Abstract

This project is to fabricate a coconut husk remover with shell cutter. At present
coconut husk is being removed manually, which employs more time and more
manpower. This coconut husk remover peels off the coconut husk from coconut
fruit to obtain de-husked coconut fruit via pneumatic controlled de-husking
device. An operator is required to handle the machine during the de-husking
process. It can be used to de-husk both matured coconut and young coconut.
This project consists of pneumatic cylinder, solenoid valve, linkages, husk
remover and base frame.In this there are two main parts are there. One part is for
removing the husk from the coconut and the other is cutting part. In both parts,
pneumatic systems are used. The husk is removed with the help of hinge joint
which connects to the pneumatic actuator. By connecting these two parts we
fabricated as "coconut husk remover with shell cutter".

1. INTRODUCTION

This new proposal claims a new method that gives an easier and safer method
to process a coconut which removes the husk and breaks its shell. It is much better
than the earlier method by using knives which are harmful to the person and it needs
more time. We have put forward this proposal in order to avoid those drawbacks of
the earlier methods. By this new method we can remove the husk without producing
any stress and also remove the shell in a very safe way. Coconut is the tree of
heaven, provides many necessities of life including food and shelter. It is mainly
cultivated for its nuts; it yields oil, oil cake and fiber. Water from tender coconut is a
common refreshing drink and has been used as an excellent isotonic in several
tropical countries. It is not only a thirst-quenching liquid, but also a mineral drink,
which is beneficial to human health (Poduval et al., 1998). It contains traces of
proteins, fats, and minerals like Na, K, Ca, Fe, Cu, P, S, Cl, vitamin C, vitamins of the
B group like nicotinic acid, pantothenic acid, riboflavin and biotin. Coconut water
contains organic compounds possessing healthy growth promoting properties. It
carries nutrients and oxygen to cells, raise the human metabolism, boost human
immune system, detoxifies and fight viruses, control diabetes and also aids the human
body in fighting against viruses that causes flue (Poduval et al., 1998).
The pneumatic type remover is a mechanical device which is widely used in
agricultural works. The pneumatic husk remover for agricultural purposes reduces the
time of the man (operator) in removing the husk and also shell removal. The reason
for the development and the introduction of the pneumatic husk remover with shell
cutter for agricultural purposes is given below. The pneumatic husk remover for
agricultural purposes is one of the improved devices.
LITERATURE REVIEW

The machine proposed in this work basically does two processes. They are
dehusking and crown removing. De- husking is the process of removing the
fibrous portion (husk) from the nut. It has been a problem from time

immemorial. Even though many types of equipment have been developed to dehusk coconuts [1,3,4], a majority of de-husking is carried out manually which
goes to show that there are no superior machines developed to handle the
coconuts. Coconut de-husking is the most fundamental issue in terms of finding
labor and improving productivity. Few machines which are in current practice are
described below. The tool in the figure 1 is most commonly used for de-husking
coconuts and is even highly domesticated. It consists of a sharpened edge on
which the coconut is placed by applying force. Then the hinged edge is opened with
the help of the lever. This in turn, cuts and opens the husk of the coconut. This is
done in various orientations and the remaining husk is pulled out till the coconut is
completely de-husked .It is a manual process and requires a lot of effort from the
worker. It is also dangerous as an in-experienced worker may hurt himself in the
process.

Fig.1. Manual Dehusking tool

The machine shown in the figure 2 is called the husk peeling machine and is
one of the modern and more innovative methods developed for de-husking
coconuts. The innovation lies in the fact that the machine peels of the coconut husk
as easily as one peels the outer skin of the banana fruit. It is a good solution in terms
of quality of de-husking and completes the process of de-husking to the highest
possible efficiency. Even though it requires no force to be exerted by the worker,
it still remains non productive because it requires an operator to operate the
machine at all times. It makes use of links which are actuated by pneumatics or

toggle mechanisms to peel off the coconut husk. It also is a very time consuming
process. One other disadvantage is that the husk after peeling is not as easily
conducive as in other methods for coir processing.

Fig.2. Coconut Husk Peeling machine

The method in the figure 3 is by far, the best methods available for de-husking and
is now being used in mass production. It has two horizontal rollers with blades.
This is similar to the work [1]. The coconuts however have to be held in place by
some clamping force. The coconut is held to the rotating rollers either by hand or
through some leverage. The projected sharp edges do the husk removal process.
This also requires continuous labor force. It does speed up the process of dehusking, even though the final productivity in terms of numbers largely depends on
the speed and ability of the worker.

Fig.3. Horizontal roller dehusking machine

The crown of the coconut is also a part of the coconut that is processed in the
proposed machine. Crown is the fibrous portion that is protruding from the
coconut. It is usually seen covering the eyes of the coconut. It is very difficult to
manually remove the crown from the nut. Crown removal is done for oil
production and cooking after then the coconut is cut into two halves.

Fig.4. Coconut crown

1. Experiments and Data collection

The dimensions of the mature coconut are very much significant as far as the
machine design is concerned. Various farms and sites were visited to comprehend
the band of dimensions involved in the mature coconut. Some coconuts from
Andaman and Nicobar Islands are very big when compared to the areas thrived
with coconuts in India like Tamil Nadu and Kerala. The machine has been
designed to overcome a large range of coconut sizes, with equal importance to

productivity. Various places in and around Tamil Nadu and Kerala have been
considered predominately to arrive at a conclusion on the size of coconuts. The
dimensions have been measured using an external caliper. Majority of coconuts
appear to have the dimensions such that the Y and Z direction dimensions are
almost identical. However the critical and concerning dimension for this
machine design is the dimension X.

Fig.5. Coconut dimensional axes

The dimensions of the coconuts collected from various places have been
coalesced and few dimensions are presented in ascending order in the below table.
The dimensions in the first row represent the smallest coconut with husk and the
dimensions in the last row represent the maximum size coconut with husk.

Table 1. Dimensions of the coconut with husk

No.
1
2
3
4
5

X121
axis(mm)
157
182
246
276

Y-axis(mm)
113
146
161
218
230

Z-axis(mm)
109
142
165
214
227

287

269

263

In addition to the above data, the dimensions of the coconut after the husk being
removed are required as they would play a greater role in the design of the crown
removal station of the machine.
Table 2. Dimensions of the dehusked coconut
No.
1
2
3
4
5
6

X97axis(mm)
114
125
147
162
132

Y-axis(mm)
86
98
115
129
135
124

Z-axis(mm)
86
96
109
125
134
122

Based on the above data, the Stroke length of the Pneumatic Cylinders involved
in the Dehusking Unit and Crown removal unit has been derived.
In addition to the above, some data on the loads acting on the coconut to
dehusk it are required. The husk is removed from the Machine through the shear
force exerted by the fixed toothed rollers in the machine. So, in relation to that
the amount of shear load required to dehusk the coconuts has been determined.
Both dry and mature coconuts of various sizes are tested experimentally in the
Standard Universal Testing Machine (UTM). The mechanical properties of the
coconut fiber are studied from the works [7,8] for this purpose.

Fig.6. Coconut specimen I in UTM Fig.7. Coconut specimen II in UTM

Fig.8. Shear Force reading in the UTM

The Shear load required to dehusk the mature coconut of different sizes are listed
below
Table 3. Shear Load required to dehusk mature coconuts

No.
1

Dimension
in
128

X-axis (mm)

Shear Load (kN)

145

0.35

178

0.39

212

0.45

248

0.52

Mature Coconut

0.32

Similarly the Shear load required to dehusk the dry coconut of different sizes are
listed below.
Table 4. Shear load required to dehusk dry coconuts

No.
1

Dimension
in
133

X-axis
(mm)

Shear Load (kN)

154

0.26

174

0.29

208

0.36

252

0.42

Dry Coconut

0.24

It is evident from the table that the load required for de-husking the dry coconut is
higher than the load required for de-husking the mature coconut. Also, graphs are
plotted for both dry and mature coconuts in such a way that X-Dimension of the
coconut is taken as an independent parameter in X-axis and the shear load is taken

along the Y-axis. This is due to the fact that the shear load varies based on the size
of the coconut. The graphs are shown below.

Shear load (kN)

Dry coconut

0.6
0.5
0.4
0.3
0.2

0.52
0.45
0.320.350.39

0.1
0

128

145

178

212

248

Coconut X-direction Dimension (mm)

Fig.9 .Graph between X-direction dimensions of the dry coconut and shear load
to de-husk the coconut.

Shear load (kN)

Mature coconut

0.5
0.4
0.3
0.2

0.42
0.290.36
0.240.26

0.1
0

133

154

174

208

252

Coconut Xdirection
Dimension
(mm)
Fig.10 .Graph between X-direction
dimensions of the mature coconut and shear
load to de-husk the coconut From the graphs

it

be inferred that the shear load varies linearly

can

with respect to the size of the coconut.

1. SCOPE OF THE PROJECT

Part I

Figure: 1 Husk removing part

This proposal is a new step to the future, because at this 21st century people are
looking for an easier method to do jobs. This proposal is just put forward to reduce the
human effort and to save the valuable time. By applying this method lots of time gets
saved and more output is obtained. Our proposal is mainly based on the coconut oil
refineries, nowadays these refineries are using human labour for processing coconuts.
Anyway, they need human to remove the coconut husk and to break the shell.
By the implementing this method the human effort will get reduced. By manual
method there are chances of accidents, by using this method the safety problems will be
solved. This is a permanent set up, so that saving money is possible. For workers, we
have to give daily wages, this machine does not need that, all it needs is a proper care
and service, which should be carried out once in a week. This will maintain the
efficiency of the machine.
This machine needs less than half a minute to do all process. So the production rate
will get increased and also the economic value also gets increased. This machine is not
huge, so it needs less space, but we have to keep it in a proper place.
2. NEW PROPOSED DESIGN
The new proposed design if depicted in the below figure with description.
This part is needed for removal of husk from the coconut. In this there are
two pneumatic actuators. One is placed at the bottom of structure, it's for Holding the
coconut and another one is placed on the top of the structure connected with hinge
joint for peeling the husk.
In hinge joint there are five linkages used for de- husking the coconut. These
are operated with the help of pneumatic actuators. The actuations are controlled by the
5/2 DC solenoid valve. After the de-husking process the coconut shell is taken to the
next stage.

Part II

Figure: 2 Coconut Cutter with pneumatic actuator

This part is used for cutting the coconut shell. Here one pneumatic actuator is
being used. For cutting operation the knife is attached to the pneumatic actuator.
When the pneumatic actuator is actuated, the knife comes down with high force,
breaking the coconut into two.

Characteristics

Dimension (mm)

Height(H)

179.7+_5.3

Diameter(D)

160.2+_5.6

Shell height(h)

99.3_+ 4.2

Shell diameter(d)

105.3+_6

Vertical height b/w shell & stem (b1)

45.4+_5.2

Vertical distance b/w shell & fruit base

32.7+_2.5

Table: 1 Coconut specifications

Weight

Force

S.N
o

of

required

coconut
2.5

for

1.75

491

476

1.5

456

579

S.No

Weight

of Force required

coconut (kg)

for cutting(N)

2.5

579

1.75

491

476

1.5

456

Table: 2 Force required for cutting

8. DESIGN CALCULATIONS
Design calculation for pneumatic cylinder (100 x100)
Mini pressure applied in the cylinder (p) = 3 kgf/cm2 Diameter of the cylinder (D) = 50
mm
Stroke length

= 100 mm

Area of cylinder (A)

= /4*(D2)

= 0.785*(0.1002)
= 7.85x10-3 m2
Force exerted in the piston (F):
Pressure * applied area of cylinder Force (2.94x 105 )(1.96 x10-3)
288.68 N
For lifting one kg weight, the force required is given by,
Force = m x a 1 x9.81

Force = 9.81 N
And the pressure required for one pneumatic cylinder to lift I kg is given by,
Pressure, P = Force/ Area
= 9.81 /7.85x10-3
= 1249.68 N/m2
Pressure = 0.012496 bar Maximum load in the cylinder, Pressure*area
1249.68 x 7.85 x10-3
Maximum load in the cylinder = 9.80 N Total load in the cylinder = m x a
9.80 x 9.81
Total load on the cylinder = 96.13 kg

Design calculation for pneumatic cylinder (50 x100)

Mini pressure applied in the cylinder: p= 1.5 kg f/cm2 = 1.47 x 105 n/m2
Diameter of the cylinder (D) = 50 mm Stroke length
Area of cylinder (A)

= 100 mm

= (3.14/4*(D2))
= (.785x(.0502)
= 1.96 x10-3 m2

Force exerted on the piston:

F = Pressure applied * Area of cylinder
Force (F) =(1.47 x 105 n/m2) * (1.96 x10-3m2) F = 288.68 N
For lifting one kg weight, the force required is given by,
Force = m x a = 1 x9.81 = 9.81 N
And the pressure required for one pneumatic cylinder to lift I kg is given by,

Pressure,(P) = Force/ Area

= 9.81 /1.96 x10-3
= 4998.72N/m2
Pressure,(P) = 0.0499872bar
Maximum load in the cylinder = Pressure*Area
= 4998.72 x 1.96 x10-3
Maximum load on the cylinder = 9.79 N Total load in the cylinder = m x a
= 9.79 x 9.81
Total load on the cylinder = 96.03 kg
Design calculation for pneumatic cylinder (32 x100)
Mini pressure applied in the cylinder (p) p= 2x105N/m2
Diameter of the cylinder (D = 32 mm
Stroke length

= 100 mm

Area of cylinder (A)

= (3.14/4*(D2)
= (.785x.0322)
= 8.0384 x 10-4m2

Force exerted on the piston (F): Pressures applied * Area of cylinder Force
= (2 x 105) x(8.03 x 10-4)
Force = 160.68 N
For lifting one kg weight, the force required is given by,
Force = m x a = 1 x 9.81 Force = 9.81N
And the pressure required for one pneumatic cylinder to lift I kg given by,
Pressure, P = Force/ Area = 9.81 /8.03 x10-4 Pressure, P = 12203.92 N/m2

Pressure = 0.1220392 bar

Maximum load in the cylinder

= Pressure x area

= 160.68 N
Total load in the cylinder = m x a
= 160.68 x9.81
= 1576.27 kg
9. COST ESTIMATION
Material Cost
Mild steel (squire pipe)

= 1,200

MS Solid rod

= 300

Pneumatic Actuator (100*100) = 3,620 Pneumatic Actuator (50*100) = 2,450

Pneumatic Actuator (32*100)

= 1,650 5/2 DC Solenoid Valve (3 Nos)

3*500
= 1,500
Knife

= 220

Flexible hose (PU) 8 Meter = 8*26

= 208
Total

Rs.11,148/=

Labour Cost
Drilling

= 300

Welding

= 3,000

Bending

= 200

Grinding

= 300

Painting

= 300

Logistics

= 1,200

Total

Rs.5,300/=

Overhead Charges
The overhead charges are calculated by
manufacturing cost
Manufacturing Cost = Material Cost + Labour Cost 11,148+5,300
Rs.16,448/=
Overhead Charges:
20% of the manufacturing cost (16448)*(.20)
Rs.3,289/=
Total Cost
Material Cost + Labour Cost + Overhead Charges
11,148 + 5,300 + 3289
19,737
Total cost for this project: Rs.19,737/=

10. CONCLUSION
The semi-automatic coconut husk remover with shell cutter is an advanced method which
removes the husk and cuts the shell in an easy way of operation. This will reduce the human
effort and avoid chances for accidents of the manual method of operation. It reduces the
operational cost of the work, comparing
to the manual method, the proposal is a very effective and advantageous method. This machine is
mainly based on the coconut oil factories where it will increase the rate of production and also

saves more valuable time. This project describes the designing of a machine which is able to two
operations; one followed by another, which shows that it is a multi stage process machine
includes the complicated work by manually. The manual method includes the peeling of the husk
it is a very difficult process and it would take more time for a less skilled person. And the cutting,
we have to be more careful while doing the cutting manually. In order to solve these problems the
coconut husk remover with shell cutter is a better option to be considered.

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