abe 415 presentation

Apple Sanitation SystemSponsored by: ISU Horticulture Research Station

Michael BellZach Torres

Josh SampsonYoussef Al-Yakoob

ABE 415, Agricultural and Biosystems Engineering Design I

Client Contact

Iowa State Horticulture Research Station

Nick Howell, Farm Superintendent• (515) 291-1559• nhowell@iastate.edu

Brandon Carpenter, Ag. Specialist III• (515) 232-4786• bracarp@iastate.edu

Current State

Small Scale GrowersLarge Scale Orchard Production

Apple Sanitation System Overview

Stage 1• Initial Conveyor• First cull remover

• Chain belt

Stage 2• Wash Bay 1

Apple Sanitation System Overview

Stage 3• Wash Bay 2• Wax & Polisher

Stage 4• Apple Sorter

• Five sizes• Cull, small, medium,

large, and extra-large

Project Scope

• Develop a system to remove superficial diseases from apples, integrate Good Agriculture Practices (GAP) safety into the current system, and automate control and filtration system

• Secondary focus is to minimize water usage and capability of using the system for other produce.

Problem Brief

Sooty Blotch and Flyspeck (SBFS)

• Superficial disease on apples• If not removed, apple grade is

lowerIn order to rid this problem, the apples are required to be soaked ina chlorine solution.

GAP Safety and GMP Safety

• USDA/FDA regulations are becoming more stringent (may soon become law)

• GMP, Good Manufacturing Practices, includes sanitizing equipment, water cleanliness, and worker hygiene

Current Options

• Lakewood Process Machinery• Lawrence, MI

• JMS Industries• Coimbatore, India

Main Objectives

• Ensure that new design can be integrated into current setup with minimal changes

• Provide electronic control of new system

• Maintain a design that is scalable and cost effective for growers of all sizes

Criteria & ConstraintsCriteria• Should maintain or increase efficiency• Should integrate electronic controls for entire system• Minimize space occupied and cost to build• Adapts to current system and have a diversified capability for other

produceConstraints• Must have electronic on/off switch• Must meet GAP & GMP Standards• Must be made of stainless steel• Must have a water flush system

Conveyor System (manual filter)• Chain Link conveyor with

paddles• Gravity fed into/out tank• 22 Bushel/hour (max)

estimated• Manual filter system (push

button)• Reservoir for exchanging

water

Conveyor SystemManual water filter system

• Not fully automatic • System must meet or exceed GAP Standards

• Filter may require daily cleaning

• Cost effective• Simple controls (push button)• No downtime (versus no filter)• Recycles water• Electronic control for majority of

process

Advantages: Disadvantages:

Advantages:• Pre-made tanks available• Easily change throughput• Fully submerges apples• Compact (4’x2’ footprint)

Conveyor SystemConveyors

Challenges:• Construction of conveyor

• Need multiple idler pulleys• Chain conveyor needs custom built

• Tank modifications• Interior dividers

• Optimizing capacity• Different sized apples (paddle

spacing)

Waterwheel System

-Utilization of a water wheel-System specs: • Integrated into current system • Waterwheel• Push button• No filter • Brush wheel• Ramp

Waterwheel SystemAnatomy

Waterwheel Material : Acrylic• Rectangular acrylic platforms fit in between

waterwheel and act as paddles for picking up apples.

• Stainless steel rod acts as axle of the waterwheel.

• Steel rod is fitted with a bearing.• The bearing is the mechanism of

movement for waterwheel• Acrylic parts are glued together using an

acrylic solvent cement that is water-friendly. • How would waterwheel be powered?

Waterwheel SystemPower Source

• Utilization of a belt pulley powered by a motor

• Belt hooks onto bearing of the water wheel axle

• Motor can be turned on/off at operator’s discretion

Waterwheel SystemAcrylic Properties

Numerous pros of using acrylic:

• Cheap/readily available

• Water friendly and non-reactive with bleach

• Strong polymer

• Easy to clean

• Parts can be cut from acrylic sheets, using a water jet or laser cutting

Advantages of Waterwheel Option

• Aesthetics• Innovative• Water wheel can be operated at user’s discretion• Easily maintained/cleaned

Float System● Gravity Fed● Float with overhead

sprayer● Hook wheel with

interlocking ramp● In-line filter with

recirculation pump

Float System

Advantages: Disadvantages:

● Simple Design● Easily Integrated● Easily Maintained● Able to Prototype● Recycles Water

● High Space Requirement● High Cost with Stainless Steel● Apples Not Fully Submerged

Float Conveying

Float SystemFilter System

Disadvantages:● Simple design● Automated cleaning● Minimal operator control

required● Monitors pH level and

bleach concentration

● High Cost● Requires Maintenance

Advantages:

Design MatrixOption 1:Conveyor

Option 2:Waterwheel

Option 3:Float System

416 Future Plans• Finalize idea beginning of next semester• Pick best pieces from each proposal• Start prototyping immediately

• Wood/acrylic prototype• Prove that our system will work

• Research can be done using prototype

Questions?