DEVELOPMENT AND OPTIMIZATION OF DRY GRAIN GRINDING MACHINE

BY

OKOCHA PRECIOUS CHIGOZIRIM

2020/129544/REGULAR

&
TOCHUKWU EMMANUEL EPELLE
2019/119292/REGULAR

BEING A PROJECT PROPOSAL SUBMITTED TO

THE DEPARTMENT OF MECHANICAL ENGINEERING,
FACULTY OF ENGINEERING,
ABIA STATE UNIVERSITY, UTURU

IN PARTIAL FULFILMENT OF THE AWARD OF BACHELOR OF ENGINEERING

B.ENG IN MECHANICAL ENGINEERING

SUPERVISOR: ENGR. S.O. ISAAC

SEPTEMBER, 2024

i
 APPROVAL PAGE

A project proposal presented by Tochukwu Emmanuel Epelle & Okocha Precious Chigozirim

with Matriculation number: 2019/119292/Regular & 2020/129544/Regular students of the

Department of Mechanical Engineering.

…………………………………………. ………………………
Engr. S. O. Isaac Date
(Supervisor)

…………………………………………. ………………………
Dr. Engr. C. P. Nwadinobi Date
(Head of Department)

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 TABLE OF CONTENTS

Pages

Title page i

Approval Page ii

Table of Contents iii

List of Figures vi

List of Tables vii

CHAPTER ONE: INTRODUCTION

1.1 Background of the Study 1

1.2 Aim and Objectives of the Study 2

1.3 Statement of Problem 3

1.4 Scope of the Work 4

1.5 Justification/Significance of the Study 5

CHAPTER TWO: LITERATURE REVIEW

2.1 Overview of Grain Grinding Machine 8

2.2 Technological Advancements in Grain Grinding 11

2.2.1 Electric Grain Mills 12

2.2.2 CNC Technology 12

2.2.3 Advanced Materials 12

2.3 Types of Grain Grinding Machines 13

2.3.1 Hammer Mills 13

2.3.2 Burr Mills 13

2.3.3 Roller Mills 14

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2.4 Challenges and Issues in Grain Grinding 14

2.4.1 Energy Consumption 14

2.4.2 Maintenance and Durability 14

2.4.3 Consistency and Quality 15

2.5 Optimization Techniques in Grain Grinding Machines 15

2.6 Common Types of Optimization Techniques 16

2.6.1 Statistical Optimization 16

2.6.2 Stochastic Optimization 16

2.6.3 Deterministic Optimization 16

2.7 Case Studies and Real-World Applications 17

2.7.1 Rural Applications 17

2.7.2 Industrial Applications 17

2.8 Problem Statement 17

2.9 Energy Consumption 18

2.9.1 Energy Consumption in Grain Grinding Machines 18

2.9.2 Wear and Durability of Grinding Components 18

2.9.3 Consistency and Quality of Ground Products 18

2.9.4 Automation and Control Systems 18

2.9.5 Case Studies and Practical Applications 19

CHAPTER THREE: MATERIALS AND METHODS

3.1 Research Design 20

3.1.2 Design and Simulation 20

3.1.3 Prototype Development 20

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3.1.4 Performance Testing 20

3.1.5 Refinement and Iteration 21

3.2 Materials and Equipment 21

3.2.1 Hopper/Feeder
21

3.2.2 Electric motor 23

3.2.3 Grinding Wheels 23

3.2.4 Determination of Component of the Machine 24

3.3 Optimization Techniques Applied 26

3.3.1 Design Optimization (DO) 26

3.3.1 Framework Optimization 26

3.3.2 Parameter Optimization 26

3.4 Measurement Instruments 27

3.5 Ethical Considerations 27

3.6 Limitations 27

3.7 Budget 28

References 30

v
 LIST OF FIGURES

Pages

Fig 3.1: Diagram of a hopper 22

Fig 3.2: Structure of Grain Grinding Machine 29

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 LIST OF TABLES

Table 3.1: Machine Component 25

Table 3.1: Cost estimate 25

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 CHAPTER ONE
INTRODUCTION

1.1 Background of the Study

Grain grinding is a fundamental process in various agricultural and food production activities,

crucial for transforming raw grains into consumable forms. This process is especially significant

in rural communities where agriculture is the primary livelihood. Grains like maize, millet,

sorghum, and wheat are staples, and their processing directly impacts food security and

economic stability (Nnaji, 2016).

Traditionally, grain grinding has been carried out using manual tools such as stones, pestles, and

mortars (Rowe, 2013). These methods, while effective in small-scale applications, are labor-

intensive and time-consuming. In many developing countries, including Nigeria, these traditional

methods are still prevalent due to the lack of access to modern machinery (Olufemi, Akindinola,

& Sedara, 2022) This reliance on manual methods limits productivity and hampers the economic

growth of these communities.

With the advent of industrialization, mechanized grain grinding machines were developed,

significantly improving efficiency and productivity. According to Rowe et al. (1996), these

machines use electric or diesel engines to automate the grinding process, reducing the time and

effort required (Polat & Yagdi, 2017). However, the high cost of these machines and the need for

regular maintenance and technical expertise have made them inaccessible to many rural

communities. Additionally, the design of many commercial grain grinding machines does not

consider the specific needs and conditions of rural users, further limiting their adoption.

The importance of grain grinding extends beyond mere food preparation. Efficient grain grinding

can enhance the nutritional quality of food, improve storage stability, and increase market value

(Chen et al., 2022). For instance, finely ground grains can be used to produce a variety of food

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products, ranging from traditional staples to modern snacks, contributing to dietary diversity and

nutritional improvement.

In rural Nigeria, where small-scale farming is predominant, the development of a cost-effective,

efficient, and user-friendly grain grinding machine can have a transformative impact. By

improving the grinding efficiency, farmers can increase their productivity, reduce post-harvest

losses, and enhance their income. Furthermore, an optimized grain grinding machine can

empower women, who are often the primary processors of food in rural households, by reducing

their labor burden and allowing them to engage in other productive activities (Wu et al., 2019).

This study seeks to develop and optimize a grain grinding machine tailored to the needs of rural

communities. By focusing on efficiency, cost-effectiveness, and ease of use, the project aims to

provide a sustainable solution that can enhance agricultural productivity and improve the

economic well-being of rural inhabitants.

1.2 Aim and Objectives of the Study

Aim

The primary aim of this study is to develop and optimize a grain grinding machine that is

efficient, cost-effective, and suitable for use in rural communities.

Objectives

The specific objectives of this study are:

1. To design a grain grinding machine with improved efficiency and performance.

2. To optimize the machine's performance through systematic testing and modifications.

3. To evaluate the economic viability of the machine in rural settings.

4. To ensure the machine's durability and ease of maintenance, making it suitable for rural

use.

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 5. To assess the impact of the optimized grain grinding machine on the productivity and

economic development of rural communities.

1.3 Statement of Problem

Rural communities in Nigeria and other developing countries face significant challenges in grain

grinding. Traditional methods, involving manual labor with tools like pestles and mortars, are not

only labor-intensive but also time-consuming. These methods are inefficient and cannot meet the

growing demand for processed grains, resulting in reduced productivity and economic

stagnation.

Mechanized grain grinding machines available on the market, while more efficient, are often

prohibitively expensive for rural households and small-scale farmers. These machines require

substantial initial investment, regular maintenance, and technical expertise for operation and

repair. The high cost and complexity of these machines make them unsuitable for many rural

users who lack the financial resources and technical skills needed to operate and maintain them.

Moreover, the design of many commercial grain grinding machines does not consider the unique

conditions and needs of rural communities. For example, many rural areas lack reliable access to

electricity, making electric-powered machines impractical. Diesel-powered machines, while

more feasible, still pose challenges in terms of fuel availability and cost.

The inefficiency of traditional methods and the inaccessibility of commercial machines result in

significant post-harvest losses. Grains that are not processed in a timely manner are susceptible

to spoilage, pest infestation, and quality degradation. These losses directly impact the food

security and income of rural households, perpetuating cycles of poverty and hunger.

This study aims to address these problems by developing a grain grinding machine that is

affordable, efficient, and user-friendly. By optimizing the design and performance of the

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machine, the project seeks to enhance the productivity and economic well-being of rural

communities. The machine will be designed to operate with minimal technical expertise and

maintenance, ensuring its sustainability and long-term usability in rural settings.

1.4 Scope of the Work

This project will encompass the following activities:

1. Design Phase: Conceptualizing and creating detailed designs for the grain grinding

machine. This phase will involve the use of CAD software to create precise models and

simulations.

2. Fabrication Phase: Building the machine based on the design specifications. This will

include selecting appropriate materials, assembling components, and ensuring structural

integrity.

3. Optimization Phase: Testing the machine's performance and making necessary

adjustments to enhance efficiency and effectiveness. This phase will involve iterative

testing, data collection, and analysis.

4. Economic Evaluation: Assessing the cost-effectiveness of the machine in a rural setting.

This will include a cost-benefit analysis and comparison with existing methods and

machines.

5. Usability and Maintenance Assessment: Ensuring the machine is user-friendly and easy

to maintain. This will involve testing the machine in real-world conditions and gathering

feedback from potential users in rural communities.

The project will focus on grinding common grains such as maize, millet, and sorghum, which are

staples in many rural diets. The geographical scope will be limited to rural communities in

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Nigeria, with the potential for broader application in similar settings in other developing

countries.

1.5 Justification/Significance of the Study

The significance of this study lies in its potential to address critical challenges faced by rural

communities in grain processing by developing an optimized grain grinding machine, this project

aims to:

Enhance Productivity

By providing a more efficient method of grain grinding, the machine will increase the

productivity of small-scale farmers and households. Efficient grinding allows for the

processing of larger quantities of grain in less time, which can significantly boost

agricultural output. This increased productivity can lead to higher incomes for farmers,

enabling them to invest in better farming practices and improve their overall quality of

life.

Reduce Labor

The manual grinding of grains is a labor-intensive task, often performed by women and

children in rural households. This labor can be physically demanding and time-

consuming, limiting the time available for other productive activities. The introduction of

an optimized grain grinding machine will reduce the physical effort required for this task,

freeing up time for other economic or educational pursuits. This can contribute to gender

equality by alleviating the burden on women and children and enabling them to engage in

other meaningful activities.

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Improve Economic Viability

The cost-effective nature of the optimized grain grinding machine will make it accessible

to rural communities. By reducing the costs associated with grain processing, the

machine can enhance the economic viability of small-scale farming. Farmers will be able

to retain a larger portion of their income, which can be reinvested into their farms or used

to improve their living conditions. Additionally, the machine can create new economic

opportunities, such as small-scale grain processing businesses, further stimulating local

economies.

Promote Food Security

Efficient grain processing is essential for food security in rural areas. The optimized grain

grinding machine will ensure that households have adequate access to processed grains

for consumption and sale. By reducing post-harvest losses and improving the quality of

processed grains, the machine will contribute to a stable and secure food supply. This, in

turn, can enhance the nutritional status of rural populations, leading to better health

outcomes and overall well-being

Foster Technological Advancement

The development and optimization of this grain grinding machine will contribute to

technological advancements in agricultural machinery. By creating a machine tailored to

the specific needs of rural communities, this project will serve as a model for future

innovations. The knowledge and experience gained from this project can inform the

design of other agricultural tools and technologies, promoting a culture of innovation and

technological adoption in rural areas.

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 Environmental Impact

The optimized grain grinding machine will also have a positive environmental impact.

Traditional methods of grain grinding often involve the use of firewood for energy,

contributing to deforestation and environmental degradation. Mechanized grinding can

reduce the reliance on firewood, thereby preserving local forests and reducing carbon

emissions. Additionally, the machine will be designed to operate efficiently, minimizing

energy consumption and reducing its overall environmental footprint.

In conclusion, the development and optimization of a grain grinding machine hold significant

promise for improving the lives of rural inhabitants. By addressing the inefficiencies and high

costs associated with traditional and commercial grain grinding methods, this project aims to

foster economic development, enhance productivity, and promote sustainable agricultural

practices in rural Nigeria and beyond. The machine's potential to enhance food security, reduce

labor, and improve economic viability makes it a valuable tool for rural development.

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 CHAPTER TWO

LITERATURE REVIEW

2.1 Overview of Grain Grinding Machine

Grain grinding machines play a pivotal role in the agricultural and food processing industries,

especially in rural communities where they serve as a cornerstone for food security and

economic stability (Subramanian & Madopothula, 2021). This chapter aims to provide a detailed

review of existing literature on the development and optimization of grain grinding machines. By

examining various studies, this review will highlight the historical evolution, technological

advancements, types of machines, and the challenges faced in grain grinding. Furthermore, it

will identify trends and gaps in current research, project the problems the current project aims to

address and justify the significance of this research in enhancing the efficiency, affordability, and

sustainability of grain grinding machines.

Grain grinding has been a critical part of agricultural practices since ancient times. According

to Kishore et al. (2022), these early innovations were pivotal in transitioning societies from

subsistence farming to more organized agricultural systems. Kishore, et al. (2022) provides a

comprehensive historical account, detailing the gradual shift from manual to mechanized

grinding methods, which laid the foundation for modern grain grinding technology. Early

methods involved hand tools like mortars and pestles (Okpara, 2015), which were labor-intensive

and inefficient. Historical records show that the use of querns and saddle stones dates back to

ancient civilizations such as the Egyptians and Romans, who used these tools for milling grains.

The Industrial Revolution brought significant changes with the introduction of mechanized mills.

Steam-powered mills in the 19th century replaced manual labor, leading to increased

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productivity and efficiency. These mills primarily catered to urban centers, leaving rural areas

with limited access.

According to Culpin (1992), grinding of grains has been practiced since very early times when a

device resembling a pestle and a mortar was employed in the production of meals for human

consumption. The first mills were modifications of this device, in which a grain was put through

an opening in a disc-shaped stone which was caused to rotate upon another. The gradual

development of this type of mills over thousands of years has led to the evolution of the burr

stone mill. The earliest records of food production in Africa show that indigenous grains have

long been milled to produce coarse flour for cooking. Traditional crops such as sorghum, millet,

and maize have been grounded for centuries either with a crude mortar and pestle fashioned from

a tree stump and branch or by using flat stones or rubbing stones. All these types of grinding

systems are still in common use throughout Africa today.

Brain and Rottger (2006) reported that in the mid-nineteenth century, electric motors were

invented, and higher-speed machines, such as hammer and plate mills, began to replace

traditional stone grinders. A relatively low-speed, water-cooled diesel engine can, for example,

power a hammer mill, producing maize flour of acceptable quality. These mills are in widespread

use in rural parts of the world in areas where no electricity grid is available. Diesel-powered

grain mills are limited to areas with access to fuel and spare parts. Many people still cannot

afford to pay for commercial grain-grinding services and they grind by hand using traditional

techniques. Therefore, pounding is a common sight and sound in many areas. It is often a social

activity, carried out predominantly by women, and many hours are spent each day in this

laborious and time-consuming task. The pestle may weigh up to 4 kg, and pounding requires a

lot of effort (FAO, 2005). For several decades, men were faced with the challenges of particles

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being ground alongside grains with the available grinders, however, the ground products were

unknowingly consumed by the consumers and thereby caused series of illnesses in the human

system (Chen et al., 2022).

Globally, moving away from traditional foods to more refined Western diets has been linked to

increases in the prevalence of chronic non-communicable diseases (Suleyman, 2014) which over

the years, the means to overcome this challenge has been searching for. Madopothula et al

(2021) studied the effect of grinding mechanisms using an alumina grinding wheel on the

formation of white layers in AISI 52100 steel. Further, the grinding power variation was

correlated with the metallurgical changes noticed in the ground material. (Huang et al., )

investigated the effect of grinding parameters such as grinding depth, wheel speed, wheel wear,

work piece speed, and cooling condition on the thickness of the white layer by performing a

grinding experiment on AISI 52100 hardened steel. It was concluded that the grinding depth,

wheel speed, wheel wear, and coolant significantly affect the thickness of the white layer.

The grinding mechanism in most grinding designs is the burr plate (Kareem and Akinode, 2018).

This method also uses a worm gear (auger) to initially crack the maize and transfer it to the burr

plates (Clarke and Rottger, 2006). A commercial grinding machine can be used to grind both soft

and hard food materials due to their capacity (Malkin and Guo, 2008; Johnson, 2018).

Most developing countries like Nigeria experience high mortality rates and this is exacerbated by

poor health delivery and inadequate monitoring of foodstuffs which results in high intake of

unwholesome food. High level of trace metals in food is a potential source of disease when

consumed by humans and constant monitoring of foodstuff for trace metal contamination is

crucial for the health of the citizenry due to the various diseases they induce. Unhygienic

grinding of grains for foodstuff with old and worn-out grinding machines is the usual practice in

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Nigerian markets and the operators do not appreciate the health risks involved in their operations

(Jude and Prosper, 2016). Heavy metals disrupt basic metabolic functions in two ways: on one

hand, they disrupt the functioning of vital organs and glands such as the heart, brain, kidney,

bone, or liver, on the other hand, they move nutrients that are essential minerals and prevent

them from fulfilling their biological functions. For example, aluminum as a chelator can capture

and prevent the uptake of essential elements such as calcium, zinc, and copper, and disrupt the

proper use of many of them (Dabonne et al, 2010). This metal is heavily involved in the onset of

Alzheimer’s disease. It is responsible for the alteration of neurons (Bharathi et al., 2008).

Depending on the heavy metal in question, toxicity can occur at levels just above naturally

occurring background levels, meaning that consumption of foods with a high heavy metal

concentration can cause acute or chronic poisoning (Llobet et al, 2003). Poisoning can result in

damaged or reduced mental and central nervous function, as well as damage to blood

composition, lungs, kidneys, liver, and other vital organs. Long-term exposure to heavy metals

may result in slowly progressing physical, muscular, and neurological degenerative conditions as

well as cancer (Llobet et al, 2003). In recent years, several new engineering materials such as

composites, ceramics, and super alloys have been developed, which find numerous applications

in the electronic, military, space, medical, power, and automobile sectors (Kishore et al., 2022).

2.2 Technological Advancements in Grain Grinding

The 20th and 21st centuries have witnessed substantial technological advancements in grain

grinding machines, focusing on efficiency, durability, and automation. Several key innovations

have been documented in the literature (Guo, Li, & Zhou, 2019):

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2.2.1 Electric Grain Mills

Electric grain mills have revolutionized the grain processing industry by offering significant

advantages over traditional manual methods. These machines employ high-speed motors to

power grinding mechanisms, resulting in substantially increased throughput and reduced labor

requirements. Moreover, electric mills often feature adjustable settings for particle size, enabling

greater control over the final product. This precision is crucial for various applications, from fine

flour for baking to coarser textures for animal feed.

2.2.2 CNC Technology

The integration of Computer Numerical Control (CNC) technology has ushered in a new era of

precision and customization in grain grinding. CNC-equipped machines utilize computer

programs to regulate grinding parameters such as feed rate, rotor speed, and screen size. This

level of control allows for the production of highly consistent and uniform products.

Furthermore, CNC technology facilitates rapid adjustments to grinding settings, enabling optimal

performance for different grain types and desired product characteristics. Chen et al. (2020)

pioneered research on a Novel CNC Worm Grinding Machine, demonstrating enhanced control

over grinding parameters and further emphasized the positive impact of CNC technology on

product quality, reporting a substantial improvement in product uniformity

2.2.3 Advanced Materials

The durability and longevity of grain grinding machines have been significantly enhanced

through the incorporation of advanced materials. Traditional materials, such as cast iron and

steel, have been supplemented or replaced by wear-resistant alloys and ceramics. These materials

exhibit superior hardness, abrasion resistance, and corrosion resistance, resulting in extended

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component lifespan and reduced maintenance costs. Consequently, the overall efficiency and

reliability of grain grinding operations have been improved. Zhang et al. (2018) studied the

impact of these materials on the lifespan of grinding components, finding that ceramics, in

particular, significantly reduced wear and maintenance needs. Parveez et al., (2022) conducted a

comparative analysis, revealing that components made from advanced materials had a lifespan of

up to two years, compared to less than one year for traditional materials.

2.3 Types of Grain Grinding Machines

Grain grinding machines can be categorized based on their design and functionality, with each

type offering unique advantages and challenges:

2.3.1 Hammer Mills

Hammer mills are widely used for their simplicity and efficiency in grinding various grains.

Mugabiet al (2019) analyzed the performance of hammer mills, noting their effectiveness in

breaking down tough grains such as corn, noting their effectiveness in breaking down tough

grains such as corn and sorghum. Miller et al. (2017) provided a detailed performance

comparison, showing that hammer mills could achieve higher throughput but at the cost of

increased energy consumption.

2.3.2 Burr Mills

Burr mills are known for producing consistent and fine flour, making them popular in small-scale

and artisanal settings. According to Alhendia et al. (2022), burr mills produce higher-quality

flour compared to other milling methods. A study by Bressiani, et al. (2017) demonstrated that

burr mills provided better control over particle size compared to hammer mills.

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2.3.3 Roller Mills

Roller mills are predominantly used in large-scale commercial operations due to their high

throughput and energy efficiency. As noted by Campbell et al. (2020), advancements in roller

mill technology have led to significant reductions in energy consumption. Research by Fang et

al. (2018) found that roller mills consumed 30% less energy than hammer mills, making them

more cost-effective for large-scale operations.

2.4 Challenges and Issues in Grain Grinding

Despite technological advancements, several challenges persist in the design and operation of

grain grinding machines:

2.4.1 Energy Consumption

High energy consumption is a critical issue, particularly in regions with limited access to

electricity. Also, the energy demands of different grain grinding machines, noting that traditional

methods remain energy-intensive. Recent findings show that energy costs could account for up to

40% of the total operational costs in small-scale milling operations. This study emphasized the

need for energy-efficient solutions, especially in developing countries.

2.4.2 Maintenance and Durability

Frequent maintenance and wear of grinding components increase operational costs and

downtime. Kishore et al. (2022) explored the factors affecting the durability of grinding

components, identifying wear resistance as a critical factor. The average lifespan of grinding

components was less than one year, necessitating frequent replacements. Their research

suggested that the adoption of advanced materials could significantly extend the lifespan of these

components, reducing maintenance costs and improving machine reliability.

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2.4.3 Consistency and Quality

Achieving consistent particle size and quality of the ground product is a significant challenge,

particularly in multi-grain applications. Chen et al (2019) investigated the impact of grinding

parameters on particle size distribution, finding that variations could lead to inconsistent product

quality. Their findings underscored the importance of precise control and optimization of

grinding parameters to ensure uniformity and quality.

2.5 Optimization Techniques in Grain Grinding Machines

One of the simplest definitions for optimization is “doing the most with the least” (Gomez et al.

p. 301, 2006). Lockhart and Johnson (1996) define optimization as “the process of finding the

most effective or favorable value or condition” (p. 610). The purpose of optimization is to

achieve the “best” design relative to a set of prioritized criteria or constraints. These include

maximizing factors such as productivity, strength, reliability, longevity, efficiency, and

utilization. (Merrill, Custer, Daugherty, Westrick, & Zeng, 2007). Optimization is the process of

obtaining the best result under given circumstances. In design, construction and maintenance of

any engineering system, engineers have to take many technological and managerial decisions at

several stages (Abbas, 2009). The ultimate goal of all such decisions is either to minimize the

effort required or to maximize the desired benefit. A number of optimization methods have been

developed for solving different types of optimization problems. Optimization problems can be

classified based on the type of constraints, nature of design variables, physical structure of the

problem, nature of the equations involved, deterministic nature of the variables, permissible

value of the design variables, separability of the functions and number of objective functions.

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2.6 Common Types of Optimization Techniques

2.6.1 Statistical Optimization

This technique involves the application of statistical methods and optimization algorithms to

improve performance, efficiency, and decision-making in engineering designs and processes.

These techniques include the estimation of parameters, use of classical and numerical

optimization methods, and analysis of system performance through evaluation.

2.6.2 Stochastic Optimization

This techniques refers to methods designed to solve optimization problems that involve

randomness or uncertainty. These techniques generate and use random variables to account for

variations in the system or environment, allowing for more robust solutions in complex

scenarios. They are particularly useful for optimizing functions that are influenced by inherent

noise, nonlinearities, or uncertain parameters.

2.6.3 Deterministic Optimization

This technique refer to methods that systematically exploit the specific characteristics of a

problem to find the optimal solution. These techniques are designed to converge to a global

optimum using analytical properties, providing theoretical guarantees that the solution obtained

is indeed the best possible one for the given problem. They rely on precise inputs and

assumptions rather than probabilistic or random factors, aiming for consistent and repeatable

outcomes.

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2.7 Case Studies and Real-World Applications

2.7.1 Rural Applications

Solar-powered grain grinders have significantly improved food security and economic stability in

rural African communities. These machines increase grain processing capacity and reduce

manual labor, enhancing overall productivity (Chen et al., 2022).

2.7.2 Industrial Applications

Large-scale grain processing plants have adopted advanced roller mills and automated control

systems to meet high demand. These integrations have led to increased production efficiency,

cost savings, and improved product quality.

2.8 Problem Statement

Despite the progress in grain grinding technology, several gaps remain. This project aims to

address the following issues:

Energy Efficiency: Developing a more energy-efficient grinding machine suitable for rural areas

with limited power supply.

Cost-Effectiveness: Designing an affordable machine for small-scale farmers and cooperatives.

Durability: Enhancing the durability and lifespan of grinding components to reduce

maintenance costs.

Consistency: Improving the consistency and quality of the ground product to meet diverse

consumer needs.

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2.9 Energy Consumption

2.9.1 Energy Consumption in Grain Grinding Machines

Energy consumption remains a critical concern in the operation of grain grinding machines.

Traditional hammer mills are particularly energy-intensive, and optimizing the grinding process,

including the use of advanced materials and innovative designs, can reduce energy consumption

significantly.

2.9.2 Wear and Durability of Grinding Components

The durability of grinding components influences operational costs and machine reliability.

Advanced materials such as high-performance ceramics and composites exhibit lower wear rates

and longer service lives, reducing maintenance costs and improving machine reliability.

2.9.3 Consistency and Quality of Ground Products

Achieving consistent particle size and high-quality ground products is crucial for both consumer

satisfaction and product performance. Precise control and optimization of grinding parameters

ensure uniformity and high-quality output.

2.9.4 Automation and Control Systems

The integration of automation and control systems in grain grinding machines offers significant

benefits in terms of efficiency, precision, and adaptability. Automated systems can dynamically

adjust grinding parameters based on real-time data, improving processing efficiency and

reducing operational errors.

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2.9.5 Case Studies and Practical Applications

The practical applications and case studies of optimized grain grinding machines provide

valuable insights into their real-world impact. Deploying solar-powered grain grinders in rural

communities significantly improves food security and economic stability, while advanced roller

mills in industrial settings enhance production capacity and reduce operational costs.

The findings of this review underscore the need for continued research and innovation to address

the gaps identified and contribute to the advancement of grain grinding technology. The project

aims to build upon these insights to develop a more efficient, cost-effective, and durable grain

grinding machine that meets the needs of both rural and industrial applications.

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 CHAPTER THREE

MATERIALS AND METHODS

3.1 Research Design

The research employs a hybrid approach, integrating experimental and computational

methodologies. The research process is structured into the following phases:

3.1.2 Design and Simulation

Based on the literature review, multiple design concepts will be generated and evaluated.

Computer-aided design (CAD) software will be utilized to create detailed three-dimensional

models of the machine components, including the grinding chamber, rotor, screen, and feeding

mechanism. Finite element analysis (FEA) will be employed to assess stress distribution,

deformation, and vibration characteristics under various operating conditions. Optimization

techniques, such as response surface methodology (RSM) or genetic algorithms, will be

implemented to refine the design and identify optimal dimensions and material selections.

3.1.3 Prototype Development

A physical prototype will be fabricated based on the optimized design. The selection of materials

and manufacturing processes will be guided by considerations such as cost-effectiveness,

durability, machinability, and compatibility with the grinding process. Rapid prototyping

techniques may be employed for initial iterations to accelerate the design-build-test cycle.

3.1.4 Performance Testing

A comprehensive test matrix will be established to evaluate the prototype's performance under

diverse operating conditions. Independent variables, including feed rate, rotor speed, screen size,

grain type, and moisture content, will be systematically varied. Dependent variables such as
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grinding efficiency, energy consumption, particle size distribution, capacity, product quality

(including flour color, protein content, and mineral composition), and machine wear will be

meticulously measured and recorded.

3.1.5 Refinement and Iteration

Based on the data analysis and optimization results, the machine design will undergo iterative

improvements. Modifications may involve design alterations, component replacements, or

material substitutions. The modified prototype will be subjected to retesting to evaluate the

efficacy of the changes. This iterative process will continue until the predefined performance

targets are achieved.

3.2 Materials and Equipment

The successful development of the grain grinding machine hinges on the judicious selection of

materials and equipment. The following resources are proposed:

3.2.1 Hopper/feeder

The grinding machine has different machine components such as; Feeding Chamber that consist

of hopper and feeder which is the point at which the products is loaded into the hopper where

coiled spring/feeder will channel the compressed products into the grinding chamber. Grinding

chamber consist of grinding discs, adjustable screw and cone which is the point at which the

feeded products will be grinded/blend through the two grinding discs rubbing together during the

operation. The transmission chamber that is consists of lever, shaft and control lever bearing

which is the point at which the hand driver lever will transmit the motion through the shaft to the

grinding discs where the work will be done. Also the adjustable lever at the opposite side of the

driver lever is used to increase the effect of the grinding discs in the chamber. The extractor

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chamber that consist of compacted magnetic substance in an enclosed sheet ferrous metal

rectangular plate mounted at the exit point of the chamber with an angle approximately 450

which will allow free flow of grinded product but trap the ferrous metallic substance. The hopper

is mounted in such a way that the products have free flow into the grinding chamber in a control

manner. As the lever rotate, it pushes the product into the grinding section and as the two discs

rubbing each other the product is grinded into powder. As the powder trying to drop the ferrous

metallic particles were trapped at the exit point of the machine through the help of the extractor

and the grinded powder product without ferrous metallic particles dropped in a container.

Fig 3.1 Diagram of a hopper

Mass of the hopper = Density of mild steel X volume of hopper.

M=ρxV

Volume of hopper = External volume of the hopper – Internal volume of the hopper

T = Driving Torque = Resisting Torque (N/m)

Where d, d1, d2 and d3 are the diameters of the equivalent shaft, (1), (2) and (3) respectively.

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Determining the Composite Shaft Diameter

Mass of each shaft: mi = m1 + m2 + m3

Diameter of each shaft: di = d1 + d2 + d3

Capacity of the Feeding Chamber V = πr2h

Where: V = volume (cm3) r = radius (m) h = height (h) Angle of twist for the composite sheet

3.2.2 Electric motor

The electric motor in a grain grinding machine functions as the primary actuator that drives the

grinding mechanism. It produces rotary force (torque) that powers the belt and pulley system to

ultimately grind the grains into flour or meal. Specifically,

The Electric motor was selected based on the speed and required power output for the smooth

and efficient operation of the machine. The specifications of the diesel engine as available on its

tag are:

3.2.3 Grinding Wheels

Alumina (Aluminum Oxide): Common abrasive material for a variety of grinding applications.

Silicon Carbide: Used for harder materials; ideal for non-ferrous metals and ceramics.

Diamond: Extremely hard and used for precision grinding of hard materials.

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3.2.4 Determination of Component of the Machine

Determination of Pulley Diameter

The pulley diameter was determined using this equation as recommended by Khurmi and Gupta

(2005).

N1 D2
N2
= D1

N1 is the electric motor speed, N2 is the machine speed, D1 is the diameter of driver pulley, and D2

is the diameter of driven pulley. For a horsepower of 1Hp which gives1400 rpm. N 1= 1400 rpm,

N2 650 rpm, D1 65 mm. Substituting the values into equation 3, D 2, will be 140 mm. the diameter

of driven pulley used was 140 mm.

Centre Distance of the Pulley

The centre distance of the pulley was calculated using equation 4 as recommended by Khurmi

and Gupta (2005).

D 1+ D 2
C= + D1
2

Substituting D1 = 65 mm and D2 = 140 mm. C will be 167.50 mm. Therefore, the center distance

of the pulley of 167.50 mm was used.

Determination of the Bending Moment of the Shaft

Bending moment of the shaft was determined using this equation

Mb = √ ¿ ¿

Where: Mb is the maximum bending moment (nm), MBV is the maximum vertical bending

moment. MBH is the maximum horizontal bending moment.

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Determination of the length of the belt

The length of belt was calculated using the equation

L = 2C + 1.57(D+d) + ¿ ¿

Determination of belt speed

The belt speed was estimated using

V = πDN

V is the speed of belt (ms-2),

D = diameter of the driver pulley (mm),

N = number of revolution per minute (rpm)

Table 3.1: Machine component

S/ Machine Criteria for selection Most Suitable Materials Reason for
N components Materials Selected Selection
1 Shaft Strength, machinability, Mild steel, cast Mild steel High strength
surface finish, weight, iron and light
cost, availability. weight
2 Belt guard Strength, machinability, Mild steel, Mild steel Surface
surface finish, weight carbon steel finish, light
weight
3 Grinding unit Weight, good wearing Mild Steel, Stainless steel Cost, Usage
property, availability Galvanized and
Steel, stainless availability
4 Pulley Weight, good wearing Mild steel, cast Mild steel Availability
property, availability iron and weight
5 Rubber or for vibration isolation Good quality Good quality Availability
polyurethane and noise reduction
6 Cast Iron Provides stability and Cast iron Iron cast Iron cast
vibration dampening

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3.3 Optimization Techniques Applied

3.3.1 Design Optimization (DO)

In engineering design, it refers to the process of systematically improving the performance or

other desirable characteristics of a product, system, or process through the use of mathematical

algorithms and computational tools. The goal of design optimization is to find the optimal

solution that meets a set of specified design requirements and constraints while minimizing cost,

weight, or other objective functions. The optimization process involves the use of models to

simulate the behavior of the system under different conditions and the application of

optimization algorithms to search for the best design parameters.

3.3.1 Framework Optimization

Framework optimization in involved the use of structured approaches and methodologies to

improve the performance of designs beyond initial concepts. These frameworks help in making

design decisions by evaluating trade-offs, thereby enhancing efficiency and effectiveness in

engineering solutions. Examples of frameworks include Design By Expectation (DBE) which

focuses on setting and meeting expectations in design performance.

3.3.2 Parameter Optimization

In Parameter Optimization, it refers to the process of determining the optimal values of design

variables to achieve the best measurable performance for a given problem. This involves

identifying the most effective parameters that influence the machine's operation and overall

efficiency.

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3.4 Measurement Instruments

i. High-precision scales for measuring grain input and product output.

ii. Tachometer for measuring rotor speed.

iii. Power meter for measuring energy consumption.

iv. Laser particle size analyzer for determining particle size distribution.

v. Moisture meter for measuring grain and product moisture content.

vi. Colorimeter for measuring product color.

3.5 Ethical Considerations

The research was conducted in accordance with ethical principles and guidelines. Safety

protocols will be strictly adhered to during machine operation, handling of materials, and data

collection. Personal protective equipment (PPE) will be provided and used to minimize risks to

researchers. Data privacy and confidentiality will be maintained throughout the research process.

Data will be securely stored and accessed only by authorized personnel.

3.6 Limitations

The scope of this research is focused on the development and optimization of a grain grinding

machine for specific grain types and capacities. The findings may not be directly transferable to

other grain types or machine configurations.

The accuracy of the results is dependent on the precision of the measurement instruments

available and the control of experimental conditions.

External factors, such as variations in grain quality and environmental conditions, may influence

the machine performance and data reliability.

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The optimization process is based on a set of defined performance criteria and may not capture

all relevant factors affecting the overall system performance. Additional research may be

required to address the identified limitations and expand the applicability of the findings.

3.7 Budget

Table 3.2: Cost estimate

ITEM COST (NGN)

Surfing Subscription and Communications 15,000

Travels and Logistics 30,000

Miscellaneous 20,000

Work Review, Printing and Binding 50,000

Electric Motor 60,000

Framing 70,000

Driven Pulley 25,000

Total 270,000

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Fig 3.2: Structure of Grain Grinding Machine

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