Introduction

Background of the Study

The coconut palm (cocos nucifera) is found all over the globe, where it has
mingled into the lives of the local people. It provides almost all the requirements
of humans such as food, drink, fire woods, medicines, domestic utensils etc.
Because of these reasons, it has been called the “tree of heaven’’ and ‘’tree of
life’’. Each part of the tree has its own commercial value that can be formed into
various products and usages including to cater for traditional and modern
needs. In the Philippine statistics indicated that areas planted with coconut
covers 3.517 M hectares equivalent to 26% of the total agricultural land (PSA,
2015). Sixty eight (68) out of (81) provinces are considered coconut areas
representing 1,195 coconut municipalities. In year 2015, the recorded number
of bearing trees reached 329.9 million with an average production of 14,902
billion nuts in the last three years (PCA, 2017).
This study proposes on the design and manufacturing of coconut husking,
cutting and grating machine consists of three operations, namely peeling of
coconut fibers, husking of coconut, breaking the coconut into two parts , cutting
and grating of coconut, removing out the copra (edible white part). For husking
process, the method selected for removing the fibers is the opposite
movements of toothed shafts whose spiked pins are inserted into the fibrous
layer of coconut for its removal. If copra is the desirable product then it will be
sent to cutting process where it will be cut into two halves. After this, grating will
be executed.Sub-assemblies of each operation are made separately to test the
working of each process without any interference.
Statement of the Problem

The manual husking, cutting, and grating process requires the use of the
strength in order to produce and sell a processed coconut in the market.
Presently no commercial mechanical husking, cutting, and grating has been
developed even though the manual method is hampered by poor productivity. A
machine that can easily processed the coconuts should be developed to
replace the inefficient methods, time consuming, and laborious problems of
manual process. Furthermore, this machine should produce more hourly and
daily outputs as well as minimizing the risk of manual coconut processes.

Significance of the Study

This study aims to design and fabricate a coconut machine, this is all
around process of coconut, producing a good quality of products out of coconut.
This design of machine specializes the process in husking, cutting and grating a
coconut. This study allows the authors to help the small scale coconut farmers
simplify their work, with the help of this machine they can create good quality
grated coconut with much more faster and efficient production.
Objectives of the Study

The general objective is to come up a prototype coconut husking, cutting,

and grating machine.
Specifically the study aims to:

1. To compare the performance of manual process and prototype coconut

machine.
2. To produce a range of 50 to 100 husked, cut, and grated coconut per
hour.

Scopes and Limitation

The study focuses in designing and fabricating a coconut machine which

consist of husking, cutting, and grating in order to produce a processed coconut
without hassle and lessen the time of work.
The authors of this study is expecting many problems that they may
encounter during actual application of this study, so there are limitation that this
study may face. This limitation is that the proposed machine will have a semi
automatic coconut grating process because of the complexity of the process to
become automatic and also for the shortage of budget and time of the authors.
Review of Related Literature

Coconut

Coconut (Cocos) grows in more than 80 countries in southern and

south-western Africa, Latin America and Asia. "Cocos" in 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 [1].
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 (Deokar et.al, 2017).

The fibrous layer also known as “coir”, is a versatile natural fiber extracted
from mesocarp tissue or husk of the coconut fruit, the general process.
Generally fiber is of brownish 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 on ocean currents to be washed up on a sandy shore where it
may sprout and grow into a tree, if it has enough fresh water, because all the
other nutrients it needs have been carried along with the seed. These
characteristics make the fibers quite useful in floor and outdoor mats, aquarium
filters, cordage, rope and garden mulch (Deokar et.al, 2017).
Coconut Breaker machine

Coconut is widely used in our day to day home activities. The flesh of the
coconut is the important product used by homemakers in preparing dishes. For
this purpose, the coconut needs to be processed. The coconut is known for its
great versatility as seen in the many uses of its different parts and found
throughout the tropics and subtropics. The dimensions of the mature coconut
are very much significant as far as the machine design is concerned. Various
farms and sites were visited to comprehend the band of dimensions involved in
the mature coconut ( Sooraj,SJ et.al ,2011 ). For breaking the coconut it is
important to hit it at the right spot. This is to ensure a proper and almost
symmetrical cutting of the coconut.

Cutting tool of the coconut cutting machine by Sooraj, SJ

The machine has been designed to overcome a large range of coconut

sizes, with equal importance to productivity. The main merits of the proposed
machine are it is feasible in terms of economy, time and effort, enhanced safety
of the user by eliminating injuries caused primarily due to improper handling of
the grater tool ( Abekhan, 2011 ).
Automated coconut cutting machine by NewTech Inductries

Jerry James et al (2016), have described the proposed machine a

Coconut Breaker Extractor Grater which can break a de-husked coconut into
two pieces, collect coconut water and grate the coconut pieces into desiccated
coconut. The main highlight is that there is no contact between the tool and
hands of the user both in breaking and grating of the coconut.
Coconut Grater machine

There has been no change in the way coconut is grated, for several
decades. The only change being the introduction of a motorized blade. But still,
one has to hold the coconut. But all that is set to change with the invention of an
innovative coconut grater which can do the job in just few minutes with
improved safety and convenience .

Common electric coconut grater

The problem with all these designs is that someone should hold the
coconut near the blade all the time. Also scraping coconut using these
machines are really time consuming and laborious. Also there is less safety
while using these scrappers (Sajil,R. 2016).
Traditional graters was also have been used by other remote countries or
rural areas, in this case grating process were also very laborious and time
consuming. With this study, the authors will conduct a semi automatic grating
process as an addition to the whole process of this coconut processing
machine.
Coconut dehusking machine

Coconut Dehusking Machine for rural small scale farm Holders comprise of
two rollers with spikes, screw conveyor, barrier plates, conveyor belt, two spur
gears and a handle was developed for small scale production in the rural areas.
The main purpose of this machine is to eliminate the skilled operator involved
in de-husking the coconut and to completely automate the dehusking. Although
coconut dehusking machines have already been demonstrated in the work and
also in some small scale industries, the process is either manual or
semiautomatic. A completely automated machine with manual loading and
unloading of coconuts will yield productivity higher than the existing process.
Because of that, the current work is mainly focused on an automated machine
for dehusking ( Rishikesh,V. 2011 ).

Model of coconut dehusking machine by Rishikesh V. 2011.

The machine is designed to accommodate different sizes of the coconut

that are cultivated anywhere in the world. Also, various experiments have been
conducted on both dry and mature coconuts in order to determine the force
required to de-husk the coconut ( Abhinav Ram, 2014 ).
Shear load required to dehusk the dry coconut of different sizes are listed
below (Abhinav,R. et.al., 2014).

No. Dimension in Shear Load

X-axis (mm) (kN)
1 133 0.24
2 154 0.26
3 174 0.29
4 208 0.36
5 252 0.42
Methodology

Flow chart of the study

The flow chart of the study will start on machine design, where the authors
will plan the appropriate design to successfully dehusk, cut and grate coconut
as what is really the objectives of this study. Then, followed by materials
selection, fabrication of the machine, functionality testing, actual testing,
accumulation of data and lastly data analysis.

Machine design

Materials selection

Fabrication of the machine

Functionality testing

All parts No
Functional ?

Yes
Actual testing

Data gathering

Data analysis
Flow chart of the study
Materials Selection

Main Parts of the Machine and their function:

Dehusker:

1. Electric motor- power supply to driver pulley.

2. Pulley and Belt Drive- transmit power from the motor to the roller without
reduction.
3. Gears- it is use to rotate the two rollers with their each opposite direction.
4. Rollers- cutting tips are welded on rollers for dehusking.

Cutter:

1. Electric motor- power supply to cutting blade.

2. Pulley and Belt Drive- it transmit power fro motor directly to cutting blade
without any reduction.
3. Cutter Blade- use to cut the shell of coconut

Grater:

1. Grating Tool- it is mounted on the cutter shaft itself and hence for this
process, no extra source of power is required.
- use to grate the meat of the coconut.

Other necessary materials needed:

1. Mild Steel bars - for the supports and beams of the machine.

. Mild steel rods - for the shafts of the rollers, conveyor wheel and grating tool.
3. Pillow Block Bearings - for the support on the shafts to have efficient
transfering of power.
3. Aluminum steel - for the frames of the machine.
Theoretical Calculation

The formula used in calculating the theoretical calculations is in the book

Machine Elements in Mechanical Design Fourth Edition by Robert L. Mott.

Calculation for dehusking:

For rollers Average Shear Load of coconut:
Nmotor=1440 rpm Fcoconut = 0.314 kN or 314 N
Dpulley of motor= 6cm
Dpulley of roller= 9cm
Droller= 9cm

Calculating the speed of roller:

Npulley_roller = Dpulley_motor(Nmotor)/Dpulley_roller
Npulley_roller = 0.06m(1440rpm)/0.09m
Npulley of roller= 960 rpm ; Npulley of roller= Nroller=Ngrater

Solving for torque of the roller:

Troller=Fcoconut x Rroller
Troller= 314 N x 0.045m
Troller= 14.13 N-m

Power required to dehusked:

P=2  NT
P=2  (960rpm/60)(14.13 N-m)
P=1420 W = 1.9 hp

P=Pdehusk=Pgrater
Calculation for Cutting:
According to James, et al. The required force needed in cutting a coconut
shell is 49.05 N.

Nmotor = 1440 rpm

Dmotor= 3 cm
Dcutter= 33cm ,

Ncutter = Nmotor2 = 1440 rpm

Tblade = Fshell x Rblade

Tblade = 49.05 N x 0.165 m
Tblade = 8.09 N-m

Power required to cut the shell:

P=2  NmotorTblade
P=2  (1440rpm/60)(8.09N-m)
P=1219.94 W=1.64 hp
Projected Cost of the study

The following are the projected material and labor cost of the study, listed
below the important materials needed to fabricate the machine and the quantity
of that material and their cost.

Material Quantity Price Cost

Electric Motor 2 Php 4,000 Php 8,000
Pulley 4 Php 380 Php 1,520
Belt 2 Php 2,200 Php 4,400
Gear 3 Php 90 Php 270
Roller ( to be 2 Php 3,000 Php 6,600
fabricate )
Cutter Blade 1 Php 300 Php 300
Grating tool 1 Php 200 Php 200
Mild steel bar 7 Php 750 Php 5,250
Mild steel round 5 Php 300 Php 1,500
bar
PillowBlock 8 Php 100 Php 800
Bearing
Aluminum steel 4 Php 888 Php 3,552
Labor Php 5,000

Total Cost Php 37,392

The projected cost of the study states that the total projected cost is Php
37,392. this shows that designing and fabricating coconut dehusking, cutting
and grating machine is not really expensive but this amount is only a projected
cost and may be change in some time if there is an unexpected element may
occur or additional materials needed to successfully operate this machine.
Schedule of activities of the study

Below is the table showing the schedule of activities of the project, starting
from the month of August 2019 to May 2020. Beginning in reviewing the
machine, reviewing materials needed to select followed by the garnering of the
materials needed, fabrication, testing and actual testing of the machine and
lastly accumulation and data analysis.

Au Sep Oc No De Ja Fe Ma
g t t v c n b r
Reviewing Machine Design
Reviewing Materials Selection
Buying Materials
Fabrication of the Machine
Testing of the Machine
Actual Testing of the Machine
Accumulation of Data
Data Analysis
Working principle of the machine

The working principle of this study coconut dehusking, cutting and grating
machine starts in dehusking process then will be followed by cutting process
and lastly the grating process of the coconut.
The following will be the chronological order of the coconut dehusking,
cutting and grating machine:

1. Dehusking process

In this process, the dry coconut will be place at the top of the two spiked
rollers, this spiked rollers will be driven by the belt and pulley powered by
the electric motor. In this process the husk of the dry coconut will be remove
leaving only the shell of the dry coconut, as the dry coconut will be peeled,
it will rolls down to the rotating conveyor.

2. Cutting process

In this process, the peeled or dehusked coconut will be cut into half,
being delivered by the rotating conveyor to the cutting blade where the
cutting process will be held. The cutting blade will be driven by the belt and
pulley powered by the electric motor. The cut coconut will be drop into the
cut coconut storage that is located where the cut coconut will fall because
of the gravity.

3. Grating process

In this process, the cut coconut will be semi automatically grate, a

hands on power input of a person or worker is needed to do the grating
process. The worker will get the half cut coconut from the cut coconut
storage and grate the coconut semi automatically, the grating tool will be
connected through the shaft of the one of the roller so they share the same
power from the electric power transmitted by belt and pulley.
Machine Design

1. Rollers for dehusking

Two spiked rollers are considered as the main mechanism of the

machine. These components, which move in opposite direction, are the
ones that grip and tear the coconut husks in the dehusking process. The
spiked rollers are made of hollow iron shaft of 90 mm outside diameter, 10
mm thick and 583 mm long. Each hollow pipe was welded with 58 units of
iron spikes arranged in helical arrangement along the surface. The spikes
were designed in a conical shape of 15 mm diameter and 23 mm high. The
spacing between spikes was 51 mm.
2. Cutter blade

The cutter blade is placed at the upper part of the rotating conveyor. It
has 33cm diameter, and being driven by the 2hp electric motor.

3. Grater blade

The grater blade is connected at the shaft of the roller blade so they
share the same amount of power from the electric motor with 2hp. It has
6.5cm diameter with blades that good enough to grate the meat of the
coconut.
Solidworks Design of the Proposed Machine

Conceptual view of the Machine

Left view
Right view

Top view
Front view
References

Abrinav,R.,Rajul,R.,Ventakaramanan,S.(2014).Design and Development

of Automated Coconut Dehusking and Crown Removal Machine.

Sooraj,SJ.,Vaisakh,VS.,Vishnu,C.(2011).Development of a new Coconut

Dehusking and Cutting Machine.

Deokar,K.,Malaviya,K.,Mistry,K.(2017).Design and Manufacturing of Coconut

De-husking,Cutting and Grating Machine,Volume 7(Issue No. 4).

Sajil,R.(2016).Design of an Innovative Coconut Grating Machine Using

Tinkercad.

Rishikesh,V. (2011).Design and Development of Automatic Coconut

Dehusking and Deshelling Machine.

James,J.,Joy,J.,Shaji,A.(2016).Design and Fabrication of Coconut Breaker

Extractor Grater Machine.