Design and Development of a Rotary Dryer-Based Palletizing Machine with Multi-Purpose Drying and Cooling

Ikhwani Uzair Zubair; Irfan Abd Rahim; Z. Shayfull; Abd Ghani Hussain A.; FAZ Mohd Saat; MS Mustapa

doi:10.58915/aset.v5i1.2963

Authors

Ikhwani Uzair Zubair Universiti Malaysia Perlis
Irfan Abd Rahim Universiti Malaysia Perlis
Z. Shayfull Universiti Malaysia Perlis
Abd Ghani Hussain A. HPA Industries Sdn. Bhd.
FAZ Mohd Saat Universiti Teknikal Malaysia Melaka
MS Mustapa Universiti Tun Hussein Onn Malaysia

DOI:

https://doi.org/10.58915/aset.v5i1.2963

Keywords:

Rotary Dryer, Palletizing Machine, Product Development, Poultry Feed, Herbal Fertilizer

Abstract

High initial moisture content (≈70%) in poultry feed and herbal fertilizer pellets poses significant challenges in agro-industrial processing, leading to prolonged drying times, high energy consumption, and inconsistent product quality. This study designs and analytically validates a three-stage rotary dryer integrated with palletizing and in-line cooling to reduce moisture content from 70% to 9% at a throughput of 0.5 T/h within a 10 × 10 m footprint. A systematic product development approach was employed, incorporating agreed specifications with stakeholders, market benchmarking, and weighted Pugh concept selection. Thermal verification was conducted using heat and mass balance calculations to determine evaporation rate, heat load, airflow requirement, residence time, and power demand. The final configuration comprises a 0.5 m diameter, 21 m long rotary drum operating at 5 rpm with controlled air injection at 70–80 °C. Results indicate improved drying control, integrated cooling efficiency, and enhanced process sustainability for agro-industrial applications.

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