Paani Genie T.Bhattacharjee 1021210374

Fajal Ashraf 1021210346

Jay Puducheri 1021210349

Guide Mr: K.V Sreejith

Co Guide: Dr. Haridasan

Batch Number : M59

B.Tech (Mechanical) 4th Year

Paani Genie T.Bhattacharjee 1021210374

Fajal Ashraf 1021210346

Jay Puducheri 1021210349

Guide Mr: K.V Sreejith

Co Guide: Dr. Haridasan

What is Paani Genie?

• A water roller that has a capacity of 90 litres. • Five times the capacity of a normal pot. • Made of high density polyethylene. • Rotomoulded. • Has an easily attachable/ detachable steel rod. • Life span of 3 years and more. • Eco-friendly, prevents soil erosion.

Objective

• The purpose of implementing a device, which can eliminate the burden of daily water collection and transportation from rural life in India.

• Evidently making life simpler with the help of a simple machine, reaching the needy people.

ROTATIONAL MOULDING

.Used for hollow plastics.

.Plastic powder is used.

.Create consistency in wall thickness and density.It produces strong durable product.

PROCESS

CHARGING THE MOULD.filling of mould with determined quantity of powder metarial. .filling of material More than 80% of all the material used is from the POLYTYLINE family. Some common materials are: Polyethylene Polypropylene Polyvinyl Chloride Nylon

HEATING AND ROTATIONAL PROCESS

• Both process happens simultaneously• Time of heating is very critical• Mould is rotated on two perpendicular axies.• No pressure is being applied.

Cooling of mould and De molding.Bi-axial rotation is continued..Cooling is being done by air or water..Generally it is being done by fan..This process is quite lengthy and very time taking.

Advantages• A hollow part is made in a single piece with no

weld lines or joints• Product essentially stress-free• The molds are relatively inexpensive• There is no material wastage in this molding

process.• It is of low cost with respect to the other molding

process.• Low residual stress• It is also possible to make multilayer products

• Inserts are relatively easy to mold in

Disadvantages

• The manufacturing times are long.• The choice of molding materials is limited.• the material cost are relatively very high

because most the time we will have to add some additives to make the powder of plastics .these both the things are very expensive

• There is chance of air trapping in the mould.• Some geometrical features (such as ribs) are

difficult to mold

Application• Tanks- fuel tanks,shipping tanks,oil tanks• Automotive-door armrest,instruments

panel• Containers-planters ,airline container• Toys and Leisure-balls ,ride on toys, hobby

horses• Marine Industry-dock floats,pool

liners,docking fenders

HDPE - High-density polyethylene

Choice of material

After its experimental preparation in the 1930s the application in high frequency radar cables during World War II gave impetus to its commercial production. Today Polyethylene (PE) is one of the most widely used plastics with production in the billions of pounds each year. High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a polyethylene thermoplastic made from petroleum. With a high strength-to-density ratio, HDPE is used in the production of plastic bottles, corrosion-resistant piping, geomembranes, and plastic lumber.• Products• Properties• Applications• Features• Processing• Manufacturers 

Advantages of HDPEImpact, and wear resistant. Flexible, can have very high elongation before breaking. Generally good chemical resistance. •Food Contact Acceptable•Processability, Good•Copolymer•ESCR, High (Stress Crack Resist.)•Antioxidant•Density, Low•Density, High•Impact Resistance, Good•Toughness, Good

Disadvantages of HDPESensitive to thick sections in your part. It may have voids, bubbles or sink. Poor dimensional accuracy. Low mechanical and thermal properties. Price is low to very low. •High thermal expansion•Poor weathering resistance•Subject to stress cracking•Difficult to bond•Flammable•Poor temperature capability•Low strength/stiffness

Methodology• To manufacture Paani Genie after which we will put it through

comprehensive testing and analysis. • Hardness Test, Wear Rate through Abrasion Test, Migration

Test, UV Test, Surface Roughness Test, Yield Test among others for both Paani Genie and Hippo Water Roller.

• To implement distribution in a two phase process. In phase 1, we will distribute upto 15 rollers in our pilot village. Phase 1 will be focused on research and analysis (both test and user). Phase 2 will be larger scale production for the remainder of the pilot village at the onset of Summer 2016.

Finished Products

Tests• Visual appearance• Capacity• Overall height• Overall diameter• Internal diameter of the manhole• Material identification• Density• Melt flow index• Wall thickness • Resistance to deformation• Resistance to Impact• Tensile strength• Flexural Modulus

S.No Property Standard Units Results obtained

1Visual appearance

Both internal and external surfaces are smooth, clean and free from other defects2 Capacity litre 903 Overall height kg 8,84 Overall diameter mm 465,185 Internal diameter of the manhole mm 134,466 Material identification HDPE7 Density ASTM D792 g/cc 0,928 Melt flow index ASTM D1238g/10min 5,349 Wall thickness  mm 8,457

10 Resistance to deformation % 0,1211 Resistance to Impact No crack No Puncture12 Tensile strength Mpa 19,313 Flexural Modulus MPa 845,714 Overall Migration IS9845

at 70 deg Ca) distilled water mg/dm^2 2,86b)Ageous Solution mg/dm^2 3,46

Table showing Test Results from CIPET

Plan of Action

• To distribute Paani Genies in our pilot village, Vinayaganallur, a village close to Vedanthangal Bird Sanctuary.

• To use our research, comparison and analysis between Paani Genie and Hippo Water Roller to find out where there is space for improvement for Paani Genie and where our product is superior. We must be sure of the quality of the product.

• We plan to visit the pilot village on a daily basis during phase 1 of distribution to further get a feel for the effect Paani Genie has on the people.

• Based on our findings from phase 1 of distribution, we will generate effective solutions to any problems or challenges that may arise in usability, functionality or feasibility.

Dimensions

• 90 Litre drum: 50 x 50 x 65 cm• Rod Handle: 100 x 70 x 3 cm• Weight: 8.5 kg• Opening Diameter: 135 mm/5.3 inches

Our journey so far…

• Came across the Hippo Water Roller a year ago. • Brought a prototype to India. • Found our pilot village, Vinayaganallur, a little distance from

Vedanthangal, and we will be conducting a research project in this village over the next couple of months.

• Our Mumbai-based manufacturer (INFRA), has a plant in Chennai, located ten minutes away from the village.

• We successfully managed to design and manufacture our mould and our first prototype.

• Now further tests are to be performed on the prototype and the mould is to be used for further production of our rollers.

• May 1st : First batch of 15 rollers will arrive

• May 2nd : Our Paani Genie and the original Hippo Water Roller will be given to CIPET for testing while distribution will begin in our pilot village, Vinayaganallur.

• May 6thth : Test Results will be obtained.

• May 2nd to May 20th – Live Feedback from Paani Genie users.

• May 20th – Order 85 Paani Genie rollers if the desired test and user feedback is obtained.

• June 10th- Phase 2 (85 rollers) of distribution in Vinayaganallur, our pilot village.

What is Paani Genie’s first target village?

• Women and children in Vinayaganallur walk around 1.5km for water from April to September.

• 2-3 members per household make trips to water source more than twice a day.

• Carry 20 litre pots (kodums) either on their head or hips. • Approximate cost of one kodum (Rs. 80/-) is equivalent to one

Paani Genie roller (Rs. 100/-).

Literature

• http://www.thehindu.com/todays-paper/tp-features/tp-propertyplus/smart-water-solution/article7165265.ece

A bunch of Chennai students are making Paani Genie, a 90-litre water container that can be rolled along. Sponsors can support the project for city slums. Vishal MenonIf you live in Chennai, you cannot miss the long lines snaking in front of water tankers, as women and children wait, colourful plastic pots in hand, for their turn to come.Collecting water for domestic use is an arduous and thankless task that mostly falls upon the family’s women, taking up a good portion of their daily time.It is to change this that a bunch of youngsters from Chennai got together to find a solution.A group of 15 college students are making Paani Genie, a 90-litre plastic barrel that can be rolled on the ground with the help of a steel handle attached to it.“A standard plastic pot ( kodam ) holds 15-20 litres of water and, in most cases, women make multiple trips carrying two pots at a time to meet their family’s needs,” says Jay Puducheri, president of the Paani Genie company.“With Paani Genie, we want to reduce the trips and the physical labour.”Inspired by the Hippo Water Roller Project in South Africa, the team is now making Paani Genies for supply to a village two hours outside Chennai.“We’re working closely with the Hippo Water Roller Project and use their expertise not just to make the container but also to explain its use to the people. We have chosen Vinayaganallur, which has a significant water problem during summer. With around 100-150 houses, the village isn’t too large for us to run a product trial. Considering the fact that the village is just an hour away from college, we can go there every weekend,” says Jay.The students study mechanical engineering at SRM University.The Hippo Roller is made of linear low-density polyethylene, but Paani Genie is being made with high density polyethylene to suit India’s rough terrain.“We expect each roller to last three to five years. The idea was to create an all-terrain roller of high quality. Also, since we have no plans of giving it for free, we expect the users to take good care it and not treat it like a freebie.”It takes Rs. 3,500 to make each Paani Genie, which is raised from individual, social-minded sponsors.“

We will hand over the rollers at a reasonable cost of Rs. 100 to a few people and observe its use. When limited to a small group, it will be easier to keep track. Also, it is important to note what they do with the roller, once water supply improves after summer.”The team has no intention to patent the product. “We’re not here to make a profit. Nor do we want others to misuse it. This is why we’re going to make the product licence free. It shouldn’t be limited to a few homes and places, its reach should be wider,” says Puducheri.Paani Genie is being made with high density polyethylene to suit India’s rough terrain

The innovative design allows water to be placed inside the “wheel” rather than

carried above the wheel. The 90kg (200 pound) weight of water is borne on the

ground resulting in an effective weight of just 10kg (22 pounds) on level ground.

Children and the elderly can easily manage a full roller over most types of terrain.

Extensive field tests over many years and various awards have proven the

effectiveness of the Paani Genie. Approximately five times the normal amount of

water can now be collected in less time with far less effort.

The drum is manufactured from UV stabilized Polyethylene and has been

designed to withstand typical rural conditions such as uneven footpaths, rocks and

even broken bottles. The large opening (135 mm / 5.3 inch diameter) allows for easy

filling and cleaning of the interior. The sealed lid ensures hygienic storage of water

and the steel handle provides firm control over difficult terrain while pushing or

pulling the roller.

CONCLUSION