Introduction
The project is to make chiller for the sugarcane juice. The meeting was held with the Dixit sir , Prasad Sir and Mahesh sir. I am helping the Rahul to make the chiller for dropping the temperature of sugarcane juice and make it cold. The machine of sugarcane juice is totally operating on batteries.
Objective –
- To make the sugarcane juice cold.
- Making juice cold with proper hygiene.
- Cold the juice without adding the ice, cold by removing the heat.
- To get the fresh juice by indirect cooling.
Description
27/10/2023
The meeting was held between Dr. Dixit sir , Prasad sir and Mahesh sir and Rahul. I am also present to this meeting. In this meeting the discussion is held about the making of chiller for the sugarcane juice extractor machine. In this meeting decided that I am helping the Rahul to make the Chiller for sugarcane juice machine. After the ending of meeting I discussed with Rahul about the project. And ask all information about the project and the work he did on that project.
28/10/2023
Today we have to calculate the how much ice will require to cool the sugarcane juice flowing through pipe and also how much time require to cold the juice flowing through pipe. Firstly i understand the concept of Heat transfer and read all about that. Also write the all the formulas require to calculate the heat transfer through any medium.
I try to solve the calculation about heat transfer by using the above formula but it all goes wrong and unexpected. The big guidance about heat transfer is got from the Rahul sir. They lot of help me to solve problems. But there is no proper information available on internet that’s why my answer is not get properly. Then i show the answer to the Dixit sir and Prasad sir. They see the answer and tells to take the actual experiment trial on the heat transfer.
30/10/2023
Today we make the set up to take the test about heat transfer. we required the about 10 to 15 kg of ice for experiment. With permission of the Mahesh sir we go the Pabal to bring the ice. But the ice factory was closed from 2 years. Then we go to the Raj Kamal ice cream Factory to bring the ice but due to off season this factory was also closed. From market we cant get ice. Then we fill the utensils and put to make ice in soil laboratory.
Today we also take the people survey about the how much cold water/juice they want to drink. we take the cold water of different temperature and give to the people to drink. From that survey we concluded that people preferred the cold water of temperature between 10 to 15 degree or greater than 15 degree.
| Name | 1 to 5 degree | 5 to 10 degree | 10 to 15 degree |
| Mahesh | not preferred | not preferred | preferred |
| Pranay | not preferred | not preferred | preferred |
| Abhijeet | not preferred | not preferred | preferred |
| Abhishek | not preferred | not preferred | preferred |
| Tanmay | not preferred | not preferred | preferred |
31/10/2023
Today we set to take the readings of experiment. We collect the ice from soil lab and filled into the box. Then we flow the water through pipe fixed in the box. Then we take the readings after different interval and different temperature.
| Time | Inlet initial temp | Outlet Temp. |
| 1 min hold in pipe | 45 degree | 5 degree |
| 30 sec hold in pipe | 45 degree | 10 degree |
| continue flow 1 lit per 1:15 min | 45 degree | 22 degree |
1/11/2023
Today we conduct another trial at different temperature and interval.
| Time | inlet temp. | outlet temp |
| 1 min hold in pipe | 48 degree | 8 degree |
| 30 sec hold in pipe | 48 degree | 12 degree |
| continue flow 1 lit per 40 sec | 48 degree | 22 degree |
Calculation
By taking all he readings and calculation we show to the Dixit sir and Prasad sir. They observe the readings and said to take another one trial on tomorrow.
2/11/2023
Today we set to take another reading. This is the third trial. Yesterday evening we put the water to make the ice in soil lab. We collect the ice from lab and start the our experiment . Noted all the readings. In todays trial we set the flow rate of the inlet 1 lit/min.
| Time | Initial temp. | Outlet temp. |
| 30 sec hold in pipe | 32 degree | 9 degree |
| continue flow 1 lit/min | 32 degree | 12 degree |
| continue flow 1 lit/min | 38 degree | 14 degree |
Calculation
I show the readings and calculations to the sir. they see he calculations and said we will discuss tomorrow.
4/11/2023
The meeting was fixed yesterday but due to some work to the Dixit sir and Prasad sir the meeting held today. I show all the calculations once again. We think and discuss on the material selection and size dimension of box. Then Prasad sir tells me to draw the diagram of chiller. in meeting also decided that small pump is fixed to circulate the water. Then I complete the diagrams and show to the sir. then from drawing and available dimension we decided the fixed dimension of chiller box.
After the completion of diagram Prasad sir decided the dimensions and tell me to calculate the volume and area of given dimension.
6/11/2023 and 7/11/2023
Me Mahesh sir and Bhushan Sir fix the flat strips on both side of the front head of rickshaw to fix the sunroof easily. Next day in morning by taking Rickshaw me and Bhushan sir went to Pabal to fix the sunroof over that. About 2 hours take to fix that then we came back to ashram.
8/11/2023
Today I Fix the the Crusher , motor, and Gear box on the frame to take further trials.
9/11/2023
Today with Dixit sir , Prasad sir and Mahesh sir discussion is done about the four things.
1.First is about the strainer over the pan to filter the juice. We measures the distance we have to design and place the strainer over it. The distance is about 2 cm from bottom of crusher teeth to the pan. We decided to place the strainer in between that.
2. Second is the connection of the pan outlet to the the inlet pipe of normal juice outlet and chiller pipe inlet. We discuss lot of things about hoe to fix it. We discuss to set a tee there by using valve. Also use of valve there to operate chill and normal juice but for that we have to cut the cover so then it cancelled. Also we think about connect the plastic pipe for normal juice outlet and hang it above the chiller inlet.
3. Third discussion is the about outlet of chilled juice. where it comes is there valve can we set etc.
4. And the fourth is about the inlet of the ice in the chiller. For that we decide to use the 3 inch PVC pipe.
diagram of the topic discussion
16/11/2023
Today me and Abhishek checks the submersible pump is working or not which is ordered online. Also checks the plastic box is ok which also ordered online. And also checks the is pump working or not and is box fits in the frame.
17/11/2023
Today I show the box fittings in frame to Prasad sir and Mahesh sir then decided to cut the some parts of angle to come out little part of box out of frame. Then I cut the par of frame and then sir see. After that they tell to cut one side of frame to place box outside the frame and tell to make the new extended frame. Then i cut the remaining portion of frame which is unwanted.
18/11/2023 & 19/11/2023
Today I draw the drawing of extended portion of frame in top view , side view and 3D and show to the sir. Then show to the sir and start to making frame. With help of Abhishek i cut the angles and flat strips. Then with help of Ritesh weld it.
Diagram and Measurement of extended model
Extended frame
20/11/2023
Today I fix the connection of inlet of chiller and normal juice from the pan. Firstly by discussing with Prasad Sir and Mahesh sir we decide how to set a pipe and which pipe should we use. we decide to use 16 mm tee and silicon pipe. And we also place the dispenser to normal juice outlet.
Also make the clamp for the coil to fix it properly. Mael makes design for it and then by laser cutter we cut the acrylic of clamp size. For this design he uses fusion 360 software.
Design of clamp
21/11/2023
Today I fit the all the connections of chiller and normal juice and ready for trial. By using the water I take trial. In this trial i have to determine is water flows easily ? checking the alignment of coil. and also how much of water remain in the coil ?
From that I found that there is requirement of coil arrangement then 40 to 50 ml of water remains inside the coil due to bad alignment.
22/11/2023
Today I went to Pune to buy the aluminium pipe for making coil and plastic box for chiller making. Due to bad spiral coil and alignment of first coil i have to make new coil. And old box get cracked so this also have to change. From Ravivar peth Pune I bought the pipe and plastic box. Then I go to the bending shop to bend the pipe and make coil due to they have lot of work and it is a risky thing they told me no. By taking this pipe i came back to the ashram.
23/11/2023
Today with help of Mahesh sir Prasad sir and Anil sir we make the Coil on rolling machine as per we needed. Then we check it is fix in box. And as per requirement we make some changes in that and fix it in box. After setting new coil I Take trial with water.
24/11/2023
Today I go to pabal to buy a strainer for juice filter. we decided to use 200 mesh screen for juice filtration. But i cant get strainer but for the trial i bought the muslin cloth. Then by placing ice in chiller , making all connection fix we take trial. Abhishek and Abhijeet are with me to help me.
Noted the normal juice temperature and chilled juice temperature.
chilled juice temperature at continue flow is 8 degree and normal juice temperature is 27 degree. but normal temperature will vary with respect to cane temperature , room temperature , region temperature , etc. But we can get required chilling effect from that.
Working and testing of chiller
Testing of working of Normal juice valve
Temperature of Normal juice and chilled juice
29/11/2023
Cutting of another some portion of frame due to improper alignment. Then make the drawing of new frame.
30/11/2023
In morning session Dixit sir gives lecture on belongingness. Then in the afternoon session discussion is done with Dixit and Prasad sir about project.
1/12/2023 & 2/12/2023
Cut the old frame due not in alignment. Taking again measurements ad fixing the position of chiller make the new frame
Welding new frame
3/12/2023 & 4/12/2023
Cut the SS sheets for cover frame and bend it with bending machine.
5/12/2023
Set the cover over the frame and crusher to drill the holes to fix it.
6/12/2023 & 7/12/2023
Construction of bagasse outlet duct .
bagasse Outlet Duct
8/12/2023
Taking trial of machine. Recording the temperature of juice and watching the working of machine.
Trial of machine
Temperature of juice
9/12/2023
Fitting all the part of the machine. Ready for transport. Sticking of poster.
10/11/2023
Transport of cart to the IIsc Bengaluru for the evaluation of the project.
NOTE – 1. After taking trial seen that the juice remaining in the coil gets freezed due to very low temperature and it cause to blockage of coil. 2. At the time of trial due to the misalignment of the motor and gear box & also base breaking of gear box the chain was slipped and machine stops working.
