Development and Evaluation of a Mechanized Destalking System for Dry Chilli Processing

India is the leading global producer, consumer, and exporter of chilli (Capsicum annuum), yet the destalking of dry chilli remains a labor-intensive and health-hazardous operation. Manual removal of the calyx and stalk increases labor costs, exposes workers to respiratory ailments, and limits the adoption of post-harvest mechanization. To overcome these challenges, this research aimed to develop and evaluate the performance of a mechanized destalking system for dry chilli processing. The system consists of a perforated rotating trammel cylinder, a fixed sharp blade, internal baffles, collectors, and a 1.5 HP motor regulated through a variable frequency drive. As chillies rotate inside the perforated cylinder, the stalks entangle and are slit by the blade, allowing continuous separation. The machine achieved a maximum capacity of 60.83 kg/h, 83.80% destalking efficiency, 4.4% breakage, and 0.62 kWh energy consumption. Optimal performance occurred at 10.37% moisture content, 61.67 kg/h feed rate, 5° inclination, and 15 rpm, with an overall desirability of 0.78.