Advancements in Mini Corn Shelling Machine Design and Fabrication: A Sustainable Solution for Small-Scale Farmers

Abstract

This research article explains in detail the recent advancements in the design, fabrication, and performance test of mini corn shelling machines. Targeting the age-old issues of small farmers in corn shelling using manual methods, the study at hand seeks to provide a cost-effective, affordable, and efficient mechanical solution.The paper provides innovative design concepts such as enhanced shelling systems, easy-to-use feeding mechanisms, andefficientseparation unitsincorporatedintoefficientandcompactdesigns. Theresearchhighlightsthecomponent that newer mini cornshelling machinessignificantly enhance productivity andreduce post-harvestloss, thuscreating efficientagricultureandfoodsecurity inrural communities. Thisstudy integrateslatestresearchtoofferanoverview of the state-of-the-art in mini corn sheller technology

Introduction

Summary:

Purpose & Problem:
The study addresses the labor-intensive, inefficient, and loss-prone process of manual corn shelling among small-scale farmers. Large industrial shellers are unaffordable and impractical, while DIY alternatives lack durability and efficiency. This creates a pressing need for a low-cost, efficient, and portable mini corn sheller tailored for smallholder farmers in low-resource settings.

Objectives:

• Design a compact, easy-to-use, ergonomic mini corn sheller.

• Use locally available materials to reduce cost and simplify maintenance.

• Test performance in terms of shelling efficiency, capacity, and grain damage under various conditions.

• Compare performance with manual shelling and other small machines.

• Evaluate impact on labor savings, post-harvest losses, productivity, and food security.

Design & Methodology:

• Utilizes impact and abrasion via a rotating shelling cylinder and concave screen.

• Includes a safe feeding hopper, cleaning/separation unit, and low-power motor (compatible with solar).

• Emphasizes compactness, mobility, and operator safety.

• Constructed using mild steel, perforated sheet metal, rubber/HDPE, and standard fasteners.

• Designed for easy assembly, repair, and local fabrication.

Performance Results:

• Shelling Efficiency: Over 98%, even with varying moisture content.

• Shelling Capacity: Up to 250 kg/hr, significantly outperforming manual shelling (15–30 kg/hr).

• Grain Damage: Very low (≈1%), preserving grain quality.

• Power Consumption: Low (~0.5 kW), allowing off-grid operation with solar or small generators.

• Comparative Benefits:

  • 8–10× faster than manual shelling.

  • Major labor and time savings.

  • Improved grain quality and reduced post-harvest losses.

  • Better ergonomics, reducing physical strain and health risks.

Discussion & Impact:

• Offers a sustainable and scalable solution to mechanize smallholder corn processing.

• High efficiency and minimal grain damage make it market-ready and competitive with other models.

• Compatible with green energy, contributing to environmentally sustainable agriculture.

• Promotes local economic development via affordable manufacturing and reduced dependence on imports.

• Future improvements may include smart sensors for adaptive shelling based on moisture content.

Conclusion

The project successfully designed, conceptualized, and prototyped a mini corn shelling machine and proved to have massive potential as an affordable and efficient device for small-scale farmers. The machine had fantastic shelling efficiency (average .%), excellent shelling capacity (average kg/hr), and extremely low damage rate on the grains (average .%). These performance parameters illustrate the capability of the machine to substantially minimize human labor, reduce post-harvest loss, and enhance the general efficiency and economic position of smallholder farming societies [, ]. The successful use of cheap and accessible materials with an unstated but stable design guarantees the affordability, cost-effectiveness, and simplicity of the machine production and maintenance. It offers a sustainable and feasible alternative compared to traditional shelling manual methods and expensive industrial machineries,particularlyinregions whereresourcesarescarce and infrastructurenot wellestablished [,].Based on the detailed results of this study, the following recommendations are presented: 1) Facilitate Adoption and Dissemination: It is important to actively spread this mini corn shelling machine\'s design and manufacturing skills to small farming communities . Equally, this can be done with an eye towards special workshops, hands-on training sessions, and local manufacturing campaigns so that there is moreadoption and its overall impact to farming activity []. 2) Ongoing Optimisation and Flexibility: While the current design is functionally quite superior, ongoing research and development are advisable to pursue ongoing optimisation. This could involve research into alternative shelling mechanisms, better materials, or the integration of power sources even moreenvironmentally friendly and flexible regarding diverse environmental conditions and corn types [ ]. 3) Integration with Post-Harvest Systems: Theminicornshellingmachineshouldbeviewedaspartofapieceof equipment within a broader system of post-harvest processing. Future research could involve developing modular systems combining shelling with other important operations such as drying, cleaning, and storage to offer a more holistic solution to farmers []. 4) In-depth Economic and Social Impact Assessment:Amoreprofoundeconomicanalysis,withcomprehensive cost-benefit ratios and return on investment studies among farmers, would provide stronger empirical evidence about the machine\'s viability. It would also be helpful to identify its social impact on gender roles, labor dynamics, and community development []. 5) Extensive Field Testing and User Feedback: Extensive field testing across various geographic locations and diverse farming practices is essential. Getting real-time user feedback from farmers will give us insightful information for iterative design improvement so that the machine effectively meets their evolving needs and desires on the ground

References

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Copyright

Copyright © 2025 Mr. S. Ravindran, Mr. K. Vetri Velmurugan, Dr. C. Parswajinan, Mr. S. Shyam, Mr. N. Kumar, Mr. P. K. Mounidharan. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.