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FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL AND PROCESSING
ENGINEERING

FINAL YEAR PROJECT REPORT

DESIGN AND CONSTRUCTION OF DOMESTIC SUGAR CANE JUICE

EXTRACTION MACHINE

By

KIGULI COLLINS

BUIUP/2014/191
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Ifl: 0701531642 0"7~23(l168

SUPERVISORS: Mr. MAKUMBJ THOMAS (main supervisor)

Mr. SSEMUKASA EDWARD (co-supervisor)

A Final Year Project Report submitted in partialfulfillment of the

requirement for the award of a Bachelor of Science in Agro-Processing
Engineering of Busitema University

May 2018
ABSTRACT

This project report describes the design, construction and fabrication of domestic sugar cane juice
extraction machine which is motorized. This study is to integrate the existing extraction machines
which are complex and high capacity crushers which cannot be afforded by small scale farmers
and to encourage people to start consuming sugar cane juice which is useful to human health with
few additional features. The reason of developing the design and construction domestic sugar cane
juice extraction machine able to extract clean sugarcane juice at household level which is beneficial
to human health, easy to operate and affordable to both small scale farmers and people going to
consume the health juice which can be operated in closed room. The motorized domestic sugar
juice extractor crushes and grinds the horizontally loaded sugarcane stem and presses the
macerated stem against the 3 crushing rollers to extract the juice from the wet bagasse. The
machine consists of the housing, 3 small shaft, ball bearings, keys, spur gears, 3grooved rollers,
hopper, chain and sprockets and electric geared motor etc. The performance tests carried out on
the developed machine showed an efficiency of70.7% and an actual throughput of72kg/br at
low peripheral speeds of rotating rol1ers at 0.5 mls.

KIGUU COLLINS BU/UP/2014/191

DECLARATION

I, KlGULI COLLINS, do hereby declare that this report compiled is my original work and to the
best of my knowledge, it has never been published and submitted for the award of any academic
qualification in any institution of higher learning/University before.

Signature ~ . .

KIGULI COLLINS

BUSITEMA UNIVERSITY LIBRAR\

{'l A~S No.- .. . .
ACCESS NO.:.£g'.Q~~t;f.- .

KIGULJ COLLINS BU/UP/2014/191 ii

APPROVAL

This proposal report has been submitted to the Department of Agro-Processing Engineering for
examination with approval from the following supervisors:

Mr. Makumbi Thomas (main supervisor)

Signature .

Date .

Mr. Ssemukasa Edward (co-supervisor)

Signature .

Date .

KIGULI COLLINS BU/UP/2014/191 iii

ACKNOWLEDGEMENT

My sincere thanks go to the Almighty God for giving me strength. good health, wisdom, and
protection throughout the preparation of this work.

Thanks goes to all my dear supervisors' Makkumbi Thomas, Dr. Wandera Catherine and Mr.
Ssemukasa Edward for their selfless guidance, knowledge and encouragement given to me
throughout the writing of this report.

Finally, I thank all my friends and fellow Agro Processing Engineers for all the support and advice
they have given me during my proposal report writing.

May the Almighty God reward you abundantly.

KIGULI COLUNS BUjUPj2014j191 v

 Table of contents

ABSTRACT i
DECLARA TJON ii
APPROV AL _ iii
DEDICATION iv
ACKNOWLEDGEMENT v

C~TERONE 1
1.0 Introduction 1
1.1Background I
1.2 Problem statement 3
1.3 Justification ................................................................................................................•.......... 3
1.4 Objectives _ 3
1.4.1 Main objectives 3
1.4.2 Specific objectives 3
1.5 Scope of the study 3
1.6 Purpose of the Study _ 4
CHAPTER TWO 5
LITERATURE REVIEW 5
2.0 Introduction 5
2.) Composition of sugarcane juice 5
2.1.1 Carbohydrates 5
2.1.2 Inorganic salts 6

2.2 Importance of sugarcane juice 7

2.3 Sugar cane juice extraction machine 8
2.3.1 Vending! manual sugar cane juice extraction machine 8
2.4 Working principle of sugar cane juice extraction 10
2.5 Sugar cane juice extraction method 10
2.6 Advantages and Disadvantages of Extraction machines II
2.7 Research study on juice extraction machine 12
2.7.1 RoUers 12
2.8 Review different Existing Designs of the Sugarcane Juice extraction Machines 12

KIGULI COLLINS BU/UP/2014/191 vi

..
 2.8.1 Development of a sugarcane juice extractor for small scale industries in Nigeria 12
2.8.2 Development of a Small-Scale Sugarcane Juice Extractor using a Screw Pressing System
in Nigeria ]6
2.8.3 THE TRAPICHE t6
2.8.4 Mechanical properties sugarcane at different sizes relevant to design 17
CHAPTER THREE 20
METHODOLOGY 20
3.0 Introduction 20
3.1 Determining physical characteristics of Sugarcane varieties at Different Sizes and Loadings
Relevant to Design 20
3.2 Design considerations 20
3.3 Material SeJection .................••............................................................................................ 21
3.4 Machine description 21
3.5 Machine working principle 21
3.6 Design of machine components 22
3.6.1 The hopper/inlet. 22
3.6.2 The housing and frame 23
3.6.3 Design of the Shaft 23
3.6.4 Shaft subjected to Fluctuating Loads 24
3.6.5 Design of the crushing rollers 25
3.6.6 Surface of the crushing rollers 25
3.6.7 Permissible Angle of Twist for Crusher 26
3.6.8 Determination of actual motor torque 27
3.6.9 Angular Velocity of Crushing Shaft 27
3.6.10 Gravimetric and Volumetric Capacity of the crushing chamber 27
3.6.11 The peripberaJ speed of the crushing rollers 27
3.6.12 Power required for the crushing rollers 28
3.6.13 Drive mechanism used 28
3.6.14 Design velocity of chain drive 28
3.6.15 Length and center distance of the chain 29
3.6.16 Design of the spur gears 30
3.6.] 7 Determination of Torsional Moment, M, 31

KJGUU COLLINS BU/UP/2014/191 vii

 3.6.18 Determination of maximum Bending Moment 31
3.6.19 Bending Stress 32
3.6.20 Bearing Section 32
3.6.21 FABRICATION OF MACHINE COMPONENTS 33
3.6.22 TESTING AND EVALUATION OF THE FABRICA TED PROTOTYPE 34
3.7 Economic analysis of the sugarcane extractor 35
3.7.1 Net present value (NPV) method 35
CHAP'fER FOUR 36
4 RESULTS AND DISCUSSIONS 36
4.1 Physical characteristics of sugarcane 36
4.2 Crushing / rupture of the sugarcane varieties 36
4.3 Designing different components of sugarcane peeling machine 36
4.3.1 Hopper design 36
4.3.2 Frame /housing 37
4.3.3 Design analysis 37
4.3.4 Design of the crushing rollers 37
4.3.5 Total pressure acting on the top roller 37
4.3.6 Surface of the crushing rollers 37
4.3.7 Clearance between the rollers 38
4.3.8 Permissible angle of twist for crusher 39
4.3.9 Power selection for motor 39
4.3.1 0 The peripheral speed of the crushing rollers 39
4.3.11 Design of Chain and sprocket Drive 40
4.3.12 Load exerted on the sprocket and chain _ 40
4.3.13 Design of the shafts 42
4.3.14 Torsional moment on the shaft (torque) " 44

4.3.15 Diameter of the shaft 44

4.3.16 Weight of the shaft _ 44

4.3.17 Design of the spur gears 45

4.3.18 Bearing selection 45
4.3.19 Key 46
4.4 Performance Evaluation of the Machine 48

KIGULI COLUNS BU/UP/2014/191 viii

 4.4.1 Testing of the prototype 48
4.4.2 Procedure followed during testing of the prototype 48
4.5 The economic Evaluation of the Prototype 50
CHAPTER FIVE: CONCLUSIONS AND RECOMMENDATIONS _ S3
5.1 Conclusions _ 53
5.2 Recommendations for further improvements 53
References 54
APPENDIX S5

KIGULI COLLINS BU/UP/2014/191 ix

List of Tables

TABLE 2. 1 ; showing the composition of sugarcane 5

TABLE 2. 2; showing Carbohydrate composition 6
TABLE 2.3 ; Mineral concentration 6
TABLE 2. 4 ; Comparison table of manual and modem machine 1)

TABLE 4. I ; diameter of sugarcane 36

TABLE 4. 2; Node length of the sugarcane stalk 36
TABLE 4. 3; Power rating of a simple roller chain 40
TABLE 4. 4; Characteristics of roller chains according to IS: 2403 - 1991 41
TABLE 4.5; Principal dimensions for radial ball bearings 45
TABLE 4.6; Test results of the machine 49
TABLE 4. 7; shows the budget for the total investment for the construction of the domestic
sugarcane juice extraction machine 5)
TABLE 4. 8; Results for economic analysis of the sugarcane juice extraction machine 52

KIGULI COLLINS BU/UP/2014/191 x

List of Figures

FIGURE 2 l;showing manual sugarcane vending machine 9

FIGURE 2 2;flow diagram of working principle of machine 10
FIGURE 2 3; showing flow diagram of extraction of cane 10
FIGURE 24; Pictorial View of the Sugarcane Juice Extractor 15
FIG URE 2 5 ; showing a wooden roller press sugar cane juice extraction machine 17
FIGURE 3 1 ; Conceptual diagram of sugarcane juice extractor 22
FIGURE 3 2 ; Showing Shaft layout 24
FIGURE 3 3 ; Showing Roller layout 26
FIGURE 3 4; showing the chain and sprocket. 28
FIGURE 3 5 ; showing length of chain and sprocket 29
FIGURE 3 6 ; showing a layout of spur gear 30
FIGURE 4. I; Result of different masses of sugarcane and time 50

KIGULJ COL.LlNSBU/UP/2014/191 xi
CHAPTER ONE
1.0 Introduction

This chapter presents the general information about the research design giving its background,
problem statement, significance, objectives,justification and scope of the study.

1.1 Background

Sugarcane is a tall tropical grass with a stout, jointed and fibrous stalk that looks similar to bamboo.
It of the genus (Saccharum spp) (D'Hont et 01,1996), thought to have evolved in the Burma -
China - India and later spread to other areas of the areas of the world. Sugarcane juice is derived
from the sugarcane plant, which is also the source of the majority of white table sugar and
processed sugar that we find in our foods. Sugarcane juice is not widely known about, but it is
particularly popular in countries that have a large production of sugarcane, such as Brazil, India.
and Thailand. It is consumed as a beverage in many places, especially where sugarcane is
commercially grown such as Southeast Asia, the Indian Subcontinent, Egypt, and LatinAmerica.

Sugarcane juice is obtained by crushing peeled sugar cane in a mill and is one of the main
precursors of rum (David, 2001).

The top benefits of sugarcane juice include lowering blood pressure, strengthening the bones,
reducing cholesterol, fighting infections, soothing stress and anxiety, boosting energy levels,
supporting kidney health. strengthening the immune system, protecting the skin, optimizing
digestion and managing diabetes, among others. Even though cane juice tastes very sweet and bas
high sugar content, it is good for diabetic patients. It contains natural sugar which has low glycemic
index that prevents steep rise in blood glucose levels in diabetics, so it can act as a substitute of
aerated drinks for them. However, people with Type-2 diabetes should consume it in moderation
and after consultation with their doctors (Munir et 0/., 2012). Sugarcane juice is considered an
alkaline forming food because of the high concentration of calcium, magnesium, potassium, iron,
and manganese in it Diseases like cancer cannot survive in an alkaline environment and that's
why studies show that it is effective in fighting against cancer, especially prostate and breast
cancer. In addition, as sugar cane juice boosts protein levels in the body, it helps in maintaining
the health of the kidney. Taken in a diluted form, with lime juice and coconut water, sugar cane

KIGULI COLLINS BU/UP/2014/191 1

References

Avenue, K. G. V, & Walford, S. (1996). Composition of cane juice. Proceedings of South African Sugar

Technologists Association, 70(Table 4), 265-266.

D'Hont, A., Grivet, L., Feldmann, P., Glaszmann, J.C., Rao, S. and Berding, N., 1996, characterisation

of the double genome structure of modem sugarcane cultivars (Saccharum spp.) by molecular
cytogeneticsMolecular and General Genetics MGG, 250(4), pp.405-413.

David SS, Goel K.(2001) Knowledge, attitude, and practice of sugarcane crushers towards hand injury
prevention strategies in India. Injury Prevention journal. 200 I; 7:329-330.

Hari AK (2012). Sugarcane juice extraction as job opportunity. Annadaata Agricultural journal India
2012; 44(3): 18-20.

Munir A, AshrafMA, Nasir A, Hensel 0, Iqbal M. (2012), Ergonomics and Occupational Health in Sugar

Industry of Pakistan. Pakistan Journal of Life and Social Sciences. 2012; 10(1):74-79.
Olaoye, J. O. (2011) Development of a sugarcane juice extractor for small scale industries. Journal of

Agricultural Tecbnology 1(4):931-944.

Ravelo, SB, Ramos, Eland Torres. BM(199Ib). Comparison of the main methods of predicting sugarcane

deterioration, int Sug J 93(95): 99-102

Morel du Boil, PG (1995). Cane deterioration - oligosaccharide formation and some processing
implications. Proc S Afr Sug Technol Ass 69: 146-151

Egan, BT and Rehbein, CA (1.963). Bacterial deterioration of mechanically harvested cut-up sugar cane
during storage over weekends. Proc Queensland Soc sug Cane Technol 30: 11-25.

McKaig, N and Fort, CA (1938). The influence of soil on the chemical composition of Louisiana
sugarcane juices. Proc int Soc Sug Cane Technol VI: 319-322.

Khurm, R.S. and Gupta, J .K. (2008), Machine design Update Edition, Euresia Publishing House (PVT)
RAM Nager, New Delhi

Hugot, E., and Jenkins, G. H. 1960. Handbook of Cane Sugar Engineering, American Elsevier, New York

Olaniyan A. M. and Babatunde O. O. (2011), Development of a Small-Scale Sugarcane Juice Extractor

using a Screw Pressing System. Advanced Materials Research Online: 2011-10-24 ISSN: 1662-8985,
VoL 367, pp 699-709

KIGULI COLLINS BU/UP/2014/191 54