Sustainable Processing of Banana Agro-waste: Development and Evaluation of a Banana Stem Fiber Extraction Machine

Abstract

Banana cultivation generates approximately 30–40 million tons of agro-waste globally each year, with pseudo-stems constituting a significant portion. These pseudo-stems are a rich source of high-strength natural fibers, yet they remain largely underutilized, often discarded as waste. Banana fiber has garnered attention for its biodegradability, tensile strength, and potential applications in textiles, composites, and eco-friendly products. This study presents the design, fabrication, and performance evaluation of a mechanized banana stem fiber extractor aimed at addressing the limitations of labor-intensive manual extraction methods. The developed machine features a robust frame, AC motor, rollers, pulleys, and metal stripping components, designed to ensure durability, user safety, and optimal fiber yield. Critical design parameters—including roller diameter, blade geometry, motor rating, and belt coupling—were systematically optimized to achieve reliable operation, minimize fiber breakage, and reduce processing time. The comparative performance tests revealed that the mechanized extractor produced a fiber yield of 65–70%, substantially higher than the 47–50% yield obtained manually. Labor requirements decreased from 2–5 operators to a single user, while processing time per kilogram of pseudo-stem was reduced from 21 minutes to 6 minutes. Waste generation dropped from 50–55% to 25–30%, demonstrating improved resource efficiency. The extracted fibers were uniform in size and quality, suitable for diverse industrial applications. By converting agricultural residues into high-value materials, the mechanized extractor supports sustainable practices, rural income diversification, and scalable green manufacturing. This study highlights the transformative potential of banana fiber mechanization, contributing to environmental sustainability and economic development in banana-growing communities. The findings underscore the importance of integrating technological innovation with agro-waste management to create eco-friendly and economically viable solutions.