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Author 1 (one author only)
First Name Middle Name Role (ASABE Contact author?
(or initial) (or initial) Surname member, etc.) Email yes or no
Marvin T. Valentin Member m_valentin14@yah yes
oo.com
Affiliation for Author 1
Organization Address Country Phone for contact author
Department of Agricultural Science City of Munoz, Province of Philippines +63 9460 455 172
and Biosystems Nueva Ecija.
Engineering, College of
Engineering, Central Luzon
State University

Author 2 (one author only)

First Name Middle Name Role (ASABE Contact author?
(or initial) (or initial) Surname member, etc.) Email yes or no
Elmar M. Villota no

Affiliation for Author 2

Organization Address Country Phone for contact author
Department of Agricultural Science City of Munoz, Province of Philippines
and Biosystems Nueva Ecija.
Engineering, College of
Engineering, Central Luzon
State University

Author 3
First Name Middle Name Role (ASABE Contact author?
(or initial) (or initial) Surname member, etc.) Email yes or no
Vitaliana U. Malamug vumalamug@yaho no
o.com
Affiliation
Organization Address Country Phone for contact author
Department of Agricultural Science City of Munoz, Province of Philippines
and Biosystems Nueva Ecija.
Engineering, College of
Engineering, Central Luzon
State University
Author 4
First Name Middle Name Role (ASABE Contact author?
(or initial) (or initial) Surname member, etc.) Email yes or no
Ireneo C. Agulto ireneoagulto@yaho no
o.com
Affiliation
Organization Address Country Phone for contact author
Department of Agricultural Science City of Munoz, Province of Philippines
and Biosystems Nueva Ecija.
Engineering, College of
Engineering, Central Luzon
State University

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ASABE 2017 Annual International Meeting Page 1

 An ASABE Meeting Presentation
DOI:
10.13031/aim.20[Click here to enter paper number]
Paper Number: [Click here to enter paper number]

Design, Fabrication and Evaluation of a Potato Grader for

Village-Level Operations Prototype I

Marvin T. Valentin1, Elmar M. Villota1, Vitaliana U. Malamug1 and Ireneo C. Agulto1

Faculty, Department of Agricultural and Biosystems Engineering, College of Engineering, Central Luzon
State University, Science City of Munoz, Province of Nueva Ecija, Philippines.
Written for presentation at the
2017 ASABE Annual International Meeting
Sponsored by ASABE
Spokane, Washington
July 16-19, 2017

ABSTRACT. An initial version of potato grader was developed in this study in response to manual grading of potato tubers.
The design of the grading mechanism is cylindrical spiral with increasing gaps that allows size differentiation of the
potato tubers. The cylindrical spiral was divided into three regions: The region for the small-sized tubers with spacing
ranging from 3.0 cm to 4.0 cm. Next is the region for the medium-sized tubers with gaps from 4.1 cm to 7.4 cm while the
region for the large-sized tubers had gaps of 7.5 cm in above. The device was evaluated based on grading efficiency,
capacity, percentage of damage tubers and power consumption. Gradation of the potato tubers were based on minor
diameter. Another device coupled with the potato grader is a conveyor which was designed and fabricated primarily to
feed the potato tubers into the grading unit at a regulated rate.
Results of evaluation showed that optimum set-up of the grader is at 15 RPM giving a grading efficiency of 92.5%,
capacity of 441.5 kg/hr, less damage of 1.83% and a low power consumption of 22.6 W-hr. The cost of the grader is P31,
000.00 with a break-even quantity of 23 tons of tubers/year. The efficiency of the grader can be improved by employing
some geometric size of the spiral and use of rubberized materials to eliminate damage. Also the capacity can be improved
by considering a larger dimension of the grading unit. Consider testing the device using other spherical agricultural
products like citrus.
Keywords. efficiency, gaps, grader, spiral, potato tubers

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ASABE 2017 Annual International Meeting Page 2
 Introduction
Potato tubers are naturally variable in size necessary to undergo grading along with other postharvest treatment in order
to achieve quality market. Grading of potato harvest can be accomplished either manually or mechanically. However,
grading by hand is inconsistent, less efficient and time consuming. At one point, aside from being a value adding operation,
uniformly graded tuber is advantageous in the processing industry and it can increase efficiency of the processing line. The
same thing during planting with the use of mechanical planter where planting material of uniform size can affect the
performance of the machine.
Early in the 1950’s, a slat grader was developed, potato tubers are scattered on the slat and individually inspected as it
manually moves to the bags attached at the end. This pioneering design, although less efficient, gave birth to a more
improved device for grading potato tubers. Such improvement includes a chain conveyor belt allowing tubers to pass through
the chain to the bag provided at the end. However, lack of overall consistency and the aim to minimize or even eliminate
constant human intervention in the operation resulted to the search of more improved design.
Meanwhile, potato tubers are said to be best graded by mass as revealed in some studies (Shaym, 1982; Butler, Bernet
Manrique, 2005). However, according to Fahardi, Sakenian, and Azizi (2012), weigh sizing mechanism are not customary
because of being slow and costly. Thus, he conducted a study on the best relating physical characteristics of potato tuber
and found out that mass and diameter are related. Similar study was conducted by Tabatabaeefar (2002) and found out that
there was a strong relationship of the physical attributes of potato tubers between volume and diameters and between
diameters and mass among others. Maghirang, Rodulfo, and Kebasen (2009) also conducted the same research and provided
a basis on the classification of potato tubers as small, medium and large with minor diameters of 3.0-3.9 cm, 4.0-7.4 cm and
7.5 cm and above respectively.
This study presents the initial version of the potato grader that was later modified and evaluated at different settings as
recorded on its prototype II which was published in the IRJIEST 2015. In that study the evaluation had considered several
machine parameters coupled with a conveyor. But then it was later evaluated without the use of conveyor as published in
the CLSU-IJT 2016. Nonetheless, a variation on the results of evaluation was observed from its original concept.

Objectives of the study

This study was conducted to design, fabricate and evaluate the performance of a potato grader at three different RPM
(10, 15 and 20) of the grading unit using a fixed feed rate of 20kg/min.

Methodology
Evaluation
This study was conceptualized with the premise that grading the potato harvest before bringing to the market will increase
its value. The framework of this study was prepared with the main objective of having a device that will provide practical
means of classifying potato tubers based on the guidelines given by the Philippine National Standard (PNS). The potato
grader was evaluated based on performance indicators in terms of grading efficiency, capacity, damaged tubers and power
consumption. These were evaluated at three different speed of the grading unit (10, 15 and 20 RPM) with a fixed feed rate
of 20 kg/min. The variation in the RPM was made by changing the size of the drive pulley of the grading unit as shown in
Figure 1.

Figure 1. Drive pulley of the grading unit.

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Procedure
The procedure followed during the evaluation is presented in Figure 2.

1. A total of 180 kg potato tubers were obtained
from the market and were divided into 9 sub-
samples at 20 kg each. Tubers in each sub-
sample were selected at random containing
small, medium and large size.
2. The samples during the procurement were
manually inspected and those with initial
damages such as bruises, decayed surface,
greening skin and cracks were discarded.

3. The proportion of small, medium and large

4. The samples were loaded into the hopper of
the conveyor and conveyed it to the grading
unit. Each RPM was evaluated at three
replications using 20 kg of potato tubers. The
conveyor was operated at a speed equivalent to
a feed rate 20 kg/min of potato tubers.
tubers in each sub-sample was noted. This is to
compare the graded product if it has the same
number of tubers in each size as that with the
sample prior to grading.

5. The time of grading each sub-sample was

recorded using a stop watch beginning from the
loading of the tubers to the conveyor until the last
tubers in the grading unit had fallen to the
catchment tray. The time of operation were used
to calculate the capacity and power consumption
of the device

6. Graded potato tubers were individually

inspected and the correctly graded tubers for each
size-small, medium and large were recorded.

7. Finally damaged tubers caused by the machine

were also noted. The damaged were based on the
severe scratches on the skin of the potato tubers.

Figure 2. Procedure of evaluation

ASABE 2017 Annual International Meeting Page 4

Crop parameters
The minor diameter of the potato tubers had served as basis for grading. For small tubers, 3.0 cm to 3.9 cm, 4.0 cm to
7.4 cm for medium tubers while 7.4 cm and above for large tubers.
Statistical tool
Data were analyzed using Completely Randomized Design with RPM as treatments. Differences among means were
analyzed using Least Significant Difference at 5% confidence interval. There were three replications employed in the study.
Equations
The grading efficiency of the device was calculated by taking the product of the efficiencies of small, medium and large
region as show in Equation 1 which values were calculated using Equations 2, 3 and 4. The GE stands for grading efficiency
in percent while effs, effm, and effl are the efficiencies of the small, medium, and large region, respectively, all in decimal.
Capacity of the device in kg/hr was also calculated using Equation 5 where t is time in minute and 1.20 is a conversion
factor.

GE = effs x effm x effl x 100 (1)

Number of correctly graded small tubers

effs = (2)
Number of small tubers in the sample

Number of correctly graded medium tubers

effm = (3)
Number of medium tubers in the sample

Number of correctly graded large tubers

effl = (4)
Number of large tubers in the sample

1.20
Capacity = (5)
t
Damage index
The damage induced by the grader on the potato tubers are those with scratch and cracks inspected visually. A scratch of
5% of the total surface area of the tuber was considered damage. It was calculated by taking the ratio of the number of
damaged tubers to the number of samples.
Power consumption
Power consumption was simply the function of the time of operation and the size of the motor. It was calculated by taking
the product of the operating time with the rated size of the prime mover.

Results and Discussions

Description
The newly developed potato grader shown in Figure 3 features the use of a cylindrical spiral as grading mechanism that
was made out of round bar. The spiral formation of these round bars was installed with increasing gaps beginning from the
inlet portion of the unit. The cylindrical spiral has a constant diameter of 42.0 cm and was held by three lateral round bars
through metal tubes. The spiral assembly has three regions: the region for small, medium and large-sized tubers. The first
region has gaps that allow only small tubers to pass. The gap of the spiral in this region ranges from 3.0 cm to 3.9 cm. The
second region has gaps of 4.0 cm up to 7.4 cm allowing medium sized tubers to pass. The third is the region for the large
tubers with gaps greater than 7.5 cm. Beneath the spiral assembly is a catchment tray made of a flat GI sheet covered with
Styrofoam. It was also divided into three regions to accommodate the small, medium and large tubers. A pulley was attached
at both ends of the cylindrical spiral which serve as circumferential rotational path instead of an axle at the center. One of
these pulleys also served as power transmission through v-belt that is connected to a changeable pulley. Another device
coupled with the grader is a conveyor power by a separate motor. Its primary function was to convey the potato tubers into
the hopper of the grader at a regulated rate. The speed of the conveyor can be changed by replacing the size of its driver
pulley. This is to change the feed rate. However, in this study a fixed feed rate was used. The frame assembly of the conveyor
was also provided with adjustable mechanism for the inclination of the belt and the height to match conveying requirement
of the potato tubers. The belt was inclined at 10 degrees as determined in the preliminary testing. Greater inclination makes
the potato tuber to slide back.

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 Flat belt conveyor Cylindrical spiral Drive pulley &
Power switch
Power transmission

Hopper

Figure 3. Fabricated potato grader and conveyor

Performance
Shown in Table 1 is the performance of the potato grader during the evaluation as indicated by the average values in
Grading Efficiency, Capacity, Damaged Tubers and Power Consumption.

Table 1. Performance of the Potato Grader at Different Speed of the Cylindrical Spiral using a fixed feed rate of 20 kg/min.

Feed Rate Speed of the Performance Parameter

(kg/hr) cylindrical spiral Grading Efficiency Capacity Damaged Tubers Power Consumption
(RPM) (%) (kg/hr) (%) (kW-hr)
10 86.06b 406.18a 2.0b 24.5b
20 15 92.56c 441.50b 1.83a 22.6a
20 69.43a 446.35b 1.74a 22.3a
Means having different superscript along row differ significantly

The highest efficiency of 92.56% was obtained when the grader was operated at a speed of 15 RPM. Compared to 20
RPM, the efficiency was lowest. As observed during the evaluation, the high RPM (20 RPM) of the grading unit could have
imparted high impact to the potato tubers as indicated by their bombard motion inside the cylindrical spiral. Some tubers in
this situation jump over several gaps without passing the primary gaps. For instance, some medium tubers jump to the region
for large-sized tubers without passing the region for the medium-sized tubers which affected the efficiency. In principle, the
tubers should gradually pass he gaps of the spiral. On the other hand, lowest RPM of the grading mechanism was observed
to give lower efficiencies. This can be explained by the layer formation of the tubers in the cylindrical spiral. In this situation,
some tubers are carried into the next region, while on top of other tubers, without interacting with the gaps of the spiral. The
multi-layering of the tubers was a result of the slow speed of the cylindrical spiral that tubers were not processed at a rate
faster than the feed rate. Unlike at higher RPM, no multi-layering occurred.
The capacity of the grader using speed of 15 and 20 RPM was significantly higher than at 10 RPM. High speed (20 RPM)
induces more velocity to the tubers causing them to travel along the unit at a faster rate. However, there velocity resulted to
insufficient resident time for the tubers to interact with the spiral. This explains why efficiency was lower at very high RPM.
Conversely, lowest speed (10 RPM) resulted to slow material flow through the grading unit resulting to longer time of
operation that caused lower capacity. However, the very slow movement of tubers along the gaps of the spiral caused
accumulation of tubers which formed multi-layering. This affected the efficiency and capacity of the grader as well. As
illustrated in Figure 4, the intersection of the graph could be the optimum value for both the efficiency and capacity. But
since capacity at 15 and 20 RPM are statistically insignificant, though 446.35 kg/hr is numerically greater than 441.5 kg/hr,
the efficiency at 20 RPM is which is 69.43% is relatively lower than that of the 15 RPM, then it is safe to conclude 15 RPM
as optimum at this point.

ASABE 2017 Annual International Meeting Page 6

 95 450
Efficiency curve 92.56 446.35
90 445
441.5
85 86.06 440

Grading Efficiency, %
435
80

Capacity , kg/hr
430
75
425
70 69.43
Capacity curve 420
65
415
60 410
55 406.18 405

50 400
0 5 10 15 20 25
Speed of the Cylindrical Spiral, RPM

Figure 4. Efficiency and capacity curve of the potato grader.

Damaged tubers were minimal at 15 and 20 RPM while highest damaged of 2.0% was observed at 10 RPM. Slow speed
(10 RPM) caused accumulation of tubers in the grading unit that induced greater impacts as a result of their weight. The
combined effect of the speed of the grading unit and the heavy weight of tubers caused more impact to the tubers especially
those that were at the first layer.
Power consumption was lowest at 20 RPM. The grader operated at a faster rate causing shorter time of operation. Lowest
speed (10 RPM) resulted to more power consumption. Tubers stayed at a longer time in the unit causing more power inputs.

Economics of the Grader

The total cost of the potato grader was P31, 000.00 with an estimated life span of 5 years. It had an annual fixed cost of
P8,215.00 and variable operating cost of P72.25/hr. Assumptions include: interest, 10%; tax, insurance and shelter, 3%;
repair and maintenance, 15%; operation per day, 8 hr; annual use, 600 hr and custom rate, P0.5/kg. The grader had a break-
even point of 23 ton/year.

Conclusion and Recommendation

Conclusion
A mechanical potato grader, powered by electric motor, was designed and fabricated. The device operates with the
principle of rotating spiral as grading unit. The grading unit was formed by shaping round bars in spiral pattern with
increasing spaces thereby promoting size differentiation of potato tubers being conveyed along the length, inside the spirals.
The grader was devised with mechanism to vary the speed of the rotating spiral
The performance of the fabricated grader was evaluated on potato tubers. Grading efficiency, capacity, damaged tubers
and power consumption were observed. The optimum operating RPM for the machine was established at a speed of 15
RPM with fixed feed rate of 20 kg/min giving a system efficiency of 92.5%, capacity of 441.5 kg/hr, less damaged tubers
of 1.83%, and a low power consumption of 22.3 W-hr.

Recommendation
The device is recommended on spherical tubers. For the improvement of the efficiency, it is recommended to use some
sort of geometric figure for the spiral. Consider testing the device at several inclinations. The device is also recommended
to be tested on some spherical products other than potato tubers like orange.

References
Adamson, S. A. (1992). Potato Grader. U.S. Patent No. 1,409,353.

Clark, C. H. (1926). U.S. Patent. Potato Grader. Patent No. 1,589,367.

ASABE 2017 Annual International Meeting Page 7

Fahardi, R., & Ghanbarian, D. (2014). Potato mass modeling with dimensional attributes using regression and artificial neural networks.
Trakia Journal of Sciences., 1(47-54). Retrieved from http://tru.uni-sz.bg/tsj/N%201,%20Vol.12,%202014/R.Farhadi.pdf

Fahardi, R., Sakenian, N., & Azizi, P. (2012). Design and construction of rotary potato grader. (Part I). Bulgarian Journal of Agricultural
Sciences, 18(2), 304-314. Retrieved from http://www.agrojournal.org/18/02-21-12.pdf

Farhadi, R., Sakenian, N., & Azizi, P. (2012). Design and construction of rotary potato grader. (Part II). Bulgarian Journal of Agricultural
Sciences, 18(6), 987-990. Retrieved from www.agrojournal.org/18/06-23-12.pdf

MaCrae, D. C., Glasbey, C. A., Helrose, H., & J. Fleming. (1986). Size grading methods and their relationship to the dimensions, mass and
volume characteristics of potato cultivars. Potato Research, 29, 477-486. Retrieved from http://www.etpub.com/down/Journal-
template.doc

Maghirang, R. G., Rodulfo, G. S., & Kebasen. B. (2009). Potato Poroduction Guide. Info. Bull. No. 272/2009. College of Agriculture,
University of the Philippines, Los Baños (UPLB) College 4031, Laguna.

Paulson, J. E. (1931). Potato Grader. U.S. Patent No. 1,828,066.

Philippine National Standards. (2007). PNS/BAFPS No. 53:2007. Fresh Vegetables-Potatoes.

Tabatabaeefar, A. (2002). Size and shape of potato tubers. Int. Agrophysics, 16, 301–305. Retrieved from http://www.old.international-
agrophysics.org/artykuly/international_agrophysics/IntAgr_2002_16_4_301.pdf

Tabor, M. B. U.S. Potato Grader. Patent No.1, 458, 085.

United States Standards for Grades of Potatoes for Processing. (1983). Retrieved from http://www.ams.usda.gov/AMSv1.0/getfile

Valentin, M. T., Villota, E. M., Malamug, V. U. & Agulto, I .C. 2015. Design, Fabrication and Performance Operation of a Potato Grader for
Village-Level Operations Prototype II. International Research Journal on Innovations in Engineering, Science and Technology, 1(2), 42-
49.

Valentin, M. T., & Villota, E. M. 2016. Evaluation of a Helix-Type Potato Grader. The CLSU International Journal of Science & Technology,
1(1). Retrieved from http://clsu-iao.edu.ph/downloads/v1i1/v1i1Valentin.pdf

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