Bicol University

College Of Engineering
Legazpi City

Design, Fabrication and Testing of Rotary Bladed Pili Nut Cracking

Machine

Presented to the faculty of the

Department of Mechanical Engineering

In Partial Fulfillment of the Requirements for the Degree of

Bachelor of Science in Mechanical Engineering

Presented by:

Alvarado, Nathanielle
Cristo, Emmanuel R.
Layson, Alexander Ian R.
Miraballes, Clent John G.

March 2018

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 CHAPTER 1

BACKGROUND OF THE STUDY

This section presents the information about the project study–its

objectives, importance, limitations and cost estimates of assembly. This is

divided into four (5) sub-sections - introduction; statement of the problem;

objectives; scope and delimitation of the study; and significance of the study.

Introduction

Pili (Canarium ovatum Engl.) is one of the twenty major fruit crops of the

Philippines which deserve to be developed. It is the crop which the country

produces with greatest advantage and competitiveness on a global scale

(Orolfo, 2000). Historical accounts on this crop attests that the Philippines is the

only country which produce and process pili in commercial quantity (De Padua

et al, 1978) such that we have the monopoly of the foreign market (Coronel,

1990). The export potential of pilinuts and pilinut processed products is high

(Orolfo, 2000). Pilinut is considered superior to almond (West, 1993).

Processed delicacies of the kernel are very delicious and easily appeal to

consumers, even among foreigners. In fact, according to Lanuza (1970) the

Philippines had been exporting pilinut to several countries since pre-war years.

In 1997 the country exported 3,970 kilos of processed pilinuts to Australia and

Guam (Coronel, 1990). It is produced in at least 6 regions namely: Bicol,

Eastern Visayas, Southern Tagalog, Caraga, Western Visayas and Southern

Mindanao (Orolfo, 2000).

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 In Bicol, pili plays a significant role in the economy. It provides additional

income to some 13,435 farmers who own at least 10 trees and farm laborers

hired as harvesters (Benchmark survey, 1998). In 1996 the Bureau of

Agricultural Statistics estimated the area at 1,218 hectares throughout the

country with Bicol having the biggest area of 968 ha. (79.47%). Eastern Visayas

is a poor second with 139 has. (11.41%), Southern Tagalog 72 has. (5.9%),

Western Visayas 26 has. (2.13%) Caraga and Southern Mindanao 13 ha.

(1.07%).In Bicol Sorsogon has the biggest area devoted to pili with 669

hectares followed by Albay 145 hectares, Camarines Sur 100 hectares,

Camarines Norte 50 hectares and Catanduanes 4 hectares (Orolfo, 2000).

Bicol is the major producer of pili with a share of 57% of the domestic

production. In 1998, the regional production was estimated at approximately

9,007 MT. Of the 6 provinces Albay has the highest output with 3,549 MT (40%),

followed by Sorsogon with 3,001 MT (33%) and Camarines Sur with 1,207 MT

(13%) (Orolfo, 2000).

Because all of its parts have immense use for man, the Pili tree is fast

gaining fame as the “tree of life”, next to the coconut tree (DENR, 2017). The

pulp of Pili is used as vegetable, pickle, flour, puree, sauce, and feeds for swine.

The resin is used as lacquer, varnish adhesive, and manila elemi. The trunk is

made into furniture and wood panels. The shell is used as fuel, growing medium

for orchids and anthuriums, and crafted as fashion accessories. (Pinoy Bisnes,

2010). It’s kernel or the pili nut itself when roasted and ground is used as

ingredients for ice cream, salads, puddings, toppings for cakes, bread, pastries,

confectioneries and other delicacies like marzipan, fruit-cereal bar, fruit and nut

mix, chocolate –making and can be eaten raw or processed as roasted, fixated

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or sugar-coated and is served in the same way as cashew or almond, or

peanuts and as oil in the manufacture of sardines, salad dressings, cakes and

food preparations, as well as soaps, pharmaceuticals and cosmetics

(BusinessDiaryPh.,2017). With the various uses of its shell and kernel, there is

no doubt that pili is considered a high-value commercial crop.

However, although the pili processing industry has been sustained

through the years it remained as a cottage industry and family oriented. In the

benchmark survey conducted by BCARRD (1998) and DA (1999) the following

constraints were identified (1) unavailability of superior quality planting

materials (2) limited institutional support on production development, (3) lack of

pili nut supply, (4) Poor marketing systems, (5) unavailability of cost saving

post-harvest and processing facilities, (6) high cost of transportation, (7) drastic

fluctuation in prices and (8) lack or absence of appropriate credit support to

farmer producers (Orolfo, 2000).

In the effort of trying to aid the problem on the lack of cost saving post-

harvest and processing facilities, this study is given birth. The study is

conducted to design, fabricate and test the performance of the machine called

“Rotary Bladed Pili Nut Cracking Machine”- a device that would offer lesser

human intervention and would make the Pili nut cracking process easier. This

machine will be designed specifically to crack the nut shell leaving the kernel

whole.

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Statement of the Problem

The researchers aim to design and fabricate a rotary bladed machine to

crack Pili nut shell leaving its kernel whole. This study intends to increase the

rate of cracking process of Pili nut while securing quality shape of the kernel.

The research sought answers to the following questions:

1. What is the form and set-up of the rotary blades of the Pili Nut

Cracking Machine, so the shelled pili nut can be machine cracked

without damaging its kernel?

2. What is the performance of the Rotary Bladed Pili Nut Cracking

Machine in terms of the following:

a. Cracking rate

b. Cracking efficiency

c. Whole kernel recovery percentage

3. What is the economics of the machine?

Objectives

This undergraduate thesis aims the following:

1. To form a rotary blade so the shelled pili nut can be machine cracked

without damaging its kernel?

2. To assess the performance of the Rotary Bladed Pili Nut Cracking

Machine in terms of cracking rate, cracking efficiency, and whole kernel

recovery.

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 3. To evaluate the acceptability of the machine in terms of its first cost and

operational cost.

Scope and Delimitation of the Study

Henceforth, these are the scope of the research study:

1. Design and fabrication of the cracking machine with multiple

customized blades attached to two rotating shafts.

2. Data gathering and performance testing of the machine.

However, the study is delimited to the following:

1. Design and fabrication of kernel and shell separator.

2. Performance testing in pili nuts with different moisture content.

Significance of the Study

The result of the study is deemed significant to the following:

1. Entrepreneurs. Business people who are wired in the pili nut

processing whether macro or a cottage industry can boost the venture

through increased output and fast production.

2. Pili nut tree cultivators. Increase in production means that there will

be a subsequent increase in the demand of raw pili nut, hence, the

cultivators can expect a higher return of investment.

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3. Local farmers. In the event of some enlargement of the farm for Pili

nut tree, more local farmers are needed to maintain the farm.

4. Bicol Region economy. Since Bicol is the top region in the cultivation

of Pili nut tree and production of Pili nut products, once the industry is

boosted to reach more international market it can likewise boost the

economy of the region especially when the proposed imperialism form

of government is approved in the Philippine.

5. Future researchers. This study has a great potential that can lead a

breakthrough in Pili nut industry, however, a more detailed and

engineered innovation is needed. This study can jump-start them in their

work for future innovations and improvements.

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 CHAPTER 2

REVIEW OF RELATED STUDIES AND LITERATURE

This section presents the linked works, studies and ideas in

regards with the project study. This is divided into seven (7) sub-sections -

related literature; related studies; synthesis of the state-of-the-art; gaps in

literature; theoretical framework; conceptual framework; and, definition of

terms.

Related Literature

In achieving an efficient design of the mechanical cracker, the

researchers gathered some related literatures and studies to have a clearer

understanding of Pili and to compare whether this design of Pili nut cracking

machine could be an ideal design for a Pili nut processing industry. These

studies can also suggest some improvements if needed to the existing

products.

Pili and Pili Products

Canarium ovatum Engl., or commonly known as pili is a crop well known

in the localities of Bicol that has a major potential as an export product. It has a

wide adaptation to varying agro-climatic conditions. It can be grown alone or

intercropped with other crops. And like the coconut, another tree well known to

the Bicol region, Pili is also referred to as a tree of life, for the reason being that

all its parts are being used in several industries. It thrives satisfactorily in

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marginal soil conditions, harsh tropical climates and in low as well as high

elevation. It is resistant to typhoons and most pests. The tree reaches a height

of about 20 to 25 meters and a diameter of about a meter or two. The following

are the different parts of pili and some of its uses:

• Kernel

o When roasted and ground, it is used as ingredients

for ice cream, salads, puddings, toppings for cakes,

bread, pastries, confectioneries and other

delicacies like marzipan, fruit-cereal bar, fruit and

nut mix, chocolate -making; can be eaten raw or

processed as roasted, fixated or sugar-coated and

is served in the same way as cashew or almond, or

peanuts.

o As oil (manufacture of sardines, salad dressings,

cakes and food preparations, as well as soaps,

pharmaceuticals and cosmetics);

• Pulp

o Vegetable dishes, pickle, oil (for cooking and

lighting), feeds for cattle and swine.

• Shells

o As crafts, charcoal, firewood and combining

medium for growing orchids and anthuriums; oil

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 tests as combining material with compost and for

dyes;

• Trunks and Branches

o Trunk produces a resinous substance commercially

known as “Manila elemi”, a valuable material in the

preparation of varnishes and lacquers.

o A volatile oil extracted from the trunk is used for

numerous purposes and can be a substitute for

turpentine.

o The wood is characterized by fine straited grains

making it very ideal for the manufacture of high

quality furniture, wood panels, carved doors and

other wooden products.

o Resin-rich wood makes an excellent firewood

o The tree sap is an abundant source of natural

resins, essential oils, and possibly, insect repellant.

• Leaves

o As salads and relishes;

• Tree

o Described as “majestic tree” makes it an ideal tree

for lining avenues, border or lawn tree, developing

parks, subdivisions and golf courses. It is an

evergreen tree with evenly spreading leaves

making it an excellent shade tree and windbreaker

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 because it does not shed its leaves, shade for other

crops such as abaca, coffee, cacao, bananas,

papayas; agroforestry; its undergrowth is clean and

shady year-round.

Postharvest Management

After harvesting pili, the fruit undergoes several steps to extract different

parts of the fruit for different target market. The first step, being pulp removal

has four methods that is currently being practiced: (a) hot water treatment

(HWT) wherein the temperature of the water, where the fruit is soaked for 15 –

30 mins. before draining, is elevated to 60°-70°C. (b) pounding using a wooden

mallet (c) Retting method which is commonly used in the commercial scale

depulping of pili where the fruit is soaked for 1 – 2 days until the pulp softens,

and lastly (d) is the fermentation method which requires that the fruit is kept in

sacks of polyethylene bag and left from 1-2 days under shade to soften pulp.

The pulp softens because of the moisture and higher temperature inside the

sack.[1] After pulp extraction, the depulped fruit is then washed and dried to

remove the slimy material adhering to the shell. This phase is where the nuts

that are unfilled or devoid of a kernel is screened, if during the washing part the

nuts float in water they are discarded for that reason. After washing, nuts are

dried under full sun for 2-3 days sufficient enough for pili nuts to be stored for

at least a year. Nuts should not be dried for more than three days to avoid

shriveling of kernels. During cloudy days, nuts may be dried longer for about 4-

5 days.

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Storage and De-Shelling of Pili

Pili nuts can be stored either shelled or unshelled. Most processors place

the nuts in clean sacks which have a capacity of about 50kg. Stack sacks in

pallets and store in a well-aerated room. Sacks should not be in contact with

the walls of the storage house to prevent contact with any moisture. A regular

inspection prevents rat and insect infestation. Indigenous materials such as

cardboard boxes are more durable and result in lowest number of rancid and

shriveled kernels after a year of storage. Kernel is extracted manually. Cut the

shell crosswise at the middle portion with the use of a sharp bolo. After cutting

the shell in two, remove the kernel carefully and place in a clean collection box

or plastic basin. Great care and skill are required, and the cutting stroke should

be controlled to prevent cutting through the kernels.

Economics of Pili Products

According to the Philippine Statistics Authority, the cost of pili nut

production averaged 35,589 Php per hectare. With an average yield of 3218

kilogram per hectare in 2015, gross reciepts amounted to 125, 985 pesos. The

return of a single hectare’s worth is 99, 173 pesos upon deduction of cash and

non-cash costs. Per kg cost were 11.06 pesos while selling price of farmers

were 39.15 pesos during the year previously referred to. With these figures,

farmers had realized that with the great amount of return, investing in pili nut is

a wise choice.

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Physical and Mechanical Properties of Pili Nut

In a master’s thesis conducted by Gallego, R.B. et al. entitled Some

Physical and Mechanical Properties of Pili (Canarium ovatum Engl. cv.

Katutubo) Nut as a function of Nut Moisture Content, they had expressed the

mechanical strength required for the pili shell to be fractured using the UTM

(Universal Testing Machine). They had identified that the dimensions of the pili

nut were not significantly affected by the moisture content of the pili nut. They

had identified that the force required to initiate shell fracture is inversely

proportional to the moisture content of the shell, that is the greater the

percentage moisture, the lower force is required to break the pili nut shell. They

have also cited that longitudinal compression is a better way to de-shell pili nuts

in that it had yielded the highest percentage whole kernel recovery (97.8%) as

compared to transverse compression, although the longitudinal compression

has greater values for: force, 2.66 – 3.15 kN as against to 1.48 – 1.60 kN of the

transverse compression; deformation, 8.37 – 8.57 mm vs. 1.02 – 1.08 mm; and

specific deformation, 0.14mm mm-1 vs. 0.05mm mm-1.

In a study “Force and Velocity Required to Effectively Crack the Pili Nut

Shell” by Perez, D.J.S., 2015, Bicol University, College of Engineering,

Mechanical Engineering, she concluded that the force and velocity to effectively

crack the Pili nut is 11.4004 N and 0.2445 m/s, respectively.

The shell of the pili nut is characterized by a hard but brittle shell. A

shallow wedge action on the shell of at least 1mm deep could crack the shell

along its girth (Gerero, H.L., et Al., Bicol University College of Agriculture and

Forestry, 1999).

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 In a study “Modification, Fabrication and Testing of a Mechanically

Operated Pili Sorter” by Camato, J.J.C., et. Al., 2000 of Bicol University College

of Agriculture and Forestry, they have categorized Pili nut in three sizes: small

which ranges from 2.08cm to 2.11cm in width and 4.52cm to4.56cm in length,

medium nuts are within the range of 2.29cm to 2.33cm in width and 4.86cm to

4.97cm in length; and large nuts are within the range of 2.75cm to 2.85cm in

width and 5.76cm to 5.98cm in length.

Related Studies

In a study conducted by Ibrahim, M.G., Shehu, A.A., Dauda, S.M. and

Ahmad, D. entitled Design, Fabrication and Testing of Shea Nut Shelling

Machine which aimed to alleviate the tedious and tiring work of de-shelling

sheanut (Butyrospernum paradoxum) fruits which are indigenous to the West

African savanna zone. The research was first carried out by the determination

of the physical and mechanical properties of a sheanut shell in order to

minimize economic losses associated with the process. With this, it has been

determined that the fruit’s physical properties at 25% moisture content (wet

basis) are: major diameter (29.20 mm), intermediate diameter (21.90 mm),

minor diameter (15.00 mm), geometric mean diameter (21.90 mm), arithmetic

mean diameter (21.20 mm), angle of repose (30.280). The mechanical

properties for the shell that was determined are as follows: linear limit force

(0.80 kN), linear limit deformation

(4.60 mm), bioyield point force (1.40 kN), bioyield point deformation (6.50 mm),

rupture

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point force (2.10 kN) and rupture point deformation (9.60 mm). And with this

preliminary data, they were able to fabricate a device that would be able to aide

in the shelling of the sheanut fruit. The machine was designed to shell, clean

and separate the fruit which is powered by a 5 hp electric motor. And the result

of the research was that upon testing they had 96% shelling efficiency, 69.56%

cleaning efficiency, and 82.7% efficiency in cleaning.

Figure 2.2.1. Shea Nut Shelling Machine

In another study conducted by Ojolo, S.J., Damisa, O., Orisaleye, J.I.

and Ogbonnaya C. entitled Design and Development of Cashew Nut Shelling

Machine, the machine designed is motorized and during operation, it cracks

cashew nuts by impact when the nuts are hurled toward a fixed wall by an

impeller which is driven by the electric motor. The fully assembled machine is

shown in Figure 1(a) and (b). Fracture characteristics, that is resistance to

impact forces, of the cashew shell, at different orientations of the cashew nut,

were determined by impact load tests. The tests were uniaxial impact load tests

with each nut is carefully aligned on the equipment. The result indicated that

the lateral orientation, compared to other orientations of the cashew nut,

15
required the least amount of force (67.4 N) to fracture the shell. A force of 108.8

N was required to fracture the nutshell in the dorsal orientation – which was the

highest impact force and it was presupposed that it was the critical force that

should be applied to effectively fracture the shell. Tests showed that the shell

of the cashew nut cracks plastically under impact load, implying that there is no

conservation of kinetic energy so the impeller and shaft is designed for impact

loading where the velocity is the required parameter.

Figure 2.2.2 Cashew Nut Shelling Machine

In another study conducted by Ojolo, S.J., Orgurdare, A., and Adegbiji,

A. entitled Development of Variable Size Nut Cracker the nut cracking machine

was designed, constructed and tested to improve the efficiency of shelling

operation of quite many nuts. The machine is designed to be adaptable to the

cracking requirements of some number of nuts, whose shell can be processed

to brittleness. The machine performs two operations: shelling of the nut and

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separation of the shell from the nut. The machine comprises of a hopper,

rectangular box housing the cracking drum and compression plate, and also a

two-stage agitated separating tray (to sort the nut from the shell), and these are

all supported by a frame. The cracking drum, which is driven by a v-belt

connected to an electric motor, also provides the agitation to the separating tray

via a v-belt connected to a cam mounted shaft that helps push the tray against

stationary springs to return the tray to its initial position upon the dwell of the

cam. The continual return and compression of the tray against the spring

subjects the tray to a vibration needed to enhance the travelling of the shell-nut

mixture over it. The machine was tested with palm kernel. The strongest of the

class of nuts it was designed to crack with a cracking efficiency of 87%. The

machine operation is satisfactory with whole kernel recovery of the machine

standing at a magnificent value of 87%. Figures 1 and 2 show the front

orthographic view of the machine and exploded isometric drawing of the

machine, respectively.

Figure 2.2.3. Variable Size Nut Cracker

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 In an invention of Frederiksen, W.C. and Kim, S.Y. Nut Shelling Machine

that was patented with publication number US 4793248 A is designed and

constructed to operate with select contact implements designed to shell

different nuts. Common to the design is a mechanism that accepts, entraps,

shells and releases individual nuts in a sequence that is tailored to the particular

nut and designed to maximize the quantity of shelled whole kernels.

Furthermore, the mechanism is designed to maximize the size of the split shell

pieces to ease the task of separating meat from shell and minimize losses

resulting from small commingled bits and pieces of shell and meat.

The machine in its preferred embodiments includes a drive motor and a

gear box for rotating four juxtaposed shafts positioned in side by side pairs of

upper and lower aligned shafts.

Along each shaft is a series of cam indentions which are angularly

disposed on the adjacent pairs of the upper and lower shafts such that the

indentions are periodically coincident in an opposed arrangement that enlarges

the effective space between adjacent shafts. This periodic effective

enlargement between the shafts is designed to permit a single nut to drop

between the upper pairs of shafts and then drop between the lower pairs of

shafts. By adjusting the phase or lag time of the rotation of the lower shafts, the

enlarged opening between the lower shafts can occur a specified time after the

upper opening has occurred to provide an opportunity to act on the entrapped

nut before release.

In the preferred embodiments the shafts each have multiple cam-loke

indentions forming a series of discrete shelling stations along the shaft. The

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shelling stations are separated by dividers and are angularly staggered around

the shaft to permit a string of nuts to be shelled in a smooth, low-impact

sequence with minimal power demand.

Preferably, for maximum yield, the nuts should be pre-sized and supplied

to the shelling machine by a hopper that stream feeds the discrete, multiple

stations along the extended shafts. One of the side by side pairs of shafts is

displaceable such that the distance between one pair of upper and lower shafts

can be adjusted relative to the other pair of upper and lower shafts. In this

manner the machine can be adjusted for optimum operation for the particular

size-graded nut.

In the preferred embodiment, the machine is adapted to shell the difficult

macadamia nut by incorporation of opposed pairs of splitting blades mounted

in diagonally opposed shafts. The splitting blades are arranged and shaped

with a curved lead-edge to engage the spherical nut entrapped between the

pairs of lower and the upper shafts. Since the shafts rotate in the same direction

the relative tangential motion of the blades during occlusion is opposite. As the

shafts rotate the nut shell is impaled by the lead edges as the blades move

toward one another, is penetrated a predetermined depth with a wedge action

as the blades reach their most proxical position, and is shear split as the blades

regress. When the blades pass, the indentions of the lower shafts align,

allowing kernel and shell to drop to auxiliary equipment for separating shell from

kernel.

In another embodiment the machine is adapted to shell a walnut by

incorporation of opposed pairs of circular discs engaged by the four shafts in

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eccentric cam grooves around each shaft. The circular discs are maintained in

parallel planes with a common perpendicular axis that is parallel to the axis of

the shafts. The spaced discs, entrapped between the pairs of shafts track in the

grooves in an oscillating manner that enlarges and contracts the spacing

between the discs. A nut that drops between the upper shafts and orients its

oblong configuration axially on the pair of lower shafts when the discs are

maximally spaced, in split by impact of the discs as they move toward one

another. Again, immediately following, the space between lower discs enlarges

and the meat and shell drop to auxiliary processing equipment below. The use

of the discs can be with or without cutting blades.

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 FIG. 1 is a side elevational view, partially fragmented of the nut shelling machine.
FIG. 2 is an end view, partially fragmented, taken along lines 2.2 and FIG. 1.
FIG. 3 is a cross sectional view of the rotary feed mechanism and the four shaft shelling mechanism of a first
embodiment of the invention.
FIG. 4 is a cross sectional view of a portion of the mechanism of FIG. 3 in a second sequential position.
FIG. 5 is a cross sectional view of the mechanism in a third sequential position.
FIG. 6 is a cross sectional view of the shelling mechanism in the fourth sequential position.
FIG. 7 is a cross sectional view of the shelling mechanism in the fifth sequential position.
FIG. 8 is a cross sectional diagonal view taken along lines 8---8 of end FIG. 6.
FIG. 9 is a dramatic view of an alternate shelling mechanism for the shelling machine of FIG. 1.
FIG. 10 is a second sequential position of the alternate shelling mechanism of FIG. 9.

In another study entitled, “Design, Fabrication and Preliminary Testing

of the BUCAF Pili Nut Cracker” by Gerero, H.L., et al., Bicol University College

of Agriculture and Forestry,1999, they have conceptualized new design of a pili

nut cracker to aid the problems faced on the previous works of Catanduanes

State College and Cam Sur State College in terms of its performance. The

study has recorded the cracking capacity using small size pili nut (1.9-2.1 cm)

to be 38 kg/hr and using medium size (2.2 -2.4 cm) cracking capacity to be 40.4

kg/hr. Cracking efficiency obtained is 36.44% for medium size and 87.33% for

large size. Whole kernel recovery percentage is 56.49% for medium size and

52.22% for large size.

Figure 2.2.4. BUCAF Pili Nut Cracker

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 In the following year, a study on “Modification, Fabrication and Testing

of the Cracking Unit of the BUCAF Pili Nut Cracker” was conducted by Bilaro,

V.B., et al., of Bicol University College of Agriculture and Forestry at year 2000.

Improvements on design were made, hence, increasing the machine’s

performance.

Figure 2.2.5. Improved BUCAF Pili Nut Cracker

In the work of Engr. Arnulfo Malinis, et. al. on improvements on the

design of the Mechanical Pili Nut Cracker done by Gerero, H.L., et.al, and

Vilaro, V.B., et.al, the prototype of the equipment is composed of a six-blade

cracker powered by a one-horsepower electric motor with an energy

consumption of 0.41 kilowatt per hour. The machine consists of five major parts:

the cracking unit, conveying unit, stand/frame, transmission, and prime mover.

Technology verification of the prototype showed that on the average, it can

crack 204 pieces of pili nut in a minute or 117 kilograms per hour with a cracking

22
efficiency averaging 93 percent with 89 percent whole kernel recovery. For

eight hours a day, this simple machine could crack 16 bags of dried nuts. The

result is comparative to the output of four persons in one day. To produce the

machine an outlay amounting to P 40,000 is needed. The return of investment

is 53 percent after more than a year of use (Calleja, 2009).

In another study conducted by Bon E.A., and Hilario R.D., 2015, Bicol

University, College of Engineering, Mechanical Engineering entitled “Manually-

operated Pili Nut De-Shelling Device” they come up with the design of a Pili nut

cracker shown just below.

Figure 2.2.6. Manually-operated Pili Nut De-Shelling Device

Synthesis of the State-of-the-Art

Prior arts suggest that the common way of cracking and shelling nuts is

to subject the nut to impact force. Most of the nuts have varying and irregular

shapes and sizes that is why it had been a challenge for the developers to

design the cracking machines with highest level of compatibility, functionality

and efficiency. Customized design of machine members was made to

accommodate the desired machine performance.

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Gap on Literature

Prior works on nut crackers focused mostly on cashew, shea, and other

nuts and limited on pili nut. Moreover, most of these machines crack nuts by

impact force. In contrary, though some have developed a pili nut cracking

machine, rotary blade is not used as the cutting tool for the pili nut cracking

machine. Improvements on the design is needed to increase whole kernel

recovery percentage and to make the work output more time efficient.

Theoretical Framework

All gathered data, principles, and concepts in the Design of

Machine Elements, Strength of Materials, and Machine Design were combined

to develop a safe functional machine. This study is anchored in the theory that

with a substantial compressive force the Pili nut can be cracked.

Applying the principles and concepts of the theory on nut cracking

machine, the information and data gathered, the researcher got insight for the

theoretical paradigm as shown in the figure.

Load Crack Discharge

Figure 2.7. Theoretical Paradigm of the Machine

The researchers’ design will work in three easy stages – load, crack and

discharge. First, the Pili nut must be loaded. This is done by merely putting the

nuts into the cracker. In this project study, a trapezoidal hopper will be

fabricated and be connected to the machine’s frame to contain the nuts within

24
the cracker. Second, the nuts must be cracked. This is done by the two bladed

shafts rotating counter to each other, properly designed to produce undamaged

kernel. A blade of the wrong design can lead to total shell and kernel wreckage.

Cracking the Pili nut in made possible by applying impact or compressive force.

This research proposal will use some customized well-designed blades to crack

the Pili nut.

Finally, the nuts are discharged. This is done by simply falling from the

blades to the collecting trough right beneath the cracker blades.

Conceptual Framework

The researchers adopted the input-throughput-output technique in

describing the conceptual framework of the study.

THROUGHPUT
INPUT Fabrication,
Supplies, testing and OUTPUT
materials, tools, demontration, Efficient Rotary
equipment, and evaluation, Bladed Pili Nut
procedures for revising, Cracking Machine
prototypes. observation of
process.

Feedback

Figure 2.8. Conceptual Paradigm

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Definition of Terms

The definitions contained in this chapter shall apply to the terms used in

this project study. Where terms are not defined in this chapter or within another

chapter, they shall be defined using their ordinarily accepted meanings within

the context in which they are used.

Hopper-a container for the Pili nut typically one that tapers downward

and can discharge its contents at the bottom.

Shafts - a cylindrical rotating rod for the transmission of motive power in

a machine.

Bladed shafts- shafts attached with blade plates

Impact force-a high force or shock applied over a short time period

when two or more bodies collide.

Compressive force- the application of power, pressure, or exertion

against an object that causes it to become squeezed, squashed, or compacted.

Customized blades- specifically designed blades for a certain use

Cracking blades – specifically designed blades for cracking, these are

the cutting blades and the gripping blades of the machine

Cutter blades - the machine part with a circular shape and sharp edges

that serves as the cutter of the nut shell.

Gripping blades – the machine part the looks like a star serve as the

holder of the nuts in the machine

26
 Fatigue- the weakening of a material caused by repeatedly applied

loads

Required working life- it is the expectancy of a machine’s life set by

designers.

Gripping toothed disc plate- a specifically designed metal disc to hold

a specific object

Cutting blade- blades with cutting capabilities

Critical point of breakage - a point in an object where it is more likely

to break easily.

Key - a machine element used to connect a rotating machine

element to a shaft.

Bearings a machine element that constrains relative motion to only the

desired motion and reduces friction between moving parts.

Bolts a form of threaded fastener with an external male thread.

Nut- a type of fastener with a threaded hole

Collecting trough- a long, narrow container used to catch the Pili nuts

from the cracking blades

27
 CHAPTER 3

METHODOLOGY

This section presents the methods and procedures to be use in

the conduct of the study for the fulfilment of the objectives.

Research Design

The researchers used the experimental research method for the project

study – the preparation of material, experiments, observation, analysis,

presentation of the result as well as the process of set-up and composition.

The design is carried out with a view to evaluate the necessary

design parameters such as strength and size of materials of the various

machine components to avoid failure by excessive yielding and fatigue during

the required working life of the machine. Moreover, the Pili nut cracking

machine is developed based also on the following considerations:

1. The availability of materials locally to reduce cost of production and

maintenance of the machine.

2. Physical properties of pili nut to determine the appropriate shape of

the gripping toothed disc plate to trap the pili nut while a rotating cutting

blade cracks the nut.

3. Mechanical properties of pili nut to determine the critical point of

breakage and the possible required force to crack the nut.

28
 5. Weight considerations on blades so the motor can maximize its power

on profitable work.

Quantification of Variables

In various study on the physical and mechanical properties of Pili nut

that were conducted by different groups of individuals, they have categorized

Pili nut in three sizes: small which ranges from 2.08cm to 2.11cm in width and

4.52cm to4.56cm in length, medium nuts are within the range of 2.29cm to

2.33cm in width and 4.86cm to 4.97cm in length; and large nuts are within the

range of 2.75cm to 2.85cm in width and 5.76cm to 5.98cm in length.

In this study, the different sizes of Pili nut are the major varying factor in

the experiment. Pili nuts that are too small and too big, play an important role

in the adjustment of the blades’ center to center distance.

Description of the Machine

As shown in the Design of the rotary bladed pili nut cracking machine as

shown in figure 123 above, the major components are rotary blades, shaft,

bearing housing, gears and chains, speed reducer gearbox, driven and driver

pulleys, rubber belt and motor.

The frame houses all the components of the machine and acts as the major

structural support that hold the machine components in place. It is made by

welding 2in.x2in.x3/16in. ASTM A36. The frame has a dimension of 42cm long,

38cm wide and 61cm high. The cracker is composed of 4 blades that is

29
mounted on 2 different shafts, each shaft has 2 types of blades held

simultaneously. Each types of blades have different dimensions and design.

The blades are machined from 1/8 in. and ½ Each ASTM A36 hot rolled steel

plate matching blades opposing each other on the opposite shaft has the same

thickness.

Two shafts are used to hold the blades and one shaft is used for mounting an

idler gear to alter the rotation of the gears attached to the other two shafts. The

shaft is machined from 1 ½ in. mild steel shaft. Each shaft is 34cm, 39cm, and

26cm long. Each shaft is supported by two P205 Pillow block.

Gears and chains are used to transmit power from the gearbox to the shafting,

all the four gears attached to the gearbox and three shafts has 15 gear teeth

and uses a chain of chain number 428. The gears are sized based on the center

distance from the shaft, having enough allowance for the chains. The speed

reducer gearbox reduces the rotational speed transmitted by the electric motor

by 40-1. A ¾ hp induction motor is transmits power from the motor shaft to the

speed reducer at motor’s rated speed 7, and then to the shafts of the pili nut

cracker.

Materials and Set-Up

Materials

ASTM A36 Metal Sheet for the blades

ASTM A36 Mild Steel Bar for the shaft

E6013 Welding Rod

30
50mm x 2mm Angle Bar for the Frame

Cardboard

Wooden Blocks

Bolts

Nuts

Washers

Nails

Tools and Equipment

Weighing scale

Measuring Tape

Carpenter’s Square

Chop Saw

Grinder

Hand Drill

Drill Press

Welding Machine

Lathe Machine

Acetylene Cutter

Ratchet Set

31
Budgetary Requirements

DIRECT MATERIALS QUANTIT UNI UNIT PRICE AMOUN

(PESO) T (PESO)
USED Y T

Frame

2”x2”x3/16” Mild Steel

1 pc 598.00 598.00
ASDM Angle Bars
2”x3/16” Mild Steel
1/2 pc 450.00 225.00
ASDM Flat Bars
Welding Rod 1 kg 85.00 85.00
Grinding Stone 1 pc 50.00 50.00
7/16” Drill bit 1 pc 42.00 42.00
Labor N/A N/A 1,000.00 1,000.00
Speed Reducer
Jia Asiadrive WPS type
1 pc 5,000.00 5,000.00
1:40
Electric Motor
Capacitor Start Motor 1 pc 2,953.00 2,953.00
Others
Pillow Block P205 6 pc 220.00 1,320.00
7/16” Washer 48 pc 4.00 192.00
7/16” Bolt and Nut 20 pc 12.00 240.00
Push Button Switch 1 pc 190.00 190.00
15-T Sprocket 4 pc 60.00 240.00
B-25 Belt 1 pc 150.00 150.00
Motor Chain pitch no 428 1 pc 260.00 260.00
3”x1Bx1” Pulley 1 pc 115.00 115.00
Blades and Shafts
Direct Labor and
materials (Fabrication of N/A N/A 8,500.00 8,500.00
Blades and Shafts)

TOTAL 21,160.00

32
Step-by-Step Procedure

1.Design Stage

a. Blades’ Form Conceptualization

The pili should be held in between the roller blades in order to be

cracked, the compression between the two rotating blades will make the shell

of the pili nut crack.

1. To secure the position of the pili nut while passing in between the

blades the designers made a cut in one of the four types of blades as

shown in figure 3.3.

Figure 3.1

2. In order to crack the pili nut by compression there should be a contact

point between the two opposing blades and the pili nut, based on that

condition the designers decided to make a size variation in the

diameter of the alternating blades.

33
3. Circular blades with sharpened edges will be used to crack the pili nut

by applying concentrated pressure on the tip of the blades.

4. The designers chose the blades thickness to be 1/8 in. and ½ in.

bases on the observation of the designers about the distance that the

pili can be cracked anywhere in the transverse position that the kernel

can be easily recovered based on the own experience of the designer

in the manual cracking of the pili nut. The blades assembly is as

shown in figure 3.4.

Figure 3.2

5. The edges of the large ½ inch thick blades are tapered on the edges

to give allowance for the sharpened blades.

6. The center whole in each blade where the shaft will be fitted is known

by the given shaft diameter available given by the machine shop that

will machine fabricate the shafting, that is 1 ¼ in. thick for the shafting

and a given key and key way size of ¼ in.

7. The blade diameter of 4.0960 in. for blades 1 and 3, 2.3622 in. for

blade 2, and 2.9522 for blade 4 is chosen for the purpose of this

design.

34
8. The final design of the four individual blades is finalized as shown in

figure 3.3, figure 3.4, figure 3.5 and figure 3.6.

Figure 3.3

Figure 3.4

Figure 3.5

35
 Figure 3.6

b. Force Load Consideration

From the article published by The Philippine Agriculturist

in titled Some Physical and Mechanical Properties of Pili (Canarium

ovatum Engl.cv.Katutubo) Nut as a Function of Nut Moisture, on the

average nut needed to be transversely compressed by about 1.04 mm

(or about 5% of its height) and by 1.55 kN of force to substantially inflict

shell fracture. When compressed longitudinally , a nut needed about

2.83 kN of force and 8.49 mm of deformation (about 14% of its length)

to develop fracture in the shell ( The Philippine Agriculturist, march

2013).

Figure 3.7: Compressive force application along the longitudinal

FL and transverse FT axes of the pili nut.

36
 The Designers used 1.55 kN of force for the transverse

compression of the pili nut as the standard force required to crack the

pili in the computation for the force load consideration.

c. Material Selection

1. The material selection for various components of the machine is

influenced by the local availability and cost of production and

maintenance of the Pili Nut Cracking Machine.

2. After a material is proposed to be used, the properties of the material is

known and is evaluated with the necessary design parameters.

3. The sizing of the various machine components is done

Determination of shaft power

The Force required to inflict fracture in a transversely

compressed pili nut, F = 1.55 kN

Assuming that two out of four blades will be subjected to the

load of 1.55 kN

Blades design load, Fbd = 2xF = 2(1.55 kN) = 3.1 kN

The torque required for rotation for single loading of pili nut is,

Tb = Fbdr

where: Fbd = Force required to inflict fracture in a transversely compressed

pili nut,

r = is the radius of the large ½ in. cracking blades, Blade 1 radius,

37
 = 4.096/2 in=2.048in. =52 mm

1𝑚
𝑇𝑏 = (3.1 𝑘𝑁)(52 𝑚𝑚) ( ) = 0.1612𝑘𝑁 𝑚
1000 𝑚𝑚

Selection of shaft material and size

The most available shafting material in the locality is made of ASTM

A36 mild steel.

Table 3.1: Properties of ASTM A36 Mild Steel

Mechanical Properties Metric Imperial

Tensile Strength, Ultimate 400-500MPa 58000-79800 psi

Tensile Strength, Yield 250 Mpa 36300 psi

Elongation at Break (in 20.0% 20.0%

200 mm)

Modulus of Elasticity 23.0% 23.0%

Bulk Modulus (Typical for 200 GPa 29000 ksi

Steel)

Elongation at Break 140 GPa 20300 ksi

Poissons Ratio 0.260 0.260

Shear Modulus 73.90GPa 11500 ksi

ASME Code States that for shaft made of ASTM steel:

Shear Stress (allowable) = 30% of Yield Stress but not over 18% of

Ultimate Strength for shaft without key ways. These values are to be

reduced by 25% if the shaft has key ways.

38
Ultimate tensile Strength, Sult = 400-500 MPa, use: Sult = 475 MPa

Shear Stress (Allowable Based on Ultimate Strength),Ssu = (0.30)(475

Mpa)

Ssu = 142.5 Mpa

Yield Strength, Sy = 250 MPa

Shear Stress (Allowable, Based on Yield Strength) Ssy< (0.18)(250

MPa)

Ssy < 45 Mpa.

Selecting the smaller value i.e. Ss = Ssy = 45 Mpa.

The design the shaft used in the pili nut cracking machine has a key way,

the the Shear Strength will be reduced by 25%.

Ss = (1-0.25)(45 MPa) = 33.75

𝑇𝑐
𝑆𝑠 = ( )
𝐽

Where:
Ss = Shear Stress Allowable
T = Tourque
c = (shaft diameter/2)
J = Polar Moment of Inertia
𝜋
𝐽 = ( 2 𝑐 4)
1
2𝑇 3
𝑐= ( )
𝜋𝑆𝑠
1
3
2(0.1612 𝑘𝑁 𝑚)
𝑐= ( ) = 0.01449 𝑚
1000 𝐾𝑖𝑙𝑜
𝜋(33.75 𝑀𝑝𝑎) ( )
1𝑀𝑒𝑔𝑎

𝑐 = 0.01449 𝑚 = 14.49 𝑚𝑚

𝑑 = 2𝑐 = 2(14.49 𝑚𝑚) = 28.98 𝑚𝑚

39
d = 2.898 mm = 1.14 in.

The designers used d = 1.250 in.

d. Motor Power Determination

Upon the designers’ observation and judgement, the right

speed of the blades for proper loading in the tangs/fangs of the blades

and for the pili nut not to fly due to angular momentum of the pili when

subjected to a fast rotation of the blades is ranged from 25 to 30rpm.

Say, rotational speed, n = 27.5 rpm

The Power required on the shaft to crack the, Preq=Tbω

2𝜋𝑟 𝑎𝑑 1 𝑚𝑖𝑛
𝑃𝑠ℎ𝑎𝑓𝑡 = (0.1612 𝑘𝑁 𝑚)(27.5 𝑟𝑝𝑚) ( )( ) =
1 𝑟𝑒𝑣 60 𝑠𝑒𝑐
0.4642 𝑘𝑊

Pshaft = 0.4642 kW= 0.6225hp

e. Electric Motor Selection

The designers choose a ¾ hp at 1720 rpm, 0.55kW, 220V, 5.8A, 60Hz,

three phase electric motor to power the blades of the pili nut cracking

machine. The speed of the rotation will be reduced to 25-30 rpm so the

torque will increase.

f. Speed Identification and Reduction

40
The speed of the blades is determined by the designers by observing the right

speed of the blades for proper loading in the tangs/fangs of the blades and for

the pili nut not to fly due to angular momentum of the pili when subjected to a

fast rotation of the blades. The designers decided the range of 25 to 30 rpm for

the blades.

The rotational speed of the motor will be reduced from 1720 rpm to say 27.5

rpm.

1. the speed ratio to be met is too high, the designer used a speed reducer

gearbox to reach the desired speed.

2. Using a belt and pulley connection between in the motor shaft and speed

reducer gear box. The driven pulley is 3 in in size and the driver pulley

is 2 inches. The belt used is a b 235 belt and the center distance between

the two belts is 9.5 in. (24 cm).

𝑑𝑟𝑖𝑣𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

𝑠𝑝𝑒𝑒𝑑 𝑟𝑒𝑑𝑢𝑐𝑒𝑟𝑒 𝑖𝑛 𝑟𝑝𝑚 = ( ) (𝑚𝑜𝑡𝑜𝑟 𝑟𝑎𝑡𝑒𝑑 𝑟𝑝𝑚)
𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
2 𝑖𝑛
𝑠𝑝𝑒𝑒𝑑 𝑟𝑒𝑑𝑢𝑐𝑒𝑟 𝑖𝑛 𝑟𝑝𝑚 = ( ) (1720 𝑟𝑝𝑚) = 1146.6667𝑟𝑝𝑚
3 𝑖𝑛
𝑠𝑝𝑒𝑒𝑑 𝑟𝑒𝑑𝑢𝑐𝑒𝑟 𝑖𝑛 𝑟𝑝𝑚
𝑠𝑝𝑒𝑒𝑑 𝑟𝑒𝑑𝑢𝑐𝑒𝑟 𝑜𝑢𝑡 𝑟𝑝𝑚 = ( )
𝑠𝑝𝑒𝑒𝑑 𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑖𝑜
1146.6667 𝑟𝑝𝑚
𝑠𝑝𝑒𝑒𝑑 𝑟𝑒𝑑𝑢𝑐𝑒𝑟 𝑜𝑢𝑡 𝑟𝑝𝑚 = ( ) = 28.6667 𝑟𝑝𝑚
40/1

The gear in the gear reducer has the same gear teeth with the ones that are

attached in the shafts containing the blades. The designer did not made a

variation in the gear teeth number to reduce the angular rotation, considering

that the distance between the shafting is significantly small to make the desired

allowance for the gear and chain installment.

Blade rotational speed = 28.6667

41
2. Fabrication Stage

a. Blades and Shafts

Blades fabricated in the machine shop by a skilled machinist. He first

studied the plan designed by the researchers and think of the appropriate

technique to be used. Second, he cut the dimensions specified for the blades

on a 1/8” and ½” thick ASTM A36 mild steel metal sheet. He from the blades

based on the designed cut by an acetylene cutter, then polishes the edges.

Third, he drilled a bore on the blades and enlarged the bore into the desired

diameter, then cut a keyway.

On the same way, the shafts are fabricated in the machine by a skilled

machinist. After studying the plan, he then prepared the tools and materials to

be used. When the material for the shafts has ben cut into the desired length,

he then turned on the already set up lathe machine. He from the shafts as

specified in the given plan. He piled the shafts and finally thermal fitted the

blades on the shafts. He also put the locker.

b. Frame/Stand

The frame also called as the stand by the researchers is fabricated in a

welding shop with the supervision of a skilled person in metal works. The

researchers first cut the angle and flat bars into the desired length then joined

it by shielded metal arc welding. Second, the edges are polished by grinder.

Pilot holes are made using hand drill then bored by a drill press. These holes

are for the bolts for fastening the major machine parts. Finally, the stand is

done.

42
Assembling

1. Simulation

Before setting the machine parts on the stand/ frame, simulation is

made. The cracking blades that are already attached to the shafts with the

pillow blocks on each end are set on a table to see how it will be fastened to

the frame.

2. Setting-up

After all parts are ready, the researchers assemble the machine. Starting

with the frame, shafts and the cracking blades are fastened. Next, the speed

reducer and the motor are fastened to the base of the frame. Then the chain is

meshed with the sprockets on the shafts of the cracking blades and the speed

reducer. After the chain and sprockets are set, the belt is attached to the

sheaves of the reducer and the motor.

3. Preliminary Testing

To achieve optimum machine functionality, the designers conducted

initial testing upon setting up the machine’s parts. The designers have followed

the design parameters and assembly is done with precision specific to the

design.

Step 1. Preliminary test begun with the examination of the body’s

balancing with parts securely positioned. Fasteners must be tightly fitted.

Excessive wielding properties are flattened by the use of grinders.

Step 2. The electric motor is switched on with no belt attached.

43
 Step 3. Switch on of electric motor with secured attachment of belts to

electric motor and gearbox

Step 4. Switch on of electric motor with secured attachment of belts to

electric motor and gearbox and secured attachment of chains to gearbox and

gears connected to the rotating shafts.

Step 5. Preliminary cracking of small size pili nut with small size cracker

configuration.

Adjustments

To achieve desired fittings and results and to fix miscalculations, the

designers managed to made alterations of design. Since the purpose of the

design study is to crack pili nuts efficiently than previous related studies and be

effectively acceptable to the market, a conservative and innovatively

resourceful adjustment approach is acted for specific situations.

Loading

Pili nut struggles to slide from the hopper when loaded resulting into not

centered loading on the blades and may damage the kernel by the way it will

be cracked. A slippery tape is put to the surface of the hopper to reduce the

friction between the sliding pili nut and the material of the hopper. With smooth

sliding of pili nut it will land perfectly centered onto the blades.

Fittings

Due to vibration fittings and fasteners tends to lose. By putting extra

washers and nuts to areas near vibrating parts will help give a tight fitting.

44
Belt Slippage

The belt connecting the electric motor and gearbox is prone to slippage

when an oversized pili nut is feed to the blades. In order to prevent the belt from

slipping, the motor is elevated 5 inches with wooden blocks. A tensioner is

added below the belt for more sustainable power transmission of electric motor

to gear box.

Loose Chains

The chain used is a bit longer than the designed parameter. A small

portion of the chain is removed and placed back again for more efficient power

transmission.

Finalization of Machine Assembly

After the necessary adjustments and alterations, the machine now is

finalized for the scope being specified.

Sorting of Pili Nut according to sizes

Pili nuts are sorted into 3 sizes- small, medium, large. Small ranges from

2.08cm to 2.11cm in width and 4.52cm to4.56cm in length, medium nuts are

within the range of 2.29cm to 2.33cm in width and 4.86cm to 4.97cm in length;

and large nuts are within the range of 2.75cm to 2.85cm in width and 5.76cm

to 5.98cm in length.

45
Cracking and Recording of Data

Sorting of Pili Nut according to sizes will have a corresponding effect on

the cracking efficiency. For each size, the researchers will test 20 Pili nuts per

test for 3 trials. Video recording of each test procedures is done, and data are

tabulated based from the results of each test.

Research Procedure

1. Gathering and analyzing existing related studies and patents.

2. Analyzation of the concept and theories regarding the existing related studies

and patents and took note the problems regarding their studies. The existing

patents are further examined to ensure the uniqueness of the topic.

3. Stating the problem and formulating hypothesis on how to address these

problems. Establish a formal objective of the study to create straight-forward

goals to pursue.

4. Design and Layout of the prototype. The prototype is designed taking into

considerations the physical and mechanical properties of Pili nut to create

the most appropriate form for the blades.

5. Assessment for the availability of the materials and equipment needed

for the fabrication of the prototype.

6. Fabrication of the prototype. The researchers fabricate the prototype

based on the finalized layout and design.

46
7. Experimentation and data gathering. With the existing prototype,

experiments are conducted to gather data. Data are recorded and

tabulated.

8. Data Analysis. Data gathered were analyzed to prove whether it can

assure the possibility of the hypothesis.

9. Reevaluation of the results. Further reassessments of the results will help

researchers to improve efficiency for optimum performance. Researchers

will modify necessary modification for the prototype to work efficiently as

before.

10. Finalizing the results. After reassessment and further modifications, the

results are finalized, and conclusions are established.

11. Publication of the Thesis Paper.

47
 CHAPTER 4

PRESENTATION AND INTERPRETATION OF FINDINGS

This section presents and interprets the results or findings from the data

and observation based on calculation and experiments made by the

researchers.

Results/ Findings

After due researches, experiments, testing, and calculations, the

researchers arrived at following results and findings.

Appropriateness of Blade’s Design

Data are gathered during performance testing of the machine and the

design of the cracking blades showed good results after tests are done to

whether it can crack the shelled pili nut without damaging the kernel. Cracking

blades are in good condition after all the tests have been conducted. Cutting

blades have minimal chips and have no sign of cracks. Gripping blades are

intact and has no sign of fatigue.

Performance of the Machine

To assess the performance of the machine in terms of cracking rate, cracking

efficiency and whole kernel recovery, the researchers used the following

formulas to analyze the gathered data.

48
𝐼𝑑𝑒𝑎𝑙 𝐶𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝑅𝑎𝑡𝑒

= (𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑝𝑎𝑐𝑒𝑠 𝑜𝑟 𝑠𝑙𝑜𝑡𝑠 𝑜𝑛 𝑡ℎ𝑒 𝑔𝑟𝑖𝑝𝑝𝑖𝑛𝑔 𝑏𝑙𝑎𝑑𝑒)𝑥(𝐵𝑙𝑎𝑑𝑒 ′ 𝑠 𝑅𝑃𝑀)

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑛𝑢𝑡𝑠 𝑓𝑒𝑑

𝐴𝑐𝑡𝑢𝑎𝑙 𝐶𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝑅𝑎𝑡𝑒 = ( )
𝑡𝑖𝑚𝑒 𝑜𝑓 𝑐𝑟𝑎𝑐𝑘𝑖𝑛𝑔

𝐴𝑐𝑡𝑢𝑎𝑙 𝐶𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝑅𝑎𝑡𝑒

𝐶𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝑅𝑎𝑡𝑒 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = ( ) 𝑥 100
𝐼𝑑𝑒𝑎𝑙 𝐶𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝑅𝑎𝑡𝑒

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑟𝑎𝑐𝑘𝑒𝑑 𝑝𝑖𝑙𝑖 𝑛𝑢𝑡𝑠

𝐶𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = ( ) 𝑥 100
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑖𝑙𝑖 𝑛𝑢𝑡𝑠 𝑓𝑒𝑑

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤ℎ𝑜𝑙𝑒 𝑘𝑒𝑟𝑛𝑒𝑙𝑠 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑒𝑑

𝑊ℎ𝑜𝑙𝑒 𝑘𝑒𝑟𝑛𝑒𝑙 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦 = ( ) 𝑥 100
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑟𝑎𝑐𝑘𝑒𝑑 𝑝𝑖𝑙𝑖 𝑛𝑢𝑡𝑠

Results of the testing for the performance of the machine are shown in

forms of tables. Table 4.1. shows the record of the test for actual cracking rate,

Pili nuts are hand fed. Table 4.2 shows the cracking efficiency recorded in 3

trials for every size of Pili nut in the rotary bladed Pili nut cracking machine

Furthermore, Table 4.3 shows the whole kernel recovery percentage of the 3

trials conducted.

Table 4.1 Actual Cracking Rate (Hand Fed)

Trial Rate, nuts/min
1 44
2 43
3 41
Average 42.67

49
 Table 4.1 shows actual cracking rate obtained from 3 trials, pili nuts are

hand fed.

With a blades’ rpm of 28, and 6 slots or spaces on the gripping blades,

the ideal cracking rate is found to be 168 nuts/min. Using the formula, the

cracking rate efficiency is found therefore to be 25.60%.

Table 4.2 Cracking Efficiency

Trial Small % Medium % Large %
1 65 75 80
2 55 85 85
3 70 90 80
Average 63.33 83.33 81.67

Table 4.2 is the tabulated data of the cracking efficiency in percentage

gathered from the tests conducted on 20 pili nuts per trial for 3 trials in each

size- small, medium, large.

Table 4.3 Whole Kernel Recovery Percentage

Trial Small % Medium % Large %
1 100 86.67 93.75
2 100 88.24 88.24
3 100 83.33 93.75
Average 100 86.09 91.91

Table 4.2 shows the percentage of whole kernel recovery in each trial

conducted. Whole kernels are examined after the cracking stage and is sorted

out from the uncracked nuts and damaged kernels.

50
Economics of the Machine

For the machine to be market acceptable, economics is a major

consideration. With the overall fabrication cost of 25,000 pesos, and the

economics of the machine is computed as shown.

For the electric motor electricity consumption

V= 220 Volts

A = 5.8 Amps

𝑉∗𝐴 220 𝑉𝑜𝑙𝑡𝑠 ∗ 5.8 𝐴𝑚𝑝𝑠

𝐾𝑊𝑒 = ( )=( ) = 1.276 𝐾𝑊
𝑊 𝑊
1000 𝐾𝑊 1000 𝐾𝑊

Theoretical:

Cracking rate (Theoretical)=168 nuts per minute

Cracking rate in kg/hr=1.601kg of pili nut per minute

Actual:

Cracking rate (actual) = 43 nuts per minute

Weight of 43 nuts=0.41kg

Cracking rate in kg/hr=0.41 kg of pili nut per minute

Effective rate for Residential Consumer as of December 2017=

1ℎ𝑟
(14.77 Php/Kwh)(60𝑚𝑖𝑛)=0.2462Php/Kw-min

51
Cost of Operation

Theoretical:

Motor energy consumption∗Effective rate for Residential Consumer as of December 2017

Cracking rate

𝑀𝑜𝑡𝑜𝑟 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑛𝑠𝑢𝑚𝑡𝑖𝑜𝑛 ∗ 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦

𝐶𝑂(𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 ) = ( )
𝑐𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝑟𝑎𝑡𝑒

1.276 𝑘𝑤 ∗ 0.2462 𝑃ℎ𝑝/𝐾𝑤ℎ𝑟

𝐶𝑂 (𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 ) = ( )=
162𝑛𝑢𝑡/𝑚𝑖𝑛

=0.001939 hp / nut

Motor energy consumption ∗ Effective rate for Residential Consumer as of December 2017
Cracking Cracking rate in kg/hrrate

1.276 𝑘𝑤 ∗ 0.2462 𝑃ℎ𝑝/𝐾𝑤ℎ𝑟

𝐶𝑂 (𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 ) = ( )=
1.601
𝑘𝑔/𝑚𝑖𝑛

= 0.1962 Php/min

Motor energy consumption∗Effective rate for Residential Consumer as of December 2017

𝑂 (𝑎𝑐𝑡𝑢𝑎𝑙 ) =
Cracking rate

1.276 𝑘𝑤∗0.2462 𝑃ℎ𝑝/𝐾𝑤ℎ𝑟

( 43 ) =
𝑛𝑢𝑡/𝑚𝑖𝑛

52
Actual:

=0.007306 Php/nut

Motor energy consumption ∗ Effective rate for Residential Consumer as of December 2017
Cracking Cracking rate in kg/hrrate

1.276 𝑘𝑤 ∗ 0.2462 𝑃ℎ𝑝/𝐾𝑤ℎ𝑟

𝐶𝑂 (𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 ) = ( )=
0.41
𝑘𝑔/𝑚𝑖𝑛

=0.7662 Php/min

Based from the data of tradewindsbicol.wordpress.com, paratilad worker can

crack 100kg of pili in a day’s work. Considering the worker is paid at Sorsogon

City minimum wage at 280Php (National Wages and Productivity Commission,

2017), the machine will have an actual operation cost of cracking 100kg of pili

nut of:

(0.0056Php/kg)x100kg= 0.56Php

at a time span of:

(0.41kg:1min0x100kg:x

X=243.9min=4.065hr

53
Discussion and Interpretation

After all the substantial data, the researchers arrived at the following

interpretations.

Actual vs. Ideal Cracking Rate

200

150

100

50

Ideal Cracking Rate Actual Cracking Rate

Figure 4.1: Actual vs. Ideal Cracking Rate

Based from the graph, it is evident that the actual cracking rate is

far below the theoretical cracking rate. This result because nuts are hand fed

and an appropriate loader is not provided. Speed in feeding the nuts into the

cracker by hands played role for this big difference between the actual and ideal

cracking rate.

54
 Cracking Efficiency
90
80
70
60
50
40
30
20
10
0
Cracking Efficiency

Small Medium Large

Figure 4.2: Cracking Efficiency

As what can be interpreted from the graph, medium size Pili nuts

is the most efficient size to crack in the machine, followed by the large size,

then lastly by the small size Pili nuts. This happens because some small size

Pili nuts are too small that it just pass through the space between the cracking

and the gripping blades, therefore the blades cannot penetrate the sheel at

least 1mm to inflict cracking to the nuts.

Whole Kernel Recovery Percentage

105

100

95

90

85

80

75
Whole Kernel Recovery

100 Medium Large

Figure 4.3: Whole Kernel Recovery Percentage

55
 Figure 4.3 shows that even though the small size Pili nuts has the lowest

cracking efficiency, it has the highest whole kernel recovery percentage.

Results say that for every 10 cracked small size pili nuts, 10 whole undamaged

kernel can be recovered.

56
 CHAPTER 5

SUMMARY, CONCLUSIONS AND RECOMMENDATIONS

Summary

The study aimed to design, fabricate and conduct a performance

testing of a rotary bladed Pili nut cracking machine. The study intended to

design the blades for cracking the Pili nut without damaging its kernel,

determine the cracking rate, cracking efficiency, whole kernel recover

percentage, and the economics of the machine. Theoretical cracking rate is

found to be 168 nuts/min, however, actual testing show an average cracking

rate of 43 nuts/min. Cracking efficiency is found to be 63.33% for small size Pili

nuts, 83.33% for medium size, and 81.67% for large size Pili nuts. Whole kernel

recovery for small size is found to be 100%, for medium is 86.09%, and for large

size Pili nuts the whole kernel recovery is 91.91%.

The fabrication of the machine amounted to Php 21,160.00. The

operational cost Php 0.0056/kg.

Conclusion

Based on the data obtained from the tests conducted in the pili

nut cracking machine, the pili nut cracking concept that was proposed is

possible for efficient Pili nut cracking. The pili nut can be cracked without

damaging the kernel with the use of the rotary blades design proposed by the

57
designers, with the right machine adjustments depending on the size of the pili

nut to be cracked.

In terms of efficiency, one major factor that affects the effectiveness of

the cracker is the loading. The pili should be held in the right position in the

blade for it to be cracked successfully, if not, it is either the pili will be stuck in

between the blades or it will be crashed. If the pili is rightly loaded in between

the teeth of the blades it can be cracked successfully. The cracking rate and

efficiency of the machine is significantly lower than the expected output

because of the machine component failures occurred during the test.

In terms of physical properties, the machine is heavy and is difficult to

maneuver when moving to another location. The sharp-edged blade that is

used in cracking the pili nut should be made from a stronger material.

Although the concept of the machine works, the machine may not be

acceptable in the market because of some failures occurred during the test.

And also it still lacks a major component- the loader that will significantly

improve the efficiency of the machine.

Recommendations

For the improvements of the machine, the researchers recommend the

following:

1. Loading

Develop a loading mechanism that will place the pili nut to be

perfectly centered to the blades. It is also advisable to use other

58
 materials on the surface of the hopper or put a coating to reduce

the friction between so the pili nut will slide smoothly.

2. Power Transmission

Try using sprockets instead of belts.

3. Material Selection

Use a more durable material on cutting blades and lighter metals for

body.

4. Body

Design a body that is well balanced and more space for the motor

underneath and trough. Design machine guards that are easy to

detach for maintenance purposes and accessibility to the parts

underneath.

5. Portability

It is advised to put interlocking wheels for easy transportations of the

machine.

6. Adjustability

Develop a design for easy adjustments of the shafts for different

configuration

59
 APPENDIX
Appendix A

Machine Configuration

Figure A-1: The Machine

60
 Appendix B

Materials

Figure B-1: ASTM A36 Metal Sheet for the blades

Figure B-2: ASTM A36 Mild Steel Bar for the shaft

61
 Figure B-3: E6013 Welding Rod

Figure B-4: 50mm x 2mm Angle Bar for the Frame

62
 Appendix C
Tools and Equipment

Figure C-1: Weighing Scale

Figure C-2: Measuring Tape

Figure C-3: Carpenter’s Square

63
Figure C-4: Chop Saw

Figure C-5: Grinder

Figure C-6: Hand Drill

64
 Figure C-7: Drill Press

Figure C-8: Welding Machine

Figure C-9: Lathe Machine

65
Figure C-10: Acetylene Cutter

Figure C-11. Ratchet Set

Figure C-11. PPE’s

66
 Appendix D
Step-by-step Procedure

Design Stage
Figure E-1. Drafting the Plan for the Blades

Fabrication Stage

Figure E-2: Cutting the Flat and Angle Bar for the frame

67
Figure E-3: Welding

Figure E-4: Grinding

68
 Appendix F
Machine Members

Figure F-1: Bolts, Washer and Nuts

Figure F -2: Roller Chain 428

Figure F -3: B25 V-belt

69
 Figure F -4: P205 Pillow Block

Figure F -5: 15T Engine Sprocket

Figure F -6: 1:40 Speed Reducer

70
Figure F -7: 0.75 hp 1720 rpm Electric Motor

Figure F -8: Blades and Shafts

71
Figure C-9: Stand/Frame

Figure F -10: Loader

72
 Appendix G
Assembling

Simulation

Figure G-1: Simulation of shafts’ position.

Figure G-2: Simulation of Shaft connection to Gearbox

73
 Setting-up

Figure G-3: Fastening of Shafts to

Frame.

Figure G-4: Fastening of Motor and Gearbox to the body and attachment of
chains and belts.

74
 Preliminary Testing

Figure G-5: Check of Blade Alignment

Figure G-6: Electric motor test run

75
 Figure G-7: First Pili Nut Cracking test

Adjustments

Figure G-8: Placement of Cardboard Hopper

76
 Figure G-9: Placement of Cardboard Trough

Figure G-10: Elevation of Motor

Placement of 3 1 ½ in wooden blocks to elevate the position of electric motor

77
Figure G-10: Placement of Tensioner

78
 Appendix H
Testing and Data Gathering

Figure H-1: Sorting of Pili Nut according to sizes

Figure H-2: Cracking and Recording of Data

79
Appendix I

80
81
82
83
84
85
Bibliography:

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http://www.cigrjournal.org

7. Frederiksen, W.C., and Kim, S.Y., Nut Shelling Machine. US4793248 A

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www.tradewindsbicol.wordpress.com

86