DESC:FIELD OF INVENTION
The present invention relates generally to systems and methods for manufacturing bio-degradable products, and more particularly relates to an electro-mechanical system and an associated method for manufacturing bio-degradable products such as straws, for example.
BACKGROUND OF INVENTION
Generally, products made of bio-degradable materials can be decomposed by action of living organisms such as microbes, into water, carbon dioxide, and biomass. The bio-degradable products are being promoted and used recently as an eco-friendly alternative to harmful plastic products. Such bio-degradable products include but not limited to plates, drinking cups, bowls, bags, straws, stirrers, chop sticks, and the like.
Typically, the bio-degradable products such as straws, stirrers, chop sticks, and the like are made of paper, bamboo, hay, and other edible materials and hence have one or more drawbacks. For example, paper straws are not completely ecofriendly as the straws made of paper include a layer of petroleum wax coating. Further, manufacturing of paper straws incurs high cost. Other alternatives such as bamboo straws, hay straws, and edible straws come in fixed diameter and there is limited availability of raw materials. Furthermore, such products are typically handmade or made using small pressing machines, and hence require more manpower. Such conventional processes are expensive, and output is limited and based on the manpower.
It is conventionally known to make bio-degradable products such as drinking straw, stirrer, chopstick, and the like from coconut palm leaves. Conventional method involves using a manual method of making a straw, for example, wherein leaf portions, on either side of a midrib of a coconut palm leaf, are joined to form an elongated tubular bio-degradable structure, for example, a straw. However, such conventional manufacturing process is time consuming, requires more manpower, and hence may not be suitable for high volume manufacturing for meeting higher demands.

BRIEF DESCRIPTION OF INVENTION
In accordance with one embodiment of the present disclosure, an electro-mechanical system for manufacturing a plurality of bio-degradable products is disclosed. The electro-mechanical system includes a mid-rib removal unit, a cleaning unit, a sterilization unit, a roughening unit, a gluing unit, a rolling unit, a heating unit, a cutting unit, a buffing unit, and a packing unit. The mid-rib removal unit is configured to remove a mid-rib from a leaf. The cleaning unit is disposed proximate to the mid-rib removal unit. The cleaning unit is configured to receive the leaf after removal of the mid-rib and perform a cleaning process of the leaf. The sterilization unit is disposed proximate to the cleaning unit. The sterilization unit is configured to receive the leaf after the cleaning process and perform a sterilization process of the leaf. The roughening unit is disposed proximate to the sterilization unit. The roughening unit is configured to receive the leaf after the steaming process and perform a roughening process along at least one side of the leaf. The gluing unit is disposed proximate to the roughening unit. The gluing unit is configured to receive the leaf after the roughening process and apply glue along the at least one side of the leaf. The rolling unit is disposed proximate to the gluing unit. The rolling unit is configured to receive the leaf after applying the glue and roll the leaf to form a tubular structure. The heating unit is disposed proximate to the rolling unit. The heating unit is configured to receive the tubular structure and perform a heating process of the tubular structure. The cutting unit is disposed proximate to the heating unit. The cutting unit is configured to receive the tubular structure after the heating process and perform a cutting process of the tubular structure to form a plurality of bio-degradable products, wherein each bio-degradable product has a predefined length. The buffing unit is disposed proximate to the cutting unit. The buffing unit is configured to receive the plurality of bio-degradable products and perform a buffing process of the plurality of bio-degradable products. The packing unit is disposed proximate to the buffing unit. The packing unit is configured to receive the plurality of bio-degradable products after the buffing process and perform a packing process of the plurality of bio-degradable products.
In accordance with another embodiment of the present disclosure, a method of operating an electro-mechanical system for manufacturing a plurality of bio-degradable products is disclosed. The method includes removing a mid-rib from a leaf by using a mid-rib removal unit. The method further includes receiving the leaf after removal of the mid-rib by a cleaning unit and performing a cleaning process of the leaf. Further, the method includes receiving the leaf after the cleaning process by a sterilization unit and performing a sterilization process of the leaf. The method additionally includes receiving the leaf after the steaming process by a roughening unit and performing a roughening process along at least one side of the leaf. Additionally, the method includes receiving the leaf after the roughening process by a gluing unit and applying glue along the at least one side of the leaf. The method additionally includes receiving the leaf after applying the glue by a rolling unit and rolling the leaf to form a tubular structure. The method further includes receiving the tubular structure by a heating unit and performing a heating process of the tubular structure. Further, the method includes receiving the tubular structure after the heating process by a cutting unit and performing a cutting process of the tubular structure to form a plurality of bio-degradable products. The method additionally includes receiving the plurality of bio-degradable products by a buffing unit and performing a buffing process of the plurality of bio-degradable products. Additionally, the method includes receiving the plurality of bio-degradable products after the buffing process by a packing unit and performing a packing process of the plurality of bio-degradable products.
BRIEF DESCRIPTION OF DRAWINGS
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Figure 1 depicts a schematic view of a leaf which is used for making a plurality of bio-degradable products in accordance with an embodiment of the present disclosure;
Figure 2 illustrates block diagram of a method of manufacturing the plurality of bio-degradable products, using an electro-mechanical system, in accordance with an embodiment of Figure 1 of the present disclosure;
Figure 3 depicts a schematic diagram of the mid-rib removal unit in accordance with an embodiment of Figure 2 of the present disclosure;
Figure 4 shows a schematic diagram of the cleaning unit in accordance with the embodiment of Figure 2 of the present disclosure;
Figure 5 shows a schematic side view of the cleaning unit in accordance with the embodiment of Figure 4 of the present disclosure;
Figure 6 shows a schematic view of the sterilization unit in accordance with an embodiment of Figure 2 of the present disclosure;
Figure 7 shows a schematic view of the roughening unit is shown in accordance with an embodiment of Figure 2 of the present disclosure;
Figure 8a shows a schematic side view of the roughening unit in accordance with an embodiment of Figure 7 of the present disclosure;
Figure 8b shows a schematic side view of the roughening unit in accordance with an embodiment of Figure 7 of the present disclosure;
Figure 9 shows a schematic view of a holder in accordance with embodiments of Figures 8a and 8b of the present disclosure;
Figure 10a shows a schematic view of a roughening unit in accordance with another embodiment of the present disclosure;
Figure 10b shows another schematic view of a roughening unit in accordance with yet another embodiment of the present disclosure;
Figure 10c shows yet another schematic view of a roughening unit in accordance with yet another embodiment of the present disclosure;
Figure 10d shows yet another schematic view of a roughening unit in accordance with yet another embodiment of the present disclosure;
Figure 10e shows yet another schematic view of a roughening unit in accordance with yet another embodiment of the present disclosure;
Figures 11a shows a schematic view of a rotatable flap wheel in accordance with the embodiments of Figure 10a, 10b, 10c, 10d, and 10e of the present disclosure;
Figures 11b shows another schematic view of a rotatable flap wheel in accordance with the embodiments of Figure 10a, 10b, 10c, 10d, and 10e of the present disclosure;
Figure 12 is a schematic block diagram of the gluing unit in accordance with the embodiment of figure 2 of the present disclosure;
Figure 13a shows a schematic diagram of the rolling unit in accordance with the embodiment of figure 2;
Figure 13b shows a schematic diagram of a rod driven to spirally roll the leaf around the rod to form a tubular structure in accordance with the embodiment of figure 13a of the present disclosure;
Figure 13c shows a schematic diagram of a rod driven to spirally roll the leaf around the rod to form a tubular structure of the present disclosure;
Figure 13d shows a schematic diagram of a rod driven to spirally roll the leaf around the rod to form a tubular structure of the present disclosure;
Figure 14a shows a schematic diagram of the rolling unit in accordance with another embodiment of the present disclosure ;
Figure 14b shows a schematic diagram of the rolling unit in accordance with another embodiment of the present disclosure;
Figure 15 shows a schematic diagram of the heating unit in accordance with the embodiment of figure 2 of the present disclosure;
Figure 16a shows a schematic block diagram of the cutting unit in accordance with the embodiment of figure 2 of the present disclosure;
Figure 16b shows a schematic diagram of the cutting unit in accordance with the embodiment of figure 16a of the present disclosure;
Figure 16c shows a schematic diagram of the cutting unit in accordance with the embodiment of figure 16a of the present disclosure;
Figure 17 shows a schematic block diagram of the buffing unit in accordance with the embodiment of figure 2 of the present disclosure; and
Figure 18 shows a flow chart of a method of operating an electro-mechanical system for manufacturing a plurality of bio-degradable products in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to embodiments illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications to the disclosure, and such further applications of the principles of the disclosure as described herein being contemplated as would normally occur to one skilled in the art to which the disclosure relates are deemed to be a part of this disclosure.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
Unless defined otherwise, technical, and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terms “first,” “second,” and the like, as used herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or a method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, other sub-systems, other elements, other structures, other components, additional devices, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
Embodiments of the present disclosure will be described below in detail with reference to the accompanying figures.
Embodiments of the present disclosure disclose an electro-mechanical system and method for manufacturing bio-degradable products, such as straws, stirrers, and chop sticks, from leaves such as coconut palm leaves, palmera palm leaves for example. The proposed method of manufacturing said bio-degradable products involves using an electro-mechanical system for performing the steps of mid-rib removal, cleaning, steaming, roughening, gluing, rolling, heating, cutting, buffing, and packing.
As discussed herein, said bio-degradable products are manufactured using raw material including but not limited to coconut palm leaves, banana leaves, palmera palm leaves, or the like.
Figure 1 depicts a schematic view of a leaf 100 which is used for making a plurality of bio-degradable products in accordance with an embodiment of the present disclosure. In the illustrated embodiment, the leaf 100 is a coconut palm leaf. Although coconut palm leaf is discussed herein, in other embodiments, all other types of leaves are also envisioned. As shown, the leaf 100 includes a mid-rib 102 and two leaf portions 104 extending along respectively along both sides of said mid-rib 102. The leaf 100 may be used for manufacturing bio-degradable products including but not limited to straws, stirrers, chop sticks, and the like. In another embodiment, palmera palm leaf may be used for manufacturing bio-degradable products.
Figure 2 illustrates block diagram of a method 106 of manufacturing the plurality of bio-degradable products in accordance with an embodiment of Figure 1. In the illustrated embodiment, the method 106 is performed by an electro-mechanical system 108. The electro-mechanical system 108 includes a mid-rib removal unit 110, a cleaning unit 112, a sterilization unit 114, a roughening unit 116, a gluing unit 118, a rolling unit 120, a heating unit 122, a cutting unit 124, a buffing unit 126, and a packing unit 128. Th mid-rib removal unit 110 is configured to remove the mid-rib 102 from the leaf 100. The cleaning unit 112 is disposed proximate to the mid-rib removal unit 110. The cleaning unit 112 is configured to receive the leaf 100 after removal of the mid-rib 102 and perform a cleaning process of the leaf 100.The sterilization unit 114 disposed proximate to the cleaning unit 112. The sterilization unit 114 is configured to receive the leaf 100 after the cleaning process and perform a sterilization process of the leaf 100. The roughening unit 116 is disposed proximate to the sterilization unit 114. The roughening unit 116 is configured to receive the leaf 100 after the steaming process and perform a roughening process along at least one side of the leaf 100. The gluing unit 118 is disposed proximate to the roughening unit 116. The gluing unit 118 is configured to receive the leaf 100 after the roughening process and apply glue along the at least one side of the leaf 100. The rolling unit 120 is disposed proximate to the gluing unit 118. The rolling unit 120 is configured to receive the leaf 100 after applying the glue and roll the leaf 100 to form a tubular structure. The heating 122 unit is disposed proximate to the rolling unit 120. The heating unit 122 is configured to receive the tubular structure and perform a heating process of the tubular structure. The cutting unit 124 is disposed proximate to the heating unit 122. The cutting unit 124 is configured to receive the tubular structure after the heating process and perform a cutting process of the tubular structure to form a plurality of bio-degradable products, where each bio-degradable product has a predefined length. In one embodiment, the bio-degradable products may include a plurality of straws. The buffing unit 126 is disposed proximate to the cutting unit 124. The buffing unit 126 is configured to receive the plurality of bio-degradable products and perform a buffing process of the plurality of bio-degradable products. The packing unit 128 is disposed proximate to the buffing unit 126. The packing unit 128 is configured to receive the plurality of bio-degradable products after the buffing process and perform a packing process of the plurality of bio-degradable products.
At step 130, the mid-rib 102 of the leaf 100 is removed by the mid-rib removal unit 110. At step 132, the cleaning unit 112 receives the leaf 100 after removal of the mid-rib 102 and performs cleaning of the leaf 100. The cleaning unit 112 sprays a liquid such as but not limited to water, to remove dust and foreign particles present on surfaces of the leaf 100.
At step 132, the sterilization unit 114 receives the leaf 100 after the cleaning process and performs a sterilization, for example, steaming of the leaf 100. The sterilization process also provides flexibility to the leaf and hence facilitates rolling of the leaf. Specifically, the sterilization process generates wax formed within the leaf 100 to provide flexibility to the leaf.
At step 134, the roughening unit 116 receives the leaf 100 after the sterilization process and performs roughening along at least one side of the leaf 100. The roughening process is performed for enhancing the adhesion bonding after glue is applied along the at least one side of the leaf 100. A step 136, the gluing unit 118 receives the leaf 100 after the roughening process and applies glue along the at least one side of the leaf 100. At step 138, the rolling unit 120 receives the leaf 100 after the application of glue and performs a rolling of the leaf 100 to form a tubular structure. A fastener may then be placed on the tubular structure for a predetermined duration for enabling curing.
At step 140, the heating unit 122 receives the tubular structure and performs heat treatment of the tubular structure. The heat treatment prevents growth of any microorganisms and also enhances the rate of adhesive curing of the tubular structure. At step 142, the cutting unit 124 receives the tubular structure after the heating process and performs cutting of the tubular structure to form the plurality of bio-degradable products, where each bio-degradable product has a predetermined length. For example, the tubular structure may be cut to form a plurality of straws of uniform/equal length/dimensions. At step 144, the buffing unit 126 receives the plurality of bio-degradable products and performs buffing process of the bio-degradable products. The buffing process enables to polish and provide polished appearance to the bio-degradable products. At step 146, the packing unit 128 receives the plurality of bio-degradable products after the buffing process and perform a packing process of the plurality of bio-degradable products.
Referring to Figure 3, a schematic diagram of the mid-rib removal unit 110 is shown in accordance with an embodiment of Figure 2. The mid-rib removal unit 110 includes a pair conveying rollers 148 configured to convey the leaf 100. The mid-rib removal unit 110 further includes a drive unit 150 mechanically coupled to the pair of conveying rollers 148 and configured to drive the pair of conveying rollers 148. In one embodiment, the drive unit 150 may include but not limited to an electric motor. The mid-rib removal unit 110 further includes a switch actuator 152 coupled to the drive unit 150 and configured to switch the drive unit 150 to either an “ON” or “OFF” condition. The mid-rib removal unit 110 additionally includes a blade unit 154 disposed proximate and downstream of the pair of conveying rollers 148. In one embodiment, the pair of conveying rollers 148 is rotated in an anti-clockwise direction to convey the leaf 100 between the pair of conveying rollers 148. The blade unit 154 is configured to contact and remove the mid-rib 102 from the leaf 100.
Referring to Figure 4, a schematic diagram of the cleaning unit 112 is shown in accordance with the embodiment of Figure 2. The cleaning unit 112 includes a pair of input rollers 156 and a pair of output rollers 158 configured to convey the leaf 100. The cleaning unit 112 further includes a pair of leaf holders 160 positioned between the pair of input rollers 156 and the pair of output rollers 158. The pair of leaf holders 160 is configured to hold the leaf during the cleaning process. The cleaning unit 112 further includes a pair of roller brushes 162 positioned between the pair of input rollers 156 and the pair of output rollers 158 and configured to clean both surfaces of the leaf 100 respectively. Specifically, the pair of roller brushes 162 is disposed proximate and facing the pair of leaf holders 160. In the illustrated embodiment, one among the pair of roller brushes 162 is positioned to a right side relative to one of the pair of leaf holders 160 and other among the pair of roller brushes 162 is positioned to a left side relative to other of the pair of leaf holders 160. The cleaning unit 112 further includes a plurality of drive units 164, 166, 168 coupled respectively to the pair of input rollers 156, the pair of output rollers 158, and the pair roller brushes 162 via a suitable gear mechanism (not shown) and configured to drive the pair of input rollers 156, the pair of output rollers 158, and the pair of roller brushes 162. In one embodiment, the plurality of drive units 164, 166, 168 may include but not limited to electric motors. In another embodiment, only one drive unit may be used instead of a plurality of drive units. The cleaning unit 112 further includes a switch actuator 170 coupled to the plurality of drive units 164, 166, 168 and configured to switch the plurality of drive units 164, 166, 168 to either an “ON” or “OFF” condition.
The cleaning unit 112 further includes a water sprinkling unit 172 configured to sprinkle water for cleaning both surfaces of the leaf 100. The water sprinkling unit 172 may include a water tank and a water pump coupled to the water tank via a filter: The water pump is used to transfer water from the water tank for sprinkling the water against the leaf 100 and the pair roller brushes 162 for cleaning purpose. The water tank may also be used to collect water after performing the cleaning of the leaf 100. The filter may be used to remove particulates and foreign matter from the water before feeding again for cleaning purpose.
In one embodiment, the pair of input rollers 156 is rotated in an anticlockwise direction to convey the leaf inwards between the pair of input rollers 156. The leaf 100 is then held by one of the pair of leaf holders 160. One of the pair of roller brushes 162 is rotated to contact and clean one surface of the leaf 100. In one embodiment, each of the pair of roller brushes 162 may include a combination of hard and soft bristles for enabling cleaning of the surfaces of the leaf 100. The water sprinkling unit 172 sprinkles water continuously for aiding cleaning of the surface of the leaf 100. It should be noted herein that the roller brushes 162 are rotated at a speed higher than a speed of rotation of the pair of input rollers 156 and the pair of output rollers 158 to facilitate proper cleaning of the leaf 100. Thereafter, leaf 100 is then transferred and held by other of the pair of leaf holders 160. Another of the pair of roller brushes 162 is rotated to contact and clean other surface of the leaf 100, using sprinkled water. The pair of output rollers 158 is rotated in anticlockwise direction to convey the cleaned leaf 100 outwards between the pair of output rollers 158.
Referring to Figure 5, schematic side view of the cleaning unit 112 is shown in accordance with the embodiment of Figure 4. As discussed earlier, the cleaning unit 112 includes the pair of input rollers 156 and the pair of output rollers 158 configured to convey the leaf 100. The cleaning unit 112 further includes the pair of leaf holders 160 positioned between the pair of input rollers 156 and the pair of output rollers 158. The pair of leaf holders 160 is configured to hold the leaf during the cleaning process. The cleaning unit 112 further includes the pair of roller brushes 162 positioned between the pair of input rollers 156 and the pair of output rollers 158 and configured to clean both surfaces of the leaf 100 respectively. In the illustrated embodiment, one among the pair of roller brushes 162 is positioned to a right side relative to one of the pair of leaf holders 160 and other among the pair of roller brushes 162 is positioned to a left side relative to other of the pair of leaf holders 160.
Referring to Figure 6, a schematic view of the sterilization unit 114 is shown in accordance with an embodiment of Figure 2. In the illustrated embodiment, the sterilization unit 114 is an autoclave unit. The sterilization unit 114 includes an outer container 174 and leaf basket 176 disposed within the outer container 174. The outer container 174 is provided with a lid (not shown) and configured to store water. The lid is provided with a gasket for provide airtight sealing when the outer container 174 is closed by the lid. The leaf basket 176 may be positioned on a raised platform (not shown). within the outer container 174. The sterilization unit 114 further includes a heating coil 178 disposed within the outer container 174 and configured to heat the water to generate steam for performing sterilization of the leaf 100 placed in the leaf basket 176.
The sterilization unit 114 further includes a pressure sensor 180, a temperature sensor 182, and an electronic control unit (ECU) 184. The ECU 184 is communicatively coupled to the pressure sensor 180, the temperature sensor 182, and the heating coil 178. The pressure sensor 180 and the temperature sensor 182 are configured to detect temperature and pressure within the outer container 174. The ECU 184 is configured to control the switching “ON” and “OFF” conditions based on outputs of the pressure sensor 180 and the temperature sensor 182. In one embodiment, the ECU 184 switches “OFF” the heating coil 178 when the pressure sensor 180 and the temperature sensor 182 detects a predetermined pressure and temperature respectively within the outer container 174. A pressure display unit 186 may be coupled to the pressure sensor 180. The sterilization unit 114 further includes a steam output valve 188 coupled to the outer container 174 and configured to release steam from the outer container 174 after performing the sterilization process. The outer container 174 may also be additionally provided with an inlet pipe, an inlet valve, an outlet pipe, and an outlet valve for directing and controlling inflow and outflow of water. In one embodiment, the leaf 100 is subjected to pressurized steam at 120 degrees Celsius, for example, for a pre-determined time period (10 minutes, for example). The temperature, pressure, and duration values may be varied depending on the load in the sterilization unit 114.
Referring to Figure 7, a schematic view of the roughening unit 116 is shown in accordance with an embodiment of Figure 2. In the illustrated embodiment, the roughening unit 116 is a hole drilling unit. The roughening unit 116 is configured to drill a plurality of holes along at least one side 190 (shown in Figure 1) of the leaf 100. The roughening unit 116 includes a plurality of holders 192 coupled and disposed proximate (side-by-side configuration) to each other in a sequence. Each holder 192 includes a first end provided with a plurality of needles 196 and a second end provided with a biasing element 200, for example, springs. The plurality of holders 192 may be held together by a platform 201. Further, the roughening unit 116 includes a pressure plate 202 coupled to the plurality of biasing elements 200. Additionally, the roughening unit 116 includes a drive unit 204 coupled to the pressure plate 202 via a cam 203. In one embodiment, the drive unit 204 may include but not limited to an electric motor. Additionally, a pedal actuator 205 may be coupled to the drive unit 204 and configured to switch “ON” or OFF” the drive unit 204. The roughening unit 116 further includes a holding plate 206 disposed below the plurality of needles 196 and configured to hold the leaf 100. The drive unit 204 is configured to exert a force via the pressure plate 202 and the biasing elements 200 to the plurality of holders 192 for moving the plurality of needles 196 against the leaf 100 held by the holding plate 206, for forming a plurality of holes along at least one side 190 of the leaf 100. The pressure exerted via the pressure plate 202 is equally distributed along all the fringes. The fringes act independent since they all are not joint on link. This will provide the flexibility for them to act and exert force equally distributed on to the leaves.
Referring to Figure 8a, a schematic side view of the roughening unit 116 is shown in accordance with an embodiment of Figure 7. Referring to Figure 8b, a schematic side view of the roughening unit 116 is disclosed in accordance with an embodiment of Figure 7. As disclosed herein, the roughening unit 116 includes the plurality of holders 192 coupled and disposed proximate (side-by-side configuration) to each other in a sequence. Each holder 192 includes the first end 194 provided with the plurality of needles 196 and the second end 198 provided with the biasing element 200, for example, springs. The pressure plate 202 is coupled to the plurality of biasing elements 200. The holding plate 206 is disposed below the plurality of needles 196 and configured to hold the leaf 100 while punching the holes.
Referring to Figure 9, a schematic view of the holder 192 is shown in accordance with embodiments of Figures 8a and 8b. Each holder 192 includes the first end 194 provided with the plurality of needles 196 and the second end 198 provided with the biasing element 200, for example, springs. In one embodiment, the diameter of an end of each needle 196 may be but not limited to 0.1mm.
As disclosed herein, the purpose the purpose of the roughening unit 116 is to create a plurality of equally distant and dimension holes along the at least one side of the leaf 100. The purpose of making the plurality of holes on the leaf 100 is to enhance the adhesion/bonding property when glue/adhesive is used on the leaf 100 and rolled. The dimension of the needles 196, number of needles 196, distance between the needles 196 may be determined/designed based on the properties such as but not limited to density, viscosity, of the glue, required type of rolling of the leaf 100, and type of the leaf 100.
Referring to Figure 10a, 10b, 10c, 10d, and 10e, schematic views of a roughening unit 208 are shown in accordance with another embodiment. Specifically, figures 10a and 10b are schematic side views of the roughening unit 208. Figure 10c shows a schematic top view of the roughening unit 208. Figure 10d is another schematic side view of the roughening unit 208. Figure 10e is another schematic end view of the roughening unit 208.
The roughening unit 208 includes a stacking unit 210 having a plurality of leaf holders 212 movably disposed on a guide rail 214. The leaf holders 212 may be leaf holding trays provided with spring loaded levers (not shown) which can be moved between a closed position and an open position for respectively holding and releasing the leaf. Each leaf holder 212 is configured to holds the leaf firmly, exposing the at least one side of leaf required for roughening. The provision of plurality of leaf holders 212 facilitates to hold plurality of such leaves simultaneously. In the illustrated embodiment, the plurality of leaf holders 212 are placed one top of the other. In one example, 6 leaf holders 212 may be used. In the illustrated embodiment, the guide rail 214 has an elliptical configuration. The roughening unit 208 further includes a first drive unit 216 coupled to the stacking unit 210 and configured to drive the stacking unit 210 along the guide rail 214. The first drive unit 216 includes but not limited to an electric motor. Specifically, the first drive unit 216 is coupled to the stacking unit 210 via a pair of pulleys 211 and a belt 213. In one specific embodiment, the plurality of stacking unit 210 may be used.
The roughening unit 208 further includes a rolling unit 218 having a plurality a rotatable flap wheels 220. Further, the roughening unit 208 includes a second drive unit 222 coupled to the plurality the rotatable flap wheels 220 and configured to drive the plurality the rotatable flap wheels 220. The second drive unit 222 includes but not limited to an electric motor. The second drive unit 222 is coupled to the plurality the rotatable flap wheels 220 via a pair of pulleys (not shown) and a belt 217. The plurality of rotatable flap wheels 220 is configured to contact and roughen the at least one side of the leaf 100. In the illustrated embodiment, the plurality of rotatable flap wheels 220 are placed one top of the other. In one example, 6 rotatable flap wheels 220 may be used. The provisions of plurality of rotatable flap wheels 220 facilitates to roughen plurality of such leaves simultaneously.
When the first and second drive units 216, 222 are switched on, the stacking unit 210 is moved along the guide rail 214 and the plurality of rotatable flap wheels 220 are rotated at a predetermined speed to contact and roughen one surface of the at least one side of the leaf 100. In one embodiment, a suction unit or a fan may be used to remove the dust generated during roughening. In one embodiment, once the stacking unit 210 and the leaf are moved past the rotatable flap wheels 220, the leaf is removed from the stacking unit 210 and flipped so as to roughen the other side of the leaf.
Referring to figures 11a, 11b, schematic views of the rotatable flap wheel 220 are shown in accordance with the embodiments of Figure 10a, 10b, 10c, 10d, and 10e. Each rotatable flap wheel 220 includes a tangential slit 224 and an abrasive material 226 inserted into the plurality of tangential slits. When the flap wheel 220 is rotated, the abrasive material 226 is contacted to the side of the leaf to roughen the side of the leaf.
In another embodiment, the flap wheels 220 may be replaced with blades aligned at a pre-determined angle. In yet another embodiment, abrasive blasting method may be used for roughening the leaf where an abrasive substance such as salt or soda material is used to roughen the side of the leaf. In yet another implementation, a hard metal unit having knurled region may be used to create impressions on at least one side of the leaf and thereby roughen the leaf.
Referring to figure 12, a schematic block diagram of the gluing unit 118 is shown in accordance with the embodiment of figure 2. The gluing unit 118 includes a glue tank 228 coupled to a glue nozzle 230. The glue tank 228 is used for storing the glue and the glue nozzle 230 is used for dispensing the glue stored in the glue tank 228 to the at least one side of the leaf. Further, the gluing unit 118 includes a compressor 232 coupled to the glue tank 228 via a pressure regulator 234. Additionally, the gluing unit 118 includes an Electronic Control Unit (ECU) 236 and a pedal actuator 238 coupled to the ECU 236. The ECU 236 is coupled to the pressure regulator 234 and configured to control the pressure and duration of dispensing of glue via the glue nozzle 230. The pedal actuator 238 is configured to actuate the ECU 236. In other embodiments, the number of pedal actuators and glue nozzles may vary depending on the application.
Furthermore, the gluing unit 118 includes a leaf holder platform 240 for holding the leaf while dispensing the glue from the glue nozzle 230. The gluing unit 118 may also include a spreader/roller 241 which is used for spreading the glue dispensed to the at least one side of the leaf.
Referring to figure 13a, a schematic diagram of the rolling unit 120 is shown in accordance with the embodiment of figure 2. Referring to figure 13b, a schematic diagram of the rod 246 driven to spirally roll the leaf 100 around the rod 246 to form the tubular structure 250 is shown in accordance with the embodiment of figure 13a. The rolling unit 120 includes an actuator 242 having an actuator shaft 244. In one embodiment, the actuator 242 may include but not limited to an electric motor. The electric motor may be chosen based on the requirement, for example, 0.25 HP single phase motor operable at a speed in a range of 1000-1400 rpm. In a specific embodiment, a variable frequency drive motor may be used. Further, the rolling unit 120 includes a rod 246 having one end coupled to the actuator shaft 244 via a chuck 248. In one embodiment, the rod 246 is a stainless-steel rod coated with anti-stick layer made of Teflon. The dimension of the rod 246 may vary depending on the dimension of the bio-degradable product to be made. The provision of the chuck 248 facilitates to attach the rod 246 of the required dimension and thereby enable flexibility. In another embodiment of the present disclosure, the rod 246 is a tapered stainless-steel rod, wherein an end of the rod having a larger diameter is connected to the actuator shaft 244 via the chuck 248. The actuator 242 is configured to drive the rod 246 to spirally roll the leaf 100 around the rod 246 to form a tubular structure 250. The provision of the rod 246 having a tapered configuration enables easy removal of the tubular structure 250 after rolling.
Further, a fastener 252 is placed around the tubular structure 250 to keep the tubular structure 250 intact until glue is cured. In the illustrated embodiment, the fastener 252 is a clip. In one specific embodiment, the clip may have a sponge with a hollow configuration provided inside. The sponge may be made from low density material having a non-stick layer configured to contact the tubular structure 250. The provision of sponge facilitates to retain the shape of the tubular structure 250 without deformation.
During operation, for example, if the rod 246 has a tapered configuration, the leaf is fed to the rod 246 at an angle of 45 degrees, for example, and the actuator 242 is actuated which in turn causes the chuck 248 to rotate. As a result, the 242 also rotates causing the leaf to be rolled spirally with desired pitch. Once the leaf is rolled, the fastener 252 is placed on the tubular structure 250. The tubular structure 250 along with the fastener 252 is gently removed from the rod 246 and is kept separate until the glue is cured.
Referring to figure 13c, a schematic diagram of the rod (not shown inf FIG. 13c) driven to spirally roll the leaf 100 around the rod to form the tubular structure 250 is shown. In the illustrated embodiment, a fastener 254 which is a thread is spirally rolled over the tubular structure 250. In one embodiment, the thread may be cotton/synthetic thread.
In yet another embodiment, the fastener may be a rectangular sheet sleeve. The sheet sleeve may be made of a thin non-stick material having a Velcro mechanism, for example, to fasten both ends of the sheet sleeve after rolling on the tubular structure 250.
Referring to figure 13d, a schematic diagram of the rod (not shown in Figure 13d) driven to spirally roll the leaf 100 around the rod to form the tubular structure 250 is shown. In the illustrated embodiment, a fastener 256 is hollow tube made of plastic, metal, or any similar material. In one embodiment, the hollow tube may include an inner non-stick layer. Further, the hollow tube may include a plurality of holes for enabling faster curing.
Referring to figures 14a and 14b, schematic diagrams of a rolling unit is shown in accordance with another embodiment of the present disclosure. In the illustrated embodiment, the rolling unit may include a hollow tube 258. A rotatable rod (not shown) driven by a drive unit may be used to feed the leaf through the hollow tube 258 to spirally roll the leaf to form the tubular structure.
Referring to figure 15, a schematic diagram of the heating unit 122 is shown in accordance with the embodiment of figure 2. In the illustrated embodiment, the heating unit 122 is an incubator. The heating unit 122 includes an enclosure 260 having a plurality of trays 262 for holding one or more tubular structures. In one embodiment, the enclosure 260 is made of but not limited to stainless steel. In certain embodiments, the enclosure 260 is provided with insulating material such as but not limited to aluminum foil, thermocol, glass wool, or the like to avoid heat dissipation. The plurality of trays 262 may be slidably coupled to guide rails. The heating unit 122 further includes a plurality of heat sources 264 disposed within the enclosure 260 and configured perform heating of the tubular structure to prevent growth of micro-organisms on the tubular structure and also to enhance rate of curing of the applied adhesive. The number of trays 262 and the number of heat sources 264 may vary depending on the application. The heat sources 264 may include but not limited to incandescent bulbs/tube-lights, heating tubes/element producing light, heating coils, or the like. In one embodiment of the present disclosure, the heating unit 122 further includes one or more temperature sensors (not shown) configured to sense the temperature inside the enclosure 260. At least one controller (not shown) may be coupled to the plurality of heat sources 264 and configured to control the plurality of heat sources 264 to control the temperature inside the enclosure 260. The heating unit 122 may also include an alarm (not shown) for indicating a completion of heat treatment process or any component malfunctions during the heating process. In one embodiment, heat sources may include hot air blowers configured to blow hot air for a pre-determined time period within the enclosure 260.
Referring to figure 16a, a schematic block diagram of the cutting unit 124 is shown in accordance with the embodiment of figure 2. Referring to figure 16b and 16c, schematic diagrams of the cutting unit 124 are shown in accordance with the embodiment of figure 16a. The cutting unit 124 includes a support roller 266 having a plurality of first grooves 268 formed along an axial direction and a plurality of second grooves 270 formed along a circumferential direction and perpendicular to the plurality of first grooves 268. The support roller 266 further includes a plurality of picking pins 272 protruding outwards and arranged along a circumferential direction. The support roller 266 may be made of but not limited to aluminum. In one embodiment, the first and second grooves 268, 270 may have a semi-cylindrical configuration. The cutting unit 124 further includes a drive unit 274 coupled to the support roller 266, a switch actuator 275 and configured to drive the support roller 266. The drive unit 274 includes but not limited to an electric motor. The cutting unit 124 further includes a plurality of movable cutting blades 276 disposed proximate to the support roller 266. The number of movable cutting blades 276 may vary depending on the application. Provision of the plurality of first and second grooves 268, 270 and the plurality of movable cutting blades 276 facilitates to cut plurality of such tubular structures. The plurality of first grooves 268 enables placement of the tubular structures. The movable cutting blades 276 are configured to be placed aligned with the plurality of second grooves 270.
Further, the cutting unit 124 includes a stacking tray 278 disposed proximate to the support roller 266 and configured to hold the tubular structure. In one embodiment, the stacking tray 278 may be made of stainless steel and may be disposed inclined at a predefined angle. Further, the stacking tray 278 may have guide rails provided on both sides for feeding the tubular structure along the predefined direction to the support roller 266. Furthermore, the cutting unit 124 includes a collection tray 280 disposed below the support roller 266 and configured to collect the plurality of bio-degradable products, for example straws, obtained by cutting the tubular structure via a guide tray 279. The collection tray 280 may include a plurality of compartments 281, 283 for collecting the plurality of bio-degradable products and waste parts after the cutting process. In the illustrated embodiment, the compartment 281 is a central compartment used for collecting the plurality of bio-degradable products and the two side compartments 283 are used for collecting waste parts.
The one or more picking pins 272 is configured to transfer the tubular structure from the stacking tray 278 to the adjacent first groove among the plurality of first grooves 268 when the support roller 266 is driven by the drive unit 274. The movable cutting blades 276 are configured to be positioned proximate and aligned to the corresponding second groove among the plurality of second grooves 270. The movable cutting blades 276 are configured to cut the tubular structure to form the plurality of bio-degradable products when the support roller 266 is driven by the drive unit 274. The movable cutting blades 276 may be configured to move along X-axis, Y-axis, and Z-axis. A drive unit may be used to actuate the movable cutting blades 276. In certain embodiments, the movable cutting blades 276 may be rotary cutting blades.
Additionally, the cutting unit 124 includes an actuatable roller brush 282 positioned below the support roller 266 and configured to remove the plurality of bio-degradable products from the adjacent first groove among the plurality of first grooves 268 when the support roller 266 and the roller brush 282 are rotated.
Referring to figure 17, a schematic block diagram of the buffing unit 126 is shown in accordance with the embodiment of figure 2. The buffing unit 126 includes a plurality of buffing pads 284 and a plurality of drive units 286 coupled to the plurality of buffing pads 284 respectively. The plurality of drive units 286 is configured to actuate the plurality of buffing pads 284 respectively to perform buffing of the plurality of bio-degradable products. The drive units 286 may include but not limited to electric drive motors. The number of buffing pads 284 and the drive units 286 may vary depending on the application. An electronic control unit (ECU) 285 is coupled to the plurality of drive units 286, a power adaptor 287, and a switch actuator 289. The ECU 285 is configured to control the operation of the plurality od drive units 286.
The buffing unit 126 further includes a supporting platform 288 positioned below the buffing pads 284. The supporting platform 288 includes a groove socket 290 and grooves attachment 292 detachably coupled to the groove socket 290. The grooves attachment 292 includes a plurality of grooves configured to hold the bio-degradable products while performing the buffing process. Type of the grooves attachment 292 may be changed depending on the application.
Figure 18 shows a flow chart 294 of a method of operating the electro-mechanical system 108 for manufacturing a plurality of bio-degradable products in accordance with an embodiment of the present disclosure.
The method includes removing a mid-rib from a leaf by using a mid-rib removal unit as represented by step 296. The method further includes receiving the leaf after removal of the mid-rib by a cleaning unit and performing a cleaning process of the leaf as represented by step 298. Further, the method includes receiving the leaf after the cleaning process by a sterilization unit and performing a sterilization process of the leaf as represented by step 300. The method additionally includes receiving the leaf after the steaming process by a roughening unit and performing a roughening process along at least one side of the leaf as represented by step 302. Additionally, the method includes receiving the leaf after the roughening process by a gluing unit and applying glue along the at least one side of the leaf as represented by step 304. The method additionally includes receiving the leaf after applying the glue by a rolling unit and rolling the leaf to form a tubular structure as represented by step 306. The method further includes receiving the tubular structure by a heating unit and performing a heating process of the tubular structure as represented by step 308. Further, the method includes receiving the tubular structure after the heating process by a cutting unit and performing a cutting process of the tubular structure to form a plurality of bio-degradable products as represented by step 310. The method additionally includes receiving the plurality of bio-degradable products by a buffing unit and performing a buffing process of the plurality of bio-degradable products as represented by step 312. Additionally, the method includes receiving the plurality of bio-degradable products after the buffing process by a packing unit and performing a packing process of the plurality of bio-degradable products as represented by step 314.
The embodiments of the system and method disclosed herein automates the entire process of manufacturing bio-degradable products such as straws, for example. The exemplary embodiments disclosed herein reduces time consumption and manpower required and hence are more suitable for high volume manufacturing for meeting higher demands.
The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible.
While only certain features of the specification have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the specification.
,CLAIMS:WE CLAIM:
1. An electro-mechanical system (108) for manufacturing a plurality of bio-degradable products, the electro-mechanical system (108) comprising:
a mid-rib removal unit (110) configured to remove a mid-rib (102) from a leaf (100);
a cleaning unit (112) disposed proximate to the mid-rib removal unit (110), wherein the cleaning unit (112) is configured to receive the leaf (100) after removal of the mid-rib (102) and perform a cleaning process of the leaf (100);
a sterilization unit (114) disposed proximate to the cleaning unit (112), wherein the sterilization unit (114) is configured to receive the leaf (100) after the cleaning process and perform a sterilization process of the leaf (100);
a roughening unit (116, 208) disposed proximate to the sterilization unit (114), wherein the roughening unit (116, 208) is configured to receive the leaf (100) after the steaming process and perform a roughening process along at least one side of the leaf (100);
a gluing unit (118) disposed proximate to the roughening unit (116, 208), wherein the gluing unit (118) is configured to receive the leaf (100) after the roughening process and apply glue along the at least one side of the leaf (100);
a rolling unit (120) disposed proximate to the gluing unit (118), wherein the rolling unit (120) is configured to receive the leaf (100) after applying the glue and roll the leaf (100) to form a tubular structure (250);
a heating unit (122) disposed proximate to the rolling unit (120), wherein the heating unit (122) is configured to receive the tubular structure (250) and perform a heating process of the tubular structure (250);
a cutting unit (124) disposed proximate to the heating unit (122), wherein the cutting unit (124) is configured to receive the tubular structure (250) after the heating process and perform a cutting process of the tubular structure (250) to form a plurality of bio-degradable products, wherein each bio-degradable product has a predefined length;
a buffing unit (126) disposed proximate to the cutting unit (124), wherein the buffing unit (126) is configured to receive the plurality of bio-degradable products and perform a buffing process of the plurality of bio-degradable products; and
a packing unit (128) disposed proximate to the buffing unit (126), wherein the packing unit (128) is configured to receive the plurality of bio-degradable products after the buffing process and perform a packing process of the plurality of bio-degradable products.
2. The electro-mechanical system (108) as claimed in claim 1, wherein the mid-rib removal unit (110) comprises:
a pair of conveying rollers (148) disposed proximate to each other and configured to convey the leaf (100);
a drive unit (150) coupled to the pair of conveying rollers (148) and configured to drive the pair of conveying rollers (148); and
a blade (154) disposed proximate and downstream to the pair of conveying rollers (148), wherein the blade (154) is configured to contact the leaf (100) conveyed by the pair of conveying rollers (148) and remove the mid-rib (102) from the leaf (100).
3. The electro-mechanical system (108) as claimed in claim 1, wherein the cleaning unit (112) comprises:
a pair of input rollers (156) and a pair of output rollers (158) for conveying the leaf (100);
a pair of leaf holders (160) positioned between the pair of input rollers (156) and the pair of output rollers (158);
a pair of roller brushes (162) positioned between the pair of input rollers (156) and the pair of output rollers (158) and configured to clean both surfaces of the leaf (100) respectively;
a plurality of drive units (164, 166) coupled respectively to the pair of input rollers (156), the pair of output rollers (158), and the pair roller brushes (162) and configured to drive the pair of input rollers (156), the pair of output rollers (158), and the pair of roller brushes (162); and
a water sprinkling unit (172) configured to sprinkle water for cleaning both surfaces of the leaf (100).
4. The electro-mechanical system (108) as claimed in claim 1, wherein the sterilization unit (114) is an autoclave unit.
5. The electro-mechanical system (108) as claimed in claim 1, wherein the roughening unit (116) is a hole drilling unit comprising:
a plurality of holders (192) coupled and disposed proximate to each other in a sequence, wherein each holder (192) comprises a first end (194) provided with a plurality of needles (196) and a second end (198) provided with a biasing element (200);
a pressure plate (202) coupled to the biasing element (200) of each holder (192);
a drive unit (204) coupled to the pressure plate (202); and
a holding plate (206) disposed below the plurality of needles (196) and configured to hold the leaf (100).
6. The electro-mechanical system (108) as claimed in claim 5, wherein the drive unit (204) is configured to exert a force via the pressure plate (202) and the biasing elements (200) to the plurality of holders (192) for moving the plurality of needles (196) against the leaf (100) held by the holding plate (206), for forming a plurality of holes along at least one side of the leaf (100).
7. The electro-mechanical system (108) as claimed in claim 1, wherein the roughening unit (208) comprises:
a stacking unit (210) comprising a plurality of leaf holders (212), wherein the stacking unit (210) is movably positioned on a guide rail (214);
a first drive unit (216) coupled to the stacking unit (210) and configured to drive the stacking unit (210) along the guide rail (214);
a rolling unit (218) comprising a plurality of rotatable flap wheels (220); and
a second drive unit (222) coupled to the plurality of rotatable flap wheels (220) and configured to drive the plurality of rotatable flap wheels (220), wherein the plurality of rotatable flap wheels (220) is configured to contact and roughen the at least one side of the leaf (100).
8. The electro-mechanical system (108) as claimed in claim 7, wherein each rotatable flap wheel (220) comprises a plurality of tangential slits (224) and an abrasive material (226) inserted into the plurality of tangential slits (224).
9. The electro-mechanical system (108) as claimed in claim 1, wherein the rolling unit (120) comprises:
an actuator (242) comprising an actuator shaft (244); and
a rod (246), wherein one end of the rod (246) is coupled to the actuator shaft (244) via a chuck (248), wherein the actuator (242) is configured to drive the rod (246) to spirally roll the leaf (100) around the rod (246) to form the tubular structure (250).
10. The electro-mechanical system (108) as claimed in claim 1, wherein the heating unit (122) comprises an incubator comprising:
an enclosure (260) comprising at least one tray (262) for holding the tubular structure (250); and
at least one heat source (264) disposed within the enclosure (260) and configured to perform heating process of the tubular structure (250).
11. The electro-mechanical system (108) as claimed in claim 1, wherein the cutting unit (124) comprises:
a support roller (266) comprising a plurality of first grooves (268) formed along an axial direction, a plurality of second grooves (270) formed along a circumferential direction and perpendicular to the plurality of first grooves (268), and a plurality of picking pins (272) protruding outwards and arranged along a circumferential direction;
a drive unit (274) coupled to the support roller (266) and configured to drive the support roller (266);
a movable cutting blade (276) disposed proximate to the support roller (266);
a stacking tray (278) disposed proximate to the support roller (266) and configured to hold the tubular structure (250); and
a collection tray (280) disposed below the support roller (266) and configured to collect the plurality of bio-degradable products.
12. The electro-mechanical system (108) as claimed in claim 11, wherein the at least one picking pin (272) is configured to transfer the tubular structure (250) from the stacking tray (278) to the adjacent first groove among the plurality of first grooves (268) when the support roller (266) is driven by the drive unit (274), wherein the movable cutting blade (276) is configured to be positioned proximate and aligned to the corresponding second groove among the plurality of second grooves (270), and wherein the movable cutting blade (276) is configured to cut the tubular structure (250) to form the plurality of bio-degradable products when the support roller (266) is driven by the drive unit (274).
13. The electro-mechanical system (108) as claimed in claim 12, wherein the cutting unit (124) comprises a roller brush (282) positioned below the support roller (266) and configured to remove the plurality of bio-degradable products from the adjacent first groove among the plurality of first grooves (268) when the support roller (266) and the roller brush (282) are rotated.
14. The electro-mechanical system (108) as claimed in claim 1, wherein the buffing unit (126) comprises:
a buffing pad (284);
a drive unit (286) coupled to the buffing pad (284) and configured to actuate the buffing pad (284); and
a supporting platform (288) comprising a grooves attachment (292) positioned below the buffing pad 9284), wherein the grooves attachment (292) is configured to hold the plurality of bio-degradable products, and wherein the buffing pad (284) is configured to perform the buffing process of the plurality of bio-degradable products held in the grooves attachment (292).
15. A method of operating an electro-mechanical system (108) for manufacturing a plurality of bio-degradable products, the method comprising:
removing, by a mid-rib removal unit (110), a mid-rib (102) from a leaf (100);
receiving, by a cleaning unit (112), the leaf (100) after removal of the mid-rib (102) and performing a cleaning process of the leaf (100);
receiving, by a sterilization unit (114), the leaf (100) after the cleaning process and performing a sterilization process of the leaf (100);
receiving, by a roughening unit (116, 208), the leaf (100) after the steaming process and performing a roughening process along at least one side of the leaf (100);
receiving, by a gluing unit (118), the leaf (100) after the roughening process and applying glue along the at least one side of the leaf (100);
receiving, by a rolling unit (120), the leaf (100) after applying the glue and rolling the leaf (100) to form a tubular structure (250);
receiving, by a heating unit (122), the tubular structure (250) and performing a heating process of the tubular structure (250);
receiving, by a cutting unit (124), the tubular structure (250) after the heating process and performing a cutting process of the tubular structure (250) to form a plurality of bio-degradable products, wherein each bio-degradable product has a predefined length;
receiving, by a buffing unit (126), the plurality of bio-degradable products and performing a buffing process of the plurality of bio-degradable products; and
receiving, by a packing unit (128), the plurality of bio-degradable products after the buffing process and performing a packing process of the plurality of bio-degradable products.