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Coconut Sweetening Process Coconut Sweetening Process Elizabeth Casey Justin Dillingham Mohd Hussain Brady Stewart BAE 4022 Spring 2006 About Griffin Food Company About Griffin Food Company Founded in Muskogee, OK in 1908 by John

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Coconut Sweetening Process Coconut Sweetening Process

Elizabeth Casey Justin Dillingham Mohd Hussain Brady Stewart

BAE 4022 – Spring 2006

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4/27/2006 2

About Griffin Food Company About Griffin Food Company

  • Founded in Muskogee, OK in 1908 by

John T. Griffin

  • Major products available:

– Syrups – Jellies and preserves – Mustards – Coconut flakes

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4/27/2006 3

Problem Definition Problem Definition

  • Consumers demand the longest length of

coconut flakes possible

  • Flake length of Griffin’s coconut degrades

during processing

Before After

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4/27/2006 4

Competitor Length Comparison Competitor Length Comparison

2 4 6 8 10 12 Current Griffin's Bakers Mounds

Sample Brand Average Length (mm)

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4/27/2006 5

Project Goals Project Goals

  • Pinpoint and quantify degradation
  • Make recommendations to:

– Prevent flake length degradation – Increase processing capacity – Improve quality of work for employees

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Process Steps Process Steps

  • Delumping
  • Conveying to cooker
  • Cooking and blending
  • Tempering
  • Packaging
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4/27/2006 7

Delumping Delumping

  • Clumps of coconut form during storage
  • Delumper used to separate clumps
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Conveying to Cooker Conveying to Cooker

  • Auger transports coconut

from delumper to cooker

– Contained within PVC pipe

  • Frequently clogs
  • Limits processing speed
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4/27/2006 9

Cooking and Blending Cooking and Blending

  • Double ribbon agitation

cooker

  • Blends slurry, sugar

and coconut

  • Runs continuously

during delumping and conveying

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4/27/2006 10

Concept Development Concept Development

  • Quantifying coconut flake length

– Modified ASAE Standard S424 – Image Analysis with MatLab

  • Potential Solutions

– Proposal A – Steam Injection – Proposal B – Replacement of Auger Conveyor – Proposal C – Replacement of Cooker

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Image Analysis with Image Analysis with MatLab MatLab

  • Setup camera system
  • Prepare sample

– Separate overlapping material

  • Capture image
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Image Analysis with Image Analysis with MatLab MatLab

  • Process image in

MatLab

  • Input data into Excel

– Calculates average length

area picture MatLab strands

  • f

# 122.97 area picture actual MatLab from area Length Flake Average × × × =

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Results Results

4 8 12 16 20 Initial Delumper Auger Cooker

Process Step Average Flake Length (mm)

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Proposal A Proposal A – – Steam Injection Steam Injection

  • Researched direct steam injection systems
  • FAPC testing

– Steam table

  • Did not meet project

goals

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4/27/2006 15

Proposal B Proposal B – – Replacement of Replacement of Auger Conveyor Auger Conveyor

  • Inclined flighted belt

conveyor most suitable

– Requires half as much power as auger conveyor – Increases capacity – Extremely gentle on product

www.kamflex.com

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4/27/2006 16

Proposal C Proposal C – – Replacement of Replacement of Cooker Cooker

  • Focused on tumble

blenders

  • FAPC testing

– 8 L V-blender

  • Patterson Kelley

testing

– 8 L V-blender with intensifier bar

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Proposal C Proposal C – – Replacement of Replacement of Cooker Cooker

Type of Blender Percent Degradation

Griffin’s Ribbon Cooker 29% FAPC V Blender – Test 1 10% FAPC V Blender – Test 2 34% Patterson Kelley V Blender – Test 1 9% Patterson Kelley V Blender – Test 2 6%

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Evaluating Proposals Evaluating Proposals

  • Potential length improvement
  • Ease of transition
  • Cost
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Cost Analysis Cost Analysis

Equipment New Cost Used Cost

Image Analysis Package $2,879

  • Cleated Belt

Conveyor $10,520 $5,000 V-Blender with intensifier bar $120,000 $25,000

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Final Recommendations Final Recommendations

  • Image analysis package

– To monitor length quality

  • Kamflex Series 811 Cleated Belt Conveyor
  • Patterson Kelley 20 ft3 V-blender with

intensifier bar

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4/27/2006 21

Projected Length Improvement Projected Length Improvement

2 4 6 8 10 12 14 16 Current Griffin's Proposed Griffin's Bakers Mounds

Sample Brand Average Length (mm)

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4/27/2006 22

Acknowledgements Acknowledgements

We would like to thank the following people for their help and support:

Griffin Food Company

  • Richard Hall
  • Craig Duncan
  • David Clary
  • John Trammel

BAE Faculty and Staff

  • Dr. Paul Weckler
  • Dr. Gerald Brusewitz
  • Dr. Tim Bowser
  • Roshani Jayasekara