CHAPTER IV

PRESENTATION, ANALYSIS, AND INTERPRETAION

This chapter shows what design needed to fabricate a Bone Pulverizer and Pellet Molder that

utilizes wasted chicken and pork bones from wet-markets, food stalls and households. It presents

the different labeled views of the project including dimensions, detailed step-by-step fabrication

procedures, the assembling process, the proposed procedure in using the equipment, the

proposed maintenance and troubleshooting procedures, the testing that are needed to be done for

the edibility and quality of the equipment’s output, project cost estimation and its comparison to

the existing machines, and the discussion of how will the acceptability test will be conducted.

I. Computer Aided Design

1. Bone Pulverizer and Pellet Molder

Figure 4.1. Isometric view (front) and parts’ label of Bone Pulverizer and Pellet Molder

2. Bone Pulverizer and Pellet Molder

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 Figure 4.2. Isometric view (back) and parts’ label of Bone Pulverizer and Pellet

Molder 3. Hammermill

Figure 4.3. Isometric view with dimension and parts’ label of Hammermill

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4. Mixer blade

Figure 4.4. Isometric view with dimension of Mixer

blade 5. Pelletizer Screw

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 Figure 4.5. Isometric view with dimension and parts’ label of Pelletizer Screw

6. Bone Pulverizer and Pellet Molder

Figure 4.6. Front view with dimensions of Bone Pulverizer and Pellet

Molder 7. Bone Pulverizer and Pellet Molder

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 Figure 4.7. Back view with dimensions of Bone Pulverizer and Pellet

Molder 8. Bone Pulverizer and Pellet Molder

Figure 4.8. Side view (left) with dimensions of Bone Pulverizer and Pellet Molder

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9. Bone Pulverizer and Pellet Molder

Figure 4.9. Side view (right) with dimensions of Bone Pulverizer and Pellet

Molder 10. Bone Pulverizer and Pellet Molder

Figure 4.10. Top view with dimensions of Bone Pulverizer and Pellet Molder
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 II. Step-by-Step Fabrication Procedures

The process of fabrication was divided into the three devices: Pulverizer, Mixer, and Pelletizer.

While the assembling process is divided into the frame, steam generator and control panel.

A. Fabrication of three main parts:

1. Pulverizer

1.1. The blades are cut using milling machine. 130 mm length, 25 mm width & 4.5

mm thick stainless-steel bar grade 304.

Figure 5.1. Cutting of SUS 304 flat bar for hammer mill blades

1.2. Using drill press, 13 mm holes are created in the blades to allow the small shaft

to hold the blades during operation.

Figure 5.2. Drilling of holes in the blades

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1.3. The center disc of the pulverizer is cut manually using grinder with a diameter of

200 mm, 3 mm stainless steel grade 304 and it is drilled with five holes to hold the

four-small shaft with a diameter of 13 mm and for the main shaft with a diameter of

25 mm.

Figure 5.3. Cutting of SUS 304 plate using grinder for center disk

1.4. Using lathe machine by applying lathe machine processes such as facing and cut-

off main shaft having a diameter of 22mm ,20 mm and 19 mm, small shaft having a

diameter of 13 mm, keys and bushing are created.

Figure 5.4. Lathe process of shaft

1.5. All the parts for the pulverizer are assembled, the center disc is welded to the

main shaft. The blades are adjusted to prevent the blades to collide on its cover.

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 Figure 5.5. Hammer mill blades assembly

1.5.a. For the strainer, perforated screen with 2 mm holes are bent using shear

press. The clearance is set between the tip of the blades and the strainer, for

effective pulverizing. And also, extra tray is created to cover the blades of the

pulverizer after pulverizing.

Figure 5.5.a. Actual strainer using perforated plate

Figure 5.5.b. Bending of plate

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 1.5.b. For its cover, 3 mm stainless steel sheet grade 304 is used. Square bar is

welded on the inner surface to create rough surface on the cover for effective

pulverizing. To prevent wear of blades, proper alignment is required and the

welded square bar is reduced manually by grinder.

Figure 5.5.c. Minor adjustments in the inner surface of the cover

2. Mixer

2.1. The spiral of the mixer is formed using stainless steel grade 304, 2mm thick by

roller milling. And the spiral is welded on its arm having a length of 187.5 mm.

Figure 6.1. Forming the spiral part of mixer blade

2.2. The formed spiral and its support are welded on its shaft with a length of 570mm.

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 Figure 6.2. Actual mixer blade

2.3. For its tray, 3 mm stainless steel sheet is used; it is bent on the shear press.

Clearance is required between the mixer and the tray to mix properly.

Figure 6.3. Actual mixer and tray

3. Pelletizer

3.1. A 3mm stainless steel sheet grade 304 is used in the roller mill to form the spiral

of the pelletizer having a pitch angle and length of 61.99 degrees and 311 mm,

respectively.

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 Figure 7.1. Forming of screw type pelletizer using roller

mill 3.2. The spiral is welded on its shaft with a total length of 570 mm.

3.3. The diameter of cylinder cover for the screw is 73 mm outer and 65 mm inner,

with a total length of 346 mm.

3.4. With the use of dye with a hole diameter of 7 mm, it will serve as the extruder of

the pelletizer.

3.5. At the end of the shaft, the blades are attached so that when screw rotates, the

blades will cut the pellet according to the desired length. The blade holder has a

dimension of 25 mm outside diameter and 12 mm inside diameter.

B. Assembly

1. Frame

1.1. A 25 mm x 25 mm x 3mm grade 304 stainless steel angle bars is used for the

structure of the machine having a maximum height of 1,230 mm, 477 mm length and

923 mm width.

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 Figure 8.1. Welding of SUS 304 angle bars for the frame of the equipment

1.2 It is joint through welding.

Figure 8.2. Actual welding of angle bars

1.3. For the motor support, the space allotted is 461.4 mm length and 477 mm width

to allow adjustment of motor distance base on the length of the belt.

1.4. A42 COG belt is used for the pulverizer and mixer and A51 COG belt for the

pelletizer

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1.5. For the cover of the machine, it is designed with an opening or drawer type for

the strainer of pulverizer and tray for the mixing chamber. The design length is 405

mm, width of 419.8 mm and height of 158 mm.

Figure 8.3. Drawer Assembly

1.6. The pulverizer cover is designed to prevent the spill out of the materials to be

grind, its height is 450.12 mm, 338.5 mm length and 421 mm width. The hopper is 60

degree inclined and it is bolted to the frame.

Figure 8.4. Hopper assembly

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1.7. In the mixing chamber the opening or the drawer is design to allow user to put

the ingredients. It is connected to the cover by a pin having a height of 66.5 mm,

width of 419.8 mm.

1.8. For the molding section, hopper is design to allow the mixture to slide through

the pelletizer. It is 444 mm in length, 405 mm width and height of 184 mm.

Figure 8.5. Actual plate of the mixer

1.9. The cylinder of the pelletizer or screw is welded on the hopper.

Figure 8.6. Actual cylinder of the pelletizer

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1.10. The molding section is bolted on the frame of the machine, to allow the user to

clean the molding section.

1.11. Sliding tray at the bottom of the frame is designed to support the container to be

used by the user to collect the finish product. It is 400 mm in width and length of 422

mm.

Figure 8.7. Actual sliding tray

1.12. Adjustable footing and 38 mm caster wheel are used to support the entire

machine. It is bolted on the frame of the machine.

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 Figure 8.8. Actual footing and caster wheel

2.Steam Generator

2.1. For the container, the 3 mm stainless steel was rolled using roller mill to form a

container with a diameter of 200 mm and 250 mm length, having a capacity of 2.5 L.

1.5 L is the design amount of water to be heated, so that the steam may generate at

faster rate.

Figure 9.1. Container of steam generator

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2.2. A 25 mm nipple is welded at the top of the container that will serve as an inlet of

the container.

Figure 9.2. Inlet of the container

2.3. To generate steam, 3kW immersion heater is used having a 300 mm length of coil.

2.4. Small tube is welded at the top of the container; it will serve as exhaust of the

steam.

Figure 9.3. Exhaust of the steam generator

2.5. At the side of the container, 30 mm stainless steel pipe is welded connected to the

mixing chamber.

2.6. 1‘’ gate valve is connected to the 30 mm pipe to control the amount of steam.

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 Figure 9.4. Gate valve attached to steam pipe

3. Control Panel

3.1. For the electrical supply of the entire machine, 30 Ampere circuitbreaker is used.

3.2. 1.5 Hp single phase induction motor is used for the pulverizer, and 1 Hp

induction motor for the mixer and pelletizer. The motors are bolted in the frame. For

the wirings, #10 solid wire is use.

Figure 10.1. Induction motors used in the equipment

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3.3. A 30 Ampere push button switch is used for both motors.

3.4. To reduce the speed of 1 Hp motor, voltage regulator is used. But during the

testing the speed regulator is not enough to lower the speed of the 1 Hp motor.

Frequency regulator is recommended to use to lower the speed of the motor.

Figure 10.2. Speed regulator (left) and Frequency regulator (right)

3.5. All the switches, breaker and regulator are bolted in the stainless-steel panel.

Figure 10.3. Control panel assembly

3.6. #12 flat cord duplex wire and heavy-duty plug is used for the main line.

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 Figure 10.4. Flat cord duplex wire (left) and heavy-duty plug (right)

III. Proposed Procedure of Using the Equipment

A. Proper set-up and start-up

1. Check if the equipment is on an even surface.

2. Adjust the footing until the equipment is stable.

3. Put water on the steam generator about three fourths of the container.

4. Turn on the steam generator to start producing steam and check if the gate valve

is closed.

5. Check if the plates are in place.

6. Check if the blades hit the casing of the hopper.

7. Put a container on the outlet to catch the pelletized dog food.

8. Switch off the breaker and the motor switch before plugging the equipment.

B. Running the equipment

1. Open the breaker and switch on the motor of the pulverizer. Put a desirable

amount of dried and chopped chicken/pork bones on the hopper.

2. Put the uncrushed bones accumulated on the perforated screen back on the hopper. 54
 3. When the bones are pulverized switch off the motor of the pulverizer.

4. Put the plate between the pulverizer and the mixer. Put vegetable oil on the

pulverized bone then close the cover. Open the gate valve of steam generator for

steam to flow.

5. Switch on the motor of the mixer then adjust the speed regulator to reduce the

speed of the mixer.

6. After the pulverized bone and oil is mixed turn off the motor of the mixer, close

the gate valve and remove the plate between the mixer and pelletizer and let the

mixture fall on the pelletizer.

7. When the pellet is produced, switch off the motor, steam generator and the breaker.

C. Finished using the equipment

1. Remove the plug of the equipment.

2. Place back the plates on their places.

3. Clean the hopper, blades, mixer and pelletizer before using the equipment again.

IV. Maintenance and Troubleshooting

Scheduling of Regular Maintenance:

Cleaning the inner part of the equipment must be done by the owner every time the type

of input bones will be changed. The researchers made the input container part for both the

pulverizer and mixer a drawer type and the parts of the pelletizer to be detachable for the

owner or user can wash it easily and properly. Regular observation of the equipment’s

different parts is a must for the owner or user; researchers suggest do it at least every month.

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 Keenly, observe the volume produced by the equipment by measuring either the mass or

the number of pellets produced in a controlled volume of input.

Troubleshooting:

1. A drop of 15 to 20% in capacity is an indicator that the pelletizer needed its

screen to be changed.

2. Hammer should be replaced whenever the wear extends about 25% along with the

width of the hammer.

3. Hammer pins should be replaced whenever there is a change in hammers.

4. Bearing, Coupling, and key can be changed at least every 6 to 12 months of used.

5. Used lubricants regularly for the equipment to run smoothly and to decrease the

wear rate of different parts.

6. Check every nut and bolt in the machine, tighten if necessary, to avoid

disassembly of every part.

V. Testing to be done

The output pellet they will be produced by the equipment shall undergo a reagent test that

will be conducted by the researchers. In this test, the researchers will submerge a pellet into

different reagent solution and the chemical reaction produced will determine if the output

pellet contains nutrients such as protein and fat. Although this test is incapable of telling of

how much of these nutrients are present in the pellet. With this, the researchers decided that

they will bring the output pellet into a Bureau of Food and Drugs (BFAD) certified

laboratory to obtain the actual percent by volume of nutrients that are present.

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 VI. Project Cost Estimation

Table 3. Costing of Materials of Bone Pulverizer and Pellet Molder

Unit
Materials Description Quantity Unit Amount
Price

1HP; 1740 RPM; 220V;

1. Induction motor 1 pc 2,000 2,000
7.7A; 60Hz

2. Single phase 0.25HP, 120RPM, 220V

1 pc 5,200 5,200
induction motor

3/8" x 200mm; 3000W x

220V; single phase;

3. Immersion heater 1 pc 4,000 4,000
stainless steel; square

flange; 3 x 3

4. Wire #10; solid wire 3 m 39 117

5. Heavy duty plug 1 pc 50 50

6. Circuit Breaker w/
30A 1 pc 300 300
housing

7. Push Button 30A 1 pc 130 130

8. Speed Regulator 1 pc 200 200

9. Gate Valve 1"; brass 1 pc 500 500

10. Nipple 1x5; stainless steel 1 pc 120 120

11. Pillow block

#204 3 pc 250 750
bearing

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12. Pillow block
#205 2 pc 280 560
bearing

13. Steel matting #8; 4x8 1 pc 320 320

14. Male Plug 3/4"; stainless steel 1 pc 110 110

15. Coupling 3/4"; stainless steel 1 pc 170 170

16. Elbow 3/4"; stainless steel 1 pc 120 120

17. Cable tie 5x350 1 pack 195 195

18. Flat cord wire #12, duplex 3 m 62 186

19. Quick drying Jade green paint with

1 L 165 165
enamel paint brush

20. Belt COG belt; A41 1 pc 300 300

21. Belt COG belt; A51 1 pc 320 320

22.Coupling and Ncap Both ½ size 1 pc 70 70

23. Bone pulverizer
fabrication and materials 1 pc 68,650 68,650
and pellet molder

Materials:

1.2mm; 4mm thickness;

SUS 304 plate
hairline finish

SUS 304 angle bar 3mm x 1" x1"

SUS 304 rod 38mm diameter

SUS 304 rod 25mm diameter

SUS 304 rod 12mm diameter

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 3mm x 25mm x 4.5mm x
SUS 304 flat bar
25mm

pulley cast iron

bushing tiger bronze

3/8" diameter; schedule

SUS 304 pipe
30

2/5" diameter; schedule

SUS 304 pipe
40

SUS 304 perforated

3mm hole diameter
plate

caster wheel 38mm

Bolts and nuts

Total amount in peso: 84,533

Table 4. Estimated Cost of existing Pulverizer and Pellet Molder

Unit
Machine Description Quantity Unit Amount
Price

A machine unit used to

pulverize different types

1. Payo Hammer mill of raw products like 1 pc 60,000 60,000

bones, shells and etc.to

make feeds or other

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 related products such as

corn bran and powder.

A machine unit used for

2. KL Animal and grinding and pelletizing

Poultry Feed plate corn, grain, soybean and

1 pc 152,000 152,000
die pellet mill other beans. It is widely

machine used in feeds production

in poultry fields.

Total amount in peso: 212,000

VII. Survey Questionnaire

A. The researchers set the dog owners of Bulacan, Bamba’s Animal Shelter (also known as

Happy Endings Animal Shelter) at Marilao Bulacan as the population of this study. The wet

market vendors in Balagtas Bulacan, workers at the Wing Bites with the Students of Bulacan

State University (BulSU) will participate in the acceptability test of the study.

B. The researchers decided to use the stratified sampling technique and simple random

technique for this study. The stratified sampling technique will be applied through the

wet market vendors in Balagtas, Bulacan, workers in the Wing Bites and volunteers at

Bamba’s Animal Shelter while the simple random technique will be used in selecting

respondents among households and dog owners in Bulacan and mechanical engineering

students at BulSU.

C. The sample size of this study will be composed of five meat vendors in Balagatas,

Bulacan Wet Market, four workers at Wing Bites because they are the persons who serve

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 food to the customers, fifty pet owners in Bulacan, three professional veterinarians along

with all the volunteers in taking care of the dogs, and fifty random mechanical

engineering students.

C. Descriptive Statistics are descriptive coefficients that summarize a given data set which

represents the entire or sample of a population. It is broken down into measures of central tendency

(mean, median, and mode) and measures of variability (standard deviation, variance, ranges, and

kurtosis). In short, it helps describe and understand the features of a specific data by giving

summaries about the samples and measures of the data. These will be used by the researchers in

interpreting the results of the instruments to draw the conclusion whether the study is acceptable to

the end users. Descriptive Statistics is useful in converting qualitative results into numbers with the

help of the instruments.

VII. Procedure

 Pulverizer

Before placing the bones in the hopper, first make sure that it is dry atleast 80-90 percent

and chopped into slices or in cubes form. Have an interval of time for the next bones to

be inserted in the hopper.

 Mixer

After the bones become pulverize, it will go to the strainer which is under the pulverizing

chamber. The pulverized bones that are filtered will go into the mixing chamber. Before

opening the steam inlet, make sure that the separation plate is placed between the

pulverizer chamber and mixer chamber to prevent corrosion and damage to the pulverizer

blades. While mixing is ingoing, put all the necessary ingredients that you might want to

use for better production of pellet.

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  Pelletizer

The mix ingredients will go into the pelletizer. Cover the front with its accurate

cover. Underneath, put a container and let it fall until everything is pelletized.

Test and result:

Test trial;

 Weight of bones tested: 1kg

 Time to grind 1kg of bones: 26 minutes, 27.42 seconds
 In 1kg of bones:
Finely grounded: 108g Uncollected fine: 337g
Coarsely grounded: 329g Uncollected coarse: 104g
Total collected = 437g Total uncollected = 441g

(Some ground bones were uncollected due to accumulation and compaction on the
crusher plate during the grinding process. The small angle of the hopper also prevents the
proper flow of the bones.)

Input: 1,000g
Output: 437g + 441g = 878g
Total losses: 1,000g – 878 = 122g ~ %12.2

 Mixture that yielded the best result:

- 200g of ground bones
- 65g of corn starch
- 2 tablespoons of water
- 4 tablespoons of palm oil

Produced Pellet:

From the mixture of 349g, there is 305g of that were being pelletized. There are

formed at least 100 and not more 200 pieces of pellets.

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