CHAPTER 1

Introduction

Background of the study

A scientific and technical machines designed to grind fodder grain revealed

that the existing designs of grinding machines—those based on destruction by
impact, cutting, or chipping—have various drawbacks. Some disadvantages
include high metal and energy intensity, an uneven particle size distribution of the
ground (crushed) product, a high percentage of dust fraction, the rapid wear of
work tools (units), and heating of the product. To eliminate most of the identified
shortcomings, the design of a rotary–centrifugal grain grinder is proposed in this
paper. The optimization of the grinder’s working process was carried out using
experimental design methodology. The following factors were studied: the grain
material feed, rotor speed (rpm), opening of the separating surface, number of
knives (blades) on the inner and outer rings, technical conditions of the knives
(sharpened or unsharpened), and the presence of a special insert that is installed
in the radial grooves of the distribution bowl. The optimization criteria were
based on the amount of electricity consumed by and the performance of the
rotary–centrifugal grain grinder. The quality of performance was quantified by the
finished product, based on the percentage of particles larger than 3 mm in size.
An analysis of the results of the multifactorial experiment allowed us to establish
a relationship (interaction) between the factors and their influence on the
optimization criteria, as well as to determine the most significant factors and to
define further directions for the research of a centrifugal–rotary grain grinder.
From our experimental results, we found that the grinder is underutilized in the
selected range of factor variation. Furthermore, the number of knives installed at
the second stage of the grinder, the gap (clearance) of the separating surface, and
the technical condition of the knives are among the most important factors
influencing the power consumption and the quality of the resulting product. A
reduction in the number of knives at the first stage has a positive effect on all the
selected optimization criteria; and by varying the factors in the selected range, it
is possible to obtain a product corresponding to medium and coarse grinding.
Keywords: grain grinding; rotary–centrifugal grinder; construction optimization
criteria.

This study two-layer grain grinding machines involves an understanding of the

need for efficient and effective grinding processes in the grain processing
industry.

Grinding is a crucial step in the grain processing industry, as it transforms raw

grains into various products, such as flour, feed, or cereals. Traditional single-layer
grinding machines have been widely used for this purpose, but they often face
limitations in terms of grinding capacity, efficiency, and product quality.

To address these limitations, researchers and engineers have developed two-layer

grain grinding machines. These machines utilize two grinding layers or surfaces,
which work together to achieve improved grinding performance. The use of two
grinding layers allows for higher grinding capacities, enhanced particle size
control, and reduced energy consumption compared to single-layer machines.

The study involves recognizing the potential benefits of two-layer grain grinding
machines and the need for further research and development in this area. The
study aims to investigate the operational principles, performance characteristics,
and potential applications of these machines to optimize grain grinding processes.

By studying the two-layer grain grinding machines, researchers aim to improve

the efficiency and effectiveness of grinding processes in the grain processing
industry. This can lead to increased productivity, improved product quality, and
reduced energy consumption. Additionally, the study can contribute to the
development of new grinding technologies and equipment that can enhance the
competitiveness of the grain processing industry.

The background of the study also involves considering the current state of the art
in two-layer grain grinding machines. It may include a review of existing literature,
patents, and industry practices to identify gaps in knowledge and potential areas
for improvement. By building upon existing knowledge and addressing research
gaps, the study can contribute to advancing the field of grain grinding technology.

In the study on two-layer grain grinding machines recognizes the limitations of

traditional single-layer machines and the potential benefits of using two grinding
layers. The study aims to investigate the operational principles, performance
characteristics, and potential applications of these machines to optimize grain
grinding processes. By improving grinding efficiency and effectiveness, the study
can contribute to enhancing the competitiveness of the grain processing industry.

OBJECTIVES OF THE STUDY

The objectives of the study are;

i. To design and construct a grain grinding machine with two layer.

ii.To construct grain grinding machine with local materials.

iii. To construct a machine that can perform domestic operations.

iiii. To produce a grain grinding machine that is lesser in vibration, weight and in
size.

Design Preparing materials Two layer grain

tools and equipment grinding machine
Planning

CONCEPTUAL FRAMEWORK

INPUT PROCESS OUTPUT

Significance of the Study

The study design and construction of tow layer grain grinding machine
intended for food processing purposes and will be benefit those who teach in
Electrical Technology because this machine will be powered by electricity.

This study will benefit the student of Electrical Technology by

minimizing the time for preparing different tools and equipment and also to
lessen the manpower in grain grinding.

This study will also benefit student of Electrical Technology for them to
learn and understand the proper usage of tools and equipment in grain grinding.

Scope/Limitations of the Study

This study is on design and construction of grain grinding machine. The study will
focus on construction of a local fabricated grain grinding machine using available
local technology.

Financial constraint: Insufficient fund tends to impede the efficiency of the

researcher in sourcing for the relevant materials, literature or information and in
the process of data collection (internet, questionnaire and interview).
Time constraint: The researcher will simultaneously engage in this study with
other academic work. This consequently will cut down on the time devoted for
the research work.

Definition of terms

GRAIN GRINDING MACHINE.

A domestic grain grinding machine is equipment used for grinding maize,

beans, melon, millet and such other food crops. This equipment comprises
essentially of an electric motor, belt, pulley, transmission shaft, hopper, mills,
spiral conveyor and stands.
 CHAPTER II

REVIEW OF RELATED LITERATURE AND PRIOR ARTS

Review of Related Literature

History of Grain Grinding Machine

The history of grain grinding machines dates back to ancient times. The earliest
evidence of grain grinding comes from archaeological sites in the Near East,
where stone grinding tools have been found dating back to at least 30,000 years
ago.
In ancient cultures, manual grinding tools such as querns and mortars were
commonly used to grind grains into flour. These tools consisted of a stationary
lower stone and a movable upper stone that was rotated by hand to grind the
grains. This method was relatively slow and required a significant amount of
physical effort.

Over time, technological advancements led to the development of more efficient

grain grinding machines. The invention of the watermill in ancient Greece around
the 3rd century BCE revolutionized grain grinding. Watermills used the force of
flowing water to power a rotating millstone, greatly increasing the speed and
efficiency of grain grinding.

In the Middle Ages, windmills also became popular for grain grinding in regions
with suitable wind conditions. Windmills used the power of the wind to turn large
millstones, enabling the production of larger quantities of flour.

The industrial revolution in the 18th and 19th centuries further advanced the
technology of grain grinding machines. Steam-powered mills were introduced,
which utilized steam engines to drive the grinding process. These mills were
capable of grinding large amounts of grains at a much faster rate, leading to
increased production and availability of flour.

In the modern era, grain grinding machines have continued to evolve. Electric-
powered mills and grinders have become commonplace, offering even greater
convenience and efficiency. Today, there are various types of grain grinding
machines available, including hammer mills, roller mills, and stone mills, each
with its own advantages and applications.
Overall, the history of grain grinding machines reflects the ongoing quest for
improved efficiency and productivity in the preparation of grains for consumption.
From ancient stone tools to modern electric mills, grain grinding technology has
played a crucial role in the development of human civilization.

Synthesis

The study of two-layer grain grinding machines involves the investigation and
analysis of a specific type of grinding machine that utilizes two grinding layers for
the processing of grains. This synthesis will provide an overview of the key aspects
of such a study.

Two-layer grain grinding machines are designed with two grinding surfaces or
layers that work together to grind grains into flour or other desired particle sizes.
The layers may consist of different types of grinding mechanisms, such as stones,
discs, or rollers, which are strategically positioned to enhance the efficiency and
effectiveness of the grinding process.

The study of two-layer grain grinding machines focuses on understanding the

operational principles, performance characteristics, and potential applications of
these machines. Researchers may examine the design and construction of the
machines, including the selection of materials, components, and dimensions for
optimal functionality.

In addition, the study may involve the evaluation of various factors that affect the
performance of two-layer grain grinding machines. This can include investigations
into the speed and power requirements, grinding capacity, particle size
distribution, and energy consumption of these machines. Researchers may also
explore different grinding techniques and configurations to determine their
impact on efficiency and product quality.

Furthermore, the study of two-layer grain grinding machines may involve

experimental testing and analysis. Researchers may conduct laboratory or field
trials to assess the machine's performance under different operating conditions
and evaluate the quality of the ground grains. The collected data can be analyzed
using statistical methods to draw conclusions and make recommendations for
improving the machine's design, operation, or maintenance.

The findings of the study on two-layer grain grinding machines can have practical
implications for various stakeholders in the agricultural and food processing
industries. Manufacturers and engineers can use the research outcomes to
develop and optimize the design of these machines, leading to enhanced
productivity, energy efficiency, and product quality. Farmers and food processors
can benefit from improved grinding processes, resulting in better grain utilization
and higher yields.

The study of two-layer grain grinding machines involves a comprehensive

investigation into the design, performance, and applications of these machines.
Through experimental testing and analysis, researchers aim to improve the
efficiency and effectiveness of grain grinding processes, ultimately benefiting the
agricultural and food industries as a whole.

CHAPTER III

DESIGN CRITERIA

1. A two-layer design: The machine should have two grinding layers

to effectively process grains. The two layers should be adjustable and capable of
grinding different types of grains simultaneously.

2. Capacity: Determine the desired capacity of the machine, i.e., the amount of
grain it can process per unit of time. This will depend on the intended application
and target market. Consider factors such as grain volume, throughput, and
processing time.

3. Grinding Mechanism: Select an appropriate grinding mechanism based on the

type of grain and desired end product. Common mechanisms include burr
grinders, impact grinders, or roller mills. The choice will depend on the desired
grind size, efficiency, and maintenance requirements.

4. Size and Dimensions: Determine the overall size and dimensions of the
machine, taking into account the available space for installation and operation.
Consider factors such as height, width, and depth, as well as any specific
requirements for easy transportation or integration with existing systems.

5. Material Selection: Choose sturdy and durable materials for the construction of
the machine to ensure longevity and withstand the grinding forces. Consider
materials such as stainless steel or hardened alloys based on the specific
requirements of the grains being processed.

6. Power Source: Decide on the power source for the machine, whether it will be
electrically powered, manually operated, or powered by another source such as a
diesel engine. Consider factors such as energy efficiency, power requirements,
and availability of the chosen power source.

7. Grinding Settings: Design the machine to allow for adjustable grinding settings,
such as the fineness or coarseness of the ground grains. This ensures flexibility to
meet different customer preferences and specific grain processing needs.

8. Feed and Discharge System: Design an efficient feeding system to ensure a

constant and controlled flow of grains into the grinding layers. Consider factors
such as feed hopper capacity, feeding mechanism, and grain distribution.
Likewise, design an effective discharge system to collect and separate the ground
grains from the residual material.

9. Safety Features: Incorporate necessary safety features such as emergency stop

buttons, interlocks, and guards to protect the operator and prevent any accidents
during operation. Also, consider features like overload protection and dust
collection systems to ensure a safe working environment.
10. Maintenance and Cleaning: Ensure easy accessibility for routine maintenance
and cleaning of the machine. Design features such as removable parts, easy-to-
clean surfaces, and lubrication points. Also, consider features that facilitate easy
inspection and troubleshooting.

11. Noise and Vibration Control: Implement measures to minimize noise and
vibration during operation. This can be achieved by using vibration-damping
materials, optimizing the machine's design and structure, and incorporating noise
reduction techniques.

12. Control and Automation: Consider integrating control and automation

systems to enhance the machine's functionality, precision, and efficiency. This can
include features such as variable speed control, automated grinding settings, and
real-time monitoring of key parameters.

13. Cost-Effective Design: Optimize the design to achieve cost-effectiveness in

terms of manufacturing, assembly, and maintenance without compromising on
performance and quality. Consider factors such as material costs, manufacturing
processes, and the use of standardized components.
DESIGN PLAN

1. Machine Structure:

- The machine will have a sturdy and durable frame made of stainless steel or
hardened alloys for maximum strength and longevity.

- It will be designed in a compact and space-saving manner, with dimensions

suitable for installation in various environments.

- The machine will have two grinding layers stacked vertically, allowing for
simultaneous grinding of different types of grains.

2. Grinding Mechanism:

- Each grinding layer will be equipped with a high-quality grinding mechanism,

such as burr grinders or roller mills, depending on the desired end product and
grain type.

- The grinding mechanism will be made of hardened steel to ensure efficient and
consistent grinding performance.

- The design will allow for easy adjustment of the grinding settings to achieve the
desired fineness or coarseness of the ground grains.

3. Power Source:

- The machine will be electrically powered for ease of use and efficiency.

- It will be designed to operate on standard voltage levels, ensuring compatibility

with common electrical systems.

- The power consumption will be optimized to maximize energy efficiency and

minimize operating costs.
4. Feed System:

- The machine will have a large-capacity feed hopper for storing a sufficient
quantity of grains.

- The feed hopper will be designed to provide a controlled and constant flow of
grains into the grinding layers.

- An adjustable feeding mechanism, such as a conveyor belt or auger, will be

incorporated to regulate the grain feed rate.

5. Discharge System:

- The machine will have a separate compartment or tray to collect the ground
grains and prevent mixing with the residual material.

- A discharge mechanism, such as a chute or conveyor belt, will transfer the

ground grains to a designated container or packaging area.

- The design will ensure efficient and clean separation of the ground grains from
any remaining impurities or husks.

6. Safety Features:

- The machine will be equipped with safety features to protect the operator and
prevent accidents.

- Emergency stop buttons and interlocks will be implemented to quickly halt the
machine's operation in case of any emergencies.

- Guards and enclosures will be installed to shield moving parts and prevent
access while the machine is in operation.

- Overload protection will be incorporated to prevent damage to the machine and

ensure safe operation.
7. Control System:

- The machine will have a user-friendly control panel with intuitive controls and
digital displays.

- It will include features for adjusting the grinding settings, monitoring the
operating parameters, and controlling the feed rate.

- Automation capabilities, such as programmable settings and preset modes, may

be incorporated for enhanced convenience and efficiency.

8. Maintenance and Cleaning:

- The machine will be designed for easy maintenance and cleaning operations.

- Removable parts and access panels will allow for easy inspection, lubrication,
and cleaning of the grinding layers and mechanisms.

- Special attention will be given to areas prone to accumulation of dust and grain
residues, with provisions for effective cleaning and waste disposal.

9. Noise and Vibration Control:

- Measures will be taken to minimize noise and vibration during operation.

- Vibration-damping materials and isolation mounts may be used to reduce

vibrations and noise transmission to the surroundings.

- The machine's design will optimize the alignment and balance of rotating parts
to minimize vibrations and noise generation.

10. Cost-Effective Design:

- The design will be optimized for cost-effectiveness in terms of manufacturing,

assembly, and maintenance.
- Standardized components and modular construction methods may be utilized to
reduce production costs and simplify maintenance procedures.

- Consideration will be given to the selection of materials and manufacturing

processes to achieve a balance between performance, durability, and cost.

11. Testing and Validation:

- Prototypes of the two-layer grain grinding machine will be developed and tested
to ensure its performance meets the design specifications.

- Comprehensive testing will be conducted to evaluate grinding efficiency, particle

size distribution, power consumption, and reliability.

- User feedback will be sought to make necessary adjustments and improvements

before finalizing the design for mass production.

FABRICATION

1. Machine Structure:

- The machine will have a sturdy and durable frame made of stainless steel or
hardened alloys for maximum strength and longevity.
- It will be designed in a compact and space-saving manner, with dimensions
suitable for installation in various environments.

- The machine will have two grinding layers stacked vertically, allowing for
simultaneous grinding of different types of grains.

2. Grinding Mechanism:

- Each grinding layer will be equipped with a high-quality grinding mechanism,

such as burr grinders or roller mills, depending on the desired end product and
grain type.

- The grinding mechanism will be made of hardened steel to ensure efficient and
consistent grinding performance.

- The design will allow for easy adjustment of the grinding settings to achieve the
desired fineness or coarseness of the ground grains.

3. Power Source:

- The machine will be electrically powered for ease of use and efficiency.

- It will be designed to operate on standard voltage levels, ensuring compatibility

with common electrical systems.

- The power consumption will be optimized to maximize energy efficiency and

minimize operating costs.

4. Feed System:

- The machine will have a large-capacity feed hopper for storing a sufficient
quantity of grains.

- The feed hopper will be designed to provide a controlled and constant flow of
grains into the grinding layers.
- An adjustable feeding mechanism, such as a conveyor belt or auger, will be
incorporated to regulate the grain feed rate.

5. Discharge System:

- The machine will have a separate compartment or tray to collect the ground
grains and prevent mixing with the residual material.

- A discharge mechanism, such as a chute or conveyor belt, will transfer the

ground grains to a designated container or packaging area.

- The design will ensure efficient and clean separation of the ground grains from
any remaining impurities or husks.

6. Safety Features:

- The machine will be equipped with safety features to protect the operator and
prevent accidents.

- Emergency stop buttons and interlocks will be implemented to quickly halt the
machine's operation in case of any emergencies.

- Guards and enclosures will be installed to shield moving parts and prevent
access while the machine is in operation.

- Overload protection will be incorporated to prevent damage to the machine and

ensure safe operation.

7. Control System:

- The machine will have a user-friendly control panel with intuitive controls and
digital displays.

- It will include features for adjusting the grinding settings, monitoring the
operating parameters, and controlling the feed rate.
- Automation capabilities, such as programmable settings and preset modes, may
be incorporated for enhanced convenience and efficiency.

8. Maintenance and Cleaning:

- The machine will be designed for easy maintenance and cleaning operations.

- Removable parts and access panels will allow for easy inspection, lubrication,
and cleaning of the grinding layers and mechanisms.

- Special attention will be given to areas prone to accumulation of dust and grain
residues, with provisions for effective cleaning and waste disposal.

9. Noise and Vibration Control:

- Measures will be taken to minimize noise and vibration during operation.

- Vibration-damping materials and isolation mounts may be used to reduce

vibrations and noise transmission to the surroundings.

- The machine's design will optimize the alignment and balance of rotating parts
to minimize vibrations and noise generation.

10. Cost-Effective Design:

- The design will be optimized for cost-effectiveness in terms of manufacturing,

assembly, and maintenance.

- Standardized components and modular construction methods may be utilized to

reduce production costs and simplify maintenance procedures.

- Consideration will be given to the selection of materials and manufacturing

processes to achieve a balance between performance, durability, and cost.
11. Testing and Validation:

- Prototypes of the two-layer grain grinding machine will be developed and tested
to ensure its performance meets the design specifications.

- Comprehensive testing will be conducted to evaluate grinding efficiency, particle

size distribution, power consumption, and reliability.

- User feedback will be sought to make necessary adjustments and improvements

before finalizing the design for mass production.

EVALUATION PROCEDURE

1. Performance Testing:

- Test the machine's grinding capacity by feeding grains of different types and
sizes into each grinding layer separately and simultaneously.

- Measure the grinding output in terms of the quantity of grains processed per
unit of time.

- Evaluate the machine's ability to maintain consistent and uniform particle size
distribution in the ground grains.

2. Efficiency Testing:
- Measure the power consumption of the machine during grinding operations.

- Calculate the energy efficiency by comparing the amount of energy consumed to

the amount of grains processed.

- Evaluate the ability of the machine to achieve efficient grinding with minimal
waste or loss.

3. Durability and Reliability Testing:

- Conduct endurance tests by operating the machine continuously for an

extended period.

- Monitor the machine for any signs of mechanical failures, component wear, or
performance degradation.

- Evaluate the durability and reliability of the machine by checking its ability to
withstand repetitive and prolonged use without significant issues.

4. Safety Evaluation:

- Assess the machine's compliance with safety standards and regulations, such as
electrical safety, noise levels, and guarding requirements.

- Test the effectiveness of safety features, including emergency stop buttons,

interlocks, and protective enclosures.

- Evaluate the accessibility and ergonomics of the machine's controls and

operating areas to reduce the risk of accidents or injuries.

5. Maintenance and Serviceability:

- Evaluate the ease of accessing and removing components for maintenance and
repair.
- Assess the availability and cost of spare parts, as well as the accessibility of
service and support.

- Consider the machine's design and engineering features that facilitate routine
maintenance tasks, such as cleaning and lubrication.

6. User Feedback and Validation:

- Obtain feedback from the operators and users of the machine regarding its
performance, ease of use, and any difficulties encountered.

- Analyze the feedback to identify areas for improvement and address any user
concerns or suggestions.

7. Documentation Review:

- Review the machine's documentation, including user manuals, assembly

instructions, and maintenance guides, for completeness and accuracy.

- Evaluate the clarity and comprehensibility of the instructions and information

provided.

8. Cost-Benefit Analysis:

- Conduct a cost-benefit analysis to assess the economic viability of the machine,

considering its performance, efficiency, and maintenance requirements.

- Compare the initial investment cost to the expected benefits, such as increased
productivity, reduced labor, and potential cost savings.

9. Compliance with Standards and Regulations:

- Ensure that the machine complies with relevant industry standards, regulations,
and certifications, such as ISO, CE, or local regulatory requirements.

- Verify the machine's adherence to specific safety, hygiene, and quality standards
applicable to grain processing equipment.

INSTRUMENTATION AND DATA GATHERING

To gather data on the performance and efficiency of a two-layer

grain grinding machine, you will need to use appropriate instrumentation and
follow a specific data gathering procedure. Here is a suggested approach:

1. Instrumentation:

- Power meter: Use a power meter to measure the electricity consumption of the
machine during grinding operations. This will help evaluate the machine's energy
efficiency.

- Timer: Use a timer to measure the time taken to complete a grinding cycle or
process. This will help assess the machine's grinding capacity and productivity.

- Particle size analyzer: Utilize a particle size analyzer to measure the particle size
distribution of the ground grains. This will help evaluate the machine's ability to
achieve consistent and uniform grinding.
- Thermometer: Use a thermometer to measure the temperature of the machine
during operation. This will help monitor for any overheating or excessive heat
generation.

2. Data Gathering Procedure:

1. Preparation:

- Ensure that the machine is properly set up and calibrated according to the
manufacturer's instructions.

- Ensure the machine is clean and free of any residual grains or debris from
previous operations.

- Verify that all safety measures and guards are in place and functioning
effectively.

2. Performance Testing:

- Select a representative sample of grains to be used for testing.

- Set the machine to the desired grinding settings, such as speed, feed rate, and
layer configuration (e.g., simultaneous or separate grinding layers).

- Start the machine and initiate the grinding process.

- Use the timer to measure the time taken to complete the grinding process.

- Record the quantity of grains processed during the test.

3. Efficiency Testing:

- Connect the power meter to the machine and record the initial power
consumption.
- Monitor the power consumption throughout the grinding process and record
the final power consumption.

- Calculate the energy efficiency by dividing the quantity of grains processed by

the energy consumed.

4. Particle Size Analysis:

- Collect a representative sample of the ground grains.

- Use a particle size analyzer to measure the particle size distribution of the
sample.

- Record the results, including the average particle size, particle size range, and
any deviations from the desired particle size distribution.

5. Thermometer Measurement:

- Measure the temperature of the machine's critical components, such as the

grinding plates or motor, during operation.

- Note any abnormal or excessive temperature readings that may indicate

overheating or inadequate cooling.

6. Repeat and Average:

- Repeat the performance, efficiency, and particle size analysis tests multiple
times to ensure reliable and consistent data.

- Calculate the average values for performance, efficiency, and particle size
distribution based on the multiple tests.

7. Data Analysis and Evaluation:

- Analyze the gathered data to assess the machine's performance, efficiency, and
grinding quality.

- Compare the results to the machine's specifications and industry standards.

- Identify any areas for improvement or further optimization.

8. Documentation:

- Record all the gathered data and analysis results in a comprehensive report.

- Include descriptions of the testing procedures, measurement instruments used,

and any relevant observations or conclusions.