What it does
This project presents an affordable and sustainable solution to coconut shell waste by developing a compact charcoal production machine that helps small vendors produce clean-burning charcoal, reducing deforestation and promoting rural entrepreneurship.
Your inspiration
Malaysia produces a significant volume of coconut shells as agricultural waste, yet most of it is discarded or burned, contributing to pollution and resource waste. During our field visits and surveys with coconut vendors, we noticed a gap in affordable and practical machinery to utilise these shells efficiently. This inspired us to design a machine that could empower rural communities, reduce reliance on wood charcoal, and promote environmental sustainability.
How it works
Our design is a compact and modular machine built with a galvanised iron shell and an alumina-based refractory lining for heat insulation. The system is divided into two chambers: the lower chamber burns waste wood to generate heat, while the upper chamber carbonises the coconut shells into charcoal. Ventilation holes, chimneys, and a water filtration exhaust reduce emissions. Temperature sensors and a servo-controlled valve regulate airflow for combustion efficiency. Ash is collected in a tray, and the system is easy to operate and maintain with less than two hours of training.
Design process
Research & Market Survey: We surveyed coconut milk vendors and found strong demand for a cost-effective machine under RM 5,000. We analysed user needs and created design metrics. Concept Generation: 12 design sketches were created, filtered using the Pugh matrix and House of Quality. The best ideas were combined into a final concept. CAD & Simulation: We modelled the prototype in SOLIDWORKS, ran thermal and structural simulations using ANSYS, and selected materials based on thermal, mechanical, and cost factors. Prototyping: Fabricated using TIG welding and coated with refractory cement. Sensors and Arduino-based automation were integrated for temperature control. Testing & Iteration: Initial tests showed heat inefficiency. We added ventilation, thickened insulation, and improved sealing. Future improvements include fan integration and safer door handles. Cost Optimisation: Final prototype costs RM 924. With mass production, costs could decrease to RM 634 per unit.
How it is different
What sets our design apart is that it is purpose-built for small-scale, local applications—specifically targeting coconut vendors and micro-entrepreneurs in rural or semi-urban settings. While many charcoal production systems are industrial-scale or cost-prohibitive, ours is affordable, compact, and easy to operate, requiring less than two hours of training. The design emphasises thermal efficiency (>70%), uses readily available materials like galvanised iron and refractory cement, and incorporates basic automation (via Arduino and sensors) to improve combustion control. It also features water-based smoke filtration to reduce emissions—an uncommon feature in small-scale units.
Future plans
Improve automation using integrated fans and better temperature feedback systems. Pursue local manufacturing partnerships to scale production affordably. Conduct long-term durability and user trials in rural settings. Seek certification (e.g., DOSH) for safety compliance. Explore social enterprise models for distribution to underserved areas. Apply for incubation support and environmental grants to bring the product to market.
Share this page on