Study of The Performance of The Most Widely Used Shredders For Crops Residues in Egypt

The 15
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. Annual Conference of the Misr Society of Ag. Eng., 12-13 March, 2008
339
STUDY OF THE PERFORMANCE OF THE MOST
WIDELY USED SHREDDERS FOR CROPS RESIDUES IN
EGYPT
Mohamed Sayed Omran*
ABSTRACT
Shredding crop residues is considered the main step for benefiting from
crop residues either for feeding livestock, composting or briquetteing
production. This study aimed to evaluate the most widely used
shreddering machines (local shredder manufactured in Kader-Militry
factory, local shredder manufactured in MabroukInternational company
and Vermeer made in USA) while working on the most important crops
residues (rice straw, cotton stalks and maize stalks). The three studied
machines were operated by Massy Ferguson tractor, 60HP. under cutting
rotor speeds ranging from 1000 to 2000 rpm. Comparison between the
three studied machines was based on productivity, consumed energy,
cutting lengths and total costs. The results showed that local shredder
(Mabrouk) has the highest productivity for the three crops residues at
1800 rpm ( 0.98, 1.02 and 0.91 ton/h) for rice straw, cotton stalks and
maize stalks respectively. The Vermeer shredder had the lowest consumed
energy for cotton and maize stalks at 1800 rpm 26.60, 26.72 kW.h/ton
respectively. However the locals shredder (Mabrouk) had the lowest
operation cost and had the highest cutting length percentages for rice
straw, cotton stalks and maize stalks with local shredder (Kader) and the
Vermeer. Consequently, it can be recommended that the local shredder
(Mabrok) was the most appropriate shredder to work with rice, cotton
and maize residues.
INTRODUCTION
he world is facing continuous increase in food requirements
without corresponding increase in food productivity. It is well
known that the total loss of agricultural products may reach 70%
of what is actually produced.
* Assist. Prof., Ag. Eng. Dept., Fac. of Ag., Cairo University.
T
Agricultural mechanization and engineering
Between existing and prospected: 339-357
FARM MACHINERY AND POWER
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Shukry (2002) and El Daily (1993) mentioned that crop residues are
defined as the unused remainders of agricultural products during different
production stages. Abd El Wahab (1999) mentioned that disposal of farm
residues is one of the main problems facing Egyptian farmers (which
estimates about 38.28 million ton/year G.M.A.S 2006). Many farmers get
rid of farm residues either by burning which pollutes the environment or
by unsafe storage which hosts insects and rats. Also, this may ignite and is
considered a source of fire risks. In some trials 30% of farm residues is
utilized in inefficient ways either in feeding livestock or as inefficient
source of energy in rural areas. El- Dally (1993) and El- Gharabilly
(1983) classified farm residues according to its moisture content, due to
ability to feed livestock and according to its source. They considered that
wheat straw, legumes, rice straw, residues of cotton, maize, peanut and oil
crops are among economic farm residues. In addition, residues of pruning,
thinning and harvesting in fruit orchards and residues of some fruit crops
such as banana, palm trees and residues of vegetables crops may be used
efficiently. El-Zahaby (1996) mentioned that farm residues may be
treated and transferred either to be used as organic fertilizer or used in
feeding livestock. In this respect, Mohamed et al. (2001) developed and
evaluated a rice straw chopper. The results indicated that the productivity
of the developed machines was 0.95 ton/ h at 2000 rpm rotor speed and
the cutting lengths of (1-9 cm) reached 95.25% from the total amount of
cutting residue. El-Iraqi and El Khawaga (2003) designed a cutting
machine for rice straw and maize stalks. It was operated at five cutting
speeds ranged (6.48 10.09 m/s), three clearness between knives (1.5, 3
and 4.5 mm) and three feeding rates (0.257, 0.514 and 0.771 ton/h). Their
results indicated that the maximum percentages in cutting length of less
than 5 cm of 87.80 and 92% were obtained for rice straw and corn stalks
residues respectively, at cutting speed of 10.09 m/s, feeding rate of
0.771 ton/h and knife clearance of 1.5 mm. The energy consumed was
found to be 6.36 and 6.17 kW.h /ton at the same previous parameters for
rice straw and corn stalks, respectively. The maximum operating costs
were 5.10 LE/h (6.61 LE/ton) for cutting rice straw residues.
Imbabi (2003) tested the performance of a cutting machine for crop
residues. The results showed that the highest values of both cut length and
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machine productivity were obtained at feeding drum speed 300 rpm and
cutting drum speed 1500 rpm. The lowest costs were 12.97 LE/ton with
feeding rate 1.873 ton/h. Kamel et al. (2003) evaluated forage chopper
with 12 knives for chopping rice straw. The results can be summarized as
follows:
1- Increasing forward speed increased the distribution percentage of
short pieces (from s 0.5 to 2 cm ) and decreased the distribution
percentage of long pieces (from 2 to > 5 cm).
2- The maximum distribution percentage of short pieces (56.53%) was
obtained at 1.22 m/s forward speed.
3- The maximum energy requirement (27.4 kW.h/fed.) and the maximum
values of chopping cost were 22.07 LE/ fed. (12.46 LE/ton) were obtained
for chopping rice straw under forward speed of 0.53 m/s.
Lotfy (2003) developed and evaluated a machine powered by electric
motor for chopping agricultural residues. He found that:
- For feeding animals: the machine output was (1822, 2128 and 967 kg/h),
average cut length was (2.8, 2.5 and 2.6 cm), energy requirements were
(12.14, 11.45 and 11.03 kW.h/ton) and operating costs were (8.13, 6.80
and 7.02 LE/ton) for cutting rice straw, cotton stalk and corn stalks
respectively under 43.35 m/s cutting speed and 2m/s feeding speed.
- For composting : the machine output was (2037, 2359 and 2184 kg/h)
cut length was (4.8, 4.2 and 4.9 cm), energy requirement was
(11.74, 10.95 and 10.52 kW.h/ton) and operating cost was (6.80, 5.74 and
6.07 LE/ton) for cutting the previously mentioned crop residues
respectively under the same conditions and 2.5 m/s feeding speed.
Guzel and Zeren( 1998) found that, for cotton stalks, the consumed
energy for cutting operation ranged form 24 to 28.9 N.m. Also, the total
required power was 4.2 HP for rotary cutter. Namikawa (1997)
recommended that the cutting speed must range between 15 to 30 m/sec
for the suitable hay shredding. He also mentioned that the speeds over
than the optimum speed range caused a rapid increasing of specific energy
consumption. Ahmed (1991) found that the energy requirements for maize
stalks chopping were 50.9, 28.8, 8.45 and 10.43 kW.h /ton. Yore et al.
(2005) found that the number of stems for rice straw (crop density) was a
significant factor in cutting force and consumed energy. Haider (2002)
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recommended that chopping farm residues in pieces less than 3 cm
improves its efficiency when used in feeding livestock. Luis et al. (1993)
mentioned that the optimum particle size of the compost should be within
the range of 76.2-127 mm, the minimum particle size should not be less
than 50.8 mm, whereas the maximum size can be as much as 152.4 mm.
Church (1991) mentioned that the range of cutting crop residues 1-3 cm
is suitable for sheep and goats, while the range of 3-5 cm is suitable for
large animals. Ludwig (1994) found that 5-8 crop residues with 10-20%
powdery component gave the best results for briquette. El Berry et al.
(1999) stated that using different chopped roughage can solve serious
problems of animal feeding shortage in Egypt . But the capacity of the
available choppers in Egypt is still low, not covering the farmers need and
have high shopping cost.
Therefore the present study aimed to compare between the three most
widely used shredders in the Egyptian farms to recommend the
appropriate machine for the various aspects of crop residues shred based
on some technical and financial parameters.
MATERIAL AND METHODS
This study was carried out during the period between 2003 2005, and
was conducted in the experimental station farm, Faculty of Agriculture,
Cairo- University.
According to the field study which was carried out through questionnaires
by Taieb(2005) to determine relative importance of different farm
residues, production location, number of producers and the common
shredder machines of high productivity and simple design. The field study
showed that cotton, maize and rice crops residues had the highest relative
weight of residues and were most important and beneficial compared to
other field crop residues. Also the most widely used shredder were local
shredder manufactured in Kader- Military factory (LK shredder), local
shredder manufactured in Mabrouk international company (LM shredder)
and Vermeer shredder which is made in USA. Table (1) shows the
specifications of the three studied shredders. The three machines under
comparison were operated using Massy Ferguson tractor 60 HP at
1350 rpm (model MF265). The selected machines were compared based
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on productivity, energy consumed, cutting lengths and total costs for the
three selected crop residues, at rotor cutting speeds 1000, 1200, 1400,
1600, 1800 and 2000 rpm according to [ODoghherty and Gale (1986)
and Hakmet and Rayco (2006)]
Table ( 1) : Specifications of the studied shredding machines
Measurements and Calculations:
1- Length, diameter and moisture content of the three studied crops
residues were measured. Length in cm was measured using metric
tape, diameter was measured using Verner caliper accuracy 0.1 mm
and moisture content was measured using decimal Theta meter (type
HH1 AT Delta- T Devices Cambridge- England).
2- Twenty kg samples of different residues were measured using digital
sensitive balance (0.1 gm. accuracy).
Machine type

Subsystem
Local
shredder
( Kader )
Local
shredder
(Mabrouk )
USA
Shredder
(Vermeer)
Cutting device
-No. of flanges
-Flange thickness, cm
-Flange diameter, cm
- No. of Knives/flange
- Knives dimension
- Length, cm
- width ,cm
- thickness, cm
- cutting edge, degree

10
1.2
18
6

35
7
0.9
30

17
1.8
18
4

18
6
0.8
30

1
2.5
22
2

62
8
1.6
30
Overall dimensions, m
- Length
- width
- Height with duct

2.29
1.27
1.97

2.54
1.45
2.52

2.67
1.22
2.26
Ratio between feeding&
cutting drum speed
1 : 10 1 : 6 1 : 4
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3- Different sieves of 1, 3, 5, 7 cm holes were used several times to
separate shredding crop residues into four categories (referred to Luis
et al. 1993; Church 1991) according to their length as (s1cm, > 1-3
cm, > 3-7cm, > 7cm).
4- The rotor drum speed was determined using hand tachometer
(accuracy 1rpm).
5- The net consumed time (t) for each treatment was recorded by using
digital stop watch.
6- Statistical analysis was carried out for the obtained data using.
MSTAT program to compare between the performances of the studied
shedding machines using multiple complete block design (LSD of P
0.05) with three factors (shredders, cutting rotor speeds and crop
residues).
7- Machine productivity (Pr)
The machine productivity was calculated from equation (1).

t
W
= Pr (1)
where
Pr
= Machine productivity, ton/h;
W = Weight at crop residues, ton;
t = machine operating time, h.
8- The power requirement (BP) was calculated using equation 2.
(according to Omran, 1989).
Fc BP = 163 . 3 (2)
where
BP
= Power requirement, kW;
Fc = Fuel consumption , L/h.
9- Specific consumed energy
The specific consumed energy was calculated from equation (3).
Specific consumed energy = 3.16 Fc / Pr .(3) , kW.h/ ton

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345
10- Operating cost (Tc)
The total costs (Tc) were estimated from equation 3. (Oida 1997)
according to 2008 price levels.
) 3 .....(
) . . ( ) . . ( ) . . (
.
) 02 . 0 (
100
.
2
n
n L N n C Oc n Fc fP
Y
r P
P
i S P
Y
s P
TC

)
+ + +
|
.
|
\
|
+
(
+
+
+
=

where:
Tc = Total cost, LE/h;
P = Purchase price, LE;
= 24000 LE for Kader shredder; 26000LE for Mabrouk
shredder; 91000 LE for Vermeer and 150000 LE for
Tractor
S = Salvage value, LE;
= 0.65(0.885)
Y
* P for machine
= 0.68(0.920)
Y
* P for tractor
i = Interest rate, %; = 9%
r = Coefficient of repair and maintenance= 0.80, decimal;
Y = Anticipated length of time owned, Year;
= 5 years for the machine, and 10 years for the tractor.

fp = Fuel price, LE/lit; = 0.75
Fc = Fuel consumption, lit/h;
Oc = Oil consumption = 0.00059 * Pt + 0.02169 ,Lit/h;
C = Oil price, LE/lit; = 8
N = Number of labors = 2
L = Labor wage, LE/h; = 5
n = Yearly working hours, h/year.
= 500 for the machine and 1000 for tractor.
RESULTS AND DISCUSSION
1- Physical characteristics of rice straw, cotton stalks and maize stalks
were measured and are presented in table (1).
2- Productivity:
Data of productivity as affected by rotor cutting speed of the three studied
shredding machines (Fig 1) showed that LM shredder had the highest
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significant productivity for rice, cotton and maize residues. In addition it
reached cutting rotor speed, till 2000 rpm whereas the highest cutting
rotor speed of the other shredding machines did not exceed 1800 rpm.
The LM shredder had the highest significant productivity for the three
crop residues at 2000 rpm, followed by 1800 rpm, which was
significantly higher than that of 1600 rpm , this had similar productivity
of LK shredder at 1800 rpm.
Table (1): Physical characteristics of the tested form residues
Farm residues
Characteristics

Rice straw

Cotton stalks

Maize stalks
Value
(a)
c.v.
(b)
Value
(a)
c.v.
(b)
Value
(a)
c.v.
(b)

Stem length, cm 75.1 8.6 115.6 14.8 195.2 18.3
Stem diameter, mm 3.6 2.6 10.2 4.5 20.3 8.1
Moisture content % 14.2 9.6 24.1 5.2 11.6 7.6
(a) average of 50 values (straw or stalks)
(b) c.v. coefficient of variation (standard deviation divided by the mean value)
The lowest significant productivity was observed as a result of the
Vermeer shredder for the three crop residues. The lowest significant
productivity was observed for the Vermeer shredder at 1000 rpm for rice
straw, meanwhile, productivity of the LK shredder and the Vermeer
shredder was limited to only 1800 rpm as high vibration occurred beyond
this speed.
Therefore the LM shredder is considered of highest productivity
compared with the other two shredding machines. The productivity with
cotton stalks was highly significant with all rotor cutting speeds compared
to rice straw and maize stalks for the three studied shredder machines this
may be due to the nature of tissues as the outer surface of cotton and
maize stalks are rigid and of rice straw is hollow.
Fig. (2) showed the effect of cutting rotor speed on consumed energy of
the shredding machines. The highest consumed energy (kW.h/ ton) was
observed with the Vermeer shredder for rice straw. Meanwhile, the LM
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shredder had the lowest significant consumed energy specially at 2000
rpm as it consumed (20.19 kW. h/ton) for cutting rice straw.

Fig. (1): The effect of cutting rotating speed on the productivity of the
studied shredders.
The LM shredder had the highest significant consumed energy for cotton
and maize stalks compared with the other machines at speeds from 1400
to 1800 rpm. At low cutting speeds the LK shredder showed the lowest
significant consumed energy for cotton stalks (22.83 kW.h/ ton at 1000
rpm) and (22.63, 23.16 kW.h/ ton at 1200 rpm cutting rotor speed) for
LSD =
LSD =
LSD =
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rice straw and maize stalks respectively. On the other hand at high cutting
rotor speeds the Vermeer shredder showed the lowest significant
consumed energy compared to the local shredders ( LK and LM ) at
speeds 1600 and 1800 rpm for cotton and maize stalks . Generally , the
LK shredder had the lowest consumed energy for the three crop residues
compared to the two shredders except for rice straw at high cutting rotor
speeds.

Fig. (2): The effect of cutting rotating speed on the consumed energy
of the shredding machines.
Table (3) represent the percentage of crop residues lengths using different
shredders. The category (>37cm) showed the higher cutting percentages
for the three crop residues using LM shredder and for cotton and maize
stalks using LK shredder. Concerning the Vermeer shredder category of
(>0.5 3 cm) had significant highest percentages compared with the other
cutting length categories for cotton and maize stalks. The category > 7 cm
for rice straw had the highest cutting percentage using LK and Vermeer
LSD = 1.55
LSD = 1.55
LSD = 1.55
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shredder; this might be attributed to sticking of rice straw around the
cutting rotating shaft.
Total percentage of cutting length less than 7 cm was higher for the LM
shredder with rice straw, Vermeer shredder with cotton stalks and LK
shredder with maize stalks.
Thus the highest significant total percentage of cutting lengths specially
for rice straw was obtained from LM shredder. Meanwhile, there was no
significant difference between total percentage of cutting lengths of LK
shredder and Vermeer shredder specially for rice straw and maize stalks.
However the LM shredder showed high cutting percentage up to 2000
rpm. At higher cutting speeds the percentage of small cutting length
increases as a result of higher number of affecting cutting knives.

Fig. (4) shows that LK shredder had the lowest significantly operating
cost, compared with the other shredders. Shredding cotton stalks needed
the lowest operating costs for the three shredding machines compared
with rice straw and maize stalks. Meanwhile, the lowest operating costs
were achieved by LM shredder at cutting rotor speed 2000 rpm for the
three crop residues. For comparison cutting rotor speed of 1800 rpm had
the lowest significant operation costs for the three studied shredding
machines for the three crop residues. Concerning rice straw the lowest
significant operation costs was observed as a result of the LK shredder at
1800 rpm followed by the LM shredder at 2000 rpm. As the lowest
significant operation cost was attained by the LM for rice straw ,cotton
stalks and maize stalks at 2000 rpm as it averaged 55.17, 57.17 and 63.18
LE/ton, respectively
For cotton residues the LK shredder at 1800 rpm had the lowest
significant operating cost followed by the Vermeer shredder at the same
cutting rotor speed. For maize residues, the LM shredder at 2000 rpm had
the lowest significant operation cost followed by the Vermeer shredder at
the same cutting rotors speed.
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Table ( 3 ): Percentage of crop residues lengths using different shredding machines.
1- Local shredder ( Kader )
Cutting Rotor Rice straw length(cm),% Cotton stalks length(cm),% Maize stalks length(cm),%
Speed (rpm) 0.5 >0.5-3 >3-7 >7 0.5 >0.5-3 >3-7 >7 0.5 >0.5-3 >3-7 >7
1000 0 0.82 19.62 79.56 0.07 19.82 63.46 16.65 2.54 18.34 66.42 12.7
1200 0 1.12 25.13 73.75 6.32 23.46 56.32 13.9 8.62 23.65 55.62 12.11
1400 0 2.32 26.62 71.06 10.64 26.54 50.84 11.98 9.78 30.65 48.32 11.25
1600 1.52 3.58 38.62 56.28 13.62 30.54 50.3 5.54 16.32 25.94 50.98 6.76
1800 4.67 14.92 33.32 47.09 15.24 22.64 60.83 1.29 16.97 20.98 55.95 6.1
2-Local shredder (Mabrouk )

Cutting Rotor Rice straw length(cm),% Cotton stalks length(cm),% Maize stalks length(cm),%
Speed (rpm) 0.5 >0.5-3 >3-7 >7 0.5 >0.5-3 >3-7 >7 0.5 >0.5-3 >3-7 >7
1000 5.41 31.76 45.36 17.47 10.61 20.91 35.21 33.27 11.32 20.13 36.19 32.36
1200 5.95 32.49 47.32 14.24 12.57 22.43 37.07 27.93 15.16 21.27 39.62 23.95
1400 6.25 33.43 42.62 17.70 16.32 25.12 38.24 20.32 18.24 22.56 33.66 25.54
1600 8.21 49.45 34.65 7.69 15.65 27.32 40.32 16.71 19.36 24.69 39.17 16.78
1800 10.51 48.15 35.60 5.74 16.3 31.32 40.64 11.74 19.18 30.98 32.39 17.45
2000 12.61 47.65 36.64 3.10 23.64 35.36 36.53 4.47 20.14 28.62 39.52 11.72

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Cont. of Table ( 3 ): Percentage of crop residues lengths using different shredding machines.

3- Vermeer shredder

Cutting
Rotor
Rice straw length(cm),% Cotton stalks length(cm),% Maize stalks length(cm),%
Speed (rpm) 0.5 >0.5-3 >3-7 >7 0.5 >0.5-3 >3-7 >7 0.5 >0.5-3 >3-7 >7
1000 2.12 11.21 35.21 51.46 16.1 44.81 32.15 6.94 19.2 31.21 29.81 19.78
1200 3.82 15.32 38.34 42.52 16.4 45.04 38.14 0.42 20.85 30.53 29.43 19.19
1400 6.41 17.62 38.21 37.76 18.5 45.35 35.43 0.72 22.8 35.22 27.7 14.28
1600 7.20 25.81 41.11 25.88 21.4 46.22 30.53 1.85 24.76 34.95 25.24 15.05
1800 7.10 22.43 43.62 26.85 29.88 45.86 22.64 1.62 31.63 31.87 19.74 16.76

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352
Rice straw
0
50
100
150
200
250
300
350
1000 1200 1400 1600 1800 2000
Cutting rotor speed,rpm
O
p
e
r
a
t
i
n
g

c
o
s
t
s
,

L
E
/
t
o
n
Kader Mabrok Vermeer

Cotton stalks
0
20
40
60
80
100
120
140
160
180
200
1000 1200 1400 1600 1800 2000
O
p
e
r
a
t
i
n
g

c
o
s
t
s
,

L
E
/
t
o
n

Maize stalks
0
50
100
150
200
250
1000 1200 1400 1600 1800 2000
O
p
e
r
a
t
i
n
g

c
o
s
t
s
,

L
E
/
t
o
n

Fig. (4): Specific operating costs of cutting farm residues using widely
Shredding machines, LE / ton
LSD= 2.57
LSD= 2.57
LSD= 2.57
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353
Vermeer shredder had the highest operating costs as it had highest initial
cost with price 91000 LE. compared to 24000 LE. and 26000 LE. for LK
shredder and LM shredder, respectively (according to 2008 prices)
Although the two local shredders are of close price LM shredder had
lower specific operating costs as it achieved higher productivity
CONCLUSION
From this investigation the following conclusions can be summarized:
1- LM shredder reached cutting rotor speed up to 2000 rpm and had the
highest productivity for the three crop residues at 2000 and 1800 rpm.
2- The lowest significant productivity was found by Vermeer shredder
for the three tested crop residues.
3- The lowest energy was consumed by LM shredder for cutting rice
straw at 2000 rpm , while the higher consumed energy was found by
Vermeer shredder for cutting rice straw specially at 1200 and 1400
rpm.
4- Total percentage of cutting lengths less than 7 cm was the highest for
LM shredder with rice straw, Vermeer shredder with cotton stalks and
LK shredder with maize stalks.
5- LM shredder had the lowest significant operating cost compared to
the other shredders.
Consequently, this study recommends that the LM shredder is considered
the most suitable shredder for cutting rice straw , cotton stalks and maize
stalks at 2000 rpm rotor cutting speed.
REFERENCES
Ahmed, A.B. 1991. Modifying a chopping machine of maize stalks.
M.Sc. Thesis. Fac. of Ag. , Mansora University.
Church, D. C. 1991. Livestock Feeds and Feeding. 3
ed
Ed. Prentice Hall,
Englewood Cliffs, New Jersey 07632.
El-Iraqi, M. and S. El-Khawaga . 2003. Design and test performance of
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85 101.

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Guzel,E. and Y. Zeren 1998. The theory of free cutting and its
application on cotton stalks. AMA., VOL. 29.P:221-226.
Hakmet and Rayco . 2006. Commercial Crop Shredders " Loft ness Flail
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Imbabi, A. T. 2003. Improving a crop- residues cutting machine for
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Leatham, M. 1995. Crop residues as a strategic resource in mixed
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Lotfy, A. 2003. Development and performance evaluation of a machine
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Luis, F.C.; G. M. Savage; L. L. Eggerth and G. G. Clarence 1993.
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Mohamed, T. H.; S. M. Younis; M. I. Ghohimy and M. A. Biomy
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manufacturing. Agri. Equipment and Machinery. 9
th
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Namikawa, N. 1997. Hay and Forage Harvesting Machinery. Kyto Univ.
Japan. JICA Pub.
ODoghherty,M.J. and G.E.Gale 1986. Laboratory studies of the cutting
of grass stems. the British society for research in Ag. Eng.
Oida, A. 1997. Using personal computer for Agricultural machinery
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Machinery and Equipment, 5
th
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Omran, M. S. 1989. Comparative Study for Mechanical Methods of
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Yore, M. W., B. M. Jenkins and M. D. Summers. 2005. Cutting
Properties of Rice Straw. Paper No: 026154 ASAE, Annual Inter.
Meeting / CIGR XV
th
World Congress ,Hyatt Regency Chicago,
Chicago, Illinois, USA
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Study of The Performance of The Most Widely Used Shredders For Crops Residues in Egypt

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Study of The Performance of The Most Widely Used Shredders For Crops Residues in Egypt

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