universiti putra malaysiapsasir.upm.edu.my/id/eprint/42283/1/fk 2011 85r.pdfuniversiti putra...
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UNIVERSITI PUTRA MALAYSIA
PUA MING YEE
FK 2011 85
DESIGN AND DEVELOPMENT OF PINEAPPLE ROLL TART MAKING MACHINE
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DESIGN AND DEVELOPMENT OF PINEAPPLE ROLL TART MAKING
MACHINE
By
PUA MING YEE
Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia,
in Fulfilment of the Requirements for the Degree of Master of Science
June 2011
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Specially dedicated to…
My loving parents…
My wonderful siblings…
My friends…
For their support and encouragement…
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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfilment of
the requirements for the Degree of Master of Science
DESIGN AND DEVELOPMENT OF A PINEAPPLE ROLLED TART MAKING
MACHINE
By
PUA MING YEE
MAY 2011
Chairman: Rosnah Shamsuddin, PhD
Faculty: Engineering
Majority of pineapple rolled tarts are produced manually. Production is therefore slow
and supply is unable to meet the market demand. A rolled tart making machine is
essential for the efficient mass production of pineapple rolled tart. A machine that
would reduce processing time, labour, and operating cost and at the same time,
affordable for small-scale industries, was designed. Since food properties are varying
with time, prior to design processes, effect of dough and jam formulations on its
properties and kinetic studies of jam were studied. Effects of pineapple bakery jams
with different sugar compositions (0% to 33.3%) were evaluated at ambient temperature
based on total soluble solid (TSS), pH, viscosity, and moisture content. Simultaneously,
effects of different butter (23% to 45%), sugar (0% to 20%) and corn flour (0% to 15%)
compositions on hardness and stickiness of pineapple tart short dough were determined.
There were significantly increased (p< 0.05) in total soluble solids (TSS), viscosity, and
moisture content of jams at different sugar percentages, but no significant changes in
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pH were observed. In textural analytical test, significant changes (p< 0.05) in hardness
and stickiness of pineapple tart short dough with different compositions of butter, sugar,
and corn flour were found. Cooking rate of pineapple bakery jam was investigated and
the effects of cooking temperature (70°C to 100°C), stirring speed (20 rpm to 100 rpm)
and batch volume (2 to 6 liters) on rate constant were examined. The linear relationship
between the logarithmic total soluble solids gain ratios of cooked jam and the cooking
time showed that the cooking rate followed the equation of first-order chemical reaction.
The cooking rates increased with cooking temperature and stirring speed, but decreased
with increasing batch volume. The activation energy of cooking process was 42.49
kJ/mol. Present investigation of cooking rate constant will be useful in designing more
efficient jam cookers with higher ratio of effective heating surface to batch volume of
fruit pulp.
Engineering design processes were carried out to develop the conceptual designs, which
were generated with Computer Aided Design (CAD) software and evaluated based on
customers’ requirements. The basic decision matrix was used as a decision making tool
for selecting the best design. The fabricated machine was tested at different screw
rotating speeds and dough formulations. The rolled tart throughput rates increased
significantly (p
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mouth feel. The maximum and minimum rates for the standard dough formula were
4320 pieces per hour and 720 pieces per hour, respectively. The operating costs of
making tarts using the machine with the highest rate were reduced by 92.05%,
compared to the manual method. This machine achieved the objectives of research
which can produce tarts at high rate, low operating and labour costs and affordable for
small scale industries. This research provided the guideline how to manipulate the
dough and jam formulation, and simple way to determine the end point of jam cooking.
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Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai
memenuhi keperluan untuk Ijazah Master Sains
REKAAN DAN PEMBANGUNAN MESIN NANAS TART GULUNG
By
PUA MING YEE
MAY 2011
Pengerusi: Rosnah Shamsuddin, PhD
Fakulti: Kejuruteraan
Majoriti nanas tart gulung yang dihasilkan secara manual. Produktivitinya adalah sangat
rendah dan tidak dapat memenuhi permintaan pasaran. Sebuah mesin untuk membuat
tart gulung sangat penting dalam pengeluaran nanas tart gulung. Sebuah mesin
direkakan untuk mengurangkan masa pemprosesan, kos tenaga kerja dan kos operasi. Ia
juga sesuai untuk industri kecil. Sifat makanan adalah berbeza-beza dengan masa.
Sebelum proses rekabentuk dijalankan, kesan ramuan adunan dan jem ke atas sifatnya
dan kinetik masakan jem dikaji. Pengaruh komposisi gula (0%-33.3%) terhadap jem
nanas diuji pada suhu bilik berdasarkan jumlah pepejal terlarut (TSS), kepekatan, pH
dan kadar air. Secara bersamaan, kesan komposisi gula (0%-20% ), mentega (23%-45%)
dan tepung jagung (0%-15%) terhadap kekerasan dan kelekitan adunan ditentukan.
Terdapat perubahan yang signifikan (p
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kelekitan adunan dijumpai dengan komposisi yang berbeza mentega, gula dan tepung
jagung. Kadar masakan jem nanas telah dikajikan dengan pengaruh suhu memasak
(70°C-100°C), kelajuan pengadukan (20rpm-100rpm) dan isipadu bac (2-6liter)
diperiksa. Hubungan linear antara logaritma jumlah pepejal nisbah dan masa memasak
menunjukkan bahawa tahap memasak mengikut persamaan reaksi kimia tertib pertama.
Kadar masakan jem meningkat dengan suhu dan kelajuan pengadukan, tapi menurun
dengan isipadu bac. Tenaga pengaktifan proses memasak adalah 42.49 kJ / mol.
Penyelidikan masakan jem berguna dalam mereka bentuk periuk yang memasak jem
dengen lebih efisien and efektif. Kejuruteraan proses rekaan dilakukan untuk
mengembangkan rekaan konseptual. Rekaan konseptual yang dihasilkan dengan
Computer Aided Design (CAD) perisian dan ia dinilai berdasarkan keperluan pelanggan.
Keputusan dasar matriks digunakan sebagai alat untuk memilih rekaan terbaik. Mesin
itu telah diuji pada kelajuan skru berputar dan formulasi adunan yang berbeza.
Pengeluaran tart gulung meningkat secara signifikan (p
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dengan kadar yang tinggi, kos operasi and kos buruh yang rendah, dan ia adalah
munasabah untuk industri skala kecil. Kajian ini menyediakan garis panduan mengenai
bagaimana untuk memanipulasi doh dan penggubalan jem, dan cara mudah untuk
menentukan titik akhir masakan jem.
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ACKNOWLEDGEMENTS
I would like to express my gratitude to the members of my supervisory committee, Dr.
Rosnah Shamsuddin (Chairman), Associate Prof. Ir Dr. Johari Endan and En. Azman
Hamzah, for their guidance, constructive comments and assistance during my study. My
sincere appreciation goes to all the staff members of the Department of Process and
Food Engineering and to all of my friends for their support. My deepest gratitude goes
to my loving family and my siblings for their unfailing support.
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I certify that a Thesis Examination Committee has met on 28 June 2011 to conduct the
final examination of Pua Ming Yee on his thesis entitled “Design and Development of
A Pineapple Rolled Tart Making Machine” in accordance with the Universities and
University Colleges Act 1971 and the Constitution of the Universiti Putra Malaysia
[P.U.(A) 106] 15 March 1998. The Committee recommends that the student be awarded
the Master of Science.
Members of the Thesis Examination Committee were as follows:
Mohd Nordin Ibrahim, PhD
Associate Professor
Faculty of Engineering
Universiti Putra Malaysia
(Chairman)
Siti Mazlina Mustapa Kamal, PhD
Associate Professor
Faculty of Engineering
Universiti Putra Malaysia
(Internal Examiner)
Farah Saleena Taip, PhD
Associate Professor
Faculty of Engineering
Universiti Putra Malaysia
(Internal Examiner)
Ir Ibni Hajar Rukunuddin, PhD
Professor
Faculty of Engineering
Universiti Malaysia Perlis
(External Examiner)
SHAMSUDDIN SULAIMAN, PhD
Professor and Deputy Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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This thesis was submitted to the Senate of Universiti Putra Malaysia and has been
accepted as fulfillment of the requirement for the degree of Master of Science. The
members of the Supervisory Committee were as follows:
Rosnah Shamsuddin, PhD
Senior Lecturer
Faculty of Engineering
Universiti Putra Malaysia
(Chairman)
Ir Johari Endan, PhD
Associate Professor
Faculty of Engineering
Universiti Putra Malaysia
(Member)
Azman Hamzah
Senior Research Officer
Mechanisation and Automation Research Centre
MARDI
(Member)
HASANAH MOHD GHAZALI, PhD
Professor and Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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DECLARATION
I declare that the thesis is my original work except for the quotations and citations
which have been duly acknowledged. I also declare that it has not been previously, and
is not concurrently, submitted for any other degree at Universiti Putra Malaysia or other
institutions.
PUA MING YEE
Date:
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TABLE OF CONTENTS
Page
DEDICATION ii
ABSTRACT iii
ABSTRAK vi
ACKNOWLEDGEMENTS ix
APPROVAL x
DECLARATION xii
LIST OF TABLES xvii
LIST OF FIGURES xviii
LIST OF ABBREVIATIONS xxii
CHAPTER
1 INTRODUCTION 1
1.1 Pineapple Tart 1
1.1.1 Pineapple 2
1.1.1.1 Composition of Fruit 3
1.1.2 Jam 3
1.2 Machine Design 4
1.3 Procedure of Making Pineapple Rolled Tart 4
1.4 Problem Statements 7
1.5 Scope of the Project 8
1.6 Objectives 9
2 LITERATURE REVIEW 10
2.1 Introduction 10
2.2 History of the Biscuit Industry 10
2.3 Definition and Classification of Biscuit 11
2.3.1 Types of Biscuit Dough 12
2.4 Review of Dough Ingredients 13
2.4.1 Fat 13
2.4.2 Protein 14
2.4.3 Water 15
2.4.4 Sugar 15
2.5 Pineapple Jam 16
2.5.1 Jam Boiling 16
2.5.2 Sucrose in Jam 17
2.6 Kinetic Reaction Rate 19
2.6.1 Theory of Kinetic Studies 20
2.7 Physical Properties of Food 21
2.7.1 Dough Consistency 21
2.7.2 Texture 22
2.8 Biscuit Making Processes 23
2.8.1 Primary Processes 23
2.8.2 Secondary Processes 24
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2.9 Unit Operation of Machine 24
2.9.1 Sheeters and Gauging Rolls and Laminating Equipment 24
2.9.2 Cookie Forming Equipment 25
2.9.3 Types of Extruder 25
2.9.3.1 Screw Extruder Basic Components 26
2.9.3.2 Flows of the Screw Extruder 27
2.10 Type of Existing Rolled Tart Making Devices 28
2.11 Life of a Product 28
2.12 Design Process 29
2.12.1 Conceptual Design 30
2.12.2 Definition of Function 31
2.12.3 Selection Design 32
2.12.4 Performance Evaluation 34
2.14 Summary 34
3 EFFECT OF PRINCIPAL INGREDIENTS ON CHARACTERISTIC OF
THE PINEAPPLE BAKERY JAM AND PINEAPPLE TART SHORT
DOUGH 35
3.1 Introduction 35
3.2 Materials and Methods 36
3.2.1 Preparation of dough 37
3.2.1.1 Textural Measurement of Dough 38
3.2.2 Preparation of Pineapple Jam 40
3.2.2.1 Total Soluble Solids (TSS) 41
3.2.2.2 pH 41
3.2.2.3 Viscosity 41
3.2.2.4 Moisture Content 42
3.3 Statistical Analysis 42
3.4 Results and Discussions 42
3.4.1 Textural Analysis 43
3.4.1.1 Effect of Butter Concentration 44
3.4.1.2 Effect of Sugar Concentration 46
3.4.1.3 Effect of Corn Flour 48
3.4.2 Pineapple Bakery Jam Properties 50
3.4.2.1 Total Soluble Solids (TSS) 50
3.4.2.2 pH 51
3.4.2.3 Viscosity 52
3.4.2.4 Moisture Content 54
3.5 Summary 56
4 KINETIC STUDIES ON COOKING OF PINEAPPLE JAM 58
4.1 Introduction 58
4.2 Theory 59
4.3 Materials and Methods 61
4.3.1 Preparation of Jam 61
4.3.2 Total Soluble Solids (TSS) 63
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4.4 Results and Discussions 63
4.4.1 Cooking Rate Curve of Jam 63
4.4.2 Effect of Temperature on Kinetic Rate Constant 65
4.4.3 Effect of Stirring Speed on Kinetic Rate Constant 68
4.4.4 Effect of Batch Volume on Kinetic Rate Constant 72
4.5 Summary 75
5 CONCEPTUAL DESIGN AND DEVELOPMENT OF PINEAPPLE
ROLLED TART MACHINE 77
5.1 Introduction 77
5.2 Methods of Design Process 78
5.3 Specification 79
5.4 Conceptual Designs 81
5.4.1 Understanding the Function of Existing Devices 82
5.4.1.1 Function of Existing Dough Forming Mechanism 82
5.4.1.2 Function of Existing Feeding Mechanism 84
5.3.3.3 Function of Existing Cutting Mechanism 85
5.4.2 Conceptual Designs Development 86
5.4.2.1 Conceptual Designs of Dough Forming Mechanism 86
5.4.2.2 Conceptual Designs of Feeding Mechanism 89
5.4.2.3 Conceptual Designs of Cutting Mechanism 90
5. 5 Concept Evaluation and Selection 91
5. 5.1 Evaluation Based On a Basic Decision Matrix 91
5.6 Results and Discussions 92
5.6.1 Comparison of Alternative Designs 93
5.6.1.1 Design Criteria of Materials Flow 95
5.6.1.2 Design Criteria of Operational Steps, Easy To Control
and Operate 95
5.6.1.3 Design Criteria of Easy To Maintain, Clean, Install
and Disassemble 96
5.6.2 Alternative Designs of Feeding Mechanism 96
5.6.3 Alternative Designs of Cutting Mechanism 97
5.6.4 Comparison of Selected Conceptual Designs and Existing
Mechanisms 98
5.6.5 Dimensions Determination 101
5.6.6 Materials Selection 102
5.6.7 Assembly Drawing 103
5.7 Summary 103
6 FABRICATION AND PERFORMANCE ANALYSIS OF PINEAPPLE
ROLLED TART MACHINE 104
6.1 Introduction 104
6.2 Methods 104
6.2.1 Performance Analysis 105
6.2.2 Textural Measurement 106
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6.2.3 Operating Cost Estimation 106
6.3 Results and Discussions of Fabricated Machine 106
6.3.1 Construction and Structure of Screw Co-extrusion 107
6.3.2 Assembly of Fabricated Machine 107
6.3.3 Die (Nozzle Horn) 110
6.3.4 Barrels 112
6.3.4.1 Adhesive Wear of Thrust Bearing 113
6.3.5 Hoppers with Pneumatic Cylinder 114
6.3.6 Screws 115
6.3.7 Cutter with Pneumatic Cylinder 116
6.3.8 Drive System 117
6.3.8.1 Tension Force of Belt 120
6.3.8.2 Torsional Failure of Flange Coupling 123
6.3.9 Machine Operational 124
6.4 Results and Discussions of Experimental Testing 126
6.4.1 Effect of Dough Formula and Screw Speed 126
6.4.2 Production Rate 130
6.4.3 Textural Analysis 130
6.4.4 Die Pressure 132
6.4.5 Power Consumption of Extrusion 134
6.4.6 Operating Cost 135
6.4.7 Safety Procedure 138
6.5 Summary 138
7 SUMMARY, CONCLUSIONS AND RECOMMENDATIONS FOR
FUTURE RESEARCH 138
7.1 Summary and Conclusions of Research 138
7.2 Recommendations for Future Research 140
BIBLIOGRAPHY 142
APPENDIX 148
BIODATA OF STUDENT 151
LIST OF PUBLICATIONS AND PATENT 152
DESIGN AND DEVELOPMENT OF PINEAPPLE ROLL TART MAKINGMACHINEABSTRACTTABLE OF CONTENTSCHAPTERSBIBLIOGRAPHY