DESIGN AND DEVELOPMENT OF COCONUT FIBER

EXTRACTION MACHINE
Y. Prashant, *C. Gopinath, Vignesh Ravichandran
Department of Design, M. S. Ramaiah School of Advanced Studies, Bangalore - 560 058
*Contact Author e-mail: [email protected]

Abstract
The scope of this project was to design and develop a coconut fiber extraction machine for farmers and small scale coir
industries in India to provide an effective solution to the difficulties in existing process, reduce time and labour cost and to
develop a compact coconut fiber extraction machine which could be used in remote villages so that unutilized husks from
such areas could be tapped and fiber could be made available to the Coir Industry directly. This project was taken up to
develop a promotional strategy for a new innovation and generate public awareness regarding the availability of a coconut
fiber extraction machine in the market at a reasonable cost.
The project began with collection of information and data on user lifestyle and current process by which they perform
their job. The current difficulties were analyzed. Interviews were held with users. A comparative bench marking study was
done on similar processes used in other similar extraction processes. Along with this an ergonomic simulation was made to
understand the user difficulties and manufacturing methods to get an overview to provide solution to the user to suit their
requirement.
Concepts were generated keeping benchmarked product in view. Five concepts were generated with different functions
and operating processes for coconut fiber extraction machine. Final concept was selected by considering the users
operating environment and maintenance, which could be used in small scale coir industries and in the farm sector.
Considering the users needs and buying capacity, a prototype was fabricated. This machine works with gear mechanism, in
which 2 barrels rotates in opposite direction to extract fiber from coconut. Cutting pins are inserted in indexed holes to
separate fiber and to give linear motion to coconut shell.
Validation was carried out with the user group and the feedback was positive. It was noticed that there is potential
market for this product. Further work could be carried in terms of aesthetics, material and weight reduction by adopting
advanced manufacturing techniques.
Key Words: Coconut, Coir, Fiber Extraction, Ergonomics, Industries
and also varied end uses. The traditional production of
fibers from the husks is a laborious and time consuming
process. After separating of the nut, the husks are
processed by various retting techniques generally in
ponds of brackish waters (for three to six months) or in
backwaters or lagoons. This requires 10-12 months of
anaerobic (bacterial) fermentation by retting [3], the
husks are softened and can be decorticated and the fiber
is extracted by beating, which is usually done by hand.
After hackling, washing and drying (in the shade) the
fibers are loosened manually and cleaned. The remaining
residual pith - which was previously considered a waste
problem - has recently found new profitable markets as a
peat moss substitute for horticultural production.
Traditional practices of this kind yield the highest quality
of (white) fiber for spinning and weaving. Retted fibers
from green husks are the most suitable fibers for dyeing
and bleaching. For the production of more coarse brown
yarns shorter periods of retting may be applied. These
find an increasing outlet in geo-textile applications.
Alternatively, mechanical processes using either defibering or decorticating equipment process the husks
after only five days of immersion in water tanks.
Crushing the husk in a breaker opens the fibers. By using
revolving "drums" the coarse long fibers are separated
from the short woody parts and the pith. The stronger
fibers are washed, cleaned, dried, hackled and combed as
shown in Figure 1.

Nomenclature
F
Force (N)
N
Speed (RPM)
T
Temperature (C)
kg
Kilogram
mm
Millimeter
t
Tonne
Abbreviations
PDS
Product Design Specification
QFD
Quality Function Deployment

1. INTRODUCTION
The thickest and most resistant of all commercial
natural fibers, Coir is a coarse, short fiber extracted from
the outer shell of coconuts. India is the largest coir
producer in the world accounting for more than 80 per
cent of the total world production of coir fiber [1]. The
coir sector in India is very diverse and involves
households, co-operatives, NGOs, manufacturers and
exporters. Coconuts are grown in more than 93 countries
in the world and therefore there is considerable scope to
develop coir industry in further countries [2].
Fiber Extraction is the processes of fiber
extraction are varied, and depend on the effectiveness of
the wet processing such as bleaching and dyeing of coir

TECH Journal

SAS

64

Volume 13, Issue 1, April 2014

allowing the lifting of the three posts Boure by letting out

the retractable nuts.

Fig. 1Traditional and Mechanical Fiber

Extractions [1]
2. LITERATURE REVIEW

Fig. 3 US Patent US 4708056 A [4]

2.1 Coconut
Coconut (Cocos) grows in more than 80 countries in
southern and south-western Africa, Latin America and
Asia. "Cocos" is old Spanish/Portuguese language and
means "grinning face", which refers to the facial
expressions at the "top" of the coconut's hard shell from
which it sprouts. Coconut palms have a total production
of coconut fruits of more than 60 million tons per year.
The Philippines is the largest producer followed by
Indonesia and India, but also Thailand, Malaysia, Sri
Lanka, Ghana, Ivory Coast, Tanzania and Brazil are
major producers of coconuts [3]. The parts of the coconut
are as shown in Figure 2.

Fig. 4 EP 0188949 A1 [5]

2.3 Summary of Literature review on Coconut Fiber
extraction machine
Literature study is carried out based on the existing
patents on coconut fiber extraction machine, study gives
opportunity to develop a compact coconut fiber
extraction machine which could be used in remote
villages so that unutilized husks from such areas could be
tapped and fiber could be made available to the Coir
Industry directly.

Fig. 2 Coconut and its parts [3]

3. DATA COLLECTION

2.2 Details of Patents

In competitive market Product design is one of the

essential to success the product, Product design involves
research and on existing designs or products, GEMBA
study to be conduct while doing product design more
ever designer should understand the concepts and basic
requirements of the end user as well manufacturer also.

Chandra Dinanath [4] A machine specifically

designed to remove the husks from the coconut fruit
including a plurality of rollers rotating in opposite
directions effectively toward one another wherein each
roller includes a plurality of penetrating spikes sharpened
to penetrate and effectively engage the husk portion of
the coconut fruit (Figure 3). The interaction of the rollers
in combination with the gripping action of the spike
serves to tear away the husk from the nut leaving the nut
intact.

3.1 Coconut growing states in India

Coconut production plays an important pole in the
national economy of India. According to figures
published in December 2009 by the Food and Agriculture
Organization of the United Nations, India is the world's
third largest producer of coconuts, producing 10,894,000
tons in 2009. Traditional areas of coconut cultivation are
Kerala (45.22%), TamilNadu (26.56%), Karnataka (10.8
5%), Andhra
Pradesh
(8.93%)
and
also Goa, Orissa, West
Bengal, Pondicherry, Maharashtra and
the
island
territories of Lakshadweep and Andaman and Nicobar
[6].

This invention relates to a machine for removing the

husk from the nut portion of a coconut fruit in a manner
which leaves the nut intact and insures that the husk is
separated from the fruit and from the dehusking machine
itself.
Gilles Durand [5] A machine (Figure 4) for removing
the fibrous casing, said fill, the coconut, characterized in
that it comprises: a system of continuous operation does
not require stopping for loading the direction of chains
pins guided nut which cause three rotary blades are
designed to cut the floss after its ternary system and

TECH Journal

SAS

65

Volume 13, Issue 1, April 2014

3.2 Coir (Coconut Fiber)

COIR is a versatile natural fiber extracted from
mesocarp tissue, or husk of the coconut fruit, the general
process of which is shown in figure 5. Generally fiber is
of golden color when cleaned after removing from
coconut husk. Coir is the fibrous husk of the coconut
shell. Being tough and naturally resistant to seawater, the
coir protects the fruit enough to survive months floating
on ocean currents to be washed up on a sandy shore
where it may sprout and grow into a tree, if it has enough
fresh water, because all the other nutrients it needs have
been carried along with the seed. These characteristics
make the fibers quite useful in floor and outdoor mats,
aquarium filters, cordage and rope, and garden mulch.
The husk contains 20% to 30% fiber of varying length.

Fig. 7 Automatic De-husker [6]

3.5 Coconut Fiber Extraction Mills
The husk is collected from the de-husked source and
transported to Fiber extraction mills / industries for
further processes. Husks are buried in pits dug along
riverbanks, immersed in water-filled concrete tanks, or
suspended by nets in a river and weighted to keep them
submerged. The husks typically soak at least six months.
Based on the fiber quality and usage the fiber extraction
processes are defined.

3.3 Flow Chart for Coir Fiber Extraction Process

(Figure 5)

3.6 Market Study

Coir industry in India provides employment to the
tune of five lakhs people approximately of which 3.60
lakhs people belong to Kerala alone. About 80% of them
are women. The women are mostly engaged in fiber
extraction and spinning and men work in the coir
products sector. The industry concentrated in Kerala but
spread over in other States like Tamilnadu, Karnataka,
Orissa, Andhra Pradesh etc. The development of industry
is mainly concentrated in the area of coconut cultivation
and availability of coconut husk.
Production of coir fiber is of the order of 4.2 lakhs
metric tons and production of coir yarn is of the order of
2.8 lakhs. The coir products and rope account for 2.00
lakhs tones. The white coir fiber produced in Kerala is of
superior quality to brown coir fiber produced in other
States mainly Tamilnadu. The cost of white fiber is
double to the cost of brown fiber. In view of this
consumption of white fiber is declining. The total output
of coir and coir products in India estimated to be around
Rs.1500.00 crore including exports of Rs.350.00 crore.

Fig. 5 Flow Chart for Coir Fiber Extraction

Total cost of machineries and equipment used for

De-fibering unit is as show in Table 1:

3.4 Coconut De-Husking Method

Table 1. Market Study [7]

Mechanical De-husker
The user of mechanical De-husker method as in Figure 6:
1. Farmers A skilled husker can manually split
and peel about 2,000 coconuts per day
2. Households 1-2 coconuts per day
3. Hotels 10-20 coconuts per day

Particulars
Crusher (10 HP)
Soaking Tank
Defibering Machine (10 HP)
Revolving Screener including
motor (2 HP)
Turbo Double Cleaner (20 HP
and 15 HP)
Hydraulic bailing press (2 HP)

3,00,000
2,50,000

User study is done by observations of coconut dehusking in remote locations, villages, where farmers used
to de-husk the coconuts by manual. The Steel spear is the
tool used by farmers to de-husk the coconuts. An
experienced worker can de-husk approximately 10001500 nuts per day with the use of this tool. Other than
Steel spear, Lever operated de-husker is well reaching
user in rural market and it is used more often by farmers.

Automatic De-husker
The main users of this type of application practices
are by Oil extracting, fertilizer and food industries, etc.
with the use of coconuts in mass quantity every year.
These machines can process 2,000 coconuts per hour as
shown in Figure 7.

TECH Journal

90,000

3.7 User Study

Fig. 6 Mechanical De-husker

SAS

Cost (in Rs.)

3,50,000
4,00,000
3,75,000

66

Volume 13, Issue 1, April 2014

Pedal operated De-husker is refined design of lever

operated coconut de-husker and it is designed for the
application of farmers. This will help farmers in reducing
de-husking time and increase in productivity. It is
portable in design and height of the de-husker can be
adjusted as per user requirement. The availability and
marketing of this product is not reaching user in rural
areas.

functions forming quality, and to deploy methods for

achieving the design quality into subsystems and
component parts, and ultimately to specific elements of
the manufacturing process.

Coconuts in the husk are very bulky. The de-husked

fiber is being transported in trucks or carts to the fiber/
coir industries for the fiber extraction process.
3.8 Key Findings
With User observation and feedback by
Questionnaires and suggestion from user a few key
findings have been arrived.

The process needs a skilled labor

Difficult to get labor on time.
Difficult to fix it in dry land.
Difficult to stand and De-husk for long time.
Difficult to transport
Direct fiber material can be supplied, instead of
raw husk.

Fig. 9 Ergonomics Consideration [8]

3.9 Customer Voice

Collected feedbacks from user have been converted
to Technical voice through flowchart for understanding
its design factors & requirements are as shown in Figure
8.

Fig. 10 Ergonomics Consideration [8]

5.1 QFD Results
QFD are obtained from inputs from farmers
and coir industries as shown in Table 2. QFD house
results simple, functional, ergonomics are top priorities
as shown in Figure 11.
Machine should be compact
Functionality
Safety
Easy for assemble
Easy for maintenance
Low cost
Good Ergonomics

Fig. 8 Object Tree Mapping

4. ERGONOMIC CONSIDERATIONS
This is the Branch of Ergonomics that address and
deals with measurement of the human external body
dimension in static and dynamic condition. The
Anthropometry points as shown in Figure 9 have been
considered for Coconut fiber extraction machine which
help in deciding its dimension (Figure 10).

6. PRODUCT DESIGN SPECIFICATIONS

(PDS)
Product Design Specification will give clear idea for
the designer to understand the required specification to
design the product. Based on the QFD results, which are
derived from the vendors and customer voices market
study, user study, PDS will be generated. Here are some
of the major criteria considered for product design
specification as shown in Table 3.

5. QUALITY FUNCTION DEPLOYMENT

(QFD)
Quality function deployment (QFD) is a method to
transform user demands into design quality, to deploy the

TECH Journal

SAS

67

Volume 13, Issue 1, April 2014

concepts are generated. For generating these concepts or

proposal ready considered all the points jotted out in
QFD and product design specification (PDS).

Table 2. Quality Function Deployment

Five concepts generated with various factors which

meets the demands like functionality, safety and cost.
Final concept selected for the working prototype
manufacturing. This concept selected based on the dot
selection method.
7.1 Concept-1, Handle operated
Manual operated coconut fiber extraction machine is
considered as first concept, here handle is used to rotate,
for which gears assembled, one gear will give drive to
other gear, and Barrel rotates in opposite direction with
the help of these gears. Coconut with untapped husk is
placed in between barrels. Round coconut shell is
removed by hand after the operation and separated fiber
material is collected in sack below as shown in Figure 12.

Fig. 11 QFD Results

Table 3. Product Design Specification
SL.
No

Description

Specification

1
2
3

Name
Model
Mechanism

Coconut Fiber extraction Machine

CFEM-PKY001-2014
Gears and Pulley with belt drive

Farmers or small scale Coir industry

Target
Customer
De-Fiber
Process
De-Fiber
Function
Material

Manufacturing

Safety

Automatic / Rotary handle operated /

Pedal operated / Spring actuated
EN-08 for Shaft, Stainless Steel for
Cutting tips, Steel for Fabricated body
Machining, Indexing, Bending and
Fabrication
Avoid sharp corners, Safety guards

10

Cost

Approx. 12000/- INR

11

2-3 years

15

Life of the
product
Motor
Specification
Major Pulley
diameter
Minor Pulley
diameter
Pulley Ratio

16

Working RPM

240 RPM

17

Weight

55 KG

18

Production
Rate

100 coconuts per hour

5
6

12
13
14

7.
CONCEPT
SELECTION

Fig. 12 Concept-1 Handle operated

Motor operated

7.2 Concept-2, Handle operated

As name indicates in this concept sewing machine
type paddling mechanism is attached to the base of the
machine, with the help padding drive is given to gears.
Handle is also used to start rotation, one gear will give
drive to other gear, and Barrel rotates in opposite
direction with the help of these gears. Coconut with
untapped husk is placed in between barrels. Round
coconut shell is removed by hand after the operation and
separated fiber material is collected in sack below as
shown in Figure 13.

HP Single phase AC motor, heavy

duty, 1440 RPM
12 (12-B single)
2 (2-B single)
1:6

Fig. 13 Concept-2 Sewing Machine Type

GENERATIONS

7.3 Concept-3, Cycling Type Operated

AND

As name indicates in this concept cycling type

paddling mechanism is attached to the base of the
machine, with the help padding drive is given to gears.
Paddle with chain gear will give to drive to small chain

After all the necessary study and understanding the

customer needs, based on the major requirements

TECH Journal

SAS

68

Volume 13, Issue 1, April 2014

gear sprocket, small chain gear sprocket is attached with

large wheel, and large wheel will give drive to the
smaller wheel with the help of belt drive, which is
connected to gears. Barrel rotates in opposite direction
with the help of these gears. Coconut with untapped husk
is placed in between barrels. Round coconut shell is
removed by hand after the operation and separated fiber
material is collected in sack below as shown in Figure 14.

7.5 Concept-5, Motor Operated Type-2

Motor operated type-2 coconut fiber extraction
machine, this is also same as concept-4, motor is attached
at the base, smaller pulley at the motor end gives drive
with the help V-belt to bigger pulley which is connected
to gear. One gear will give drive to other gear, and Barrel
rotates in opposite direction with the help of these gears.
Coconut with untapped husk is fed from one end in
between barrels and round coconut shell is moved
automatically towards other end and is collected in the
tub after the operation and separated fiber material is
collected in sack below.

7.4 Concept-4, Motor Operated Type-1

Motor operated type-1 coconut fiber extraction
machine, in this type motor is attached at the base,
smaller pulley at the motor end gives drive with the help
V-belt to bigger pulley which is connected to gear. One
gear will give drive to other gear, and Barrel rotates in
opposite direction with the help of these gears. Coconut
with untapped husk is fed from one end in between
barrels and round coconut shell is moved automatically
towards other end and is collected in the tub after the
operation and separated fiber material is collected in sack
below.

In this concept cutting pins has been press fitted on

indexed hole on barrel surface as shown in figure 7.5,
cutting pins helps to remove fiber and to give linear
motion to coconut shell to exit. Cutting pin indexing
angle and distance plays the major role in this type as
shown in Figure 16.
7.6 Concept Selection (Pughs Chart)
Concept selection is done based on Pughs chart,
Sugarcane crusher is used as a Datum for generating the
concepts, main selection criteria is functionality, Safety,
Cost and the Reliability. Based on this criterias Concept5 is selected for model making prototype as shown in
Table 3.

In this concept helical serrated teeth is engraved /

Brazed on barrel surface to remove fiber and to give
linear motion to coconut shell to exit. Helical serrated
teeth play the major role in this type as shown in Figure
15.

Fig. 14 Concept-3, Cycling Type

Helical Pressed Pins

Fig. 16 Concept-5, Motor Operated Type-2

Helical serrated teeth

Table 3. Pughs Chart

Fig. 15 Concept-4, Motor Operated Type-1

TECH Journal

SAS

69

Volume 13, Issue 1, April 2014

7.7 Final Concept

Reviewed each concept and analyzed
thoroughly. Based on weighted ranking method Motor
operated Type-2 concept is selected and finalized for
model making as shown in Figure 17.
7.8 Detail Deisgning
Assembly drawing and drawings for final concept is
done. All dimensions are in mm. below are the drawings
released related to the final concept of coconut fiber
extraction machine as shown in Figure 18.

8. MODEL MAKING
8.1 Raw Material and Standard Parts
Raw materials used for development of model as
shown in Figure18:
Round Rod Dia 63x600 and 650 length
Rectangular 200x175x20
Sheet material for fabrication

Fig. 18 Detail Designing

Fig.17 Final Concept

Fig. 19 Raw Material

8.2 Machining and Assembly

8.4 Final Working Model

Selected the material, size and standard parts, and

identified the industry to proceed with machining.
Various machining processes were carried out for
development of working prototype model for coconut
fiber extraction machine. Turning the round raw material
and milling the rectangular work piece were main and
initial machining operation. Cleaned raw material and
maintained the sizes accordingly as shown in Figure 19
and assembly as shown in Figure 20.

Final working model is as shown in Figure 22.

9. PRODUCT VALIDATION
After manufacturing working model, product was
validated by checking its features and some of the key
functions. Below are the some of the functions are
checked.

8.3 Fabrication and Painting

As a part of product feedback and validation,

product was validated. Complete demo of work model
and Coconut fiber extraction process with the help of
product was presented in front of few customers. They
were very impressed with product and collecting process.
Below are the comments.

Sheet material is fabricated to Stand or base of the

machine with the tack welding. Latches and inches were
also welded and assembled for protection cover. For
partial maintenance in emergency condition latches and
inches are provided for protection cover. Hand grinder is
used to give finish for tack weld portions. After
fabrication of the product, it is taken for painting. Based
on the industrial design and modules studied, painting
color is selected for this product and painting is done as
shown in Figure 21.

TECH Journal

SAS

70

Working length to increase

RPM reduction
Pin pitch reduction

Volume 13, Issue 1, April 2014

Fig. 22 Final Working Model

QFD and PDS helped in generating concepts.
Benchmarking of existing products is also carried in
existing Coir industries. Model making gave an
opportunity to learn model making techniques,
manufacturing process and difficulties involved during
this processes. It helped to understand about each and
every process that carried out from start to completion of
the prototype work model of coconut fiber extraction
machine.
Concepts were generated keeping benchmarked
product. Five concepts are generated with different
function and operating process for coconut fiber
extraction machine. Final concept is selected by
considering the users operating environment and
method, which can be used in small scale coir industries
and in the farm. That means it should be easy to
maintain. Considering the users buying capacity a true
scaled product is fabricated.

Fig. 20 Machining and Assembly

10.2 Conclusions
Below are some of the conclusions based on new
derived process and new designed product & its
functions.
Based on the Design concepts and
development, output of the product. This
product can de-fiber 100 coconuts per hour and
it will be good for Farmers and small scale coir
industries.
Easy to assemble.
Easy Maintenance
About the market, this model is compact with
good range of productivity with low cost and
safety.

17.3 Recommendations for future work

Fig. 21 Fabrication and Painting

10. CONLUSIONS
10.1 Summary
The project comprises of research and user study.
Literature study is carried out based on the existing
patents on coconut fiber extraction machine, and it is
observed that there are difficulties for remote village to
supply unutilized husks to coir industries directly. So
there is a need to give solution to overcome their
difficulties and to arrive at solution, importance is given
towards users operating environment and mainly towards
constrains like Safety, Function and reliability.

TECH Journal

SAS

RPM to be reduced to 120rpm

Indexing pitch has to decrease
Length of the shaft can be increased
Pitch between the shaft can be reduced by 5mm
Hollow Shaft (tube) can be used.
As we are offering this product with new
design to farmers and small scale coir industry,
need to undergo further refinement.

18. REFERENCES
[1] MSME, Evaluation Study of Domestic Market
Development Assistance Scheme implemented by
Coir Board, http://msme.gov.in/Coir%20Board71

Volume 13, Issue 1, April 2014

Impact-Domestic-Market-Assistance-Scheme.pdf.
Retrieved on15 th Jan. 2014.
[2] Food and Agricultural Organization of the United
Nation,
www.fao.org/economic/futurefibres/
fibres/coir/en, Retrieved on 15th Jan. 2014.
[3] Palm
Shells,
Coconut
Palms,
http://www.palmshells.com/cocoshells.html,
Retrieved on 15th Jan. 2014.
[4] Chandra Dinanath, Coconut dehusking machine, US
patent
US4708056,
www.google.co.in/patents/US4708056, 28 Jan.
1987.
[5] Gilles Durand, Apparatus for Dehusking Coconuts,
EP0188949, Coconut breaking machine, US patent
US3605834,
http://www.google.co.in/patents/US3605834, 20th
Sep. 1971.
[6] Coconut
Machines,
www.coconutmachine.com/index.php?mid=72,
Retrieved on 15th Jan. 2014.
[7] Coir Machines, Coir Fibre Extraction Machinery,
http://www.coirmachines.net/coir-fibre-extractionmachinery.html, Retrieved on 15th Jan. 2014.
[8] Debkumar Chakrabarthi, India Anthropometric
Dimensions, NID, Ahmedabad: National Institute of
Design, pp100, 1997.

TECH Journal

SAS

72

Volume 13, Issue 1, April 2014