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5 November Project
5 November Project
5 November Project
Table of Contents
ACKNOWLEDGEMENT............................................................................................................2
DECLARATION...........................................................................................................................3
CHAPTER 1....................................................................................................................................4
1.0 INTRODUCTION.....................................................................................................................4
3.0 OBJECTIVES............................................................................................................................7
5.1 INTRODUCTION.................................................................................................................9
7.0 METHODOLOGY..................................................................................................................17
7.1 INTRODUCTION...............................................................................................................17
7.3.4 FRAME.........................................................................................................................19
11.0 BUDGET...............................................................................................................................34
12.0 REFERENCES......................................................................................................................35
ACKNOWLEDGEMENT
We would like to thank Almighty God for the grace, love and good health throughout our time
we have been relentlessly working on this project.
We also thank our project supervisor, Mr. W. Salima for being with us all the time of the project.
He was available at any time we needed him for assistance.
Special thanks goes to our coordinator, Mr. G. Nyirenda for his assistance in everything which
we were doing. We also thank our classmates (BME3) for their support and suggestions
pertaining to engineering technicalities.
Lastly, we thank all lecturers for their support.
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DECLARATION
This project report is a partial fulfilment for degree in Mechanical Engineering at third year for
the authors, David Chikuse (BME/21/ME/004), Pempho Agagi (BMMP/19/SS/003) and Idrissa
Mussa (BME/19/SS/010). We hereby sincerely declare that this project report is genuine. The
work is absolutely of students.
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DESIGN AND MANUFACTURE OF A LOCALLY BROILER DEFEATHERING MACHINE
FOR SMEs
CHAPTER 1.0
1.1 INTRODUCTION
David Kart (2013) defines poultry farming as the process of nurturing domesticated birds such as
chickens, ducks, geese, and turkeys to cultivate meat or eggs for food and other purposes. Most
of them are classified based on economic value or purpose, which may be of meat type, egg type,
game, etc. Changing food habits, globalization, industrialization, and urbanization have created a
favorable atmosphere for the development of the poultry sector. Poultry is one of the fastest
growing segments of livestock in the agriculture sector and contributes a major share in terms of
protein supplementation from eggs, and meat. As of now, the USA is the largest poultry producer
worldwide and South Africa, Nigeria, Egypt, and Ghana are the largest producers in Africa,
CASA (2020).
According to the CASA (2020) poultry annual growth in Sub-Saharan African countries shows
that Cameron is the largest followed by Malawi and then Tanzania. Nevertheless, these countries
are facing many challenges such as a lack of poultry development strategy and policy, unfair
trading and competition policies, a lack of effective regulatory framework, and poor enforcement
of poultry-import regulatory controls. Despite all these challenges, these countries strive in the
game.
Noem, K. (2015) found that the production of poultry meat in Malawi improved by 3.74% from
105,248 tonnes in 2019 to 109,186 tonnes in 2020. Some 1.3 million households are rearing
chickens and the total chicken production as of 2019 was 160 million (indigenous; 67 million,
broilers; 83 million, layers; 8 million and black Australorp, 2 million). APES report, (2018/19),
indicates that production estimates of the chicken population grew from 84.5 million in 2015 to
160 million in 2019, while egg production increased from 4700 tonnes in 2015 to 10300 tonnes
in 2019.
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Broilers are chickens that have been bred for meat and usually they reach slaughter weight at
about 42 to 56 days under good management. These chickens were bred from two breeds, the
white Cornish (male line) and the Plymouth Rock (female line) by crossbreeding of those two
lines. According to Chindikani K. (2017), available broilers in Malawi are Squab, Label, and
Conventional broilers. These broilers are much reared for subsistence and commercial purposes.
De-feathering involves removing feathers from the slaughtered bird. There are several methods
of plucking feathers from chicken. These methods include plucking by hand and machine. In
hand plucking, a chicken is immersed in hot water of at most 160ºC for 30 seconds to a minute.
Thereafter, the scalded carcass is taken to the table, and feathers are plucked off by hand. On the
other hand, de-feathering chicken by machine involves soaking chicken in hot water at a range of
temperature 66ºC to 80ºC for 90 seconds before putting it into the machine. Thereafter, it is taken
to the machine that removes feathers.
The mechanical chicken de-feathering machine is helpful to small and medium enterprises
(SMEs). David R.A (2019), stated that the machine will not take more time to pluck a chicken
feather compared to traditional method. This means that the time for de-feathering a chicken will
be reduced. Therefore therenis a need to design and develop de-feathering machine.
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1.2 PROBLEM STATEMENT
Traditionally in Malawi, de-feathering process is done manually by the use of a hand after
chicken has been soaked in hot water. Moreover, it is also time and energy consuming. This
process takes a lot of time. According to Ken Gies (2022), plucking one chicken takes an average
time of two minutes, hence in large quantities de-feathering places that de-feathers 100 chickens
will require three and half hours to complete. Moreover, research at Zimatha Lodge &
Restreurant (Lilongwe), shows that plucking one chicken by hand costs an average amount of
MK500.00. This implies that for 100 chickens the cost will be MK50,000.00. As a result SMEs
will require more labour and costs to de-feather chickens.
To overcome the challenges in manual de-feathering there is a need to design and manufacture
de-feathering machine.
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1.3 OBJECTIVES
1.3.1 Main Objective
To design and manufacture a locally de-feathering machine capable of handling 2 to 3 chickens
per run.
two-three (2-3) broiler chickens per run using AutoCAD (2019) and Solid works (2019).
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1.4 SCOPE OF THE PROJECT
This project focuses much on designing a machine that can handle three chickens per run. These
chickens will have to be soaked in hot water in a separate container. The feather collection
chamber of this machine will be removable. Most parts of the machine will be manufactured
using locally available materials.
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CHAPTER 2
2.0 LITERATURE REVIEW
2.1 INTRODUCTION
This literature review talks about the overview of different types of de-feathering machine,
operating principles as well as advantages and disadvantages. It is also talking about the main
individual components of the product. What they are made up of, how strong they are and the
reasons of using such type of materials.
2.2 OVERVIEW OF DEFEATHERING MACHINE
A de-feathering machine is an equipment used to remove feathers from poultry after being
slaughtered. Most de-feathering machines can process many types of poultry, though some may
have trouble with heavier birds such as turkeys. Depending on the model and method, most
defeathering machines takes one to six minutes to completely pluck off all the feathers of a bird.
The defeathering machine often applies a lot of force to get the feathers off the poultry, but
normally it does not damage the skin.
FIGURE 2.2.1: A FEATHER THAT CAN BE PLUCKED OFF FROM THE CHICKEN
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Interior view
Figure 2.3.1: De-feathering Machine with its interior Figure2.3.2: Bottom rotating plate
view at the left-hand side top corner
2.4 TYPES OF DE-FEATHERING MACHINE
Geldof, H. (2015), classified defeathering machine equipment for poultry into three types,
namely; A-Shaped poultry de-feathering machine, 7-Axis de-feathering poultry machine, and
Drum chicken de-feathering machine.
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Figure 2. 4.1.1: A-Shaped Poultry Defeathering Machine
Advantages:
1. High efficiency in removing the feathers
2. All cases are movable and can change position according to need.
3. Each box can be adjusted up and down, forward and backward
4. Easy to clean and maintain.
5. Long service life.
Disadvantages
1. It is fixed on one position.
2. Mounting on concreate surface is expensive
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Fig.2.4.2.1 Seven-Axis De-feathering Machine Fig. 2.4.2.2 Interior View of seven
Axis
de-feathering machine
Advantages:
It is time saving
Space between rollers is adjustable, suitable for different size poultry.
High capacity. Every 50-60 seconds, it could pluck 10 chickens; that is per run
High plucking rate up to 99%;
Easy to clean and maintain
Long service life.
Disadvantages:
It is expensive to manufacture
Fixed on one position (mounted on concrete floor)
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2.4.3 DRUM DEFEATHERING MACHINE
Drum defeathering machine is used to remove the poultry feathers automatically. According to
Geldof, H (2015), the performance of one set machine is equal to the labor of more than ten
people. Up to 99% plucking rate, suitable for the medium and large poultry industry. Geldof, H.,
also pointed out that the greatest feature of this machine is that the poultry need not be unhooked
from the conveying rail when plucking, so it saves the troubles of unhooking and re-hooking.
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3. In around 10 seconds, open the water tap to wash away poultry feather, after a while, stall the
machine and take out the products. Normally it takes only 30 seconds to clean chicken feathers
Advantages
It is movable
Easy to manufacture
Very easy to maintain
Disadvantages:
Low capacity. Maximum of 2 chickens per run.
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Fig. 2.4.4.1 Showing specific parts of the de-feathering machine
(Source: Mechanical chicken defeathering machine by Michael John Estrella
2021)
2.4.4.1 Pluckers
According to the International Journal of Multi-Disciplinary Poultry Research, (2012); finger
pluckers are produced by modern equipment, only with prime natural rubber, no synthetics, and
tested, materials provide high flexibility, long resistance, and performance. Production covers a
wide range of finger pluckers, offering the right solution to each operation of the plucking
process and products with suitable plucking plan for these pluckers can easily connect with the
stainless-steel body, ensuring stability and solidity. They are detachable for convenient
installation and replacement. There are two types of fingers and these are:
1. Ring-shaped for large feathers and
2. Ball shaped for fluff and small feathers
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Fig.2.4.4.1.1: Ring-shaped rubber finger Fig. 2.4.4.1.2. Ball shaped
rubber finger
.
2.4.4.3 Drum
The drum is the chamber in which the chicken is being thrown. It is also fitted with rubber
plucking fingers inside it. It made from either metal or plastic.
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Fig. 2.4.4.3.1 Metal Drum
2.4.4.4 Motor
This is part of drive mechanism. It is a source of power connected directly to the rotating base.
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Chapter 3
3.0 METHODOLOGY
3.1 INTRODUCTION
This section presents a detailed explanation of how the chicken de-feathering machine will
be designed. First, the major activities in conducting the study are discussed, starting from
design consideration to performance tests and validation of the machine efficiency. The
following is flowchart of the major activities.
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Flow chart 3.2.1 showing series of the activities
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3.2.1 Design Consideration
Design requirements were synthesized based on the analysis of findings in the various literatures
reviewed and from patented and commercial mechanical chicken defeathering machine gatherer.
Some of the identified design requirements were the following:
1. The machine should remove the feather from the slaughtered chicken.
2. The machine should not take up too much of the worker’s time and should speed up the
defeathering process.
3. The machine should be of intermediate technology, built local materials using local
manufacturing techniques, easy to run and maintain, functionally and structurally sound, and
require minimal tooling.
The drum will consist of stainless steel of 1mm thick, the diameter of drum is 470mm (Estrella,
2021) and a length 500mm.
3.2.3 CALCULATIONS
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Certain calculations were made on certain parameters to make correct choice in selecting them.
Design calculations were carried out on the following:
¿ 3.142∗0.47∗0.50
¿ 0.74 m 2
Length = 580 mm
Breadth = 570 mm
Area of frame = Length × Breath
length = 580mm = 0.58m
breath = 570mm = 0.57m
= 0.58 × 0.57
=0.331m2
3.2.3.3 MOTOR CALCULATIONS
workdone mgd
Power of the motor= =
time t
m=mass of the rotating plate+mass of the shaft + mass of thechickens
m=1 kg+ ( 4∗3 ) kg+ 1.6 kg=14.6 kg
g=9.81 m/ s 2
d=0.025 m
t=1 s
14.6∗9.81∗0.025
Power of the motor= =3.56 kW
1
120 f 120∗50
the speed of the motor= = =1500revs /min
p 4
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3.2.3.4 ROTATING PLATE CALCULATION
To calculate the area of the rotating plate, the following analysis was been
carried out:
A=π r2
= 3.142 × (0.43)2
= 3.142 × (0.1849)
=0.58 m2
120 f 120∗50
the speed of the rotating plate= = =1500 revs /min
p 4
The choices of the material and component will be based on the consideration of the following:
cost analysis of the material, durability of the materials and availability of the materials.
The materials selection will consist of the following:
a. Stainless plate- It has a very corrosion resistance
b. Angle bar - It is very rugged and easily to fabricate.
c. Electric motor - To transmitting the torque, with aid of V-belt.
d. Plücker’s rubber – For flexibility when plucking
e. Bolt and nut - It is used to couple the drum and frame together.
f. Paint - To enhance the resistance to corrosion
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The preliminary testing of the mechanical chicken defeathering machine will be conducted after
the fabrication. Adjustments will be made after the preliminary testing in order to attain the best
results for the final testing.
b. Testing Procedure
The first step in testing the machine will be the setting schedule at the poultry farm. Next will be
the preparation of the sample broiler chicken and materials needed in testing. The third step will
be the start of the operation by the operator in terms of scalding the chicken in hot water at about
70ᵒc for 45-50 seconds and then introduce into produce into plucking system. The timer started
when the chicken is dropped inside the plucking machine. After defeathering, the data gathering
started.
d. Final testing
The following data will be gathered for analysis during final testing:
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functionality and explore alternative means and achieving that functionality. The chart enables
solutions to be expressed and provides a structure for considering alternative combinations.
NAME A B C
DRUM
RUBER
BELT
STAND
BEARING
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MOTOR
PULLEY
BASE
GEARS
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SPROCKET
Multi-strand sprocket
Chain sprocket
CHAIN
Leaf chain
Silent chain
HANDLES
Handwheel
The concepts below were generated by choosing randomly parts from the morphological chart.
The generated concepts are as follows:
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FIGURE 4.1.1.1; MAJOR PARTS OF DRUM DE-FEATHERING
MCHINE
Description
A drum with pluckers
A rotating base fixed with pluckers
A driving motor fixed directly to the rotating base.
a motor mounted to the table
the opening is at the top of the drum
Operation
As the motor rotates, it drives the rotating base together with the pluckers fitted to it directly. As
it rotates, it generates a centrifugal force that spines the chicken in the drum and it also generates
friction force between a chicken and the pluckers thereby removing chicken feathers.
Advantages:
1. it easy to manufacture
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2. easy assemble and dismantle
3. materials are readily available
4. can be taken to other places
Disadvantages:
1. it has a fixed speed
2. manufacturing costs are a little bit higher
Description:
1. A drum with pluckers on it.
2. A horizontal rotating rotor fixed with pluckers
3. A sprocket of larger diameter is mounted to the table
4. A smaller sprocket mounted directly to a rotor shaft
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5. A chain connects a smaller and larger sprocket
6. the opening is at the side of the drum
Operation
This machine is operated manually. The person rotates a larger sprocket using a handle. It drives
the smaller sprocket by the means of chain.a This smaller sprocket drives the horizontal rotating
rotor. This generates a centrifugal force that brings motion of the chicken in the drum. This
motion brings friction force between a chicken and the pluckers thereby removing chicken
feathers.
Advantages
1. It is cheap to manufacture
2. easy assemble and dismantle
3. materials are readily available
Disadvantages
1. It is tiresome
2. it has a fixed speed
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Description:
1. A drum with pluckers
2. A rotating base fixed with pluckers
3. a motor mounted to the table
4. the opening is at the side of the drum
5. A driver pulley fixed directly to the motor
6. A driven pulley fixed to the rotating base
7. A driver and driven pulley connected by the belt
Operation
As the motor rotates, it drives the driver pulley which in turn drives the belt that drives the driven
pulley. This driven pulley drives the rotating base. This generates a centrifugal force that brings
motion of the chicken in the drum. This motion brings friction force between a chicken and the
pluckers thereby removing chicken feathers.
Advantages:
1. Speed can be adjusted
2. easy assemble and dismantle
3. materials are readily available
Disadvantages:
1. it is not easy to manufacture
2. it is expensive.
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4.1.4 MANUAL DE-FEATHERING MACHINE
Figu
re 4.1.4.1: Manual de-feathering machine
Operation
This machine is operated manually. The person rotates a handwheel using a handle. It drives the
larger gear by the means of a shaft. This larger gear drives the smaller gear. This drive es a
rotating base. This gena rates centrifugal force that brings motion of the chicken in the drum.
This motion brings friction force between a chicken and the pluckers thereby removing chicken
feathers.
Advantages
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1. It is cheap to manufacture
2. materials are readily available
Disadvantages
1. It is tiresome
2. it has a low speed
Rusett, C. (2022) states that a great ideal concept evaluation matrix incorpolates as many factors
as possible. For instance, how much will the idea cost to implement and run? How long will it
take to implement? And does it align with your strategic goals? The criteria used in this
evaluation matrix will evaluate the ideas generated thoroughly and reliably to conform to the
goal of the project.
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Criteria
Durability D + + + - D - + - + D 0 - - 0 D
Cost of + + + - - - - + - - + +
Materials
A A A A
Performance + 0 + - + 0 + + - - -
-
(efficiency)
Weight T + + + - T - - - + T 0 - + 0 T
Safety + 0 0 - - - 0 + + 0 + -
speed - - + + - + + + + - - -
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U
Easy to + 0 + - + 0 + + - - -
-
Operate
Easy to + 0 + - 0 0 + M + - 0 -
U U - U
Maintain
Easy to + + + - - - + 0 - + 0
-
Manufacture
TOTAL M
0 =5 , - =2 , + = 0=M
1, - =21 , + 0=7, - =5, + =15, 0 = 5, - = 17, M
+=
20 =5 5
KEY:
+ represent better than
0 represent neutral
NOTE:The winning concept should have more positives (+) than other concepts, so according to our
evaluation concept 1 is the winning concept.
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CHAPTER 5
Data collection
Preliminary design
Detailed design and
costing
Concept evaluation
Proposal writing
first presentation
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Proposal
submission
Material
procurement
Manufacturing and
assembling
Project budget
submission
Testing and
evaluation
Report presentation
and submission
5.1 BUDGET
ITEMS AMOUNT
Internet bundle K31,500
Solidworks software K40,000
Auto CAD software K40,000
TOTAL K115,500
CONCLUSION
In this project report, we have provided an overview of issues concerning different aspects of de-
feathering machine. This project focuses on principle of de-feathering broiler chicken and
machine parameters. The following major conclusion have been drawn from this project report;
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Historical development of the de-feathering process from ancient time to modern time.
Various parts and components of de-feathering machine have been explained
Calculations has been done in order to come up with the recommended sizes of different
components and parameters of the machine.
Different types of de-feathering machines have been discussed.
RECOMMENDATION
The machine has been designed and simulated having a capacity of 2-3 broiler chickens. The
future designers and manufacturers should consider manufacturing of this de-feathering machine.
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REFERENCES
1. http://knoema.com/atlas/Malawi/topics/Agriculture/live-stock-production-production-
Quantity/Production-of-poultry/
2. Malawi government- Department of Animal Health and Livestock Development,
Livestock production Estimates (APES), 2018/19
3. http://chindikanikaseka.blogspot.com/2012/01/broiler-production-in-Malawi-and-htmi…
4. https://www.raniche.com/horizontal
5. https://www.surehatch.com
6. Parker Hannifin Corporation, 2015; Engineering your Machines
7. David R.A. (1999). You can build your mechanical pluckers. (whizbang)
http//www.FAO.Org.
8. Nigerian Journal of Animal Production Farm Mechanization Section. Animal Production
Association of Nigeria. Vol 2
9. Zulu Bwalya Kenny, (2017), The International Journal of Multi-Disciplinary Research
10. Adeola, S. O., Omowunmi, A. S., and Lucas, E. B. (2012). Investigation into mechanized
defeathering process and optimal scalding temperature of exotic and local birds in
Southwestern Nigeria. Transnational Journal of Science and Technology vol. 2, No.3, pp
87-96.
11. Adeola, S. O. Daramola, G.A. and Gouldian, S.O. (2014); Development of a Household
Poultry Defeathering Machine with Better Efficiency. IOSR Journal of Mechanical and
Civil Engineering Vol. 11, Issue 3 Ver. VIII Pp 51-59
12. https://qdtent.en.made-in-china.com/product/bvxJSBEPsVpG/China-New-Design-
Poultry-Plucker-Defeathering-Plucker-Drum-Plucking-Machine.html
13. Charlie de Rusett, (2022), Idea Evaluation Matrix: Step-by-step guide. Article: Idea
Management
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