INDUSTRIAL DESIGN AND MANUFACTURING OF A MANUAL

DRIVEN LOW COST BANANA / TAPIOCA / YAM SLICING MACHINE

Johnny Damian Anak Tawi

Bachelor of Engineering with Honours

(Mechanical and Manufacturing Engineering)

2009

Faculty of Engineering

i

UNIVERSITY MALAYSIA SARAWAK

BORANG PENGESAHAN STATUS TESIS

Judul: INDUSTRIAL DESIGN AND MANUFACTURING OF A MANUAL DRIVEN LOW COST

BANANA / TAPIOCA / YAM SLICING MACHINE

SESI PENGAJIAN : 2008/2009

Saya, JOHNNY DAMIAN ANAK TAWI

(HURUF BESAR)

mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti

Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Malaysia Sarawak.

2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan

untuk tujuan pengajian sahaja.

3. Membuat pendigitan untuk membanguankan Pangkalan Data Kandungan Tempatan.

4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan

tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

5. ** Sila tandakan (√) di kotak yang berkenaan.

SULIT (Mengandungi maklumat yand berdarjah keselamatan atau kepentingan Malaysia

seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di

mana penyelidikan dijalankan).

TIDAK TERHAD

Disahkan oleh

_________________________ ___________________________ (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat tetap: 1134-H, Lucky Tower, DR. MOHD OMAR BIN ABDULLAH

Jalan Tanjung Batu, Nama Penyelia

97000 Bintulu, Sarawak.

Tarikh: ____________________ Tarikh: ____________________

CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda

** Jika tesis ini SULIT dan TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai

SULIT dan TERHAD.

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APPROVAL SHEET

This final year project report, which entitle “Industrial Design and Manufacturing of a

Manual Driven Low Cost Banana / Tapioca / Yam Slicing Machine” was prepared and

submitted by Johnny Damian Anak Tawi as a partial fulfillment for the Bachelor Degree

of Engineering with Honours in Mechanical and Manufacturing Engineering is hereby

read and approved by

_______________________________________ ________________

DR. MOHAMMAD OMAR BIN ABDULLAH Date

(Supervisor)

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INDUSTRIAL DESIGN AND MANUFACTURING OF A MANUAL

DRIVEN LOW COST BANANA / TAPIOCA / YAM SLICING

MACHINE

JOHNNY DAMIAN ANAK TAWI

A dissertation submitted to

Faculty of Engineering, Universiti Malaysia Sarawak

in partial fulfillment of the requirement for the

Bachelor Degree of Engineering with Honours

(Mechanical and Manufacturing Engineering)

2009

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“Dedicated to all my loved ones who always being there for me, and

continuously praying for me, that never give up hope on me.”

Thanks all.

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ACKNOWLEDGEMENT

First and foremost I would like to thank the Most High for all the uncountable

blessings the He poured out in my life. Also, to my project supervisor Dr. Mohammad

Omar bin Abdullah for his guidance and support in this project, which enable the project

to run smoothly. His teaching and his encouragement had broadened my perspective

towards the engineering world.

Besides that, I would also like to express gratitude to Universiti Malaysia Sarawak,

all lecturers from Faculty of Engineering, supporting staffs and to all my friends who

had also helped me either directly or indirectly in gathering information and opinion

provision.

Lastly, my "endless" thanks to my family for their love that have kept me going

and never giving up hope in me.

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ABSTRAK

Kegawatan ekonomi merupakan salah satu masalah utama yang mengahantui umat

dunia. Ketidakstabilan ekonomi ini turut menyebabkan prestasi industri menurun

sehingga turut ada syarikat yang muflis terutamanya industri kecil dan sederhana. Ini

turut menyebabkan kenaikan harga makanan serta barang keperluan harian yang

terdapat di pasaran.firm. Situasi seperti ini membuatkan kita untuk megetatkan lagi

perbelajaan harian dan pada masa yang sama, perkara ini turut mempengaruhi kesihatan

serta cara hidup samada tanpa anda sedari. Oleh itu, banyak kini yang telah beralih

kepada masakan di rumah daripada makan di luar ataupun mengambil makanan ringan

yang kurang menyihatkan.

Oleh sebab itu, tujuan utama projek ini dijalankan adalah untuk merekabentuk

sebuah mesin penghiris makanan seperti pisang, ubi keladi atau ubi kayu. Kebanyakan

daripada pemproses makanan yang ada di pasaran adalah diimport serta berkos tinggi.

Selain dari kos rendah, mesin yang direkabentuk ini akan digunakan untuk buah-buahan

dan sayur-sayuran. Ini turut menggalakkan budaya makan makanan yang sihat di

kalangan penduduk serta memakan kos yang jauh lebih rendah.

Projek ini bermula dengan mengenalpasti masalah yang dihadapi. Selepas itu,

kajian mengenai alat pemproses makanan yang telah sedia ada serta makanan yang

berkaitan dengan penggunaan mesin dijalankan. Selepas itu barulah proses

merekabentuk berdasarkan konsep yang diambil dari pernyataan masalah. Setelah

rekabentuk protaip selesai dibuat, proses analisis ramalan kemapuan mesin tersebut

dijalankan berdasarkan perbandingan dengan mesin-mesin pemotong yang sedia ada di

pasaran. Setelah semuanya selesai, barulah proses perbincangan serta cadangan

dijalankan.

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ABSTRACT

The economic downturn is among the worst enemy to all of mankind. The unstable

economy performance also causing industries to collapse especially the low and medium

ranged firm. This would much affect the increment of food prices and all groceries that

available in the market. This would tighten up our budget and might as well affect our

health and lifestyle indirectly. Many has turn to home-cook meals instead of going to

food stall and putting an extra ringgit on packet food which not so healthy.

Hence, the purpose of this project is to design of a manual driven low cost banana,

yam, or tapioca slicing machine. Most of the food processor available in the market is

imported and costly as well. For this project, this food slicing machine will be able to be

much applied for fresh food such as fruits and vegetables. This would create a good

eating habit and cost less compared to fast food.

The development for this machine begins by indentifying problems that occurs.

Then, studies on the food processor available in the market as well foods which are

directly related are next in line. Then only the machine is design based on the concept

adapted from the problems. Next, careful material selection process begins in order to

make sure the material used is safe for user. Next process which is comparison of the

forcasted performance between various types of slicing are done and followed by the

discussion and recommendation process.

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CONTENTS

Page

Front cover i

Borang Pengesahan Status Tesis ii

Approval Sheet iii

Title Page iv

Dedication v

Acknowledgement vi

Abstract vii

Abstrak viii

Contents ix

List of Figures xi

List of Tables & Charts xii

CHAPTER 1: INTRODUCTION

1.0 Introduction 1

1.1 Chips Production 1

1.2 Problem Statements 3

1.3 Project Primary Aims and Objectives 3

1.4 Following Chapter Overview 4

CHAPTER 2: LITERATURE REVIEW

2.0 Introduction 5

2.1 Yam 5

2.2 Banana 6

2.3 Tapioca 8

2.4 Types of Cutting Machine 10

2.4.1 Design and Construction of An Affordable Banana and

Yam Cutting Machine for Making Snacks. 10

Improvement of Banana and Yam Cutting Machine for

Village Industry Application 11

2.4.2 Banana Slicer 13

2.4.3 Multipurpose Slicer 14

2.5 Operations of Cutting and Slicing Machine 15

2.5.1 Required Knowledge of Cutting and Slicing Machine for

Operators and Tenders 15

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2.5.2 Cutting and Slicing Skills 15

2.5.3 Cutting and Slicing Activities 16

CHAPTER 3: METHODOLOGY

3.0 Introduction 18

3.1 Project Flow 18

3.2 Machine Design 19

3.2.1 Machine Components and Specifications 19

3.2.2 Design Software 20

3.3 Material selection 21

3.3.1 Aluminum 22

3.3.2 Stainless Steel 22

3.3.3 Mild Steel 23

3.4 Selection of Manufacturing Process 23

3.5 Fabrication 23

3.5.1 Milling Process 24

3.5.2 Lathe Process 24

3.5.3 Joining Process 25

3.5.4 Painting/Coating 26

3.5.5 Assembly 26

CHAPTER 4.0: RESULTS AND DISCUSSIONS

4.0 Introduction 28

4.1 Slicing Machine 29

4.1.1 Machine Working Principle 29

4.2 Discussion 32

CHAPTER 5.0: CONCLUSION AND RECOMMENDATIONS

5.0 Introduction 34

5.1 Achievements 34

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5.2 Conclusions 35

5.3 Recommendations 36

5.3.1 The Material 36

5.3.2 Machine Control 36

5.3.3 Use of CNC Machine 37

References 38

Appendix I (Technical Drawing) 40

Appendix II (Three Dimensional Drawing) 45

Appendix III (Basic Components in the Machine) 48

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LIST OF FIGURES

page

Figure 1.1 Banana Chips 2

Figure 1.2 Banana Chips 2

Figure 2.1 Banana 7

Figure 2.2 Cassava Root 9

Figure 2.3 Banana and Yam Cutting Machine 11

Figure 2.4 Improved Banana and Yam Cutting Machine 12

Figure 2.5 Banana Slicer Developed by Mr. Augustin. 13

Figure 2.6 Multi-Purpose Slicer. 14

Figure 3.1 Designing in the CATIA Environment 21

Figure 4.1 The Slicing Machine in Isometric Layout. 29

Figure 4.2 Insert banana, yam, or tapioca into feeding chute. 30

Figure 4.3 Swing the pedal to slice the food. 30

Figure 4.4 Cutting wheel slice the food. 31

Figure 4.5 Sliced food comes out from delivery chute. 31

Figure 4.6 The Sharp Blade of the Multi-Purpose Slicer. 32

xii

LIST OF TABLES & CHARTS

page

Chart 3.1: Project flow chart. 19

Table 4.1: Comparison between Few Kinds of Food Processing Equipment. 31

1

CHAPTER 1

INTRODUCTION

1.0 Introduction

In this chapter, the basic information on banana, tapioca, and yam snack production

are introduce. Banana, tapioca, and yam are foods that are directly related to this project

whereby they will be the groups of food that will be process by using this machine.

Also, there will be a brief information on chips production that as well be discussed.

1.1 Chips Production

Fried food products are very popular among the citizen both locally and globally.

Banana, tapioca, and yam are among of the few types of fruits and vegetables that

important in the local chips snack industry. They are considered as a rich source of

energy producing food. It is prepared and processed into various types of forms

especially deep fried chips. Major share of banana and yam production in the country is

consumed in the fresh form and only small amount of it is exported.

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Figure 1.1: Banana Chips

Figure 1.2: Banana Chips

Chips are the age-old snacks and fast foods in Malaysia. Figure above shows the

fried banana chips. They are consumed as snack food which very healthy and taste great

as well.

3

1.2 Problem Statements

As for the increase in the market demand for snack type of food, people nowadays

also keen to fry their own chips even at their own kitchen. Harmful additives such as

Monosodium Glutamate (MSG) are much added to the food to enhance the taste and to

increase its’ lifetime. Therefore, home cook chips is healthier compare to the packed

chips in terms of freshness and nutrients. This will make the chip slicing machine very

useful. Hence, the use of chips slicing machines that are affordable, easily operated will

be used at large. Unfortunately, local industry did not produce much of this particular

kind of slicing machine. Most of the slicing machine that available in the market usually

imported and surely be expensive.

1.3 Project Primary Aims and Objectives

The main objective of this project is to come out with a new design of a slicing

machine for banana, tapioca or yam that will be manually operated. The objective also

covers that the project to able produces a machine with minimum amount of cost but

with optimal performance. The unit enables the convenience to produce chips by only

hand driven and directly will reduce the amount of home electricity usage and as well

save the energy consumption. The size of the machine that will produce is portable that

enable it to be taken anywhere it is needed for.

The cutting machine constructed is designed to cut whole raw of bananas, tapiocas

and yams into consistent thickness slices suitable for frying in the form of chip. The

design also provides good safety measure to keep the operator away from the sharp

elements of the cutter when it is being operated. Moreover, this machine can be used to

cut various types of food other than yam, tapioca and banana, foods like carrot,

cucumber and potato would also be great fried chips and snacks.

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1.4 Following Chapter Overview

The second chapter is literature review. In this chapter we will overviews the

different types of cutting machine. The cutting machine whether manual or electrically

powered with different cutting method are in order to increase the production rate.

Moreover, this chapter also overview general operations and skills required for different

types of cutting machine.

The third chapter is methodology. This chapter briefly describes all methodology

has been used to complete this particular project starting from the concept to the

finished product. This will give the reader an overall understanding of all steps involves

in the process to carry out this project on machine development.

Chapter Four is result and discussion. This chapter represents the result which

gained from the design and analysis of the slicing machine. This chapter will also

discuss the comparison of the slicing machine with other types of food processing

equipments. The results obtained from the analysis and used as a guideline to design for

the future research.

The last chapter is conclusion and recommendation for future work. This chapter

represents the conclusion, highlight the finding from the testing on the machine and

overview some possible relevant in recommendation for future work and as a guideline

and continuous study to improve the design of the machine. The chapter followed by

summarizes the major achievement of this research work and highlight the principle

difficulties encountered during the research process. The chapter also concludes with

some suggestions about possible future enhancement of this work.

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CHAPTER 2

LITERATURE REVIEW

2.0 Introduction

The development of manually operated slicing machine is necessary in order to

produce machine that is portable and at the same time high in performance compare to

its’ size. Industries nowadays are trying hard to improve machine efficiencies to

maximize outputs. The higher the efficiencies the more amounts of energy and cost are

reduced. Hence, this will directly increase the profit. But, for manual machine wise, the

higher the efficiency, the easier the machine would be operated for it requires less

energy. Existing machine may need to be improved in terms of durability, efficiency,

weight, speed or cost (Burr and Cheantham, 1995). This chapter will briefly discuss on

foods which are directly related to the project and overview different types of cutting

machine; manual or electrically powered with different cutting method in order to

increase the production rate.

2.1 Yam

Yam is the common name for members of the genus Dioscorea (family

Dioscoveacoae). They are more than 600 species of yam. Certain species are planted for

the food consumption of their starchy tubers in Africa, Asia, Latin America and

Oceania. Potatoes and sweet potatoes are examples of plants that been consume in

similar manner as yam. There are hundreds varieties among the cultivated species

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(PFAF, 1997). The yam has a rough skin which is difficult to peel, but which softens

after heating. Yam skins vary in color from dark brown to light pink. The majority of

the yam is composed of a much softer substance known as the flesh within. This

substance ranges in color from white to bright orange in ripe yams.

Yam is a very easily grown plant that succeeds in most fertile well-drained soils

(PFAF, 1997). Position in full sun is preferred, though it will also grow in semi-shade

condition. The root edible and can grow up to 1 meter long and weight 2 kilos or more if

it is grown in a fertile deep soil. Once when get it out, the root has a very nice flavor

with a floury texture when baked, but it is not as tasty as a sweet potato. It makes an

excellent staple food and, since yams are now becoming a more common food in

Malaysia, it has a very good potential as a commercial crop here. The tubers can be

boiled, baked, fried, mashed, grated and added to soups. They store well and for a long

time. They contain about 20% starch. 75% water, 0.1% vitamin B1, 10 - 15 mg %

vitamin C (PFAF, 1997).

2.2 Banana

Banana is one of the most common and widely grown fruit crops around the world.

Banana is well adapted to well-drained, loamy, soil that is rich in organic matter

(Banana.com, 1995). Areas with an average rainfall of 4000 millimeters (mm) a year are

ideal sites for a banana plantation. A temperature between 27 to 30 degrees Celsius is

most favorable for it to grow. Banana grows at sea level up to 1,800 meters altitude. It is

susceptible to root rot when exposed to too much water. The true origin of Bananas, one

of the world's most popular fruit, is found in the region of Malaysia California Rare

(Fruit Growers, 1996). By way of curious visitors, bananas traveled from Malaysia to all

around the world. Banana fruit is normally consumed fresh. It also has various uses. The

ripe fruit is pureed, candied, and preserved in various forms when not eaten fresh. Its

extract is used in the manufacture of catsup, vinegar, and wine. The unripe fruit is

powdered and chipped.

7

Figure 2.1: Banana

In rural areas, the young leaves are pounded to suppress bleeding and treat wounds

(Morton, 2001). The leaves are also widely used as packing materials for fruits and

vegetables in market centers. Banana fiber is manufactured into rope, sack, and mat.

Sheets of paper and paperboards are also made from banana peel. Banana blossom is

exported dried. Filipino housewives use it in special dishes. The ripe banana is utilized

in a multitude of ways in the human diet from simply being peeled and eaten out of-

hand to being sliced and served in fruit cups and salads, sandwiches, custards and

gelatins; being mashed and incorporated into ice cream, bread, muffins, and cream pies.

Ripe bananas are often sliced lengthwise, baked or broiled, and served (perhaps with a

garnish of brown sugar or chopped peanuts) as an accompaniment for ham or other

meats.

Ripe bananas may be thinly sliced and cooked with lemon juice and sugar to make

jam or sauce, stirring frequently during 20 or 30 minutes until the mixture jells. Whole,

peeled bananas can be spiced by adding them to a mixture of vinegar, sugar, cloves and

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cinnamon which has boiled long enough to become thick, and then letting them cook for

2 minutes. Green plantains are popular sliced crosswise, fried until partially cooked,

pressed into a thickness of 1/2 in (1.25 cm), and fried in deep fat till crisp. The product

is called 'tostones" and somewhat resembles French-fried potatoes.

Commercial production and marketing of fried green plantain and banana chips has

been increasing in various parts of the world over the past 25 years and these products

are commonly found in retail groceries alongside potato chips and other snack foods.

Because of their impressive potassium content, bananas are highly recommended by

doctors for patients whose potassium is low. One large banana, about 9 inches in length,

packs 602 mg of potassium and only carries 140 calories (Banana.com, 1995). That

same large banana even has 2 grams of protein and 4 grams of fiber. No wonder the

banana was considered an important food to boost the health of malnourished children.

Those reducing sodium in their diets can't go wrong with a banana with its mere 2 mgs

of sodium. For the carbohydrate counters there are 36 grams of carbohydrates in a large

banana. Clearly banana is among the healthiest of fruits. The plantain, when cooked,

rates slightly higher on the nutritional scale in vitamins and minerals but similar to the

banana in protein and fiber content.

2.3 Tapioca

Tapioca is a flavourless starchy ingredient, or fecula, produced from treated and

dried cassava (manioc) root and used in cooking (Wikipedia, 2008). Tapioca is a staple

food in some regions and is used worldwide as a thickening agent, principally in foods.

Tapioca is gluten free, and nearly protein free. The commercial form of tapioca most

familiar to many people is pearl tapioca. Tapioca is a word derived from the Tupi

language of Brazil (from tipi'óka). This refers to the process through which cassava

(Manihot esculenta) is made edible.

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Figure 2.2: Cassava Root

Pearl tapioca is a common ingredient in Southeast Asian desserts such as kolak, in

tapioca pudding, and in sweet drinks such as bubble tea and taho, where they provide a

chewy contrast to the sweetness of the drink. Small pearls are preferred for use in

puddings; large pearls are preferred for use in drinks. These large pearls most often are

brown, not white, but are available in a wide variety of pastel colors.

In Asia, tapioca pearls are used and can be mistaken for sago pearls also known as

sabudana (Pearl Sago) also called 'Seeme Akki' in Kannada. Also the pearls (sabudana)

are used to make snacks. In Tamil Nadu (India), a large number of tapioca industries are

found in Attur Taluk, Salem District. Salem City has a marketing center for the sago

(known as "Javvarisi"). In Indian cuisine, the granular preparation of cassava starch is

known as tapioca. It can also be used to thicken puddings.

Purchased tapioca comprises many white spheres each about 2 mm in diameters

(although larger grain sizes are available). These are not seeds, but rather reconstituted

processed root. The processing concept is akin to the way that wheat is turned into pasta.

These tapioca pearls are made mostly of tapioca starch, which comes from tapioca, or

bitter cassava plant. In other parts of the world, the bitter cassava plant may be called

“mandioca”, “aipim”, “macaxeira”, “boba”, or “yuca”.

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2.4 Different Types of Cutting Machine

There are several types of food cutting machine or slicing machine in the market.

Each type of cutting machine has different cutting principle but the purpose is the same

which is to cut or slice the food into small pieces for further process.

2.4.1 Banana and Yam Cutting Machine

Mr. Kuan Voon Hiong (2007) has designed and constructed an affordable banana

and yam cutting machine for making snacks. Working principle of the machine is very

simple; it is powered by electric motor. The power generated by motor is transfer to

cutting wheel through belting system.

The cutting blades have two cutting edges, which means when the cutting blade

made one cycle, it will cut eight slices of chips. The machine has four holes of the upper

chute. The upper chute is where the raw material such as banana, tapioca or yam will be

placed and feed to be sliced.

The material fed through upper feeder will dropdown to the cutting blade by

gravity and the material will slice into small piece and drop to delivery chute. Delivery

chute is the place to collect pieces of the sliced product for further process.

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Figure 2.3: Banana and Yam Cutting Machine.

[Extracted from Kuan Voon Hiong (2007). Design and Construction of an Affordable

Banana and Yam Cutting Machine for Making Snacks. Thesis B.Eng Hons, UNIMAS.]

The local farmer that used the machine in the snack production, the machine

performs well (Kadir, 2007). The machine can slices approximately 26250 slices of

bananas and 22720 slices of yams just one hour. He added, if the machine is compared

to the manual slicer, the machine cutting speed is estimated to be about 275% - 425%

faster depends on the type of material to be cut. Meaning to say, when it is use to

produce chips, the production rate will increase by 275% - 425% if the cutting speed is

properly set to maximum.

Mr. Ronny Friday (2008) has come out the improved design of the banana and yam

cutting machine. The working principle is more or less the same with the previous

version which is done by Mr. Kuan Voon Hiong.

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Figure 2.4: Improved Banana and Yam Cutting Machine.

[Extracted from Ronny Friday (2008). Improvement of Banana and Yam Cutting

Machine for Village Industry Application. Thesis B.Eng Hons, UNIMAS.]

The improved machine has four upper feeders with two different sizes that allow

the diameter of the raw material that up to 80mm. Also, the new improved cutting wheel

has three cutting blades that enable the machine to cut twelve slices of product per

rotation compare to only eight slices per cutting wheel rotation of the rotation of the

previous machine. These two factors directly increase the rate of chips production of the

new machine. The new improved machine is able to produce 660 slices of banana chips

per minute compared to the previous machine that produce 437 slices per minute. For

yam slicing, this improved machine produce 540 slices per minute compared to the

previous machine that slices 379 slices per minute. It is estimated an increase of 29% -

34% in terms of production rate. This enables the farmer to make higher rate in their

chips production.

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2.4.2 Banana Slicer

Mr. Augustin (2001) from India has designed and developed a typical banana

slicer. He works as a teacher and do farming as well. He has a deep knowledge about the

agricultural products. Mr. Augustin has developed a device which was practical for

bakery and for chip processing which is the banana slicer.

Figure 2.5: Banana Slicer Developed by Mr. Augustin.

[Extracted from http://www.nifindia.org/bananaslice.html]

This banana slicer is a device that has five cylinders to put bananas and it is

working manually by operator. With the help of a blade set attached on a round plate,

the banana can be sliced. There is a holder having spring-action in the cylinders to keep

the banana vertically in it. In order to keep the banana tightly in the cylinders a spring

load system is attached, which operates easily. There is a mechanism to reduce or

enlarge the thickness of the piece in the machines itself.

The machine has a very high performance that it can slices 1200 pieces of banana

in one minute. The operation of the machine is simple. The operator just has to raise the

14

spring load system and the bananas are inserted into the cylinders. Spring load system is

then released and the handle of the machine is rotated. The bananas are sliced as the

blade rotates.

2.4.3 Multipurpose Slicer/Cutter

An existing blade that consists of a hand-held, hand-operated blade is

commercially available. Multi-purpose slicer also called manual slicer; it is widely used

in Malaysia. Home usage of multi-purpose slicer/cutter operated by manual is only can

used as a kitchen gadget. The multi-purpose slicer is a versatile classic that enjoys many

uses, perhaps because the multi-purpose slicer remains as one of the safest, easiest and

most simple kitchen items in use. However, while an excellent multi-purpose slicer can

be used for all sorts of vegetables like onions, yam, zucchinis, carrots, turnips,

cucumbers, radishes, squash etc., the traditional use of a multi-purpose slicer is to make

everybody’s favorite, “French fries".

Figure 2.6: Multi-Purpose Slicer.

15

2.5 Operation of Cutting and Slicing Machine

There are several types of cutting and slicing machine, generally the working

principle of every machine actually quite similar. Operate or tend machines to cut or

slice any of a wide variety of products or materials, such as banana, yam, tobacco, food,

paper, roofing slate, glass, stone, rubber, cork, and insulating material.

2.5.1 Required Knowledge of Cutting and Slicing Machine for Operators and

Tenders

Operator for any cutting and slicing machine must have knowledge of production

and processing, mechanical knowledge and design knowledge (careerplanner.com,

2004). Production and processing knowledge is of raw materials, production processes,

quality control, costs, and other techniques for maximizing the effective manufacture

and distribution of goods. Mechanical knowledge is of machines and tools; including

their designs, uses, repair, and maintenance. Design knowledge is of design techniques,

tools, and principles involved in production of precision technical plans, blueprints,

drawings, and models.

2.5.2 Cutting and Slicing Skills

To operate the cutting or slicing machine, the operator must possess the basic

cutting and slicing skills. These skills include operation and control, operation

monitoring, installation and quality control analysis (careerplanner.com, 2004). Also,

operation and control in charged on controlling operations of equipment or systems. The

operator must be able to control and familiar with all of the cutting and slicing machine

equipments. Operation Monitoring involve watching gauges, dials, or other indicators to

make sure a machine is working properly, installation involve Installing equipment,

machines, wiring, or programs to meet specifications and quality control analysis is

16

conducting tests and inspections of products, services, or processes to evaluate quality

or performance.

2.5.3 Cutting and Slicing Activities

The knowledge of general cutting and slicing activities and cutting principle can

help to standardize cutting equipment design. The basic cutting and slicing process are:

1. Controlling machines and processes - Using either control mechanisms or direct

physical activity to operate machines or processes.

2. Handling and moving objects - Using hands and arms in handling, installing,

positioning, and moving materials, and manipulating things.

3. Performing general physical activities - Performing physical activities that require

considerable use of arms and legs to accomplish the cutting activities.

4. Monitor processes, materials, or surroundings - Monitoring and reviewing

information from materials, events, or the environment, to detect or assess problems.

5. Documenting/recording information - Entering, transcribing, recording, storing, or

maintaining information in written or electronic/magnetic form.

6. Equipment, structures, or material inspecting - Inspect the machines equipment,

structures, or materials to identify the cause of errors or other problems or defects.

7. Repairing and maintaining mechanical equipment - Besides operating the machine,

operator must know a little about machine servicing, repairing, adjusting, and testing

machines, devices, moving parts, and equipment that operate primarily on the basis of

mechanical and also electrical principles.

17

8. Evaluating information to determine compliance with standards – Using relevant

information and individual judgment to determine whether events or processes comply

with laws, regulations, or standards.

18

CHAPTER 3

METHODOLOGY

3.0 Introduction

This chapter briefly describes the methodology that has been used to complete this

particular project that begins from the concept adapted through the primary aims for the

product initially. This will give the reader an overall understanding of the processes

involves in the process to complete this project.

3.1 Project Flow

The objective of this project is to design a new hand driven slicing machine for

home use. The concept is developed based on the ergonomics and easy handling of the

equipment. The following steps are designing the machine, material selection, machine

fabrication, performance analysis. The last process is discussion and recommendation.

19

Chart 3.1: Project Flow Chart.

3.2 Machine Design

3.2.1 Machine Components and specifications

Feeding chute - The first part is at the top of the machine. This feeding chute which is so

called upper feeder, it is used to feed banana, yam or tapioca into the machine

manually, the upper feeder has 3 holes, this means the machine can cut three pieces at

one time of banana producing nine slices per rotation.

Delivery chute - use to feed sliced bananas from slicer into the compartment. At this

stage, the orientation of the sliced product is not important as long as sliced

bananas/yams can feed into compartment.

problem statement

study on various types of

cutting/slicing machine

machine design

material selection

fabrication

machine test & analysis

discussion & recomendation

20

Cutting wheel - The cutting wheel or slicer that is made of aluminum/stainless steel and

the cutter blade is made of stainless steel that heat treated so that the hardness of the

blade is concentrated at cutting edge. The cutter blade is adjustable; hence you can

determine the thickness of the slices produce. The blade is also replaceable the blade to

sharpen the cutting edge as desired.

Repair and maintenance - Provisions is made to allow for service and replacement of the

cutting blade and bearing. Mechanical fastener method is used so that it is easy for the

components to be disassembled for maintenance purpose in order to ensure the machine

performance.

3.2.2 Design Software

Before any fabrication and assembly of a product, all the parameter and dimension

of the machine must be determined beforehand by producing design for the project. This

process is done by using CATIA fifth version release fourteenth software. C-A-T-I-A

stands for Creative Advance Three dimensional Interactive Application. This software is

developed by Dassault Systèmes. CATIA is one of the most advance software available

that have the capability to design and run simulation test on the product. This software is

widely used in the design and manufacturing industry and even Formula One (F1) race

cars. To date, nearly all of the products that been used in our daily life are designed on

computers.

21

Figure 3.1: Designing in the CATIA Environment.

For this project, CATIA software is the software used for the technical drawing

application. Three dimensional and two dimensional drawing are both implemented by

using CATIA. Each of the parts is draw and then assembled together as one machine.

Each drawing can be viewed interchangeably from three dimensional to two

dimensional.

3.3 Material Selection

Material selection is crucially important process in terms of design and fabrication.

Corrosion is one of the main criteria that need to be taken into consideration when it

comes into choosing the right material for food processing industry. The proper material

chose will not only able to avoid corrosion problem but also able reduce the

development cost.

22

Furthermore, if raw or processed materials or manufactured components are not

available in the desired shapes, dimensions, and quantities, substitutes and/or additional

processing will be required, and they can contribute significantly to product cost. Proper

selection of material also can reduce product failure or increase product life time.

Working environment also important issues are took into consideration during material

selection.

3.3.1 Aluminum

The outer parts of the slicing machine are made of aluminum. One of the main

reasons why aluminum is selected as a main material is corrosion and chemical reaction

resistance.

Coating protection of the surface is not necessary for the aluminum has a good

surface. When the cutting machine is used to cut wet food like banana and yam nor

cucumber, corrosion will occur on the metal surface rapidly. If the corrosive particle

added to the food, it will cause danger to our health. This gives another reason why

aluminum is chosen for this application.

3.3.2 Stainless Steel 304

Stainless steel is a type of steel that will not stain, corrode, or rust as easily as

ordinary steel. It is also called corrosion-resistant steel or CRES when the alloy type and

grade are not detailed, particularly in the aviation industry. There are different grades

and surface finishes of stainless steel to suit the environment to which the material will

be subjected in its lifetime. Stainless steel does in fact suffer from certain types of

corrosion in some environments. It is important and care must be taken to select a

correct grade that will be suitable for the application especially for food processing

equipment. Corrosion can cause a variety of problems, depending on the applications.

23

The components of the cutting machine made by using stainless steel are cutting blade

and handle because these parts always exposed to wet environment during the operation.

In addition, stainless steel has an excellent surface finish. Grade 304 is the most

versatile and the most widely used of all stainless steels, available in a wider range of

products, forms and finishes than any other, it has excellent forming and welding

characteristics. The components of the slicing machine made by using stainless steel are

cutting blade because this part will directly exposed to wet environment during the

operation. Also, stainless steel has an excellent surface finish. Welding process is easily

applied on stainless steel by using TIG (Tungsten Inert Gas) welding machine. Its

chemical composition, mechanical properties, welds ability and corrosion/oxidation

resistance provides the best all-round performance stainless steel at relatively low cost.

3.3.3 Mild Steel

Some of the machine components and parts that are not exposed to the food

directly are made of mild steel. Mild steel is a carbon steel typically with not more than

0.25% of Carbon and cheaper steel compare to the rest of steel types in the family.

Uncoated mild steel can easily form corrosion. Therefore, all surfaces for the frame are

coated with oil paint. The components that are made of mild steel include body frame,

stand, rotating shaft, and the gearing system in the machine.

3.4 Selection of Manufacturing Process

Many techniques are implemented in order to manufacture the machine parts and

components. For this project, there are few manufacturing processes been applied.

Machining, joining and finishing. Few machining processes are selected including

lathing, milling and shaping, joining process includes welding, and mechanical

fastening. And finishing includes coating and painting.

24

3.5 Fabrication

The slicing machine are consist of a upper feeding chute tilted perpendicularly with

the machine base, delivery chute tilted at a 21 degree vertical angle with the machine

base and a cutting wheel is perpendicular to the machine base that movement which is

hand driven. The upper feeding chute has four holes; it can be take off for cleaning. The

number of banana/yam can be cut at the same time depends on the size of banana/yam.

For big size of banana/yam, maximum 3 pieces bananas/yams can be cut at the same

time.

No tools or excessive force required to make adjustments on the banana and yam

cutting machine, and during adjustment, there will be no binding or jamming of moving

parts. The cutting machine also can used to cut hard vegetable like carrot. Cutting blade

can work without jamming or stalling, and without tearing or crushing the banana/yam.

When the machine is been pedal, the cutting blade (slicer) shall rotate such that, below

the chute, the cutting edge travels away from the inlet. The cutting edge or serrations, as

applicable, have their cutting edge facing the orthogonal direction as the wheel rotation.

3.5.1 Milling Process

Two types of milling process are used to make components in this project, face

milling and end milling. In Face milling, the cutter is mounted on a spindle having an

axis of rotation perpendicular to the work piece surface. The cutter rotates at a rotational

speed N rpm and the work piece moves along a straight path to remove material. For the

various profiles, it can be produce by end milling. The end-milling cutter is rotates on a

perpendicular to the work piece to remove material on the work piece surface. Milling

machine also used to do a drilling process by just change the milling chuck to drilling

chuck.

25

3.5.2 Lathe Process

There are three primary types of cutting method or cutting tools used in this

project, they are facing, slicing, and boring. The facing tool used to smoothing the face

of a part such as rotating shaft and beating housing outer surface. The slicing tool cuts a

larger piece into several smaller pieces, it is also called parting tools. The boring tool

drills a hole into the material that is used to make bearing housing and pulleys hole. The

lathe is a machine that generates cylindrical material by using cutting tools that touch

the material as it rotates, a piece of material is firmly fixed to the chuck of the lathe. The

chuck is then rotated and the cutting tool can be moved in three axes to allow for

precision.

Three factors that affect the lathe process are the rotating speed, a cutting depth,

and the sending speed. These are the factor need to take an attention during lathe

process. The rotating speed is the number of rotations (rpm) of the chuck of the lathe.

When the rotating speed is high, processing speed becomes quick, and the finished

product is finely finished. The cutting depth of the tool affects the processing speed and

the roughness of surface. When the cutting depth is large, the processing speed becomes

quick, but the surface temperature increases, and it has rough surface. The sending

speed of the tool also affects to the processing speed and the roughness of surface.

When the sending speed is high, the processing speed increases. When the sending

speed is low, the surface will have a finer finish.

3.5.3 Joining Process

To join some of the components together, welding process is applied to the joint is

a must. There are two types of welding method that applied in order to accomplish the

joining process. They are Gas Tungsten Arc Welding which also called as tungsten inert

Gas (TIG) and Stick Welding which also known as Shielded - arc welding (SMAW).

Stick welding method is the oldest, simplest and most versatile joining process. The

26

electric arc is generated by touching the tip of coated electrode against the work piece

and then withdrawing it quickly to a distance sufficient to maintain the arc. For the

frame of the machine, the material used is mild steel. Hence, the stick welding process is

used to weld part that of mild steel.

Gas Tungsten Arc Welding is suitable to do a welding process on stainless steel

material whereas Stick Welding more suitable for ferrous material such mild steel. Gas

Tungsten Arc welding can also used to weld mild steel, the welded surface finish is very

good if compare to the other types of welding machine. TIG welding uses a tungsten

electrode that is non-consumable. In other words it does not burn up. The tungsten acts

as the torch; it generates heat, which melts the metal and filler metal. Thin metals can be

joined by TIG welding without using filler metal. All metal sheets used to fabricate

machines body, frame and slicer is a thin metals. It can be weld easily without using

filler rod.

The arc is started with a tungsten electrode shielded by inert gas. An inert gas

shields the arc from the ambient to prevent oxidation. Because there is neither spatter

nor flux created from a TIG weld, it is an ideal option for applications on stainless steel

where the surface welded can maintain their shining surface.

3.5.4 Painting/Coating

Painting process is only applied on mild steel surface that tend to occur oxidation.

Because of its decorative and functional properties such as environmental protection,

low cost, relative ease of application and the range of available colors, paint is chosen to

use as a surface coating. Canned spray painting will be used for this purpose. The most

common purpose use of coatings is for corrosion control of steel especially for mild

steel.

27

3.5.5 Assembly

When the frame fabrication has finished and the rest of the components are ready,

and the assembly process is next in line. Most of the components within the machine are

joined together by using mechanical fasteners. The very basic types of machine-

threaded fasteners used are nuts and bolts and also screws. Their great advantages

include the ease of assembly, which generally requires no special equipment, and it is

easy to be de-assemble and reassemble without (much) damage to the joint. Nuts &

bolts are used with pre-drilled holes. Access from both sides of the component during

assembly is required, although this may not be necessary if captive or welded nuts can

be used. Some component of machine is assembled by using this type of joining

method. Two reasons for nuts and bolts been applied for mechanical fastening for its

high strength as well as part maintenance requirement. Maintenance has to take into

consideration for repairing where de-assembly and re-assembly components may be

required.

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CHAPTER 4

RESULTS AND DISCUSSION

4.0 Introduction

This chapter presents the result which gained from the design of the slicing

machine. Due to the limitation of time and lacking resource of raw material, the analysis

of this project can only be done through comparison with some other food processing

equipments.

But for the real test, it is proposed that few types of fruit and vegetable can be used

for testing such as banana, yam, or tapioca. The feeding method is by gravity. Feeding

by gravity means the material drop down from upper chute to the cutting wheel

automatically without any additional force. The operators only need to place the

material to the upper chute.

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4.1 Slicing Machine

Figure 4.1: The Slicing Machine in Isometric Layout.

4.1.1 Machine Working Principle

This is basically the working mechanism for the banana, yam, or tapioca slicing

machine. The figure below will explain step by step the process involved.

30

Figure 4.2: Insert banana, yam, or tapioca into feeding chute.

Figure 4.3: Swing the pedal to slice the food

31

Figure 4.4: Cutting wheel slice the food

Figure 4.5: Sliced food comes out from delivery chute

32

Basically, the slicing machine just required a small amount of energy by swinging

the pedal to slice the food. The machine also does not required electric power. Therefore

we can save electricity and we can use this machine anywhere for it is small and

convenient to carry..

4.2 Discussion

Table 4.1: comparison between few kinds of food processing equipment

Equipment

Multi-Purpose

slicer

Electric powered

Banana & Yam

Cutting Machine

Low Cost

Manual Driven

Banana, Yam or

Tapioca Slicing

Machine

Capacity

Small

Medium

Small

Size

Small

Large

Small

Power

Manual Driven

Electricity

Manual Driven

cost

Low

Medium - High

Low

Speed

Dependent

High Speed

Dependent

Safety

Fair

Good

Good

From the table above, we can say that the low cost manual driven banana, yam, or

tapioca slicing machine has all the good attributes needed. Small in size, means that it

can be easily taken anywhere. Moreover, it is manually driven and therefore we can

33

save electricity and reduce the energy consumption. Besides that, it is cheap and

affordable for customer.

For multi-purpose slicer, it is also small in size, manually driven and also low cost.

Its attributes did not differ much with the slicing machine except for the safety measure.

For multipurpose slicer, once the sliced food getting shorter, our hand may accidently

cut by the blade. This could be dangerous for anybody who uses it.

Figure 4.6: The Sharp Blade of the Multipurpose Slicer.

For the electrical powered banana and yam cutting machine, it is a machine that is

high in capacity which is suitable for small to medium size industry. The machine is

large in size; require high power input to propel the motor which rotates the cutting

wheel of the machine. In terms of speed, the motor provide high RPM by the constant

direct current (D.C.) input which enable the cutting machine to produce high amount of

chips in a short a time. Hence, for its high performance and size, the machine cost much

higher and its motor would require maintenance to ensure the machine life period.

Although it is not suitable for home use, but small and medium enterprise is probably

much interested in this machine for it cost much less compare to imported machine of

that kind.

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CHAPTER 5

CONCLUSIONS AND RECOMMENDATION

FOR FUTURE WORK

5.0 Introduction

In this chapter contains conclusion, the highlights of findings from project and

overview some possible and relevant recommendations for future work. This will be a

guideline for future researcher in order to improve the design and enhance the working

performance of the machine.

The following sections will summarize the achievements of this project and

highlight the difficulties encountered during the research process. The chapter also

concludes for the whole project undergone.

5.1 Achievements

During the course of this thesis, most of the goals and objectives were met. Hence,

further reaches over the design of cutting machine should be carrying out with more

detailed. By referring to the chapter one, section 1.3; the primary aim of the current

project which is to design a Slicing Machine for banana, tapioca or yam that will be

manually operated. It is also a low cost and affordable slicing machine. We can also

conclude that almost all objectives and primary aims of the project have been achieved,

35

although there are still rooms for improvement in order to come out with a better and a

flexible machine.

The progress of this project might be slow and time management was not really

been fully optimized. Many problems were encountered and limitation has been faced

during the course of this project development. This problems and limitation might be

useful to avoid possible problems and to be able to cope with the situation in the future.

5.2 Conclusion

As mentioned in the early chapter, the main objective for this project is to design a

slicing machine for banana, tapioca or yam that will be manually operated which is

affordable and ease of use.

Engineering design is one of the challenging aspects especially in manufacturing

area. To enhance the quality product, a detail study on the product must be carry out in

order is to improve the prototype. Continuous improvement should be implemented in

order to enable the product perform at optimum level as well as to be able to compete

with the available product in the market.

Upon the success and the failure of this project, most of the objectives that set in

chapter 1 have been achieved. But, unfortunately there are still left a few limitations and

to be highlighted in order to improve this design and prototype. Thus, recommendation

available here would perhaps ignite some of the great new ideas in designs and as well

to be able to identify parts or components which are not suitable and need to be

improved for optimum performance.

Lastly, it is strongly recommended so that this machine will be further improved in

terms of performance as well as the outer design. Further research study can be done for

the machine, where it is very useful for critical thinking by igniting fresh new ideas for

36

industrial need in order to cope up with problems faced in the engineering world

especially in this new challenging millennium. Problems such as maintenance

prevention of an equipment and instrument within a production plant would practice this

type of critical thinking whereby requires a lot of experience as well as brilliant idea to

solve the problem.

5.3 Recommendation

From the analysis had been taken, there are some improvement can be implement

in order to achieve the objectives specifically. As a guideline and to encourage further

enhancement and development for this machine, the following recommendations are

suggested to be taken seriously.

5.3.1 The Material

The entire body of the prototype is made and fabricated by mild steel and

aluminum as a major material; it is recommend all parts of the machine such as frame,

cover, holder, cutting wheel and shaft to be change to stainless steel grade 304 which is

more resistance to corrosion that is it would not react with the food chemical

compositions. Stainless steel widely used in food processing machinery, even the

manufacturing cost is higher than the other types of steel but it is healthy and low

maintenance cost. Stainless steel is a material suitable to replace mild steel and

aluminum.

5.3.2 Machine Control

It is recommended that the improved blade be would be adjustable and able to slice

the product into various kinds of sizes and shapes such as fries shape. The existing

37

machine can only produce one shape. Various shapes and sizes of the slices would make

this machine very flexible in terms of its outputs.

5.3.3 Use of CNC Machine

Some components within the machine such as cutting blade cannot be fabricated by

using conventional machine. It is suggested that components for the slicing machine be

fabricate by using CNC machine. Fabrication using CNC machine will be much useful

to fabricate this component into shapes for it is capable to fabricate more complicated

design. The accuracy of shapes are determined based on the input value and thus

improve the outlook of outer and inner design of the machine. Moreover, the student

will also able to learn operating a CNC machine in terms of programming which is a

valuable skill required in manufacturing sector. By using CNC machine, student will

also able to reduce fabrication/manufacturing time and improve surface finish of the

product fabricated.

38

REFERENCES:

1. Barry Hyman. (1998). Fundamentals of Engineering Design, Prentice Hall Inc,

New Jersey.

2. Mahmoud M. Farag. (1997). Materials Selection for Engineering Design,

Prentice Hall, Europe.

3. Burr, A.H. and Cheantham, J.B. (1995). Mechanical Analysis and Design,

Prentice Hall, Inc.

4. Mr. Joy Augustin (2001). Banana Slicer.

5. Career Planner (2004). Job Description for: Cutting and Slicing Machine

Operation Tenders.

http://www.careerplanner.com/JobDescSearchTool.cfm, 30th

August 2008

6. Plant for a Future (January 1997). Plant Portrait – Diosorea batatas – The Hardy

Yam.

http://www.pfaf.org/friends.php, 11th

September 2008

7. Banana.com (1995). The Origin of Bananas.

http://www.banana.com/nutrition.html, 11th

September 2008

39

8. Morton, J. (2001). Banana.

http://www.hort.purdue.edu/newcrop/morton/banana.Html#Description, 16th

September 2008

9. Hiong, K.V. (2007). Design and Construction of an Affordable Banana and Yam

Cutting Machine for Making Snack. Mechanical and Manufacturing

Engineering. Kota Samarahan, Universiti Malaysia Sarawak: 76 pages

10. Ronny F. (2008). An Improvement of Banana and Yam Cutting Machine for

Village Industry Application. Mechanical & Manufacturing Engineering. Kota

Samarahan, Universiti Malaysia Sarawak: 68 pages

11. Guide to Minimize Microbial Food Safety Hazards of Fresh-cut Fruits and

Vegetables.

http://www.cfsan.fda.gov/%7Edms/prodgui4.html, 13th

May 2009

12. Stainless steel 304

http://www.lenntech.com/Stainless-steel-304.htm

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APPENDIX I

TECHNICAL DRAWING

41

1. Technical Drawing

42

2. Front View.

43

3. Left View.

44

4. Top View.

45

APPENDIX II

THREE DIMENSIONAL VIEWS

46

1. Isometric View (Wireframe)

47

2. Isometric View (Shading)

48

APPENDIX III

BASIC COMPONENTS IN THE MACHINE

49

1. Mild Steel Frame.

50

2. Cutting Wheel.

51

3. Feeding Chute.

52

4. Delivery Chute.

53

5. Gearing System.

54

6. Pedal.