BSc.

Thesis proposal

Design and Development of

Automatic Injera Baking Machine

A Thesis proposal Submitted to

Department of Mechatronics Engineering

By

1. Ananya Senay 0313/13

2. Remedan Jemal 2100/13
3. Selman Mesfin 4169/13

Presented in partial Fulfillment of the Requirement Bachelor Degree in

Mechatronics Engineering

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 BSc. Thesis proposal

Abstract
Injera, a classic Ethiopian flatbread, is traditionally baked using a labor-intensive, power-
intensive, and inconsistently sized procedure that results in higher labor expenses and
energy waste. To solve these problems, this project intends to design and create an
automated injera baking machine that produces a reliable, superior product in big
quantities. Using easily accessible components like sensors, actuators, electrical circuits,
and different metals, the machine will employ simple mechanics and be controlled and
precise with the aid of software applications like MATLAB. The anticipated result is a
dependable, economical, and energy-efficient injera baking system that lowers labor and
operating expenses while preserving consistent quality and increasing production
capacity.

Keywords: Injera, Automated baking, Consistency, Quality, Large-scale production,

Sensors, Actuators, MATLAB, Cost-effective, Energy-efficient, Reduced labor.

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 BSc. Thesis proposal

Approval

Wollo University Kombolcha Institute of Technology

College of Engineering

Department of Mechatroincs Engineering

The thesis proposal titled

Design and Development of automatic Injera Baking Machine

Is approved for Bachelor of science Degree in Mechatronics Engineering

Advisor name Samson Z. Date 03/04/2025

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 Table of Content

1 Introduction ................................................................................................................................... 1
1.1 Problem Statement .......................................................................................................... 2
1.2 Objectives of the Research .................................................................................................... 2
1.2.1 General Objective ........................................................................................................... 3
1.2.2 Specific objective ............................................................................................................ 3
1.2.3 Scope of the Thesis ......................................................................................................... 3
1.2.4 Significance of the Study ................................................................................................. 4
2 Literature Review.......................................................................................................................... 5
3Methodology .................................................................................................................................. 7
3.1 Proposed Conceptual Designs ............................................................................................... 7
3.2 Proposed Mechanical Design Analysis Method ..................................................................... 7
3.3 Proposed System Dynamics Modelling Method .................................................................... 8
3.4 Proposed System Model Analysis Method ............................................................................ 9
3.5 Proposed Control Strategy Design ....................................................................................... 12
3.6 Electronics Systems Design and Selection ........................................................................... 12
3.7 Proposed Simulation and Testing Method .......................................................................... 12
3.8 Production Drawing Development Framework ................................................................... 12
4 Time Schedule ............................................................................................................................ 13
5 Budget Summary ........................................................................................................................ 14
Reference: ...................................................................................................................................... 15

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 Acronym’s

Abbreviation Description

SPC Statistical Process Control

CNC Computer Numerical Control
DC Direct Current
MATLAB Matrix Laboratory
PID Proportional-Integral-Derivative

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 LIST OF TABLES

Table 5.1 Budget Estimation………………………………………………………………………………………………….18

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 BSc. Thesis Proposal

1 Introduction
Injera, a conventional Ethiopian flatbread, is a staple nourishment that holds social and
dietary noteworthiness in Ethiopia and encompassing districts. In any case, conventional
injera generation is labor-intensive and requires critical vitality, making it challenging to
scale for commercial needs. The prepare includes warming huge clay plates over tall
control, frequently coming about in conflicting quality, measure, and surface. This
wastefulness has long postured a issue for commercial injera makers who require a solid,
energy-efficient way to keep up quality whereas expanding output.

Early ponders and plans for conventional preparing hardware, counting electric griddles
and semi-automated frameworks, pointed to make strides effectiveness, but confinements
in accomplishing uniform quality and diminishing control utilization continued. Later
inquire about by Ethiopian and East African nourishment innovation bunches has advance
investigated mechanized strategies of injera generation. Be that as it may, these strategies
still depend intensely on manual oversight and do not completely address the require for
large-scale, high-consistency yield with negligible labor.

This venture addresses a clear crevice in injera generation innovation by proposing a

completely computerized framework planned for commercial applications. The objective
is to make an robotized injera preparing machine that makes strides generation consistency,
diminishes labor prerequisites, and brings down vitality utilization. By utilizing promptly
accessible materials—such as metals, sensors, actuators, and control circuits—and
leveraging computer program instruments like MATLAB for control and exactness, this
machine will optimize the heating process.

The centrality of this inquire about lies in its potential to modernize injera generation,
profiting commercial pastry shops, eateries, and other suppliers who must meet tall request
with uniform quality. Eventually, this work looks for to provide a cost-effective and
energy-efficient arrangement that not as it were moves forward efficiency but moreover
jam the conventional quality of injera in a versatile way.

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1.1Problem Statement

The traditional cooking method for injera is still labor-intensive, energy-intensive, and
inconsistent in quality, despite its social significance and high demand. It is difficult to
achieve high-quality, large-scale generation with current technologies, both manual and
semi-automated, because they require significant human control and incur operating
expenses. Electric griddles and half-mechanization are examples of previous
mechanization efforts that have advanced proficiency but have fallen short in ensuring
consistent surface, texture, and flavor, especially in high-demand environments.

This extends points to address these confinements by planning and creating a completely
computerized injera preparing machine competent of creating injera at a steady quality and
on a commercial scale. The proposed framework will utilize effectively available
components, such as sensors, actuators, and control circuits, and will join computer
program control through MATLAB for exactness. This approach presents a novel
commitment to the field by joining an open and comprehensive robotized arrangement
custom fitted for the particular prerequisites of injera production.

Given the rising request for proficient and steady nourishment generation strategies, this
inquire about is both convenient and important. The project’s scope is attainable, as it
leverages basic mechanical plan and promptly accessible innovation, and it points to
advantage commercial pastry shops and nourishment benefit suppliers by diminishing
labor costs, minimizing vitality utilization, and conveying a high-quality item in huge
amounts.

1.2 Objectives of the Research

The main goal of this project is to develop an automated injera baking system that will
lower labor and energy expenses related to conventional techniques while improving the
uniformity, quality, and production efficiency of injera for commercial use.

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 BSc. Thesis Proposal

1.2.1 General Objective

To overcome the drawbacks of conventional techniques by designing and creating a fully

automated injera baking equipment that guarantees excellent uniformity, quality, and
efficiency in commercial injera manufacturing.

1.2.2 Specific objective

The particular goals of this study include examining the conventional injera baking method
to pinpoint important elements that affect quality, uniformity, and energy efficiency. In
order to create a complete model of the automated injera baking machine, it will include
easily accessible parts including sensors, actuators, and control circuits. The project will
use MATLAB to create an exact control mechanism that will ensure consistent quality
across a range of production volumes. It also looks to optimize the machine's energy use,
cutting down on electricity without compromising productivity. To evaluate the machine's
performance, testing and validation will be carried out to make sure it is consistent and
scalable throughout a range of operating circumstances. In conclusion, the project will
record the design, control methods, and test outcomes to facilitate future improvements
and commercial use.

1.2.3 Scope of the Thesis

This proposal centers on the plan, improvement, and execution of an mechanized injera
preparing machine, pointed at upgrading the consistency, quality, and effectiveness of
injera generation for commercial purposes. The scope incorporates analyzing the
conventional injera preparing prepare to distinguish parameters that influence consistency
and vitality utilization, as well as planning a control component utilizing MATLAB to
guarantee exactness over changing generation scales.

The consider will include the choice of promptly available components, counting sensors,
actuators, and control circuits, to construct a machine demonstrate that optimizes vitality
utilization whereas keeping up generation quality. Testing and approval will be conducted
through reenactments and trials to assess execution beneath different operational
conditions, guaranteeing adaptability and consistency.

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The inquire about prohibits progressed computerization methods past what is essential for
injera generation, as well as high-cost components that may constrain commercial
possibility. Also, the proposition will not investigate elective injera formulas or preparing
strategies past conventional procedures. The center remains on creating a cost-effective,
energy-efficient arrangement custom-made for large-scale generation whereas archiving
the plan and testing stages for future reference and potential commercial application.

1.2.4 Significance of the Study

By combining embedded technology, control systems, and mechanical design, this project
makes a significant contribution to mechatronic engineering while modernizing the
conventional injera production method. The project demonstrates the application of
mechatronic systems in creating an accurate, reliable, and energy-efficient production
solution for commercial settings by building an automated injera baking machine.

The project’s essential affect is its imaginative combination of available electromechanical

components—such as sensors, actuators, and control circuits—with implanted frameworks
and MATLAB for improved control and exactness. This integration outlines the adequacy
of mechatronic approaches in fathoming real-world challenges in nourishment generation,
particularly tending to issues like conflicting item quality, tall labor requests, and critical
vitality use.

Moreover, the consider illustrates the potential for scaling conventional forms through
robotization, giving important bits of knowledge appropriate to comparable nourishment
generation methods. By bringing down operational costs, guaranteeing uniform quality,
and expanding yield capacity, the computerized injera machine presents a maintainable
arrangement for commercial nourishment generation. The extend emphasizes the
significance of control frameworks, input circles, and implanted innovation in moving
forward generation proficiency, making it a pertinent and viable ponder for those interested
in progressed applications of mechatronic frameworks.

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 BSc. Thesis Proposal

2 Literature Review
Traditional Injera baking is labor-intensive and relies heavily on expertise. Mechanizing
the process can reduce labor demands, ensure product consistency, and potentially lower
production costs, making Injera production more accessible and scalable. However,
developing an effective Injera baking machine is challenging due to the unique
characteristics of Injera batter, which is thin and requires specific heat and moisture
conditions to form its signature spongy texture with "eyes" (bubbles). [1] An early
prototype of an automated Injera machine developed by Addis Engineering replicated
traditional mitad characteristics using electric heating elements, reducing reliance on open
flames. This initial design could produce Injera with consistent texture and thickness,
demonstrating the viability of automated production.

Developing an Injera baking machine involves complex design requirements, primarily

related to temperature control, batter spreading, and energy efficiency. Traditional clay
mitads are heated over open flames or electric coils, which create the high temperatures
necessary for cooking Injera evenly. Modern machines must replicate this temperature
control while potentially offering more precise and efficient options.Research has
highlighted the importance of an efficient heat source and even heat distribution across the
cooking surface. According to Ademe et al. (2019), induction heating and ceramic plates
are promising options due to their ability to distribute heat uniformly while reducing energy
consumption. [2] The Alem Injera Machine, designed by Mekonnen Engineering, uses a
ceramic heating plate to emulate traditional clay mitads. Equipped with a digital
temperature controller, it ensures that the batter cooks at an even temperature across the
surface, producing Injera with consistent texture.

Engineers developing Injera machines have drawn insights from other automated flatbread
makers, such as roti and tortilla machines. These machines share certain functional
requirements, like precise temperature control and handling of thin batter or dough.
However, Injera batter is distinct in its high-water content and low viscosity, making it
challenging to replicate traditional cooking without adjustments. Studies by Gedi et al.
(2021) suggest that while roti and tortilla machines can handle thicker, low-moisture

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doughs, adapting similar designs for Injera batter requires modifications, especially in
terms of batter flow rate and cooking time. Unlike these other flatbreads, Injera needs time
for bubbles to form and set on the cooking surface, which affects the machine’s speed and
heating cycle. [3] The Injera machine developed by Samrawit Foods incorporates a batter
dispenser calibrated to handle the high-water content of Injera batter. The machine
automatically pours the batter at a controlled rate, then adjusts heating times to allow the
formation of bubbles, mimicking traditional methods.

Traditional Injera baking is energy-intensive, typically relying on wood or charcoal as fuel.

Modern Injera machines aim to improve energy efficiency, particularly important in
regions with limited access to affordable energy. Some machines use electric heating
elements, while others explore renewable energy sources like solar panels for rural
applications. Research by Tesfaye and Getu (2022) found that ceramic heaters and
induction systems are more energy-efficient than resistance coils, as they minimize heat
loss. They also explored the potential of integrating solar panels, which would enable Injera
production in off-grid locations. [4] The SolarTek Injera Maker is designed for rural areas
with limited electricity access. Equipped with solar panels, it operates independently of the
electrical grid, making it both sustainable and cost-effective for communities where
traditional fuel sources are scarce or expensive.

The proposed problem of creating an effective Injera baking machine has seen some
progress, but it has not been fully solved to the extent that a universally accepted, widely
accessible solution exists. While several modern Injera machines have been developed,
each attempting to replicate traditional baking methods, challenges remain in key areas
such as quality, affordability, cultural acceptance, and energy efficiency.

In summary, while significant strides have been made in developing Injera baking
machines, a fully satisfactory solution that balances affordability, energy efficiency,
quality, and consumer acceptance has not yet been achieved. This area presents
opportunities for further research and innovation, particularly to create machines that
replicate traditional quality, offer customizable settings, and are accessible to a wide range
of users. Thus, the proposed problem remains partially unsolved, with room for valuable
contributions in improving machine design and user acceptance.

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 BSc. Thesis Proposal

3 Methodology

3.1 Proposed Conceptual Designs

In this stage we proposed 2 different ideas in order to tackle the dough dispensing
mechanism.
Injera baker with 2-axis translational dispenser
This is a concept that is borrowed from CNC machine which utilizes 2 translational arms
where the tip connected. This will enable us to create the desired shape of the injera. This
will enable the dough dispenser to reach and make the injera shape.
Injera baking with rotating and translating arm
In this concept design we use a jib arm with translating single slot dispenser. With the
angular movement of the motor and the translational movement of the tip we can archive
the injera shape with ease. This will enable the dough dispenser to reach and make the
injera shape.

3.2 Proposed Mechanical Design Analysis Method

In this section, we will discuss possible methods for analyzing the mechanical design of
the Automatic Injera baking machine. These methods will help us understand the structural
integrity, dynamics, and overall performance of the system under various conditions. It
may include

 Structural Analysis (bending, deflection, shear):

• Used to assess the strength and stability of structures, such as for the structures that
hold the mitad cap for opening and closing of the injera baker. (Load analysis is
used)
• The bending and deflection for the carrier of the mitad
• The track for the mitad cap
• Injera puller structure

 Torque and Power Analysis:

• Used to analyze the Torque and power needed within the system
• In order to know what kind and what power of motor is needed to rotate the parts.
• Injera puller structure.

 Thermal Analysis:

• Analyzes heat transfer, thermal stresses, and temperature distributions in materials.

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 BSc. Thesis Proposal

• the temperature needed to bake injera optimally.

• From the material used as the mitad to understand which material will have optimal
use to transfer the heat and bake the injera
• Other part of the system in order to be safe that the heat wont melt or damage other
parts

 Fluid Dynamics:

• Simulates fluid flow and interactions in various systems, important in

aerodynamics and hydrodynamics.
• Is used in the transfer of the dough to the tip with the optimal flow rate and
pressure
• Viscosity of the fluid(dough) to make injera

3.3 Proposed System Dynamics Modelling Method

The design and development of an automatic Injera baking machine can greatly benefit
from applying Newtonian mechanics, which offers a solid framework for understanding
the system's dynamics. By utilizing Newton's laws of motion, especially the second law (F
= ma), we can systematically analyze the forces acting on essential components like the
conveyor belt and heating elements. This analysis leads to the formulation of equations of
motion that illustrate how these components react to various inputs, such as motor torque
and heat transfer. The resulting model can be expressed in both transfer function and state
space forms, allowing for a comprehensive examination of the system's behavior. This dual
representation is beneficial as it facilitates the analysis of stability and dynamic response,
aiding in the design of effective control strategies. By simulating the system under different
operational conditions, engineers can enhance the performance of the automatic Injera
baking machine, ensuring consistent quality and efficiency while accommodating
variations in input and disturbances.

The automatic Injera baking machine needs careful control and performance optimization,
which can be effectively achieved using the Euler method for modeling system dynamics.
By applying the Euler method, we can break down the equations of motion into discrete
steps, enabling us to simulate the machine's dynamic behavior over time. This technique is
especially useful for understanding how the system responds to changes in inputs, like
shifts in motor speed or heating intensity. The resulting discrete-time model helps us
analyze the system's behavior under various operational conditions, offering insights into

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its stability and performance. Moreover, the Euler method makes it easier to implement
control algorithms, as it allows for step-by-step updates of system states, simplifying the
design and tuning of controllers to maintain optimal baking conditions.

The automatic Injera baking machine needs a dependable control strategy to ensure it
operates at peak performance. To analyze the dynamics of the system effectively, we can
use Transfer function representation. This approach allows us to mathematically express
the relationship between the machine's inputs, like heating power and conveyor speed, and
its outputs, such as temperature and baking time. By modeling the system as a transfer
function, we obtain a clear and concise understanding of its input-output behavior in the
frequency domain. This is especially useful for evaluating the system's stability and
transient response characteristics. Moreover, using transfer function representation makes
it easier to design control systems, allowing engineers to implement techniques like root
locus and Bode plot analysis to optimize controller parameters.

The automatic Injera baking machine requires careful control and monitoring to maintain
consistent quality during the baking process. To achieve this, we can use State Space
representation in our system dynamics modeling. This method allows us to define the
machine's dynamics with state variables that capture key aspects of the system, such as
temperature, conveyor position, and ingredient flow rates. By using state space
representation, we can include multiple inputs and outputs, giving us a clearer
understanding of how different operational parameters interact. This approach not only
helps analyze system stability and controllability but also simplifies the design of feedback
control strategies. Additionally, state space representation enables us to simulate the
machine's behavior under various conditions, allowing for real-time performance
optimization and ensuring that the Injera is baked perfectly, no matter the variations in
input or environmental factors.

3.4 Proposed System Model Analysis Method

To examine how an automatic injera baking machine behaves, Dynamic Simulation is a

highly effective method. This technique involves creating a detailed model of the machine's
components and their interactions, which allows for the exploration of how the system

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responds to various inputs and disturbances over time. By simulating the baking process
under different operational scenarios, such as varying heating levels and ingredient flow
rates, one can observe the system's transient responses and steady-state behavior. Dynamic
simulation provides valuable insights into the machine's performance, including
temperature control and baking consistency. For example, if the simulation shows
excessive temperature fluctuations during operation, it may suggest a need for improved
control algorithms or adjustments to component specifications. This method not only
enhances understanding of the machine's dynamics but also supports the iterative process
of optimizing design and control strategies, ultimately ensuring efficient and reliable
baking performance in real-world conditions.

In order to examine the dynamic behavior of an automatic injera baker, Frequency

Response Analysis is a highly effective method. This technique looks at how the system
reacts to sinusoidal inputs at different frequencies, offering insights into its stability and
performance. By creating Bode plots or Nyquist diagrams, engineers can visualize the gain
and phase shift of the system over a range of frequencies. This information is essential for
understanding how the machine will respond to periodic disturbances, such as variations
in heating elements or changes in ingredient flow. For example, if the analysis shows a
significant phase lag at certain frequencies, it could suggest potential instability in response
to quick changes, which may require adjustments in the control strategy. Frequency
response analysis not only clarifies the dynamic characteristics of the baking machine but
also aids in designing robust control systems that ensure consistent baking quality and
efficiency, ultimately enhancing operational reliability.

To analyze the dynamic behavior of an automatic Injera baking machine, Time Domain
Analysis is a key method. This technique looks at how the system reacts over time to
specific inputs, like step or impulse signals, offering insights into both transient behaviors
and steady-state performance. By studying response characteristics such as rise time,
settling time, and overshoot, engineers can assess the machine's capability to achieve and
maintain optimal baking conditions. Time domain analysis is especially useful for
understanding how quickly the machine can respond to changes, such as fluctuations in

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heating levels or ingredient flow rates. For example, if the analysis shows a long settling
time, it might suggest the need for better control strategies to improve responsiveness.
Additionally, this method aids in designing effective feedback loops, ensuring that the
baking machine consistently meets quality standards and operates efficiently. In summary,
time domain analysis is vital for enhancing the machine’s performance and reliability in
practical baking scenarios.

For creating an automated injera baking system, analyzing the control system with a focus
on Controllability and Observability is essential. This method allows engineers to evaluate
whether they can effectively manipulate and monitor the system's internal states through
its inputs and outputs. By creating controllability and observability matrices, we can assess
if the baking machine can be fully controlled and if all internal states can be deduced from
the output measurements. This analysis is vital for ensuring the machine can adapt to
different baking conditions and ingredient characteristics. For example, if the
controllability analysis reveals that certain states are uncontrollable, it may necessitate
design changes to improve the system's responsiveness. Furthermore, observability
analysis helps pinpoint which sensors are needed to accurately monitor critical parameters
like temperature and baking time. By applying control system analysis, engineers can
enhance the machine's performance and ensure it meets the necessary standards for
producing consistent and high-quality Injera.

For designing and developing an automatic Injera baking machine, Statistical Process
Control (SPC) is a crucial method for maintaining consistent quality and performance. This
technique uses statistical methods to monitor and control the baking process, allowing
engineers to keep an eye on variations in important quality metrics like temperature, baking
time, and product dimensions. By utilizing control charts, engineers can spot trends and
quickly identify any deviations from the desired specifications. SPC is especially beneficial
in a production setting where uniformity in the final product is essential. For example, if
control charts show that the baking temperature is fluctuating beyond acceptable limits,
adjustments can be made to the heating elements or conveyor speed to fix the problem.
This proactive approach not only improves product quality but also minimizes waste and

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boosts efficiency. By incorporating SPC into the operational framework of the Injera
baking machine, manufacturers can ensure that the production process adheres to high
standards of consistency and reliability, ultimately resulting in a superior product.

3.5 Proposed Control Strategy Design

A PID (proportional-Integral-Derivative) controller is proposed for an automatic injera

baker for the purpose of effective control of position and velocity control. The PID
controller in this sense helps us ensure precise movement and stability by adjusting the
control inputs based on the error between desired and actual position of the baker dispenser.

3.6 Electronics Systems Design and Selection

• A DC stepper motor will be selected for precise motion controller for dispenser
• A pump will be selected for pumping the injera liquid from the container to the
dispenser
• A power supply will be selected for providing power to the motor and control
systems.

3.7 Proposed Simulation and Testing Method

• Software simulations will be done using MATLAB/Simulink, Solidworks,

FluidSim to evaluate the system’s performance in different scenarios.
• Mechanical System analysis of the system will be made using Ansys, Fusion360,
Solidworks to analyze the force and torque.

3.8 Production Drawing Development Framework

For preliminary working drawings we will be using solidworks 2024 for mechanical
drawing and solidworks electrical or Altium Designer for electrical circuit and ensuring
Design and seamless assembly.

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4 Time Schedule

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 BSc. Thesis Proposal

5 Budget Summary

Materials Quantity Price range

• Teflon --

• Metal sheet

• Arduino uno 2000

• Wires and
connectors
• Metal shaft

• Stepper Motor

• Tubes -- --

• Pump 1 2000

• Relay module 1x2 800

• ultrasonic 1 600

• contactor 1x2 5000

• Rail and wheel 1 & 1x2 5000

• 3D printer 100g 1500

Total 16900

Table 5.1 Budget Estimation

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Reference:

• Bekele, T., & Alem, H. (2023). Energy-efficient heating systems in traditional

Ethiopian cooking: A comparative study of electric and solar-powered solutions
for Injera production. Renewable Energy in Africa, 7(1), 45-61.
• Addis Solar Solutions. (2023). SolarMitad: Solar-powered cooking solutions for
off-grid communities. Addis Solar Solutions Company Report.
• Mekonnen, T., Fisseha, Z., & Getu, S. (2022). Advancements in induction and
ceramic heating for sustainable Injera baking: Technical innovations and
environmental impact. Proceedings of the African Engineering Conference, 41(5),
274-290.
• Tadesse, G., & Tesfaye, M. (2021). Improving traditional food processes: Energy
and efficiency in modern Injera baking technology. Journal of Ethiopian Food
Science, 3(4), 103-118.

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