BSME 4B
DESIGN AND
DEVELOPMENT OF A
FLAT-DIE TWIN-ROLLER
BIOMASS PELLET
MACHINE MAKER
ME 424 D – Machine Design 2
PRESENTED BY: PRESENTED TO:
Fronda, Alea Bianca C. ENGR. ABE LOR T. MENDOZA
Gonzales, David Anthony B.
Samin, Christalee Ian B.
Santiago, Jay-Em
Santiago, Jester H.
Abstract
This report presents the design and
development of a flat-die twin-roller biomass
pellet machine aimed at producing high-
quality fuel pellets from agricultural and
forestry waste. The machine emphasizes
energy efficiency, durable construction, and
suitability for small to medium-scale
applications. Key features include a flat-die
twin-roller extrusion system, durable
materials for high wear resistance, and an
energy-efficient motor optimized for biomass
compression. Mechanical analysis is
conducted to ensure operational integrity,
performance, and safety.
04 Introduction
Contents 05 Design Requirements
06 Design Process
08 Analysis and Calculations
09 Manufacturing Process
10 Cost Analysis
11 Conclusion
12 Recommendations
INTRODUCTION
The increasing global emphasis on renewable energy
has boosted interest in biomass pellets as an
alternative to fossil fuels. Biomass energy is widely
recognized for its renewability, carbon neutrality,
and potential to create value from agricultural and
forestry residues. Flat-die pellet machines offer a
practical solution for converting these biomass
wastes into dense, energy-rich fuel pellets that can
be used for heating, cooking, and industrial
applications.
These machines stand out for their mechanical
simplicity, affordability, and flexibility, making
them particularly attractive in developing regions
or decentralized energy systems. Compared to
ring-die machines, flat-die models are lighter,
easier to maintain, and more adaptable to varying
feedstock sizes and types. This versatility
enhances their usability across different
geographic and socio-economic settings
Objectives, Scope, and
Importance
OBJECTIVES SCOPE IMPORTANCE
Design an efficient flat-die Processing biomass materials This machine promotes
such as rice husks, sawdust, sustainable energy use by
twin-roller pellet machine
and crop residues. converting waste into valuable
tailored for biomass processing.
biomass pellets. It supports
Use of a flat-die twin-roller decentralized energy
Ensure structural reliability, production, especially in rural or
system for extrusion.
ease of operation, and off-grid areas, and offers an
maintenance. affordable alternative to fossil
Design focused on small-
scale to medium-scale users. fuels. The flat-die twin-roller
Optimize the machine’s output pellet machine empowers local
performance and energy entrepreneurs, reduces biomass
efficiency. waste, and contributes to
environmental conservation.
Functional Standards and Performance
Constraints
Requirements Regulations Requirements
Convert biomass Budget limit: Compliant with Pellet output:
into uniform, dense safety standards for
pellets. 50,000php mechanical and 10–20 kg/hour
electrical devices.
Maintain consistent Compact size;
Power input:
operation with weight: Prioritization of
minimal manual recyclable and eco-
1–2 kW.
intervention. <90 kg friendly materials.
Efficiency:
>85%.
Design Requirements
Design Process
Concept Development
The primary design concept focused on a stationary flat-die mechanism with rotating rollers
to compress biomass through the die holes. This design is proven effective for hard, fibrous
biomass materials and easier to maintain than ring-die systems.
Design Alternatives Final Design Selection
Ring-die pelletizer The flat-die with twin rollers was selected due to its
suitability for variable biomass types, mechanical
simplicity, and proven performance in small-scale fuel
Screw press extruder
pellet applications.
Sketches and Diagrams
CAD layout of flat-die and twin-roller system
Exploded views of main components
hopper
3 H P m o to r
G r a n u l ato r S u b - a s se m b ly
CArt
ta b l e
Flat Die Twin-Roller Pellet Machine
Granulator Sub-assembly
hopper
Roller
f l at d i e
s h a ft
l o w e r c r a n k c a se
upper casing
pl at e
receiver pulley
Transmission
v - b e lt
Driving pulley Receiver pulley
idler pulley
Flange
Roller Roller Sub-Assembly
b ea r i n g
s h a ft Nut
B ea r i n g s h a ft i n g
Circlip
circlip
b ea r i n g
Washer
Receiver pulley
Matrix Sub-Assembly
F l at d i e
s h a ft
Analysis and Calculations
Shaft Motor
Property Value
Material AISI 1020 Steel
Power 3HP = 2237.1 W
Length 351 mm
Diameter 24 mm
Type Solid circular shaft
Operation Continuous
Rational Speed 300 rpm
Analysis and Calculations
Shaft Motor
Torque Calculation
Factor of Safety (AISI 1020 Yield
Torsional Shear Stress Shear Strength ≈ (220 MPa)
Analysis and Calculations
Shaft Motor (Keyway Dimensions)
Property Value
Length (L) 24 mm
Width (w) 8 mm
Height (assumed standard) 7 mm
Type Rectangular parallel key
Torque to Transmit (T) 71.2 Nm
Shaft Diameter (d) 24 mm
Analysis and Calculations
Shaft Motor (Keyway)
Force On the Key Stress on the Key
Analysis and Calculations
Shaft Motor (Keyway)
Recommendation
Use AISI 1045 Steel for the key.
It offers a great balance of strength, wear resistance, and cost.
If you're expecting very high torque shocks or impacts, go with AISI 4140.
Analysis and Calculations
Driving Pulley
Property Value
Motor HP 3 HP
Rotational Speed 300 Rpm
Material AISI 1030
Analysis and Calculations
Driving Pulley Dimensions
Property Value
Hub Diameter 50 mm
Hub Projection 12 mm
Hub thickness 13 mm
Bore 24 mm
Outside Diameter 84 mm
Face Width 16 mm
Groove Angle 34 Degrees
Groove Depth 11 mm
Analysis and Calculations
Shaft Motor to Driving Pulley
Force Transmitted by the Hub Bearing (Crushing)
Shaft to the Pulley Stress
Driving Shaft connected to Driving pulley
Property Value
Motor HP 3 HP
Rotational Speed 300 Rpm
Material AISI 1030
Analysis and Calculations
Driving Pulley and Shaft Dimensions
Property Value
Shaft Length 300 mm
Main Diameter 24mm
Step Diameter 34 mm
Step Length 12 mm
Pulley Position 46mm
Keyway 8 mm wide, 2.5 mm deep
Distance to Pulley Center 46 mm + 5 mm = 51 mm
Torque 71.2
Pulley Load Radius 12 mm (OD/2)
Analysis and Calculations
Shaft Motor to Driving Pulley
Torsional Shear Stress Bending Stress (due to radial pulley
force)
Torsional Shear Stress
M= F x A = 5933 x 46 = 272,918 N mm
Bending stress:
Analysis and Calculations
Shaft Motor to Driving Pulley
Combined Stress (VonMises) Factor of Safety
Analysis and Calculations
Idler Pulley Dimensions & Properties
Property Value
Groove 1 (large) 200 mm OD – connects to driving pulley (V-belt)
Grooves 2 & 3 75 mm OD — connect to receiver pulleys (C-belts)
Face width 46.86 mm
Groove depth 11 mm (for all)
Spacing between small grooves 12 mm
Distance from large to nearest small groove 18.86 mm
Analysis and Calculations
Idler Pulley Dimensions & Properties
Analysis and Calculations
Idler Pulley Bearing
Bearing Setup
Property Value
Bearing OD 40 mm (matches bore)
Bearing ID 17 mm (shaft size)
Bearing width 12 mm
Mounted on shaft with bolt and nut for
retention
Analysis and Calculations
Bolt and Nut Dimension
Bolt and Nut Dimension (Using ISO Standards
Property Value
Nominal Size M16
Thread Pitch 2.00 mm (Coarse)
Thread Length 32 mm or more
Head Type Hex (Standard)
Tensile Strength 800 Mpa
Nut Type M16 Hex Nut (ISO 4302)
Washer M16 Washer (ISO 7089)
Analysis and Calculations
Stress Analysis of the Idler Pulley
Radial Interference Pressure (Press Fit) Hoop Stress in Hub Wall
Analysis and Calculations
Stress Analysis of the Idler Pulley
Factor of Safety Rotational Speed of Idler Pulley
Analysis and Calculations
Receiving Pulley Dimension
Property Value
Outside Diameter 304 mm
Number of Grooves 2
Face Width 28 mm
Hub Inside Diameter 20 mm
Hub Outside Diameter 65 mm
Hub Thickness 17 mm
Analysis and Calculations
Receiving Pulley Dimension
Analysis and Calculations
Receiving Pulley
RPM of Receiving Pulley Torsional Shear Stress in the Hub
T = Torque (686.6 Nm = 686600 N· mm)
Torque on Receiving Pulley ro = Outer radius (65 mm ÷ 2 = 32.5 mm)
Motor Power = 3 hp = 2238 w
J = Polar moment of inertia of a hollow
shaft
Since it is equally shared by 2
grooves
= 686.6 Nm/2 = 343.3 Nm
Analysis and Calculations
Receiving Pulley
Bearing Stress (Contact Stress)
Analysis and Calculations
Calculating the Volume of the Pellet
Calculating the volume of the Pellet
D pellet= Diameter of the pellet = 10 mm = 0.01 m
L pellet= Length of the pellet = 20 mm = 0.02 m
Analysis and Calculations
Calculating the Volume of Pellets Produced per Revolution:
Calculating the Volume of Pellets Produced per Revolution:
Number of die holes = 213
Volume per revolution =
Number of die holes × Volume of a single pellet
Analysis and Calculations
Calculate the Volume of Pellets Produced per Hour:
Calculate the Volume of Pellets Produced per Hour:
Number of revolutions per hour = 31.1 RPM × 60
minutes/hour
= 1866 revolutions/hour Volume per hour =
Volume per revolution × Number of revolutions per
hour
Analysis and Calculations
Calculate the Volume of Pellets Produced per Hour:
Calculate the Mass Output per Hour:
Mass output per hour =
Volume per hour × Bulk density of pelleted
material
1.1Material Selection
Flat-die Rollers Frame
High-carbon alloy Surface-hardened Stainless steel for
steel, heat-treated for steel with sealed corrosion protection.
wear resistance. bearings.
Fabrication Assembly Tools and
Methods Process Equipment Used
Precision CNC CNC machines, TIG
Component fitting
machining for die welder, hand tools,
with alignment jigs.
and rollers. torque wrench, drill
press.
Welding for frame Roller-to-die
assembly. clearance
calibration.
Surface treatments:
galvanization and
powder coating for
durability.
Manufacturing
Process
Material Costs
Component Cost (php)
Stainless Steel Frame 6,000
Roller and Die 10,000
Electric Motor 12,000
Miscellaneous Parts 3,000
Manufacturing Costs
Process Cost (php)
Machining 6,000
Welding 3,000
Total Cost : 40,000 php
Thank you
