CHAPTER I

INTRODUCTION

Background of the Study

Coconut (Cocos nucifera L.) is one of the most important crops and remain as a

major export of the Philippines. Behind the Philippines is the second largest producer of

coconut in the world, next to Indonesia. The Major Philippine traditional coconut

products include copra, copra meal, coconut oil, desiccated coconut, coconut shell

charcoal, activated carbon, and oleochemicals (PCI, 2020). The fresh coconut is

converted to copra that obtain from matured coconuts through various process like husk

removal, cut into half, shelling and drying. The drying process may be done by traditional

or mechanical method.

Drying is the oldest and a common post-harvest technology in copra. Drying is a

heat and mass transfer phenomena, which result in reducing the moisture content under

the controlled condition. It is done by supplying energy by passing hot air through the

surface of products therefore the products get heated and release the moisture to attain the

desired moisture content. It ranges from simple natural sun drying to large-scale

industrial drying. Based on the temperature required for drying, the processes may be low

temperature and high temperature drying (Goswami, 2004).

Coconut has an initial moisture content of 55 percent (w.b) which to be reduced of 7

percent (w.b) to achieved good quality copra. In order to obtain a good quality copra, the

coconuts need to dried to its final moisture content (Balaji and Velmurugan, 2014).

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 The Philippine coconut industry give an opportunity to the coconut farmers to

improve their coconut production but one third of them are poor and most of the Filipino

farmers rely on coconut as a major livelihood income (PCA, 2019). Such in Masbate

specifically in the Municipality of Mandaon the local farmers prior source of income

depends on copra production. And they used traditional method for drying that has created

many quality problems leading to hygienic and health issue.

Therefore, this study aims to develop a coconut dryer (kukum dryer) using a hot air-drying

process in order have a good quality copra.

Statement of the Problem

Copra is major product of the Province of Masbate considering that it is blessed of

hundred hectares of coconut. However, drying of coconut is a serious problem in terms

of drying quality (M. Sandig, 2013). Most of local farmers particularly in barangay Sta.

Fe, Manadon used traditional method for drying coconut which the major problem of

slow and continual drying, contamination of dust and resulting in low quality copra.

Objectives of the Study

The general objective of this study is to redesign, develop, and evaluate the

performance of coconut dryer especially in our community.

The specific objectives of this study are:

1. To redesign and develop the modified coconut dryer.

2. To measure the temperature distribution of the dryer in the drying bed of coconut and,

3. Compute the thermal efficiency of the dryer

4. To perform a simple cost analysis.

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Hypothesis of the Study

Alternative Hypothesis (Ha)

The designed and develop coconut dryer has significant differences in terms of

temperature distribution in every section of copra bed compartment.

The designed and develop coconut dryer has no significant differences in

terms of drying hours between the two modified kukum dryer and the develop coconut

dryer.

Significance of the Study

Coconut is one of the important crops in the Province of Masbate. It is the major

source of income of all local farmers. Drying of coconut is the major problem of the

farmers in terms of quality. Their products may be dried through traditional drying

process that can cause the low-quality copra and cause reducing the selling price. In line

of this, this study will encourage coconut farmers to use a hot air dryer for their coconut.

This study can help the buyer or the consumer in preserving the quality of the

copra product for the safety and security of the consumer.

The result of this study will serve as a reference for some researchers who want

to pursue the development and improvement in this study.

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Scope and Limitations of the Study

This study was limited to redesigning, and developing of coconut dryer. It

focused on developing and testing of the develop coconut dryer using coconut meat and

available materials on the farm. This study is conducted to measure the temperature

distribution of dryer and the drying hours.

This study will be conducted at Brgy. Sta. Fe, Mandaon, Masbate starting from

December 2022 to February 2023.

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 CHAPTER II

REVIEW OF RELATED LITERATURE

This chapter includes ideas, finished studies, generating conclusions and others.

Those that were included in this chapter helps in familiarizing information that are

relevant to the study presented.

The following are the related studies:

1. Coconut properties

2. Studies on Copra drying

3. Copra dryer design/types

Coconut is an edible crop known as tree of life, it is one of most important

crops of the tropic. Coconut flesh is high in fat and can be dried or eaten fresh or

process like coconut oil. Beside that edible kernel and the drinks obtained from

green or young nuts. The harvested coconut process into copra, a dried meat which

the coconut oil processed.

Mature coconut is ovoid or ellipsoid in shape with 30-45 cm in length and

15-20 cm diameter. It is had a thick fibrous husk surrounding the single seeded nut. A

hard shell encloses the embryo with its abundant endosperm and compose both meat

and liquid.

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Copra drying

Copra is a dried coconut meat obtain from mature coconuts, a fresh coconut

contains 50% moisture. Generally, coconut meat should be dried until the moisture

content reached the safest or the equilibrium moisture content of copra to store safely.

The equilibrium moisture content of copra is around 6% to 7% in tropical countries

(Raghavan, 2010). A well dried copra contains moisture around 6% to 7%, a higher

moisture content and presence of protein lead to development of bacteria and fungi. But

at around 6% moisture, molds in copra is inhibited (Shahidi, 2005). To prepare good

quality copra, first split the coconut into two and dried using drying method. When it is

dried remove the meat in shell easily.

Drying of copra into a safer moisture level is always a vital requirements to avoid

formation of aflatoxin, it is a group of toxic chemical produced by the aspergillus mold,

particularly aspergillus flavus and parasiticus (Roberto,C. Guarte,et al 1998). In the

Philippines the Natural Resource Institute of UK found that the safest moisture content

of dried copra is below 8% and for smoke copra is around 11%. The higher tolerable level

of moisture for smoked dried copra is because of smoke particles inhibiting mold growth

(Krishana Raghavan, 2010).

The effect of drying temperature and position of dehusked coconuts. The drying

characteristic of copra by the moisture reduction against the drying time were

significantly affected by the temperature but not the position at which the coconut placed

on the dryer. The desired moisture content of 7% (w.b) was significantly reduced when

the temperature increased from 40-90 degree Celsius but not exceed 90 – 100-degree C.

when the temperature increases to 90-degree C both copra quality and CNO quality where

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unaffected but when the temperature rises to 100-degree C it caused excessive browning.

It suggests that 90-degree C temperature is optimum for the production of high-quality

copra.

Types of copra dryer

Modified Kukum dryer. The modified coconut dryer (kukum dryer) is a hot air

dryer measuring of 1.8 width x 2.7 length x 1.7 height. Its heat exchanger is made up of

one steel drum. It had a chimney with 2.5 m height for the exit of combustion gases, the

frame is covered by G.I sheet and plywood inside and outside respectively. The furnace

also provides slanting grate and door to regulate the air.

The result of this modified dryer in terms of temperature ranges the rear and front of the

drying bed is higher than to the original dryer resulted with 25 and 34diferrence

respectively.

The modified coconut dryer (kukum dryer) produce a good quality copra. However, the

heat cannot distribute properly because of the distance of the drying bed and heat

exchanger. The materials used in the furnace is inflammable due to the tenuity of the G.I

sheet. See in the figure 1.

Figure 1. the modified PCA Kumkum dryer

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Copra drying in Solar and Biomass integrated dryer

The experimental study on drying characteristic of copra dying in solar tunnel dryer

integrated with biomass hot air generation system. Its facilities drying to continued under

all weather condition and overcomes the limitation of conventional drying methods. The

total drying of 108.3%from dry basis to 5.6% final moisture content (d.b) is 48 hours of

drying. It reduces about 5 to 7 days of drying time from conventional methods. It provides

a good coconut oil.

Solar Tunnel Greenhouse Dryer

The solar tunnel greenhouse dryer had a dimension of 4m(W) x 10m(L) x 3m(H)

was constructed using available materials. It is covered by UV (200µ) stabilized

polyethylene film. Also, it has a three-exhaust vent with adjustable butterfly valves at the

roof. The STD runs with 5000 nuts per load, it was found that the coconuts has an initial

moisture content of 53.84%(w.b) were dried at the final moisture content of around

7%(w.b) in a solar tunnel greenhouse dryer for a time of 56 hours. Also, the quality of

dried coconuts in the solar tunnel greenhouse was found to be free from fungal and

bacterial infection which prove the possibility of production of superior quality coconut

from the dryer than open sun method.

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 CHAPTER III

METHODOLOGY

The procedure of the research development is enclosing this chapter. This

chapter present the materials and methods use in undertaking the study. Specially, the
design of the dryer, statistical analysis, material and methods and other important
information regarding this study were include in this chapter.

Basis of the design

The aims to develop a coconut dryer was based on the test data of the
previous study of coconut dryer (kukum dryer) as shown in figure 1.

Figure 1. the modified kukum dryer cross sectional area.

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Design considerations
The modified coconut dryer (kukum dryer) 2013 was the basis of the design.
Below is the design consideration for coconut dryer.
• Slope of area where the dryer constructed
• Availability of the materials

Design development.
The overall dimension of the develop dryer are 1.2 m width 2.4 m length
and 2 m height. It is a hot air-drying process consist of steel furnace and steel drum
tube as heat exchanger. It also provides a chimney for the combustion gases came
from the firing area. The frame is covered with metal sheet and plywood inside and
outside respectively. The copra tray is made up of mesh wire with coco lumber
connected to the frame, the tray had a space above between the heating drum in
order to have turbulence in the hot air rising. The ground is filled with sand and
gravel with a height of 25mm to maintain the heat inside, absorb some moisture
and can decrease the require space of the dryer. At the heating tube it has a
ventilation to help the hot air flow above and to prevent over heat. The over all
design of the dryer will see in figure below (figure 3).

Figure 4. the design of develop coconut dryer in perspective view.

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 Description of the dryer

Figure 4. The develop coconut dryer in cross sectional view.

Firing Chamber/furnace: it has a dimension of 500mm length and 800mm

width, it was connected to the frame of dryer and it was before the steel tube.
Heating drum: the heating drum was under the drying bed. It was connected
to the firing chamber and has a dimension of 980mm (H), 500mm(D), 6mm top
thickness and 6mm body thickness.

Fabrication and Construction Procedure

The details for fabrication and construction of the coconut dryer proceed for
the following procedure:
1. Outline approval of the panel
2. Cleaning the area for construction
3. Canvass and procurement of the materials needed
4. Assembling of the furnace, heating drum and chimney was at the machine shop.
Hammer, measuring tape, and other materials for construction were used.
5. Testing of the fabricated materials and final construction of the dryer.

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Data gathering
Preliminary testing

After the fabrication the fire were used to check if the hot air flowed at the tube,

then other parts were also checked whether it needed to change it or not.

Final testing

After the preliminary testing and fixing all the materials of the dryer and in attaining

the objective of this study.

Preparation of the loading compartment

The loading compartment or copra bed was divided into three section.

Preparation of coconut samples

The coconut sample that used for testing was fully matured and unhusked.

The sample were cut into half and put on the drying bed after air drying.

Preparation of biomass fuel to be used

The coconut husk was the fuel used for testing for the develop coconut dryer and

had a weight of 3kg per batch based on the recommended fuel for drying.

Process for loading the sample

In every section of the drying bed will filled with coconut, each section had 100

pieces or it had a total of 300 pieces of coconut every loading.

Determination of temperature distribution

In determining the laboratory temperature, the thermometers were placed at the

center of drying bed in every section. the temperature was measuring every 1 hours after

the start of firing at the furnace and it was recorded throughout the operation at an hourly

interval.

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 Determination of drying hours

After placing the coconut samples and the start of firing at the furnace with prepared

coconut husk. The start and the end time of dying process was recorded.

Process flow

start

loading of the samples

firing of the fuel at the

furnace/firng chamber

monitoring of temperature
and drying hour

unloading the samples

Estimation of drying efficiency

The drying efficiency of the develop coconut dryer was computed using the

equation (Sing et al, 1999) 1:

𝝋(𝑴𝒐−𝑴𝒇)
Thermal efficiency =𝑊(100−𝑀𝑜) 𝒙𝟏𝟎𝟎

Where:

Mo – the initial moisture content of coconut (% w.b)

Mf – the final moisture content of coconut (% d.b)

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 W – quantity of fuel used (kg)

𝝋 − 𝒒𝒖𝒂𝒏𝒕𝒊𝒕𝒚 𝒐𝒇 𝒕𝒉𝒆 𝒇𝒊𝒏𝒂𝒍 𝒅𝒓𝒊𝒆𝒅 𝒑𝒓𝒐𝒅𝒖𝒄𝒕 (𝒌𝒈)

Data Analysis

The economic and data analysis was done at the data gathered

Statistical Analysis

The t- test was used to compared gathered data between the modified dryer.

Cost Analysis

The following formulas will be needed to attain the cost analysis:

Fixed Cost

Interest on Investment

𝐈𝐎𝐈 = 𝐈𝐑 𝐱 𝐈𝐂 (Eqn.2)

where,

i is rate of interest, decimal.

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 Repair and Maintenance

𝐑&𝐌 = 𝟏𝟎 𝐨𝐟 𝐭𝐡𝐞 𝐢𝐧𝐯𝐞𝐬𝐭𝐦𝐞𝐧𝐭 𝐜𝐨𝐬𝐭 (Eqn.3)

Deprecation Cost

𝐏−𝐒 (Eqn.4)
𝐃=
𝐋

where, D is depreciation, Peso/yr;

P is purchase price of corn husking machine, Peso;

S is salvage value, Peso; L is life, Year.

Note: This study assumed that salvage value is 10% of the purchased price.

Variable Cost

Labor and Electricity Cost

Total Annual Cost

TC = FC + VC (Eqn.5)

Annual Benefits

𝐀𝐁 = 𝐌𝐂 × 𝐍𝐎𝐇 × 𝐂𝐆 (Eqn.6)

where,

AB is Annual Benefits;

MC dryer capacity;

NoH is Number of Hours of operation in a year;

CG is Cost of drying.

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Net Benefits

𝐍𝐁 = 𝐀𝐁 = 𝐓𝐎𝐂 (Eqn.7)

where,

NB is Net benefits;

AB is Annual benefits;

TOC is Total operation cost

Return on Investment

𝐍𝐢 (Eqn.8)
𝐑𝐎𝐈 = × 𝟏𝟎𝟎
𝐈𝐂

where,

ROI is Return on investment;

Ni is Net income;

Ci is Cost of investment.

Payback Period (Pp)

𝐓𝐈𝐂 (Eqn.9)
𝐏𝐏 =
𝐀𝐁

where,

Pp is Payback period;

TIC is Total investment cost;

AB is Annual Benefits.

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Breakeven Operation

𝐅𝐂 (Eqn.10)
𝐁𝐫𝐞𝐚𝐤𝐞𝐯𝐞𝐧 =
𝐒𝐂 − 𝐕𝐂

where,

FC is Fixed cost;

HC is husking cost;

VC is Variable Cost

References:

s. Arun, K. Velmurugan, S. Shankar Balaji “Experimental study on drying Characteristics of coconuts

in a solar Tunnel Greenhouse dryer” International Journal of Innovative technology and Exploring
Engineering, 2014, vol. 4, pp. 51- 52

M. Sandig “Modification of philippine Coconut Authority KuKum Dryers” DEBESMSCAT, 2013, pp. 8-
10

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