Development and optimization of a fresh lotus embryo piercing machine

Abstract

Crispy lotus seeds were a healthful snack suitable for all ages and commonly available in modern commerce outlets. The production process requires removing the lotus embryo before crisping. Traditionally, manual labor separated the embryo from the lotus seeds. Operators use specialized equipment to separate the lotus embryo from the lotus seeds. This requires a lot of work time and may cause injury to the operator due to the equipment used. Many research works have created machines to help process lotus seed products, but their performance is lacking. This research focused on creating and developing a fresh lotus seed embryo removal machine to improve precision and reduce seed damage during extraction. The prototype machine included a frame construction, a seed feeding tray, a piercing unit, and a PLC control panel. Two types of needles are used to pierce the lotus embryo. The sharp needle produced the best results when tested with sharp and blunt needles at piercing speeds of 16.7, 25.0, and 33.3 mm/s. The findings revealed a 91.7% success rate in embryo removal, 13.9% seed splitting, 2.8% seed damage, a processing capacity of 0.7 kg/hr, and an energy usage of 0.4 kW-hr. Economic engineering research revealed that employing the lotus embryo removal machine for 1,440 hours per year resulted in an average cost of 83.3 THB per kilogram, a 26.4-month payback period, and a breakeven threshold of 1,233.3 hours per year (863.3 kg per year). The prototype performed at least twice as quickly as manual labor (0.3 kg/hr).