Chapter 1

INTRODUCTION

A. Background of the study

A crusher is a machine that is structured with the end goal to decrease the

measure of broad rocks into small rocks. It isn't just for that; in reusing of the waste

materials it is utilized by the machine. It is a multi-dimensional machine and has

the capacity of changing the type of an item to be crushed. In rock ores, the

material is utilized for decreasing in size or for making bits of a solid mix i.e.,

composed of different raw materials and these pieces are used for the composition

study of different raw materials (Jalal Afsar, August 2012). The machine has many

sorts of applications in many industries including crushing large rocks, crushing

metals, crushing sea shells like oysters, clams, spider conch and in managing

waste. Usually, these objects are subject such as;

A stone found in the ground that is often used for building. In general, large

rocks are subject to crushing usually crushed in a plantation. The stone that are

crushed are usually used in commodities. It is abundant, widely available, and

inexpensive in the market. This crushed stones is familiar with people in almost all

parts of the world. (Hobart King, 2005)

Ocean shells are hard, defensive exoskeleton framed by invertebrate

creatures that live in the ocean and are regularly discovered appearing on

shorelines throughout the world (Adam Purcell, 2013). Individuals often eat

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seafood particularly ocean shells and dispose of them by simply tossing them out

the yard or in the waste.

Every year, the seafood industry produces over 100 million pounds (45.3

million kg) of waste from shellfish and crustaceans. Most of the consumed shells

that are from the industry basically sent to landfills, and ways to recycle these

materials are becoming more sought.(Anibal Ramirez, 2002)

The proper disposal of shell waste in the landfill can eliminate and reduce

waste. "Reusing shell squander is an ideal case of an economy, especially as

shells are a significant biomaterial, in addition to the fact that they improve the

manageability of the aquaculture business moving advances, however they can

likewise give optional monetary advantages to shellfish producers and processors

too," (Dr James Morris, July 2017)

Shell waste, for example, lambis lambis named for spider conch has an

exceptionally extensive, hard and substantial shell. Embellishers frequently use

these shells. Dissimilar to different material are pound into grains for animal feeds.

For this matter, the researchers have decided to develop and fabricate

crushing machine in crushing stone and seashells. Specifically spider conch shell

waste as a cheap source of calcium supplements in poultry feed formulations and

as an aggregate for hollow concrete blocks and as a material the construction

industry.

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 B. The Objective of the study

General Objective

This study aims to develop and fabricate a crushing machine.

Specific Objectives

1. To determine the productivity of the machine

1.1 The Yield

1.2 The Efficiency

2. To figure the output power

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 C. Significance of the study

The content of the study is that the machine is to equip with a motor which

can depreciate the time and operation in crushing the spider conch shell. Also, to

provide a high quality and effective spider conch machine in the place where

buyer and seller meet their demand.

To the teachers: The proposed research project may serve them as an injunction

reference to encourage their students to do more applicable and efficient designs.

To the School (PIT): To provide a high quality of education in the field of

Engineering.

To Agricultural business: The proposed study will help the agricultural custom

in making an easy and convenient machine. It will also help the seller/operator in

terms of fast and smooth use, reduce time, physical effort of a human being and

earn more income shortly.

To future researcher: The proposed study will benefit and help the future

researcher as their guide. This can also open doors in the development of this

study.

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To the community and environment: It would be beneficial to the community

and environment for it would be able to provide a high quality and productive

socioeconomic life.

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D. SCOPE AND LIMITATION OF THE STUDY

This study will only concentrate on designing, developing and

fabricating a machine which can crush a spider conch shell with a maximum

size of 7 cm. It will also condense on finding the yield and efficiency of the

equipment.

E. CONCEPTUAL FRAMEWORK

Figure 1 shows the paradigm of the concepts from inputs, process, and

output of the researchers. The outline below illustrates the steps to be taken

by the researchers from the identification of the input, the process to

develop a crushing machine, and the output.

INPUT PROCESS OUTPUT

 Conduct a  Design, Develop

FIGURE 1: Research Paradigm of the Study

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F. DEFINITION OF TERMS

The following terms are in the context of this study:

 Parameter - a numerical factor forming one of a set that defines a system.

 Spider Conch shell - the empty shell of a small sea creature, often one

found lying on the beach, the empty shell of a sea animal.

 Milling – grinding grain in a mill.

 Pulverizing - reduce to fine particles.

 Flowrate- the mass of a substance which passes per unit of time taken.

 The Efficiency of the machine- measure of the extent to which input is

well used for an intended task or function (output). It is also the ratio of work

performed by the machine.

 Backflow- the flow of crushed shell in reverse direction

 Batch operation-the product comes in and out in groups and not

continuously.

 Hopper- a container for a material such as grain or rock that fall downward

and is able to release its contents at the bottom.

 Housing- a cover which protects the machine.

 Shaft-a handles to connect or change its movement in the machine.

 Strainer-many small holes device and that is used to hold back solid

pieces while powder passes.

 An Electric motor- is an electrical machine that converts electrical

energy into mechanical energy.

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 CHAPTER 2

Related Review Literature

A study made by Lynch and Rowland (2005) the historical backdrop of

crushing started toward the beginning of agribusiness and outlines how size

reduction developed over the centuries. Specialized accomplishments have

prompted the machines of today, which can pulverize hard particles at the rate of

a massive number of tons every day. One sureness is proceeding with the

requirement for size decrease to create and fit the feed styles of domesticated

animals both today and later on.

Additionally, Ekmay and Coon (2010) revealed that the objects of crushing

ocean shell for poultry feed ventures are to deliver good fineness level that can

build acceptability, decline surface response, and encourage blending with

different constituents of the feed proportion. They indicated that calcium sources

and molecule sizes influence the egg shell quality and egg interior quality. They

demonstrated that the fineness level of smashing required for youthful chick 1.6

mm and for grown-up poultry 3.2 mm, pulverizing is one of the vital expending

forms in the human and creature feed industry. This procedure devours from 70%

up to 90% of complete power necessities amid the feed processing. The

devastating vitality employ relies upon the activity and geometrical parameters of

the granulating machine and the dependable fineness degree (molecule estimate

dispersion) of the processed material.

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 Another study conducted by Hassan (1994) discovered that expanding the

screen size of hammer mill from 3.2 to 4.8 and 6.33 mm gave a decrease of 30

and 55% in crushing energy under working conditions at drum speed 2930 rpm,

no. of sledges 12 mallets and dampness content 5.1%. Expanding of drum speed

from 1460 to 2930 and 3910 rpm gave a diminishing of 59.1 and 67.9% in pounding

vitality under working conditions at a screen size of 6.35mm, no. of sledges 12

mallets and grain dampness content 5.4%.At a screen size of 6.35mm, no. of

hammers 12 hammers and grain moisture content 5.4%.

Another study by Yang, et.al (2006) built up a numerical model dependent

on the Discrete Element Method (DEM) in a lab plant (reproduce the IsaMill). They

examined the impacts of parameters identifying with molecule material (i.e., sliding

grinding coefficient and damping coefficient) and operational conditions (i.e., turn

speed and brawny stacking) on the stream speed, compressive power and power

draw of the devastating factory. They showed that the contemplated parameters

effectively affected the stream properties. They demonstrated that expanding the

sliding erosion made the stream speed and compressive power have least

qualities because of the focused components for vitality exchange and

dissemination, but expanded the power draw.

Another research work by Nwadinobi Chibundo Princewill (2017)

revealed that his created machine could aid in the crushing of nourishment and

animal feed materials into grain sizes that have the ability to serve the ideal

interest. The Hammer plant can suit different grain molecule sizes as required

through the openings of the screen situated underneath the sledge get together.

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The crushing procedure is accomplished activities of the pounding chamber in

beating the material encouraged into it. The fineness to be accomplished relies

upon the punctured entire size of the divisible screen. This improved mallet factory

has a devastating effectiveness of 92.6%. It is dust-free and furthermore because

of appropriate air dissemination does not crush the flour created by overheating

which is ideal for nourishment and feed-material quality and protection.

Additionally, Jayasundara et al. (2012) considered the impact of crushing

medium size on the wet processing execution in mixed plants utilizing a

consolidated numerical and trial approach. They performed Physical investigations

in a 1.4L crushing plant with the circles pivoting at various rates to crush aluminum

hydroxide powders with chromatic measured glass globules. The outcomes

demonstrated that the pounding procedure pursued the initial request energy and

the granulating grade expanded with expanding plate speeds.

A research study of Developing a Hammer Mill for Crushing Seashells

(Refaay, M. M. and A. S. El_Sayed 2002) developed a reliable machine for

grinding the seashells to be used as a cheap source of calcium supplements in

poultry feed formulations. The developed mill was fabricated locally in Egypt based

on the theory of grinding hammers that included some specially manufactured

roughness hammer knives. It is powered by a 40 hp (horsepower) electrical motor

that could be driven through a merged inverter to control its speed and load.

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 CHAPTER 3

METHODOLOGY

This chapter covers the research design, project development, which

includes the fabrication procedures, development cost and time element involved

in the designing and fabricating procedures conducted by the researcher.

A. Research Design

The research study used the Developmental Method and Experimental

Method. Developmental Method is defined as the systematic study of

designing, developing, and evaluating instructional programs, processes, and

products that must meet criteria of internal consistency and effectiveness.

Experimental Method is defined as a systematic approach to research in which

the researcher manipulates one or more variables, and controls, and measures

any change in other variables.

B. Detail design of the Spider Conch Crusher Machine

(1), while, its schematic drawing shown in Fig. (2).

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 Table 1

Main specifications of the crushing machine.

Items Specifications
Made Ormoc
Shackle and Chains 8 shackle and 16 chains
Size of the screen 3/8 inches, 53 holes
Power source Single phase electric motor
Motor power, HP (kW) 1 HP (0.75 kW)
Operating speed, r.p.m. 1700
Overall height, cm 113
Overall length, cm 81
Overall width, cm 58
Overall weight, kg 72

Shown in Figure 2 are the significant parts of the Spider Conch crusher machine

namely: Feeder, Housing, Shaft, V-belt, Electric Motor and the Hopper.

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C. Fabrication Procedure
The designing, development and fabrication of a crushing machine

is undertaken in the following procedure according to assembly and

fabrication parts.

Housing:

1. Prepare the tools and materials needed.

2. Produce 10 x 7 inches high-pressure pipe as the housing.

3. Reface both ends of the pipe using a lathe machine.

4. Use lathe machine to get the 12-inch diameter steel plate of the front

cover plate and drill a 1 1/8 inch diameter at the center.

5. Cut another steel plate for the back cover plate of the pipe.

6. Weld the back-cover plate using electric arc welding.

7. On the back, use a lathe machine to get the center of the housing.

Drill a 1 1/8 inch at the center for the 1-inch shaft.

8. After drilling the hole at the back, use a 1-inch diameter pillow block

bearing with four holes for the bolt and nuts. Make sure to align the

center hole of the pillow block is to the center of the housing.

Measure the holes needed for the flange bearing to be attached.

9. Drill a hole for the flange bearing to be attached.

10. Insert bolts with nuts then tighten using the right tools.

11. For the front cover plate, drill the hole aligned to the center hole for

the pillow block bearing to be attached.

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12. For the front cover plate to stay intact wield 4 bolts outside the

housing.

13. Drill 4 holes aligned to the bolts wielded outside the housing.

14. Insert bolts with nuts then tightened using the right tool.

15. Using cutting outfit, cut a 4 inches diameter hole on the top left of the

housing for the feeder.

a. Feeder

1. Prepare the tools and equipment.

2. Cut a stainless pipe (schedule 40) in the size of (4 x 19

inches) for the feeder.

3. Assemble the feeder to the housing if the hole is the

exact size as the pipe.

4. Weld using electric arc welding.

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b. Shaft

1. Prepare the tools and equipment.

2. Produce a shaft to measure the flat bar to be attached.

3. Cut two pieces of the flat bar according to the size 7/16

thickness x 1 ½ width x 6 ¾ length.

4. Weld the flat bar to the left and right of the shaft using

a tig welding.

5. Drill 4 holes on the right flat bar, and drill 4 holes on the

left side. Make sure that the holes are alternate to each

other

6. Assemble the 2 chains to the shackle. (8 shackles, has

2 chains)

7. Hook the shackle to the drilled holes of the flat bar.

8. Measure the distance between the chains and the

housing. (1/4 inch)

9. Attach a 3-inch diameter pulley at the back of the shaft.

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 c. Screen/ Strainer

1. Prepare the tools and equipment.

2. Cut a rectangular shape (5 x 2 ¾ inches) on the right

side of outside the housing for the outlet.

Stand

1. Prepare the tools and equipment.

2. Cut 4-angle bars into two sizes; 2 (7 inches) and 2 (14 inches).

3. Form the angle bar into a rectangular shape.

4. Wield the flat bars using electric arc welding.

5. Assemble the housing to it and see to it that it fits.

6. Cut a pipe into 3 sizes, 2 pieces of 7 inches, 2 pcs of 14 inches

and 4 pieces of 16 inches (for the legs)

7. Assemble the legs according to the design.

8. Wield the pipe using electric arc welding

9. Wield also the housing to the stand.

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Screen/ Strainer

1. Prepare the tools and equipment.

2. Cut a steel plate in a rectangular shape of a size (3 ½ x ¼

inches)

3. To smoothen the cut area, use angle grinder.

4. Drill a 3/8-inch diameter into the steel plate (53 holes).

5. Cut a steel plate in a rectangular shape of a size (6 x 3 ½

inches) for the screen to be attached.

6. For the body of the output passage, cut a steel plate into the

size of (5 x 2.5 inches).

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Hopper

1. Prepare the tools and equipment.

2. Make a catcher from a cut c-furling of a size of 4x 4.5 inches.

3. Cut a C-furling in a size of 1/8 thickness x 4 width x 14 length

inches.

4. To cover the c-furling, cut a steel plate into the size of 1/8 x 4

x 9 inches.

5. To smoothen the cut edges, use a portable grinder.

6. Assemble the catcher, c-furling and the cover if the

measurement is right.

7. Weld them using an electric arc welding.

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 The Platform for motor stand

1. Prepare the tools and equipment.

2. Prepare a flat bar of 1/8 inches thickness x 1 ½ width x 16

length

3. Cut the flat bar in 5 pieces into the size of 16 inches and 2

pics of 7 inches.

4. Assemble the flat bar according to the design.

5. Weld the flat bars using electric arc welding.

6. Then weld it to the right side of the stand.

7. To support the bottom of the motor stand, wield a flat bar to

the main podium on the front and the back

8. Weld 4 bolt tosser on the platform of the motor for the belt

adjuster

9. Insert the nuts to the bolts of the base of the engine after fixing

the belt tension and tighten using the right tools.

After the Fabrication, attach a V-belt on the 3 inches diameter pulley of the

shaft and the 5 inches diameter pulley of the motor. After assembling and testing

the machine, the machine then comes to the last stage, the coating stage where

the first coating is painted red and dried, then to the second coating which is

black paint mixed with thinner. After the second coating, the machine is left to

dry.

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 D. Design Calculation

Motor power = 1 hp
= 750 watts
Speed of motor =1700 rpm
Diameter of pulley (d) = 3 in. (7.62 cm)
Speed (N1) =1700 rpm
Diameter of pulley (D) = 5 in. (12.7cm)
Speed (N2) =?
Solve for N2:
D/d = N1/N2

12.7/7.62 = 1700/N2
N2 = 1020 rpm

Center distance of pulley:

C = 2(D+d)

= 2(12.7+ 7.67)

= 40.74 cm

P= 2𝜋NT/60

𝑇 = 60𝑃/2𝜋𝑁

T= 60(750)/(2*3.14*1360)

T= 5.27 watts

S = V = (πDN1)/60000

= 1.13 m/s

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E. The Yield of the machine/ Machine Productivity
To determine the developed machine for each investigated treatment by

dividing the product weight on time consumed in.

To compute the Yield/ Machine productivity:

F. The Efficiency of the machine- it is a measure of the extent to which input

weight of output material and weight of input material.

G. Development Cost
The total project cost was twenty-three thousand eight

hundred fifty-four pesos (P 23,854.00).It includes all the substantial

utilized in developing and fabricating the machine which amounted

to seventeen thousand four hundred eighty-five pesos (P17, 485.00).

The details of the bill of materials based on a standard found in

Appendix A.

The labor cost amounted to six- thousand pesos (P 6,000).

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 H. Time allotted in Design, Develop and Fabrication of the Machine.

Table 2

TIME SPENT FOR EVERY ACTIVITY

SCHEDULE
Activities Involved
November Decemb January February March
2018 er 2019 2019 2019
2018
1. Planning and Designing

2. Procurement of tools and

materials

3. Assembly of Parts

4. Operation and Testing

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 CHAPTER 4

RESULTS AND DISCUSSION

This chapter presents data gathered, the interpretation of data, the findings

of the study, the conclusion reached and the recommendations made by the

researcher.

Testing is a vital step in the process of machine development. After design

and construction, testing is necessary to determine the performance efficiency of

the machine, and afterwards, point out areas of possible improvement where

required. Based on the design, a fabricated prototype, as shown in Figure 8. To

evaluate its performance, one parameter was tested: Yield.

The experimental material was a spider conch and had a length of not more

than 7 cm. A productivity test performed under a rated condition of motor. Each

trial lasted for about 145-290 seconds and ten times iterated. The amount of

product at each test weighed with a digital balance, and the averaged value for the

ten tests was used as the final productivity.

Test Procedure

A range of 200 grams to 475 grams of four spider conch was fed into the hopper

and the Spider Conch crusher machine was switched on. A stop watch recorded

the crushing time for each run. Then, repeated for ten times and the mean value

recorded and used for calculation. Then recorded the output rate.

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The Yield of the machine:

The machines yield is 1.5 grams per second Thus, the machine has the better

performance and effectiveness than manual.

The Efficiency of the machine:

A 13.28 percentage of losses during the operation. It resulted to 86.72 percentage

of the efficiency of the machine.

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Findings of the study

The researchers tested the equipment and observed some problems occurred

during the exertion. Here are the results:

1. Backflow operation. The electric motor was turned on, and the

machine was ready to be tested. The v-belt and shaft indicate that

the operation is counterclockwise. A spider conch shell tested to the

equipment where the researchers found out that there is a backflow

on the operation, where the crushed shells went through the feeder

flying. As a result, the researchers added a cap on the feeder the

safety of the operator and for the crushed shell will not be scattered

everywhere.

2. Feeding rate. Hence the cap was installed for the feeder. In result,

the operation will be by batch. The researchers suggested drilling a

hole on the right side of the feeder for the inserted stopper. Before

the electric motor is turned on, the researchers inserted the stopper

after loading the feeder with 4 spider conch so that the spider conch

will not slide down after loading. The feeder is closed using the cap,

the electric motor was turned on, and the researchers slowly pulled

the stopper, and the crushed spider conch shell being processed.

The next batch will be loaded if there is no noise or no crushed shell

are left inside the housing. This set-up formed easy access to the

operation of the machine and prevented the electric motor from

overloading.

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 CHAPTER 5

CONCLUSION AND RECOMMENDATION

Conclusion

Based on the performance test conducted on the crushing machine

operated by an electric motor of 0.75KW and a rotor speed of 1700 rpm, and

obtained a grinding efficiency of 86.72%. During the performance test, the product

input-output ratio stood at 3: 2 average weight values. For the performance of the

machine and obtained a flow rate of 1.5 grams per second. It resulted that the

equipment has an acceptably performance in productivity.

Recommendation

Based on the given findings and conclusion, these are the following

recommendation:

1. There should be a cover for the v-belt for the safety of the operator.

2. The output passage should be adjusted at the exact angle for continuous

flow of the output.

3. There should be a wheel on the legs with a lock so that it will be easier to

transfer it from one place to another.

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 Crusher/ Crusher Types, Construction Machinery, August 10, 2012, Jalal

Asfar

Web: http://www.engineeringintro.com/all-about-construction-

equipments/crusher-crusher-types/

 Jean-François Hamel1 & Annie Mercier1, June 2006, Note on the

spawning and development of the common spider conch Lambislambis

 Anibal Ramirez , Steve D. Barker , Timothy J. Love, Edward J. Milazzo,

Lawrence P. McGillicuddy, WASTE SHELL CEMENT COMPOSITE,

WORCESTER POLYTECHNIC INSTITUTE

 Society for Experimental Biology, Sea shells for sale: A new source of

sustainable biomaterials.

Web: https://phys.org/news/2017-07-sea-shells-sale-source-

sustainable.html#jCphttps://phys.org/news/2017-07-sea-shells-sale-

source-sustainable.html

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 Ekmay R.D. and C. N. Coon (2010). The effect of limestone particle size

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