Design and Fabrication of a Semi-Automated Garri Frying Machine: Enhancing Efficiency, Safety, and Quality in Cassava Processing

This study presents the design, fabrication, and performance evaluation of a semi-automated garri frying machine engineered to address critical inefficiencies in traditional cassava processing. Leveraging computational modeling and advanced thermal analysis, the machine integrates an optimized dual-axis stirring mechanism, an aluminium alloy 5052 frying chamber, and precision temperature control to achieve uniform heat distribution (thermal variation: 4.5°C) and superior product consistency. Experimental results demonstrate a 97.8% operational efficiency—surpassing existing models by 4.5%—with a 28-minute batch processing time, reducing energy consumption by 22% compared to conventional methods. Key innovations include a brushless LPG burner (581 g/h consumption), a gear-driven stirrer (289.78 rpm), and IoT-compatible safety interlocks, ensuring compliance with ISO 22000 and IEC 60204-1 standards. Fabricated at a cost-effective $120 (₦186,200), the machine enhances scalability for smallholder farmers while mitigating occupational hazards (e.g., burns, smoke inhalation). Statistical optimization via response surface methodology (RSM) validated the interplay of stirrer speed (200–350 rpm), temperature (140–180°C), and batch size (15–27.16 kg) on output quality, achieving 98.5% stirring homogeneity. The study advances sustainable agro-processing by proposing renewable energy integration (solar/biomass) for future iterations, aligning with SDGs 2 (Zero Hunger) and 9 (Industry Innovation). These findings underscore the machine’s potential to revolutionize garri production, bridging the gap between artisanal practices and industrial-scale automation in sub-Saharan Africa.