DESIGN AND DEVELOPMENT OF COCONUT FIBER

EXTRACTION MACHINE
Y. Prashant, *C. Gopinath, Vignesh Ravichandran
Department of Design, M. S. Ramaiah School of Advanced Studies, Bangalore - 560 058
*Contact Author e-mail: gopinathc@msrsas.org

Abstract
The scope of this project was to design and develop a coconut fiber extraction machine for farmers and small scale coir
industries in India to provide an effective solution to the difficulties in existing process, reduce time and labour cost and to
develop a compact coconut fiber extraction machine which could be used in remote villages so that unutilized husks from
such areas could be tapped and fiber could be made available to the Coir Industry directly. This project was taken up to
develop a promotional strategy for a new innovation and generate public awareness regarding the availability of a coconut
fiber extraction machine in the market at a reasonable cost.
The project began with collection of information and data on user lifestyle and current process by which they perform
their job. The current difficulties were analyzed. Interviews were held with users. A comparative bench marking study was
done on similar processes used in other similar extraction processes. Along with this an ergonomic simulation was made to
understand the user difficulties and manufacturing methods to get an overview to provide solution to the user to suit their
requirement.
Concepts were generated keeping benchmarked product in view. Five concepts were generated with different functions
and operating processes for coconut fiber extraction machine. Final concept was selected by considering the users’
operating environment and maintenance, which could be used in small scale coir industries and in the farm sector.
Considering the users’ needs and buying capacity, a prototype was fabricated. This machine works with gear mechanism, in
which 2 barrels rotates in opposite direction to extract fiber from coconut. Cutting pins are inserted in indexed holes to
separate fiber and to give linear motion to coconut shell.
Validation was carried out with the user group and the feedback was positive. It was noticed that there is potential
market for this product. Further work could be carried in terms of aesthetics, material and weight reduction by adopting
advanced manufacturing techniques.
Key Words: Coconut, Coir, Fiber Extraction, Ergonomics, Industries
and also varied end uses. The traditional production of
Nomenclature fibers from the husks is a laborious and time consuming
F Force (N) process. After separating of the nut, the husks are
N Speed (RPM) processed by various retting techniques generally in
T Temperature (ºC) ponds of brackish waters (for three to six months) or in
kg Kilogram backwaters or lagoons. This requires 10-12 months of
mm Millimeter anaerobic (bacterial) fermentation by retting [3], the
t Tonne husks are softened and can be decorticated and the fiber
is extracted by beating, which is usually done by hand.
Abbreviations After hackling, washing and drying (in the shade) the
fibers are loosened manually and cleaned. The remaining
PDS Product Design Specification residual pith - which was previously considered a waste
QFD Quality Function Deployment problem - has recently found new profitable markets as a
peat moss substitute for horticultural production.
1. INTRODUCTION Traditional practices of this kind yield the highest quality
of (white) fiber for spinning and weaving. Retted fibers
The thickest and most resistant of all commercial from green husks are the most suitable fibers for dyeing
natural fibers, Coir is a coarse, short fiber extracted from and bleaching. For the production of more coarse brown
the outer shell of coconuts. India is the largest coir yarns shorter periods of retting may be applied. These
producer in the world accounting for more than 80 per find an increasing outlet in geo-textile applications.
cent of the total world production of coir fiber [1]. The Alternatively, mechanical processes using either de-
coir sector in India is very diverse and involves fibering or decorticating equipment process the husks
households, co-operatives, NGOs, manufacturers and after only five days of immersion in water tanks.
exporters. Coconuts are grown in more than 93 countries Crushing the husk in a breaker opens the fibers. By using
in the world and therefore there is considerable scope to revolving "drums" the coarse long fibers are separated
develop coir industry in further countries [2]. from the short woody parts and the pith. The stronger
fibers are washed, cleaned, dried, hackled and combed as
Fiber Extraction is the processes of fiber shown in Figure 1.
extraction are varied, and depend on the effectiveness of
the wet processing such as bleaching and dyeing of coir

SAS TECH Journal 64 Volume 13, Issue 1, April 2014

 allowing the lifting of the three posts Boure by letting out
the retractable nuts.

Fig. 1Traditional and Mechanical Fiber

Extractions [1]

2. LITERATURE REVIEW
Fig. 3 US Patent US 4708056 A [4]
2.1 Coconut
Coconut (Cocos) grows in more than 80 countries in
southern and south-western Africa, Latin America and
Asia. "Cocos" is old Spanish/Portuguese language and
means "grinning face", which refers to the facial
expressions at the "top" of the coconut's hard shell from
which it sprouts. Coconut palms have a total production
of coconut fruits of more than 60 million tons per year.
The Philippines is the largest producer followed by
Indonesia and India, but also Thailand, Malaysia, Sri
Lanka, Ghana, Ivory Coast, Tanzania and Brazil are
major producers of coconuts [3]. The parts of the coconut
are as shown in Figure 2.
Fig. 4 EP 0188949 A1 [5]
2.3 Summary of Literature review on Coconut Fiber
extraction machine
Literature study is carried out based on the existing
patents on coconut fiber extraction machine, study gives
opportunity to develop a compact coconut fiber
extraction machine which could be used in remote
villages so that unutilized husks from such areas could be
tapped and fiber could be made available to the Coir
Industry directly.

Fig. 2 Coconut and its parts [3]

3. DATA COLLECTION
2.2 Details of Patents
In competitive market Product design is one of the
Chandra Dinanath [4] A machine specifically essential to success the product, Product design involves
designed to remove the husks from the coconut fruit research and on existing designs or products, GEMBA
including a plurality of rollers rotating in opposite study to be conduct while doing product design more
directions effectively toward one another wherein each ever designer should understand the concepts and basic
roller includes a plurality of penetrating spikes sharpened requirements of the end user as well manufacturer also.
to penetrate and effectively engage the husk portion of
the coconut fruit (Figure 3). The interaction of the rollers 3.1 Coconut growing states in India
in combination with the gripping action of the spike Coconut production plays an important pole in the
serves to tear away the husk from the nut leaving the nut national economy of India. According to figures
intact. published in December 2009 by the Food and Agriculture
This invention relates to a machine for removing the Organization of the United Nations, India is the world's
husk from the nut portion of a coconut fruit in a manner third largest producer of coconuts, producing 10,894,000
which leaves the nut intact and insures that the husk is tons in 2009. Traditional areas of coconut cultivation are
separated from the fruit and from the dehusking machine Kerala (45.22%), TamilNadu (26.56%), Karnataka (10.8
itself. 5%), Andhra Pradesh (8.93%) and
also Goa, Orissa, West
Gilles Durand [5] A machine (Figure 4) for removing Bengal, Pondicherry, Maharashtra and the island
the fibrous casing, said fill, the coconut, characterized in territories of Lakshadweep and Andaman and Nicobar
that it comprises: a system of continuous operation does [6].
not require stopping for loading the direction of chains
pins guided nut which cause three rotary blades are
designed to cut the floss after its ternary system and

SAS TECH Journal 65 Volume 13, Issue 1, April 2014

3.2 Coir (Coconut Fiber)
COIR is a versatile natural fiber extracted from
mesocarp tissue, or husk of the coconut fruit, the general
process of which is shown in figure 5. Generally fiber is
of golden color when cleaned after removing from
coconut husk. Coir is the fibrous husk of the coconut
shell. Being tough and naturally resistant to seawater, the
coir protects the fruit enough to survive months floating Fig. 7 Automatic De-husker [6]
on ocean currents to be washed up on a sandy shore 3.5 Coconut Fiber Extraction Mills
where it may sprout and grow into a tree, if it has enough
fresh water, because all the other nutrients it needs have The husk is collected from the de-husked source and
been carried along with the seed. These characteristics transported to Fiber extraction mills / industries for
make the fibers quite useful in floor and outdoor mats, further processes. Husks are buried in pits dug along
aquarium filters, cordage and rope, and garden mulch. riverbanks, immersed in water-filled concrete tanks, or
The husk contains 20% to 30% fiber of varying length. suspended by nets in a river and weighted to keep them
submerged. The husks typically soak at least six months.
3.3 Flow Chart for Coir Fiber Extraction Process Based on the fiber quality and usage the fiber extraction
(Figure 5) processes are defined.
3.6 Market Study
Coir industry in India provides employment to the
tune of five lakhs people approximately of which 3.60
lakhs people belong to Kerala alone. About 80% of them
are women. The women are mostly engaged in fiber
extraction and spinning and men work in the coir
products sector. The industry concentrated in Kerala but
spread over in other States like Tamilnadu, Karnataka,
Orissa, Andhra Pradesh etc. The development of industry
is mainly concentrated in the area of coconut cultivation
and availability of coconut husk.
Production of coir fiber is of the order of 4.2 lakhs
metric tons and production of coir yarn is of the order of
2.8 lakhs. The coir products and rope account for 2.00
lakhs tones. The white coir fiber produced in Kerala is of
superior quality to brown coir fiber produced in other
States mainly Tamilnadu. The cost of white fiber is
double to the cost of brown fiber. In view of this
consumption of white fiber is declining. The total output
of coir and coir products in India estimated to be around
Rs.1500.00 crore including exports of Rs.350.00 crore.
Fig. 5 Flow Chart for Coir Fiber Extraction
Total cost of machineries and equipment used for
3.4 Coconut De-Husking Method De-fibering unit is as show in Table 1:
Mechanical De-husker Table 1. Market Study [7]
The user of mechanical De-husker method as in Figure 6:
Particulars Cost (in Rs.)
1. Farmers – A skilled husker can manually split
and peel about 2,000 coconuts per day Crusher (10 HP) 3,50,000
2. Households – 1-2 coconuts per day Soaking Tank 4,00,000
3. Hotels – 10-20 coconuts per day Defibering Machine (10 HP) 3,75,000
Revolving Screener including
90,000
motor (2 HP)
Turbo Double Cleaner (20 HP
3,00,000
and 15 HP)
Hydraulic bailing press (2 HP) 2,50,000

3.7 User Study

Fig. 6 Mechanical De-husker
User study is done by observations of coconut de-
Automatic De-husker husking in remote locations, villages, where farmers used
The main users of this type of application practices to de-husk the coconuts by manual. The Steel spear is the
are by Oil extracting, fertilizer and food industries, etc. tool used by farmers to de-husk the coconuts. An
with the use of coconuts in mass quantity every year. experienced worker can de-husk approximately 1000-
These machines can process 2,000 coconuts per hour as 1500 nuts per day with the use of this tool. Other than
shown in Figure 7. Steel spear, Lever operated de-husker is well reaching
user in rural market and it is used more often by farmers.

SAS TECH Journal 66 Volume 13, Issue 1, April 2014

Pedal operated De-husker is refined design of lever functions forming quality, and to deploy methods for
operated coconut de-husker and it is designed for the achieving the design quality into subsystems and
application of farmers. This will help farmers in reducing component parts, and ultimately to specific elements of
de-husking time and increase in productivity. It is the manufacturing process”.
portable in design and height of the de-husker can be
adjusted as per user requirement. The availability and
marketing of this product is not reaching user in rural
areas.
Coconuts in the husk are very bulky. The de-husked
fiber is being transported in trucks or carts to the fiber/
coir industries for the fiber extraction process.
3.8 Key Findings
With User observation and feedback by
Questionnaires and suggestion from user a few key
findings have been arrived.


The process needs a skilled labor


Difficult to get labor on time.
Fig. 9 Ergonomics Consideration [8]

Difficult to fix it in dry land.


Difficult to stand and De-husk for long time.


Difficult to transport
Direct fiber material can be supplied, instead of
raw husk.
3.9 Customer Voice
Collected feedbacks from user have been converted
to Technical voice through flowchart for understanding
its design factors & requirements are as shown in Figure
8.

Fig. 10 Ergonomics Consideration [8]

5.1 QFD Results
QFD are obtained from inputs from farmers
and coir industries as shown in Table 2. QFD house
results simple, functional, ergonomics are top priorities

 Machine should be compact

as shown in Figure 11.

 Functionality
 Safety
Fig. 8 Object Tree Mapping  Easy for assemble
 Easy for maintenance
 Low cost
 Good Ergonomics
4. ERGONOMIC CONSIDERATIONS
This is the Branch of Ergonomics that address and
deals with measurement of the human external body 6. PRODUCT DESIGN SPECIFICATIONS
dimension in static and dynamic condition. The (PDS)
Anthropometry points as shown in Figure 9 have been
considered for Coconut fiber extraction machine which Product Design Specification will give clear idea for
help in deciding its dimension (Figure 10). the designer to understand the required specification to
design the product. Based on the QFD results, which are
derived from the vendors and customer voices market
5. QUALITY FUNCTION DEPLOYMENT study, user study, PDS will be generated. Here are some
of the major criteria considered for product design
(QFD)
specification as shown in Table 3.
Quality function deployment (QFD) is a “method to
transform user demands into design quality, to deploy the

SAS TECH Journal 67 Volume 13, Issue 1, April 2014

 Table 2. Quality Function Deployment concepts are generated. For generating these concepts or
proposal ready considered all the points jotted out in
QFD and product design specification (PDS).
Five concepts generated with various factors which
meets the demands like functionality, safety and cost.
Final concept selected for the working prototype
manufacturing. This concept selected based on the dot
selection method.
7.1 Concept-1, Handle operated
Manual operated coconut fiber extraction machine is
considered as first concept, here handle is used to rotate,
for which gears assembled, one gear will give drive to
other gear, and Barrel rotates in opposite direction with
the help of these gears. Coconut with untapped husk is
placed in between barrels. Round coconut shell is
removed by hand after the operation and separated fiber
material is collected in sack below as shown in Figure 12.

Fig. 11 QFD Results

Table 3. Product Design Specification
SL. Description Specification
No
1 Name Coconut Fiber extraction Machine
2 Model CFEM-PKY001-2014
3 Mechanism Gears and Pulley with belt drive
4 Target Farmers or small scale Coir industry
Customer Fig. 12 Concept-1 Handle operated
5 De-Fiber Motor operated
Process 7.2 Concept-2, Handle operated
6 De-Fiber Automatic / Rotary handle operated /
Function Pedal operated / Spring actuated As name indicates in this concept sewing machine
7 Material EN-08 for Shaft, Stainless Steel for
type paddling mechanism is attached to the base of the
Cutting tips, Steel for Fabricated body machine, with the help padding drive is given to gears.
8 Manufacturing Machining, Indexing, Bending and Handle is also used to start rotation, one gear will give
Fabrication drive to other gear, and Barrel rotates in opposite
9 Safety Avoid sharp corners, Safety guards direction with the help of these gears. Coconut with
untapped husk is placed in between barrels. Round
10 Cost Approx. 12000/- INR
coconut shell is removed by hand after the operation and
11 Life of the 2-3 years separated fiber material is collected in sack below as
product shown in Figure 13.
12 Motor ¼ HP Single phase AC motor, heavy
Specification duty, 1440 RPM
13 Major Pulley 12” (12-B single)
diameter
14 Minor Pulley 2” (2-B single)
diameter
15 Pulley Ratio 1:6
16 Working RPM 240 RPM
17 Weight 55 KG
18 Production 100 coconuts per hour
Rate Fig. 13 Concept-2 Sewing Machine Type
7.3 Concept-3, Cycling Type Operated
7. CONCEPT GENERATIONS AND
SELECTION As name indicates in this concept cycling type
paddling mechanism is attached to the base of the
After all the necessary study and understanding the machine, with the help padding drive is given to gears.
customer needs, based on the major requirements Paddle with chain gear will give to drive to small chain

SAS TECH Journal 68 Volume 13, Issue 1, April 2014

gear sprocket, small chain gear sprocket is attached with 7.5 Concept-5, Motor Operated Type-2
large wheel, and large wheel will give drive to the
smaller wheel with the help of belt drive, which is Motor operated type-2 coconut fiber extraction
connected to gears. Barrel rotates in opposite direction machine, this is also same as concept-4, motor is attached
with the help of these gears. Coconut with untapped husk at the base, smaller pulley at the motor end gives drive
with the help V-belt to bigger pulley which is connected
is placed in between barrels. Round coconut shell is
removed by hand after the operation and separated fiber to gear. One gear will give drive to other gear, and Barrel
material is collected in sack below as shown in Figure 14. rotates in opposite direction with the help of these gears.
Coconut with untapped husk is fed from one end in
7.4 Concept-4, Motor Operated Type-1 between barrels and round coconut shell is moved
automatically towards other end and is collected in the
Motor operated type-1 coconut fiber extraction tub after the operation and separated fiber material is
machine, in this type motor is attached at the base, collected in sack below.
smaller pulley at the motor end gives drive with the help
V-belt to bigger pulley which is connected to gear. One In this concept cutting pins has been press fitted on
gear will give drive to other gear, and Barrel rotates in indexed hole on barrel surface as shown in figure 7.5,
opposite direction with the help of these gears. Coconut cutting pins helps to remove fiber and to give linear
with untapped husk is fed from one end in between motion to coconut shell to exit. Cutting pin indexing
barrels and round coconut shell is moved automatically angle and distance plays the major role in this type as
towards other end and is collected in the tub after the shown in Figure 16.
operation and separated fiber material is collected in sack
below. 7.6 Concept Selection (Pugh’s Chart)

In this concept helical serrated teeth is engraved / Concept selection is done based on Pugh’s chart,
Sugarcane crusher is used as a Datum for generating the
Brazed on barrel surface to remove fiber and to give
linear motion to coconut shell to exit. Helical serrated concepts, main selection criteria is functionality, Safety,
teeth play the major role in this type as shown in Figure Cost and the Reliability. Based on this criteria’s Concept-
15. 5 is selected for model making prototype as shown in
Table 3.

Fig. 14 Concept-3, Cycling Type

Helical Pressed Pins

Helical serrated teeth Fig. 16 Concept-5, Motor Operated Type-2

Table 3. Pugh’s Chart

Fig. 15 Concept-4, Motor Operated Type-1

SAS TECH Journal 69 Volume 13, Issue 1, April 2014

7.7 Final Concept
Reviewed each concept and analyzed
thoroughly. Based on weighted ranking method Motor
operated Type-2 concept is selected and finalized for
model making as shown in Figure 17.
7.8 Detail Deisgning
Assembly drawing and drawings for final concept is
done. All dimensions are in mm. below are the drawings
released related to the final concept of coconut fiber
extraction machine as shown in Figure 18.

8. MODEL MAKING
8.1 Raw Material and Standard Parts
Raw materials used for development of model as
shown in Figure18:
 Round Rod – Dia 63x600 and 650 length
 Rectangular – 200x175x20
 Sheet material for fabrication

Fig. 18 Detail Designing

Fig.17 Final Concept

Fig. 19 Raw Material
8.2 Machining and Assembly
8.4 Final Working Model
Selected the material, size and standard parts, and
identified the industry to proceed with machining. Final working model is as shown in Figure 22.
Various machining processes were carried out for
development of working prototype model for coconut
fiber extraction machine. Turning the round raw material 9. PRODUCT VALIDATION
and milling the rectangular work piece were main and
initial machining operation. Cleaned raw material and After manufacturing working model, product was
maintained the sizes accordingly as shown in Figure 19 validated by checking its features and some of the key
and assembly as shown in Figure 20. functions. Below are the some of the functions are
checked.
8.3 Fabrication and Painting
As a part of product feedback and validation,
Sheet material is fabricated to Stand or base of the product was validated. Complete demo of work model
machine with the tack welding. Latches and inches were and Coconut fiber extraction process with the help of
also welded and assembled for protection cover. For product was presented in front of few customers. They
partial maintenance in emergency condition latches and were very impressed with product and collecting process.
inches are provided for protection cover. Hand grinder is Below are the comments.

used to give finish for tack weld portions. After


fabrication of the product, it is taken for painting. Based Working length to increase


on the industrial design and modules studied, painting RPM reduction
color is selected for this product and painting is done as Pin pitch reduction
shown in Figure 21.

SAS TECH Journal 70 Volume 13, Issue 1, April 2014

 Fig. 22 Final Working Model
QFD and PDS helped in generating concepts.
Benchmarking of existing products is also carried in
existing Coir industries. Model making gave an
opportunity to learn model making techniques,
manufacturing process and difficulties involved during
this processes. It helped to understand about each and
every process that carried out from start to completion of
the prototype work model of coconut fiber extraction
machine.
Concepts were generated keeping benchmarked
Fig. 20 Machining and Assembly product. Five concepts are generated with different
function and operating process for coconut fiber
extraction machine. Final concept is selected by
considering the user’s operating environment and
method, which can be used in small scale coir industries
and in the farm. That means it should be easy to
maintain. Considering the user’s buying capacity a true
scaled product is fabricated.
10.2 Conclusions
Below are some of the conclusions based on new
derived process and new designed product & its

 Based on the Design concepts and

functions.

development, output of the product. This

product can de-fiber 100 coconuts per hour and
it will be good for Farmers and small scale coir

 Easy to assemble.
industries.

 Easy Maintenance
 About the market, this model is compact with
good range of productivity with low cost and
safety.
17.3 Recommendations for future work


RPM to be reduced to 120rpm
Fig. 21 Fabrication and Painting

Indexing pitch has to decrease


10. CONLUSIONS Length of the shaft can be increased


Pitch between the shaft can be reduced by 5mm
10.1 Summary

Hollow Shaft (tube) can be used.
The project comprises of research and user study. As we are offering this product with new
Literature study is carried out based on the existing design to farmers and small scale coir industry,
patents on coconut fiber extraction machine, and it is need to undergo further refinement.
observed that there are difficulties for remote village to
supply unutilized husks to coir industries directly. So 18. REFERENCES
there is a need to give solution to overcome their
difficulties and to arrive at solution, importance is given [1] MSME, Evaluation Study of Domestic Market
towards users operating environment and mainly towards Development Assistance Scheme implemented by
constrains like Safety, Function and reliability. Coir Board, http://msme.gov.in/Coir%20Board-

SAS TECH Journal 71 Volume 13, Issue 1, April 2014

 Impact-Domestic-Market-Assistance-Scheme.pdf.
Retrieved on15 th Jan. 2014.
[2] Food and Agricultural Organization of the United
Nation, www.fao.org/economic/futurefibres/
fibres/coir/en, Retrieved on 15th Jan. 2014.
[3] Palm Shells, Coconut Palms,
http://www.palmshells.com/cocoshells.html,
Retrieved on 15th Jan. 2014.
[4] Chandra Dinanath, Coconut dehusking machine, US
patent US4708056,
www.google.co.in/patents/US4708056, 28 Jan.
1987.
[5] Gilles Durand, Apparatus for Dehusking Coconuts,
EP0188949, Coconut breaking machine, US patent
US3605834,
http://www.google.co.in/patents/US3605834, 20th
Sep. 1971.
[6] Coconut Machines,
www.coconutmachine.com/index.php?mid=72,
Retrieved on 15th Jan. 2014.
[7] Coir Machines, Coir Fibre Extraction Machinery,
http://www.coirmachines.net/coir-fibre-extraction-
machinery.html, Retrieved on 15th Jan. 2014.
[8] Debkumar Chakrabarthi, India Anthropometric
Dimensions, NID, Ahmedabad: National Institute of
Design, pp100, 1997.

SAS TECH Journal 72 Volume 13, Issue 1, April 2014