Misr J. Ag. Eng.

, 23(1): 192 216

UTILIZATION OF ELECTRONIC CIRCUITS TO OPERATE

A GRADING PROTOTYPE MACHINE FOR SOME FRUITS
AND VEGETABLES ON WEIGHT BASE
S.M. Gomaa*, H.M.H. Sorour**, O.M. Kamel***, and E.M. Ghazy****
ABSTRACT
The constructed automatically grading prototype was tested and
evaluated in Rice Mechanization Center (R.M.C.) by using two different types of
fruits. The performance evaluation was conducted during grading the Cara
potato and Navel orange under four feed speed, four grading unit belt speeds
and two positions of starting weight
The measurement which were accomplished in the present study include
physical and mechanical properties for Cara potato and Navel orange. That
they can be exploited in designing and fabricating the proposed grading
prototype, productivity, efficiency and costs of the constructed grading
prototype have been determined.
Results indicated that the grading prototype is quite successful for
grading both Cara potato and Navel orange under study. The optimum
operational conditions for obtainging a maximum grading efficiency were 0.14
m/s feeding chain speed, 0.30 m/s weight belt speed and 0.125 m starting weight
position.
Technical evaluation showed that the productivity valnes of the grading
prototype machine were 0.369 and 0.530 Mg/h for Cara potato and Navel,
orange respectively at the optimum operational methods. The cost of material
and fabricating of automatically grading prototype was 5000 LE. The total
costs (fixed + variable) of machine was 3.87 LE/h, but the total costs were
10.49 and 7.30 LE/Mg for both Cara potato and Navel orange at the optimum
operational methods.

1.INTRODUCTION

rading includes two basic processes. The first one is sorting the product
for removing undesirable and rotten material; such a process runs in
most cases manually and by dint of trained workers. The second process
is sorting out the product into categories in term of distinctive features suchlike
shape, size, weight or maturity degree; such a process runs either manually or
mechanically yet, the whole process of grading runs
*Prof. of Agric. Eng.,Agric. Mech. Dept., Faculty of Agric.,Kafr El-Sheikh, Tanta Univ.
**Assoc. Prof. of Agric. Eng.,Agric. Mech. Dept., Faculty of Agric.,Kafr El-Sheikh,
Tanta University
***First under Secretary and Head of Agric. Mech. Sector, Ministry of Agriculture.
****Agric. Eng., in Rice Mechanization Center (R.M.C)
Misr J. Ag. Eng., January 2006

192

mechanically, it is preferred, since manual grading is less efficiency and more

costly. Actually, the mechanical methods of grading counts are difference in
characteristic as for as the fruit is concerned- like length, width, weight, etc. In
case of fruits that are of systematic dimension, size- related methods are best;
while in case of fruits that are not of systematic dimensions, weight- related
methods are most fitting.
Electronic grading is one of the modern grading systems, which is
applied to both processes and has been studied and implemented for different
agricultural products such as citrus, apple, tomatoes and potatoes. It includes the
presentation of objects separately to a measuring unit; individual measurement
of objects, classified by means of signal processing and routed by a transport
mechanism in different direction, and the use of different successively operating
components, such as sensors and actuators, each performing a specific task.
Brennan et al. (1979) stated that many fruits (e.g. apples. pears and
citrus fruits) and vegetables (e.g. potatoes, carrots and onions) are sorted by
weight. Typical weight sorting machines carry fruits in tared canvas pockets
attached to pivoted beams fitted with counterbalance weights. As the beam pass
along the sorter, the beam fulcrum is moved
towards the counterbalance weight until such time as the weight of the fruit
causes the beam to tip discharging the fruit into padded chutes in weight
categories. They add that recent development in weight-sorting machines
involve the use of Electro-mechanical and hydrostatic transducers to sense
weight differences and improved devices, often computer-controlled, for
directing the weighed units into collection chutes. A novel approach to the
problems of high-speed weighing is represented by a machine, which measures
electronically the cross-section dimensions of potatoes at 0.635 cm. intervals
along their length axes. These dimensions are converted into weights by a
computer, which then sorted the potatoes into 4 weight categories at rates up to
4500 kg/h.
Mcrae (1985) showed that the application of electronics to weighing
systems has led to the development of high-speed check-weighers and beltweighers. These use load transducers, which can weigh about five objects per
second.
Peleg (1985) reported that another class of weight sizers employs a
single weighing mechanism (electronic scale), which weight all fruits in a single
file. An electromechanical or elector optical memory apparatus counts and
signals a mechanical push-off or activates a compressed air stream, which sends
the appropriate fruits to their respective side delivery belts or packing bins. The
main disadvantage of weight sizers is the relatively long time required to weight
each fruit. Even continuous flow scales actually have a weighing cycle of
about 1or 2 s. The length of the weighing cycle is proportional to the accuracy
of the scales. Thus, throughput is quite limited if a reasonable weighing
Misr J. Ag. Eng., January 2006

193

accuracy is specified. Another drawback is relatively high cost and considerably

more complexity, as compared to dimensional sizer.
Ball (1986) reported that the produce must be fed singly over any
weigher system. The mechanical method for this is to channel it into a single
stream in a chute of vee section, and deposit it onto a cupped singulator
conveyor. Feeding the weigher spacing on the singulator is achieved by running
it faster than the channel feed, so that each item is taken away before the next
one drops. The cups on the singulator are shaped in an attempt to allow them to
hold only item, so that doubles and trebles are eliminated. This is often aided by
sloping or vibrating the cups, and hand correction can be applied at this stage.
The singulator and weight grader tend not to run at 100 percent cup filled
capacity. This better ensures that each cup contains only one item.
According to Amin, (1994). The grading productivity has been
calculated by using the following equation:
C

M x 60
TG

......................................................................................................1

Where:
C = Grading productivity of the machine, Mg / h;
M = Mass of classified fruit, Mg and
TG = Grading time, min.
Peleg (1985) and Amin (1994) cited that the efficiency of grading for
an outlet can calculated according to the following equation:

M1
100 ..................................................................................................2
M
Where:
M1 = Mass of the fruits falling within the size category of an outlet, kg
and
M =Total mass of pre-classified fruits for the outlet, while
the total grading efficiency is the summation for all
outlet, kg.

The main objective of the present study was to construct and fabricate an
automatic grading prototype for grading some vegetables and fruits on weight
base. The electronic circuits have been designed and utilized to operate the
grading prototype automatically. The physical and mechanical properties of the
Cara potato tubers and Navel orange fruits had been investigated to determine
the main operational and designing parameters affecting the performance of the
proposed grading prototype.

Misr J. Ag. Eng., January 2006

194

2. MATERIALS AND METHODS

Materials:
a. Tested crops: Cara potato and Navel orange crops were used in the present
study.
b. Automatically grading prototype:
An automatic grading prototype on the weight basis has been constructed
and developed locally at the engineering workshop of Ric Mechaichition
Center, Meet EL-Dyba, Kafer EL-Sheikh Governorate. (R.M.C). It grades the
different vegetables and fruits automatically on the weight basis. The fabricated
automatic grader is sketched in Fig.1 and it consists of the following main parts:
1- Frame;
2-Feeding unit;
3- Weight and grading unit;
4- Distribution unit 5- Transmission system and
6- Control system.
1- Frame:
The grader frame consists of three parts which are main frame ,
distribution unit frame and feeding unit frame.
The main frame of the fabricated grading prototype has been was
manufactured from square shape iron steel. Another four square sectors were
vertically fixed on it . A free wheel was fixed at the ends of each bar.
The distribution unit frame was used for carrying the distribution unit,
and constructed from hollow cylinder made from metal sheet, the distribution
unit is fixed on the top of the cylinder. Three iron bars have been fixed on the
cylinder sides to carry the distribution table.
The feeding unit frame has been constructed from angle steel bars. The
feeding chain and hopper are fixed on it. This frame consists of two opposite
right triangles, between of them a feeding chain which is fixed on three gears in
the triangle vertexes. It is driven by means of the gear fixed in the right angle by
another chain connecting with the transmission unit. The feeding hopper is fixed
on the chord of the right triangle in its down end.
2- Feed unit:
The main function of the feed unit is to feed the weight and grading unit
with single fruits at equal times which could be controlled. The feed unit
consists of the following main parts:

Misr J. Ag. Eng., January 2006

195

3
2

Gram

Weight ad j.

Auto.

OFF

Z ERO
DOWN

UP

OVER & LESS

CATEGORY(1)
CATEGORY(2)

OFF
Maximum weight, Category(1)

Minimum weight, Category (1)

Minimum weight, Category (2)

Minimum weight, Category (3)

+

CATEGORY(3)
CATEGORY(4)

ON

A
D
J
U
S
T

ADJUST

OVER LOAD

Motor start

Auto.

180

Manual

Screen reset

Minimum weight, Category (4)

BALANCE ADJUST
POWER
OFF
STANDBY

ON

OPERATING

START

85

11

No.

Part name

1
2

Distribution table
distribution disc frame

3
4

Weight unit

Orientor

Feed chain

7
8
9
10
11
12

Synchronous unit

Cub
Feed hopper
Control box
Main frame
Feed unit frame
Distribution unit frame

12
10

27

88

75
250

60

Dim. in cm.

Fig. 1: Schematic diagram of grading prototype machine

a- Feed hopper:
A rectangular feeding hopper was designed fabricated and fixed on the
feeding unit frame of the proposed grading. It was made from galvanized steel.
The hopper dimensions were 50 cm length, 45 cm width and 67 cm height. To
ensure that a shallow of fruits is presented in front of the feeding spoon (cups),
this hopper is divided by means of lateral slider diaphragm to avoid the spoon
from passing through a dense layer of fruits. Consequently, reducing the
damage, which may occur to the fruit sprouts during the grading operation. The
base sides of the hopper sloped gradually at angle over the repose angle of about
38 deg of the fruit to keep the flow of fruits at continuos rate. To avoid the free
falling of fruits from the hopper bottom at the outlet chamber, a semi-cylindrical
tube with diameter of 10 cm and height of 20 cm was joined to the hopper
bottom, which is regarded to be more than the distance between two
consecutive spoons.
b- Feed chain:
The feed chain was made of iron with 364 cm length, 20 spoons have
been fixed on the feed chain along the chain to pick the fruits from the hopper.
This chain is mounted on three supported iron gears as shown in Fig.1. The
three gears have been fixed on the right triangle vertexes. The fixed gear on the
right angle of the triangle called the drive gear of the feeding chain. Another
two gears fixed also on the shaft of the drive gear. One of them transmits the
motion from the main operating motor to the shaft of the drive gear,
Consequently transmits the motion to feeding unit. But, the second one
transmits the motion from the shaft of the drive gear to the distribution unit.

Misr J. Ag. Eng., January 2006

196

c- Spoons (cups) of the feeding chain:

The spoons of the feeding chain have been constructed from aluminum
metal. Each spoon has two turgids to pick and carry the single fruit from the
hopper to the weight and grading unit.
d- Fruits orientation:
A cuboid orientor, which has been used in the fruits orientation, has been
fixed in the upper angle of feeding chain frame. The orientor can be bind the
fruits between its outer wall and feeding chain at changing the fruit orientation
as a result for rotating it. So, the fruit fall from the end of orientor onto the
weight and grading unit belt.
3- Weight and grading unit:
The weight and grading unit has been consisted of two hollow opposite
rectangular frames. The electronic circuits required for adjusting the
synchronization between the weight and distribution, infrared lamps concerning
to the weight operation. There were two plastic rollers between the two frames,
The weight and grading unit belt has been fixed on the back and front rollers.
The back roller is rotated by electrical motor, 12 volt DC which is separated
than the transmission group of the grading prototype. The weight and grading
unit has been fixed on a free axial near the back edge of the weight and grading
unit frame with the frame which carries the feed units. It was attached to the
feed frame by means of two ball bearings. A bar has been fixed in the down part
of the two rectangular frames, a slice of iron was connected in the center of the
bar, which was fixed between two side of copper pulley connected on the
middle of the weight sensor.
4- Distribution unit:
The distribution unit was mainly consisted of the main following parts:
a- Synchronous unit.

b-The distributor disk.

c- The distributor table.

a- Synchronous unit:
The feeder of the distribution unit called synchronous unit, it has been
consisted of two gates which were formed semi-cylinder at closing it as shown
in Fig.1. The synchronous unit received the weighted fruit and opened for
falling the fruit into the gates of distribution unit. The gates of synchronous unit
have been opened and closed by means of solenoid, which was controlled by
using an electronic circuit.
b- The distribution disk:
The distribution disk has been consisted of two circular rings, which
were constructed from metal sheet. The diameter of the outer ring was 70 cm
Misr J. Ag. Eng., January 2006

197

but, the diameter of the inner ring was 20 cm. The distance between the outer
and inner rings was divided into 10 equal sections each of them equipped with a
vertical moving gate on the horizontal axial. It is fixed below each gate a spring
for its attracting into an electromagnet.
A lead weight has been jointed with the inner back edge of each gate for
adjusting the balance around the horizontal axial of the gate. The gates have
been closed during the operation by electromagnets which take their orders
from the gates control circuit.
The distribution disk was carried on a hollow roller which was attached
to the distribution frame by means of two ball bearings. The distribution disk
has been driven by means of a chain through out the power transmission unit
consequently, the distribution disk is rotated. It has been fixed on the inner ring
the electronic circuits required for closing and opening the gates which take
their orders by wires connected with slippers which were fixed on the hollow
roller.
c- The distribution table:
The distribution table is a circular disk, which was fixed below the fruits
distribution disk. Number of baskets were put on the distribution table to
receive the graded fruits.
5- Transmission system:
The transmission system has been consisted of two electrical motors
were used for driving each of feeding and distribution units in addition to
weight and grading unit. A main electrical motor, which has gear box (Model:
M425-201), 100 volt AC, 25 W, 1400 -1700 r.p.m and variable speed, has been
used for operating the feeding unit by means of a drive shaft. The motion is
transmitted from the drive shaft to the distribution unit by means of chain, two
gears and gear box with reduction ratio 10:1. An another electrical motor, 12
volt DC, 50 W, 40 r.p.m., variable speed was used for driving the belt of weight
and grading unit. There were a synchronization between both of the feeding and
distribution units by means of different gears in the diameter and number of
teeth.
6- Control system:
The control system has been comprise number of electronic circuits for
controlling in the feeding rates by means of the control in the feeding chain
speed and weight and grading unit belt speed. The control system also weight
the fruits singly by means of processor which has been controlled in the position
of the fruit outlet according to its category which has been determined by means
of a programming circuit. The control system consists of the following main
electronic circuits:
a- Power supply circuits;
Misr J. Ag. Eng., January 2006

b- Pulses generating circuit;

198

c- Weight circuit;
e- Screen circuit and

d- Programming circuit;
f- Controlled gates circuit.

a- Power supply circuits:

The main function of these circuits is to supply all the electronic circuits
and its additional, namely: coil and relays, with the voltage required for their
operating according to the design. Three groups of the power supply have been
used in this design.
b- Pulses generating circuit:
The main function of this circuit was to generate pulses which were used
for determining the gates position. The pulses generating disk was a circular
disk, its out circumference divided into ten equal sections by slits with 5mm
depth in the same direction of center. These slits were numbered from zero to
nine and were used to generate the synchronization pulses (Clock pulses). On
the other hand, an another slit is located between the ninth slits and the zero slits
at a small distance from the disk center and it was used to generate the reset
pulses. This disk has been fixed in the driven shaft of the distribution unit and
during its rotating passes between two group of photo coupler each of them has
been consisted from infrared transmission LED(Light Emitting Diode) and
infrared receiving LED.
The clock and reset pulses have been generated during rotation the disk
and at locating the slit between the transmission and receiving LEDs the
infrared rays pass from the transmission LED through the slit to the receiving
LED consequently, a pulse has been generated. When the disk rotates one
round, ten pulses are generated for determining the position of gates. After
generating the ten clock pulses and before starting a new cycle of the pulses
generating disk, a reset pulse has been generated as a result for passing the
infrared rays through the slit located between the ninth slit and the zero slit.
c- Weight circuit:
The main function of the weight circuit was to determine the weight of
the graded fruits as a volt value. This circuit has been consisted of the following
electronic circuits:
1.
2.
3.
4.

Sensor;
Amplifier and zero adjusting circuit;
Volt to frequency convertor circuit;
Timing circuit;
a-Starting weight position circuit;
b-Timer circuit;
5. Frequency pass controlling circuit and
6. Frequency to volt convertor circuit.

Misr J. Ag. Eng., January 2006

199

1- Sensor:
A piezoelectric sensor, Germany made Type DW1, has been comprised
electronic circuit which convert the pressure on the sensor disk to mA (milli
Ampere).
2- Amplifier and zero adjusting circuit:
The main function of this circuit was to amplify the sensor signal using a
variable resistor. The weight and grading unit presses on the sensor during the
grading operation consequently, a volt is generated which is suitable with the
weight and grading unit. During motion the fruit with the weight and grading
unit belt, a volt is generated from the sensor as a result to the fruit pressure on
the sensor.
3- Volt to frequency convertor circuit:
The main function of this circuit was to convert the output voltage from
the sensor, which was amplified, to frequency as linear regression (one volt
equal 1000 Hz).
4- Timing circuit:
The timing circuit, which has been used in this designing, consisted of
two main parts. The first part included starting weight position circuit. But, the
second one was timer circuit.
a- Starting weight position circuit:
The main function of this circuit was to determine the position of the
weight starting on the weight and grading unit belt by using transmitter and
receiver LEDs. During the motion of the fruit on the weight and grading unit
belt, it passes between the receiving and transmitting LEDs consequently, it
prevents conveying the ray from the transmitter to the receiver thus, it gives
signal which was used for operating the timer circuit.
b-Timer circuit:
The main function of the timer circuit was to determine the time of
sample weight with a high accuracy where, the mistake ratio was not exceed
about one per million. At passing the fruit between the transmitter and receiver
LEDs, a pulse has been generated from the starting weight position circuit for
operating the timer circuit to generate and determine the time of the sample
weight, its value 100 ms.
5- Frequency pass controlling circuit:
The main function of this circuit was to control in passing the generated
frequency as a result to weight the fruit during the operation interval of the
timing circuit.
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200

6- Frequency to volt convertor circuit:

The main function of this circuit was to convert the frequency resulting
from weight the fruit, during the determining time, into volt and its enlarging in
addition to fixing this volt until it was compared in the programming circuit
with the determined volt for each grading category.
d- Programming circuit:
The main function of the programming circuit was to determine the
maximum and minimum weight of each grading category and showed the value
of weight by screen during programming operating.
e- Screen circuit:
The main function of this circuit was to display the fruits weight during
the grading operating or display the weight during the programming operation
addition to display the value of belt speed of weight and grading unit during
adjusted its speed belt
f- Gates control circuit:
The main function of the gates control circuit was to control in opening
the gate which carries a fruit determined category in its falling position. The
main gates control circuit has been consisted of ten similar circuits in the
function and construction, each of them controls in the open of a determined
gate.
g- Signals transmission circuit:
The main function of the signals transmission circuit was to convey the
data concerning with the fruits category from the gates control circuit into the
distribution unit to carry out the orders. This circuit has been consisted of two
main circuits as follows:
1-Parallel to sequent data converting circuit.
2-Sequent to parallel data converting circuit.
1- Parallel to sequent data converting circuit:
The main function of this circuit was to convert the signals passing from
the parallel to sequent for transmitting it into the distribution unit by means of
one slipper instead of ten slippers
2- Sequent to parallel data converting circuit.
The main function of this circuit was to convert the transmitted signals by
means of slipper from sequent to parallel and its distributing for the relays in
order to control the opening and closing the gates.
At carrying the gate with fruit during the grading operation, the gate stays
closed until reaching the convenient position of the fruit weight consequently,
the signal passes through the transistor of this gate which cut off the electrical
Misr J. Ag. Eng., January 2006

201

current about the coils by relay and the magnetic field avoid thus, the gate is
opened and the fruit falls in the suitable position.
METHODS:
Mass of fruit :
One hundred sample for each Navel orange and Cara potato were
randomly selected to determine the average mass of each fruit by using an
electronic balance with an accuracy of 0.01 g.
Coefficient of friction:
Coefficient of friction for the Cara potato and Navel orange have been
measured by using two friction surfaces which were smooth rubber and
galvanized steel. According to (Abd El-Mageed and Abd Alla, 1994) the fruits
or tubers have been placed over the friction surface and the tension force on the
fruit surface was gradually increased and stopped when the fruit begin to move.
Coefficient of friction has calculated using following equation:
P

tan ................................................................................................3
M
Where:
= Coefficient of friction, dimensionless;
P = Force required to start fruit movement on the horizontal plan, N;
M = Mass of fruit, N and
= Angle of friction, deg.
Rolling angle:

The rolling angle has measured by using an inclined plan with two types
of surface galvanized steel and smooth rubber. The orange fruit or potato tubers
have been placed on the horizontal surface of the inclined plat one by one and
then by gradually increasing the angle of inclination, until the fruit begin to roll,
and the recorded angle is considered as the rolling angle of the fruit or tuber.
Impact height:

Impact height of potato tubers and orange fruit were accomplished by

free fall dropping of each sample from different height ranged from 0.3 to 2 m.
The tested sample have been marked and sorted for weeks in room temperature
(Amin, 1994). The bruised samples were separated based on the visual
inspection of discoloration appeared on the flesh surface of the impacted fruits
and tubers.
Productivity:

The productivity and efficiency of grading machine have been

determined according to (Amin, 1994). The productivity has been calculated
according the following equation:
Misr J. Ag. Eng., January 2006

202

M 60
TG

................................................................................................... 4

Where:
C = Productivity of the machine, Mg / h;
M = Mass of classified fruit, Mg and
TG = Grading time, min.
Grading efficiency:
The grading efficiency of each outlet has been calculated according to
the following equation:
M 1 100 ............................................................................................ 5
i
M
Where:
i = Grading efficiency of fruit, %;
MI = Mass of the classified fruits for each outlet, Mg and
M = Total mass of the fruits for each outlet in the machine, Mg.
The total efficiency of the grading machine has been calculated using the
following equation:
M1 M 2 M 3
x 100 ........................................................................... 6

M
Where:
= Total grading efficiency of the machine, % ;
M1 + M2 + M3 = Masses of the proposed
classified fruits for first,
second and third outlets,
Mg. and
M = Total mass of the fruits for each outlet in the machine, Mg.
Power unit requirements for the machine operation:
The consumed power ( kW ) has been estimated by using the multimeter, 700 volt (AC), 10 ampere- (Japan made) to measure the line current
strength and the electric potential. The electric power required for operating the
grading machine has been computed according to (Abd-Alla et al. 2000) by
using the following equation:
I E cos
........................................................................................... 7
P eL
1000
where:
PeL = The electric power required by the graing machine, kW;
I
= Electric current, Ampere;
E = Electric potential, Volt and
Cos = power factor, equal 0.64.

Misr J. Ag. Eng., January 2006

203

The power unit required operating grading achine has been calculated by
using the following equation:
Power unit = power, kW / poducivity, Mg.
Cost of grading operation:

The total cost of grading machine includes charges for ownership and
operation. Ownership costs are seemingly independent of use and are often
called fixed costs or overhead costs. Fixed costs include depreciation, interest
on investment, taxes, housing and insurance. Costs for operation vary directly
with the amount of use and are often called variable costs, or operating costs.
Variable costs include repair and maintenance, electricity and labour. Grading
cost LE/ h or LE/ Mg for the proposed grading machine was estimated
according to (El -Khawaga, 1999) as follows:
A- Fixed costs (FC ):
1- Depreciation (D):
D P - S .......................................................................................................9
L
Where:
D = Depreciation cost, LE;
P = Machine purchase price, LE;
S = Salvage value at the end of machine life (0.1 P), LE and
L = Machine life, year.
2- Interest (I):
I P - S i ................................................................................................10
2
Where:
I = Interest on investment. LE / year and
i = Interest rate, decimal.
3- Taxes, housing and insurance cost:
The taxes, housing and insurance costs had been assumed to be 2 % of
the purchase price of the machine (P).
Then:
Fixed costs ( LE / year ) = D + I + 0.02 P
Fixed costs ( LE / h ) = (D + I + 0.02 P) / yearly operating hours.
B- Variable costs (VC ):
1- Repair and maintenance costs (RM):
The repair and maintenance costs (RM) = 100 % depreciation cost / total
operating hours per year, LE/ h.
2- Energy (Electricity) cost (E):
E = Energy consumption (kW.h) x power price (0.25 LE/ kW), LE/.h.
3- Labour cost (La):
La = 1.5 (LE/h) x 2 labours
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204

= 3 LE/h.
Then:
Variable costs (VC ) LE/h = RM + E + La
C- Total costs (TC ):
Total costs (LE/h) = Fixed costs (LE/h) + Variable costs (LE/h).
D- Important assumptions:
The following assumptions indicated in Table 1 were used for estimating
the cost of the proposed grading machine:
Table 1: Assumption for cost of the machine
No
1
2
3
4
5
6
7

Item
Machine price ( P ), LE
Salvage value ( S ), LE
Housing and insurance ( Hi ), LE
Interest rate ( i ), LE
Energy price ( e ).
Machine life ( L ), year.
Yearly operation ( h ), hours.

Value
5000
10 % of ( P )
2 % of ( P )
12 %
0.25 LE/ kWh
8
2000

The present study aims to:

1- Design, fabricate and test a locally automatic grading prototype for
grading some vegetables and fruits on the weight basis
2- Test and evaluate the grading prototype performance and efficiency
under different operation methods.
a) Four feed speeds: 0.14, 0.17, 0.21 and 0.24 m/s;
b) Four speeds of weight unit belt: 0.3, 0.45, 0.6 and 0.75 m/s and
c) Two positions of starting weight: 0.08 and 0.125 m from connected
point between weight and grading unit and sensor.
3- Estimate the cost of the machine production.
The automatic grading prototype has been fabricated, tested and
evaluated technically and economically under different operating conditions at
the development section and engineering workshop of Rice Mechanization
Center, Kafr EL-Sheikh, Governorate, Agricultural Engineering Research
Institute, Egypt during 2003, 2004 and 2005 years.
3. RESULTS AND DISCUSSION
1- Physical properties of the graded fruits:

The physical properties of the Cara potato tubers and Navel orange fruits
have been measured as one of the important factors affecting on the designing
and fabricating the weight grading prototype and also affecting the transporting,
handling and exporting operation of these fruits. The physical properties, which
have been measured of the potato tubers, include length, width, thickness,
Misr J. Ag. Eng., January 2006

205

volume, mass, density, shape index, length shape and thickness shape the
physical properties, which have been measured of the Navel orange fruits,
include length, diameter, shape index, volume, mass and density as tabulated in
Table 2.
Table 2: Physical properties for Cara potato and Navel orange.
Items

Crop

Length, Width, Thickne Shape Length Thickne Mass, Volume, Density,

mm

mm

ss, mm

index

shape,

ss

cm3

g/cm3

71.70

63.10

50.40

1.28

14.30

80.07

133.2

120.2

1.11

Orange 72.50

72.40

-----

1.00

-----

-----

191.50

230.3

0.8

Potato

88.00

81.00

66.00

1.53

45.90

99.00

198.00

185

1.25

Orange 84.00

84.00

------

1.10

------

------

295.00

153.0

0.5

Potato

55.00

50.00

41.00

1.09

0.13

61.98

77.00

70.0

0.9

Orange 60.00

63.00

-----

0.80

------

------

114.00

423.0

1.2

Potato

7.32

6.04

9.29

0.11

9.30

7.36

31.92

29.5

0.1

Orange

4.60

4.51

------

0.04

------

------

43.25

42.8

0.2

Potato

10.21

9.59

10.49

8.54

61.30

9.15

23.03

23.6

7.2

Orange

6.34

6.23

------

4.00

------

-----

22.64

18.6

18.8

Potato
Av.

Max.

Min.

S.D.

C.V.

2-.Mechanical properties:
a- Coefficient of friction :

The suitable surface which gives high value of friction coefficient

between the grading machine surface and the tested fruits surface must be found
to satisfy the design requirements. The average values of static Coefficient of
friction () for the potato tubers and orange fruits have been determined on a
various surfaces used for the proposed design (galvanized and smooth rubber).
The values of coefficient of friction were 0.5 and 0.41 for potato tubers and
orange fruits, respectively, using smooth rubber sheet surface. The
corresponding coefficient of friction were 0.76 and 0.55 for potato tubers and
orange fruits, respectively, using galvanized steel. The previous mentioned
results revealed that, the maximum value of friction coefficient was 0.76 which
was obtained using the galvanized steel surface with Cara potato . But,

Misr J. Ag. Eng., January 2006

206

minimum value was 0.41 due to using the smooth rubber sheet surface with
Navel orange.
b-.Rolling angle:

The rolling angle was an important factor which was used for
determining the slope of the inner surface of tuber tank in addition to determine
the slope of the transport belts. The rolling angle on smooth sheet rubber and
galvanized sheet surfaces for potato tubers and orange fruits have been
measured. The experimental work has been conducted at one position of fruit
movement where the long axis of fruit was laid vertical to the direction of
motion.
The obtained values of rolling angle at smooth sheet rubber and
galvanized sheet surfaces were 0.27 rad ( 15.7 deg) and 0.29 rad (16.59 deg)
respectively, for the Cara potato. The corresponding values for Navel orange
were 0.08 rad (4.59 degree) and 0.11 rad ( 6.45 degree) using smooth sheet
rubber and galvanized steel surfaces, respectively. It can be noticed that the
rolling angle on the smooth sheet rubber surface was smaller than which was
recorded with the galvanized steel surface for the two tested fruits. However,
the potato tubers recorded higher angles of rolling than which were achieved
with the orange fruits.
c- Impact height:

Impact height must be studied as one of the important factor for

determining the height which caused the fruit damage and the corresponding
potential energy of fruit to avoid damage. The maximum impact heights, which
caused damage for potato tubers and orange fruits, were 1.7 and 1.5 m,
respectively. While, the corresponded impact height which cased bruise of
potato and orange were 1.4 and 1.3 m, respectively. The above mentioned
results had been considered at calculating the proper dropping height of fruits at
different positions of the grading prototype. In general, the maximum used
height 10 cm.
3- Efficiency of grading prototype:
a- Effect of the feed speed on the grading efficiency:

The effect of increasing the feed chain speed from 0.14 to 0.24 m/s on
the grading efficiency of the constructed automatic grading prototype for all
speeds of weight and grading unit belt in range of 0.3 - 0.75 m/s and at two
positions of starting weight of 0.08 and 0.125 m under different fruits ( Cara
potato and Navel orange ) has been indicated in Table 3. It can be noticed that
increasing the feeding chain speed during the grading process tended to
Misr J. Ag. Eng., January 2006

207

decrease the grading efficiency of the automatic grading prototype for all the
belt speeds and starting weight position under two different grading crops.
The obtained grading efficiencies from the automatic grading prototype
were 91.7, 88.2, 63.3 and 55 % at feed chain speeds of 0.14, 0.17, 0.21 and 0.24
m/s respectively, with belt speed of 0.3 and starting weight position of 0.08 m
for the Cara potato. The other belt speeds and starting weight positions had the
same above mentioned trend. The results indicated that increasing the feed
chain speed from 0.14 to 0.24 m/s caused a corresponding decrease in the
grading efficiency of the automatic grading prototype of about 40 % at 0.30
m/s weight belt speed and 0.08 m starting weight position. This trend may be
attributed to increase the fruit speed on the weight unit belt as a result to
increase feeding chain speed consequently, decrease the fruit stay interval on
belt thus, decrease the accuracy of the weight and increase the overlapping
percentage which tends to decrease the efficiency.
Also, the feed chain speed of 0.14 m/s achieved the maximum grading
efficiency compared with the other feed speeds for all the belt speeds and
starting weight positions. While, the minimum grading efficiency had been
obtained with the maximum feeding chain speed of 0.24 m/s. Using the
automatic control for adjusting speed of the feeding chain by means of
electronic circuits has been caused increasing the feed uniformity consequently,
increasing the grading efficiency.
Table 3: Effect of feed speed on the grading efficiency as percentage of Cara
potato and Navel orange fruits under different weight belt speeds and
starting weight positions.
Feed
speed,
m/s

Starting
weight
position,

Weight belt speed, m/s

Cara potato

Navel orange

0.30

0.45

0.60

0.75

0.30

0.45

0.60

0.75

0.080

91.7

91.5

86.0

85.0

95.0

94.2

93.3

88.0

0.125

95.0

95.0

89.0

88.0

98.3

98.0

96.7

93.3

0.080

88.2

85.0

85.0

82.5

94.0

93.3

90.0

85.8

0.125

92.5

90.0

87.5

85.0

96.0

95.7

93.3

88.3

0.080

63.3

72.5

80.0

82.5

63.3

80.0

82.0

83.0

0.125

67.5

77.5

84.2

85.0

65.8

84.2

85.0

86.0

0.080

55.0

63.3

65.0

79.2

60.0

71.7

78.3

79.0

0.125

61.7

68.3

70.0

82.5

65.0

78.3

81.7

82.0

0.14

0.17

0.21

0.24

Misr J. Ag. Eng., January 2006

208

b- Effect of the weight belt speed on the grading efficiency:

From Table 3, it has been concluded that, at the lowest values of feeding
chain speeds (0.14 and 0.17 m/s), increasing the weight belt speed tended to
decrease the grading efficiency of the automatic grading prototype at all the
starting weight positions and the tested fruits.. But, the grading efficiency of the
automatic grading prototype increased when the speed of weight belt increased
at the highest values of feeding speeds (0.21 and 0.24 m/s).
However, at the minimum values of feeding chain speeds, increasing the
weight belt speed tended to decrease the grading efficiency for all the starting
weight positions and graded fruits. This trend may be attributed to decrease the
fruit stay interval on the weight and grading unit belt consequently, increasing
the fruit weight interval until the pocket of Synchronous feed unit was opened
which caused overlapping as a result to vary the synchronization time.
But, the grading efficiency of the automatic grading prototype has been
increased when the weight belt speed was increased at the maximum values of
the feeding chain speeds for all the starting weight positions and the graded
fruits. The reason for this was due to increase the fruit stay interval on the
feeding chain therefore the fruit take the same weight belt speed and
synchronize with the pocket of synchronous feed unit opening.
The results also indicated that the weight belt speeds of 0.30 m/s
recorded the highest grading efficiency at the minimum values of feeding chain
speeds ( 0.14 and 0.17 m/s) while, it achieved the lowest grading efficiency at
the maximum values of feed chain speeds (0.21 and 0.24 m/s) for all the other
variables under study. From Table 3, it can be noticed that the results for
grading Navel orange fruits take the same above maintained trend for Cara
potato tubers.
c- Effect of starting weight position on the grading efficiency:
The obtained data in Table 3 represents the values of grading efficiency
as affected by the starting weight position under different speeds of feedi chain
and weight belt for the Cara potato and Navel orange. It can be noticed that, for
all the feeding chain and weight belt speeds, the starting weight position of
0.125 m has been accomplished the maximum values of grading efficiency
compared with the 0.08 m starting weight position for both type of graded
fruits.

It can be also seen from the same Table, for all the starting weight
positions, feeding chain and weight belt speeds, the grading efficiency of the
automatic grading prototype was higher at grading the orange fruits compared
with the Cara potato tubers. This reason may be due to increase the uniformity
of fruit shape, which has a spherical shape, consequently increasing the
accuracy of the weight thus, increasing the grading efficiency. But, the potato
Misr J. Ag. Eng., January 2006

209

tubers had not uniform shape which affects on the weight accuracy therefore,
the grading efficiency.
Finally, the effect of study variables on the grading efficiency could be
concluded as follows:

for all the weight belt speeds and starting weight positions, increasing the
feeding chain speed tended to decrease the grading efficiency for the
automatic grading prototype.

Increasing the weight belt speed tended to decrease the grading

efficiency at the minimum values of feed chain speeds (0.14 and 0.17 m/s) and
increasing the grading efficiency at the maximum values of feeding chain
speeds (0.21 and 0.24 m/s) for all the starting weight positions and the graded
types.
For all the feeding chain and weight belt speeds, the starting weight position
of 0.125 m accomplished the highest values of grading efficiency compared
with the other starting weight position of 0.08 m with the potato tubers and
orange fruits.

The automatic grading prototype recorded higher grading efficiencies

with the orange fruits compared with the potato tubers for all the starting
weight positions, feeding speed chain and weight belt speeds.

The optimum conditions for grading both Cara potato tubers and Navel
orange fruits, which had been recorded the maximum grading efficiency, were
using the automatic grading prototype at feeding chain speed of 0.14 m/s,
weight belt speed of 0.30 m / s and weight starting position of 0.125 m.
4- Productivity of automatic grading prototype:

The data presented in Table 4 represents the calculated productivity of

the automatic grading prototype as affected by the feeding chain speed under
two different types of crop.
Table 4: Effect of feed speed on the grading productivity for Cara
potato tubers and Navel orange fruits.
Productivity, Mg/h

Feed speed,
m/s

Potato tubers

Orange fruits

0.14

0.369

0.530

0.17

0.448

0.644

0.21

0.553

0.795

0.24

0.632

0.909

Misr J. Ag. Eng., January 2006

210

The productivity of grading prototype increased as a result to increase

the feeding chain speed for the two graded fruits. Increasing the feeding chain
speed from 0.14 to 0.24 m/s tended to increase the productivity of the automatic
grading prototype by 71.3 % during grading the potato tubers. While increasing
the feeding chain speed tended to increase the productivity of grading prototype
which has been increased by 71.5 % during grading the Navel orange.
From the above data presented in the previous Table, it can be noticed
that the obtained productivity values, during grading the orange fruits were
higher than which were given with the potato tubers for all the feeding chain
speeds. This trend may be attributed to increase the fruit weight average than
the tuber weight average but, graded number of fruits equal graded number of
tubers per time unit.
The results also illustrated that the productivity of automatic grading
prototype increased by 43.8 % in case of grading the orange fruits compared
with the potato tubers at feed chain speed of 0.24 m/s. On the other wise, for the
potato tubers and orange fruits, increasing the feeding chain speed tended to
increase the productivity and decrease the grading efficiency of the automatic
prototype as shown in Figs. 1 and 2

Efficiency

Productivity

100

100

0.9

90

0.9

90

80

0.7
70
0.6
60

0.5

50

0.4
0.3
0.12

0.14

0.16

0.18 0.2 0.22

Feed speed, m/s

0.24

40
0.26

Fig. 1: Relationship between feed speed,

efficiency and grading productivity of
Cara potato.

Misr J. Ag. Eng., January 2006

0.8
G r a d in g e f f ic i e n c y
P r o d u c t iv it y

0.8
P r o d u c tiv i ty

Efficiency

80

0.7
70
0.6
60

0.5

50

0.4
0.3
0.12

G r a d i n g e f f ic ie n c y

Productivity

0.14

0.16

0.18

0.2

0.22

0.24

40
0.26

Feed speed, m/s

Fig. 2: Relationship between feed speed,

efficiency and grading productivity
of Navel orange.

211

5- Power unit required for grading operation:

The power required for operating the automatic grading prototype had
been consumed for driving both of feeding unit chain, distribution disk and
weight and grading unit belt as well as the power required for operating the
solenoid of synchronization unit. The automatic grading prototype has been
operated at 220 volt and 1.7 ambere so, the power required for grading
prototype operation was approximately constant i.e. 0.374 kW at the different
operating conditions. The data listed in Table 5 represent the calculated power
unit for operating the automatic grading prototype as affected by the different
feeding chain speeds under two different types of the graded crops.
Table 5: The Power unit consumed during grading Cara potato tubers
and Navel orange fruits.
The power unit consumed, kW/Mg

Feed speed,
m/s

Potato tubers

Orange fruits

0.14

1.01

0.71

0.17

0.83

0.58

0.21

0.68

0.47

0.24

0.59

0.41

6-Cost analysis:

The cost evaluation for the grading machine at suitable operating

method at feeding chain speed 0.14 m/s. The results presented indicated that the
total fixed cost was 0.5 LE/h while , the variable cost was 3.37 LE/h at the
lowest feeding chain speed of 0.14 m/s. However, the total costs required for
grading operation were 3.87 LE/ h.
The total cost of Cara tubers grading using the automatic grading
prototype was 10.49 LE/ Mg while it was 7.30 LE/ M g for Navel orange fruits.
For all the feeding chain speeds, the grading costs for Navel orange fruits were
less than which were recorded with Cara potato tubers. This may be attributed
to increase the grading productivity in case of grading Navel orange fruits
compared with Cara potato tubers.
4- Summary and conclusion

1. The grading efficiency of the automatic grading prototype has been increased
when the feed chain speed decreased for all the weight belt speeds and
starting weight positions under two graded fruits.

Misr J. Ag. Eng., January 2006

212

2. The results indicated at the lowest values of feeding chain speed (0.14 and
0.17 m/s), increasing the weight belt speed tended to decrease the grading
efficiency of the automatic grading prototype at all the starting weight
positions and the tested fruits
3. For all the feeding chain and weight belt speeds, the starting weight position
of 0.125 m has been accomplished the maximum values of grading efficiency
compared wit the 0.08 m starting weight position with the different graded
fruits.
4. The automatic grading prototype recorded higher grading efficiencies with
the orange fruits compared with the potato tubers for all the starting weight
positions, feeding speed chain and weight belt speeds.
5. The optimum conditions for grading both Cara potato tubers and Navel
orange fruits, which had been recorded the maximum grading efficiency,
were using the automatic grading prototype at feed chain speed of 0.14 m/s,
weight belt speed of 0.30 m/s and starting weight position of 0.125 m.
6. The productivity of grading prototype increased as a result to increase the
feeding chain speed for the two graded fruits. Increasing the feeding chain
speed from 0.14 to 0.24 m/s tended to increase the productivity of the
automatic grading prototype by 71.3 % during grading the potato tubers.
7. The obtained productivity during grading the orange fruits were higher than
which were given with the potato tubers for all the feed chain speeds.
8. The power required for grading prototype operation was approximately
constant i.e. 0.374 kW at the different operating conditions.
9. The power unit consumed for driving and operating the automatic grading
prototype decreased when the feeding chain speed increased for the two
graded fruits.
10. The total cost of Cara tubers grading using the automatic grading prototype
was 10.49 LE/ Mg while it was 7.3 LE/ Mg for orange fruits. For all the
feeding chain speeds, the grading costs for orange fruits were less than which
were recorded with potato tubers. This may be attributed to increase the
grading productivity in case of grading orange fruits compared with potato
tubers.
5. REFERENCES
Abd-Alla, H. El.; S.M. Radwan ; M.M. El-Kholy and M.S. Radwan (2000).
A weight grading machine for different fruits and vegetable Misr J. Agric.
Eng., 17(3): 675-696.

One American dollars = 5.85 Egyptian pound (LE) according to price of 2005.
Misr J. Ag. Eng., January 2006

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Abd El-Mageed, H.N. and H. E. Abd-Alla. (1994). A simple machine for

grading fresh tomatoes. J. Agric. Sci., Mansoura Univ., 19 (9): 3033
3047.
Amin, E. A. (1994). Development of grading machine for some Egyptian farm
crops. J. Agric. Sci., Mansoura Univ., 19 (7): 2398 2411.
Balls, R.C. (1986). Horticultural engineering technology fixed equipent and
buildings. Macmillan Publishers 18-31.
Brennan, J.G.: J.R. Butters: N.D. Cowell and A.E.V.Lilly (1979). Food
engineering operations (Second Edition). Applied Science Pub. Limited
London 36-39.
El-Khawaga, S. E. (1999). Developing of a harvesting machine for some fruit
crops. Unpublished Ph. D. Thesis, Agric. Mech. Dept., Fac of Agric.,
Mansoura. Univ.
Mcrae, D.C. (1985). A review of developmments of potato handling and
grading. J. Agric. Eng. Res., 31: 115-138.
Peleg, K. (1985). Produce handling, packaging and distribution. AvI Pub.
Comp., INC. Westport, Connecticut. 91-103.

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