<b>Development and Performance Analysis of a Pedal-Operated <i>Wadi</i> (Nuggets) Making Machine</b>

This study presents development and performance evaluation of a pedal‑operated wadi (nuggets) making machine, designed to improve productivity, hygiene and product uniformity compared with traditional hand‑forming methods. Conventional wadi preparation is highly labour -intensive and often produces inconsistent products, whereas the proposed system reduces direct manual handling, enhances hygienic conditions and increases throughput. The machine consists of a hopper, a pair of grooved rollers, a pedal-driven transmission system, and a manual cutting unit. During operation, the pedaling action of the operator is converted into continuous rotary motion via a pedal–wheel and pulley arrangement. This motion drives the synchronized grooved rollers, which control the flow of the batter, while a manually operated cutting blade periodically cuts the extruded batter into uniform wadis. Process parameters were optimized using Response Surface Methodology (RSM) with a Central Composite Design (CCD). Roller speed (18–30 rpm), batter moisture content [45%–70% wet basis (wb)], and cutting speed (20–30 strokes min-1) were taken as independent variables, and throughput was used as the response variable. The optimum conditions of roller speed of 19.9 rpm, batter moisture content of 63.4% (wet basis), and cutting speed of 28 strokes min-1 yielded a predicted throughput of 10.62 kg h-1, which was in good agreement with experimental results, with a desirability value of 1.0. The cost–economic analysis indicated a payback period of about 1–2 months, suggesting that the machine is well suited for small‑scale and rural food processing enterprises.