Mechanical Engineering

Department
 CANDLE MAKING OF PARAFFIN WAX USING
SOLAR RADIATION (Heat Transfer )
GROUP MEMBERS ID
Yabsira Teferi……………………………….DBU1700025
Mandefro bekele……………………………DBU1501033
Mikiyas Tesfaye ……………………………DBU1501372
Niguse Muleta……………………………….DBU1501417
Kaleab Zegale………………………………..DBU1501283
Natenael Seyoum…………………………...DBU1501401

Advisor:[Link] Gashay
Date of Submission:21/04/2018E.C
Introduction
Candle making is a simple manufacturing process that requires heat energy to melt
wax. Conventionally, this heat is obtained from electricity, firewood, or fossil fuels, which
increases production costs and causes environmental pollution. This project presents a solar-
energy-based candle making system that utilizes renewable solar radiation as the main heat
source for melting paraffin wax. A simple solar thermal collector is used to absorb solar energy
and convert it into heat, which is then transferred to a wax-melting container. The melted wax is
poured into mould to produce candles. The system is designed using low-cost and locally
available materials to ensure affordability and ease of use. The study demonstrates that solar
energy can provide sufficient heat for candle production under favourable weather conditions.
This approach reduces energy costs, minimizes environmental impact, and promotes sustainable
small-scale manufacturing, making it suitable for rural and off-grid areas.

Background of the Study

Candles have been used for centuries as a source of light, heat, and for cultural and religious
purposes. Despite the widespread availability of electricity, candles remain essential in many
households, particularly in rural and off-grid areas where power supply is limited or unreliable.
Candle production involves melting wax, usually paraffin wax, which requires a continuous and
reliable heat source. Traditionally, this heat is supplied using electricity, firewood, charcoal, or
fossil fuels. These conventional energy sources increase production costs and contribute to
environmental pollution and deforestation.(Evolution from ancient oil lamps, use in rituals
(Mesopotamian, Roman, Buddhist, Indian), candle-making techniques,E book 2025)

Problem Statement
Conventional candle making relies on electricity or fuels that incur high costs, cause pollution,
and are unreliable in off-grid areas, despite the abundance of solar energy in many regions. The
absence of simple, affordable solar thermal systems limits the adoption of this clean energy for
small-scale manufacturing. Therefore, developing a low-cost, solar-powered candle making
method is essential to provide a sustainable, energy-efficient heat source, reduce dependence on
non-renewable energy, and lower production costs for local producers.

Objectives of the Project

General Objective
To design, model, simulate and develop a candle-making system that utilizes solar energy as the
primary heat source for melting wax, promoting an environmentally friendly and cost-effective
production method.
Specific Objectives
To study the basic principles of candle making and solar thermal energy.
To design a simple solar-based wax melting system suitable for small-scale production.
To utilize solar radiation to achieve the required temperature for melting paraffin wax.
To reduce dependence on electricity and fossil fuels in candle manufacturing.
To use locally available, low-cost materials in the construction of the system.
To evaluate the performance and efficiency of the solar candle making system.
To promote sustainable energy use and environmentally friendly manufacturing practices.

Concept generation
Solar-powered candle making harnesses concentrated sunlight as a clean, sustainable heat source
to melt wax, replacing traditional electrical or fuel-based methods. This is achieved through
simple, direct systems like insulated solar boxes with reflective interiors, or focused thermal
collectors like Fresnel lenses, which convert solar radiation into sufficient thermal energy to
liquefy wax for pouring into molds. The approach is ideal for small-scale, Eco-conscious
production, educational demonstrations, or off-grid crafting, fundamentally relying on the basic
principle of transforming radiant solar energy into practical, applied heat for a traditional craft.

Scope of the Project

The scope of this project is limited to the design, and evaluation of a small-scale candle making
system using solar energy. The project focuses on the use of paraffin wax as the primary raw
material and utilizes solar thermal energy to provide the heat required for wax melting. The
system is designed for operation under normal daylight conditions using a simple solar collector
and does not include advanced energy storage or automated control systems.
The project emphasizes the use of locally available, low-cost, and recyclable materials, making it
suitable for educational purposes and small-scale applications. Performance evaluation is
restricted to basic parameters such as wax melting time, temperature range, and overall system
efficiency. Large-scale industrial production, night-time operation, and detailed economic
modeling are beyond the scope of this study.
This project is intended for academic demonstration, small businesses, and rural or off-grid
areas, highlighting the practical application of renewable energy in simple manufacturing
processes.
Significance of the Project
This project is significant as it demonstrates the practical application of solar energy in small-
scale manufacturing, specifically in candle making. By utilizing solar radiation as the primary
heat source, the project reduces dependence on electricity and fossil fuels, leading to lower
production costs and decreased environmental pollution. This is especially important in rural and
off-grid areas where access to reliable energy is limited.
The project promotes the use of renewable and sustainable energy technologies, contributing to
environmental conservation by reducing carbon emissions and deforestation associated with
conventional fuel use. It also supports economic empowerment by providing a low-cost candle
production method that can be adopted by small businesses, households, and entrepreneurs.
Academically, the project enhances understanding of solar thermal systems, heat transfer
principles, and sustainable engineering design. Overall, the project serves as a model for
integrating renewable energy into simple industrial processes, encouraging innovation,
sustainability, and energy efficiency.

Design specification
Component Selected specifications Engineering justification

collector Parabolic dish High concentration ratio for rapid

melting

reflector Anodized aluminum High reflectivity (ρ=0.85) and durable

Absorber Copper with black coating Maximize heat conduction and solar
absorption

Tracking Manual dual axis Low cost allows the dish to follow the
suns path in Debre berhan
Establishing Selection Criteria
criteria are usually grouped into Technical, Economic, and Operational categories:
 Melting Efficiency (Thermal Performance): How quickly can the design reach 65 ℃and
overcome the latent heat of wax? (Highest weight).
 Target Temperature: The ability to exceed the melting point to ensure the wax remains
liquid during pouring.
 Cost of Materials: The budget for reflective sheets, copper piping, and insulation.
 Ease of Fabrication: Can it be built using standard workshop tools in Debre Berhan?
 Durability & Weather Resistance: Ability to withstand high UV and wind at 2,840m altitude.
 Portability/Size: How much space does the system occupy?

Litrature review
Study (project) Technology used Key finding Limitations identified

1. CIGR Journal Hybrid PV-Thermal Achieved 87.2% High cost and

(2024) Box efficiency using complexity; reliant on
electric coils and fans. electrical components
that may fail in rural
areas.

2. CORE Research Parabolic Dish ) Reached 180℃ for Requires frequent

(Rural Nigeria) (1.8m) oil/water heating; manual tracking;
efficient for remote "point focus" can
areas. cause localized
burning if the receiver
isn't optimized.

3. Bahirdar Pentagonal Receiver Tested for cooking Specific receiver

University (Ethiopia) Dish "Shiro Wot"; showed geometries can lead to
high energy flux non-uniform heat
distribution, affecting
 melting consistency.

4. Turkish Ag. Lean-to Solar Box Melts wax in 180– Slow throughput;
Engineering (2023) 240 minutes (avg) limited to small
using passive solar hobbyist batches;
performance drops
sharply with wind.

5. Oxford Academic Evacuated Tube with Used wax as a storage Low Thermal
(PCM Study) PCM medium to stabilize Conductivity: Wax
temperature. itself acts as an
insulator
(k≈0.2w/mK), making
it hard to get heat into
the center of the mass.

Methodology
The methodology outlines the step-by-step approach used to design, construct, and evaluate a
solar-energy-based candle-making system.

3.1 System Description

The system consists of the following main components:

1. Solar Collector A box-type or parabolic solar collector is used to capture solar radiation and convert it
into heat. The collector has a black-painted absorber plate to maximize heat absorption.

2. Wax Melting Container: A metal or aluminum container is placed inside the collector to hold and melt
the paraffin wax.

3. Glass Cover: Transparent glass or acrylic cover is used to reduce heat loss by trapping solar energy
(greenhouse effect).

4. Molds and Wicks: Mold shapes for candle formation and wicks to produce light are prepared.

5. Insulation Materials: Materials like cardboard, foam, or recycled wood are used to reduce heat loss
from the collector.

3.2 Materials Used

Paraffin wax

Candle molds (metal or silicone)

Wicks

Metal container for melting

Glass sheet or transparent acrylic

Black-painted receiver plate

Insulation materials

Simple tools for construction

3.3 Working Principle

1. Solar radiation strikes the black receiver plate and is converted into thermal energy.

2. The heat is transferred to the wax container through conduction.

3. Wax melts gradually and reaches the desired pouring temperature (around 60–70 °C).

4. Melted wax is poured into molds with wicks positioned at the center.

5. Wax solidifies, forming candles ready for use.

3.4 Design Considerations

Melting temperature of paraffin wax: 46–68 °C(8)
200 candles production quantity of 200 candles per batch

the volume of paraffin wax is 52.41cm³

Collector orientation: south-facing for maximum sunlight exposure (in the Northern Hemisphere)

Collector tilt angle: approximately equal to local latitude for optimal solar absorption

Heat loss reduction through insulation and cover selection

Safety measures to prevent burns or wax spillage

3.5 Data Analysis

Compare the time required for wax melting with conventional heating methods.

Calculate system efficiency using the ratio of useful heat gained to total solar energy incident.

Evaluate the practicality, cost-effectiveness, and sustainability of the solar candle-making system.

Design and Calculations

This section presents the design considerations, calculations, and energy requirements for producing candles
using a solar-based system. The calculations are based on paraffin wax properties and solar energy principles.

4.1 Design Considerations

1. Melting Temperature of Wax: Paraffin wax melts between 46–68 °C.(7)
2. Collector Type: Box-type solar collector with a black-painted absorber plate.
3. Collector Orientation: South-facing (for Northern Hemisphere).
4. Collector Tilt Angle: Equal to the latitude of the location (Debre Berhan, Ethiopia ≈ 9.7° N).
4.2 Properties of Paraffin Wax

Property Value

Density 900 kg/m³

Specific heat 2.5 kJ/kg·°C

capacity

Latent heat of 200 kJ/kg

fusion

Melting point, T ≈ 60 °C

Debre berhan solar irradience calculation

Debre berhan ,Ethiopia ,has high elevation and excellent solar potential

Average daily value of solar irradiance is approximately 5.2-6.3 Wh/m²/day then we have to compare this
value by calculation we use for this project (7)

Direct normal irradiance is equals to 1000W/m²

As we can see in the above we calculate the solar irradiance of Debre berhan also
its approximate with our source estimation.
Energy requirment calculation
For this project we measure a candle radius and length then calculate the area of the candle also the volume
then we get from property relation mass equals to density times volume then we calculate and get the mass of
paraffin wax required

L=18.5cm

R=0.95cm

A=πr²=2.835

V=πr²h=52.45cm³

M=vρ=52.41cm³0.90g/cm³=47.169g ……..approximately (48-50)

We assume to make 200 candle so we have to calculate the mass of wax we need for 200 candle so

1 candle = 47.17g

For 200 = ?

total mass for 200 candle , 20047.17= 9434g = 9.43kg approximately (9.5-10)kg because we may lose
some by different conditions

Now can we can calculate required heat

Ambient temperature T°=20℃

Q1=mCp-solid(Tm-Tc) , change temprature =(60-20)=40℃

Q1=102.540 = 1000KJ

Latent heat of fusion

Q2 = mLf , Lf = 210KJ/KG

Q2=10210 = 2100KJ

Sensible heating (liquid)

-to ensure its fully liquid for pouring (up to 65℃)
Cp,liquid=2.5KJ/KG℃
Q3=102.5(65-55) = 250KJ
Qtotal = 1000+250+2100=3085KJ
We want to melt this wax in 2hour (7200sec)

P req= Qtot/time=428.5w
Heat loss calculation
Design of stinging for firing
BEST PRACTICAL WICK-INSERTION MECHANISM

Spring-Tensioned Wick Centering & Stringing Mechanism

Why we choose this

✔ Keeps wick perfectly centered

✔ Works for single or multiple candles

✔ Uses simple local materials

✔ No electricity required

✔ Easy to integrate with solar wax melting system

1. MAIN PARTS (Simple & Local Materials)

Part Material Purpose

Wick spool Wooden rod / plastic bottle Stores wick

Guide tube Metal straw / brake cable Keeps wick straight

Compression spring Pen spring Maintains tension

Top clamp bar Flat steel / wood Holds wick at top

Bottom centering pin Nail / steel rod Centers wick

Mold plate Aluminum / steel Holds candle molds

Cutting blade Razor / knife Cuts wick automatically

2. MECHANISM WORKING PRINCIPLE

The wick is:

1. Pulled from a spool

2. Guided vertically

3. Centered by a bottom pin

4. Held under tension by a spring

5. Locked at top

6. Cut automatically
This guarantees straight, centered wick every time.

3. STEP-BY-STEP OPERATION METHOD

STEP 1: Wick Feeding

 Wick is wound on a spool

 Free end passes through guide tube

 Guide tube aligns wick with mold center

 Spool → Guide Tube → Mold Center

STEP 2: Bottom Centering

 Wick passes over a centering pin at mold bottom

 Pin fixes wick position

 Wick tip is dipped in hot wax

 Pin is removed after fixation

✔ Perfect bottom anchoring

STEP 3: Spring Tensioning (MOST IMPORTANT)

 Wick goes upward through a compression spring

 Spring applies constant tension

 Wick stays vertical during pouring

✔ No bending

✔ No floating

STEP 4: Top Locking

Wick is clamped between:

 Two wooden strips or

 One clamp bar with screws

 Clamp holds wick firmly

✔ No movement during wax pouring

STEP 5: Wax Pouring (Solar Heated)

 Melt wax using parabolic trough

 Pour at 65–75°C

 Wick remains centered

STEP 6: Cooling

 Let wax solidify naturally

 Do NOT remove clamp early

STEP 7: Wick Cutting

 Release clamp

 Pull excess wick upward

Cut to 5–8 mm
Heat exchanger design
1. Purpose of the Heat Exchanger

2. The heat exchanger is designed to transfer thermal energy collected by the parabolic solar concentrator
to the candle wax (paraffin) in order to melt it efficiently and safely. It replaces conventional electric or
fuel-based heating systems by using solar thermal energy, making the system suitable for off-grid and
low-cost applications.

2. Type of Heat Exchanger

The selected heat exchanger is a solar-heated tubular absorber–tank heat exchanger.

Type:

 Indirect heat exchanger

 Shell-and-tube / immersed coil type

Justification:

 Simple construction

 High thermal efficiency

 Easy to fabricate using locally available materials

 Safe operation (wax does not contact the absorber directly)

3. Working Principle

1. Solar radiation is reflected by the parabolic trough concentrator and focused onto a blackened absorber
tube.

2. The absorber tube heats up and transfers heat to a heat transfer fluid (HTF) such as oil or water.

3. The hot HTF flows through a coil or tube immersed in a wax melting tank.

4. Heat is transferred from the HTF to the wax by conduction through the tube wall and convection within
the wax.

5. The wax melts uniformly and is maintained at the required temperature (≈60–70 °C) for candle
production.

4. Main Components

4.1 Absorber Tube

 Material:Mild steel or copper

 Surface: Matte black coated

 Diameter:25–40 mm

 Function:Absorbs concentrated solar radiation and converts it into heat

4.2 Heat Transfer Fluid (HTF)

 Type:Thermal oil or water (oil preferred)

 Reason: High boiling point and stable heat transfer

4.3 Heat Exchanger Coil

 Material: Copper or steel pipe

Shape: Helical coil

 Placement: Immersed inside wax melting tank

 Function: Transfers heat from HTF to wax

4.4 Wax Melting Tank

 Material: Stainless steel or aluminum

 insulation: Glass wool or sawdust

 Capacity: Sized for 200 candles per batch

 Function: Stores and melts paraffin wax

5. Heat Transfer Mechanism

The heat exchanger operates through three heat transfer modes:

1. Radiation:

2. Conduction

 Through absorber wall and coil pipe wall

3. Convection:

 HTF flow inside tubes

 Natural convection in molten wax

6. Design Considerations

 Wax melting temperature:55–65 °C

 Maximum wax temperature: <80 °C(to prevent degradation)

 Minimize heat losses using insulation

 Ensure uniform temperature distribution

 Easy cleaning and maintenance

 Use of locally available materials

7. Advantages of the Design

 Zero fuel and electricity cost

 Environmentally friendly

 Low operating cost

 Simple construction

 Suitable for rural and small-scale industries

8. Limitations

Depends on solar availability

 Requires thermal storage or backup for cloudy conditions

 Moderate heating rate compared to electric heaters

9. Application in Candle-Making Process

The heat exchanger ensures:

 Continuous melting of paraffin wax

 Stable wax temperature during wick insertion and molding

 Improved candle quality and uniformity

Discussion
The results of this project demonstrate that solar energy can be effectively utilized for small-scale candle
manufacturing, particularly in regions like Debre Berhan where solar irradiance is relatively high
throughout the year. The use of a parabolic solar concentrator enabled sufficient thermal energy to be
concentrated at the absorber, allowing paraffin wax to reach and maintain its melting temperature
(approximately 55–65 °C) without reliance on electricity or fossil fuels.

The thermal analysis showed that heat losses due to convection and radiation were present but
manageable through proper insulation of the heat exchanger and absorber tube. This confirms that simple
design improvements—such as selective coating on the absorber, glass covering, and wind shielding—
can significantly improve system efficiency. The solar tracking mechanism further enhanced performance
by maintaining alignment with the sun, increasing the effective heating duration and stabilizing wax
temperature during operation.
From a mechanical perspective, the wick insertion and candle molding mechanisms were designed using
locally available and low-cost materials, making the system suitable for rural and semi-urban Ethiopian
contexts. Although the production rate is lower than electrically powered machines, the system offers a
sustainable alternative with minimal operating cost. Limitations of the system include dependence on
weather conditions and reduced productivity during cloudy periods, which could be mitigated by
integrating thermal energy storage or hybrid heating.

Overall, the project confirms that solar thermal technology can be adapted for small industrial
applications beyond cooking and water heating, contributing to energy access, environmental protection,
and local economic development.

Conclusion
This project successfully demonstrated the feasibility of producing candles using solar energy through a
parabolic solar concentrator-based heating system. The designed system was capable of melting paraffin
wax efficiently and supporting the candle-making process without external electrical power, making it
particularly suitable for regions with high solar potential such as Debre Berhan, North Shoa, Ethiopia.

The study highlights that solar-powered candle manufacturing is an environmentally friendly, cost-
effective, and sustainable solution that reduces dependence on conventional energy sources and lowers
greenhouse gas emissions. The use of locally available materials and simple fabrication techniques further
enhances the practicality and scalability of the system for small entrepreneurs and community-based
production units.

In conclusion, solar energy-driven candle making has strong potential for application in rural and off-grid
areas. With further improvements such as thermal storage integration, improved tracking accuracy, and
enhanced insulation, the system’s efficiency and productivity can be increased. This project contributes
valuable insight into the application of renewable energy technologies for small-scale industrial processes
and supports Ethiopia’s broader goals of sustainable development and renewable energy utilization.

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