Production of Chips of Porang (Amorphophallus Oncophyllus) by Slicing Machine With Rotating Double...

International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2763 Issue 09, Volume 3 (September 2016) www.ijirae.com

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Production of Chips of Porang (Amorphophallus Oncophyllus) by Slicing Machine

With Rotating Double Cutters Kristinah Haryani 1 Suharto2 Suryanto3 1Chemical Engineering Dept., 2Mechanical Engineering Dept., 3Mechanical Engineering Dept Faculty of Engineering, UNDIP Semarang State Polytechnic, Semarang State Polytechnic, Semarang, Indonesia Semarang, Indonesia Semarang, Indonesia

Abstract — Chips of porang (amorphophallus oncophyllus) is slice of tubers of porang as a main material for glucomannan flour-making. Glucomannan flour containing high glucomannan is very useful to the food industry, non-food and health. Chips of porang production among the farmers in Magelang, Central Java, still use manual method that resulting low chips quality that does not meet for further processing, namely manufacturing of flour glucomannan. This applied research is intended to design the tubers chips maker with double rotating cutters to produce chips of uniform and the same thickness. The method used is engineering design approach starting from process of machine design, manufacture engine components, and engine performance testing. The result is a slicing machine with rotating cutters for producing chips of porang with the specifications: length dimension: 1000 (mm), width 750 (mm), height 1000 (mm), the weight of the machine: 85 (kg), the drive unit: motor gasoline of 5.5 HP. It was found that best performance of cutting process of the rotating double cutters is at 120 rpm, cutter angle of inclination is of 30o, and production capacity is of 310 kg per hour.

Keywords— chips of porang, rotating double cutters

I. INTRODUCTION

Tubers of porang (amorphophallus oncophyllus) or in Indonesia often called “iles-iles” including araceae family that grows in warm sub-tropical climate to tropical areas like East Asia, South China, Japan, to Indonesia as in [1]. Tubers of porang size varies from diameter of 100 mm to 200 mm with a weight of up to 1 kg as shown in Figure 1. Chips are sliced tubers of porang with a thickness of 8 mm that has been dried. Tubers of porang flour obtained by milling process and filtered with 80 mesh. Glucomannan flour contained the resulted porang flour can be separated by applying cyclone separation method. Through the process of cyclone glucomannan flour mass separated from lighter mass of flour potassium oxalate. Thus the manufacture of qualified chips of porang is the starting point of glucomannan flour production. Learn the process of making glucomannan flour starting from tubers of porang crops, washing, slicing, drying, flouring, flour separation, purification processes, to obtain a high starch content of glucomannan. Based on experiments the ratio of wet tubers of porang compared to dry porang chips is 7 : 1, it means that 7 (seven) kilograms of wet tubers of porang will become 1 (one) kilogram of dry chips through a washing, slicing, and drying processes. Previous studies such as [2]describes porang glucomannan flour is quite high (15-64% dry basis). Referrence [3] explained that porang tubers are used as raw material for the food industry since 1000 and last year in Japan and China. Furthermore, [4]; [5], and [6] explained that glucomannan is a soluble fiber content of foods with a high water, low in calories and specific hydrocoloid. Utilization of tubers of porang into flour is one option for easy storage and processing into food, non-food, and healthcare.




Figure 1. Tubers of porang with size of 100 to 150 mm in diameter

Figure 2. Production processes from tubers into chips of porang

There are three main stages to produce chips of porang, i.e. (1) washing; (2) slicing; and (3) drying. Figure 2 shows the stages of the process of making chips from tubers of porang. The process of making chips are generally done manually with a single cutter as illustrated Figure 3. The wet chips resulted from slicing process are then dried on open air. The process of making these chips do not guarantee the quality of the resulting dry chips for the process of glucomannan flour quality. This leads to the development of slicing method using double cutters mounted on a rotating stand. The objective of development of slicing method is to increase chips productivity and quality of the chips that appropriate to glucomannan flour-making industry.

Figure 3. Manual method of chips porang production and drying chips resulted




Slicing process of tubers of porang to produce chips that done manually has shortcomings on the uniformity of sizes resulted and low quality of chips. Slicing the tubers manually also potentially be accident on the operator's hands. The use of double cutters on a rotating holder for the manufacture of wet chips increase productivity and uniformity of shape and size of the chips, comfort and safety for the operator.

This applied research is intended to produce a simple tubers of porang slicing machine generated by gasoline engine, by which these research activities starting from the design, manufacture, and testing of performance of the slicing machine. Benefits of the machine will be usefull for the farmers to produce chips of porang easily and cheaply.

II. METHOD

This applied research is of engineering approach based on three main activities, namely designing, manufacturing and testing. This method of applying engineering approach is an exercise as of expressed by [7], [8], [9], that applied research is research being undertaken with a view to implementing, testing, and evaluating the ability to provide solutions to certain problems in practice.

First, the design process is inisiated by functional aspect of the designed machine, cost of manufacture of the machine, cost of operation of the machine, time of manufacture, aspects of ergonomics, ease of finding the machine components that available on local market, ease of maintenance and repair, security in the operation of the machine, and aesthetics, then set one design selection. All of these considerations are then carried out to be a technical drawing to illustrate the prototype of the machine. Based on the technical drawing the process of making machines are begun, in which all componnents of the machines are manufactured or supplied. Then the assembly of the machine is then conducted accordingly. Testing of the machine performance is then carrie out to determine if it can work properly or not. If the machine is not functioning properly then do repairs machines to perform well in line with expectations. Figure 4 shows the process of flow diagram to manufacture the machines.

Figure 4. Process of flow diagram to manufacture the machines




DESIGN PROCESS. Design considerations include the following: (1) use of a single cutter is done manually and is less efficient and prone to operator; (2) thickness of the slice desired is 8 s.d 10 (mm); (3) tubers of porang containing potassium oxalate itchy skin contact; (4) tubers of porang size ranges from 100 to 150 (mm); (5) production capacity of the wet chips is 300 (kg / h) with a slice direction and a uniform thickness. Based on these considerations the design process starting from (1) selection of materials for construction, (2) calculation and analysis of the strength of materials, which includes cutting force, torque, cutting power, gears, pulleys, belts, shafts, pins, bearings, fasteners, cutter material, and rotating cutters holder by using formulas elements of machines and machine design as in [10], [11]. While working drawings were made following the ISO standardization of componnents in [12] . Result of the design process is working drawings of prototype of slicing machine with rotating cutters for producing chips of porang shown in Figure 5.

Figure 5. Prototype of slicing machine with rotating cutters for producing chips of porang

MANUFACTURING COMPONENTS. The process of manufacturing of machine components based on the design of working drawings. Manufacturing of components will be done mainly for special components of the machine designed according to the needs. Other components are standard components which are generally available through procurement. The manufacture of special components primarily using a lathe, milling, drilling machines, bench work, and welding with the calculation of working time and production costs. The following components are to be manufactured: cutters, rotating disc with double cutters, shaft, body stand, mounting for gasoline engine, hopper input and output tunnel. The standard components are bearings, gears, belts, pulleys, and gasoline engine unit.

ASSEMBLY. Assembly is a process of preparation and pooling all component parts into a device or machine that has a specific function as already designed. Assembly begins with preparing the components that have been made and standard components prepared. If the componnents are joined perfectly and occupied the correct position, then the machine will ready to be tested for the operation of slicing of tubers of porang.

Working mechanism of slicing machine with rotating cutters for producing chips of porang:

(a) Check carefully all parts of the machine accordingly; (b) Turn on the key to start the gasoline engine and control its steady rotation; (c) Enter tubers of porang into hopper (with its load itself tubers of porang will drop down through a double rotating

cutters); (d) After slicing process the resulted chips will drop on the tunnel output; (e) Thick of chips can be set using the regulator screw cutters to be 8 to 10 (mm) in thick. The hole in the disc is made

at least three times of chips thick to facilitate resulting chips easily dropped out and not damaged or broken; (f) The process of slicing tubers of porang carried out through double rotating cutters horizontally and tubers of

porang entered through two input hopper; (g) If the tubers of porang is running out, put the next tubers of porang respectively; (h) Operate the machine to produce chips of porang repeatedly, in order to work optimally with the resulted chips of

uniform shapes and sizes; (i) Place the chips resulted from collector under the out put tunnel to drying process area.




III. RESULT AND DISCUSSION

SLICING MACHINE WITH ROTATING CUTTERS. Process of flow diagram to manufacture the machines has been realized accordingly and the slicing machine with rotating cutters has been resulted as illustrated on Figure 6. Slicing machine with rotating cutters for producing chips of porang is designed to help people of Magelang, Central Java, who processing tubers of porang into chips. This activity is carried out as public service program conducted by Team of Hi-Link Program (2016-2018), Semarang State Polytechnic, Semarang, in collaboration with the Service of Agriculture, Animal Husbandry and Fisheries Affairs, Magelang City in order to improve the local economy through the cultivation, processing and utilization of tubers of porang. Production of chips manually have been constrained by the low quality of chips resulted and sustainability of production in order to meet consumer needs at Magelang City.

(a) Covered (b) Uncovered

Figure 6. Slicing machine with rotating cutters for producing chips of porang

MACHINE SPECIFICATIONS :

NAME OF MACHINE : SLICING MACHINE WITH ROTATING CUTTERS FOR PRODUCING CHIPS OF PORANG POWER GENERATOR : GASOLINE ENGINE 5,5 (HP) CAPACITY : 300 (KG/HOUR) SIZE OF CHIPS PRODUCED : 8 TO 10 MM IN THICK DIMENSION : 100 X 75 X 100 (CM) WEIGHT : 85 (KG)

Novelty of this slicing machine is on the cutter design that is easily available in the local market. When the cutter is getting dull, it can be removed and replaced easily. The size of chips resulted by this machine is 8 to 10 (mm) in thick.

Figure 7. Percentage of quality and varieties of thickness of chips




REMARKS: QUALITY A = THICK AND UNIFORM SHAPE, CLEAN AND PERFECT QUALITY B = THICK AND UNIFORM SHAPE, CLEAN AND UNPERFECT QUALITY C = THICK AND NON-UNIFORM SHAPE, DIRTY AND BROKEN SIZE OF TUBERS OF PORANG IS 100 TO 150 MM IN DIAMETER, AND AVERAGE EACH WEIGHT IS 1,5 KG PERFORMANCE TESTING OF THE MACHINE. Testing the performance of the machine is an attempt to determine the performance chips of porang resulted based on test functions and the work of the machine. The testing process is done with cutter type and rotation variables of the machine. In doing so the test is to observe the results of slicing of tubers of porang. The results of all the tests performed are recorded and tabulated as test data. Results of testing the performance of the machine shown in Figure 7 and Table 1.

It was found that quality of chips resulted depends on thick of cutter, angle of cutting edge, cutter rotation speed. The best result of quality of chips was found on the following parameters: thick of cutter of 2 mm, angle of edge of 30o, and cutter rotation speed of 140 rpm. With these parameters the slicing machine can produce 300 kg/hour chips of porang by entering input of tubers of porang1,5 kg (average). The quality of chips of porang yielded were quality A (80%), B (20%), and C (0%).

Figure 8. Tubers of Porang and Chips of Porang

TABLE 1

PERFORMANCE TESTING OF THE SLICING MACHINE FOR PRODUCTION CHIPS OF PORANG

NR. EXPERIMENT

THICKNESS OF CUTTER (MM)

ANGLE OF CUTTING EDGE O)

CUTTER ROTATION SPEED (RPM)

TIME (SECOND)

QUALITY OF CHIPS RESULTED

1 5 45 90 18 A=75%; B=25%; C=0 2 5 45 105 18 A=77%; B=23%; C=0 3 5 45 140 18 A=78%; B=22%; C=0 4 5 45 150 17 A=77%; B=23%; C=0 5 5 45 160 15 A=78%; B=22%; C=0 6 2 30 90 17 A=83%; B=17%; C=0 7 2 30 105 16 A=84%; B=16%; C=0 8 2 30 140 15 A=85%; B=15%; C=0 9 2 30 150 14 A=82%; B=18%; C=0 10 2 30 160 13 A=81%; B=19%; C=0

IV. CONCLUSIONS

Effort to overcome shortcomings in production of chips of porang, especially in Magelang City, using manual slicing device can be alternatively to switch operating the slicing machine with rotating cutters for producing chips of porang as already designed and tested. The specifications of the machine are as follows: capacity of chips production 300 kg/hour, dimension 1000 x 750 x 1000 mm, weight 85 kg, and power generation of gasoline engine 5,5 HP. It was found that the best result of quality of chips will be reached with the following parameters: thick of cutters 2 mm, angle of edge 30o, and cutter rotation speed 140 rpm. In addition upon these parameters the slicing machine can produce 300 kg/hour chips of porang based on average weight each tubers of 1,5 kg. The quality of chips of porang yielded were: quality A (85%), B (150%), and C (0%). By operating this machine safety of the operator can be assured compared with operating of hand slicing device.




ACKNOWLEDGMENT

The authors extend special thanks to the Director of Semarang State Polytechnic, Head of Service of Agriculture, Animal Husbandry and Fisheries Affairs, Magelang City, and Chairman of Research and Public Service Center (P3M), Semarang State Polytechnic, Semarang, upon which a collaboration between these institutions can be conducted for Hi-Link Program for Public Service (2016-2018) funded by Ministry of Research, Technology, and Higher Education, Republic of Indonesia.

REFERENCES

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[2] Anni Faridah, Simon Bambang Wijanarko, Aji Sutrisno, & Bambang Susilo, 2014. Optimasi Produksi TepungPorangdari Chip Porang secara Mekanis dengan Metode Respons.

[3] Zhang, Y., Xie, B., & Gan, X., 2005. Advance in Apllication of Konjac Glucomannan and its Derivatives. Carbohydrate Polimers, 60, 27-31.

[4] Katsuraya, K., Okuyama, K., Hatanaka, K., Oshima K., Sato, T., & Matsuzaki, K., 2003. Contitution of Konjac Glucomannan: Chemical Anlysis and 13C NMR Spectroscopy. Carbohydrate Polymers, 53, 183-189.

[5] Gao, S.J, & Nishinari, K. 2004. Effect of Degree of Acetilation on Gelation of Konjac Glucomannan. Biomacromolecules, 5, 175-185.

[6] Yang, X. H., Zhu, W.L., dan Yan, J.F., 2006. A Time Temperature Rheological Study of Konjac Glucomannan Hydrocolloid. Journal of Biomaterial Science, 17 (1–2), 53–59.

[7] Husein Umar, 2008. Metode Penelitian untuk Skripsi dan Tesis Bisnis. Jakarta. Raja Grafindi Persada. [8] Endang Mulyatiningsih, 2012. Metode Penelitian Terapan Bidang Pendidikan. Bandung. Alfabeta. [9] Sugiyono. 2013. Metode Penelitian Pendidikan (Pendekatan Kuantitatif, Kualitatif, dan R & D). Bandung. Alfabeta. [10] Sularso & Kiyokatsu Suga, 1997. Dasar Perencanaan dan Pemilihan Elemen Mesin. Jakarta. PT Pradnya Paramita, [11] Khurmi, R.S. & Gupta, J.K., 1980. A. Text Book of Machine Design. Eurasia Publishing House (Pvt) Ltd. [12] G. Takhesi Sato, & N. Sugiarto Hartanto.2005, Menggambar Mesin Menurut Standar ISO, Jakarta, PT Pradnya

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