Chapter 1

INTRODUCTION

Situation Analysis

Rice plays a significant role in meeting the world's food demands and is one of

the top three grain crops in the world. Rice crops will always play a part on a global scale

in order to ensure food security both now and in the future. Different production

techniques are used to grow rice throughout Asia, the Americas, Australia, Europe, and

Africa [1] such as direct seeding, transplanting, [2] system of rice intensification, [3]

aerobic, rainfed and organic rice production. [4] These are some of the techniques used to

grow rice and are used based on factors such as water availability, labor availability,

climate conditions, and farmer preferences.

Rice is a staple food for the world's population, particularly in regions of Asia

where it is consumed daily by millions of people. Rice is a basic necessity for people

across the globe because of its versatility, affordability, and the fact that it provides

essential nutrients such as carbohydrates, proteins, and vitamins. It is also a reliable

source of energy and sustenance in many developing countries, playing a crucial role in

combating hunger and malnutrition. Additionally, rice plays a significant cultural and

social role in many societies, often being the centerpiece of traditional dishes and

celebrations [5].
 For about half of the world's population, rice is a fundamental food and the

second most extensively produced cereal crop. Over 3 billion individuals eat more than

100 kilograms of rice annually. Over the past 30 years, rice has been grown on 155.5

million acres at an average annual growth rate of 0.39%. The world's limited water

resources for agriculture, the growth of the urban and industrial sectors in Asia, where

land is already scarce, and the high costs of creating new rice-growing regions in Sub-

Saharan Africa and Latin America mean that there will not be many opportunities in the

near future to expand areas under rice-based systems. The average growth rate of rice

yield was 3.68% per year in the early 1980s, but it has decreased to 0.74% per year in the

late 1990s [6].

Rice is one of the world’s most important and essential crops, and its production

generates a significant amount of agricultural waste, including rice hulls. Rice hulls, also

known as rice husks, are the outer protective layer of the rice grain that are removed

during the milling process. They account for approximately 20% of the total weight of

paddy rice and are often considered a byproduct or waste material [7].

While rice husk waste can be utilized and beneficial in many ways, there are some

potential negative effects associated with its improper disposal or mismanagement. These

include air pollution where nitrogen oxides, sulfur dioxide, carbon monoxide, and large

volumes of particulate matter can be released into the atmosphere when rice husk waste is

burned without the required controls. Not only may these toxins harm human health and

the environment, but they can also contribute to air pollution [8].
 Similarly, if rice husk waste is improperly disposed of in water bodies such as

rivers or lakes, it can lead to water pollution. The waste can introduce organic matter and

nutrients into the water, leading to eutrophication, algal blooms, and a decrease in oxygen

levels. This can be harmful to aquatic ecosystems and impact the water quality for

humans and wildlife.

Additionally, when rice husk waste is used as a soil amendment without proper

management, it can lead to soil degradation. The high silica content in rice husk can

cause soil compaction, reduce water infiltration, and affect soil fertility. It can also lead to

the leaching of chemicals and nutrients, impacting soil quality and crop growth [9].

Furthermore, if rice husk waste is anaerobically decomposed, it can produce

methane gas. Methane is a potent greenhouse gas, and its release contributes to climate

change and global warming.

Rice husk waste is highly flammable, and if not stored or managed properly, it can

pose a fire hazard. Improper storage or handling of rice husk waste can lead to accidental

fires, risking property damage, environmental pollution, and posing a threat to human

safety [10].

Lastly, Southeast Asia, China, India, Bangladesh, Brazil, and the United States of

America are among the rice-producing nations with an abundance of rice husk (RH). Up

until now, RHs have only been recycled for low value uses, despite the enormous amount

of production that occurs every year throughout the world. RH has been more popular

among rice mills in rice-growing nations as means of providing energy for mill

operations and rural household lighting. RHA, or rice husk ash, is created when RHs are
burned. RHA has a low bulk density, which makes disposal in open fields or landfills

challenging and potentially harmful to human health and the environment [11].

To minimize these negative effects, it is important to implement proper waste

management practices. This can include controlled combustion or gasification processes

to utilize rice husk waste as an energy source, proper storage, and handling to prevent

fires, and appropriate treatment and disposal methods to minimize environmental

contamination.

With the above-mentioned, this research study about rice hull is perceived as a

need for several reasons stated below. Recent researches and innovations have shown that

rice hulls can be effectively utilized, creating new opportunities for waste management

and value creation.

Rice husk is a byproduct of rice milling, and globally, a large amount of rice husk

is generated as waste. [7] Conducting research on rice husk can help explore ways to

utilize this abundant agricultural waste product effectively. By finding innovative uses for

rice husk, such as fish feed, [12] fertilizer, [13] or landscaping material, we can maximize

resource utilization and reduce waste [14].

Rice husk can have detrimental effects on soil and water when disposed of

improperly. [9] Researching ways to manage and recycle rice husk can contribute to

sustainable agricultural practices. Finding environmentally friendly ways to use or

process rice husk can help reduce pollution, improve soil health, and minimize the

negative impact of agricultural waste on the environment [15].

 Rice husk has significant energy potential due to its high carbon content.

Researching efficient and clean energy conversion technologies, such as biomass

combustion or gasification, can contribute to the development of renewable energy

sources. By utilizing rice husk as a biomass fuel, we can reduce dependency on fossil

fuels and mitigate climate change [16].

Proper management and utilization of rice husk contribute to environmental

conservation. Research can help identify sustainable techniques for processing and

disposal, minimizing air and water pollution risks. [8] By mitigating the environmental

impacts associated with rice husk waste, we can protect ecosystems, preserve

biodiversity, and safeguard human health.

Exploring novel applications and value-added products derived from rice husk

can create economic opportunities. Research can uncover new business prospects for

industries related to agriculture, energy, construction, and manufacturing. By

transforming rice husk into valuable commodities, we can stimulate economic growth

and generate income for farmers and local communities.

Hence, this project study entitled "Development of Rice Hull Pulverizer and

Pelletizer" focused on creating fertilizers from the pulverized rice hull and fish feeds

from the rice hull pellets and other additives. The products depended on the clients'

preferences and are based according to their needs. According to D. Singh Karam et al.,

pulverized rice hulls are rich in organic matter, which helps to improve the structure and

fertility of soils. When incorporated into the soil, they provide essential nutrients and

promote microbial activity, creating a favorable environment for plant growth. Rice hulls
have excellent water retention properties. They can absorb and retain moisture, reducing

water evaporation from the soil. This helps to keep the soil moist for a longer period,

preventing water stress in plants and reducing the need for frequent watering. [17]

According to V. K, D. Rajakumar, M. Joseph, and M. Gomathy, as rice hulls

decompose, they release essential nutrients such as potassium, silica, and trace minerals

into the soil. These nutrients are gradually available to plants, promoting healthy growth

and improving nutrient availability in the soil. Lastly, Rice hulls increase the porosity of

the soil, allowing better air circulation and root development. They prevent compaction

and improve soil drainage, preventing waterlogging and root rot in plants. [18]

As for the fish feeds, the researchers will base from the project study entitled,

“Screening local feed ingredients of Benin, West Africa, for fish feed formulation,” and

will make use of pulverized rice hull mixed with fishmeals, soybeans, wheat, oils and

vitamins in creating fish feeds. Rice hulls are rich in dietary fiber, which can help

improve the digestive health of fish. Fiber aids in proper digestion and nutrient

absorption, leading to improved overall health and growth. Likewise, rice hulls are rich in

silica, which can contribute to the development of fish scales and bones. Silica promotes

skeletal strength and can support healthy bone growth in fish. Lastly, rice hulls contain

carbohydrates that can provide energy for fish. Carbohydrates serve as an important

energy source for fish metabolism and growth. [19]

Therefore, this research study focused on designing and development of a rice

hull pulverizer and pelletizer to address the challenge of rice husk waste management in

agricultural regions. The researchers aimed to create a cost-effective solution that can
process rice husk into fine particles and then compress them into pellets for use as fish

feed, fertilizer, or other applications. Additionally, the developed equipment had the

ability to optimize the pulverization and pelleting process to enhance the efficiency and

quality of the final product. By expanding our knowledge and finding innovative

solutions, we can unlock the potential of rice husk and create a more sustainable future.

Likewise, there are several potential business opportunities and/or target market

or beneficiaries that can be linked with the research on Development of Rice Hull

Pulverizer and Pelletizer such as the Equipment Manufacturing and Sales, Biomass Fuel

Production, Waste Management Services, Research and Development, and Consulting

and Training.

Foremost, there is a market demand for rice hull pulverizers and pelletizers,

especially in agricultural regions where rice husk waste is abundant. The research

findings can be used to develop and manufacture portable equipment, which can then be

sold to farmers, millers, and biomass fuel producers. Secondly, rice husks can be

processed into pellets and used as biomass fuel in various industries, such as power

generation, heating, and cooking. By investing in a portable pulverizer and pelletizer,

entrepreneurs can set up biomass fuel production facilities and sell the pellets to

customers in need of renewable energy sources. Moreover, entrepreneurs can offer waste

management solutions by providing on-site pulverization and pelleting services to rice

millers and farmers. This business opportunity involves collecting the rice hull waste,

processing it into pellets, and either selling the pellets or disposing of them in an

environmentally friendly manner. Penultimately, the research findings can be further

utilized by companies or organizations involved in research and development. They can

explore innovations and improvements in the design and functionality of the

Development of Rice Hull Pulverizer and Pelletizer to enhance its efficiency,

productivity, and cost-effectiveness. Lastly, entrepreneurs with expertise in rice husk

waste management and the operation of pulverizers and pelletizers can offer consulting

and training services. They can provide guidance and knowledge to individuals and

businesses interested in setting up their own rice husk processing facilities, including

technical support, troubleshooting, and training on equipment operation and maintenance.

Overall, this research study may not solve the entire problem of rice hull

agricultural waste but would address a critical part mainly by using pulverizer and

pelletizer, the rice husks will and can be efficiently processed and converted into valuable

products, reducing the amount of waste generated.

The use of agricultural by-products has drawn a lot of attention lately because of

its potential to address environmental issues and advance sustainable practices. Rice hulls

are one such by-product that has potential to be a rich resource with a variety of uses.

This thesis explored the many facets of rice husk, looking at its physical characteristics,

and its applications in a range of sectors. This research intended to contribute to

environmental conservation and the development of novel solutions in materials science

and agriculture by exploring the sustainable use of rice hull.

In addition, this research aimed to assess the economic feasibility of integrating

rice hull into current industrial procedures, assessing the effects on waste minimization

and cost effectiveness. It is becoming more and more important to comprehend the entire

range of qualities and uses for rice hulls as the demand for environmentally friendly
materials grows worldwide. This thesis sought to illuminate the unrealized potential of

rice husk by filling in knowledge gaps and suggesting useful applications. By doing so, it

provided insights that helped create a future that is more resource-efficient and

sustainable.

It has been shown that rice hulls are a renewable raw material with a unique

makeup. It was proposed to use a technique that yields a mixture of non-condensable

gases, a liquid organic product, and a solid product to transform rice hulls into

polyfunctional materials. The solid product can be utilized as a filler for elastomers and

poultry fodder supplements, as well as a sorbent for the recovery of noble and rare

metals. In the beneficiation of complicated refractory ores, the liquid solution acts as an

antibacterial, a regulator of plant growth, and an incredibly selective collector of lead

minerals. The mixture of non-condensable gases can be used to create carbon black or as

a high-calorific fuel [20].

The researchers’ Development of Rice Hull Pulverizer and Pelletizer project study

had many benefits for themselves and can benefit to other people, and the whole

community. Foremost, the researchers gained valuable knowledge and experience in

developing, constructing, and testing a machine that would be beneficial to the

environment. Other people can benefit from this project study because it created a viable

solution for the production of fertilizers and pellets, which are crucial in agriculture and

livestock farming. Additionally, this project study can have a positive impact on the

whole community, as it reduced agricultural waste, mainly rice hulls, which resulted to

numerous problems such as pollution and soil degradation.

 This project study also can have a positive impact on target markets and

beneficiaries. The use of a portable pulverizer and pelletizer can create opportunities for

economic growth and income generation. Farmers who produce rice husks as a byproduct

can turn this waste into a valuable commodity by processing it into pellets. This can

allow them to diversify their income and tap into new markets. Additionally, businesses

involved in the production and sale of rice husk pellets can create employment

opportunities, particularly in rural areas where rice production is prevalent. Moreover, the

portable pulverizer and pelletizer provide the opportunity to diversify products and enter

new markets. Rice husk pellets can be used in various applications, including fish feed,

bedding material, and biochar production. This can open up opportunities for farmers,

entrepreneurs, and businesses to expand their product offerings and cater to a wider

customer base. The versatility of rice husk pellets allows for market diversification and

value addition. Likewise, in many rural areas, access to clean and affordable energy is

limited. The portable pulverizer and pelletizer enable the production of biomass fuel

pellets from rice husks, which can be used as a renewable energy source. This can benefit

households and communities by providing them with a reliable and cost-effective

alternative to traditional fuels, such as firewood or charcoal. The use of rice husk pellets

as fuel can reduce the reliance on fossil fuels and contribute to the mitigation of climate

change. Finally, the project would benefit local communities by providing a source of

employment and potentially reducing the cost of fertilizers and pellets.

The driving force behind this research is the commitment to making this

alternative accessible to a wider audience. By achieving a harmonious balance between

affordability and functionality, this innovation has the potential to revolutionize

manufacturing industries, making it accessible to a broader spectrum of users and, in turn,

contributing to increased industrial productivity.

Statement of the Objectives

The main purpose of this study was to develop a Rice Hull Pulverizer and

Pelletizer. Specifically, it sought to achieve the following objectives:

1. To design a Rice Hull Pulverizer and Pelletizer;

2. To construct a Rice Hull Pulverizer and Pelletizer;

3. To test the Technical Performance of Rice Hull Pulverizer in terms of its

Pulverizing Efficiency (%);

4. To test the Technical Performance of Rice Hull Pelletizer in terms of:

4.1) Pelleting Efficiency (%)

4.2) Size Quality of Pellet (%)

Time and place of the study

This research was carried out at Don Mariano Marcos Memorial State University,

Mid La Union Campus, College of Engineering, Mechanical Engineering Department,

Catbangen, City of San Fernando, La Union, from the first semester to the second

semester of the academic year 2023-2024.

Definition of terms

For better understanding of the study, the following terms are specifically

defined:

Pulverizing or Pelleting Efficiency is the ratio of the weight of pulverized

rice hull or pellets produced to the initial weight of input.

Size Quality of Pellet is the ratio of the weight of pellets with the common

length of 10 mm to the weight of the output pellet.

Rice the starchy seeds or grain of an annual marsh grass, Oryza

sativa, cultivated in warm climates and used for food.

Rice hull the coatings of seeds, or grains, of rice.

Rice Hull Pelletizer is a mechanical device that converts rice hulls into

pellets.

Rice Hull Pulverizer is a mechanical device for grinding rice hulls.

Rice milling to remove the hulls and bran from harvested, dried rough rice

and to produce a milled, polished, or white rice.

Rice production refers to the process of cultivating, harvesting, and

processing rice crops to yield the final rice product for consumption.
 Chapter 2

METHODOLOGY

Research Design

The study employed and utilized the developmental research design as its design

framework. Developmental Research Design is adopted for the study specifically for

attaining the first and second objectives. Highlighted by Richey (2005), developmental

research design is an organized and systematic study for design and development. Based

on the established circumstances stated in the situation analysis, developmental research

design had set up the formulation for an engineering-oriented design as a

conceptualization required in the first objective of the study. Similarly, developmental

research design was the main building block for obtaining the second objective of the

study, and it was the foundation of the construction and assembly of the Development of

Rice Hull Pulverizer and Pelletizer based on the conceptualized design.

The efficiency of the Development of Rice Hull Pulverizer and Pelletizer

was based on the thorough treatment of the materials, tools, and equipment,

correct implementation of processes and methods, adequate supervision, and

sufficient effort. With the proper execution of all the processes involved, such as

experimental designing, machine designing, testing the efficiency of the machine,

and treatment of the statistical data acquired through different methods of

experimentation, the researcher had an output that was substantially functional,

practical, and ecologically sustainable.

Materials and Procedures

Materials and cost. The needed supplies and materials that was used in

crafting the Development of Rice Hull Pulverizer and Pelletizer was shown in

Table 1, presents the materials needed in developing the machine with its current

price.

Table 1. Bill of Materials

Quantity Unit Description Unit cost Total

cost
1 pc Pulverizer w/ motor (3HP) 13500.00 13500.00
2 pc Angle bar, (1/4 x ½) 750.00 1500.00
2 pc Steel plate (4ft x 8ft) 350.00 700.00
10 kg Bolts and nuts (1/4x ½) 5 50.00
1 pack Metal screw #4 80.00 80.00
1 pc Paint thinner (450 ml) 65.00 65.00
1 pc Paint (green enamel) 200.00 200.00
2 pcs Shafting 1ft x 6 inches 360.00 360.00
1 pc Paint brush (4’) 70.00 70.00
1 kg Special welding rod 140.00 140.00
1 pc G.I Plain sheets (1.1mm) 1,300.00 1,300.00
1 pc V-Pulley 7” 600.00 600.00
1 pc V-Pulley 2” 320.00 320.00
2 pc Flat Sheet (4ft x 4ft) 900.00 1800.00
1 pc Double Groove 350.00 350.00
2 pc Belt (B type) 72” 380.00 760.00
1 pc Belt (B type) 48” 320.00 320.00
2 pc Bearing 200.00 400.00
1 kilo Welding rod 100.00 100.00
1 pc Flat bar 5/16 380.00 380.00
1 pc Flat Sheet 720.00 720.00
1 kilo Special welding rod 300.00 300.00
 Materials 24,707.00
Labor Cost 22,500.00
Over Head Cost 4,000.00
Total cost: Php 51,307.00

Tools and Equipment: Tools and equipment that was used in the

assembly and construction of the Development of Rice Hull Pulverizer and

Pelletizer is listed below. These tools were used to precisely fabricate the

machine.

Table 2. List of the Tools and Equipment

Tools and Equipment Function

Plate rolling machine Used to curve metal plates.

Screw Driver Used to fasten the screws in the frame.

Riveter Used to interlock aluminum bars or angle bars.

Metal Saw Used to cut steels into workable sizes.

Metric Tape Used to measure distance in the perimeters of machine.

Multi-meter Used to measure voltage to the voltage regulator.

Timer Used to record time from raw materials to output.

Welding Rod Used in welding process as jointer between two

different m materials.

Scale Used in weighing the rice hull

Power Drill Used to bore a hole in metal surfaces and can also be m

used to fasten the screws around.

Grinder Used to cut metals like the angle bars and will

smoothen m welded areas and make creases for the stainless sheet.
Welding Machine Used to weld objects for them to hold together

Procedures: The Fig. 1 shows the Process Flow Diagram that is

conducted and followed by the researchers to complete the Development of Rice

Hull Pulverizer and Pelletizer. The researchers conducted planning first, which is

critical in the completion of the study.

The next step in the Process Flow Diagram was designing. The researchers

designed the machine thoroughly using different mechanical engineering

disciplines, especially machine design. Calculations and computations were

conducted to get the best and most economical materials while considering the

safety and design suitable for the machine. The researchers also calculated the

size of the pulverizing chamber that suits the purpose of the machine. Another

important matter that is considered was the rigidity of the machine frame to hold

the parts together.

Fig. 1. Engineering Design Process Flow Diagram
 The researchers followed the design in fabricating the machine as a part,

with the help of experts. Materials was bought suitable for the design. The

researchers employed machinists to help in creating the machine. The researchers

started in December to gather data that will justify and supplement the study,

which was concerned with the production and manufacturing of local products.

They concentrated their study on this subject matter.

Pretesting was done after the fabrication of the machine, scheduled for the

next semester in the same school year (S.Y. 2023-2024). Further tests,

evaluations, and revisions was conducted.

Testing is done to test the effectiveness and efficiency of the machine in

pulverizing and pelletizing rice hull. Sufficient testing is conducted to determine

if the Development of Rice Hull Pulverizer and Pelletizer is operating properly.

Revisions was made when the machine does not work properly as expected during

the testing.

As a first step in the development of the Development of Rice Hull

Pulverizer and Pelletizer (DRHPP), the researchers gathered concepts and

information to conceptualize the final design of the machine. Using the principles

learned, the researchers considered the information that is gathered to design the

said machine.

The researchers consulted and employed experts on how to fabricate the

Development of Rice Hull Pulverizer and Pelletizer. Good machinists with

expertise related to the machine are consulted.

Data Gathered

In gathering data, trial testing is conducted for the assessment of Development of

Rice Hull Pulverizer and Pelletizer Machine. The researchers had their checklist,

weighing scale for the rice hull, and timer for recording the time consumed. Data are

gathered for the following (for five trials): individual and average pelleting and

pulverizing efficiency; weight of the husk before being pulverized and pelletized; weight

of husk after pulverization and pelleting; and size quality of the pellet.

The first step for the data gathering was to weigh the rice hull using a

digital scale before the testing for it was used in solving the pelleting and

pulverizing efficiency. The next step was recording the processing time. The

researchers had five trials each for pulverizing and pelleting the rice hull. The

researchers may choose to stop the process after pulverizing but may also

continue it until pelleting. The size quality of the pellet (final product) was

checked and assessed if the process is continued to pelleting. Lastly, recorded the

weight of the pulverized and pelletized rice hull.

Data Analysis
 The gathered data is used to determine the machine’s function ability, pulverizing

and pelleting efficiency, and size quality of pellets. The methods that are used to analyze

the data include Arithmetic Mean, and Percentage. Arithmetic mean is used in

determining the average pulverizing and pelleting efficiency, and size quality of pellets of

five trials. The machine’s pulverizing efficiency, pelleting efficiency and size quality of

pellets are measured as a percentage. To express efficiency as a percent, E=(Wp/Wi) ×

100% is used, where E is the pelleting or pulverizing efficiency (%), Wp is the weight of

pellets produced or pulverized rice hull (kg), and Wi is the initial weight of input.

Likewise, total weight of 10 mm pellets over the total weight of output pellets multiplied

by a hundred percent is used for determining the size quality of pellets.

 Chapter 3

RESULTS AND DISCUSSION

Over the research, careful planning, designing, fabricating, assembling,

and testing was carried out. A number of deliberate changes was made to the

machine’s structure in order to improve its ergonomics and produce superior

pelletizing and pulverizing results. In addition, the researchers made sure that the

DRHPP testing yielded the necessary data to determine the precise values of the

technical parameters or performance of the study which is the main focus of the

research. These include the size quality of the pellet as well as throughout

efficiency of the pulverizer and pelletizer. After that, the testing data was tallied

and summarized, and the researchers then analyzed the results.

Design of the Rice Hull Pulverizer and Pelletizer

 By applying their combined knowledge, the researchers came up with the

final design of the machine. The objective for the design of the DRHPP was to

make a 2 in 1 machine that would cater the needs of the small-scale farmers,

fisherman’s and households when it comes to fertilizers and fish feeds by using

agricultural waste such as rice hull. Figure 2 shows the orthographic view and the

isometric view of the machine

Fig. 2. Orthographic View of the Development of Rice Hull Pulverizer and Pelletizer
 The pulverizer was responsible for grinding and crushing the solid rice

hull with corn into smaller particles or powder. It is 28cm x 34cm x 37cm in

length, width, and height, respectively (without frame). Once the mixture has

been pulverized to the desired particle size, it is discharged from the pulverizer

through a discharge mechanism. The pulverized material is collected, sieved, and

processed further as needed and may continue to be pelletized with additional

mixture.

Plate 1: Installation of Pulverizer

 The DRHPP Frame is made up of ¼" by 2" angle bar that is welded

together to form the desired structure for the machine. It supported and connected

the key parts of the machine. Hence, it must be properly designed so that the

motor, shaft, pulley, pulverizer and pelletizer are interconnected to each other and

function accordingly.
 Plate 2: Constructed Frame of DRHPP

The motor, which is the prime mover of the machine allowed the machine

parts to move and serve their specific purpose. It converted electrical energy into

mechanical energy which is transmitted by the belt and pulley drive to the various

part of the machine. Hence it is the driving force of the DRHPP in order to

function according to its designed purpose. DRHPP motor drove the machine and

it has rating of 3 HP.

 Plate 3: Installation of Motor

The belt cover played a critical role in protecting the belt and pulleys. The cover

acted as a barrier between the belt and external elements such as dirt, dust, debris and

moisture. Likewise, the cover helped enhance safety in the workplace by reducing the

risk of accidental contact with moving parts, such as the belt and pulleys.
 Plate 4: Constructed belt cover

The bearing enabled smooth and efficient rotation or linear motion of the machine

components by reducing friction and supporting loads. It allowed components to move

relative to each other in a controlled manner.

 Plate 5: Installation of bearing

Assembly of the Development of Rice Hull Pulverizer and Pelletizer

Several steps were involved in the whole process of making the OWSP. It

includes the fabrication and assembly of the frame, transmission system, shredder
 blades, shredder Shell, screw conveyor and pelletizer blade compactor, pellet die,

and installation of the motor.

3 5
4 6

7
1

2 8 9

10

11
14

13

12

Figure 3: Exploded View of DRHPP

Legend:

1. Roller 8. Shafting
2. Electric Motor 9. Single
3. Pulverizer 10. Bearing
4. Double groove pulley 11. Belt housing
5. Roller (Type 150) 12. Belt
6. Pelletizer 13. Frame
7. Pelletizer cone 14. Double groove pulley

Procedures in Constructing DRHPP

 The process of constructing a rice hull pulverizer and pelletizer commenced with the

meticulous crafting of a sturdy frame that served as the foundation for both machines. Skilled

fabricators diligently worked on the frame, ensuring its strength and durability to support the

components of the pulverizer and pelletizer. Following the completion of the frame, the

pulverizer was expertly installed onto the structure, with precise alignment and secure

connections made to facilitate the grinding and pulverizing of raw materials effectively.

Simultaneously, the construction of the pelletizer began, involving the assembly of key

components such as the feeder, die, and rollers. Each element was meticulously integrated to form

a cohesive unit for pellet production. The shaped the raw material into uniform pellets of the

desired size (4-5mm) and shape (cylindrical). The pellet die was carefully installed within the

pelletizer, ensuring accurate alignment for the production of consistent pellets. The next step

involved the installation of the rollers, which played a crucial role in compacting the material and

forming pellets with the die. Subsequently, the belt and pulley system were integrated into the

machine to ensure the smooth rotation of components and efficient transfer of power within the

system, enabling seamless operation.

Finally, the motor was installed to power both the pulverizer and pelletizer, providing

the necessary energy for their operation. Each step in the construction process was essential in

creating a reliable and functional pulverizer and pelletizer system capable of efficiently

processing raw materials into high-quality pellets for various industrial applications. Overall, the

fabrication and assembly of the machine needed the help of an experienced craftsman. The labor

costs a total of 22,500 pesos.

Testing of the Development of Rice Hull Pulverizer and Pelletizer

 Proceeding the construction and fabrication of the DRHPP, trials and

testing were conducted to observe and record the performance of the machine. In

the initial testing, there were several problems encountered by the researchers thus

the machine undergone several modifications and revisions corresponding to the

needs and problems which arise in the key parts of the machine. And after all of

the considerations and careful adjustments, the researchers came up with a more

functional machine. Thus, the final testing recorded were done using the final

DRHPP design.

Being that the goal of the study is to help in alleviating the problem when

it comes to agricultural waste materials such as rice hulls, which are one of the

contributors of soil and water pollution in the Philippines, the rice hull with

additional additives such as corn, fish meal, molasses oil and water are used to

test the efficiency of the machine. Rice hulls were particularly selected due to its

availability and for the reason that these are the common waste materials from

farms, meanwhile the additives were chosen based from the common ingredients

to make fish feeds.

Initial Testing

After the primary construction of the machine, initial testing was conducted to

observe its performance with regards to its pulverizing and pelleting efficiency for the

selected materials of the study. During the operation, the researchers noticed some defects
that affected the machine's capability to work efficiently. Some of the flaws include the

following:

The researchers detected problems in the DRHPP structural design during

the initial testing phase. The speed of the motor was too fast for the pulverizer and

pelletizer so the researchers decided to put reducers to slow down the motor

speed.

The researchers also discovered that the input was not properly pulverized

due to the rice hulls’ thinness. Thin materials like rice hulls may be more resistant

to fracture and deformation compared to bulkier materials. This resistance made it

harder for the pulverizer blades to efficiently broke down the thin rice hulls into

smaller pieces. As a remedy, the researchers resolved it by adding corn in the rice

hull, creating a mixture. Corns were thicker and denser compared to rice hulls.

When mixed together in the pulverizer, the thicker corn helped in creating a more

effective grinding process. The harder and larger particles of corn acted as

grinding agents for more effective rice hull pulverization.

Lastly, the researchers noticed that the pelletizer can hardly produce a

product. The initial mixture used in the testing was too coarse, hence affected the

compression required to form pellets. As a countermeasure, the researchers

decided to make a new design and consulted another fabricator that knew very

well how to solve this problem. Also, only using water as an additive was not

enough so the researchers decided to use molasses oil as a binding agent.

Final Testing

After careful analysis of the problems that arouse from the initial testing,

the researchers came up with a final design for the study. To begin, the researchers

prepared 500 grams of mixture of corn and rice hull to be used in the final testing,

which will include 5 trials of pulverizing. The trial's results were obtained using a

weighing scale and a timer. Each pulverizer trial uses 100 grams of rice hull and

400 grams of corn combined. The next step was to mix the pulverized output with

the chosen additives that was then used in pelleting. The pelletizer uses 500 grams

of mixture per trial (5 trials). The trial's results were also obtained using a

weighing scale and a timer.

Evaluation of the Organic Waste Shredder and Pelletizer

To obtain the needed information, the researchers conducted five (5) trials

for each raw material based from the chosen category namely; pulverizing

efficiency, pelleting efficiency, and size quality of the pellet. The researchers used

a weighing scale and a timer to acquire the needed result of the trials. Table 3

shows the technical performance of the rice hull pulverizer and pelletizer.

In gathering of the data, the researchers prepared 100 grams of rice hull

and 400 grams of corn that was used in pulverizing. After which, the pulverized
 mixture was weighed to calculate the pulverizing efficiency of the machine using

the formula stated in data analysis. The next step was to prepare and combine 500

grams of pulverized mixture with the additives. The mixture was then put in the

pelletizer, and weighed the pellet output to solve for the pelleting efficiency, by

also using the same formula. Lastly, to determine the size quality of pellet, the

researchers separated the pellets individually according to the desired/common

pellet size which is 10 mm. All pellets that did not passed the required size was

considered losses.

Table 3: Summary of Data During the testing of the Development of Rice Hull Pulverizer

and Pelletizer

Trial Initial Mass Final Mass Pulverizing Efficiency

1 500 grams 463 grams 92.6%

2 500 grams 458 grams 91.6%

3 500 grams 467 grams 93.4%

4 500 grams 462 grams 92.4%

5 500 grams 452 grams 90.4%

Average: 92.08%

Trial Initial Mass Final Mass Pelletizer Efficiency

1 500 grams 470 grams 94%

 2 500 grams 463 grams 92.6%

3 500 grams 468 grams 93.6%

4 500 grams 472 grams 94.4%

5 500 grams 464 grams 92.8%

Average: 93.48%

Trial Total weight of 10- Total weight of Size Quality of pellets

mm pellets output pellets

1 290 grams 470 grams 61.70%

2 285 grams 463 grams 61.56%

3 282 grams 468 grams 60.26%

4 297 grams 472 grams 62.92%

5 294 grams 464 grams 63.36%

Average: 61.96%

Analysis of the Development of Rice Hull Pulverizer and Pelletizer Testing Data

The testing data for the development of rice hull pulverizer and pelletizer

involved conducting trials to assess the efficiency of both processes as well as the

size quality of the pellets produced. In the first set of trials, five experiments were

conducted with 500 grams of input material, resulting in different output weights

ranging from 452 grams to 467 grams. The pulverizing efficiency was calculated
 to be 92.08% based on these results. This indicated that the pulverizer was able to

effectively break down the rice hulls and corns into smaller particles, with a high

level of efficiency.

In the subsequent set of trials, also consisting of five experiments with 500

grams of input mixture, the output weights varied between 463 grams and 472

grams. The pelleting efficiency for this process was determined to be 93.48%.

This demonstrated that the pelletizer was successful in compacting the mixture

into pellets with minimal loss of material during the process.

Lastly, the size quality of the pellets produced was evaluated and found to

be 61.96%. This metric indicates how closely the actual size of the pellets

matched the desired specifications. A size quality percentage of 61.96% suggests

that there may be some variability in the size of the pellets produced, potentially

requiring further adjustments or fine-tuning in the pelletizing process to achieve

more consistent results. Overall, these results provided valuable insights into the

performance of both the rice hull pulverizer and pelletizer, highlighting areas

where improvements can be made to enhance efficiency and consistency in pellet

production.

Return on Investment of Organic Waste Shredder and Pelletizer

Return on Investment is a financial metric that is widely used to measure

the probable gains from an investment as defined by Beattie, A. (2022). It follows

the formula:
 )
❑
ROI= (
Net Return on Investment
Cost of Investment

Where the Net Return on Investment covers the financial savings and

income of the farmers and households who will be using the machine to make

organic fertilizers and fish feeds. While the Cost of Investment is the overall cost

of fabrication and construction of the DRHPP.

The calculated net return on investment of the machine is PHP 27793.00

while the overall cost of the investment is PHP 50207. Using these values, the

ROI of the machine is 55.36% per production. And according to the Social

Finance Incorporated (2021), generally about 7% ROI per year is considered to be

a good return on investment. This figure based from the historical average return

of the S&P 500 has always been used by many investors. S&P 500 is an

abbreviation of Standard and Poor's 500 which is a stock market index in the

United States. Therefore, the DRHPP is economically viable and the machine can

be recommended for use with its high percent ROI.

 Chapter 4

SUMMARY, CONCLUSIONS, AND RECOMMENDATIONS

Summary

The research aimed to develop a machine that has the ability to pulverize

and at the same time, can pelletize rice hulls that can be used for farms and fish

feeds. Hence, Project Developmental Research Design is used as the research

design of the study while applying the Engineering Design Process in the making

of the Development of Rice Hull Pulverizer and Pelletizer.

According to the concepts and expertise of the studies, as well as the

advice and recommendations of the experts and evaluators, the DRHPP was

created and developed. To show how the machine functions, some preliminary

testing was done. It brought to light a number of issues, which the researchers also

dealt with later.

 Thus, a final design was developed by the researchers. For every material utilized

to collect accurate data for the study, the machine underwent five (5) trials.

The salient findings of the study were as follows:

1. The Development of Rice Hull Pulverizer and Pelletizer was designed

to be compact with a motor rating of 3HP.

2. The Development of Rice Hull Pulverizer and Pelletizer was assembled

according to its design.

3. The Development of Rice Hull Pulverizer and Pelletizer has undergone

initial and final testing.

4. The overall pulverizing and pelleting efficiency were 92.08% and

93.48% respectively. Moreover, the size quality of pellet is 61.96%.

5. The DRHPP has a 55.36% per production return on investment per

production.

Conclusions

The following conclusions are drawn after many machines test and

consideration of the study’s data:

1. The Development of Rice Hull Pulverizer and Pelletizer design is

possible.
 2. The Development of Rice Hull Pulverizer and Pelletizer was assembled

as a multi-purpose machine that satisfies the specifications of the design.

3. The test was successful with minor revisions.

4. Its overall performance is considered efficient since the Development of

Rice Hull Pulverizer and Pelletizer has a high pelletized and pulverized efficiency.

5. The Development of Rice Hull Pulverizer and Pelletizer is said to be

economically viable due to a high percentage of return on investment.

Recommendations

Based on the study's results and conclusions, the researchers would like to suggest

the following:

1. The design of the DRHPP may be improved to become more efficient and

functional by considering precisely the clearance and allowances of the pellet die

of the machine.

2.For optimal results, the type of material used for the machine's fabrication and

assembly must be chosen based on its intended use. For example, stainless steel.

3.To make the study even better, a comprehensive testing and assessment of more r

aw materials is required.

4.The machine's goods may be sold as an additional source of income, so take that

into consideration when calculating the net return on investment.

 5. To protect the motor and power transmission system, consider a machine cover.

6. The Development of Rice Hull Pulverizer and Pelletizer is recommended for use

to its end users.

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