Plastic Pulverizing Machine with Furnace and Molding Apparatus

CHAPTER 1

THE PROBLEM AND ITS BACKGROUND

1.1 Introduction

Plastics are the most versatile material ever invented in terms of

functionality. They are pretty much moldable into anything, to be used as bags,

appliances and as body parts of machines, especially cars. Plastics belong to the

family of synthetic or semi-synthetic organic materials, just like wood, paper, or

wool that are used in a huge and growing range of applications. They are

composed of cellulose, coal, natural gas, salt and crude oil. With its sizeable and

shapeable property, plastics allow other materials to be integrated into other

products making them ideal for a wide range of functions.

Here in the Philippines, plastics are one of the most used material. It can be

seen in any corners of our homes and industries. They are widely used in

packaging, cosmetics, fashion and apparel, construction, electronics, automotive

etc. Plastics are independently perceived to be weak but when mixed with other

aggregates, they become stronger and longer lasting. The lifespan of average

plastics is approximately 450 years, passing through couples of generations −

piling up on the dumpsites and even worse, polluting our oceans.

1.2 Background of the Study

The use of plastics is being abused here in the Philippines leading to a huge

pile of environmentally unfriendly waste. Based on the national estimates on

annual per capita use of plastic, the average Filipino uses 591 pieces of

sachets,174 shopping bags, and 163 plastic labo bags yearly, summing up to 17.5

billion pieces of shopping bags,16.5 billion pieces of plastic labo, and 1.1 billion

diapers annually for the whole country. (PLASTIC EXPOSED: How Waste

Assessments and brand Audits are Helping Philippine Cities Fight Plastic Pollution,

n.d.). Aside from plastic bags and sachets, PET (Polyethylene Terephthalate)

bottles are one of the most rampant plastic product used in the Philippines and

even though Philippines have the 90 percent retrieval rate, (PET bottles have 90

percent retrieval rate in the Philippines, n.d.) huge amount of PET bottles still add

up to the unimaginable plastic pollution. These wastes are filling up the ocean and

greatly affects the aquatic life. It also clogs the sewers leading to floods that

burdens the people in the low-lying areas.

There is no great chance to lessen its production since it plays a vital role

in the modern living, from simple bag of groceries to the most complicated product

made from plastic. Recycling them is one of the solutions in saving the

environment from being suppressed by plastics. This proposal aims to recycle

plastics such as: PET (Polyethylene Terephthalate); HDPE plastics; PVC

(Polyvinyl Chloride); LDPE (Low Density Polyethylene); PP (Polypropylene).

Through the pulverizing process, these plastics will be easily burnt and be formed

into new household products as proposed. This also aims to greatly lower the
containment volume of used plastics as these plastics will be converted into an

almost powder form. Plastic pulverizer are already available and in active use in

the industry but not for domestic use. This proposal will develop a pulverizer that

will be available to the domestic or small enterprise sectors such as junkshops or

small recycling facilities.

Pulverized plastics are more economical than non-pulverized plastics since

packaging will require little effort and can be easily transported to recycled plastic

buyers from junkshops. Furthermore, plastics in their unbroken form poses greater

risk to the lives of natural organisms and human beings since these plastics are

more potent in clogging sewers that eventually intensifies flooding. Pulverized

plastics are also easier and less toxic to burn compared to regular sized plastics.

Decreased in the individual surface area acts as catalyst during the incinerating

process, thus less fuel needed and less carbon emission.

1.3 Statement of the Problem

Plastic wastes are abundant here in the Philippines, it is piling up the land,

clogging coastlines, spilling into the bodies of water that harms the maritime

resources and corrupts the body of water itself. Whenever there are typhoons,

huge piles of garbage are being stockpiled on the shore. In 2018, (find exact data)

tons of garbage piled up the bay walk of manila mostly comprised of plastics.

According to the government data as of 2018, 4,609 tons of plastic wastes

are being generated daily. Dr Erik van Sebille from Utrecht University in the
Netherlands is an oceanographer who tracks plastics in our seas stated that, "We

need a radical shift in how we deal with plastic waste. On current trends, it will take

until 2060 before more plastic gets recycled than landfilled and lost to the

environment. That clearly is too slow; we can't wait that long,".

1.4 Objectives

The study aims in developing a prototype of domestic plastic pulverizer to

recycle Polyethylene Terephthalate, High Density Polyethylene, Polyvinylchloride,

Low Density Polyethylene and Polypropylene plastics. This project aims:

1. To design a prototype of domestic plastic pulverizer machine using

computer-aided drawing.

2. To fabricate and assemble the designed prototype with accuracy and

precision.

3. To test the designed prototype whether it is or not aligned to its working

principle.

4. To evaluate the result of the test using identified standards both on the

machine and the product.

1.5 Significance of the study

This study aims to recycle plastics that will be turned into mold to help

lessen the unwanted waste of plastics. This project is intended to design and

fabricate machine that pulverize plastics and mold it into plastic blocks. Using this
prototype can provide another type of recycling that can help in the innovation of

recycling process. With the use of this machine, plastic pollution can be lessened

and at the same time turn it into reusable material without sacrificing the quality of

the plastic.

1.6 Research Framework

INPUT PROCESS
• Knowledge • Design
Requirements ✓ Software
✓ Machine design design
✓ Instrumentation analysis
and Control ✓ Calculations
✓ Thermodynamics • Fabrication
✓ Kinematics • Assembly
• Hardware Requirements • Operation and
✓ Materials Testing
✓ Equipment • Modification
• Software Requirements • Evaluation
✓ AUTOCAD
✓ SolidWorks

OUTPUT
Plastic Pulverizing
Machine with
Furnace and
Molding Apparatus

Figure 1: Conceptual Model

This structure consists of all the concepts being used in the research. The input

are all the knowledge, materials, tools and equipment the researchers used in

designing the prototype machine. The process explains how the entire prototyping
happens from designing, fabrication, assembly of the parts, actual operation and

testing of the machine, further modifications and evaluation. The expected output

is the desired machine.

1.6 Definition of Terms

1. Pulverize – a process of crushing a material to its coarse powder state.

2. Furnace – an enclosed structure wherein a material is heated at a very

high temperature.

3. Plastic – is a material that consist of synthetic or semi-synthetic organic

compounds that can be shaped into solid objects and are often non-biodegradable.

4. LDPE (Low Density Polyethylene) - commonly used as wrappers,

grocery or shopping bags and food containers

5. PP (Polypropylene) - commonly used as tupperware, medicinal bottles,

and other containers

6. PET (Polyethylene Terephthalate) - commonly used as energy drink,

water, or juice containers

7. HDPE (High Density Polyethylene) - commonly used as milk jugs, toys,

cleaning product containers and similar products.

8. PVC (Polyvinyl Chloride) - commonly used as food wrap, pipes or

conduits, tiles and windows.

 9. Plastic Labo - are thin transparent plastic bags that are commonly used

in Philippine markets and convenience stores.

10. Recycling - process of collecting and reprocessing of any used

materials to be turned into a new product.

11. Shredding – process of breaking down a material into thin long strips.

12. Carbon Emission – a production of carbons by any process and

disseminating carbon particles into surrounding environment.

13. Molding – process of shaping a liquid or gel using a fabricated pattern

or matrix.

1.7 Scope and Limitation

The study focuses on the development, design, fabrication, testing, and

evaluation of the Plastic Pulverizing Machine with Furnace and Molding Apparatus.

The machine is designed to process only used recyclable plastic such as

Polyethylene Terephthalate, High Density Polyethylene, Polyvinylchloride, Low

Density Polyethylene and Polypropylene plastics. The machine is designed to

process plastics at least to its coarse pulverized state or size. Plastic breakdown

stages must be limited to a minimum of three stages and maximum of five stages,

until plastics appear to be coarse enough. Furnace must be limited to 260 degree

Celsius operating temperature. Molding apparatus may be available in any

quadrilateral or circular shape depending on the request of the client.

 CHAPTER 2

Review of Related Literature

2.1 Plastics

Plastics are made of synthetic or non-synthetic materials also known as

polymers. Polymers are long molecules composed of chains of carbon atoms,

typically hydrogen, oxygen, sulfur, and nitrogen that fills up the spaces (Woodford,

2019)

Figure 2.1 Molecular Structure of Plastic

Retrieved from Woodford, 2019

The process of producing plastics starts with distillation of crude oil in an oil

refinery. It separates the heavy crude oil into parts of lighter components that is

called fractions. Each fraction composed of hydrocarbon chains, which differ in

terms of its size, shape and structure of their molecules (How Plastics are Made,

Retrieved from www.plasticseurope.org)

2.1.1 Thermoset Plastics

These plastics contains polymers that are cross-linked together

during the curing process to form an irreversible chemical bond. These are

heat resistant, chemical resistant and has good structural integrity that is

why it is used in high-heat applications such as electronics and appliances.

Because of its structural integrity, these kinds of plastics can’t be recycled

easily. (Thermoset vs. Thermoplastics, Retrieved from

www.modorplastics.com)

Figure 2.1.1 Examples of Thermoset Plastics

Retrieved from www.modorplastics.com

2.1.2 Thermoplastics

Thermoplastics have a simple molecular structure comprising

chemically independent macromolecules. Thermoplastics have these special

characteristics of being easily melted and molded into various shapes. The

material can be reheated, reshaped and frozen repeatedly. Some of the

most common types of thermoplastic are polypropylene, polyethylene,

polyvinylchloride, polystyrene, polyethylene terephthalate and

polycarbonate (Thermoplastics, Retrieved from www.plasticseurope.org)

Figure 2.1.2 Examples of Thermoplastics

Retrieved from www.plasticseurope.org

2.1.2.1 Polyethylene Terephthalate (PET/PETE)

Polyethylene terephthalate is a strong, stiff synthetic fiber and resin.

It is under the thermoplastic because of its characteristic of being easily

melted and molded. PET is produced by the polymerization of ethylene

glycol and terephthalic acid. When heated together under the influence of

chemical catalysts, ethylene glycol and terephthalic acid produce PET in

the form of a molten, viscous mass that can be spun directly to fibres or

solidified for later processing as a plastic.

 The presence of a large aromatic ring in the PET repeating units

gives the polymer notable stiffness and strength, especially when the

polymer chains are aligned with one another in an orderly arrangement by

drawing (stretching). PET has become widely used in carbonated-beverage

bottles and in jars for food processed at low temperatures.

PET is the most widely recycled plastics. PET bottles and containers

are commonly melted down and spun into fibres for fibre fill or carpets.

When collected in a suitably pure state, PET can be recycled into its original

uses, and methods have been devised for breaking the polymer down into

its chemical precursors for resynthesizing into PET (Polyethylene

Terephthalate, Retrieved from www.britannica.com).

Figure 2.1.2.1 Examples of PET Plastics

Retrieved from www.britannica.com
2.1.2.2 High Density Polyethylene (HDPE)

High Density Polyethylene is a thermoplastic polymer produced from

the monomer ethylene. They are sturdy and is known for its toughness.

These kinds of plastics are usually used in jugs of milk or bleach bottle and

laundry detergent. It is difficult to tear and has burst resistant. The opaque,

colored plastic resists cracking or corrosion making it suitable for detergents

and household cleaners. It is also a food-grade plastic, but it is not designed

for long term food storage. HDPE is easier to recycle than PET, it melts at

relatively low temperature and is easy to form. (What is HDPE Plastics?

Retrieved from www.sciencing.com)

Figure 2.1.2.2 Examples of HDPE Plastics

Retrieved from www.sciencing.com
2.1.2.3 Polyvinyl Chloride (PVC)

Polyvinyl Chloride, also known as chloroethylene, is used in enormous

range of applications. It can be used in building and construction, health care,

electronics, in products ranging from piping and siding, blood bags and tubing, to

wire and cable insulation, windshield system components and more.

PVC is made by subjecting vinyl chloride to highly

reactive compounds known as free-radical initiators. Pure PVC finds application in

the construction trades, where its rigidity, strength, and flame resistance are useful

in pipes, conduits, siding, window frames, and door frames. It is also blow-molded

into clear, transparent bottles. Because of its rigidity, it must be extruded or molded

above 100 °C (212 °F)—a temperature high enough to initiate chemical

decomposition (Polyvinyl Chloride, Retrieved from www.britannica.com).

Figure 2.1.2.3 Examples of PVC Plastics

Retrieved from www.britannica.com
2.1.2.4 Low Density Polyethylene (LDPE)

Low Density Polyethylene is a thermoplastic made from

the monomer ethylene. It is known from its good balance of flexibility, strength,

barrier properties, and cost and can come in a wide combination of properties.

LDPE has high clarity, is chemically inert, and has good impact strength and

excellent tear and stress crack resistance. Low-density polyethylene (LDPE) has

applications in sterile blister packs for drug packaging (Low Density Polyethylene,

Retrieved from www.sciencedirect.com).

Figure 2.1.1 Examples of LDPE Plastics

Retrieved from www.sciencedirect.com

2.1.2.5 Polypropylene plastics (PP)

Polypropylene is a thermoplastic “addition polymer” made from the

combination of propylene monomers. It is used in a wide range of applications to

including packaging for consumer products, plastic parts for various industries

including the automotive industry, special devices like living hinges and textiles.
 PP is the most produced plastic in the world. According to some reports, the

current global demand for the material generates an annual market of about 45

million metric tons and it is estimated that the demand will rise to approximately 62

million metric tons by 2020.

According to some reports, the current global demand for the material

generates an annual market of about 45 million metric tons and it is estimated that

the demand will rise to approximately 62 million metric tons by 2020. The major

end users of polypropylene are the packaging industry, which consumes about

30% of the total, followed by the electrical and equipment manufacturing, which

uses about 13% each. Household appliances and automotive industries both

consume 10% each and construction materials follows with 5% of the market.

Other applications together make up the rest of the global polypropylene

consumption (Everything you need to know about Polypropylene Plastic, Retrieved

from www.creativemechanisms.com).

Figure 2.1.1 Examples of Polypropylene Plastics

Retrieved from www.creativemechanisms.com
2.2 Related Studies

2.2.1 Design and Construction of a Plastic Shredder Machine for

Recycling and Management of Plastic Wastes

A shredding machine is designed to reduce large solid material objects into

a smaller volume, or smaller pieces. Shredding machines are usually used to

reduce the size and shape of materials so they can be efficiently used for the

purpose intended to. Shredding just like crushing can be defined as the process of

transferring a force amplified by mechanical advantage through a material made

of molecules that bond together more strongly, and resist deformation more, than

those in the material being crushed do. The shredding materials must possess a

better strength and toughness than the plastic materials. This machine consists of

hopper, shredding chamber, mesh, gusset channel, main frame, flywheel, cover

plate (Atadious, Oyejide, 2018)

Figure 2.2.1 Table of Results

Retrieved from Atadious, Oyejide, 2018
 Figure 2.2.1 Design of Plastic Shredder Machine
Retrieved from Atadious, Oyejide, 2018

2.2.2 Design and Development of mini plastic shredder machine

The developed model is simple, efficient, requires less time and cost

effective when compared to the existing available model. Importance is given

towards user friendly in operation and mainly towards safety. The rotating

elements like belt and pulley and gears are covered, so it is fully safety to operator

The overall performance of shredder machine was satisfactory by considering the

quantity of powder produced with respect to time. It is consists of shaft, cutting

blades, electric motor and transmission drive (Sudhakara, Thaju, 2018).

 CHAPTER 3

Methodology

This chapter includes the different stages involved in the project

development starting from the problem analysis up to the fabricated final design of

the project. This chapter consists of the research design, project development,

data gathering, and the official design. For the deeper view of the project, operating

processes of the final design of the machine are also included here.

3.1 Research Design

The basis of this machine, plastic shredders, are already available in the

market and patents are available in some publications. By thorough investigation

of these studies, the researchers found out that the final appearance of the plastics

are not even close to a coarse powder appearance. Most of these machines only

processes plastics to its long strip sizes thus only decreasing the packaging

volume.

The complete machine setup of this project includes series of plastic

shredder, furnace, and molding apparatus, unlike the basis machines, to further

utilize the coarse powdered plastics into rectangular blocks. These blocks can be

then fabricated into useable appliances such as shoe racks, simple cabinet, etc..

The plastic pulverizing machine is consisted of series of integrated shredders to

further reduce the size of plastic strips into coarse powder. A choice from three to

five stages is suggested. Each stage will consist of pair of shafts and each shaft
will consist of five crusher blades. A hopper will be installed over the shredder

where the plastics will be poured into. Next to pulverizer is the furnace. The furnace

will be completely enclosed to lessen carbon emission and to speed up the burning

process. At the end of the setup is the molder or molding apparatus which will give

shape and cool the burned plastics. The molder will be equipped with weights to

press and enhance the fluid into a compact shape.

3.2 Project Development

CONCEPT AND DATA GATHERING

DESIGNING
(CALCULATIONS AND
SIMULATIONS)
(CALCULATIONS AND
SIMULATIONS)

FABRICATION AND
ASSEMBLY

OPERATION AND TESTING

EVALUATION
3.3 DATA GATHERING

The proponents studied previous researches about plastic shredding,

burning, and molding processes and came up with multiple designs to emphasize

the suggested improvement and changes. Trials will be conducted to finalize the

number of stages in the pulverizing process. An experiment will also be performed

to analyze the type of plastics to be burned together and what needs to be

separated.

3.4 DESIGN

The design is leaned on the materials available in the Philippine market.

The proponents deliberated the final design of the project using the patents of

previous researchers. Significant factors are also considered such as the strength

of the plastics to be pulverized, strength of the blades, melting temperature of

specific plastics, vibration of the machine and stresses that will affect the durability

of the machine.

Initial design was sketch by free hand and then finalized using a computer

aided drawing software. Simulation will also be performed for the processes

involved to indicate the stressed area and to partially determine the feasibility of

the machine.
❖ Process Flow

HOPPER
HOPPER (LOADING OF PLASTICS)
(LOADING OF PLASTICS)

SHREDDER (Stage
SHREDDER (Stage 1):
1): LONG
LONG STRIPS
STRIPS

SHREDDER (Stage
SHREDDER (Stage 1):
1): SMALLER
SMALLER STRIPS
STRIPS

SHREDDER
SHREDDER (Stage
(Stage 1):
1): GRANULES
GRANULES

SHREDDER (Stage
SHREDDER (Stage 1):
1): COARSE
COARSE POWDER
POWDER

FURNACE (INCINERATION)

MOLDER (MOLDING)

COOLING

WITHDRAWAL FROM MOLDER

First stage shredder Second stage shredder Third stage shredder (optional)
with 25mm thickness with 10mm thickness with 2mm thickness