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Design and Simulation of a Vegetable Shredding and Washing Machine .

International Journal of Excellence Innovation and Development

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 International Journal of Excellence Innovation and Development
||Volume 2, Issue 3, Mar. 2019||Page No. 33-41||

Design and Simulation of A Vegetable

Shredding and Washing Machine
B. O. Akinnuli1, O.O. Ojo2, O.O. Caleb3, K. A. Okeyedun4
1,2
Department of Industrial and Production Engineering, Federal University of Technology, Akure, Nigeria
3,4
Department of Mechanical Engineering, Federal University of Technology, Akure, Nigeria

Abstract––Value addition to vegetables prior to mechanical damage. These losses have been estimated to
domestic use can be attained via processes such as be more than 50% in the tropics and sub-tropics. To
hygienic washing, shredding, and packaging. Manual reduce these losses and derive maximum utilization and
processing of vegetables is time-consuming while economic gains from vegetables, adequate preservation by
contamination and additional manpower are the notable way of processing vegetables is required. Quality
drawbacks of existing vegetable cutting machine. With preservation, safety and enhanced long shelf life of
the outlook of circumventing these challenges, this paper vegetables are areas of interest in modern manufacturing.
studies the design and simulation of a motorized electric-
driven vegetable shredding and washing machine. The Washing and cutting are the major operations required for
capacity of the designed machine in terms of the mass of the processing of vegetables. These unit operations are
vegetable that can be processed per hour is 83 kg/hr. The carried out via traditional techniques. The output of the
static structural components of the machine were traditional technique has been found to be low and wastes
simulated to test for the possibility of failure. The time due to the drudgery of the process. Shredding
maximum stress (190.12 MPa) that occurred on the (slicing, cutting or dicing) of vegetables by using kitchen
components of the machine was found to be less than the knife exposes human to the danger of knife cut. On the
material yield strength (250MPa). The simulation results other hand, washing of fresh vegetables can reduce the
confirm that the designed shredding and washing overall potential for microbial food safety hazards. This is
machine will have a long service life. Antimicrobial an important step since most microbial contamination is
agents are recommended as liquid constituents (for on the surface of vegetables or fruits [6] [7].
vegetable washing) in order to inhibit contamination and Contamination and spreading of human pathogens and
microbial reactions. microbes to a greater portion of vegetables ensue if they
are not removed, controlled or inactivated [3] [8-10].
Index Terms––Design, simulation, washing machine, Hussain et al. [11] recommended that fruits and
vegetables, vegetable shredding, shredding and washing vegetables must be cleaned after they are harvested to
improve product appearance and edibility, and to remove
INTRODUCTION harmful microorganisms that can shorten the life of the
Vegetables are referred to as edible plants or the edible products. Likewise, vegetables need to be prewashed to
parts of plants [1] that help in preventing micro-nutrient get rid of immediate surface dirt and pesticide residues.
deficiencies and other nutritional diseases [2]. Mechanical cleaning system has been identified as an
Vegetables are valuable nutritional sources of vitamins, effective approach of removing mites and other surface
minerals, and fiber [3]. The high fiber nature of arthropods from fruits [12] and this can be adopted for
vegetables controls blood sugar levels, prevents vegetables as well.
constipation, lowers the risk of digestive conditions,
cardiovascular diseases, and blood cholesterol levels [2]. Diverse works have been carried out on cutting or slicing
In fact, vegetables with the right proportion of process. For instance, Ndukwua and Onyenwigwe [13]
antioxidants, minerals, and phytochemical help in worked on the development of a motorized parboiled
keeping blood sugar in balance, create better energy in cassava tuber shredding machine in 2013. Leo and
the body and build up the immune system (with the Balogun [14] developed a functional multi-crop slicing
addition of fruits). Non-leafy vegetables like garlic and machine while Raji and Igbeka [15] invented a pedal
onions contain allicin, the anti-viral, antibacterial, and operated chipping and slicing machine for tubers. Food
anti-fungal phytochemical that can act antibiotics [4]. processor [16], vegetable shredder [17], and processing
The human-body need for vegetable cannot be apparatus for leafy vegetables [18] have been developed
overemphasized because vegetables are essential dietary over the years. Recently, Kamaldeen and Awagu [19]
requirements for a healthy living. However, huge post- developed a tomato slicing machine. Klintham et al. [20]
harvest losses of vegetables are experienced by farmers employed microbubbles (MB) technology as a washing
and marketers due to the high perishability nature of mechanism/process to reduce the microbial contamination
fresh vegetables, poor handling, and inadequate storage on leafy vegetables. Tony et al. [21] designed and
facilities. FAO [5] reported that over 23 % of most developed an automated vegetable cutting machine.
perishable fruits and vegetables are lost during their
journey (harvesting, transportation, processing, and Frank [22] worked on blade assembly for paper
packaging) through the agricultural food chain due to shredder. Nithyananth et al. [23] and Joseph [24]
spoilage, physiological decay, water loss, and designed waste shredding machines for waste seize

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Design and simulation of a vegetable shredding and washing machine Akinnuli et al.

reduction, while Mandal [25] made available data required Design Calculations and Analysis
for design of shredder blades. Gear protection device of a Some factors were considered in the design of the
paper shredder was developed by Frank [26]. The blade vegetable shredding and washing machine. These
for the paper shredding cutting tool was designed and include capacity, drudgery reduction, simplicity and
produced by Emily [27]. Mark et al. [28] worked on flexibility of the machine, and strength of materials.
lubrication caring substrate for shredder maintenance, the Hopper, shredding discs, power drive mechanism, shaft
rotational speed controlling the system for shredder design, the power requirement of the pump, bearings,
motors was investigated by Hunag [29]. Hunag [30] also supporting frame, and capacity of the machine were
studied elliptical acetabuli for blade for shredder. designed for.

Many of the existing vegetable cutting machines do not Hopper

incorporate or have washing chamber and consequently, It has a trapezoidal shape connected to a shaped
operators are required to collect the shredded vegetables extension. The base of the hopper opens into this
and subject them to manual washing via random extension from the top so that the feeding of vegetable
movement of hands on the vegetables in a sizable bowl of can be aided by gravity. This was achieved through a
water. Thus, there is a need to have a mechanized process proper choice of inclination of the hopper to the
or a machine capable of shredding and washing horizontal which was made greater than the angle of
vegetables in order to a time-optimizing process (time- repose (angle of 450 was chosen). Figure 1 shows the
saving and increased production). This paper focuses on schematic illustration of the hopper.
the development and simulation of a vegetable shredding
and washing machine that is capable of processing a small
to medium scale quantity of leafy vegetables.

CONCEPTUAL DESIGN OF THE

MACHINE
Description of the Designed Machine Fig. 1: Hopper
The conceptual design of the vegetable shredding and
washing machine was carried out. The machine was Shredding Discs
grouped into four units namely feeding (hopper), The diameter (D) of the shredding disc is assumed to be
shredding, washing and frame/support. The hopper higher than the average diameter of a cabbage. Thus, D
(feeding unit) is the unit through which the vegetable is taken to be equivalent to 115 mm and the morphology
material can be fed into the machine for processing and of the shredding disc is shown in Figure 2.
the feeding will be aided by gravity.

The bottom end of the hopper connects to the shredding

unit. Inside the shredding unit is the cutting shaft which is
the primary transmission component that does the
shredding operation. The shaft has keyways through
which the main shredding disc can be keyed to the shaft
during cutting so as to counteract vibration that may arise
as a result of the cutting action. Two bearings are fixed at
the two ends of the shaft such that one end of the shaft is
connected by means of pulley and belt drives to an electric
Fig. 2: shredding disc
motor (located slightly below the shredding unit) which
drives it. The electric motor has its own pulley so that it is
The total kinetic energy stored in the disc is given in
connected to the upper unit and the downward unit
Equation 1. Where I is a moment of inertia (kg-m-2) and
(washing unit) by means of a belt and pulley. The material
w is the angular velocity (rad/s). Equations 2 and 3 show
from the shredding chamber enters the washing chamber
the expressions for the estimation of the moment of
through the delivery chute.
inertia and angular velocity for the shredding disc,
respectively.
The washing unit facilitates the washing of the vegetables.
The electric motor is also connected to the washing unit (1)
by means of a belt, pulley and bevel gears respectively. (2)
The bevel gear drives the three-dimensional pedals
located inside the washing drum. These pedals rotate via (3)
the gear drive and facilitate the vigorous movement of the Where, Wd is the weight of the disc (kg), is the density
water inside the drum. The washing basket is simply a of the shredding disc material (stainless steel, equivalent
medium sized perforated mesh whose handles are placed to 7930 kg-m-3), R is the radius of the shredding disc
on the edges of the washing drum. The vegetable ( ), g is the acceleration due to gravity, t is the
materials after being washed are collected by removing thickness of the disc ( ), is the angular distance in
the perforated mesh. Lastly, the frame is the supporting rad/s (360 rad/s), and is the time in second (4 s). The
unit on which the entire components will rest/sit. computed values of I and w based on equations 2 and 3

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 International Journal of Excellence Innovation and Development
||Volume 2, Issue 3, Mar. 2019||Page No. 33-41||

are equivalent to and 90 rad/s (9)

respectively. Thus, the total kinetic energy stored in the
disc (according to Equation 1) is estimated to be 332 J. (10)
Where T1 is the tension at the tight-side (N), T2 is the
tension at the slack side (N) and R1 is the radius of the
The Power Drive Mechanism motor pulley (35.5 mm). Equation 11 is obtained by
A single phase electric motor of 1hp was chosen for the substituting the values of T and R1 into Equation 10.
drive mechanism. The electric motor selected (rated 1hp)
delivers a speed of 1440 rpm which was stepped down to T1– T2 = 140.08 (11)
the required speed by appropriate shredding shaft pulley.
The diameter of the motor shaft pulley was taken to be The ratio of the tensions in the belt is expressed as
71mm. Equation 12. Where, µ is the coefficient of friction of
leather on steel (0 ), and is the angle of contact of
The friction coefficient and friction velocity threshold the belt on the smaller pulley, in rad. The substitution of
between the belt and each of the pulleys was assumed to the values of T and into Equation 12 produced
be the same. In determining the speed of the shredding Equation 13.
shaft pulley, the expression (Equation 4) given by
Khurimi and Gupta [31] was used according to rotor- (12)
motor shaft arrangement shown in Figure 3.
T1 = 2.085T2 (13)

Substituting T1 (2.085T2 or Equation 13) into Equation

11, tensions at the slack side (T2) and at the tight-side
(T1) are obtained as 129 N and 269 N respectively.

Shaft Design
The combined twisting moment and the equivalent
bending moment were considered in order to obtain the
correct diameter of the shaft during the shaft design. The
Fig. 3: Rotor-motor shaft configuration. loading diagram of the shredding shaft is illustrated in
Figure 4. RA and RB are the reactions at A and B
(4) respectively. The weight of the evenly distributed
shredding discs is 800 N. The estimated values of RA
Where, D2 is the diameter of the pulley on the shredding and RB are 266.7 N and 533 N respectively.
shaft (180 mm), D1 is the diameter of motor pulley (71
mm), N1 is the speed of the electric motor (1440 rpm),
and N2 is the speed of the shredding shaft pulley.
According to equation 4, the speed of the shredding shaft
pulley was estimated to be 568 rpm. The minimum
center distance (Cm) is estimated to be 161 mm by
employing Equation 5. The length of the belt (Lb) is
Fig. 4: Loading diagram of the shredding shaft.
evaluated as 546 mm via the use of Equation 6.
The shear force and bending moment diagrams of the
(5) shredding shaft are shown in Figure 5. The maximum
(6) bending moment is indicated as “B.M = max” at a point
G (center of the shaft) on Figure 5.
The identification of the tensions in the belt (tight and
slack tensions) requires prior knowledge of the angle of
contact on the pulley. By employing Equations 7 and 8,
the angles of contact on the pulleys are determined.
Where, R2 is the radius of the shredding shaft pulley (90
mm), R1 is the radius of the motor shaft pulley (35.5
mm), and is the angle of contact of the belt on the
smaller pulley (estimated to 2.94 rad).

(7)
(8)

The torque transmitted is estimated to be 4970 N-mm via

Equation 9. Where P is the power transmitted (750W).
Similarly, the torque transmitted can as well be Fig. 5: Shear force and bending moment diagrams of the
estimated using Equation 10. shredding shaft

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Design and simulation of a vegetable shredding and washing machine Akinnuli et al.

The maximum bending moment is computed according tangential force acting on the shaft, WRH is the axial
to Equation 14 to be 60000N-mm. Where M is the force acting on the shaft, WRV is the radial force acting
maximum bending moment in N-mm, L is the distance on the shaft (27.12 N), RA is the reaction at A and RB is
between the bearings (300 mm) and W is the weight of the reaction at B. RB and RA were estimated to be 23.73
the shredding disc (800 N). N and 3.39 N respectively.

(14) The diameter of the bevel gear shaft needs to be

estimated and a procedural approach is followed
The torque transmitted by the shaft is estimated to be according to Gupta, (2005). The torque (T) on the gear is
4970 N via the use of Equation 15. Where T is the torque estimated to be 4970 N-mm according to Equation 21.
transmitted by the electric motor in N, P is the power Where P is the power transmitted (750 W), and N is the
transmitted by the electric motor (1hp = 750W), and N1 speed of the motor (1440 rpm). The specifications in
is the speed of the electric motor (1440 rpm). Table 1 were employed for the bevel gear and shaft
design in this section.
(15)

Similarly, the equivalent twisting moment ( ) is

computed as 60205.728N-mm by employing Equation
16 (by substituting the values of Equations 14 and 15
into Equation 16).

(16)

Thus, the diameter of the shredding shaft is evaluated as

19.4 mm by employing Equation 17. Where is the Fig. 6: Loading diagram of the bevel
allowable shear stress (42 MPa for a shaft with
allowance for keyway), d is the diameter of the shaft in (21)
mm and is the equivalent twisting moment
Table 1: Properties employed for the design
(17) S/N Properties Specification/values
1 Material Hardened steel
On the other hand, when the equivalent bending moment 2 Yield strength 250 MPa
(see Equation 18) and twisting moment (see Equation 3 Tensile strength 400 MPa
19) are employed for the estimation of the shaft 4 Factor of safety for 4
diameter, a value of 19.39 mm was obtained. Where, steel
is the equivalent bending moment, is the
5 Allowable static 250/4 = 62.5MPa
equivalent twisting moment, is allowable bending
stress (84 MPa for a shaft with allowance for keyway), stress =
and d is the diameter of the shaft. Conversely, the 6 Power 1hp[750W]
diameter of the shaft was taken to be 20 mm because the 7 Gear teeth
value is closest to the standard value. composite system
(Khurmi, R.S. (2005))
(M +Te) (18) 8 Angle between the 900
two shaft axes
(19)
The pitch angle ( ) of the gear, the formative number
Power Requirement of The Pump of teeth ( ), tooth form factor ( ) were calculated by
The power required by the pump is calculated by the
using Equations 22, 23, and 24 respectively. The values
employing Equation 20. Where P is the pump power
of 450, 14.1420, and 4.727 were obtained the pitch
(watt), Q is the flow rate, m3/s (0.013 m3/s), H is the
angle, formative number of teeth and tooth form factor
differential head (1 m), is the density of water, kg/m3
respectively.
(1000 kg/m3), g is the acceleration due to gravity, m/s2,
and η is the pump efficiency which is taken to be 80%.
The pump power was estimated to be 0.17 KW. Thus, in (22)
order to overcome head of 1 m, a pump with 0.3hp was (23)
chose (24)

(20) The tangential load ( ) on the gear is expressed

η
according to Equation 25 to be equal to 994.58/m
Design of the bevel gears and shaft: The loading diagram provided is equal to . Where m is the module, T
of the shaft is shown in Figure 6. Where, WT is the is equal 4970 N and is 10 in value.

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 International Journal of Excellence Innovation and Development
||Volume 2, Issue 3, Mar. 2019||Page No. 33-41||

(25) diameter can be estimated. Where, is the equivalent

twisting moment (Nmm), is the shear stress in MPa and
d is the shaft diameter. The (shear stress) is assumed to
Pitch line velocity (V) is expressed by using Equation 26 be 0.2 of the yield strength (250 MPa) and this is
to be (m is the module). Where N is the estimated as 50 MPa. Thus, the diameter of the shaft was
speed of the motor (1440 rpm). estimated as 28.3 mm and a standard shaft diameter of
30 mm was chosen from ASME since the calculated
(26) value was nearest to the standard value (30 mm).

Velocity factor ( ) and line of pitch cone element (L) (35)

are estimated via the use of Equations 27 and 28 (36)
respectively. L is estimated as (m is the (37)
module) while is and is equal to . The
substitution of Equation 28 (or the value of L) into Bearings, Supporting Frame and Capacity of The
Equation 29 gives the value of the face width (b) to be Machine
(m is the module). The designed machine has four bearings, two of which
are located at the two ends of the cutting shaft and the
(27) other two bearings are located between the bevel and the
driven pulley. Static and dynamic load conditions and
(28)
design life requirement were the factors considered in
(29) selecting the bearing. Sealed pedestal bearing, the
diameter of bore was selected as it satisfied the design
requirement. The impact of the weight of raw material
The tangential load ( ) acting on the gear is estimated
the hopper is going to accommodate, shafts, the
according to Equation 30. Meanwhile has been
bearings, washing chamber were considered in designing
estimated to be equal to 994.58/m (from Equation 25).
the frame. The proposed capacity of the machine was
The value of M is computed as by
calculated through the use of Equation 45 in terms of
substituting b, and L (having the unknown m in them) mass of vegetables per batch that can be processed by
into Equation 33. The allowable stress ( ) is 62.5 MPa. the machine. Where M is the mass of the vegetable that
can be processed per batch in kg, V is the volume
(30) vegetable will occupy in mm3, is the density of
vegetable. The density of vegetable was taken to be the
Based on the obtained module (m is equal 5.9 mm), the average density of cabbage that is 0.000034kg/m3 [32].
addendum (a is equal to 1m), dedendum (d is equal to
1.2m), working depth (Wd is equal to 2m), minimum (45)
clearance (Cmin is equal to 0.25m), pitch diameter (
is equal to ), length of pitch element (L is equal The volume to be occupied by the vegetable is taken as
to ) are estimated as 5.9, 7, 11.8, 1.475, 59 and the volume of the hopper and this is estimated via the
41.7 mm respectively. The mean radius (Rm) and the use of Equation 46. Where V is the volume of the
tangential force acting on the mean radius are estimated hopper, L is the length of the hopper (400 mm), B is the
as 33.54 mm and 148.3 N respectively according to breadth of the hopper (350 mm), and H is the height of
Equations 31 and 32. the hopper (550 mm). Conversely, the mass is computed
to be 2.31 kg via the use of Equation 45 and this is
(31) adjudged as the proposed capacity of the machine (2.31
kg per batch). The capacity of the machine (C) is
(32) estimated to be 83 kg/hr according to Equation 47.
Where C is the capacity of the machine in kg/hr, M is the
The axial ( ) and radial ( ) forces acting on the mass per batch of the vegetable (2.31 kg/batch) and T is
shaft are computed as 27.12 and 27.12 N respectively, the operating time per hour.
according to Equations 33 and 34.
(46)
(33) (47)
(34)
Figures 7 and 8 show the isometric drawing and the
The bending moment ( ) due to and and exploded views of the designed vegetable shredding and
that due to ( ) are estimated. The resultant washing machine. The washing of the shredded
bending moment (M) is evaluated to be 22468 Nmm vegetables will be carried out in antimicrobial agents
according to Equation 35. The shaft is also subjected to a like chlorinated water because it has been reported by
twisting moment, therefore the equivalent twisting Baur et al. [33] that the damaged or cut cells of
moment ( ) is evaluated to be 222523.57 Nmm via the vegetables significantly lower free chlorine consumption
use of Equation 36. According to Equation 37, the shaft and charge of residues in the wastewater. Other novel

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Design and simulation of a vegetable shredding and washing machine Akinnuli et al.

antimicrobial agents like quaternary ammonium machine. The application of a torque of 4970 N-mm on
compounds (benzalkonium chloride and didecyl the driving bevel shaft transmitted the torque to the
dimethyl ammonium chloride), and isothiazolinones (a driven bevel shaft and generated a pressure of 2107 MPa
mixture of methylchloroisothiazolinone and in Figure 9.
methylisothiazolinone) can be used as alternatives for
washing the shredding vegetables [34].

SIMULATION OF MACHINE
COMPONENTS
Based on the designed vegetable shredding and washing
machine, the essential parts of the machine were
simulated. Figure 9 shows the components of the
machine where forces are acting on. The entire machine
was reduced to the model shown in Figure 9 as most of
the stresses act on the shown structural parts. The
regions or components with red profiles are critical parts
where movements or relative motions take place in the Fig. 7: Isometric view of the machine.

Fig. 8: Exploded view of the machine.

Fig. 9: Structural components with their respective.

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 International Journal of Excellence Innovation and Development
||Volume 2, Issue 3, Mar. 2019||Page No. 33-41||

Fig. 10: Washing chamber

Fig. 11: Gears for motion transmission.

Figure 10 is discretized into 68823 nodes and 22967 machine subjected to stresses will not fail under service
elements while the gear components in Figure 11 were condition since they will not undergo plastic deformation
finely meshed prior to the assignment of boundary or yielding.
conditions (according to the designed parameters in
Section 3) and the simulation process. Figures 10 and 11 CONCLUSION
show the results of the stress analysis on the washing The design and simulation of a motorized electric-driven
and motion transmission mechanisms. The values of the vegetable shredding and washing machine have been
maximum Von Misses stress were found to be lesser successfully carried out. The capacity of the machine is
than the material yield strength for the washing chamber about 83 kg/hr. The static structural simulation of the
and the motion transmitting components. The maximum machine reveals the capability of the machine to
stress (190.12 MPa) that occurred on the components of withstand deformation or operational force/loading
the machine was found to be less than the material yield effect. The maximum stress (190.12 MPa) that occurred
strength (250MPa). Thus, the components of the on the components of the machine was found to be less

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Design and simulation of a vegetable shredding and washing machine Akinnuli et al.

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