project proposal

ALETA WONDO CONSTRUCTION AND INDUSRIAL COLLEGE
ALETA WONDO INDUSTRIAL AND

CONSTRUCTION COLLEGE
DEPARTMENT OF MECHANICS
PROJECT PROPOSAL FOR DESIGN AND
MANUFACTURING OF COMBINATION KOCHO
PROCESSING MACHINE
PREPARED BY:-ENICHA HUSSIEN
APRIL 2022
A/WONDO ETHIOPIA
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AKNOLEDGEMENTS
First of all I want to provide grateful thanks for Almighty lord Jesus Christ who supports(protects)
me to accomplish the task. Next I want my thanks to our college Dean Mr. Duguna Eshine for his
sustainable commitments and support throughout my work. Next I want thanks Mechanics
department Instructors Mr. Adamo Amaje , Mr.Tafese Boe and Getu Bejiga for their commitment
during manufacturing process. Next I want provide my grateful thanks for all furniture
department Instructor for their commitments for production of wood part of squeezing machine.
Next I want express my appreciation for our level 4 trainers trainer Lemilem Tesema and trainer
Asichalew Tesfaye for their amazing commitments and involvement for production of metal parts
of the machine. Additionally I want provide my grateful appreciation for Instructor Guluma
Moltot for his constructive advices have provided for me regarding material selection. Finally I
want thanks finance department purchasing officers for their committed material provision.
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ABSTRACT
Kocho products are main source of food for Sidama and southern Ethiopia people. More than 20
million people consume this product. Kocho processing takes cumbersome steps to make it well
fit for feeding.Amog the steps, Rubbing/spreading/squeezing/frying/and sieving are most
common. During those steps of preparation women exposed to different injury, since steps
undertaken through man power.Squuezing even kills the women by hitting their chests.
Pulverizing corms also very tedious steps that accomplished by women. Those steps are
ergonomically endangered the women. It takes long time, effort to accomplish. This designed
combination mult-purpose machine performs many activities. Combination Kocho processing
machine is combination of screw conveyer machine, squeezing machine, and sieving machine.
Screw conveyer machine itself can accomplish the tasks of
(rubbing/smoothing/squeezing/frying/corm pulverizing/,the second machine performs squeezing
operation, and third machine performs sieving operation for both Kocho and other crops by
changing the grades of sieve. So in this project we have all this purpose and the cost of the
machine,feasiblity study,litrature study, methodology and design analysis are included.
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Table of Contents
Table of Contents
AKNOLEDGEMENTS ........................................................................................................................................ 2
ABSTRACT ....................................................................................................................................................... 3
Table of Contents ........................................................................................................................................... 4
List of Abbreviations ....................................................................................................................................... 8
V.List of Symbols ............................................................................................................................................. 9
VI.List Figures and Tables ............................................................................................................................. 10
1.CHAPTER ONE ............................................................................................................................................ 11
1.1.INTRODUCTION .................................................................................................................................. 11
1.2.BACKGROUND OF THE PROJECT/TECHNOLOGY ................................................................................. 12
1.3. STATEMENT OF PROBLEMS ............................................................................................................... 12
1.4. OBJECTIVES ..................................................................................................................................... 12
1.4.1. GENERAL OBJECTIVES ................................................................................................................ 12
1.4.2. SPESFIC PROBLEMS ..................................................................................................................... 12
1.5.SCOPE OF THE PROJECT. ..................................................................................................................... 12
1.6.LIMITATIONS....................................................................................................................................... 13
1.7.SIGNIFICANCE OF THE TECHNOLOGY. ................................................................................................ 13
2.CHAPTER TWO ........................................................................................................................................... 14
2.1.LITRATURE REVIEW............................................................................................................................. 14
2.1.1.Uses of "Enset" Plant ................................................................................................................... 14
2.2.THE PROCESSING OF "ENSET .............................................................................................................. 15
2.2.1.A.TRADITIONAL "ENSET’ PROCESSING IN THE................................................................................. 16
SIDAMA AREA ........................................................................................................................................... 16
2.2.1.a.Pit Preparation.......................................................................................................................... 16
2.2.1.b. Decortications.......................................................................................................................... 16
2.2.1.c.Pulverization ............................................................................................................................. 17
2.2.1.d.Burying...................................................................................................................................... 18
2.2.1.e.Squeezing, Shredding and Sifting ............................................................................................. 18
2.2.1B"ENSET' PROCESSING IN THE WOLAYITA AREA .............................................................................. 21
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2.2.1B.1.Preparation and fixing of the stem processing equipments .................................................. 21

2.2.1B 2.Pseudo stem Processing Operation........................................................................................ 21
2.2.1B.3.Extraction of the liquid food from the parenchyma tissue .................................................... 22
2.2.1B.4"Enset" corm processing operation ........................................................................................ 23
2.2.1B.5.Pounding follows until the material is finely ground. ............................................................ 23
2.2.1B.6.Squeezing of fermented mixture of parenchyma tissue and pulverized corm. ..................... 24
2.3.Some physical characteristics of "Kocho" .......................................................................................... 25
2.4.PAST ATTEMPTS MADE TO IMPROVE "ENSET’ PROCESSING EQUIPMENTS ...................................... 26
2.4.1The Hawassa College of Agriculture ............................................................................................. 26
2.4.2.Sodo Appropriate Technology Center. ........................................................................................ 26
2.4.3.Institute of Agricultural Research (located in the vicinity of Nazareth) ...................................... 27
2.5.Brief survey of possible existing mechanical methods of processing Fibrous plant psudostems and
corms ........................................................................................................................................................ 29
2.6.Smashing or hammering against a hard surface ................................................................................ 30
2.7.IMPROVEMENT OR ADOPTION OF EXISTING METHODS OF FERMENTATION, .................................. 31
SQUEEZING, KNEADING, SHREDDING AND SIFTING................................................................................. 31
2.8.PREPARATION OF PRE-DESIGN MEASURING EQUIPMENTS FOR FIELD TESTS ................................... 33
2.9.INFORMATION GATHERING ON THE PERFORMANCE OF "ENSET" PROCESSING ............................... 35
2.9.1.Processing and Operators Information ....................................................................................... 37
3.CHAPTER THREE......................................................................................................................................... 38
3.1.METHODS OF DATA COLLECTION ....................................................................................................... 39
3.1.1.Primary sources:- ......................................................................................................................... 39
3.1.2. Data collection ............................................................................................................................ 39
Planning and Preparation ...................................................................................................................... 39
3.1.3 Survey Area. ................................................................................................................................. 39
3.1.4.Survey Period:.............................................................................................................................. 40
3.1.5.Target Respondents..................................................................................................................... 40
3.1.6.Study Team. ................................................................................................................................. 40
3.2. Gathering Tool Development ............................................................................................................ 40
3.3.Method of Data Analysis .................................................................................................................... 41
3.3.1.Design Methodology ................................................................................................................... 41
3.3.2.Mechanisms Used for Designing combination Kocho processing machine. ............................... 41
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3.3.3Describing Mechanisms of each machine .................................................................................... 41

3.4.Failure Theory and other possible designing concepts. ..................................................................... 41
3.4.1.Failure of mechanical parts on Multi-purpose helical conveyer machine .................................. 41
3.4.2.Mechanical properties of the above listed materials.................................................................. 42
3.4.3.Mechanical properties of stainless steel to resist mechanical forces ......................................... 42
3.4.4.Where would failulity may occurs ............................................................................................... 42
3.4.5.Properties of materials used in squeezing press ......................................................................... 42
3.5.Machine design .................................................................................................................................. 43
3.5.1.Theoretical Frame work .............................................................................................................. 43
3.5.2.Design of the capacity of the Kocho processing helical conveyer machine ................................ 44
3.5.3.Development tools used (software and equipments)................................................................. 45
3.6.Sample Size & Sampling Technique used ........................................................................................... 45
a. Composition of respondents ................................................................................................................. 45
b. Academic Background ......................................................................................................................... 46
3.7.Feasibility analyses ............................................................................................................................. 47
3.7.1.Technical Aspect .......................................................................................................................... 48
3.7.2.Economic Aspect ......................................................................................................................... 48
3.7.3.Social Aspect ................................................................................................................................ 48
3.7.4.Environmental Aspect. ................................................................................................................ 48
4.CHAPTER FOUR .......................................................................................................................................... 49
4.1.THE DESIGNING PROCESS ................................................................................................................... 49
4.1.2.DESIGNING OF COMBINATION KOCHO PROCESSING MACHINE. ................................................ 49
4.1.3.Design of a modified hand operated pineapple juice extraction machine. ................................ 49
4.1.4.Working principle of the machine design.................................................................................... 50
4.1.5.Design specifications ................................................................................................................... 50
4.6. Design calculations, Results and Discussion ...................................................................................... 52
4.6.1. Design Calculations ..................................................................................................................... 52
4.6.2.Design of screw shaft................................................................................................................... 53
4.6.3.Part manufacturing processes of Combination Kocho processing machine ............................... 55
4.7.Part and 3D drawings of Press squeezing machine ............................................................................ 59
4.7.1.Part and 3D drawings of mult-purpose helical conveyer machine ............................................. 74
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4.72.Part and 3D drawings of Kocho sieving machine ......................................................................... 92

4.8.Mentainance of the machine ........................................................................................................... 109
4.9.Cost Analysis ..................................................................................................................................... 109
4.9.1.Direct material cost ................................................................................................................... 109
4.9.2.Direct Labor Cost ....................................................................................................................... 110
4.9.3.Manufacturing overhead cost ................................................................................................... 110
4.9.4.Factory Overhead cost............................................................................................................... 110
5.Conclusions. ............................................................................................................................................. 112
6.Recommendation .................................................................................................................................... 113
7.References ............................................................................................................................................... 114
8.Appendix .................................................................................................................................................. 116
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List of Abbreviations
IAR= Institute of Agricultural Research
RHS =Rectangular Hollow Steel

TVET=Technical and Vocational Education Training
C – Clearance at both ends
PL – Pitch length
MIG=Metal inert gas
MAG= Metal active gas
TIG =Tungsten inert gas
3D=Three dimensions
2D= Two dimensions
HP=Horse power
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V.List of Symbols
𝞴=Lambda
𝞹=pi=3.14
Ƴ=Gamma
ф=Diameter
R=Radius
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VI.List Figures and Tables

figure 1. 1 Decorticating saw tool ................................................................................................................. 17
figure 1. 2 decorticating bone tool ................................................................................................................ 17
figure 1. 3 rubbing the Kocho by hands........................................................................................................ 18
figure 1. 4 shreading Kocho .......................................................................................................................... 19
figure 1. 5 sifting Kocho ............................................................................................................................... 19
figure 1. 6 Kocho processing cardboard and manual sieve........................................................................... 20
figure 2. 1 Kocho squeezing in Wolaita........................................................................................................ 24
figure 3. 1.Sidama region map ...................................................................................................................... 39
figure 4. 1Hooper .......................................................................................................................................... 51
figure 4. 2.helical conveyer .......................................................................................................................... 53
figure 4. 3 failure analysis of lower timber by stress analysis of simulation. ............................................... 57
figure 4. 4 Stress analysis simulation of upper screw holder upper RHS ..................................................... 57
figure 4. 5 Exploded view of the machine .................................................................................................... 58
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1.CHAPTER ONE
1.1.INTRODUCTION
Enset plant is staple crop for southern part of the Ethiopia. Around 20 million of the country
which found in Sidama,SNNPR and western oromia(Arsi,Wench etc) use Enset as a main crops
of consumption. In our context in Sidama around six million people use this crop. From this crop
different outputs of the foods are obtained. For instance Kocho,Bulla,Hamicho(corms)are the
main types of foods. Those foods are mostly prepared by women and girls. There are cumbersome
steps for production of Kocho from garden fermentation up to preparing for ripened food. Among
the garden fermenting processing scrapping the stems and pulverizing corms are tedious steps
which performed by women. This undertaken by using wood and metal scrappers. Corms are
pulverized with bones of front limbs of oxes.This step is cumbersome which creates high pain on
chests and hands of women. The other steps of Kocho preparation squeezing and make it dry. The
dry Kocho is used for different food stuffs like;Omolcho,Bread(Tima),Burisame,Chukame.During
squeezing steps there are different operation accomplished for making Kocho well fit for
operation. These operations are rubbing Kocho with the palms of hands along time with kneeling
on the ground and by placing it on Traditional wood made timber called Badiro. This rubbing
consumes long time woman feel pain and kneeling continuously affects their body structure
position. Recently ongoing squeezing system has its own high risks since it is operated with piece
of wooden stick and flour covering plastics(bags) by twisting it and removing Juice content.
During twisting women must use high effort and twists side way highly and this affects their
health badly. Additional and worst dangers of twisting are it kills and hurts(damages) body parts
of the women if twisting wooden sticks are removed from the locks they putted on. The next step
of twisting of Kocho is make the dry Kocho flour by using hands and this steps also taking effort
and time. Then the flour and fibers are separated with using traditional sieve and hits with hands.
This operation has its own drawbacks that is women costs alot of effort for hitting and shaking the
flour. Additional they use other filtering process after filter by sieve. Generally there are low
quality of filteration.In general this Kocho processing combination machines are combination of
three machine working together. This machine performs, corms pulverization, Kocho rubbing,
squeezing(two machines independently),Kocho powdering, and sieving/filtering. Additionally
one of the machine also performs onion chopping operation.
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1.2.BACKGROUND OF THE PROJECT/TECHNOLOGY

As explained above large number of population in Southern Ethiopia use Kocho as a main food.
Kocho processing has long steps those are time consuming, Effort consuming, Hurts women
ergonomically and exposes them for different disablties,injuriers and even lastly for death.
Recently Kocho processing mechanisms are performed with traditional methods and backward
tools. Those tools and operating mechanisms has exposed the operators for different illness and
injuries. So this combination machine needed for overcome those problems.
1.3. STATEMENT OF PROBLEMS

As explained above introduction mass of population in our locality consume kocho.Kocho
processing has long and cumbersome steps. These steps need different efforts of manpower and
exposes operators for different injuries. During data collection of Sidama
region,Hula,Teticha,Aleta Wondo Woreda and town we have collected different real data about
Kocho processing. It is public secrets for those who know the problems that face Kocho
processing. Kocho processing like corm pulverization,rubbing,squeezing powdering and filtering
steps are cumbersome, effort consuming, time killer, ergonomically affects women, exposes
women for different health problems and generally exposes for death. So this machine solves all
those problems.
1.4. OBJECTIVES
1.4.1. GENERAL OBJECTIVES
The general objectives of this project are solving problems faced during Kocho processing by
designing and manufacturing and transferring combination Kocho processing machine.
1.4.2. SPESFIC PROBLEMS

Preparing detail design for combination machine
manufacturing combination machine
Transferring it for enterprises
Advertising technology on different media
Creating opportunities of dissemination by creating connection with stakeholders
Creating healthy community
creating danger free environment for women
creating work opportunity for enterprises.
1.5.SCOPE OF THE PROJECT.

This project covers designing processes, manufacturing prototype, testing sample, preparation full
document for technology and transferring it to enterprises.
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1.6.LIMITATIONS
During manufacturing of combination Kocho processing I have faced different problems. Those
are:-
Fail to use right materials like Aluminum and stainless steel. This affects the quality of my
work. The main reasons for this are shortage of budget due to inflation of the cost of the material.
Fail to use right welding gases like Mig/MAG/TIG due to lack of argon gas in the college.
This is due to fail of bidders to provide the gas on time.
Lack of using right manufacturing operation like drilling hole. This is due to our drilling
machine has no complete accessories to drill and it is not functional.
1.7.SIGNIFICANCE OF THE TECHNOLOGY.

Implementation of this technology has many siginificances.As mentioned above about 20 millions
of southern parts of country use Kocho as a main source of food. Those population pays unwanted
efforts ,times for its processing. This processing has long steps from garden fermenting up to
ripening. These steps needs,pulverzing corm,rubbing,squuezing,powdering,filtering.During these
steps women faced for different health problems, operating systems are back warded and operated
with using backward tools. So by using this combination machine society perform their operation
in safeway.All operations are completed in safe way. This machine is cost effective,
environmentally friendly, Ergonomically feasible, simple to operate and feasible that means it
operated with manually and motorized. This machine also purchased independently or in set.
Individual family or hotels should use this machine to finish their work safe way and without any
problems of health.
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2.CHAPTER TWO
2.1.LITRATURE REVIEW
2.1.1.Uses of "Enset" Plant
"Enset" is a multipurpose crop. It is used for human consumption, animal feed and for extraction
of long fibers ("Kacha") used for making bags, rags, robe, gunny bag, etc. The leaves are used to
form the inner lining for the pit in which the decorticated corm and pseudo stem are buried for
fermentation (4). Some varieties of "enset" and food from these varieties are also considered to
have medical value (7). The following are examples of medical uses of the "enset" plant: food
prepared from immature corm of "enset" plant is fed for healing broken bones. Gruel or porridge
made of bulla is fed to new mothers to clean out the uterus, for milk production, and for
strength. Bulla gruel or porridge is given for newly circumcised children. Highly fermented
"Kocho" in its dry form is also given for treating amoebiasis and for stomach cramps. Edible
parts of the "enset" plant are the corm (root part) and the pseudo stem (inner bark). The parts of
the "enset" plant used for human consumption are Kocho", "Bulla" and "Amicho". These
products of the "enset" plant are used to make different dishes such as the following:
Kocho Kita (thin, unleavened bread)

Bulla Genfo (porridge type)
Bulla Atmit (gruel type)
Bulla or Kocho Ferfer (shredded flake)
Amicho - Located at the base of the pseudo stem and is eaten after boiling like potatoes.
The nutritional value of dishes prepared from "bulla", Kocho", or Amicho" are high in
carbohydrate and low in protein .Products of the enset" plant are often blamed for causing protein
deficiency disease when eaten alone as a staple food. It is true that Kocho or bulla contain very
little protein (0.5 gm in 100 gm of edible portion). However it should be mentioned that dishes
made out of ’ enset" products are traditionally served with good alternative protein sources.
Information gathered in Wolaita and Sidama areas indicate that dishes prepared from these
products (Kocho. bulla, etc.) are supplemented either with milk, meat, or legume which enrich the
protein value of the prepared food.
Table 1 Nutritional Value of Kocho and Bulla/l00gm of Edible Protein
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B u lla Kocho
Food energy (Kcal) 200 186
Moisture(%) 7.9 53.5 48.7
Protein (g) 0.6 0.5
Fat (g) 0.3 0.4
Carbohydrates (g) 49.0 44.8
Calcium (mg) 82.0 70
Phospherous (mg) 36.0 45
Iron (mg) 3.7 7.9
Source: Food Composition Table for use in Ethiopia, 1968 (2).
Table 2 Kocho/Bulla Dishes of Wolaita and Sidama Areas and Types of Protein Sources
Area Name of Dish T yp e

Wolaita Bachira Stif porridge
Mucho Shredded, flake
Godctta Thin bread
Bulla Genfo Porridge
Sidama chukame Flake type
sherko Porridge
Omolcho Sandwich type
duwame Wrapped and baked
Torosho Dry thin bread
Buluko Gruel
kocho dishes of sidama and wolayta
2.2.THE PROCESSING OF "ENSET

The planting and transplanting of "enset" is carried out by men. "Enset'' harvesting and
processing is the responsibility of women. The harvesting and processing of "enset" for extracting
edible and non-edible parts is probably one of the most cumbersome household responsibilities
women in enset-culture areas have to carry out. Information gathered from women in two "enset"
culture areas of Wolaita and Sidama indicates that the processing of "enset" is the most laborious
household activity. The strategy used by women in these areas to reduce the work load is to have
a labor pool support system which they call Hasa. Small groups of women assist a fellow woman
in processing her "enset". The assistance could be free, with payment or in return of labor
whenever the woman processes her "enset" (7). Though the house wife gets assistance from the
neighbors, the entire responsibility relies on her. The survey done in Wolaita area indicates that
86% of the household "enset" processing is done by the wife and another 14% is contributed by
neighbors.
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2.2.1.A.TRADITIONAL "ENSET’ PROCESSING IN THE
SIDAMA AREA
2.2.1.a.Pit Preparation
The primary job of ’enset" food product preparation in the Sidama area starts with the digging of
a pit in the ground near a sturdy tree, then a flexible pseudo stem of the "enset" plant is placed to
cover the soil. Broad "enset" leaves are lined in the pit over the flexible "enset" bark. The purpose
of the leaves is to collect and prevent the juicy part from leaking into the ground while
keeping scraped pseudo stem clean. Using the same pit, half of it is arranged in a way to allow the
juicy part to flow down gently and accumulate separately. A long rectangular board is placed on
the leaves in the pit and r is secured with "woficho" string Cutting and digging out of "enset"
plant The thick dry outer bark of the "enset" plant are removed. After the first thin lining of the
bark are discarded, layers of the pseudo stem are removed and readied for scraping.
2.2.1.b. Decortications
A single pseudo stem is secured on the wooden pole with "woficho" string. Using a bamboo split,
the woman from a strenuous sitting position scrapes the fleshy part of the pseudo stem down
towards the pit. She secures the pseudo stem on the board by raising one leg and pressing it with
her limbs so that the stem will not slip down. This process leaves the fiber in the stem.
The other half of the scrapped pseudo stem is also turned upside down, and the stem is secured
with the fiber extracted from the first scraping. This processing separates the fleshy part of the
pseudo stem from the fiber (about 1 meter and 10 cm in length) while letting the juice flow down
in the pit lined with "enset" leaves. After a short while the juicy part sediments into a moist sticky
substance known as "bulla". Usually the clear solution on the "bulla" sediment is discarded. The
remaining thick sticky white substance, "bulla", is spread in order to be dehydrated. Later on, a
handful of "bulla" is wrapped with fresh "enset" leaves and tied with "woficho" string in order to
be fermented. Care is taken not to expose the "bulla" to air and light in order to avoid an
unwanted color change, i.e., white "bulla" has more market value than non-white "bulla".
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figure 1. 1 Decorticating saw tool

2.2.1.c.Pulverization
Using a local digging hoe, the corm (root part) is dug out and transported to where the pseudo
stem is processed. A serrated animal bone (scapula) is used to pulverize the corm . This process
turns the corm into smaller grated pieces which have to be kept aside in order to be mixed with
the fleshy scraped pseudo stem.
figure 1. 2 decorticating bone tool
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2.2.1.d.Burying
The squeezed mixture (pulverized corm and decorticated stem) is buried in a pit lined with
"enset" leaves. A pre-fermented pseudo stem base us also added as a starter to initiate the
fermentation of the mixture. Just as possession of cattle represents wealth for the pastoral people,
having more fermented "Kocho" pits is also taken as a symbol of wealth in the "enset" culture
areas.
2.2.1.e.Squeezing, Shredding and Sifting

A handful of the fermented pseudo stem and the pulverized corm mixture is wrapped with "enset"
fiber (Kocho). The wrapped mixture is placed on a pointed cone-shape piece of wood, and the
woman presses it with her knees by rotating the wrapped mixture into different directions . This
process squeezes out the unwanted liquid part. The semi-dry food mixture is finely chopped on a
wooden board with a local knife. The purpose of this process is to chop the remaining fiber in the
feed mixture as finely as possible. Finally the "Kocho" is sifted using a local sieve. This method
allows the "Kocho" powder to pass through the sieve separating it from unwanted fibrous part.
figure 1. 3 rubbing the Kocho by hands
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figure 1. 4 shreading Kocho
figure 1. 5 sifting Kocho
19
figure 1. 6 Kocho processing cardboard and manual sieve
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2.2.1B"ENSET' PROCESSING IN THE WOLAYITA AREA

Selection of "enset" tree for food processing To be considered for processing the "enset" tree must
be mature. The sign of its maturity is usually the flowering stage. In addition, when the height of
the stem reaches about 190 cm and the diameter at the base is around 65 cm, the tree is said to be
mature enough for the processing.
2.2.1B.1.Preparation and fixing of the stem processing equipments

Because there are normally no vertical structures in the "enset" yard where the food processing
takes place, one of the "enset" trees is used as a support for the decortications board during the
removal of the parenchyma tissues from the pseudo stem. At the foot of this tree a pit with a
diameter of 80 cm and a depth of about 25 cm is dug by first chopping all the soft roots that
sprout from the tree, using a local forked hoe and knife. Semi-dry "enset" leaves are gently folded
and curved around the lateral side of the hole, totally covering the surface and extending about 20
cm above the ground. The leaves are tied together at intervals to form a bottomless cylinder. The
bare bottom ground as well as the side of the pit is then entirely covered by criss-crossing fresh
leaves. Another layer of mature, tougher and brownish leaves is finally laid on top of all the
previous leaves. In the Wolaita zone, it is customary to use a decorticating board of roughly 20 x
190 cm "Cordia Africana" ("wanza") wood with a 15 cm forked end . This board is placed in the
leaf covered pit on one end and made to rest on its forked end on the upper part of the tree. The
inclination of the board (20 - 25°) thus created is generally acceptable for the operation. Its upper
end is then securely tied to the tree using strips of the semi-dry stem fibers known as
"woficho".For scraping the parenchyma tissues from the plant’s pseudo stems, a devised bamboo
rod of 5 - 6 cm in diameter and 50 - 60 cm in length is used. Half of the middle section of the
hollow rod is removed leaving two end handles and a scraper in the middle.
2.2.1B 2.Pseudo stem Processing Operation

The outer semi-dry stems of the selected trees to be processed are cut at their bases and disposed
of. The fresh light green and fleshy stems that are immediately visible are served from the tree
and their leaves cut to leave about 100 cm long stems ready for decortications.Decortication of the
'enset", through the local method, in principle requires scraping of the fleshy part of the plant
while resting the stem against the wooden board and securing its upper end with fibers. About 30
cm of the upper part of the stem folds over the fiber string to ensure tightness during
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decortications. The removal of the parenchyma tissues begins when the operator, customarily a
woman, who while standing . holds the bamboo scraper with her hands on each end, presses the
sharp edge on the stem and drags it downwards scraping off the fleshy part of plant into the pit.
The process is repeated until the soft tissue is completely removed from the lower half of the stem
leaving the white fibers only. By exchanging the position of the unprocessed and that of the
scraped end of the stem and using its fibers to tie it to the board string, this opposite end of the
stem is then decorticated in the same manner as the first half. The last greenish layer of the
scraped tissue, which is markedly different from the upper white tissue, does not seem to be
favored by the operator and is normally discarded from the fermentable portion each time a stem
is decorticated. In fact, its removal is necessary only to make use of the freed fibers. The
operation continues until all the pseudo stems of the tree are decorticated. To facilitate easy
scraping of the tissue from the fiber, the lower part of the stem resting on the board is slashed
along the narrow side with a series of cuts using the bamboo scraper. The fibers that are severed
along with the parenchyma tissue into the pit are then picked out and disposed of. When the
operator feels that the accumulated parenchyma tissue in the leaf covered pit below is too chunky,
she chops the stuff with a stick until it is satisfactorily broken down into tiny pieces. The operator
is frequently observed sharpening the bamboo scraper during the entire operation. The average
time required to pick a stem of usually about 100 cm length, twice tie and untie it to the board,
provide a series of notches, decorticate it and pick out the undesirable fibers from the accumulated
tissue in the pit is about 2 minutes and 50 seconds.
2.2.1B.3.Extraction of the liquid food from the parenchyma tissue

"Itma", by which the milky liquid food is known in Wolaita, is extracted by squeezing it out from
the accumulated mass of parenchyma tissue. With bare cleaned feet, the operator repeatedly steps
on the juicy food stuff placed under "enset" leaves to squeeze out the liquid. During the operation,
the "Itma" is channeled from the fleshy tissue to a collection pot through an inclined "enset" leaf
resting on the ground .When the "Itma" is for some time left in the pot, its fine and slimy white
substance settles to the bottom of the container. The white stuff, which is considered as an "enset"
food specialty is separated from the clear liquid above it and left wrapped from one to four days
to ferment before it is ready for consumption.
22
2.2.1B.4"Enset" corm processing operation

Once all the psudostems are cut from the tree and decorticated, the operator proceeds with the
task of pulverizing the chunky root of the tree known as the corm. The tree, now left only with the
core stem and some leaves on top, is cut and reduced to a height of about 120 cm. Some outer
semi-dry stems not yet severed from the lower part of the tree are spread out in all directions.
without being detached from their bases and the remaining part of the stems are cut right above
the corm. With its roots still in the ground, the corm is pounded on its top using a wooden pole of
8cm (dia) x 100cm (length). With each pounding, the teeth of the serrated end of the pole chops
the substance in the middle of the corm. As pulverization advances, a cavity is skillfully created
with the outer walls of the corm still intact. Under these circumstances the operator continues to
pound until she reaches the bottom of the edible root. The mouth of the corm cavity is further
enlarged by cutting its rim and placing the material inside the hollow space to be pounded along
with the already chopped material. When the desired quality is achieved, the cavity is emptied of
the pulverized corm, which is tem polarity placed in a clay pot. Some of the pseudo stem s
(excluding the core stem), that are cut last to give way for pulverizing the corm, are shredded and
put in the cavity.
2.2.1B.5.Pounding follows until the material is finely ground.

Once again the product is removed and the empty corm cavity is serrated from inside with a local
knife Operators say that a cavity is more hygienic for meshing the "enset" food than a wooden
mortar, which often requires thorough cleaning before use. The healthy parts of twelve local
spices are shredded, placed inside the cavity, pounded and rubbed with a hand against the internal
serrated wall. In the Wolaita area, the local names of these starter spices are: "shuko", "hireyo",
"waro", "dal’isa", "gemako" (king of spices), "zemo", "chechiwa", "setiwa", "ayidame", "koseret",
"zeli’amta" and "fura" (rotten "enset" bark).Some of the processed corm and stem products that
were removed earlier are placed back into the cavity. Pounding begins over the small quantity of
product and continues as more and more of the materials are poured into the cavity until it is filled
to the brim. Since the enset' food stuff inside the cavity is expected to settle with fermentation,
some more of the product is heaped at the top before it is tightly shut off from air and water. Fresh
"enset’ are wound on the crown of the overfilled corm cavity to totally cover the protrusion of the
food stuff. The semi-dry leaves once left spread on the lifted and effectively used as a second
cover and / moreover they firmly tie the first fresh leaf cover to the " corm . As a further
23
precautionary measure, additional "enset" leaves are placed on top of the wound up corm to shed
away any rain water that might fall and penetrate into the laboriously produced food product.
2.2.1B.6.Squeezing of fermented mixture of parenchyma tissue and pulverized corm.

Two to three weeks after it is neatly stored, the food stuff is considered as fermented and ready
for the final process. A batch about 600 g is picked by hand and placed in the middle of a dry
"enset" fiber band which is about one meter in length. The fiber is folded lengthwise until it
completely covers the food stuff and with two operators at both ends vigorously wringing the
strip, the liquid is squeezed out until no more of it comes out. As a result of squeezing, a moist
fibrous "Kocho" is produced, which, on a wooden tray, is collected, kneaded and shredded with
the local knife like green 25: vegetables . The shredding process is believed to cut to tiny pieces
the fibers that escape into the food stuff during decortications.
figure 2. 1 Kocho squeezing in Wolaita

Name of "Enset" Processing Tools and Estimated Cost
Name of Tool Use Cost (Birr)

Wooden tray Tray for kneading, shredding and sifting 10.00
Kincho (pointed wood) Squeezing 3.00
Meta (flat pole) Decortications 1.00
Sisicho (saw tootled metal) Scraping 3.00
Keho (scapula) Pulverizing 0.25
Shole (big knife Cutting "enset" plant 4.00
Worme (smaller knife) Shredding 2.00
Memo (sieve) Sifting 2.00
24
Hanticho (fiber) Squeezing 0.10

enset processing tools and their names
2.3.Some physical characteristics of "Kocho"

It was believed that establishing the contents and some physical characteristics of "Kocho"
beforehand would facilitate any attempt in improving the design of the processing equipments.
Therefore, the food stuff was subjected to a series of laboratory tests to establish the force
required to extract the optimum amount of liquid from a given quantity of fermented "Kocho’ and
the maximum depression of the dough under such force. The tests carried out in the lab used
fermented dough from some localities under investigation. The equipment used was an arbitrary
hollow steel cylinder of 50.7mm in diameter (with a closed bottom) and with 3 mm holes drilled
in grid, having distances of 15 mm between centers of holes, on the entire lateral surface. In each
test the cylinder was filled with fermented "Kocho". Its volume was 88.8cm’.
A serrated end shaft slightly less in diameter than the cylinder was placed on top of the dough and
subjected to a gradually increasing force for two minutes while it was being vigorously rotated
clockwise and counter-clockwise by hand as it compressed the "Kocho". to achieve maximum
extraction of the liquid. The minimum force required to achieve the maximum depression was
40KN.Consequently, analysis of the sample to establish some physical characteristics that may be
essential for the work was carried out and the results were as tabulated below. For easier reference
the volume of the "Kocho" was increased to 1000cm3 and the commensurate weight and density
were also adopted.
Volume, Weight and Density of "Kocho" Before and After Squeezing
Food stuff Volume Weight (gm) Density Volume

(cm3) (g/cm3 reduced
through
compression
(%)
"Kocho" Before 1000.00 1136.50 1.14 0%
fermented for squeezing
14 days using After 594.5 478.5 0.81 41.5%
traditional squeezing
method applying a
force of 40
KN
volume,density.weight of Kocho before and after squeezing
Weight Percentage Distribution of l00gm "Kocho" Elements Before Extraction of Liquid
Kocho" Elements %
25
Air-dry "Kocho" powder 32.6%
Squeezed liquid extract 58.0%
Moisture in powder before air-drying 58.0%
Dry fiber 8.2
weight percentage distribution of 100 gm Kocho
From table, two important phenomenon relevant to the investigation were established: The
maximum amount of liquid expected to be extracted through a minimum pressure, and the
compressibility of the dough expressed in terms of the percentage of the original mass of
"Kocho". it can be observed that the amount of liquid extracted is almost twice as heavy as the
"Kocho" powder left after squeezing. It is hoped that the above findings may serve as yardsticks
of some of the aspects of the evaluation of the performance as well as the product of an y
improved "enset" processing equipment.
2.4.PAST ATTEMPTS MADE TO IMPROVE "ENSET’ PROCESSING EQUIPMENTS

In the late 70s, some institutions initiated improvement of "enset” processing projects in an
attempt to upgrade or totally change the existing local processing tools in the "enset" culture
zones of Ethiopia.
2.4.1The Hawassa College of Agriculture

The Wood and Metal Workshop of the Agricultural Engineering Technology of the Hawassa
College of Agriculture made impromptu practical improvements of the decorticating board and its
sitting arrangements towards the end of 1978, following some observations of the local tools and
processing practices in the immediate rural surroundings of Hawassa town(former).It was a
praiseworthy attempt made to improve the processing tools and ease the extremely strenuous
processing practices in the rural areas of the Sidama Zone(former). However, while the
decortications board was well placed and its clamping device acceptable, the wooden armchair
was not simple enough to be produced by local craftsmen. No attempts were made to produce the
remaining equipments that deal with pulverization, squeezing, kneading and shredding.
2.4.2.Sodo Appropriate Technology Center.

The appropriate technology center in Sodo Wolaita has also put its effort for producing tools for
"enset" processing. In 1988 the center came up with the first trial "enset" processing tools. A
26
report written in 1992 stated that these devices have advantages and some limitations (5). This
indicates the need for continuous improvement of "enset" processing tools.
2.4.3.Institute of Agricultural Research (located in the vicinity of Nazareth)

From the institute’s 1984 and 1985 progress report of the Agricultural Implements Research and
Improvement Team of the Department of Agricultural Engineering, we understood that the
research involved in the improvement of local "enset" processing tools "assumed the national
responsibility for ' enset’ processing project and attempted in a coordinated manner to develop an
appropriate technology that will contribute positively to the problems."The equipments were
being developed by the institute based on the following objectives:
a."The devices to be developed should be based on locally available row materials."
b. "Rural craftsmen should be able to manufacture, repair and maintain the devices."
c. "Should fulfill the need to individual and community users."
d. "Preserve the usual taste of v Kocho.’
e. "Should be simple and cheap enough to be afforded by v enset’ growers."
Accordingly they set out to investigate and produce the following devices:
a."Enset" stem processing equipment.

i. Included plank/clamp decorticator
ii. Horizontal plank/clamp decorticator
iii. Adjustable rotary blade pulverizer
b. "Enset" corm processing equipment
i. Grater/slicer (wood worker jack plane)
ii. Non-adjustable rotary blade pulveriser
iii. Adjustable rotary blade pulveriser
c. "Bulla" extraction equipment
27
i. Flat board squeezer
ii. Bucket type squeezer
In accessing the performance as well as the practicability of the devices, the IAR maintained
in its report that, while the equipment registered some improvements in the convenience of their
use, there were some evident draw backs:
a. Decortications
i. The inclined plank decorticator "was not as efficient as the traditional tool ."
ii. The horizontal plank decorticator was causing "very great stresses" "on limited part of the
operators’ muscles"
iii. The motorized decorticator was still under development
b. Pulverization
i. The grater "sliced materials varied in sizes," causing fermentation process to slow followed by
some discoloration of food.
ii. The non-adjustable rotary blade pulverizer "lacked adjustable clamping mechanism to
accommodate various sizes and configuration of enset corm."
iii. The adjustable rotary blade pulverizer needed "extensive field testing for its social and
economical suitability." although technically the problem of enset corm processing is more or less
solved."
c. "Bulla" extractors
i. The flat board squeezer "lacked sufficient mechanical strength to do the intended job and as a
result it was discarded immediately.
ii. The bucket type squeezer "was found to be efficient... but field testing and evaluation will
continue for its social and economic soundness."
28
There were no further reports of improvement and evaluation on the devices on the subsequent
IAR progress report. The institute has done a commendable job in figuring out the problems
encountered in "enset" processing. It also came up, for the first time, with devices that will deal
with the processing of the raw food stuff in an effort to reduce the intensive labor that women in
rural area are undertaking.
However in the construction of some of the devices, objectives "a", "b" and "e" do not seem to
have been strictly adhered to. For example, the installation of over one meter of threaded bar the
sprocket wheel and chains, the steel cranking shafts and cutting wheel of the "enset" corm
pulverizer is far beyond the means of the average peasant to "afford", not to mention the huge
space (200 x 60cm) the machine takes in the humble grass hut dwelling, only to perform one of
the three major tasks of processing. The materials, therefore, were neither "locally available” nor
could they said "Rural craftsmen... manufacture, repair and maintain the devices.
2.5.Brief survey of possible existing mechanical methods of processing Fibrous

plant psudostems and corms
Decortications of Psudostems
In principle the parenchyma tissue can be mechanically removed from the fibrous stem by:
a. scraping through a reciprocating motion
b. scraping through a rotary motion
c. smashing or hammering it against a hard surface
In assessing the above methods, with the aim of employing them in the rural areas, and based on
the parameters set out at the beginning of this study, the following pros and cons were identified:
a. Scraping through a reciprocating motion
Schematic concept: Resting the stem against a board and scraping.
Advantages:
i. traditional practice of local population
ii. easy to operate
iii. inexpensive
iv. safe to operate
29
v. simple to produce the equipment through local craftsmen
vi. local materials can be used to produce the equipment
vii. practically no maintenance is required
viii. simple to store
ix. quality of decortications could easily be checked at anytime
Disadvantages:
i. too much energy exerted and time wasted to produce comparatively small quantity of end
product.
ii. fixing the end of each stem before decortications
is found to be cumbersome
iii. hygienic and efficient collectors of product need
to be installed
b. Scraping though a rotary motion
Schematic concept: Applying a rotating scraper on the fixed stems.
Advantages:
i. may be faster for decortications
ii. time saver and efficient if motorized for large quantities of stem, as already observed in sisal
factories.
Disadvantages
does not conform with local practice expensive cannot be produced through local artisans may not
be produced using local materials may not be easily maintained by the rural operators not safe to
operate with young children around requires more power to manually operate takes more time to
clean after and before use would be more easily damaged or corroded if not properly stored in
rural environments would be very difficult to find energy source and operate it in the rural area.
2.6.Smashing or hammering against a hard surface

Schematic concept: Fixing several stems to a wheel and letting it rotate at high speed to smash
them against a fixed flat surface.
Advantages:
30
surface may be time saver and efficient if motorized
Disadvantages:
does not conform with local practice expensive it may not be possible for the main body, being
metal, to be produced by local craftsmen may not be hygienic if a local material such as wood is
used there may be too many moving parts in the device not easy to maintain too many stem fixing
devices would be needed takes more time to clean after and before use too bulky to store
Considering this background information on the possible systems of freeing parenchyma tissue
from the fibers, it is all too clear that scraping through reciprocating movement stands out as the
most viable method for adoption in equipment design for the rural population at this point in time.
In this connection it is proposed that, during the processing, the parenchyma tissue can be
collected on a local grain sieve placed on top of a pot. It can then be pressed by hand to free the
white "bulla" from the fleshy substance. The "bulla” collected in the pot and the parenchyma
tissue are usually stored separately for a subsequent fermentation process.
Pulverization of the corm
Again, there are only two main methods to consider in grating the corm into tiny pieces:
Maneuver tools to a) move back and forth or up and down b) rotate.
A reciprocating tool pulveriser was found to be simpler to make, less expensive, safe to operate
and in conformity with the local practice. But, if motorized and safety could be observed during
operation, a rotary pulveriser would be much more efficient and easier to operate. Of course, the
high cost is the one thing that always becomes a hindrances to the acceptability of such a tool b y
the rural population.
2.7.IMPROVEMENT OR ADOPTION OF EXISTING METHODS OF FERMENTATION,
SQUEEZING, KNEADING, SHREDDING AND SIFTING

Fermentation
Fermentation of the "Kocho", to the satisfaction of the consumer, occurs in no less that 14 days.
The fresh mixture of parenchyma tissue and pulverized corm is tightly covered and is entirely
shut away from air and water for the whole period of fermentation. To do this, the investigators
recommend the use of some wide mouthed clay pots with lids and small perforations at the
bottom to ooze the excess liquids. The "Kocho" could be wrapped tightly with "enset" leaves and
placed in the pots. Care should be exercised so that the pots are filled to the brim to avoid or
lessen the air pockets created between the wrapped "Kocho" and the internal surface of the pots
and their lids. The closed pots with their contents could be buried about 20cm below the ground
surface or stuffed with leaves, tightly closed and shelved to ensure adequate insulation during the
31
process of fermentation. Similarly, the accumulated "bulla" could also be tightly closed in smaller
pots and stored for the designated period of fermentation.
Squeezing
Traditional practice demands that some of the liquid in the fermented mixture of parenchyma
tissue and pulverized corm has to somehow' be removed before consumption. If a mechanical
means is employed without drying the dough and also not affecting its traditional taste, one is left
with only two alternatives:
a) exposing the "Kocho" to centrifugal force
b) confining the food stuff in a perforated container and applying pressure.
Contemplating on the application of centrifugal force as a means of extracting the liquid from the
dough, would be too unrealistic to consider at the moment. The cost of the material and the know-
how needed to build the machine would make it unaffordable to the peasant population. Besides,
the operation, storage and maintenance of a centrifugal liquid extracting mechanism would, at
present, be too complicated to be handled by villagers. The lack of hygienic handling of the
equipment in the rural environment could not also be underrated. Therefore, the investigators
were left with the option of using the principle of compression as a viable solution of freeing the
liquid from the dough.
Two types of squeezers were selected for adoption, pending the outcome of the assessment of
their performance and practicability:
a) confining the sample inside a perforated cup and applying a pressure on the open end.
b) wrapping the food stuff with a loosely knit fiber band and wringing the cloth from the two ends
until the liquid is removed to an acceptable degree.
The maximum amount of liquid which could be extracted through a compressive force from a
given quantity of "Kocho" has already been established. Consequently, it was realized that the
amount of this liquid which can be squeezed out using the traditional method is about 70% of
laboratory extracted liquid. Hence, any improved squeezer should not extract more liquid than
that of the local devices which are already in use.
Kneading, shredding and sifting
Kneading shredding and sifting are subsequent processes in the final stages of the production of
the edible part of "enset". Short of motorizing these processes, kneading is done manually on a
tray and can be followed by randomly shredding the escaped fibers in the "Kocho" powder
against the base of the tray using a sharp knife. Once the fibers are satisfactorily shredded to
pieces, the slightly moist "Kocho" can be sifted with a sieve to get rid of the fibers. In the
32
production of simple and inexpensive equipments, the above three traditional practices can be
considered for adoption.
ADOPTION OF A CONFIGURATION OF ENSET PROCESSING CONCEPTS
Based on the analysis made earlier on the various methods of processing, equipment concepts
were formulated and integrated in some combinations in an effort to arrive at a solution which
most conforms with the objectives set out at the beginning of this study. While the traditional
method of removing the parenchyma tissue from the stem was found to be effective, safe and
inexpensive and therefore adopted, the inclined board was necessarily elevated to give way for a
comfortable sitting arrangement.
Two more processing options can be incorporated on the same board: Corm pulveriser chamber
on one side, and a fermented "Kocho" kneading and sifting tray on the other. Shredding of the
corm could be performed using a serrated hand grater. A squeezer designed to extract the
fermented Kocho' dough could be attached to a lever that is connected to and manipulated by the
seat. A simpler design that employs wringing of "Kocho" wrapped in fiber band to get rid of the
excess moisture (as applied in cloth laundry) could be adopted as an alternative.
A number of configurations of the conceptual components of the equipment, with regards to their
formation were first considered before one was opted for on the basis of the simplicity of its
structure, efficiency and convenience.
2.8.PREPARATION OF PRE-DESIGN MEASURING EQUIPMENTS FOR FIELD TESTS

Adjustable "enset" decortications board
Concept No. 4 being adopted, the length, angle, elevation of the decortications board and the
height of the seat from the ground had to be based on the outcome of field tests. Therefore, an
adjustable "enset" decortications board and seat were developed in order to measure the preferred
dimensions of each operator of the site. The collection of related information using the form was
planned to help settle the acceptable size of the anticipated improved equipment.
Corm Pulverizes
Box grater
A nail perforated sheet metal box, with the open end facing down was used as a grater.
The corm was moved back and forth rubbing against the perforated rough surface. The corm was,
however, too heavy to manipulate for rubbing and corm product was darker as a result of staining
by the metal. An attempt was also made to use the box as a rubbing tool while holding the corm
on a wooden board. It required too much force to rub the corm and at the same time to
hold it firmly on one fixed position.
33
Rotary Cylinder Grater
A revolving hollow cylinder, made out of nail perforated sheet metal (like a cheese grater) with
both ends open and mounted, through its spokes, on a steel shaft was made and manually tried if
it could pulverize the corm.
It did grate the corm finely as desired, but was immediately clogged and this was followed by
metal staining of the slimy substance as a result of trying to force cutting on the corm.
Rectangular Plate Grater
A flat rectangular sheet metal with toothed strips fixed at interval and parallel to the short side and
with a handle on the other side was tried for pulverization.
It was applied the way a shoe brush would be used. It was too difficult to rub against the corm as
there were too many cutting edges. With a few movements the toothed strips were leveled with
clogging. When more rubbing was attempted discoloration began to appear.
Rotary Disc Grater
A number of toothed strips radially fixed on a horizontal axis rotating sheet metal disc were found
to be more effective in grating than the three above mentioned devices. However, pulverization
was observed to be frequently stopped when the corm was fed into the manually rotating plate
beyond the depth of the grating teeth. When the toothed disc was driven forcefully, resisting the
stoppage caused by the corm. discoloration of the product soon became apparent. The problem of
the slimy corm sticking to the disc’s saw was still not avoided. The disc size was also observed to
determine the strength required to perform the task.
Vertical Handled Coarse Toothed Grater
It was observed that the hammering action of the local pulverizes on the corm considerably
increases the power of grating. In tiying to implement this phenomenon and improve the
traditional pulverizes version, a vertical handled grater was devised. Each triangular tooth on the
tool was punched out of the sheet metal base and bent, while still attached to its base. This left a
triangular hole on the base which was expected to effectively discharge the slimy and fibery
product during the processing. Although the tool’s effectiveness was realized, the drawback was
that punching out the coarse teeth out of the sheet metal was not easily carried out in an ordinary
metal shop. As the product of the above process was much coarser than the corm ground through
the traditional method, the production of a pulverizer with finer teeth as a substitute, was
attempted in the shop. But it was soon learnt that unless this was made with a special metal
punch, it may not be realizable through the ordinary metal shop process. Nevertheless, this
particular tool was later tentatively selected as a field testing pulverizer until a less expensive and
equally effective device was produced.
34
Helical Saw Toothed Grater
In order to avoid frequent contact between the corm and the metal that are not directly involved in
the cutting action, which was the cause of discoloration, a toothed helical strip was welded to a
shaft and attached to the underside of the decortications board . It was manually rotated through
its crank. Consequently, the results were encouraging in that it has succeeded in smoothly
scraping the corm and producing an acceptable shredded product. At times, non- homogenous
lumps originating from inside the corm could be seen escaping the pulverization. This was
improved by narrowing the gap between the helical blades in a subsequent trial. In the last version
it was observed that scraping was effective. But there were two distinct disadvantages:
a) The corm had to be sliced in sizes equal to the small opening at the lower end of the
decortications board.
b) A tremendous side pressure was generated, as a result of the helical blade rotating and driving
the corm to the side of the wooden opening. This had tended to split the lower end of the
decortications board.
2.9.INFORMATION GATHERING ON THE PERFORMANCE OF "ENSET"

PROCESSING
EQUIPMENTS AND OPERATORS
A randomly selected five households, with well developed "enset" yards, in each of the zones,
were made to be involved in assessing the performance of the testing device. The equipments
consisted mainly of an adjustable decortications board and stool.
An improved psudostems scraper, corm pulverizer, "bulla" and "Kocho" fermentation clay pots
and squeezer were also included.
In the two trips that were made to each zone, a comparative study of the performance of the local
and improved "enset" processing equipments was conducted using a form which was especially
prepared for the purpose. The results of the findings were as follows:
Decortications of psudostems
In both the Wolaita and Sidama Zones, the time the operators took to decorticate psudostems
using the improved testing device was, on the average, lower by 20% than when using the local
equipments. But the very great advantage 80% of the operators appreciated was the provision of a
comfortable seat. By this arrangement all the women interviewed in Sidama expressed relief of
not having to sit on the ground and pressing, with one of their stretched legs, the upper part of the
psudostems against the decortications board until all the stems were decorticated. The instant
stem clamping device was also an added advantage in the processing. In like manner, the women
in Wolaita, were obliged to stand and lean forward to decorticate during the whole operation. But
when interviewed, only 60% supported the provision of seating arrangements.
35
Pulverization of corm
As stated in the preliminary observation, there is a great difference in the local practice of corm
pulverization between the two zones. Each of these practices has no doubt, its own advantages
over the other. However the investigators used the already improved metallic corm pulverizer, as
a viable option. This tool can fairly well be accepted in the zones in spite of their diversified
cultures.
A woman operator that favour customary practice such as pounding with a serrated stick in
pulverization of corm, rather than using any less expensive and improved pulverizer was
encountered once. A few were even expecting factor) produced metallic machineries to replace
the local equipments. However, the researchers attempted to explain to them the need and
advantages of having improved tools which can be made of locally available materials, capable of
being produced by local craftsmen, simple to use and economically affordable.
Squeezing of "Kocho"
After a two weeks period, all the sites were revisited to evaluate the fermented "Kocho" and carry
out the final process of squeezing, kneading, shredding and sifting of the substance. There were
considerable reduction in volume of all the "Kocho" placed in the pits and pots. They were
measured to be 40 - 58% of the original "Kocho" stored. The variations in volume reduction may
have been caused by the variety, maturity and moisture content of the "enset" plants; porosity of
storage facilities and roughness in the stem, corm and "bulla" extraction processing. Throughout
the sites the Kocho" fermented through the local method was found to be drier. On the other hand,
those stored to ferment in perforated clay pots had pleasant odor and whiter appearances, which
are desirable qualities of the "Kocho" in both zones. The improved method of squeezing in
Wolaita had reduced the time by an average of 21% of what was required to squeeze through the
traditional practice. Although no time was saved with the use of the improved equipment in
several sites of the Sidama Zone, the performance of two operators showed a very significant
reduction of 53% in squeezing time.
If some lady operators have not gained squeezing process time through the use of the new
equipment, it may be due to their lack of adaptability with fiber band squeezer. It is expected that
through more experience they will overcome the obstacle. Two women complained that the fiber
band squeezer was not letting out enough liquid as the local one. When field test results were later
compared, the performance of the improved squeezer in letting out the unwanted liquid was found
to be less by about an average of 12% than the traditional squeezer.
The researchers realized that the impermeability of the fiber band was due to the tightly knit fiber
band which was employed in the improved squeezer. After some strands were randomly removed
from the fabric and the squeezer used again, some of the "Kocho" itself was tending to come out
through the material towards the end of the process. The application of the concept is the most
inexpensive, effective safe and hygienic and therefore very difficult to find a replacement at this
36
time. However, more has to be done to improve it so that the element of porosity in the band
would not be compromised by its inability to hold back the "Kocho" during processing. No
problems were encountered in kneading, shredding and sifting of the semi-dry "Kocho", as
methods similar to those of the traditional practice were applied.
2.9.1.Processing and Operators Information

The information on the "enset" processing operators, status conditions, experiences, performances
and views as tabulated below, was considered to be very valuable factor that would contribute
towards the improvement of the existing processing equipments.
Remarks of Operators on Pulverization of "Enset"
Type of Process Zones

Pulverization Sidama(former data) Wolaita
The traditional bone pulverizer is Because pulverization with our local
found to be inefficient and tools is found to be tedious and time
moreover wears out quickly. consuming, we appreciate if a better
They request, therefore, that this way of pulverization is improvised,
be replaced with metal Same as in no.
pulverizer. Similar to no. The
improved pulverizer should be
provided with sharper teeth,
Same as in
Remarks of Operators on Squeezing of "Enset"
Type of Process Zones

Squeezing Sidama(former data) Wolaita
The traditional vertical
squeezing wood is slippery and
can cause injury, Therefore it
would be welcomed if the
equipment could be changed.
The improved method of
squeezing had its draw backs:
i. The grain sack was too thick
to allow sufficient liquid to flow
out ii. When the sack was
thinned some "Kocho” started to
come out from the big openings
and rendered squeezing
inconvenient.
Summary of the Remarks
Traditional equipments Improved equipments (testing equipments)
37
No. of Suggested No of operators Suggested improvement from

operators improvement from suggesting female operators
Suggesting female operators
7 Include sitting 7
arrangements in the Avoid very coarse or very fine
new equipment design teeth in metal corm pulverize
1 Provide back support 2 A more loosely woven material,
for the seals. that allows the liquid to freely
flow under pressure and at the
same time does not let the
"Kocho" come out with the liquid,
to be considered for squeezing.
3 Replace bamboo with
steel "enset" scraper
4 Improve 1 Decortications board (used for
performances of local testing) to be crowned in the
pulverizes. middle, so that the scraper will not
scratch the edges of the board
during operation.
3 Hazardous Sidama
traditional "enset’
squeezer to be
radically improved.
2 The equipments used, for testing
operators’ performance on
decortications, to be improved,
(the testing equipment was
vibrating during operation, due to
its unsteady structure)
summary of remarks
38
3.CHAPTER THREE
METHODOLOGY
3.1.METHODS OF DATA COLLECTION
We have collected data by using quantitative method
3.1.1.Primary sources:-This data are collected by using direct interview of respondents,

Disseminating questionnaire and directly observing the problems of the respondents
Secondary sources;-We have referred different journals,pappers,research findings videos from

you tube to get adequate data for technology development.
3.1.2. Data collection
Planning and Preparation
After the selection of sector and sub sector to develop value chain analysis for enset production,
the following were taking into consideration in planning and preparation stage;
3.1.3 Survey Area.
The team visited survey areas in order to acquire the existing situation (AS IS) for value chain in
Sidama National Regional State. The survey area covers 3 Woreda namely Hula (GaseKebele,
Wita Bono), Teticha (Dabichakebele, HangaeKebele, SolleCharichokebele and WonjalaKebele)
Aletawondoworeda (BultumaKebele, Woto, Gowadamo) and 1 town administration (Aletawondo
town Chefe and Mesalemeyakebele)
figure 3. 1.Sidama region map
39
3.1.4.Survey Period:
The survey will be conducted for the period from Hidar 15 to 17/2014 E.C in both woredas to
obtain ASIS activities
3.1.5.Target Respondents.
Specific number, name of producer/ service provider within the target survey area. Farmers,
Kebeles.
3.1.6.Study Team.
For this enset value chain development the following experts were involved. The members of
team were composed of different technical expertise related with the sector and subsector for
value chain development as shown in the table .
: Survey Team Members
S.N Participant Name Working place Phone No

1 Seyoum Abraham Arbegona TVET college +251939813452
2 Lamiso Shura Hawassa university +251913642516
3 Tejitu Mude SNRS Job, Skill and Enterprises +251916851374
Development Bureau
4 Enicha Husen Aleta wondo TVET College +251916649687
5 Fiseha Dansamo Hawassa city Agricultural office +251916134426
survey team
3.2. Gathering Tool Development

In able to collect all the information needed for value chain development, a set of gathering tools
were developed. To do the mapping of the AS IS which define as the existing activities and
practices of products of enset, a composition of qualitative and quantitative questions was
developed. Varieties of tools (questionnaires, interviews, literature reviews, observations etc.)
were used to assist in the data gathering process during vale chain development on enset
production. Each type of tool provides alternative means to illustrate, explain and specify exactly
what must be delivered to meet the intended goals. The gathering tool covered the name of the
product and services selected, the background and information of the selected model farmers, the
inputs or initial resources to start production of enset at farmer’s level, the main chain or the
sequence of the main process and also the sub chain or the activities supporting the main chain.
The tool also includes the statement of the real problems and solutions existing within the farmers
and finally the interventions given by the governmental and non-governmental organizations.
40
3.3.Method of Data Analysis

We have analyzed collected data by using tabulation method and using bar graphs.
3.3.1.Design Methodology
3.3.2.Mechanisms Used for Designing combination Kocho processing machine.
combination Kocho processing machine is combination of three different machine those performs
activities jointly. Those machines namely, squeezing press, Rotary sieving machine, and
multipurpose helical conveyer machine. Those machine perform
squuezing,rubbing(shredding),powedering,corm pulverizing, bulla squuezing,onion chopping and
fiber filtering tasks.
3.3.3Describing Mechanisms of each machine
Multi-purpose helical conveyer machine:-For this machine I have used helical rotary motion.
The main part of the machine is helical conveyer which is rotated with both manually and by
using single phase electrical motor. The conveyer rotates by power supplied from the motor and
performs pulverization,squuezing,rubbing,powdering and onion chopping activities. Additionally
conveyer is rotated directly by man power by using handle.
Squeezing Press machine:-This machine performs squeezing activity by pressing Kocho by
using screw press mounted on the head of the machine. This operation is performed by the
rotation of screw thread by manually.
Rotary sieving machine:- This machine is operated both by electrical and manual mechanisms.
After adding the powder of Kocho the filtration mechanisms are undergone by supplying power
on dynamo or simply rotating handle manually.
3.4.Failure Theory and other possible designing concepts.

3.4.1.Failure of mechanical parts on Multi-purpose helical conveyer machine
Materials used for manufacturing this machine:-
stainless steel sheet metal(2mm) for cylinder construction.
stainless steel sheet metal(2mm) for helical conveyer construction.
20x20x2mm thick angle iron for leg frame construction.
2mm thick stainless steel sheet metal for circular sealing disc construction.
6204 Roller bearing are used for actuating motion.
Single phase 1HP electrical motor.
C-Grade belt
60mm diameter Aluminum ingot pulley
41
17mm mild steel bolt

20mm stainless steel round bar
3/4 galvanized pipe for handle
13 mm mild steel bolt for handle and fastening sealing disks.
3.4.2.Mechanical properties of the above listed materials.
Amount of power and torque applied by single phase 1 Hp induction motor.
Engineering tool box.com expressed that single phase induction motor can apply 0.75 watt
power.
3.4.3.Mechanical properties of stainless steel to resist mechanical forces
contains a minimum of 11% chromium
is ferrous alloy(contains iron)
usually magnetic
High tensile strength
Advantages of stainless steel
high tensile strength
heat resistant
very durable
low mentainance
highly corrosion resistant
recyclable
applicable for kitchen sinks
3.4.4.Where would failulity may occurs
suspected failure should occurs on welded point of connection cylinder with leg frame due
to high tension and rotational torque of the motor during operation.
3.4.5.Properties of materials used in squeezing press.
Materials used in squeezing press:-
Wanza timber
mild steel pressing screw
RHS
Angle iron
stainless steel sheet metal
42
Maximum load bearing capacity of mahogany(let) tree timber is 7.6 pound/feet. The suspected
failure should occurs there.
3.5.Machine design
The squuezing,rubbing and powdering part will have a hopper, squeezing chamber, Kocho and
fluid outlet and a stand. The cylindrical drum houses a uniform diameter screw conveyor to
enhance Kocho juice extraction, powdering and rubbing. The conveyor presses the Kocho
against the drum to enhance fluid extraction and rubbed Kocho flow. The main component of the
extraction chamber will be made of stainless steel used to handle food products. The Kocho
squeezing part will use a screw conveyor installed in a cylinder perforated at the base, this will
ensure most of the outputs is obtained out of the inputs.
3.5.1.Theoretical Frame work
The design of the Kocho processing machine will be done from locally available material to
enable Kocho production.
There are engineering design factors that may affect the design of the machine; the design of the
screw shaft, designing the efficient mechanism to be used to rotate the screw shaft and
determining the capacity of the screw conveyor.
Design of screw conveyor The screw conveyor is the main component and most functional
unit of the Kocho squeezing
chamber. Using Ps as 0.1m, N 50rpm,N=1400rpm for motor, D 0.11m, d 0.05m, therefore inlet
velocity V is 0.016m/s.
The screw will be designed using the expression in the equation below as:
4𝑉𝐷𝐿
Equation 1: Screw pitch Ps = 𝜋 2−𝑑2
𝐷 𝑁
4
Equation 1
Where;
Ps = is the screw pitch,
V is the inlet velocity of raw material,
D is the outside diameter of screw,
d is the inside diameter of screw,
L is the length of the screw shaft, and N is the shaft speed.
F21/35968/2010
43
Therefore, left at both ends of the screw shaft for the fittings of the bearing at both ends was
determined thus:
1
Equation 2: Clearance at both ends C = 2
L - PL
Equation 2: Clearance at both ends

PL – Pitch length
Design of screw shaft
In operation, the screw shaft is meant to convey, press and squeeze the chopped ha'micho pieces
and kocho. To safeguard against bending, the diameter of the shaft is determined from
the equation given by Khurmi and Gupta (2008) as:
16 𝐾𝑏
Equation 3: Diameter of screw shaft ds3 = � � � 2 𝐾𝑡𝑀𝑡2� 12
𝜋𝑆𝑆 𝑀𝑏
Equation 3: Diameter of screw shaft

Where;
ds is diameter of the screw shaft, Ss is maximum shear stress, Kb is combined shock and fatigue
factor for bending, Kt is combined shock and fatigue factor for torsion, Mb is bending moment
of
the shaft and Mt is torsional moment of the shaft.
Taking Ss = 40 x 106 N/m2, Kb= 1.5, Kt = 1.0, Mb= 21.10 Nm, Mt = 69.18Nm and π = 3.142;
hence, ds = 0.021 m. Therefore, the diameter of the screw should be of stainless steel not less
than 21 mm our diameter is 20mm so it is safe.
3.5.2.Design of the capacity of the Kocho processing helical conveyer machine
The processing capacity of the multi-purpose Kocho processing machine will be taken as the
capacity of the screw conveyor which is the main functional unit of the processing chamber of
the machine. It will be determined from the equation given below as:
Equation 4: Processing capacity
Q = 3600 X S X V X γ X K Where;
S – Conveyor housing field area
V – Travelling speed of the conveyor
γ - Material density
K – Material decrement coefficient
44
𝑡,𝑛
Travelling speed, V (m/s) = 60
𝜆
Conveyor housing field area, S (m2) =4 𝜋𝐷2
3.5.3.Development tools used (software and equipments)

I have used the solid works software for developments of design for combination multi-purpose
machine.
Machine and tools
Steel rule
Ball pen hammer
plastic hammer
center punch
scriber
drill bit
Lathe machine cutter
sand paper
Welding machine
Set of Diestock
planner machine
jigsaw
sander machine
nail hammer
Grinder
compressor
3.6.Sample Size & Sampling Technique used

Data collected during field study
a. Composition of respondents
During data collection the team addresses farmers service providers and merchants. the overall
profiles of the respondents were as shown in the following table.
Table 1: Respondents profile
N No of only No of only No of service Both (farmers and Total

o farmers merchants providers merchants) respondents
45
1 M F T M F T M F T M F T M F T
4 6 10 - - - 1 1 2 0 4 4 5 11 16
Respondent profile
From the above data the composition of the respondents is justified as follows:
male respondents accounts 31.25% and female respondents accounts 68.75% from here according
to their career only farmers accounts 62.5%, service providers accounts 12.5% and both farmers
and merchants accounts 25%. Majority of the respondents were depending on the agriculture and
therefore, almost 75-100% out of their incomes from the agriculture.
b. Academic Background
12
10
10
8
8
6
4 3
2 2 2
2 1 1 1 1 1
0
0
M F T M F T M F T M F T
Illiterate(less than Elementary less than high Secondary school Diploma

elementary school
Academic back ground of the respondents

As it is indicated in the figure 2, Illiterate accounts 62.5%, elementary less than high school
accounts 6.25%, secondary school accounts 18.75% and diploma accounts 12.5%.
Responses for how they pulverize corms

No By using man power and traditional By using modern technologies
tools
M F T M F T
5 11 16 - - -
Respondents for how to pulverize corms
from the above data we observed that women use the bone of forelimbs of the cow/ox in order to
breakdown the ground of the enset. As a before explanations it consumes power, time .
Responses to how the collect the bula from the scratched Kocho?
46

tools
M F T M F T
5 11 16 - - -
Respondents for bula collection methods
as data indicates women collect the bula by smoothing the scratched Kocho by their hands and
legs for long times and it very tedious time and force consumer.
Responses to question how to squeeze Kocho?

tools
M F T M F T
5 11 16 - - -
Respondents for how to squeezing Kocho
from the data 100% of respondents reply that the used manually twisted stick with the sacks of
flour.
Note :-As respondents told that stick hits alot of women and girls and exposed them for injury
and even kill their life.
Responses to how they rubbing Kocho?
No By using hand By using modern technologies

M F T M F T
5 11 16 - - -
Respondents for how they rubbing Kocho
All respondents reply that all of they use their hands to rub Kocho.
Responses to how they filter the Kocho flour
No By using hand By using modern technologies

M F T M F T
5 11 16 - - -
Responses for how they filter Kocho
From the above data all respondents filter Kocho by using traditional sieve.
3.7.Feasibility analyses
Combination Kocho processing machine is feasible for end users. This machine is cost effectively
and every one can purchase it in low price. It saves time, efforts and increases the yield of
production. This machine performs task in Kaizened manner so it is feasible to accomplish tasks
in organized manner. Additional it save women from injury that faces during the operating of
47
traditional tools.Detal feasibility analysis of combination Kocho processing machine is listed

below.
3.7.1.Technical Aspect
Technically our college is well organized with tools and equipments to manufacture this machine.
Man power are also well enough and qualified to produce this machine. Enterprises around our
locality are also well skilled by man power and other resources to manufacture it. When we
observed technical this machine increases yield over traditional one. This machine performs man y
kinds of tasks accomplished by women. So our machine minimizes effort save time, increase
yield and save women from pain, Disease and even from dangerous death.
3.7.2.Economic Aspect
Economically this machine provides high support for MSES by creating market linkage for end
users. Since this machine are needed by mass number of population there are high economic
value for manufactururs.Additionally hotels are also gain high profit by minimizing the number of
workers. The every end users can gain income by chopping onion and renting machine for others
in low cost.
3.7.3.Social Aspect
Most of the society needs improvements on their life. In every family there are at list one person
educated. Since our society are eagerly expects improvement on Kocho processing there might no
negative social impacts to use this technology. The observed data shows that most of the
respondents need improvements on Kocho processing.
3.7.4.Environmental Aspect.
This machine is environmentally friendly machine and there are no any chemicals ejected from
machine to environment. It uses only electric and man power to operate and there are no any
chemicals used in this machine that affects environments.
48
4.CHAPTER FOUR
4.1.THE DESIGNING PROCESS
4.1.2.DESIGNING OF COMBINATION KOCHO PROCESSING MACHINE.
DESIGN ANALYSIS FOR MULT-PURPOSE HELICAL CONVEYER MACHINE.
Main parts of the machine:-
Single phase motor

Helical conveyer blade
conveyer shaft
v-belt
Pulley
Roller Bearing
Bolt
The other thing should be considered is mechanical properties of Kocho
cylinder
Material selection
Electrical motor is already readymade and its properties are determined by manufacturers
Stainless steel sheet metal with 2mm thickness
stainless steel round bar
C-type v-belt
Aluminum ingot
Readymade bearing
stainless steel bolt
Main parts of press squeezing machine
Pressing screw
Pressing chamber
stand
screw holder
Main parts of sieving machine
Shaft
Rotating drum
4.1.3.Design of a modified hand operated pineapple juice extraction machine.
4.1.3.1. Design considerations

The parameters considered in the design of the machine include;
Overall height of the machine to facilitate ease of operation
Overall width and breadth of the machine for the purpose of the machines efficiency.
49
4.1.4.Working principle of the machine design

This machine will processes Kocho from the wet Kocho and crushed whereby the chopped
corms will be crushed and pressed continuously. The machine is to be operated by applying force
to rotate the crank handle and alternatively by motor belt.
The motion of the handle and belt will facilitate the rotation of the screw shaft, which will
squeeze, powdering and rubbing the against the perforated cylindrical drum to extract fluid and
processed Kocho.
The Kocho will be collected at the bottom while the fluid will be discharged at the extreme end.
4.1.5.Design specifications
The design of this juice extraction machine is based on design specifications whose choices are
based on;
Availability of construction materials for fabrication
Cost of materials
Desired machine size
Mach inability (installation)
Durability
Prolonged life of the machine
Overall machine dimensions 570mm X 205mm X 210 mm
Screw shaft 600 mm in length and 20 mm in diameter
Hopper of overall height 100 mm, inlet allowance 100 mm X 60 mm
Handle of length 100 mm and height 50 mm
Steel bars 3/4 inch and 2mm thick
Design analysis
Housing design
𝜆
Conveyor housing field area (m2) = S=4 𝜋𝐷2
50
Hopper design
figure 4. 1Hooper
The volume of the Hooper is calculated by
v=L1XW1XH1+L2XW2XH2
The main frame
The main frame supports the entire weight of the machine, that is;
Weight of hopper and casing

Weight of screw shaft and handle
Bearings, Nuts and bolts
Single phase motor
The two design factors considered in determining the material required for the frame are weight
and strength. In this design work, angle steel bar of 1.5 ” by 1.5 ” and 2mm thickness is to be
used.
Shaft design
A shaft is a rotating or stationary member, usually of circular cross-section having such elements
as gears, pulleys, flywheels, cranks, sprockets and other power transmission elements mounted
on it Shingly (1986).
The design in this paper comprises a screw shaft joined to a crank handle and pulley at the end.
The shaft design consists primarily of the determination of the correct shaft diameter to ensure
satisfactory strength and rigidity when the shaft is transmitting power under various operating and
loading conditions.
For this design a shaft of diameter 20mm and length 60mm shall best serve the interests of
achieving the overall machine width and also lower the costs of materials that would be required
if the machine is to be constructed.
Bearing selection
Bearing must be selected based on its load carrying capacity, life expectancy and reliability (PSG
Tech 1989). The relationship between the basic rating life, the basic dynamic rating and the
51
bearing load is:

C = [L/L10]1/KP, or C/P = [L/L10]1/K
[C/P]K = L/L10, or L10 = [C/P]K/L.
But L = 60n/106 million revolutions, therefore, L10 = (106/60n) x [C/P] K,
Where:
L10 = life of bearing for 90% survival at one million revolutions;
L = required life of bearing in million revolutions (mr);
n = rotational speed (rev/min);
C = basic dynamic load rating (N);
P = equivalent dynamic bearing load (N);
K = exponent for life equation with:
K = 3 for ball bearing;
K = 10/3 for roller bearing.
Also, P = radial load + axial load,
P = (XFr + YFa),
Where:
X = radial load factor for the bearing;
Y = axial load factor for the bearing;
Fr = actual radial bearing load (N);
Fa = actual axial bearing load (N).
The table below shows the recommended life value in operation
Recommended life value of bearings
4.6. Design calculations, Results and Discussion

4.6.1. Design Calculations
Design of the screw conveyor
The screw conveyor is the main component and most functional unit of the processing
52
chamber. The screw will be designed using the expression in the equation below as:
4𝑉𝐷𝐿
Ps = 𝜋 2−𝑑2
𝐷 𝑁
4
figure 4. 2.helical conveyer

Where;
Ps = is the screw pitch,
V is the inlet velocity of raw material,
D is the outside diameter of screw,
d is the inside diameter of screw,
L is the length of the screw shaft, and N is the shaft speed.
Using inlet velocity, V of 0.0818 m/s, N 50rpm,1400rpm D 0.11m, d 0.02m
Therefore, left at both ends of the screw shaft for the fittings of the bearing at both ends was
determined thus:
C= L - PL
PL – Pitch length = 0.4 m = 400 mm
L – Shaft length = 0.6 m = 600 mm C = (0.6–0.4) = 0.02 m = 20 mm
A clearance of 20 mm will be left at both ends for fitting the bearings.
4.6.2.Design of screw shaft

The screw shaft is meant to convey, press and squeeze the chopped corm pieces and Kocho ,
53
To safeguard against bending, the diameter of the shaft is determined from the
equation given by Khurmi and Gupta (2008) as:

16 𝐾𝑏
ds3 = �𝜋𝑆𝑆 �𝑀𝑏� 2 𝐾𝑡𝑀𝑡2� 12
Where;
ds is diameter of the screw shaft, Ss is maximum shear stress, Kb is combined shock and fatigue
factor for bending, Kt is combined shock and fatigue factor for torsion, Mb is bending moment of
the shaft and Mt is torsional moment of the shaft.
Taking Ss = 40 x 106 N/m2, Kb= 1.5, Kt = 1.0, Mb= 21.10 Nm, Mt = 69.18Nm and π = 3.142;
16 𝐾𝑏
ds3 = � � � 2 𝐾𝑡𝑀𝑡2� 12
𝜋𝑆𝑆 𝑀𝑏
ds= 0.021 m = 21 mm
Hence, ds = 0.021 m. Therefore, the diameter of the screw should be of stainless steel not less
than 21 mm
Design of the capacity of the Kocho processing conveyer
It will be determined from the equation given below as
Q = 3600 X S X V X γ X K
Where;
S – Conveyor housing field area
V – Travelling speed of the conveyor
γ - Material density
K – Material decrement coefficient

𝑡,𝑛
Travelling speed, V (m/s) = =0.11*1400/60=2.56 m/s
60
𝜆 𝜆
Conveyor housing field area, S (m2) =4 𝜋𝐷2 4
𝜋 ∗ 0.112 =3.0m2
54
Therefore; Q = 3600 X 3 X 10-3 X 0.083 X 650 X 1
= 582.66 kg/hr=0.16 kg/min.
But, the bulk density of Kocho is 0.86 g/ml (Dagem alemayehu ayele et al.food sci nutr.2021)
Processing capacity = 582.66/0.86 = 677 Kg/hr=0.188 Kg/min
let Hopper Volume = = 2 X 10-3 m3
Kocho bulk density = 860 kg/m3, Mass of feed, m = 860 * 2 X 10-3 = 1.72 kg
Assume 15 minute operation

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑘𝑜𝑐ℎ𝑜 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 1.72∗60
Conveying capacity (kg/hr.) = 𝑇𝑖𝑚𝑒 𝑠𝑝𝑒𝑛𝑡 𝑓𝑜𝑟 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔
= 15
= 6.88 Kg/hr
Conveying capacity = = 6.8 kg/hr But, Kocho bulk density = 860 kg/m3
Conveying capacity (Kg/hr.) = 6.8 * 1000/860 = 7.9 kg/hr.
Design analysis for press squeezer machine
Let F= 40N
Area of the pressing box=0.49mx0.3m =0.147m2
Pressing pressure = F/A = 40N/0.147M2=272.1N/m2
Total press squeezing volume = 0.49mx0.3mx0.24m=0.03528m3
squeezing capacity = 1.72x60/5=20Kg/hr
4.6.3.Part manufacturing processes of Combination Kocho processing machine

The first steps of manufacturing processes is design preparation
Material selection
The following steps are manufacturing process of multi-purpose Kocho processing machine
Part and assembly drawing preparation
55
Prepare the Hooper part according to the drawing

cut-stainless steel 2mm sheet metal according to the dimension
Weld it by using Mig/mag
Drill 4 holes with 17mm diameter
Weld galvanized angle iron of dimension 20x20mm
split the Hooper in to two parts
surface finishing by using polishers
Finally after checking the assembly fit paint the Hooper.
Manufacturing process of cylinder
Cut-stainless steel sheet metal with thickness of 2mm
Roll it with manual rolling machine
then weld it with Mig/mag welding
Cut-hole for Kocho inlet and out let according to given dimension
weld the Hooper and outlet on it
Weld the ring with the 160mm diameter on it to fasten the machine at both sides
\then finish surface by polisher
After finishing surface assembly it with other parts.
Manufacturing process of the screw conveyer
Cut the stainless steel sheet metal with 2mm to circles of number 20
remove the pitch
twist it by putting on anvils
join it side by side on the shafts prepared
then weld it on the shaft by using Mig/mag
Manufacturing processes of the stand frame
Cut-angle iron of 20x20 mm according to given dimension
Cut-Rhs according to given dimension
then join them by using arc welding
Manufacturing processes of wood press squeezing machine
Prepare squeezer box by cutting timbers prepared according to measurements
cut the upper and lower supporting timbers by using measuring dimensions
Prepare upper and lower squeezer chamber pressing pads
Prepare stand frame by using 40x40 mm angle iron
Prepare screw press according to dimensions given.
Manufacturing processes of sieving machine
Prepare drum by using 1mm stainless steel sheet metal
Split the cylindrical drum in to two parts
prepare round bars with no 6 and weld them equally around the 230 mm diameter rings
weld two circular plates on both sides
Turn the stainless steel shaft
weld the hinge
56
weld the inlet door

weld the fermo to lock
Prepare the stand frame by using 20x20mm angle iron
Drive mechanisms and animation of the machine
Multi-purpose screw conveyer machine is derived by single phase motor and by manually.
Single phase motor rotates the screw conveyer and the conveyer pulverizes corm, crushing
onion, squeezing kocho,rubbing Kocho and powdering it. If there is no access of electricity
we can operate it manually.
Screw press wooden machine is operated by rotating the screw conveyer by and rotating it
until the required moisture content is remaining.
Sieving machine is operated by both manually and electricaly.Electrically it is connected with
single phase motor by belt and manually galvanized handle is prepared and rotated by it.
figure 4. 3 failure analysis of lower timber by stress analysis of simulation.
figure 4. 4 Stress analysis simulation of upper screw holder upper RHS
57
figure 4. 5 Exploded view of the machine
58
4.7.Part and 3D drawings of Press squeezing machine

Juice ejector part of the machine which is made up of stainless steel
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
4.7.1.Part and 3D drawings of mult-purpose helical conveyer machine
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
4.72.Part and 3D drawings of Kocho sieving machine
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
4.8.Mentainance of the machine

All parts of the machine is dismantled and designed according to the mentainance
consideration principled.
The conveyer parts of the machine should cleaned after the operation if the sold particle
blocks operation.
The wooden part of the pressing machine should cleaned after squeezing
Grease should added to screw to make motion ease.
4.9.Cost Analysis
The cost analysis of combination Kocho processing machine is calculated as follows
4.9.1.Direct material cost
No Item specification measurement Quantity u n it total remark

cost cost
1 Sheet metal 1000x2000x2mm pieces 1 2000 2000
2 Angle iron 20x20x6000x2mm pieces 1 800 800
3 Angle iron 40x40x6000x2mm pieces 1 1300 1300
4 Round bar ϕ10x6000mm pieces 1/ 2 300 300
5 Round bar ϕ20x6000mm pieces 1/4 750 750
6 Ball bearing 6204 pieces 4 150 600
7 Rhs 40x40x6000x2mm pieces 1 1300 1300
8 Timber Wanza pieces 2 400 800
9 Electrode ϕ2.5 E6013 pack 1 350 350
10 Electrode ϕ3.2 E6013 >> 1 400 400
11 Spray silver silvery pieces 5 150 75 0
12 Spray blue blue >> 1 150 150
13 Belt C-Grade >> 2 150 300
14 pulley ϕ 60 mm >> 2 100 200
Aluminum
15 Ant-Rust - >> 1/4 175 175
16 Paint Pale green >> 1/4 175 175
17 Electric 0.75 Hp single >> 2 3000 6000
motor phase
18 galvanized 3/4" >> 1/12 75 75
pipe
19 sieve medium grade >> 68x50 mm 15 0 15 0
20 cricketo/lock metal type >> 1 20 20
21 Hinge - >> 1 20 20
22 Bolt and Nut M-13 >> 20 15 300
23 Bolt and Nut M-10 >> 20 5 100
Total Cost 17,015
109
4.9.2.Direct Labor Cost

No Position Qualification quantity salary
1 Designer Manufacturing 1 150 per product
2. Wood machine operator L-4 1 100 per product
3 Machinist l-4 mechanics 1 100 per product
4 Quality controller l-4 mechanics 1 150 per product
5 Finishing operator l-4 mechanics 1 100 per product
Total cost 600
4.9.3.Manufacturing overhead cost
Indirect Material cost
No Item Specification unit of quantity Unit Total
measurement cost cost
1 Varnish Mural piece 1/20 15 15
2 Stucko Standard/Latico piece 1/8 37.5 37.5
3 Cola/Glue Standard piece 1/8 31.25 31.25
4 Metal stucko Latico piece 1/ 4 500 125
5 Cutter Disc ϕ180 mm piece 3 150 450
6 Grinder disc ϕ180 mm piece 2 150 300
7 Sand paper fine grade piece 1/40 50 5
8 Dulentin Standard liter 1/12 100 100
Total cost 1,063.75
Indirect Labor costs

No Position Qualification Salary per unit product
1 Manager Degree 50
2 finance manager Degree 50
3 Purchaser L-4 Mechanics 40
4 Advertiser L-Welder 40
5 cleaner Grade 10 25/day
6 Guard Grade 10 25
Total Cost 230
4.9.4.Factory Overhead cost
No overhead expenses Amounts per product
1 Electricity 5
2 Water 5
3 Telephone 10
4 Mentainance 3
5 insurance 20
6 Allowance 5
8 others 100
Total overhead cost 148
Total costs paid for the production of combination Kocho processing machine
110
TC = Dc + Oc
❖ Where, TC = Total Cost DC = Direct Cost and OC =
Overhead Cost
i. Direct cost = Direct Material Cost + Direct Labor Cost, = 17,015 birr + 600 birrs =
17617 birr/ unit
ii. Overhead cost = Indirect Labor + Indirect Material + other costs (lease, insurance)
= 230 birrs + 1063.75birrs + 148 birrs = 1,441.75 birr/ unit
iii. Total Cost of Products (Production Cost) = Direct Cost + Overhead Cost
= 17,015 birr+ 1,441.75birrs = 18456.75 birr/ unit
iv. Profit = total production cost × 20 % = 18456.75 birr × 20/100 = 3,691.35birr/unit
v. Our machine price per unit cost = 22,148.1 ETB.Avegage price=7382.7
111
5.Conclusions.
Combination Kocho processing machine is core problem solver for society. Around 20 million
people consume Kocho as a main source of the food. In different hotels and restaurants Kocho
becomes favorable food for consumption.So,even if the it is favorable for consumption Kocho
processing mechanisms are cumbersome. Women exposed to different health related matters and
sometimes they lost their life by dangers of hitting squeezing stick. This machine solves those all
problems. We can also prepare high amounts of Kocho in short time by using this machine. It is
also low cost and manufactured with environmentally available materials. Also it is affordable for
everyone who want to use it. It creates work opportunity for enterprises and its marketability is
also high considered with other machines.
112
6.Recommendation
Based on the project accomplished I have recommended the following ideas:-
This work Must disseminated to end users by making collaboration with stake holders
The manufactured prototype is not the end products so, other findings should be improved.
Woreda stake holders should take responsibility to advertise the work and disseminate lo the
farmers and hotels
Enterprises should use this opportunity and they must create work opportunity
The prototype for the next time should be manufactured by right materials.
Triple starting treads and half nut should used next time to minimize the time consumption by
revolving square screw.
It is better to design circular cylindrical pressing chamber
Kocho outlet chamber should be prepared for next time
right/optimal squeezing portion of the area should be experimented well
113
7.References
A Diagnostic Survey of Ezo Tula Peasant Association in Chencha, North Omo
(1994), FARM AFRICA, p 59.
2. Agren, G. and R. Gibson (1975). Food Composition Table For Use in Ethiopia.
Stockholm: Almaqvist and Wiskall.
3. Alasebu Gebreselassie (1983). Women on Settlement. National Workshop on Women
in agriculture Development. Awassa.
4. Hanna Kebede (1978). Improving Village Water Supplies in Ethiopia: A Case Study
of Socio-Economic Implications. United Nations, Economic commission for Africa.
5. Chaka, W. and Kifle, D. (1992). A Report on Improved Enset Food Preparation.
Sodo, (unpublished).
6. Deckers J., Kefale A., Sandford S. and Swennen R. Paper on Interdisciplinary
Ecological Research Effort for Enset in Ethiopia (unpublished). FARM AFRICA
7. ILCA (Information Center for Low-Extended Input and Sustainable Agriculture
(1993). Enset - a multipurpose crop. Volume 9 no. 3, pp 9 - 10. ETC Foundation,
Netherlands.
8. Judit S. and Hellen Kassa. Paper on the Effects of Gender on Resource
Contributions, Decision Making And Influence; A Comparison Between Enset, Teff
And Maize (unpublished). FARM AFRICA
9. Overholt, C., Anderson Mary B., Cloud, K., Austin James E. (1991). Gender Roles
in Development Projects. Kumarian Press, Inc Connecticut, U.S.A.
10. Sandford S., and Alemu K. (1991). Enset in North Omo. FRP Technical Phamplet
1, pp. 8 - 10 FARM AFRICA.
65
11. Taye Bizuneh (1984). Evaluation of Some "Enset" ventricosum clones for Food Yield
114
with Emphasis on the effects of Length of Fermentation on carbohydrate and calcium
Content. Journal of tropical agriculture (Trinidad). 61(2) 111-116.
12. Westphal E. (1975). Agricultural Systems in Ethiopia. Center for Agricultural
Publishing and Documentation. Wageningen, the Netherlands 123-125.
13. Wudnesh Hailu (1991). Rural Family of Ethiopia: Economic activities, Household
Analysis, and Standard Household Type comparisons. Hamburg: Verl. Weltarechiv.
14Carlos III University, Mechanical Engineering Department. “ Srew Conveyor”
15.Khurmi, R. S., and Gupta, J.K. (2008).A Textbook of Machine Design

(14thed.).Eurasia
Publishing House (PVT) Ltd., New Delhi, India, 1230 pp.
115
8.Appendix
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APPENDIX 2
PICTORIAL 3-D ASSEMBLY
figure 8. 1combination Kocho processing machine
167
168

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ALETA WONDO CONSTRUCTION AND INDUSRIAL COLLEGE

ALETA WONDO INDUSTRIAL AND

PREPARED BY:-ENICHA HUSSIEN

2.2.1B.1.Preparation and fixing of the stem processing equipments .................................................. 21

3.3.3Describing Mechanisms of each machine .................................................................................... 41

4.72.Part and 3D drawings of Kocho sieving machine ......................................................................... 92

IAR= Institute of Agricultural Research

RHS =Rectangular Hollow Steel

VI.List Figures and Tables

1.2.BACKGROUND OF THE PROJECT/TECHNOLOGY

1.3. STATEMENT OF PROBLEMS

1.4.2. SPESFIC PROBLEMS

1.5.SCOPE OF THE PROJECT.

1.7.SIGNIFICANCE OF THE TECHNOLOGY.

Kocho Kita (thin, unleavened bread)

Table 1 Nutritional Value of Kocho and Bulla/l00gm of Edible Protein

Area Name of Dish T yp e

2.2.THE PROCESSING OF "ENSET

2.2.1.A.TRADITIONAL "ENSET’ PROCESSING IN THE

figure 1. 1 Decorticating saw tool

figure 1. 2 decorticating bone tool

2.2.1.e.Squeezing, Shredding and Sifting

figure 1. 3 rubbing the Kocho by hands

figure 1. 4 shreading Kocho

figure 1. 5 sifting Kocho

figure 1. 6 Kocho processing cardboard and manual sieve

2.2.1B"ENSET' PROCESSING IN THE WOLAYITA AREA

2.2.1B.1.Preparation and fixing of the stem processing equipments

2.2.1B 2.Pseudo stem Processing Operation

2.2.1B.3.Extraction of the liquid food from the parenchyma tissue

2.2.1B.4"Enset" corm processing operation

2.2.1B.5.Pounding follows until the material is finely ground.

2.2.1B.6.Squeezing of fermented mixture of parenchyma tissue and pulverized corm.

figure 2. 1 Kocho squeezing in Wolaita

Name of Tool Use Cost (Birr)

Hanticho (fiber) Squeezing 0.10

2.3.Some physical characteristics of "Kocho"

Volume, Weight and Density of "Kocho" Before and After Squeezing

Food stuff Volume Weight (gm) Density Volume

Weight Percentage Distribution of l00gm "Kocho" Elements Before Extraction of Liquid

Air-dry "Kocho" powder 32.6%

Squeezed liquid extract 58.0%

Moisture in powder before air-drying 58.0%

Dry fiber 8.2

weight percentage distribution of 100 gm Kocho

2.4.PAST ATTEMPTS MADE TO IMPROVE "ENSET’ PROCESSING EQUIPMENTS

2.4.1The Hawassa College of Agriculture

2.4.2.Sodo Appropriate Technology Center.

2.4.3.Institute of Agricultural Research (located in the vicinity of Nazareth)

a."The devices to be developed should be based on locally available row materials."

c. "Should fulfill the need to individual and community users."

d. "Preserve the usual taste of v Kocho.’

e. "Should be simple and cheap enough to be afforded by v enset’ growers."

a."Enset" stem processing equipment.

ii. Horizontal plank/clamp decorticator

iii. Adjustable rotary blade pulverizer

b. "Enset" corm processing equipment

i. Grater/slicer (wood worker jack plane)

ii. Non-adjustable rotary blade pulveriser

iii. Adjustable rotary blade pulveriser

c. "Bulla" extraction equipment

i. Flat board squeezer

ii. Bucket type squeezer

iii. The motorized decorticator was still under development