area of 30cm x 24cm, and outlet area of 20cm x 16cm with a height of 23.25cm.

      2. Outer Cylinder: this is a semi-circular drum and has the hopper welded to it. At the lower end, a semi-circular hole is made on it and a flat plate to

         its base. It is through this that the seed is ejected. Also at the lower part of the cylinder a collecting funnel was attached so that extracted juice can flow out into a container.

      3. Lower Perforated Drum: the drum is perforated to have a roughened interior; which breaks the fruit for the juice to flow out through the hole. It also encloses the conveyor.

      4. Decreasing Pitch Screw Conveyor: this is a type of screw conveyor with a variable pitch in the decreasing order with the aim of using compressive force to extract the juice from the mango fruit.

      5. Shaft: it has the screw plate on its circumference. The shaft is of length 700mm and diameter 32mm. on the shaft, a pulley was mounted, which with the help of a v-belt arrangement transmit power to the machine from the power source. The beaters are welded to the section of the shaft near the bottom of the hopper to help beat the fruits for ease of juice extraction.

      6. Pulley and Belt: the pulley and belt transmit the rotary motion developed by te electric motor to the shaft.

      7. Bearing: bearings were used to support and align the shaft. They carry the shaft to absorb torque and make the operation almost frictionless.

      8. Machine Frame: this was made of 40 x 40mm angle iron and has a thickness of 2mm. This is the main part of the machine on which other parts are welded.

      9. Motor: this supplies the power needed to drive the extractor. It is mounted on the machine frame below the shaft pulley and has its pulley connected to that of the shaft through a v-belt.

      10. Beating Chamber: it consists of a cylinder which encloses a shaft to which flat iron bars are welded at an angle of 450. This was done so that the beaters can combine both the function of beating and conveying the fruits towards the right side of the beating chamber from where they drop into the extraction chamber.

   2. Mode of Machine Operation

      When the motor was switched-on to enable the machine rotate speed of 98rpm with the aid of pulley and belt, the hopper was then fed uniformly with the bush mango. The beater beats the bush mango fruit and conveyed into the perforated drum, pressed against the roughened surface. Owing to the nature of the screw conveyor (decreasing pitch type), compression and extraction of the bush mango juice from the fruit was achieved thereby ejecting the bush mango seed out of the drum. The juice which was released through the perforated drum and collected through a funnel attached to the bottom.

   3. Design Calculations

      The following assumptions were made during the design of the machine components:

      1. Expected capacity of the extractor = 2000kg of juice per hour

      2. Average size of bush mango = 5.25 x 5.25 x 4.75cm

      3. Average size of bush mango seed = 3.25 x 2 x 1cm

      4. Average mass of one fruit = 1.132kg

      5. Average mass of juice extractable from one bush mango = 0.094kg

      6. Mass of bush mango fruit required to be processed per hour in order to achieve the above capacity = 24, 085kg/hour (i.e capacity of conveyor

      7. Density of bush mango = 1002kg/m3

      8. Density of mild steel = 7840kg/m3

      9. Power of electric motor = 3.73kW (5hp)

      10. Selected length of shaft = 700mm

      1. Allowable shear stress of mild steel = 55 x 106mN/m2 for shaft without keyway (Khurmi and Gupta, 2005)

      2. Combined shock and fatigue factor applied to bending moment, kb = 1.5 (Khurmi and Gupta, 2005)

      3. Combined shock and fatigue factor applied to torsional moment, kt = 1.0 (Khurmi and Gupta, 2005)

      4. Selected speed of shaft = 98rpm

      5. Material factor = 0.5

      6. Shear stress for bush mango = 10.2kN/m2 (Ledger, 2003)

      7. Coefficient of friction between belt and pulley = 0.52

      8. Selected diameter of motor pulley = 65mm

      1. Determination of the first Screw Conveyor (auger) Pitch

         The first screw pitch was determined using the equation;

         1. Selected capacity of hopper = 60 bush mango fruits

         2. Acceleration due to gravity, g = 9.81m/m2

            Cs 60

            x x (D2 d 2 )N 4

         3. Motor speed = 1440rpm

         4. Maximum weight of shaft pulley = 40N

         5. Electric motor efficiency = 85%

            Where, Cs = theoretical capacity i.e required auger capacity (m3/h)

            Cs

            auger capacity in kg / hour

            density of bush mango in mango in kg / m3

            mango fruit and extract juice before reaching the last pitch as well as preventing crushing of the seed. As a result of this expectation, the conveyor was designed such that the

            24085 24m3 / hour

            1002

            Where D = screw diameter (0.245m) d=shaft diameter (0.032m)

            = screw pitch

            =filling factor (assumed 0.8) N = shaft speed (98rpm)

            24 60 x (0.2452 0.0322 ) x x 98 x 0.8

            Therefore, 24 188.5 x 0.059001 x x 0.8

            4

            24 871.94

            4

            last pitch is just a little wider than average length of a bush mango seed (3.25cm).

            The formula is given by:

            P(x) 4vDL (Jones and Kisher, 1995)

            (D 2 d 2 )N

            4

            Where P(Xn) = nth pitch (m)

            v = inlet velocity of material (m/s)

            D = outside diameter of the screw conveyor (0.245m) d = inner diameter of the screw conveyor (0.032)

            L = Length of the screw conveyor (0.5m) N = speed in rev/min of the shaft (98rpm) P(X1) = 0.11

            4 x 0.245 x 0.5 x v

            0.11m

            Hence, the first pitch of the screw was taken as 0.11m

            0.11

            x (0.2452 ) x 98

            4

      2. Determination of the pitches of the decreasing pitch screw conveyor

         The screw conveyor was designed using a method by Jones and Kisher (1995). The conveyor must have pitches of decreasing order. In determination of the pitches, iteration method was used. A value was assumed for the first pitch (P(x)) in other to obtain a value for the inlet velocity (v) and then evaluate the remaining four pitches using iteration. The summation of the five pitches must not be greater than the total length of the conveyor (0.5).

         Due consideration were given to the size and shape of the bush mango such as length, breadth and width in order to ensure that the first pitch can contain the bush

         0.11

         0.49v

         4.54

         v 1.274 m s

         P(X2) =

         4×0.245x(0.5 0.11)x1.274

         x(0.2452 x0.0322 )x98

         4

         0.4869

         4.54

         0.107m

         P(X3 )

         4×0.245x(0.39 0.107) 1.274

         x(0.2452 x0.0322 )x98

         4

         4×0.245x(0.39 0.107) 1.274

         4.54

         0.3533

         4.54

         0.078m

         Fig 4: Free body diagram of the shafts

         Where Wp= weight of pulley 2 T1=T2= tensions in the belt

         Assuming maximum weight of pulley (Wp) = 40N = 0.04kN

         Taking the distance between the pulley 2 and the left bearing to be 15cm,

         T1and T2 can be calculated from; P = T x

         Where P = power of the electric motor (3.73kW) T = torque, N= motor speed in rpm (1440rpm),

         PX

         4×0.245x(0.283 0.078)x1.274

         = angular velocity (rad/sec)

         4 x(0.2452 0.0322 )x98

         2N

         2NT

         60P

         i.e. P , T

         4

         4×0.245x(0.283 0.078)x1.274

         x(0.2452 0.0322 )x1.274

         60 60

         60×3.73

         2N

         4.54

         0.2559 0.056m 4.54

         T 0.0247kNm 24.7Nm 2×3.142×1440

         Taking the motor efficiency to be equal to 85%,

         PX 5

         4×0.245x(0.205 0.056)x1.274

         x(0.2452 0.0322 )x98

         Effective torque (T ) 24.7x 85

         100

         But, torque (T) = F x r

         20.995Nm

         4

         4×0.245x(0.205 0.056)x1.274

         4.54

         0.1860 0.041m 4.54

         Therefore, the required pitches are 0.11, 0.107, 0.078,

         0.056 and 0.041m respectively. Sum of the pitches

         = 0.11+0.107+0.078+0.056+0.041 = 0.392m

      3. Determination of the Diameters of the Shaft

      A shaft was used in transmitting power and it could be solid or hollow. The most important considerations in the design of shafts are the pulley weight and reactions at the

      Where F = tangential force (N), r = radius of motor pulley (m), Diameter of motor pulley = 65mm,

      r 0.065 0.0325m, 20.995 Fx0.0325

      2

      F 20.995 646N 0.0646kN

      0.0325

      But, F = T1=T2 = 0.646kN

      Total force (Wt) acting at point A (left end of the upper shaft) is given by: Wt Wp T1 T2

      Wt 0.04 0.646 0.0646 1.332kN

      From the above body diagram, maximum bending moment occurs at point B and is due to the total force (Wt) acting at point A. therefore, maximum bending moment is given by:

      bearing that support the shaft. The following free body diagram was used to evaluate the shaft diameter:

      M 1.332x 150

      b 1000

      kNm 0.01998kNm

      For solid shaft, we have;

      D Lf Bf Wf

      5.25 5.25 4.75

      d 3 16 x

      (kxm )2 (k xm )2 (Khurmi and

      f 3

      cm

      3

      5.08cm Then, L

      5.08cm Then, L

      5.08×2 cm 10.17cm

      5.08×2 cm 10.17cm

      b b

      b b

      t t

      t t

      xSs

      Gupta, 2005)

      Where d = shaft diameter (m)

      Ss = allowable shear stress (55 x 106N/m2 for shaft without

      Volume occupied by 8 bush mango fruit (V (10.17)3cm3 = 1051.87cm3

      8f) = L3 =

      keyway)

      Kb = combined shock and fatigue factor applied to bending moment

      Kt = combined shock and fatigue factor applied to torsional

      The hopper is expected to accommodate 60 pieces of mango fruits. Hence, volume occupied by 60 pieces of bush mango fruit (V) is given by:

      V 60 xV 7.5×1051.87 7889.025cm3

      moment

      For load applied gradually, K

      = 1.5 and K = 1.0

      60 f

      8 f

      8

      8

      b t

      M = maximum bending mo t (0.1998 )

      i.e. expected volume of hopper is = 7889.025cm3

      b men kNm

      Mt=maximum torsional moment (0.0247kNm) Therefore,

      e) Power Requirement

      The total power required for complete operation of the

      d 3

      16

      x(55×106 ) x

      (1.5×0.1998)2 (1.0×24.7)2

      machine is given by the summation of the following:

      1. Power required for driving the two shafts (Ps)

         d 3 16×300.716 , d 3 0.000027844

         172.8×106

         0.03031m 30.31mm

         taking a factor of safety to be 30% of the designed value, actual diameter of the shaft is given by;

      2. Power required for driving the three pulleys (Pp)

      3. Power required for extraction of the juice (Pe)

      Total power required (Pt) = Ps + Pp+Pe

      a) Power required for driving the two shafts (Ps) According to Jones and Kisher (1995), the power required

      d 32 30

      100

      x32 41.6mm

      for driving the upper shaft is given by:

      D2 xd 2 gNpfl

      P

      Therefore, the diameter of the upper shaft was taken as 42mm. The same diameter was assumed for the lower shaft

      1.e. 42mm.

      1. Design of the Machines Hopper

         To design a hopper for the bush mango juice extractor, the arrangement of the fruits inside the hopper has to be taken into consideration. Considering the dimension

         us 8000

         Where D = diameter of the beater (0.245m)

         d = shaft diameter (0.032m), p = beater pitch (0.11m) = density of the material (1002kg/m3)

         N = speed of the shaft in rev/min (250rpm) f = material factor (0.5)

         Therefore,

         0.2452 0.0322 x1002x9.81x250x0.11×0.5×0.5

         of the bush mango fruit (5.25 x 5.25 x 4.75cm), a

         spherical shape was assumed for the bush mango

         Pus

         8000

         fruits. Then if this is so, the following arrangement is possible inside the upper:

         0.060025 0.001024x1002x9.81x250x0.11×0.5×0.5 8000

         3987.2 0.498kW 8000

         Therefore, power required for driving the shaft is 0.498kW. The lower shaft power (Pls) was calculated as 0.693kW using shaft speed of 98rpm

         1. Power required for extraction of the juice (Pe) is given by:

            Pe = T Where T = torque (Nm)

            W = angular speed (rad/sec) But, T

            d 3

            16

            Where d = diameter of the inner cylinder (perforated cylinder), 0.275m and = shear stress (10200N/m2)

            x0.2753 x10200

            T

            16

            x0.0208×10200 16

            Fig. 5: Arrangement of fruits inside hopper

            From the above, average diameter of the bush mango fruit (Df) is given by:

            666.42

            16

            41.65Nm, W

            2xx98

            60

            Where N = number of rev/min of the shaft (98rpm)

            Therefore,

            W 2xx98 615.75 10.26rad / sec

            60 60

            Pe 41.65×10.26 427.43W 0.427kW

         2. Power required for driving the three pulleys (Pp) Power required for driving pulley 2 was calculated from Pp2 T

            Where T = torque (Nm)

            = angular speed (rad/sec) But, T Fxr Wxr

            Where W = weight of pulley 2 (40N)

            D

            r = radius of pulley 2 (m) =

            2

            Where D = diameter of pulley 2 (374.4mm)

            374.4

            Fig 6: The Constructed Machine

   4. Testing Procedures of the Machine

      1. The 3hp electric motor was mounted on the frame

         Therefore, r

         2

         187.2mm 0.1872m

         of the machine

      2. One belt was fitted to both the motor pulley and

         Hence, T 40×0.1872 7.488Nm

         But, 2xxN

         60

         Where N = speed in rev/min of pulley 2 (250rpm)

         2xx250 26.18rad / sec 60

         Therefore, Pp 2 7.488×26.18

         195.966W 0.196kW

         The same procedure as above was used to calculate the power required for driving pulley 3 and 4. It was calculated as 0.077kW each, using weight; 40N each, radius; 3m and 2m and speed; 250 and 98rpm respectively.

         Therefore, power required for driving the three pulleys is given by

         Pp Pp 2 Pp3 Pp 4

         0.196 0.077 0.077 0.35kW

         The total power required by the extractor is given by:

         Pt Ps Pe Pp 0.693 0.472 0.35 1.515kW

         Let x be the required horse power, 1 hp electric motor = 0.746kW

         the pulley attached to the left side of the beater, and another belt was fitted to both the pulley attached to the right hand side of the screw conveyor

      3. The already weight bush mango fruits (25 fruits) were then fed into the beating chamber through the hopper

      4. The electric motor was plugged to the electricity source and switched on

      5. The beaters beats and conveyed the fruits towards the right side of the beating chamber which were then dropped into the extraction chamber

      6. With the help of the screw conveyor inside the extraction chamber, the fruits were pressed and the juice extracted which flows into the collection terminal below which existed a juice collection basin which collects the extracted juice.

      7. After collecting the juice, the juice and seeds were weighed together before and after oven drying

      8. The taken for the extraction was taken and recorded

      9. Above procedures were repeated using another set of bush mango fruits

      10. Finally, the efficiency of the machine was calculated

          Therefore, x

          1

          0.745

          x1.515 2.03hp

3. RESULTS AND DISCUSSION

   After carrying out the fabrication of the bush mango juice and seed extractor, its performance was evaluated based on the following parameters:

   1. Extraction efficiency (E.E) of the machine

   2. Actual machine capacity (Ca) and

   3. Juice recovery rate (Jrr) d)

   1. Extraction Efficiency (E.E)

      The machine was tested twice using 25 bush mangoes in each batch of the extraction process. The performance test data obtained are analyzed below:

      Table 1: Performance Test data

      Batch No.	No. of bush mangoes	Initial weight of fruits(kg)	Weight of recovered juice/pulp (kg)	Weight of recovered juice (kg)	Weight of dried seeds (kg)	Time of juice extraction (min)
      1	25	2.7410	1.5948	0.8252	0.3245	1.5
      2	25	2.4960	1.4278	0.7282	0.2994	1.5
      Total	50	5.2370	3.0226	1.5534	0.6239	3

      Average number of fruits mango fruits fed into the machine. The machine has low

      total number of

      2

      fruits 50 25

      2

      maintenance cost and replacement of pars can be done with ease because the machine was made from locally and readily available materials.

      Average weight of recovered juice/pulp

      3.0226 1.5112kg

      2

      Average weight of bush mangoes

      5.2370 2.6185kg 2

      Average weight of dried seeds

      0.6239 0.31195kg 2

      Hence, extraction efficiency (E.E)

      The following are recommended:

      1. The length of the beater should be increased in order to increase the beating time and hence allow for easy and efficient juicing

      2. The length of the auger should be increase and should cover about 95% of the shaft for proper juicing and easy ejection of seeds

      3. The perforation of the inner cylinder should be increased in order to allow free flow of the extracted juice

      4. Pulping machine should be incorporated to separate the juice from the fruit pulp hereby avoiding blockage of the perforations

      5. Stainless steel could be used in lieu of mild steel

         1.5113

         2.6185 0.31195

         x100 66%

         for all parts in contact with the fruit

         REFERENCES

   2. Actual Machine Capacity (Ca)

   1. Ainge L, Brown N. Irvingia gabonensis and

      J rr

      Actual mass of

      juice obtained

      x100

      Irvingia wombolu. A State of Knowledge Report undertaken for The Central African

      Theoretical massof juice in the

      Theoretical mass of juice obtained

      75

      fruits

      Regional Program for the Environment. Oxford Forestry Institute.

      Department of Plant Sciences. University of

      100

      x1.5113 1.1333kg

      Oxford. United Kingdom. 2001.

   2. Akubor P.I. The suitability of African bush mango juice

      Actual mass of juice obtained

      1.5534 0.7767kg

      2

      for wine production. Plant Foods Hum Nutr . 1996;49(3):213-219.

   3. George IN, Zhao Y. Pharmacological activity of 2,3,8- tri-O-methyl ellagic acid isolated from the stem

      Therefore, J rr

      0.7767 x100 69%

      1.1333

      bark of Irvingia gabonensis . Afr J Biotechnol . 2007;6(16):1910- 1912.

   4. Jones and Kisher, 2005. Mechanical Engineers

   Lost juice 100% 69% 31%

   After testing the machine with 50 bush mangoes for 3 minutes at a beater speed of 98rpm, the extraction efficiency of the machine was found to be 66%. The actual machine capacity was found to be 104.7kg/hr and the juice recovery rate was found to be 69% with juice loss of about 31%

4. CONCLUSION AND RECOMMENDATION

In conclusion, after testing the machine, it was found that the machine has efficiency of 66% and the machine was capable of extracting the juice without crushing the seeds. It was observed also that the efficiency of the machine could be increased by increasing the quality of the bush

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