For this design exercise, a machine was designed to allow a pancake manufacturer to be able to produce masala dosas to be able to capitalise on a new market. A main set of requirements was produced, and factors such as assembly and manufacturing were taken into consideration. The overall footprint of the machine was 1486x1998x1500mm. Ergonomics were also considered, with for example the height of the handles of the machine (which will be in frequent use) set to the 5th percentile of shoulder height of women to ease user interaction. The machine would cost approximately £6300, wrapping one dosa at a rate of approximately 9 seconds. The machine has been produced taking into consideration sustainability of the local economy and the environment. The design could potentially be improved by using a guide system to ensure the position of the frozen dosa blocks for the folding assembly. In addition, the transition from the conveyor to the cantilever could be evaluated further. The machine has been designed to use food safe materials wherever there is a chance of contact with the food, and should be used within a sterile environment, with the users wearing food safe protective clothing, to ensure the products are not contaminated.
The outline task was to create a machine capable of turning flat pancakes, and a stack of frozen fillings, into a wrapped masala dosa ready for further freezing, with minimal human interaction beyond loading the stack of fillings.
The fillings were to be 150mm x 60mm x 20mm and the pancake to be of 300mm diameter, though the machine should be able to handle slight tolerances on both of these.
The context for the machine design was that the folded and filled masala dosa was to be sent for rapid freezing and packaging at another unit, which was beyond the scope of this design, though having the possibility for a conveyor belt to come off the end would be advantageous.
The idea was to use a large number of bought in parts, in order to associate with the design brief that ten of these units were to be produced initially.