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Design And Fabrication Of Maize Corn-On-Cob Tray Dryer

5 Chapters
|
65 Pages
|
1,750 Words

The design and fabrication of a maize corn-on-cob tray dryer involves creating a specialized drying apparatus tailored to efficiently dehydrate maize corn cobs while preserving their quality and nutritional value. This process necessitates meticulous engineering to ensure optimal heat distribution, airflow, and moisture control within the dryer chamber. Key components include a sturdy frame constructed from durable materials such as stainless steel or aluminum, perforated trays to hold the corn cobs in a single layer, a heating system powered by electricity or alternative energy sources like solar or biomass, and a ventilation system to facilitate air circulation and moisture evaporation. Additionally, temperature and humidity sensors coupled with automated controls enhance process monitoring and regulation for consistent drying results. The fabrication process involves precision machining, welding, and assembly of the components to create a robust and efficient maize corn-on-cob tray dryer capable of meeting the demands of small to medium-scale agricultural operations. This innovative drying solution not only increases the shelf life of maize corn but also offers economic benefits by reducing post-harvest losses and improving market competitiveness in the agricultural sector.

ABSTRACT

This study was carried out to generate a design data, design and fabricate a
maize corn-on-cob tray dryer used by maize farmers. Ripped maize corns with
husks were bought from the market and preserved to retained its moisture
content, dehusked and thereafter, dried to a given percentage moisture content
of 15%. This was done by laboratory dryer. The drying rate data was generated
and the high rate of 2.0g/hr was used afterwards to design and fabricate the
corn-on-cob dryer. From the results, drying of a sample of maize corn-on-cob
by the laboratory dryer took a period of three days and six hours to reach the
15% moisture content (wet basis) needed. A test run was carried out on the
fabricated dryer and seventeen hours was used to dry a sample of maize corn-
on-cob to the same 15% moisture content. This implies that design data is
satisfactory as its application in the fabrication of the dryer resulted in an
increased flow rate of air in the dryer thereby increasing the rate of drying at the
same drying temperature of 40oC.

TABLE OF CONTENT

Title page
Certification
Dedication
Acknowledgement
Abstract
Nomenclature
Table of content

CHAPTER ONE
INTRODUCTION
1.1 Background of study1
1.2 Statement of the problem2
1.3 Objective of the research project3
1.4 Significance of the research4
1.5 Scope of the research4

CHAPTER TWO
LITERATURE REVIEW
2.1 Maize farming in Nigeria5
2.2 Drying5
2.2.1 Some basic definitions on drying8
2.2.2 Drying rates12
2.2.3 Classification of dryers18
2.2.4 Tray dryer20

CHAPTER THREE
MATERIALS AND METHODS
3.1 Sourcing and preservation of the raw material22
3.2 Drying22
3.2.1 Maize corn-on-cob bone drying23
3.2.2 Generation of dryer design data from maize corn-on-cobs24
3.3 Dryer design and materials of fabrication24
3.4 Design considerations27
3
3.5 Test running of the dryer31

CHAPTER FOUR
RESULT AND DISCUSSION
4.1 Result33
4.2 Discussion35

CHAPTER FIVE
SUMMARY, CONCLUSIONS AND RECOMMENDATIONS
5.1 Summary37
5.2 Conclusion37
5.3 Recommendation38
REFERENCES40
APPENDICES41
Appendix A (Graphs) 41
Appendix B (Tables) 55
Appendix C (Calculations) 58

CHAPTER ONE

BACKGROUND OF STUDY
Cereal grains have been and will continue to be a major source of food for
humans and animals throughout the world. Amongst all cereals, the most
important is the maize grain. (Leonard et al, 1963). Maize corn and products can
be used for various purposes; human food, alternative medicine, chemicals, bio
fuels, ornamentals, fodder, to mention but a few (Leonard, Warren H., and John
H. Martin). Maize crop is intensively and extensively cultivated in all the geo-
political zones of Nigeria. Early maize is planted between late March and late
May while the late maize is planted between August and September. The
harvest time for the early maize is usually between late July and September.
During this period, corns are harvested fresh and cannot be preserved by drying
owing to the unavailability of sunshine during the rainy season. It is usually
roasted or cooked fresh. This practice does not encourage maize farmers as they
would sell the maize corn at a give-away prices and this does not guarantee
returns on their investment. In addition to this, dried maize grains will guarantee
food sufficiency during the scarce period. Notably, corn of high moisture
content does not stored very well and is usually vulnerable to damage due to
deterioration, molds, and insects during the period of storage.
However, open air-sun drying as practiced in most rural areas often yields poor
quality dried corn, since the product is not protected against dust, moisture,
wind, rodents as well as other domestic animals while carrying out the drying.
As a result, they are often contaminated with pathogens. Another common
practice in maize corn-on-cob drying is drying over a fire place. This has its
own problems as the maize grains are contaminated with smoke. Moreover, the
temperature of drying is not properly controlled such that grains become dead
after drying. There are various research works that have been carried out on
grain drying (Zare et al, 2006; Mellmann, et al 2011; Adzimah and Seckley,
2009). These works were silent on drying and dryer design for maize corn-on-
cobs.
There are four major drying techniques; open air sun drying, fire wood /fuel
drying, electrical drying and solar drying(Anyanwu et al 2006, Scanlin 1997
and Whitefield 2000). This research project will address these problems
associated with postharvest handling of maize corn-on-cobs, in particular
drying, by designing and fabricating electrically operated tray dryer that will be
simple but very robust in operation.

1.2 STATEMENT OF THE PROBLEM
Maize corns are usually stored when dried to certain percentage moisture
content. In Nigeria, maize corn drying is done in dry season because of low
humidity of atmospheric air and adequate sunshine. However, it is a common
place to see peasant maize farmers dry their maize corn-on-cobs over fire place,
but this practice contaminates the dried maize corn with smoke and usually
small quantity of maize corn-on-cob are dried. The reverse is the case during the
rainy season. Unfortunately, bulk of the maize corn is harvested in the rainy
season and farmers can not dry the fresh maize corn rather they sell them at
very cheap prices to corn roasters and for other delicacies. To give value to
farmers and also to guarantee maize corn sufficiency during scarce period, it
becomes necessary that a simple but robust corn-on-cob dryer should be
designed and fabricated to assist farmers have good returns on their investment
especially during post-harvest handling of maize corn during rainy season.

1.3 OBJECTIVES OF THE RESEARCH
The aims of this research include:
i. To develop a drying rate curve for maize corn-on-cob at constant drying
condition.
ii. To generate design data for tray dryer to be used to dry maize corn-on-
cob.
iii. To develop and draw working diagrams for the tray dryer.
iv. To fabricate a tray dryer.
v. To test run the tray dryer.

1.4 SIGNIFICANCE OF THE RESEARCH
Some of the benefits derivable from this research project include:
i. It will encourage maize farmers by giving them good returns on
their labour and enhance maize corn production.
ii. It will provide Nigerian populace with a cleaner dried maize grains.
iii. It will attract foreign exchange for Nigeria as cleaner dried maize
can be export.
iv. It will ensure maize grain sufficiency during the scarce period.

1.5 SCOPE OF THE RESEARCH
This research will be restricted to the following areas;
i. Generation of design data for corn-on-cobs.
ii. Designing the corn-on-cob dryer.
iii. Fabrication of the dryer.
iv. Test run.

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Design And Fabrication Of Maize Corn-On-Cob Tray Dryer:

Designing and fabricating a maize corn-on-cob tray dryer involves several steps, from conceptualization and planning to construction and testing. Here’s a general guide on how to proceed:

1. Define the Requirements:

Determine the capacity of the dryer (i.e., how many corn cobs it should handle at once).
Decide on the heat source (electricity, gas, solar, etc.).
Consider safety measures and energy efficiency.

2. Gather Materials and Tools:

Depending on your design, you will need metal sheets, angle iron, insulation material, heating elements, temperature control systems, fans, and various tools (welding equipment, saws, drills, etc.).

3. Design the Dryer:

Create a detailed schematic drawing or CAD model of the dryer, including the dimensions, tray layout, airflow design, and heating system placement.

4. Fabricate the Dryer:

Assemble the metal framework for the dryer using the angle iron.
Cut and weld the metal sheets to create the outer casing and trays.
Install insulation material to reduce heat loss.
Attach heating elements (e.g., electric heating coils) to the inside of the dryer.
Include a fan system for airflow to distribute heat evenly.
Install a temperature control system to regulate the drying temperature.

5. Safety Measures:

Ensure that the heating elements and electrical components are properly grounded.
Implement safety features like thermal cutoff switches to prevent overheating.
Include proper ventilation to avoid the buildup of combustible gases if using a gas heat source.

6. Test the Dryer:

Before using the dryer for production, conduct thorough testing to ensure it operates as intended.
Measure the temperature distribution within the dryer to ensure uniform drying.
Test the control system to maintain the desired drying temperature.
Assess the energy efficiency and adjust the design if needed.

7. Fine-Tuning:

After initial testing, make any necessary adjustments to improve performance and efficiency.

8. User Manuals and Safety Instructions:

Create user manuals and safety instructions for operating the maize corn-on-cob tray dryer. Include guidelines on loading, temperature settings, and maintenance.

9. Installation:

Set up the dryer in its intended location, ensuring it has proper electrical or gas connections.

10. Maintenance and Troubleshooting:

Provide guidelines for routine maintenance and troubleshooting common issues.

11. Production and Scaling:

Once the dryer is fully operational, you can start using it for drying maize corn cobs on a larger scale.

Remember to adhere to safety standards and regulations relevant to your location when designing and fabricating the tray dryer. Additionally, consider consulting with experts or engineers experienced in dryer design to ensure the success of your project.