PERFORMANCE EVALUATION OF AUTOMATED CASHEW

GRANULAR PACKAGING MACHINE

PRESENTED BY

ODELUSI BOSEDE LOVETH

FPA/ME/20/3-0040

SUBMITTED TO
DEPARTMENT OF MECHANICAL ENGINEERING
SCHOOL OF ENGINEERING
THE FEDERAL POLYTHECNIC ADO-EKITI,
EKITI STATE, NIGERIA

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE

AWARD OF HIGHER NATIONAL DIPLOMA IN MECHANICAL
ENGINEERING

i
 DECEMBER, 2022.

DECLARATION

I, ODELUSI BOSEDE LOVETH, with matriculation number FPA/ME/20/3-

0040, submitted this final year project report titled “PERFORMANCE
EVALUATION OF AUTOMATED CASHEW GRANULAR
PACAKAGING MACHINE” to the department of Mechanical Engineering in
partial fulfilment of the requirements for the award of Higher National Diploma
(HND) in Mechanical Engineering Technology. I asserted, in complete
agreement with my supervisor(s), that this project is my original work and that
it has not been submitted in this or any familiar form at any other institution.

Name: ___________________________ Matric No: ________________

Signature: ________________________ Date: _____________________

MR. A.B. FALANA _____________ _______________

Project supervisor Signature Date

ENGR. I.S. AJAYI _____________ _______________

Project supervisor Signature Date

ENGR. DR. S.O. EJIKO _____________ _______________

Project Supervisor Signature Date

ii
 CERTIFICATION

This is to certify that the final year project titled “PERFORMANCE

EVALUATION OF AUTOMATED CASHEW GRANULAR
PACAKAGING MACHINE” was duly prepared and submitted by ODELUSI
BOSEDE LOVETH with matriculation number FPA/ME/20/3-0040 submitted
this final project report entitled to the Department of Mechanical Engineering
Federal polytechnic, Ado-Ekiti in partial fulfilment for the award of Higher
National Diploma (HND) in Mechanical Engineering.

MR. A.B. FALANA _____________ _______________

Project supervisor Signature Date

ENGR. I.S. AJAYI _____________ _______________

Project supervisor Signature Date

ENGR. DR. S.O. EJIKO _____________ _______________

Project Supervisor Signature Date

ENGR. DR. S.O. EJIKO _____________ _______________

Head of Department Signature Date

iii
 DEDICATION

This report is dedicated to God Almighty, the giver of life and the maker of all
things who has been there for me right from the onset to this very point and who
made this Higher National Diploma Programme to be successful for me. Also
special dedication to my beloved and supportive parents for their moral,
spiritual and financial support right from the beginning of my pursuit in
engineering field.

iv
 ACKNOWLEDGEMENT

I give glory to God almighty for his grace, wisdom and strength being given
unto me and for seeing me through my entire stay on campus and for the
knowledge being given to me to complete this project successfully.

Special appreciation goes to my beloved parents, relatives and friends for their
caring attitude, unconditional love, financial and inspirational support from the
beginning of our program to this very point.

I’m profoundly grateful to my supervisors, Engr. Dr. S.O. Ejiko, Engr. I.S.
Ajayi and Mr. A.B. Falana for their intellectual support and assistance rendered
to me in the course of this special project.

Also special thanks to the H.O.D in person of Engr. Dr. S.O. Ejiko for his
contribution and many words of encouragement towards us throughout our
programme.

I also would like to appreciate my project mates in person of Fatola Ayodeji

Isreal and Ojibutu Gbenga Joseph for their immense support and cooperation
towards the success of this project.

A big thanks to all lecturers and staffs in the department of Mechanical

Engineering for their academic, inspirational and moral guidance. Thanks to
you all and God bless you all.

v
 ABSTARCT

The cashew nut, a by-product of the cashew tree, is very important to humanity
and is greatly sought after because it contains oil that may be consumed directly
or utilized as a raw material for other goods. They are considered to be good
source of nutrition such as copper, magnesium and manganese also the tree has
other uses which includes medicines and construction. The purpose of the
automated cashew nut granular machine is to decrease labour intensive tasks,
increase processing capacity, and assess the processing loss of nuts after
granulating, conveying, and sealing. This paper presents the performance
evaluation of automated cashew granular packaging machine. The electrically
operated three -in- one cashew granular packaging machine comprises of the
granulator, conveyor and sealing machine with three electric motors of
1horsepower each were all designed with several factors put into consideration
to enable effective and efficient performance of the machine and were all
evaluated. The machine was made to improve the packaging process'
effectiveness when processing cashew nuts. The machine milling efficiency is
98.5% synchronizing two of the three compartments such that a single motor
will serve for both the milling and conveyor part, will significantly reduce the
cost of production. The application of the machine by farmers will give room
for the production of package uncontaminated powder cashew nut at higher
efficiency.

vi
 TABLE OF CONTENT
Title Page i
Declaration ii
Dedication iii
Certification iv
Acknowledgement v
Abstract vi
Table of content vii
List of tables x
List of figures xi

List of graphs xii

CHAPTER ONE: INTRODUCTION 1
1.1 Background of study 1
1.2 Statement of Problem 5
1.3 Aim of the study 6
1.4 Objectives of the study 6
1.5 Scope of study 6
1.6 Significant of study 7
CHAPTER TWO: LITERATURE REVIEW 9
2.1 Cashew production 9
2.1.1 Botanical Characteristics 9
2.1.2 Varieties 10
2.2 Agricultural practices, propagation and culture 11
2.2.1 Sowing 11
2.2.2 Seasonal planting 13
2.2.3 Raising seedlings in a nursery 13

vii
2.2.4 Layering 14
2.2.5 Air-layering 15
2.2.6 Approach-grafting or inarching 17
2.3 Land preparation 19
2.4 Spacing 19
2.5 Fertilizer use in cashew 20
2.5.1 Basal dressing at planting 21
2.5.2 Rate of application of fertilizer 22
2.5.3 Method of fertilizer application 23
2.5.4 Frequency and timing of application 23
2.6 Diseases 24
2.7 Pests 25
2.8 Harvesting 28
2.8.1 Drying of the raw material 30
2.9 Storage 31
2.10 Infestation of harvested nuts 32
2.11 Post harvest handling 33
2.12 Cashew Plant Description 33
2.1.3 Postharvest Processing of Cashew Nut 34
2.1.4 Uses of Cashew 35
2.1.5 Related Shelling Machines for Cashew nuts 35
CHAPTER THREE: MATERIALS AND METHODOLOGY 37
3.1 Design analysis 37
3.1.1 Cashew nuts processing 38

3.2 Specification of part used in construction 38

3.2.1 Nut milling design 39

viii
3.2.2 Bearing selection design 39
3.2.3 Coupling design 39
3.3 Mode of operation 40
3.4 Component and part of the machine 40
3.5 Design consideration 41
3.6 Materials used and part description 48
3.6.1 Components description 48
3.7 Drawing of parts and assembly 49
CHAPTER FOUR: RESULTS AND DISCUSSION 53
4.1 Result and analysis 53
4.2 Preliminary tests 53
4.3 The Performance Evaluation 54
4.4 Bill of materials 58
CHAPTER FIVE: CONCLUSION AND RECOMMENDATION 59
5.1 Conclusion 59
5.2 Recommendation 60
References 61
Appendices 65

ix
 LIST OF TABLES

Table 2.1: Young plant mixture 21

Table 2.2: Adult plant mixture 21
Table 2.3: Rate of application of fertilizer 22
Table 2.4: Recommended/Promising cashew Varieties in the Philippines 34
Table 3.1: Some components of the fabricated machine 48
Table 4.1: Performance test on the developed cashew nuts milling M/C 55
Table 4.2: The total bill of materials for performance evaluation 58

x
 LIST OF FIGURES

Figure 2.1: Air-layering. 15

Figure 2.2: Inarching 18
Figure 2.3: Inarching 18
Figure 2.4: Cashew 34
Figure 3.1: Diagram of machine 48
Figure 3.2: Diagram of machine frame 49
Figure 3.3: Diagram of conveyor 50
Figure 3.4 Diagram of sealing machine 51
Figure 3.5 Exploded view of the machine 52

xi
 LIST OF GRAPHS
Figure 4.1: Graph of Speed against number milled 56
Figure 4.2: Graph of Speed against unmilled 56
Figure 4.3: Graph of speed against milled weight 57

xii
xiii
 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF STUDY

Cashew, Anacardium occidentale, is held in great esteem in many customs and

cultures. It is a resilient and fast-growing evergreen tree that can grow to the

height of about 20 m (Davis, 1999). The cashew seed is a pseudocarp, and in

biological terms, is the thickened stem of a fruit which the actual fruit, the

cashew nut, is attached. It is known to originate from South and Central

America, that is, from Brazil to Mexico (Naturland, 2000; Davis, 1999). Around

the nineteenth century, plantations were developed, and the trees spread to a

number of countries in Africa, Asia and Latin America (Mandal, 2002). Which

the trees is used to prevent erosion.

Cashew products contribute in various ways to local livelihood: they are

considered to be good sources of nutrition and the tree has other uses which

includes medicines and construction (Nazneen, 2004). The nut is one of the

most valuable processed nuts on global commodity markets, being also an

important cash crop for farmers. It has the potential to generate employment

through processing and export revenue for developing countries (Nazneen,

2004).

1
Three main cashew products are traded on the international market – raw nuts,

cashew kernels and cashew nut shell liquid (CNSL). The cashew apple, being a

fourth product, is consumed locally (Azam-Ali and Judge, 2004). The three

main cashew products are always on the international market, they includes the

raw nuts, cashew kernel and cashew nut shell liquid (CNSL). cashew apple is

consumed locally and the raw cashew nuts, though eight to ten times less than

the weight of the cashew apple, is the main commercial product of the cashew

tree. (Kilanko, 2005).

The raw nuts are either exported or processed prior to export. The cashew nut is

also a popular dessert nut, eaten out of hand, with other mixed nuts. It is also

made into cashew butter and nut milk, and used in baking and confectionaries

(Davis, 1999). Processing of the raw nuts releases the by-product CNSL that has

industrial and medicinal applications (DermNet, 2007; Davis, 1999). The skin

of the nut is high in tannins and can be recovered and used in tanning of hides.

The fruit of the cashew tree surrounds that kernel can be made into a juice with

a high vitamin C content and fermented to give a high proof of spirit (Azam-Ali

and Judge, 2004; Davis, 1999; Naturland, 2000; Calvalante et al., 2005).

Data collected in the year 2000 shows that cashew factories is ranks third in the

world production of edible nuts, and also that Africa produced about 35.6 per

cent of the total cashew produced globally, with Nigeria contributing about 40.7

2
per cent of this (Azam-Ali and Judge, 2004). However, bulk of the harvested

nuts has gone to India and other countries in Asia where there is a large

processing capacity (Adetumbi, 2001). This is because of the low processing

capacity for cashew nut in Nigeria.

The local way of extraction of the kernel from the shell of the cashew nut has

been a manual operation (Intermediate Technology Development Group

(ITDG), 2002). The nuts are kidney shaped and brittle which makes it difficult

to remove the shell without breakage. The most significant difficulty in

processing cashew nuts is that the shell, which contains a caustic oil, CNSL,

which can burn the skin and produce noxious fumes when heated (Nazneen,

2004). During the traditional method, sun-dried nuts are first dunked briefly in

water, and then roasted over fire in pans with holes in them while being stirred

constantly to prevent the nuts from burning. This method is called open pan

roasting. The shells break open during the process, whereby some of the cashew

nut shell oil drips out through the holes and into the fire. The split-open shells

are collected in ash or sawdust to soak up the rest of the oil (Naturland, 2000;

Davis, 1999; Azam-Ali and Judge, 2004; ITDG, 2002).

Another possibility is to roast the nuts in a wood-fired roasting oven, also called

drum roasting. There is no conditioning such that the CNSL is not removed

from the shell, and can be used as industrial oil. The nuts are roasted for so long

3
until the shells are completely brown to black, else there is the danger that the

shells will be difficult to break open, and that seeds may become damaged

(Naturland, 2000; National Seed Industry Council (NSIC), 2005; Nazneen,

2004; ITDG, 2002; Tasiwal, 2008). The oil bath roasting, where sun-dried nuts

are placed in wire baskets and dipped into baths containing hot cashew nut shell

oil at about 200ºC for 90 seconds, is also used. The shell become brittle, and

some of the CNSL can flow into the oil bath. The baskets are finally removed to

let the oil drip back into the bath and the nuts are dried (Naturland, 2000; Davis,

1999; ITDG, 2002; Tasiwal, 2008). Steam roasting involves treating the raw

cashew nuts in a pressurized cooker filled with steam for about 15 minutes. The

treated nuts are then spread out on the floor for cooling and then sent to the

shelling section (Tasiwal, 2008; NSIC, 2005; Nazneen, 2004). Shelling is the

first stage of the processing comes next is peeling, follow by grading and

packaging.

Shelling is done to get the embedded cashew kernel out from the dry roasted

shell with an objective of producing clean, whole kernels free of cracks, as

whole kernels have a better market value than broken kernels. This can be

achieved by manual and the manual shelling process involves placing the

roasted nuts on a flat stone and cracking with a wooden mallet or batten. An

average sheller can open ten nuts per minute which amounts to 4,800 nuts or

about 5 kg of kernels. Experienced shellers can produce only half as much, with

4
a quality of 90 per cent whole kernels. The manual traditional method of

shelling cashew nut using hammer is a labour intensive, slow and tedious

process. It also has some health implications due to the corrosive action of

CNSL on human skin (Ojolo and Ogunsina, 2007; DermNet, 2007). Recently,

roasted nuts have been cut by semi-mechanised shelling such as the impact-

shelling machine (Nazneen, 2004). The pedal-operated knife cutter (Ajav, 1996)

has been developed. A semi-mechanised process that has been used in Brazil,

uses a pair of knives, each shaped in the contour of half a nut had a daily

production of about 15 kg of kernels (ITDG, 2002). A motorized cashew nut

sheller developed by (Jain and Kumar 1997) has a capacity of 18 kg h21 and a

shelling of 70 per cent and whole kernel yield of 50 per cent. Ojolo and

Ogunsina (2007) developed a cashew nut cracking device with a capacity of 21

kg of kernels per day and whole kernel recovery of 67 per cent. The challenge

of designing and actualizing the successful fabrication of a motorized cashew

nut shelling equipment should be accepted by engineers and investors as a result

of the discovery of a dearth of mechanized system of cashew nut shelling in

most cashew nut processing industries in many countries, especially in Nigeria.

Therefore, this project is important because it will proffer solution to the

drudgery associated with manual cashew nut shelling. The main objective of

this work is to design and develop a motorized cashew nut shelling equipment

and evaluate it for optimum performance (Oloso A.O and Clarke B. 1993).

5
1.2 STATEMENT OF PROBLEM

The efficiency in terms of whole cashew granules packaging machine could be

improved by improving the pre-treatment measures on the nuts.

1.3 AIM OF THE STUDY

The main aim of the study is to carry out the performance evaluation of

automated cashew granular packaging machine.

1.4 OBJECTIVES OF THE STUDY

The objectives of this project work are:

i. to investigate the physical and mechanical characteristics of the automated

cashew granular packaging machine

ii. to investigate the load values and load analysis of the machine part

iii. to calculate the projection velocity in sizing and design of the optimum

configuration of the shelling impeller, and;

iv. to calculate the design analysis of the machine part.

1.5 SCOPE OF STUDY

6
Traditionally the various processing operations were performed manually by

experienced semi-skilled workers. This is still the case in India, which is the

world's largest producer of cashew kernels. Since the 1960s, various

mechanized pieces of equipment have been developed and are available in

several countries. The processes that have been mechanized are roasting,

cashew nut shell liquid extraction and shelling. For the most part, the cleaning

of raw materials and sizing and kernel grading have remained labour intensive

manual operations. There are significant differences in investment requirements,

labour skills, health requirements and levels of efficiency between the Indian

manual technology and the medium to large-scale mechanical and semi-

mechanical operations. In general the Indian processing system involves lower

investment and variable costs and achieves far greater efficiency in terms of

kernel material yield and the proportion of whole kernels extracted. However

this system requires large numbers of experienced workers who work at

unhealthy levels of exposure to CNSL. The mechanized systems are more

vulnerable to breakdown due to shortage of spare parts, require large volumes

of nuts for efficient operation and operate well below manufacture

specifications when strict grading and sizing activities are not in place prior to

shelling (Jaffee and Morton, 1995).

1.6 SIGNIFICANT OF STUDY

7
The normal packaging used for the export of granules is airtight rubber bags of

11.34 kg (25 lbs) weight capacity. The packaging material needs to be

impermeable, since cashew kernels are subject to rancidity and go stale very

quickly. The can will be familiar to most tropical countries as it is a replica of

the four gallon kerosene or paraffin oil can. Cans can be locally made in order

to reduce costs. Parts purchased overseas can be locally fabricated. This may be

done by arrangement with can manufacturers. The output of a can

manufacturing line is usually too large for a single consumer, but some cashew

nut processors have installed their own can manufacturing plants and supply

other processors.

After filling and weighing, the cap should be soldered in preparation for the vita

pack process. This consists of removing all the air from the can and substituting

it with carbon dioxide (CO2). The advantages of packing cashew kernels in

carbon dioxide are two-fold. Firstly, carbon dioxide will not support life so any

infestation that may have been present is therefore arrested. Secondly, carbon

dioxide is soluble in cashew oil and goes into solution as soon as the can is

sealed. Within a short period of time, a decrease in pressure takes place as the

carbon dioxide goes into solution and the sides, top and bottom of the can are

drawn inwards. The kernels are therefore tightly sealed in the can, thus

preventing movement and breakage during transport. Carbon dioxide, being a

heavy gas, causes the upward displacement of air and will remain in the cans

8
after filling. Some large-scale machines will operate on six cans at a time,

creating a vacuum in each and subsequently filling it with carbon dioxide,

(Balasubramania D. 2006)

Some processors do not have vacuum pumps and displace the air in the can by

feeding in carbon dioxide through a small hole in the bottom of a side of the

can. The carbon dioxide valve is turned off when all the air has been replaced.

Holes in the can are then sealed, with the hole at the bottom of the side of the

can being sealed first and the one at the top last, Ogunsina and Odugbenro

(2005).

CHAPTER TWO

LITERATURE REVIEW

2.1 CASHEW PRODUCTION

2.1.1 Botanical characteristics

The cashew tree, Anacardium occidentale L., belongs to the Anacardiaceae

family of plants, which also includes the mango, the pistachio and the poison

ivy. The tree is native to Brazil, but has spread to other parts of tropical South

and Central America, Mexico and the West Indies. In the 1600s, Portuguese

traders introduced the cashew tree into India and Africa to prevent soil erosion.

It is now widely cultivated for its nuts and other products in the coastal regions

9
of South Africa, Madagascar and Tanzania and in South Asia, from Sri Lanka to

the Philippines, Balasubramania D. (2001)

The cashew tree is a tropical evergreen, resistant to drought, unexacting as to

soil (although it prefers deep, sandy soil), which grows up to 12 metres high and

has a symmetrical spread of up to approximately 25 metres. It has leathery oval

leaves. Reddish flowers grow in clusters and the pear-shaped fruits, referred to

as cashew apples, are red or yellowish in colour. At the end of each fruit is a

kidney-shaped ovary, the nut, with a hard double shell (Figure 1). Between the

shell and nut is black caustic oil, which is difficult to remove and can be used in

varnishes and plastics.

The cashew tree grows with a minimum of attention and is easily cultivated. It

is usually found from sea level to an altitude of 1 000 metres (3 000 feet), in

regions with annual rainfall as low as 500 mm (20 inches) and as high as 3 750

mm (150 inches). For maximum productivity, good soil and adequate moisture

are essential. Optimum conditions include an annual rainfall of at least 889 mm

(35 inches) and not more than 3 048 mm (120 inches). The tree has an extensive

root system, which helps it to tolerate a wide range of moisture levels and soil

types, but commercial production is only advisable in well-drained, sandy loam

or red soils. The cashew tree can flourish in the sand of open beaches, but it

grows poorly in heavy clay or limestone. Most cashew trees start bearing fruit in

10
the third or fourth year and are likely to reach their mature yield by the seventh

year if conditions are favourable. The average yield of nuts of a mature tree is in

the range of 7 to 11 kg per annum.

Although the cashew tree is capable of living for 50 to 60 years, most trees

produce nuts for about 15 to 20 years.

2.1.2 Varieties

Cashew seedlings present great variation in growth habit, quality of crop and

yield. The tree cross-pollinates freely and this has further contributed to high

variability although there are as yet very few named varieties of cashew trees.

Generally a distinction is made only between those with yellow or red cashew

apples. Tests have indicated that very large nuts usually have inferior kernels,

low density and slow germination (Caribbean Technological Consultancy

Services

Network, 1993).

2.2 AGRICULTURAL PRACTICES, PROPAGATION AND

CULTURE

2.2.1 Sowing

The cashew tree is usually grown from seeds placed directly in the field, since

seedlings do not transplant well due to their delicate root system. Seed nuts

should be thoroughly dry, clean and free from insect or fungal attack. Seeds

11
should be stored until the next rainy season before they are planted in the field,

unless irrigation facilities are available, or seedlings are raised in polythene bags

in a nursery where water is available. After a few months, stored nuts gradually

lose their germination capacity.

Seeds should be water tested prior to planting those that sink should be chosen

as they have a high success rate and tend to germinate quickly. Seeds should be

planted at a depth of about 5 cm. The maximum depth at which a seed should be

sown is about 10 cm, depending on the soil conditions. Two or three seeds

should be planted together, stem end up, at a slight incline and covered with 5 to

8 cm of soil. Germination usually takes place in 15 to 20 days, although seeds

of low density (i.e. those that float in water) may require as long as eight weeks

to germinate. Using seeds of high density, from selected trees, considerably

increases the chance that some of the seeds at one site will perform well. Two

months after sprouting, the two weakest seedlings should be removed from the

site, leaving only the strongest one to grow. By planting more than one seed, the

occurrence of gaps in a plantation is reduced (Ohler, 1979). In orchard practice,

pits measuring from 30 cm ´30 cm´ 30 cm to 60 cm ´60 cm´ 60 cm are dug and

left to weather for a month or two. They are then filled with soil, which has

been mixed with rotting manure about two weeks before seeding. In loose soils

of sufficient fertility, the root system of the seedlings develops so quickly that,

when growing naturally, root lengths would exceed the size of the planting hole

12
within a few months and therefore in optimum growing conditions planting

holes are not essential.

Advantages of sowing

 The plant can develop its root system and especially its root tap quickly.

 It is the cheapest method of planting.

 It is the quickest method of planting as one person can plant 400 to 500 sites

each day.

Disadvantages of sowing

 Lower rate of germination.

 Danger of serious damage by animals.

 Less opportunity for selection of seedlings than when planting seedlings that

are raised in plastic bags in the nursery.

2.2.2 Seasonal planting

Cashew seeds should be sown or planted during the rainy season in areas that

lack irrigation facilities. The best time for planting is during periods of regular

rainfall, so that the soil does not dry out again. If the soil dries out before the

germinated seeds have become securely rooted, they may die. The advantage of

early planting is that it gives the seedlings more time to develop before the onset

of the dry season. In climates with irregular rainfall and short rainy seasons, the

13
risk of germinated seedlings drying out can be reduced by pre-soaking the seeds

before planting, deep sowing (5 to 10 cm) and covering the site with mulching

material to reduce evaporation. The mulching material should be carefully

selected and any weeds with mature seeds should be removed. (Hall, 1965)

2.2.3 Raising seedlings in a nursery

Where it is necessary to raise seedlings in a nursery, the seeds should be sown

in containers of a type that can be set in the ground and readily disintegrate. In

Cuba, baskets of ova-grass or cona brava are used and cut away before setting

the plant into the ground. In Jamaica, it has been found that nursery seedlings

can be raised in the ground and transplanted with 90 percent success, providing

the plant is taken up with a good ball of soil and the top is cut back by one third,

when it is put into the field. It is recommended that the seedlings be

transplanted within a week of emerging, to ensure that the transplantation is

successful (Caribbean Technological Consultancy Services Network, 1993).

Seedlings can also be planted using plastic bags as containers. The seedlings

should be lifted into their planting holes in the plastic bags, which are then

carefully slit with a sharp knife and removed.

2.2.4 Layering

Ground layering

14
The lowest branches of the cashew tree tend to trail on the ground at a distance

of several metres from the trunk. Where branches touch the ground,

spontaneous rooting may occur. Covering such branches with soil and keeping

the area moist encourages rooting, a method which has been used in India for a

long time. However, such layers cannot be easily transplanted to other places

and the shape of the material tends to produce low trees of spreading habit. The

number of layers that can be obtained in this way is also rather low.

The stem is girdled to induce root formation above the cut. The girdled stem is covered

with damp moss. Aluminium foil or plastic sheeting is wrapped around the moss and tied

at both ends. This cover is removed 2 to 3 months after tying or when the roots can be

seen.

Figure 2.1: Air-layering.

2.2.5 Air-layering

15
A strip of bark about 0.5 cm wide is removed from either a year-old branch or a

pencil-thick shoot (about 1 cm diameter) of the current season, at about 20 to 30

cm from the growing point. The exposed wood is wrapped with twine to prevent

the bark from growing over it during the healing process and covered thickly

with moist moss, wood shavings or sand. It is then wrapped securely in a sheet

of 100 to 150-gauge plastic and the ends are tied tightly to the branch with

twine (Figure 2.1). After 20 to 30 days, callus is formed at the foot of the layer

and 40 to 50 days later, small roots emerge from the callus tissue. After

approximately 75 days, there should be adequate root formation (five or more

well-formed roots measuring 1.0 to 1.5 cm long) to separate the twig from the

tree. The part of the twig below the layer is cut about halfway through. One

week later, the cut is deepened and a few days later the layer can be removed

and transplanted into plastic bags or other containers and hardened off before

planting. If the layer is separated from the tree in one cut, the shock will be too

great for it to survive. The whole process takes about two and a half months,

although the time varies depending upon the period of the year when the layer is

being prepared. Layers that are produced early in the rainy season have time to

establish themselves and develop a large enough root system to survive the dry

season. Air-layering has been one of the most successful methods of vegetative

propagation in cashew. The method is rather laborious and the cost is relatively

high, but the advantages of obtaining a plantation from high yielding, uniform

16
material make these costs extremely worthwhile. A large disadvantage of this

method, as with all methods of layering, is the relatively small number of layers

that can be produced by one tree per year. It is estimated that from one tree, 80

to 120 successful layers can be obtained. In order to obtain sufficient material

for a fairly large plantation, the first generation of air layers should be grown to

maturity and only then, from many trees of the same quality, could sufficient

material be obtained for later plantings.

2.2.6 Approach-grafting or inarching

The technique of approach-grafting is relatively easy but labour intensive and

like air-layering has to be done in the field. Seedlings to be grown as rootstocks

are raised in containers. Once they are 8 to 9 months old, they are cut back to

half their height and kept in grass baskets for a month in the shade until new

shoots appear. The basket is replaced by a sheet of 100-gauge plastic to retain

moisture and the seedling is joined to a year old branch of the same diameter on

a selected tree as described below.

From the stem of the seedling and from the shoot with which it will be united,

strips of bark and inner wood, measuring about 5 to 8 cm in length, are removed

(Figure 2). Both cut surfaces, which should be of the same size, are bound

17
together with twine and the join is firmly tied with string, binding the seedling

stem and the shoot together. In 90 days the union should be complete and the

grafted plant is gradually separated from the parent (Figure 3). A "v" cut is

made half way through the branch 2 cm below the graft and a similar cut is

made in the rootstock 2 cm above the graft. Seven or eight days later the cuts

are deepened and after a further period of four days the severing is completed.

About 60 percent take is expected.

Two independent plants with stems approximately the same size. For example, seedling

plants in containers and established plants. Identical slices of wood and bark (2.5 to 5 cm

long) are cut from both stems. The stems are placed closely together.

18
 Figure 2.2: Inarching.

The stems are bound tightly together with string, tape or raffia. After graft union heals, the

stock plant is cut above the union and the scion is cut below the union.

Figure 2.3: Inarching

2.3 LAND PREPARATION

Cashew seedlings are very sensitive to competition with weeds, but in many

areas, especially on sloping land, the vegetation should not be removed

completely before planting because of the danger of water and wind erosion. In

tropical countries with a marked dry season and where the rainy season tends to

start with torrential rains, the danger of erosion increases if large areas of land

have been cleared. If the soil is very sandy and subject to strong winds, clearing

the land may result in severe wind erosion, which is virtually impossible to stop.

In these areas, the land should be cleared in strips, which are perpendicular to

19
the direction of the prevailing winds, Bambang S. (2000). Once the cashew trees

have developed to such an extent that their rows act as wind breaks, the

remaining land can be cleared. Another important reason for leaving strips of

natural vegetation is to ensure that the insect population required for pollinating

the cashew flowers is maintained. The removal of tree stumps is an expensive

but essential part of the clearing process. The sprouting stumps need to be

slashed each year as they compete with the cashew trees and prevent a good

view between the rows.

2.4 SPACING

To promote maximum development and reduce competition for available

moisture, it is recommended that the seedlings be planted 10 to 15 metres apart.

This is considered to be the most productive spacing for mature trees. The

average yield per hectare will be 700 to 1 000 kg but yields outside these limits

are encountered. However, cashew trees are normally planted more closely,

which results in overcrowding and they are often intermixed with other trees

either in small orchards or in the wild.

2.5 FERTILIZER USE IN CASHEW

Cashew is often grown as a casual crop by smallholder farmers and as a result

its fertilizer requirements are overlooked. Also the trees are long standing and

are frequently grown in soils that are of poor quality. As each season passes, the

20
soils become more depleted and productivity gradually declines. Yields of trees

grown in this way are very much lower than the potential that could be gained if

fertilizer was applied. Experiments have demonstrated that regular application

of the major plant nutrients (nitrogen, potassium and phosphorus) is beneficial

for healthy trees and increased cashew yields. In addition, application of

magnesium to cashew is beneficial. Two separate mixtures of fertilizer, based

on the combination of nitrogen (N), phosphorus (P) and potassium (K), have

been recommended according to the growth stage of the plant.

Young plant mixture

This mixture is recommended for cashew plants from field planting up to 5

years of age. It contains N:P:K in the ratio of 4:3:2.

For 100 kg of young plant fertilizer, the following is used:

Table 2.1: Young plant mixture

Compound weight (kg)

Urea 38

Rock phosphate 47

Muriate of potash 15

Adult plant mixture

21
This mixture is recommended for cashew plants from 5 years onwards. It

contains N:P:K in the ratio of 4:3:4.

For 100 kg of adult plant fertilizer, the following is used:

Table 2.2: Adult plant mixture

Compound weight (kg)

Urea 33.5

Rock phosphate 41

Muriate of potash 25.5

2.5.1 Basal dressing at planting

Each planting hole should be filled with topsoil mixed with young plant mixture

and dolomite and if possible with organic matter. In a hole that measures 60 cm

´ 60 cm ´ 60 cm, 250 kg young plant mixture and 300 kg Dolomite are required,

plus 1 to 2 kg organic manure. The soil is removed from the hole and mixed

with the chemical fertilizer. The hole is then re-filled with the mixture of soil

and fertilizer. This should take place before the rains to allow the soil and

fertilizer time to settle before the seedlings are planted. If the seedlings are

planted directly into the fertilizer, the tender roots may be damaged. To avoid

damage, the seedlings should be planted at the beginning of the monsoon or

four to six days after refilling the hole. ( Agnoloni and Giuliani, 1977).

2.5.2 Rate of application of fertilizer

22
During the early stages of growth, it is better if the amount is split and applied

in two separate doses at the end of each season, to avoid the heavy rains.

Table 2.3: Rate of application of fertilizer

Time after transplant Young plant mixture

(years) (g/plant/year)

1 200

2 350

3 500

4 650

5 800

After five years of age, the rate of application of adult mixture varies with the

plant yield.

Average yield/plant Adult plant mixture

(kg/plant/year) (kg/plant/year)

<10 1

10 to 15 1.5

15 to 20 2.0

23
>20 2.5

2.5.3 Method of fertilizer application

Fertilizer should only be applied after weeding and cleaning the base of the

individual trees within a 1 to 2 metre radius, to avoid the competition for

nutrients from weeds. In the early years (up to 1.5 year), fertilizer should be

broadcast close to the plant, covering an entire full circle up to a distance of 0.5

m from the base of the plant. The fertilizer should be lightly mixed with the soil.

As the plant grows older, the area should be gradually extended to reach 1.0 m.

Mulching the fertilized area is encouraged as it is beneficial. With adult plants,

the fertilizer should be broadcast in a circular strip (1 to 1.5 m wide) and about

0.5 to 1.0 m away from the base of the tree. The fertilizer should be lightly

mixed with the soil.

2.5.4 Frequency and timing of application

Fertilizer should be applied to young plants twice a year at the end of each

monsoon rain. It is applied to adult plants annually at the end of the monsoon

rains and before flowering. The fertilizer should be applied when the soil is

moist, at the end of the monsoon season so as to avoid the heavy rains.

Application of fertilizer during the dry season is not advisable as the nutrients

require water to be dissolved and absorbed by the roots.

24
2.6 DISEASES

Cashew seedlings can be affected by a number of different diseases. The

fungus, Colletotrichum glocosporioides, is one of the most common pathogens

in cashew (Ohler, 1979). Initial symptoms show the development of reddish-

brown, shiny, water-soaked lesions, followed by resin oozing out onto the

affected parts. As the lesions grow, the affected shoots and inflorescences are

killed and the leaves become crumpled. The affected nuts and apples decay and

shrivel and the flowers turn black and fall off. The trees can be sprayed with

various fungicides, including Bordeaux mixture, to control the fungus.

Several diseases that result in the terminal twigs dying off are grouped under the

name "die-back" or "pink disease" which is produced by Glocosporium. There

may be associated pitting of the surface of the nut. This serious disease requires

the affected branches to be pruned and sprayed with a 1 percent Bordeaux

mixture or other copper-based fungicides.

Characteristic symptoms of other infections which attack cashew include

wilting and withering; the yellowing of the lower leaves; the seedlings turning

pale and showing water-soaked girdles of darkened tissue around the stems; or

the rotting of the underground portion of the stem. Powdery mildew may appear

on young leaves and inflorescences during dry weather.

2.7 PESTS

25
Insect pests are a major source of crop loss in all cashew-growing areas of the

world. More than 60 species of insects attack the crop during its different stages

of growth. These pests include sap-sucking bugs, leaf-chewing caterpillars,

beetles, aphids, scales, trips and some mites. They can cause considerable

damage to the tree and the crop by bringing about the death of the floral-

flushing shoots, the early abortion of young nuts and loss of yield.

The adult weevil, or borer, is dark grey in colour and about 2 cm long. The larva

has a curled whitish body with wrinkled skin and dark brown head. The eggs

are laid singly in small holes made by the female in the bark of the trunk or the

main branches of the cashew tree. After hatching, the larvae tunnel down just

beneath the bark, eating the sapwood. The grubs should be removed as soon as

they are detected because they cause gum leakage and will eventually kill the

tree. To control the borer, all heavily-infested trees should be cut down and the

bark should be cut away in places that show signs of weevil attack. Once the

wood has dried out sufficiently, it should be burned, to kill all the remaining

larvae and eggs. Alternatively, the base of the tree can be sprayed with

Malathion and the bore holes filled with the spray. Gibbon D. and Pain A. (1985)

The tea mosquito bug (Helopeltis antonii Sign.) is a common pest found in Sri

Lanka, causing up to 30 percent loss of yield. The adults and nymphs of the

species feed on tender shoots and floral branches, as well as on the developing

nuts and apples, by piercing and sucking the sap (fao.org, 2006). Helopeltis

26
populations increase during the rainy season, reaching a maximum at the end of

the rainy season and the beginning of the dry season. This coincides with the

emergence of a new flush. Insecticide application should be started when the

new flush emerges. The damage caused by Helopeltis is of two types. Primary

damage, which is seen as brown lesions surrounding the feeding punctures,

causes affected leaves and young shoots to turn brown, wither and die.

Secondary damage occurs when the puncture holes are infected by secondary

pathogens and the whole stem or branch dies back or is affected by blight.

Helopeltis can be controlled by chemical spray. Three applications of a 0.1

percent mixture of Carbaryl are recommended at flushing, onset of flowering

and the fruiting season. However, Carbaryl is indiscriminate and will kill other

beneficial insects. Special attention must be paid to the second spray at the onset

of flowering, to minimize the effect of insecticide on pollinators. The optimum

time to spray is between 0600 hours and 0800 hours and again between 1600

hours and 1900 hours, when the Helopeltis bug is active.

A copper fungicide or Bordeaux mixture (1 percent) can be used to control

inflorescence die-back, which may occur. Helopeltis damage can be limited by

careful cultural practices. The plantation should be kept weed-free to remove

alternative hosts of the bug. Removal of non-productive and diseased branches

from the trees allows for improved air circulation and solar radiation within the

27
crop canopy and can then reduce the humidity of the canopy. This in turn can

reduce the damage caused by the pest.

Thrips are known in many countries to attack cashew leaves, causing a

symptom called "silvery leaves". They suck the leaf juices and leave a

"scorched" area. Heavy attacks will stunt the growth of young plants but can be

controlled by spraying with a 0.05 percent solution of Malathion.

The caterpillar of the leaf miner attacks young plants by tunnelling through new

leaf tissues. The first signs are winding trails on the leaves. Later the infestation

shows as patches of white blisters. The adult is a tiny, silvery-grey moth. The

larvae appear red when they are fully-grown and are about 6 mm long. Affected

trees should be sprayed with a 0.06 percent solution of "Folidol E.605" (30 ml

in 50 litres of water).

A sporadic leaf-eating caterpillar, which has poisonous stinging hairs,

sometimes occurs in swarms and defoliates the cashew tree. It pupates in silky

cocoons and the adult moth is large and reddish-brown in colour.

The mealy bug attacks the cashew inflorescence but can be controlled by

spraying with a 0.06 percent solution of "Folidol E.605" (30 ml in 50 litres of

water). Among the other pests are leaf webbers, flea beetles, spider mites and

scales. Rodents, such as rats, squirrels and porcupines, may cause serious

damage to cashew seedlings, particularly when they emerge above the ground.

28
Cashew apples are sometimes attacked by fruit flies. Monkeys are partial to ripe

apples and cashew can cause damage to the cashew trees whilst foraging for the

fruit. Bats and parrots also eat cashew apples.

2.8 HARVESTING

The harvesting and processing of cashew is very labour intensive. After

producing clusters of flowers, cashews produce the edible apple and also a nut

encased in a heavy shell, which is the true cashew fruit. The cashew tree flowers

for two or three months and fruit mature about two months after the bloom. The

cashew nut forms first at the end of the stem. Subsequently, the stem swells to

form the "apple" with the nut attached externally.

The cashew nut is 2.5 to 4.0 cm (1.0 to 1.5 inches) long and kidney shaped. Its

shell is about 5 mm thick, with a soft leathery outer skin and a thin hard inner

skin. When fully ripe, it falls to the ground. Harvesting generally involves

collecting the nuts once they have dropped to the ground after maturing.

Workers scour the area and detach the nut from the fruit. For the nuts to be

easily traced, the surface under the tree has to be free from weeds. In some

places, the whole area under the tree is swept free of dry leaves. The nuts are

generally collected in baskets or sacks. Cashew fruit are generally left to fall to

the ground before being collected, as this is an indication that the kernel is

29
mature. If fruit are picked from the trees, the cashew apple will be ripe, but the

kernel will still be immature.

The quantity of nuts, which can be harvested, depends upon the yield of the

trees. Where many nuts fall together, much less time is required for walking in

search of them. On average, each individual can harvest a maximum of 50 kg

per day. A very limited number of nuts fall at the beginning of the production

season. A peak in the number of nuts falling is gradually attained and

production slowly declines. Although activities are labour intensive and time

consuming, they are not heavy and women and children can help.

In very dry climates where the topsoil remains dry overnight, nuts can be left

under the trees for several weeks without their quality being affected. However,

where humidity of the air or soil causes moisture and dew formation, the nuts

should be reaped at least twice a week. This is not very economical, unless it is

carried out on smallholdings with relatively high labour intensity, as there will

not be adequate numbers of nuts to harvest sufficient quantities to achieve

collection levels of 50 kg per day (Ohler, 1979). Apples to be used for

processing into products such as jam or juices should be picked from the tree

before they fall naturally. On falling to the ground, apples may become

damaged. Once damaged, the apples may ferment and deteriorate quite rapidly.

The riper the apple, the sweeter the taste. It is therefore recommended that the

30
apple be picked as it is about to fall. At this stage the nut is fully-grown for

about two weeks and is ripe and ready for harvest.

Apples, which are not within reach of the picker's hands, can be harvested using

a small basket or sack attached to a ring at the end of a long stick. Fully ripe

apples will drop into the sack when the tree is shaken. Apples that have not

matured completely should be cut off with a small knife attached to the stick.

The nuts must remain attached to the apple, since some juice may be lost on

their removal.

The cashew apple will only keep for 24 hours after it has been picked.

Transporting large quantities of apples is difficult for this reason. When stacked

in layers, apples may burst and lose their juice because of the weight on top of

them.

2.8.1 Drying of the raw material

Cashew nuts are dried in the sun for two reasons:

 To reduce the moisture content of the nut,

 To mature the seed in the infrared and ultra-violet rays of the sun.

Cashew nuts should keep for 12 months or more, provided that they are dried to

moisture content of eight percent or below, packed in sealed polythene bags and

stored under dry conditions. The moisture content of cashew nuts at harvest is

dependent on climatic conditions, moisture content of the soil, on which the

31
nuts have fallen, weed growth density under the tree and the time between nut

fall and harvest. High moisture content may cause deterioration of the kernel

due to mould or bacterial attack or enzyme action. Drying the nuts immediately

after harvesting is essential in preserving their quality, but this process is often

neglected.

Sun drying of cashew nuts can be done on specially prepared drying floors or

mats made of bamboo or palm leaves. The drying areas should be smooth and

slightly sloping, so as to allow rainwater to run off. The cashew-nut layer on the

drying floor should not be thicker than 10 cm, thus allowing for about 60 kg of

nuts per square metre. The nuts should be cashew constantly raked in order to

ensure that they all receive the same benefit of the sun's rays and therefore they

are dried evenly. The nuts should be heaped together and covered in the

evenings. If the nuts are heaped while still warm, they will continue to dry

under the cover of a tarpaulin. The nuts should be checked the following

morning to ascertain the need for further drying.

Dried nuts should make a rattling sound when falling. Drying may take between

one and three days depending upon local climatic conditions. As soon as the

nuts are dry, they should be stored and protected from rain.

2.9 STORAGE

Technical requirements for storage are dependent on weather conditions. As

cashew nuts are usually produced in climates with a long dry season, simple

32
buildings with concrete floors and walls and roofs of corrugated metal, should

provide adequate storage.

Certain prerequisites must be satisfied to ensure safe storage:

 A waterproof, dry floor,

 A firm and secure roof,

 Openings in the wall must be protected in order prevent water from entering

the room,

 Headroom must be adequate to allow the bags in a stack to be moved around

if large quantities are to be stored,

 The store should be easily inspected: there must be sufficient clearance

between the wall and the bags, to allow individuals to walk around and

check the condition of the stack,

 The stack must be placed on a raised wooden platform, in order to prevent

moisture from being drawn from the floor to the nuts.

2.10 Infestation of harvested nuts

Raw cashew nuts, stored in sacks, sometimes in the open awaiting shipment and

frequently without protection from rain, are subject to infestation through the

stem-end. This may go undetected until damage has progressed to the point of

heavy loss. Infestation also occurs in the shelled kernels at various stages of

handling. Andrighetti L, et al., (1994).

33
2.11 Post harvest handling

The nut is encased in a rock hard shell that is virtually impossible to penetrate

after harvest. In order to extract the nut, the whole shell is soaked in water,

softened by steaming and carefully air-dried to the final moisture content (9

percent).

Each nut is hand massaged and cracked via a manual process that entails putting

the nut against one sharp blade and bringing another blade, which is on a foot

powered lever, through the outer shell. The blade on the foot lever is raised by

an enthusiastic stomp allowing the outer shell to separate from the nut. The nut

inside is carefully picked out of the outer shell using a nut pick

2.12 Cashew Plant Description

The cashew plant is an evergreen tree that grows up to 12 meters tall, with a

dome-shaped canopy bearing its foliage on the outside, where flowers and fruits

are found. The fruit has a kidney-shaped nut, about 3 cm x 1.2 cm attached to a

much enlarged receptacle forming the fruit-like cashew apple. The cashew

apple is pear-shaped, 10-20 cm x 4-8 cm, shiny, red to yellow, soft, and juicy.

Having the most commercial value, the cashew fruit is composed of the cashew

apple (pseudocarp) and the seed. Botanically considered as the fruit, the seed

consists of the nut (kernel) and shell or pericarp.

34
 Cashew apple

Cashew nut

Figure 2.4. Cashew

Cashew nuts consist of 35-45% kernel and around 55-65% of shells. The shells

contain 15-30% oil. A ton of seeds contains around 200 kg nuts and 180 kg oil

(cashew nut oil or cashew nut shell liquid “CNSL“).

Table 2.4: Recommended/Promising cashew Varieties in the Philippines

2.1.3 Postharvest Processing of Cashew Nut

The process consists of five main steps:

1. Shelling: removal of the outer shell and cashew nut shell liquid (CNSL)

35
 2. Peeling: After the kernels are taken out of the shells, the testa (the thin

skin covering the kernel) must be removed

3. Grading: into different sizes and colours in accordance with standard

grading

4. Drying or humidifying: to a final moisture content of 5%

5. Packing: into airtight bags or cans, depending upon the scale of operation

2.1.4 Uses of Cashew

Cashew nuts are processed into different forms like dried, roasted, salted, fried,

brittle, caramelized, and chocolate-coated. Cashew apples are also processed as

prunes, wine, vinegar and juice.

2.1.5 Related Shelling Machines for Cashew nuts

Ojolo, et al, 2010 designed and developed a cashew nut shelling machine. It

consists of feed hopper, shelling impeller, drive motor and casing. The machine

operates on the principle of impact in which the velocity is the required

parameter. The machine has a shelling capacity of 15.57 kg/h with shelling

efficiency of 95% and whole kernel recovery of 70%. Jagtap, et al, 2008

developed a machine in which cashew are carried by the chain conveyer for de-

shelling. It consists of two powered cutter discs each having four knifes. The

two powered cutter discs attack the nut simultaneously and the shell needs to be

36
separated manually. This machine can process over 25 kg cashew nuts per day.

The Philippine Center for Postharvest Development and Mechanization

(PHilMech) designed a whole cashew kernel sheller that splits the shell without

injuring the nut. It uses a specialized blade that fits the irregular shape of the

cashew nut shell. It has low investment cost, durable, easy to operate and is

made of locally available materials.

37
 CHAPTER THREE

MATERIALS AND METHODOLOGY

3.1 DESIGN ANALYSIS

The machine was designed in a plant model, the milling machine mills the

cashew nuts. During operation, it granulates, conveys and packages cashew nuts

by impact when the nuts are hurled inside a roller which is driven by the electric

motor. The fully assembled machine is shown in Figure 3.1

Preliminary tests were first carried out to determine the moisture content of the

cashew nut; the maximum safe moisture content of cashew nuts was estimated

between 8.9 and 9.2%, being that in equilibrium with surrounding air at 70%

R.H. Also, impact load tests were carried out to determine the fracture

characteristics of the nuts.

38
 Figure 3.1 diagram of machine

3.1.1 Cashew nuts processing: the processing of cashew nuts is in line

comprising of the following;

 Cashew nut milling

 Cashew nut conveying

 Cashew nut sealing

3.2 SPECIFICATION OF PART USED IN CONSTRUCTION

The parts and specification used for the construction of the machine are as

follows;

39
3.2.1 Nut milling design

Some sufficient thick mild steel of dimension 616.6 mm × 308.4 mm and

thickness 10mm are fabricated from the length of mild steel. These fabricated

steels are the pressing plate. For each pressing plate two ball bearings are

attached to middle of its side. A pressing plate is welded to all sides of the

machine to serve as support or compressive springs.

3.2.2 Bearing selection design

Bearing is selected based on its load carrying capacity, life expectancy and

reliability, the bearing used is of diameter 19mm made of stainless steel. Four

bearings are made used of in this project. These bearings are force fitted on a

mild steel of 20.5mm diameter which are in turn welded to the pressing plate.

3.2.3 Coupling design

Coupling is a machine component which connects two shafts together to ensure

transmission of power from prime mover to the other end of application. Two

couplings are used in this project. The coupling are machined to (diameter of

40mm and 60mm for hydraulic pump and industrial motor) fit onto the shaft of

hydraulic pump and industrial motor.

40
3.3 Mode of operation

The electric motor provides the primary motion required to power the machine

which comprises of three segments, the granulator, conveyor and sealer. The

motion and torque is transmitted through the roller in the granulator then the

granulated portion is released to the conveyor then moved to the sealer which

then automatically filled each bags in a computerized amount and seals them.

3.4 COMPONENT AND PART OF THE MACHINE

Frame

The frame which is mainly made with the Mild steel of angle bar. The Mild

steel is used to make frame rigid. This is used to secure all the segments in

position in all its sides and create a support stand for all the parts.

Body

The body of the machine is made with mild steel plate of 1.5mm thickness to

guide the parts.

Roller

The rollers are very significant part of the machine and it can be found in the

granulator, it is necessary for grinding of nuts.

41
Pulley

The pulley aids the rotational of the roller by connecting the rollers to

electric motors with belts.

Belts

Belts connects the shaft of roller to pulleys of electric motors for rotational

movements.

Ball-Bearing-HousingUCP206

Bearings are mounted on machine frames with bolts to hold shafts of rollers

and other necessary parts.

LCD Controller

This is a significant part of sealing machine connected to a switch which

powers the machine.

3.5 DESIGN CONSIDERATION

This chapter present the design theory and the mathematically analysis of the

automated cashew granular machine parts, and the applicable engineering

presentation.

42
In the design of the cashew granular packaging machine, several factors were

considered which encompasses: strength, external loads which are imposed on

them, overall height of the machine to facilitate ease of production, availability

of materials and cost application. Other factors considered was the use of rigid

load bearing members to prevent buckling during high pressure operation. The

applied loads causes’ external stresses in the parts or elements, hence the stress,

safety factor, durability and reliability.

Parameters used are carefully explained, equations are used where applicable.

Shaft design and calculations

This consist of determination of the correct shaft diameter

The shaft is powered by the electric motor and the electric motor is instrumental

in determining the shaft specification, hence the need to utilize equation 1 given

by Khurmi and Cupta (2005).

2 πNT
Power = 60 , (1)

where

T= Torque

P= Power =?

N= Number of rev/min = 2760rev/min

43
F(s) = Factor of safety and for the purpose of the work is consider to be 2.28

Therefore, 1hp = 0.75kw

3hp = x

3× 0.75
x = 1

x = 2.25kw

3hp = 2.25kw

2 πNT
P = 60

P × 60
T = 2 πN

2.25× 60
T = 2× 3.142× 2760 =2.25 ×60

1.350
= 17.346

= 77.82 ×103 N

The design of the shaft is based on tensional and lateral loads since it is

horizontal

Therefore,

The required diameter of a solid shaft having tensional load was calculated

using equation 2 as given by Khurmi, (2005).

44
 16 τ
T= 3
(2)
πd

where

T =¿ Torque developed from the motor

τ =¿ Maximum stress allowable

d=¿Diameter of the shaft

But τ =¿ Maximum permissible working shear stress for transmission shafts

without allowance or keyways is 56 mpa Khurmi and Cupta, (2005).

16 τ
d =
3
πT

3
3 16 ×77.82 ×10
d= 6
π ×56 ×10

3 1245120
d =¿
175,952,000

= 7.076 ×10−3 mm

d=0.1920 mm

Since the factor of safety,

F ( s ) = 2.28

Design diameter

= d × F (s )

Design diameter

= 0.1920 ×2.28

45
= 0.4378 mm

Determination of the stress of the pulleys: the major function of pulley in this

machine is to drive the roller through the aid of the belt.

The following equations according to Khurmi, (2005) are applicable

πND
V= ( 3)
60

N 1 D1=N 2 D 2 (4 )

where

V =¿ Linear speed or velocity of the pulley (m/ s)

N=¿Speed of the pulley (rev /min)

D=¿ Diameter of the pulley ( m )

NOTE: D can be D1or D2and N can be N 1 N 2e.t.c.

Therefore, for Driving motors pulley i.e. the driver from equation

π N1 D1
V =V 1=
60

where,

N 1=¿ Speed of the electric Motor ¿ 2760 rev /min

D1=¿ Diameter of pulley on electric motor ¿ 0.072

N 2=¿ Speed of driven shaft

46
D2=¿ Diameter of driven pulley ¿ 0.093 m

By measurement

D1=¿ 0.25

N 1=¿ 2760rev /min (from motor)

π ×2760 × 0.25
V =V 1=
60

V =36.13 m/ s

V =36.1m/ s

Linear speed or velocity ¿ V =10.1 m/s

Driven pulley previous equation;

D2=0.35 mm

Using equation (4)

N 1 D1=N 2 D 2

2760× 0.25
N 2=¿
0.35

N 2=1971.4 rev /min

By verification, using equation (3)

V =V 1=V 2=V 3

47
Belt Design and Calculation

The function of belt in the design is to transmit the required power and torque

from the electric motor to drive the roller.

In estimating the length of the belt, equation 5as given by Khurmi, (2005) was

applied;

D2 −D 1
L=2 C+ 1.57 ( D2+ D 1 ) + (5)
4C

where,

C=¿Centre of distance

D2=¿ Diameter of the driven pulley

D1=¿ Diameter of the driver pulley

L1=L2

D1
C=
2

0.25
C=
2

C=0.125

using the equation;

0.35−0.25
L=2 ( 0.125 ) +1.57 ( 0.35+ 0.25 ) +
4 (0.125)

L=0.25+ 0.942+0.2

48
L=1.392 m

3.6 MATERIALS USED AND PART DESCRIPTION

3.6.1 Components Description

The following parts were fabricated using the materials and processes shown

below

Table 3.1: Some Components of the fabricated machine

S/N Components Material Description Dimension Operation

1 Machine Frame Mild Steel Full length 1524mm Marking out

Breadth

2 Pressing Plate Mild steel Length 240mm Covers exo-

Breadth 129mm posing areas

3 Roller Stainless - Grinding

steel

4 Pulley Mild steel Diameter 0.35mm Transmitting

torque

5 Belt Rubber 1.392 Transmits

torque

6 Electric motor iron 1hp 80mm Transmitting

49
 power

7 Conveyor Stainless - - Conveying

Steel granules

8 Sealer Mild steel - - Sealing gra-

nules in nylon

9 Heater - - - Sealing
nylons

10 LCD - - - Control sea-

ling machine

3.7 DRAWING OF PARTS AND ASSEMBLY

50
Figure 3.2 diagram of machine frame

51
Figure 3.3 diagram of conveyor

52
53
Figure 3.4 diagram of sealing machine

54
 Figure 3.5 exploded view of the machine
CHAPTER FOUR

RESULTS AND DISCUSSION

4.1 RESULT AND ANALYSIS

The performance evaluation of a cashew granular packaging machine was

carried out with 10 kg of roasted cashew nuts, the machine was connected to

electricity, then 900 ml of cashew nuts were poured in the granulator and

allowed for it to grind for 2 minutes then the granulator released the meshed

nuts to the conveyor which then transfers it to the sealer in 5minutes, it took the

sealing machine about a minute to package and seal the meshed nuts. The sealer

is the third and last segment of the machine. In the sealer, the already grinded

nuts were automatically filled in certain amounts in a clean transparent plastic

bag and it is ready to be picked for final consumption.

4.2 THE PERFORMANCE EVALUATION

The machine's performance is important in determining how well it does the

job for which it was designed, as well as whether it is affordable, easy to

finance, easy to set up and operate, and provides high quality in a short

55
period of time, all of which will invariably help reduce the problem of

collapsed buildings.

Also, two electric motors of 1hp each were welded to the lower parts of the

granulator, but connected together electrically, also inside the granulator are

rollers being driven by pulleys powered by 2hp electric motors and then

connected to other segments of the machine which are the conveyor which

also has 1hp electric motor bolted to one end of it while the third segment is

the sealer.

A part of evaluating a machine's performance is determining its capacity.

The term capacity refers to the amount of work that can be done in a given

amount of time. According to the readings in Table 4.1, the machine's

capacity was computed and represented.

Table 4.1: Performance Test on the developed cashew nut milling M/C
Number of Weight Speed Milling Unmilled Number Milled
Cashew nuts unmilled rev/min time (min) milled weight
400 500g 800 6 12 3 397 496.25

400 500g 1000 5 13 4 396 495.00

400 500g 1250 6 12 6 394 492.50

400 500g 1400 5 13 7 393 491.25

400 500g 1650 5 13 10 390 480.50

56
From the table, it was found that, the total time taken for the granulating and

packaging was calculated as;

The Average Time Taken

total timetaken 397+396 +394+393+ 390 1970

= number of specimen = 5
=
5
=394 minutes

Efficiency of the machine

average timetaken 100
= 400
× 1

394 1 00
= 400 × 1 = 98.5%

398

396

394
Number milled - Y axis

392

390

388

386
800 1000 1250 1400 1650
Speed - X axis

Figure 4.1: Graph of Speed against Number Milled

57
 12

10

8
Unmilled - Y axis

0
800 1000 1250 1400 1650

Speed - X axis

Figure 4.2: Graph of Speed against Unmilled

500

495

490
Milled Weight - Y axis

485

480

475

470
800 1000 1250 1400 1650
Speed - X axis

Figure 4.3: Graph of speed against milled weight

58
4.3 BILL OF MATERIALS

Table 4.2: The total bill of materials for performance evaluation

S/N Component Material Quantity Cost (#)
1 Mild steel plate Mild steel 1 18,000

2 Electrode - 1(pack) 2,000

3 Cashew nuts - 10kg 40,000

4 Transportation - - 6,000

5 Cable - 6(yards) 1,700

6 Reparation - - 4,000

7 Research & market survey - - 4,000

8 Painting - - 7,000

59
9 Labour cost - - 20,000

10 Miscellaneous - - 12,000

TOTAL 114,700.

CHAPTER FIVE

5. CONCLUSION

A cashew nut packaging machine has been designed to improve the efficiency

of the packaging operation as a means of processing the cashew nut. The testing

speed of the machine was between 800 – 1650rev/min and as the speed

increases the number of unmill also increases; though the speed can be

maintained at 800rev/min for the nut to be milled better. The objectives of the

machine were to design; the design of the shaft was based on tensional and

lateral loads since it is horizontal, therefore the value of diameter of shaft was

0.1920mm. Also in the fabrication process, angle bar was used in the fabricating

60
the frames while stainless steel was used in covering the parts; the machine

consist of three (3) parts which are the granulating machine, conveyor and

sealing machine, the granulating and conveyor were operated with 2hp and 1hp

respectively while the sealing machine total temperature for effective

performance was between 10 - 40ºC. The average time taken was calculated as

total time taken divided by number of specimen which was 394minutes while

the efficiency of the machine was calculated to be 98.5%. The machine

performed satisfactorily and can still be modified for better performance, in

order to improve the packaging, and the manufacturing cost. The advantage of

reduced unit cost can be derived from large-scale commercial production of this

machine.

5.1 RECOMMENDATION

he machine is designed to operate other additional accessories and systems

that make the current design to become easier for operation. Making the

machine easier and simple in relation to standard design. The machine could

be automatically controlled especially in the feeding and evacuation

mechanism. This will improve its performance and the safety of the

operator.

61
In addition, the moisture content of the cashew nuts was checked so as to get

an accurate result from the machine especially the granulator. The machine

has the ability to granulate, convey and seal within a short period of time

with a clean and no contamination of product. We therefore recommend the

usage of this cashew granular packaging machine to farmers and agro-based

industries to produced well granulated cashew nuts.

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 APPENDICES
Appendix 1

66
Mild steel plate

Appendix 2

Conveyor

Appendix 3

67
Sealing machine

Appendix 4

68
Granulating machine

69
Appendix 5

Plastic film sealer

70