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Philippines is one of five countries that produce half of world’s plastic waste based on
UN report. data from the 2015 study plastic “Plastic waste inputs from land into the
ocean” shows that the Philippines wastes 6,237,653kg (6875.84 tons) of plastic per day,
of which 81% is mismanaged. There are advantages and disadvantages of plastic but the
disadvantages are more than advantages. So there is need to recycle the plastic, to reuse
and to decrease the use of plastic. This machine is used for shredding and extruding
plastic to make waste management easier. The proponents will make this project model
for recycling of plastic wastage in schools, homes, industries etc. in which the plastic
waste is large in quantity. Currently, available machines used to recycle this waste are
costly. The intention behind this project is to process the plastic waste as cheap as
possible. Moreover, benefits of this machine are the reduction of labor work which
results in cost reduction. The machine will be built by following the conventional process
of constructing a plastic shredder and extruder while being integrated through a double
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CHAPTER I
INTRODUCTION
Plastics have become an essential part of our day to day life since their
introduction over hundred years ago. It is one of the most commonly used materials in the
world today. They come in five major categories; the Polyethylene terephthalate (PET),
the High density polyethylene (HDPE), the Polyvinylchloride (PVC), the Polypropylene
(PP) and the Low density polyethylene (LDPE). The huge quantities of these plastic
categories currently being marketed will ultimately find their way to the waste dump sites.
This is creating waste products problems due to its high amount of waste generated, non-
biodegradability and the fastest depletion of natural resources regarding its short life
cycle, therefore increased amount of material utilized in its production, and waste
plastic waste material that would otherwise become solid waste are collected, separated,
processed and returned to use.( Ayo et al., Int J Waste Resour 2017)
designer Dave Hakkens. The idea was to make a series of machines that were to decrease
the problem of plastic waste throughout the world by reshaping it into new products on a
local basis. Hakkens suggested that people all over the world could build their own
production line. Thus, this inspired the proponents to make a version. To make them
easier to build using basic materials that are easily available cheaper.
The machine that will be constructed and developed in this study is based on this
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Plastic shredder is a machine that reduces used plastic bottles to smaller flake
sizes to enhance its portability, easiness and readiness for use into another new product.
The fundamental design principle of this machine was got from the ancient tradition
method of using scissors to cut materials into reduced form and scratching used by
rabbits when digging or tearing. These two traditional methods were applied in the design
of the machine by fabricating cutting blades to cut the waste plastic while some of cutting
blades have sharp curved edges to draw-in the plastic into the cutting blades teeth. The
waste plastic shredder comprises of four major components, namely; the feeding unit, the
shredding unit, the power unit and the machine frame. The machine will be driven by
double ended shaft AC motor which then will be integrated with an extruder. Plastic
extruder executes extrusion process in which raw plastic is melted and formed into a
continuous profile. The process starts by feeding plastic materials from a hopper into the
barrel of the extruder. The material is gradually melted by the mechanical energy
plastic shredder with integrated extruder at minimum costing and innovative version
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1.3 What development can be made to improve the performance output quality,
Hakkens (2013) was clear in his instructions that the Precious Plastic machines
are not perfect and so is under ongoing development by the community. Consequently,
problems were expected to arise during construction and testing since variations in
dimensions and tolerance will depend on the precision of the material, supplier and
manufacturing methods. The actual setup would have to be modified to fit whatever
power supply unit (PSU) that was finally used. To summarize, the main objectives of the
b. Make an easily detachable modular PSU that can be used for other future
applications.
c. Redevelop the machine by modifying its design in terms of size, orientation and
section c.
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e. Minimize building cost by using cheaper materials and building a smaller
prototype.
homes and industries. Its main significance is for recycling of plastic materials and
developing a low cost machine use in recycling and extruding moreover, the reduction of
Specifically,
To the Schools. This machine will aid in the school campaigns in promoting
materials that later can be used as raw materials in developing projects and other
To the Industries. The machine will make recycling of plastics in the industries
To the Future Researchers. Knowledge gained from this study will aid in the
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Scope and Delimitation
2.1 Scope
The project ranged from the complete building and testing of the plastic shredder
and extruder. It will be provided by the open source community and the proponent’s idea
to the development of a new design of shredder and extruder by integrating the 2 systems
through the application of a double ended shaft AC motor. Ultimately, the goal was to
build a physical and functioning version of the new design. No deeper analysis was made
of the throughput of the machine in any of its versions other than a cursory examination if
the desired functionality is fulfilled. To keep the costs to a minimum, the building of the
machine will be done in the school workshop at Eastern Visayas State University- main
2.2 Delimitation
The costs will not be accurately calculated as a considerable part of the machining
will be carried out by the availability of the materials furthermore, labor will not be
included. This will be done in between other work which made it difficult to assess the
time spent on this project and the corresponding costs. Besides, the majority of the costs
will be that of the PSU and as such is highly dependent on what is available and varies
greatly. The project will not comprise any type of manual for the machine or protocols
regarding safety in operating or handling the machine. It is up to any user of the machine
to use it responsibly and exercise caution on personal safety and integrity of the machine.
No specific type of plastic will be utilized during the prototype testing. As long as
the machine will be able to shred the material, it will be considered as qualified subject of
the machine. The project duration is from August 2018 to May 2019.
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CHAPTER II
surge of environmental concerns uprising. One of this is plastic pollution which take over
400 years to decompose thus, creating too much environmental impact. This inspired the
The large particles of plastic need to be broken down into small pieces to reduce
storage and transportation space requirement. Such broken down HDPE, PP, and LDPE
plastics can be sold as raw material for plastic production without any further processing.
On the other hand, it can be re-extruded to produce pellets for plastic manufacturing. For
other reason, crushing can also be done to reduce the storage space requirement and easy
transportation for further processing. A crusher should be used for this purpose and the
resultant broken pieces of plastics should be the flake size or less. It is important to
prevent mixing of plastic types to maintain the quality and value of the plastic. Mixed
crushed plastics can be used only for low value and low quality products such as junction
boxes used in electrical work or plastic lumbers. The shredder should comprise of a
rotating set of blades, feeding hopper, and motor. The size of the feeder depends on the
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The basic operation of the extrusion process begins with the entering of the
feeding material over the feed hopper. Very often the filling of the extruder barrel from
the hopper is done by gravity forces but sometimes it is supported by vertical orientated
conveying screws. The extrusion material falls hereby into the gap between the extrusion
screw and the barrel and is thereby bounded by the positive and negative flank of the
screw also called “screw channel”. The extrusion screw is thereby rotation inside of the
stationary barrel. Friction forces between the extrusion material and the barrel or
respectively the screw surface are responsible for the transport of the solid state. During
the movement of the plastic material through the barrel it is heated up by frictional heat
and the barrel heaters. If the temperature of the material reaches melting point a melting
film is formed on the barrel surface. The border where one material state changes
depends on polymer properties, machine geometry and operating conditions. When the
solid material moves further into the die direction the amount of plastic material is
reduced because of the melting process. When all solid material is molten the so-called
“plasticating zone” is over and the melt conveying zone begins where the liquid plastic is
finally pumped to the die hole. During the flow through the die channel the plastic
material adopts the shape of the die. After leaving the die channel the material keeps
more or less the shape of the cross section of the die. The pressure needed to force the
liquid plastic material to flow through the channel is also called the die head pressure and
depends on the shape of the die, the temperature of the molten plastic, the flow rate
through the die channel and the rheological properties of the plastic melt. (Proschek,
2012)
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Plastic Overview
According to Hassan 2016, plastics are made up of long chain molecules called
polymers. Various types of polymers can be made from hydrocarbons derived from coal,
natural gas, oil and organic oils which are transformed into materials with desirable
properties. Waste is now a global problem, and one that must be addressed in order to
solve the world's resource and energy challenges. Plastics are made from limited
resources such as petroleum, and huge advances are being made in the development of
methods to make plastic products and feedstock recycling methods that use plastic as a
raw material in the chemical industry have been widely adopted, and awareness has also
Conceptual Framework
plastic shredder with integrated extruder powered by a double ended shaft AC motor.
The process starts with the feeding of plastic materials to the shredder. The accumulated
shredded pieces will then be introduced to the extruder for the extrusion process where it
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Definition of Terms
The following terms are defined in accordance with its usage in the study.
Extruder- a machine that uses heat and compression to melt the plastic.
Plastic- a synthetic material made from a wide range of organic polymers that can
be molded into shape while soft and then set into rigid or slightly elastic form.
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CHAPTER III
METHODOLOGY
This chapter will cover the detailed explanation of methodology that is being used
by the proponents to make this project complete and working well. The method that will
be used in this study is based on the relevance and needs of the research to achieve the
objectives.
Research Design
This research will be using four major steps to implement and to answer the
objective of the study. Starting from conceptualization and design development, drawing
and autocad design, fabrication and assembly and testing (Fig. 1.3). All methods that will
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Conceptualization and Design Development
Initial design and planning is being drafted in this section, considering the drafted
scope of the project and the design features required. The establish idea is being finalized
Conceptualization
The arising need of plastic recycling due to its rampant negative impact to
the environment propelled the proponents’ idea in developing a machine that can
help in recycling. Through open project sources such as precious plastic, the
The proponents established idea and design are being defined through drawing
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Figure 3.2 Pre-prototyping Design
Based on the design, parts and components needed are being manufactured /
fabricated in preparation to build the prototype. After which, when the parts are
This allows the proponent to minimize the effect of all the variables except the
baseline to compare groups and assess the effect of that intervention. Modification is
Testing
This area will be taking measures to check the quality, performance and reliability
of the research output. It will reveal the strength, capabilities and weakness of the
prototype.
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System Flowchart
The system flow chart in figure 3.3 shows how the machine will work. Given the
integration of the motor which will provide the driving force and electricity to power the
system. Plastics will be collected, cleaned and or sorted before feeding to the hopper of
the shredder to execute the shredding. Amount of shredded plastic which then will be
feed to the extruder is controlled and the extrusion process will start. Conventional
electric fan unit will be utilized to fasten the cooling of the extruded material.
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Data Collection
Data collection is a stage in any area of study. At this point, the proponents will
plan the project resource and requirements, literature study and schedule to get more
All the data will be collected from open source projects, journals, text books and
Research Instruments
The machine prototype will be built with 3 major sections. The shredder, the
3.1 Shredder.
machine, boring operation on lathe machine, keyway cutting on slotting machine, flame
cutting using oxyacetylene gas welding machines, grinding for good finishing, electric
welding using arc welding machine. Basically, these constructional techniques were
broken down into four sub-heading namely; cutting operation, machining operation,
welding operation and assembly; and finishing operation. Major parts of the shredder that
Hopper- it will serve as the entry point of the plastic that will be shredded.
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Blades- they will be responsible for the cutting of the materials that will be
Shafting- it will be the handle of the blades. Mechanical force will be channeled
Casing- it will serve as the house and the protection of the machine.
The motor will be an AC type with double ended shaft. It will serve as the
interconnection of the two systems. The motor will be responsible for producing
mechanical energy to generate rotation between the shafts. It will be controlled through
installation of a control system. Regarding of its speed and other aspects. Motor
3.3 Extruder
machine, boring operation on lathe machine, keyway cutting on slotting machine, flame
cutting using oxyacetylene gas welding machines, grinding for good finishing, electric
welding using arc welding machine. Major parts of the extruder in the extrusion process
includes:
Hopper- it will serve as the feeding point of the shredded plastic that will undergo
extruding.
Screw – it will serve as the transmission system of the liquid to the nozzle.
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Barrel-it will serve as the casing of the screw, heat generating system will be
attached in here.
Heater and Thermocouples- they will generate and provide the heat through the
extrusion process.
Nozzle of the Extruder- its function will be in controlling the dispense ratio of the
Control Box- it’s the heart of the machine. It will control the heat and other
TOP VIEW
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FRONT VIEW
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Integration of Plastic Shredder and Extruder Machine Using Double Endeed Shaft
AC Motor; A System Design Alteration and Application for MicroWaste
Management.
BY:
CARINO, DONALD
GACUTARA, RENZO
PERALTA, JOSHUA
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TABLE OF CONTENTS
Abstract............................................................................................................................................1
Chapter I..........................................................................................................................................2
Chapter II.........................................................................................................................................7
Plastic Overview.....................................................................................................9
Definition of Terms...........................................................................................................11
Chapter III......................................................................................................................................12
Methodology....................................................................................................................12
Research Design...................................................................................................12
Conceptualization ..................................................................................13
Testing.................................................................................................................15
Research Instruments..........................................................................................16
Side View
Top View
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