The Ultimate Coffee Experience Final Design

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The Ultimate Coffee Experience Final Design

• Malachi Gordon
• Chad Greene
• Chris Knowlton
• Thao Lai

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Specifications
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Specifications

• Difficult Specs to Meet
• Size
• Three machines in one
• Easy to Clean
• Many parts in 3 machines
• Hard to take parts out to clean
• Chaff collection in ductwork

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Roast BeansExperimental Setup

• Hot Air Roaster
• Controlled Variables
• Set amount of beans
• Temperature (roaster cooled before use)
• Tested variable
• Time
• Color

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Roast BeansExperimental Setup
Various Roasting Profiles Desired
Popcorn Popper Roaster
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Roast Beans

• Experimental Procedure
• The popcorn popper was filled with varying
  amounts of green beans at a time
• Roasting was monitored and timed until the
  desired roast shade was produced.
• Criteria for Success
• The beans are light, medium, and dark roasted to
  the appropriate shades.
• The shades must be even throughout the roast
  specimen.

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Roast Beans Results
Medium Roast
Light Roast
Dark Roast
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Roast Beans Results

• Light Roast approx. 5-6 minutes
• Medium Roast approx. 11-12 minutes
• Dark Roast approx. 25-30 minutes.
• How will results impact final design of coffee
  machine?
• The times calculated will set the times
  programmed into the machine for roasting at
  various roasting profiles.

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Final Design Roaster

• Similarities
• Convection will be used
• Directional slots for stirring will be used
• Differences
• Screw assembly will not be used
• Slower fan

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Overall Design Concept

• Combine existing roasting, grinding, brewing
  techniques
• Side paddle wheel metering design
• Beans fall into roaster
• Hot popper roaster
• Similar to popcorn popper
• Gravity bucket dumping beans into grinder
• Smoke and Smell pushed through Filters
• Burr grinder
• Fan moves grinds from burr grinder to the brewer

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Bill of Materials
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Design Assembly

• Use sub-assemblies
• Metering system
• Filter system
• Grind Transport system
• Position and secure sub-assemblies

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Material Process Selection

• Injection molding
• Acrylic Hopper box clear, good surface finish
• ABS Meter Case, Grinder top base, Slides,
  Grinder burr holder, Roast bottom, Grinder burr
  bottom good impact strength, high moldability

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Material Process Selection

• Stamping
• Stainless steel Housing Base, Heat Plate
  Cover good surface finish, aesthetic, durable
• 316 Stainless steel Roast paddle food grade
• Sheet metal Roast cover, Exhaust hood, Ductwork
  cheap
• Aluminum Roast cup high thermal diffusivity

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Material Process Selection

• Extrusion
• Stainless steel Corner brackets good surface
  finish, aesthetic, durable

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Design For Assembly Analysis

• Estimated time 563 seconds or approx. 9 minutes
• Final estimated cost 295
• 50 parts
• Efficiency 18.75

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Cost Estimation

• Average of 2,000 per mold (protomold.com)
• 10 parts
• 20,000 for tool and molds
• DFA analysis cost 295 per machine
• Total
• Approx. 14.77 million
• Not including store bought parts and material cost

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Design Strengths

• Incorporates existing systems proven to work
  successfully
• Dependability increases
• Cost decreases if parts already exist
• Smell Smoke
• Low HC count Max 1 HC ppm

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Design Weaknesses

• Transfer grinds
• Time to transfer all of the grinds
• Aerodynamic Flow
• Cleaning
• Small components
• Difficult to reach
• Grinds stick to sides

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Improvement Recommendations

• Further testing required
• All systems together
• Design of grind transfer
• Chaff collector
• Removable tray
• Bigger coil
• Quicker times for roasting

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Questions?