BUTAJIRA POLYTECHNIC COLLEGE

PROJECT TITLE: DESIGN, MODIFY AND CONSTRUCTION OF

HAMMER MILL MACHINE

PREPARED BY:
1. Abel Teshome M.sc MTM
2. Fasil Worku B.sc MT
3. Nahom Nigusse B.sc IAT
4. Abreham Fikadu B.sc IAT
2014 E.C
ACKNOWLEDGEMENTS
First of all we would like to give our grateful thanks for almighty God. Secondly we
gave our thanks for Butajira poly technic college who provide requirements for our
project. In addition to this we also like to give our respectful thanks for Dean Mr.
AbdulWahid Mohammed. Lastly we also like to thanks all technology group
members who supporting us with in all technical, professional and design issues.

Poultry nutrition mill document Page 1

Abstract
The design, construction and performance evaluation of the poultry Nutrition miller
was carried out at Butajira polytechnic college using locally available materials. It
was evaluated and confirmed that the machine can mill up to 400 kg/hr of ingredients.
The Nutrition milling operations in particular is of great importance, since milling is
the means through which two or more ingredients that form the Nutrition are
interspersed in space with one another for the purpose of achieving a homogenous
mixture capable of meeting the nutritional requirements of the target livestock,
poultry or aquatic life being raised. The cost of design and construction of the
machine is affordable to the small and medium enterprises, although this machine has
been designed with high standard in mind, there is however possibility of human
error, therefore, any criticism regarding to the enhancement of the outlook and
general performance of the machine is accepted.

Poultry nutrition mill document Page 2

Table of Contents
ACKNOWLEDGEMENTS

0
Abstract 1
CHAPTER ONE

5
1.1 Background of the Study 5
1.2 Statement of problem 7
1.3. Objective of the project 7
1.3.1 This project has the following specific objectives

8
1.4. Significance of the project 8
1.5. Scope of the project 10
1.6. Limitation of the project 10
Cost Effective:

10
Increase in Productivity:

10
Poverty Reduction and Job Creation:

10
Usage and Observation by Local Fabricators:

10
Decrease in Joblessness

11

Poultry nutrition mill document Page 3

 Inspire direct as well as Indirect Investment:

11
Economic Improvement and Industrial development:

11
CHAPTER TWO

12
2.0 LITERATURE REVIEW 12
2.1. A REVIEW ON GRAIN PROCESSING 12
2.2 History of Hammer Mill 13
Developing a Screen less Hammer Mill

14
2.3 What is a Mill? 14
GRAIN PROCESSING EQUIPMENTS

16
Low Speed mill

16
Medium Speed mill

17
Vertical spindle roller mill

17
2.4 Hammer Mill utilization in Ethiopia 19
CHAPTER THREE

21
3.0 METHODOLOGY 21
3.1 POULTRY NUTRITION MILLING MACHINE DESIGN ANALYSIS 21

Poultry nutrition mill document Page 4

 THE EFFECT OF FEED PARTICLE SIZE ON THE DIGESTIVE SYSTEM 24
OPTIMAL FEED PARTICLE SIZE 24
SELECTIVE EATING BY BIRDS

25
Concept Generation 33
Hammer Mill 33
3.2. MANUFACTURING METHODS 34
3.2.1 Materials and Methods

34
3.2.2 LIST OF PARTS

34
Functional Description 36
Safety Considerations 38
Addressing Potential Hazards: 38
3.3 DESIGN CONSIDERATIONS. 39
Determination of the Shaft Speed

39
3.4 Testing Procedures of the performance evaluation 42
CHAPTER FOUR

43
4.1 Manufacturing process 43
Shafts Design Consideration 43
Types of manufacturing techniques implemented 44
Cutting process 44
Shearing 44
Machining process 44
Turning 44
Facing 44
Drilling 45

Poultry nutrition mill document Page 5

 Welding process 45
Fabrication process 45
4.2. Steps for manufacturing of different parts 45
Limits, Fits and Tolerances 45
4.3 cost estimation 46
I. Useful life time of each fixed asset 47
II. Brief description capacity of the project per month 48
ORGANIZATION AND MANAGEMENT PLAN

48
ORGANIZATIONAL STAFF COST

48
ADMINISTRATIVE EXPENSES

49
FINANCIAL PLAN

49
Sources of funding 49
CAPITAL REQUIREMENT

50
Chapter five

50
RESULTS AND DISCUSSION

50
Chemical Analysis: 51
Impact energy required:- 51
Impact bending stress: 52
Impact energy required: 52
Fineness 52
CHAPTER SIX

54
5.0 CONCLUSION AND RECOMMENDATION 54
5.1 CONCLUSION 54

Poultry nutrition mill document Page 6

5.2 Recommendation

55
References

55

Poultry nutrition mill document Page 7

 CHAPTER ONE
1.0 Introduction

1.1 Background of the Study

Most poultry nutrition substances have its origin in plants, although some foods are
obtained directly from plants and others from animal. But even animals that are used
as food sources are raised by Nutrition food which are derived from plants. Grains
have been cultivated for thousands of years and they’ve been a major component of
the human diet. Additionally, any food made from wheat, rice, oats, cornmeal, barley
or another cereal is a grain product. These refined grain products are used in the
making of bread, pasta, oatmeal, breakfast cereals, and grits. Cereal grain is a staple
food that provides more food energy worldwide than any other type of crop. Corn
(maize), wheat, and rice – in all of their varieties – account for 87% of all grain
production worldwide "Production STAT". 2008. The various types of grains include
the following including wheat, oats, rice, corn (maize), barley, sorghum, rye, and
millet. Grains are defined as a small, hard, dry seeds, with or without its fruit layers,
harvested for human or animal consumption. Babcock, P. G., ed. 1976. The two main
types of commercial grain crops are cereals such as wheat and rice, and legumes such
as beans and soybeans. After being harvested, dry grains are more durable than other
staple foods such as starchy fruits (plantains, breadfruit, etc.) and tubers (sweet
potatoes, cassava, and more). Hence this durability has made grains well suited to
industrial agriculture, since they can be mechanically harvested, transported by rail or
ship, stored for long periods in silos, and milled for flour.
Why process grains?
In layman’s language, processing refers to the act of converting any material from
one form to another. In agriculture, crop processing machinery is used to transform
grains and other produce from their raw form to the refined and edible form. Crop
processing also aims at preparing crops for convenient transportation, storage, and
also for market and Nutrition ing to livestock. Based on latest technologies, these
machines not only reduce time of operation but also save the labor cost. It has been
observed that grains tend to last from season to season, hence we can’t digest them
raw. Grains must be flaked, cracked, puffed, popped or grounded before being

Poultry nutrition mill document Page 8

consumed. And with the usage of mechanical devices in crop processing it reduces
the quantity of the wastage to a greater degree.
There are various reasons why grains need to be processed. One of which is that it
adds value to the grain which results in the development of new products or the
improvement of existing ones. Processing allows grain to be mixed with supplements,
thereby increasing its digestibility, and affects its palatability, digestion and passage
rates. Hence there is a high demand for grains to processed. Also in a developing
country like Ethiopia where most raw materials and finished flour product is being
imported due to the unavailability of refined grained products, this lead to inflation of
the price of similar food product that depends strictly on refined grain produce. hence
the need for such grains to be cultivated and processed locally so as to reduce the cost
food products.
One of the major type of processed grain that is widely used in our present society is
flour. Flour is a powder made by grinding uncooked cereal grains or other seeds or
roots (like cassava). It is the main ingredient of bread, which is a staple food for many
cultures, making the availability of adequate supplies of flour a major economic and
political issue at various times throughout history. Wheat flour is one of the most
important ingredients in Ethiopia and other various North African cultures, it is the
defining ingredient in their styles of breads and pastries.
Ethiopia is an important market for grains with a big population. Its government is
moving to achieve greater levels of self-sufficiency. Ethiopia is a huge export market
for wheat with a very high demand for wheat flour for the production of bread,
noodles, pasta, crackers and biscuits (cookies) etc. Hence, the processing of grains is
one of the most important processing activities that need to be carried out in the
agricultural sector of Ethiopia. This will in turn help to boost the nation economy and
serves as an avenue for job creation. This will in turn influence the prices of some
processed food which requires grains as one of its major constituent.

1.2 Statement of problem

In Ethiopia today despite the giant strides in modernization other areas still remain
quite backwards in its production and food processing industries. There’s a high
demand for the supply of wheat-based food, the cassava flour import has increased

Poultry nutrition mill document Page 9

over the years and with present state of the economy there is a steady rise in cost of
such refined grain products. Hence this has resulted to the emerging need for these
refined grain products such as flour to be produced locally.
There are various traditional or indigenous way of processing grains in our rural
areas, one of which is, by pounding the dried grains in a mortar with a pestle and
sieving it with a screen, but this can no longer meet the demand for the refined grain
flour. Although there have been some mechanized methods adopted by small scale
farmer and food processing unit, but this method has proven to be time and energy
consuming and does not result in high quality grade produce and are bulky and
therefore avoided by the indigenous manufacturers. Some of these machines only
provide on function, either grinding or sieving, therefore are not feasible, since some
part of the process still needs to be carried out manually.
Also, the existing mills such as the attrition mill, the hammer mill used by some
industries show some inefficiency. Such inefficiencies are:
I. Inability to produce uniform grind of the refined grain flour.
II. Time taken to crush material to the size of the screen as in the hammer
mill.
III. Contamination of refined grain flour due to multi-purpose nature of the
mill, particularly in non-specialized production processes

To solve this problem a machine is needed that can process the major function of
grinding, sieving and storage. It has to be affordable and reasonably small in size, to
allow use by average indigenous farmers in grain processing. Without these,
unrefined grains will have little value in the commodity market.

1.3. Objective of the project

The main objective of this project is to design and fabricate a modified milling
machine which combines both impact and shearing milling action coupled with a
pneumatic conveying and clarifying action. The combined action is intended to lead
to efficient milling of grains into fine powder. Unlike the normal hammer mill, it does
not use a screen classifier; rather it employs air classifier in which the fine product is
carried in the air-stream through the blower’s chamber. Also, less time is required for
pulverization and due to the air-tight nature, dust spillage is minimized. The air

Poultry nutrition mill document Page 10

circulating in the machine helps to cool the processed flour which improves the
Quality of the flour produced.

1.3.1 This project has the following specific objectives

To develop a compact and portable in size allowing for easy transportation
and less installation space.
To design a poultry miller, which will be cost effective, and reasonably
affordably.
To fabricate a mill which will be easy to operate and maintain
incorporated to vibration and noise.
To design a poultry miller which will reduce the time of production and
easy to operate and maintain.
To develop a fully integrated machine which will be able to poultry miller
various grains and transport them to a storing unit for further processing
and packaging.
To develop a compact and portable in size allowing for easy transportation
and less installation space.
To design a mill, which will be cost effective, and reasonably affordably.
To fabricate a mill which will be easy to operate and maintain
incorporated to vibration and noise.
To design a mill which will reduce the time of production and easy to
operate and maintain.
To increase productivity of MSE’s income in butajira area.
Mainly for every TVET institution, small and macro enterprises with low
cost.
To operate by any labor with low maintenance cost, easily repairable
To manufacturing light weight and portable machine.
To increase the quality of the product.

1.4. Significance of the project

Engineering and technological advancement in our society has helped improve the
standard of living in our present day world. Grain processing plays a key role in the
socio-economic development of most east African countries. In Ethiopia refined
grains flour are used for the production of bread, pasta, and biscuits (cookies). This
has contributed to Ethiopia wheat market which was estimated at just over $1 billion
in U.S. import as of 2010. Also the Demand for other grains such as corn, sorghum,
millet is also very high but, there is a Production deficit of processed grains locally

Poultry nutrition mill document Page 11

which results to the importation of various refined grains. However, Ethiopia has a
potential to increase its production through the application of improved processing
methods and better marketing (Gourichon H, 2013).
In most food processing industries, Conventional hammer mills that are extensively
employed in the processing of solid minerals and grains suffers from a number of
weaknesses that greatly hamper their productivity, efficiency and effectiveness. These
weaknesses include the following
i. The conventional hammer mill cannot produce materials whose particle size is
less than 400µm. For the most commonly processed food minerals like grains,
tubers, cassava, etc.
ii. The particle sizes produced are relatively large and they cannot be directly
used for processing grains as flour to make bread, biscuit and foo-foo for local
consumption [Beintema and Stads, 2004], [Eyo, 2008].
iii. The fineness of the particles produced depend on the hole size of the screen
sieve employed. Large particles can block the holes of the sieve screen
thereby, reducing the output of the hammer mill.
iv. To maintain the output, the screen sieves are continuously changed. Hence, it
requires the acquisition of a lot of expensive accessories which cannot be
produced locally.
v. Excessive dust particles are usually released into the atmosphere where
hammer mills are operating. This constitutes a health hazard for the human
operators and environmental pollution for the surrounding plants, animals and
human communities.

The defects and shortcoming of currently used hammer mills have meant that most
hammer mill operators and owners in Ethiopia are running their business at marginal
profit levels. This is because virtually all the hammer mills being utilized are of old
designs and pulverization is not achieved in these systems.
Since Poultry Nutrition mill is basic equipment in poultry farm industry, and which
involves increasing the productivity of the farm.
The Beneficiaries form this project the following parties are come in to beneficial
Macro and small enterprise
TVET colleges
Farmers

Poultry nutrition mill document Page 12

1.5. Scope of the project
This project will detail the process of manufacturing an integrated mill for grain
processing as carried out by the trainer involved in the project work. It will consider
the steps of manufacturing and possible limitations and draw backs that may arise as a
result of the production and manufacturing processes. It will also consider the design
that should be incorporated into the design of the blower so as to obtain maximum
efficiency during grinding. The mill grinding is basically used for agricultural
application and other various area of manufacturing where the need is of high
importance.

1.6. Limitation of the project

The main constraint in this project can be said to be the availability of necessary
funding. Due to the fact, that this is a manufacturing project, the procurement of raw
materials, metal sheets, motor, blades and other components necessary for the
completion of the machine requires considerable funds.

Benefits of machine

Cost Effective:
It has low as well as reasonable cost. Easy and affordable for small scale poultry
farmers. Besides, it needs slight or no recurrent looking after.

Increase in Productivity:
Productivity increment brings about affluence increase of a nation. Productivity of
poultry farmers drive maximally in bringing about extent of increase in productivity
level of a nation which will rise worth totaling to GDP

Poverty Reduction and Job Creation:

Its assistance in job creation is enormous as seen it its necessitating reduction in the
migration between rural urban.

Usage and Observation by Local Fabricators:

Ever since the machine is invented locally, the procedure drives local producers to
modernize or improve in their construction. Therefore, cumulative the health rural

Poultry nutrition mill document Page 13

Decrease in Joblessness
The decrease of joblessness are those machine fabricators as well as those using the
machine will be the recipients

Inspire direct as well as Indirect Investment:

It drives hastily growth in industrial creation for machine manufacturing as well as
further Nutrition processing projects.
It will likewise intensify speedy growth and development of the nation’s economy.

Economic Improvement and Industrial development:

It will help in economic improvement and industrial development for the reason that
it necessitates the formation of fresh asset culture, affluence establishment as well as
enlarged economic plus social welfare. Entirely, these bring about enhanced
application of Nutrition beforehand to avoid spoiled owing to small shelf life.

Poultry nutrition mill document Page 14

 CHAPTER TWO

2.0 LITERATURE REVIEW

2.1. A REVIEW ON GRAIN PROCESSING
The use of grinding machine is one of the oldest and simplest methods of processing
agricultural raw material alternative to the traditional methods of grain processing
using stone, mortar and pestle. However, in considering the food processing industry,
it has been characterised by a labour and production output shortage due to the lack of
support by the government and the ideology on the pursuit of white collar jobs by
most Ethiopian graduates. Ethiopia now due to the failing of its agricultural sector
now depends on mostly imported refined grains to meet up with the high demand and
shortage of processed food. Although there have been recent developments which has
led to the Mechanization of most field activities in agriculture, and to a certain extent
it has overcome some basic challenges faced by small scale farmers and local food
processing industries. The advancement of science and technology reduces
complexities from many agricultural processes. Modern technologies in area of
irrigation, plantation, harvesting, has made the entire agricultural cycle more
economical and easier than ever. This led to the fabrication of various machineries
such as Nutrition mill, grain dryers, rice huller, winnowing machine, threshing
machine etc. These machines are co Mechanization was not only used to replace
human labour but also increased productivity and the areas covered. Over the years
there have been various modification made on theses equipment so as to increase its
output efficiency and specialization. Thus the development of a mill pulveriser. This
system consists of a conventional hammer mill integrated with a blower and a sieve.
Which aids the pulverization by making only fine grounded grain particles is being
covey through its passage unit and stored.
A mill pulveriser is a modification of a hammer mill that utilizes air flow to separate
various particles. The development of a mill pulveriser incorporates the design of a
hammer mill and a blower. A hammer mill is a type of crusher, which can be used for
grinding rock, forage, grains or other large size particles into smaller pieces by the
repeated blows of little hammers. It is designed to convert larger pieces of material
into smaller particle sizes.

Poultry nutrition mill document Page 15

2.2 History of Hammer Mill
The invention of hammer mill dates back to the 4 th century around Zhao dynasty
period in china (1050 BC -221 BC). The invention, involved conversion of rotary
water wheel energy to linear trip hammer energy. The trip hammer evolved out of the
use of mortar and pestle which in turn gave rise to the tilt-hammer and then trip
hammer device. This device was used in the pounding and polishing of grains, which
help reduce the labour of pounding manually with hands and arms. In Chinese
mythology Fu Hsi was said to have invented the pestle and mortar, which is so useful,
and later on it was cleverly improved in such a way that the whole weight of the body
could be used for treading on the tilt-hammer, thus increasing the efficiency ten
times. Afterwards the power of animals donkeys, mules, oxen, and horses was applied
by means of machinery, and water-power too used for pounding, so that the benefit
was increased a hundredfold. (Caves Books Ltd 1986).
Although Chinese trip hammers in China were sometimes powered by the more
efficient vertical-set waterwheel, the Chinese often employed the horizontal-set
waterwheel in operating trip hammers, along with recumbent hammers. The
recumbent hammer was found in Chinese illustrations by 1313 AD, with the
publishing of Wang Zhen's Nong Shu book on ancient and contemporary (medieval)
metallurgy in China. There were also illustrations of trip hammers in an encyclopedia
of 1637, written by Song Yingxing (1587–1666).
This gave rise to future designs which has evolved over the years. A patent was first
issued in 1830 for a machine with a wooden box containing a cylindrical drum,
revolving at 350 revolutions per minute, on which hammers were attached. The
machine was designed to shatter any rock fed into the box. This machine never went
into commercial production, but is considered as the forerunner to the hammer mill.
The hammer mill has gone on to become the most widely used crusher utilizing high-
velocity impacts to break rocks.
However, while initially designed to crush rocks, the hammer mill was adapted for
grinding grain for livestock Nutrition. It was discovered that many types of forage
benefit in nutritive value after being broken down.

Poultry nutrition mill document Page 16

The Gehl Company produced the first grain grinding hammer mill in the 1920s. It
dominated the market for 30 years, during which time it also developed a portable
truck mounted mill.

Developing a Screen less Hammer Mill

In 1990, Carl Bielenberg of Appropriate Technology International (ATI) began
developing a screenless hammer mill. His prototype separated flour from larger
particles through an opening in the circumference of the grinding chamber. Flour
passed through the opposite side of the rotating blades while the larger pieces
continued inside the chamber.
Initial tests produced a larger, courser material than conventional hammer mills. He
developed a series of improvements, but was incapable of designing a machine that
could perform to the standards of conventional mills. He presented his machine to a
series of MIT students in hopes that they could produce a more successful machine.
An MIT student named Amy Smith headed the project. Her redesigned mill was
capable of running continuously without clogging. It was also capable of being
manufactured in a small village workshop. This second aspect was extremely
important to Smith. After discovering the failings of conventional hammer mills, she
was determined to develop a machine that would be useful for third world countries.
Many African women used the hammer mill to grind grain, but its screen was prone
to breaking. Screens cannot be produced locally and are expensive to replace. So
Smith dedicated her research to “the African women who cannot afford the 5 cents it
takes to mill a kilogram of flour and thus spend hours performing the back-breaking
labour necessary to prepare food for their families. Hence the development of screen
less hammer mill also known as a mill pulveriser

2.3 What is a Mill?

A mill is a device that breaks solid materials into smaller pieces by grinding,
crushing, or cutting. Such comminution is an important unit operation in many
processes. There are many different types of mills and many types of materials
processed in them. Historically mills were powered by hand (e.g., via a hand crank),
working animal (e.g., horse mill), wind (windmill) or water (watermill). Today they
are usually powered by electricity. The grinding of solid matters occurs under

Poultry nutrition mill document Page 17

exposure of mechanical forces that trench the structure by overcoming of the interior
bonding forces. After the grinding the state of the solid is changed: the grain size, the
grain size disposition and the grain shape.
Milling could also be referred to the process of breaking down, separating, sizing, or
classifying aggregate material. For instance, rock crushing or grinding to produce
uniform aggregate size for construction purposes, or separation of rock, soil or
aggregate material for the purposes of structural fill or land reclamation activities.
Grinding may serve the following purposes in engineering:
 Increase of the surface area of a solid
 Manufacturing of a solid with a desired grain size
 Pulping of resources.

For the purpose of our study we will be considering majorly mill pulveriser. This is
the most effect type of mill for achieving high quality refined grains.
A conventional mill pulveriser is a device consisting of a rotating head with free-
swinging hammers, which reduce rock, grains or similarly hard objects to a
predetermined size through a perforated screen [Sci-Tech Dictionary, 2003].
A mill pulveriser commonly known as a screenless hammer mill is like a regular
hammer mills, is used to pound grain. However, rather than a screen, it uses air flow
to separate small particles from larger ones. Conventional hammer mills in poor and
remote areas, such as many parts of Africa, suffer from the problem that screens
break easily, and cannot be easily bought, made or repaired. Thus regular hammer
mills break down and fall into disuse. The screenless hammer mill uses air flow to
separate small particles from larger ones, rather than a screen, and is thus more
reliable. The screenless hammer mill is claimed to be 25% cheaper and much more
energy efficient than regular hammer mills, as well as more reliable.
Hammer mills pulveriser are widely utilized in the agricultural, wood, mining and
chemical industries. The vast majority of Ethiopians live in the rural areas
[Okpala,1990] and are predominantly engaged in agriculture[Anifowoshe,1990].
Ethiopia is blessed with equatorial [Morgan and Moss, 1965], tropical [Clayton,
1958], guinea [Jones, 1963], sudan [Olajire, 1991] and sahel [Pande, et al, 1993]
climatic zones; thus making her suitable for the profitable cultivation and production
of a wide variety of grains [FAOSTAT,2004]. The farmers rely on ancient and

Poultry nutrition mill document Page 18

antiquated methods that are inefficient for storing the grains and processing [Biewar,
1990], [Igbeka and Olumeko, 1996], [Adejumo and Raji, 2007], and thus lead to large
storage losses due to rodents, damp, fungi and natural decay [Agboola, 1992],
[Agridem, 1995]. Furthermore, the grains and other similar farm products in their
unprocessed states are bulky, difficult to transport and fetch very low prices in the
market [Dixon, et al, 2001], [Taylor, et al, 2006]. This is a major cause of poverty
amongst rural farmers [Killick, 1990], [Umoh, 2003] that encourages rural-urban
migration [UNEP, 2006]. Thus, to guarantee access to food [Simon, et al, 2003],
[Sanchez, et al, 2005], reduce rural-urban migration and encourage sustainable
development [Barber, 2003], [Altieri, 2004], the processing of agricultural products
like grains or solid minerals like clays and feldspars into more valuable products by
the use of hammer mills must be encouraged and fostered.
GRAIN PROCESSING EQUIPMENTS
In many countries worldwide, grain processing is of economic importance, producing
flour and cereal from the refined grain. In addition, with success small farming and
micro food processing unit has evolved over the years in developing countries and
utilises the use of some basic equipment’s. Grain processing equipment’s used in
refining grains may be classified by speed, as follows
 Low Speed
 Medium Speed
 High Speed

Low Speed mill

A low speed mill utilizes the principle of impact and attraction. An example of a low
speed mill is the Ball and tube mills. A ball mill is a pulveriser that consists of a
horizontal rotating cylinder, up to three diameters in length, containing a charge of
tumbling or cascading steel balls, pebbles, or rods. A tube mill is a revolving cylinder
of up to five diameters in length used for fine pulverization of ore, rock, and other
such materials; the material, mixed with water, is fed into the chamber from one end,
and passes out the other end as a slurry.
Both types of mill include liners that protect the cylindrical structure of the mill from
wear. Thus the main wear parts in these mills are the balls themselves, and the liners.

Poultry nutrition mill document Page 19

The balls are simply "consumed" by the wear process and must be re-stocked,
whereas the liners must be periodically replaced.
The ball and tube mills are low-speed machines that grind the grain with steel balls in
a rotating horizontal cylinder. Due to its shape, it is called a tube mill and due to use
of grinding balls for crushing, it is called a ball mill, or both terms as a ball tube mill.
The grinding in the ball and tube mill is produced by the rotating quantity of steel
balls by their fall and lift due to tube rotation. The ball charge may occupy one third
to half of the total internal volume of the shell. The significant feature incorporated in
the mills design is its double end operation, each end catering to one elevation of a
boiler. The system facilitated entry of raw grains and exit of pulverized fuel from
same end simultaneously. This helps in reducing the number of installations per unit.

Medium Speed mill

This type of mill consists of two types of rings separated by a series of large balls,
like a thrust bearing. The lower ring rotates, while the upper ring presses down on the
balls via a set of spring and adjuster assemblies, or pressurised rams. The material to
be pulverized is introduced into the centre or side of the pulveriser (depending on the
design). As the lower ring rotates, the balls to orbit between the upper and lower
rings, and balls roll over the bed of grain on the lower ring. The pulverized material is
carried out of the mill by the flow of air moving through it. The size of the pulverized
particles released from the grinding section of the mill is determined by a classifier
separator. If the refined grain is fine enough to be picked up by the air, it is carried
through the classifier. Coarser particles return to be further pulverized.

Vertical spindle roller mill

Similar to the ring and ball mill, the vertical spindle roller mill uses large "tires" to
crush the grain seeds. These mills are usually found mostly in large food processing
plants. Raw grains and minerals are fed through a central Nutrition pipe to the
grinding table where it flows outwardly by centrifugal action and is ground between
the rollers and table. Hot primary air for drying and grain transport enters the wind
box plenum underneath the grinding table and flows upward through a swirl ring
having multiple sloped nozzles surrounding the grinding table. The air mixes with

Poultry nutrition mill document Page 20

and dries grains in the grinding zone and carries pulverized grain particles upward
into a classifier.
Fine pulverized grains exit the outlet section through multiple discharge pipes leading
to the storage unit, while oversized grain particles are rejected and returned to the
grinding zone for further grinding. Pyrites and extraneous dense impurity material fall
through the nozzle ring and are ploughed, by scraper blades attached to the grinding
table, into the pyrites chamber to be removed. Mechanically, the vertical roller mill is
categorized as an applied force mill. There are three grinding roller wheel assemblies
in the mill grinding section, which are mounted on a loading frame via pivot point.
The fixed-axis roller in each roller wheel assembly rotates on a segmentally-lined
grinding table that is supported and driven by a planetary gear reducer direct-coupled
to a motor. The grinding force for grain pulverization is applied by a loading frame.
This frame is connected by vertical tension rods to three hydraulic cylinders secured
to the mill foundation. All forces used in the pulverizing process are transmitted to
the foundation via the gear reducer and loading elements. The pendulum movement
of the roller wheels provides a freedom for wheels to move in a radial direction,
which results in no radial loading against the mill housing during the pulverizing
process.
Depending on the required grain fineness, there are two types of classifier that may be
selected for a vertical roller mill. The dynamic classifier, which consists of a
stationary angled inlet vane assembly surrounding a rotating vane assembly or cage,
is capable of producing micrometre-fine pulverized grain particles with a narrow
particle size distribution. In addition, adjusting the speed of the rotating cage can
easily change the intensity of the centrifugal force field in the classification zone to
achieve grain fineness control real-time to make immediate accommodation for a
change in fuel or boiler load conditions. For the applications where a micrometre-fine
pulverized grain is not necessary, the static classifier, which consists of a cone
equipped with adjustable vanes, is an option at a lower cost since it contains no
moving parts. With adequate mill grinding capacity, a vertical mill equipped with a
static classifier is capable of producing grain fineness up to 99.5% or higher <50
mesh and 80% or higher <200 mesh, while one equipped with a dynamic classifier

Poultry nutrition mill document Page 21

produces refined grain fineness levels of 100% <100 mesh and 95% <200 mesh, or
better.

2.4 Hammer Mill utilization in Ethiopia

These machines were originally designed and manufactured in Britain and the United
States of America in the early 1930’s (Lynch and Rowland, 2005). They were
brought into Ethiopia by the tin mining companies in Jos and were copied by local
artisans. Since then, there have been no significant improvements in their design or
method of operation. The lack of innovation in the areas of design and operating
principles of hammer mills has constituted the greatest hindrance facing the growth of
solid minerals and grains processing industries in Ethiopia. Although it is known that
highly efficient, economical and fast speed models of hammer mills and pulveriser
are being utilized in the chemical, powder, nuclear and food or grain processing
industries, a recent search on the internet revealed that there is no single drawing of
any type, model or prototype available on the web. This implies that manufacturers of
this equipment regard their designs as proprietary. Moreover, there are no published
articles describing the working principles of these new designs. Thus, a successful
growth and development of the solid minerals and grains processing sector of the
Ethiopian economy would depend largely on the design and fabrication of indigenous
machines and equipment [Spangenberg, 2002]. These would be machines and
equipment whose technology, maintenance, replacement, upgrading, efficiency and
reliability are well understood and undertaken locally without the need for minimal
contribution from any foreign expert or technology. This paper reports on the design
and construction of a hammer mill with end suction lift capability and hopes that the
commercialization and widespread application of the device will contribute
significantly to the growth of the grains processing industries in Ethiopia.
The problems experienced by the refined grain production include the following:
(a) Design faults
(b) Construction faults
(c) Difficulty of financing
(d) Operational problems due to incorrect screen size or poor maintenance and

Poultry nutrition mill document Page 22

(e) Organizational problems arising from the differences of approaches and lack of
coordination.
All these aspects need to be taken into account. Therefore, the general design was
based on the process of allowing a strong and durable metallic object inform of
hammers to beat any material that obstruct its way during operation, thereby resulting
into breakage of the material which can also be referred to as size reduction in
comminution operation. This usually occurs in an enclosed chamber called the
crushing chamber. From which it falls through a sieve located directly under the
crushing chamber which is then transported with the aid of a suction compressor fan
which will help to transport the crushed grains into a storage unit. The physical and
mechanical properties of the mineral to be crushed were studied as this would help
immensely in the design of various components of the rotor. The engineering
properties and some other parameters are the main factors considered before design of
the machine.

Poultry nutrition mill document Page 23

 CHAPTER THREE

3.0 METHODOLOGY
3.1 POULTRY NUTRITION MILLING MACHINE DESIGN ANALYSIS
Design is the transformation of concepts and ideas into useful machinery (Bernard et
al., 1999). The procedures in the design and construction of the modified cassava
milling machine are explained. Theoretical design and material selection:
The materials for the construction of the modified cassava milling machine are: the
shaft, pulley, belt, electric motor, the bearing, the mild steel plates, mild steel angle
bars and mild steel cylindrical tube. These materials were selected based on the power
requirement in the milling of dried cassava chips to flour. By mere feeling, it was
found that cassava chips when dried to moisture content of 5% (wb) can be crushed
into powder with the human fingers. Thus, the power required for its milling is low.
Hammer mills for fine pulverizing and disintegration are operated at high speeds. The
rotor shaft may be vertical or horizontal, generally horizontal (Perry and Don, 1998).
The shaft carries hammers, sometimes called beaters. The hammers may be T-shaped
element, bars, or rings fixed or pivoted to the shaft or to disks fixed to the shaft. The
grinding action results from impact and attrition between lumps or particles of the
material being ground, the housing and the grinding elements. It also consists of a
heavy perforated screen (Henderson and Perry, 1982) which can be changed. Though
it is a versatile machine and its hammer wear does not reduce its efficiency, yet the
power requirement is high and it does not produce uniform grind. Common types
available in the industry include the Imp Pulveriser, the Mikro Pulveriser, the Fitz
Mill, etc. Another class of size reduction machines is the Ring roller mills. They are
equipped with rollers that operate against grinding rings (Perry and Don, 1998).
Pressure is applied with heavy springs or by centrifugal force of the rollers against the
ring. Either the ring or the rollers may be stationary. The grinding ring may be in a
vertical or a horizontal position. Ring-roller mills also are referred to as ring roll mills
or roller mills or medium-speed mills. Ring-Roller mills are more energy efficient
than hammer mills. The energy to grind grain to 80% passing 200 mesh was
determined as: hammer mill-22hp/ton; roller mill- 9hp/ton (Luckie and Austin, 1989).
Common types available include the B/W Pulveriser and the Roller Mill. The third

Poultry nutrition mill document Page 24

class available is the Attrition Mills. The disc attrition which is sometimes called the
Burr mill consists of a set of two hard surfaced circular plates pressed together and
rotating with relative motion (Onwualu et al., 2006). Stones are replaced by steel
disks mounting interchange metal or abrasive grinding plates rotating at higher
speeds, thus permitting a much broader range of application. They are used in the
grinding of tough organic materials, such as wood pulp and corn grits (Perry and Don,
1998). Grinding takes place between the plates, which may operate in the vertical or
horizontal plane. The material is fed between the plates and is reduced by crushing
and shear. Though the power requirement is low, operating empty may cause
excessive burr wear and a lot of heat is generated during shearing action. The
objective of this study is the development of a modified milling machine which
combines both an impact and shearing milling action with a pneumatic conveying and
clarifying action. The combined action is intended to lead to lead to efficient milling
of cassava into fine powder. Unlike the normal hammer mill, it does not use a screen
classifier; rather it employs air classifier in which the conceptual design was based on
the principle of design by analysis (Nortion, 2006). The methodology was to
introduce special features into the hammer mill pulveriser so that certain lapses
noticed in the convectional hammer mill are reduced to a bearable level.
It is not enough that investors and engineers be able to develop new technologies and
other products. After they have developed a new product, they must then be able to
manufacture it at a sufficiently low manufacturing cost. Each component part should
be designed so that it can be manufactured at the lowest possible cost. This does not
imply a so-called “cheap” part. It means that the part should be correctly designed
and manufactured. The primary aim is that a part must be designed to be satisfactory
in all ways for its intended purposes. Another aim which is almost as important is to
design a part for the most economical method of manufacturing. This may be
accomplished by considering all feasible manufacturing methods and selecting the
manufacturing method which appears to be most advantageous during the early stages
of the design of a part. Ordinarily the most important consideration in this selection is
the total cost per day. After a manufacturing has been selected, the designer should
keep this manufacturing method in mind as the design progresses. Thus he will tend
to make the design more adaptable to the manufacturing method, and he will obtain

Poultry nutrition mill document Page 25

the best combination of design and manufacturing method. Each different
manufacturing processes uses its own basic principle or principles for imparting
desired shape, accuracy of dimensions, surface smoothness, or a desired property
within the material.
It was observed that, for the mechanization of agriculture in Ethiopia to succeed. It
must be based on indigenous design, development, and manufacture of most of the
required machines and equipment, to ensure their suitability for the crops as well as
for the farmers‟ technical and financial capabilities. The above illustration shows how
theme of our research project was derived. For the United Nation Sustainable
development goals, to be reached, everyone needs to do their part: governments, the
private sector, civil society and people like you, that is why we
are making our contributions, [18] Do you know that the Average Ethiopian Farmer is
still making use of only the same Out-dated Manual Farm Tools - like Cutlass and
Hoe - as their Fore-fathers used since many Centuries ago?
Do you also know that instead of using some Affordable Modern Agricultural
Techniques or Simple Machines; the Farmers in that part of the World Have
Changelessly adhered to various Archaic Agricultural Methods and Practices that
were copied from their Ancestors? In short, their use of these kinds of Archaic and
Out-dated Tools and Techniques, constitutes a very great set-back in the Country's
Food and Agricultural Out-puts.
Investment in agricultural science and technology, generally in the form of research
and extension services, has proved to be highly valuable for improving crop yields
and lessening poverty in developing countries.
Nevertheless, such investments should reflect all the parties‟ needs for knowledge
(World Bank 2007b). There is broad consensus that innovation is critically important
for meeting the challenges race, including the need to improve competitiveness,
sustainability and equality in agriculture.
Agriculture also needs to produce more food for a growing population, using a
limited amount of farmland, while at the same time reducing its greenhouse gas
emissions to avoid worsening climate change. This suggests that agricultural
production needs to use more intensively, which means it must innovate. The benefits
of topic are summarized below [19] Income generation as benefits of poultry; No

Poultry nutrition mill document Page 26

doubt it, poultry farming is a source of generating income. No amount of money
spends in setting up a poultry farm that is waste; you will surely make gain from your
investments.

THE EFFECT OF FEED PARTICLE SIZE ON THE DIGESTIVE SYSTEM

Digestive tract development is influenced by feed particle size. Birds consuming feed
with large particles will develop larger and more muscular gizzards and longer
intestinal tracts. Larger feed particles require more time in the gizzard to grind feed
into smaller particles before they can enter into the small intestine. Larger feed
particles have a longer transit time through the intestine. The length of microvilli in
the intestine is greater, which increases the absorptive surface area, and thereby
positively affects digestibility and nutrient absorption. Some researchers have
speculated that the inclusion of larger feed particles in the diet increases localized
digestive enzyme secretion in the small intestine, which benefits overall nutrient
digestibility.
When the diet is composed of predominately fine particles these smaller feed particles
quickly pass through the gizzard without grinding and pass into the proventriculus.
The result is a small gizzard, enlarged proventriculus and reduced intestine length.
Diets containing excessive levels of fine particles should not be fed.

OPTIMAL FEED PARTICLE SIZE

Feed particle size of the diet plays an important role in regulating the feed intake by
the bird. Optimal feed particle size increases with age with development of the beak,
gizzard and digestive tract. The laying hen has a preference for larger particles, and
the preference grows stronger with age.
For the first six weeks, a starter diet is generally given as a crumble, which is made
by breaking up pellets consisting of fine particles into a crumble size of 1–3 mm.
Crumbled feed is ideal for young chicks because each crumb is a composite of
different constituents of the diet. Continued provision of crumbs beyond the starter
diet reduces the length of the small intestine and size of the gizzard.
After the starter diet, a well textured mash (meal) diet is preferred. This ensures
proper development of the digestive tract. Well textured mash (meal) diet has 55–
85% of the feed particles between 1 and 3mm in diameter, with an approximate

Poultry nutrition mill document Page 27

Geometric Mean Diameter (GMD) of 1200 microns (see Figure 1). Beginning with
the prelay diet, a well-textured mash diet includes large particles of limestone (2–4
mm diameter). Large particle limestone is needed to maintain good eggshell quality.

Figure 1. Optimal feed particle profile using the Hy-Line Sieve Shaker.
SELECTIVE EATING BY BIRDS
Mash (meal) feed is generally a mixture of coarse and fine particles. Birds
preferentially consume larger feed particles. These large particles are frequently
coarse-ground corn, which is an important source of gross energy. Fine feed particles
usually contain the synthetic amino acids, phosphorus, vitamins and trace minerals.
The vitamin/mineral premix is usually fine particle. Birds that overconsume larger
feed particles generally have high energy intake and low intake of other important
nutrients, such as Vitamin A, vitamin D, riboflavin, sodium, lysine and methionine.
Many egg production and shell quality problems are due to inconsistent nutrient
intake caused by selective eating.
Birds that are fed too often or in excessive amount are not encouraged to eat the fine
feed particles. Fine particle feed can accumulate in the feeders if not properly

Poultry nutrition mill document Page 28

managed. Encourage the consumption of fine feed particles by leaving a gap of 2–4
hours mid-day. This allows birds to clean the feeders and consume fine particles
during this time. Farmers should monitor the feed bins and feeders to assess feed
disappearance to determine the appropriate feeding frequency and feed depth that
optimizes the daily consumption of both large and small feed particles.
It is important that birds consume both large and fine feed particles on a daily
basis to ensure a balanced nutrient intake.

GRANULOMETRY (DETERMINING FEED PARTICLE SIZE)

The standard method for determining particle size is The American Society of
Agricultural Engineers (ASAE) procedure S319.1. (http://animalscience.unl.edu/
Research/RumNut/RumNutLab/21-ParticleSizeAnalysis.pdf). The procedure involves
passing feed or ingredients through a series of 14 screens (sieves) of progressively
smaller diameter for 10 minutes. The results are reported as Geometric Mean
Diameter (GMD) and a measure of particle size uniformity (standard deviation or
coefficient of variation [CV]). Properly manufactured feed should have a CV of less
than 10%. This procedure is normally only done by large feed mills.
For evaluation of feed particle size on the farm Hy-Line has its own hand-held sieve
Shaker that can determine particle distribution of mash feeds (Figure 1). This is
Useful tool for farmers to check feed deliveries from the feed mill and check particle
size in the birds' feeder.

Figure 2. Test sieves. Image courtesy Gilson Company, Inc.

Poultry nutrition mill document Page 29

Figure 3. Sieves of varying sizes used to separate a mash feed sample by particle size.
Image courtesy Gilson
Company, Inc.

THE EFFECT OF MILLING PROCESS ON FEED PARTICLE SIZE

Raw material particles undergo multiple changes through the feed milling process.
The biggest factor affecting particle size is how the diet is milled. Raw materials,
such as soybean meal, fishmeal and premixes, are usually in a form that does not
require further particle size reduction. Cereal components (i.e. corn, wheat and other
whole grains) of diets always undergo a grinding process. Different ingredient types
will behave differently when ground. For instance, wheat will produce a different
particle size than corn run through the same grinder.

Hammer and roller milling are two of the most common methods used to grind raw
materials.

Hammer mills (Figure 4) are comprised of rotating sets of hammers that use impact
force to break down the grain. The hammers rotate at high velocity and break down
the material until it can pass through the surrounding screen.

Particle size and uniformity produced by a hammer mill depends on the size, shape,
speed and wear of the hammers, as well as the type and diameter of the screen used.
Hammer mills are able to produce a wide range of particle sizes. They work well with
fibrous materials like wheat by-products.

Poultry nutrition mill document Page 30

 Figure 4. Hammer mill. Image courtesy CPM Roskamp Champion.

Roller mills
Utilize cylindrical rollers, usually in pairs, to compress and sheer (tear) grains into
smaller particles. Feed passes through a series of 2–6 roller pairs which have
corrugations or grooves cut into the surface. One roller typically rotates faster and in
the opposite direction to create sheering force (Figure 5).

Poultry nutrition mill document Page 31

 Figure 5. Roller mill. Image courtesy CPM Roskamp Champion.

Particle size is determined by the number of rollers, distance between rollers, roller
diameter, and speed and corrugation pattern.

Generally, roller mills grind grain into more uniformly sized particles than hammer
mills (Figure 6).

Figure 6. Difference in particle size distribution between a hammer mill and a roller
mill. Generally, more uniform particles are produced in a roller mill. Data: M.
Heimann, American Soybean Association, 2008.

Poultry nutrition mill document Page 32

FEED DELIVERY SYSTEMS
There are three methods of delivering feed in automated feeding systems.
Chain type feeders (Figure 7) - feed is distributed by dragging feed around the feed
system with a chain. Chain feeders can cause feed particles to separate by size as it
moves feed. The chains can grind the feed particles while being conveyed through the
system, although new chain type systems minimize this effect. Slow-moving chain
feeders might be problematic as birds at the beginning of a feed line can select out the
larger feed particles.

Figure 7. Chain feeder.

Auger type feeders (Figure 8) - an auger are used to distribute the feed. The auger
moves feed more rapidly with less feed particle separation and grinding than with
chain feeders. Auger feeders typically deliver less feed volume than chain feeders
with each feeding.

Figure 8. Auger feeder Image courtesy Chore-Time.

Hopper type feeders (Figure 9) - a traveling hopper distributes feed by moving down
the feed line, dropping feed by gravity. This system causes minimal separation and
grinding of feed particles compared to other types of feeders. Management of the
feeders is important to minimize the negative effects of feed particle separation and

Poultry nutrition mill document Page 33

prevent the accumulation of fine feed particles. Frequent feedings of smaller
quantities minimizes the accumulation of fine feed. Chain feeders generally deliver a
larger volume of feed, making the accumulation of fine particles possible. Allowing
the birds to clean the feeders daily will prevent the accumulation of fine particles.
Ensuring that there is enough feeder space for all birds to eat at one time will create
more uniform nutrient intake in the flock.
Each system has potential feed particle segregation issues that must be monitored by
farm managers. Drag chain systems have more side-to-side segregation, where the
fine particles are concentrated in the middle of the trough, but the larger particles
congregate near the trough walls. In auger systems, there is more top-to bottom
segregation, with fine particles settling at the bottom of the trough and the larger
particles remaining near the feed surface. Repeated cycling of the auger can reduce
this separation.

Figure 9. Hopper feeders drop feed directly into the feed trough. Image courtesy laso.

Poultry nutrition mill document Page 34

 TROUBLESHOOTING
No Problem Cause Cause Remedy
1. Feed won't Excessive use of bulky feed Feed does not move Avoid excessive levels of bulky
auger into the materials (rice bran, wheat properly in feed system; materials; match amounts of bulky
house bran); excessive fine feed poor feed distribution in materials with auger size; avoid
particles feeders; reduced feed in grinding materials which are already
take a small particle size, additional
grinding creates excessively fine
material in the end product
2. Feed is too finely ground Bridging of feed in bins Grind cereal grains in mash feed to
and feed manifolds; 1000 to 1200-micron average particle
Sticky feed
sticky feed puts extra size, increase screen size in hammer
work on feed motors mills, or change from a hammer mill
and feeder chains, to a roller mill (or from a single-stack
resulting in electrical roller mill to a double-or-more-stack
overload roller mill)
3. Too much added fat or Potential fat oxidation; Reduce the quantity of liquid fat
poor mixing of fat within lower feed palatability added to the diet and/or ensure better
the mash distribution of fat within the mix; use
good mixing technique when adding
fat or liquid ingredients to mixer;
excessive fine particles exacerbate
the effect of feed sticking and form
large aggregates
4. Selective Excessive levels of large Dominant birds Provide optimum feed particle size
feeding by birds particles in the feed; consume too many distribution (see Figure 1); CV of
rankers and feeders on same coarse feed particles, feed particles should be < 10%;
side of cage, resulting leading to uneven uniform feed is less likely to
in dominant birds occupying nutrient intake desegregate; place drinkers away
feeder space from feeders to encourage bird
rotation between feeders and
drinkers; provide more feeder space
per bird.
5. Poor particle Excessive conveying of Separation of feed Use a minimum of 0.5% liquid oil/
size distribution mash diet resulting in particles according to fat in mash diets to incorporate fine
in the feed separation of dense and density particles and improve particle size
bulky materials; additional distribution
grinding of feed in feed
trough by some feeder
systems; slow feeder speed
6. Accumulation Too many feedings; poor Uneven nutrient Ensure there is adequate time
of fine feed feeder management where intake; fine feed daily for birds to "clean up" feed
particles in feed birds do not "clean up" fine increases house between feed runs; do not use feed
trough particles daily dust; dust can lead to ingredients which are too dusty;
poor air quality and do not grind material which does
increase respiratory not need to be ground; remove
disease accumulated fine particle feed
refused by birds weekly

Poultry nutrition mill document Page 35

Concept Generation
After clearly defining the problem and identifying what is needed from our final
product, our team conducted several ideation sessions to come up with different
solutions to the problem. The ideation sessions were meant to focus on a single
function needed from the product and create multiple solutions.
With each function each team member independently brainstormed as many solutions
as possible, once done each member’s designs were compiled to have a large amount
of solutions. These solutions were quickly analyzed on feasibility then modified to
make them a bit more applicable, and ideas that were still too abstract were removed.
With those solutions we chose the best one and put it through S.C.A.M.P.E.R:
substitute, combine, adapt, modify purpose, eliminate, and rearrange. The
S.C.A.M.P.E.R. technique allows for updating and reworking the initial design to
improve it. In our maize mill we defined 2 different functions: grinding and safety.
Through the ideation and S.C.A.M.P.E.R. sessions we defined five different methods
that could be used to grind the maize into flour; also we defined five methods to
increase safety.

Figure 10 Hammer mill sketch

Hammer Mill
This mill is one of the most commonly used mills in the large scale flour production,
a typical set-up sketch can be seen above in Figure a. The high flour production
usually correlates to a large required power input. From the article Small Scale Mills
in Africa, explain that an average hammer mill requires a minimum 1 kilowatts of
power to operate correctly and efficiently.

Poultry nutrition mill document Page 36

The construction of the hammer mill includes an outer housing, large rotor, and
various free swinging bars or “hammers.” The free swinging bars are attached to the
outer radius of the rotor and create the large amount of braking force as they contact
fixed breaker bars attached to the outer housing. A large fan is usually used to keep
crushed maize particles circulating within the housing and also help the sieving
process. Some of the pros of having a hammer mill would be the large amount of
benchmarking behind it and having the current model in Malawi as a reference. The
cons of this mill are the large amount of power required to be effective, the size of the
total assembly, and also complications with trying to add a fan into the project. The
large amount of information on the hammer mill is intriguing, but trying to make it
perform effectively off of the small amount of available power can be very difficult.

3.2. MANUFACTURING METHODS

3.2.1 Materials and Methods
A motorized vertical poultry Nutrition miller is efficient and economically viable was
designed and fabricated with readily available and cheap materials (suitable
engineering materials that could give optimum performance in service). Materials for
fabricating the machine were chosen on the basis of their availability, suitability,
economic consideration, viability in service etc. The components parts of the machine
were designed fabricated and tested. The parts and their quantity are given in the part
list below.

3.2.2 LIST OF PARTS

The major components of the new hammer mill are
 Inlet tray,
 Throat,
 Rotor shaft,
 Crushing chamber,
 Hammer mill body,
 Hammers/Beaters,
 Screen,
 Bearings,
 Table or stand,
 Mechanical drive,
 Pulleys.

Poultry nutrition mill document Page 37

  Hopper

Inlet tray/Hopper: This is the pathway through which the material to grinded will be
pour into the hammer mill. The inlet tray was fabricated with a 3mm thickness metal
plate (Mild steel). The tray was braced on the sides by 1inch by inch angle iron of the
same dimension. Inside the tray we have a gate which is used in regulating the flow
of Nutrition into the crushing chamber of the hammer mill.
Throat: This provides the passage for the material to be grind into the crushing
chamber. This was also fabricated with 3mm thickness metal plate.
Rotor: This is shaft of 30mm diameter that is holding 4 circular discs of diameter
90mm and is these circular discs that are carrying the hammers/beaters.
Crushing chamber: This is unit houses the rotor that holds the beaters and the screen
for sieving.
Hammer mill body: This was made of 4mm thickness plate with dimension 100mm
length & 315mm width & height 420mm. The hammer mill body is made in such a
way that it can easily be assembled & disassembled.
Hammers/Beaters: The hammers/beaters are a rectangular 3mm thickness metal that
does the grinding of material. It is 85 x 30mm in dimension with a drill hole of 12mm
at 30mm interval from both ends.
Screen: The screen act as a sieve for grinded materials before it will be finally
discharged. It was fabricated with 6mm thickness metal plate with many drilled hole
which will act as the sieve for the grinded material.
UCP Bearings: The bearings provide sliding motion between the main shaft and the
shaft holding the hammers.
Discharge: This is the section through which the grinded material will be passed out
it will also be made with a 3mm thickness metal sheet.
Table or stand: This is the platform on which the whole machine is mounted. It was
made with mild steel RHS. It was made of 60*60*4mm by 4mm sheet metal iron. It is
the base to which the hammer mill body and the prime mover is bolted.
Mechanical drive: A 5.5Hp, 2800rpm AC motor was used as the prime mover of the
machine through belt transmission.

Poultry nutrition mill document Page 38

Pulleys: Two pulleys were used for this machine which was the driver and the driven
pulleys respectively. The driver pulley is mounted on the mechanical drive engine
while the driven pulley is mounted on the rotor of the hammer mill machine.

Functional Description
There are five main functional components of our mill design: the stationary burr
plate, rotating burr plate, auger, hopper and shaft. The grinding mechanism is driven
by the rotation of the shaft and powered by the bicycle transmission. The unground
maize is first placed into the hopper. Gravity then Nutrition s the maize into the
auger. The auger is driven by the shaft and is shaped in such a way that it Nutrition s
the maize forward into the burr plates with the rotation of the shaft. The initial
cracking of the maize is accomplished by the auger compressing the kernels against
the center of the rotating burr plate. The crushed maize begins at the center of the
interface of the two burr plates and is then pushed outwards, being ground across the
burr plates. This is when the maize is ground into fine flour. The flour is then
discharged at the edges of the burr plates. An exploded view and full assembly view
can be seen below in Figure. Full drawings of all custom parts and assemblies can be
found on the drawing document.

Poultry nutrition mill document Page 39

 Figure 11 3D Model
Other components of the design include the hopper, base RHS, collar and base plate.
The hammer plates makes up the main body of the mechanism and encases the auger
and much of the shaft. The stationary burr plate is also fixed to the auger housing.
The rotating burr plate support holds the rotating burr plate and supports the free end
of the auger.
The shaft is a 40mm round bar with a D-Slot machined on one end for connection
with the pulley. The shaft will also be slotted on the opposite end in order to connect
into the key.
The auger has a spiral shape in order to turn the rotational motion of the shaft into
translational motion of the maize moving forward into the burr plates. The auger was
designed so that the negative space between its teeth would transfer the proper
amount of maize required to achieve our grinding rate of 500 kg/hr.
The auger housing has a cavity in its center and holes at both ends for containing the
maize, auger and shaft. The housing also has a rectangular hole in the top for the

Poultry nutrition mill document Page 40

Nutrition of maize from the hopper. The mounts of the auger housing are slotted so
that the housing may be moved back and forth in order to change the proximity of the
burr plates.
The hammer plates have for grinding the crushed maize into fine flour. The proximity
of the plate decreases towards the outside of the plates so that the flour becomes more
finely ground as it moves towards the outside of the plates. The stationary plate has a
large hole at its center so that the auger may pass through it. The stationary plate also
has three screw holes so that it may be fixed to the auger housing. The rotating burr
plate has a small hole at its center so that the protrusion at the end of the auger may
pass through it. Notches on the backside of the rotating burr plate allow it to be fixed
to the auger protrusion using a clevis pin.
The hopper has a square top that tapers down into a rectangular base. At its base there
is a 1 inch long straight section for interfacing with the auger housing. The straight
section is dimensioned so that it fits tightly into the rectangular hole at the top of the
auger housing.

Safety Considerations
Addressing Potential Hazards:
Putting hand in between the belt: We will make the slot that Nutrition s maize
to the auger small enough to make it difficult for children place their hands
near the spinning auger.
Rock caught in mill: If a rock were to be fed into the mill along with the
maize there could be catastrophic effects. The rock could break the burr plates
of the mill or be ground into the flour, making it inedible. We will remedy this
by instructing the users, in the operator’s manual, to sift through their maize in
search for foreign objects prior to milling.
Metal bits shearing off: It is conceivable that metal fragments could shear off
of the burr plates since there is such close proximity and high torque between
the burr plates. We intend to prevent this by making the burr plates out of a
high-strength material that is unlikely to shear under the given torque.
We also intend to make a calibration gauge/spacer for the assembly of the
mill. This gauge would be placed between the burr plates during assembly in

Poultry nutrition mill document Page 41

 order to set the correct distance between the two plates. This would guarantee
that there is no interference between the burrs.
Harmful material in mill: It is possible that someone may misuse the mill and
introduce a material into the mechanism that should not be ingested. An
example of this would be the use of a poisonous lubricant. In order to prevent
this we will specify in our operator’s manual the exact guidelines for what
materials may be used in the mill and emphasize the dangers of introducing
foreign substances.
A hazards checklist can be found in Appendix H. All potential failure modes
of the mill can be found in the Failure Modes & Effects Analysis

3.3 DESIGN CONSIDERATIONS.

Determination of the Shaft Speed
The transmission system used is belt transmission via a pulley (specifically v-belt
selection) using a mechanical drive petrol engine of 3600rpm with pulley of diameter
130mm (D1) and the diameter on that of the rotor is 198mm (D2).
Thus to calculate the shaft speed, the following parameters are used:

……………………… (1)

Where
N1 = revolution of the smaller pulley, rpm.
N = revolution of the larger pulley, rpm.
This shaft speed is only obtained when there is no slip condition of the belt over the
pulley. When slip and creep condition is present, the value (3600 rpm) is reduced by
4%
Determination of the Belt Contact Angle The belt contact angle is given by

……………………… (2) [Hollowenko et al, 2004]

Where R = radius of the large pulley, mm r = radius of the smaller pulley, mm
The angles of wrap for the pulleys are given by

……… (3) [Hollowenko et al, 2004]

Poultry nutrition mill document Page 42

 ……… (4) [Hollowenko et al, 2004]
Where
α1 = angle of wrap for the smaller pulley, deg
α 2= angle of wrap for the larger pulley, deg
μ a/sin ½
Comparing the capacities, e θ of the pulley,
Where μ = coefficient of friction between the belt and the pulley = 0.25 (assumption);
= angle of groove ranges from 300to 400. Assume = 400 (Joseph E. Shigley,
Choles R.Mischke: Mechanical Engineering Design, 2001) and
Using μ = 0.25; Θ = 40
0.25 x 3.04/sin20
For the smaller pulley = 9.22
0.25 x 3.04/sin20
For the larger pulley = 10.68
Since that of smaller pulley is smaller, the smaller pulley governs the design.
2.1.3. Determination of the Belt Tension
The belt tension is given below [Khurrmi and Gupta, 2007]
Maximum Tension in belt
…………………………… (5)
Centrifugal Tension in belt
…………………………… (6)
…………………………… (7)
To get tension in slack side using the relationship below

……………………………… (8)
Where
T1 = the tension in the tight side of belt, N
T2 = the tension in the slack side of belt, N
S1 = the maximum permissible belt stress, MN/m
The allowable tensile stress for leather belting is usually 2-3.45MPa [3]
Let 2.4MPa = 2.4

Poultry nutrition mill document Page 43

M = mass per unit length of belt
Let = belt density = 1000kg for leather belt
A = area of belt,
B=Belt breadth= 12.5mm T=belt thickness= 8mm
v = linear velocity of belt

V=
N = speed of motor =
N2 = 36006rpm,
d= diameter of motor pulley=130mm
mv2= centrifugal force acting on the belt
2.1.4. Determination of the Torque and Power Transmitted to the Shaft Power
required by the shaft is given by
………………………… (9)
1hp = 0.75kw
Maximum power of petrol engine is 5.5hp and power required by engine is 3.23hp so
2 hp was an appropriate selection.
Torque at the main shaft is given by
…………………… (10)
Determination of the Hammer Weight
…………………………… (11)
It can be seen that the action of the weight of hammer shaft on the main shaft is
negligible.
Determination of the Centrifugal Force Exerted by the Hammer
Centrifugal force exerted by the hammer can be calculated as given by: … (12)

Hammer Tip speed ……………………… (13)

The angular velocity of the hammer is given by

………………………………………………… (14)
The centrifugal force on the hammers, Fh, is given by
…………………………………..………… (15)
Where,

Poultry nutrition mill document Page 44

= centrifugal force
= number of hammers
= mass of each hammer
= radius of hammer
= angular velocity of hammer
Assuming inelastic impact between the hammers and material, the velocity of
material, Vm, given by

........................................ (16) . Where

Vm = velocity of material being milled
Mm= mass of material being milled
Nm = number of material impacted
The minimum width of hammer, wh, to withstand the centrifugal force at impact is
given by

............................. (17)

Where
= width of hammer
= diameter of hammer
= thickness of hammer
= working stress on hammer
Determination of the Hammer Shaft Diameter
The bending moment on the shaft is given by

…………………… (18)

3.4 Testing Procedures of the performance evaluation

The modified machine was tested on poultry nutrition miller machine, while the
testing apparatus were stop watch, weighing balance and sets of sieves. Two
kilograms of the materials sample was fed into the crushing chamber of the machine
through the Nutrition hopper. The time taken to crush the sample i.e. the sample to
fully discharge was noted. The weight of the crushed sample was taken after which
the crushed sample was taken for a sieve analysis to separate the finely crushed

Poultry nutrition mill document Page 45

materials from the coarsely crushed sample. The weight of both the fine samples and
that of the coarse samples were recorded according to the sieve sizes. The process
was repeated for samples weight of 4kg and 6kg respectively. The process of crushing
the weights 2kg, 4kg and 6kg were taken as the trials and one sieve analysis is
presented here from all the trials. This procedure was used for both material used as
presented in the results for original and redesign using the following equation
according to PHILIPPINE NATIONAL STANDARD PNS/PAES 217:2005 (PAES
published 2004) ICS 65.060 .
Crushing efficiency= (mass of output material) / (mass of input material) *100%
Crushing capacity = total mass crushing material (kg)/total time taken (hr)
Loss = (Mb-Ma) / Mb
Where
Mb = Mass before grinding (kg)
Ma = Mass after grinding (kg)

Poultry nutrition mill document Page 46

 CHAPTER FOUR

4.1 Manufacturing process

A motorized vertical poultry Nutrition miller, efficient and economically viable was
designed and fabricated with readily available and cheap materials (suitable
engineering materials that could give optimum performance in service). Materials for
fabricating the machine and for Nutrition and pelleting were chosen on the basis of
their availability, suitability, economic consideration, viability in service etc. The
components parts of the machine were designed fabricated and tested. The parts and
their quantity are given in the part list below.

Shafts Design Consideration

The shaft is a cylindrical solid rod for transmitting motion through a set of load
carried on it. The shaft uses for the pelleting is loaded by a press screw auger,
bearings, pulley, and belt tension. All these forces act on the shaft. The design is
based on Fluctuating torque, bending moment and shearing force. These called for
knowing the combined shock and fatigue on the shaft.

Types of manufacturing techniques implemented

Production of the obtained design includes understanding and preparation of the
design material. Some important procedures and processes that may be used for the
manufacture of the product or the project are included as recommendations beside a
material specification to ease preparation. These procedures are supported by
workshop drawings to ease the processes.

Cutting process
Cutting operation is required in most of the production that incorporate sheet metal
processing and may include use of simple hand tools while further shaping of
components like die, punch and handle is done through machining. The raw material
has to be cut to size. This is done with a variety of tools;

Shearing
It is an operation that is used to cut sheet metals in to the required dimensions. The
machine used for this purpose is called shearing machine. There are different types of

Poultry nutrition mill document Page 47

shearing machines based on the thickness of the blade. Proper utilization of the
machine based on the thickness of the blade is important for its durability.

Machining process
It is an occupation or hobby or a class of material-working processes that involves
using a power-driven machine tool, such as a lathe, milling machine or drill, to shape
metal. Machining is a part of the manufacture of almost all metal products.

Turning
It is a lathe operation in which an external cylindrical surface is produced. The cutting
tool is first adjusted for the desired depth of cut, using the cross slide. Then as the
work piece rotates, the cutting tool is advanced relatively slowly in a direction
parallel to the rotational axis of the spindle.

Facing
It is a lathe operation which generates an internal cylindrical surface with a single-
point tool. It can be described as internal turning, if the work piece is rotated as in a
lathe. As in turning, depth of cut is adjusted with the cross slide and the Nutrition is
obtained with the carriage movement.

Drilling
It is one of the cutting operations using drill bits to produce rough holes. The machine
tool involved in this case is a drill press. There are two cutting edges that produce
chips similar to those produced in turning on a lathe and a certain web region that
extrudes the metal at the center of the hole which is not removed by the cutting edges.
Both lips (cutting edges) of a drill operate with variable rake angle, inclination angle,
and clearance angle along the cutting edge. The flutes of a drill play the important
role of conveying the chips out of the hole and the helix angle of the drill is important
in this connection.

Welding process
Welding may be defined as the metallurgical joining together of two metal pieces to
produce essentially a single piece of the metal. It produces what is known as a”
permanent fastening”. Welding is a fabrication method in which portions of metal
plate, various rolled sections, castings and other metal pieces are joined to produce

Poultry nutrition mill document Page 48

desired shapes. Its products are known as “weldments”. Welding is also useful as a
method of repairing broken, worn or defective metal parts. The types of welding used
in these manufacturing processes are lap-joint, T-joint, corner joint, edge joint.

Fabrication process
Fabrication, when used as an industrial term, applies to the building of machines and
structures by cutting, shaping and assembling components made from materials.
Metal fabrication is a value added process that involves the construction of machines
and structures from various raw materials. A fabrication shop will bid on a job,
usually based on the engineering drawings, and if awarded the contract will build the
product.

4.2. Steps for manufacturing of different parts

Limits, Fits and Tolerances
The maximum and minimum limitations for a given feature are known as the limits.
To ensure that an assembly will function correctly, its component parts must fit
together in a predictable manner. Now, in practice, no component can be
manufactured to an exact size, and one of the problems facing the designer is to
decide the upper and lower limits of a size which are acceptable for each of the
dimensions used to define shape and form and which will ensure satisfactory
operation in service. The algebraic difference between the upper and lower limit of
size is known as the tolerance.
The process selection relates to the characteristics of material, the dimensional
tolerance, surface finish obtained and manufacturing cost.
The choice of manufacturing process is held in various considerations:-
 The characteristics and properties of the material
 The shape, size, thickness of the material
 The dimensional tolerance and surface finish requirement
 The function requirement of the part
 The production volume(quantity)
 The level of automation required to meet production volume and production
rate

Poultry nutrition mill document Page 49

  The cost involved in individual and combined aspects of the manufacturing
operation.

4.3 cost estimation

I. List of Fixed Assets Needed and Their Cost
No Item Quantity Unit Total
price price
1. Center punch 1 20 20birr
2. Scriber 1 30 30 birr
3. Forging hammer 1 80 80 birr
4. Try square 1 50 50 birr
5. Divider 1 60 60 birr
6. Venire caliper 1 600 600 birr
7. Steel ruler 1 50 50 birr
8. meter 1 90 90 birr
9. Plastic hammer 1 60 60 birr
10. Welding machine 1 12500 12500
11. Grinding machine 1 5000 5000
12. Drilling machine 1 5000 5000
Total cost 23540
Table 1 List of Fixed Assets
II. List of raw material needed/BOM
Unit Total
No. Part name Description unit Qty. Rrk
cost cost
1. Sheet metal 2000*1000*3mm Pcs 1 3000 3000
2. Sheet metal 2000*1000*5mm Pcs 1 5000 5000
3. RHS 40*40*6000*3mm Pcs 2 1500 3000
4. Angle iron 30*30*6000*5mm Pcs 2 1500 3000
1800 1800
5. AC Motor Three phase 5.5Hp 2850 rpm Pcs 1
0 0
6. Contactor Telemechanic, 220V Pcs 1 400 400
7. Overload relay Telemechanic, 220V Pcs 1 400 400
Start push Telemechanic, Normally
8. Pcs 1 80 80
button open
9. Indicating lamp Red ,green, yellow Pcs 3 50 150
10. Electric cable 3*1*4mm2 Meter 10 300 3000
Stop push Telemechanic, Normally
11. Pcs 1 80 80
button close
12. Electrode Dia 2.5 permanent Pct 5 400 2000
13. Electrode Dia 3.2 permanent Pct 5 400 2000
14. Metal Paint Nifas silk Gallon 3 600 1800
15. Anti-rust Nifas silk Gallon 3 600 1800

Poultry nutrition mill document Page 50

 16. UCP bearing rectangular Germany 4 holes pcs 2 2875 5750
17. sieve Different size meter 4 100 400
M10-
18. bolt and nut Different size m10-m30 10 30 300
M30
5016
 Total cost of material
0
Table 2 List of raw material
III. Factory overhead expenses
No Overhead expenses Amount
per month
1. Electricity 100
2. Advertising 100
3. Telephone 100
4. Water 100
5. Maintenance 250
6. Depreciation of fixed 178
capital
7. Total factory overhead 828
per month

Table 3 Factory overhead expenses

I. Useful life time of each fixed asset
No Investment item Life span in Deprecation Investmen Total
years (%) t cost deprecation
1 Buildings 20 5 ------ ---------
2 Simple machine 15-20 6-5 986 192.2
3 Hand tools 3 33.3 56 114
Total 306.2

Table 4 the useful life time of each fixed asset

II. Brief description capacity of the project per month

Month 1 2 3 4 5 6 7 8 9 10 11 12
No of products 1 8 7 10 10 20 9 15 15 8 12 17
Table 5Brief description capacity of the project per month

Poultry nutrition mill document Page 51

 ORGANIZATION AND MANAGEMENT PLAN
Organizational structure

ORGANIZATIONAL STAFF COST

No Position Qualification Salary per Remark
month/BIRR
1. General manager MTM 10150
2. production manager MT 7071
3. Finance manager Accounting 4000
4. Production worker GMFA 3000
5. Purchaser Accounting L-4 3000
6. Secretary It 2500
Total staff cost 29721
Table 6 Organizational Staff cost
ADMINISTRATIVE EXPENSES
No Administrative expenses Amount
1. Allowance 1000
2. Supplies 500
3. Communication 300
Total Administrative expenses 1800
Table 7 Administrative expenses
Calculation of the project cost
 Total material cost = 50150 birr
 Direct labor cost= 29721birr

Poultry nutrition mill document Page 52

  Indirect cost = 1800birr
 Total machine cost = 2500
 Labor cost = Direct labor cost + indirect labor cost
= 29721birr +1800birr
= 31521 birr
 Overhead cost = 828 birr
Total production cost = Total material cost+ Overhead cost+ Labor cost+ Material
cost
= 50150birr+ 828 birr+ 31521+2500 birr
= 84999 birr
Profit = Total production cost ×15%
= 84999 birr × 15/100
= 12,749.85 birr
Selling price = Total production cost+ Profit
= 84999 birr + 12,749.85 birr
= 97748.85 birr

FINANCIAL PLAN
Sources of funding
Type Source Conditions Amount
(duration
/interest)
Equity Own saving 25,000
capitals Partner 25,000
Loan 1 Credit cooperation 250,000
Government scheme
Bank loan
TOTAL FUNDING 300,000Birr
Table 8 Sources of funding

Poultry nutrition mill document Page 53

CAPITAL REQUIREMENT
Capital requirement( project cost ) Amount
Investment or Fixed Assets
Land Gov’t
Building Gov’t
Equipment( with machine) 30287.4
Others 1000
Total fixed Assets 31287.4
Working capital /operational costs of one month
Raw materials costs one month 50150
Administrative expenses 1800
Overhead expenses 828
Staff cost of one month 29721
Total working capital in one month 82499
Total Capital requirement 113786.4birr
Table 9 Capital requirement

Poultry nutrition mill document Page 54

 CHAPTER FIVE
RESULTS AND DISCUSSION
3.1 Properties of the original and new hammer:
The original hammer Figure (5) was tested and analysis in the CMRDI laboratory and
it found has the following
Specifications:-
1. Sample - ID: Crusher Hammer
2. Sample Material:

Heat Treatable Carbon Steel

DIN No: 20Mn5
Mat No: 1.1133

Figure (5): The original hammer

Chemical Analysis:

Table: 2. the average analysis of three sparks detected

Impact energy required:-

The rotor mass is much greater than mass of single particle in the Nutrition. Linear
velocity of the crushing hammer before impact is more considered than the particles
velocity, and then kinetic Energy (KE) of particles is negligible.

Poultry nutrition mill document Page 55

 Figure (4): Particle during the rotor with horizontal hammer crusher
Assumed that most of the particles enter in the medium part of the impact area of
the hammer, consider of linear movement before and after impact the mass energy
(Em) given by the following equation:-

Em = 0.5 R + 0.5H 2 ------- (1) (Nilolov 2004)

Where:-
R: Rotor radius, mm
H: Height of the impact surface, mm
: Rotor velocity (rpm)
Impact bending stress:
To insure the new design of the hammer is safe in this experiment conditions, the
maximum allowance moment (Ma) should be greater than or at less equal the actual
maximum moment (Mmax). The two moments were calculated according to the
following equations:-
Max. moment (Mmax) = p* Hhw/2-------------(2) (Khurmi and Gupta 2005)

P= w (h+y)
Where:
P: is the equivalent static force N.mm
w: impact force N
h: height of fall material mm
y: defalcation mm

Max. Allowable moment (Ma) =CsLZ2*2/12------ (3) (Khurmi and Gupta 2005) where:
Cs: allowable stress N/mm2
L: Length of bar m m
Z: Thickness of bar m m

Poultry nutrition mill document Page 56

Impact energy required:
Impact energy calculated per unit mass according to Equation1, considering the
conservation of liner moment before and after the impact energy mass which is the
required impact energy was 5.5 PH where the rotor radius equal 12.5 cm, height of
impact surface equal 25 cm and the rotor velocity was 2800 rpm.

Fineness
The flour mass produced through the milling process should pass through a number
50 mesh. This designates a maximum discharged particle size of 0.297 mm in
diameter to be considered fine flour. This specification was obtained through testing
of a current on-the-market hand crank mill and research into maize flour particle size.
Progressivedairy.com recommends a mean particle size of “1,500 microns for high-
moisture maize compared to 800 microns for dry maize.” This is consistent with the
maize flour that we obtained by using an Estrella Crank maize Grain Grinder.
Manufacturing
Our goal is for the poultry nutrition mill to be built completely in Malawi. All chosen
parts and materials should be available in Malawi and any necessary manufacturing
and machining should be able to be performed in Malawi. Currently our prototype
will be made outside of Malawi, but all chosen parts and processes should follow this
standard.
Assembly
We will create a manual that will include instructions for the assembly and use of the
poultry nutrition mill. Without any engineering or machining experience, Ethiopian
poultry farmer should be able to assemble (after manufacturing) and maintain the
mill.
Durability
The finalized project must endure harsh conditions and be able to deal with any
foreign objects that may be included with the input. In the harvesting procedure
objects such as rocks and nails may pass through visual inspection. The Mill project
will need to have a “fail safe” in order to account for any of these objects being
present in the grinding process. Creating a mill that is able to encounter a foreign
object and then stop is the purpose of this specification.

Poultry nutrition mill document Page 57

 Figure 12 assembly drawing

Poultry nutrition mill document Page 58

 CHAPTER SIX

5.0 CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION
Poultry Nutrition mill is designed and fabricated to have capacity and time saving
efficiency. This Poultry nutrition mill considers local areas. The fabricated Poultry
nutrition mill was used to mix different ingredients under controlled conditions
yielding an acceptable output hereby saving time and energy. The machine is safe to
use and efficient. It was cost effective because the design and fabrication were done
manually.
In general any one can take a further modification on the whole part of the machine
for better performance. The poultry Nutrition mill was designed, fabricated and the
performance evaluation was successfully carried out on the Poultry nutrition mill. It is
relatively cheaper than the Poultry nutrition mill available at present used for the
same purpose in the market and its performance evaluation shows that it is an
efficient Poultry nutrition mill.
5.2 RECOMMENDATION
To improve our country’s poultry farm productivity, research and development is key
for success. Technology always go together to enhance productivity. The Poultry
nutrition mill we develop is part of the contribution to agricultural sector. The Poultry
nutrition mill is not the final stage of its design but because of time and scope
limitations on the working of the project, we recommend any interested person,
enterprise, or government organ to improve or upgrade the poultry Nutrition mill’
performance. Some upgrading actions can be:
Making it high efficiency.
Also making it light weight.
Low cost and affordable for enterprises.

Poultry nutrition mill document Page 59

 REFERENCES
1. Wilson, J. E. (1990). Raw Materials – Animal Protein. Nutrition Tech V
Revised (Ist ed.)
2. Grafman, L. (2007). Original: Small scale Manufacture of Compound
Animal Nutrition
http://www.appropedia.org/Original:Small_scale_Manufacture_of_Comp
ound_Animal _Nutrition _7
3. Lindley, J. A. (1991). Mixing Processes for Agricultural and Food
Materials, Journal of Agricultural Engineering Research 48:153-170.
4. Akpobi J.A, Ovuworie G.C., Computer-Aided Design of the Critical
Speed of Shafts, Journal of Applied Science and Environmental
Management, 2008, 12, p. 79-86.
5. Akpobi J.A., Ardey M., Computer-Aided Design for Machine Vibrations,
Technical Transactions of the Ethiopian Institution of Production
Engineers, 2002, 7(3), p. 41-62.
6. Akpobi J.A, Lawani I.A., Computer Aided Design of Flywheels,
Advances in Engineering Software (Elsevier Publishers), 2006, 37(4), p.
222-235.
7. Okojie V.A., Software Approach in Solving Shaft Design Problems,
Project Solutions Domain Journal of Mechanical Engineering, 2011, 1, p.
15-28.
8. Ear T.S, Johnson B.P., Production engineering, Third Edition, Tata
Mcgraw Hill Company Limited, New Delhi, 2007
9. Khurmi R.S., Gupta J.K., A Textbook of Machine Design, Fourteenth
Edition, S. Chand and Company Limited, New Delhi, 2005
10. Volosciuc, P. (2015). Granulator 300kg/h. www.youtube.com/watch?
v=ELTmmy4x14g
11. Peter, K. I. (2013). The organic farmer, (biovision). The magazine for
sustainable agriculture in East Africa, No. 102. November 2013.
12. http://www.biovision.ch/fileadmin/pdf/d/services/downloads/
organic_farmer/org_farmer 102_13_red.pdf
13. Balami, A. A, Adgidzi, D, & Mua‟zu, A. (2013). Development and
Testing of an Animal Nutrition MixingbMachine, International Journal
of Basics and Applied Sciences, Insan Akademika Publications, P-ISSN:
2301 – 4458; E – ISSN: 2301-8038.
14. ASAE Standards, (ASAE S380 DEC1975 R2006). Test Procedure to
Measure Mixing Ability of Portable Farm Batch Mixers, pp. 261 – 262.
15. Rufus Ogbuka Chime etal, (2018) Design, Modelling and Simulation of
Nutrition Mixing Machine by Journal of Emerging Trends in

Poultry nutrition mill document Page 60

 Engineering and Applied Sciences (JETEAS) 9(1): 44- 49 © Scholarlink
Research Institute Journals, 2018 (ISSN: 2141-7016) Journal of
Emerging Trends I
16. [22] R.O.Chime ,F .O. Odo (2018)Analysis of Garri Frying Machine
Manufacturing in Ethiopia: Design Innovation published by Advances in
Science, Technology and Engineering Systems Journal Vol. 3,
17. No. 6, 403-411 (2018) www.astesj.com.
18. Rei Reinhardt H. Howeler, Christopher G. Oates and Antonio Costa
Allem, Strategic environmental assessment: an assessment of the impact
of cassava production and processing on the environment and
biodiversity. Food and Agricultural Organisation of the United Nations
/International Fund for Agricultural Development, Rome, vol. 5: 7, 2001.
19. Kolawole,P.O., Agbetoye, L.A.S. and Ogunlowo, S.A., Sustaining world
food security with improved cassava processing technology: The Nigeria
Experience, 2010.
20. Stephen, K.A. and Eric, K.G. Modification of the designs of cassava
grating and cassava dough pressing machines into a single automated
unit. European Journal of Scientific Research 38(2):306-316, 2009.
21. Nyerhovwo, J.T. Cassava and the future of starch. Electronic Journal of
Biotechnology 7(1), 2004.
22. Stephen. A. and Eric, K.G., Modification of the design of cassava grating
and cassava Dough pressing machine into a single Automated Unit.
European Journal of Scientific Research. 38 (2): 306-314, 2009.
23. Anderson, S. 1994. Large Rotor High Speed Hammermills: Beyond
Screen Size. Nutrition Management, Vol. 45, No. 9, 20-22.
24. Bliss, B. 1990. Hammermilling Technology. Bliss Industries, Inc., Ponca
City, OK. Goodband, Robert, Mike Tokach, and Jim Nelssen. 1995.
25. The effects of diet particle size on animal performance. Cooperative
Extension Service, MF-2050. Kansas State University, Manhattan.
26. Igbeka, J. C., Jory, N. and Griffon, D., Selective mechanization for food
processing. Journal of Agriculture Mechanization in Asia and Latin
America 23(1):45-50, 1992.
27. Odighoh, E. U., grain production, processing and utilization. In Chan Jr.,
H.T. (Ed.), Handbook of Tropical Foods. Marcel Dekker, Inc., 145-200,
1983.
28. Olayeni O.O., Gender analysis of training needs on the prevention of
hazards associated with processing in Osun State, Nigeria. Unpublished
M.Sc. thesis Obafemi Awolowo University Ile-Ife, 75. 2012.
29. Omolehin, R.A.;Ogunfiditimi, T.O. Adeniji, O.B., Factors influencing
adoption of chemical pest control in cowpea production among rural

Poultry nutrition mill document Page 61

 farmers in makarfi local government area of Kaduna state, Nigeria. 54-
56, 2007.
30. Ogunjimi, S. I., K.S. Obaniyi and Adedeji I. A, Peri-urban and urban
farmers’ perceptions of mini-livestock farming in southwestern Nigeria.
The international journal’s Research Journal of Social Science and
Management. 02(02):81-83 June-2012,
31. Jibowo A.A., Essentials of Rural sociology. Gbemi Sodipo press,
Abeokuta, Nigeria. ‘Second Impression, pp 229-236, 2000.
32. Rogers E. M, Shoemaker P.C., Diffusion of innovations. The Free Press
of Glancoe, N.Y., pp 367.
33. Adesoji S. A., Assessment of Fish farming management practices in
Osun state Nigeria PhD Thesis Obafemi Awolowo University. 4-10,
2009.
34. Ajala, A.O., Ogunjimi, S.I and Farinde, A.J., Assessing the effectiveness
of improved cassava production technologies among cassava farmers in
Osun state, Nigeria Wudpecker Journal of Agricultural Research
1(7):281-288, August 2012.
35. Kehinde, A. T. Adefemi, J.O. Tayo, O.S. Michael and O.A. Obafemi
Technology Choice and Technical capacity in grain Production. Food
Reviews international, 7 (1): 89, 2007.
36. Davies, R.M., M.O. Olatunji and W. Burubai, Mechanization of maize
processing in Iwo Local Government Area of Osun State, Nigeria. World
Journal of Agricultural Sciences 4 (3): 341-345, 2008.

Poultry nutrition mill document Page 62