Design Development and Performance Evaluation of a Sugarcane Leaf Trash Shredder

Abstract

Sugarcane leaf trash management is a critical challenge in mechanized farming, often leading to open burning and environmental pollution. This study aimed to develop a prototype sugarcane shredder designed to improve shredding efficiency, evaluated by the reduction in residue size and field-tested for engineering economic viability. The machine utilizes a dual-shaft mechanism: shaft A employs C-shape 24 blades for initial cutting, while shaft B features 12 sets of Y-shape flail blades operating at high linear speed of 16.7 m/s (800 rpm) for fine shredding. The performance was evaluated under varying blade linear speeds for shaft A (7.4, 9.6, and 11.7 m/s) and forward speeds (0.5 and 1.2 km/h). Statistical analysis indicated that the optimal condition was a blade linear speed of 11.7 m/s combined with a forward speed of 1.2 km/h. This configuration significantly reduced residue size, with the average width decreasing by 78.6% (to 0.7 cm) and the average length by 77.7% (to 28 cm). Economic analysis revealed a field capacity of 1.1 rai/h, with a break-even point of approximately 114.6 rai/year. This developed sugarcane shredder offers an efficient mechanical solution to support zero burn policies, enhancing biomass incorporation into the soil while remaining commercially viable for farmers.