Professional Documents
Culture Documents
Mixer Shea Butter
Mixer Shea Butter
Mixer Shea Butter
Sponsors:
Shea Yeleen International Inc.
Mr. Larry Matthews
Faculty Advisor:
Dr. Camille George
Team Members:
Amber Beck
Nick Dalbec
James Zoss
School of Engineering
University of St. Thomas
May 2005
Abstract
The women in Mali, North Africa lack the efficient tools and education to develop a
better means of processing Shea butter products. The current processes are physically
exhausting and time demanding, taking several hours to complete. Women consume
their products as well as sell them at the local markets. Shea butter is becoming
internationally known as a skin care product used for moisturizing. In order to help
African women establish fair-trade Shea Yeleen International, a non-profit organization,
was founded. This project seeks to develop a better means of mixing using a manually
operated machine. After thoroughly researching, designing and experimenting, a final
machine was developed optimizing the mixing process. The mixing time was
successfully reduced form several hours to thirty minutes. All other engineering and
customer design requirements were met. Through the success of our design, Shea Yeleen
International will be able to disseminate the machine and hopefully help fight poverty in
Africa.
Table of Contents
I.
II.
III.
Project Background.3
IV.
Mission Statement4
V.
VI.
Project Management...8
VII.
Concept Generation...14
X.
Prototype Progression...17
XI.
Manufacturability..22
XII.
Testing Results...22
Conclusions.29
XVI. References...30
XVII. Appendices
Appendix A: Gantt Chart
Appendix B: Blade Concept Analysis
Appendix C: Scale Reduction Testing
Appendix D: Power Source Concept Analysis
Appendix E: Procedure/Assembly
Appendix F: CAD Drawings
Nick Dalbec
Manufacturing Prototype, Bill of Materials, Project Budget, Cost Analysis, Testing
Procedures
James Zoss
Computer Animated Design (CAD), Testing Procedures, Manufacturing, Prototype
Evaluation
The final product is going to Mali, North Africa and may also be used in other
African countries. With this in consideration, the final product has a target cost of $100
US or less.
The mixer design will be affordable and parts will be available from local
markets. There are basic hardware stores and machine shops in Mali, but prices vary
because of shop owner and customer bartering. The mixer will be manufactured from
commonly available materials and should not use a custom manufactured container.
Fabrication should be reasonably simple, using methods of cutting and welding that a
local Malian machine shop can perform.
There are few tools for everyday use, so assembly and maintenance must be
reasonable for a typical Malian in the local community. The machine will have minimal
moving parts. The simplicity of the design will allow for quick and simple repairs.
Machine drawings and instructions will be provided for Shea Yeleen International
contacts in Mali to enable local fabrication.
The container must be open so water can be easily added to the paste. The design
must use stainless steel or plastic to provide protection from corrosion. In order to
prevent contamination of product and mold growth, the machine will be easy to clean.
The mixer should not be damaged by environmental conditions, insects or other pests.
There will not be any toxic materials associated with the mixer, so it will not pose any
environmental threat to the people. The design will be safe for the user, with no sharp
edges exposed.
The mixer will be manually powered with the possibility of alternative forms of
power. The motion of the manual power source will be less physically exhausting then
the current processing. Current mixing processes take several hours to complete; the new
machine will reduce this time as much as possible.
Groups of Malian women will form cooperatives where they can have access to
the mixing machine. The machine shall produce enough Shea butter products for
personal consumption and to sell in local and international markets, thus providing an
opportunity to earn a regular source of income.
The mixer will improve oil extraction and increase the product inventory for the
local Malian women. This project should have a positive impact economically and
financially on the people of Mali. There will be culturally appropriate training materials
in French and Malian languages supplied along with the final design. Illustrations will
accompany the training materials to show operation techniques. The final design will be
sent to local Shea Yeleen International contacts to continue implementation of the
machine. Table 3 shows how the engineering requirements relate to the customer
requirements.
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Engineering Requirements
Local Materials
Non-Corrosive
Safe
Customer
Easy to Use
Requirements
Simple Design
Cost Effective
Quality Control
X
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Preliminary
Research
Experimenting
& Design
Blade Concept
Testing
Project Selection
Shea Nuts
Meet Team
Members
Prototype
Testing in
Mali
Horizontal Hand
Crank
List of Supplies
Hand Bicycle
Design
Travel to Mali
Final Design
Address Design
Issues
Other Methods of
Meet with Advisor Oil Extraction
Container Testing
Modify
Send out
Observed Current Procedures to
Processes
liaisons
Set-Up Schedule
Containers
Phase Test
On-Site Design
Testing in Village
Contact Liaisons
Blade Designs
Temperature
Analysis
Final Design
Adjust Machine
Purchase New
Parts
Shea Butter
Journal
Testing in Village
Nigerian Thesis
User Survey
Substitute Product
Material
4"x 4" x 10' Pine Post
2"x 12" x 10' Pine Board
1/4" Threaded Rod
5/8" Washers
1/4" Wing Nuts
2.75" Screws
1/20" Stainless Steel Sheet Metal
5/8" Round Stock Stainless Steel
3/8" Round Stock Mild Steel
5/8" Bronze Oil Impregnated Bushing
3/8" Bronze Oil Impregnated Bushing
3/8" Pulley (3 39/32" pitch)
5/8" Pulley (1 29/32" pitch)
60" V-Belt 3L
1/2" PVC Pipe (Handle)
Container
Quantity
1 pc
1 pc
7 ft
15 pcs
13 pcs
20 pcs
2 lbs
1 lbs
1 lbs
2 pcs
2 pcs
1 pc
1 pc
1 pc
1 pc
1 pc
Price/Unit
$9.19 ea.
$13.95 ea.
$0.23 /ft
$0.06 ea.
$0.13 ea.
$0.05 ea.
$2.00 /lb
$2.00 /lb
$0.40 /lb
$1.56 ea.
$0.47 ea.
$6.52 ea.
$3.62 ea.
$6.58 ea.
$0.15 ea.
$10.00 ea.
The overall cost per unit is under $70 US, which meets the design requirement of
$100 US.
10
The cost in Mali is under $50, but will vary depending on the village and
availability of parts.
Bill of Materials in Mali, Africa
Material
8cm x 8cm x 1m
8cm x 30cm x1m
1/4" Threaded Rod
5/8" Washers
1/4" Wing Nuts
2.75" Screws
1/20" Stainless Steel Sheet Metal
5/8" Round Stock Stainless Steel
3/8" Round Stock Mild Steel
5/8" Bronze Oil Impregnated Bushing
3/8" Bronze Oil Impregnated Bushing
3/8" Pulley (3 39/32" pitch)
5/8" Pulley (1 29/32" pitch)
60" V-Belt 3L
1/2" PVC Pipe (Handle)
Container
Quantity
3 pcs
3 pcs
2m
15 pcs
13 pcs
20 pcs
2 lbs
1 lbs
1 lbs
2 pcs
2 pcs
1 pc
1 pc
1 pc
1 pc
1 pc
Price/Unit
$1.70 ea.
$3.20 ea.
$1.80 /m
$0.04 ea.
$0.15 ea.
$0.07 ea.
$3.00 /lb
$3.00 /lb
$0.40 /lb
$1.00 ea.
$0.50 ea.
$2.10 ea.
$2.10 ea.
$5.00 ea.
$0.40 ea.
$3.00 ea.
Labor
Fabrication of Blades
Welding Blades
Fabrication of Handle
Hrs
0.35
0.25
0.15
$47.25
$US/hr
$3.00
$3.00
$3.00
Total
$1.05
$0.75
$0.45
$2.25
$49.50
On-site we were able to redesign and develop the machine using the tools and
materials locally available. Through purchasing items locally we were able to get an
accurate cost analysis of the machine and it was evident that our new design could be
manufactured in Mali.
While purchasing materials in Mali, it was apparent that items like wood, steel,
pulleys and belts were easily obtainable. These items were common and cost efficient.
11
Stainless steel was more difficult to find and more expensive to purchase, however
Professor Ouane at the Ecole Nationale dIngenieurs assured us that stainless steel can be
obtained at an affordable price. He also helped establish prices for non-regular items (i.e.
bushings, pulleys, belts, stainless steel). The design requirements of cost, non-corrosive
materials and safety were all met using the items discussed above.
The fabrication shop rates varied depending on if you were in the village or in the
city. The local craftsman determined his own price depending on the complexity and
demand for his labor. In the village, a local craftsman charged only 500CFA (about
$1.00) for welding, grinding, and re-work required of the blades and shaft for 20 minutes
of his time. Therefore, an average shop rate of $3/hr in Mali, Africa was calculated.
Labor
Associate Engineering Hours
Consulting Engineering Hours
Materials
Testing Medium
Laboratory Equipment Use
Steel
Fabrication
First Semester Total
Hours
Cost
440
35
$11,000.00
$1,750.00
$15.00
$100.00
$10.00
$25.00
$12,900.00
12
Labor
Associate Engineering Hours
Consulting Engineering Hours
Hours
Cost
390
25
$9,750.00
$1,250.00
Materials
Pulleys, Belts, Bushings
Screws, threaded rod, nuts washers
Lumber
Stainless Steel, Mild Steel
Container
$15.00
$5.00
$63.00
$97.00
$10.00
$11,190.00
Trip Costs
Labor
Associate Engineering Hours (in Africa)
Consulting Engineering Hours (in Africa)
Trip Planning Assoicate hours
Trip Planning Consulting hours
Plane Tickets, Hotels, Meals, transportation
Out of Pocket expense
Total Trip Expenses
Hours
Cost
252
80
60
25
$6,300.00
$4,000.00
$1,500.00
$1,250.00
$10,000.00
$1,500.00
$24,550.00
$48,640.00
Table 7: Budget
The first semester budget is broken down into two major parts: labor and
materials. The team consisted of four associated engineers, putting in ten hours a week
for eleven weeks. The salary was calculated at $25 per hour based on a $50,000 entrylevel engineer. Consulting hours consisted of Dr. George, Harry Gebbens, and contacts
from Shea Yeleen International. Their salary was estimated at $100,000 per year at $50
per hour.
13
The materials purchased first semester consisted of parts for fabrication and shop
tools used. All other parts and components used for experimenting were accounted for.
The total cost for first semester was: $12,900.
The second semester and J-term budget consisted of everything except the March
trip to Africa. Three associate engineers remained on the team after first semester.
During J-term only two associates were able to work on prototype development and
testing. Associate hours for J-term and second semester totaled 252 hours. The total cost
for second semester and J-term was: $11,190.
The trip to Mali contributed to almost half of our budget. Three engineers and
one consulting engineer (Dr. George) were considered as part of the trip cost (tickets,
hotels, food) at $2,500 per person. Other expenditures were accounted for such as: travel
agencies, booking fees, materials, translators and preparations for departure. A $500
travel fee paid by each of the three associated engineers was also included in the budget
report. The total cost for the trip to Mali was: $24,550. The project total throughout the
entire year totaled to $48,640.
14
mixer was separated into three main components: blades, container, and power
source/transmission.
15
Hand Crank
The hand crank consists of an offset vertical shaft directly connected to the blade
via a horizontal link. It is a simple and effective way of rotating the shaft. One problem
is that it can be quite difficult to rotate the shaft.
Hand Bicycle
This idea was originally derived from a standard bicycle drive system. The
concept was adapted to a hand powered style to accommodate for the preferred range of
motion for the Malian women. The hand bicycle concept is composed of two handles on
opposite sides that rotate horizontally around a fixed point. A gear or pulley is placed
between these handles for the accompanying transmission of power. A gear ratio can
easily be applied to reduce the amount of energy required to turn the crank. This power
source can be manufactured simply through then bending of round bar. A person could
use one or both handles for manual power, or two people could use the opposing handle
to combine their efforts.
Transmission Concepts
The first concept was to use a set of bevel gears to transfer rotation of two shafts.
This concept can be seen in many mechanical systems. This idea was mainly thought of
by the examination of differentials in automobiles. Bevel gears are a very effective way
of transferring power however, they can also be costly. This concept was discarded.
The next transmission idea was that of a twisted belt around two perpendicular
shafts. This was an idea seen by the examination of vacuum cleaner transmission. Since
16
this concept is an effective way to transfer motion while still being cost effective, it was
selected to be used as a transmission.
Container Concepts
The concepts for a container came down to two different options; a plastic bucket
or a hand made bucket. One successful shea butter processing method in Ghana uses a
hexagonal container for shea butter mixing. Our contact claims that it is the hexagonal
shape of the container that is vital for the oil extraction4. The container is custom-made
out of stainless steel in order remain non-corrosive. Stainless steel is expensive and to
manufacture a hand made container would not be as simple as buying a plastic one.
Therefore, after results of testing revealed that that oil could in fact be extracted without
the hexagonal design, we selected the plastic container. This is explained more
thoroughly in the Testing section and in Appendix C.
X. Prototype Progression
From the different experiments and proof of concept studies performed, the
plastic bucket, angled asymmetrical blades, and a horizontal bicycle style hand crank
with a twisted belt transmission were the options chosen for our machine prototype.
Materials selected for the initial prototype were based upon the implied availability and
manufacturing capabilities in Africa. The machine developed on-site in Mali used
materials and manufacturing techniques found in local markets.
Failure with our second prototype during the initial testing phase in Mali proved
to be greatly beneficial for our product development.
17
Prototype Progression:
1st Prototype
Qualities:
Problems:
Difficult to turn.
2nd Prototype
Qualities:
Twisted belt.
18
Problems:
Very unstable.
3rd Prototype
Qualities:
One-handed crank.
Problems:
19
4th Prototype
Qualities:
Problems:
5th Prototype
Qualities:
20
Single piece of metal with slot used for vertical tension bars.
Drilled a hole in the post for tensioning bar and added a wing nut and washer
eliminating the need for a vice grip.
Problems:
To produce the slot in the single piece of metal used to clamp down the container
may be difficult.
21
XI. Manufacturability
With limited availability of shop tools in the village, the final design of the
mixing machine requires minimal tools necessary for assembly. Wing-nuts are used to
reduce the need for special tools in assembling the machine. All other parts are either
hand-drilled or hand-tightened further eliminating the need for expensive tools. Screws
are used to secure wood fixtures and a screw-driver set was left in the village to ensure
the local Malians would have adequate tools for manufacturing the machine. Cutting
wood, drilling holes and alignment of parts were all done effortlessly by the local
Malians.
Welding will be completed by the local craftsmen. Working with the craftsman in
Mali, it was evident that his capabilities and skills were exceptional for the work required
to manufacture the blade assembly. Any failures or problems resulting from daily use of
the machine will be easily maintained and fixed in Mali.
22
Design 1
1st Prototype
Africa
Test
Location
Environment
Conditions (in shade)
94.8 degrees F
Quantity of Shea
Paste (approx.)
10 pounds of paste
Time
(min.) Paste Temp
Paste Appearance
0
Oily, no foam present
90.6
5
92
Removed container/blades
from the base. Instability
was laborious. Attached
hand crank directly to
92.1
blades and continued the
experiment. Took
observations of container
and blade design.
10
20
89.5
25
Notice Oil in water
30
35
45
50
60
70
User Comments
88
The first prototype test was unstable and frustrating. We removed the pulley
transmission and attached a hand drill to the shaft of the blades to continue testing the
blade. Although the machine lacked significant stability control and was tiring for the
woman, it proved the blade configuration was successful for extracting oil.
23
The machine design for the second test was significantly improved. The design
was simple, the range of motion was comfortable and the features of a hand crank were
more desirable. Successful results were obtained after just 58 minutes of mixing the
paste.
D esign 2
B am ako Prototype
Africa
Test
Location
Environment
Conditions (in shade)
Quantity of Shea
Paste (approx.)
96 degrees F
D id not take tem p. readings of paste,
previous testing showed little to no
significant changes in paste tem p.
T ested with 10 lbs. of paste
T im e
0
5
10
20
25
30
35
45
50
55
58
User Comments
Paste Appearance
O ily and m ore viscous
com pared to test one
24
The third test was conducted back at St. Thomas with our final redesigned
machine based off comments made by the local woman. After simulating the Malian
environment in a room at 85 degrees Fahrenheit, successful oil extraction was obtained
after just 30minutes of mixing.
Design 3
Final Design
United States
Test
Location
Environment
Conditions (in shade)
Quantity of Shea
Paste (approx.)
85 degrees F
Time
0
5
10
20
25
30
User Comments
Paste Appearance
Warm water was added to the
paste approximately 1:1 ratio
paste to water. From Nigerian
studies and experience in
Africa we knew to add warm
water (94 degrees) Results of
Nigerian studies showed 3
parts water, but after adding
one part to our paste we
decided it would be best not to
begin with that much. There
was not a lot of paste to start
with. After 10 minutes paste
temp. was 84.6
African water drip test, WE
COULD SEE OIL!!!
Added more water
Successful white
foam extraction!
25
120
110
Temperature (F)
100
90
80
70
60
50
0
200
400
600
800
1000
1200
1400
1600
1800
Time (Seconds)
26
2000
27
The cost of the mixer meets the requirement at approximately $50.00 (in Mali).
All parts in contact with shea paste are made of stainless steel or plastic.
The mixer can accommodate many different sized containers. The use of a wide
container allows for easy access to the paste.
Benefits/Features
The final design was intended to be flexible and easy to use. The most complex piece
of the design is the blades, which consists of three different lengths of stainless steel, all
8mm wide. They are welded onto the shaft at a 45 degree angle. Fabrication of the blade
design is within the production capabilities of villages. Other parts for the machine are
available in local markets. The design is adjustable so that different container sizes can
be used. Since the setup/disassembly of the mixer requires no tools, it is easy to use and
28
clean. Mixing time is greatly reduced and the larger bucket allows for greater batch sizes
of shea butter to be produced.
XV. Conclusions
Through research and experimentation the Mali Mixer team was able to develop a
successful prototype. Using feedback from the Malian women was vital for the final
design. User comfort was kept in mind for ease of use, range of motion, and the location
of the power source. The manually powered machine met all customer and engineering
design requirements. Using the mixer, the women in Mali were able to produce twice as
much shea butter with little to no physical strain. The final design was able to extract oil
in 30 minutes, greatly reducing the average mixing time. With reduced mixing time,
reduced physical strain and an increase in batch size, production of shea butter products
will increase.
The Mali Mixer team is optimistic for the future of this project. Shea Yeleen
International (SYI) will be able to disseminate the machine and educate the local village
women in how to form cooperatives and establish fair-trade. Using the assembly
instructions and drawings provided, SYI contacts will be able to teach people how to
build, maintain, and optimize production from the machine. With the increase of shea
butter production in the villages, women will be able to sell their products and create
more income for themselves. As SYI begins working with more and more women in
Mali, the establishment of fair-trade and the fight against poverty will be set in motion.
29
XVI. References
1. Wright, Rahama; Shea Yeleen International. 280 Madison Avenue,
Suite 912, New York, NY 10016. rahamatuwright@yahoo.com
(2004).
2. http://sheabutter.web.aplus.net/id10.html (Oct. 2004).
3. http://www.un.org/ecosocdev/geninfo/afrec/vol15no4/154shea.htm
(Oct. 2004).
4. Akuete, Eugenia; motherakuete@hotmail.com (Dec. 2004).
5. http://www.weather.com (Jan. 2005).
6. Olaoye, Joshua. Oil Recovery Process From Shea Butter Seed
Through Modified Clarification. Thesis: April 1994.
7. Olaoye, J.O. and Babatunde O.O.; Development and Testing of a
Milled Shea Nut Mixer. Journal Food Science Technology, Vol. 38
N. 5 pp. 471-475, 2001.
30
XVII. Appendices
ii
iii
iv
ri c
et
al
ic
el
H
ol
lo
lo
sy
/ In
se
rt
al
la
B
d
ol
H
ng
le
A
id
de
s
r ic
et
et
m
Sy
m
sy
A
So
l
lid
So
ei
gh
t
Pe
r
ce
nt
ri c
al
al
prototype designs.
Manufacturing Ability
17
Cost
18.5
Torque Required
12
Mixing Efficiency
22.5
Maintenance Required
12.5
Safety
17.5
Total:
Weighted Total:
100
5
5
4
5
29
29
22
21
4.88 4.775 3.605 3.555
Description
Scale
Measure by time
and tools necessary
to manufacture
5 Easy -> 1 Difficult
Material Cost and
Labor involved
5 Cheap -> 1 Costly
Measure the time it
takes to mix
5 Easy (less torque) ->
efficeintly
1 Hard more torque)
How long it took to 5 Thoroughly -> 1 Not
mix thoroughly
Thorough
5 Little to none
maintenance- > 1
How easy is it to
High Maintenance
clean parts?
vi
The blades have the most influence in fulfilling the requirements of efficiency and
product quality in our design. During the mixing process, the blades are in direct contact
with the Shea paste. As the blades mix water into the paste, they induce the separation of
oil.
The first step in developing blade proof of concepts was to research different
types of blades from existing technology. One project liaison is a Peace Corps volunteer
named Rahama Wright. Rahama lived in Mali for over three years and while there she
produced a video of the traditional production of Shea Butter. The information obtained
from Rahama provided a foundation for research and helped aid in defining the customer
requirements.
The video of the Malian women processing the shea paste provided a blueprint for
the mechanical mixer. In the current process, the women sit hunched over mixing in a
manner similar to kneading bread dough. Their hands are immersed in the viscous Shea
paste. Occasionally water gets added to the paste, interrupting the mixing process.
Figure 1 depicts the traditional kneading process in Mali.
vii
With the motion of the Malian womens hand movement in mind, other mixing
methods were looked into for similarities. The proven mixing systems that were
researched were an ice cream mixer and a butter churn. Ice cream mixers gently mix to
keep the fluid content homogenized. This motion prevents large ice crystals from
forming while gradually extracting heat and freezing the cream. The project liaison
suggested an old-fashioned butter churn because the Malians are familiar with the motion
required for churning. Through research it was found that butter churns are simple in
design and provide agitation to dairy fluids. One butter churn was found online that had
a solid paddle blade mounted on a vertical shaft with a hand crank. This blade design
was also observed in a few of the ice cream makers and seemed simple to recreate.
Industrial mixer manufacturers were also researched. One industrial mixer for
viscous fluids employed an auger blade that rotated axially. It was diagonally mounted
on an arm that rotated the auger along side of the container. All industrial mixers were
extremely expensive and complex, most with multi-axial blades. Even though the
complexity of these mixers was out of production capabilities the auger idea seemed like
a plausible concept. It not only provided transaxial fluid movement but also axial.
Another group of industrial mixers had a propeller design with blades mounted
diagonally onto their rotating shafts. As with the helical blade, this design induced an
axial flow of fluid like an airplane propeller.
Kitchen mixers were also researched. Most electrical kitchen mixers
manufactured by companies such as KitchenAid, CuisineArt, and Bosch came with three
different blades: a whisk, a dough hook, and a heart shaped hollow blade. Whisks are
designed for non-viscous fluids such as eggs. However, Shea paste is too thick and
viii
viscous to mix with a whisk. The dough hook was considered but it did not fit the
appropriate application. Shea Butter mixing must accomplish a range of viscosity that
starts as a thick paste and ends as a fluid. The final fluid is similar to the consistency of a
milk shake. The heart shaped hollow blade, which was made for medium viscosity
ranges like pancake dough, seemed applicable to the project. This blade looked like an
outline of a leaf made out of bent extruded bar stock.
With further research, the ideas from different types of mixers were put together
and modified to the project. As a result, five proof of concept blades were fabricated:
helical, solid symmetrical, solid asymmetrical, angled, and the hollow asymmetrical
blade.
All proof of concept blades were made out of welded steel because it proved
quick to assemble and made a durable product. All blades have a solid 16mm diameter
shaft that fits into the mounting apparatus in the same manner.
Helical Blade
This blade proof of concept was created to simulate an auger. The helical blade
(Figure 2-A) has 15 individual whisk blades, each 117mm long and 6.4mm diameter.
They were then welded onto the main shaft in a helical formation with approximately an
inch of separation.
ix
Figure 2-B:
Symmetrical Blade
Figure 2-C:
Asymmetrical Blade
Angled Blade
This blade proof of concept was created to model the industrial mixer propeller
design. The angled blade (Figure 2-D) used three individual blades that measured
102mm x 76mm x 2.75mm thick steel sheet metal first welded onto rebar 101mm in
length by 13.6mm diameter. They were then welded onto the main shaft.
Hollow Blade
This blade proof of concept was created to model blade designs of kitchen mixers.
The hollow blade (Figure 2-E) was fabricated with welded sections of rebar resulting in a
U-shape design 123mm on length and 115mm in height. Four of these U-shaped rebar
were then welded asymmetrically onto the main shaft.
Testing Procedures
Shea paste is necessary for testing the mixing process of our machine. This Nut is
only found in West Africa and is very difficult to get overseas. In order to begin proof of
concept testing, a substitute product was required.
Through research it was determined that peanut butter would be the best substitute
for Shea paste. The process of making peanut butter is very similar to making Shea
Butter. The main difference is that when making peanut butter the process stops at the
grinding stages. The goal is to keep the oils in peanut butter, not extract them. One of
the project contacts who had worked with Shea Butter also said that the viscosity of
peanut butter felt the most like that of Shea paste. The problem with peanut butter is that
it is very expensive.
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In order to keep the cost down, it was decided to use a mixture of flour and water
for the proof of concept testing. The testing looked for differences in the mixing based
on blade design. While it was understood that viscosity would play a factor in the final
product, the group chose to simply examine the differences in mixing with the current
procedure in order to get a better understanding of mixing processes in general.
The testing of the blades was first done by creating a mixture of flour and water.
The mixture used was a ratio of 4.52 kg of flour with 7.25 L of water. The flour and
water was then mixed by kneading until a uniform consistency was achieved. This
mixture had a similar consistency to that of pancake batter. A consistency resembling
that of peanut butter (viscosity of 1290 kg/m3) was originally desired to simulate the Shea
paste. Density figures were unavailable for Shea paste. Because flour has an ability to
compact, an accurate density was difficult to obtain. The final mixture ratio of flour and
water was determined by inspection.
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Testing Procedure
Required Equipment
1. Container ( circular or hexagonal)
2. 250g of Shea Paste
3. Water bath basin
4. 2 stands
5. General Signal Lightnin mixer
6. Poly Science water heater
7. blade shaft
8. 800 ml beaker
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Procedure
1. Place Poly Science water heater into water bath filled with water.
2. Set water heater to heat to 35 C.
3. Place Shea paste into container, and place container into water bath.
4. Attach blade shaft to mixer and place shaft into container so that the end of
the shaft is centered and not touching the bottom of the container, then fasten
mixer to stand.
5. Place space heater about 2 feet away from water bath set-up and turn on to
800 watts setting and a medium temperature.
6. Allow paste to heat to 27 C
7. Set mixer to mix at 60 rpm
8. Add 4 tablespoons of water to paste, and begin mixing; record paste
temperature, air temp, and wattage being used by the mixer.
9. Add 1 tablespoon of water to paste every minute for 3 minutes.
10. At t = 10 minutes, add 2 tablespoons of water, record data.
11. At t = 15 minutes, add 1 tablespoon of water, record data.
12. At t = 20 minutes, add 2 tablespoons of water, record data.
13. Monitor paste and add 1 to 2 tablespoons of water as needed. Record data
every 5 minutes.
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14. Remove oil from top as needed and place into separate container.
From this testing, we were able to see that oil separation was able to occur in
circular containers, and that the asymmetric angled bladed extracted this oil in the
shortest amount of time.
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are prevalent, however there is no method for recycling them, and their disposal often
leads to the contamination of ground water.
A concept hand crank was made using steel tubing, wood, copper bushings and a
length of galvanized pipe. A handle made of flat steel plate and a round steel bar was
connected to the galvanized pipe. The galvanized pipe was bored out to allow it to fit
over the blade shaft. A hole was drilled into the pipe as well as each shaft and the shaft
and pipe were attached using a pin. This allowed for the rotation of the handle to be
transmitted to the blade shaft. This concept hand crank can be seen in Figure 1.
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required to turn the blade was consistent. Five blade designs were tested using this
method.
Test Results
Based off of test procedures and methods used, calculations were made to
determine the best results of the power source alternatives. Four power sources were
considered and compared based on given design requirements. The hand crank was the
only power source constructed due to time constraints and current manufacturability.
The power source alternatives were evaluated using the design requirements given
by the client. In addition, engineering requirements were added to evaluate overall
performance. Each one was weighted according to its contribution as a power source.
Torque required was our main focus, weighted at 22.5%, followed by cost, reliability,
manufacturability and maintenance required.
Each power source was scored based on its performance in each of design
requirement fields. A score of five was the best option available for the given category.
The data was compiled and the power source design rankings were compared. Three
designs stood out as plausible options. The hand crank, hand bicycle, and treadle
receiving 3.47, 3.395, and 3.36 respectively were top choices. The treadle design was
ruled out due to inconsistent information from several primary sources as to availability
of materials. The two other designs will be pursued in future prototypes.
The primary concern when choosing a power source is the transmission required
to rotate a shaft for the blades. A 90-degree rotational shift from one plane to another
could prove prohibitively expensive. A beveled gear could make the transformation but
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would also add to the cost of the design. Further investigation for a twisted v-belt to
B
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bu
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Manufacturing Ability
13.5
Cost
16.5
Torque Required
22.5
Maintenance Required
13.5
Safety
Reliability
Functionality
9.5
13.5
11
100
2
25
3
24
3
23
Total:
Weighted Total:
Description
Scale
Measure by time and tools
5 Easy -> 1 Difficult
5 necessary to manufacture
Material Cost and Labor
involved
1
5 Cheap -> 1 Costly
Measure the time it takes to
5 Easy (less torque) -> 1 Hard
mix efficiently
more torque)
5
5 Little to none maintenance- > 1
High Maintenance
2 How easy is it to clean parts?
How dangerous are the parts
5 good -> 1 no good (moving
parts)
1 involved?
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Appendix E: Procedure/Assembly
MATERIALS
Wood/Lumber
5cm x 30cm
8cm x 8cm
Nuts/Washers/Screws/Threaded Rod
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Threaded rod
*The Diameter of Rod Determines Wing-Nut size, washer size, holes to drill
4 - 0.635cm diameter threaded rod 50cm (length)
1 0.635cm diameter threaded rod 30cm (length)
Wing Nuts
Washers
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Screws
Metal
Stainless steel
Steel
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Pulleys/Belt/Bushings
Pulleys
*Must be able to find belt to fit pulleys. Also, shafts from above section must fit through
hole in pulley and must be able to lock to shafts
1 Pulley approximately 10cm in Diameter with 1cm shaft able to slide through it
1 Pulley approximately 5cm in Diameter (half the size of other pulley) with 1.5cm
shaft able to slide through it
Belt
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Bushings or Bearing
*Shaft Diameter is important to match. Outside Diameter is not crucial but will need Drill
Bit to match size
TOOLS
1 Dill
1 Screw driver
1 Hammer
1 Welder
Various Drill bit Sizes
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STEPS
*Container purchased will minimally affect design. Slight modifications will need to be
made with container obtained.
Blades
3 blades will need to be cut from the stainless steel sheet metal.
1) Measure container to determine radius at the bottom, middle, and top of container.
These will determine how long your blades will be.
2) First blade will be 2cm shorter than radius at bottom of container by 8cm wide. (It
will be 2cm shorter due to width of shaft attaching it to and human error)
3) Second blade will be again 2cm shorter than middle radius of the container by
8cm wide.
4) Third blade will be 2cm shorter than top radius of container by 8cm wide.
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Handle
1) Take shaft approximately 1cm Diameter x 50cm (length) and make marks at
15cm and 35cm. Bend shaft at 15cm mark 90degrees then 90degrees opposite
direction at 35cm so it looks like:
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Post Handle
1) Take 8cm x 8cm x 100cm (length) and measure 25cm from one end and 4cm in
from side to find center of hole to drill
2) Drill a hole at mark using drill bit that is the same size as the outside diameter of
the Bushing with Shaft Diameter of 1cm
3) Press the 2 Bushing with Shaft Diameter of 1cm into the wood.
4) Slide handle through
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Top Table
1) Take the 5cm x 30cm x 100cm (length) draw a line down center of the board
2) Measure 4cm from each side of line and draw a line whole length of the board.
Again measure from the centerline 4cm PLUS the diameter of the threaded rod to
both sides of center line.
3) Find center of board and measure out the top radius of the container from the
center. Measure 2cm in from this distance and 8cm out from this distance,
creating an approximately 1cm x 10cm(length) slot. These will be your slots to
make it adjustable to containers needs.
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Container Post
1) Take the 8cm x 8cm x 100(length) and place it on top of your container. Cut it to
size but allowing 15cm over hang on one end and about 20cm on other. Find
center of container on 8cm x 8cm post and mark it.
2) Drill a hole at mark using drill bit that is the same size as the outside diameter of
the Bushing with Shaft Diameter of 1.5cm
3) Press the 2 Bushing with Shaft Diameter of 1.5cm into the wood.
4) Slide blade shaft through bushings.
5) Cut out a section of the post 2cm deep by 25cm long from the end that over hangs
the bucket by 20cm.
6) Next drill a hole 30cm deep (or as deep as you can) and the same diameter as the
threaded rod in the end of 8cm x 8cm post on the end that over hangs on the
bucket 20cm. This act as a belt tensioner later.
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Anchoring Plate
1) Cut/grind slots 0.635cm wide (size of threaded rod) in anchoring plates as
follows.
Assembly
1) Take the 5cm x 30cm x 100cm (length) board and attach with screws the four
8cm x 8cm x 30cm (length) posts to the corners.
2) Attach with screws the 5cm x 30cm x 200cm (length) board to step one as such.
3) Attach Handle post off center in front of top table with screws
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4) Attach the other 8cm x 8cm x 100cm (length) with screws and cut to appropriate
length and cut ends on angle accordingly.
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