DESIGN AND FABRICATION OF COCONUT FIBER EXTRACTION MACHINE

CHAPTER 1
INTRODUCTION
1.1 OVERVIEW OF COCONUT
Coconuts (Cocos nucifera) are an integral part of tropical and subtropical landscapes,
renowned for their diverse uses and cultural significance. Often referred to as the "tree of
life," They are the fruit of the coconut palm tree, scientifically known as Cocos nucifera,
which is native to tropical regions of the world. Coconuts are known for their distinct flavour,
aroma, and numerous uses in various industries, including food, cosmetics and healthcare.
Coconuts are highly nutritious fruits that provide a rich source of vitamins, minerals, and
healthy fats. The meat of the coconut is high in fiber, protein, and healthy fats, including
medium-chain triglycerides (MCTs) that are known for their potential health benefits.
Coconuts are also a good source of essential minerals such as manganese, copper, and iron, as
well as vitamins like vitamins C and B . These are a versatile ingredient used across the world.
Different parts of the coconut, including meat, milk, and oil, are used in cooking to add
flavour, texture, and nutritional value to dishes. Apart from their daily purpose, coconuts are
utilized in various industries for their unique properties and sustainability Some industrial
applications of coconuts include Cosmetics, Hair Care, Biofuel, Handicrafts, etc. In this
overview, we will go through the various aspects of coconuts, including their nutritional
content, health benefits, culinary uses, and industrial applications.

1.2 GLOBAL SCENARIO OF COCONUT

Agriculture sector contributes for about 14% of the nation’s GDP, about 11% of its exports
earnings and half of the population still relies on agriculture for their employment and as its
principal source of income. Coconut palm provides food security and livelihood to large size
of population in the world particularly in Asia Pacific Countries. Considering the versatile
nature of the crop and the multifarious uses of its products, coconut palm is eulogized as
KALPAVRIKSHA (Tree of Heaven). Coconut is a source of food, beverage, medicine,
natural fiber, fuel, wood and raw materials for units producing a variety of goods. Coconut is
also interlinked with socio economic life of large number of small and marginal farmers in
the peninsular India. It is estimated that about 12 million people in India are dependent on the
coconut sector in areas of cultivation, processing and trading activities. With an annual
production of around 21,892 million nuts, coconut contribution to nation’s GDP is about
15,000 crores rupees. The figure 1.1 shows about the worldwide coconut production.

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DESIGN AND FABRICATION OF COCONUT FIBER EXTRACTION MACHINE

Fig.1.1: Worldwide coconut production

Coconut has several commercial and traditional cultivars which can be sorted mainly into tall
cultivars, dwarf cultivars, and hybrid cultivars (hybrids between tall and dwarf plants). Some
of the dwarf cultivars such as 'Malayan dwarf' have shown some promising resistance to
lethal yellowing, while other cultivars such as 'Jamaican tall' are highly affected by the same
plant disease. 'West coast tall' (India) cultivar is drought resistant and the 'Hainan Tall'
(China) variety is cold tolerant. Other aspects such as seed size, shape and weight, and copra
thickness are also important factors in the selection of new cultivars. Some cultivars such as
'Fiji dwarf' form a large bulb at the lower stem and others are cultivated to produce very
sweet coconut water with orange-coloured husks (King coconut) used entirely in fruit stalls
for drinking (Sri Lanka, India).

1.3 PRODUCTION OF COCONUTS IN INDIA

The Coconut (Cocos nucifera) is a benevolent tree, a nature’s gift to mankind. The coconut
tree provides clothing, utensils and shelter therefore, is an important source of earning
livelihood to the people of coconut growing states. The coconut crop is grown in 12.2 million
hectares of land which constituted about 0.7% of net crop area of the world. India contributes
about 15.46% in area and 26.34% in terms of production of coconut in the world. The major
coconut crop acreage is concentrated in the states of Kerala, Karnataka, Tamil Nadu and
Andhra Pradesh. Karnataka stands second in area (507 thousand hectare) and production
(5893 million nuts).

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Fig.1.2: Production of coconuts in India

India is the third largest coconut producing country in the world. As per the survey reports
conducted by coconut development board in 2013-14 the annual production of coconut in
Kerala is 5798.04 million nuts and the state has become the 3rd largest coconut producing
state in the country. In Kerala about 60% of the coconuts are used for the manufacturing of
oil and the rest for the preparation of food. Copra and coconut oil are the two major products
of the coconut processing industry. Nearly 60% of the total production of nuts is utilized for
food uses and the rest goes in for oil extraction. In spite of the fact that Kerala has the
necessary raw material to launch new product lines, minimum efforts has been taken place for
producing more value-added products like coconut chips. Figure 1.2 shows about the
production of coconuts in India.

Coconut vinegar, desiccated coconut powdered has taken place in the application of modern
technology for full utilization of various coconut products such as desiccated coconut,
coconut cream powder, partially defatted coconut gratings, bottled coconut water, etc.,
Desiccated coconut is widely used in the preparation of sweets, confectionery, curry
preparation etc. At present about 4000 tons of desiccated coconut is produced annually.

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The main concentration of units producing desiccated coconut is in Kerala, Tamil Nadu,
Andhra Pradesh, Karnataka, Orissa and Maharashtra. Desiccated coconut is not only a value-
added product but it being a labor-intensive industry will also generate a large number of
employment opportunities.

1.4 PRODUCTION OF COCONUTS IN KARNATAKA

As per the latest statistics available, Karnataka is the second state, next to Kerala, having
largest area under coconut cultivation and coconut production in India. The state contributes
about 25% of the coconut area and 27% of the production in the country. Productivity of the
state is 11628 nuts/Ha., compared to national productivity of 10736 Nuts/Ha. Among thirty
districts, Tumkur and Hassan are the major coconut growing districts. For the study 894
sample holdings was covered spread across seven districts and yield data from 8940 palms
recorded. Majority of the palms covered under the study was Tall, within the age group of 15-
60 years. Average holding size in the state as per survey findings is 1.13 Ha, which varied
from 0.51 Ha in Dakshina Kannada to 1.63 Ha. In Tumkur. Coconut palm density for the state
is found to be 131 per Ha., whereas the bearing palm density is 118 per Ha. Bearing palms in
the sample gardens selected constitute to almost 90 per cent of the total palms selected in the
state. Yield per palm estimated varied widely from 31 to 86. The lowest of 31 is in
Chikkmagalur district while the highest of 86 is estimated in the district of Mandya. Based on
the analysis of data collected the annual per hectare yield is 5289 nuts in the state.

Production of coconuts in Karnataka state in 2012-13 is estimated to be 23451 lakh nuts,

which was 44083 lakh nuts as per the latest figures released by Department of Economics &
Statistics, Karnataka, the decline in production in Karnataka, as per the study was primarily
because of the severe drought coupled with pest and diseases. Increase noticed in intervals
between bunches and number of nuts existing in bunches relating to earlier stage seems less
compared to that in later stage (Table number) Production in Mandya and Mysore districts is
not affected to a great extend since better irrigation facilities are available in those two
districts. The central team under the chairmanship of Dr. Gorakh Singh, Horticulture
Commissioner, Ministry of Agriculture, visited the drought / disease affected coconut
plantations in seven districts of Karnataka i.e., Tumkur, Hassan, Chikmagalur, Ramanagara,
Mandya, Mysore, Chamarajanagara. Some pictures of the severely affected gardens are
appended below.

Below figure shows the various coconut producing districts across Karnataka.

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DESIGN AND FABRICATION OF COCONUT FIBER EXTRACTION MACHINE

Fig.1.3: Coconut growing areas in karnataka

Area under coconut cultivation in Chikkamagaluru constitutes to 9% of total area under

coconut cultivation in the state. Out of the 7 taluks in Chikamagalur, two Talukas viz. Kadur
and Tarikere were selected for the study. Kadur has the maximum area under coconut
cultivation in the district and constitutes to about 76% of the total coconut cultivated area.
Average holding size as per survey findings is 1.02 Ha. Coconut palm density for the district
is found to be 107 per Ha., whereas the bearing palm density is 88 per Ha. Bearing palms in
the sample gardens selected constitute to 82 per cent of the total palms. Based on the data
collected the annual per palm yield in the district is estimated as 31 nuts and per hectare yield
as 2728 nuts and production of coconuts in Chikamagalur for 2012-13 is estimated to be 1040
lakh nuts.

Dakshina Kannada contributes to 4% of total area under coconut cultivation in the state. This
is the eighth district in Karnataka as far as cropped area under coconut is concerned. The
district comprises of 7 taluks, of which Belthangadi has the maximum area under coconut
cultivation in the district and constitutes to about 32% of the total coconut cultivated area.
Average holding size as per survey findings is 0.51 Ha. Coconut palm density for the district
is found to be 152 per Ha., whereas the bearing palm density is 138 per Ha. Bearing palms in

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DESIGN AND FABRICATION OF COCONUT FIBER EXTRACTION MACHINE

the sample gardens selected constitute to 90 per cent of the total palms. Based on the data
collected the annual per palm yield in the district is estimated as 56 nuts and per hectare yield
as 7728 nuts and coconut production in Dakshina Kannada for 2012-13 is estimated to be
1244 lakh nuts.

Hassan has the second largest coconut area in the State. Nearly 14% of area under coconut
cultivation in Karnataka is from this district. The district comprises of 8 taluks, of which
Arisekere and Channarayapatna were selected under the study. Of the 8 Taluks in Hassan,
Arisekere and Channarayapatna contributes maximum towards the coconut production in the
district (almost 81%). Average holding size as per survey findings is 0.74 Ha. Coconut palm
density for the district is found to be 141 per Ha., whereas the bearing palm density is 106 per
Ha. Bearing palms in the sample gardens selected constitute to three fourth of the total palms.
Based on the collected data the annual per palm yield in the district is estimated as 39 nuts
and per hectare yield as 4134 nuts and production of coconuts in Dakshina Kannada in 2012-
13 is estimated to be 2587 lakh nuts.

Mandya is the fifth largest district in Karnataka as far as area under coconut cultivation is
concerned. Nearly 6% of area under coconut cultivation and more than 8% of coconut
production in Karnataka is from this district. Average holding size as per survey findings is
0.62 Ha. Coconut palm density for the district is found to be 119 per Ha, where as the bearing
palm density is 107 per Ha. Bearing palms in the sample gardens selected constitute to 90 per
cent of the total palms. Based on the collected data the annual per palm yield in the district is
estimated as 86 nuts and per hectare yield as 9202 nuts, which is the highest among all the
districts selected for the study. Estimated coconut production for Mandya in 2012-13 is
estimated to be 2459 lakh nuts.

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DESIGN AND FABRICATION OF COCONUT FIBER EXTRACTION MACHINE

1.5 Coconut Palm

Coconut palms are tall, single-trunked trees that can reach heights of up to 30 meters (98
feet). The trunk is cylindrical, smooth, and greyish-brown, The coconut palm is a tall, slender
tree that can reach up to 30 meters in height. It has a smooth, greyish-brown trunk which is
typically unbranched. The tree is topped with a crown of large, pinnate leaves that can grow
up to 4-6 meters long.

The coconut tree provides food, fuel, cosmetics, folk medicine and building materials, among
many other uses. The inner flesh of the mature seed, as well as the coconut milk extracted
from it, form a regular part of the diets of many people in the tropics and subtropics.
Coconuts are distinct from other fruits because their endosperm contains a large quantity of
clear liquid, called "coconut water" or "coconut juice". Mature, ripe coconuts can be used as
edible seeds, or processed for oil and plant milk from the flesh, charcoal from the hard shell,
and coir from the fibrous husk. Dried coconut flesh is called copra, and the oil and milk
derived from it are commonly used in cooking – frying in particular – as well as in soaps and
cosmetics. Sweet coconut sap can be made into drinks or fermented into palm wine or
coconut vinegar. The hard shells, fibrous husks and long pinnate leaves can be used as
material to make a variety of products for furnishing and decoration.

Fig.1.4: Coconut tree

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The mature fruit can be green, yellow, or brown depending on the tree is characterized by a
crown of large, feathery leaves, each composed of numerous leaflets arranged on either side
of a central rib. These leaves can be 4-6 meters (13-20 feet) long and are pivotal in the
photosynthesis process that sustains the tree. The coconut fruit, botanically a drupe, has three
layers: the exocarp (outer skin), the mesocarp (fibrous husk), and the endocarp (hard shell).

Fig.1.5: Coconut Palm

 Exocarp: The exocarp, commonly known as the husk, is the tough, fibrous outer
layer of the coconut fruit. It is composed of densely packed fibers that provide
strength and resilience, shielding the inner nut from environmental hazards such as
pests, moisture, and physical damage. This protective layer not only ensures the
survival of the coconut seed but also facilitates its dispersal by enabling it to float on
water for extended periods, aiding in its journey across oceans to new habitats.
Microscopically, the exocarp is composed of a thick cuticle, epidermal cells, and a
layer of parenchyma cells. The cuticle is a waxy layer that helps in reducing water
loss and protecting against microbial invasion. The epidermal cells beneath the cuticle
are tightly packed, providing structural integrity and further protection. The
parenchyma cells form a supportive tissue that helps maintain the exocarp's rigidity
and durability.

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Fig.1.6: Exocarp

 Mesocarp: The mesocarp, nestled between the tough outer exocarp and the inner seed
of the coconut, is a vital layer that contributes to the fruit's structure and nutritional
value. Also known as the "coconut meat" or "copra," the mesocarp is the fleshy, white
tissue that fills the interior of the coconut shell.
The mesocarp is composed primarily of coir, a natural fiber extracted from the husk of
the

coconut. This fibrous layer can vary in thickness depending on the coconut variety
and maturity.

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Fig.1.7: Mesocarp

The primary components of the mesocarp include:

Lignin and Cellulose: These are the major structural components of the fibers.
Cellulose provides strength and rigidity, while lignin gives the fibers their tough,
woody nature. The proportion of lignin and cellulose can influence the properties of
the coir, such as its durability and water resistance.
Hemicellulose and Pectin: These substances act as binding agents within the fiber
matrix. They contribute to the flexibility and cohesiveness of the fibers, playing a
vital role in the mesocarp’s overall structure.
Microbial Flora: The mesocarp naturally harbours a variety of microbes that can
affect its properties. These microbes can play a role in the decomposition of the fibers
when used in agricultural applications.

 Endocarp: The endocarp of the coconut, often referred to as the shell or the inner
husk, is the hard, woody layer that encases the edible kernel or meat of the coconut. It
is the innermost protective covering of the fruit, providing a sturdy barrier against
external elements. The endocarp's impermeability prevents moisture loss and helps
maintain the ideal conditions for the coconut's internal environment, ensuring the
longevity of its contents. The endocarp is the hard, woody layer that encases the
coconut seed. It is known for its remarkable durability and resistance to

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environmental stresses. The endocarp is composed primarily of lignin and cellulose,

which give it its toughness and rigidity.
 Kernel: The kernel of the coconut, nestled within its hard shell and fibrous husk, is a
treasure trove of nutrition and flavour. Also known as the coconut meat, the kernel is
the fleshy, white part of the fruit that lines the inner cavity. The coconut kernel is the
white, fleshy part found inside the hard shell of the coconut. It varies in thickness and
consistency depending on the maturity of the coconut. The composition of the
coconut kernel includes:
 Water: The water content of the coconut kernel decreases as the fruit matures.
Young coconuts have a higher water content, resulting in softer, jelly-like flesh,
while mature coconuts have firmer, drier meat.
 Lipids (Fats): The kernel is rich in fats, particularly saturated fats. Key fatty acids
found in coconut oil include lauric acid, myristic acid, and palmitic acid. Lauric
acid is especially notable for its antimicrobial properties and health benefits.
 Proteins: The protein content in coconut kernel is relatively low compared to
other nuts and seeds, but it provides essential amino acids that contribute to its
nutritional value.
 Carbohydrates: The carbohydrates in coconut kernel are primarily in the form of
fiber and sugars. Dietary fiber in the kernel aids in digestion and contributes to
overall health.
 Vitamins and Minerals: The kernel is a good source of several vitamins and
minerals, including vitamin C, E, B vitamins (such as folate), and minerals like
potassium, magnesium, iron, phosphorus, and zinc.
 Phenolic Compounds: These are antioxidants that help in protecting the body
against oxidative stress and inflammation. The phenolic content can vary based on
the processing and maturity of the coconut.

1.6 VARIETIES OF COCONUT

Coconuts are broadly categorized into two main types based on their growth patterns and uses
TALL and DWARF varieties.

1.6.1 Tall Varieties:

Tall varieties are the most common type of coconut palms and are primarily cultivated for
copra (dried coconut meat) and oil production. Key characteristics include:

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 Height and Longevity: Tall coconut palms can reach up to 30 meters and have a
lifespan of 60-80 years.
 Fruit Bearing Age: They begin to bear fruit around 6-10 years of age.
 Nutrient Content: The coconuts produced by tall varieties often have a higher oil
content, making them suitable for copra (dried coconut meat) production and coconut
oil extraction.
 Yield: These palms can produce 50-200 coconuts annually, depending on growing
conditions. Tall varieties are often preferred for large-scale commercial production
due to their higher yield and longevity.
 Various types of tall varieties: East Coast Tall, Philippines Ordinary (Kera Chandra),
East Coast Tall, Chandrakalpa or Lakshadweep Ordinary.

Fig.1.8: Tall varieties coconut

1.6.2 Dwarf Varieties:

Dwarf coconut palms are smaller and often grown for fresh consumption and ornamental
purposes. Key characteristics include:

 Height and Longevity: Dwarf varieties reach about 6-12 meters in height and have a
shorter lifespan of 40-50 years.

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 Size and Growth: Dwarf coconut palms usually grow to a height of 5-15 meters (16-
50 feet), significantly shorter than the tall varieties which can reach up to 30 meters
(98 feet). They have a slower growth rate and a more compact canopy.
 Fruit Bearing Age: They start bearing fruit earlier, around 3-4 years of age.
 Yield: Dwarf varieties generally produce fewer coconuts per year compared to tall
varieties but are prized for their ornamental value and ease of harvest.
 Dwarf varieties are often found in gardens and small farms due to their manageable
size and quicker fruiting period.
 Various types of Dwarf coconuts: Malayan Yellow Dwarf Coconuts, Fiji Dwarf,
Golden Malay, Kalpa Jyothi

Fig.1.9: Dwarf varieties coconut

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1.7 USES OF COCONUT

Food and Beverage

1. Coconut Water:
 The clear liquid inside a young, green coconut is known as coconut water.
 It is a popular beverage, valued for its refreshing taste and electrolyte content.
2. Coconut Milk and Cream:
 Coconut milk is made by grating the coconut meat and mixing it with water, then
straining the mixture.
 Coconut cream is a thicker version obtained from the first pressing of grated
coconut meat.

3. Coconut Oil:
 Extracted from dried coconut meat (copra), coconut oil is used for cooking,
baking, and as a dietary supplement.
 It is also a popular ingredient in cosmetic products due to its moisturizing
properties.

Fig.1.10: Uses of coconut in food beverage

4. Desiccated Coconut:
 Shredded and dried coconut meat used in baking and confectionery.

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 It is commonly found in desserts like macaroons, cookies, and cakes.

Non-Food Uses

1. Coir:
 The fibrous husk of the coconut is processed to produce coir, a natural fiber.
 In generally there are two types of coir brown coir and white coir.
 Brown Coir: Derived from mature coconuts, brown coir is strong and durable. It is
primarily used for products that require high tensile strength, such as brushes,
floor mats, and upholstery padding.

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Fig.1.11: Non-food uses

 White Coir: Extracted from immature green coconuts, white coir is finer and
softer compared to brown coir. It is mainly used in making ropes, fishing nets, and
finer brushes.
 Coir is used to make ropes, mats, brushes, and sacks, as well as for horticultural
purposes like soil conditioning and erosion control.
2. Coconut Shell:
 Coconut shells are the hard, outer coverings of coconuts, providing protection for
the inner meat and water of the fruit. They are a versatile byproduct of the coconut
industry, used in various applications due to their durability, density, and
resistance to moisture.
 The hard shell is crafted into various products such as bowls, spoons, and
decorative items.

Eig.1.12: Uses of Coconut shell

3. Timber and
Leaves:
 The wood of
older coconut
palms,
known as
"coconut
timber" or
"coco wood," is used in construction and furniture making.

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 The leaves are woven into mats, baskets, and roofing materials, especially in
traditional housing.

Fig.1.13: Uses of Timber and leaves

4. Energy and Fuel:

 Biofuel: Coconut oil can be processed into biodiesel, providing an alternative,
renewable energy source.
 Biomass Fuel: Coconut shells and husks are used as biomass fuel for heating and

energy production.

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Fig.1.14: Production of Bio- Fuel

1.8 COCONUT FIBER EXTRACTION

Coconut fiber extraction is a process that involves obtaining fibers from the husk
of coconuts, known as coir, which is a versatile material with a wide range of
applications. This natural fiber extracted from coconut husks has gained significant
importance due to its various applications and benefits.

1.8.1 Importance of coconut fiber extraction

 Sustainable Resource: Coconut fiber extraction utilizes a byproduct of the coconut

industry, the coconut husk, which would otherwise be considered waste. By
extracting fibers from coconut husks, this process contributes to the sustainable use
of resources and reduces environmental waste.
 Horticulture: Coir is a popular growing medium in horticulture and agriculture due
to its water retention properties, aeration, and ability to promote healthy root
growth.
 Erosion Control: Coir mats and blankets made from coconut fiber are used for
erosion control on slopes, riverbanks, and construction sites to prevent soil erosion
and promote vegetation growth.
 Geotextiles: Coir geotextiles are used in civil engineering projects for soil
stabilization, erosion control, and landscaping applications.
 Handicrafts: Coconut fiber is used in the production of handicrafts, mats, rugs, and
other decorative items due to its natural texture and durability.
 Eco-Friendly Alternative: Coconut fiber extraction offers an eco-friendly
alternative to synthetic fibers and materials. Coir is biodegradable, renewable, and
free from harmful chemicals, making it a sustainable choice for various
applications.
 Soil Improvement: Coir has the ability to improve soil quality by enhancing
moisture retention, aeration, and nutrient availability. When used as a soil
amendment, coconut fiber can help improve soil structure, promote microbial
activity, and support plant growth.
 Economic Benefits: Coconut fiber extraction contributes to the economy of
coconut-producing regions by creating employment opportunities in the coir

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industry. The processing and manufacturing of coconut fiber products generate

income for farmers,
labourers, and
businesses involved
in the supply chain.

1.9 METHODS OF
COCONUT
FIBER EXTRACTION

Fig.1.15: Methods of coconut fiber extraction

1. Retting Process:

The retting process in coconut fiber extraction is a crucial step that involves the
decomposition of the non-fibrous tissues surrounding the coconut husk to facilitate the
extraction of fibers. Retting is a natural process that breaks down the pithy material, allowing
the separation of the strong and durable coconut fibers.

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Retting is the process of separating the fibers from the non-fibrous material in the
husk. This involves the use of water or other agents to facilitate the decomposition of the
husk's cellular tissues, making it easier to extract the fibers. The retting process can be carried
out through several methods, including traditional water retting, mechanical retting, chemical
retting, and biological retting. The figure 1.16 shows the retting process.

Fig.1.16: Retting process

1. Mechanical Decortication:

Mechanical decortication is a key process in coconut fiber extraction that involves

the mechanical separation of fibers from the coconut husk. This method utilizes machinery
and equipment to break down the husk, extract the fibers, and prepare them for further
processing. Mechanical decortication is an efficient and effective way to obtain high-quality
coconut fibers for various industrial applications. The figure 1.17 shows the mechanical
decortication process.

The mechanical decortication

process involves several
stages, utilizing various types of
machinery designed to handle
different aspects of the task.

 Husk Removal: The first

stage involves the
removal of the outer husk.
This is typically done using
a decorticator machine equipped with rotating blades or rollers. The coconut is fed

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into the machine, where the blades cut through the husk, and the rollers help to
separate it from the nut.
 Fiber Extraction: After husk removal, the fibers (coir) can be extracted. The coir is
then processed further for various applications, such as in the production of ropes,
mats, and other products. Machines designed for fiber extraction ensure that the coir
is separated cleanly and efficiently from the rest of the husk material.
 Nut Cleaning: Once the husk is removed, the inner nut is cleaned to remove any
remaining fiber. This step ensures the nut is ready for subsequent processing, such as
copra production (dried coconut meat) or extraction of coconut water and oil.

Fig.1.17: Mechanical Decortication

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2. Manual Decortication:

Manual decortication is a traditional method of extracting coconut fibers from the

husk using manual labour and simple tools. This labour-intensive process involves hand-
stripping the fibers from the coconut husk, a technique that has been practiced for centuries in
coconut-producing regions. Manual decortication requires skilled workers to carefully
separate the fibers from the husk, resulting in high-quality fibers that are used in various
industries.

Manual decortication involves several steps and requires skill and precision to
ensure the coconut is not damaged in the process. The traditional methods vary slightly
depending on the region and available tools, but the core principles remain the same. The
figure

Tools Used in Manual Decortication

1. Machete or Parang: A large, sharp knife used to cut and strip the husk.

2. Husking Spike: A metal spike driven into the ground, against which the coconut is
levered to remove the husk.

3. Wooden Mallet: Used to pound and loosen the fibers.

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4. Small Knife: Used for finer work, such as removing stubborn fibers.

Fig.1.18: Tool used in manual Decortication

1.10 Advantages of Coconut Fiber Extraction:

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1. Abundant and Renewable Resource: Coconuts are widely cultivated in tropical

regions around the world, making coconut fiber a readily available and renewable
resource. The continuous production of coconuts ensures a steady supply of coconut
husks for fiber extraction.

2. Biodegradability: Coconut fiber is completely natural and biodegradable, meaning it

can decompose naturally without causing harm to the environment. This makes it an
eco-friendly alternative to synthetic fibers, which can take hundreds of years to
degrade.

3. High Tensile Strength: Coconut fiber is known for its high tensile strength, making it
durable and long-lasting. This strength makes it suitable for various applications
where strong and resilient fibers are required, such as in ropes, mats, and geotextiles.

4. Water Retention and Drainage: Coir fiber has excellent water retention properties,
allowing it to hold moisture while also promoting proper drainage. This makes it an
ideal material for use in potting mixes, soil amendments, and erosion control mats,
where maintaining optimal moisture levels is essential for plant growth and soil
stability.

5. pH Neutral and Non-Toxic: Coconut fiber is pH neutral and does not contain any
harmful chemicals or toxins, making it safe for use in gardening, landscaping, and
agricultural applications. It does not leach any harmful substances into the soil,
ensuring the health and safety of plants and the environment.

6. Versatility: Coconut fiber is a highly versatile material that can be used in various
industries and applications. Apart from its use in horticulture and agriculture, it is also
used in erosion control, landscaping, construction, automotive, and textile industries,
among others.

7. Insulating Properties: Coir fiber exhibits natural insulating properties, making it an

excellent choice for use in thermal and acoustic insulation applications. It can help
regulate temperature and reduce noise levels, contributing to energy efficiency and
comfort in buildings.

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8. Resistance to Rot and Decay: Coconut fiber is naturally resistant to rot, decay, and
pests, thanks to the presence of lignin and other natural compounds. This resistance
ensures the longevity of products made from coconut fiber, even in humid and damp
environments.

9. Cost-Effective: Coconut fiber extraction is a cost-effective process, especially in

regions where coconuts are abundantly available. The relatively low cost of raw
materials makes coconut fiber products affordable and accessible to a wide range of
consumers.

10. Supports Rural Economies: Coconut cultivation and fiber extraction provide
livelihoods for millions of people in rural communities around the world. By creating
employment opportunities and supporting local economies, coconut fiber extraction
plays a significant role in sustainable development.

1.11 Disadvantages of Coconut Fiber Extraction:

 The cost of purchasing and installing machines can be significant.

 Manual extraction of coconut fiber can be labour-intensive, requiring significant
manual effort to separate the fibers from the husks.
 While coconut fiber itself is biodegradable and eco-friendly, the extraction process
may have environmental impacts if not managed properly.
 Improper disposal of waste materials such as coconut dust and wastewater can pollute
waterways will harm local ecosystems.
 Mechanical processes require a reliable power source, which can increase operational
costs.
 Automation may reduce the number of jobs available for manual labourers.

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CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION
Coconut fibre, or coir, is derived from the fibrous husk of the coconut and has numerous applications
ranging from agricultural uses such as soil erosion control to industrial applications like
manufacturing brushes, mats, and geotextiles. Efficient extraction of coir is crucial to meet the
growing demand for natural fibres. Coconut fibre, or coir, is derived from the husk of the coconut and
has significant industrial value due to its durability, buoyancy, and resistance to microbial
degradation. The extraction of coir involves several stages, including retting, decorticating, and
further processing to produce fibres suitable for use in various applications. With the growing demand
for natural fibres in composite materials, geotextiles, and eco-friendly products, efficient coconut fibre
extraction has become a focal point of research and development.

Fibre extraction is the process of removing the outer covering called husk from the coconut.
Separation of its husk from the nut (dehusking) constitutes the first, most difficult operation in its
processing. Dehusking is done by traditional manual methods or using tools and machinery. The use
of which is the popular traditional methods for coconut dehusking poses threat and unsafe to the life
of people, some cut their hands, and face as it usually bounces back on hitting the husk, laborious, and
time consuming. This chapter deals with review of research work done in past by various
investigators on the topic under study. This chapter reveals the review related to various technological
developments on coconut dehusking.

2.2 HISTORICAL BACKGROUND OF FIBER EXTRACTION

Historically, the extraction of coconut fibre was a manual process, labour-intensive and time-
consuming. Traditional methods included retting the husks in water to soften the fibres, followed by
manual beating to separate the fibres from the pith. This process, though effective, was not suitable
for large-scale production due to its inefficiency and variability in fibre quality.

The advancements of mechanization in agriculture brought about the first generation of coconut fibre
extraction machines. These early machines were primarily mechanical devices designed to replicate
the manual beating process on a larger scale. They improved production rates but often compromised
fibre quality and involved significant manual intervention.

Coconut fibre extraction was a labour-intensive process that relied heavily on manual labour.
Traditional methods included retting, where coconut husks were soaked in water for extended periods

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to loosen the fibres. This was followed by manual beating to separate the fibres from the pith.
According to studies by Chandramohan and Marimuthu (2011), these traditional methods were
inefficient and resulted in inconsistent fibre quality.

The process of retting often took several months, depending on environmental conditions, and
resulted in significant water pollution due to the release of organic matter. Manual beating required
extensive labour and produced fibres with varying lengths and qualities, limiting their industrial
applications (Chandramohan & Marimuthu, 2011).

Y. Prashant, et al., Worked on Design and Development of Coconut Fiber Extraction Machine
Opportunity to develop a compact coconut fiber extraction machine which could be used in remote
villages so that unutilized husks from such areas could be tapped and fiber could be made available to
the Coir Industry directly. [10]

In 2014, Y. Prashant C. Gopinath, Vignesh Ravichandran it is observed that there are difficulties for
remote village to supply unutilized husks to coir industries directly. So there is a need to give solution
to overcome their difficulties and to arrive at solution, importance is given towards users operating
environment and mainly towards constrains like Safety, Function and reliability.

In 2020, OMONIYI, Temidayo Emmanuel and AYODELE, Emmanuel Bayo A laboratory scale coir
fibre extraction machine had been developed and its performance evaluated. It was observed that the
machine was cost effective compared to imported machine of similar specification. The performance
of the machine was dependent on the moisture contents of the fibre as the efficiency increased with a
decrease in the moisture contents.

In 2021, P. B. Mohan, R. Thiruppayhi, S. Sampath Kumar, Y. Mohamed Yasar Arabath, T. Pavithran

the project comprises of research and user study. Literature study is carried out based on the existing
patents on coconut fibre extraction machine, and it is observed that there are difficulties for remote
village. So, there is a need to give solution to overcome their difficulties Below are some of the
conclusions based on new derived process and new designed product and its functions.

In 2022, Daniel A. AMOSHIE, Heather R. BEEM, the global demand for cocoa is increasing, calling
for faster cocoa production processes. Cocoa pod breaking is a key step in the process and reliance on
manual methods has largely remained unaddressed. One adverse effect of reliance on manual labour is
the level of child labour in cocoa production increases.

In 2023, Mr. Omkar Surve, Mr. Sarvesh Gawas, Mr. Manthan Sankar, Prof. Ashish Suware The
project aims to design and develop a machine for extracting coco peat from coconut husk efficiently
and cost-effectively. Coco peat, also known as coir pith, is a by-product of the coconut industry and
has several uses; the extraction of coco peat from coconut husk traditionally involves manual labour,

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which is time-consuming, labour-intensive, and not cost- effective. The machine is expected to
increase the efficiency and productivity of coco peat extraction, reduce labour costs, and improve the
quality of the final product.

The extraction of coconut fibre has evolved significantly from manual methods to sophisticated
mechanical and automated systems. Technological advancements have enhanced the efficiency,
quality, and sustainability of fibre extraction, meeting the growing demand for natural fibres in
various industries. However, challenges such as husk variability, fibre quality, environmental impact,
and cost remain. Addressing these challenges through continued innovation and research will be key
to the future success of coconut fibre extraction machines. The integration of advanced robotics,
artificial intelligence, and sustainable practices will likely shape the next generation of extraction
technology.

2.3 SCOPE AND OBJECTIVES OF THE PROJECT

The scope of this project is to design and fabricate a coconut (coir) fibre extraction machine for
farmers and micro-scale coir industries in India. The present study addresses to provide an effective
solution to the crushing process, reduce time and labour cost. Coconut fibre extraction machine which
could be used in remote villages so that, unutilized coconut husks from such areas could be tapped
and fibre could be made available to the Coir Industry directly. The remains of the coconut after
extracting coir can be used to prepare coco peat. The coco peat is presently used as major ingredient
in organic farming. This project also focuses on reducing the problem of disposing of coconut shell
which otherwise used for domestic heating or goes to land filling.

2.3.1 OBJECTIVES OF THE PROJECT

1. To design and fabricate the low-cost coconut (coir) fibre extracting machine.

2. To produce the coco peat bricks after extracting coir (fibre) from crushing.

3. To achieve a production rate of 200 coconuts per hour.

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CHAPTER 3

MATERIALS AND METHODOLOGY

This methodology for the present study involves the separation of coconut fibers and
cocopeat powder from the coconut husks, and an approach for the design of coconut fiber
extraction machine.

3.1 DETERMINATION OF PROPERTIES OF COCONUT

Physical properties like size, sphericity, weight, thickness of husk etc. were the major
properties of coconut. The properties determinations are described below.

3.1.1 Coconut size

Coconuts vary widely in size depending on the variety and growing conditions. The size of a
coconut can influences its use and economic value. The coconut size was determined by
measuring the dimension of the principal axis; major, intermediate and minor of randomly
selected coconut fruits using steel scale. The major, minor and intermediate axes for coconuts
are shown in Fig. 3.1. The size of completely dry and moderately dry coconuts was measured
and recorded in the Table 3.1 and 3.2 respectively.

Fig.3.1: Coconut size

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3.1.2 Sphericity of nut

The sphericity of a coconut refers to how closely it resembles a perfect sphere in shape.
While coconuts are commonly associated with being spherical, their actual shape can vary
depending on several factors such as variety, growth conditions, and maturity. A direct
measurement of the major, intermediate and minor axis of the seeds using a scale was done.
Calculation of sphericity was carried out using the following formula:

∛ xyz
Sphericity= - Eqn. (1.1)
X

Where, a, b, c are major, intermediate and minor axes.

Values of sphericity is recorded in Table 3.1 and 3.2.

3.1.3 Weight of coconut

The weight of a coconut can varies depending on several factors, including its size, maturity,
and water content. On average, a mature coconut typically weighs between 1.4 to 2.3 kg.
However, larger coconuts can weigh up to 4.5 kg or more, while smaller ones may weigh as
little as 0.9 kg. The samples of 15 green and dry coconuts were randomly selected for
determining the weight. The weight of the coconut was measured using an electronic
weighing balance and the observations were averaged, the randomly coconut samples were
selected and weighted on electronic weighing machine.

C
d= - Eqn. (1.2)
π

Where,
d = diameter of the shell, mm
C = circumference of the nut, mm

3.1.4 Thickness of husk

The thickness of the coconut husk was measured by preparing sharp needle at the centre of
coconut up to the hardshell and mark is made on needle. Then needle is moved from the husk
and with the help of steel scale length of penetration of needle is measured up to the mark
that we have made on needle.

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Table 3.1 Measured values of physical property of completely dry coconuts

Sample Major axis Minor axis Intermediate Sphericity Thickness Weight

(X), (mm) (Y), (mm) axis(Z), (mm) of Husk (gms)
(mm)
1 221 135 130 0.719 25.3 547
2 205 144 117 0.737 19 584
3 195 120 130 0.743 19 633
4 205 129 135 0.746 20 900
5 212 141 128 0.738 15 648

Table 3.2 Measured values of physical property of green coconut

Sample Major axis Minor axis Intermediate Sphericity Thickness Weight

(X), (mm) (Y), (mm) axis(Z), (mm) of Husk (gms)
(mm)
1 107.4 98.7 95.3 0.934 14 1213
2 123.5 101.3 89 0.839 16.9 1175
3 150 105 94.6 0.761 17.8 1191
4 220 148 132 0.739 20 1319
5 235 161.2 172 0.794 22.5 1279

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3.2 METHODOLOGY OF THE PRESENT STUDY

The methodology involved in the present project is represented in Fig. 3.2

Components:
1. Base
2. Hooper
3. Motor
4. Screener unit
5. Handwheel

Fig. 3.2: Methodology of the present study

1. Collection of coconut Husks: The coconut husks are collected from various coconut
vending shops from the local market.
2. Designing and fabrication of coconut (coir) fiber machine which
involves the list of following mechanisms.
a) Feeding mechanism: This provides the passage for coconut
husk to be processed into the crushing chamber.
b) Crushing mechanism: Crushing mechanism is the process
responsible for breaking the coconut husk.
c) Driver and driven mechanism: This mechanism involves
an electric motor that will drive the crushing unit.
d) Sieving and Screening mechanism: The device was designed to hold, sieves
of different sizes, which are agitated to sieve the processed fibers into the
desired size.
e) Collection mechanism: The sieved fibers are collected through an open for
drying.
3. The remains of coconut husk after crushing are used for making coco peat bricks.

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CHAPTER 4

DESIGN AND FABRICATION OF THE MACHINE

Design and fabrication of the machine involves several processes and parameters related to
CAD design and material for the fabrication of machine.

The various steps involved during the fabrication of machine are listed below:

1. Preparing design calculations

2. Preparation of CAD model
3. Purchasing of components
4. Fabrication of Machine
5. Assembly and painting to machine

4.1 PREPARATION OF CAD MODEL

The preparation of a Computer-Aided Design (CAD) model involves several key steps to
create a digital representation of an object or product. Initially, we gathered requirements and
specifications for the intended design. Using specialized CAD software, we have done 2D
sketch of the model, typically starting with 2D drawings that outline the basic shapes and
dimensions. From there, they progress to creating 3D models, adding depth and detail to the
design. This process may involve various tools and techniques, such as extrusion, lofting, and
Boolean operations, to shape and manipulate the geometry of the model. Throughout the
preparation phase, attention is paid to accuracy, scale, and alignment with design
requirements. Additionally, we have used features such as fillets, chamfers, and surface
finishes to enhance the aesthetics and functionality of the model. Once the CAD model is
complete, it can be further refined, analysed, and optimized before being used for
prototyping, manufacturing, or visualization purposes. Effective preparation of a CAD model
requires a combination of technical expertise, creativity, and attention to detail to ensure the
final design meets the desired objectives and specifications.

The preparation of CAD models is a multifaceted process that requires a combination of

technical expertise, creative thinking, and attention to detail. By following a systematic
workflow, employing advanced techniques and tools, and adhering to best practices, CAD
modelling serves as a powerful tool for innovation, collaboration, and problem-solving across
a wide range of industries, driving advancements in design, engineering, and manufacturing.

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4.2 COMPUTER AIDED DESIGN

Computer aided design or CAD has very broad meaning and can be defined as the use of
computers in creation, modification, analysis and optimization of a design. CAE (Computer
Aided Engineering) is referred to computers in engineering analysis like stress/strain, heat
transfer, and flow analysis. CAD/CAE is said to have more potential to radically increase
productivity than any development since electricity.

CAD/CAE builds quality form concept to final product. Instead of bringing in quality control
during the final inspection it helps to develop a process in which quality is there through the
life cycle of the product. CAD/CAE can eliminate the need for prototypes. But it required
prototypes can be used to confirm rather predict performance and other characteristics.
CAD/CAE is employed in numerous industries like manufacturing, automotive, aerospace,
casting, mould making, plastic, electronics and other general-purpose industries. CAD/CAE
systems can be broadly divided into low end, mid end and high-end systems. In this project,
CREO PARAMETRIC software is used for designing and modelling.

4.3 CREO PARAMETRIC

Creo Parametric, developed by PTC, is a leading 3D CAD software widely used in various
industries such as automotive, aerospace, manufacturing, and consumer products. Originally
launched as Pro/ENGINEER in 1988, it was rebranded as Creo in 2010 to reflect its focus on
creativity and innovation. Creo Parametric is known for its robust feature set that includes
parametric modelling, feature-based design, and associativity, which allows for easy
modifications and consistent updates across related parts. It excels in assembly modelling,
advanced surfacing, sheet metal design, and offers integrated simulation tools for structural,
thermal, and fluid flow analysis.

The software also supports detailing and documentation, ensuring comprehensive 2D

drawings from 3D models. Advanced capabilities such as Creo Simulation Live, generative
design, augmented reality, additive manufacturing, and IoT integration further enhance its
functionality, making it a versatile tool for designing smart, connected products. PTC
provides extensive training, certification, and support to help users maximize the software's
potential. Overall, Creo Parametric empowers designers and engineers to create innovative
products efficiently and accurately.

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4.4 MACHINE DESCRIPTION

The table frame is the main supporting structure upon which the other components of this
machine are mounted. The frame is a welded structure, constructed from the dimensions of
950 ×520 mm in which 950mm is height., 520mm in width. The drive mechanism comprises
a motor, speed reduction worm gearbox, hooper, crushing blades, and sieving unit. A three-
phase 1.5 HP induction motor with a speed of 1440 rpm is used to drive the components. The
machine uses a gearbox with a 40:1 ratio and is connected to a shaft of the motor and
crushing blade unit. Crushing unit is attached with hooper and the after dehusking of
coconuts the extracted fiber is transferred to the screener and sieving unit for the separation
of coconut fibers and cocopeat powder.

The design of machine involves following list of components;

1. Body Frame
2. Hooper
3. Motor
4. Gear transmission box
5. Screener
6. Handle

1) BODY FRAME:

The frame is the main supporting structure upon which other components of this
machine are mounted. The frame is a welded structure constructed from a 950 ×520 mm in
which 950mm is height., 520mm in width with mild steel material The steel is rigidly fixed
onto the frame so that the vibration and weight are uniformly distributed to the support frame
below. The symmetric structure of the main frame is designed to give a good shape and also
better ability to the entire structure.

The Creo Parametric CAD model of the frame is shown in Fig.3.3.

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Fig. 3.3: Body frame

2) MOTOR
An electric motor is an electrical machine that converts electrical energy into mechanical
energy. Most electric motors operate through the interaction between an electric motor's
magnetic field and winding currents to generate force. Here for our work, we used 1.5 HP
three phase motor to drive crushing unit.
A 1.5 hp motor is a versatile and commonly used electric motor that provides sufficient
power for a wide range of industrial, commercial, and residential applications. Whether
driving machinery, circulating air, pumping water, or powering appliances, these motors
play a crucial role in various systems and processes. Understanding their characteristics,
applications, and maintenance requirements is essential for selecting, operating, and
maintaining 1.5 hp motors effectively.

Fig. 3.4: Motor

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3) GEARBOX (WORM WHEEL REDUCTION BOX)

A gearbox designed using a worm and worm-wheel is considerably smaller than one
made from plain spur gears and has its drive axes at 90° to each other. With a single start
worm, for each 360° turn of the worm, the worm-wheel advances only one tooth of the gear
wheel, and the worm arrangement is considerably smaller in volume Therefore here we used
a worm gearbox to reduce motor speed, Gearbox with 40:1 gear is used ratio. Worm wheel
principle is used in the reduction gear box.

It is mainly used in the area where the high speed is to be reduced and thus increasing
the torque. Electric motors are generally high speed and low torque; hence the speed needs to
be reduced and torque needs to be increased to dehusk the coconut. A readily available gear
box is procured for this machine. It has the gear ratio of 4:1. That is 4 rotations of input shaft
turns the output shaft by one rotation.

Fig. 3.5: Gear box

4. CRUSHING BLADES

Crushing blades are critical components used in coconut fiber extraction machines, playing
a fundamental role in the process of breaking down coconut husks to extract fibers. These
blades are specifically designed to efficiently shred and disintegrate the tough and fibrous
husks, separating the desirable coconut fibers from the outer shell. The crushing blade unit
is attached to the hooper and it is also connected to worm gearbox shaft. This unit consists
of five set of blades which is joined through bearings. The below CAD Model shows the
crushing unit.

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Fig. 3.6: Crushing blades

5. HOOPER:

The hopper is a critical component of coconut fiber extraction machines, facilitating the
efficient and reliable processing of raw coconut husks into valuable fibers. By serving as a
feeding mechanism, material distributor, safety enclosure, and conditioning chamber, the
hopper plays a pivotal role in the overall operation and performance of the extraction system.
Coconut Hooper is used to feed the dry coconuts into the crusher blades which are attached to
the hooper.

Fig. 3.7: Hooper

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6. SCREENER AND SIEVING UNIT:

The screener and sieving unit play a pivotal role in the process of extracting high-quality
coconut fibers from raw husk material in coconut fiber extraction machines. Through the
application of vibratory screening principles, this unit efficiently separates fibers from husk
particles based on size, shape, and density, resulting in clean, uniform fiber products suitable
for various industrial and commercial applications. By optimizing screening parameters and
configurations, manufacturers can achieve maximum throughput, fiber yield, and product
quality while minimizing operating costs and environmental impact. As demand for
sustainable and renewable fiber materials continues to grow, the screener and sieving unit
will remain an indispensable component of modern coconut fiber extraction processes,
driving innovation and efficiency in the industry. In this unit, the extracted fibers are fed into
the screener for the separation of fibers and coco peat powder.

Fig. 3.8: Screener and

sieving unit
7. BEARINGS:
A pillow block (or Plummer block) is a pedestal used to provide support for a rotating shaft
with the help of compatible bearings & various accessories. Housing material for a pillow
block is typically made of cast iron or cast steel. A pillow block usually refers to a housing
with an included anti-friction bearing.

A pillow block refers to any mounted bearing wherein the mounted shaft is in a parallel
plane to the mounting surface, and perpendicular to the centre line of the mounting holes, as
contrasted with various types of flange blocks or flange units. A pillow block may contain a
bearing with one of several types of rolling elements, including ball, cylindrical roller,
spherical roller, tapered roller, or metallic or synthetic bushing. The type of rolling element

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defines the type of pillow block. These differ from "Plummer blocks" which are bearing
housings supplied without any bearings and are usually meant for higher load ratings and a
separately installed bearing.

Fig.3.9: Bearings

4.5 ASSEMBLED VIEWS OF THE COMPONENTS

Fig. 3.10: Front view in Creo parametric

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Fig. 3.11: Top view in Creo parametric

Fig. 3.12: Side view in Creo parametric

Fig. 3.13: Isometric view in Creo parametric

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4.6 COMPLETELY FABRICATED COCONUT FIBRE EXTRACTION

MACHINE

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Fig. 3.14: completely fabricated coconut fibre extraction machine

1) Body Frame
2) Hooper
3) Motor
4) Gear Box
5) Screener and sieving unit
6) Handle

C
HA PT
ER 5

WORKING PRINCIPLE

5.1 WORKING PROCEDURE OF COCONUT FIBER EXTRACTION

MACHINE

Coconut fibre, also known as coir, is a natural fiber extracted from the husk of the coconut.
This fiber is highly valued for its versatility, durability, and biodegradability, making it useful
in a variety of applications such as ropes, mats, brushes, and geotextiles.

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The extraction of coconut fiber from the coconut husk involves several manual and
mechanical processes, including collection of coconut husks from retailers, drying of
coconuts, feeding mechanism, crushing mechanism, Driver and driven mechanism, Sieving
and Screening mechanism, Collection mechanism. which can be efficiently performed using a
coconut fiber extraction machine.

The working procedure of a coconut fiber extraction machine is discussed below, detailing
each step of the process and the mechanisms.

5.2 STEPS INVOLVED IN FIBER EXTRACTION PROCESS

Fig.5.1: Steps involved in fiber extraction process

5.2.1. COLLECTION OF COCONUT HUSKS:

In this step the various coconuts have been collected from various retailers in local
market. The figure shows the collection of coconuts from retailers.

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5.2.2 DRYING OF
COCONUT HUSKS:

Drying coconut husks is a vital step in the processing of coir fibers and cocopeat. Traditional
sun drying, mechanical drying, and solar drying are the primary methods employed, each
with its own advantages and challenges. Ensuring that the husks are dried to the correct
moisture content is crucial for the quality and efficiency of subsequent processing steps.
Advances in drying technology and a focus on sustainability continue to improve the drying
process, making it more efficient and environmentally friendly. The below figure shows the
drying of coconut husks.

5.2.3 FEEDING OF
COCONUT HUSKS INTO
HOOPER

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This process provides the passage for coconut husk to be processed into the crushing
chamber. In this process the coconut husks are feed into the hooper at the rate of five to six
coconuts at a time into the hooper. Below figure illustrates the feeding of coconut husks into
the hooper.

5.2.4 CRUSHING OF COCONUTS

In this process the crushing unit is used for breaking the coconut husk, and then extracted
fibers are collected and transferred to the screener and sieving unit. The below figure shows
the crushing of coconut husks in the crushing unit.

5.2.5 COLLECTION OF EXTRACTED FIBERS

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The collection of extracted fibers from coconuts, known as coir, is an essential process within
the coconut industry. Coir fibers, derived from the husk of the coconut, are valued for their
durability, resilience, and versatility, finding applications in a wide range of products such as
ropes, mats, brushes, and even eco-friendly materials like geotextiles.

5.2.6 TRANSFERRING TO SCREENER

Transferring extracted coconut fibers to a screener is a critical step in the processing of coir,
ensuring that the fibers are cleaned, graded, and prepared for their various end uses. This
phase involves several key processes designed to maximize the quality and usability of the
fibers. Below figure shows the transferring of coconut husk powder and fibers into the
screener.

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5.2.7 SEPARATION OF FIBERS AND COCOPEAT POWDER

The crushed material is passed through screens or sieves to separate the long fibers from the
finer particles, which include the short fibers and cocopeat. Vibrating screens or oscillating
sieves are commonly used for this purpose. The different mesh sizes of the screens allow the
smaller cocopeat particles to fall through, leaving the longer fibers on top. The figure shows
the separation of extracted fibers and cocopeat powder.

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DESIGN AND FABRICATION OF COCONUT FIBER EXTRACTION MACHINE

CHAPTER 6

DESIGN CALCULATIONS

6.1 DESIGN CONSIDERATIONS

To develop a coconut fiber extraction machine the first and foremost is to know about the
components, material used for fabrication and some of the mechanical properties which are
listed below:

1. Material Properties
2. Load analysis
3. Power requirements
4. Safety and ergonomics

 Material Properties: The material properties of components used in a coconut fiber

extraction machine are crucial for ensuring durability, efficiency, and safety in the
processing of tough coconut husks. The selection of appropriate materials involves
understanding the mechanical stresses and environmental conditions that the machine will
face during operation. Understanding the physical and mechanical properties of the
coconut husk, such as hardness, toughness, and fiber length, is crucial. These properties
influence the choice of materials and the design of the blades and rollers.
 Load Analysis: Load analysis is a crucial aspect of designing a coconut fiber extraction
machine, as it ensures that the machine can withstand the forces and stresses encountered
during operation without failure. The primary loads in such a machine include static
loads, dynamic loads, and impact loads, each of which must be carefully considered and
calculated to ensure the machine's structural integrity and functionality. The machine
must withstand the forces generated during the extraction process. This includes
calculating the loads on various components, such as the bearings, shafts, and structural
frame.
 Power Requirements: Determining the power needed to drive the rollers and other
components is essential. This involves calculating the torque and speed required for the
extraction process and selecting an appropriate motor or engine.
 Safety and Ergonomics: The design must ensure the safety of the operator, with features
such as protective covers, emergency stop buttons, and ergonomic loading heights.

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6.2 DESIGN OF HOOPER

The trapezium-shaped hopper with a top length of 300mm, bottom length of 150 mm, height
of 300 mm, and width of 300 mm, constructed from 3 mm thick mild steel, is adequately
designed to handle the load of coconut husks for the extraction machine. The stress
calculations confirm that the material can support the loads without risk of deformation or
failure.

6.2.1 Hopper Dimensions

The hopper has a trapezium-shaped cross-section

with the following parameters:

 Top Length (L1): 300mm

 Bottom Length (L2): 150 mm

 Height (H): 300mm

 Width (W): 300mm

6.2.2. The area of the Hooper:

The area of the hooper is calculated by using the Eqn. 6.1

1
A= × ( L1 + L2 ) × H Eqn. [6.1]
2

1
¿ × ( 300+150 ) × 300
2

2
¿ 675000 m m

6.2.3. Volume of the hopper:

The volume of the hopper is determined by:

V = A ×H Eqn. [6.2]

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2
V =675000 mm × 300 mm
3
V =20250000 mm

Where:
V = Volume of the hopper, (m3)
A = Area of the hopper, (m2)
H = Height of the hopper, (m)

6.2.4. Structural Strength:

Material for Hopper: Mild Steel

Density of Mild Steel: 7850 kg/m3
Thickness of Hopper (t): 3 mm

Weight of Coconut Husk (W): 5 kg

Force due ¿ weight of husk =W × g Eqn. [6.3]

2
¿ 5 ×9.81 m/s

¿ 49.05 N

6.2.5. Capacity of Hooper:

Weight of husk to be processed per batch (W): 5 kg

Density of coconut husk (ρ): 0.2 kg/L (typical value)

W
Volume of husk(V)¿ Eqn. [6.3]
ρ

5 kg
¿
0.2 kg/l

¿ 25 L

3
¿ 0.25 m

6.2.6. Stress Calculation:

Assuming the force is uniformly distributed over the bottom area:

Stress on Base is calculated by using the Eqn. 6.4

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F
(σb) ¿ Eqn. [6.4]
A

Where:

F= Force due ¿ weight of husk

A= Area of Hooper
49.05
¿
675000

−5 2
¿ 7.266 ×10 N /mm

6.3 DESIGN OF CRUSHING UNIT

The crushing unit for the coconut fiber extraction machine, with dimensions of 200 mm
length, 50 mm width, and 5 mm thickness, made from high carbon steel, is designed to
effectively handle the cutting force without yielding or failure.

6.3.1. Material Selection

 Material: High Carbon Steel

 Yield Strength (σy): 300 MPa

 Ultimate Tensile Strength (σu): 600MPa

6.3.2. Crushing Unit Dimensions

 Length (L): 200 mm

 Width (W): 50 mm

 Thickness of blades (t): 5 mm

6.3.3. Cutting Force Calculation

The force required to cut through the coconut husk depends on the shear strength of the husk
and the area of contact.

 Shear Strength of Coconut Husk (τ): 10 MPa

The area of contact (A) is calculated by using the Eqn. 6.5.

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𝐴 = 𝑊× 𝑡 Eqn. [6.5]

= 50 mm×5 mm

= 250 mm2

Cutting force (F) is calculated by using the Eqn. 6.6.

𝐹= 𝜏 × 𝐴 Eqn. [6.6]
= 10 × 250

=2500 N

6.3.4. Stress Analysis

To ensure the blade can withstand the cutting force without yielding, we calculate the
bending stress.

 Moment of Inertia (I):

Moment of inertia is calculated by using the Eqn. 6.7

3
W ×t
I= Eqn. [6.7]
12
3
50 mm× 5 mm
¿
12
4
¿ 520.83 N /mm

 Distance from Neutral Axis (y):

t 5
y= = =2.5 mm
2 2

 Maximum Bending Moment (M):

The Maximum Bending Moment is calculated by using the Eqn. 6.8.

Assuming the force is applied at the tip of the blade:

L
M =F × Eqn. [6.8]
2

¿ 2500 N ×100 mm

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3
¿ 250 ×10 Nmm

 Bending Stress (σb):

Bending stress is calculated by using Eqn. 6.9.

M× y
σ b= Eqn. [6.9]
I

3
250× 10 ×2.5
¿
520.83

¿ 1200 MPa

Since 1200 MPa exceeds the ultimate tensile strength of the material (600 MPa), the crushing
unit would fail under this bending stress. Thus, we need to increase the thickness.

 Revised Blade Thickness Calculation

To ensure the blade does not exceed the yield strength, we solve for the required thickness
'
M× y
(t'). σ b=
I'
3
' W ×t
I=
12

' t'
y=
2

Rearranging:

'
M× y
σ b=
I'

t'
250 ×10 3 ×
2
300=
50 ×t 3
12
6
'2 3× 10
t =
300 ×50

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t =√ 200
'

'
t =14.1 mm

Thus, the revised thickness of the blade should be 14.1 mm to ensure it operates within the
yield strength of the material.

CHAPTER 7

COST ANALYSIS

BUDGET Amount in Rs.

a) Materials / consumables
 Motor 3HP 3,800.00
 Sheet Metal Plate 1,500.00

 M.S rods & bars 1,200.00

 Crusher Blades 2,500.00

 Coco peat Screener 1,000.00

b) Labour 1,500.00

c) Travel 1,000.00

d) Miscellaneous 2,000.00

Total amount in Rs. 14,500.00

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DESIGN AND FABRICATION OF COCONUT FIBER EXTRACTION MACHINE

CHAPTER 8

RESULTS AND DISCUSSIONS

1. Performance Evaluation of the Coconut Fiber Extraction Machine

The performance evaluation of the coconut fiber extraction machine involved testing various
parameters such as time required to crush the coconut husks, crushing efficiency, sieving
efficiency. The results from these tests are summarized below:

2. Crushing efficiency

The crushing efficiency of coconut fiber extraction machine was calculated by the following
formula.
T otal number of crushed coconut husks
η c= Eqn. [7.1]
Total number of coconut husks
Seven samples of green and dry coconut husks were taken for this calculation. Firstly 8 green
coconut husks were feeded into the hooper, as the coconut husks are completely wet the
machine could not crush it completely. The same number of dry coconuts is feeded into the
hooper, the machine has crushed 7 coconut husks out of 8, So the machine is not suitable for
the green coconut husks. Table 7.1 and 7.2 shows the sample results of green and dry coconut
husks feeded into hooper and total number of coconut husks crushed in the machine. The
graph 7.1 illustrates the average crushing efficiency of coconut husks.

Table 7.1 Sample results of green coconut husks crushed.

Sample No. of coconuts No. of coconut No. of coconut Efficiency of the

feeded into hooper husks crushed husks uncrushed machine (η) in %

1. 8 4 4 50
2. 6 5 1 83.33

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3. 5 3 2 60
4. 4 3 1 75
5. 3 2 1 66.66
6. 2 1 1 50
7. 1 1 0 100

Table 7.1 Sample results of green coconut husks crushed.

Sample No. of coconuts No. of coconut No. of coconut Efficiency of the

feeded into hooper husks crushed husks uncrushed machine (η) in %
1. 8 7 4 87.50
2. 7 7 0 100
3. 6 5 1 83.33
4. 5 4 1 80
5. 3 3 1 100
6. 2 1 50
7. 1 1 0 100

2. Sieving Efficiency

The Sieving efficiency of coconut fiber extraction machine was calculated by the following
formula.

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Total weight sieved husk ∈ grams

η s= Eqn. [7.2]
Total weight of crushed husk

Seven sample weights of dry coconut husks were taken for this calculation. Firstly, the
crushed coconut husk is transferred to the screener and sieving unit, the screener will separate
the fibres and cocopeat powder from the crushed material. The average efficiency of the
collected material is tabulated by using the Eqn. 7.2. Table 7.3 shows the sample weights of
dry coconut husks feeded into hooper and total weight of crushed coconut husks in the
machine. The graph 7.2 illustrates the average crushing efficiency of coconut husks.

Sample Weight of crushed Weight of coconut Weight of coconut Efficiency

coconut husk husk sieved husk remained in (η) %
(Grams) (Grams) screener (Grams)
1. 848 754 94 88.91
2. 654 533 121 81.49
3. 535 426 109 79.62
4. 480 376 104 78.33
5. 268 183 85 68.28
6. 109 77 15 70.64
7. 53 42 10 84.00

CHAPTER 9
CONCLUSION AND SCOPE FOR FUTURE WORK

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In this study, we have explored the design, development, and performance evaluation of a
coconut fibre extraction machine. Coconut fibre extraction plays a crucial role in the
utilization of coconut husks, which are a significant agricultural waste product. Our machine
aims to streamline the process of fibre extraction, enhancing efficiency, and reducing manual
labor. Through a comprehensive review of existing literature, coupled with experimental
trials and analysis, we have evaluated the effectiveness of our machine design.

Further work could be done to improve the aesthetics, materials, and weight reduction of the
machine through advanced manufacturing techniques.

Exploring opportunities to automate more aspects of the fibre extraction process to further
improve efficiency and productivity.

Investigating ways to integrate the machine with other post-processing equipment to create a
more comprehensive solution for the coir industry.

Conducting detailed market research and developing a comprehensive commercialization

strategy to promote wider adoption of the coconut fibre extraction machine.

Overall, the developed machine provides a promising solution to the challenges faced by
farmers and small-scale coir industries, enabling more efficient and cost-effective coconut
fibre extraction. Further refinements and commercialization efforts could help unlock the full
potential of this innovation.

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