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Design and Construction of a Small Scale Sugarcane Juice Extractor

Article  in  Asian Research Journal of Agriculture · October 2019

DOI: 10.9734/arja/2019/v11i430064

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American Journal of Engineering Research (AJER) 2019
American Journal of Engineering Research (AJER)
e-ISSN: 2320-0847 p-ISSN : 2320-0936
Volume-8, Issue-7, pp-91-97
www.ajer.org
Research Paper Open Access

Design And Fabrication of Sugarcane Juice Extractor

1 2 3
Azeez, N.A, Okpara, I.N and Ologunye, O.B.
1,2,3
Department of Mechanical Engineering Technology, Federal Polytechnic Ede Osun State, Nigeria.
Corresponding Author: Azeez N.A

ABSTRACT: Over the years, small-scale farmers have supported Nigerian sugar cane production, which finally
stop using its teeth to bite the rind and to chew the inner tissues to sweet the juice. At the concentration level, the
juice is extracted. In order to boost the production of the sugar cane and its product, we have embraced a project
called SUGARCANE JUICE EXTRACTOR. Assessment of the sugar cane extractor functionality as regards its
effectiveness in the extraction of juice. The approach in this project is to design a machine that consists of the
2.0-hp gear motor and crush mechanism of the machine, consisting of gears, latchers and three rollers which
have then been mounted with the juicer and inlet and outlet on the frame.
KEYWORD: Fabrication, Juice Extractor, Roller and Sugarcane
----------------------------------------------------------------------------------------------------------------------------- ----------
Date of Submission: 30-06-2019 Date of Acceptance: 19-07-2019
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I. INTRODUCTION
Sugar cane is commonly referred to as the source of grain of sugar for daily use. It is also difficult to
crush the cane to extract the savory ones. There is strong fiber in the plant. It is also known for its power and
shape, a long straight plant like bamboo. It is also used for the production of sugar by extracting a healthy juice.
In the subcontinent of Nigeria, Asia, and India, sugar cane juice which migrates thousands of years ago is
popular. The juice can be drunk directly after pressing the sugar cane (Abamaster, 2010). A very powerful roller
is needed in order to crush this tough sugar cane and force it to crush and the juice is therefore squeezed from the
plant. The sugar cane and juice was crushed by hand since early days. Over the years, small farmers have been
promoting Nigerian cane production, who end up bite-rinding with their teeth and chewing the internal tissue for
sucking juice at a comsuntional rate. (Soetan, 2018)The interest in drinking this juice at present is reduced, as it is
difficult to find a clean and appropriate process during juice manufacture. Sugar cane juice was mostly sold on
the side of the road that was not clean due to dust and wind germs. The sugar cane juice is best, fresh and chilled.
A clean processing mechanism and the proper disposal of its fibers constitute an interesting option for better
marketing for the crusher press. (Anonymous, 2018) After extraction, the sugar fiber plant is called bagasse.

1.1 STATEMENT OF THE PROBLEM

Most sugar cane juice was sold by a small business with a conventional extraction machine. The sugar
cane farmer generally provides direct supply to small companies. It's the default method. A new transition in the
sugar cane juice industry could change the chain cycle of farmers and cane sugar sellers. Sugar cane will be sent
to the cleaning, skinning, cuts and packaging house of goods. The sugar cane will be transported from the
warehouse to the sugar cane seller. An extractor of sugar cane juice with an orderly disposal shopping complex.
A cane farmer uses bagasse as decomposed fertilizer from an extractor machine.

1.2 AIM AND OBJECTIVES

To produce a sugar cane extractor with an appropriate disposal for the bagasse and can be used in a closed room.
 Manufacture of sugar cane juice extractors with local materials.
 Evaluation of the functionality of the sugar cane extractor in relation to its juice extraction efficiency.
 Develop a prototype of the sugar cane juice bagasse extractor.

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1.3 SCOPE OF STUDY

This project includes
1. The development of juice extraction mechanisms for the extraction of sugar cane juice.
2. Develop a system of cleaning.
3. Cut and collect the bagasse.
4. Set the sugar cane juice filter up.

The study would benefit industry people and the community as well. The study offers people
information about sugar cane and the advantages it offers. This will provide a new company for the industry to
sell the sugar cane juice as a drink.

II. LITERATURE REVIEW

2.1 HISTORY OF SUGARCANE
Depending on the taxonomical system, sugarcane is one out of 6 to 37 species in large, long-term
grasses (Naturland, 2010). Sugarcane is a tropical grass in the same family as sorghum, johnsongrass and maize
(Purseglove 2018). It is of the kingdom of Planteae, phylum magnoliophyte, Poales, Poaceae and Saccharum L
genus. Only rarely can sugarcane make sprouting seeds. It is from the kingdom of Plantea, phylum
magnoliophyte, Poales, Poaceae and Saccharum L genus (munocotes, commelinides). Cross-fertilization between
S is most of the several hundred used clones. S.sinensis (adjustable), S. officinarum (high sugar content). S. and
spontaneum. Strength (resistant disease). The most common clones are octaploid and propagated vegetatives
(Naturland 2010), with eight corresponding clones, similar in position, structure, function or characteristics in a
cell of chromosome sets.

2.2 MILLING AND JUICE EXTRACTION

The picked sugar cane is cleaned and washed first in the mill. They are then broken down for removal,
and several rollers (2-18 roll combinations) are made before they are transmitted to roller mills. The sugar cane
juice extraction machine would be suitable for the factory's design and function. The collected juices contain
between 10 and 15% of sucrose and fibrous substances, called bagasse, which are burned for fuel. For sugar
mills, Bagasse makes energy self-sufficient. In the production of animal feed, paper or electricity for sale, surplus
bagasse is used. 24 The next thing to adjust pH to 7 is the cinnamon juice. (Boyel, 2019). This mix arrests
sucrose decline and precipitates certain impurities into glucose and fructose. The mixture sediments and allows
for the calyx to settle and other hanging solids. In a multi-effect evaporator, the clarified juice is concentrated to
form syrup of approximately 60% by weight. It is concentrated further in vacuum and is over saturated until
crystalline sugar is added to the syrup to activate syrup-like sugar crystallization. More sugar crystallizes the
syrup when cooled. The sugar is separated from the molasses by a centrifuge. More sugar are extracted from
additional crystallizations, the final residue is called blackstrap.

2.3 EXISTING SUGARCANE EXTRACTORS

Modern sugar cane juicer has gone far from the traditional wooden roller used by native people in
countries such as Panama and Colombia. The commercial cane juice extractor is very expensive. The search for a
home model can also prove difficult. This can be difficult to find and could require an order from another
country, such as Malaysia, Singapore and India, which provides a sugar cane tabletop press (Naturland, 2010).
Some food traders in the United States have become a cane extractor to tap the market for organic juices. Some
extractors can process around 170 ducks an hour while others have an easy filter system. Extractors by Munoz,
(2018) also have differing prices. A less expensive model can be found in a highly powerful savory and vegetable
extractor where true sugar cane extractors can amount to up to $3000 to large industrial plants.

THE TRAPICHE
The Panamanian and Colombian people use a traditional timber press for extracting sugar cane juice as
trapsiches. This is the Spanish language for sugarcane crousher, when it is applied in a machine or a sugarcane
mill. (DEP, 2018). The machine consists essentially of wood and has various sizes. There are two vertical rollers
in the sugar cane. These rollers are held in place by a wood frame, while a longitudinal twisting grove receives
and transmets the rotating movement towards the second crushing roller. The extraction of juice is done by hand
or by boiling animals (mostly for the larger and the static ones found in the molding).

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Figure 2.1: The Trapiche (Heiser, 2013)

III. MATERIALS AND METHOD

The extractor machine consists of gears, crushing rollers, rollers, coupling, fixtures, metal frames and
gear engines. The following are the various parts of the extractor of sugar cane juice:

3.1.1 THE CRUSHING UNIT/ ROLLER

The crush unit consists of three rollers, one big roller and two tiny rollers. The wide roller with a
diameter of 100 mm and the longer, mild steel and the two wide rolls of 77 mm with a length of 300 mm and a
mild roller of steel. The diameter of the rollers is 300 mm. These rollers are made of mild steel due to their
resistance to compression. The mild steel bars have been coated by a lathmachine and become aggressive,
forming a rib-like structure. These provisions ensure that, unless removed, slipping in the case of plain crushing
rollers occurring during feeding with sugar cane will be reduced to minimal.

3.1.2 GEARS
The top-mounted roller controls the movement of two bottom-mounted rollers. The roller gears are 23
teeth mesh, which means that the three rollers depend on each other. The two other rollers move at the same
speed as the top roller shaft, but in the same direction. The transmission is carried through the gear motor to two
more rollers. The dental gear decreases the transmission rate to the broken roller so that the transmission torque
on every roller increases. This increases the crushed strength of the roller surface.

3.1.3 POWER SOURCE

The electric gear engine is 2 hp. The input is connected with the input. The engine speed is reduced to
1:55 of the speed reducer from the engine, which is 1440rpm. The gear motor speed is 26.2 rpm for this power
source.

3.1.4 THE MACHINE FRAME

This part consists mainly of the mild steel angle bars. Two flat shaped "H" profiles are made from mild
steel. This is mounted on an angle bar stand ; the engine is placed on top of the stand.

3.2 MATERIALS
 T he Steel plate:- the stainless steel plate would be used.The used plate is 1.5 mm thick and the buying
measurement reaches 700 mm by 500 mm.

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 Bolt and nut: - For coupling the cut out details together, selecting bolts and nuts having a threading
diameter of 10mm.
 Cutting disc and grinding disc: - These are attached to the angle grinder to power its operation. The cutting
disc when it is attach it would be used to cut the plate metal to the desired shape and orientation, while the
grinding disc would also be used to smoothed the roughness on the cut detail.
 Welding electrode: - A welding electrode of the required specification is used. Details which need to be
permanently held together are joined through welding process.
 Non-polar solvent: - This is chosen based on market availability. The purpose of the solvent is to wash and
clean the metal parts which have been packed with dust and debris. The choice of solvent was one of the
petroleum hydrocarbon products e.g. petrol, kerosene.
 Iron Wire brush: - It would be used to brush off the corroded surfaces. This would prepare the surface for
painting.
 Paint: - Silver-colour paint would be used to coat, protect and add lustre to the extractor.
 Painting brush: - This is used in paint application to the machine surfaces.

3.3 DESIGN CALCULATION

 Based upon research, on this two 2 mm average sugar cane squeeze its juice manually at a thickness of 2.5 -
3.5 mm, the thickness with assumed thickness was used with these 100 mm, 75 mm and 65 mm rollers.

Design Analysis
Maximum force of failure (Mf) = 120 N
Safety factor (SF) of 1.6
RPM=1440rpm
Gear motor ratio: - 55:1
Gear motor rpm: - 26.2rpm
Force require to crush the sugarcane= 120n
Crushing force for the design 𝐹𝑐 = 𝑀 𝑓 x 𝑆𝑓
𝐹𝑐 = 120 x 1.6 = 192N
𝑀𝑠= 130 g = 0.13 kg s
 Design of Roller Size
Diameter of big roller, 𝐷 = 100mm=0.1m, r = 0.05m
Angular velocity (𝜔) =2 𝜋N/60= 3.142 x 2 x 1440/60 =150.8rad/s
Velocity (v) = 𝜔 x r = 150.8 x 0.05 = 7.54m/s
 Power Selection for Motor
Torque transmitted to the big roller
𝑇=𝐹𝑥𝑟
T= 192 x 0.05= 9.6Nm
Power required P = T𝜔
P= 9.6 x 150.8 = 1447.68w=1.448Kw
1hp = 746w ---------- constant
x = 1447.68
x = 1 x 1447.68 / 746 = 1.94= 2hp
i.e. 2.0Hp motor of 1440 rpm is required

 Determination of Actual Motor Torque

The angular velocity of motor,
𝜔 = 148.72 rad/s
Motor torque, 𝑇𝑚 = 𝑚𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 (𝑃𝑚) An𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜(𝜔)

 Gear Mechanism

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Figure 3.1 Gear movement and direction of rotation

 Gear Data
Depth = circular pitch /2
Number of teeth = 31
OD = 100mm
Width = 20mm
Bore diameter = 28mm

3.4 PROCEDURE OF FABRICATION

Following the designed work drawing for each section, the materials were sorted. Rotation of rollers,
gear cutting and gear motor sorting. The angle bar was trimmed to the necessary size and the frame was covered
with mild steel plate material.. Before the major joint and assembly processes started, the required drilling was
done. When the details are taken, four (4) major components constitute the mechanism of the work on the
sugarcane juice extractor. These include::
1. Electric gear motor
2. Spur gear
3. Rollers
4. Bearings

3.5 OPERATION INVOLVED

3.5.1 LATHE OPERATION
The Lathe machine used to manufacture roll shaft turning steps in both ends; the first stage with 30 mm
and 58 mm diameter and length, the second step with 100 mm and 150 mm diameter and lenght, and the next step
with diameter and length, 30 mm and 132 mm. Last step with 30 mm diameter and 77 mm length, from the end
of second end. Twists of 50 mm diameter and 50 mm length coupling and the bore and boiling of the coupling
also produce a diameter of 229 mm.

3.5.2 SHAPING OPERATION

The shaping machine was used to cut and shape the spur gear of 3 Nr 4(involute) module, outer diameter
of 99mm,depth of 7mm, width of 20 and the number of teeth of 31.

3.5.3 DRILLING OPERATION

The pillar drilling machnine is used to drill 6mm thick plate and bore to the diameter of 32mm. The
hand drilling machine was also used to drill the body for easy fasterning.

3.5.4 CUTTING OPERATION

The use of the cutting machine is used for detailed measurements.

3.5.5 WELDING OPERATION

For all joints of the single component of the sugarcane juicer, the welding machine was used. 3.5.6 GRINDING

OPERATiON
The grinding machine was used to mow the joint, component surface in deburr, and the sharp ripples in order to
have a smooth surface before painting the body.

3.6 PRINCIPLE OF OPERATION

The 3 rollers in a sugarcane juicer with a larger diameter of up to 100 mm, the transmission by coupling
of torque by the electric gear motor, and a reverse rotation of both rollers with the diameter of69 mm and 79 mm

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as shown in Figure 3.1 above, draw the sugar cane and squeeze the baggage (residue) on the outside,
respectively.

3.7 TEST PARAMETERS AND PROCEDURE

After the machine was assembled, the machine was checked for efficiency to know whether the
modification was adverse to or beneficial to the machine.

3.7.1 TEST PROCEDURE

For the test, the following equipments and materials were used.
1. Lengths of harvested sugarcane.
2. The sugarcane juice extractor.
3. A 2.0 hp electric gear motor
4. A weighing balance for weighing the sugarcane, juice or bagasse.
5. Vernier calliper for measuring diameter.
6. A measuring tape for measuring the sugarcane length
.7. A container for collecting the extracted juice.
8. A stopwatch.
9. Calculator
10. polythene bag
When the sugar cane was purchased from the market, it had been cleaned prior to the production and
registration of large dimension quantities like the average diameter, length and weight. In addition, sugar cane
was split and labelled A to G in specimens. The motor is warmed up for 10 minutes before the sugar cane juice
extractor is used. Preliminary testing was progressively performed on the machine using specimens A, B and C,
while the main final test was performed using specimens D to G. At 75 ° angle between the rollers in the
operating chamber, all specimens were fed into by hand, and the juice collected downwards while the bagasse
was extracted by the channel on the rear. The stop-clock is activated from the beginning and stop at the end of the
extraction process for each specimen extraction. After each specimen of sugarcane has been subject to a 5-fold
process of extractions, the bagasse is collected in a marked polythene bag and its weight is recorded, the
calculations to check the machine efficiency are carried out when the process is read.

IV. RESULTS AND DISCUSSION

4.1 DIMENSIONS OF SUGARCANE SPECIMEN
The dimensional characteristics of the purchased specimen of sugarcane were highlighted in the previous chapter.

Table 4.1: Dimensions and weight of the sugarcane specimens

Sugarcane Head diameter Middle Tail diameter Average Length Weight (g)
specimen (mm) diameter (mm) (mm) diameter (mm) (mm)
A 31 32 32 31.67 600 806.3
B 36 37 35 36 550 1000.5
C 34 35 36 35 490 997.3
D 37 36 36 36.33 600 1130.4

Following measures, specimens A and B were used as described in the previous ch. for preliminary
testing, while specimens C and D were used to test the improved machine finally. As shown in the previous
chapter.

4.2 TESTING
When the sugar cane was inserted into the sugar cane extractor, the juice is then extracted and the
baggases removed by turning the three rollers.

4.2 EFFICIENCIES OF JUICE EXTRACTION

The values and result of the preliminary test carried out at the first test of the machine are shown in
Table4,2, which estimates and assumes the maximum juice release of the sugar cane to 85% of its initial weight
(Soetan, 2008). The machine's main test is then performed and presented in Table 4.3. In order to obtain machine
efficiency results, all formulas are used as appropriate.

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Table 4.2: Result Of Performance Text
Specimen Length (mm) Initial weight Bagasse weight Weight of juice 85% of initial Extraction
(g) (g) extracted (g) weight (g) efficiency (%)
A 600 806.3 486 320.3 685.4 46.7
B 550 1000.5 580.3 420.2 850.4 49.4
C 490 997.3 530.2 467.1 847.7 55.1
D 600 1130.4 630.1 500.3 960.8 52.1
Mean/Average 50.8

4.4 THE RATE OF JUICE EXTRACTION

The total weight of the extracted sugar cane juice (wj) is calculated to be 17079 g, parameter as shown
in Table 4.2 above. The total time required for the removal process (tj) is 160 seconds. The machine extraction
rate of the juice extraction rate is measured.
Thus, the rate of extraction ɳr = 17079g = 106.74g/sec or 384.3kg/hr
160
(Rate of extraction in litres) = 0.10674 l/s or 0.3843 l/h
Therefore, this sugarcane juice extractor can produce 0.10674 liters /seconds

V. CONCLUSION AND RECOMMENDATIONS

5.1 CONCLUSION
The extractor of sugar cane juice has a unique design that is quiet during operation (can be operated in
an enclosed door) as well as compact. It squeezes any sugar cane of a diameter of less than 52 mm. The
interaction between contaminants and extracted juice is considered negligible with the supplied isolation of the
extraction process from the environment. Due to the electric transmission motor used, the rollers worked without
being stuck independent of the sugar cane juice.

5.2 RECOMMENDATIONS FOR FURTHER IMPROVEMENTS

Therefore, if additional work is to be carried out on the machine, the following and modifications to the
manufactured machine are recommended.
1. In areas where contact is made between the juice and the side plate which holds the rollers of the machine
when used industrially, stainless steel can be used. This would improve the machine's hygiene.
2. A sieve can be used to collect small bagasse particles which can be drawn with the extracted juice via the juice
chute or exhaust.
3. Add a travel wheel to help the machine mobility from one area to another.
4. A cutting section to cater can be constructed and attached to the machine to complement its operation and
scrap the sugar cane before the juice is extracted.
5. The crushing mechanism, when feasible, can be adjusted to vary the gap between the rollers and thus vary in
crushing and extracting juices in different diameters.

REFERENCES
[1]. Abamaster (2010), Counter top Sugarcane Juice Extractor. Retreived from: www.abamaster.com/productSpecWeb.
php?modelId=2000
[2]. Anonymous (2018), Sugarcane Bulgaras. Florida State University Publication.
[3]. Boyel, H. (2019), Distribution of Sugar Cane Production in Cuba. Economic Geography 15
[4]. DEP Agro Machineries Private Limited, (2018). Sugarcane Crushers. Retrieved from www.depagro.com
[5]. Heiser, C. B. (2013), Seed to Civilization: The Story of food. Second ed. W. H. Freeman and Co., San Francisco. 254pp.
[6]. Munoz, R. A., Suchman, E. A., Baztarria, J. M., Lehtola, C. J. (2018). Sugarcane Cultivation and Processing.
www.ilo.org/encyclopedia.
[7]. Naturland (2010), Organic Farming in the Tropics and Subtropics: Sugarcane, First Edition.www.naturland.de
[8]. Soetan, C. A. (2018). The Development of a Sugarcane Juice Extractor for the Cottage Industry. B. Eng. Project Requirement.
Department of Agricultural Engineering, University of Agriculture, Abeokuta, Nigeria.

Azeez N.A " Design And Fabrication of Sugarcane Juice Extractor " American Journal of
Engineering Research (AJER), vol.8, no.07, 2019, pp.91-97

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