I

DESIGN AND FABRICATION OF DOUGH

MIXER AND BALL MAKER

PROJECT REPORT

Submitted by

ATHUL KRISHNA KK
PCE15ME007
MAHESH M
PCE15ME017
MOZANASKARI M
PCE15ME019
RASHIB AHAMAD M R
PCE15ME027
to
the APJ Abdul Kalam Technological University
in partial fulfillment of the requirements for the award for the Degree
of
Bachelor of Technology
In
Mechanical Engineering

Department of Mechanical Engineering

Prime College of Engineering

Erattayal, Palakkad-678551

JUNE 2019
II
 DECLARATION

We undersigned hereby declare that the project report “Design and Fabrication of
Dough Mixer and Ball Maker”, submitted for partial fulfillment of the requirements
for the award of degree of Bachelor of Technology of the APJ Abdul Kalam
Technological University, Kerala is a bonafide work done by us under supervision
of Mr. Sajithgopi KV. This submission represents our ideas in our own words and
where ideas or words of others have been included, We have adequately and
accurately cited and referenced the original sources. We also declare that we have
adhered to ethics of academic honesty and integrity and have not misrepresented or
fabricated any data or idea or fact or source in our submission. We understand that
any violation of the above will be a cause for disciplinary action by the institute
and/or the University and can also evoke penal action from the sources which have
thus not been properly cited or from whom proper permission has not been obtained.
This report has not been previously formed the basis for the award of any degree,
diploma or similar title of any other University.

Palakkad
12/04/2019

III
 DEPARTMENT OF MECHANICAL ENGINEERING
PRIME COLLEGE OF ENGINEERING, PALAKKAD

CERTIFICATE
This is to certify that the report entitled ‘DESIGN AND FABRICATION
DOUGH MIXER AND BALL MAKER’ submitted by
PCE15ME007 ATHUL KRISHNA K K
PCE15ME017 MAHESH M
PCE15ME019 MOZANASKARI M
PCE15ME027 RASHIB AHAMAD M R
to the APJ Abdul Kalam Technological University in partial fulfillment of the
requirements for the award of the Degree of Bachelor of Technology in Mechanical
Engineering is a bonafide record of the project work carried out by him under my/our
guidance and supervision. This report in any form has not been submitted to any other
University or Institute for any purpose.

Internal Supervisor(s)

PG Coordinator HEAD OF THE DEPT

IV
 ACKNOWLEDGEMENT

It is a great pleasure for us to acknowledge all those who have assisted and
supported to make our project a great success. First of all we would like to
thank God Almighty for blessing with his grace for the success. We express
our gratitude Prof. Dr. S.I MANJUR BASHA, Principal, Prime college of
engineering for support. We specially acknowledge our H.O.D
Mr. SAJITHGOPI K V, for helping us through thick and thin advices. Above all,
it is out pleasure to thank our guide Mr. SAJITHGOPI K V, HOD of
Mechanical Engineering for his technical support and guidance, steering us to the
successful completion of this project. We thank all the staff and Faculty members of
our college for their cooperation during this project. Finally, We thank my friends
and well- wishers who have supported us directly or indirectly during the course of
this project.

V
 ABSTRACT
Now dough balls are made by using man power, so this increases the working
time and the productivity is less. Hence the profit is not as per expected. Dough Mixer &
Ball Maker can solve all these problems.

Dough Mixer & Ball Maker reduces the human effort, and by using this it increases
the productivity. By using human effort now per minute, 10 dough balls are made. With
this machine per minute, 17 dough balls can be made. Hence the productivity can be
increased up to 58%. So there will be a huge raise in profit by using this machine. With
the effect of machine, per minute there is a increase of 7 dough balls. And per day, the
balls made by the human can be increased twice by using this machine. This machine
will do all the work which is done manually currently. This design introduces, mixing
of flour as well heating it at the same time inorder to obtain the dough as needed by
recipe. After mixing is done, then this dough is made to balls as per the specified size. So
the working time can be reduced.

VI
 CONTENTS

CHAPTER NO. TITLE PAGE NO.

TITLE PAGE IⅠ

DECLARATION III

CERTIFICATE IV

ACKNOWLEDGEMENT V

ABSTRACT VI

CONTENTS VII

LIST OF TABLES IX

LIST OF FIGURES X

NOTATIONS XI

1. INTRODUCTION 1

2. LITERATURE REVIEW 2

3. PARTS 3

3.1 MOTOR WITH BELT – PULLEY 3

3.2 BURNER 4

3.3 CIRCULAR PLATE WITH SPIRAL PASSAGE 4

3.4 SUPPORT STRUCTURE 5

3.5 STIRRER AND PUSHER PLATES 6

3.6 STAINLESS STEEL VESSEL 6

3.7 EXTRUSION PIPE 7

4. WORKING 9

4.1 DOUGH MIXER 9

VII
 4.2 BALL MAKER 9

5. CALCULATIONS OF REAL TIME PROJECT 10

5.1 THICKNESS OF VESSEL 10

5.2 DESIGTN OF SHAFT 10

5.3 DESIGTN OF PULLEY 11

5.3.1 HEAT CONDUCTION 12

5.4 DESIGN OF SPIRAL PASSAGE 12

5.4.1 DESIGN OF RACK 12
5.5 DESIGN OF PINION
13

6. CALCULATION OF PROTOTYPE 14

6.1 THICKNESS OF VESSEL 14

6.2 DESIGN OF SPIRAL PASSAGE 15

7 COST ANALYSIS 16

8 LAYOUT 17

9 RESULTS AND DISCUSSION 19

10 REFERENCE 20

VIII
 LIST OF TABLES

No Title Page No
1 Cost Analysis 16

IX
 LIST OF FIGURES

No. Title Page No.

3.1 Simple Belt-Pulley Mechanism 3

3.2 Burner 4

3.3 Circular Plate with Spiral Passage 4

3.4 Support Structure 5

3.5 Stirrer and Pusher Plates 6

3.6 Mild Steel Vessel 7

3.7 Extrusion Pipe 8

8.1 Dough Mixer with Electric Motor 17

8.2 Dough Ball Maker with Spiral Passage 18

X
 NOTATIONS
A Area , m2
C centre distance , mm
d diameter of vessel , cm
F force , N
h height of vessel , cm
L standard length of belt , m
m mass of mixture , Kg
N speed , rpm
P pressure , N/m2
R centre to end distance of spiral passage
T torque , Nm
t wall thickness of the basin , cm
V volume of vessel , m3

Greek symbols
ρ density , Kg/m3
ω angular velocity , rad/sec
ϭ stress , N/mm2
τ shear stress
η efficiency
π pie

Subscripts
c centrifugal
d diametrical
e equivalent
i intensity
max maximum
min minimum
o outer diameter
w weight
y yield

XI
 CHAPTER 1
INTRODUCTION
Kozhukatta is a popular South Indian sweet dumpling made from rice flour. It is
similar to modak made in other parts of India. So this dish is famous all over India in
different names. Kozhukatta is usually eaten as breakfast or as a snack with tea. It is a
traditional food in Kerala as it is popularly associated with Oshana Sunday evening
celebrations of Saint Thomas Christians. Kozhukatta is the same as modak made during
Ganesh festival. Rice dumplings are made with coconut and jaggery filling. There are
variety of fillings used for making the dish. Kozhukatta is so delicious so almost every
persons will like this dish.

At present, this dish is made by using manpower. As the dish is prepared in the
small scale industry bulk number of balls are to be made per day. So the mixing of the rice
flour and filling with the man power becomes so difficult. Due to this, per day the number
of balls made is not as per expected. So these problems can be solved by using a machine.
If a machine is installed it can do work twice than the work done by human, hence the
human effort can be reduced. So here there is a design for the machine which satisfies all
the needs and which makes dish as per the customer needs.

1
 CHAPTER 2
LITERATURE REVIEW
Vinay V Kumar J, Shashidhar, Suraindir Malhothra, Veeranagouda,
[Link] (2017), their research about the DESIGN AND FABRICATION OF
RAGI BALL MACHINE. Their research concluded that This equipment will help in
reducing the effort to make mudde in large quantities. Mass producers of mudde like in
temples, hostels, restaurants can make good use of the machine. It also saves the time
required to clean after cooking in it due to the non-stick coating. Thus, it helps to produce
healthy ragi mudde which is very soft, tasty and completely free from lumps.

Siraj [Link] (2017), his design of SMART DOUGH MAKING MACHINE.

He concluded that by using the machine, user will get the benefits of, The AC motors are
interfaced with microcontroller successfully and balanced properly resulting proper dough
kneading. The input is fed into the pot or container. And Mechanical design of machine
was successfully implemented

Basil E. Okafor (2015), his design is about the DESIGN OF POWER DRIVEN
DOUGH MIXING MACHINE. He concluded that the mixer was fabricated and tested
and the performance was very satisfactory. Also the cost was found quite affordable. The
machine acquired efficiency of 86%.

Nilesh R. Badgujar, Prof. Sachin R. Shinde and Prof. Vivek S. Shinde (2017),
their project is DESIGN AND MANUFACTURINGBHAKRIMAKING MACHINE
WITH MODIFIED MIXING OF DOUGH &MODIFIED HEATING SYSTEM. They
concluded that In Sorghum and millet dough mixing the exact composition are
measured(1:1), which is in accordance with research paper. The quantity of dough
(sorghum and millet) required for the number of bhakri is made at a time with minimum
time. In Experiments the minimum time required for heating one singlebhakri is 60sec. In
present study three bhakri are in process of making one after another. Using simplified
heating method saving in cost of ₹0.08 per bhakri.

2
 CHAPTER 3
PARTS

3.1 MOTOR WITH BELT - PULLEY

The electrically powered motor is used for rotate the vessel. The mixing,
stirring and heating is integrated to a single unit. These processes are done inside the
vessel with the help of a stirrer which is mounted on the support structure. To run
the vessel for mixing, it is powered using a 0.5HP AC motor. Motor is
maintained at a required speed to rotate the vessel. The belt pulley is provided to
transmit power from the motor shaft to the vessel holder. A pulley system consists
of two pulley wheels each on a shaft, connected by a belt. This transmits rotary
motion and force from the input, or driver shaft, to the output, or driven shaft. Belt
with V cross section is used in this machine. The motor is coupled with the vessel
by a simple belt pulley type.

Fig (3.1) Simple Belt-Pulley Mechanism

3
 3.2 BURNER

Gas burner is a device that produces a controlled flame by mixing a fuel

gas such as acetylene, natural gas, or propane with an oxidizer such as the ambient
air or supplied oxygen, and allowing for ignition and combustion. It is placed at
the bottom of the vessel to heat the mixture to the required temperature powered by
a gas cylinder. The burner is placed with a clearance so the rate of flame can visually
study.

Fig (3.2) Burner

3.3 CIRCULAR PLATE WITH SPIRAL PASSAGE

The rolling of dough into a complete ball shape is done by the circular plate
with spiral passage. It is accompanied with two plates with spiral passage. Among
these plates one plate is another plate is fixed. The rotating plate provides a friction
and the ball making is completed. The spiral passage is placed in between the two
plates. The spiral passage is used to pave a path the ball to the exit and helps in the
completion of the dough ball making. The stainless steel of grade 304 is used for the
rotating plate, fixed plate and spiral passage because the food particles are come in
contact with these components.

4
 Fig (3.3) Circular plate with Spiral passage

3.4 SUPPORT STRUCTURE

Support structure helps the vessel rest on it to accompany the overall

procedure. Support structure withstand all vibrations and forces induced in the
machine on running conditions. The support structure is made up of mild iron. It
also provides for accommodating motor, gear box along with batteries to run the
machine. The support structure holds the complete components in the dough ball
mixer

5
3.5 STIRRER AND PUSHER PLATE

The stirrer is used to complete the mixing process in the dough ball mixer.
The zigzag shaped stirrer is provided at the center supported by support structure.
These zigzag shaped stirrer provides a complete mixing of dough ball. This stirrer
cover more portion of the rotating vessel’s area and complete the mixing process.
The two pusher plates are provided at an angle of 180 degrees to each other and
which is mounted on the inner surface of the vessel. This prevents the dough to stick
on the vessel. The stirrer and pusher plates are also designed according to the food
grade. That is stainless steel of grade 304 is used for the stirrer and pusher plate

Fig (3.5) Stirrer and Pusher plate

3.6 MILD STEEL VESSEL

The mixing, stirring process is done inside the vessel. The vessel used here
is made of stainless steel 304 of 5mm thick. The vessel is mounted on the rotating

6
disc which is connected with the motor powered belt pulley mechanism. It helps to
store the mixture of rice flour and water during the preparation. It also houses the
stirrer blades and the pusher plates used for stirring the mixture inside it.

Fig (3.6) Mild steel vessel

3.7 EXTRUSION PIPE

After the mixing, stirring, and heating process the mixed dough is transferred
to the hopper. The hopper serves as a storage and supplies the dough to
extrusion pipe provides constant flow of dough and the amount of dough is same
at every point.

7
Fig (3.7) Extrusion pipe

8
 CHAPTER 4
WORKING
4.1 DOUGH MIXER

Heat is supplied on the vessel by the burner which is placed under the vessel. The
ingredients are added to the vessel and the liquid state dough is added with the ingredients,
then the motor switch is turned to ON position. When the vessel starts to rotate the stirrer
is placed inside the rotating vessel to mix the ingredients with the exact proportion to the
liquid dough. When the liquid dough is settle into semi-solid state the motor switch is
turned OFF position and the heat supplied from the burner is stopped.

4.2 BALL MAKER

The semi-solid dough is then manually taken and it is placed in to a hopper to make
the dough into balls. There the extrusion process of the dough into the extrusion pipe is
done by using the rack and pinion mechanism. A DC motor with a rotating blade is placed
at the end of the extrusion pipe to cut the ball of same mass and same diameter with equal
interval of time. The balls after the cutting operation is free to fall into a spiral plate of
having two disc where one is rotating and the other one is placed constant. when the ball
is fall in to the rotating plate of having a spiral passage, when this ball rotates and comes
through the spiral passage it will be in a ball shape. So after the final process we will be
getting the ball of same size, mass, and shape.

9
 CHAPTER 5
CALCULATIONS OF REAL TIME PROJECT

Diameter of vessel d = 50 cm
Height of vessel h = 55 cm

Volume of vessel V = пr2h = 1.07 m3

𝑚 10
Density = = 1.07 = 9.35 Kg/m3
𝑣

5.1 THICKNESS OF VESSEL

𝑃𝑖 𝑑
Circumferential stress on mixing basin Δt = 2𝑡

Δt ≤ 5MPa
Pi = pressure due to (centrifugal force + weight of mixture)
Pi = Pc + Pw

Centrifugal force on mixture Fc = mrω2

2ПN
ω= 60
𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦
N = 120 x 𝑁𝑜 𝑜𝑓 𝑃𝑜𝑙𝑒𝑠

Frequency = 50HZ
2Π × 1500
No of Poles = 4ω = 4 x = 157.07 rad/sec
60

Fc = 10 x 0.25 x (157.07)2 = 61677.46 N

Pw = ρgh

Pw = 9.35 x 9.81 x 0.55 = 50.44 N/m2

Area on which Fc acts = Ac = 2Πrh
Ac = 2Π x 0.25 x 0.55 = 0.86m
𝐹
Pc = 𝐴𝑐 = 61677.46/0.86 = 71717.97 N/ 𝑚2
𝑐

Pi = 71717.97 + 50.44 = 71768.41 N/ 𝑚2

𝑃𝑑
𝑖
t = 2∆t
71768.41 x 0.50
t= = 0.003m = 3mm
2 𝑋 5 𝑋 106

5.2 DESIGTN OF SHAFT

2𝜋𝑁𝑇
P= 60

Assume P = 1 HP

10
 60 X .745 X 103
T= = 4.74 N-m
2 𝑋 𝜋 𝑋 1500

Commonly used shaft material is mild steel with Grade C45

From PSG data book Pg:No 1.9
Ϭy = 360 N/mm2
τ = 180 N/mm2
By considering the diameter of the burner and the tolerance di = 40mm
𝜋
T= 16τdo3(1 – k4)
𝑑
K = 𝑑𝑖
𝑜

𝜋
4.74 = 16 180do3(1 – k4)

do = 55 mm
5.3 DESIGN OF PULLEY
Motor RPM (N) =1500
Vessel RPM (n) = 300
Power = 0.745kW
From PSG DB Pg:No 7.58
Load 0.75-5kW , A type belt is used
From PSG DB Pg:No 7.62
de-max = 125mm
de-min = 75mm
de-max = d × Fb
From the table value of Fb = 1.12
𝑑𝑒𝑚𝑎𝑥
d= = 112mm
𝐹𝑏

From Pg:no 7.61

𝑁
D = 𝑛 dη

η = 0.98
D = 548mm

From Pg:no 6.71

𝐷
= 1.66
𝑑
𝐶
= 1.2
𝐷

11
C = 1.2 x 548
= 660mm
Cmin = 0.55(D + d) + T
From Pg:no 7.58
T = 8mm
Cmin = 0.55(548 + 112) + 8
Cmin = 371mm
Cmax = 2(D + d)
= 1320mm
C is between Cmin and Cmax
𝜋 (𝐷+𝑑)2
L = 2C + 2 (D + d) + 4𝐶

L = 2.42m
From pg:no 7.59
The standard length of belt L = 2.47m

5.3.1 Heat Conduction

Q = kAdT
A = 2πr2 = 0.4m
Q = 970×0.4×(1920-173)

=677.83×103 W
5.4 DESIGN OF SPIRAL PASSAGE
𝑅2 𝑋 𝜋 2502 𝑋 𝜋
L= = = 4m
𝑇+𝐶 20+30

5.4.1 Design of Rack

Length = 445mm

No of teeth = 78
Width of rack = 12mm
Thickness of rack = 12mm
Module of rack m = 2.5mm
Pressure of angle = 20o
Addendum = 1 x m = 2.5mm
Dedendum = 2.25 x m = 3.125mm
Tooth depth = 2.25 x m = 5.625mm

12
Working depth = 2 x m = 5mm
Tip and root clearance = 0.25 x m = 0.625mm
5.4.2 Design of Pinion
Diameter = 50mm
No. of teeth = 20
Thickness = 10mm
𝐷 50
Module m = 𝑇 = 20 = 2.5mm

Addendum = 1 x m = 2.5mm
Dedendum = 1.25 x m = 3.125mm
Circular pitch Pc = π x m = 7.85mm
𝑇
Diametrical pitch Pd = 𝐷 = 0.4mm

13
 CHAPTER 6
CALCULATION OF PROTOTYPE
Diameter of vessel d = 23.5 cm
Height of vessel h = 30 cm
Volume of vessel V = пr2h = 0.13 m3
𝑚 3
Density ρ = = 0.13 = 23.07 Kg/m3
𝑉

6.1 THICKNESS OF VESSEL

𝑃
Circumferential stress on mixing basin Δt = 2∆𝑡𝑖

Pi = intensity of internal pressure

d = internal diameter of mixing basin
t = wall thickness of the basin
Δt ≤ 5MPa
Pi = pressure due to (centrifugal force + weight of mixture)
Pi = Pc + P w
Centrifugal force on mixture Fc = mrω2
m = mass of mixture
2𝑋𝜋𝑋𝑁
ω= 60

r = radius of basin
ω = angular velocity
Frequency
N = 120× No of poles

Frequency = 50HZ
2 × 𝜋×30
No of poles = 4 ω = = 3.14 rad/sec.
60

Fc = 3 x 0.1175 x(3.14)2 = 3.47 N

Pw = ρgh
ρ = density of mixture.
h = height of mixture.
Pw = pressure due to weight of mixture
Pw = 9.35 x 9.81 x 0.30 = 67.89 N/ m2

Since Fc is acting on the circumference of the mixing basin.

Area on which Fc acts = Ac = 2Πrh
Ac = 2Π x 0.1175 x 0.30 = 0.22 m

14
 𝐹 3.47
Pc = 𝐴𝑐 = 0.22 = 15.77 N/ 𝑚2
𝑐

Pi = 15.77 + 67.89 = 83.66 N/ 𝑚2

𝑃𝑑
𝑖
t = 2∆𝑡
83.66 x 0.235
t= = 0.93 mm = 1mm
2 𝑋 5 𝑋 105

6.2 DESIGN OF SPIRAL PASSAGE

𝑅2 𝑋 𝜋
L= 𝑇+𝐶

T = Thickness of pipe
C = clearance between pipe
R = centre to end distance
L = approximate length of pipe
1502 𝑋 𝜋
L= = 0.9m = 1m
10+15

15
 CHAPTER 7
COST ANALYSIS
[Link] REAL TIME PROJECT PROTOTYPE

ITEMS PRICE ITEMS PRICE

1. ½ HP Motor (1) 3500 Wiper motor (1) 450

2. ¼ HP Motor (1) 2500 Wiper motor (1) 450

3 Drum casing 2000 Drum casing (mild steel) 400

(stainless steel)
4. Burner with valve 1000 Burner with valve 220

5. Base frame 2000 Base frame 600

6. Rack and pinion 1500 By manual 0

7. Screw conveyor 2000 Spiral passage 250

8. SS 304 Sheet metal 3500 Mild steel 600

9. MS raw material 2500 MS raw material 450

10. Bearing, 2000 Bearing, 300

pulley, belt etc… pulley, belt etc…
11. Bolt 1500 Bolt ,nut,washer,spring 100
,nut,washer,spring

TOTAL = 24,000 TOTAL = 3820

Table No 7.1 Cost Analysis

16
 CHAPTER 8
LAYOUT

Fig 8.1 Dough Mixer with Electric Motor

17
Fig 8.2 Dough Ball Maker with Spiral Passage

18
 CHAPTER 9
RESULTS AND DISCUSSION
Dough mixer and ball maker will offer a better, inexpensive method to reduce man
power and human efforts is eliminated. Mass producer of kozhukatta like in temples,
hotels, restaurants can make good use of the [Link] also saves the time when compared
to the conventional type of production of kozhukatta. We can make 17 balls per minute
and it increases profit and reduces the labour cost by 75% of conventional [Link] meet
the increased demand it is required to produce them hygienically at large scale. Thus, it
helps to produce healthy kozhukatta which is very soft, tasty and completely free from
lumps.

19
 CHAPTER 10
REFERENCE
[1] Siraj M. Tamboli, (2017) Smart Dough Making Machine, Vellore Institute of
Technology University.

[2] Basil E. Okafor, (2015) Design of Power Driven Dough Mixing Machine,
International Journal of Engineering and Technology Volume 5 No.2, February, 2015,
Department of mechanical engineering, Federal university of technology, Owerri- Imo
state, Nigeria.

[3] Vinay V Kumar J, Shashidhar, Suraindir Malhothra, Veeranagouda, T.

Madhusudhan, (2017) Design and Fabrication of Ragi Ball Machine. UG Student,
Department of Mechanical engineering, SJB Institute of technology, Uttarahalli,
Banglore, India. Professor and HOD, Department of Mechanical engineering, SJB
Institute of technology, Uttarahalli, Banglore, India

[4] Nilesh R. Badgujar, Professor. Sachin R. Shinde and Professor. Vivek S. Shinde,

(2017) Design and Manufacturing of Bhakri Making Machine with Modified Mixing of
Dough and Modified Heating System. Mechanical engineering department, Savitribai
Phule Pune University, TCOER, Pune-411048.

20