A Study on Design and Control the herbal foot bath salt production line

This file is a research to design and control method using for the herbal foot bath salt production line. This thesis includes mechanical (drawings + designed 3D model), electrical, and the control method for 4 machines module such as: extracting - concentrating system, horizontal mixing machine, drying machine and V - blender mixing machine. This thesis also has the simulation process and results for each designed module. So, I hope it can be useful for everyone who want to research or design in industrial machines.

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY Faculty of Mechanical Engineering – Department of Mechatronics

CAPSTONE PROJECT

A STUDY ON DESIGN AND CONTROL HERBAL FOOT

BATH SALT PRODUCTION LINE

Student’s name:

1 Dang Ngoc Tri

2 Nguyen Phuoc Vinh Student’s ID:

1 1953039

2 1953101 Lecturer: Assoc Prof Vo Tuong Quan

Ho Chi Minh City, 2024

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First and foremost, we would like to extend our sincerest gratitude to all the esteemed teachers at Ho Chi Minh City University of Technology, especially for teachers in Faculty of Mechanical Engineering – Department of Mechatronics for their wholehearted dedication to teaching and imparting invaluable knowledge of engineering over the past years It is through their efforts that we have been equipped with the strongest knowledge foundation, enabling us to successfully complete this project

We would like to express our deepest appreciation to Assoc Prof Vo Tuong Quan, our direct instructor, who has not only guided us but has also closely monitored our progress, provided insightful feedback, and tirelessly addressed any issues that arose throughout the project His unwavering support and encouragement have been instrumental in our achievements

To the members of the Biomech Lab, we extend our heartfelt thanks to Mr Khuu Nguyen Huu Loc, Mr Vu Tran Thanh Cong, Mr Tran Hoa Binh and Mr Le Tran Vu Long for their attentive listening, prompt assistance, and invaluable guidance during the project's execution

We are also deeply grateful to all our friends who have stood by us, offering unwavering support and encouragement throughout our four − year academic journey

at this university

Special recognition and gratitude are reserved for our families, whose unwavering support has been a constant source of strength, providing both emotional and material support, especially during the most challenging times of our academic pursuits

Once again, from the depths of our hearts, we extend our utmost appreciation to everyone involved We are truly thankful for the collective efforts that have shaped an unforgettable journey at our beloved university We wish everyone continued good health, success, and everlasting joy and fulfillment on their chosen paths

Expressing our heartflet gratitude to all

Ho Chi Minh City, 19𝑡ℎ May 2024

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Salt is an abundant product in coastal area of Vietnam, specially Can Gio district Although produced in abundant quantities, most still have a large amount left over from exploitation during production and processing Thus, creating added value from excess waste products for goals such as: saving and optimizing the value of salt is an extremely necessary The topic of thesis to research and design herbal foot bath salt production line,

it will contribute to creating a new produce for excess salt during production and harvesting in Can Gio district, by taking advantages of available products, maximizing production efficiency, also increasing income for people

Through the research for this project, the production line of fine salt granules has been implemented at Can Gio district by Bach Khoa Research Center for Manufacturing Engineering (BK – RECME) With the actual situation implemented as above, this project also provides additional research for herbal foot bath salt production line for above purposes From research on the processing method to produce herbal foot bath salt, the principle diagram of each machine in production line is suggested and design and linked together into a complete system

The contents of this project is presented by 7 chapters:

- CHAPTER 1: OVERVIEW

- CHAPTER 2: METHOD SELECTIONS

- CHAPTER 3: MECHANICAL DESIGN

- CHAPTER 4: ELECTRICAL DESIGN

- CHAPTER 5: CONTROL SYSTEM DESIGN

- CHAPTER 6: SYSTEM SIMULATION

- CHAPTER 7: SUMMARY AND DEVELOPMENT ORIENTATION OF THE PROJECT

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TABLE OF CONTENTS

ACKNOWLEDGEMENT iii

ABSTRACT iv

TABLE OF CONTENTS i

INDEX OF FIGURES vii

INDEX OF TABLES xv

CHAPTER 1: OVERVIEW 1

1.1 Overview about situation of salt production in Can Gio district 1

1.2 Vietnamese standard for salt when using 4

1.3 Introduction of the herbal foot bath salt 6

1.3.1 Some herbal foot bath salt products on the market 7

1.3.2 Using Can Gio salt to applied to produce herbal footbath salt 9

1.4 Manufacturing process of herbal foot bath salt 10

1.4.1 Introducting the manufacturing process was researched by Ho Chi Minh City Medicine and Pharmacy University (YDS) 10

1.4.2 The production line is designed in this project 14

1.5 Machines in herbal foot bath salt line production process 15

1.5.1 Grinding machine 16

1.5.2 Extraction system 18

1.5.3 Concentration system 24

1.5.4 Mixing machine 27

1.5.5 Drying machine 36

1.5.6 Granulating machine 42

1.5.7 Packaging machine 45

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1.6.1 Problem statement of the project 47

1.6.2 Goal of the project 48

1.6.3 Specific topic of the project 49

CHAPTER 2: SELECTION METHOD 51

2.1 Method selections for grinding machine 51

2.1.1 Technical requirements 51

2.1.2 Mechanical principle selection for grinding machine 52

2.1.3 Transmission method selection for grinding machine 53

2.1.4 Electrical component selection for grinding machine 55

2.1.5 Grinding control method selection 56

2.2 Method selections for extracting and concentrating system 57

2.2.1 Method selections for extracting system 57

2.2.2 Method selections for concentrating system 65

2.3 Method selections for horizontal mixing machine 72

2.3.1 Technical requirements 72

2.3.2 Mechanism of mixing process 73

2.3.3 Select the mechanical principle of the mixer 73

2.3.4 Transmission method selection for mixing machine 76

2.3.5 Electrical components selection for horizontal mixing machine 77

2.4 Method selections for granulating machine 78

2.4.1 Technical requirements 79

2.4.2 Selecting the granulating method 79

2.4.3 Selecting the mechanical principle of the granulator that corresponds to the the choosen method 81

2.4.4 Selecting an electrical plan for the granulator 82

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2.5 Method selections for air circulation drying oven 84

2.5.1 Technical requirements 84

2.5.2 Select the drying method 84

2.5.3 Choose the mechanical principle of the dryer that corresponds to the convection drying method 86

2.5.4 Selecting heat transfer materials 87

2.5.5 Selecting electrical components for the dryer 88

2.5.6 Selecting drying machine control method 90

2.6 Method selections for V – blender mixing machine 91

2.6.1 Technical requirements 91

2.6.2 Parameters affecting the mixing process 91

2.6.3 Mixing process mechanism 94

2.6.4 Select the operating principle of the mixer 94

2.6.5 Select the mechanical principle of the mixer 96

2.6.6 Mixer electrical components slection 97

2.7 Method selections for filling and packaging machine 98

2.7.1 Technical requirements 98

2.7.2 Selecting the filling and packaging method 99

2.7.3 Selecting the mechanical principle of the filling and packaging system that corresponds to the the choosen method 102

2.7.4 Selecting electrical plan for the system 103

2.7.5 Selecting the machine for production line 104

2.8 Material slection for the machines in production line 106

CHAPTER 3: MECHANICAL DESIGN 107

3.1 Extraction – condensation system design 107

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3.1.2 Concentration system calculation 131

3.1.3 Extracting – concentrating system model design 188

3.2 Horizontal mixing machine design 190

3.2.1 Design overview and factors related to mixing process 191

3.2.2 Calculate the power consumption of the machine 201

3.2.3 Power of motor calculations 205

3.2.4 Belt transmission calculation 208

3.2.5 Shaft calculation and testing 214

3.2.6 Bearings calculation and selection 222

3.2.7 Horizontal mixing machine module design 226

3.3 Air circulation convection drying machine design 227

3.3.1 Input parameters 228

3.3.2 Energy balance calculating 228

3.4.3 Material balance calculation 232

3.3.4 Calculation of main equipment 233

3.3.5 Calculate the design of the insulation layer 234

3.3.6 Calculate the design of auxiliary equipment 237

3.3.7 Designed drying machine module 240

3.4 V – blending mixing machine design 241

3.4.1 Input parameters 241

3.4.2 Mixing tank volume and mixing tank size 242

3.4.3 The rotation speed of the barrel 244

3.4.4 Mixing time 244

3.4.5 Productivity of the machine 245

3.4.6 Power of motor calculation 246

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3.4.8 Shaft calculation and testing 256

3.4.9 Bearings calculation and selection 262

3.4.10 Designed V − blender mixing machine module 265

3.5 Requirements for dynamic balance of the production line system 266

3.6 Line production maintenance requirements 269

3.6.1 Checking process 271

3.6.2 Repairing process 271

CHATER 4: ELECTRICAL DESIGN 287

4.1 Electrical system of the extracting – concentrating system 287

4.4.1 Motor and pump 287

4.4.2 Sensors 289

4.4.3 Controller 289

4.4.4 Thermistor 290

4.4.5 Calculating current supply for system 290

4.2 Electrical system of the horizontal mixing machine module 294

4.3 Electrical system of the drying machine module 298

4.3.1 Heating resistor 298

4.3.2 Motors − Fans 299

4.3.3 Calculating current supply for system 301

4.4 Electrical system of the V – blender mixing machine module 306

CHAPTER 5: CONTROL SYSTEM DESIGN 311

5.1 The flowchart of the production line 311

5.2 The flowchart of the extracting – concentrating system 312

5.3 The flowchart of the horizontal mixing module 314

5.4 The flowchart of the drying module 315

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CHAPTER 6: SIMULATION 318

6.1 Introduction of software using for simulation 318

6.1.1 Ansys Workbench 2023 318

6.1.2 Rocky Dem Simulation 4.4 2022 318

6.1.3 Solidworks 2022 318

6.1.4 COMSOL Multiphysics 2023 319

6.2 Simulation process 319

6.2.1 Extraction – condensation system simulation 319

6.2.2 Horizontal mixing machine simulation 328

6.2.3 Air circulation convection drying machine simulation 339

6.2.4 V – blending machine simulation 342

CHAPTER 7: SUMMARY AND DEVELOPMENT ORIENTATIONS OF THE PROJECT 348

7.1 Summary of the results 348

7.2 Some limitations of this project 349

7.3 Development orientations 350

7.4 Product quality control process 350

7.4.1 Salt product quality control process 350

7.4.2 Factors that need to be controlled for salt quality can be implemented at small production region 351

REFERENCES 353

Figure 1 1 Salt production in Can Gio district [2] 1

Figure 1 2 Can Gio salt poducts [3] 2

Figure 1 3 The entire salt "refining" line was installed and tested at Can Gio Tuong Lai Cooperative (Can Gio district, Ho Chi Minh City) of BK - RECME 3

Figure 1 4 Herbal foot bath salt products 7

Figure 1 5 The production line is design in this project 14

Figure 1 6 Hammer crusher mechanism 16

Figure 1 7 Working principles of disc mill 17

Figure 1 8 Working principle of roll crusher 18

Figure 1 9 Direct extraction process 19

Figure 1 10 Immersion extraction system X − 60 Brewer [25] 20

Figure 1 11 Ultrasonic extraction system of Scientz [26] 21

Figure 1 12 The working principle of ultrasonic extraction system 22

Figure 1 13 Supercritical extraction method of Accudyne, Inc [27] 23

Figure 1 14 The working principle of the vacuum concentration process 26

Figure 1 15 Rotary drum mixer of Permix [9] 27

Figure 1 16 The working principle of rotating drum mixer 27

Figure 1 17 The working principle of vertical screw mixer [11] 28

Figure 1 18 Horizontal ribbon mixer of Shuanglong Group Co , Ltd (S&L) [13] 29

Figure 1 19 The working principle of horizontal ribbon mixer 30

Figure 1 20 Anchor stirring mixer from HANA mechanical company [14] 31

Figure 1 21 The working principle of turbine stirring mixer 32

Figure 1 22 Working principle of the paddle stirring mixer 33

Figure 1 23 The working principle of the planetary mixer machine 34

Figure 1 24 Dough kneading machine INTSUPERMAI 20l Spiral [19] 35

Figure 1 25 Principle diagram of high viscosity kneader [20] 35

Figure 1 26 Fluidized bed drying [35] 37

Figure 1 27 The working principle of the fluidized bed drying 37

Figure 1 28 VSD − 800 Pilot and Production Spray Dryer [21] 38

Figure 1 29 Heat pump dryer [22] 39

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Figure 1 31 The drying oven RXH − 14 − C warm air cycle drying machine [24] 40

Figure 1 32 The working principle of the air circulation drying machine 41

Figure 1 33 Plastic granulator machine of Rhong [31] 42

Figure 1 34 Metal granulator of Gold & Silver grains casting [32] 42

Figure 1 35 Chemical granulator of Jiangsu Hanyoo Pharmatech Co , Ltd [33] 43

Figure 1 36 Automatic swing pharmaceutical chemical Food/Sway/Pendular granulator [34] 43

Figure 1 37 Fertilizer granule machine RKME 03 of R K Metal [36] 44

Figure 1 38 Working principle of roller compactor granulators 44

Figure 1 39 Working principle of extrusion granulator 45

Figure 1 40 Automatic packaging machine of HOPAK Co , Ltd [39] 46

Figure 1 41 Semi – automatic packaging machine of RAMAC S r l [40] 46

Figure 2 1 YK90 oscillting granulator of Jiangnan Co., Ltd 83

Figure 2 2 Rotary drum mixing equipment [68] 96

Figure 2 3 AF1 Series Auger Fillers machine [38] 104

Figure 2 4 Accutek automatic induction sealer [39] 105

Figure 2 5 AccuCapper BT machine [42] 105

Figure 3 1 Working principle diagram of the extracting – concentrating system 107

Figure 3 2 Mixing tank volumetric frame diagram 112

Figure 3 3 Normal balanced heat system diagram 119

Figure 3 4 Ellipse lid [48] 125

Figure 3 5 Some methods to harden the holes in pressure environment 129

Figure 3 6 The flange dimensions 130

Figure 3 7 Relationship between saturation vapor pressure of pure solvent Ps and solute in solution P and temperature t 133

Figure 3 8 Normal balanced heat system diagram 141

Figure 3 9 Diagram of heat transfer through the wall 144

Figure 3 10 Stainless steel SUS304 148

Figure 3 11 TECO - AEEEF pump 3.7kW − 5Hp 154

Figure 3 12 The relationship betwwen P0 and Re of some types of impellers 41 156

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Figure 3 14 The relationship between the liquid viscosity and the type of impellers

[47] 158

Figure 3 15 Some type of axial flow impellers [69] 159

Figure 3 16 Some type of radical flow impeller [69] 160

Figure 3 17 Hydrofoil impellers [69] 161

Figure 3 18 High shear impellers [69] 161

Figure 3 19 Structure of intermediate mixing tank [67] 162

Figure 3 20 Transmission structure of intermediate mixing tank module [67] 164

Figure 3 21 The geometry dimensions of the motor AESU1S – 90S − 0.75kW [45] 165

Figure 3 22 The dimension parameters of the motor AESU1S – 90S − 0.75kW [45] 165

Figure 3 23 Stirring shaft of intermediate mixing tank 166

Figure 3 24 Stirring shaft of intermediate mixing tank in the concentrating process 166 Figure 3 25 Stress acting on shaft in operation 167

Figure 3 26 Stirring blade design for intermediate mixing tank in concentration process 170

Figure 3 27 Testing the displacement of the stirrer in the concentrating tank 170

Figure 3 28 Vacuum pump Fiona SV − 020 172

Figure 3 29 Heat exchanger tube arrangement assembly 177

Figure 3 30 The air humidity diagram 178

Figure 3 31 Preliminary dimensions of Baromet tube 180

Figure 3 32 Diagram of Baromet condenser 183

Figure 3 33 The outside diameter of the isolation layer related to the thickness of insulation diagram 188

Figure 3 34 Create mesh for frame of extracting – concentrating system model 188

Figure 3 35 Results of load analysis on beams in extracting − concentrating system 189

Figure 3 36 Extracting − concentrating system 190

Figure 3 37 The working principle diagram of horizontal mixing machine 190

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Figure 3 39 Density distribution function qr(d) and total density distribution function

Qr(d) [68] 193

Figure 3 40 Mixing tank volumetric frame diagram 197

Figure 3 41 Force acting on impeller diagram 201

Figure 3 42 Radius of the inner and outer ring of the scarf 202

Figure 3 43 Diagram for determining depth in the figure htb 204

Figure 3 44 Motor TECO AESU1S 2 HP − 1.5kW [45] 205

Figure 3 45 Dimensions of Motor TECO AESU1S 2 HP − 1.5kW [45] 206

Figure 3 46 Dimension profile of Motor TECO AESU1S 2 HP − 1.5kW [45] 206

Figure 3 47 Profile size according to model 112M of TECO Co Ltd [45] 206

Figure 3 48 Comparison figure and selection of trapezoidal belt cross−section 208

Figure 3 49 Preliminary calculation of shaft dimensions 219

Figure 3 50 Force acting on shaft analysis 219

Figure 3 51 Shaft design and calculation the foce acting on shaft in Inventor software 219

Figure 3 52 Diagram of force in Y − axis 220

Figure 3 53 Diagram of force in X − axis 220

Figure 3 54 Diagram shear force acting on shaft 220

Figure 3 55 Total elastic strain, equivanlent stress and total deformation of shaft 221

Figure 3 56 Torsion wing when installed on the shaft 221

Figure 3 57 Testing the displacement model of the twisted wing when integrated onto the shaft 222

Figure 3 58 Lower frame testing in static 3D space 226

Figure 3 59 Horizontal mixing machine 227

Figure 3 60 The working principle diagram of the drying machine 228

Figure 3 61 Mollier diagram sketch to determine the air’s parameters after passing through the heat exchanger 230

Figure 3 62 Distribution network structure 233

Figure 3 63 Butterfly valve motor parameters UM230Y − F − L 1 239

Figure 3 64 Air circulation convection drying machine 241

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Figure 3 66 V – blender mixing machine structure 242

Figure 3 67 Servolift V – blender mixing machine catalogue 243

Figure 3 68 V - blender tank dimensions calculating 243

Figure 3 69 Full geometric dimensions of V tank 244

Figure 3 70 Mass, density and volume of V – tank 246

Figure 3 71 The center of mass determination by the software 246

Figure 3 72 Motor TECO AESU1S − 100L (1.5 HP − 1.1kW) 248

Figure 3 73 Dimension profile of Motor TECO AESU1S-100L (1.5 HP − 1.1kW) 248 Figure 3 74 Profile dimensions according to model 112M of TECO Co Ltd 249

Figure 3 75 Comparison figure and selection of trapezoidal belt cross−section 250

Figure 3 76 Shaft installing on the V – blending tank 258

Figure 3 77 Force and setting position in Inventor software 258

Figure 3 78 Diagram of force in X − axis 259

Figure 3 79 Diagram shear force acting on shaft 259

Figure 3 80 Shaft testing diagram 259

Figure 3 81 V – shell simulation diagram 260

Figure 3 82 Bearing frame for the system 260

Figure 3 83 Force acting on the frame of V – blender mixing machine 260

Figure 3 84 V – blender mixing machine 265

Figure 3 85 Timwave graph transfers to frequency spectrum graph 267

Figure 3 86 Imbalance of stability of shaft in horizontal mixing machine simulation 267

Figure 3 87 Modal damping ratio in imbalance of shaft during operating process simulation 268

Figure 3 88 Rotational velocity of shaft according to frequency when dynamic imbalance occurs simulation record 268

Figure 3 89 The vibration severity per ISO 10816 269

Figure 3 90 Time when failure begins to occur during operation 269

Figure 4 1 Electrical principle diagram of the extracting – concentrating system 294

Figure 4 2 The electrical principle diagram of the horizontal mixing machine 298

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Figure 4 4 Electrical drawing for V – blender mixing machine 310

Figure 5 1 The flowchart of the herbal foot bath salt production line 312

Figure 5 2 The flowchart of the extracting – concentrating system 313

Figure 5 3 The flowchart of horizontal mixing module 314

Figure 5 4 The flowchart of the drying module 315

Figure 5 5 The flowchart of the V – blender mixing machine module 316

Figure 6 1 Durability of the extraction tank simulation result 320

Figure 6 2 Extraction module using to simulation which is inserted from Solidworks 320

Figure 6 3 Meshing the extracting module in COMSOL 321

Figure 6 4 Heat transfer process of medicinal extracting module 321

Figure 6 5 The temperature of heat source region at the rib between body and bottom of the extraction tank 322

Figure 6 6 Durability of the concentrating tank simulation 324

Figure 6 7 Concentrating module which is inserted from Solidworks software to COMSOL software 324

Figure 6 8 Meshing the concentration module in COMSOL 325

Figure 6 9 Heat transfer process of medicinal hearbs concentration process 325

Figure 6 10 The maximum and minimum of heat transfer process of medicinal hearbs concentration process 326

Figure 6 11 Mixing tank and stirring impeller which is create in Mixer model of COMSOL 326

Figure 6 12 Meshing the tank and the stirring impeller after set up dimension parameters 327

Figure 6 13 The results of intermediate mixing process in concentrating process simulation 327

Figure 6 14 The durability of horizontal tank simulation 329

Figure 6 15 Insert geometry and set up the input for the materials 330

Figure 6 16 Horizontal mixing module is at in the Rocky Dem Simulation 330

Figure 6 17 Create the motion frame and assign the rotation frame to the axis 331

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332

Figure 6 19 The dimensions of particle is set up in the process 332

Figure 6 20 Set the particle concentration area and limit the active area of the mixing process 333

Figure 6 21 Limitation of mixing region of the process 333

Figure 6 22 Mixing process simulation 334

Figure 6 23 The change of liquid mass and particle surface area in mixing process 334 Figure 6 24 The graph shows the change of liquid mass between concentrated medicinal herbs and salt in mixing process 335

Figure 6 25 Set up the Eulerian Statistics method to analyse in the software 335

Figure 6 26 The number of particles changed in mixing process using Eulerian Statistics method 336

Figure 6 27 The change of the average number of particles by using Eulerian Statistics method 336

Figure 6 28 The volume fraction changed continuously in mixing process using Eulerian Statistics method 337

Figure 6 29 The change of the average volume fraction in mixing process using Eulerian Statistics method 337

Figure 6 30 The void fraction changed continuously in mixing process using Eulerian Statistics method 338

Figure 6 31 The change of the average void fraction in mixing process using Eulerian Statistics method 338

Figure 6 32 Durability of drying machine’s mechanical structure simulation 340

Figure 6 33 Test case 1 simulation results for drying machine 340

Figure 6 34 Test case 2 simulation for drying machine results 341

Figure 6 35 Test case 3 simulation for drying machine results 342

Figure 6 36 Insert geometry of the V – blender mixing machine 343

Figure 6 37 Create the motion frame and assign the rotation frame to the axis 343

Figure 6 38 The dimensions of particle is set up in the process 344

Figure 6 39 Limitation of mixing region of the process 345

xiv Figure 6 41 The change of particle coordinates in Oxyz plane 346 Figure 7 1 Product quality control process 351

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Table 1 1 Sensory requirements of refined salt according to TCVN 9639: 2013

standards [5] 2

Table 1 2 Physical and chemical requirements of refined salt according to TCVN 9639: 2013 standard [5] 3

Table 1 3 Comparion between before and after applied refining line production of BK − RECME 4

Table 1 4 Some salt standards for certain segments in the market 5

Table 1 5 Some herbal foot bath salt on the market 7

Table 1 6 Standards of testing method for salt samples in Can Gio district [8] 9

Table 1 7 The remedy of Huoxue Tongluo and Zen Master Minh Khong [8] 11

Table 1 8 The remedy of Huoxue Tongluo [8] 11

Table 1 9 The materials that need for herbal foot bath salt according to YDS research 12

Table 1 10 Herbs that need for product 1 based on YDS reseach to produce semi – finished extraction [8] 12

Table 1 11 The steps of the Product (1) according to Ho Chi Minh City Medicine and Pharmacy University (YDS) [8] 13

Table 1 12 The machines that need for the production line 15

Table 1 13 The weight of the materials after scaling in this project 15

Table 1 14 Tasks and assignments table for this project 48

Table 2 1 Mechanical principles of grinding machine comparison 52

Table 2 2 Transmission method for grinding machine comparison 54

Table 2 3 Type of motors comparison table 55

Table 2 4 Grinding machine control comparison and selection 56

Table 2 5 Extracting method comparison and selection 58

Table 2 6 Providing heat method comparison and selection 60

Table 2 7 Heat sensors comparison and selection 62

Table 2 8 Controller selection method for extracting system 63

Table 2 9 Concentrating method comparison and selection 65

Table 2 10 Providing heat method comparison and selection 67

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Table 2 12 Controller comparison and selection for concentrating system 70

Table 2 13 Mechanical principle selection method for horizontal mixing machine 73

Table 2 14 Transmission method selection for horizontal mixing machine 76

Table 2 15 Comparison of 4 suitable granulating method 79

Table 2 16 Comparison and selection method for mechanical principle of the granulator 81

Table 2 17 Specifications of YK90 oscillting granulating machine 83

Table 2 18 Compare drying methods based on these following criteria 85

Table 2 19 Compare dryer equipment options 87

Table 2 20 Compare the advantages and disadvantages of heat transfer materials 88

Table 2 21 Comparison and selection of heat sensors 89

Table 2 22 Comparison and selection of humidity sensor 89

Table 2 23 Summary of drying machine selection method 91

Table 2 24 Results of particle size distribution analysis (1) 92

Table 2 25 Comparison of equipment for mixing bulk materials together 94

Table 2 26 Comparison of double cone mixer and Permix V – blender mixing machine [9] 96

Table 2 27 Comparison filling method 99

Table 2 28 Comparison sealing method 100

Table 2 29 Comparison of jar cap screwing method 101

Table 2 30 Comparison mechanical principles of the filling machine 102

Table 2 31 Specification of the machine of the AF1 Series Auger Fillers 104

Table 2 32 Specification of the automatic induction sealer machine 105

Table 2 33 Specification of the semi automatic screw capping machine 106

Table 3 1 The amount of extractable substance in the medicinal extract sample depends on the number of extraction times 8 108

Table 3 2 The amount of extractable substance in the medicinal extract sample depends on the time to extract 8 109

Table 3 3 Herbs which is used for the extraction process 110

Table 3 4 GMP standards for medicinal products 112

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Table 3 6 Table of qc value according to Reference [48] 128

Table 3 7 The flange dimension using for the body – the lid 130

Table 3 8 Correction factor coefficient table 134

Table 3 9 Summary table of heat value in the condensed system 138

Table 3 10 Summary table of parameters in the balanced energy 142

Table 3 11 Table of A value chosen depending on tm 144

Table 3 12 Chemical and physical parameters of solution at tW and t 145

Table 3 13 Summary table of heat transformation for concentration system 148

Table 3 14 Factors of local resistance efficient and values 150

Table 3 15 Parameters of motor from TECO Co , Ltd 153

Table 3 16 Recommended speed related to type of stirring blades [44] 163

Table 3 17 Parameters of motors 0.75 kW − 6 poles from TECO Co , Ltd 164

Table 3 18 Vacuum pump Fiona SV − 020 parameters 171

Table 3 19 Preliminary dimensions of Baromet tube 180

Table 3 20 Summay dimensions of condenser system 182

Table 3 21 Summery table about heat transfer of condensing system 185

Table 3 22 Input parameters table before mixing process 195

Table 3 23 Percentage of finished products in 100kg of finished products 196

Table 3 24 Appropriate ratio between length L and diameter D of the mixing tank 197 Table 3 25 There are several types of mixers and corresponding operating speeds 200

Table 3 26 Experimental constant table 200

Table 3 27 AESU1S motor parameters [45] 205

Table 3 28 Technical specification table of the machine 208

Table 3 29 Parameters of trapezoidal belt 209

Table 3 30 Summarizing the calculated values of the belt 214

Table 3 31 Specifications of stainless steel 40CrNi 215

Table 3 32 Parameter of equal key 218

Table 3 33 Parameter of contact ball bearings 223

Table 3 34 Selected bearings with parameters 225 Table 3 35 The summary table of necessary modules in horizontal mixing machine 225

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Table 3 37 Humid air parameters of each stage of the drying process 230

Table 3 38 Selected parameters and calculated values for insulation layer thickness236 Table 3 39 The calculation of flow based on cross – section of input and output air gate 238

Table 3 40 Centrifugal fan KBR/F 280DV F400 240

Table 3 41 Input parameters and requirements of V – mixing machine 242

Table 3 42 Dimensions related to V − angle 243

Table 3 43 Parameters of the TECO AESU1S − 100L (1.5 HP − 1.1kW) motor 248

Table 3 44 Specification table of the transmission system 250

Table 3 45 Parameters of trapezoidal belt 251

Table 3 46 Summarizing the calculated values of the belt 256

Table 3 47 Specifications of stainless steel 40CrNi 257

Table 3 48 Parameter of equal key 261

Table 3 49 Angular contact ball bearing of SKF Co Ltd 262

Table 3 50 Selected bearings with parameters 265

Table 3 51 Some failures happen on lifting and lowering the horizontal mixing machine 272

Table 3 52 Some failures happen on worm gear in mixing machines in the project 273

Table 3 53 Suggested maintenance schedule for worm gear reducer 274

Table 3 54 Some problems related to belt transmission during operation process 275

Table 3 55 Suggested maintenance schedule of belt transmission 276

Table 3 56 Some problems of bearings happen in operating process 277

Table 3 57 Lubricating oil standard for used bearings and maintenance schedule 279

Table 3 58 Some problems happen to valve during operation process and how to solve 280

Table 3 59 Suggested maintenance schedule for vavle using in this project 280

Table 3 60 Some problems happen for pipe system during operation process and how to solve 282

Table 3 61 Demand of the pipe line requirements 283

Table 3 62 Extracting – concentrating tank maintenance demands 285

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Table 4 2 The specifications of 𝐴𝐸𝑆𝑈1𝑆 − 90𝑆 − 0.75𝑘𝑊 motor 288 Table 4 3 VFD 𝐹𝑅𝐷 − 720 − 0.75𝐾 Mitsubishi specifications 288 Table 4 4 Specifications of vacuum pump 𝐹𝑖𝑜𝑛𝑎 𝑆𝑉 − 020 289 Table 4 5 Thermalcouple type type K specifications 289 Table 4 6 𝐻𝑎𝑛𝑔𝑦𝑜𝑢𝑛𝑔 𝐴𝑋4 − 𝑈𝑆𝑁𝐴 − 𝐴1 specifications 289 Table 4 7 The specifications of Megasun 2𝑘𝑊 thermistor 290 Table 4 9 Electric devices for extracting – concentrating system 292

Table 4 10 Specifications of 𝐹𝑅 − 𝐷740 − 2.2𝐾 295

Table 4 11 Specifications of potentiometer 𝑅𝑉24𝑌𝑁 20𝑆 𝐵103 − 10𝐾 295 Table 4 12 Electrical devices using for horizontal mixing machine 296 Table 4 13 Summary of the number of used electrical equipment 297 Table 4 14 Specifications of 𝐷𝑒𝑡𝑜𝑛 𝑆𝐹𝐺3𝐺 − 4 299 Table 4 15 𝑄𝐿𝑇 − 6𝑃01 centrifugal fan specifications 299 Table 4 16 Specifications of Mitsubishi 𝐹𝑅 − 𝐷740 − 0.4𝑘𝑊 and 𝐹𝑅 − 𝐷740 −0.75𝑘𝑊 300 Table 4 17 The conductor size for the drying machine 302 Table 4 18 Electric devices using for drying machine 302 Table 4 19 Specifications of ATV310HU15N4E VFD 307 Table 4 20 Specidications of potentiometer RV24YN 20S B103 308 Table 4 21 Electrical equipments for V – mixing machine module 308 Table 4 22 Summary of the number of used electrical devices 309 Table 7 1 The parameters testing of the YN – CLVI device 352 Table 7 2 QCVN 8 – 2: 2011 standards heavy metal contamination limitation for salt used in food and medicine 352

The content of this chapter refers to the situation of salt production in Can Gio district, assessing the production situation and surplus products in the production process to be able to re − produce finished products according to the group’s research topic

This chapter also introduces products currently on the market, evaluates some of the strengths of some products on the market for the customers of each product for customers' health After research about the health of herbal ingredients, this chapter also introduces a scientific research conducted by Ho Chi Minh City Medicine and Pharmacy University (YDS) about the herbal foot bath salt with 4 – remedies for health After carefully researching the research method of the topic and the way to produce the product, from there, set a specific topic and goal of the research project, developing a production line system for herbal foot bath salt to produce products which benefits for consumers

1.1 Overview about situation of salt production in Can Gio district

Can Gio is a district located in the Southeast of Ho Chi Minh City (HCMC), about

50 𝑘𝑚 from the city center According to statistics up to year in 2015, Can Gio district has a natural area of 704.35 𝑘𝑚2, with 11% for salt land

According to statistics from the Department of Economic Cooperation and Rural Development (Ministry of Agriculture and Rural Development), Vietnam's salt production area in 2021 will reach 11.593 ℎ𝑒𝑐𝑡𝑎𝑟𝑒𝑠 Diverse salt products, especially those used in eating and drinking, are divided into 4 main groups: coarse salt, refined salt, industrial salt and food salt [1]

Figure 1 1 Salt production in Can Gio district [2]

2

The project emphasizes the planning of salt production development in the direction of reducing the area from 1609 ℎ𝑒𝑐𝑡𝑎𝑟𝑒𝑠 (2010) to 1000 ℎ𝑒𝑐𝑡𝑎𝑟𝑒𝑠 (2015), focusing on two communes Ly Nhon and Thanh An By 2025 , salt output will be increased to 80000 𝑡𝑜𝑛𝑠/𝑦𝑒𝑎𝑟 and post − salt products will be promoted

However, the actual salt production in 2023 shows that 1547 ℎ𝑒𝑐𝑡𝑎𝑟𝑒𝑠, of which approximately 1000 ℎ𝑒𝑐𝑡𝑎𝑟𝑒𝑠 are applied the improved method (crystallization on tarpaulin fields) [2] Harvest output reached 87527 𝑡𝑜𝑛𝑠 in 2023 The average income reached 13.4 𝑚𝑖𝑙 𝑉𝑁𝐷/ℎ𝑎 This level is down compared to 2015 statistics of 16.6 𝑚𝑖𝑙 𝑉𝑁𝐷/ℎ𝑎 The decreasing is caused mainly due to reduced salt prices, because most people sell raw products to traders, so people's income is always at the lowest level [3]

In a research which is published in the Science and Technology Development magazine (2016), author Ms Ngo Thi Phuong Lan identified the main difficulty of Can Gio salt farmers as the output for the product is still very limited

Figure 1 2 Can Gio salt poducts [3]

Some properties present in the composition of salt harvested during production based on Vietnamese standards is shown in the 𝑇𝑎𝑏𝑙𝑒 (1.1) and the 𝑇𝑎𝑏𝑙𝑒 (1.2) below:

Table 1 1 Sensory requirements of refined salt according to 𝑇𝐶𝑉𝑁 9639: 2013

standards [5]

3

Taste The 5% solution has a pure salty taste typical of salt,

without any strange taste

Table 1 2 Physical and chemical requirements of refined salt according to

𝑇𝐶𝑉𝑁 9639: 2013 standard [5]

𝑁𝑎𝐶𝑙 content, % dry matter mass, not less than 99.00 Content of substances insoluble in water, % dry matter mass, not

Calcium ion content (𝐶𝑎2+), % dry matter mass, not more than 0.2

Magnesium ion content (𝑀𝑔2+), % dry matter mass, not more than 0.25

Sulfat ion content (𝑆𝑂42−), % dry matter mass, not more than 0.8

In such situation, Bach Khoa Research Center for Manufacturing Engineering (BK – RECME), successfully implemented a clean food salt purification process previously

at the request of Can Gio district according to 𝑇𝐶𝑉𝑁 3974: 2015 [4] in order to gradually solve the above urgent needs of most salt farmers in Can Gio district

Figure 1 3 The entire salt "refining" line was installed and tested at Can Gio Tuong

Lai Cooperative (Can Gio district, Ho Chi Minh City) of BK - RECME

4

After applying the salt “refining” production line of Bach Khoa Research Center for Manufacturing Engineering (BK – RECME), the results of the salt changed is recored by the 𝑇𝑎𝑏𝑙𝑒 (1.3) below:

Table 1 3 Comparion between before and after applied refining line production of

External

inspection

_Large seeds, yellowish white Slightly clumpy

_Large seeds, yellowish white Dry, separate

_White, bright, dry, discrete, about 1𝑚𝑚 in size, odorless

_White, bright, dry, discrete, about 1𝑚𝑚 in size, odorless

1.2 Vietnamese standard for salt when using

Some salt standards are specific to certain segments of the market

When salt is used in industries or commercially, it needs to meet minimum standards for organoleptic, physical and chemical properties, and microbiological criteria Depending on the purpose of use, salt will have to meet the corresponding standards, the number of standards for salt in Vietnam and around the world is shown as follows in the 𝑇𝑎𝑏𝑙𝑒 (1.4) below:

5

Table 1 4 Some salt standards for certain segments in the market

The standard applies to food salt (not applicable

to salt is a by – product in chemical industries matter) Includes criteria for: 𝑁𝑎𝐶𝑙 content, 𝐼𝑜𝑑𝑖𝑛𝑒 content, naturally occurring by – products and contaminants, carriers, contaminants and ion content

Standards apply to Iodized salt

Including indicators on: 𝑁𝑎𝐶𝑙 content, 𝐼𝑜𝑑𝑖𝑛𝑒 content, water insoluble substance content, heavy metal content (𝐴𝑠, 𝐶𝑢, 𝑃𝑏, 𝐶𝑑, 𝐻𝑔)

𝐶𝑋 𝑆𝑇𝐴𝑁 150 − 1985, 𝑅𝑒𝑣 1

− 1997 𝐴𝑚𝑒𝑛𝑑 1 − 1999

𝐴𝑚𝑒𝑛𝑑 2 − 2001

𝐴𝑚𝑒𝑛𝑑 3 − 2006

[𝑈𝑆𝐴]

The standard applies to food salt

Includes standards for: minimum 𝑁𝑎𝐶𝑙 content and product naturally present secondary products and contaminants

Standard for salt used in industry

Includes criteria for: impurities insoluble in water or acid, sulfate content, calcium and magnesium content, weight loss when drying at 110°𝐶

For pharmaceuticals

Vietnam Pharmacopoeia 𝑉

Standard for salt used in pharmaceuticals

Includes indicators on: physicochemical properties (determined reaction properties, clarity and color of the solution, acid − alkaline limit), bromide, ferocyanide, iodine, nitrite, phosphate, sulfate, aluminum, 𝐴𝑠, 𝐵𝑎, 𝐹𝑒, 𝑀𝑔 and alkaline earth metals, 𝐾, heavy metals, loss of mass due

to desiccation and bacterial endotoxins

1.3 Introduction of the herbal foot bath salt

Today, in addition to salt products used in food preservation and processing (iodized salt, dried salt, granulated salt) or industrial use, salt can also be used in health support preparations, typically the product herbal foot bath salt products These products contain ingredients that include: mainly salt and medicinal herbs (in the form of ground medicinal herbs, or medicinal extracts that have been converted into solid form) aim to stimulate peripheral circulation, supports the treatment of numbness in the limbs, joint pain, sweaty feet, or has a relaxing effect for people with insomnia

7

Figure 1 4 Herbal foot bath salt products

When using herbal foot bath salt, some notes is considered to choose a right products according to customer’s needs as follows:

- Choosing herbal foot bath salt based on needs

- Carefully learn the ingredients of herbal foot bath salt

- Choose according to packaging of herbal foot bath salt

- Determined according to herbal foot bath salt treatment

1.3.1 Some herbal foot bath salt products on the market

On the market, there are lots of herbal foot bath salt products from many brands with specific health benefits Currently, on the market there are 5 outstanding products introduced as follows in the 𝑇𝑎𝑏𝑙𝑒 (1.5) below [23]:

Table 1 5 Some herbal foot bath salt on the market

No Products Image Benefits

Epsom salt, eucalyptus, umbrella temple, activated charcoal

inflammation, smooth skin

𝐵𝑜𝑥, 𝑝𝑎𝑘𝑎𝑔𝑒 450

Mineral salt, mint,

cinnamon, rose, activated charcoal, chrysanthem

um, jasmine, and

Dead sea mineral salt, urea,

rosemary essential oil

dissolves bruises, helps relax the mind

Granulated salt, ginger, cinnamon, wormwood, bloodroot, mint, camphor

Sea salt, fragrant flowers, mugwort, lemongrass,

9

cinnamon, ginger

1.3.2 Using Can Gio salt to applied to produce herbal footbath salt

Before using Can Gio salt for produce herbal foot bath salt products, salt’s properties evaluation is need to check the quality (pros and cons) based on some standards compared to other type of salts The collected information plays an important role in guiding product preparation as well as information published in the future commercialization process [8]

a) Collecting data of Can Gio salt samples

The method of collecting about salt samples is based on the Vietnamese standard 𝑇𝐶𝑉𝑁 3974: 2015 as follows [8]:

- With the salt samples at Can Gio district, collecting the samples as calculation:

3 𝑠𝑎𝑙𝑡 𝑓𝑎𝑟𝑚 × 3 𝑏𝑎𝑡𝑐ℎ 𝑜𝑓 𝑠𝑎𝑙𝑡 = 9 𝑠𝑎𝑚𝑝𝑙𝑒𝑠 / 𝑠𝑎𝑙𝑡 𝑟𝑒𝑔𝑖𝑜𝑛

- The required mass of salt sample is 500𝑔, homogenized before sending samples for testing

b) Salt’s properties analysis

Salt’s properties samples are evaluated at Quatest 3 (Ho Chi Minh City) with standards of testing methods shown in the 𝑇𝑎𝑏𝑙𝑒 (1.6) below [8]:

Table 1 6 Standards of testing method for salt samples in Can Gio district [8]

Specifications Testing method standards

Total number of yeasts and molds 𝐼𝑆𝑂 21527 − 2: 2008

Anaerobic sulfite − reducing bacteria 𝐼𝑆𝑂 15213: 2003

Sulfite − reducing anaerobic heat

− resistant bacteria & spores 𝐼𝑆𝑂 15213: 2003

1.4 Manufacturing process of herbal foot bath salt

According to the research of the YDS about the fucntion of the herbal foot bath salt for customers Group must to suggest a new production line that suitable for Can Gio salt production situation

1.4.1 Introducting the manufacturing process was researched by Ho Chi Minh City Medicine and Pharmacy University (YDS)

Ho Chi Minh City Medicine and Pharmacy University (YDS) also introduced a production process with 2 health − supporting remedies with the main input material being salt obtained in Can Gio district [8]:

- (1) Enhance peripheral circulation, reduce bone and joint pain, and rheumatism

- (2) Reduce complications and peripheral nerve disorders in diabetic patients For the 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 (1) is establised based on the remedy of Huoxue Tongluo and Zen Master Minh Khong (origin in China) with the listed medicinal herbs in 𝑇𝑎𝑏𝑙𝑒 (1.7) below:

11

Table 1 7 The remedy of Huoxue Tongluo and Zen Master Minh Khong [8]

Table 1 8 The remedy of Huoxue Tongluo [8]

Table 1 9 The materials that need for herbal foot bath salt according to YDS research

1 Semi − finished extraction

1 Weigh the mixture containing 125 𝑔 Aerosil, 2200.0 𝑔 Sodium

Crosscarmellose along with 31600.0 𝑔 of pre − ground Can Gio salt

2 Sift the ingredients through a 0.5 𝑚𝑚 sieve; Salt is sifted through

a 1.2 𝑚𝑚 sieve

14

3

Dry mix 31600.0 𝑔 𝑠𝑎𝑙𝑡 , 2200.0 𝑔 Sodium Croscarmellose and 125 𝑚𝑔 Aerosil in a high − speed mixer, for 10 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 , impeller speed 240 𝑟𝑝𝑚 (create mixture 𝐴)

4 Combine the remaining 125𝑔 of aerosil into 2500.0𝑔 of herb extracts, stir well to create mixture 𝐵

5

Gradually disperse mixture 𝐵 into powder mixture 𝐴 in the high − speed machine, wet knead and granulate for 10 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 Mixing blade speed 240 𝑟𝑝𝑚, guillotine blade speed 1500 𝑟𝑝𝑚

6 Wet granules are processed through a vertical axis grain editing device, mesh size 1.5 𝑚𝑚, to obtain wet granules

7 Dry the granules in the oven at 55 °𝐶 until the moisture is below 4%

8 The grains are cleaned through a 1.5 𝑚𝑚 mesh

9 The green rice is packed into aluminum bags using the manual packaging method

1.4.2 The production line is designed in this project

According to the research of Ho Chi Minh City Medicine and Pharmacy University (YDS), to optimize the process to save costs but still ensure product quality, the team also proposed a similar process, including specific machines and functions expressed through the 𝐹𝑖𝑔𝑢𝑟𝑒 (1.5) belows:

Figure 1 5 The production line is design in this project

15

After referring to the steps given in YDS's research, based on that, the team came

up with a production process and the necessary machines to carry out the production process are listed in the 𝑇𝑎𝑏𝑙𝑒 (1.12) below:

Table 1 12 The machines that need for the production line

The herbal foot bath salt production line designed based on YDS research

1 Grinding machine

2 Extraction – concentration system

3 Horizontal mixing machine

4 Granulating machine

5 Drying machine

6 V – blender mixing machine

7 Packaging and filling machine

In this project, with the output demand of products is different compared to research of (YDS) with a change in the quantity of products obtained is

850 𝑗𝑎𝑟𝑠 𝑝𝑒𝑟 1 ℎ𝑜𝑢𝑟𝑠, with specifically 100𝑔 𝑝𝑒𝑟 𝑗𝑎𝑟 So that, the weight of salt and herbs is calculated in the 𝑇𝑎𝑏𝑙𝑒 (1.13) as follows:

Table 1 13 The weight of the materials after scaling in this project

1.5 Machines in herbal foot bath salt line production process

To achieve the requirements and processes of the production line, the line can be divided into 7 − types of machine: grinding machine, extracting – concentrating system,

a) Hammer crushing machine

A hammer crusher is a crusher in which a hammer hits the material that is being grinding machine In the hammer crusher, crushing takes place by impact between the hammers and breaker plates

Figure 1 6 Hammer crusher mechanism

The working principle of hammer crusher is presented as follows:

The ingredients to be crushed are put inside the machine through the feed port Due to the impact of the material with the rotating hammer blades and with the inner wall of the machine, the material will deform and break into smaller − sized components To crush, the kinetic energy of the hammer when rotating must be greater than the deforming work to break the material

Advantages

- High efficiency and can ensure relatively good grinding particle size

- Can grind materials with high hardness

Disadvantages

- Materials are easily splashed when entering the machine

- It is difficult to adjust the machine's output size because the entire mesh must be

replaced

17

b) Disc mill

A disc mill is a type of crusher that can be used to grind, cut, shear, shred, fiberize, pulverize, granulate, crack, rub, curl, fluff, twist, hull, blend, or refine It works in a similar manner to the ancient Buhrstone mill in that the feedstock is fed between opposing discs or plates The discs may be grooved, serrated, or spiked

The working principle of disc mill is shown in the 𝐹𝑖𝑔𝑢𝑟𝑒 (1.7) as follows:

Figure 1 7 Working principles of disc mill

Disc mill for grinding powder with medium and fine grinding levels The machine consists of two grinding discs installed in the machine housing, between the two discs

is a grinding slot that can be adjusted by moving one of the two discs

Advantages

- Optimization in the design of grinding discs

- Output material size can be adjusted simply

Disadvantages

- Can only grind materials with relatively small output sizes

c) Roll crushing machine

A type of secondary or reduction crusher consisting of a heavy frame on which two rolls are mounted These are driven so that they rotate toward one another Rock fed in from above is nipped between the moving rolls, crushed, and discharged at the bottom The working principle of roll crusher is shown in the 𝐹𝑖𝑔𝑢𝑟𝑒 (1.8) as follow:

18

Figure 1 8 Working principle of roll crusher

The working principle of the roller mill is to let the material to be crushed pass through the gap between the two rollers The two rollers are placed horizontally and parallel, have a very hard surface, the surface can be smooth or machined depending on the material being ground

Advantages

- Has a simple structure and working principle

- Small size, easy to assemble and install in the line

- Material size can be adjusted easily

- Simplicity in inputting and collecting crushed materials

- Dissolution of solute into solvent

- Diffusion of solutes in solvents

- Movement of solute molecules through plant cell walls

Extraction process is directly described in the 𝐹𝑖𝑔𝑢𝑟𝑒 (1.9) below: