초록 ▼

○ 연구결과
알타리무 전처리 가공시스템을 종합적으로 연구하여 상품화 가능한 가공기계와 가공라인을 개발한 것이 연구결과의 핵심이다. 주요 연구결과로는 무청과 뿌리꼬리절단 및 삭피 작업용 칼날의 최적형상을 구명하고, 기계화 작업이 가능한 최적의 장치를 개발하고, 이들 작업을 일관 자동화한 가공기계를 개발하였다. 장치 및 기계개발과 병행하여 효율적 시스템 구성에 대한 연구를 수행하였고, 최종적으로 삭피기계와 세척장치를 연결한 가공라인을 개발하는데 성공하였다. 이 가공라인은 작업자 1인이 무를 라인에 공급하면 자동으로 무청 절단, 뿌

○ 연구결과
알타리무 전처리 가공시스템을 종합적으로 연구하여 상품화 가능한 가공기계와 가공라인을 개발한 것이 연구결과의 핵심이다. 주요 연구결과로는 무청과 뿌리꼬리절단 및 삭피 작업용 칼날의 최적형상을 구명하고, 기계화 작업이 가능한 최적의 장치를 개발하고, 이들 작업을 일관 자동화한 가공기계를 개발하였다. 장치 및 기계개발과 병행하여 효율적 시스템 구성에 대한 연구를 수행하였고, 최종적으로 삭피기계와 세척장치를 연결한 가공라인을 개발하는데 성공하였다. 이 가공라인은 작업자 1인이 무를 라인에 공급하면 자동으로 무청 절단, 뿌리꼬리 절단, 삭피 및 세척 작업을 완벽하게 수행하였으며, 작업속도는 9초/개로 인력의 6배의 작업능률을 가졌다. 본 가공시스템의 개발로 알타리무 가공비 80%절감, 김치생산비 40%절감, 국내 관련 시장규모 750억인 기계산업 활성화 및 김치수출 활성화에 기여하게 되었다.

Abstract ▼

Ⅳ. The results of the research and development and the proposal for practical use
On this study, to contribute to reducing cost and sanitary production of the Altari radish kimchi on factories and others, a processing machine and processing line that feasible to commercial production were develop

Ⅳ. The results of the research and development and the proposal for practical use
On this study, to contribute to reducing cost and sanitary production of the Altari radish kimchi on factories and others, a processing machine and processing line that feasible to commercial production were developed by the synthetic study on the processing systems before kimchi preparing. The results of this study were as follows.
Section 1 Results of the research and development
1. Development of the devices and machines
A. Study on the optimum shapes of the peeling blades for the Altari radish
To investigate the optimum shapes of the peeling blades for the mechanization of the peeling works that were important to automatize the processing systems of the Altari radish kimchi, the circumferential and longitudinal peeling tests of the Altari radish were conducted. The peeling tests, as the peeling speeds within the range as the blades were not vibrated but digged the skin of the radishes and could be continuous operation, were carried out with the peeling depth and width of the blade at 2 ㎜ and 10 ㎜, respectively. The results of the analysis on the peeling resistances were summarized as follows.
1) At the circumferential and longitudinal peeling tests, the effects of the shape of the blades to the peeling resistances were displayed higher than those of the peeling speeds and the effects of the rake angles of the blades were higher than those of the blade angles among the blade factors.
2) The peeling resistances on the longitudinal peeling were lower than those of the circumferential peeling, and in that case, peeled surfaces were processed cleanly. At the longitudinal peeling, plane type peelings could be fitter than those of the groove type peelings for mechanization.
3) Actually, the peeling of the Altari radishes were performed on longitudinal and plane type, the optimum peeling conditions of these case were the peeling speed was 0.2 m/s, blade angle was 20˚ and the rake angle was 60˚, and the peeling resistance of each blade showed as 15 N at these conditions.
4) The peeling resistances according to the lapse days after harvest were exhibited as increased gradually to the stored days, and the freshness of the Altari radishes were maintained within 4 days after harvest, the peeling operation, therefore, could be established in these duration.
B. Optimum shapes of the radish leaves cutting blades
The conditions of the cutting leaves that essential to develop of the Altari radish processing were revealed. As the results of the cutting resistance tests of the leaves of the radish depending on the variation of the shear angles of the blades, the optimal conditions of the blades for leaves were brought out as the thickness was 2 ㎜, the blade angle was 25˚, the shear angle was 40˚ and the cutting speed was at 0.5 m/s, respectively.
C. Optimum shapes of the root tails cutting blades
The conditions of the cutting root tails that necessary to develop of the Altari radish processing were confirmed. As the results depending on the shear angles of the blades, the optimum conditions of the blades for root tails were showed as the thickness 2 ㎜, the blade angle 20˚, the shear angle 30˚ and the cutting speed was 0.5 m/s, respectively
D. Washing effect on the high pressure water injection
This study was conducted to inquire into washing aspects according to the injection pressure with construction a high pressure water injection device fitted to washing for removing soil or sundries on the surface of the radishes and fine roots. The selected injection nozzles were Teejet ones that feasible to use for washing the materials. To high density injecting, 3 nozzles were fixed with intervals as 3 ㎝ on the nozzle base horizontally (vertical of the nozzle hole), and then, high pressured water injected on the rotating radish which isolated 25 ㎝ from nozzle and fixed horizontally and vertically to the base. Tests were carried out with the injection pressure as 5 kgf/㎠, 10kgf/㎠ and 15 kgf/㎠, and the results were summarized as follows.
1) There were no significant washing aspects according to the injecting directions, pressures and duration within the possible limit of the mechanization as washing time was testified at less 30 sec. and injecting pressure was at less 15 kgf/㎠.
2) It was impossible to remove the fine roots and soil or sundries by high pressure water injection to the double-head drum type rooted radishes (kinds of Sinjin and Namgang) among the kinds of the Altari radishes, for they had many thick fine roots on the radish and many grooves on the fine rooted place.
3) It is possible to wash cleanly at 30 sec. and 15 kgf/㎠ by high pressure water injection to the kinds of straight rooted radishes.
E. Development of the peeling machine
This study was performed to design and manufacture a peeling device that were convinced of the possible ways with some plan, and to inspect the optimum peeling methods of the Altari radishes with tests, and to develop a practicable machinery. The results were summarized as follows.
1) The planned peeling method was with blade belt, brush and rotating blade, but the peeling works were not established so well and the troublesome like adhesion of the chip on the blades and the difficulties produce the blade parts were come out on this type of the peeling device.
2) The peeling operations of the rotating blade type peeling devices were completed without needs to cleaning, and it was considered that it would be possible to practical mechanization for it's construction was simpler than the other methods.
3) The prototype peeling machine that applied the peeling device modified by the rotating blade type peeling devices, and composed by radish leaves cutting device, radish root tails cutting device, transferring device and auto control device was developed.
4) With the developed peeling machine, it could be operated to leaves cutting, root tails cutting and radish peeling as the operating speed as 10 sec. per each radish in regular sequence by only putting radishes on the processing line by a man. It was credited that this peeling machine would be possible to commercialize.
F. Development of the processing line of the Altari radish
Automated processing lines of the Altari radish processing which possible to be mechanized and organized such operations as leaves cutting, root tails cutting, radish peeling and washing was developed, as the level as the commercialization.
The peeling device was improved with the performances of the prototype machine as noted former section, the washing device was developed with applications of the swirled water washing and the water flow transferring method, the control of the processing lines were applied PLC control devices. This processing line was designed and constructed in maximum considerations of conveniences of the operator, easiness and cost reduction of the machine manufacture, accuracy of the operation and merchandise of the outputs. The processing line manufactured as a prototype was one raw peeling method mounted only one raw of peeling device, and then, operating efficiency was 9 sec. per each (128 ㎏/h), rate of successful peeling was 98%, and the other operations were conducted perfectly.
2. Study on the effective system
A. Status of the production and processing of the Altari radishes
The results of the surveys with the status production and processing of the Altari radishes though the data, questionnaires and field investigations were summarized as follows.
1) It is proved that the cultivated area of the Altari radishes were 1,500∼2,000 ㏊ and productions per year were about 330,000 M/T, and it was estimated as 20% of the common radishes productions (about 1,650,000M/T) in our nation. The rate of the Altari radish kimchi output compared with that of the overall kimchi (radish + cabbage) was showed as 8.43%.
2) The employed labors to work for kimchi processing in manufacturers were 3.5, and the continuous processing time was 5 hours on an average, and they processed kimchi 200∼500 ㎏ per day.
3) It is surveyed that the working efficiencies were around 12.5 ㎏/h․person on Altari radish processing by labors in manufacturers, and working speeds of the person were calculated as 1.5 min./each․person based on the weight of one Altari radish was as 315 g.
4) At present, the kimchi processing manufacturers are maintaining such lined processes as the orders as carrying in the raw materials → grading/ selection → salt water preparation → salting → washing → dehydration → condiments preparation → blending (materials + condiments) → packaging → storing and ripening. But most of these operations, except transferring on lines were done with belt conveyer and carrying works were with manual wheeled carrier, were depended upon labors.
B. Physical properties of the Altari radish
For the mechanization of the peeling processes on the Altari radish processing for kimchi, the characteristics of the Pyeonggang and Sachul radish kinds, such as the geometric shapes, compressive strengths of the root parts, compressive strains, surface hardness and shearing stresses of the leaves and root parts, were measured and analyzed. The results were summarized as follows.
1) The dimensions of the Pyeonggang radishes on average were appeared as, leaves length as 325.4 ㎜, radish root length as 102.4 ㎜, head part diameter as 49.8 ㎜, mid part diameter as 51.9 ㎜, bottom part diameter as 50.3 ㎜. And in case of the Sachul radishes were showed, leaves length as 283.1 ㎜, radish body length as 94.3 ㎜, head part diameter as 33.2 ㎜, mid part diameter as 29.9 ㎜ and bottom part diameter as 48.2 ㎜, respectively.
2) The weight of one Altari radish include leaves was surveyed as 320 g on average.
3) For the Pyeonggang radishes, the vertical compressive strengths were ranged 83.8∼171.7 N/㎠ and horizontal compressive strengths were distributed 113.0∼191.7 N/㎠. And for Sachul radishes, the vertical compressive strengths were ranged 91.3∼168.3 N/㎠ and horizontal compressive strengths were distributed 132.6∼186.9 N/㎠. The compressive strengths were affected by loaded directions rather than locations of the radishes.
4) The shearing strength of the connected part of the Pyeonggang radishes was 100.6 N, and that of the Sachul radishes was 103.4 N on average.
5) The maximum surface hardness of the Pyeonggang radishes was 52.1 N/㎠ and that of the Sachul radishes was 67.8 N/㎠ on average, at the depth of 1∼2 ㎜ on both kinds of radishes.
6) The torsional moment to remove leaves on radish was 15.2 N·㎝/㎠ at rotational speed was 8 rpm, and this torsional moment was decreased rapidly from 5 days after harvest.
C. Study on the optimization of the processing line
To investigate the optimum processing line, to research processing procedures and working methods of the Altari radishes through the field surveys and questionnaires on manufacturers and sales rooms of the kimchi, these studies were performed to establish the processing procedures and orders suitable for mechanization, and selected adequate machineries and devices to each processing procedure, and conducted the economic analysis on the developed machine. The results of the studies were summarized as follows.
1) The peeling work speed was brought out as 90 each/h․man (40 sec/eac h․man) calculated by daily handling of the Altari radish for one labor on kimchi manufacturer and 10 of house wives.
2) It was realized that the effective lined operating process of the Altari radish processing were constructed as follows. Those were, primary selecting (by labor) → removing inedible parts (leaves, stems) ((by labor) → loading on the operating line (by labor) → cutting of the leaves and root tails → peeling → washing (swirled water) → transferring (water flow) → temporal storing bin → chain belt conveyer → salting water bin → taking out (by labor).
3) It was considered that the possible processing procedures on mechanization before blending kimchi were processing lines and washing line, that is, the processes of the leaves cutting, root tails cutting, peeling and washing.
4) The differences of root lengths of the Altari radishes that had same cultivated area and come out periods were proved about 30 ㎜ at 95% level. It was regarded that mechanical processing, therefore, should be processed with 3 steps by grading of lengths of the radishes, and then, the accurate peeling would be accomplished with decreased losses of those.
5) It was concluded that sanitation and taste of the mechanized processed Altari radishes kimchi were same nearly compare with hands made, and those were suitable for manufactory of kimchi as the short term ripening and storing kimchi.
6) Developed Altari radish processing machinery with one raw peeling method and two raw method that compared with hand processing method, it was analyzed that the break-even yearly working days were 28 days and 19 days, and the break-even yearly processing amount were 28,700 ㎏, 32,400 ㎏, respectively.
7) It was concluded that this developed processing systems could be presented as a commercial model based on the results of the studies and evaluations of the concerns of the kimchi manufactories and experts of the food machineries.