RANCANG BANGUN HOPPER DOUBLE SCREW CONVEYOR UNTUK SISTEM PENAMPUNGAN DAN PACKAGING PADA INDUSTRI ES KRISTAL

SUBHI, IMAM (2025) RANCANG BANGUN HOPPER DOUBLE SCREW CONVEYOR UNTUK SISTEM PENAMPUNGAN DAN PACKAGING PADA INDUSTRI ES KRISTAL. S1 thesis, Universitas Mercu Buana Jakarta.

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Abstract

This research aims to design and develop a hopper double screw conveyor as a storage and packaging system in the crystal ice industry, replacing the manual process that is inefficient, labor-intensive, and unhygienic. The methodology includes identifying industrial needs, designing with the Pahl and Beitz method, selecting materials (stainless steel 304 as the main component), analyzing structural strength, calculating flow capacity, motor power, bearing life, and conducting performance tests. The final design consists of a hopper with a U-trough double screw system, a screw inclination angle of 40°, and a pitch of 175 mm. Structural simulation analysis indicated a factor of safety greater than 2.5, confirming its reliability. Performance testing showed an average flow rate of 980 kg/hour, approaching the target of 1 ton/hour, with 20 kg of crystal ice completely discharged within 45.7–49.5 seconds. Ice mass loss due to melting was only 2–3%, significantly lower than manual handling (±7%). Productivity increased by 30%, while the required workforce was reduced from four operators to two. From an economic perspective, the fabrication cost of the hopper double screw conveyor was recorded at Rp 16,850,000 with an annual maintenance cost of approximately Rp 300,000. Payback period analysis demonstrated that the investment can be recovered within 10–11 months through labor cost savings and increased production capacity. Bearing life calculations indicated a durability of 48,283 operating hours (over five years under normal use), ensuring long-term feasibility. In conclusion, the designed hopper double screw conveyor successfully improves material flow efficiency, minimizes ice loss, reduces operational costs, and ensures product hygiene. This research also provides recommendations on optimal screw angle and pitch settings, regular maintenance of transmission components, and future development toward a fully automated system to support the sustainability of smallscale crystal ice industries. Keywords: hopper, double screw conveyor, crystal ice, production capacity, energy efficiency, payback period Penelitian ini bertujuan merancang dan membangun hopper double screw conveyor sebagai sistem penampungan dan packaging pada industri es kristal untuk menggantikan proses manual yang kurang higienis, boros tenaga kerja, serta kurang efisien. Metodologi penelitian meliputi identifikasi kebutuhan industri, perancangan menggunakan metode Pahl dan Beitz, pemilihan material (stainless steel 304 sebagai material utama), analisis kekuatan struktur, perhitungan kapasitas aliran, daya motor, umur bearing, serta pengujian kinerja alat. Hasil perancangan menghasilkan hopper dengan sistem double screw yang dipasang pada penampang U-trough, sudut kemiringan screw 40°, dan pitch 175 mm. Analisis simulasi struktur kerangka menunjukkan nilai factor of safety > 2,5 sehingga dinyatakan aman. Pengujian kinerja menunjukkan laju aliran rata-rata 980 kg/jam, mendekati target 1 ton/jam, dengan waktu pengosongan 20 kg es kristal dalam 45,7–49,5 detik. Tingkat kehilangan massa akibat pencairan hanya 2–3%, lebih rendah dibandingkan sistem manual (±7%). Produktivitas meningkat 30% dengan berkurangnya kebutuhan tenaga kerja dari empat orang menjadi dua orang. Dari aspek ekonomi, biaya pembuatan hopper double screw conveyor tercatat Rp 16.850.000 dengan estimasi biaya perawatan Rp 300.000 per tahun. Analisis balik modal (payback period) menunjukkan alat ini dapat kembali modal dalam waktu 10–11 bulan melalui penghematan biaya tenaga kerja dan peningkatan kapasitas produksi. Perhitungan umur bearing menunjukkan daya tahan 48.283 jam operasi (lebih dari lima tahun pada pemakaian normal), sehingga layak untuk penggunaan jangka panjang. Kesimpulannya, hopper double screw conveyor yang dirancang terbukti meningkatkan efisiensi aliran material, mengurangi kehilangan es, menekan biaya operasional, serta menjaga higienitas produk. Penelitian ini juga merekomendasikan pengaturan sudut screw dan pitch yang tepat, pemeliharaan rutin pada komponen transmisi, serta potensi pengembangan menuju sistem otomatis penuh untuk mendukung keberlanjutan industri es kristal skala UMKM. Kata kunci: hopper, double screw conveyor, es kristal, kapasitas produksi, efisiensi venergi, balik modal.

Item Type:	Thesis (S1)
Call Number CD:	FT/MSN. 25 091
NIM/NIDN Creators:	41321120018
Uncontrolled Keywords:	hopper, double screw conveyor, es kristal, kapasitas produksi, efisiensi venergi, balik modal.
Subjects:	600 Technology/Teknologi > 620 Engineering and Applied Operations/Ilmu Teknik dan operasi Terapan > 621 Applied Physics/Fisika terapan > 621.8 Machine Engineering, Machinery/Teknik Mesin 600 Technology/Teknologi > 690 Buildings/Teknik Bangunan > 692 Auxiliary Construction Practices/Lain-lain yang Berhubungan dengan Pekerjaan Konstruksi > 692.5 Estimates of Labor, Time, Materials/Prakiraan Biaya Tenaga Kerja, Waktu dan Bahan-bahan
Divisions:	Fakultas Teknik > Teknik Mesin
Depositing User:	khalimah
Date Deposited:	29 Aug 2025 03:40
Last Modified:	29 Aug 2025 03:40
URI:	http://repository.mercubuana.ac.id/id/eprint/97245

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