DESIGN, DEVELOPMENT AND FABRICATION

OF SEMI-AUTOMATIC MULCHING MACHINE

KARTIK KANAWADE,ONKAR KHER, SHUBHAM PITHE, ATHARVA HAJARE

GUIDED BY .PROF.S.V. GOSAVI, DEPT. OF MECHNANICAL ENGINNERING,

SAVITRIBAI PHULE PUNE UNIVERSITY, PUNE, INDIA.

productivity, reduced labor dependency, and improved sustainability in
Abstract the agriculture

The purpose of this project report is to present the design,

development, and fabrication of a Semi-Automatic Mulching Sector. In light of these considerations, this project focuses on the design,
development, and fabrication of a semi-automatic mulching machine. The
Machine, which aims to enhance efficiency and productivity in
machine aims to simplify the process of mulch application by combining
agricultural practices. Mulching is a crucial technique used in manual operation for mobility with automated mechanisms for mulch
farming to protect the soil from erosion, conserve moisture, suppress dispensing, hole cutting, and mulch covering. Through the integration of
weed growth, and improve overall crop health. However, manual appropriate materials, components, and control systems, the machine
mulching is labor-intensive and time-consuming, limiting the scale strives to enhance operational efficiency, improve crop yield, and promote
and effectiveness of the process. The objective of this project was to sustainable agricultural practices.
design and develop a semi-automatic mulching machine that can
automate and streamline the mulching process, reducing manual 1.2 BASIC PRINCIPLES
effort and increasing productivity. The machine incorporates various Mulching: Mulching is a widely-practiced agriculture technique that is
mechanical components and control systems to achieve efficient beneficial for crops when done properly. It is the act of covering the soil
mulching operations. The design phase involved extensive research with mulches, such as bark, wood chips, leaves, and other organic or
and analysis of existing mulching techniques, machinery, and inorganic material, to preserve moisture and improve the condition of the
relevant industry standards. Based on the requirements, a conceptual soil. Mulching can be classified further into two types, which are
design was developed, considering factors such as mulch material
1.2.1 Organic Mulching Organic mulches originate from living materials.
handling, application rate, power source, and operator ergonomics. In
They can consist of grasses, leaves,
the development phase, the selected design was refined and translated
into detailed engineering drawings. The machine comprises a robust
frame, a mulch material holder, cutting mechanisms, and control
systems. The fabrication process involved procuring high-quality
materials, machining components, and assembling them to construct
the mulching machine. Rigorous testing and iterative improvements
were carried out to ensure optimal functionality, safety, and
durability. The semi-automatic mulching machine developed in this
project demonstrates significant improvements in mulching
efficiency compared to traditional manual methods.

1. INTRODUCTION
The agricultural industry plays a pivotal role in meeting the world’s
growing demand for food and ensuring global food security. As the
global population continues to increase, the need for efficient farming
practices becomes even more crucial. Mulching is a well-established
technique used in agriculture to improve crop growth, conserve soil
moisture, control weeds, and enhance overall productivity. It involves
the application of a protective layer, known as mulch, over the soil
surface surrounding the crop plants.Traditional mulching methods
typically involve manually laying mulch materials, such as plastic
film or biodegradable paper, on the soil beds. These methods are
labor-intensive, time-consuming, and require substantial physical
effort from farmers or laborers. The manual nature of the process
often leads to inconsistent mulch coverage, imprecise spacing of
planting holes, and increased vulnerability to weed growth.
The integration of modern control systems, such as microcontrollers
and sensors, enables the automation of key processes in mulch
applications. These systems provide precise control over mulch
dispensing, cutting hole placement, and covering operations.
Moreover, by incorporating intelligent algorithms and feedback
mechanisms, the machines can adapt to varying soil conditions, crop
types, and specific requirements, further enhancing their
effectiveness. While there have been advancements in mulching
machine designs and technologies, there is still a need for cost-
effective, user-friendly, and reliable semi-automatic mulching
machines suitable for small to medium-scale agricultural operations.
The development of such machines can contribute to increased
Fig 1.1 Organic Mulching using Straws
straws, shredded bark, pine needles, or compost. Organic mulches help
condition the soil, even inviting earthworms to naturally aerate the soil, and
help reduce soil compaction. While decomposing, they add nutrients such
as potassium, nitrogen, phosphorus, and trace elements to the soil. But
because they decompose, they have to be replaced regularly. The image
shown above gives an example of how Straws are used to cover the soil
and serve the purpose of mulching without causing any waste, in an eco-
friendly manner.
1.2.2 Inorganic Mulching:
Inorganic mulches consist of synthetic materials such as plastics, landscape
fabrics (geotextiles), stones, and rocks. They are generally used because the
materials don’t decompose, or only break down after extended periods.
Thus replacement costs are reduced. While organic mulches are the
preferred choice due to their soil-improving qualities, inorganic options
have their place. Gravel and river stone work well for plants that like
additional heat and require good drainage. Gravel and river stone are also
good choices for purely aesthetic purposes where plantings are few or non-
existent. Plastics and landscape fabrics reduce wind and soil erosion, help
warm the soil, and radiate heat better than some organic options for certain
plantings.
 The above image shows the various types of plastic mulches used in
common agricultural practices by farmers in various parts of the world,
depending upon the climatic conditions of their surroundings.
Fig 1.2 Inorganic Mulching using Plastic Polymers.
The above image gives an example of the widely used plastic mulches
laid in farmlands by farmers to gain the benefits of Mulching.
Different types of Plastics are used in Inorganic Mulching practices
such as,
1. Black plastic film.
A. It helps in conserving moisture, controlling weeds, and reducing
outgoing radiation. It is majorly used in desert or sandy areas and in
saline water areas.
2. Reflective silver film
a. It is used for crops that require cooler soil temperatures, as this film
keeps the root zone temperatures cooler than the ambient temperature. It
also repels insects and can be used advantageously in areas infested by
insects or pests.
3. Transparent film.
A. It increases the soil temperature and is used where the crop requires
higher soil temperatures than the ambient temperature. It is also used to
control weed growth using solarization.
4. Degradable plastic mulch.
A. Photo-degradable plastic mulch.
i. This type of plastic mulch film gets degraded or breaks down by
sunlight in a shorter period.
B. Bio-degradable plastic mulch.
i. This type of plastic mulch film is easily degraded in the soil over
some time due to the action of bacteria or other microorganisms on it.
Fig 1.3 Different types of plastic mulch films
2.LITERATURE REVIEW
Prof. Amay Tipayale [I] et al., explained about the mulching paper
laying machine. Mulching the plastic paper film near the root area of
plants is for eliminating the rise of weeds also to retaining water and
avoiding de-moisturizing the soil but this process requires lots of
capital and time. So, the Drip irrigation pipe and Mulching paper
laying machine‟ will reduce the labor cost and time, it will do both
jobs i.e., laying irrigation pipe and mulching paper on the ground at a
time. By using various mechanisms, this machine will lay the
irrigation pipe and mulching paper at the same time it will make the
holes on the paper to provide plantation area after laying the drip
irrigation pipe and mulching paper.
To meet the growing needs of the farmers who wish continuously to
improve the profitability of their farming by using more efficient
materials and machinery this will be one of the methods which will
help for improving it. Drip irrigation pipe and Mulching paper laying
Machine‟ will be able to do the laying of the irrigation pipe as well as
mulching paper simultaneously. “A pneumatic dibbling machine for
plastic mulch”, American Society of Agricultural and biological
engineers, applied engineering in Agriculture.
In this paper, the author designed an “Advanced Mulching Paper
Laying Machine” application which is in Agriculture, which is going
to Laying paper by reducing human effort and also the cost required
for employees to laying Mulch Paper on Bed. This system does not
need more human labor, Mulch paper avoids wastewater and Stops the
growth of grass. Also, in this method, we use some Mechanical means
so the working time is less as compared to the conventional method.
Mr. A.V. Rangbhal [II] et al., observed that plastic mulch applications
in agriculture are based on type, source, and degradability. There is
increasing interest in the use of plastic mulching for fruit and
vegetable crops in the Agriculture field. Globally the mulching area
has increased by about 50 percent since 1991. Mulching can make
effective changes to increase horticulture crop production in the water
scarcity regions. Plastic mulching using black polyethylene paper is
recommended for vegetables and has advantages for earliness
production, better fruit quality, and greater total yield.
Agriculture is the most important sector of the Indian Economy. The
agriculture sector accounts for 18 percent of India‟s gross domestic
product (GDP) and employs 50 percent of the country’s workforce.
India has emerged as the second-largest producer of fruits and
vegetables in the world. Formerly agriculture was more dependent on
nature and all the operations were carried out manually, however, new
technologies have been developed to increase the production and
productivity of crops. Mulching with organic or inorganic materials
aims to cover soils and forms a physical barrier to limit soil water
evaporation, control weeds, maintain a good soil structure, and protect
crops from soil contamination. Natural mulches are those derived from
animal and plant materials. If properly used, they can offer all the
benefits of other types of mulches. Natural mulches help in
maintaining soil organic matter and tilth (Tindall et al. 1991) and
provide food and shelter for earthworms and other desirable soil biota.
This review has covered the major concerns about the plastic mulch
application in Agriculture like its type, source, and degradability.
There is increasing interest in the use of plastic mulching for fruit and
vegetable crops in the Agriculture field. Globally the mulching area
has increased by about 50 percent since 1991. Mulching can make
effective changes to increase horticulture crop production in the water
scarcity regions. Plastic mulching using Black polyethylene paper is
recommended for vegetables and has advantageous for earliness
production, better fruit quality, and greater total yield. Manual or
mechanical techniques are used for mulch laying among that
mechanical mulching practices have greater efficiency and
uniformity which reduces human efforts. Mulching maintains the
moisture content level of soil also it helps in weed and insect
control.
Z.M. Khazimov [III] et al., studied that the increase in crop
productivity using film mulched soils occurs due to the saving of
moisture in the soil top layers, improvement of thermal properties
in soil air layers, and the top soil layer, fewer weeds in crops,
saving of the top soil layer in more friable condition. Using plastic
films allows for avoiding the application of herbicides and provides
for early planting (Kadorkina and Kurtijakova, 2006).
In 1968–1970 the influence of soil mulching using a transparent
plastic film was studied with cucumbers, eggplants, and peppers on
black soil, in conditions of Kazakhstan (Chebotar, 2006). With the
help of mulching, the acclimation of seedlings of cucumbers and
eggplants increased to 15% and pepper to 8%, and maturing of
fruits was accelerated by 2–3 days. The yield of commodity
cucumbers was increased by 7.9%, and pepper and eggplants by
2.8%. n regard to the various schemes of planting and sowing of
crops in soil mulching, the width of plastic film can vary. The
width of the most often used plastic film in big areas in foreign
countries is 140 cm. The majority of authors noticed that mulching
with plastic in wide strips (1 m) is the more effective method, than
narrow strips.
Most of the machines used for laying mulch film are imported from
foreign countries. In these machines various technical decisions are
offered, in most cases, they are in the form of multi-use machines
which perform multiple operations. All the machines perform
similar technological processes consisting of unwinding the plastic
film roll, allaying it on the soil surface, and fixation the film edges
with soil, punching planting holes through the film, and seeding or
planting into the holes formed in the soil. However, all studied
machinery for planting vegetable seedlings under mulch required
two passes of the device. On the first pass the soil surface is
mulched, on the second pass seedlings are planted.
To devise complex machines for the cultivation of arable crops
under mulching plastic, it is necessary to have a specialized seeder
that performs synchronous punching of holes in the plastic,
seeding, and closing of seeds at set a distance in the row. The
common element of all previously mentioned mechanical activities
is a punching wheel intended for punching holes in the plastic and
covering seeds. The same is required when planting seedlings of
vegetables.
Harshvardhan K. More [IV] et al., observes that the mulching paper
laying machine was developed to mechanize the conventional
mulch paper laying process. The mulching paper roll is mounted on
the equipment’s main frame and the soil covering assembly is
mounted on the frame structure. The pulling arrangement for this
machine is suitable for bullock carts and also for tractors. Forces
are to be calculated as per the soil density. This machine is to be
developed as per cheap manufacturing cost and also to be portable
for handling purposes and disassembling. Various parameters like
soil temperature and soil density are to be considered from the
catalog.
After the literature review of various research papers mentioned
above, we learned a lot of things about mulching machines such as
the importance of mulching in agriculture and the benefits it has
and provides the farmers when they perform mulching in their
farms like weed control, moisture retention, prevent soil erosion.
Furthermore, many authors have also mentioned the advantages of
a mulching machine working on the fields rather than the manual
mulch laying process and elaborated on the importance of mulching
machines. Mulching machines provide various advantages over the
manual mulch laying process such as reduced labor costs, reduced
human efforts, and faster process completion. We also found out about
the various crops that benefit from mulching and the various types of
mulch used for various environmental conditions and various crops.
Moreover, the study of these research papers also gave us a slight idea
about how to design a mulching machine by describing the basic
design considerations and parameters that we have to take into account
while designing and developing a mulching machine.
3.Design of Semi-automatic Mulching Machine
Computer-Aided Design (CAD) is a powerful technology that has
transformed the design and engineering industries. With CAD software,
designers can create, modify, analyze, and optimize designs with greater
efficiency and accuracy compared to traditional manual drafting methods.
CAD has become an indispensable tool in various fields, including
architecture, engineering, manufacturing, automotive, aerospace, and
product development.
CAD provides several advantages that have revolutionized the design
process. First and foremost, CAD significantly increases efficiency.
Designers can create and modify designs much faster using CAD tools.
Features like copy-paste, parametric modeling, and design libraries allow
for quick iterations and design changes, reducing design time and boosting
productivity. One of the key advantages of CAD is improved accuracy.
CAD software provides precise measurements and ensures designs meet
specific dimensional requirements. Designers can easily align and
manipulate objects, ensuring geometric precision and eliminating human
errors and inconsistencies that are common in manual drafting.
CAD also enhances visualization capabilities. Designers can create realistic
2D and 3D models of their designs, allowing stakeholders, clients, and
team members to better understand the design intent. Visual representations
help identify potential issues, make informed decisions, and improve
communication throughout the design process. Another significant
advantage of CAD is the ease of modifications. CAD designs can be easily
modified and updated, even after the initial design phase. Designers can
make adjustments without starting from scratch, reducing rework and
facilitating efficient design iterations.
This flexibility is crucial, especially when responding to design changes or
feedback. CAD software often includes analysis and simulation tools that
enable designers to test the functionality and performance of their designs.
Engineers can analyze factors like stress distribution, fluid flow, and
thermal properties. This capability allows for the early identification of
potential problems and the optimization of designs for better performance.
Furthermore, CAD promotes collaboration and documentation. CAD files
can be easily shared electronically, allowing multiple team members to
work on the same design simultaneously. This improves coordination,
reduces errors, and enhances overall productivity. Additionally, CAD
provides comprehensive documentation, including detailed drawings, parts
lists, and assembly instructions, ensuring clarity and consistency
throughout the design and manufacturing processes.
In summary, CAD has revolutionized the design and engineering industries
by offering increased efficiency, improved accuracy, enhanced
visualization, easy modifications, design analysis capabilities, collaboration
support, and integration with manufacturing processes. These advantages
have resulted in faster design cycles, cost savings, and the ability to create
innovative and high-quality products. CAD continues to evolve,
empowering designers and engineers to push the boundaries of creativity
and technological advancement.
We drafted our first model in Solidworks based on the information
gathered from the various research papers referred to during the
literature and market review phase of our project.

The above figures represent the model’s geometry from

different angles of projections such as the top view and
side view respectively.

Fig. 4.1 Isometric View of the Machine

The above figure shows the isometric view of our semi-automatic
mulching machine. With this design, we started to visualize the actual
geometry of the machine for the first time since the problem definition
and literature review phases of our project. No material was selected Fig 4.4 Drafting of the Model
just yet for this preliminary design of this machine.
The above figure shows the dimensions of our model
previously assumed as safe dimensions as per the various
Other views include the top view and side view of the model which are published papers we referred to during the literature
shown below, reviewphase of our project.

4.Motor calculation
Consider,
Weight to be lifted = 30 kg
= 30 x 9.81
=249.3 N ≈ 300 N

Fig 4.2 Top View of the Model

Diameter of wheel = 220mm

Torque is given by,

Torque = Force x Radius of Wheel
= 300 x 110 = 33 Nm …………(Thisactual torque )
So we have to select the motor having the torque greater than that of the
actual torque. So, we will select the motor from the availability in the
market. Motor Specifications: Voltage = 24V

Power = P = 150W
Speed = N =30Rpm
Weknow that, P = 2 x π x N x T/60 T

Fig. 4.3 Side view of the Model =47.74 Nm

References

1. “Advance Mulching Paper Laying Machine” by Prof. Amay

Tipayale, Mayur
S. Salunke, Samadhan U. Thete, Tushar S. Thete, Sandip B.
Thete.

2. “Performance of Mechanical Plastic Mulch Laying Practices:

A Review” by Mr.

A.V. Rangbhal, Dr. S.V. Pathak. International Journal of Engineering

Science Invention (IJESI), ISSN (Online): 2319 – 6734, ISSN (Print):
2319 – 6726 www.ijesi.org, Volume 7 Issue 3 Ver. 3, March 2018

3. “Development of a dual action planting and mulching

machine for vegetable Seedlings” by Z.M. Khazimov, G.C.
Bora, K.M. Khazimov, M.Z. Khazimov, I.B. Ultanova, A.K.
Niyazbayev.

4. “Design and Development of Mulching Paper Laying

Machine” Harshvardhan K. More, Dr. Subm Khan, Dr. S. S.
Pardeshi, ISSN (online): 2321-0613, Vol. 7, Issue 05, 2019.

5. “Design and Fabrication of Mulching CUM Automatic Paper

Rolling and Tree Planting Machine”,Abhishek Navghare,
Anshul Tambekar, Harshit Pandey, VickyNavghade,
Prof..Ranjeet Mane,ISSN XXXX XXXX © 2017 IJESC
Volume 7 Issue No.3