The Development of Coffee

Dehuller and Winnowing Machine

A Thesis

Submitted to

The Faculty of the Mechanical Engineering Department

University of Mindanao

In Partial Fulfilment

Of the Requirements for the Degree

Bachelor of Science in Mechanical Engineering

Submitted by

Joriko Paolo Asidoy

Kevin Cabalquinto

Remans Daniel Ramos

March 2017
 I. Introduction

Coffee is the world’s second most tradable commodity after oil, which means it is

big business. It is because everywhere in the world, innumerable people enjoy a daily

cup of coffee. However, it is a long way from the coffee plant to the roasted bean and

those steps must be carefully planned and implemented (Paige, 1998).

According to Census of Agriculture (1991) coffee production is dispersed across

many countries. Brazil accounts for about 20%-25% of world production, followed by

Colombia (13% to 18%) and Indonesia (6% to 7%). The Philippines accounts for only

2% of world supply.

Introduced in the Philippines in 1740, coffee remains one of the country’s

leading export commodities. And as long as there are coffee drinkers, coffee culture

will remain a profitable business venture. As of 2014, the Philippines produces 25,000

metric tons of coffee and is ranked 110th in terms of output. However local demand for

coffee is high with 100,000 metric tons of coffee consumed in the country per year. The

Philippines is one of the few countries that produce the four main viable coffee varieties;

Arabica, Liberica (Barako), Excelsa and Robusta and being is dominated by small

farmers. The average size is 1-2 hectares (ha), with most of the farms being owned by

the farmers themselves. Most of the farms are intercropped, such as with vegetables,

coconut, fruit trees and even forest trees (especially in the case of Arabica coffee). There

are very limited commercial scale plantations in the country (Flores, 2014).

Coffee production in the Philippines continues to be lorded over by Mindanao,

with Region 12 or the Soccsksargen region remaining as the top regional coffee

producer of the country. Jennifer Remoquillo, Department of Agriculture (DA) national

coordinator for High Value Crops Development Program, said that Mindanao accounts

for 77percent of the country’s coffee production. Trailing far behind in coffee

production is Luzon at 17 percent and Visayas at six percent, she added. In terms of

area planted to coffee, 67 percent is in Mindanao, 23 percent in Luzon and 10 percent

in the Visayas (Sarmiento, 2015).

Success in coffee industry depends on knowing what’s happening at every point

between supply and demand. In an industry like this, where the chain stretches across

continents, challenges are bound to arise.

The researchers observed that the processes in the production of the coffee is

very costly because of the factors such as the labour, usage of different machine

equipment, land rental, transportation and etc. Also, coffee production is time

consuming for the reason that it would take weeks before the finished coffee is being

manufactured. The small farmers which are also dominating the coffee farming in the

Philippines are the most affected of this setback since they only have minor budget to

spare for the labour, equipment, land rental and etc. This study aims to create a machine

that hulls and winnows the coffee beans before it is being further processed and being

roasted. This research study is intended for coffee production and coffee marketing as

raw materials for construction. The possible output of this study is either electrical or

fuel-powered huller & winnower machine for the purpose of easier, faster and

affordable hulling and winnowing of coffee beans. This technology can minimize the

time consumed in the processing and will guarantee an inexpensive, maintainable,

sustainable and productive operation.

II. Objective of the Study

 This research intends to design, improve and examine a huller and winnower

machine for coffee beans. Specifically, it pursues to achieve the following specific

objectives:

1. To design and assemble a huller and winnower machine for coffee beans.

2. To verify the amount accumulated in the expenses of making the machine from

its other similar equipment.

3. To determine if there is a significant difference between the costs saved by

building an alternative machine or from buying the existing ones.

III. Importance of the Study

Searching for an alternative way to dehull and winnow coffee beans shows an

important part here in our country. Coffee farming dominated mostly by the small

scale industry just don’t have enough funds to purchase dehulling and winnowing

machines. The use of a substitute apparatus for this kind of process is a significant

knowledge especially if it would become cheaper and more practical. This project

will benefit the coffee farmers to their production of dehulled and winnowed coffee

beans.

IV. Target beneficiaries/clients

This study will be advantageous to the following:

Small Coffee Farmers. This study will showcase for them a design of a machine that

will make their production process quicker, more efficient, cheaper and produce high

quality coffee products.

Research Community. The results of this study will give them more information,

statistics, learning and background for further studies and research.

General Public. They will get high quality coffee bean merchandises for their personal

use.

V. Review of Related Literature

This part of the study presents some literatures that have bearing in the present work.

Reviewed are articles taken from the different sources like journals, manuals, books,

web sites and other printed materials to support the relevance and findings of the study.

These also provide the researchers some insights and directions in the conduct of the

study and basis of giving recommendations.

Coffee

Coffee beans are the seeds of berries coming from the Coffea group of plants

(Maurin et al 2007). Coffee plant, which originated from Africa produces coffee drink

that are infused from the roasted beans. Coffee is notably known for its stimulating

effect caused by an alkaloid named caffeine and also belongs to the one of the most

marketable product worldwide because of its popularity together with tea and water

(Myhrvold 1999).
 Coffee are divided into two variations namely: varieties and cultivars. Varieties

naturally take place by transmutation. The difference between varieties and cultivars is

that cultivars’ alteration are done by human intervention (Kolbu, 2015).

There are only three types of coffee plants that are profitably sustainable: the

Coffeea Arabica or Arabica, Coffea Canephora or Robusta and Coffea Liberica or

Liberean Coffee (Martin 2013).

Arabica accounts around 70 percent of the international market for the coffee

beans. It is also said that this coffee has enhanced quality because it is harvested in sheer

terrain which means it can be picked manually ensuring a better selection of beans. On

the other hand, the Robusta accounts around 27 percent of the global coffee market and

frequently used for producing instant coffee which means it is cheaper and has lesser

taste quality compared to Arabica (Bakersville 2016).

The harvesting period of coffee usually happens twice or once annually

preferably throughout the dry periods of the year. Picking can be done mechanically or

by handpicking. During harvesting period, the coffee pickers usually pick coffee

cherries every 8 to 10 days. There are two types of methods in coffee processing namely:

dry mill and wet mill method. In dry mill, the coffee is then being dried after being

collected and this can be done by using dry mill for up to four weeks or driers. After it

is being dried, it will undergo a process called dehulling which removes the external

coating of the bean. After dehulling it will be examined further and then polished to

remove the shaft before roasting. On the other hand, wet mill method can be done by

using machine-driven apparatus and considerable quantity of water. Just few moments

after being harvested, the cherries will immediately undertake different processes called
Pulping, which gets rid of the covering; Fermentation with the aid of yeast, fungi and

bacteria; Washing, which results to a tidy, light presence; and lastly Drying, when the

bean reaches a humidity level around 10 to 12 percent. For the both processes, the wet

mill method results for better quality. After being milled, the processed coffee will be

packed or aged to improve the quality of the beans (Schuett 2012).

Dehuller

One roadblock to the increased production of the ancient grains and spelt is the

need for dehulling capacity, since these grains do not thresh free of the hull in the

combine process (Baker, et., al (2014). One focus of their study was on the current

dehulling options for both larger-scale and small-scale growers, including custom

dehulling, new and used dehullers, modification of milling/cleaning equipment to

dehull, and building one’s own dehuller.

According to Navarra (2014) grains have the potential of being a value added

crop for farms. The dehulling process continues to be a roadblock in the production of

grains. They do not thresh free of hulls. After harvesting the grains they then must be

cleaned and dehulled. This isn’t unique, other crops including coffee, rice, barley, oats,

sunflower and buckwheat have hulls that need to be removed. Baker (2014) further

surmised that despite having a hull, these grains are gaining in popularity largely due to

their in-field stress tolerance, distinct flavor differences and higher selling prices. Some

varieties are very disease tolerant and drought tolerant.

Kutka (2014), co-coordinator of the Farm Breeding Club also noted that

dehulling is only one step in the process to preparing grains for final sale. Before grains
are put through a dehulling machine, they must be dried. Efficiency decreases and loss

increases when there is more moisture in the grain,” Baker said. Grains should also be

run through a screen to remove any debris collected at harvesting time. It’s slower and

reduces the grain quality when it’s not clean.

Schmaltz (2014) grows emmer in North Dakota and most recently takes his grain

to a mill that currently processes barley. He loses up to 40 percent from mill damaged.

Working closely with the mill, he’s designed a custom built mill at the facility. He’s

hoping the new machine will be more efficient and result in less damage. Commercial

mills require high-volume minimums and may not be located close to the farm,

increasing transportation costs.

During travels to France in 2009, Dyck, coordinator of Organic Growers’

Research and Information-Sharing Network (OGRIN), found that many organic farms

were processing their grains on the farm with small scale dehullers, an option that was

not readily available in the Northeastern United States at the time. On-site dehullers can

help farmers reduce expenses and increase profits.

Dehulling on the farm reduces the bulk weight of the grain leading to lower

transportation costs and higher profit margins when the finished product is transported

(Vipinhari, 2005). The hull by products can also offer growers additional sales potential.

Dairy farmers like the hulls because they are high in protein, the hulls can also be sold

for bedding for poultry, used for pillows (similar to buckwheat pillows) and used for

filtering juices. To sustain an on-site dehulling machine, the farm has to be able to

produce enough grain for the machinery to pay for itself. Aside from the initial

investment, the machines require time for setup, cleaning and quality control.
Winnowing

Winnowing is a process to separate a heavier and a lighter component from a

heavier component by throwing it from a height the lighter material blows away from

wind and heavier component is down. The concentration of larger class as smaller ones

are removed by water or wind. Winnow means to separate the seed from the husks. A

seed winnower works on the principle that the husks of the seed are lighter than the seed

that has not been opened by the birds so the fan in a winnower. Threshing is done by

beating the sheaves against the wooden bars to separate the grains from the stalks.

Winnowing is the process of removing the unwanted husk from chaff. Winnowing

machine is used for separating chaff using the wind winnowing is the separation of

solid-solid separated by size and weight whereas sieving is the separation solid-liquid

judged by shape and size.

VI. Scope and Limitations

The study includes the design and development of a machine that hulls and winnows

of what is left of the fruit from the are several varieties of coffee (Scientific Name:

Coffea sp. L.) such as Arabica, Liberica, Excelsa and Robusta and is mainly made from

locally available parts and fabricated within Davao City and Tagum City. The output of

the machine will hull and winnow the coffee beans.

 VII. Method

This chapter covers the explanation of the research design, data tool & subject

of the study. It also shows the method of conducting the study. This includes the design

of the research, its process, the materials used and numerical treatment of data.

Method of Research

This study uses an applied type of research since the researchers intends to

fabricate a coffee dehulling and winnowing machine. Therefore, applied research is

performed for the purpose of applying theories and assessing its effectiveness.

Therefore, it includes the pursuit of science to acquire solutions to problems regarding

effectiveness of coffee hulling and winnowing machine.

Research Procedure

These are the step-by-step procedures we undergone to obtain the objectives of

our study:

Gathering of ideas. The researchers collected concepts, information and

thoughts through educational materials such as books, newspapers, magazines and

journals coming from the internet.

Designing of research. The researchers were capable to create a sustainable and

effective design by gathering important information related to our project.

Acquisition of approval. The researchers were able to use the required tools and

equipment for the fabrication of the project by requesting permission from the

authorized personnel.
 Preparation of materials. The researchers prepared the materials for the

fabrication after they figured out what measurements and dimensions will be used.

Fabrication. The materials prepared were being used to create the designed

dehulling and winnowing machine.

Function Testing and Data Gathering. Before starting the engine, inspections

were made to ensure engine is intact to the base, the pulleys and belts are checked to

ensure proper alignment and tension. After initial check, the fuel valve is opened and

the ignition is switch to on position. The tension cord is then wounded and pulled to

start the engine. The coffee is then placed in the hopper and the timer is started. The

machine rotates at ____RPM.

Preparation of Materials

Materials were first purchased in hardware and junkshops for alternative

economic purposes. The proponents prepared the materials for the fabrication of the

coffee dehulling and winnowing machine. Other equipment needed for the fabrication

of the juice extractor system was obtained from Mechanical Engineering laboratory of

the University of Mindanao.

Acquisition of Approval

The proponents asked permission from the authorized personnel to use

necessary tools and equipment in the Mechanical engineering laboratory for the

fabrication of the coffee dehulling and winnowing machine.

Conceptual Framework

The conceptual framework of the study shows the figurative illustrations of this

research. The framework falls under three conditions, namely input, process, and

output. The first set is the input where the factors that affect the production of the

machine are presented, namely the time, force and the adjustment of the blade.

The second is the process which covers the design and fabrication of the coffee

dehuller and winnowing machine. It also includes the testing of the machine and

retrieving the efficiency of the said machine.

The third is the output. This encompasses the data surrounding the developed

Coffee Dehuller and Winnowing Machine.

INPUT PROCESS OUTPUT

Time, force needed Design, Fabrication

to dehull coffee
cherry, Adjustment
of the blade
Fabricated Coffee
and Testing of Coffee
Dehuller and
Dehuller and
Winnowing machine
Winnowing Machine

Figure 1. Conceptual Framework of the Study

Constraints

The proponents use factors that limit and restrict the scope of conceptualizing

the design of the coffee dehuller and winnowing machine. It is the main factor in

selecting the final deign to be fabricated in the study.

Economic

The analysis based on the material costs, production costs, labour costs.

The fabricated device must be focused on the small-scale consumers and farmers.
 Sustainability

The ability of the machine to operate under normal operating conditions

for a long time. It covers the machines lifespan, maintenance and efficiency.

Manufacturability

The ease in fabrication of the machine. The availability of the materials,

the total number of parts and the cost of the parts and materials are considered in

fabrication of the machine.

Design Procedure

This research study will be done through the designing, fabrication of a coffee

dehuller and winnowing machine, testing the functionality and efficiency of the

machine, and to present a accost analysis of the study. In fabricating the machine, the

design of the screw and the air flow rate is very important. The screw will ensure that

the coffee are properly dehulled and the air flow rate of the winnower will separate the

coffee seeds from the skin.

In the fabrication of the machine, several materials will be used. These

materials are selected based on the design that determine the machines rigidity and

strength. These are plane sheet,

Specifications of Materials

Design Considerations
Testing Set-up
VIII. Findings of Study

IX. Conclusion and Recommendation

X. References

 Experimental/Field Layout/Technical Design

  Statistical Design

Design parameters

The following parameters were some physical properties of the coffee:

Seed used for the design calculations;

Density of the seed = 1226.5 kg/m2

Seed width = 4-5 mm

Seed length = 5-8 mm

The Assumed machine capacity = 400 g/min =

Determining of the Volume of coffee seed

M M
ρ= ;V =
V ρ

Where: ρ=density

V=Volume

Density of coffee was obtained as 1226.5 kg/m3 and assumed mass = 400g

Therefore, Volume = 3.2613x10-4 m3

Expressing the capacity in volumetric rate;

Volume x 60 min = 3.2613x10-4 m3 x (60 min/hr) = 0.0196 m3/hr

Determining the Screw Diameter

CMPH = (D2 – d2)xpxNx60

Where:

CMPH = capacity of the machine (m3/hr) = 0.147 m3/hr

d = diameter of the shaft = 25 mm = 0.025 m

D = diameter of the screw of auger = ?

p = pitch of the auger = 20 mm = 0.02 m

N = speed of the auger = 500

Shaft Diameter

16T
σ=
πd3

where:

d = shaft diameter

T = Torque of the shaft

σ = Maximum permissible work stress

Research Design
 The objective applied in the main approach is to develop a Coffee Dehuller and

Winnowing Machine that will improve the researchers’ ability in addressing the

problems of the small scale farmers.

Research Materials

This shows the materials being used in making this study including their

respective functions:

Angle bar. It is made up of steel and used as support to structure so that it could

withstand the weight applied on them.

Moulded cast iron. Serves as the composition for the lower body and upper body

of the huller.

Steel sheet. Used to fabricate the hopper and the

Screw.

Bolts. Used to fasten components together.

Rollers. It makes the project portable.

Closure clamp. It locks the lower body and upper body of the huller together.

Hulling knife. Helps in hulling the coffee further.

Adjustment screw for hulling knife. Guides the hulling knife inside the huller.

Sieve. It helps in removing the outer layer of the coffee bean as it passes.

Drivetrain pulley for v-belts.

Pillow blocks. It holds the huller shaft in place.

Supply hopper. It stores the coffee

Exit mouth. It guides the hulled coffee bean going to the winnower.
 Plane sheet.

V-belt. A component which drives the pulleys in the huller and winnower.

PVC pipe. Used to create a draft tube to enable suction of unwanted hulled coffee

skins

Measuring instruments

These are the instruments being used for the data collected during testing:

Digital Weighing Scale. This tool was used in measuring the mass of the coffee

before and after being hulled.

Tachometer. This tool was used in measuring the angular velocity of the motor

and pulleys.

Anemometer. This tool is used to measure the winnower inlet and outlet air

velocity which is used to compute the air volume flow rate.