MoringaLeafDryer

MattJohannes
AndrewEntriken
JorgeJimenez
AbdullahHajjyeah

ENGR493:LeadershipPrinciples
Spring2015
April27,2015

LeafDryingTeam1

1.Abstract

TheMoringaLeafDryingteamwasgiventhetaskofdesigningtwoleafdrying
prototypes:onethatcanbemountedonthebackofapickuptruck,andanotherthatcanbeused
industriallyinZimbabweforourclient,Roberta.Followingtheresearchphaseoftheprocess,
whereimportantinformationaboutthedesignswasdetermined,threedesignconceptswere
generated,givingtheteamflexibilityintheirfinaldesignchoice.Thetruckbeddesignswillthen
bebuiltandtestedandoneoftheothertwodesignswillbesenttoRobertaforindustrialuse.

LeafDryingTeam2

TableofContents

1. Abstract1
2. Introduction3
1. Background3
2. ProblemStatement3
3. Objectives3
3. ProcessSteps4
1. EstablishingDirection4
i.
Mission4
ii.
Vision4
iii.
Values4
iv.
Strategies4
2. ConceptGenerationandSelection5
3. ScaledUpDesign7
4. ConstructionProcess7
5. TestingResults7
4. FutureWork11
5. Recommendations12
6. LeadershipLessons13
7. Acknowledgements14
8. References15
9. Appendix16
1. AppendixA:GanttChartLink16

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2.Introduction

2.1Background
MoringaOleiferaareaverynutritioustypeoffoodandisnativetoareasinCentral
America,theCaribbean,northerncountriesinSouthAmerica,Africa,SoutheastAsia,and
Oceania.IthasaveryhighhealthvaluesincetheleavesalonecanintroduceVitaminsA,B,C,
andKintodiets,inadditiontomanganese,protein,andotheressentialnutrients.

2.2ProblemStatement
Thereiscurrentlynocosteffectiveandelectricityindependentmachinetodrymoringa
leavesaftertheyarestrippedfromtheirbranches.Ourclient,RobertaPippet,isinneedofsucha
machineinordertoallowherfactorytoefficientlyproducedriedmoringaleavesinZimbabwe.

2.3Objectives
TheobjectiveoftheMoringaLeafDryingTeamistodesignandconstructa
costeffectiveleafdyerthatiseasilybuiltandoperatedandisadaptableforuseinvarious
locations.Thedesignmustalsobeelectricityindependentandmusthavetheabilitytoeventually
beexpandeduponsothatitcanbeoperatedatnight.

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3.ProcessSteps

3.1EstablishingDirection

3.1.1Mission

Themissionofthemoringaleafdryingteamistoprovideenergyefficientandelectric
powerindependentleafdryingmechanismsthatfacilitatetheharvestingprocessandincreasethe
productionrateofpureleaves.

3.1.2Vision

Thevisionofthemoringaleafdryingteamisthatwewillproducequalityandeasily
manageableproductthatcanbeusedtoboosttheeconomyintechnologicallystarvedareas.

3.1.3Values

Thevaluesofthemoringaleafdryingteamareasfollows:
1. Respondpositivelytocriticism
2. Remainopentonewanduntestedideas
3. adapttotheconfinementsofvariouslimitingsituations
4. beawareofexistingvaluesandpractices

3.1.4Strategies

InordertokeepupwithourGanttChartgoals,themoringaleafdryingteamisaimingto
meetatleastonceaweekinordertocollaborateandupdateeachotherontheprogressofour
individualtasks.Eachmembersisexpectedtospend36hoursaweekworkingontheproject,
whichshouldbeasufficientamountoftimetostayonscheduleandcompletetheprojectina
timelymanner.Inaddition,theteamisgoingtomaintaincontactwithRobertatoensurethatour
goalsandprogressarealignedwithherexpectations,thussecuringthattheprojectismovingin
therightdirection.

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3.2ConceptGenerationandSelection

Conceptgenerationwasfocusedontheleafdryingmachineitself,ratherthantheother
componentsofRobertasfactory.Theprocessbeganwithbenchmarkingcurrentdesignswe
foundonlinetodeterminewhatwouldbethemostefficientgenericdesignstructure.Wethen
decidedtodesignthreeprototypes:onethatwouldfitinatruckbed,anindividualmachinefor
thefactory,andamachinethattakesuptheentireroomofthefactory.

Concept1:
ProfessorErdmanassignedthisdesignasan
auxiliaryassignmenttoassistwiththedryingprocess
duringthetransportofmoringaleaves.Thisbeingsaid,
thedesignwasfocusedonconstructingaportable
moringaleafdryerthatwascapableoffittingand
functioningonatruckbed.Becauseoftherapidrateof
moldgrowthoftenassociatedwithmoringaharvesting
process,thisdryerconceptfocusesprimarilyon
portability.Thisdryerwillallowthemoringaharvesters
tobegindryingthebranchesinstantlyafterbeingcut
fromthe
tree.The
truckbed
leafdryer
willultimatelyreducethetimeneededtodrythe
leavesatthefactory,willallowforsimplifiedleaf
separationatthefactory(becauseofthelackof
moisture)andwillsignificantlyreducethemold
growthontheleaveswhilestillinthefield.The
portabletruckbedleafdryerincludestwo
differentmodules:theleafboxandtheheatpanel.
Thedryerboxitselfistobeconstructedofa
combinationof1x1,2x4andstandard
plywoodboards.Itisdesignedtohold8totaltrays,each
17x22indimension.Fourtraysaretobeinsertedoneachsideofthetruckinorderto
maintainstructuralstability(avoidissuesrelatedtotopheaviness).Thedryingtraysaretobe
constructedwithawoodenframeandascreenbottomthiswillprovideadurabletraythat
allowsforampleairflowthroughtheharvestedbranches.Thesecondmodulethatthisdesign
requiresistheheatingpanel.Sincethetruckbeddryerisheatedsolelyusingnaturalconvection,
thispanelisdesignedtobothgeneratesubstantialamountofheatanddirectitintothedrying
box.Anaveragetruckbedrangesfrom5480inwidth,andsothisheatingpanelhasbeenset

LeafDryingTeam6

at50inchestoassureversatility.Thisboxistobeconstructedwithawoodenframe,black
corrugatedroofingsheets,andaplexiglasssheeting.Theplexiglasswillmagnifythesunrays
directlyontotheblacksheetingplacedwithinthebox.Thiswillheadtheairwithin,causingitto
moveupwardsintotheboxwhilesimultaneouslydrawingmoreairfromtheoutsideintothe
heatingmodule.Thetopofthethinmoduleisconnectedtoasmallventinthebottomofthe
dryerbox,andisangleddownwardstothebaseofthetruckbed.Thiswillallowforairto
naturallyheatandflowupwardsintothedryerboxbecauseoffundamentalheatflowproperties.
Afterimplementingthisdryingunitintothefield,workerswillbeabletoharvestmorequickly
andreducemoldgrowth,consequentlyprovidingacleanerandmorepureproductforsaleand
distribution

Concept2:
Theseconddesignwasintendedtofunction
asindividualunitsthatRobertacanbuildingandplace
inherfactoryroomsassheseesfit.Itismadeupof
threemaincomponents:theairheatingsection,the
furnace,andtheventilationtube.Theairheatingsection
islocatedoutsidethefactoryandconsistsofaglass
coverwithablackbackgroundthatairflowsinto,at
whichpointitisheated,causingtheairtoriseintothe
furnacechamber.Thefurnacechamberconsistsof
dowelrodsrunningperpendiculartothedoorthathold
traysofmoringaleavesandonesthatrunparalleltothe
doorthatcontrolhowfarinthetrayscango.Theedge
ofthetrayslineupagainsttheparalleldowelrodsina
slantedlinepattern,allowingthehotairtoflowaround
thetraysasitrisesandfortheleavestobeheated
evenly.Theairthenfinallyleavesthefurnacechamberthroughtheventilationtube,whichhas
theabilitytocontrolthetemperatureofthefurnacechamberbycontrollingthediameterofthe
exittube.Thesmallerthediameter,thehotterthechamberstays,allowingustoregulatethe
temperatureandproducethebestproductpossible.

Thedimensionsofthisdesignareflexiblesincethatsthegoalofthisdesign:Robertacanfititto
anyroomsheneedsto.Theonlyrestrictionisthatitneedstobelocatednearanexteriorwallso
thatitiseasytoheattheexteriorairtodrytheleaves.Ifthereisalargedistancebetweenthe
outsideairandthesystem,thenmoreheatwillbelostalongthewayandthatwillcostRoberta
moremoneytoinsulatethepipesbetter.

Concept3:
Thethirddesignisthecompleteroomdesignintendedtohavethewallslinedwith
traysholdingtheleaves,leavingahallwaytocross.ThisdesignthoughrequiresRobertato

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changeherdesigntohave8x10designsinsteadof4x10,inessencemergingthe4rooms
into2.Wedecidedtomakethisdesignmoreaccessiblebymakingtheroomsitselfthedryerbut
thetraysareinrackswhicharemoveabletomakeexchangingtheleaveseasier.Eachroomwill
fit4racksmeasuring2x4.5toallowroomspaceinthemiddletoaccessthetrays.Thevents
wouldbeplacedinthesamewayconcept2worksbutappliedtotheroomitselfinsteadofthe
specificdryer.

3.3:ScaledUpDesign

Oneoftheoriginalissueswiththescaleupdesignwasthatithadtobesmallenoughto
shiptoAfrica,whichmeantthatthedesigndimensionsweregoingtohavetobealteredandthe
compactnessofthedesignwasgoingtohavetochangeaswell.Toaccomplishthis,theairentry
intothedryerboxwasmovedintoamoreinternalpositionandtheventilationstackwas
removedaswellinfavorofventilationholes.Inaddition,theairheaterhadtobealteredsothat
itwaslesswideandcouldbefoldedup,bothofwhichwerechangedwithrelativeease.The
resultwasadesignthatcouldbefitinthepackagingrequirementsintermsofsizeandweight,
butdidntsacrificetoomuchperformancefrompreviousdesigns.

3.4:ConstructionProcess

Followingthescaleup,theconstructionoftheheatingboxbegan.Thefirststepinthis
processwastocompileamaterialslistusingtheSolidWorksfilesofourfinaldryerbox.After
performingthedesignbreakdown,wewerethenabletoputtogetheranaccuratematerials
analysissheet.Forourpurposes,wealsoincludedthepricesofeachmaterialinordertohave
thischartdoubleasourcostanalysistable.Threeseparatetableswerecomposed:oneforthe
dryerunit,oneforthetrays,andonefortheheatingunitthatconnectstothedryer.Anexample
ofoneofthesetablesisshownbelow:

LeafDryingTeam8

Afterfinalizingthematerialsanalysistable,allofthenecessarymaterialswerepurchased
atHomeDepotusingdonationsgenerouslyallottedtousthroughPennState.Theinitial
constructionofthedryerboxbeganinReiberandwasfinishedatthelearningfactory.
Aspreviouslystated,webrokedowntheconstructionofourfinaldeviceintothree
separatestages:thedryingbox,theheatingunit,andthetrays.Thefirstmodulethatwechoseto
buildwasthedryingbox.Wemeasured,cut,andscrewedtogetherthe2x3boardsinorderto
frameoutthebox.Afterwards,eachfaceoftheboxwascoveredby11/16thicksheetof
plywood.Adoorwasplacedonthefrontfaceofthedryerwithtwohingestoallowforeasy
accesstothedryingtrays.Inordertoassurethattheheatedairwouldnotleakfromthebox,we
insulatedthefrontfacewithkerfdoorsealinsulation.Thisisthematerialthatsurroundsmost
commondoorwaysandactsasinsulatorfromtheoutsideelements.Thefrontfacingdoorwas
attachedataspecificdistancesoastoassurethattheinsulatorwasunderconstantpressure,
providinggoodinsulation,wheneverthedoorwasshut.
Oncethedryerunitwascomplete,wethencontinuedontotheconstructionofthetrays
andheatingunit.Wedistributedresponsibilitiesamongstourteammatesandwereableto
completethesetwoprojectssimultaneously.Thetrayswererelativelysimpletobuild,
incorporatingonlya1x3inchsquareframeandascreenbottom.The1x3boardswerecutin
halfhorizontally(leavingtwo1x1.5boards),ascreenwasstapledtothetopfaceofthebottom
square,andthenfinallypinchedbetweenthetwosectionsasthetopsquarewasreattached.In
essence,itwasasifwehadconstructed8smallersquareframesandfastenedthescreening
betweentwoofthem.Afterthetrayswerecomplete,thelastsectionofthedryertobuildwas
theheatingunit.Thiswascomposedofa2x4frame,plywoodbottom,andanacrylictopcover.
Wefirstbuiltthisunitasasinglepiecesoastoassurethatallpieceslinedupandfitour
designatedspecifications.Inordertoaccommodateshippingconstrictions,wethenseveredthe
entiredryingunitintwoandattachedthemtogetherwithtwoindustrialgradehinges.This
allowedtheentireramptofoldhalf,thereforesignificantlyreducingtheareathatitoccupied.
Intotal,approximately30hoursoflaborwasrequiredtocompletetheconstructionofthe
box.Itwasveryrewardingtoseeaprojectofwhichwehadbeenplanningthemajorityofthe
semesterfinallytakeshape.Onthenextpage,afewphotosofourcompletedboxareshown.
Pleaserefertothebelowreferencestomatcheachphototoitsdescription.

Figure3.1Isometricviewofdryingboxunit
Figure3.2Frontviewofdryingboxunit
Figure3.3Viewofkerfdoorinsulatorthatisusedtokeepheatinbox
Figure3.4Dryingunitwhilefoldedinhalf

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3.5:TestingResults

ThedryingboxwastestedonWednesday,April15thbehindtheLearningFactory.The
testinginvolvedstrippingtheleavesfromthetreeandfillingalltraysinthebox.Theplacement
oftheheatboxwasofmajorconcernasitwouldonlyreceivedirectsunlightforacoupleof
hoursduetobeingdirectlybehindabuilding,sowerotateditevery2hours(3times)toenhance
itsperformance.However,duetothefluctuatingtemperatureandcoldwindsthedryerwasonly
warmatthesunspeakandbeganarapiddeclineintemperaturetowardstheafternoon.These
conditionsare,ofcourse,quitedifferenttotheonesitllbedealingwithinZimbabwe,butwe
stillfeelitisimportanttotestitbeforesendingittoprovewithoutadoubtthatitisabletodoits
intendedjob.

Figure3.5.1&3.5.2TraysfilledwithMoringaLeavesfortestpreparation

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4.FutureWork

ThenextstepforthisprojectistoshipourprototypetoRobertasothatshecantestitin
Zimbabweandworkoncreatingmoredryersforherindustrialgradeproduction.Wewillalso
havetosendherinstructionsonhowthedryerworkssothatshehasastartingpointsforher
testing.
Ourbiggesttaskmovingforwardisgoingtobecreatingasynopsisofoursemesterso
thatthenextleafdryingteamdoesnthavetogothroughthisentireprocesslikewedidandhasa
basisforstartingtheirdesigns.WewillalsohavetoleavethemRobertascontactinformation
andalistoftheothergoalsshewantedtoaccomplish,suchasdryingleavesthroughoutthe
night,sincewedidnthavethetimetodesigneverythingshewantedustocreate.

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5.Recommendations

Forfutureleafdryingteams,werecommendthattheyconsultourinstructionspage
beforetheybeginbuildingandthattheycontactRobertatoseewhatneedstobechangedbased
onhertestingandscaleup.Inaddition,futuregroupshouldmakesurethattheyhaveatleastone
personwhoisqualifiedtousealltheequipmentatthelearningfactorysinceitmakesthe
buildingprocessmucheasierthanhavingtoasksomeoneelsetocutmaterialsforthegroup.

LeafDryingTeam13

6.LeadershipLessons

Oneofthemainlessonslearnedthissemesterwashowtoorganizeaneffectivemeeting.
ThiswaskeywhenwehadourphoneconferenceswithRobertasinceitallowedustohavea
focuseddirectionwhiletalkingtoherandmadesureweaskedtherightquestionssothatwe
couldeffectivelymoveforwardwiththeproject.Inordertoorganizeourselves,webrainstormed
questionsbeforehandsothattherewasalogicalflowtotheconversationandsothatwecould
perfectourwordingforwhenwetalkedtoRoberta.Inadditiontopreparingquestionsfor
Robertasmeetings,wealsomadesurethatourgroupmeetingshadadefinedobjectivebefore
themeetingoccurred.Thisallowedustostayontopicduringourmeetingsandmadesure
everyonehadampletimetopreparetheirmaterialsforthemeetingstopresenttotherestofthe
team.Eachmeetingtypicallyendedwithusdefiningwhatwewouldbeworkingonforthenext
weekaswell,ensuringthatwewouldbeabletomakeprogresswithouthavingtoalwaysmeetas
agrouptogetworkdone.

Asateam,weeachhadsimilargoalsindevelopingourleadershipskills,discussionsabout
leadershiptopicsinENGR408madeeachteammemberunderstandonespersonalityand
concludearealisticapproachtonegotiatewithoneanother.Asateam,weagreethatthisproject
developedourskillsofinteractingwithdifferentpersonalitieswithintheteamaswellasmaking
criticaldecisionsinordertosavetime,increaseproductivityandmeettheclientsdemands.

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7.Acknowledgements

TheleafdryingteamwouldliketothankProfessorErdmanandTAsMikeandHeather
forhelpingguideusintherightdirectionthroughouttheproject.Inaddition,wedliketothank
RobertaandBarbarafortheircontinuedcontactwithusthroughouttheprojectthathelpedensure
ourprogresswasmeetingRobertasguidelines.

AcademicAcknowledgments

PennStateUniversity
ProfessorErdman
TheEntireENGR408and493Team

SpecialThanks:

Roberta&Barbara

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8.References

Adelaja,A.O.,andB.I.Babatope."AnalysisandTestingofaNaturalConvectionSolarDryer
fortheTropics."
JournalofEnergy
2013(2013):18.Web.10Feb.2015.
"SolarDryers."
NeverEndingFood
.NeverEndingFood,2015.Web.6Feb.2015.
Weiss,Werner,andJosefBuchinger."SolarDrying."
AEEINTEC
(n.d.):n.pag.
AEEINTEC
.
AustrianDevelopmentCooperation.Web.4Feb.2015.

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9.Appendix

9.1AppendixA:GanttChartLink

https://docs.google.com/spreadsheets/d/1c_dAVA4YTX8DYnTGz9CvkEO0yWpP3_SjObKZoh
vHbmw/edit#gid=1688732048