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01/29/2023 4:55 AM
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2nd drum roaster
witoldb
I will definitely come to the event.
Not sure yet about the training.
Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
Ringo
Great roaster. I just wanted to say if you cut glass dry with a cutoff wheel be very careful with the dust. A small amount inhaled can give you silicosis, or scars to the lungs. Very dangerous.
All you need in life is ignorance and confidence, and then success is sure. Mark Twain
 
witoldb
At last I made some progress on my roaster.
ET and BT probes are electrically isolated from the body. There is 60mm space at the back of the drum.
Drum motor is a stepper with rpm's adjustable via pot.
Drum cover is made from 2 layers to reduce heat loss. I will see later if I need insulation.
Tray holding heating elements will be insulated from the bottom with castable refractory.
I did some trials without power, with up to 500g greens and rotating the drum by hand to determine best location for BT probe.
Beans are mixing nicely, unload quickly and don't get trapped between vanes.
I had to cut back little bit of inner vanes to avoid bumps against the trier.
I'm not sure if large pulley on the shaft won't get too hot - maybe I will need to install some kind of aluminium disk with fins to act as a heat sink.
I went for stepper motor and belt drive because it was generating vibrations/noise from drum when driving the shaft directly, even through flexible coupling.
Also I've tried few geared DC motors but they were noisy.
Drum housing with the drive can pivot for cleaning.
Shaft is fixed in front bearing with rear floating.
Next I have to start working on a cyclone.
witoldb attached the following images:
10_et_probe.jpg 9_bt_probe.jpg 8_drum_motor.jpg 7_dump_valve.jpg 6_rear_2.jpg 5_rear.jpg 4_right_side.jpg 3_left_side.jpg 2_front_2.jpg 1front_1.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
Some more photos.
witoldb attached the following images:
19_without_drum.jpg 18_with_drum.jpg 17_open_for_cleaning.jpg 16_hopper_3.jpg 15_hopper_2.jpg 14_hopper_1.jpg 13_vanes_2.jpg 12_vanes_1.jpg 11_drum.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
Lylabrown
Thanks for posting an update, the build quality and workmanship are top notch.

It looks like your drive pulley will act as a heat sink to keep the belt cool. Drilling a few holes in it will likely enhance the effect. Same goes for the motor mount plate. Maybe some 'hot' testing is in order to see if any changes are necessary. I certainly learned a lot when firing my roaster up the first time regarding expansion and sensitive components getting a little too hot.

Keep the updates coming.

Russ
 
witoldb
I made some progress on cyclone and exhaust fan casing.
witoldb attached the following images:
26_cyclone_cone_3.jpg 25_cyclone_cone_2.jpg 24_cyclone_cone_1.jpg 23_cyclone_components.jpg 22_cyclone_trial.jpg 21_fan_casing_2.jpg 20_fan_casing_1.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
allenb
This is turning into the DeLorean of drum roasters and is quite a masterpiece!

I agree with Russ that the pulley should not overheat at all and will sink away most of the heat picked up from the shaft.

Love the brass bodied blower in your last post. I'd like to have one like that just to display on a shelf!

Thanks for the detailed photos and hope you're planning on a nice video of the roaster browning some beans. BBQ grill

Allen
1/2 lb and 1 lb drum, Siemens Sirocco fluidbed, presspot, chemex, cajun biggin brewer from the backwoods of Louisiana
 
witoldb
Cyclone completed and tested - I was surprised how well it works, Bill Pentz design is brilliant.
Fan cannot be heard when room AC is working.
I fed it with bread crumbs and dry Bougainvillea leaves cut to small pieces.
Everything ends up in the jar and I can't see anything in the outlet duct, not even smallest bread crumbs dust.
witoldb attached the following images:
33_cyclone_air_ramp_2.jpg 32_cyclone_air_ramp.jpg 31_cyclone.jpg 30_motor.jpg 29_motor_name_plate.jpg 28_fan_assembly.jpg 27_cyclone_assembly.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
Fan assembly/cyclone outlet details.
Gasket between impeller casing and aluminium cover plate is from silicone baking sheet.
Gap between impeller casing and cyclone cylindrical portion sealed with o-ring.
I need to make some brackets to bolt down fan assembly into cyclone body and to compress the o-ring.
witoldb attached the following image:
34_fan_assembly_2.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
Avyossii
Hello
Can you expand on the measures of the cyclone?
I'm building my own coffee roaster and I'm now in the phase of the filter element...
Thank you
Yossi
 
witoldb
I've used Bill Pentz worksheet and entered following dimensions:
ducting size DS = 38 mm (I made it similar to impeller inlet size)
Impeller type IT = 0
motor size MS = 0
lid thickness WT =1 mm
fixed cyclone diameter D Fixed = 92 mm
fixed inlet width IW Fixed = 0 (Auto calc)
fixed inlet height IH Fixed = 0 (Auto calc)
cone length ratio CLK = 1.64
tab overlap TW = 8 mm
After entering these, you will get all dimensions for cutting.
I made cross sectional area of the fan casing outlet similar to cross section of 38 dia ducting.
Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
I'm busy drilling SS sheet for cooling tray.
Plate is 3 mm thick, 220 x 220 mm, holes 3.5 mm dia in 5 mm triangular pitch.
There are approx. 1600 holes.
I'm using special drill bits for SS, slow rpm's and cutting oil, so far used 3 bits for around 60% holes.
witoldb attached the following image:
cooling_tray_sheet.jpg

Edited by witoldb on 06/01/2014 2:57 PM
Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
Completed cooling tray.
Minature ball bearing (ID=3 mm) in the middle acts as a support for mixer shaft.
witoldb attached the following images:
38_front_cooling_tray.jpg 37_cooling_tray_sheet_closeup.jpg 36_cooling_tray_sheet.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
Roaster, cooling tray and exhaust ducting.
witoldb attached the following image:
39_complete_roaster.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
I had to drill drum pulley and install small fan as belt was getting bit warm.
Fan also cools SSR heatsink.
witoldb attached the following image:
40_pulley_cooling_fan.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
Full setup with extraction hood, fan speed is adjustable with a dimmer.
witoldb attached the following image:
41_roaster_extraction_hood.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
Control box with PID controller, TC4C, SSR with 4-20 mA input, stepper motor driver and 3 small SSR's for switching on cyclone, tray cooling fan and tray mixer motor.
Drum RPM is adjustable with a pot.
witoldb attached the following images:
43_control_panel.jpg 42_electronics.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
I made SSR with 4-20 mA input to have better heater control.
witoldb attached the following image:
4-20ma_ssr_rev3.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
I roasted up to 600 grams and maximum current signal from PID was around 17 mA with 1500 W heating elements.
Attached is log for 550 grams Mysoore Nuggets EB.
Please let me know what adjustment would you recommend in this profile - I can enter up to 60 segments in my PID.
My ET probe is at the back of the drum but I'm thinking to use it as inlet temperature and install 2 more probes for ET and MET on the front plate.
I think that ET probe in the front will be better as it will take into account heat generated during 1C.
What will be the best locations?
I have space above trier and inside the chute below hopper dump valve.
witoldb attached the following image:
mysoore_roast_550_f_sizeg.png

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
MikeW
Nice work!

Remember that the term "MET" means maximum environment temperature and refers to a "not to exceed" temperature for the air inside the drum. See:

http://www.sweetm...staub.html

From what I've read there's no right way to roast. But, it's common for people to try to hit a BT of 150*C around a range of 4 to 5 minutes from the time the beans are introduced into the drum. If you haven't already take a look at Scott Rao's book / web site for some good basic guidelines on roasting. Also look at allenb's and Ringo's past posts on roasting here at HRO. They contain excellent guidance.
 
Omega
Wow! What a project!

It takes real commitment and vision to accomplish what you have on this roaster. I'm astounded and very impressed!

Barry
 
witoldb
ET probe installed in the outlet chute.
It is 1.45 mm dia ungrounded K thermocouple.
witoldb attached the following images:
47_et_bt_probes_3.jpg 46_et_probe_2.jpg 45_et_probe_1.jpg

Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
witoldb
Roasted 575 grams Mysoore Nuggets with probe in outlet chute and connected to TC4 as ET and to PID as PV input.
Inlet data is temperature before inlet to the drum.
I think that I need to reduce load size or preheat to higher temperature.
During first 10 min heaters could not deliver enough heat to reach temperature as per
SV settings (current to heaters was at maximum).
witoldb attached the following images:
49_mysoore_log_575g_new_et_probe.jpg 48_mysoore_575g_new_et_probe.jpg

Edited by witoldb on 10/02/2014 4:33 PM
Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
allenb
1500 watts can roast 1 lb in a drum roaster but leaves no headroom. 2kw is recommended to be able to make tighter turns. Is the pan that houses your tubular elements double wall or insulated? If not, you will have quite a bit of BTU loss through the pan's bottom and side walls. Another factor with tubulars is distance between them and the drum. Closer the better.

I would try a 350 gram batch and see if this improves your rate of rise capability.

Great looking roaster! ThumbsUp

Allen
1/2 lb and 1 lb drum, Siemens Sirocco fluidbed, presspot, chemex, cajun biggin brewer from the backwoods of Louisiana
 
witoldb
Housing of the heaters is insulated with mineral fire blanket.
Also drum cover is double wall with fire blanket in between.
Distance of heating elements from the drum is approx. 50 mm.
I've dropped the load to 350g and RoR has improved.
Time till end of 1C got shortened from 16 min for 575g load to 11 minutes for 350g (chart in the background).
witoldb attached the following image:
50_mysoore_350_575g.jpg

Edited by witoldb on 10/03/2014 3:05 PM
Home: Breville DB, Mahlkonig Vario+K30
Work: Nuova Simonelli single group Aurelia I +MDX grinder
300g DIY drum roaster
 
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