ADIGRAT UNIVERSIYY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
(MANUFACTURE ENGINEERING)

DESIGN AND MODELING OF SEMI-

AUTOMATIC BUTTER EXTRACTING MACHINE
A thesis submitted in partial fulfillment in BSc.
degree in mechanical engineering (manufacture
engineering)
PREPARED BY: -
NAME ID NO
1. ASMELASH GEBREHIWOT------------------------------RU/3842/09
2. HAFTOM ABRHA--------------------------------------------RU/3841/09

ADVISER: KALAYU (Dr.)

Adigrat University, Ethiopia Tigray

March 2024
 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

DECLARATION
This thesis presents work carried out by ourselves and we modified from the incorporate
previous acknowledgment where due reference is made in the text; and all substantive
contributions by others to the work presented, including jointly authored publications, are
clearly acknowledged.

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 ACKNOWLEDGEMENT
First, we would like to thanks Almighty God the more beneficent and merciful for guiding
us more patient in order to finish through this project. Secondly, we would like to thanks for
special of our appreciation and gratitude to our advisor for the project, Mr. KALAYU (Dr).
For their patience and constructive advice, throughout the project. Furthermore, we are
grateful to him for the reviewing of our project with great care and attention, and for their
precise and exact comments and suggestion that contributed much to the improvement and
completion of this project. Lastly, we want to thank for our families and our friends, who
gave us physical, financial and emotional assistance in our project.
 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

TABLE OF CONTENTS
DECLARATION .......................................................................................................................i
ACKNOWLEDGEMENT ....................................................................................................... ii
TABLE OF CONTENTS ....................................................................................................... iii
LIST OF FIGURES .................................................................................................................. v
LIST OF TABLE .....................................................................................................................vi
ACRONYOM ..........................................................................................................................vi
ABSTRACT ..............................................................................................................................i
CHAPTER ONE ....................................................................................................................... 1
1 Introduction............................................................................................................................ 1
1.1Background of the project ............................................................................................... 1
1.2Problem statement ........................................................................................................... 5
1.3 Objective of the project .................................................................................................. 5
1.4. Significance of the project ............................................................................................. 5
1.5. Scope of the project ....................................................................................................... 5
1.6 Expected outcomes ......................................................................................................... 6
1.7 Limitation of the project ................................................................................................. 6
CHAPTER TWO ...................................................................................................................... 7
2 Literature Review .................................................................................................................. 7
2.1. Concept description for the proposed design ........................................................... 10
CHAPTER THREE ................................................................................................................ 11
3 Material and Method ............................................................................................................ 11
3.1Material .......................................................................................................................... 11
3.2. Method ......................................................................................................................... 11
3.3 Working principle ......................................................................................................... 12
CHAPTER FOUR .................................................................................................................. 13
4. DESIGN AND FORCE ANALYSIS ............................................................................. 13
4.1. Design specification................................................................................................. 14
4.2. Design of bevel gear .................................................................................................... 15
4.3. Shaft design ................................................................................................................. 22
4.4. Design of key ............................................................................................................... 23
4.5. Design of cylinder ........................................................................................................ 26
4.6. Bearing selection ......................................................................................................... 29

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 4.7. Design of crank shaft ................................................................................................... 31
4.8. Design for cylinder holder ........................................................................................... 31
4.9. Design of frame ........................................................................................................... 33
4.10. Design of bolt and nut................................................................................................ 34
4.11. Design the sliding bar ................................................................................................ 37
4.12. Design of blade .......................................................................................................... 38
4.13. Motor Selection ......................................................................................................... 38
4.13.1. Selection of Belt ................................................................................................. 39
4.14. Design of housing ...................................................................................................... 41
CHAPTER FIVE .................................................................................................................... 42
5 RESULT AND DISCUSSION ........................................................................................ 42
5.1 RESULTS ..................................................................................................................... 42
5.2 Discussion ..................................................................................................................... 42
5.3 COST ESTIMATION ................................................................................................... 43
CHAPTER SIX ....................................................................................................................... 44
6. Conclusion and Recommendation ...................................................................................... 44
6.1. Conclusion ................................................................................................................... 44
6.2. Recommendation ......................................................................................................... 45
Reference ................................................................................................................................ 46
APENDIX ............................................................................................................................... 47
 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

LIST OF FIGURES
Figure 1. 1Traditional process of making butter in Raya ......................................................... 2
Figure 1. 2 Some-Churning Methods In Ethiopia A) Pot Rolling B) Pot Oscillating C) Rope
Supported Agitation .................................................................................................................. 3
Figure 1. 3.Plunge Churn Or Dash Churn ................................................................................ 3
Figure 1. 4.Paddle Churn .......................................................................................................... 4
Figure 1. 5.Barrel Churn ........................................................................................................... 4
Figure 4. 1.Bevel gear ............................................................................................................. 16
Figure 4. 2.shaft ...................................................................................................................... 22
Figure 4. 3.Cylinder ................................................................................................................ 26
Figure 4. 4. Ball Bearings ....................................................................................................... 29
Figure 4. 5. Cylinder base holder ............................................................................................ 31
Figure 4. 6.blade ..................................................................................................................... 38
Figure 4. 7Motor ..................................................................................................................... 39
Figure 4. 8V-belt ..................................................................................................................... 40
Figure 4. 9.housing ................................................................................................................. 41

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 LIST OF TABLE
Table 3. 1materials for the design project .............................................................................. 11
Table 3. 2.the churning efficiency obtained with the traditional clay pot churn in Ethiopia . 15
Table 5. 1.Result and discussion............................................................................................. 42
Table 5. 2Cost estimation ....................................................................................................... 43

ACRONYOM
 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Vc = volume of cylinder D = outer diameter

H =height d = internal diameter
L = length p = pitch
Fsep= separation force A = area
N = numbers of revolutions dc = core diameter
T = twisting moment Z = number of threads
Tg = number of gear teeth I = moment inertia
Tp = number of pinion teeth Tc = centrifugal tension
Dg = pitch diameter of Gear ρ = density
Dp = pitch diameter of pinion ω = angular velocity
VR = velocity ratio τall= allowable shear stress
b = face width δy = yield stress
Wt = tangential load δt = tensile stress
V = velocity δc = crashing stress
M = bending moment ɵp1 = pitch angle of pinion
F = force ɵp2 = pich angle of gear
n = factor of safety ɵs = angle b/n two shafts
t = thickness
ᵦ= grove angle

ABSTRACT
Many countries like Ethiopia have not a problem on natural resources rather it is
obviously known that there are problems how to use these natural resources properly.
Even currently, there is no proper usage of the product of mammals that is milk, butter,
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& yogurt. Meaning that, there is not sufficient butter in our country due to the
traditional way of gathering and extraction method. Because of this, the supply of
qualified butter is less in our country. In our country, (especially in village called Raya
Azebo and borena where many cattle are bred) the people use traditional ways to
extract butter from milk. They waste their time and energy as well as they get poor
extracted butter. To solve this problem, it is planned to design & modelling butter
extractor machine by considering less operating time and simplest method of
mechanism than the traditional one. A butter extractor (churner) machine is a portable
machine consisting of a mechanical mechanism used to convert cream to butter.
Although a butter churner is a simple device that used to convert cream to butter,
various types of loads; proper size, strength, and stability are essential requirements for
design of the butter extractor from safety consideration aspects. In this design it is
going to determine; the stress developed and force required, the power and dimensions
of gears and pinion, the required torque to churn the butter, efficiency of the churner,
and operational of the system. The working of this machine is when the motor shaft is
turned by electric motor, then, the motion will be transferred to output shaft by means
of bevel gears. When the gear is turned, it transfers the motion to the smaller gear that
is connected to the blade. The blade rotates with the same velocity (speed) that of gear
attached to it. The rotational motion of the blade disrupts the milk fat and converts
cream in to butter. The upper working of the churn could be removed from the lower
container and this allowed for rapid cleaning after use.

Key word: churn, disrupt, bred, extracted

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CHAPTER ONE
1 Introduction
Consumption of butter in Ethiopia is increases as the result of increasing demand brought about
by the rapid population growth and improved living standards of the rural areas. As a result,
there has been a serious shortage of edible butter on the market and exaggerated rise in price
where the government was forced to intervene. The intervention of the government, however,
has not brought about a sustainable solution and it has opted to ensure a different direction.
Believing that fixing the price alone cannot ameliorate the shortage sustainable; it is working
hard to adopt technologies that will play pronounced role in improving the availabilities of the
most demanded goods like butter by producing them locally.[1]

To assess the existing situation of the butter industries in Ethiopia, a number of researches
indicate that the significance of the edible butter sub-sector in the Ethiopian economy has been
declining. For instance, the edible butter sub-sector accounted for 1.5 percent of the value added
of the Ethiopian manufacturing sector in 1995/96, while the level of contribution, at 0.7%,
shrank by half in 2003/04. [3]

On the other hand, Ethiopia is one of the highest potential butter-rich mammals’ producers.
Ethiopia is the tenth world in number of mammals. Ethiopia, as one of the major producers has
shown the potential to benefit from this opportunity by exporting to the European Union. [3]

Today, the scope of supply for butter making includes cream treatment, complete butter plants,
butter buffer and butter pumping systems, butter extraction, butter packaging, blending of
different types of butter, butter reworking and butter melting. The designed extraction machine
be equipped with advanced general or the special-purpose molds and easy operation, high
efficiency, warmly welcome by the customer. [1]

1.1Background of the project

Butter is the smooth, fatty substance obtained from churning cream with fat content of at least
35%. It is a dairy product made by churning fresh or fermented cream or milk, to separate the
butterfat from the buttermilk. It is generally used as a spread and a condiment, as well as in
cooking, such as baking, sauce making, and pan-frying. Butter is consisted of butterfat, milk
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proteins and water. Mostly butter is made from cows' milk, and, it can be manufactured from the
milk of other mammals, including sheep, goats, buffalo, and yaks. [3]

1.1.1How butter is made?

Simple agitation of the cream in machines known as churns ruptures the membranes of fat
globules and these globules then group into granules of butter. Because only the milk fat is used,
ten liters of whole milk is required to produce 500 g of butter. [5]

Butter is made by separating cream from milk. Since fat-based cream portion of milk is lighter
than water and milk portion, the cream of fresh milk eventually will raise to the top of the milk
over time if the milk is simply stopped. However, a centrifuge, which features very strongly,
can be used to accelerate this process. I.e. when the milk is centrifuged, the lighter cream will
stay closer to the center and the heavier water and solid portions will air on the outside of the
centrifuge. Once the cream has been separated from milk, it can be churned until it reaches a
semi-solid state. This product is what we call butter. [5]

1.1.2Types of churning machines

A.Manually operated

1. Traditional shaker:

These are traditional methods of churning which extract butter from milk by shaking or
oscillating a pot full of milk. Figure 1 shows traditional process of making butter in Raya and
figure 2 shows different methods in other cultures of Ethiopia i.e. figures (a) shows pot rolling,
(b) pot oscillating, (c) rope supported agitation. [3]

Figure 1. 1Traditional process of making butter in Raya

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Figure 1. 2 Some-Churning Methods In Ethiopia A) Pot Rolling B) Pot Oscillating C) Rope

Supported Agitation

2.Plunge churn or dash churn

A stick called a dasher or churn dash is moved up and down by hand in an upright container,
usually made of wood or earthenware. A churn lid from 1400 years ago, with a hole for the
stick, shows that this method has a long history. The stick might be perforated, or it could have
a wooden circle, or crossed boards attached, but even with those to help beat the cream, this
method took longer than using the more complex kinds of churn, which were introduced in the
18th century, and became popular in the 19th century. [2]

Other names for this long-established kind of churn are “up and down” churn, churning tub,
plunger churn, plumping churn, knocker churn, plump-kirn, or plowt-kirn. (Kirn is a Scots and
Northern English word for churn.) Other names for the dash are dasher-staff, churn-staff,
churning-stick, plunger, plumper, or kirn-staff. Churns based on a pot and sticks are used in
Asia too. Ropes and pulleys, handled by one or two people, often operate Indian churns. Tibetan
yak butter is also made with a dasher in a container, as pictured right. [4]

Figure 1. 3.Plunge Churn Or Dash Churn

3. Paddle churn

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A wooden box or earthenware crock had a paddle inside attached to a rod, which is turned by a
handle on the top or side. These contraptions, which could also be metal, are widely sold as
small, convenient household churns in 19th century America or this early 20th century glass one
in use in the US in the 1940s. This sort of churn was also used for domestic butter making. [2]

Figure 1. 4.Paddle Churn

4. Barrel churn

The whole churn might be turned round by a handle, or the handle would operate a crank
turning paddles inside the barrel. Some were squarer looking and called box churns. There are
also barrel- and box-shaped churns, which swung or rocked instead of turning. More elaborate
barrel churns were probably for larger-scale farm production and don't really count as household
items. [1]

Figure 1. 5.Barrel Churn

B. Semi-automatically Operated

The help of motor rather than manual operates this machine. In this case, the motor rotates the
input shaft by the help of electric force and then the gear transfers rotation to the output shaft.
The shaft has impellers attached to its end, which are used to produce centrifugal force. This
force is used to separate butter from milk. [7]

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1.2Problem statement
Traditionally, Butter extracting methods has not been produced the qualified butter output.
Because, it was observed that most butter extraction was done by redundant movement of local
pots. This take a lot of time with high level of wastage; but low efficiency, this tends to be
unable to increase productivity even with some hand operated simple tools. The operating time
of traditional extractors, which works with compression, is very low to compare the other
system and the manually operated butter extraction machine is more labor energy consume,
more time consumes, low performance of butter produced and the quality of butter produced is
low.

1.3 Objective of the project

1.3.1. General Objective

To design and modeling of semi-Automatic Butter extracting machine.

1.3.2. Specific objectives

 To design components of butter churner machine
 To minimize butter churning time consumption and force through force analysis
 Parts & Assembly drawing with the help of software
1.4. Significance of the project
The merit of this project is to satisfy the customer who wants to buy smart semi-automatic
Butter extraction machine with an appropriate cost. The design will be a good capacity as the
user keeps their time. Someone may be able to repair this extraction machine simply so, it
solves the problems of extraction. To use this machine and give service just the worker will
disassemble in a simple method because it has not a complex system and parts.

1.5. Scope of the project

This paper gives a real emphasis about the current issue of butter extraction. The paper
illustrates introduction and background of the butter churning, literature reviews that define and
give emphasis about butter with respect to its extraction, material selection, design and
geometrical analysis as well as part design calculation via assembly by using a software (like

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solid work), results and discussions of the calculation with conclusion and recommendation on
the discussed result.

1.6 Expected outcomes

From this project will expect that the design will have high aesthetic value, faster, structurally
durable, ecofriendly and low-cost butter extractor. Farther more, the expected results of this
project will include:
Be easily maintainable and marketable machine for the case of productivity.
Provides its function up to 10 years and above by maintaining.
Be simple in operation providing high production rate and low cost
machine.

1.7 Limitation of the project

Limitation of this study to go beyond the scope of the study is related with finance, time and
other constraints, in addition to this the internet access, resulting in lack of confidence and
commitment by others.

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CHAPTER TWO
2 Literature Review
(Berhanu Gebremedhin 2014) studied and analysis the Ethiopian butter value chain and his
study was based on two sets of data: one is the Improving Productivity and Market Success of
Ethiopian Farmers (IPMS) project’s rapid butter market appraisal and the other is the Livestock
and Irrigation Value Chains for Ethiopian Smallholders (LIVES) project’s baseline data. The
rapid assessment study describes the butter production and marketing system. He concluded that
to improve processing of butter, collective action to churn butter could result in a reduced labor
burden on women as well as reduced labor cost per unit of butter. Introducing improved, larger
capacity butter churns as well as group formation maybe explored to encourage such
development. Marketing of butter may be improved through collective action. However, it is
recommended that an assessment of the existing private butter marketing system (including the
Addis Ababa market) be conducted to identify possible improvements.

(Aljaafreh 2015) Propose a new method to determine the physical ripening time of the butter
churning process based on the acoustic emission in Math Lab software. They used digital signal
processing techniques to extract features from the sounds of the churning phases. They
categorized the churning sounds in to three categories; 1) the churn, 2) the butter begin, and 3)
the buttercollection phase. They considered each sound as a class and artificial neural network,
which is used as a classifier. An average correct classification rate of 98% is obtained. Finally,
they conclude that acoustic emissions are efficient features that can be used for butter churning
automating process.

(Paropate and Gorde 2016) Designed and developed a pedal operated churner machine for
rural areas. They show that a churner is the mechanism, which is used to stern creamy mixture
or curd and turn out butter. In their work they found that in churning process the fatty particles
from creamy mixture gets separated and forms layer at the top of the pot due to density
difference. This layer is then collected and known as butter. Finally, they concluded that by
using this mechanism milkman can save time as well as efforts with producing high quality and
quantity of butter. they observe that initially time required to produce butter from 5 litter of milk
average time required by conventional process(manually) is 15.02 min and oxygen consumption

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is increased by 3.80. By using this mechanism time required to produce butter from 5 litter milk
average time is 5.62 min and oxygen consumption is increased by 2.01. Hence, this mechanism
can save time 9.4 min with minimum oxygen consumption i.e. 1.79, which indicate less efforts
are required compare to conventional process.

(Gender and Case 2017) Conduct joint experimentation (participatory innovation

development) that takes into account gender aspects in improving the design of new modified
churner to have better performance in terms of simplicity of use, saving time and productivity
rate. In their experiment, they compare the traditional and the new modified manually operated
churner. More effort exerted in the traditional compared with the new design. Also, the two
hands were used in churning process when traditional is used, in the new design only one hand
is used in the operation. The cleaning is so easy in the newly designed compared with the
traditional one. Furthermore, they found that churning time for the traditional churner is 45 min
and churning time for modified churner is 30 min. From their work they concluded that the new
churner gives good results in cleaning process, hygienic and less effort exerted.

(Mohammed, E. Tadesse, and T. Gemechu 2017) conducted a study in two district places of
West Arsi zone to demonstrate and evaluate improved plastic milk churner there by reducing
women’s workload in churning activity. They distributed and evaluated 17 improved plastic
milk churners by participating women farmers grouped in farmer’s research groups (FRGs). The
results showed a significant difference in time of churning resulting in 0:39± 0.01hrs for the
improved plastic milk churners and 1:05±0.01 hr. for the traditional clay pot churners. But they
didn’t find statistically significant difference on butter yield between the churners in the study
areas. Nevertheless, the improved plastic churner were found to be more time saving than the
traditional clay pot churners and they recommended for further scaling up works.

(Zelalem Yilma 2003) Evaluated four butter-making methods (3 traditional: clay pot - CP,
'mesbekia' - M - a wooden agitator with three to five finger like projections at one end, and a
combination of the two - CP+M; and one improved internal wooden agitator fitted to the
traditional clay pot - IWA) evaluated for their efficiencies in terms of fat recovery and churning
time at 12 smallholder milk producers in the central highlands of Ethiopia. Thy collected about
21 liters of milk which is needed to produce one kg of butter (83% total solids). An average
churning time of 222 min was recorded for the three traditional methods with a mean fat
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recovery of about 90%. Churning time was significantly reduced by 65% for the IWA as
compared to the average of the 3 traditional methods.

(Tsedey 2018) Conducte an experiment to evaluate of butter making efficiency, churning time
and butter amount obtained from the traditional butter churner (clay pot) in relation to improved
manual butter churner in Sidama zone. She select a total of 54 women farmers from three
dairying potential districts where milk processing for butter making has long tradition. She
evaluated the efficiency of both churners by using five-liter milk obtained from local breeds.
The volume of both of the churning equipment was 20 liter. She found that the improved
churner gives significantly higher quantity of butter (0.41 kg/5liter) than traditional clay pot
(0.26kg/5liter). Furthermore, the traditional mechanism of butter processing took significantly
longer churning time (59 minute) than improved churner (26minute). She ranked the quality of
butter obtained from improved churner from very good to excellent by 96% of respondents
while the butter obtained from traditional churner was favored only by 15% of the respondents.
In contrary, the butter milk obtained from improved churner was ranked from very good to
excellent by about 48% respondents compared to 59% for the butter milk obtained from the
traditional churner. The findings have also figured out that butter making efficiency of improved
churner was almost double (82%) than the traditional churner (50%). Finally, she concluded that
improved churner is preferred to local one for its ability to yield better amount of butter, more
butter making efficiency and shorter churning time it required. For rural areas of Ethiopia where
women are responsible for feeding the family and investing almost all income to the family,
obtaining more butter could enhance income and dietary diversity of the household. Moreover,
the improved butter churner has saved workload and drudgery of rural women by reducing their
churning time. Using improved churners could also contribute for reducing gender disparity
through participating men in milk churning process Therefore, it is suggested that improved
milk churner needs to be introduced, demonstrated and promoted to smallholder dairy farmers
not only within the study region, but also beyond. Market linkage need also to be established
between suppliers of improved churner machine and dairy farmers at reasonable cost.

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2.1. Concept description for the proposed design

In this project, it is proposed for suitable materials for fabrication based on the principle of the
milk churning instead of shaking as in the traditional methods. The churning is done by using
blades attached to a shaft, driven by a motor, which is connected, to the shaft using bevel gears.
The blades are submersed in the milk to agitate it until the butter separates. In our design, we
will decide to use materials that do not affect milk quality. This process makes the milk
churning easy with high rate in quantities, by transmitting high mechanical torque, from the
motor to the agitating blades. The design made simple to meet the local manufacturing abilities.

The design principle of the churn is based on agitating the milk until the butter separation
happens, instead of shaking, as in the traditional methods. Therefore, it is composed of number
of parts acts as an agitator shaft with blades attached on bearings fixed to a bar that could be
adjusted to the desired height. The plastic bucket is placed on the base, so the agitator
mechanism to be inserted inside it. All parts made from plastic, stainless steel, alloy steel, and
assembled by riveting, bolting and welding. When the milk is well prepared as sour milk, it is
then placed in the cylinder hall to about 2/3 limit and submersing the agitator inside in a
position of center. The motor starts rotation if it becomes on. This motion is then transmitted to
the shaft via the gear. This action generates high turbulence in the milk molecules, which makes
the butter, assembles and floats on the top surface of milk.

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CHAPTER THREE
3 Material and Method
3.1Material
Table 3. 1materials for the design project

Part No. Part Quantity Material

1 Cylinder holder 1 Alloy steel
2 Frame 2 Mild steel
3 Cylinder 1 Stainless steel
4 Shaft 2 Stainless steel
5 Blade 6 Stainless steel
6 Gear 2 Alloy steel
7 Motor 1
8 Housing 1 Alloy steel
9 Belt and pulley 1&2
10 Bearing 2
11 Key 4 Mild steel

3.2. Method
Project design

On this project, the design contains different types of mechanical components, which are done
by analytical processing and modeling as well.

Data types, sources and instruments of data collection

 Books
 Internet.
Data processing and analysis

 Identify the components

 Selecting materials for the component

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 Check the strength of the components using maximum shear stress theory and maximum
principal theory
 To prepare modeling of the components using solid work.
 part drawing and assembly drawing

Start

Literature review

Concept generation

Design assumption

Material selection

Design analysis
No
Result and Discussion Is it safe?

Yes
3D modeling by solid work

Conclusion and recommendation

3.3 Working principle

To develop semi-automatic butter extraction machine mainly contains cylinder, shaft
with blades, crankshaft, electrical motor, gear housing, bearing, belts, pulley and bevel
gear. In semi-automatic butter extraction machine is simply done by using motor. In this
case, the motor is connected on the crankshaft to transmit rotational applied force by
using of belt. The belt is directly attached to the pulley, which is fixed on the end of
crank Shaft. that can drive the bevel gears and the bevel gear is connected with blade
shaft. Then after, the blade rotates to churn the yoghurt which is inside the cylinder. This
action generates high turbulence in the milk molecules, which makes the butter and
floats on the top surface of milk.

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CHAPTER FOUR
4. DESIGN AND FORCE ANALYSIS
Design is the creation of new and better machines and improving the existing ones. A new
semi-automatic better extraction machine is one, which is more economical in the overall cost
of production and operation.

General Considerations in Design

Following are the general considerations in designing machine components:
i. Type of load and stresses caused by the load.
ii. Motion of the parts or kinematics of the machine
iii. Selection of materials.
iv. Form and size of the parts.
v. Convenient and economical features
vi. Use of standard parts.
vii. Safety of operation
viii. Cost of construction.
ix. Assembling.

Milk properties

1) The density of milk decreases, if the temperature increases.

2) The density of raw milk varies between approx. 1.026 g/cm3 and 1.034 g/cm3 at 20°C
3) Temperature coefficients of milk is 2.7 to 3.1 x 10-4 g/cm³/°C
4) The freezing point of milk is usually in the range of -0.512 to -0.550° C with an average
of about -0.522° C.
5) Specific heat at 40 OC is about 2.1 kJ/ kg K
6) Specific gravity of milk is 1.035
7) Cow’s milk contains about 87% of water content.

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4.1. Design specification

Volume of the cylinder, Vc =25 liters =25*10-3m3

Height of cylinder, hc=400mm=0.4m. Vc=πr2hc ;

25 L= πr2hc=25*10-3m3

25*10-3 m 3 = πr2*0.4m.

r = 141mm

Where, r is the radius of the cylinder. Therefore, diameter of the cylinder gives us
ɸ=141mm*2=282 mm.

From this assumption, we can take diameter of the blade to be 140mm.

Now, we can calculate the separation force between milk & butter as follows

Specifications;

Density of butter ρ1=911─940 kg/m3

Density of milk, ρ2 =1026 ─1035kg/m3;

For our design, we have taken the density of butter, ρ1=911 kg/m3.

And density of milk ρ2 =1034kg/m3.

Separation force, Fsep = (ρ2─ ρ1) ω2r

Take, ρ1=911 kg/m3And ρ2 =1026 kg/m3.

2𝜋𝑁
Where, ω ˭ = (2*π*300)/60=31.4 rad/sec
60

Fsep= (1034─911)*(31.4) 2*0.07

540.7 N/L.

Note that this is only for one liter of milk; therefore, for 25 liters the separation force is,

Fsep =25L*540.7N/L=13.5KN.

Churning efficiency

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Since the traditional churning machine consumes more time to extract butter because, the
revolution of the milk or the churn is minimum.
Table 3. 2.the churning efficiency obtained with the traditional clay pot churn in Ethiopia

No. Milk quantity in litter Milk acidity in (%) Temp. in (oc) Time (min)
1 11 0.89 16 150
2 13 0.74 19 105
3 7 0.84 15 105
4 11 1.15 20 32
5 4 0.92 19 18
6 17 1.04 17 219
7 18 1.03 18 98
8 17 0.43 19 303

From the above data, we can know the number of revolution, N in rpm.
For manual butter extraction machines take N = 0.5 r/sec = 30 rpm.
For our specification, we need the time required at 20 oc with manual extraction machine. t@
20 oc =32 minutes, when the milk acidity equals to 1.15% and volume=11 litter.
This manual extraction machine rotates with a rotation of 27.5 rpm.
For our design, (the semi-automatic operated churning machine) N is 300rpm. Since the number
of revolutions is much greater than that of the manually operated butter extraction machine,
mathematically we can manipulate the time taken as follows:
300𝑟𝑝𝑚
N = 27.5𝑟𝑝𝑚y=32min.
10.9y = 32 min
y=2.93min.

For 25 liters, the time required is;

11liter = 2.93min
25 liter = t
t= 6 min.
Bear in mind that this time is quit differ from that of the manually one.
4.2. Design of bevel gear
Gear is the geometry, kinematic relations, and the forces transmitted by the four principal types
of gears: spur, helical, bevel, and worm gears. The forces transmitted between meshing gears

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

supply torsional moments to shafts for motion and power transmission and create forces and
moments that affect the shaft and its bearings.

Bevel Gearing—General

Material selection for bevel gear

The standard material we selected for bevel gear is Alloy steel with a Yield stressof 200 (MPa),
Allowable static stress 105 (MPa) and a tensile stress of 300 (MPa).

It is obvious that Alloy-cast iron has significant properties such as; high wear resistance, high
strength and has good Corrosion resistance.

Figure 4. 1.Bevel gear

Assume that;

T g =number of gear teeth

T p = number of pinion teeth

Dg= pitch diameter of gear

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

DP= pitch diameter of pinion

ωp= angular speed of pinion

ωg=angular speed of gear

VR= velocity ratio which =5 for our design

θp1= pitch angle of pinion

θp2= pitch angle of gear

θs= angle between two shafts = 90° for our

design.

1 1
Θp1 =tan-1𝑉𝑅 =tan-15=11.3°

θp2=tan-1VR=tan5=78.7°

Note: For satisfactory operation of bevel gears, the face width (b) should be from 6.3m -9.5m
and ratio of l/b should not exceed five. And also the number of teeth in the pinion must not less
than

48 = 48 =20
1+(VR) (2)1+(5)2

Hence T p = 20 and

T g = 100

Strength of bevel gears

Wt= (δox Cv) b π M y’ (1-b/1)

Where δo= allowable static stress, which 105 MPa for our design

Cv=velocity factor = 3/(3+v) for teeth cut by form factor

V= peripheral speed in m/s

M=module

y’=tooth factor = 0.124 - 0.686/Tep for pressure angle 14.5°

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Tep= the number of teeth equivalent of spur gear

=Tp x secθp1

b= face width

Wt= tangential load

1-b/1 =bevel factor

l= slant height of pitch cone

𝐷𝑃
=
2𝑠𝑖𝑛𝜃𝑝1𝜃

Since the allowable static stress (δo) for both pinion and gear is the same (105 MPa) the pinion
is weaker. Thus, the design should be based on pinion.

𝑇
𝑊𝑡 =
𝐷𝑝/2

=2T/MTp = 2x6.65/(20M)=13300/20*M=665/M.

2𝜋𝑁𝐷𝑃/2
V= =16*200/6000=12.5M (m/s)
60∗100

𝐷𝑃
L= 2𝑆𝑖𝑛𝜃𝑝1=20m/2sin11.3o=51M where Dp= number of teeth x module =Tp x M
b=L/3=51M /3=17M.

Tep=Tp x secθp=20xsec11.3°=20.4

y’p= 0.124 -0.686/Te =0.124 - 0.686/20.4=0.09

Cv=3/(3+V) =3/(3 + 12.5M)

Wt= (δoxCv) bπMy (1-b/1)

615/M= (105) (3) /(3+12.5M) ×π

×(17M)
×M×0.09(51mm−17mm/51mm)

665/M =(315/3+12.5) *4.8M2*(34/51)

M3 =665/M.

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

M3 - 8M -2 = 0.

Solving the expression by hit and trial method we find: M= 2.96 say 3 mm

b= 17M=17x3= 51 mm

L=51 *3 =153mm.

Dp=M * Tp =20 *3 =60mm

Dg=MxTg =100 * 3 = 300mm

Addendum =a=1 x M=1x3= 3mm

Dedandum=d=1.2 x m= 1.2 x3=3.6 mm

Addendum diameter of pinion = Dp + 2acosθp

=32+2x2 cos18.34

=35.79mm take 36mm

Addendum diameter of gear= 35.795x3

=107.385mm take 108 mm

The proportion of the bevel gear

Addendum=1M=1*3=3mm

Dedendum, d=1.2M=1.2*3=3.6mm

Clearance, c=0.2M=0.2*3=0.6mm

Working depth=2M=2*3=6mm

Thickness of the teeth, 1.5708M=1.5708*3=4.7124mm

Addendum diameter of pinion,=Dp+2a* cosθ1

= 60mm+2*3*cos11.3

=65.88mm

Addendum diameter of the gear, 65.88*5=329.4mm

Dedundum diameter of the pinion DPd=DP-2dcos cosθp1

=60-2*3.6cos11.3

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

=52.9mm take 53 mm

Dedundum diameter of the gear=52.9*5=264.6mm

Dedendum angle, it is the angle subtended by the face angle of the tooth at a cone center and it
is denoted by β.

Mathematically β=tan-(d/l) =Tan-(3.6/153) =1.35

Where, d= dedundum

L=come distance

Addendum angle is subtended by the addendum of the tooth at a come center.

Addendum angle, a= tan-(a/L) =tan-(3/150) =1.23

The face angle, it is the angle subtended by the face of the tooth at a cone center.

The face angle is equal to the pitch angle plus addendum angle ɸ=11.3+1.23=13.899

Check limit of wear load

Check for static tooth load

Ws= δebπmy (L-b/L)

δe= flexural endurance limit=126N/mm2

Ws=static tooth load

50.6−16.8
Ws=126N/mm2(0.0833x16.87mmxπ2mm)( )=741.6N
50.6

Since static tooth load is greater than tangential load the design is safe.

Check for limit wear load

Ww = (Dp b θK) / (cosθp).

Where; Ww = maximum lift of wear load

2𝑇𝐸𝐺
θ=2𝐸𝐺+𝑇𝐸𝑃

K=load- stress factor

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

K= (δes)2 sinφ(1/EP+1/EG) δes = surface endurance limit

=630N/mm2 for alloy cast iron φ=pressure angle

EP=EG=Young’s modules of the material =100 kN/mm2

Dp =diameter of pinion

T =formative (equivalent number of teeth for gear)

T =equivalent number of teeth for pinion

I=16.865 from the previous calculation

T =100 x sec78.7=510.3

T =TPsecθP1 = 20sec11.3 = 20.4

θ=2TEG/ TEG+TEP = 2*510.3/530.7 = 1020.6/530.7 = 1.923.

The load stress factor, K is calculated as follows:

K = (( δes )2sinφ)/1.4) * (1/EP+1/EG)

Where; δes is surface endurance limit for cast iron δes = 630N/mm2.

This is also when the Brinel hardness number is 160.

Hence, K= (630)2 sin (14.5) (1/100000+1/100000) / (1.4) =1.419N/mm2

Ww = (D p b θK) / (cosθp1)

= (60x51 x 1.923 x1.419) /cos11.3 = 8515N

Since the wear load is much greater than tangential load on the tooth, therefore the design is
satisfactory.

Check for static load

Ws = δeb π M y p ((L-b)/L) for cast iron.

Flexural endurance limit is at Brinell hardness №160 is 84 MPa.

Ws = 84N/mm2 * 51 * π *3 * 0.09 * (153-51/153) = 2422.5N.

Wt = =2∗6.65∗ =221.7
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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Again, since the static tooth load is much greater than tangential load on the tooth, therefore the
design is safe.

4.3. Shaft design

Figure 4. 2.shaft
Material selection for shaft
Shaft is not affect by strength, but rather by stiffness as represented by the modulus of elasticity,
which is essentially constant for all steels. For that reason, rigidity cannot be
Controlled by material decisions, but only by geometric decisions.

Toque, T = Fsep * r.

Where; radius of the blade, r = 70 mm.

Hence, T=13517N * 0.07m = 946Nm.

The tangential force acting on the mean radius of the pinion:

Wt = T/Rm = 946000Nmm/25mm = 37840N.

Then find the axial and radial force acting on the shaft

Axial force; WRH =Wt*tanɸ *sinϴp1

= 37840 N * tan14.5 * sin11.3 =95090N.clockwise

Radial force WRV= Wt*tanɸ *cosϴp1

= 37840N * tan14.5 * cos11.3 acting = 29876N.clockwise

Bending moment due to WRV and WRH:

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

M1= WRV * over hang ─ WRH * rm

= (-29876N * 350) ─ (-95090N *25) = 23274Nmm.

Bending moment due to Wt

M2 = Wt * over hang

= 37840N * 350mm

= 93100Nmm.

M =√M12+M22=√232742+931002

= 95965Nmm.

Since the shaft is subjected to twisting moment, (T) and bending moment (M) , therefore, the
equivalent twisting moment:

Te =√𝑀2 + 𝑇 2 =√959652 + 65502

= 96195Nmm.

According to maximum torsional moment,

16𝑇𝑒
τall= 𝜋𝑑3 where τall=allowable shear stress.

Take safety factor, n=3 τall = 𝜏𝑦/𝑛 and τy = δy/2,

𝜎𝑦
where δy= yield stress of material. τall=2𝑛

τall=275/(2x3)=45.84 MPa.

d3 = 16Te/𝜋𝜏𝑎𝑙𝑙 =16*96195/𝜋 ∗ 45.84 =10647 mm3

3
d=√10647= 19.96mm say 20 mm

4.4. Design of key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

the axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
Crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key. For preventing relative motion or rotation between shaft and gear we have
to use key.

Types of Keys

The following types of keys are important from the subject point of view:

1. Sunk keys, 3. Tangent keys,

2. Saddle keys, 4. Round keys, and

5. Splines.

For our design, sunk key is better than others are in case of directional suitability of key way
and cost and size reduction. There are two types of sunk key; Square and rectangular sunk key.
Square sunk key is better than the rectangular in case of crushing stress. Therefore, we choose
square sunk key.

Parallel sunk key.

The parallel sunk keys may be of rectangular or square section uniform in width and
thickness throughout. It may be noted that a parallel key is a taper less and is used where the
pulley, gear or other mating piece is required to slide along the shaft.[1]

Square sunk key.

The only difference between a rectangular sunk key and a square sunk key is that its width
and thickness are equal, [1] i.e. w = t = d / 4
Material selection for key
We selected mild steel for key in case of its wear resistance in addition to its farther Interesting
properties which make it a valuable material for engineering purposes are its low cost, good
casting characteristics; high compressive strength wears resistance and excellent machinability.
The compressive strength of mild steel is much greater than the tensile strength. Following are
the values of ultimate strength of mild steel

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Tensile strength = 100 to 200 MPa

Compressive strength = 400 to 1000 MPa

Shear strength = 120 MPa.

T=F×d/2=

F= the area resisting * crushing stress F=l*t/2* σc

τk = σt/2F*s=295/2*2=295/4=73.75N/mm2

τmax=275/4=68.75N/mm2

T=π/16*τk *223

= π/16*73.75*223 =154,191.33Nmm =154.191Nm

The maximum shear stress for the key

Where;

T = Torque transmitted by the shaft,

F = Tangential force acting at the circumference of the

shaft, d = Diameter of shaft, l = Length of key, b= Width of

key.

h= Thickness of key, and

As=Area of shearing=lb

Ac=Area of crushing=lxh/2

τAnd σc = Shear and crushing stresses for the material of key respectively. Given that from
the standard; h=7mm where by the shaft diameter is 22mm. Again, its width be, b= 8mm.

Now, l=1.571d=1.571x22=9.854say 10mm.

Area of shearing=lb=35*8=280mm2

Area of crushing=lxh/2=35*7/2=122.5mm2

F=2xT/d=2x154, 191.33Nmm /22mm=7,008.69N

Permissible crushing stress of cast iron is

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

σc=200MPa/n=200/3.5=57.1428MPa

Permissible shear stress of cast iron is

τ=100MPa/n=100/3.5=28.57MPa

Check for shearing τ= F/As = F/lb =

7,008.69 /8*35 = 25.03MPa

Which is less than the allowable strength, hence the dimensions are in safe

limit. Check for crushing σc=F/Ac = 2xF/lh =2*7,008.69N /35*7=57.2N/mm2

Which is less than the allowable strength, hence the dimensions are in safe limit.

Therefore, the dimensions for key are:

b=8mm, h=7mm and l=10mm.

4.5. Design of cylinder

Figure 4. 3.Cylinder
Cylindrical shells are more economical than other shell types and now the milk vessel is
designed as having a cylindrical shell. On a butter extraction, the inner wall of the milk storage
or cylinder and any equipment that is exposed to milk, and any container used for the storage
must be:

Constructed of non-corrosive material and manufactured in such a way that not to affect the
milk.

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Smooth and free of cavities and loose particles

Non-toxic and resistant to damage from cleansers and sanitizers.

It is suitable for the purpose for which it is intended to be used;

It is rigid and free from deformation under normal conditions of transport

It shall be easy to clean and inspect.

Material selection for cylinder (container)

Milk storage reservoir should be made of stainless steel having a tensile stress of 600-900 MPa
and Yield stress of 275 (MPa).
Because, Stainless steel is generally need where there are concerns regarding hygiene or
corrosion. Stainless steel has the following benefits:

Corrosion resistance: All stainless steels have a high resistance to corrosion.

High and low temperature resistance: Some grades will resist and maintain high strength at very
high temperatures, while others show exceptional toughness at low temperatures.

Ease of fabrication: The majority of stainless steels can be cut, welded, formed, machined and
fabricated readily.

Strength: The cold work hardening properties of many stainless steels can be use in design to
reduce material thicknesses and reduce weight and costs.

Aesthetic appeal; It is easily and simply maintained resulting in a high quality, pleasing
appearance.

Hygienic properties: The clean ability of stainless steel makes it the first choice in hospitals,
kitchens, food and pharmaceutical processing facilities.

Life cycle characteristics: Stainless steel is a durable, low maintenance material and is often the
least expensive choice in a life cycle cost comparison.
The outer wall of the milk transportation (storage) tanker of milk must be constructed of hard,
smooth, non-corrosive washable, waterproof material. The vessel must be insulate such that the
temperature of the milk cannot raise or lower during transportation.

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

The cylinder holds milk with volume of V=25 x 10-3m3. Hence the forces acting on the
container: F=mg + pressurized force =V g + Fp

Which acts on the bottom part of container area = (𝜋(𝐷2 − 𝑑2)/4).

Force = weight + pressurized force

=25x10-3x9.81x1034 kg/m3 + 95N = 348.5N

Since the maximum force acts on cylinder is weight of the milk. Hence, the design should be
based on this weight.

𝛿 = 𝐹/𝜋(𝐷2 − 𝑑2)/4Where𝛿 all= allowable normal stress

D=outer diameter

d=inner diameter=

382mm

n=3 is safety factor

𝛿all= 275/3MPa=91.67MPa=91.67N/mm2 D2 – d2 = 4F/ 𝜋𝛿 all

= 348.5*4/𝜋91.67= D2 – (282mm) 2

45.88+79,524=D2

D2 = 382.08mm; say400 mm

Hence diameter D=285mm.

Consequently, thickness of the cylinder can be calculate from the net of both internal and
external diameters.

i.e., thickness, t = D - d

= 285mm – 282mm = 3mm.

The resisting force of h cylinder, FR =stress*resisting area

= 𝛿𝑡*𝜋d*tWhere; 𝛿𝑡 = 𝑝 ∗ 𝑑/4𝑡 =

P=F/A=F/πr2= 95/0.2497 = 380.45N/m2

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

𝛿𝑡 = 𝑝 ∗ 𝑑/4𝑡 = 380.45*0.282/4*0.003 = 8940 N/m2

FR =stress*resisting area = 𝛿𝑡*𝜋 d*t

=8940 N/m2 * *0.282m*0.003m

=23.75N

the efficiency of the cylinder,

𝑝∗𝑑 380.45∗0.282
ἠ = 4∗𝑡∗𝜎𝑡 = 4∗0.003∗8940 = 99.99%

4.6. Bearing selection

Bearing is a machine element, which supports another moving machine element (known as
journal) .It, permits a relative motion between the contact surfaces of the member, while
carrying of the load.

A bearing may be as simple as a hole machined into a cast-iron machine member. It may still be
simple yet require detailed design procedures, as, for example, the two pieces grooved pressure
fed connecting rod bearing in an automotive engine. Alternatively, it may be as elaborate as the
large watercooler, ring-oiled bearings with built-in reservoirs used on heavy machinery. The
solid bushing is made by casting, by drawing and machining, or by using a powder-metallurgy
process.

Figure 4. 4. Ball Bearings

The torque acts on shaft is 6,650Nmm.

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

The load acts radial on holder shaft P=T/r where

r=length of crank shaft =16 cm for our design

P=6650Nmm/160mm =41.56N

The dynamic equivalent load (W) acts on ball bearing is given by:

W=x*v* WR + y*WA

Where; x=radial load factor

y=thrust load factor

v=rotational load factor

v=1 for inner face is rotating

Since y=0 and WA=0

W=xv WR=x WR where (WR= radial load acts on bearing)

For radial load = 41.56 N at 67 rpm for an average life of 3 years at 8 hours per day.

Life of bearing, LH= 3x315x8=7560 hours (assume 315 working day in a year).

L=LHx60xN=60x67x1200

4824000rev=4.824x106rev

Since WA/ WR =axial load / radial load = 0, x=1 and y=0

W=1x WR=1x41.56N=41.56N

Taking service factor (KS) =1.5 for light shock load

W= (41.56x1.5) =62.34N

Basic dynamic load rating, C =W (L/106) 1/k

C= 62.34N (4.824*106/106) 1/3, K=3 for ball bearing

C=105.5 N

105.5 N=0.1055KN which is <4 KN.

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Hence, the nearest force (basic dynamic load rating) from standard table may be 4KN with the
bearing number 205 may be select.

With this load and bearing number:

Bore=25mm

Outer side diameter =52mm and

Width= 15mm

4.7. Design of crank shaft

The preferable material for crank and shaft is stainless steel

The maximum torque acts on crank and shaft is 6650 Nmm.

Torque =(𝜋/16)d3𝜏all

Where d = diameter of it

𝜏all=allowable shear stress

𝜏all=( 𝛿y/2)/3=200MPa/6.0=33.34MPa

d3=1016.04

d=10.05mm; say 10mm.

4.8. Design for cylinder holder

Figure 4. 5. Cylinder base holder

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Alloy steel is preferable material for container base holder design.

The weight acts on container holder are the weight of the milk and weight of the container.

Weight of butter = mg=𝜌𝑣𝑔 where

V=volume of container

𝜌=Density of milk =9.81m/s2

W = 𝜌𝑣𝑔= 1034 kg/m3x25x10-3m3x9.81=253.5885N

Weight of cylinder =mg= 𝜌𝑐 ∗ 𝑣𝑐 ∗ 𝑔𝑐 where

vc=volume of container

ρc=density of container material=7850kg/m3

Wc= vc* 𝜌c* gc= (285−282)350=467586.7966mm3=46.758x10-5m3

Wc=29.518x10-6x7850x9.81

Wc=36N

Weq

25cm

Ia 60cm

60cm B A

Weq =W+WC=253.5885N+36N=289.5885N

Take ∑ A=0

RBx60-289.5885x30=0

RB= (289.5885x30)/60=144.794N

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

Again taking ∑ Y=0

RB+RA – Weq=0

144.794N+RA – 289.5885N=0

RA=144.794N

The bending moment analysis

289.5885N

B A

30 30

144.794N 144.794N

Sectioning the part

B o Mb

144.794N

For section 0<x<15 mm

Taking moment about point o:

144.794*Xcm-Mb=0

Mb=144.794*X Ncm; at X=0, Mb=0

At X=15cm, Mb=144.794*300=43438.2Nmm

Since the moment of inertia A and B =0 the maximum bending moment is 43.438KNmm

4.9. Design of frame

We have selected an alloy cast iron for designation of frame because of its listed properties in
the other parts design.

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

The summation of weight acts on frame is the weight of milk plus the weight of container
holder and container.

Weight of Cylinder holder (Wh) is

Wh= Vgρ where v= volume and ρ =density

Vc=90x10-6m3

ρ =7780kg/m3, for cast iron.

Wh= Vh ρg=90x10-6m3x7780x9.81=6.867N

Weq=253.5885+6.867+36=296.4556N

Bending moment (Mb) =296.455x30mm=8893.665Nmm

Let we use the hollow cylindrical to get large dimension which helps the material to be stable
and to get high strength, and take the smallest diameter 35mm.
32𝑀𝑏𝐷 32∗8693.665𝐷
𝛿all=𝜋(𝐷4 −𝑑4 ) = 𝜋(𝐷 4 −𝑑4 )

Where𝛿all =66.667N/mm2, for cast iron.

𝛿all =π(D4-d4)=32*8893.665D

209.43D4-4714352.47-284597.28D=0

We get D=36.434 say 40mm

4.10. Design of bolt and nut

Material selection

When a bolt and nut is made of medium carbon steel, the effective height of nut is made equal
to the nominal diameter of bolt. The desirable properties of bolt materials are follows:- It should
have sufficient strength to with stand stress due to external load and applied torque.

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 SEMI-AUTOMATIC BUTTER EXTRUCTING MACHINE

It should poses high wear resistance

It should have good machinability

Bolts are made from plain carbon steel such as 30c8, 40c8, 45c8 and alloy steel like 40cr1. But
we select 45c8 medium carbon steel (ultimate tensile strength= 630 Mpa,
Harden ability =229HB yield strength =380 MPa). The bolts are case hardened by nitrating
process.
Design specification of bolt and nut:-

From table 11.1 (coarse series) textbook of machine design:-

Pitch, p = 0.8mm

Nominal diameter bolt and nut, d = 5mm

Pitch diameter for both bolt and nut, =4.48 mm

Core diameter for bolt, = 4.019mm

Core diameter for nut, = 4.134mm

Depth of thread of bolt = 0.491mm

Stress area = 14.2

Diameter of the hole = 8mm

Head of the bolt = 3mm

In addition, from the material properties of the material:-

Tensile strength of bolt material, = 630Mpa

Ultimate tensile strength of nut material, = 190Mpa

There is relative motion between bolt and nut and wear is inevitable. The material for the nut
should be soft and conformable to that of bolt. The wear is always restricted to softer surface.
Therefore, if at all component is to be replaced, it should be the nut that is less co sty compared
with bolt. Bronze is ideal material for nut. The material for the nut is tin, bronze and phosphorus
bronze (Sut= 190MPa)

Where, d= nominal diameter

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dc = core diameter of the bolt n= number of bolts

δt = tensile strength of the bolt material = 630 Mpa

P = applied force = 95 N

Let assume, the nominal diameter of the bolt is 5mm, we find that the corresponding core
diameter of the bolt is 4.019mm from table 11.1… [Coarse series, atextbook of machine design]

P = πdc2 δt*n/4 = 95N

4∗95
From this equation, n =P/ πdc2 δt/4𝜋∗630∗4.0192

n= 1 but, we need n= 4bolts.

We know that for a leak proof joint, the circumferential pitch of the bolts should lie between
20 √𝑑1to 30√𝑑1

Maximum circumferential pitch of the bolt =30√𝑑1=30√7=79.37mm

And minimum circumferential pitch of the bolt = 20√7 =52.9 mm

Since the circumferential pitch of the bolts obtained above is within 52.9mm and 79.37mm. The
size of the bolt chosen is satisfactory.

The length of the thread at the end of the bolt is 10mm.

The total length of the bolt is, L = width of the bar + 2 times of the thickness of the cover plate
+ thickness of the nameplate + the thickness of the base + the length of the head.

L = 25 + 2*2.85 + 5 + 10 + 10

L = 55.7mm

Therefore, size of the bolt is M5 ………[from text book of machine design] , design dimensions
of screw threads, bolts and nuts according to IS: 4218 (part iii) 1976 (reaffirmed 1996) refer
table: 11.1

For nut: - the permissible bearing pressure between bolt and bronze nut is 10N/ . The number
of threads required to support load is, z

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Z = 4w/πsb(d2─dc2)… from design of machine element book

Where: z= number of threads

d= nominal diameter of the bolt

dc= core diameter of the bolt

4∗95
Z =𝜋∗10(52 −4.0192)

Z= 2

The axial length of nut (H) is given by ………… [From design of machine element book]

Where: P= pitch of the thread

H= 2* 2= 4 mm

The transverse shear stress at the root of the threads in the nut is given by,

𝜏n = 𝑤/𝜋𝑑𝑡𝑧= 95/π*2.85*2 = 1.06Mpa

The factor of safety based on ultimate strength of 190Mpa from table 3 the value of safety factor
in textbook of machine design is 5 for soft material and alloys.

4.11. Design the sliding bar

The sliding bar moves up down caring the upper part. It slides in the frame and its cross-section
is rectangular the maximum load acts on it is the turning force which acts (applied) on crank
and may produce bending effect on this bar.

The bending moment acts on it =(290mmx 20.78N)/2. =3013.1Nmm

Take shock factor 1.5, Mb=4519.65 Nmm

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M/I=𝛿𝑎𝑙𝑙/𝑌 , I= ba3/12 take a=35 mm, and hole diameter 7mm I=b/12 (353 -73)

I=3568.833bmm4

b=(Mb*Y)/656.25*100N/mm2=(4519.65*225mm)/100*3568.8 =2.85 mm

4.12. Design of blade

Figure 4. 6.blade
Material selection for blades

Stain less steel is select for blade design.

The maximum bending moment acts on each blade is 6650/4(there are 4 blades) which is
MY
=1662.5 Nmm 𝛿all = 𝐼

𝑏ℎ3
Where, I= 12 =b (80)3/12=256000mm3b; b is the blade thickness.

1662.5∗80
b=58∗256000= 8.957*10-3take, b= 9mm

Weight of the blade, Wb =ρvg=7850kg/m3 *80mm*35mm*2.63mm*9.81m/s2

Wb = 0.56N

4.13. Motor Selection:

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An electric motor is a machine, which converts electrical energy into mechanical energy. When
a motor is in operation, it develops torque. This torque can produce mechanical rotation.

The difference b/n one phase and three phases motor

 Single-phase electrical power: is the distributer of alternating current electric

power using a system in which all the voltage of the supply vary in unison. Single-phase
distribution is used when load are mostly lighting and heating with few large electric
motor single-phase power supply only (1ph 110v, 220v, 230v, 240v, etc. especially in
house hold appliance.
 Three phase electric power: is a common method of alternating current
electric power generation, transition and distribution wound. It is a type of poly
phase system and it is the most common method used by electrical grid worldwide to
transfer power .it is also used to power large motor and other heavy load. Three
phase asynchronous ac motor is widely used in industrial and agricultural production
due to its simple structure , low cost , easy maintenance , and easy operation .

Figure 4. 7Motor

4.13.1. Selection of Belt

V-belts are advantageous over other types in the following ways:

 The V-belt drives compactness due to the small distance between centers of pulleys.
 The drive is positive, because the slip between the belt and the pulley groove is
Negligible.
 Since the V-belts are made endless and there is no joint trouble, therefore the drive is
smooth.
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 It provides longer life, 3 to 5 years.

 It can be easily installed and removed.
 Less expensive than gear or chain drives
 Have flexible shaft center distances where gear drives are restricted.
 Operate smoothly and with less noise at high speeds.
 They can be designed to slip when an overload occurs in the machine.
 They require no lubrication, as do chains and gear

Figure 4. 8V-belt
The V-belts are mostly used in situations where great amount of power is to be transmitted from
one pulley to another and when the two pulleys are very near to each other. They are made of
fabric and cords molded in rubber and covered with fabric and rubber. The wedging action of
the V-belt in the groove of the pulley results in higher forces of friction. Analysis shows that the
wedging action and the transmitted torque is more if the groove angle of the pulley is small. But
a small groove angle requires more force to pull the belt out of the groove which result in loss of
power and excessive belt wear due to friction and heat? Hence the selected groove angle is a
compromise between the two. Usually the groove angles of 30° to 40° are used. A clearance
must be provided at the bottom of the groove in order to prevent touching of the bottom as it
becomes narrower from wear. The V-belt drive may be inclined at any angle with tight side
either at top or bottom. In order to increase the power output, several V-belts may be operated
side by side. It may be noted that in multiple V-belt drive, all the belts should stretch at the same
rate so that the load is equally divided between them. When one of the set of belts breaks, the
entire set should be replaced at the same time.

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4.14. Design of housing

Figure 4. 9.housing
Material selection, for the housing we select steel because steel have the following properties:

1 it has good hardness

2. Have ability to resist corrosion

Specification of the material,

The density of the steel=7850kg/mm3

Modules of elasticity of the steel=100 to 200Gpa

Modules of rigidity =80 to 100Gpa

Area of body = A=

The volume of the housing=Ah=855.29mm2*204mm

=174481mm3

Know the Weight of the housing,

Wb=ρvg = 7850kg/m3*174481*10-9m*9.81m/s2=13.48N

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CHAPTER FIVE
5 RESULT AND DISCUSSION
5.1 RESULTS
Table 5. 1.Result and discussion

Parts Types Of quantity Height(mm) Diameter(mm) Width(mm)

Material

1 Cylinder Stainless 1 400 285 20

steel

2 Blade Stainless 1 270 20

shaft steel

3Crankshaft 1 120 20

4 Blades Stainless 6 50 140 2

steel

5 belt and - 2&1

pulley

6 Housing Mild steel 1 280 300 20

7 motor - 1

8 Frame Mild steel 1 800 40 80

9 gear Alloy steel 2

10 key Mild steel 4 5 10 5

5.2 Discussion
By using this mechanism milkman can save time as well as efforts with producing high quality
and quantity of butter. We observe that initially time required to produce butter from 25 litter of
milk the average time required by semi-automatic butter extraction machine is 6min. Hence this
mechanism can save time minimum 11min with great quality.

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5.3 COST ESTIMATION

Table 5. 2Cost estimation

No Material type (Item) Unit Specification Quantity Birr

1 Cylinder 285 mm dia. 1 1300

2 Bevel gear 120 & 60 mm dia. 1&1 2000
3 frame 800mm 2 300
4 Bearing 32millimeters dia. 2 500
5 Blade 70mm radius 6 300
6 Bolt ,pin& screw 2,4 &1 450
7 key 4 190
8 Blade shaft 350mmh&15mm dia. 2 250
9 Gear box housing 1 500
10 Cylinder holder 600*600mm 1 800
11 Motor 1 2000
Total 8590

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CHAPTER SIX
6. Conclusion and Recommendation
6.1. Conclusion

The agitation of the cream caused by mechanical motion of the device disrupts the milk
fat, substantially forming clumps known as butter grain. Butter churn is the device used
to perform the above process. It reduces the time and force needed, and give maximum
output with high quality.

This paper tangibly reduces the time, force when we compare from that of traditionally,
and manual extractor machine. The previous manually Butter churner cannot work
properly with small amount of force, in a specified time required. In case of this, it is
mandatory to design new semi-automatic butter extraction machine.

Therefore, the new designed semi-automatic butter extractor machine can solve the
above problems.

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6.2. Recommendation
We would like to recommend due to the shortage of time we have-not prepare a
prototype and assemble drawing with help of animation or motion
In the butter making industry and even in private dairy farmers, there is a demand for modern
procedures with which maximum hygiene standards and cost-efficient operation can be
achieved.

In addition, it is mandatory to prepare or to manufacture the real semi-automatic extracting

machine with its appropriate designation parameters to keep its standard and efficient quality of
butter extraction. The design of semi-automatic butter extraction machine installation is
particularly important for meeting these requirements.

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Reference
[1] A. T. Gemechu and Y. B. Tola, “Traditional butter and ghee production , processing and
handling in Ethiopia : A review,” African J. Food Sci., vol. 11, no. April, pp. 95–105,
2017, doi: 10.5897/AJFS2016.1544.

[2] D. Levowitz and P. A. Van Der Meulen, “A STUDY OF SOME FACTORS IN THE
BUTTER,” J. Dairy Sci., vol. 20, no. 10, pp. 657–665, 1937, doi: 10.3168/jds.S0022-
0302(37)95725-4.

[3] P. I. D. Gender and A. Case, “The Development of an Improved Churner for Butter
Extraction,” Inst. Technol. Res. Natl. Cent. Res., vol. 4, no. 3, pp. 1–24, 2017.

Sfor Rural Area,” IJESC, vol. 6, no. 5, pp. 5019–5021, 2016, doi: 10.4010/2016.1238.

[5] A. Aljaafreh, “Butter Churning Process Automating Based on Acoustic Signals,”

Researchgate, no. May, 2015.

[6] A. Tsedey, “Implications of Introducing Improved Butter Churner on Churning Time and
Butter Making Efficiency Implications of Introducing Improved Butter Churner on
Churning Time and Butter Making Efficiency,” ResearchGate, no. September, 2018.

[7] B. Gebremedhin et al., “Developing the Butter Value Chain In Ethiopia,” Int. Food
Policy Res. Inst. (IFPRI), Addis Ababa, Ethiop., no. October, p. 172405, 2014.

[8] F. Mohammed, E. Tadesse, and T. Gemechu, “On-Farm Demonstration and Evaluation

of Improved Plastic Milk Churner in West Arsi Zone of Oromia Regional State ,
Ethiopia,” Int. J. Res. Stud. Agric. Sci., vol. 3, no. 3, pp. 32–37, 2017.

[9] Zelalem Yilma, “Manufacturing efficiencies and microbial properties of butter and Ayib
- Ethiopian cottage cheese,” Livest. Res. Rural Dev. 19 2007, 2003.

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APENDIX

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