DEPARTMENT OF PRODUCTION ENGINEERING

The aim of this project was the design, fabrication, and testing of an easy-to-operate and affordable small-scale palm oil clarifier fit for farm use. This was accomplished by the design and selection of materials for the manufacture of the individual components of the clarifier, the production of the working drawings, and fabrication. A performance test, in terms of oil recovery rate, was carried out on the clarifier. On average, we had 91.30% and 91.54% oil recovery rates. Comparatively, these rates are within the range of the results from industrial and more automated systems with large-scale farms, which typically strive for recovery rates between 90% and 95%

This project focuses on the design and fabrication of an improved twin blades yam pounding machine to enhance the efficiency, speed, and quality of pounded yam production. Pounded yam, produced mainly from Dioscorea rotundata, is a staple food widely consumed in Nigeria and other West African countries. Traditional pounding using mortar and pestle is labor-intensive, time-consuming, and often unhygienic, while many existing mechanized pounders use single blades that limit effective tumbling and crushing of larger yam quantities. Experimental analysis was conducted to determine the crushing force of cooked yam, and detailed engineering design calculations were performed for motor selection, shaft design, pulley system, and bearing selection. A decision matrix was used to compare two design concepts, leading to the selection of the twin blade configuration due to its superior pounding efficiency. Performance evaluation of the fabricated machine showed that it pounded 1 kg of yam in 2 minutes, 1.5 kg in 2.27 minutes, and 2 kg in 3 minutes, compared to 6–8 minutes for single-blade machines and 15–20 minutes for manual pounding. The machine achieved a throughput capacity of 292.8 kg/hr and an efficiency of 97.6%. The results demonstrate that the improved twin blades yam pounding machine provides faster operation, better texture uniformity, and higher productivity, offering a more hygienic and efficient alternative to traditional and existing mechanical methods.

Advancements in technology have led to a steady decline in the effort required to produce work, with better designs offering an effective and economical means to achieve desired outcomes with reduced effort. Power screws serve to transform rotary motion into translator y motion, as exemplified by the screw jack, where a minor horizontal force elevates or descends a substantial load. Operating akin to an inclined plane, the mechanical advantage of a screw jack is determined by the ratio of load to effort applied. Adjustment of the jack's height is facilitated by turning a lead screw, achievable either manually or through integration of an electric motor. The whole components is designed on a base plate of relatively good resistance to deformity and act as a support to weight balancing during the operation of the motor
This project analyzes the fabrication of a motorized screw jack by incorporating an electric motor in the screw in order to make load lifting easier. In this fabrication design, the power screw is rotated by connecting motor through universal joint and gear axle to power the screw jack plugged to the automobile 12 V battery source to generate power for the prime mover (motor), which transmits its rotating speed to the power screw to be rotated with required speed reduction and increased torque to drive the power screw. The significance of this project to design a car jack in form of motor operating condition in order to make the operation easier, safer and more reliable in order to reduce health risks especially back ache problems associated with doing work in a bent or squatting position for a long period of time. The motorized screw jack is easy to use by women or whoever had problem with the vehicle tyres along the road. It will also save time and requires less human energy to operate. Based on results, the project provide a motorized jack able to effectively lift a load of 750kg to 1000kg and also provide a safe usage during maintenance of vehicle.

This project involves the design and fabrication of a solar water heating system utilizing the thermosiphon principle. The system consists of a 30-liter and 15-liter tank, an absorber plate constructed from copper rods and aluminum sheets, and an integrated pump and battery for enhanced performance. The project commences with a comprehensive review of previous researches on various solar water heating systems, majoring on the types of Solar water heating systems, its components, materials and method of fabrication of the system, its design considerations, as well as the importance and significance of the project. The system’s efficiency and effectiveness in heating water using solar energy are evaluated, demonstrating its potential as a sustainable and cost-effective solution for water heating applications. The performance of the system was evaluated under various operating conditions, and the results showed a significant increase in water temperature, demonstrating the system’s potential for efficient solar water heating. The average temperatures of the hot water for the 1 st, 2 nd and 3 rd days of testing are 45.4 oC, 46.5 oC and 45.9 oC respectively. The use of locally sourced materials and simple design make this system an attractive option for rural and urban areas here access to hot water is limited. This project contributes to the development of sustainable and renewable energy solutions, aligning with global efforts to reduce carbon emissions and promote energy efficiency.

Cobwebs are a common nuisance in both residential and commercial spaces, often requiring manual removal that can be time-consuming and tedious especially hard to reach corners. This project focuses on the development of an efficient and cost- ffective cobweb remover using locally available materials like electric motor (rotational motion), brush (removal of the cobweb), Rechargeable Battery (as the power source) and telescopic pole (for high buildings). The primary objective is to design a device that simplifies the process of cobweb removal while minimizing the need for expensive or specialized equipment providing 75% efficiency. The outcome of this project is an innovative cobweb remover that is not only effective but also accessible to a wide range of users, including homeowners, cleaning services, and facility managers. By utilizing locally sourced materials and promoting sustainable design, this project contributes to eco-friendly cleaning practices while improving the quality of life for individuals in various environments. It was successfully fabricated and our results were compared with the traditional methods. And it was observed that the cobweb remover has an efficiency of 78% while the traditional method of removing cobweb was 60.7% which shows that the design is more efficient and reliable.

The machine is developed to cut different metal materials with high precision using plasma arc technology controlled by a computer system. The CNC plasma cutter improves cutting accuracy, reduces manual effort, and increases productivity in metal fabrication industries. The project includes the design process, material selection, fabrication of the frame, installation of electronic components, and testing of the machine.

This project explores the quality assurance (QA) practices in Prime Feed and Flour Mill
Limited, aiming to improve product safety, ensure regulatory compliance, and enhance
customer satisfaction. With the increasing demand for high-quality food and animal feed,
alongside the public health threats posed by contaminated or inferior products, it is crucial to
maintain consistent quality throughout production processes. The research investigates the
existing QA frameworks utilized by the quality control sector, assesses their conformity with
national regulatory standards established by NAFDAC and SON, and identifies prevalent
challenges in their implementation. Data was gathered through document analyses from the
laboratory results and log book.
The results recognize that various factors affect quality standards, including insufficient staff
training, inadequate documentation, limited QA infrastructure, and weak enforcement
mechanisms. The study emphasizes key quality indicators such as moisture content, aflatoxin
levels, microbial load, and packaging integrity as vital control points.
Recommendations include regular QA training for personnel, strengthening internal audits,
improving record-keeping systems, and adopting technology for process monitoring. The
study concludes that a more structured and proactive quality assurance system is necessary to
meet both regulatory and consumer expectations in the feed and flour production sector in
Nigeria.

The application of metaheuristic approach in optimising some welding parameters in TIG welding of mild steel is presented in this work. The study aims to optimise arc efficiency (AE) and thermal efficiency (TE) of the TIG welding process by applying metaheuristic optimisation techniques (MTOs), specifically the Genetic Algorithm (GA) and Particle Swarm Optimisation (PSO). The investigation focuses on identifying the optimal combination of welding parameters current, voltage, and gas flow rate that maximise process efficiency while maintaining physical validity and conformity with established TIG welding standards. The research methodology involved implementing mathematical models of arc and thermal efficiency based on the Goldak double-ellipsoidal heat source model. These models were coded and executed using MATLAB R2024b, where GA and PSO algorithms were used independently to optimise the input parameters within defined physical ranges obtained from validated literature. Simulation runs recorded iteration-wise outputs for each parameter, allowing convergence analysis and comparative assessment between both algorithms in terms of solution quality and computational performance. The results revealed that for arc efficiency, GA achieved optimum values at 75.59A, 14.80V, and
11.27L/min, yielding an AE of 0.81, while PSO attained optimal conditions at 63.16 A, 15.57 V, and 6.97 L/min with an AE of 0.97. For thermal efficiency, GA recorded optimum values at 67.26A, 17.21V, and 13.69L/min giving TE of 0.89, whereas PSO produced 92.09A, 18.82V, and 8.47L/min resulting in TE of 0.99. The optimised efficiency values were validated with literature and found to be in close agreement with the established efficiency range for TIG welding (0.36– 0.90), confirming the reliability of the metaheuristic approach.

A crucible furnace is an equipment used in the foundry workshop or industry for melting metals for casting operations. They are the oldest type of melting furnaces used for melting and holding small batches of non-ferrous alloys for which a refractory crucible filled with metal is heated through the crucible wall. This paper focuses on the development of a 38-kilogram capacity LPG butane gas-fired crucible furnace used to melt aluminium metal. Drawings were produced to aid the fabrication of the furnace using a mild steel sheet while the other components needed for the fabrication were selected based on functionality, durability, availability of local materials and cost. The test was carried out on the furnace to evaluate the performance and the results obtained showed that it took the furnace 24minutes to completely melt 38kg of aluminum scrap between 630 0C to 700 0C. The heating rate is 56.110 C/min, melting rate of 1.58kg/min and a 39.6% maximum efficiency, which is quite impressive when compared with the conventional crucible furnace.

This project focuses on the design and fabrication of a hybrid (solar–electric) dryer for agricultural materials. The aim is to develop a low-cost and efficient drying system that utilizes both solar and electrical energy to ensure continuous operation under varying weather conditions. The dryer was designed with major components, including a solar collector, drying chamber, heating element, and forced draft fan powered by both photovoltaic and electrical sources. Locally available materials such as sheet metal, glass, insulation, and mild steel were used in the fabrication process to promote affordability and sustainability. Performance tests were carried out using cassava chips as the sample material, and relevant parameters such as temperature variation, drying time, and moisture reduction were recorded. Results showed that the hybrid dryer achieved faster and more uniform drying compared to traditional open-sun drying. The system proved reliable, environmentally friendly, and capable of maintaining operation during periods of low sunlight. This innovation demonstrates a practical approach to reducing post- harvest losses and improving the preservation of agricultural produce in regions with inconsistent power supply