University Malaya

Faculty of Engineering
Department of Engineering and
Manufacture
KCEC 3171: Industrial Project

Group
:7
Name of coordinator : Mr. Raja Ariffin
Name of panels
: Prof.Imtiaz and
Mr. Edzrol
Date of Submission
: 14/Dec/2011
Group members:

Name
Ching Han Leong
Pang Sze Kuan
Shamsinah Binti Shofian
Nur Aribah Binti Abdullah
Ummu Nazirah Binti Mohd Yassin
CONTENT

Matric Number
KEP090006
KEC090026
KEP090025
KEC090022
KEP090030

Contact Number
010-2590982
017-6122818
012-3275196
019-6518747
013-3316595

1. Preface
1.1 Abstract------------------------------------------------------------- 3,4
1.2 Acknowledgement------------------------------------------------ 5
1.3 Project Team Structure------------------------------------------- 6
2. Introduction
2.1 Project Title--------------------------------------------------------- 7
2.3 Literature Review-------------------------------------------------- 7-9
2.4 Problem Statement------------------------------------------------- 10
2.5 Objectives----------------------------------------------------------- 11
2.6 Project Risk--------------------------------------------------------- 11, 12
2.7 Project Benefit------------------------------------------------------ 12, 13
3. Project Planing
3.1 Task and Time Planing-------------------------------------------- 14, 15
3.2 Activity Identification and Planing------------------------------ 16-18
4. Market Studies
4.1 Market target-------------------------------------------------------- 19, 20
4.3 Market Analysis & Data Interpretation-------------------------- 20, 21
4.4 Technology Benchmarking---------------------------------------- 22-26
4.5 Product Benchmarking--------------------------------------------- 27
5. Design Requirement and Objectives
5.2 design target specification----------------------------------------- 28
5.3 list of metric needs-------------------------------------------------- 29
5.4 Quality Functional of Deployment (Phase 1) ------------------- 30
5.5 Model calculations-------------------------------------------------- 31-36
6. Concept Generation
6.1 Defining Design Problem and Solution exploration------------ 37
6.2 Physical Decomposition-------------------------------------------- 38
6.3 Functional Decomposition----------------------------------------- 39
6.4 Morphological Box-------------------------------------------------- 40
6.5 Concept Sketch------------------------------------------------------- 41-48
7. Concept Selection
7.1 Evaluation Matrix---------------------------------------------------- 49-50
7.2 Final Conceptual Design-------------------------------------------- 51, 52
8. Reference------------------------------------------------------------------------- 53

1. PREFACE

1.1 Abstract
Industrial Project is the way for us as cad/cam and manufacture engineering
student to learn and study how to produce a product from the conception to disposal
stage. From there, we can recognize the steps and processes of how to build a product
from an idea to a marketable product. In addition, this project can enhance our knowledge
and experience before we become an engineer.
Our projects title is the loose fruit collection device for palm oil
plantation. Loose fruit is the ripest in the bunch and drop naturally to the ground.
Historically, loose fruit was not given much attention. They were deemed insignicant
compared to the Fresh Fruit Bunch which is larger in size. Hence the collection of loose
fruit was never taken seriously. Many of the fruit was left to rot.
Loose fruit contain 40% oil. Poor collection of loose fruit due to the tedious work
is therefore often the underlying cause of a low oil extraction rate among oil plantation in
South East Asia. Loose fruit are currently collected by way of raking or picked by hand.
Challenges in these operations are being identified and new approaches to the problem
and solutions are being considered. We need to invent or create the new product to pick
the loose fruit. Compared to a whole Fresh fruit bunches whose oil to weight ratio is
between 20% and 25%, loose fruit would have an oil-to-weight ratio of about 40%. This
basically means that if the weight of one loose fruit is about 10 grams, four grams of it
would be the weight of the oil.
One of this project expectation is a device can improve the collection of loose
fruits from the group efficiently. Besides that, this cost of the device should be less than
RM 2000 as motivate the small holder to collect the loose fruit. Other requirements from
the user and plantation environment are observed by doing research and interview.
Indeed, we know what customer needs from this device. Besides that, due to the needs of
the user, research and development is done to make the device easy to maneuver and suit
for all types of field condition around the bases of the palms. Hence, a device to collect
loose palm fruit is designed.

The benefits of our new invention can increase palm oil quality and reduce back
pain of the loose fruit collector because before this they are using hand to collect the palm
fruit. Besides that, it also can separate the loose fruit from debris.
This industry project provide us with the opportunity for a conducting background
investigation and analysis of the way to collect the loose palm fruit currently, detailed
design work and component selection, manufacture and assembly, and practical
examination and communication of the outcome. We also have the chance to work in a
real environment, follow a disciplined process and learn to deal with the problems that
arise. We also will discover and familiarize the common practices followed in the
industry.
We strongly believe that our product will be able to compete and get place in the
market especially in Malaysia because the device to collect loose palm fruit is still new in
industry.In summary, we hope that our project will be successful.

1.2 Acknowledgement

We would like to acknowledge and extend our heartfelt gratitude to the following persons
who made the completion of this Industrial Report possible.
Our coordinator, Mr. Raja Ariffin bin Raja Ghazilla, for his understanding and helpful
that gave us good comments and great ideas. Without your guidance we probably could
not make our project successful.
We also would like to thank the panels, Professor Dr. Imtiaz Ahmed Choudhury and Mr.
Edzrol Niza bin Mohamad, for the excellent cooperation in giving comments needed for
completing this project. This also goes to the rest of the class which we all care and love
for giving their cooperation in giving information more about the project. Everyone is
being very helpful and having good sense of understanding between each other.
Last but not least a special thanks to our group members especially our group leader Mr.
Ching Han Leong and the rest of the group members, Miss Pang Sze Kuan, Miss
Shamsinah binti Shofian, Miss Nur Aribah binti Abdullah and Miss Ummu Nadzirah binti
Mohd Yassin for the great support, wonderful effort and cooperation of completing this
project. Without the good communication and understanding among us we probably
would not complete the project on time and successfully.
And to God, who made all things possible. Thank you very much.

1.3 Project Team Structure

Panels: Professor Dr. Imtiaz Ahmed Choudhury and Mr. Edzrol Niza bin Mohamad
Group members:
Name
Ching Han Leong
Pang Sze Kuan
Shamsinah Binti Shofian
Nur Aribah Binti Abdullah
Ummu Nazirah Binti Mohd Yassin

Matric Number
KEP090006
KEC090026
KEP090025
KEC090022
KEP090030

Product Development Organisation Chart

Contact Number
010-2590982
017-6122818
012-3275196
019-6518747
013-3316595

Panel
Mr. Edzrol Niza Bin
Mohamad

Project Leader
Ching Han Leong
KEP090006

Project
Secretary
Treasurer
Assistant
Runner
Shamsinah
Nur
Ummu
Pang
Aribah
Sze
Nazirah
Kuan
Binti
Binti
Abdullah
Shofian
Mohd
KEC090026
KEC090022
KEP090025
Yassin
KEP090030

2. INTRODUCTION
2.1 Project Title
Design and fabrication of a prototype loose fruit collection device for palm oil plantation

2.3Literature Reviews

Palm oil extraction has been declining over the years due to the incomplete collection of
loose palm oil fruits. Sime Darby (2008) stated how important the collection of loose
fruits at the plantation. The Vice President II of Sime Darby R&D Centres Technology
Centre & Advisory, En.JamaluddinNasir, has been quoted to say that loose fruit has the
highest oil to weight ratio due to them being the ripest. The article continued to highlight
the loss in benefit from the uncollectable loose fruits, quoting that the company would

make an extra RM30 million in net profit if estate workers collect six loose fruit per
tree.We consider the facts presented by this article important and crucial in our product
development since Sime Darby has been established as one of the major player in the
palm oil industry.
The main factor for the low collection rate is believed to be caused by labour
shortage.MohdSolahDeraman, Abd Rahim Shuib and MohdSallehJaafar (2009), stated
that labour shortage is the main factor to poor harvesting practices which in turn leads to
longer harvesting intervals and higher quantities of loose fruits left uncollected. The
current methods used to collect these loose fruits are raking and manual method. They are
said to be not only labour-intensive and time-consuming but also tedious and laborious.
This article is published for the MPOBs research archive for the purpose of developing a
roller picker to solve the problem at hand. Therefore we have decided to follow close to
this particular product as our benchmark and improvise the design of the roller picker.
There is also another popular method in loose fruit collecting that is suction method.
According to Abdul-Shukor Abdullah (2006), a group of student fabricated a suction
device that uses Teflon nozzle that was said to provide an efficient suction power by
creating high velocity of air flow in the region of 22.2 m/s to carry the loose seeds
until they reach the collecting bag. However, based on the findings from the test session,
the suction power is still inadequate when the fruit seeds are stuck in mud. Besides that,
the weight of the device is also a major problem. The article later continued to state how
the device can be improved which is by conducting a thermodynamic test and reducing
the product weight by using DFA technique. We decided not to pursue the design in this
direction since we have stronger core in mechanical grounds. Other than that, based on

this article, the testing appeared to have only touched the suction power and the
ergonomic aspect of the product but not the overall experience of the user. The weight of
the loose fruits collected also has to be taken in to account.

The followings are the extracts from the articles mentioned above:

Findings of the test sessions are summarised as follows:

1. The suction power is poor when the fruit seeds stuck in mud.
2. Suction power is inadequate when the seeds are more than 20 mm from the tip of the nozzle.
3. The worker has indicated that the weight of the machine is manageable.
4. Collection time using the machine is reduced considerably.
5. Further design improvement must be done to reduce the noise level.
6. The machine minimises the workers chances of getting injured or back pain.
Poor suction power and weight are two criticaldesign factors which required furtherinvestigation. The
former can be furtherevaluated and improved if the team canconduct a thermodynamic test and a
furtherweight reduction can be achieved if theproduct can be assessed using DFA technique.
-

Abdul-Shukor Abdullah., (2006) Collaborative Learning Analysis In Mechanical

Engineering Design Project.Unisel, Malaysia.

358

The decline in the rate of palm oil extraction is due to a great extent to the incomplete collection of loose
oil palm fruits. This has worsened with labour shortages, which have been repeatedly mentioned as the
most critical factor in ensuring all bunches and loose fruits are harvested and collected. Labour shortage
continues to pose greatest challenge for the oil palm industry. Such shortages will lead to poor harvesting
practices resulting in longer harvesting intervals and higher quantities of loose fruits left uncollected.
Uncollected loose fruits account for about 3%-5% of bunch weight. Consequently, prolonged failure to
collect and process these loose fruits will contribute to further reductions in oil extraction rate and profits.
Loose fruits are currently collected by way of raking and or picked by hand. These techniques are not only
labour-intensive and time-consuming but also tedious and laborious. Besides, the debris content when
raking is practised can be as high as 60% by weight.

A study was thus carried out on the approaches of collecting and separating loose fruits and to design a
cost-effective device for loose collection.
The benefits in using the Roller Picker are:

The task is less strenuous and reduces back pain of the loose fruit collector;
It results in debris-free collected loose fruits; and
Increased palm oil quality is achieved at the mill

The capital investment of the Roller Picker is considered attractive with a payback period of one year.
The investment is economically feasible as it is expected to yield a benefit-cost ratio (B:C) of 2.14, a net
present value (NPV) of RM892.35 and an internal rate of returns (IRR) of 46%.
-

MohdSolahDeraman,Abd Rahim Shuib,MohdSallehJaafar.,(2009)Roller-Type Oil Palm Loose

Fruit Picker. MPOB Information Series. ISSN 1511-7871.

However, loose fruit is not only the concern of the estate management but the companys top
management including the President and Group Chief Executive Dato Seri Ahmad ZubirMurshid who had
touched on this matter during the townhall meetings. He had also been quoted in Business Times in
November last year that the company would make an extra RM30 million in net profit if estate workers
collect six loose fruit per tree. Such is the impact of the loose fruit.

Sime Darby., (2008) Seedlink : Loose Fruits vs Lost Income, Vol 2/6., Sime Darby Plantation.

2.4 Problem Statement

Current harvesting process of palm fruits often leads to loose fruits scattered on the
ground from the fruits bunch, although loose contain about 40% of palm oil.
After the team meeting with MPOB officer, we summary the reason why most of the
plantation owner does not buy a loose fruit collector and why the worker do not want to
carry up the loose fruits.
a. Time Consuming
The workers lazy to pick up the small divided loose fruit from the ground, this is
because the amount is too big and not easy see where is the loose fruit from the
grass. Besides that, the worker have to pick up one by one of the loose fruit from
the group, it is totally wasting their time and lower their productivity.

b. Lead back pain to workers

Once the worker goes to pick the loose fruit from the ground, they have to bend
down their body and pick the fruit. If this action keeps continuous, this may lead
the back pain to the worker, the owner has to pay responsible for their medical
fees. Therefore, this would not bring any win-win situation for both sides, either
worker or the plantation owner.
c. High cost for current loose fruit collector
The current loose fruit collector is too expensive and the operation cost of the
machine or maintainer cost is far behind the total revenue of loose fruits. This is
one of the reasons why the owner gives up in picking up the loose fruits.

2.5 Objectives

To design a loose fruits collection device for palm oil plantation to make
sure there are no more loose fruits wasted.

To fabricate out a prototype loose fruits collection device and tested by

engineering tests to ensure it can be used widely in future.

After the brainstorming among the group members, we plan to design the following
product features so that the worker able to collect or pick up the fruits with more easily.
However, all the design features must fulfill the following objectives.

Design a device that can easy to collect or pick up the loose fruits from the
ground.
To reduce the time that is needed to collect the loose fruit.
To separate the loose fruits from debris.
To increase the quantity and quality of palm oil at the mill.
To reduce works back pain of the loose fruits collector

2.6 Project Risk

Time Constraints
Completion of whole loose fruit collector project takes only two semesters. The total
time available might not enough to complete the project development process.
Besides that, prototyping and detailing design of every small part are time consuming.

Cost
This research of loose fruit collector might require higher cost because we buy
accessories with small amount quantity. We might overrun the budget for project or
lack of funding for the prototyping.

Prototype Testing
Testing which has been done might not as accurate as the true value due to lack of
available facilities and technical skills. The final prototype might fails as inaccurate
result get from testing.

Management Risk
Management of the project and cooperation among the team members would be the
most important part to ensure that the successful of project. In addition, resources
management such as human resource, time management and work life commitment
would be important to relish this project.

2.7 Project Benefit

Benefit to the group

a. After the group discussion, we able to figure out project planning, market studies,
design requirement, concept generation, concept selection and embodiment
product design.
b. Group members become more willing to state out their points and ideas.
c. The interaction between the group members becomes stronger.
d. Group members pay more attention to visibility of product, including the concept
design and operation select.
e. Able to establish the natural match relations between customer needs and
engineering design.

Benefit to the department

a. Once the product is designed successfully, the reputation of CAD/CAM and
Manufacturing Department will be improved.
b. Create a cooperate culture between students and staffs of department.

c. Once the product is designed successfully and efficiency, there are more research
opportunity will be given from FELDA and MPOB.

Benefit to the nation and society

a. Once the product is designed successfully and efficiency is proven, we may
improve the Gross National Income of palm oil industry.
b. From the economics views, once the quantity supply of a particular product was
increased caused by the improvements of technology, a lower equilibrium price
will be reached. Directly, the price of raw palm oil decrease will also decrease the
cost of production for palm oil industry. Finally the society will get the maximum
total surplus from palm oil products.
c. Support the small plantation holders in term of increase the percentages of
harvesting fruits.
d. Increase the entire value chain from plantations to downstream activities once the
amount of collecting fruits increase.

3. PROJECT PLANNING
3.1 Task and Time Planning
Semester 1:

Dates

10/1

17/1

24/1

31/10

Introduction
12/1
Literature review

0
12/1

Problem statement

0
12/1

Objectives

0
19/1

Project risk
Project benefit
Project Planning

0
19/1
0
26/1

Task planning
Activity identification and planning
Market Studies
having a tour to MPOB serdang
survey and interview
Market analysis
Product Benchmarking

0
26/1
0
1/11
2/11
2/11
2/11

Technology Benchmarking

2/11

Dates 7/11 14/11 21/11 28/11

Design Requirement and Objectives
Customer Need Analysis
9/11
Requirement Analysis
9/11
Metric development
11/11
Standard Search
11/11
Calculation models
11/11
Quality Functional of Deployment
(Phase 1)
Concept Generation
Defining design problems
Solution exploration
physical decomposition
functional decomposition
Morphological Box
Concept sketch
Concept Selection
Concept testing
Concept analysis (FEA/CFD/ etc)
Evaluation Matrix
Report Hands Up

5/12

12/12

16/11
23/11
23/11
23/11
23/11
25/11
30/11

7/11
9/11
9/11
9/11
14/12

3.2 Activity Identification and Planning

Contents
1. Introduction

Descriptions

Person In Charge

1.3 Literature Review

1.4 Problem Statement
1.5 Objectives
1.6 Project Risk
1.7 Project Benefit

Overview of the project

TEAM

Overview of the project

Pang Sze Kuan

3.1 Market target

3.2 Market Survey Form and

Determine the target customer

Collecting data

Ching Han Leong

Ummu

Interview
3.3 Market analysis & Data

interpreting data into customers

Shamsinah

Interpretation
3.4 Technology Benchmarking

needs
Making comparisons between

Aribah

2. Project Planning
2.1 Task and Time Planning
2.2 Activity Identification and
Planning

3. Market Studies

existing technology or platform to

3.5 Product Benchmarking

pick the loose oil palm fruit

Making comparisons between
existing products in the market
and benchmarking on relevant
technology

4. Design Requirement and

Objectives

Aribah

4.1 Customers' Need Analysis

identify the existing problem that

Shamsinah

customers faced and solving the

4.2 Quality Functional of
Deployment (Phase 1)

design problem
translating customer requirements

Ummu

into engineering requirements

5. Concept Generation
5.1 Defining Design Problem and

defined problem and the sub

Ching Han Leong

Solution Exploration
5.2 Physical Decomposition

functions for solution

defined the part of the design and

Aribah

its function
5.3 Functional Decomposition
5.4 Morphological Box

chart with all the possible design

Shamsinah
Pang Sze Kuan

5.5 Concept Sketch

for each part

design sketch with pros and cons

TEAM

analysis, rough FEA

use scoring method to use the best

Pang Sze Kuan

TEAM

6. Concept Selection
6.1 Concept Testing and Analysis
6.2 Evaluation Matrix

design

7. Embodiments
7.1 System Architecture

review the flow of force, material

Ching Han Leong

7.2 Quality Functional of

and signal on the machine

translating engineering

Ummu

Deployment (Phase 2)
7.3 Geometry Layout (Standard
Part Indentification)

7.4 Technical Design Drawing

requirements into each part

needed
to defined de roughly size of each

Pang Sze Kuan

part and the machine

detail drawing of design and

TEAM

component
7.5 System and Component CAD
7.6 Material Selection and
Justification

selection and identify material

needed in design

Ching Han Leong

7.7 Product Calculation

provide needed calculation for

TEAM

designing parameter, calculate

considered factor with engineer
knowledge, detail appropiate
7.8 Fishbone

calculation
defined the problem exist for the

Ummu

7.9 Failure Mode Effects and

design
defined the problem and how

Shamsinah

Analysis
7.10 Detail component testing

offen it occurs
carry out needed experiment for

Aribah

getting actual engineering value

which needed for design
7.11 Prototyping

8. Manufacturing Planning
8.1 Manufacturing Process
Selection
8.2 Assembly Process

identify suitable manufacturing

Ching Han Leong

process, description for particular

fabrication process needed
sequence of relevant assembly

Aribah

process

9. Prototype
9.1 Prototype Costing
9.2 Prototype material supplier
9.3 Fabrication

prototying cost
teasting
fabrication

TEAM

4. MARKET STUDIES
4.1 Market Target
According to Economics Transformation Report, as 2009, Malaysia has the total land
area of palm plantation is 4.7millions hectares. New plantation expansion of Malaysian
companies abroad due to land limitations in Malaysia. There is currently a total of 6.6
million hectares of land for agricultural use in Malaysia, of which 4.7 million hectares
(71 percent of total) is used for oil palm plantations.

a. Our focus customers group can be divided into two for palm plantation in Malaysia,
they are Private Estate and Government Estate.
b. Understand the customers group will help us to understand the purchasing power for
our product.
c. According to pie chart, Private Estate as our major customers group. However, there
are some reason for us to Government Estate as our primary customer for the
product.

plantation ownership in Malaysia

11

2
16

60

Plantation companies in our Malaysia(customers) :

4.3 Market Analysis & Data Interpretation

We had conducted an interview with Mr.Muzzammil, who are officer of environmental
department at Malaysian palm oil board (MPOB). Mr. Muzzammil received his degree in
computer aid design program from the university Malaya in few years ago. Currently, he
is taking Master in palm oil research from MPOB.
INTERVIEW #1 (Mr. Muzzammil)
Preparing for the product design (market stage)
Mr Muzzammil stated that majoring in Computer Aided Design is the first step in
preparing for his profession. He pointed out that palm fruit are important for our country
this is because Malaysia are the bigger palm fruit exportation country in the world,
followed by Indonesia. As it has over 100 years of experience and a strong market
leadership in terms of productivity and R&D, the Malaysian palm oil industry play an
important role to the Malaysian gross national income, which present about RM52.7
million for the palm oil industry.

Knowing what the customer needs can also be very helpful in our product design,
according to Mr.Muzzamil. With that information, we can utilizes our product
characteristics and match with the customers needs. He also pointed out that not only
design is a design work, but understand who is our customers, size of the market,
potential of the market, and customer needs are very important.
Realities of the product design.
He state that, design a product with low cost but efficiency, is a difficult task for us. For
him, the definition of efficiency for our product (loose fruits collector) is influenced by
three factors, they are low debris, high capacity and lower damage percentage for the
loose fruits. However, he also pointed out that, most of their customers emphasize the
cost of the product, customers always try to get maximum benefit from the particular
product, which is low cost and high effieciency. He also pointed out that, some of the
plantation owners, especially the small scale plantation, they rather to ask their worker to
pick up the loose fruits by their own than buy a collector to collect the loose fruits. The
main reason is they want to save the cost instead of spend money and buy a collector
device. Therefore, even we able to design a high efficiency product, but the plantation
owners still choose not to purchase our product because of the cost.
Anyway, he encourage us take the current loose fruits collector as a reference and try to
modify it so that the product features can be improved in term of the efficiency.
Nowadays, big size of vacuum machine only available in the big company such as
SimeDarby and IOI plantation. They make a lot of convenience to take workers, but they
cannot separate the debris with the loose fruits very well when they use the pipe to suck
all the things from the ground to the machine.

4.4 Technology Benchmarking

Source

Technique

Power,
kW

Collec
ting
rate,

Debris
,

Injury
,

kg/mi
n
Muhammad
Salih
(1988)

Mohd.
Zohadie
(1992)

Rubber Strain
atoolto collectthe oil palm fruit
using therubberstrain.
Fruitcollectedone by one. The rate
of collectionis75pieces/ min(0.75
kg/min) and nodebris iscollected.
However, fruitinjuryis high.

Rotating Brush Collector

Press
method

0.75

20

1.4

< 30

Push
method

1.67

<10

It uses a brush broom to pick the

fruit off the ground. Mohd. Zohadie
(1992) has adapted the design
above and found that a machine
driven by 4 kW petrol engine is
able to reap all the fruits on the
ground. Preliminary observations
indicate that the machine is able to
collect 1.4 kg / min and there was a
30% percentage of debris.

Parameseven

Plate Collector

(1992)

the main components of the device

includes a main frame, rubber
collector plates, barrier pieces,
collector box, regulator of fruit and
castor wheels.
This tool is rolled over the fruits.
Fruit will be caught in between the

plates which indirectly acts as a

front wheel. Seeds that are caught
will be in accordance with rotation
of the plates and will be barred by a
barrier that serves to push the fruit
into the containers.
The average capacity of the
collection was 1.67 kg / min.
However, the fruit collected are
injured even though there is no
debris.
Harris

Modified Plate Collector

(1995)

They pay more attention to

reducing injuries in the oil palm
fruit. The design of this tool is
divided into two main systems of
the driver and store system.

Push
method

0.66

18

2.25

0.3

The driver system will ensure that

the fruit is in a position parallel to
the movement of the wheel to ease
the wheel to clamp the fruits before
it is lifted into the container. The
carrier is a disc-shaped and coated
with soft plastic to avoid any injury
to the oil palm fruit. The efficiency
of this device on the average is
80% and has the ability to collect
0.66 kg / min. Percentage of debris
is zero, but the fruit is injured by
18%.

Wan

Indirect Vacuum Collector

(1993)

It uses the concept of producing a

blow that will produce suction. The
machine is designed with several
key components, namely:

i. Blow unit,
ii. Suction unit, and
iii. Venturi unit.
This machine is creating a suction
power at a venturi unit as a result
from the changes in velocity after
getting power supply from the blow
unit.
Preliminary observations indicate
that this machine is 100% debris
free and have the ability to collect
0.3 kg / min with a 2.25 kW of
power.No fruit is injured during the
collection.
Ahmad
Zamri
(1994)

Direct Vacuum Collector

Waste suction machine has been
modified and developed to suck the
oil palm fruit. Air is sucked by the
fan through the suction nozzle of
the machine. A lift effect was
created and the palm fruit along
with the debris are sucked in
together and separated by a filter.
Transported oil palm fruits were
collected in containers driven by
3.75 kW engine, while debris
through the propeller blades and
sprayed out by the propeller.
Preliminary observations indicate
that the machine could suck 1.13 kg
/ min. Present the percentage of
waste is less than 8%.Muhammad
Salih, and MohdTaufiq (1995) has
adapted the machine on with a little
change in results in debris

3.75

1.13

<8

separation.
Ahmad
Hitam

Direct Vacuum Collector

(1995)

Suction force is obtained from the

petrol engine and they are
connected to two large container
that serves as a storage for palm oil
and debris. Field tests demonstrated
the ability of this machine is
between 1.0 to 1.2 kg / min of
accumulated waste content of less
than 10% compared with 0.7 - 1.4
kg / min and trash content
exceeding 20% of the common way
of collecting.

Khalina

Indirect Vacuum Collector

(1996)

By using the principles of blowsuction, the air velocity is used as

the main medium to produce a
suction forceThe main part of this
machine consists of 25.2 kW of
power blowing machine, a filter
unit which is located at the end of
the suction duct, a container,
vessels and blow ducts. From
preliminary observations, the
machine is capable of collecting oil
palm fruits at 1.2 kg / min without
any injuries. No debris collected
during this test done.

MohdSolahD
eraman

The roller is rolled with a little

pressure against the ground causing
the wires or rods of the case to split
open and to trap the loose fruit
inside the case. Once the loose
fruits are entrapped inside, the
wires or rods of the case will return

(2010)

3.75

1-1.2

< 10

2.25

1.2

Roll
Method

0.75

<10

to their normal position. All debris

smaller than the spaces between the
wires or rods will drop from the
case, and therefore will result in
only debris-free loose fruits being
collected.

4.5 Product Benchmarking

Manufactur
er/Model

Kingoya
Kingoya
Method

MPOB
Roller Type
Loose Fruit
Picker

Bag-A-Nut
16-Mac
Pick-Up
Removable
Basket

EikSeng
Machinery

Diagram

Power,

Dimension

kW
Pull
Technique

Push-Pull
Technique

Width 280mm

Collecti
ng Rate,

Debris
,

Fruit
Injury,

kg/min

0.5

0.75

10

Diameter
120mm
Length
1000mm

Push
Technique

Basket Width
16

30

3.6

(40 x 54 x
80)cm

4.5

50

45

Length: 209"
Wheelbase: 80
1/2"
Height: 76"

Vacuum
Collector
for Palm
Oil VCPO77
Weiss
McNair
836 P.T.O.
Hazelnut
Harvester

5. DESIGN REQUIREMENT AND OBJECTIVES

No

Customer needs

Rank

Lightweight

Easy to install

Multifunction

High efficiency

Easy to maneuver

High capacity

Use mechanical mechanism

Mobile (move freely)

low price

10

High durability

11

Acceptable size

12

Environmental friendly

13

Easy to maintain

14

easy to operate

15

easy storage

16

Lasts a long time

17

Is safe in a crash

18

Detachable

19

Good appearance

20

Simple

Specification

5.2
Design
Target

5.3 List of Needs-metrics

No
1
2
3
4
5
6
7
8
9
10
11

metric
Egornomic Design
Number Of Components
Lifespan Of Device
Total Mass
Stability Of The Device (Mass Distribution )

Hardness Of Material
Time To Assemble/Disassemble
Volume Of Storage
The Position Centre Of Gravity
Bending Strength
Melting Point Of Material

Need Nos
5,8,14
1,2,8,11,13,14
10,13,16
1,5,8,14
5,8,14
9,10,16
18
1,6
5,8
1,9,10,17
10,16

Units
Subj
Subj
years
kg
s
m3
m
Pa
C

12
13
14
15
16

Size Of Device
Warranty
Density Of Material
Corrosion Resistance Of Material
Type Of Material Use

1,2,5,8,11,14,15,17
17
1,5,8,9
9,10,12,16
1,5,8,9,10,12,16,17,1

17

Total Cost

9
9

m2
years
kg/m3
Subj
RM

5.5 Calculation model

1. Power to move the machine
a. P = F x V
Where F = force to move the machine, V = velocity of the machine
b. P = T x
Where T = torque of the wheels, = angular velocity of wheel
2. Rotational energy of the machine
a. K = (1/2) x I x 2
Where I = inertia of wheel, = angular velocity of wheel
3. Kinetic energy of the machine
a. K = (1/2) x M x V2
Where M = mass of the machine, V = linear velocity of the machine
4. Modulus of resilience
Explanation: the energy that can be absorbed per unit volume without
creating a permanent distortion.
a. Ur = y2 / 2E
Where y = yield strength of the material, E = modulus elasticity
5. Modulus toughness
Explanation: energy of mechanical deformation per unit volume

Energy/volume =

d
0

6. Size of the fruit storage tank

Volume of the tank storage = w x t x h
Where w = width of the tank, t = length of the tank, h = height of the
tank
Numbers of loose fruits that can be store =
(Total volume of the tank) / (average volume for one loose fruit)
7. Stability of the machine at the incline slope
Here, we ensure the centre of mass of the machine do not fall out the
base area of the machine on the slope. (Static condition)

Tan = L / h
Where = incline angle, L = length of the machine, h = height of the
machine
8. Maximum load /critical load for the hollow rod
For the round shape hollow rod,
Area, A =

( 4 )

(d02 d12)

Inertia moment, I =

Pcr =

4
4
64 (d0 d1 )

x E x I) / L2

For the square hollow beam

Area A = b02 b12
Inertia moment, I = (1/12)(b04 b14)
Pcr =

x E x I) / L2

9. Beam deflection
y = (PL3)/ (3EI)
Where P = force, L = length of the beam, E = elasticity modulus, I =
moment of inertia
= (PL2)/ (2EI)
Where P = force, L = length of the beam, E = elasticity modulus, I =
moment of inertia
a. Handle design in term of deflection
- Determine deflection of end C cause by force P

Portion AB:
Bending energy = (P2LAB3) / (6EI)
Torsion energy = (P2LBC2LAB) / 2GJ
Portion BC:
Bending energy = (P2LBC3) / 6EI
Total energy, U = (bending energy + torsion energy) portion AB +
( bending energy)portion BC
Deflection, = (2U) / P
(Deflection at the end C caused by force P)
b. Pathway design for the roller collector
Let say the collector roller move from point A to point C, determine
the deflection at the end C

c = (2/3) (PL3) / (EI)

Deflection at end c
= (1/6) (PL2) / (EI)
Deflection angle at C
c. Base of the machine
Determine the reaction force at each support, A = collector roller, B
= front wheel, C = rear wheel, assume that there are no deflection
at the point A.

Reaction force at C,
Rc = (1/2)(RA) + (1/2)(RB)
Portion AB

Deflection energy,
(UAB) / ( RA) = (1 /24) (RAL3) / ( EI)
Portion BC
Deflection energy,
(UBC) / ( RA) = (RAL3) / (12EI) + (WL4) / (48EI)
By the assumption deflection point A is 0,
(UAB) / ( RA) + (UBC) / ( RA) = 0
Therefore the reaction force at each point,
RA = -(1/6) (WL)
RB = (3/4) (WL)
Rc = (5/12) (WL)
W = total weight of the machine after the storage tank is full. L =
total length of the base beam
10.
Shear stress at the pin or screw point
a. For double shear,
= (F) / (2A)
Where F = force act on the pin / screw, A = area of shear
b. Bearing stress,
= (1/2) (F) / (A)
Where F = force on the pin / screw, A = bearing area
11.
Maximum shear stress in the beam
= (VQ) / (It)
Where V = transverse shear force, Q = first moment of area, I =
moment of inertia, t = width of the section

12.

Factor of safety

F.S = (allowable force or stress) / (ultimate force or stress)

13.

Size of the collector roller

Assumptions and comparison:

a. The roller is perfectly cylinder shape
b. We taking the average weight of a loose fruit, which 10g
(reference :
http://www.simedarbyplantation.com/upload/Newsletter_March_200
8.pdf)

c. To increase the capacity of collector roller, we compare the roller

with the size of MPOB roller. In our design, we target the capacity
storage is more than the MPOB roller.
(Reference: http://palmoilis.mpob.gov.my/publications/TOT/TT419.pdf)
Therefore, the design criteria for the roller must
i.
Width > 280mm
ii.
Diameter > 120mm
d. We assume there are no debris inside the roller
e. The oil palm fruits are ovoid in shape varying in length from about 2
cm to more than 5 cm
and in weight from 3 grams to 30 grams. Botanically, the fruit
consists of a nut surrounded by fleshy fibrous mesocarp. The nut
consists of the kernel within its shell (endocarp)
(Source: The Oil Palm C.W.S Hartley 2nd Edn.)
(Reference:
http://www.uneca.org/fssdd/events/WorkshopTradeJan2011/Docume
nts/asia/study%20paper/Case%20study%20Palm%20oil
%20Malaysia.pdf)

13a. Volume of the collector roller

V = (r2) x L
Where r = radius of the roller, L = length of the roller
13b. Maximum numbers of loose fruits inside the roller
N = (volume of the collector roller) / (average size of one loose fruit)
13c. maximum weight inside the loose (fully loose fruits)
W = N x (average weight of one loose fruits, 10g)
13d.

Size between the gaps of wires.

Average size of one loose fruit, length from about 2cm to 5cm,
diameter from about 1cm to 2.5cm.
Therefore, to design the gap distance, we must fulfill the above
criteria.

6. CONCEPT GENERATION
6.1 Defining Design Problem and Solution Exploration

1.

Design requirements
Low cost and high efficiency

2.

design
Counter back pain

3.

Decrease the rate of debris

4.

High mobility

5.

Increase the storage capacity

6.

Avoid in using electricity and

petrol for the collector device

Design Solution
a. Materials selection
b. Design features
a. Do some mathematic calculation to
the product design
b. Ergonomic design
a. Design an external part to separate
b.
c.
a.
b.
c.
a.

the fruit and debris

Design features on the collector part
Weight increasing
Material selection
Design features
Ergonomic design
Design an external part to store the

loose fruits
b. Weight increasing
a. Design a simple and efficient product
b. A mechanical design that can
minimize the human power

7.

Long lasting and reliable

consumption
a. Material selection
b. Know stress distribution analysis for
the whole part of product.

6.2 Physical Decomposition

6.3 Functional Decomposition

csCFPmr olurUeoplsa vhNeiln tr/ cspCal ftowu erToludi soI metOloh flgesbNrop tuarso Aeivtp sneL f, itr nfaouArntlomi dt m ophd nr t ohul poer oiwsn et op at hr ate o fr tah n e d b i g s i z e s t o n e s t a y o n
bslfDhptro heaor uEplgni rsndaCet rlegeaO pBfetraoMu r ia tP oO r S I T I

ON

6.4 Morphological Box

Parts

Types

Collector
- Vacuum

Movable
- Wheel

Storage
- Box
Power generator

- Human Power

- Plastic/Cloth
- Electrical

- Battery

- Motor(fuel)

Separator

- Separate with a net

- Separate with a cage and fan

6.5 Concept Sketch

Concept 1

60cm

Top View

3D view

35cm

90cm

Front View

Side View

ADVANTAGES

Low cost
Included separator
Bigger capacity
Movable
Lightweight
Use only human power
Environmental friendly

DISADVANTAGES
Easy to maneuver
Hard to refill
Need to design a specific rod/way

Ways to operated:

Push the loose fruit collector onto the loose fruits.

The loose fruits are collected by going thru the gap into the roller in front of the
machine.
When the loose fruits in the roller are almost full, pull the handle to lift up the roller
along the pathway and turn at the top to pour out all the loose fruits in the separator.
Rocks which bigger size than the loose fruits are separated and loose fruits go thru
the funnel and keep in the bag.

Concept 2

170cm

ADVANTAGES

Wide collecting area

Use mechanical
Environmental friendly
Save time
Capacity

Top View

500cm

Front View

Ways to operated:

DISADVANTAGES
Big size
No separator to separate fruits

from debris
Low durability
Mobility
Cost high

3D View

350cm

Side View

 Loose fruit collector is attached together with the bulldozer.

This machine work together with the bulldozer to save time because workers can
collect the loose fruits at the same time when collect the big bunch of the oil palm
fruits.
When this machine passes by between the oil palm
trees, The two side of the collector will closed.
This action can make sure that all the loose fruits can
be collected by only one time passing by.

Concept 3

ADVANTAGES

Lightweight
Easy to maneuver
Human power
Mobility
Small size
Separated
Environmental friendly
Lower cost

DISADVANTAGES
Time consuming time
Low capacity
Low durability

Top View

3D View

55cm

100cm
70cm

Front View

Side View

Ways to operated:

Using manpower to push the loose fruit collector onto the loose fruits.
The loose fruits are collected by going thru the gap into the roller.
When the roller is full, workers have to press the gripper on the handle.

The both side of the roller will push inside and the gap will become bigger.
Pour out the loose fruits thru the bigger gap into the basket.
The basket can be removed from the handle.

Concept 4

50cm

50cm

Top View

3D View

ADVANTAGES

DISADVANTAGES

Well separated
Fast collecting rate
Use less human power
Consumption high
High durability

Higher cost
Complex design
Heavy
Waste power
Hard to maintain

100cm

Front View

Side View

Ways to operated:

Run by motor.
Switch on the vacuum and suck all the loose fruits on the ground.
The loose fruits will follow the pathway into a cage.
There is a fan which runs together with the motor.
The fan blows away all the debris where the loose fruits will be trapped in the cage.
The cage can be taken out to collect the loose fruits.

7. CONCEPT SELECTION
7.2 Evaluation Matrix
Concept screening
Analysis of Concept:

No.

Concept 1

Concept 2

Concept 3

Concept 4

rating
+
+
0
0
+
+

rating
+
+
0
+
0
0
+
+
-

rating
+
+
+
+
+
+

Selection criterion

1
2
3
4
5
6
7
8
9
10

Easy to maneuver
Low cost
Durability
Light weight
Multifunction
High capacity
Move freely
Easy to maintain
Separator
High efficiency

rating
+
0
+
+
0
+
+
+
+

11

easy to operate

12

Simple
Sum +s

+
9

+
7

Sum 0s
Sum -s
Net score
Rank
Continue?
- = worse than

2
1
8
1
yes

0 = same as

2
6
-2
4
no

3
2
5
2
yes

6
0
3
no

+ = better than

Concept Scoring

NO

SELECTION

CRITERION

1
2
3
4
5
6
7
8
9
10
11
12

Easy to maneuver
Low cost
Durability
Light weight
Multifunction
High capacity
Move freely
Easy to maintain
Separator
High efficiency
easy to operate
Simple
Total score

Rate the concepts:

Relative performance
Much worse than reference
Worse than reference
Same as reference
Better than reference
Much better than reference

weight
5
5
5
3
1
3
5
3
4
5
4
5

CONCEPT 1
RATING
weighted
4
2
0
2
5
4
3
3
5
5
3
3
39

Rating
1
2
3
4
5

score
20
10
0
6
5
12
15
9
20
25
12
15
149
CHOSEN

CONCEPT 3
RATING
weighted
4
4
0
4
1
1
5
4
0
2
4
4
29

score
20
20
0
12
1
3
25
12
0
10
16
20
142

7.2 Final Conceptual Design

This is the final conceptual design that is chosen for the industrial project.

7.2 Final Conceptual Design

This is the final conceptual design that is chosen
for the industrial project. This design is taken
from the concept 1 as it got the highest point for
the concept screening and concept scoring. This
is
a
simple

concept with low cost, low

maintenance, and no need much skill
it.

handle

This loose fruit collector is design as shown in picture. Human power used to move this
machine onto the loose fruits.
Loose fruits are collected by going thru the gap into the roller. When the roller is almost
full, the roller can be lifted up along the pathway as shown in picture below.

Then the roller is turn vertically by the

handle and the loose fruits will drop on the
separator. The separator can be taken out
from behind to throw away the stones
which collected together.
Loose fruits without debris and stones go
thru the funnel and keep in a bag.

8. REFERNCES
Abdul-Shukor Abdullah (2006). Collaborative Learning Analysis In Mechanical
Engineering Design Project. Unisel, Malaysia.
Christie F.R; Sathianathan M. (2011). Improving the Environmental Sustainability and
the Export Competitiveness in the Food Sector: Case of the Malaysian palm oil
Industry.
http://www.uneca.org/fssdd/events/WorkshopTradeJan2011/Documents/asia/study
%20paper/Case%20study%20Palm%20oil%20Malaysia.pdf
General Information.
http://www.ipni.net/ppiweb/filelib.nsf/0/9BF9AC573FE5E3DB48256B49002F64E7/$file
/OP%20HB%20Mat%20p1-8.pdf
Nurulhuda Kasim (April 2009). Separation Technique of Crude Palm Oil at Clarification
Area via Optimum Parameters. http://umpir.ump.edu.my/862/1/Nurulhuda_Kasim.pdf
Sime Darby Plantation Sdn Bhd (March 2008). Bimonthly Publication, Loose Fruit VS
Lost Income, pp8.
http://www.simedarbyplantation.com/upload/Newsletter_March_2008.pdf

Solah Deraman; Rahim Shuib; Salleh Jaafar (June 2009). Roller-type Oil Palm Loose
Fruit Picker. http://palmoilis.mpob.gov.my/publications/TOT/TT-419.pdf
Wikipedia. http://en.wikipedia.org/wiki/Oil_palm