e-ISSN: 2582-5208

International Research Journal of Modernization in Engineering Technology and Science

( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:06/June-2022 Impact Factor- 6.752 www.irjmets.com
DESIGN AND MANUFACTURING OF PLASTIC BOTTLES
CRUSHING MACHINE
Prof. Mr. R.V. Pethkar*1, Mr. Omkar Bharat Nangare*2, Mr. Omkar Dattatray
Bartakke*3, Mr. Abhishek Madhukar Pawar*4, Mr. Ganesh Balu Bengade*5
*1Professor, Department Of Mechanical Engineering, Jaywant College Of Engineering And
Polytechnic, K.M.Gad, Maharashtra, India.
*2,3,4,5Student, Department Of Mechanical Engineering, Jaywant College Of Engineering And
Polytechnic, K.M.Gad, Maharashtra, India.
ABSTRACT
Today the world is facing a huge problem of waste management. Multiple industries like construction,
manufacturing, medical, automobiles, food industry, packaging, etc. have plastic playing a vital role. Plastic is
one of the most used materials due numerous advantages. But plastic has many serious disadvantages which
can harm the ecosystem. Plastic if disposed unsafely, then it can lead to degradation in quality of soil, water, air
and all the natural resource. Plastic waste has the highest percentage of non-biodegradable waste. The plastic
waste cannot be incinerated as it will emit hazardous chemicals into the environment which lead to increase in
environmental pollution. As the plastic waste does not decompose, it will require huge space for storage in
landfills. This plastic waste is very difficult to store as it has large volume. Hence breaking down the plastic
waste into very small piece can help the problem of storage. A shredding can be used for effective management
of plastic waste. This paper gives information regarding design of crushing machine. This machine can be used
for breaking down the plastic waste into small manageable size. The blades of shredder are designed in a way
that they withstand the forces during cutting of plastic parts. These small flakes of shredded plastics then be
recycled into numerous ways. The main consideration for this design is cost effective and efficient. Thus, the
use of shredding machine can also reduce the labour cost. This will hence reduce the burial and dumping of
waste in the earth.
I. INTRODUCTION
Plastic is a material consisting of any of a wide range of synthetic or semi- synthetic organic compounds that
are malleable and therefore can be molded into solid objects. Plasticity is the general property of all materials
that involves permanent deformation without breaking. Polymers’ name is derived from their flexible and
plastic properties. Plastics are typically organic polymers of high molecular mass, but they often contain other
substances. They are usually synthetic and most commonly derived form petrochemicals. However, today’s
focus on the environment has led to a growing number of plastics to be derived from renewable materials such
as polylactic acid from corn or cellulosic from cotton linters. Plastics have been adopted in a significant, and
ever-expanding, range of products thanks to their relatively low cost, ease of manufacture, versatility, and
imperviousness to water. They can be found in products as simple as paperclips or as complex as planes. A
large source of diverse plastic material is available across a widespread manufacturing spectrum, one of the
most recent and exciting manufacturing domains is in 3D Printing. As new applications for 3D Printing are
discovered almost daily, a diverse array of plastic objects have already been produced using 3D Printing
process. These objects can be found in prototyping labs, toys, mechanical gearboxes, medical prosthetics, and
many more A plastic material is any of a wide range of synthetic or semi synthetic organic solids that are mold
able lastics are typically organic polymers of high molecular mass, but they often contain other substances.
II. PRINCIPLE OF OPERATION
In this, as the motor rotates the motor is having a smaller pulley connected to its shaft, the smaller pulley
through the v-belt is connected to secondary pulley (Larger pulley) on another shaft which rotates it. Another
i.e. third pulley (Smaller pulley) is mounted on the same shaft next to the secondary pulley, and is connected to
the fourth pulley (Larger pulley) which is on the main shaft by means of v-belt. This arrangement has been done
solely for the purpose of reduction of speed. Except that there also automation has been done, such as there I

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:06/June-2022 Impact Factor- 6.752 www.irjmets.com
have placed a sensor until and unless sensor senses the obstacle (i.e. a Can/ Plastic bottle) the machine will not
start. The machine is powered by a Single-phase medium speed electric motor. The machine, being a medium
sized crusher, has the capacity of crushing half a ton of plastic in a day depending on the type of reused plastic
crushed. The degree of linear correlation, r squared for observed and predicted values of variables evaluated
are within acceptable region. The efficiency of crushing based on polymers processed is 81.04% for PET bottles.
The developed crusher can be used to reduce the volume of plastic waste dump. The findings from this
technical brief is adopted and commercialized, the menace of plastic waste will be ended.

Fig 1: Crushing mechanism

Design and Material Selection
Some relevant factors were considered in the design and development of the crusher; such factors are cost of
maintenance, power requirement and ease of replacement of various components and labor requirement. The
machine is easy to maintain. The rectangular shaft impacts strong impact force on the crushing chamber to
achieve crushing into desired granular size, materials fed into it. So, following are the components required to
be designed,
1) Frame.
2) Shaft.
3) Chamber.
4) Blades.
5) Flywheel and Pulley.
Manufacturing of Component and Experimentation
It should include proposed layout of test rig. Process for manufacturing. Procedure for carrying out
experimentation. Plastic crusher designed and constructed comprises of the following parts -:
 Hopper: Hopper is the section through which the waste plastic is fed into the crushing chamber. It is made up
of mild steel.
 Crushing Chamber: The crushing unit is where the waste plastic is cut into smaller sizes either through
shredding or impact force of a crusher or shredder as the case may be.

 Transmission Shaft: The shaft is made up of cast iron block.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:06/June-2022 Impact Factor- 6.752 www.irjmets.com
 Rotary Blade: The rotary blade cut the plastic into granules with its sharp edges.

 Bearing: Bearing is a mechanical device that supports another part and reduces friction. The Pillow Block
type of bearing used.
 Belt Drive: A band that used to transfer power or motion from the pulley of the prime mover to the
transmission Shaft pulley.

 Counter Weight: This is a heavy mass of steel mechanically linked in opposition to a load. It supports the
machine and maintains balancing.
 Motor: An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most
electric motors operate through the interaction between the motor's magnetic field and electric current in a
wire winding to generate force in the form of torque applied on the motor's shaft.

 Member Frame: The frame supports the other component parts on it in order to make the entire assemble
stable.

Preparation of Manufacturing Drawing

Manufacturing Drawing (Detail and Assembly) a suitable assembly drawing will be prepared which will help
visualize actual drawing and make necessary adjustment taking into consideration the design and placement of
various components. Which should include limit, fit, tolerance, bill of material, standard component list etc.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:06/June-2022 Impact Factor- 6.752 www.irjmets.com

Fig 2: Final Drawing

Final Readings:
 Crushing Machine Power =1 HP = 0.75 KW
 Torque of Crushing Machine = 4.9054 N
 RPM of Crushing Machine = 1460 rpm
 Crushing Pet Bottles 24.8 kg per hours
 Pet Bottles Crushing Create 15 mm pieces
 Work Efficiency of Crushing Machine is 81.0483 % more Efficient
 Bending moment of simply supported beam = 7.87 E 3 N/mm
 Maximum Bending Moment of Shaft is 12.15 N
 Minimum Bending Moment of Shaft is 3.56 N
 Condition of load Static or Dynamic Loads
 Static Loads -
Diameter of shaft = 26.99 mm
Stress of shaft = 0.1222 N/mm
Bending stress of shaft = 4.0753 N/mm
Shear Stress of shaft = 1.2953 E 3 N/mm
 Dynamic Loads -
 Diameter of shaft = 27.2 mm
 Stress of shaft = 4.0752 N/mm
 Bending stress of shaft = 4.0753 N/mm
 Shear Stress of shaft = 1.2938 E 3 N/mm
Selection of Belt
V-belts are also selected from the manufacturer’s catalogue. Following is the procedure for selection of a flat
belt:
1. Select Suitable V-Belt Section
Five types of standard V-belt sections are available. Dimensions of these are given in Table 1.1 Refer figure 20.1
for basic dimensions of the trapezoidal section of V-belt.

Fig 3: V-belt section

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:06/June-2022 Impact Factor- 6.752 www.irjmets.com
Table 1.1: Dimensions of V-belt Sections

Section A B C D E

Pitch Width, wp (mm) 11 14 19 27 32

Nominal Top Width, w (mm) 13 17 22 32 38

Nominal Thickness, t (mm) 8 11 14 19 23

Recommended Velocity (m/s) 25 25 25 30 30

Recommended Power Range (kW) 0.4 - 4.0 1.5 - 15 10 - 70 35 - 150 70 – 260

Recommended Minimum
125 200 315 500 630
Pitch Diameter of Pulley (mm)

2. Determine Diameters of Pulleys

Recommended diameter of smaller pulley (d) for selected cross-section. Diameter of larger pulley (D) can be
calculated, for required velocity ratio i.e. for given input speed (N1) and required output speed (N2), using the
following relationship:
N1d = N2D
3. Calculate Design Power
For design purpose, maximum power transmitted by the belt is obtained by multiplying the required power (P)
by service factor (Ks). Value of Ks can be taken between 1 and 2, depending upon the service conditions i.e.
light, medium, heavy or extra-heavy duty, type of driver and driven machinery and operational hours.
P Design = Ks X P
4. Determine Pitch Length and Centre Distance
Calculate length of the belt from its relation with d, D and C. Select the nearest standard value of belt pitch
length from table 1.2. Calculate exact centre distance, C from the relation again.
Table 1.2: Angle of Contact Factor, Ka
Belt Pitch Length(mm) Pitch Length Correction Factor
Belt cross –section K Length
A B C D E
1430 3080 6100 0.96
Table 1.2
Social Impact
1. The problem of waste plastic is reduced.
2. Easy recycling of the plastic parts.
3. Reduction in environmental pollution.
4. Landfills will not be occupied with plastic waste.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:06/June-2022 Impact Factor- 6.752 www.irjmets.com
III. RESULT AND DISCUSSION
Table 1.3
Table Brand Of Length after
Length Width
Head bottle Crushing
1 Bisley 275 80 140
2 Aquafina 275 86 140
3 Kinley 270 85 140
4 oxylith 270 84 140
The experimentation was conducted after the manufacturing process was completed. In this phase, the
components of Machine were checked for smooth operation and movement. Then the experimentation on
crushing was performed. The objective of design was to manufacture a Plastic bottle crushing machine to crush
plastic bottles of different dimensions. Experimentation was also conducted to test the agility of machine. Thus
Plastic Bottles of different dimensions and quality were collected and an experiment was conducted. The
Experimentation data for Crushed Plastic Bottles is mentioned below in Table-1.4.
Table 1.4
Mass of Bottles Fed into Crushing Time MTC
S/N
Crushing Machine (kg) (sec) (kg/sec)
1 3.4 56 0.061
2 9.6 104 0.092
3 16.7 122 0.137
4 20.4 144 0.142
5 25 182 0.136
IV. CONCLUSION
Bottles crushing machine was successfully designed in this study. The plastic bottle crushing machine was
designed for bottles as well as plastic waste recycling mainly for commercial and industrial applications.
Performance evaluation was carried out on the crushing machine and the results obtained indicated that the
machine was efficient and could be used for reduction of bottle wastes littering our environment particularly in
developing countries where there is insufficient technologies to handle this menace. The designed Bottles
crushing machine can be used to reduce the volume of bottle wastes dump indiscriminately, and this will
ensure the wellbeing of the world’s populace in a healthy environmental condition. Moreover, efficiency of
81.0483% was recorded for the machine design which indicated that the machine can be used industrially in a
small scale.
V. REFERENCES
[1] International Journal of Information & Compute ring Science. ISSN NO: 0972- 1347 “Fabrication of
Crushing Machine for Plastic Wastes” Mr. Swapnil Kumar Singh, Dept. of Mechanical Engineering
Rabindranath Tagore University, Bhopal.
[2] International Journal of Engineering Research & Technology (IJERT) ISSN NO: 2278-0181 Vol. 3 Issue
10 October – 2014 “Design and Development of a Plastic Bottle Crusher” Yeshwant M. Sonkhaskar Asst.
Professor, Department of Mechanical Engineering. Shri Ramdeobaba College of Engineering &
Management, Katol Road, Nagpur, Maharashtra, India.
[3] International Journal of Engineering Technologies-I jet Ikpe Et Al., Vol.3, No.3, 2017 “Design of Used
PET Bottles Crushing Machine for Small Scale Industrial Applications” Ikpe Aniekan E. Owunna
Ikechukwu Department of Mechanical Engineering, University of Benin, Nigeria In this study, PET
bottles crushing machine was designed to convert used PET bottles into shreds readily available for
recycling.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:06/June-2022 Impact Factor- 6.752 www.irjmets.com
[4] International Research Journal of Engineering and Technology (IRJET) eISSN: 2395 -0056, p-ISSN:
2395-0072, Volume: 04 Issue: 06 | June-2017 “Design and Fabrication of Water Bottle Crusher”
Prashanth.P1, Mohammed Ali2, Kaushik S Patel3 1,2,3Final year student, Department of Mechanical
engineering, Mangalore Marine College & Technology, Karnataka, India. This project is to increase the
recycling habit of the people and to keep the city clean, to minimize the core material consumption. Our
main intension is to keep the city clean.

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