Design and Development of Compact Industrial

Cookie Manufacturing Machine

for Nut Crunch

A Thesis presented to the

Manufacturing Engineering and Management Engineering
College of Engineering
De La Salle University

In Partial Fulfillment of the

Degree of Bachelor of Science in
Manufacturing Engineering and Management

By

Jing Angelo Clet

Noel De Castro
Anferli Elijah Delfin
Crizoe Rodillo
Intel Joseph Urbano

July 2017
 Table of Contents
LIST OF FIGURES . 3
LIST OF TABLES .. 5
DEFINITION OF TERMS . 6
CHAPTER 1 - INTRODUCTION
1.1 Introduction .. 7
1.2 Background of the Study . 7
1.3 Statement of the Problem 11
1.4 Significance of the Study . 12
1.5 General Objectives ... 12
1.6 Specific Objectives .... 12
1.7 Scope and Delimitations .. 12
1.8 Conceptual Framework ... 13
1.9 Methodology . 15
1.10 Gantt Chart 16
CHAPTER 2 REVIEW OF RELATED LITERATURE
2.1 Introduction .. 19
2.2 Thermal influences during rotary draw bending of tubes from stainless steel.. 19
2.3 Pumps for food extrusion 20
2.4 Equipment for portioning out pieces of a doughy product. 22
2.5 Depositor Apparatus Including Flow Meter .. 25
2.6 High-viscosity dough depositor machine 28
2.7 Depositor system ... 30
2.8 Liquid food dispensing apparatus with programmably controlled
depositor modules .. 32
2.9 Theoretical Framework . 34
2.10 Summary .. 35
REFERENCES . 36
APPENDICES
APPENDIX A - Interview 38
APPENDIX B Economic Analysis 40
2
 List of Figures

Figure 1.1. Well-Known biscuit products. Sky Flakes, Bread Stix, and Nissin Wafer

Figure 1.2 MONO Omega Plus with Wirecut and MONO Omega Touch

Figure 1.3 Various Shapes of Biscuits and Die Templates Used..

Figure 1.4 Formatic R-Series Cookie Machine ..

Figure 1.5 Different types of cookies formed by cookie machine .

Figure 1.6 Sample product of Nut Crunch from Grandulce ..

Figure 1.7 Manual Extrusion of Cookie Dough from Pastry Bag ..

Figure 1.8 Conceptual Framework ..

Figure 1.9 Summary of Methodology ..

Figure 2.1 True stress vs. true strain under varying temperatures

Figure 2.2. Centrifugal pump for low viscosity food extrusion ..

Figure 2.3. Positive displacement pump for high viscosity food extrusion.

Figure 2.4. Lateral view of the lobe rotor pump...

Figure 2.5. Front view of lobe rotor pump for hopper applications.

Figure 2.6. Isometric view of lobe pump for hopper application...

Figure 2.7 Side view of an embodiment of a depositor apparatus.....

Figure 2.8 Side view of an embodiment of a mass flow meter for use with the depositor

apparatus...

Figure 2.9 Block diagram of flow meter...

Figure 2.10 Block diagram of control of depositor machine..

Figure 2.11 High Viscosity Dough Machine hopper design......

Figure 2.12 Wire cut assembly of the machine..

3
Figure 2.13 Perspective view of the dispensing device according to the present invention

Figure 2.14 Peristaltic pump mechanism used by Wells and Cremeens....

Figure 2.15 Front view of an exemplary liquid food dispensing apparatus....

Figure 2.16 Side view of the liquid food dispensing apparatus...

Figure 2.17 Theoretical framework

4
 List of Table

Table 1.1 GANTT Chart Part A.

Table 1.2 GANTT Chart Part B.

5
 Definition of Terms
1. Deposit - a process of laying something down or letting something fall
Deposit. (n.d.) In Merriam Websters collegiate dictionary. Retrieved
from https://www.merriam-webster.com/dictionary/deposit Commented [LMFB1]: Include references of definition
of terms in the References section

2. Extrusion manufacturing process in which a softened material is forced through a shaped

metal piece or die to produce a desired form
Extrusion. (n.d.) In BusinessDictionary. Retrieved from
http://www.businessdictionary.com/definition/extrusion.html

3. Cookie - a small flat or slightly raised cake.

Cookie. (n.d.) In Merriam Websters collegiate dictionary. Retrieved
from https://www.merriam-webster.com/dictionary/cookie

4. Biscuit - a small quick bread made from dough that has been rolled out and cut or dropped
from a spoon.
Biscuit. In Merriam Websters collegiate dictionary. Retrieved
from https://www.merriam-webster.com/dictionary/biscuit

5. Dollops - a lump or glob of something soft or mushy.

Dollops. In Merriam Websters collegiate dictionary. Retrieved from
https://www.merriam-webster.com/dictionary/dollops

6. Hopper usually funnel-shaped receptacle for delivering material (such as grain or coal).
Hopper. In Merriam Websters collegiate dictionary. Retrieved from
https://www.merriam-webster.com/dictionary/hopper

6
Chapter 1 - Introduction

1.1. Introduction
In this chapter, section 1.2 discusses background of the study while section 1.3 states the
statement of the problem. In sections 1.4 and 1.5, the general objectives and specific
objectives will be presented discussing the cookie manufacturing machine for Nut Crunch.
Section 1.6 states the significance of the study. Sections 1.7 discusses the scope and
limitations. Section 1.8 presents the conceptual framework of the study while section 1.9
shows the methodology to be followed by the researchers. At section 1.10, the Gantt chart
was presented.

1.2. Background of the Study

The food sector in the Philippines is known to be one of the countrys leading GDP
contributors with up to 24% of the GDP [1]. It has also shown an annual growth rate of
9.8% [2]. This increasing trend of the sector has been observed since January of 2015 with
the country being the fastest growing food sector in Asia. The National Economic and
Development Authority has stated that there is a need for investments and developments
in the agribusiness and manufacturing industry [3].

Part of the growing food industry of the Philippines is the cookies and biscuit
manufacturing industry. Biscuits continued to be regarded as a convenient snack option
which consumers can consume while on the go. Current trends have shifted to a more
nutritional perspective and biscuits are perceived to be more nutritious than potato chips
as a snack. A steady demand is established from school-aged children and busy individual
due to its affordability. The biscuit industry was dominated by large companies offer Commented [LMFB2]: that offer

brands like Sky Flakes, Nissin Waffer, Bread Stix, and others. These brands of biscuits
offers variety of ingredients, shapes and size. Sky Flakes has rectangular-shaped biscuits
which has crooked edges. Bread Stix, however, has biscuits has elongated stick-like
shapes [4]. However, some products like Nissin Wafer have fillings inside like chocolate

7
or vanilla. These indicates that there is a variety on the biscuits and cookies that are being
manufactured by the industry.

Figure 1.1. Well-known biscuit products. Sky Flakes, Bread Stix, and Nissin Wafer Commented [LMFB3]: Create a caption formatting.
This will help you automatically generate a list of
figures.
Commented [LMFB4]: Call out the figures in the text,
Cookies make use of different dough types depending on the bakers preference. Fat and
ex: Figure 1.1 shows popular cookie and biscuit
water content are the main factors in differentiating the dough mixtures. Consistency of brands like Sky Flakes, Bread Stix and Nissin Wafer.
the dough is determined by the water content and the temperature of the dough. Increase Commented [LMFB5]: Add references for figures

in water content and temperature will produce softer doughs. There are two types of
dough--short dough and hard or developed dough. Short dough has higher fat and lower
gluten content while hard dough has higher water and gluten content. Short dough requires
a balance between water and fat content which yields a cookie that is easy to pull apart.
Short dough makes use of high shear mixers in order to incorporate bubbles [5]. Variations
in dough mixture require specific machines to achieve the optimum quality.

With the different types of dough being used in producing biscuits and cookies, several
machines were developed in order to answer the demand in the cookie industry. Dough
forming is considered to be one of the most time-consuming processes in cookie making.
However, not all machines fit cookie recipe variations. Various designs of dough
extruders are also available. Among these are the MONO Omega Touch Depositor and
Formatic R-SERIES Cookie Machine. With the MONO Omega Touch Depositor,
different hopper and die template options are available. This machinery is used for
confectionery products like doughnuts or short dough cookies [6].

8
Figure 1.2 MONO Omega Plus with Figure 1.3 Various shapes of
Wirecut and MONO Omega Touch biscuits and die templates used

`
On the other hand, the Formatic R-SERIES Cookie machine is for the manufacturing of
dog cookies, veggie patties, play dough, potato pancakes, and various types of cookies.
The machine makes use of a rotating drum with a predetermined embossed shape to press
the dough [7].

Figure 1.4 Formatic R-Series Cookie Machine

Figure 1.5 Different types of cookies formed by cookie machine

9
The cost, size and capacity of these machines are used to meet the demand of the market
and to supply bulk or large orders because of this they are suitable only to large scale
manufacturers. The cost of cookie depositing machine ranges from 130 thousand pesos to
1 million pesos [8]. The sizes of these machines require large workspaces or warehouses
in order to operate efficiently. It can be seen that most cookie making machines can only
mass produce a certain type of biscuit. One type of machine is optimal for manufacturing
biscuits with filling while another type of machine is used for a rectangular type of biscuit.
With this, proper machineries are chosen or designed to suit the need of the recipe and the
manufacturer. Various factors such as cost, product size, demand, and ingredients are
taken into account to obtain the optimum machine for the job. Most industrial machines
are expensive, bulky, and produces too much for the small companies. As such, these
machines cannot cater to small manufacturing enterprises or home-based companies like
Grandulce.

GranDulce is home-based companies that offers healthier pastry choice for its consumers. Commented [LMFB6]: Follow this up with a discussion
of Grandulces demand.
Their products are usually found on gas stations in Bohol, Philippines. The primary
Bonus: forecast Grandulces demand and compare
ingredients that they are using in their products came from local communities [9]. with their existing capacity.
Commented [LMFB7]: Discuss Grandulce before
Currently, the GranDulces Nut Crunch is being produced manually with the primary industrial machines
ingredients sourced from local communities. The owner of the company has asked the > Cookies
> Grandulce cookies
researchers to create a machine that will aid in speeding up the process of creating the Nut > Grandulce wants to expand capacity
> capacity expansion options (industrial machines)
Crunch. The process begins with mixing the dough, which, as described by the owner is
a complex procedure and needs close attention. The dough used for the product Commented [LMFB8]: Instead of just discussing
Grandulces process create a flow diagram
necessitates a much gentler process when compared to the traditional cookie dough
mixing. Afterwards, the dough is extruded using a pipe to form a soft C-shape dollop. This
process takes the most skill to perform and has a tight time frame with the dough hardening
within an hour. This process is considered to be the bottleneck and the main productivity
factor for the manufacturing of the product. It takes two to three seconds for the baker to
extrude the dough from the pastry bag. However, there are inconsistencies in the output
of the extrusion like the amount extruded the spacing between the dough. There is no Commented [LMFB9]: Better if you can show pictures
of examples of these inconsistencies
fermentation process needed for the Nut Crunch dough and are immediately baked when
a batch is done. After baking, the product is then packaged according to the predetermined

10
weights. The current set-up for the manufacturing of the Nut Crunch has found it difficult
to meet the demand. With this, the owner has asked the researchers for help with the
bottleneck of the process which is extrusion. Thus, this study aims to create an extrusion
machine that increases the output of the product while decreasing the time spent. The
machine will operate at a faster time than the current set-up of 20 minutes for each batch
[10].

Figure 1.6 Sample product of Nut Crunch from Grandulce

Figure 1.7 Manual Extrusion of Cookie Dough from Pastry Bag

11
1.3. Statement of the problem
The need for automation for mass producing Nut Crunch cookies of the GranDulce calls
for a compact machine that allow faster extrusion process with uniform output increasing Commented [LMFB10]: There is no discussion in the
background about the need for a compact machine
the production rate of the company.

1.4. Significance of the Study

One advantage of using the Compact Industrial Cookie Manufacturing Machine for Nut
Crunch is that it will be able to produce 60 Nut Crunch cookies faster than the manual
moulding process which is 3 minutes per tray. This machine will also produce more
uniform-shaped and amount of output in comparison with the manual process. The compact
industrial cookie manufacturing machine would also give the opportunity for the company
(GranDulce) to open up opportunities for expansion/branching, given a better follow-
through. It will also introduce new systems and processes of pump mechanisms for
extrusion of viscous materials, which can be used for future references in machine design.

1.5. General Objective

To develop and design a compact machine that will increase accuracy, production speed, Commented [LMFB11]: Specific objective addressing
this?
and ensure uniform product output of the Nut Crunch.

1.6. Specific Objectives

To come up with the optimal design and prototype of an extruder mechanism for Commented [LMFB12]: Eliminate

the production of nut crunch pieces

To extrude 8 x 8 pieces of soft C shape dollops on the tray for baking.

To produce a batch of 64 Nut Crunch pieces in 3 minutes or less. Commented [LMFB13]: Why 3 minutes or less?

To produce uniformly-shaped dough on the tray. Commented [LMFB14]: Define

To provide a tray locking mechanism to ensure that the dollops is extruded in the Commented [LMFB15]: are

trough of the corrugations

12
1.7. Scope and Delimitations
The machine focuses only on the output of the extrusion process.
The premixed dough is to be manually loaded to the hopper of the extruder.
The machine does not make changes to the properties or consistency of the dough
Positioning of the extruder will be based on uniform preset measurements of the
corrugated tray.
It is not designed to compensate on any deviations from the dimensions of the tray. Commented [LMFB16]: The machine

The baking process of the cookies is not included in the research.

The machine is designed specifically for the needs of Nut Crunch production (i.e.
compact, c-shaped output, and fast).
The tray is manually loaded to the machine.
The chosen design among the prototypes will be fabricated. Commented [LMFB17]: Eliminate

1.8. Conceptual Framework

The cookie manufacturing machine consists of two main parts namely the depositor
and the base. The depositor has two main parts; the hopper and the deposit chamber.

The hopper of the depositor will receive the premixed dough. The hopper will use
rollers in order to extrude the dough into the deposit chamber. The deposit chamber will
utilize a pump which will push the dough through the tubes. The dough will then exit
through the deposit valves or die templates and will be dropped on the corrugated trays in
the base of the depositor. The amount of dough being extruded will be measured by setting
time parameters to the deposit valve. The time parameters will then set the wire-cutter to
move in order to cut the extruded dough with the correct amount needed. The corrugated
tray is locked in place in order for the deposit valves to correctly extrude the dough. For
the base, the researchers will design a locking mechanism in order to position the tray
correctly when the depositing process takes place.

13
 Premixed
Dough

Depositor Pump

Hopper

Volume
measurement
Deposit Valve / Die Wire-cutter
Template

Patterned tray

Figure 1.8 Summary of Conceptual Framework

14
1.9. Methodology Commented [LMFB18]: Discuss
Commented [LMFB19]: Incorporate project
management concepts you learned in MREPROM
Phase 1
- Research for possible topics
- Brainstorm for final topic
- Find related literature
- Consult topic proposal Phase 4
- Conduct field Trip - Collect results
o H&Y Company - Summarize and analyze results
o WL Foods - Make conclusions
- Basis study: Process and - Final draft of paper
efficiency control in biscuit - Final consultation
manufacture - Final defense
- Mock defense - Publish thesis paper
- Revisions of paper
- Final preliminary defense
- Final Revisions

Phase 2 Phase 3
- Consult machine design experts - Fabricate parts
- Develop design o Mixer Assembly
o Mechanical o Mold Assembly
o Materials o PLC Assembly
o Electronics - Test and troubleshooting
- Canvass materials
- Consult design
- Make revisions
- Find fabricators
- Computation of total cost
- Purchase materials

Figure 1.9 Summary of Methodology

15
1.10. Gantt Chart

Table 1.1 GANTT Chart Part A

2017
Activity
May Jun Jul Aug Sep Oct Nov Dec
Research for feasible
topics
Brainstorming for top
topics
Approval to proffesors
Interview with
Grandulce owner
Creation of chapter 1
Gathering related
literature
Create first thesis
proposal draft
Oral Defense
Edit thesis proposal
Interview with owner
of Grandulce
Final revision of
chapter 1 and 2
First thesis oral
defense
Design of different
extruders for testing

2018
Activity
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Design of
different
extruders for
testing
Testing using
Nut Crunch
Dough
Experiment on
Nut Crunch
dough
Decide
optimal design

16
 Table 1.2 GANTT Chart Part B

2018
Activity
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Specify
materials
needed
Canvas
materials
Canvas for
fabrication
Compute for
cost and ROI
Approval of
experts of
machine
design
Make
revisions for
design
Find
sponsorship
Make final
revisions of
paper and
design
Purchase
materials
Fabricate
machine parts

17
 Table 1.2 GANTT Chart Part C

2019
Activity
Jan Feb Mar Apr May Jun Jul Aug
Fabricate
machine parts
Post
Assembly
Test
Test
efficiency of
machine
Final Thesis
paper
Reliability
Run
Final Defense

18
Chapter 2 Review of Related Literature

2.1 Introduction
Section 2.2 explains the effect of temperature during rotary draw bending of tubes form
stainless steel. Section 2.3 discusses different pump used for food extrusion. Section 2.4
gives examples about equipment used for portioning dough into pieces. 2.5 to 2.8 explains
different designs and processes of machines for deposition of doughs. Section 2.9
explains the theoretical framework of the study. Section 2.10 summarizes the theoretical
framework of the study

2.2 Thermal influences during rotary draw bending of tubes from

stainless steel Commented [LMFB20]: Move to chapter 3 or
restructure your RRL
Due to the expansion of the application of stainless steel in the industry, most of its
properties are now being studied for the optimization of its applications. A common
application of AISI 304 is for the food manufacturing machineries, or those that has a
higher sensitivity for load contamination.

AISI 304 is one of the most common type of steel that are used in the food manufacturing
industries. This is due to its certain properties that are usually non-reactive with the food-
processing ingredients and setup. Such ingredients include organic chemicals, dyes, and
a variety of inorganic materials. It is as well resistant with sulfuric and nitric acid at
moderate temperature ranging from 20 degrees celsius up to 87 degrees celsius, so that it
is commonly used in the extruder parts of food shaping manufacturing lines. Many
applications also include the storage of liquefied gases,for cryogenic storage systems,
kitchen equipments, and even hospital equipments. [11] Commented [LMFB21]: equipment
Commented [LMFB22]: equipment

19
 Such applications may include stainless steel small tubings for the flexible transfer of the
content. Machining these small diameter tubes requires knowledge about the rotary draw
bending, heat flow in uniaxial tensile stresses, and the flow curves that are produced under
isothermal machinings. The finite element simulation must also be considered due to the
resulting Mandrel balls (both extrados and intrados) when a material is bent. [12] Commented [LMFB23]: ?

In varying temperatures, the influence is becoming more noticeable from the true strains
of ca. 0,1 on. After this threshold, the slope is becoming more dependent on the
temperature. In lower temperatures, the flow stresses are higher. In the experiment which
was conducted were the results below (Table 1). The range of the temperatures were
higher than the maximum temperature when the steel is under constant pressure. Using
the Finite Element Simulation, the curves were linearised to observe clearly the trend of
the line. [12]

Figure 2.1 True stress vs. true strain under varying temperatures [12].

2.3 Pumps for food extrusion

In food processing, solids such as powders and small sized bits are transported using a
pneumatic convoy. On the other hand, fluids, whether if it is viscous or sluggish, are
conveyed by gravity alone or using pumps. The two commonly used pumps for fluid flow
are the centrifugal pumps and positive displacement pumps. [13]

20
Centrifugal pumps works by forcing the material to create a centrifugal force to attain its
tangential velocity by accelerating it in the rotary sense. As the fluid contacts with the
walls of the pump cavity, the flow will then reach a point to be transported into the
impeller tip or the output tube. The flowrate is controlled by choosing the right diameter
of the impeller as well as the rpm and torque of the pump drive. The pump however, is
only applicable to low viscosity liquids or those considered sluggish such as tart mixtures.
If it is used for higher viscosity liquids such as cookie doughs, the pump cavity will not
be filled per revolution which will in turn reduce the efficiency of the said pump. [13]
Another disadvantage of this pump is that it has a no constant flow rate due to the
gravitational factor opposing the output flow.

Figure 2.2 Centrifugal pump for low viscosity food extrusion [13].

The positive displacement pumps usually is composed of either a reciprocating or a

rotating cavity in the middle of two lobes or gears and a rotor. The pump acts as a vacuum
due to the difference of pressures between the inlet and the outlet of the system. The
material is first pushed by gravity and is transported via the walls of the cavity due to the
opposing rotary sense of the lobes or the gears. It has also a constant flow rate which is
also called as the timing pump. [13] The system has no frictional loss so it will be ideal
in transporting heat sensitive dough due to the absence of heat production in the frictional
forces along the walls of usual pumps.

21
 Figure 2.3 Positive displacement pump for high viscosity food extrusion [13].

2.4 Equipment for portioning out pieces of a doughy product

Lobe rotor pumps are a kind of a positive displacement pump and are usually used for
transporting small solids such as cherries without damaging it. It can also be used in the
translation of fluid with high viscosity due to its torque provision. Such pumps can be
applied in the extrusion for the food industries. [14]

The common rotor pumps have two lobe rotors that interengage and rotate in opposite
directions. The pump usually works by rotating the two rotors that are mounted by shaft
usually by a bolt or a screw in the bore, which both axes lie on the same plane. The rotors
are secured inside a casing where the fluid will be translated. However such setup,
according to George W. Ellis, some of the fluid or dough can be in contact with the nut
and shaft ends. Even though O-rings have been provided a solution for this particular
problem, it cannot be still a considerable design. Though this flaw is not viewed as a
serious issue for the general usage (e.g. plastic moldings), it is a however a problem for
the manufacturing firms of the food and drug industry which has a stringent parameters
for the inclusion of foreign objects in the mixture. The solution was to provide a casing
for contrarotation of the two parallel axes within the casing itself. With the improvement
of the casing, the contamination of the fluid is now contradicted. [14]

An equipment was developed so as to cater to the need for the precision of the extrusion
of food products. The design provides the needed predetermined weight of the doughy

22
product by utilizing the rpm and torque of the lobe rotor pump connected to the discharge
duct. The lobe controls the flow of the doughy material and is able to cut it to the extent
that is needed. The input from the lobe rotor is from the hopper and is acting as a suction
unit as the rollers rotates about its parallel axes with each ones opposite senses of rotation
which is shown below. By performing such rotations, excess dough is then returned to
the hopper via the sides of each rotor in contact with the walls of the hopper whilst the
input flows in between. [15]

Figure 2.4 Lateral view of the lobe rotor pump [14]

23
Figure 2.5 Front view of lobe rotor pump for hopper applications [15]

Figure 2.6 Isometric view of lobe pump for hopper application [15]

24
2.5 Depositor Apparatus Including Flow Meter
In the biscuit manufacturing industry, different types of dough depositors are developed
in order increase production with less time. Depositing is the fundamental processes in
order to manufacture dough pieces. In this process, it forces the dough through holes in a
die plate wherein it is customized according the shape to be produced [16].

In a patent released by Balnoschan et al, the depositor apparatus for depositing discrete
amounts of a flowable product includes a product source, a valve that dispenses the
product and a pump that pumps the product from the food product source to the valve
along a line. A flow meter is also installed in the said apparatus [17].

The infeed hopper that contains an amount of the food product. A pump and
motor operatively connected to the pump are provided for pumping the food product from
the hopper to a pair of accumulators which act as a pressure reservoir that holds the food
produ ct under controlled pressure for delivery. The accumulators are connected to a
distribution valves which let divides the dough into the flow meter. The flow meter
measures product flowing through the apparatus. The flow meter delivers the dough into
the tubes and then to the deposit valves. The deposit valves delivers the mixed dough to
the conveyor portion for receiving. The valve is operated by a processor that controls the
valve by closing the valve after a set amount of product has passed through the flow meter.
[17].

25
 Figure 2.7 Side view of an embodiment of a depositor apparatus [17]

Figure 2.8 Side view of an embodiment of a mass flow meter for use with the
depositor apparatus [17]

26
 Figure 2.9 Block diagram of flow meter [17]

Figure 2.10 Block diagram of control of depositor machine [17]

27
2.6 High-viscosity dough depositor machine
In the machine presented by Rodrigues, the high-viscosity dough depositor machine is
adapted for use in the manufacturing of non-traditional baked goods and methods related
there to. The diverse properties of non-traditional dough from the traditional one gives a
setback in using the manufacturing machines of the traditional dough. In accordance, the
machine is adapted to operate the non-traditional dough [18].

The machine is comprised of a hopper, forming portion, dough delivery mechanism,

cutting assembly, and a controller. Each of those parts are adapted for use with non-
conventional dough. The hopper receives the dough supply. The forming portion
comprises a die with at least one transfer port, enabling the dough to be extrudable with
a predetermined shape. The dough delivery mechanism connects the hopper and forming
portion, having at least one roller assembly that has replaceable bearing inserts supported
in a separable bearing housing. The cutting assembly is comprised of a frame with
reinforced mounting structure and is mounted to a drive shaft. The frame supports a
cutting wire, and the driveshaft comprises a surface treatment to limit the movement of
the frame with respect to the drive shaft. The controller comprises of a two drive systems.
The first one controls the delivery mechanism of the dough, with a variable speed, and
the second one controls the speed of the cutting assembly. The drive systems are each
controlled independently [18].

28
Figure 2.11 High Viscosity Dough Machine hopper design [18]

Figure 2.12 Wire cut assembly of the machine [18]

29
2.7 Depositor system
The depositor system introduce by Wells and Cremeens uses a peristaltic pump with four
rollers to increase the productivity compared with the traditional peristaltic pumps. The
mechanism is operated by a servo-motor drive which also acts as the speed dependency
of the production. A shut-off valve closes the conduit when the desired amount of dough
is met. The pump element and the flexible conduit can be adjusted to attain the required
amount of dough output. The patent includes a conveyor which is positioned beneath the
output tube for dough depository [19].

The dough should be previously mixed when put in the hopper and then covered with the
holed stainless steel cover. The device uses a peristaltic pump to move the dough from
the first end of the conduit, through the soft plastic tube, then to the small opening of the
shaper. The servo-motor setup includes the servo motor, the drive shaft and the gear box.
A conveyor is positioned below the output tubing for which the containers and molders
are placed and moved depending on the desired operation of the peristaltic pump. The
peristaltic pump is composed of a pair of plates and occlusion rollers that are held by
spacer bolts. The shoe is the one where the conduit lays and acts as the pressure surface
for the dough displacement. The conduit is deformed and occluded against the shoe and
creates a pressure for the either sucks and/or breaks the flow of dough. The servo motor
rotates the peristaltic driver based on the required speed [19].

30
 Figure 2.13 Perspective view of the dispensing device
according to the present invention [19]

Figure 2.14 Peristaltic pump mechanism used by Wells and Cremeens [19]

31
2.8 Liquid food dispensing apparatus with programmably
controlled depositor modules
According to Gaetano, a liquid food has a fluid characteristic which makes it difficult to
dispense in one type of dispenser. Liquid food dispenser apparatus consisting of product
manifold, depositor module, detachable nozzle, lift mechanism and rotation mechanism.
In the dispensing apparatus, a modular construction is installed which allows
configuration of liquid food and to accommodate a variety of food and its application.
The depositor module is actuated by the actuator module to draw a quantity of liquid food
and discharge it. A nozzle may be attached to the depositor module so that the liquid food
may be discharged in a desired pattern. The lift and rotation mechanisms lift the depositor
module and rotate the nozzle so the liquid food may be dispensed in a variety of
applications. In addition, the vertical translation mechanism comprises a programmable
linear servo motor. Rotation mechanism comprises a worm drive and a programmable
servo motor [20].

In addition, an alternative filling line may be configured with only the dispensing devices
needed for a filling operation such as filling lines. However, filling lines are not very
versatile because a change in filling operations requires a change in the dispensing devices
configured on the filling line. The changeover of dispensing devices associated with one
filling operation to dispensing devices associated with another filling operation is time
consuming and costly. It is not efficient to configure a filling line with dispensing devices
dedicated to only a filling operation [20].

32
Figure 2.15 Front view of an exemplary liquid food dispensing apparatus [20]

Figure 2.16 Side view of the liquid food dispensing apparatus [20]

33
2.9 Theoretical Framework Commented [LMFB24]: Discuss the figure

Hopper Rollers
D. Rodrigues, High-viscosity dough
depositor machine, 2016.
Design and
Development of
Compact Industrial
Soft Plastic Tubes Cookie
D. Wells and J. A. Cremeens, Depositor
Manufacturing
system, 2009.
Machine for Nut
Crunch

Peristaltic Pump
D. Wells and J. A. Cremeens, Depositor
system, 2009.
Depositor
Design
Nozzle Mechanism
G. Gaetano, "Liquid food dispensing
apparatus with programmably controlled
depositor modules, 2008.

Wire-Cut
D. Rodrigues, High-viscosity dough
depositor machine, 2016.

2.17 Theoretical Framework

34
Summary

The compact industrial cookie-manufacturing machine of the researchers requires the

design of the depositor and base where the tray is placed.

The depositor requires more complexity than the design for the mixers. The researchers
able to find basis for the design of components of the depositor, which are the hopper
roller, soft plastic tube, peristaltic pump, flow meter, nozzle and wire cut. Hopper rollers
pushes down the dough to the tubes [18]. The soft plastic tubes are designed to be flexible
in order to transfer the dough mixture upon applying pressure. Peristaltic pumps would
be the source of the pressure that will enable the dough to travel in the tubes [19]. Upon
exiting the depositor, designs for nozzle and wire cut are applied in order to achieve the
exact shape and volume required for each cookie [18][20].

35
References

[1] Philippine Food Industry. [Online]. Available at

http://webcache.googleusercontent.com/search?q=cache:http://www.ifexphilippines.co
m/en/General-Info/Philippine-Food-Industry. [Accessed: July 19, 2017]

[2] "Gross National Income & Gross Domestic Product. [Online]. Available at
http://psa.gov.ph/nap-press-release/sector/Manufacturing. [Accessed: July 19, 2017].

[3] "Philippines food processing set to rebound. [Online]. Available at

http://www.bworldonline.com/content.php?section=Economy&title=philippines-food-
processing-set-to-rebound&id=128477. [Accessed: July 19, 2017].

[4] Bakery in the Philippines. [Online]. Available: http://www.euromonitor.com/bakery-

in-the-philippines/report. [Accessed: October 7, 2017].

[5] D. Manley, Types of Dough. [Online]. Available:

http://www.thebiscuitdoctor.com/manufacturing-processes/72-resources/processes-
types-of-dough/170-types-of-dough. [Accessed: October 7, 2017].

[6] Mono Omega Touch. [Online]. Available at

http://www.monoequip.com/commercial-products/patisserie-and-confectionery-
equipment/confectionery-depositors/omega/mono-omega-touch-. [Accessed: October
23, 2017].

[7] Formatic R-SERIES Cookie Machine. [Online]. Available at

http://erikarecord.com/cookie-machines/r-series-cookie-machine/. [Accessed: October
23, 2017]

[8] Cookie depositor. [Online]. Available at

https://www.ebay.com/sch/i.html?_nkw=cookie+depositor&_sop=16. [Accessed:
October 26, 2017].

[9] Grandulce: Business Info. [Online]. Available at

https://www.facebook.com/pg/Grandulce/about/?ref=page_internal. [Accessed:
October 26, 2017].

[10] J. Loquellano, About Nut Crunch. Coreon Gate, Archer's Place, 2017

[11] Designer Handbook - Stainless Steel for Machining, Specialty Steel Industry of
North America, Washington D.C.. [Online]. Available:
http://www.ssina.com/download_a_file/machining.pdf [Accessed: October. 28,
2017].

36
[12] R. Steinheimer and B. Engel, Thermal influences during rotary draw bending of
tubes from stainless steel, Journal of Procedia Engineering, vol. 81, pp. 2165-2170,
October 2014. [Online]. Available: .
http://www.sciencedirect.com/science/article/pii/S1877705814015823. [Accessed:
October. 28, 2017].

[13] Park et al. (nd). Principles of Food Processing. [Online]. Available:

http://nfscfaculty.tamu.edu/talcott/courses/FSTC311/Textbook/1-
Chapter%201%20Principles%20of%20Food%20Processing.pdf. [Accessed: October.
29, 2017].

[14] G.W. Ellis, Lobe rotor pumps, U.S .Patent 4621994 A , November 11, 1986

[15] O.T. Jonsson and S.R. Carlsson, Equipment for portioning out pieces of a doughy
product, U.S. Patent 4813860 A, March 21, 1989.

[16] D. Manley, Extruding, wire cutting and depositing, Biscuit, Cookie and Cracker
Manufacturing: Manual 3 - Biscuit Dough Piece Forming. Cambridge, England:
Woodhead Publishing Limited, 1998, pp 74-83

[17] G. Balnoschan et al., Depositor Apparatus Including Flow Meter, U.S. Patent
20100147419 A1, June 17, 2010.

[18] D. Rodrigues, High-viscosity dough depositor machine, U.S. Patent 9439441 B1,
September 13, 2016.

[19] D. Wells and J. A. Cremeens, Depositor system, U.S. Patent 20090090432 A1,
April 9, 2009.

[20] G. Gaetano, "Liquid food dispensing apparatus with programmably controlled

depositor modules", US20100133360 A1, December 1, 2008.

37
APPENDIX A Interview

38
39
APPENDIX B Economic Analysis Commented [LMFB25]: Bonus: Use net present value
method

Return of Investment Computations

Overall frame and chassis

Price: Php 40,000.00

*Fabrication fee and materials included

User Interface
Raspberry Pi Microcontroller

Price: Php 2,499.00

Source: https://circuit.rocks/raspberry-pi-3-model-b.html

40
 Display and controls

Price: Php 300.00

Source: https://www.alibaba.com/product-detail/High-quality-popular-cheap-16x2-
COB_338173497.html

Depositor:
Hopper roller
Grain Mill with 11lb Hopper and 3 Rollers, Model: KM11GM-3R

Price: $120.00 = Php 5,400

Source: http://www.beveragefactory.com/homebrew/pre-fermentation-equipment/kegco-
KM11GM-3R-grain-mill.html

41
 High viscosity peristaltic pump and soft plastic tubes
The Verderflex VF 25 peristaltic pump

Price: Php 13,500.00

Source: https://www.verderliquids.com/int/en/purchasing-peristaltic-hose-and-tube-
pumps-verderflex/verderflex-vf/vf-25/

Nozzle
Russian Piping Tip

Price: Php1,125.00
Source: https://www.amazon.com/Russian-Piping-Tips-Baking-
Supplies/dp/B01LZ1Q0IO

42
 Temperature Sensor
Industrial Temperature Sensors Coolant Temp Sensor

Price: Php 450.00

Source: http://www.mouser.ph/ProductDetail/Amphenol-Advanced-
Sensors/WTF083B001-
00/?qs=sGAEpiMZZMud6ugn6h0MdtZHT0zqHuX%252bgItL7M7ha976%2fnaAiS1MP
w%3d%3d

Desired mechanism Price

Overall frame and chassis Php 25,000.00
Raspberry Pi Microcontroller 2,500.00
LED Display and controls 300.00
Grain Mill with 11lb Hopper and 3 Rollers, 5,400.00
Model: KM11GM-3R
The Verderflex VF 25 peristaltic pump 13,500.00
Russian Piping Tips 1,125.00
Industrial Temperature Sensors Coolant Temp 450.00
Sensor
Total: Php 48, 275.00

Nut Crunch Production

Php35.00 per 45g package
Php0.78 per gram = Php777.78 per kg

43
Return of Investment
35 pcs of Nut Crunch cookie per 45g package
80,785 / 35 = 2,308.15
2,308 pieces of 45g packages will be needed

**Assumptions:
1. Minimum of 20 packs of Nut Crunch are sold per day
2. No middleman fees are present (e.g. delivery fee, advertisements, etc.)
3. Php35.00 is the mandatory retail price per pack
4. There is a constant supply and demand of the product
5. The profit is 50% of the total revenue
6. The profit will be used to breakeven the machines price

Revenue per day:

20pcs a day x Php 35.00 per pack = Php 700.00

Profit per day:

Php 700.00 x 50% = Php 350.00

ROI:
Php 48,275.00 / Php 350.00 per day = 137.93 days, or 138 days
It will take about 4 months and 16 days for the investment to return.

44