Design Calculations

The following were the calculations of the design that helped provide data to
the researchers to attain the desired output of the Ginger and Turmeric Extractor
Using Four-Way Roller Press Assembly. The data were thoroughly calculated and
computed in order to attain the right dimension and specifications of the required
materials. Machine Design and Machine Elements were used.

For the design, we have taken some assumptions based on the existing
machine and some other parameters. The following factors were considered:

1. The machine consists of four rollers.

2. Each roller has a diameter of 3.5 inches (88.9 mm) to ensure efficient
compression of turmeric and ginger.
3. The roller length is 6.50 inches (165.1 mm), based on the number of turmeric
it can handle simultaneously.

Design of roller

Determination of ginger and turmeric size

We have measured 3 different sizes of ginger and turmeric to obtain the

maximum and minimum size that can be crushed by the machine. From the research
and observation, we have made so far, by measuring 3 ginger and turmeric we get
the diameter. Measured values are listed in the table below:

Number Type Diameter (mm)

1 Small 7
2 Medium 9
3 Large 10
So, the maximum size of the ginger and turmeric is 10 mm and the minimum size is
7mm.

From the research and observation, we have made, the maximum thickness
is 10 mm and the minimum thickness is 7 mm.

Solving for the size of the roller to accommodate the varying sizes of ginger
and turmeric
 The clearance that can accommodate the maximum and minimum size of
ginger and turmeric that can be fed into the extractor is determined using equation 1

( )
1
R+
2 equation 1
x=2 −r
cos ∅

Where;

x=¿ ginger∧turmeric that can be fed into machine

r =radius of theroller , mm

c=clearance between the top∧feed roller ,mm

2 θ=nip angle

The nip angle is a function of the coefficient of friction, µ, between the roller
surface and the ginger and turmeric surface, and the relationship between the nip
angle and the coefficient of friction is such that;

−1
θ=tan μ

Where;

μ=coefficient of friction between the roller surface ( engineering plastic )

¿ the ginger∧turmeric

μ=0.25

−1
θ=tan 0.25

θ=14.04 °

From equation 1 the formula of clearance is derived below:

Where;

c max =maximum gap between roller 1∧2

c min =minimum gap between roller 3∧4

Roller 1 c max Roller 2

 Roller 3 Roller 4
c min
( )
x
c max =2 + R cosθ−2 R
2

c max =2 ( 112 +44.45) cos 14.04−2 ( 44.45)

c max =7.05 ≈ 7 mm

c min =2 ( 72 +44.45) cos 14.04−2 ( 44.45)

c min =4.14 ≈ 4 mm

Minimum gap between the two rollers which is 4mm and the maximum gap is 7 mm.

Solving for the shaft’s thickness

A cylindrical shaft is used to build the roller; this shaft’s thickness must be
calculated to check for its ability to withstand the compressive strength of the ginger
and turmeric by equation 2.

Pd
t= equation 2
2 σt

Where;

t=thickness of the roller

σ t=tensile strength of theroller ,34.5 MPa

P=roller pressure , 8.55 MPa

d=diameter of the roller

8.55 x 88.9
t=
2 x 34.5

t=11.01≈ 11mm

It is the minimum thickness of the roller to withstand the compression strength.

Weight of roller

The weight of the crushing roller is estimated from equation 3.

 W =pvg equation 3

Where;

W =weight of crushing roller , N

kg
ρ=density of the crushing roller material , 2200 3
m
3
v=material volume of the roller ,m

m
g=acceleration due ¿ gravity , 9.81 2
s

The volume of the roller is calculated using the following formula,

( ) ( )
2 2 2
π Do π d i π di
v= − l+2 t equation 4
4 4 4

Where;

DO =outer diameter of the roller , m

d i=inner diameter of the roller , m

l=length of the roller

'
t=shaf t s thickness

Substituting from Equation 3 and 4 we can determine the weight of the roller,

[( ) ( )]
2 2 2
π Do π d i π di
w=ρ − l+2 t g
4 4 4

w=2200 ¿

w=7.40 N

Crushing force of the roller

F c =Rf x F s

Where;

R f =Rapture force of turmeric ,116.68 N (Shelake , 2018)

 R f =Rapture force of ginger , 20.12 N (Jayashree , 2011)

F s=Factor of safety ,2(Tadese ,2021)

F c =(116.68 N + 20.12 N ) x 2

F c =273.6 N

Crushing torque of roller

T =F c x r

Where;

T= torque on the shaft

Fc=crushing force of sugar cane

r= radius of the roller,m

T =273.6 Nx 0.04445 m

T =12.16 Nm

Rotating speed of the roller

Zeleke (2021) in his laboratory manual entitled, “Particle Technology”

indicated that the peripheral speeds vary about 1m/s for small rolls up to about
15m/s for largest rolls. Use 1m/s.

Solving for the speed of crushing roller

The speed of crushing roller formula was used below

Where;

N r =speed of roller

v=velocity of theroller

r =radius of theroller

60
Nr= v
2 πr

60
Nr= (1)
2 π ( 0.04445 )
 N r =215 rpm

Angular velocity

2 πN
ω=
60

2 π ( 215 )
ω=
60

rad
ω=23
s

Solving for the Motor Hp

TN
Motor Hp=
63000

( 107.55 lb−¿ )( 215 rpm )

Motor Hp=
63000

Motor Hp=0.367 Hp

Motor Hp=0.5 Hp

Solving for the diameters of pulley

Assume that the minimum diameter is 3 inches from table 17.1 by Faires.

D2=2 D1

Considering the maximum permissible ratio of diameter of shaft pulley to that

of electric motor is 2:1 based on a journal entitled “Development of Ginger Juice
Extractor”. (Dela Cruz, 2016)

Where;

D1=smaller diameter of pulley

D2=larger diameter of pulley

D2=2 ( 3 inches )

D2=6 inches

Solving for the Speed of the line shaft

 Considering a speed of 1740 rpm (Dela Cruz et.al, 2016) based on journal
entitled, “Development of Ginger Juice Extractor” to increase at 1760 rpm because of
the load.

N 2=N 1
( )
D1
D2
(V . M Faires)

Where;

N 2=speed of the line shaft

N 3=speed of the pulley connected ¿ thereducer

SR=speed reducer ratio ¿ pulleys

N 2=(1760 rpm)¿

N 2=880rpm

Solving for the Speed Reducer Ratio

Considering a speed of 540 rpmrequired ¿ extract the juce ( Salawudeen , 2022 )

N2
SR=
N3

880
SR= =1.6296
540

SR=2 :1

For Speed Ratio Adder

Considering a desired speed reducer ratio of 1:60 for driving heavy load (Abiad,
2021).

desired speed ratio

Additional Reduction= pulleys ¿
speed reducer ratio ¿

60
Addtional Reduction=
1.6296

Addtional Reduction=36.8189

Final Speed ratio=speed reducer ratio ¿ pulleys x additional reduction

 Final Speed ratio=1.6296 x 36.8189

Final Speed ratio=60

Use a speed reducer ratio of 1:60

N2
N 3=
SR

880
N 3=
60

N 3=14.67 rpm

Design of Screw Press Type Conveyor

Considering the 70 mm as the diameter of screw used in juice extractor based

on a journal by (Eyeowa,2017), we will be using 65 mm in our design since our raw
material is not larger. Also, based on the diameter of screw, the pitch will be half of it.

D
S=
2

65
S=
2

S=32.5 mm ≈1 inch

Since, the ginger an turmeric is considered as average flow ability, the

minimum loading ratio is 0.25 and the maximum loading ratio is 0.30. The screw is
installed without inclination based on our design, the correction factor will be 1.

π 2
Q=60( )D SNαρC
4

Where;

kg
Q=screw capacity ∈
h

D=screw diameter ∈m

S=screw pitch∈m

N=screw speed
 α =loading ratio

kg kg kg
ρ=material density ∈ 3
, ginger=471.49 3 ,turmeric=570.38 3
m m m

C=inclination factor For ginger

π 2 kg
Q=60( ) ( 0.065 ) (0.0325)(14.67 rpm)(0.30)(471.49 3 )(1)
4 m

Q=13 kg/hr

For turmeric

π 2 kg
Q=60( ) ( 0.065 ) (0.0325)(14.67 rpm)(0.30)(570.38 3 )(1)
4 m

Q=16 kg/hr

Solving for the length of Screw

L=S x number of worms

L=32.5 mm x 12

L=390 mm

Solving for the helix angle

S
tan a=
2 πD

32.5 mm
tan a=
2 π ( 65 mm )

tan a=0.0796

a=tan−1 ( 0.0796 )

−1
a=tan ( 0.0796 )

a=4.55 °

According to Adesina et.al (2017), the length of stainless rod is 475 mm and
the length of screw is 335 mm, it shows that there is an additional length of 140 mm.
Based on this journal, we will also add 140 mm.
 Lr =L1+ L2

Where;

Lr =length of stainless rod

L1=length of screw

L2=additonal length ,140 mm

Lr =390 mm+140 mm

Lr =530 mm

Solving for the Diameter of Screw Shaft (Equation by Khurmi and Gupta)

3 16
d s= ¿¿
π Ss

Where;

d s=diameter of the screw shaft

6 N
S S=maximum shear stress , 40 x 10 2
( ASME code for steel shafting )
m

K b =combined shock ∧fatigue factor for bending ,

1.5 ( Table 14.2 , Machine Design by Khurmi∧Gupta )

K t =combined shaft ∧fatigue factor for torsion ,

1.0 ( Table 14.2 , Machine Design by Khurmi∧Gupta )

M b=maximum bendingmoment , 21.10 Nm (Olaniyan, 2014)

M t =maximum twisting moment , 69.18 Nm(Olaniyan ,2014 )

3 16
d s= ¿¿
N 6
π ( 40 x 10 2 )
m

d s=0.02110660648 m=21.11mm

d s ≈ 25 mm

Solving for the total force exerted on the shaft

 F t=F 1 + F2 + F 3

Where;

m
F 1=1 kg x 9.81 2
=9.81 N
s

m
F 2=3 kg x 9.81 2
=29.43 N
s

m
F 3=5 kg x 9.81 2
=49.05 N
s

F t=9.81 N +29.43 N + 49.05 N

F t=88.29 N

According to (Shelake,2018), the rupture force of turmeric is 116.68 N in his

journal entitled, “Effect of Moisture Content on Physical and Mechanical Properties”.
The rupture force of ginger is 20.12 based on the journal entitled, “Mechanical and
Thermal Properties of Ginger” (Jayashree,2011)

Solving for the torque of the Screw Press

T =Fr (V . M Faires )

Where;

T =torque of the screw press

F=force required ¿ press

r =radius of the screw shaft

101.97 kg f 2.205 lb f
F=(0.08829 kN +0.11668 kN +0.02012 kN ) x x =50.61 lb f
1 kN 1 kg f

T =¿ ( 50.61 lb f ) ¿

T =¿ 49.60 lb−¿

Solving for the transmitted Hp in Screw Shaft

According to Salawudeen (2022), a shaft speed of 540 rpm is required to

extract juice in his study entitled “Design and Fabrication of Mango Juice Extractor”.
 TN
Motor Hp=
63000

(49.60 lb−¿)(14.67 rpm)

Motor Hp=
63000

Motor Hp=0.0115 Hp

Motor Hp ≈ 0.5 Hp

Solving for the torque of the motor

63000 Hp
T=
N

63000 ( 0.5 )
T=
880

T =35.80 lb−¿

Solving for the motor Hp

TN
Motor Hp=
63000

(35.80 lb−¿)(1760)
Motor Hp=
63000

Motor Hp ≈ 1 Hp

In order to prevent the motor from overloading by the simultaneous

crushing and extracting operations of the machine, we will use a Motor Hp =
1.5 Hp.

Design of flat belt

Solving for the belt width

V m =π D1 N 1

V m =π ( 123 )( 1760 rpm )

V m =1382.30 fpm
From table 17.1 (Machine Design by Faires),
13
Use Heavy , single ply with a thickness of inches
64

V m (fpm) Hp
¿
1200 2.5
1382.30 2.8646
1400 2.9
Based on ALBA

Hp
b=
Hp
( ¿ )C m C p C f

Where;

C m=correction factor for the type of drive ,

1.0 for electric motor (Table 17.2by Faires)

C p=correction factor for smaller pulley ,0.5 (Table 17.2 by Faires)

C f =correction factor for the environmental conditions ,

0.83 ¿)

1.5
b=
( 2.8646 ) ( 1.0 )( 0.5 )( 0.83 )

b ≈ 1.5 inches

Solving for the center distance

C=2 D2

C=2 ¿

C=12 inches

Solving for the belt length

π
L= ( D1 + D 2 ) +2 C+ ¿¿
2
 π
L= ¿
2

L=38∈¿

Solving for the maximum allowable stress

From table 9.1 (Machine Design 2: Flexible Power Transmitting Elements by Engr. J.
Francisco)

For rubber type belt

Su=4200 psi

N=12

From table 9.2 (Machine Design 2: Flexible Power Transmitting Elements by Engr. J.
Francisco)

For Joint Factor

Cemented by belt maker , JF=1.0

Su
st = JF
N

Where;

st =maximum allowable stress

Su=ultimate stress , psi

N=factor of safety

JF= joint factor

4200
st = (1.0 )
12

st =350 psi

Solving for the net belt tension

F 1=s t ( bt )

Where;
 F 1=tight side belt tension

F 2=slack side belt tension

b=belt width ,inches

t=belt thickness ,inc h

F 1=( 350 psi ) ¿

F 1=106.64 lb

33000 Hp
( F 1−F 2) = Vm

33000(1.5 Hp)
( 106.64 lb−F 2 )= 1382.30 fpm

F 2=70.83 lb

Solving for the belt tension ratio

F 1 106.64 lb
=
F 2 70.83 lb

F1
=1.51
F2

Design of sprocket

For Driving Sprocket:

number of teeth=1 6

From Table 9.2 (Machine Design 2: Roller Chain Sizes by Engr. J. Francisco)

5
Use , chain ¿50∧ pitch=
8

For driven sprocket

T 2=T 1
( )
N1
N2

Where;

T 1=number of teeth of smaller sprocket

 T 2=number of teeth of larger sprocket

T 2=16 ( 1760
880 )

T 2=32 teeth

T2
SR=
T1

32
SR=
16

SR=2 :1

Solving for the transmitted Hp through the roller chain

The required transmitted Hp was calculated using this equation below.

transmitted Hp=Hp(ns )

transmitted Hp=0.5(2)

transmitted Hp=1 Hp

Solving for the Design Hp of chain

From table 17.7 (Faires), N sf =1.4

D esign Hp=N sf ( Nominal Hp )

design Hp=1.4 ( 1 )

design Hp=1.4 Hp

Solving for the Rated Hp of chain

The required rated Hp was calculated using this equation (Roller-Bushing Impact)
below.

( )
1.5
100 T 1 0.8
Rated Hp=K r P
n1

Where;

P=chain pitch ,inches

 T 1=number of teeth of the smaller sprocket

n1=rpm of the smaller sprocket

K r =17 for chain 40 ¿240

nm
n1 =
SR

1760
n1 =
2

n1=880 rpm

( )()
1.5 0.8
100(16) 5
Rated Hp=17
880 8

Rated Hp=28.62 Hp

Considering a 1-strand chain since 1.4 Hp ¿28.62 Hp with a pitch of 0.625 inch

Solving for the sprocket pitch diameter

P
D 1=
sin
( )
180
T1

Where;

P= roller chain pitch, inch

T= number of teeth of sprocket

Assumptions: Chain number 50, P= 5/8 and T= 16 teeth

5/8
D 1=
sin ( )
180
16

D1 ≈ 4∈(101.6 mm)

P
D 2=
sin
( )
180
T2
 5
8
D 2=
sin
180
32( )
D2 ≈ 6∈(152.4 mm)

Design of Chain

Solving for the center distance

Use a center distance of 30 in (General rule in Machine Design 30P≤ C≤50P)

30 ( 58 )≤ C ≤ 50( 58 )
18.75 ≤C ≤31.25

30
C= =48 pitches
5/8

C=48 pitches

Solving for the length of chain

2
T 1+ T 2 ( T 2−T 1 )
L=2 C+ +
2 40 C

Where;

T 1=number of teeth for smaller sprocket

T 2=number of teeth for larger sprocket

C=center distance

L=length of chain , pitches

2
16+ 32 ( 32−16 )
L=2(48)+ +
2 40(40)

L=120.16 ≈ 120 pitches

Solving for the number of chains

L
Number of chains=
5 /8
 120
Number of chains=
5/8

Number of chains=192