Project Readiness Package 12/18/13

INTRODUCTION:

Farmers in the cooperative KGPB in Borgne, Haiti requested help to obtain more income from their agricultural products by transforming them for export or by implementing improved storage methods to reduce waste. The main crops are mango, cocoa, coffee, orange, grapefruit, pineapple and breadfruit. Preserving crops could allow them to be stored and selling them locally during the hungry season. Improving quality and value could allow products to sell for the export. Farmers in the Borgne use organic methods. Here our goal is to evaluate various methods for preserving fruits in a way by drying them or converting them into other forms e.g. Powdered Juice, Canned Juices, extracting oils, drying entire fruit. This PRP will focus on mainly converting the mango pulp into powdered form, which will increase the shelf life and ease of transporting the product to the market, thereby preventing wastage of mangoes.

ADMINISTRATIVE INFORMATION:

Project Name (tentative): Production of Mango Juice Powder using Mango pulp Project Number, if known: xxx

Preferred Start/End Semester in Senior Design:

Faculty Champion:

Name Dept. Email PhoneSarah Brownell ISE sabeie@rit.edu 585-330-6434

Other Support, if known:

Name Dept. Email PhoneFrancius D.Estimable KGPB, Haiti fdestimablo@yahoo.frProf. John Kaemmerlen ISE,RIT jxkpdm@rit.edu  585-475-2767

Project “Guide” if known:

Primary customer, if known (name, phone, email) :KGPB, Haiti & Francius. D. Estimable ( Haitian farmer).

Sponsor(s):

Name/Organization Contact Info. Type & Amount of Support Committed

KGPB fdestimablo@yahoo.fr Grants RIT,NY Building Up project+ Grants

Project Overview: Page 1 of 15

Fall 2014 Spring 2015

Project Readiness Package 12/18/13

After lot of research and interviews with KGPB about the extreme weather conditions and about high waste of crops in Haiti, suggested that the fruits were the one, which involved highest amount of wastage. Mangoes relatively rank top in amount of wastage. These losses were due to large production but less demand and not having appropriate means of storage for long-term use of it.

Here the main intention of the project is to improve farm productivity and thereby obtain increased profit. One of the most important parts from which high profit can be obtained is converting Mango fruit into some other form such as juice/pulp, but this have a low shelf life and also transportation being is a issue due of high percentage of water content making the product bulky. The goal of this MSD project is to further process the Mango pulp/juice into concentrate, Mango Juice powder. So accordingly, MSD team will select the most feasible solution that is possible to implement in Borgne, Haiti

and is economical and highly productive. This will increase shelf life and amount of quantity per transport. Hence, this overall project will lead to obtain a product that will increase profits. This PRP is for the project that will create a solution to processes involved to get finalized product, Mango Juice Powder. (Image source: http://www.virtualherbarium.org/tropicalfruit/mangotrees.html)

DETAILED PROJECT DESCRIPTION: Customer Needs and Objectives:

Number Category Description1.1 Profit High output/Input Ratio for the product. 1.2 Profit Protects quality1.3 Profit Increases shelf life2.1 Feasibility Less Automated technology and More manually Operated2.2 Feasibility Shared amongst farmers, due to high project cost involved2.3 Feasibility Uses available resources3.1 Cost Low Investment ( Cost of designing/manufacturing plant, Operating cost)3.2 Cost Low Maintenance Cost (Cheap Replaceable Parts)3.3 Cost Low energy cost (fuel, electricity, etc.) or Manual Use4.1 Safety Withstand repetitive use4.2 Safety Easy to clean and sterilize4.3 Safety Plant easy to operate and designed according to workers safety4.4 Safety Survive extreme weather5.1 Ease of use Requires little technological background or training5.2 Ease of use Involves less Automation5.3 Ease of use Easy to handle the process

6.1 Easy to maintain Easy to Repair

6.2 Easy to maintain Durable/Rugged

6.3 Easy to maintain Requires infrequent Maintenance

Functional Decomposition:

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Potential Concepts:

Dehydrating using Drum Drying : This involves drying the pulp using internally steam heated stainless steel/cast iron hollow drum rotating at the required speed in the opposite direction to each other and the scraping the dried film over the drum and grinding it to get the final product. This can be one of the most economical ways for making powder especially when considering conditions in Haiti.

Drum drying process vary depending upon there their configuration and number of drums used in the process.

Types of Drum Drying process (www.sciencemadness.org)

Dehydrating using Refractive window drying: This involves drying by passing pulp over conveyors, which pass over the boiling water. There entire process takes place in the refractive window chamber. Finally, the dried film is scraped and grinded to get desired powder product. This is also one of the economical ways and not any extensive energy conversions are required.

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Project Readiness Package 12/18/13

www.mtcapra.com

Setup of refractive Window Drying

Dehydrating using Spray Drying process: Spray drying is a process wherein the feed such as paste, solution or suspension sprayed in droplets in a stream of hot air using an atomizer to accomplish evaporation and produce a free flowing dry powder. High scale production plants use this process and this requires lot of energy consumption.

Simple Spray dryer plant (www.geaseasia.com)

Specifications (or Engineering/Functional Requirements):

FunctionMetrics(units)(Direction) Units Direction Target Marginal

CR Ref.

Accept Mango Juice/Pulp

Quantity kg Up 500 300-400

1.1

 Additive/Preservatives

Time for mixing Blending Preservatives Min down 5 >=5<8 

1.2;4.2 5

(E.g. Sugar/Chemicals) Fruit Pulp:Maltodextrin  Ratio down 55,45 50,50

1.23

Temp at which Mixing is done

Degree C down 50 40-50

4.35

Brix  °Bx down 14 14-15 2

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Pasteurize/Sterilize

Temp at which Pasteurization is done DegreeC down 70 70-74

1.25

Time Sec up 15 15-30 1Dehydrate Pulp

Moisture Content in final Juice Powder % down 3 3-5

1.3;2.3;5.3 2

Remove water(Process Dependent) Operating Temp for dehydration

Degree C up

150-180 or 95-97

140-200 or 90-100

3.3;1.3 2

  Residence Time Sec down 20 19-21 1.1 1 

Time for Dehydrating Min              do

wn              Process dependent  

1.1;3.3  

Manual Grinding & refining powder To get required refinement level of 

mango juice powder(Mesh Size) up 80 35-80

5.2;6.3;2.1 1

Flavor remains unchanged

% of people that still find product with desired same taste % up 90 80-90

1.2 

AffordableAmount of manufacturing +Installation +Transport of device $ down 5000

     5000-10000

3.13.23.3  

Ease of Transporting Equipment

Number of workers required to carry Machinery to Place of Installation

# of people down =<2 =< 4

5.3;4.3

 Ease of Use

Number of Hours running of plant/Equipment once started after cleaning Hours Up 10-12 8-10

6.1;6.2;6.3;4.1  

Ref No. Reference

1http://research.wsulibs.wsu.edu/xmlui/bitstream/handle/2376/4271/Caparino_wsu_0251E_10486.pdf?sequence=1

2 http://www.sciencedirect.com/science/article/pii/S0260877412000301

3 http://www.engr.usask.ca/societies/asae-csae/papers/asaepapermbsk02-201.pdf4 www.elsevier.com/locate/jfoodeng5 Principles of small and medium scale fruit juice Processing-FOA Agricultural Service bulletien 146

Concept Generation and Selection:

  A B C Potential Combinations

# Drying Process Heating treatment source for Dehydration

Grinding/Filtering for final product A1+B2+C2

1 Spray Wood Manually operated A2+B4+C12 Single/Double Drum Heating Coils Automated A2+B3+C1

3 Refractive Window Drying Gasoline   A3+B4+C1

4 Freeze Propane   A3+B2+C2

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7 New design?      

  Concepts      

  A B C D E          (Reference)Selection Criteria A1+B2+C2 A3+B2+C2 A2+B2+C1 A2+B4+C1 A3+B4+C1Cost - - 0 + 0Weight - 0 - 0 0Strength + 0 + + 0Energy Consumption - - - 0 0Time to produce final product + + 0 - 0

Manufacture/Design - 0 0 0 0Automation (Require Less) - - + 0 0

Sum + 's 2 1 2 2 0Sum 0's 0 3 3 4 7Sum -'s 5 3 2 1 0

Rank 5 4 3 2 1

Feasibility: (See appendix and edge for details)

- Research and analysis showed that amongst all options drum drying and refractive window drying could be implemented in Haiti.

- After manufacturing of the product, the transportation cost from the Borgne to port of prince, found to be $110 roundtrip to market for selling the products.

- Using Drum drying example with feed rate & when plant works for seven hours a day the production rate is around 350-400kgs of mango juice powder per day

- According to the current worldwide scenario the cost of Mango juice powder is found to be $10-20 per kg. Assuming that revenues obtained can be 400*20= $8000 ( Operating cost, maintenance cost, labor cost not included) ( See Appendix for calculation and detailed feasibility analysis)

- Refractive window drying one of the concepts can also be implemented compared to drum dryer and may involve less manufacturing costs for the equipments used.

- Also in case of fuel used for steam generation to heat the drums internally or to heat conveyor belt by boiling the water, using propane for purpose of boiling is favorable and economical. Which is available at low rates and incase if not available in haiti, cylinders can be imported from neighboring country(Dominican Republic) $1.50/Kg propane (Wholesale rate, US).

Constraints:

1) Unavailability of continuous and enough existing power supply for implementation of project at the desired location.2) Weight of the overall plant 3) Entire project should be within allotted budget.4) Design most of the plant equipments for manual operation.

Project deliverables: Mango Juice powder production plant having high durability and robust enough to withstand extreme weather conditions design for ease in use

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Budget Estimate: This budget reflects a rough estimate/assumed costs for this project. Actual costs may vary and this budget may be low for the actual cost of this project.

TYPE QTY UNIT PRICE($) COST ($)EQUIPMENTS      Drum Dryer      Manufacturing Drums 2 500 1000 AssumedSlurry/pulp Pump 1 400 400 ConfirmedSteam Jacketed stainless steel mixing tank 1 350 350 Assumedpressure vessel 1 800-1000 1000 ConfirmedRefractive Window Dryer      Conveyor system stand 1 400-1000 1000 confirmedconveyor belt( Mylar DuPont) 10-20mtr 10/mtr 200 confirmedheaters/boiling tank 1 500-800 650 confirmedOver head stainless steel refractive window 1 400-700 550 AssumedCommon Equipments      Grinder 1 300 300 confirmedMotor to drive Drum/belt 1 400 400 AssumedRefining Meshes 5 (Different sizes) 20 100 confirmedDoctor blades 2 85 170 confirmedPipes, Fitting, Accessories & electrical supplies     300

Assumed

Stand for placing Equipment 2 200 250 AssumedFUEL: Propane (Initial) per gallon As Required 1.5 50 confirmedPulp storage tank 1                         1           800   AssumedTOTAL COST (Drum Dryer)     5100TOTAL COST (RW Dryer)     4770

Intellectual Property (IP) considerations: Any technical design and development will be the intellectual property of RIT, and should not share with any other parties. Except that, the completed production plant will be deliverable to KGPB, Borgne, Haiti.

Continuation Project Information, if appropriate: This project is related not completely but partially to the following DPL Projects:

R14700: 1 : MANGO JUICE PRODUCTION PLANT 2 : PRODUCTION OF DRIED FOOD PRODUCTS

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Anticipated Staffing Levels by Discipline:

Discipline How Many? Anticipated Skills Needed (concise descriptions)

EE1 Working Knowledge of sensors and Synchronizing it with analog

circuits, circuits design, control feedback, implementation of electromechanical actuation equipment.

ME 3 Design and development of mechanical components, DFM, Machining, Thermodynamics, Heat Transfer, FEA, Modeling, Concept Generation

Chem.E1-2 Mass transfer and separation process design, Basic Process Control,

Environmental science and sustainability, Chemical reactor design: chemical kinetics, equilibrium, and catalysts. Engineering lab skills.

ISE2 Production systems design, Systems design – product/process design,

DFx -- Manuf., environment, sustainability, Facilities planning, Materials processing

Other

OTHER RESOURCES ANTICIPATED:

Category Description Resource Available?

Faculty

Environment Availability of water for cleaning and non carpeted floor in place of installation, walls and roof surrounding the plant for safety.

Equipment Machining Equipments, SolidWorks, ANSYS

Materials Steel, Cast Iron for Manufacturing of equipments

Other

Prepared by: Charudatta M Choudhari Date: 18/18/2013

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Appendix:

STUDENT STAFFING:

Skills Checklist: Mechanical Engineering

1 3D CAD AerodynamicsMATLAB programming CFD

1 Machining (basic) Biomaterials3 Stress analysis (2D) 1 Vibrations2 Statics/dynamic analysis (2D) Combustion engines1 Thermodynamics 1 GD&T (geometic dimensioning &

tolerancing)3 Fluid dynamics (CV) Linear controls

LabView (data acquisition, etc.) CompositesStatistics 1 DFM

2 Robotics (motion control)1 FEA Composites1 Heat transfer Other:

Modeling of electromechanical & fluid systems

Other:

3 Fatigue & static failure criteria (DME) Other:2 Specifying machine elements

Reviewed by (ME faculty):

Industrial & Systems Engineering

Statistical analysis of data – regression 2 Shop floor IE – methods, time studyMaterials science 2 Programming (C++)

1 Materials processing – machining lab2 Facilities planning – layout, material handling 1 DOE2 Production systems design – lean, process

improvement1 Systems design – product/process design

1 Ergonomics – interface of people & equipment (procedures, training, maintenance)

Data analysis, data mining

Math modeling – linear programming), simulation

2 Manufacturing engr.

3 Project management 1 DF -- Manuf., environment, sustainability

Engineering economy – ROI Other:Quality tools – SPC Other:

2 Production control – scheduling Other:

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Reviewed by (ISE faculty):

Electrical Engineering

1 Circuit design: AC/DC converters, regulators, amplifier circuits, analog filter design, FPGA Logic design, sensor bias/support circuitry

Digital filter design and implementation, DSP

1 Power systems: selection, analysis, power budget determination

1 Microcontroller selection/application

System analysis: frequency analysis (Fourier, Laplace), stability, PID controllers, modulation schemes, VCO’s & mixers, ADC selection

Wireless protocol, component selection

1 Circuit build, test, debug (scopes, DMM, function generators)

Antenna selection (simple design)

2 Board layout Communication system front end design

2 MATLAB Algorithm design/simulationP Spice 2 Embedded software design/

implementation2 Programming: C, Assembly Other:

Electro-magnetic (shielding, interference) Other:Other:

Reviewed by (EE faculty):

Chemical Engineering

Energy and material balances on chemical systems Electrochemistry2 Fluid dynamics and Heat transfer Inorganic chemistry3 Thermodynamics (traditional and chemical) 2 Environmental science and

sustainability1 Mass transfer and separation process design:

distillation, multistage absorption and stripping, batch and fixed-bed adsorption, liquid-liquid extraction, crystallization, membrane separations.

Advanced material science, polymer science

1 Chemical reactor design: chemical kinetics, equilibrium, and catalysts.

Surface tension and interfacial phenomena

1 Engineering lab skill: Pressure, temperature, concentration. Pilot lab systems; delivery system assembly including pumps, valves and pressure sensors.MATLAB and EXCEL: solve complex chemical engineering mathematics problems

1 Advanced chemistry knowledge: general, physical, and organicMicro- and Nano scale phenomena and process

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Project Readiness Package 12/18/13

design Basic chemistry-based material science

2 Basic engineering economics Other:1 Basic Process Control Other:

Other:

Reviewed by (ChemE faculty):

Feasibility Analysis :(Juice Powder Plant) In the mango juice powder processing Plant. The main things involved are the Dryer used in it. Considering the current conditions in Haiti, use of Drum drying/Refractive window drying are the best possible methods. Selection of type of drum dryer or refractive window drying is dependent on the MSD team.Here some part of the analysis is done referring to the drum drying.Energy Consumption : Problem: Unavailability of sufficient or required electrical supply

Known: No power supply. High amount of solar energy can be harnessed and good availability of workers for manual work.

Unknown: Availability of solar system in Haiti.

Assumptions/Analysis: (E.g. Drum Dryer)Drum size 300mm diameter x 200mm long and Max material feed rate 45 kg/hr, following observation are seen in case of drum drying

Drying duty:Max water evaporated 30 kg/hrSteam consumption 40 kg/hr @ 4 bars ( At which drum drying is carried out)Most of the energy consumption is associated with generation of steam. Power required to generate steam at the required pressure can be operated using solar panels.Cost of Energy Consumption Calculated Below.

Heat Energy Consumption :

(Considering Drum Drying for Example)Based on the Engineering requirements and the available information of Mangoes we calculate Quantity of heat energy required per unit weight of material:Example:Known Data:Mango Moisture Content: 81%Required moisture Content: 5%Initial temp of Pulp: 23°CThe latent heat of vaporization of water at 152°C and at 500 kpa 70 psi is 2109 kJ kg-1.Specific heat capacity of the food is 3.78 kJ kg-1 °C-1 and of water is 4.186 kJ kg-1 °C-1

Calculating for 1 kg food                  Initial moisture = 81%810 g moisture are associated with 190 g dry matter.

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Final moisture = 5 %(Required condition for fruit Powder) ,50 g moisture are associated with 950 g dry matter,Therefore (50 x 190)/950 g = 10 g moisture are associated with 190 g dry matter.1kg of original matter must lose (810-10) g moisture = 800 g = 0.8 kg moisture.(Approx)Heat energy required for 1kg original material                                                  = heat energy to raise temperature to 152°C + latent heat to remove water                                                 = (152 - 23) x 3.78 + 0.8 x 2109                                                  = 487.62 + 1687.2                                                 = 2174.8 kJ = 2060.55 BTU Energy/kg water removed, as 2174.8 kJ are required to remove 0.8 kg of water,                                                 = 2174/0.8                                                 = 2717 kJ.From this value, we can calculate the approximate cost of production of 1 kg of juice powder, based on the location or cost of electricity at that specific place where the plant is to be installed.

Heat Transfer Analysis:In drying the rate of heat transfer is given byGoverning Equation:

q = UA (Ti– Ts )

Known: where U is the overall heat-transfer coefficient, Ti is the drum temperature (usually very close to that of the steam), A is the area of drying surface on the drum

Unknown: Ts is the surface temperature of the food (boiling point of water or slightly above)

Assumptions: The value of U can be estimated from the conductivity of the drum material and of the layer of foodstuff. And this value can be substituted as the overall heat transfer.Values of U have been quoted as high as 1800 J m-2 s-1 °C-1 under very good conditions and down to about 60 J m-2 s-1°C-1 under poor conditions. [1]Actual value can be considered around 750-800 J m-2 s-1°C-1 for normal working

Cost Problem: if budget exceeds the allocated budget

Governing Equation: Total Cost= Equipment Manufacturing Cost + Production cost+ Transportation cost+ Installation cost+ running cost of the plant.

1) Transportation Costs:

Distance from the production site to the market where the product is sold, the approximate distance is 255 Km[2], so assuming the general efficiency of the truck to be 15 mpg [3] we calculate cost of transportation of product of a roundtrip using the calculator [4] Distance Map (Haiti)(Google maps) We see that for the round trip approximately $105 are required.

2) Energy Cost:

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Considering 400lb (Assumed quantity for calculation of rough estimation) of mango at the start, this is 181kg approx. The drying has a production rate of around 30-50 kg /hrm^2. [1] So if we run the plant for 7 hrs at the rate of 50kg/hr based on specification of the above drum dryer example then we would get 50*7= 350 kg of Mango Juice Powder

Using propane as Fuel to generate steam, we consider the Lower heating Value which is 46350 KJ/Kg= 43931.32 BTU/Kg [6]

Dollars per Gallon of propane excluding Taxes: Approximately $1.5/Gallon (Wholesale propane) [7] 2060.55 BTU/kg is required to generate steam and dehydrate 1 kg of mango pulp assuming no losses

Therefore 43931.32/2060.55 = 22 Kg of Mango pulp is dehydrated with 1 kg of propane.

Therefore 350/22= 15.90 approximate to 16 kg of Propane required to run plant 7 hrs

Propane weighs 4.2 pounds (1.90kg) per gallon; approximately, we consider 2kg per gallon. [8] So to run the plant we will require 8 Gallons of Propane/ Day to obtain 350 kg of Final product.There for 8*$1.5= $12 per day

Total Cost= $200 (Inputs: additive etc) +$1000(Equipment manufacturing exact value not known, onetime cost) + $500(Assumption) (include setting of shades, walls, foundation for installation, onetime cost and rented area)+ $4000(Include installation or operating Costs of steam generating unit: Based on type of generator used, in Haiti we need to do this using natural resources) [5] ….Respectively = $5700

Later the Powder sold at $10-$20/ kg based on quality. From about 181 kg of mango, actual mango powder obtained is approximately 40-50kg.

Assuming 50 kg, 50*$20=$1000. There actual profit behind 400lb of mango is $1000. (Rough Estimates)Therefore, profit for approximate total of 1267 Kg of Mango pulp 350kg of final product produced with revenue of $7000

Known: Estimation of manufacturing costs prior manufacturing if machine/equipment parts in US. Production cost per kg of powder produced if type of process for manufacturing is fixed. Costs of fuel to run generators if required.Unknown: Cost of manufacturing and manufacturing availability in Haiti, Actual transportation costs in Haiti, changes in costs of importing items such as preservatives, additives or chemicals.Assumptions:Manufacturing of some parts in HaitiSet a budget target of $6000, which will help in cutting down unnecessary costs.Safety:Problem: to protect the plant or equipment from the environmentKnown: There is always a cyclone or flood in the area where the plant or the processing unit is to be installedUnknown: Availability or any methods of protection as of now Availability of simple structural things to build a small area with four walls and canopy resistant to natural disastersPossible: A big structure built with shades to protect from natural disaster

Hygiene & Cleanliness:

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Problem: Improper hygiene condition and low level of cleanliness can spoil the product.Known: Currently no hygienic conditionsUnknown: availability of proper cleaning products and equipments Currently available bleach and alcohol for sanitation purpose Possible: knowledge of cleanliness and hygiene, its importance should be taught to Haiti workers. Train them to use clean apparatus and make them use gloves, masks, hairs nets while working.Availability of production resources:Problem: Availability of production resourcesKnown: Mango is a seasonal fruit, so reduction in supply can cause to stop the plant. Also we know citrus fruit is available so we can think of converting the same in citrus powder.Unknown: If we can design universal machine (citrus and mango) Can mango be imported? for supply throughout the year and if yes will it be feasible.Assumption: Supply of mango and required preservative and additives through the year

References:[1] http://www.nzifst.org.nz/unitoperations/drying1.htm#htreqs[2] https://www.google.com/maps[3] http://cta.ornl.gov/vtmarketreport/pdf/chapter3_heavy_trucks.pdf[4] http://www.numbeo.com/gas-prices/country_result.jsp?country=Haiti[5] http://www.alibaba.com[6] http://en.wikipedia.org/wiki/Heat_of_combustion[7] http://www.eia.gov/dnav/pet/pet_pri_wfr_a_EPLLPA_PWR_dpgal_w.htm[8] http://www.propane-generators.com/propane_usage.htm

Faculty Sign off Sheet:

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