DESIGN AND FABRICATION OF A CONTINUOUS POP CORN
MAKING MACHINE
BY
OMOLADEAHMED ADEBOLA
(2004119005EM)
Department Of Mechanical Engineering School Of Engineering and
Engineering Technology Federal University of Technology, Minna,
Nigeria
January, 2010.
DESIGN AND FABRICATION OF CONTINUOUS POPCORN
MAKING MACHINE
BY
OMOLADE AHMED ADEBOLA
(2004/19005EM)
A Project Report Submitted in Partial Fulfillment of the
Requirements for the Award of Bachelor of Engineering (B. Eng)
Degree in Mechanical Engineering, Federal University of
Technology Minna, Nigeria.
January, 2010.
CERTIFICATION
.s is to certify that the work recorded in this project was carried out by me, Omolade
Federal University of
ed Adebola, in the Department of Mechanical Engineering,
'echnology, Minna.
roject Supervisor.
SignaturelDate
ead of Department.
SignaturelDate
External Examiner
SignaturelDate
III
DEDICATION
.s project is dedicated to our ever-loving, caring, hospitable, amiable, supporting,
generous, unequalled, and everlasting God for making me a stronger person to
Ie life and its conflict to the best of my understanding, for the more He eares the more
IV
AKNOWLEDGEMENT
First and foremost, 1 want to appreciate the Almighty God who is the inspiration behind my
studies, for sparing my life, for giving me grace and for sparing my family.
Secondly, 1 won't fail to appreciate my Project Supervisor Dr. Vincent Ogwuagwu for the
pains taken in going through my work and for his guidance. Special thanks to my level
adviser Engr. Muriana and the entire staff of Mechanical Engineering department under the
leadership of the head of department Prof. Khan
1 humbly acknowledge the following people of unparallel impact on me in this surgeon of
mine: my parents, Alhaji and Alhaja Omolade my mentor Mr. Kunle Olajubu Daniels, and
my beneficiary Alhaji. K.B.Omolade
To my siblings,Oluwatoyin Omolade(GIITO),Tajudeen Omolade(Structural
Engineer),Oluwakemi Omolade(Aso Savings and Loans)1 love you all! To my dearest
nephew Temiloluwa Wicklliffe, you are my world!
Till the wind of destiny blows me to its final destination, 1 shall continue to learn. "As men
have leant to shoot without missing"says Eleke'the bird' "I have learnt to shoot.
v
ABSTRACT
Jht' project work in\ ' olVl'~; [ill.' design ,mel /'lIlxi cu[io n o/'cOn[inliOllS popcorn maki ng mac hine,
The work has help
[0
minimize the prob lems assoc iaied in popp ing process of popcorn anc!
clcctric motor. /\ 11 thc lll'lleri<ll s used 1'0 1' the (',Ibric<llioll wc rc loca ll y so urced, Till: tot.\1 hl:<)[
req uired 1'01' popping
(J , 71 ()~ 76kg
or corn \\ as cidcrmincc\ to be 356777. 199 J. The outp ut
capacity or th e 1llachinl.' \\',IS round to be 0.7 163 76kg per 356. 7772secs.(O.0978kg/s) .
VI
ABLE OF CONTENTS
PAGE
Contents
Title page
ii
Declaration
111
Certification
iv
Dedication
v
Acknowledgement
vi
Abstract
vii
Table of contents
CHAPTER ONE
.0
Introduction
.1
Objectives of the project
.2
Limitation of the project
.2
Justification of the project
2
2
2
CHAPTER TWO
0
4
Literature review
4
legend of popcorn
4
Prehistory of popcorn
5
Early popcorn history
6
Recent popcorn history
7
The history of popcorn poppers
8
How does a popcorn pop
VII
2.2.1
How heat blows up a popcorn (Explosive)
8
2.2.2
What makes popcorn pop
9
2.2.3
What is expansion ratio on popcorn and what is the optimum
9
2.2.4
What is the best way to keep popcorn machine clean
10
2.2.5 Popcorn quality
10
2.2.6
II
Why hard-coat Anodized Aluminum kettles considered the best
2.2 .7 Popcorn and its nutrients
II
2.2.8
12
Popcorn trivia
2.2.9 Popping perfect popcorn
12
2.3.0
13
Upping the puff
2.3 .1 Effect of moisture content on popcorn
14
2.3.2 Vibrations
14
2.3.3 EfTect of"oil
14
CIIAPTER
TIIRI~ E
3.0
Theoretical design analysis
16
3.1
Energy forms and conversion within a system
16
3.2
Heat energy
17
3.3
Modes of heat transfer
17
3.3 .1
Conduction
18
3.3.2
Convection
20
3.4
Continuous flow of the popped corn
20
3.5
[)eterm ination of" heat transfer during popping of corn
21
3.6.
Energy balance
22
3.7
Determination of system dimension
22
3.7.1
Volume of"the aluminium pot
22
VIII
3.7.2
Volume of the hopper
23
3.8.
Source of heat energy
24
3.9
Design calculations
25
3.9.1
Calculation of mass of popcorn without moisture
25
3.9.2
Calculation ol'volume of the hopper
25
3.9.3
Calculation of volume of aluminium pot
25
3.9.4
Calculation of mass of corn in the aluminium pot
26
3.9.5
Calculation of the quantity of heat to vapourize water in popcorn
26
3.9.6
Calculation of the total quantity of heat required for popping
27
3.9.7
Calculation of the quantity of heat required to raise pot to popping temperature
3.9.8
Calculation of the time required to raise temperature of pot to 200°C popping
27
temperature
28
3.9.9
Calculation of the total energy required '
28
3.9.10
Calculation of the total time required for
3.9.11
Calculation of the temperature change required to give to pop corn
'.
~p'rn
to pop
28
29
CHAPTER FOUR
4.0
Material selection/design descriptions/testing and costing
30
4.1
Material section and design description
30
4.2
The popcorn machine consists of essential units which are
30
4.2.1
The control unit
31
4.2.2
The processing unit
31
4.2.3
The housing unit
31
4.3
Operation of the popcorn mach ine
32
4.4
The power transmission unit
32
4.5
Machines used
32
IX
4.6
Tools used
32
4.7
Costing and cost analysis
33
4.8
Results
35
Discussion
35
4.9
('I I!\PTI-:R FIvl ·:
5.0
Conel usion and recollllllendalion
36
5..!
Conclusions
36
Recommendations
36
Refereilces
37
5.2
x