UNIVERSITI PUTRA MALAYSIA

PUA MING YEE

FK 2011 85

DESIGN AND DEVELOPMENT OF PINEAPPLE ROLL TART MAKING MACHINE

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DESIGN AND DEVELOPMENT OF PINEAPPLE ROLL TART MAKING

MACHINE

By

PUA MING YEE

Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia,

in Fulfilment of the Requirements for the Degree of Master of Science

June 2011

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Specially dedicated to…

My loving parents…

My wonderful siblings…

My friends…

For their support and encouragement…

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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfilment of

the requirements for the Degree of Master of Science

DESIGN AND DEVELOPMENT OF A PINEAPPLE ROLLED TART MAKING

MACHINE

By

PUA MING YEE

MAY 2011

Chairman: Rosnah Shamsuddin, PhD

Faculty: Engineering

Majority of pineapple rolled tarts are produced manually. Production is therefore slow

and supply is unable to meet the market demand. A rolled tart making machine is

essential for the efficient mass production of pineapple rolled tart. A machine that

would reduce processing time, labour, and operating cost and at the same time,

affordable for small-scale industries, was designed. Since food properties are varying

with time, prior to design processes, effect of dough and jam formulations on its

properties and kinetic studies of jam were studied. Effects of pineapple bakery jams

with different sugar compositions (0% to 33.3%) were evaluated at ambient temperature

based on total soluble solid (TSS), pH, viscosity, and moisture content. Simultaneously,

effects of different butter (23% to 45%), sugar (0% to 20%) and corn flour (0% to 15%)

compositions on hardness and stickiness of pineapple tart short dough were determined.

There were significantly increased (p< 0.05) in total soluble solids (TSS), viscosity, and

moisture content of jams at different sugar percentages, but no significant changes in

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pH were observed. In textural analytical test, significant changes (p< 0.05) in hardness

and stickiness of pineapple tart short dough with different compositions of butter, sugar,

and corn flour were found. Cooking rate of pineapple bakery jam was investigated and

the effects of cooking temperature (70°C to 100°C), stirring speed (20 rpm to 100 rpm)

and batch volume (2 to 6 liters) on rate constant were examined. The linear relationship

between the logarithmic total soluble solids gain ratios of cooked jam and the cooking

time showed that the cooking rate followed the equation of first-order chemical reaction.

The cooking rates increased with cooking temperature and stirring speed, but decreased

with increasing batch volume. The activation energy of cooking process was 42.49

kJ/mol. Present investigation of cooking rate constant will be useful in designing more

efficient jam cookers with higher ratio of effective heating surface to batch volume of

fruit pulp.

Engineering design processes were carried out to develop the conceptual designs, which

were generated with Computer Aided Design (CAD) software and evaluated based on

customers’ requirements. The basic decision matrix was used as a decision making tool

for selecting the best design. The fabricated machine was tested at different screw

rotating speeds and dough formulations. The rolled tart throughput rates increased

significantly (p<0.05) with screw rotating speeds and butter percentages of dough.

However, it decreased significantly (p<0.01) with sugar and corn flour percentages. The

hardness of baked tart and the hardness and stickiness of unbaked tarts showed no

significant difference between various screw rotating speeds and the manual method. It

was found that the rolled tart produced by this machine was acceptable in texture and

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mouth feel. The maximum and minimum rates for the standard dough formula were

4320 pieces per hour and 720 pieces per hour, respectively. The operating costs of

making tarts using the machine with the highest rate were reduced by 92.05%,

compared to the manual method. This machine achieved the objectives of research

which can produce tarts at high rate, low operating and labour costs and affordable for

small scale industries. This research provided the guideline how to manipulate the

dough and jam formulation, and simple way to determine the end point of jam cooking.

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Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai

memenuhi keperluan untuk Ijazah Master Sains

REKAAN DAN PEMBANGUNAN MESIN NANAS TART GULUNG

By

PUA MING YEE

MAY 2011

Pengerusi: Rosnah Shamsuddin, PhD

Fakulti: Kejuruteraan

Majoriti nanas tart gulung yang dihasilkan secara manual. Produktivitinya adalah sangat

rendah dan tidak dapat memenuhi permintaan pasaran. Sebuah mesin untuk membuat

tart gulung sangat penting dalam pengeluaran nanas tart gulung. Sebuah mesin

direkakan untuk mengurangkan masa pemprosesan, kos tenaga kerja dan kos operasi. Ia

juga sesuai untuk industri kecil. Sifat makanan adalah berbeza-beza dengan masa.

Sebelum proses rekabentuk dijalankan, kesan ramuan adunan dan jem ke atas sifatnya

dan kinetik masakan jem dikaji. Pengaruh komposisi gula (0%-33.3%) terhadap jem

nanas diuji pada suhu bilik berdasarkan jumlah pepejal terlarut (TSS), kepekatan, pH

dan kadar air. Secara bersamaan, kesan komposisi gula (0%-20% ), mentega (23%-45%)

dan tepung jagung (0%-15%) terhadap kekerasan dan kelekitan adunan ditentukan.

Terdapat perubahan yang signifikan (p <0.05) pada TSS, kepekatan dan kadar air jem

dengan peratusan gula yang berbeza. Namun, tidak ada perubahan signifikan dalam pH.

Pada ujian analisis tekstur, signifikan (p <0.01) perubahan dalam kekerasan dan

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kelekitan adunan dijumpai dengan komposisi yang berbeza mentega, gula dan tepung

jagung. Kadar masakan jem nanas telah dikajikan dengan pengaruh suhu memasak

(70°C-100°C), kelajuan pengadukan (20rpm-100rpm) dan isipadu bac (2-6liter)

diperiksa. Hubungan linear antara logaritma jumlah pepejal nisbah dan masa memasak

menunjukkan bahawa tahap memasak mengikut persamaan reaksi kimia tertib pertama.

Kadar masakan jem meningkat dengan suhu dan kelajuan pengadukan, tapi menurun

dengan isipadu bac. Tenaga pengaktifan proses memasak adalah 42.49 kJ / mol.

Penyelidikan masakan jem berguna dalam mereka bentuk periuk yang memasak jem

dengen lebih efisien and efektif. Kejuruteraan proses rekaan dilakukan untuk

mengembangkan rekaan konseptual. Rekaan konseptual yang dihasilkan dengan

Computer Aided Design (CAD) perisian dan ia dinilai berdasarkan keperluan pelanggan.

Keputusan dasar matriks digunakan sebagai alat untuk memilih rekaan terbaik. Mesin

itu telah diuji pada kelajuan skru berputar dan formulasi adunan yang berbeza.

Pengeluaran tart gulung meningkat secara signifikan (p <0.05) dengan kelajuan skru

berputar dan peratusan mentega. Namun, ia menurun secara signifikan (p <0.01) dengan

peratusan gula dan tepung jagung. Kekerasan tart gulung yang dipanggang, kekerasan

and kelekitan tart gulung yang belum dipanggang tiada perbezaan yang signifikan di

antara pelbagai kelajuan skru berputar dan kaedah manual. Hal ini ditemui bahawa tart

gulung yang dihasilkan oleh mesin ini dapat diterima di tekstur dan mulut terasa.

Pengeluaran maksimum dan minimum untuk formula adunan piawa adalah 4320 ketul

per jam dan 720 ketul per jam. Kos operasi pembuatan tart gulung yang menggunakan

mesin dengan pengeluaran tertinggi dikurangkan sebanyak 92.05 %, berbanding dengan

kaedah manual. Mesin ini mencapai objektif penyelidikan yang boleh menghasilkan tart

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dengan kadar yang tinggi, kos operasi and kos buruh yang rendah, dan ia adalah

munasabah untuk industri skala kecil. Kajian ini menyediakan garis panduan mengenai

bagaimana untuk memanipulasi doh dan penggubalan jem, dan cara mudah untuk

menentukan titik akhir masakan jem.

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ACKNOWLEDGEMENTS

I would like to express my gratitude to the members of my supervisory committee, Dr.

Rosnah Shamsuddin (Chairman), Associate Prof. Ir Dr. Johari Endan and En. Azman

Hamzah, for their guidance, constructive comments and assistance during my study. My

sincere appreciation goes to all the staff members of the Department of Process and

Food Engineering and to all of my friends for their support. My deepest gratitude goes

to my loving family and my siblings for their unfailing support.

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I certify that a Thesis Examination Committee has met on 28 June 2011 to conduct the

final examination of Pua Ming Yee on his thesis entitled “Design and Development of

A Pineapple Rolled Tart Making Machine” in accordance with the Universities and

University Colleges Act 1971 and the Constitution of the Universiti Putra Malaysia

[P.U.(A) 106] 15 March 1998. The Committee recommends that the student be awarded

the Master of Science.

Members of the Thesis Examination Committee were as follows:

Mohd Nordin Ibrahim, PhD

Associate Professor

Faculty of Engineering

Universiti Putra Malaysia

(Chairman)

Siti Mazlina Mustapa Kamal, PhD

Associate Professor

Faculty of Engineering

Universiti Putra Malaysia

(Internal Examiner)

Farah Saleena Taip, PhD

Associate Professor

Faculty of Engineering

Universiti Putra Malaysia

(Internal Examiner)

Ir Ibni Hajar Rukunuddin, PhD

Professor

Faculty of Engineering

Universiti Malaysia Perlis

(External Examiner)

SHAMSUDDIN SULAIMAN, PhD

Professor and Deputy Dean

School of Graduate Studies

Universiti Putra Malaysia

Date:

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This thesis was submitted to the Senate of Universiti Putra Malaysia and has been

accepted as fulfillment of the requirement for the degree of Master of Science. The

members of the Supervisory Committee were as follows:

Rosnah Shamsuddin, PhD

Senior Lecturer

Faculty of Engineering

Universiti Putra Malaysia

(Chairman)

Ir Johari Endan, PhD

Associate Professor

Faculty of Engineering

Universiti Putra Malaysia

(Member)

Azman Hamzah

Senior Research Officer

Mechanisation and Automation Research Centre

MARDI

(Member)

HASANAH MOHD GHAZALI, PhD

Professor and Dean

School of Graduate Studies

Universiti Putra Malaysia

Date:

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DECLARATION

I declare that the thesis is my original work except for the quotations and citations

which have been duly acknowledged. I also declare that it has not been previously, and

is not concurrently, submitted for any other degree at Universiti Putra Malaysia or other

institutions.

PUA MING YEE

Date:

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TABLE OF CONTENTS

Page

DEDICATION ii

ABSTRACT iii

ABSTRAK vi

ACKNOWLEDGEMENTS ix

APPROVAL x

DECLARATION xii

LIST OF TABLES xvii

LIST OF FIGURES xviii

LIST OF ABBREVIATIONS xxii

CHAPTER

1 INTRODUCTION 1

1.1 Pineapple Tart 1

1.1.1 Pineapple 2

1.1.1.1 Composition of Fruit 3

1.1.2 Jam 3

1.2 Machine Design 4

1.3 Procedure of Making Pineapple Rolled Tart 4

1.4 Problem Statements 7

1.5 Scope of the Project 8

1.6 Objectives 9

2 LITERATURE REVIEW 10

2.1 Introduction 10

2.2 History of the Biscuit Industry 10

2.3 Definition and Classification of Biscuit 11

2.3.1 Types of Biscuit Dough 12

2.4 Review of Dough Ingredients 13

2.4.1 Fat 13

2.4.2 Protein 14

2.4.3 Water 15

2.4.4 Sugar 15

2.5 Pineapple Jam 16

2.5.1 Jam Boiling 16

2.5.2 Sucrose in Jam 17

2.6 Kinetic Reaction Rate 19

2.6.1 Theory of Kinetic Studies 20

2.7 Physical Properties of Food 21

2.7.1 Dough Consistency 21

2.7.2 Texture 22

2.8 Biscuit Making Processes 23

2.8.1 Primary Processes 23

2.8.2 Secondary Processes 24

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2.9 Unit Operation of Machine 24

2.9.1 Sheeters and Gauging Rolls and Laminating Equipment 24

2.9.2 Cookie Forming Equipment 25

2.9.3 Types of Extruder 25

2.9.3.1 Screw Extruder Basic Components 26

2.9.3.2 Flows of the Screw Extruder 27

2.10 Type of Existing Rolled Tart Making Devices 28

2.11 Life of a Product 28

2.12 Design Process 29

2.12.1 Conceptual Design 30

2.12.2 Definition of Function 31

2.12.3 Selection Design 32

2.12.4 Performance Evaluation 34

2.14 Summary 34

3 EFFECT OF PRINCIPAL INGREDIENTS ON CHARACTERISTIC OF

THE PINEAPPLE BAKERY JAM AND PINEAPPLE TART SHORT

DOUGH 35

3.1 Introduction 35

3.2 Materials and Methods 36

3.2.1 Preparation of dough 37

3.2.1.1 Textural Measurement of Dough 38

3.2.2 Preparation of Pineapple Jam 40

3.2.2.1 Total Soluble Solids (TSS) 41

3.2.2.2 pH 41

3.2.2.3 Viscosity 41

3.2.2.4 Moisture Content 42

3.3 Statistical Analysis 42

3.4 Results and Discussions 42

3.4.1 Textural Analysis 43

3.4.1.1 Effect of Butter Concentration 44

3.4.1.2 Effect of Sugar Concentration 46

3.4.1.3 Effect of Corn Flour 48

3.4.2 Pineapple Bakery Jam Properties 50

3.4.2.1 Total Soluble Solids (TSS) 50

3.4.2.2 pH 51

3.4.2.3 Viscosity 52

3.4.2.4 Moisture Content 54

3.5 Summary 56

4 KINETIC STUDIES ON COOKING OF PINEAPPLE JAM 58

4.1 Introduction 58

4.2 Theory 59

4.3 Materials and Methods 61

4.3.1 Preparation of Jam 61

4.3.2 Total Soluble Solids (TSS) 63

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4.4 Results and Discussions 63

4.4.1 Cooking Rate Curve of Jam 63

4.4.2 Effect of Temperature on Kinetic Rate Constant 65

4.4.3 Effect of Stirring Speed on Kinetic Rate Constant 68

4.4.4 Effect of Batch Volume on Kinetic Rate Constant 72

4.5 Summary 75

5 CONCEPTUAL DESIGN AND DEVELOPMENT OF PINEAPPLE

ROLLED TART MACHINE 77

5.1 Introduction 77

5.2 Methods of Design Process 78

5.3 Specification 79

5.4 Conceptual Designs 81

5.4.1 Understanding the Function of Existing Devices 82

5.4.1.1 Function of Existing Dough Forming Mechanism 82

5.4.1.2 Function of Existing Feeding Mechanism 84

5.3.3.3 Function of Existing Cutting Mechanism 85

5.4.2 Conceptual Designs Development 86

5.4.2.1 Conceptual Designs of Dough Forming Mechanism 86

5.4.2.2 Conceptual Designs of Feeding Mechanism 89

5.4.2.3 Conceptual Designs of Cutting Mechanism 90

5. 5 Concept Evaluation and Selection 91

5. 5.1 Evaluation Based On a Basic Decision Matrix 91

5.6 Results and Discussions 92

5.6.1 Comparison of Alternative Designs 93

5.6.1.1 Design Criteria of Materials Flow 95

5.6.1.2 Design Criteria of Operational Steps, Easy To Control

and Operate 95

5.6.1.3 Design Criteria of Easy To Maintain, Clean, Install

and Disassemble 96

5.6.2 Alternative Designs of Feeding Mechanism 96

5.6.3 Alternative Designs of Cutting Mechanism 97

5.6.4 Comparison of Selected Conceptual Designs and Existing

Mechanisms 98

5.6.5 Dimensions Determination 101

5.6.6 Materials Selection 102

5.6.7 Assembly Drawing 103

5.7 Summary 103

6 FABRICATION AND PERFORMANCE ANALYSIS OF PINEAPPLE

ROLLED TART MACHINE 104

6.1 Introduction 104

6.2 Methods 104

6.2.1 Performance Analysis 105

6.2.2 Textural Measurement 106

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6.2.3 Operating Cost Estimation 106

6.3 Results and Discussions of Fabricated Machine 106

6.3.1 Construction and Structure of Screw Co-extrusion 107

6.3.2 Assembly of Fabricated Machine 107

6.3.3 Die (Nozzle Horn) 110

6.3.4 Barrels 112

6.3.4.1 Adhesive Wear of Thrust Bearing 113

6.3.5 Hoppers with Pneumatic Cylinder 114

6.3.6 Screws 115

6.3.7 Cutter with Pneumatic Cylinder 116

6.3.8 Drive System 117

6.3.8.1 Tension Force of Belt 120

6.3.8.2 Torsional Failure of Flange Coupling 123

6.3.9 Machine Operational 124

6.4 Results and Discussions of Experimental Testing 126

6.4.1 Effect of Dough Formula and Screw Speed 126

6.4.2 Production Rate 130

6.4.3 Textural Analysis 130

6.4.4 Die Pressure 132

6.4.5 Power Consumption of Extrusion 134

6.4.6 Operating Cost 135

6.4.7 Safety Procedure 138

6.5 Summary 138

7 SUMMARY, CONCLUSIONS AND RECOMMENDATIONS FOR

FUTURE RESEARCH 138

7.1 Summary and Conclusions of Research 138

7.2 Recommendations for Future Research 140

BIBLIOGRAPHY 142

APPENDIX 148

BIODATA OF STUDENT 151

LIST OF PUBLICATIONS AND PATENT 152