DESIGNING A PINEAPPLE MACHINE

7ULKURNAIN BIN SALIM

This project is submitted in partial fulfillment of the requirements for the degree of Bachelor of Engineering with Honours

(Mechanical Engineering and Manufacturing Systems)

Faculty of Engineering UNIVERSITI MALAYSIA SARAWAK

2004

ACKNOWLEDGEMENTS

Alhamdulillah, Thank God for all His blessing and permission I was able to

complete this Final Year Project. First and foremost I would like to take this

opportunity to thank my supervisors, En. Rash Muslimen and Dr. Ghazali Tambi for

their valuable advices, their patience and willingness to assist me completes this

report. Without their support, the work is never have been finished. I would like to

mention my special thanks to my mother and my father, my parents for their

continuous encouragement and support in my life. I am forever grateful to them for

that.

I would like to thank Mr Masri and Mr Rhyier and other lab technicians for

their technical advice and information. They have always been exceptionally helpful

whenever I faced any problem in developing the idea for this project.

i

Designing A Pineapple Machine

Zulkurnain bin Salim

ABSTRACT

The purpose of this study is to learn about the operation of pineapple machine and

redesigned the new machine. To do this project, a few pineapple machines are

studied to learn the main process of pineapple machine. From this information, new

machine will be redesigned to fulfill the user needs. The existing machines are too

complicated in term of operation and not efficient. So, for the redesigned machine,

the improvement is made so that it is easy to use and at the same time improved the

whole operation of the machine. Besides redesigning, analysis is made to determine

its capability to operate in a desired condition. As a result of this study, an improved

pineapple machine which performs the operation of slicing and coring has been

designed.

11

Merekabentuk Mesin Nanas

Zulkurnain bin Salim

Abstrak

Projek ini adalah bertujuan untuk mengkaji operasi beberapa jenis mesin nanas dan

merekabentuk semula sebuah mesin baru. Bagi melaksanakan projek ini, beberapa

mesin nanas dikaji untuk mengetahui proses utama bagi mesin nanas. Daripada

maklumat yang tersebut, mesin yang baru direkabentuk untuk memperbaiki mesin

yang sedia ada untuk memenuhi kehendak pengguna. Mesin yang sedia ada terlalu

komplikateddari segi operasi dan tidak cukup efisyen. Oleh itu, bagi mesin yang

direkabentuk semula ini perlu dibuat supaya senang digunakan dan pada masa yang

sama memperbaiki operasi keseluruhan mesin. Selain merekabentuk, analisis dibuat

untuk menentukan keupayaannya untuk beroperasi dalam keadaan yang diingini.

Hasil rekabentuk yang diperolehi ialah mesin nanas yang dapat melakukan proses

menghiris dan mengupas.

111

Table of Contents

Contents

ACKNOWLEDGEMENTS

ABSTRACT

ABSTRAK

CONTENTS

LIST OF FIGURE

LIST OF TABLE

INTRODUCTION

1.1. Introduction

1.2. Problem statement

1.3. Aims and Objectives

1.4. Scope

1.5. Summary

2. LITERATURE REVIEW

2.1. Overview of Pineapple Machine

2.2. Pineapple Processing

2.3. Pineapple Description

2.4. Samarahan Pineapple

2.5. Review on Ginaca Machine

2.5.1. The Synchronization of Ginaca machine

Page

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iv

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viii

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1

2

3

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4

5

5

6

7

9

10

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iv

2.6. Pineapple Machines Today

2.7. Pineapple Machine In Samarahan

2.8. Summary

3. METHODOLOGY

3.1. Basic Step In designing

3.1.1. Study on relevant subject

3.1.2. Design The Machine

3.1.3. Design Analysis

3.1.4. Material Selection

3.2. Summary

4. DISCUSSION

4.1. Pineapple Parameter

4.2. Existing Machine

4.3. Concept Generation

4.4. Evaluation of Concept

4.5. Redesigned Machine

4.6. Design Analysis

4.7. Comparison of the existing machine (improved features)

4.8. Summary

5. CONCLUSION AND RECOMMENDATION

6. REFERENCES

7. APPENDICES

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82

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LIST OF FIGURE

FIGURE

NUMBER

Figure 1.1

Figure 2.1

Figure 2.2

Figure 2.3

Figure 2.4

Figure 2.5

Figure 2.6

Figure 2.7

Figure 2.8

Figure 2.9

Figure 3.1

Figure 3.2

Figure 3.3

Figure 3.4

Figure 3.5

Figure 3.6

Figure 4.1

Figure 4.2

Figure 4.3

Figure 4.4

PAGE

An officer of IADP Samarahan

Smooth Cayenne pineapple

Basic model of Ginaca machine

1919 model Ginaca

1925 Ginaca machine

ELLIOT HAND-OPERATED SLICER

SINGLE KNIFE PINEAPPLE SLICER

FILTER CENTRIFUGES

Squeezer machine that is used to produce pineapple cordial

Some part in squeezer machine

Basic steps in design

Example of contradiction table

Example of comparison table

Shaft parameters

Portion of double-strand roller chain

General properties of steel

Pineapple parameter

Elliot Hand-operated slicer

Explosive diagram of Elliot hand-operated slicer

Concept I

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8

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12

12

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15

16

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18

20

27

28

30

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V1

Figure 4.5 Concept 2

Figure 4.6 Concept 3

Figure 4.7 Redesigned machine

Figure 4.8 Explosive diagram of redesigned machine

Figure 4.9 Physical decomposition

55

56

60

61

62

vii

LIST OF TABLE

TABLE PAGE

NUMBER

Table 2.1: The characteristics of pineapple variety in Samarahan 9

Table 3.1: Basic design considerations 22

Table 3.2: Design considerations 23

Table 3.3: PREFERENCE RATING TABLE 28

Table 3.4: Service factor for bending 30

Table 3.5: Service factor for difference conditions 34

Table 3.6: Horsepower table 36

Table 3.7: Values of K 38

Table 3.8: Slow speed factor 39

Table 3.9 Design Considerations 42

Table 4.1: Specifications of Elliot hand-operated slicer 47

Table 4.2: Part by part Elliot hand-operated slicer 47

Table 4.3: Contradiction table 53

Table 4.4: PREFERENCE RATING TABLE 58

Table 4.5: The Criterion Comparison Table for AHP 58

Table 4.6: The Completed. Criterion Weights 59

Table 4.7: Redesigned machine specifications 62

Table 4.8: Part by part features of redesigned machine 63

Table 4.9: Recommended shaft diameters 66

V111

Table 4.10: Types of chains 71

Table 4.11: Types of bearing 75

ix

Df: 51G\ING A PINFAPPLF MACFiINF.

CHAPTER 1

INTRODUCTION

This chapter described the whole project. First, it describes the area of the study.

Then, a few problems are identified from the existing machines. From the problems

identified, we will bound the scope of the project to be focused on. In addition, the

aim and objectives of the project will be determined.

1.1 Introduction

Pineapple processing in a large quantity is quite a challenge in manufacturing

industry. But it can be done by using large machine with complex system. This

machine cost a lot of money and this why pineapple processing usually involves big

company with sophisticated machine to perform processes such as peeling, slicing

and coring.

In this project, a new machine that are capable to process pineapple with low

cost and suitable to process pineapple in Kota Samarahan will be designed. The

focus is on how we can process pineapple in a large quantity with low cost, with

simple manual to operate the machine so that the pineapple can be marketed for

small industry in Kota Samarahan area.

The machine that is going to be designed must be simple enough to meet the

requirement for Kota Samarahan. In addition, the machine must be flexible to cope

with the unplanned pineapple planting in Samarahan. For those reasons, the suitable

process are coring and slicing. Coring process involves the process of cutting out the

skin of pineapple. Slicing is the process of cutting the pineapples into slices. Both of

1

DENIGN ING A P1NI=, -IPPLE=. I\1 A('I[iN E:

the processes can be combined in one machine so that the final product is the

pineapple that has been cored and sliced.

Basically, pineapples in Samarahan are planted not for commercialized purpose.

Most of the farmers in Kota Samarahan are prefer to sell them directly to customers

or sell them to the wholesalers. Because of that, pineapples in Samarahan are planted

in small scale with the unplanned schedule. It is meant that pineapples plant in

Samarahan are depend on the farmers themselves. It causes the unbalanced supply

for pineapples in Samarahan because of the unsynchronized planting.

1.2 Problem Statements

The main purpose in this project is to design new machine for Samarahan area.

This is due to the need for suitable machine in processing pineapple in Samarahan.

Accordings to En. Esuwandi Seruji , the existing machine in market does not fulfill

the requirement for Samarahan area in term of capacity of pineapple that can be

supplied by farmers monthly. Most of the machines are large scale machine that

require about 1000 pineapples every month. This capacity is out of capability of the

farmers in Samarahan. So, it is a requirement to design new machine for small scale

to process pineapple in Samarahan.

According to En. Esuwandi Seruji, an officer at Samarahan IADP , most of the

farmers in Samarahan are practicing traditional ways to plant pineapple. The

plantation of pineapples in Samarahan are unscheduled and the capacity of the

pineapple can not be maintained. Samarahan area need for new machine which are

lower in cost and can be flexible with the capacity of pineapple in Samarahan.

2

pESIGNTNGA P(NI:. A('PLEM. ACHINI

Figure 1.1 : En. Esuwandi Seruji, an officer at IADP Samarahan who is

responsible for pineapple plantation in Kota Samarahan

1.3 Aims and Objectives

The aim of this project is to design a machine that capable to perform the

process of slicing and coring for Kota Samarahan area for the purpose of small and

medium industry. The objectives of this project are :

" Learn how the pineapple can be processed by slicing and coring.

" Find the way or methods to reduce the cost of the machine so that it can be

used in small and medium industry.

" Learn the process of designing.

" Design pineapple machine for slicing and coring.

1.4 Scope

This project is focus on designing for a new pineapple machine to fulfill the

requirement in Samarahan. This machine is designed for the application of farmers in

Kota Samarahan. The criteria that should be considered are the capability of the

3

DESIGNING A PINEAPPLE MACHINE

farmer in Kota Samarahan to use the machine, cost of the machine and the flexibility

to cope with the capacity.

The machine should suitable with the pineapples in Kota Samarahan in term of

sizes and weight so that suitable system can be applied to the machine. The machine

should also be suitable for the variety of the pineapple in Kota Samarahan.

1.5 Summary

In this chapter, the purpose of the project is clearly defined to redesigned new

pineapple machine to improve the existing machine. A few considerations are taken

into account in order to improve the machine. The considerations are based on the

problem statements which determine the scope of the project.

4

DESIGNING A PINEAPPLE MACHINE

CHAPTER 2

LITERATURE REVIEW

The purpose of this chapter is to study the parameters that are involved in this

project. The scope of the project based on the objectives that are stated in the first

chapter. The relevant subjects are studied to be used as a guide for this project. The

first subject is the pineapple itself that is to be processed. This chapter is also focus

on the principle operation of pineapple machine. For this purpose, a few examples of

existing pineapple machines are studied to realize the new pineapple machine that is

going to redesign.

2.1 Overview of Pineapple Machine

Usually pineapple processing machine involves the process of peeling, slicing

and coring. Each of the process needs for a sophisticated machine to perform the

process. Processing pineapple in large quantity usually involves big company for

heavy industry which required high capital cost. One of the most popular machines

to process pineapple is GINACA machine. This machine was revolutionized by

Henry Ginaca in 1911 [The American Society of Mechanical Engineers, 1993]. The

revolution of Ginaca machine bring to the increasing of production volume to more

than triple compared by using manual method that fully depend on the labor.

Ginaca machine was then implemented by DOLE company which is one of the

largest company that produce product based on pineapple. Until now, Ginaca

machine is widely used around the world after the great revolution in 1911 and many

5

DESIGNTNG A PINEAPPLE MACHINE

improvements have been achieved so that it can be applied for heavy industry. Most

of the machines are fully automated or semi-automated and used in big factory [The

American Society of Mechanical Engineers, 1993].

2.2 Pineapple Processing

The production of pineapples in industry began in Hawaii because of its natural

condition that has basaltic soil with hilly terrain (good drainage). Other factor is

because of the cheap labors. It produced sugar, a primary ingredient for syrup in

early pineapple packs. Canned pineapple began to be commercialized in 1890. All

the processes utilize hand labor include the processes of peeling, coring and filling

the can. These early factory production rate are about 15 pineapples/minute. The

using of machine to process pineapple was started by James D. Dole when he hired

Henry G. Ginaca (1876 - 1918) to design a machine to peel and core pineapples. As a

result, the machine that had been developed (called Ginaca machine until now) had

tripled the production rate and decrease the direct depend on labor. Current Ginaca

machines run at speeds around 100 pineapples/minutes and big canners utilize about

20 machines/factory. [Mitsui, 2004]

The procedures that had been developed based on classifying the fruit into a

number of grades by diameter centering the pineapple on the core axis and cutting

fruit cylinders to provide slices to fit the No. 1,2 and 2-1/2 can sizes [The American

Society of Mechanical Engineers, 1993].

The basic process in pineapple processing involves the process of coring, peeling

and slicing. Coring is done to center the pineapple so that the next process can be

done easily, while the process of peeling is done to cut out the skin and unused part

6

DESIGNING A PINEAPPLE MACHINE

from the pineapples. More important process is slicing where the pineapples are cut

into pieces depend on the way of packaging.

2.3 Pineapple Description

Pineapple is the family member of Bromeliad which embraces about 2,000

species. It is also known as Ananas comosus Men. (syns. A. sativus Schult. f.,

Ananassa sativa Lindl., Bromelia ananas L., B. comosa L. ). Usually, pineapple plant

can achieve high around 2 2.5 to 5 ft (0.75-1.5 m). The leaves spread about 3 to 4 ft

(0.9-1.2 m). The leaves is green in color or striped with red , yellow or ivory. It

plants from flower that joint together forming cone shaped, compound, juicy, fleshy

fruit to 12 in (30 cm) or more in height. Pineapple is a tropical plant which can grow

in temperature range of 65°-95°F (18.33-45°C). The rainfall that suitable for

pineapple planting is about 45 in (1,143 mm). [Morton, 1987]

Pineapple can be grouped into four main classes according to the international

trade. There are ̀ Smooth Cayenne', ̀ Red Spanish', ̀ Queen' and ̀ Abacaxi'. Type of

pineapple that can be found in India, Sri Lanka, Malaysia and Thailand is variety of

`Smooth Cayenne'. This pineapple can achieve weight from 1.8- 4.5 kg. Other

variants of `Smooth Cayenne' are Hilo (Hawai), St. Michael (Azores) and Esmeralda

(Mexico). `Smooth Cayenne' is planted because it is suitable for canning, can be

sliced and has great flavor. [Morton, 1987]

The most famous pineapple in West Indies, Venezuela and Mexico is from class

`Red Spanish'. This pineapple is approved more dependable than other class of

pineapple in that area. The most important thing is this pineapple is suitable for

7

DESIGNING A PINEAPPLE MACHINE

canning because it is more or less round, orange-red in colour with weight around 3

to 6 1bs (1.36- 2.7 kg). [Morton, 1987]

Figure 2.1 : Smooth Cayenne pineapple [Morton, 1987].

`Mauritius' is a variant of pineapple that can be found easily in Malaysia. It is also

known as `Malacca Queen, `Red Ceylon' and `red Malacca'. This pineapple is quiet

small with the weight around 3 to 5 lbs (1.36-2.25 kg) and its external colour is

yellow.

The second place is taken by `Singapore Red' which also known as `Singapore

Queen'. It's leave is usually all-green in colour and sometimes have a reddish stripe.

The fruit is also quiet small about 3.5 to 5 lbs (1.6-2.25 kg) in weight [Morton,

1987].

Another variant of pineapple that can be found in Malaysia is `Green Selangor'

which also known as `Green Spanish' and `Selassie'. With all-green leaves, it has

golden-yellow flesh with dots and suitable for canning [Morton, 1987].

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DESIGNING A PINEAPPLE MACHINE

2.4 Samarahan Pineapple

There are several variety for Samarahan pineapple. The varieties are Morris,

Josapine, N36, Gandul, Sarawak pineapple and Sawit. Therefore, the most

common pineapple in Samarahan is Morris pineapple.

Variety Weight

(kg)

Stem

(mm)

Amount of

solidity

(%)

Acid (%) Quality of

storage

Morris 1.0 24 15.9 0.49 ***

Josapine 1.3 28 16.8 0.63 *****

Sarawak 2.2 28 13.7 0.61 ***

Table 2.1 : The characteristics of pineapple variety in Samarahan.

[MARDI, 1998]

Key : ***** = very good

*= bad

Most of the pineapples in Samarahan are sold directly to the customer. There is no

industry to commercialize the pineapple in Samarahan. But when there are surplus of

pineapples, they are processed to produce cordial using the machine that is supplied

by IADP Samarahan. It is depends on the farmers themselves whether to process the

pineapple to produce cordial or not.

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DESIGNING A PINEAPPLE MACHINE

2.5 Review on Ginaca machine

The production of pineapple for commercialized was started about 1890 in Hawai.

The process is fully man-power which was needed for high labor. It becomes change

when the pineapple machine is introduced into the industry which strongly increases

the production rate. But, the requirement for the high labor was still the issue. This

issue needed for automated pineapple machine as a solution.

The operation of Ginaca machine is basically involves the process to center the

pineapple on the core ; cut out a fruit cylinder ; eradicate the crush and juice material

; cut off the end ; and remove the central fibrous core. In early when the machine was

innovated, it can process 50 pineapples per minute manually and needed for high

labor.

Ginaca is a combination of separated devices. First part is consisted of a chain

provided with pusher, a centering head and a stationary sizing knife. Second part

consisted of a six-pocket turret mechanism. Third part consisted of a skin eradicator

to remove the juice material.

After the innovation of basic Ginaca machine in 1911, there were some

improvement that were achieved to increase the capacity of the machine and decrease

the needed for high labor. The important achievement were happened on 1919., 1925

and after world war. The improvements were included the addition parts of Ginaca

machine like stationary curved tube and vertical turret mechanism [The American

Society of Mechanical Engineers, 1993].

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DESIGN ING A PINEAPPLE.. MACHINE

Figure 2.2: Basic model of Ginaca machine [The American Society of

Mechanical Engineers, 19931

2.4.1 The synchronization of Ginaca machine

1919 model Ginaca

The development of pineapple machine brings to the new model of Ginaca in

1919. The totally different are the using of inclined sizing knife and vertical turret

compared between the models before it. The maximum speed of this machine can

produce 65 pineapples per minute.

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DESIGNING A PINEAPPLE MACHINE

Figure 2.3: 1919 model Ginaca [The American Society of Mechanical

Engineers, 1993]

1925 Ginaca machine

This model has a capability to process from 90- 100 pineapples per minute. 1925

model was developed by aligning the turret with the sizing knife. The improvement

had hardly improves the eradicators, feeds, auxiliary drives and construction.

Figure 2.4: 1925 Ginaca machine [The American Society of Mechanical

Engineers, 1993]

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DESIGNING A PINEAPPLE MACHINE

Post-world war designs

After world war, there were a few attempts to improve the basic design of Ginaca

machine. The improvement was involved the combination of gravity force. The

improvement was also included the using of `jet transfer' ;a method which used

resulting pressure between the free cylinder into the turret to replace the gravity force

so that the process can be made horizontal. Most of the attempts to improve the

machine were fail to achieve their objectives due to the complexity of the machine

and failure to operate as an expected. But, the improvement that had been achieved

has increase the capacity up to 100 pineapples per minute. It was also had been

approved that basic Ginaca machine which operate base on gravity transfer are more

efficient.

2.6 Pineapple Machines Today

Nowdays, there are various types of pineapple machine that perform various types

of processes like coring, peeling and slicing. The examples of these machines are

FCPM-80 pineapple peeler, Elliot hand-operated slicer and single knife pineapple

slicer. These machines meet their requirement when applied for heavy industry. But,

they are not efficient to be applied for Samarahan area which is not large in scale for

heavy production. Other factors are the high cost for the machine and the limited

capability of the farmers in Samarahan area to operate the sophisticated machines.

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DESIGNING A PINEAPPLE MACHINE

ELLIOT HAND-OPERATED SLICER

This slices pineapple into a hollow cylinder shape for canning. The cored pineapple

fruits are fed by hand to a V-block, located underneath the cutting assembly. When

the pineapple fruit rests on the knife assembly, it passes through a series of slots

which cut the pineapple cylinder into slices. Throughput: 600-720 pineapple fruits

per hour. Dimensions: 91 x 61 x 168cm [FMC CORPORATION, 1999]

Figure 2.5: ELLIOT HAND-OPERATED

SLICER (FMC CORPORATION, 19991

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