International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 11 | Nov 2025
p-ISSN: 2395-0072
www.irjet.net
Automatic Dough Extruder and Fryer Adit Jorwekar 1, Jatin Bhise2, Jui More3, Tejaswini Kapse4, Pratik Kankam5 Department of Mechanical Engineering, Vishwakarma Institute of Technology, Pune, Maharashtra, India ---------------------------------------------------------------------***--------------------------------------------------------------------2. METHODOLOGY Abstract - The Automatic Dough Extruder and Fryer is a novel equipment that uses a fully integrated 3D extrusion and air-frying technology to automate the shaping and 2 frying of classic Indian snacks like chakli (murukku). Traditional chakli manufacture requires manual shaping and deep frying, which leads to uneven product quality, high labor demand, and wasteful oil consumption. The machine's components include a dough hopper, screw extruder, rotary cutter, air-frying chamber, and a programmable control system based on PLC and HMI. A conveyor-based transfer system synchronizes the extrusion and air-frying processes, ensuring precise shape and uniform oil-free cooking. The technology decreases human intervention, lowers oil usage by up to 90%, and improves production uniformity. With its compact, modular design, the machine is suitable for 2 domestic, small-scale, and commercial snack manufacturing. The developed prototype demonstrates a significant improvement in uniformity, hygiene, and process efficiency compared to traditional methods. Key Words: Food automation,, 3D extrusion, Air fryer, PLC control, Snack processing, Mechatronics, Sustainable food manufacturing 2
1. INTRODUCTION
2.1 System Overview The invention comprises two major modules: 1.
Dough Extrusion Unit: Includes hopper, screw extruder, nozzle, rotary cutter, and drive motor.
2.
Air-Frying Unit: Consists of heating coils, fan, air ducts, and conveyor mechanism. These units are integrated on a steel frame for compactness and stability, ensuring coordinated operation.
2.2 Control System Design The process is controlled using a Programmable Logic Controller (PLC) and Human Machine Interface (HMI). The PLC regulates extrusion speed, nozzle motion, temperature, and frying duration. Feedback sensors such as temperature, proximity, and pressure sensors ensure accurate process control and safety. 2.3 Operation Process
Preparing traditional Indian delicacies like chakli or murukku can be time-consuming and unreliable. Manual shaping, cutting, and deep-frying need competent operators, but they also result in uneven cooking and extra oil absorption, increasing health concerns. To overcome these challenges, automation in food preparation has become increasingly popular. With advancements in electromechanical systems and programmable controllers, it is now possible to construct small, automated, and health-conscious food preparation equipment.
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Step 1: The user fills the hopper with chakli dough.
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Step 2: The extruder forms the chakli shape using a nozzle guided by PLC commands.
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Step 3: The formed chaklis are automatically transferred to the air-frying chamber.
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Step 4: Hot air circulates uniformly within the chamber, ensuring oil-free, even frying.
The Automatic Dough Extruder and Fryer combines extrusion and air-frying technologies in a single device. Unlike typical chakli-making machines, which solely handle extrusion, this design incorporates a synchronized process that combines shape and frying into a single automated cycle. This development contributes to the "Make in India" movement by facilitating efficient, smallscale, and sanitary snack production.
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Step 5: After frying, the chaklis are discharged automatically onto a cooling tray.
This continuous cycle results in uniform product quality and reduced manual intervention. 2.4 System Overview The invention comprises two major modules: 3.
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Dough Extrusion Unit: Includes hopper, screw extruder, nozzle, rotary cutter, and drive motor.
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