Development and Performance Evaluation of an Optimized

Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management,

Detroit, Michigan, USA, August 10 - 14, 2020

© IEOM Society International

Development and Performance Evaluation of an

Optimized Screw type Domestic Oil Expeller

Naquib Mahmud Chowdhury and Faisal Mahmud

Department of Industrial and Production Engineering

Bangladesh University of Engineering and Technology

Dhaka-1000, Bangladesh

[email protected], [email protected]

Abstract

Domestic extraction of oil from different types of seeds and agricultural products is a common practice in many agricultural countries. Consumers depend mostly on local mills to extract the desired oil from different agricultural

products in those countries which involves few difficulties and limitations. Consumer surveys were conducted locally

to identify the related difficulties associated with the oil extraction processes. From consumer surveys, it was identified

that, poor oil extraction efficiency, high power consumption, large space requirements, high purchasing cost and lack

of portability due to increased weight are the most common problems in locally available oil expeller machines. Since

these problems are highly prominent in those available machines, an improved screw type oil expeller machine was

designed for domestic uses considering the consumer requirements. Focusing on the improvement of oil extraction

efficiency (OEE) and elimination of those existing difficulties, few necessary modifications were done while

designing the product using Taguchi design methodology and design of experiments (DOE). Consequently, structural

analysis for different parts of the product based on its operating conditions were performed using ANSYSTM before

developing the product. Finally, the conclusion and scope of improvements are presented.

Keywords Screw Oil Expeller, Oil Extraction Efficiency, Quality Function Deployment, Design Analysis, Design of Experiments

1. Introduction

Oil extraction from different plant sources is a common practice in agricultural countries. There is a wide variety of

oils extracted from different plant sources such as olive oil, palm oil, soybean oil, mustard seed oil, corn oil, peanut

oil and other vegetable oils are used for different purposes in these countries. There is not any convenient and cheaper

solution for the domestic consumers to extract the oil from these sources. As a result, domestic consumers depend

mostly on local mills to extract the oil from their desired sources. For industrial oil extraction, screw oil expeller is

the most widely used machine. Screw oil expeller is a mechanical device which can generate pressure from rotation

of feed to expeller screw manually or automatically. Screw press method for oil extraction is a mechanical method for

extracting oil from raw materials. Extracted oil from screw pressing are used either as a food product or as an industrial

product.

To develop a modified and improved screw oil expeller, we initiated with a customer survey to identify the customer

needs, requirements and drawbacks of existing products in the market. Some major drawbacks of available screw

press expeller were identified from this customer survey which includes poor oil extraction efficiency, heavyweight,

high purchasing cost, difficulties in maintenance and cleaning mechanism etc. After that, quality function deployment

or, QFD analysis was performed to convert those customer needs into technical requirements and prioritization was done accordingly. A functional decomposition using the black-box model was performed subsequently. Both

quantitative and qualitative analysis were accomplished for the selection of material, manufacturing and joining

process followed by the CAD design. In this developed screw expeller, seeds are confined in barrel through a hopper

and extraction of the oil is accomplished by exerting sufficient force on confined seed. The residue of the material

from which oil has been expressed exits from the unit and is known as the cake. The seeds are continuously fed to the

expeller screw which grinds, crushes and presses the oil out as it passes through the machine. A strip heater is

incorporated with the barrel for heating of seeds for better oil extraction efficiency. A design of experiment was

implemented while fabrication to identify the potential factors affecting oil extraction efficiency. By implementing

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structural design simulation, verification of parts used in screw expeller were performed and helped in increasing

overall performance efficiency. Screw shaft is the most vital element of screw expeller as it provides the required

amount of pressure for extracting oil from the raw materials. It is evident from this study that, the failure of screw shaft will result into extra costs which is undesirable. In addition, excess stress, bending, displacement may cause

major overhaul of the press. So, to increase the life of screw press and efficiency of oil extraction, it is necessary to

find exact stress and bending of the screw shafts. The research design and simulation were performed by SolidWorksTM

and FEA (Finite Element Analysis) with ANSYSTM software.

2. Literature Review

Homburg et al. (2015) defined product design as a set of constitutive elements of a product that consumers perceive

and organize as a multidimensional construct comprising the three dimensions of aesthetics, functionality, and

symbolism. Alsyouf et al. (2015) investigated how to assess and improve the performance of products. According to

this study, the main objectives were to assess the products flaws and their causes, analyzed the most critical problems,

suggested and chose the best solution. The main contribution of this paper is to introduce a verified procedure that

combines a variety of tools and methods from different disciplines used in a new context in product design. The paper

suggested four steps in improving product design such as: assess the current performance using fishbone diagram,

Pareto analysis, FTA, RBD, FMECA; identify the stakeholders needs through customer survey; establish target

specification performing QFD and HOQ to translate the stakeholders’ requirements into product technical specification (TS) and testing and final specifications using design of experiments through analysis of variance tool

ANOVA. Many studies have been carried out in mechanical expression of oil from screw based oil expeller.

Srikantha (1980) estimated that, nearly 90% of the total oilseeds produced in India are crushed using mechanical

expression. In that study, mechanical screw presses (oil expellers) used in India had been stated as inefficient since they leave 8 to 14 % of the residual oil in the cake and thus, a large quantity of precious edible oil (about 0.6 million

tons) goes with the cake. Merrikin and Ward (1981) performed a comparison analysis of the commercial and small-

scale expeller units for processing sunflower seeds. They developed hypothetical curves of radial and axial pressure

inside small expellers. Mrema and McNulty (1985) stated mechanical expression of oil from vegetable oilseeds as the

most widely used method for oil extraction. The conventional theory of mechanical oil expression suggests that the

oilseed cells must be ruptured by a combination of physical (crushing) and thermal (cooking) pretreatments before

substantial oil expression can occur. Rosenthal et al. (1996) also stated mechanical screw pressing as the most popular

method of oil separation from vegetable oilseeds in the world. Ali and Watson (2014) performed a comparative

analysis between improved expeller and standard expeller and revealed that optimal operation of the expeller was not

achieved. He also noted that:

The driving mechanism needed improvement as the small worm frequently broke down into pieces.

Energy consumption of the modified expeller was higher when compared to the standard improved expeller.

Absence of any standard specification while manufacturing, were producing substandard oil expellers.

Isobe et al. (1992) developed a screw press based on twin screws and reported an oil recovery of over 93% from

untreated and raw sunflower seed. Singh and Bargale (2000) designed and developed a modified oil expeller based on

a novel principle of single feed, double stage compression to improve the efficiency of oil recovery. Bamgboye and

Adejumo (2008) also developed and modified a screw press for sunflower oil expeller. Modh and Mevada (2011)

designed and made improvement in some components of oil expeller machine and also carried out the thrust ball

bearing analysis and results to compare with analytical results. Deli et al. (2011) studied the effects of physical parameters of a screw press machine on oil yield of N. sativa seeds using a KOMET Screw Oil Expeller. Different

nozzle size, extraction speed and diameter of shaft screw were applied in their study. From their study, they found that

different nozzle size, diameter of shaft screw and rotational speed effects the percentage of oil yield. Moses (2014)

conducted a performance evaluation test to investigate efficiency of oil expeller machine, the effect of kneading

temperature on the oil yield and the extraction losses of the machine. Fakayode and Ajav (2019) developed and

evaluated a screw press moringa oil expeller in terms of oil expression efficiency (OEE), material balance efficiency

(MBE) and expression loss (EL). Four different models were fitted to the output variables.

3. Methodology

Khoo and Ho (1996) defined quality function deployment (QFD) as a planning methodology for translating customer

needs into appropriate product features. In QFD operation, relationship matrices are used to describe the relations

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between different customer needs and design requirements. The best way to transform customer needs into engineering

characteristics for a product or service is quality function deployment (QFD). For obtaining QFD, we identified our

target market those are rural farmers and urban domestic users. We performed a survey on 89 potential consumers for developing consumer needs for our domestic oil expeller through direct questionnaires, online surveys, and interviews.

The customer needs can be summarized into three different categories which is showed by the following table:

Table 1: Customer requirements with preference

High Preference

High oil extraction efficiency

Low power consumption

High durability

Lightweight

Moderate Preference

Easy cleaning mechanism

Easy maintenance

Flexibility

Low Preference

After sales service

Compact design

Touch control mechanism

Converting this customer requirements to design requirements, in order to perform QFD:

Figure 1: House of quality for domestic oil expeller

From house of quality, screw specification, motor specification and material are identified as the three most important

technical requirements for this product. After this, function decomposition was performed followed by black box

analysis and component hierarchy. Feng and Zhang (1999) defined functional decomposition of a product, device or

system as a process of making a complex function simpler by segmenting into parts. Kurtoglu et al. (2008) explained

black box analysis as a method of testing that examines the functionality of a product without peering into its internal

structures or workings.

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Figure 2: Black box analysis for domestic oil expeller

The component hierarchy of domestic oil expeller is given below according to the consisting units for the product:

Figure 3: Component hierarchy for domestic oil expeller

Functional decomposition was carried out for individual units of the product. Functional decomposition for heating

unit of domestic oil expeller is given below:

Figure 4: Functional decomposition for heating unit of domestic oil expeller

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A design of experiment was carried out while fabricating the product. Zhang et al. (2007) defined Taguchi design

technique as a powerful tool for improving productivity during research and development, so that high quality products

can be produced quickly and at low cost. It is applied to plan the experiments. For the improvement of oil extraction efficiency of domestic oil expeller, design of experiment analysis was performed. In depth investigation into the

problem primarily identified four potential factors responsible for lower oil extraction efficiency. The following table

shows the current levels (-) and experimental target levels (+), which are assured to affect oil extraction efficiency.

Table 2: Two levels of four factors

Factors Levels (- or +)

Current value (-) Experimental value (+)

(T) Heating temperature 700 C 900 C

(S) Rotational speed 90 rpm 75 rpm

(P) Pitch diameter 1.8 cm 2.2 cm

(L) Length of screw shaft 36 cm 38 cm

Several experiments with the above four factors, each with two levels, were performed and oil extraction efficiency

were calculated accordingly, as shown in the combinatorial matrix given in the following figure.

Figure 5: Combinatorial matrix for four factors of domestic oil expeller

Once, all the 16 combinations of experiments (or cells) are executed and scores/defects are recorded, column-wise

and row-wise total scores are calculated. For instance, S- column has a total score of 247.1, obtained by adding all the

average readings in that column. The contribution of individual factors are calculated subsequently for performance

evaluation. From the contribution matrix, we have identified the relation between oil extraction efficiency with

individual factors. The contribution matrix for the domestic oil expeller is given below:

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Figure 6: Contribution of individual factors

A full factorial ANOVA for the domestic oil expeller has been performed to identify the main effects and interaction

effects between the design variables.

Table 3: Full factorial ANOVA table

Though, there is not any significant interaction effects between the design parameters, but the main effects of the

design parameters are statistically significant. From analysis, it was found that heating temperature, screw pitch and

rotational speed of the screw shaft have a positive relation with oil extraction efficiency (OEE). The oil extraction

efficiency increases with the increase in heating temperature, screw pitch and rotational speed of screw shaft. On the

other hand, oil extraction efficiency has negative relationship with pitch diameter and decreases with the increase in

pitch diameter.

4 factors

interactions

T S P L TS TP SP TL SL PL TSP TSL TPL SPL TSPL

1 - - - - + + + + + + - - - - + 56.1

2 + - - - - - + - + + + + + - - 61.2

3 - + - - - + - + - + + + - + - 63.7

4 + + - - + - - - - + - - + + + 66.9

5 - - + - + - - + + - + - + + - 64

6 + - + - - + - - + - - + - + + 68.8

7 - + + - - - + + - - - + + - + 70.1

8 + + + - + + + - - - + - - - - 71

9 - - - + + + + - - - - + + + - 61.1

10 + - - + - - + + - - + - - + + 65.9

11 - + - + - + - - + - + - + - + 67.8

12 + + - + + - - + + - - + - - - 72.3

13 - - + + + - - - - + + + - - + 65.9

14 + - + + - + - + - + - - + - - 73.8

15 - + + + - - + - + + - - - + - 71.8

16 + + + + + + + + + + + + + + + 75.5Main and

interaction

contribution

34.9 42.3 45.9 32.3 -10.3 -0.3 -11 6.9 -0.9 -6 -5.9 1.3 4.9 -0.5 -1.9

Cell

Group

Factors 2 factors interacions 3 factors interactionsOutput

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The interaction effects between the parameters for the domestic oil expeller is shown in the figure below:

Figure 7: Interaction effects between parameters for the domestic oil expeller and ANOVA table

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The F value, P value and signal to noise ratios were also calculated subsequently for each individual parameters and

their interactions for performing analysis of variance. While designing the product, these main and interaction effects

between the design parameters were studied with utmost importance. As the interaction effects had not been found as statistically significant, only the main effects for the parameters were considered in designing the final product with

appropriate dimensions and measurements.

The CAD design using SolidWorksTM for individual parts and components of domestic oil expeller are given below:

Table 4: CAD design of different components of domestic oil expeller

Part CAD Design Part CAD Design

Hopper

Material Flow Channel

Valve

Motor

Gear 1

Gear 2

Cage Barrel

Shaft Screw

Choke

Strip Heater

Box Cover

Stand

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Gear, Screw Shaft and

Motor Sub-Assembly

Final CAD Assembly

The structural analysis using ANSYSTM for different components of domestic oil expeller has been carried out for

identifying the critical stress areas.

Figure 8: Stress analysis for screw shaft

Figure 9: Stress Analysis for gear and screw shaft assembly

Figure 10: Stress analysis for cage barrel

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Table 5: Performance analysis of domestic oil expeller

Parameter Conventional oil expeller Modified domestic oil expeller

Average power consumption/1kg seed 900W 660W

Availability of usage versatility Yes Yes

Oil extraction efficiency(Rapeseed) 73% 75.5%

Oil residue in cake/wastage(Rapeseed) 27% 24.5%

Average weight 35 kg 10.5 kg

Average dimension 1.6m*0.9m*1.2m 0.5m*0.25m*0.35m

Design flexibility No Yes

Portability No Yes

4. Conclusion

The scarcity of cost effective and efficient options for domestic oil extraction is very prominent in agricultural

countries. Modified domestic oil expeller offers a perfect solution for this specific problems. The steps of product design from customer surveys to the manufacturing processes were strictly followed. Design of experiment analysis

using Taguchi design method was performed for improving design parameters. Subsequently, the domestic oil expeller

was tested against different parameters and it was observed through the results that screw shaft length, pitch diameter,

heating temperature and rotational speed have a significant impact oil extraction efficiency. However, the design is

effective for only domestic uses. It needs to be refined and amended to increase its output for usage in industrial

sectors effectively. We can also explore the quality (e.g. density, viscosity etc.) of extracted oil and perform

comparative analysis. These can be scopes of future studies in this field. So, by removing existing limitations, domestic

oil expeller can be an attractive and efficient solution for domestic customers of all sectors inhabiting in both urban

and rural areas.

Acknowledgements

This study has been done under fully cooperation and resources of Department of Industrial and Production

Engineering, Bangladesh University of Engineering and Technology (BUET). The authors express gratitude for all

the efforts and cooperation to complete the research.

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Biographies

Naquib Mahmud Chowdhury is a novice researcher and a final year undergraduate student from the Department of

Industrial & Production Engineering of Bangladesh University of Engineering and Technology. His research interest

includes manufacturing process, supply chain management, total quality management, artificial intelligence and

machine learning.

Faisal Mahmud is a novice researcher. He is currently a final year undergraduate student from the Department of

Industrial and Production Engineering of Bangladesh University of Engineering and Technology (BUET). He is

interested in research topics like uncertainty modeling, reliability analysis, stochastic process, supply chain

management etc. He has published one conference paper on a case study of maintenance availability of pharmaceutical

industry.

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Documents

Development and Performance Evaluation of an Optimized