300 Kilogram Coffee Roaster

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1 300 Kilogram Coffee Roaster Brian Biggerstaff Jeff Biggerstaff Justin Ludwig Jess Webb 1

2 US Roaster Corp Owner Dan Joliff Serving the roasting industry for 33 years Located in Oklahoma City, Oklahoma Provide various companies with coffee roasters to complete their production plants Specialize in the fabrication of new coffee roasters and rebuilding old roasters 2

3 Objectives Design of a 300 kg coffee roaster drum Roast 300 kg every minutes Drum 40% full Find Material with proper thermal expansion properties Design a fire tube, modify roaster drum, and change the location of the air flow input Ensure the final design is easy to manufacture at U.S. Roaster Corp s facility 3

4 Scope of Work Regularly met and discussed progress with project affiliate Obtained a general knowledge of the process of coffee roasting Conducted patent research on roaster designs Researched different types of steel to withstand high temperatures Investigated 4 alternative roaster designs 4

temperatures until 2 nd crack phase Once desired roast

5 Roasting Process Green coffee beans enter from the top via a hopper Beans enter drum and are spun at desired temperatures until 2 nd crack phase Once desired roast is reached, the beans are ejected into a cooling pan and mixed 5

6 Roasting Process Bean stages: Green stage Yellow Stage: 200 F 250 F Light Brown Stage: 250 F 300 F First Crack: 355 F 400 F Second Crack: Up to 440 F Process time: Minutes depending on desired roast 6

7 Patent Searches Most patents applied to small scale designs International Patents WO 2009/075893, WO 03/ Recirculated Airflow, Filtered Exhaust Airflow United States Patent US 7,003,897 Coffee Roaster Drum with Rocker Arms 7

8 Patent Searches United States Patent US 7,003,897 Coffee Roaster Drum with Rocker Arms 8

9 Desired Modifications Change the location of heating source on the drum Heat sets directly under the drum Using a different type of metal with lower thermal expansion properties Drum expansion can cause rubbing or leaking Evaluate different support systems for the drum Currently, a shaft supports the drum s weight Roller system is considered 9

10 Materials Considered US Roaster Corp currently uses 304 stainless steel Our client advised us to look into 400 series stainless Find the metal that is applicable to the process Find a supplier Narrowed the metal to three choices 422 Stainless 430 Stainless 436 Stainless 10

11 Linear Thermal Expansion l = L 0 α T l = change in length in L 0 = initial length in α = linear expansion coefficient T = change in temperature in in 11

12 Radial Thermal Expansion d = πd 0 + πd 0 C p T π d = change in diameter in d 0 = initial diameter (in) C p = temperature expansion ( in in ) T = change in temperature 12

13 300 Kilo Roaster Thermal Expansion Initial length = 62 in α, C p = 6.30 x 10 6 in in Initial diameter = 52 in T =

14 Materials Considered Metal Type Cp ΔL ΔD 304 Stainless 9.20E RA E Stainless 6.50E Stainless 6.20E Stainless 6.30E Stainless 6.10E Inconel 7.80E

15 Design Alternative 1 Rotates about center shaft Grooved Face Plate allows for expansion Shaft supported by plates welded to upper frame Use many aspects of current 150 kg roaster Heated air is directed into back of drum through screens 15

16 Design Alternative 1 Pros US Roaster Corp is already familiar with this design Relatively simple Proven on a smaller scale Cons Stress on the shaft Complications from drum expansion 16

17 Design Alternative 2 Similar to Alternative 1 Stub shafts replace center shaft Drum supported and driven by rollers Rollers powered by electric motor Fewer expansion issues between shaft and drum 17

18 Design Alternative 2 Pros Expansion Simplicity Addresses shaft loading issue Cons Patents Heating of rollers Noise of rollers 18

19 Design Alternative 3 Stationary drum Heat applied through center shaft and exits out agitator arms Drum Weight supported by stand Rotating agitators Multiple heating locations allows for more controlled heating 19

20 Design Alternative 3 Pros Fewer issues with the drum expanding Centralized heating Even, controlled heating No shaft loading issue Cons The agitator will damage the beans Complexity Difficult to remove beans 20

21 Design Alternative 4 Conveyor Oven Burners underneath Constant flow Vibrating conveyor belt to equally heat beans Similar to a pizza oven 21

22 Design Alternative 4 Pros Continuous flow of roasted coffee No rotating drum so less worries about expansion Capable of various roast sizes Cons Design is too different and radical to implement Would need to design on a small scale before large 22

23 Selected Design Alternative 1 23

24 Design Justification Select Design Alternative #1 Performed engineering calculations to verify design Bending Stress Deflection 2000 Pounds Reactions 24

25 Design Justification Beam Stress Equation σ = MY I σ = bending stress (KSI) M = Maximum bending moment (Kip-in) Y = distance from centroid to outer edge of beam (in.) I = moment of inertia of beam (in 4 ) 25

26 Design Justification Beam Deflection Equation Y AB = FBX 6EIL (X2 + B 2 L 2 ) Y AB = the maximum vertical displacement of the shaft (in.) E = modulus of elasticity of the material (lbs/in 2 ) F= Force applied (lbs.) B= distance of force from the right side of the beam (in.) I = moment of inertia of beam (in 4 ) L = length of the beam (in) X= distance from the left side of the beam (in.) 26

27 Design Justification Pipe Size (in.) Schedule Displacement (in.) Stress (KSI) Factor of Safety Max Displacement 27

28 Scope of Project 2.6 Times More 36 Surface Area Fire Tube Burner Mount 2300 F Fire Tube 300 Kilogram Roasting Drum Rear Baffle Hole 600 F Operation 1000 F Maximum 62 28

29 Stands, Shielding, and Face Plates Fire Tube Cradle Exploded View Baffle (4in. From Assembled View Rear Fork Shield) Lift Braces Support Rods Fire Tube Stand 29

30 Drum Function 30

31 Fire Tube Plumbing Expansion Joint 16 Piping 31

32 Fire Tube Plumbing 32

33 Fire Tube Plumbing Fire Tube Inlet to Drum 33

34 Future Work 34

35 Prototype Fabrication Heating tube stand Roaster stand 35

36 Prototype Fabrication 36

37 Prototype Fabrication Drum Fabrication Face Plate Fabrication 37

38 Drum Assembly Cost Analysis Roaster Drum Face Plates and Shields Baffle Shroud and Wrap Drum Stand Support Rods Spider Assembly Material $ 3, Labor $ 5, Material $ 5, Labor $ 1, Material $ Labor $ Totals Material $ 1, Material $ 11, Labor $ Labor $ 11, Material $ Total $ 23, Labor $ Material $ Labor $ Material $ Labor $ 2,

39 Fire Tube Assembly Cost Analysis Fire Tube Fire Tube Back Mount Burner Mount Support Stand Fire Tube Stand Fire Tube Piping Material $ 4, Labor $ Material $ Labor $ Material $ Labor $ Totals Material $ Material $ 49, Labor $ Labor $ 4, Material $ Total $ 53, Labor $ Materials $ 42, Dampers $ Expansion Joint $ 1, Labor $ 1,

40 Total Cost Analysis Fire Tube Assembly Drum Assembly Miscellaneous Material $ 11, Labor $ 11, Material $ 49, Labor $ 4, Material $ Labor $ 1, Totals Material $ 61, Labor $ 17, Total $ 78,

41 Conclusions The objectives were effectively completed US Roaster Corp is currently completing the remainder of our design Roaster and heating tube stands as well as the heating tube back plate were all manufactured at the Biosystems Design Lab Final assembly expected in July,

42 Acknowledgements US Roaster Corp Mr. Dan Jolliff Mr. Joel Bomgren Mr. Roger Scott Mr. Richard Satter Dr. Tim Bowser Dr. Paul Weckler Dr. Dan Thomas BAE Shop Mr. Wayne Kiner Mr. Nick Semtner Mr. Mike Fleming Mr. Jason Walker 42

43 Questions? 43

U.S. Roaster Corp. Spring Semester Design Report: 300 Kilogram Roaster. Brian Biggerstaff. Justin Ludwig. Jeff Biggerstaff.

U.S. Roaster Corp. Spring Semester Design Report: 300 Kilogram Roaster. Brian Biggerstaff. Justin Ludwig. Jeff Biggerstaff. U.S. Roaster Corp Spring Semester Design Report: 300 Kilogram Roaster Brian Biggerstaff Justin Ludwig Jeff Biggerstaff Jess Webb Advisor: Dr. Tim Bowser 1 Table of Contents 1.0 Project Overview... 4 1.1