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www.ijird.com August, 2020 Vol 9 Issue 8
INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH & DEVELOPMENT DOI No. : 10.24940/ijird/2020/v9/i8/ AUG20075 Page 297
Design and Development of Plastic Crusher for a
More Efficient Waste Management Practice
1. Introduction
1.1. Background Information of the Study
Plastic is a synthetic material made from a wide range of organic polymers such as polyethylene terephthalate
(PET), high density polyethylene (HDPE), Polyvinyl chloride (PVC) and low-density polyethylene (LDPE) that can be
moulded into a rigid or slightly elastic form. Plastic materials produced from oil by a chemical process are non-
biodegradable, light in weight and do not break easily. Any property of a large number of synthetic polymers materials
usually organic that have a polymeric structure and can be moulded when soft and then set, such materials are subspecies
of a class of materials known as polymers. These are composed of large molecules formed by joining many, often
thousands of smaller molecules (monomers) together. Other kind of polymers is fine, film, elastomers (rubber) and
biopolymers.
The plastic industry, owing to its use in a wide variety of sectors, such as the automotive, construction, electronics,
healthcare, textiles, drink industry, etc., is amongst the fastest growing markets. (RRN Bhattacharya, 2018). As the world’s
population continues to grow by leaps and bound, so does the amount of plastic waste that people produce. On-the-go
lifestyles require easily disposable products, such as soda cans or bottles of water and soft drink, but the accumulation of
these products has led to increasing amounts of plastic pollution around the world. As plastic is composed of major toxic
pollutants, it has the potential to cause great harm to the air, water and land. (Amandeep, 2019).
Plastic pollution is when plastic has gathered in an area and has begun to negatively impact the natural
environment and create problems for plants, wildlife and even human population. Often, this includes killing plant life and
posing dangers to local animals. Plastic is an incredibly useful material, but it is also made from toxic compounds known to
cause illness, and because it is meant for durability, it is not biodegradable. (Amandeep., 2019).
Plastic waste is a constituent of the solid waste stream of which polyethylene terephthalate (PET) is a part. PET is
used to produce plastic bottle and several other plastic products. Most bottles produced by PET are transparent in nature
and are used for packaging water, soda etc. Plastic are non- bio degradable. It prevents or reduces the seepage of water
into the soil. They clog/block the domestic pipelines and sewage lines. Direct burning of plastic leads to the emission of
ISSN 2278
–
0211 (Online)
Muyiwa A. Okusanya
Lecturer, Department of Agricultural and Bioenvironmental Engineering,
Federal Polytechnic Ilaro, Ogun State, Nigeria
Gbenga W. Ibrahim
Lecturer, Department of Mechanical Engineering,
Federal Polytechnic Ilaro, Ogun State, Nigeria
Abstract
:
One of the prevalent environmental problems encountered in most developing countries is solid waste management.
Plastic waste such as polyethylene terephthalate (PET) bottles and other plastic materials is one of the solid wastes
hampering the developmental and aesthetical state of our environment. This is as a result of indiscriminate disposal
and indiscriminate burning of solid waste. Environmental pollution caused by this indiscriminate disposal and burning
necessitated the development of plastic crusher to recycle plastic waste generated within our environment. The
machine components are hopper, crushing chamber, crushed material outlet, counter weight, transmission shaft with
spiral blade around it, channel and body frame. The machine is powered by a 3-phase 10Hp 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 recyclable 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 are 90%
for HDPE, 68% for LDPE, 45% for PVC and 10% for PET bottles. The developed crusher can be used to reduce the
volume of plastic waste dump. If the findings from this technical brief is adopted and commercialized, the menace of
plastic waste will be ended.
Keywords: Polyethylene Terephthalate (PET), High Density Polyethylene (HDPE), Polyvinyl Chloride (PVC), Low
Density Polyethylene (LDPE), Plastic Waste Management
www.ijird.com August, 2020 Vol 9 Issue 8
INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH & DEVELOPMENT DOI No. : 10.24940/ijird/2020/v9/i8/ AUG20075 Page 298
toxic fumes and gases, which in turn affect human health. Emission of carbon dioxide during burning of waste plastics
causes rise in earth temperature i.e. global warming. Better industrial practices have led to minimizing exposure of plant
workers to harmful fumes. For example, there have been problems in the past resulting from worker being exposed to
toxic vinyl chloride vapour during the production of polyvinyl chloride. Many chemical ingredients of plastics are highly
carcinogenic.
According to Bhattacharya ( 2018( ,one of the sustainable alternatives that could be considered to deal with plastic
waste is to develop bio-based and biodegradable plastic which utilizes starch ,cellulose ,and poly lactic acid as raw materials for
short-te rm use products. However, these are more expensive and are presently at a lab scale, which needs to be up scaled.
It was further reported that incentive-/subsidy-based strategies for product development and research would assist in
facilitating this up scaling into biodegradable plastics. Applications of bio-based products extend to the manufacturing of
green packaging, disposable cutlery, agricultural mulch films, and manufacturing of superabsorbent materials, that can be
used for a sustained release of pesticide/fertilizer in the agricultural sector. Further, these can also be used as eco-friendly
alternatives for the removal of toxic dyes and heavy-metal contaminants from water bodies. (Bhattacharya, 2018(
Plastic bottles are made from petroleum product known as polyethylene terephthalate (PET) and they require
huge amount of fossils fuels to both make and transport them. It is harder to recycle plastic bottles than one thinks. Some
plastic bottles consumed throughout the world, most of them are not recycled because only certain types of plastic bottle
can be recycled by certain municipalities. This simply means that more resources are being used to meet the increasing
demand for plastic. Thus, more waste is generated in this line, and to reduce some of these problems, plastic crushing
machine was designed, fabricated and tested in the department of Agricultural and Bio Environmental Engineering
technology, Federal Polytechnic Ilaro, Ogun State, Nigeria, to recycle plastic waste constituting menace around the
metropolis.
Nitulet al (2015) studied the overview of recycle of various types of plastics. The report reveals that plastics are
generally categorized into two types namely, recyclable and non-recyclable types. The recyclable plastics are PET, HDPE,
LDPE, PVC, etc. while non-recyclable is plastic Bakelite, Nylon, etc. Sorting, Cleaning, Shredding, crushing and extrusion are
the general steps which are involved in recycling plastics. This research endeavour focuses on one of major processes
involved in recycling plastic, plastic crushing.
Plastic crusher is a machine that reduces used plastic bottles to smaller particle sizes to enhance its portability,
easiness and readiness for use into another new product. Plastic crusher designed and constructed comprises of four
major components namely; the feeding unit, the crushing chamber unit, the power unit and the machine frame.
2. Literature Review
2.1. Common Plastic Types
Plastics are synthetic materials made from a wide range of organic polymers that can be moulded into a rigid or
slightly elastic form. They are malleable solids that have strong resistant to corrosion and chemicals. Owing to the fact that
they are cheap and light in weight, a wide variety of sectors, such as the automotive, construction, electronics, healthcare,
textiles, drink industry, etc., use them as either component part of their products or as packaging materials. Plastic
industry is therefore amongst the fastest growing markets in the world. The common types are polyethylene terephthalate
(PET), high density polyethylene (HDPE), Polyvinyl chloride (PVC) and low-density polyethylene (LDPE), Polypropylene
(PP), Polystyrene (PS), Polyethylene (PE), Acrylonitrile-Butadiene-Styrene (ABS), Polycarbonate (PC) etc.
2.2. Plastic Waste Management Problems
Plastics are polymers, a very large molecule made up of smaller units called monomers which are joined together
in a chain by a process called polymerization. The polymers generally contain carbon and hydrogen with, sometimes, other
elements such as oxygen, nitrogen, chlorine or fluorine. Plastics have become an integral part of our lives. The amount of
plastics consumed annually has been growing steadily as the population growth is on steady increase. Its low density,
strength, user-friendly designs, fabrication capabilities, long life, lightweight, and low cost are other factors behind the
excessive accumulation of plastic waste.
Plastics have been used in packaging, automotive and industrial applications, medical delivery systems, artificial
implants, other healthcare applications, water desalination, land/soil conservation, flood prevention, preservation and
distribution of food, housing, communication materials, security systems, and other uses. With such large and varying
applications, plastics contribute to an ever-increasing volume in the solid waste stream.
The world’s annual consumption of plastic materials has increased from around 5 million tons in the 1950s to nearly 320
million tons in 2015 (Beckman, 2018). Quantities of waste plastics have been rising rapidly during the recent decades due
to high increase in industrialization and the considerable improvement in the standards of living. Unfortunately, majority
of these waste quantities are not being recycled but rather abandoned causing certain serious problems such as the waste
of natural resources and environmental pollution (See plates 1 and 2 below for details of pollution impact of plastic).
In the recycle industry, the component must be crushed or melted to form a pellet. Therefore, the plastic bottle
must be cut into smaller pieces appropriate with the machine condition before it is then transferred to the industry as raw
material for further processes such as injection moulding (Vanessa Goodship, 2007). There are two systems used in
crushing machine, namely impact system and rotary system.
www.ijird.com August, 2020 Vol 9 Issue 8
INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH & DEVELOPMENT DOI No. : 10.24940/ijird/2020/v9/i8/ AUG20075 Page 299
Figure 1: Plastic Waste Dump at Idimu Area, Lagos, Nigeria
Figure 2: Waste Dump at Egbeda Area, Lagos, Nigeria
2.3. Causes of Plastic Waste Management Problems in Nigeria
Plastics are synthetic organic materials produced by polymerization. They are non-bio degradable materials and
can stay unchanged for as long as 4500 years on earth causing menace to our land, streams and drainage system.
The plastic waste percentage of waste generated by humans is high and this causes a lot of environmental pollution like
eyesore and leachate generation from land filling, dioxin and photochemical smog from incineration, etc.
Indiscriminate disposal and indiscriminate burning of plastic waste are the root cause of exponential increase in
pollution index of most urban and industrial settlements like Lagos and Ogun State, Nigeria. Other causes of waste
management problems are: population increase; increased level of urbanisation and industrialisation; culture of turning
waste to wealth that is not popular in developing economies; and regulatory policies on environmental cleanliness that are
not popular. So as to reduce the effect of plastic waste impact, a plastic crusher became the focus of this technical brief.
2.4. Methods of Plastic Waste Management
In reducing toxic effects of plastic wastes on the environment and public health, waste management plays a
major role. For global reduction of plastic litters and ocean pollution, there is need for improvement in proper plastic
waste collection, treatment and disposal (Jambeck et al, 2015). Various methods of plastic waste management in
practice are land filling, incineration, gasification, pyrolysis, bio-plastic adoption, reuse and recycling.
2.4.1. Land Filling
A landfill is often thought of as a big hole in the ground where bulldozers indiscriminately plough solid waste into
the earth. In most cases, landfills are municipal solid waste facilities that collect and bury whatever is not sent to municipal
recovery facilities. This includes food waste, paper, glass, plastic and other products that could otherwise be recycled.
Inadequate management of landfills will make way for harmful chemicals in plastic wastes to leach into the
environment, polluting the soil, air and underground water (Jambeck et al, 2015). This waste management practice
should be discouraged as much as possible as its major drawback (eyesore and seepage of leachate into underground
water) affect humans and endangers plants and animal life.
2.4.2. Incineration
Incineration is a waste treatment process that involves the combustion of solid substances contained in waste
materials (Knox, 2005).Incineration and other high-temperature waste treatment systems are described as thermal
treatment as it converts waste materials into ash, flue gas and heat. Empirical facts gathered reveal that fossil fuel causes
climate changes. What is less known is that plastic is also a climate polluter, as it is made from fossil fuels, such as crude
oil, coal, and natural gas. Although, incineration is one of the common ways to manage plastic waste effectively, burning
plastic creates harmful dioxins and if incinerators are inefficient, these leak into the environment causing air pollution,
dioxin emissions, bisphenol and photochemical smog that are carcinogenic to human health.
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INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH & DEVELOPMENT DOI No. : 10.24940/ijird/2020/v9/i8/ AUG20075 Page 300
2.4.3. Bio-Plastics Adoption (Eco-Friendly Alternative)
According to Bhattacharya ( 2018( ,one of the sustainable alternatives that could be considered to deal with plastic
waste is to develop bio-based and biodegradable plastic which utilizes starch ,cellulose ,and poly lac tic acid as raw materials for
short-term use products. However, these eco-friendly alternatives are more expensive and are presently at a lab scale; the
research needs to be up scaled.
2.4.4. Reuse
It is difficult to make it through a day without acquiring some form of plastic. That is where reuse comes in. Once
plastic is in one’s possession, one has chance to be creative and find different usages for it. Also, anything that cannot be
reused can be donated as it will serve to help others who are in need of it. Most people skip this step and go directly to
recycling, but reusing plastics can reduce the demand for new plastics to be created. The drawback this method of waste
management has is in its adoption for corporate businesses where products have to be sealed to promote hygiene of
practice. Figure 3 below shows the picture of an on-going constructional work with PET bottles and concrete blocks at
tourism village of Federal Polytechnic Ilaro (FPI), Ogun State, Nigeria.
Empirical facts gathered from published work reveal that plastic waste can be used in road construction projects.
As we search for new ways to use plastic, using it in roads provides literally miles and miles of possibilities. If the sheer
volume of plastic waste generated by the municipal is channelled to meet the requirements for road construction and their
upkeep, there is a future that helps to take care of waste management problem in our environment (Poweth et al, 2018).
Micro plastic is in good turn homogenised into polymer-modified bitumen before it is used for road construction to avoid
accumulation of leachate which then sips into nearby water table to pollute it.
Figure 3: Use of PET Bottles Waste for Building Construction
Attourism Village, FPI
2.4.5. Recycling
Recycling is a good option after plastic has been reused as many times as one can and one is ready to dispose of it.
Recycling plastic takes less energy than making plastic from raw materials. However, with a little planning, commitment
and effort, it is easy to make steps towards reducing one’s carbon footprint. The biggest impact is made by avoiding
plastics in the first place and if that cannot be done, reuse and recycling are the next best steps. Conscious effort should be
made to reduce the amount of plastic material being used by trying to replace plastic with something more sustainable
whenever possible. Any plastic that has already been acquired can be reused. More also, used plastic can be recycled to
keep it out of the waste stream as this will serve to reduce demand for new plastic. Recycling will help to reduce plastic
pollution and keep our planet clean and healthy for future generations. The drawback with this practice is waste collection
problems, sorting problem and high initial cost of machines used in recycling the plastic.
2.5. Recyclable and Non-Recyclable Plastic
Recyclable plastic materials are materials once collected can be turned into new products while non-recyclable
plastic materials are the types that cannot be processed into new product after use. The recyclable types are
thermoplastics while the non-recyclable are thermosets. A thermoplastic is a material usually a plastic polymer which
becomes softer when heated and hard when cooled. Thermoplastic materials can be cooled and heated several times
without any change in their chemical or mechanical properties. They can be repeatedly reformed into new products.
Thermoplastic polymers are the focus of this technical brief. The thermosetting polymers on the other hand are materials
which remain in a permanent solid state after being cured one time. Direct implication is that thermosets will not melt
even when exposed to extremely high temperatures. They are often used in electrical applications and are not suitable for
recycling in most cases. Examples of recyclable plastic are PET bottles, HDPE, LDPE, PVC, acrylic, polyester etc. while the
unrecyclable types are polyester resin, polyurethanes, vulcanized rubber, bakelite, vinyl ester and thiolyte used as
electrical insulating materials.
2.6. Steps Involved in Recycling Plastics
Plastic recycling refers to the process of recovering waste or scrap plastic and reprocessing the materials into
functional and useful products. This activity is known as the plastic recycling process. The goal of recycling plastic is to
reduce high rates of plastic pollution while putting less pressure on virgin materials to produce brand new plastic
products. This approach helps to conserve resources and diverts plastics from landfills or unintended destinations such as
oceans or water courses leading to the municipal.
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INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH & DEVELOPMENT DOI No. : 10.24940/ijird/2020/v9/i8/ AUG20075 Page 301
Plastic recycling is broken up into a few distinct steps. Generally, these steps remain the same for most types of
recycling facilities, but certain steps can be combined or omitted in some situations. The steps involved are:
Plastics collection - common practice involves road side collections, use of special recycling bins, direct
collection from industry, etc.;
Manual sorting - various plastics collected are sorted into PET, HDPE, LDPE, PVC, etc.;
Chipping – machines like crusher, shredder, bailer, etc. Are used to reduce the size of the polymer under
process into desired granular size;
Washing – washing of shredded plastic assist in removing contaminant from the materials before they are
then taken to the next stage of the process.
Pelleting – machines like extruder, pelletizer, etc. Are used in turning the shredded and washed plastics into
pellets under intense heat and pressure. Pelleted plastics are afterwards sold as raw materials for other
processes like making of PET bottles, PVC pipes, buckets, etc.
2.7. Benefits of Recycling
The benefits of waste recycling include the following:
The process of recycling plastic helps waste management by saving available space in landfills.
Recycling conserves the natural resources and the energy that would be required to produce plastic from scratch.
Plastic Recycling helps in mitigating global warming and reducing pollution
Wealth generation - there are companies that pay cash for trash and patronizing the recycled products saves
money because they are less expensive.
Plastic Recycling recovers the scrap or the waste plastic and reprocesses the material into useful products.
Plastic Recycling protects the environment.
Plastic recycling promotes judicial and sustainable use of resources
Plastic recycling creates green jobs.
Despite the efficiencies and benefits of most recycling facilities, there can still be some difficulties involved
with the process of recycling plastic. Materials such as dyes, heavy metals, pharmaceuticals, and sometimes pieces
of biodegradable plastic can potentially contaminate an entire batch of petroleum-based plastics and it will all need to
be thrown away. This is why it is very important for one to follow the guidelines of one’s recycling company regarding
which plastics can and cannot be accepted for recycling.
3. Materials and Methods
3.1. Design Consideration
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 labour requirement. The machine is
easy to maintain. Mild steel plate of 6mm thickness was considered for the construction to avoid shearing of parts and
eventual machine failure while in operation. The spiral shaft impacts strong impact force on the crushing chamber to
achieve crushing into desired granular size, materials fed into it.
3.2. Component Parts of the Machine
Plastic crusher is a machine that reduces used plastic to smaller particle sizes to enhance its portability, easiness
and readiness for use into another new product. Plastic crusher designed and constructed comprises of the following
parts:
Hopper: is the section through which the waste plastic is fed into the crushing chamber. It is made up of mild steel
of 6mm thickness with dimension of 480mm x 300mm x 427mm.
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. The crushing chamber consists of a shaft that is 539
mm length and 65 mm in diameter. Attached to the shaft are cutters made of 12 mm mild steel flat blade of
270mm × 74mm welded to 270 mm cylindrical drum to form spiral blade.
Transmission shaft: The shaft is made up of cast iron block of 539 mm length and 40 mm in diameter
Spiral blade: The spiral blade cut the plastic into granules with its sharp edges. It is made up of 12mm thick mild
steel of dimension 270mm x 74mm.
Screen: The screen is of dimension 375mm length and 392 diameter. The pore space on the screen is 8mm in
diameter.
Bearing: Bearing is a mechanical device that supports another part and reduces friction. The type of bearing used
is pillow bearing.
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 iron mechanically linked in opposition to a load. It supports the machine
and maintains balancing.
Member frame: The frame supports the other component parts on it in order to make the entire assemble stable.
It is made up of mild steel of 480mm x 480mm x 400mm.
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INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH & DEVELOPMENT DOI No. : 10.24940/ijird/2020/v9/i8/ AUG20075 Page 302
Discharge outlet: The crushed plastic passes through an outlet provided at the peripheral of the machine. It is
made up of mild steel of dimension 378 mm × 151 mm x 110mm.
Prime mover: is a machine that receives and modifies energy as supplied by some natural sources or fuel and
transform it into mechanical work. It is powered by electric motor of 10hp.
Channel: It is the platform that maintains the stability of the machine. It carries the load and weight of the
machine. It is made up of angle iron.
3.3. Material Selection
Machine
Component
Criteria
For
Material Selection
Machine
Selected
Dimension
Remark
Hopper
Must be strong and
able to acquire
more material
Mild steel of 6mm
thickness
400mm x 300mm x
427mm
It does not
twist
and has ability to
occupy more
material
(fabricated)
Crushing chamber
Ability to withstand
spiral blade
vibration and
impact force
Mild steel of 6mm
thickness
394mm x 394mm x
250mm
Durable
(fabricated)
Shaft
Must be strong
Iron rod
539mm long and ф
40mm
It was machined
Spiral blade
Must be strong and
have sharp cutting
edges
Mild steel of 12mm
thickness
270mm x 74mm
It has strong and
sharp edges for
crushing(machined)
Screen
Ability for ease of
passage of material
under process
Mild steel of 3mm
thickness
275mm x 392mm
Available (bought
readymade)
Belt
Must be strong and
not flexible
Leather
B64
Stable (bought
readymade)
Pulley
Ability to have a
good wear
property
Cast iron block
200mm x 75mm
Bought readymade
Bearing
Must be durable
and strong
Mild steel
Pillow bearing of
40m internal bore
Bought readymade
Counter weight
Ability to withstand
load of the shaft for
balancing
Cast Iron block
200mm x 75mm
Available and
durable
Channel
Must able to
withstand dead
load imposed by
the self-weight of
the crusher
Angle iron of 6mm
thickness
1047mm x 365mm
x 80mm
Constructed
Bolts and nuts
Must be hard and
durable
Alloy steel
Bought readymade
Prime mover
Must be a medium
or high speed
Electric motor
10hp
Bought readymade
Table 1: Material Selection
3.4. Machine Description and Operation
The waste plastic crusher has four main components; the feeding unit, the crushing unit, the power unit and the
machine frame (See figure 2, 3and 4for details on pictorial view, orthographic projection and part drawing of the crusher).
The feeding unit is made of mild steel sheet of 6 mm thickness and the machine dimension is 1050 mm ×525 mm x
1250mm. Hopper is the section through which the waste plastic is fed into the crushing unit. The crushing unit is where
the waste plastic is cut into smaller sizes either through shredding or impact force of a shredder or a crusher. The crushing
chamber consists of a shaft that is 539 mm length and 40 mm in diameter. Attached to the shaft are cutters made of 12 mm
mild steel flat blade of 270 × 74 welded to 270 mm cylindrical drum to form spiral blade. The radius of the spiral blade
from the centre of the shaft is 53mm. There is a clearance 3 mm between the spiral blade and the adjustable stationary
blade. The rubbing of the spiral blade against the stationary blade when the machine is loaded with the materials to be
processed brings about the crushing effect on the plates fed in. The spiral blade has the same length with the stationary
blade bolted to the blade holder on the member frame in the chamber. Underneath the crushing unit is the screen of
375mm length and 392 diameters. The pore space on the screen is 8mm in diameter. The crushed plastic passes through
an outlet provided at the peripheral of the machine. The outlet dimension is 378 mm × 151 mm x 110mm. The crushed
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waste plastic discharge freely from the crushing unit through the outlet (See Figure 16 for details). The machine is
powered by 10Hp electric motor with the aid of belt and pulley arrangement (belt drive). The driving and the driven pulley
are respectively 100mm and 150mm. Figure 4 below shows the flow chart of processes involved in recycling plastic. The
processes are plastic waste collection, screen, sorting, size reduction such as granulation, washing/cleaning, forming into
moulds and packaging.
Figure 4: Flow Chart of Plastic Waste Recycling
Figure 5: Pictorial View of the Plastic Crusher
Figure 6: Orthographic Projection of the Plastic Crusher
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Figure 7: Part Drawings of the Crusher
3.5. Design Calculation of the Plastic Crusher
3.5.1. Hopper Capacity Design
Figure 8: Hopper Design Section
Volume of the hopper = Area of cross-section of the hopper × width of hopper= ½ (a + b) h ×
width....................................................................................... (1) (See figure 4 and 5 for details)
=½(245+270) x 417×245
Hopper capacity = 26 × 10⁻³ m³
Volume of PET bottle in the shredding chamber:
Volume of PET bottle (Coca-Cola bottle)
= Area × height = πd⁴ / 4 × h............................................................. (2)
= 7.7 × 10⁻⁴
Number of bottles to fill the hopper = volume of hopper/ volume of PET Bottle (IJETSR, 2017)
= 26×10⁻³ / 7.7×10⁻⁴
=34 bottles
3.6. Design Calculations
3.6.1. Input Power Measurement
The input power measurement can be determined from the name plate information of the prime mover used to
power the machine. It can also be determined from the drive for the transmission shaft of the machine. In this endeavor,
the input power for the crusher was calculated from the belt drive used for power transmission.
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={1−2}() …………………….………………………. (1) (Hall etal, 1973)
T1 = belt tension in tight side (N)
T2 = belt tension in loose side (N)
V = belt speed, m/s
V = wr, where w = angular speed and r = radius of shaft or pulley under consideration.
In finding the required power, equations 2, 3and 4 below are needed.
{1−2}/{2−2} = {
Ɵ}
……………………….... (2) (Hall etal, 1973)
= density of belt = 970 kg/m3 for leather belt
= 1800 or for flat belt, b = width of belt, t = thickness of belt
m = mass in kilogram
3.6.2. Load Carrying Capacity
Load carry capacity is calculated for pulley with lower {
Ɵ}
value
For the rice thresher, the following parameters were taken from the design:
C = 650mm, ∅2 = 150 mm, ∅1 = 100mm, b (15/8) = 81.28cm, t (10)= 63.5cm (Assume B57 belt was used
C = shaft center distance, ∅2 = ℎ,∅1 = ℎ
= ………………………………………………………………………….. (3) (Hall etal, 1973)
={97010.85.7}
{10001000}
m = 0.0597 kg/m
11 = 22 ………………………………………………………………………..………..…(4)
Where N1 = ∅1 = prime mover speed, D1 = Diameter of pulley on prime mover shaft.
N2 = Transmission shaft speed, D2 = ∅2 = Diameter of pulley on transmission shaft.
N1 = 1770rpm (from name plate information of 10Hp electric motor used), N2 =? D1 = 100mm, D2 = 150mm
11 = 22
1770100 = 2150
From equation 4, Transmission shaft speed, N2 = 1180 rpm
=
60 ={1501180}
{601000}
= 9.27 m/s
1 = …………………………………………………………………………(5) (Hall etal, 1973)
Where s = maximum allowable stress = 2Mpa for flat belt
From equation 5, 1 = =10.8
1000 5.7
1000 210
= 123.12N
Angle of Rap ()
If f is assumed to be 0.3, where f = coefficient of friction between belt and pulley
1 = 180 −2,
2 = 180 + 2 , c where = ^{−{}
}
Where 1 and 2 are angle of rap for tight and slack side of belt dive.
1 = 180 −2sin^{−{}
} …………………………………………………………..……..(6)
2 = 180 + 2sin^{−{}
} ………………………………………………………..……..... (7)
1 = 180 −2sin^{−1150
2−100
2
650 }
= 180 – 2 x 2.204
1 = 175.590
From the formula in equation 7, 2 = 184.4080
From equation 2,../
Ɵ = 2.509 for 175.590, where belt factor f = 0.3
Also
Ɵ=../
Ɵ= 2.78 for 194.860. Remember that Sin ½ = Sin 90 = 1, where = 180
Hence, smaller pulley governs.
From equation 2 again,
{1−2}/{2−2} = {
Ɵ}
Therefore,
...
{..}= 2.509 , making T2 the subject,
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T2 = 51.113 N
3.6.3. Power Requirement
From equation 1, power requirement is as calculated below:
={1−2}
=
= 9.27 m/s ={123.12 −51.113}9.27
= 667.51W
≈ 0.668KW (the minimum power required to crush the plastic).
3.6.4. Motor Name Plate
Given the following nameplate information about the 10Hp electric motor used to power the crusher:
Ss = Synchronous speed in rpm = 18000
Sr = Name plate full load speed = 1750
Sm = Measured speed in rpm = 1770
Pnp = Nameplate rated horsepower = 10Hp
={}
{−}100(%)={−}
{−}100(%)
={1800 −1770}
{1800 −1750}100
=60%
Pload (KW) = 60%100.746
=60
100 100.746
=4.476 KW (this is the power of the motor under full load).
The size of the electric motor chosen in terms of power is within range as it can conveniently carry the transmission shaft
under full load and high starting torque. i.e. 4.476KW >>> 0.668KW. Where the motor has insufficient rating, there will be
frequent damages and shut downs due to over loading, and this is not intended.
3.6.5. Torque Requirement
Load torques are often times classified as either active load torques or passive load torques. Load torques under
consideration in this endeavor is passive type as it is torque due to friction cutting of plastic in the crushing chamber. The
torque developed by the motor at the instance of starting is called starting torque and in some cases, it is greater than the
normal running torque.
=(1−2) ……………………………………………………………….(8) (Hall etal, 1973)
R = Radius of bigger pulley =(123.12 −51.113) 75
1000
= 5.40 Nm.
3.6.6. Shear Force and Bending Moment Calculation
In determining Shearing force and bending moment, certain weights were determined:
Weight of pulley, W1= 5kg × 9.81N/m2 = 49.05N
Weight of the four blades on the main shaft in the crushing chamber W2= 8kg × 9.81N/kg =78N
Weight of the counter balance W3 = 5kg × 9.81N/m2 =49.05N
Weight of the main Shaft W4 = 10kg x 9.81N/m2 = 98.1N
Weight of each bearing, W5 = 5Kg x 9.81 = 49.05N
Weight of materials (plastic) to be processed per operation, W6 = 2Kg x 9.81 = 19.62N
3.6.6.1. Shear Force Calculation
RA + RB = W1 + (W2 +W4) + W6 + W3 = 49.05 + (78 + 98.1) + 19.62 + 49.05 = 293.82N
RA + RB = 293.82N as shown below (i.e. upward force = downward force)
ΣBM: 49.05(50+67.4+67.4+67.4+67.4) + 9.81(67.4+67.4+67.4) + 176.1(67.4+67.4) + 9.81x67.4 -269.5 RB – 49.05x50 = 0
From there, 269.5 RB = 39606.936
RB = 146.96N, RA + RB = 293.82
RA = 293.82 – 146.96 = 146.86N, RA = 146.96N while RB= 146.86N
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Figure 9: Force Analysis of the Plastic Crusher RA and RB Reaction at Two Bearing Sections
3.6.6.2. Bending Moment Calculation
1. Bending Moment at A = 49.05 x {269.5 + 50}/1000 Nm = -15.67Nm
2. Bending Moment at B =146.86x 269.5/1000 = 39.58Nm
3. Bending Moment at C = {(9.81+ 176 + 9.81) x 134.8} / 1000 = -26.37Nm
4. Bending Moment at D = 169.18 x 0 = 0
5. Bending Moment at E = {49.05 x 50}/1000 = 2.45Nm
3.6.6.3. Shear Force and Bending Moment Diagram
Weight of main shaft, Ws= 50N. Also, weight Wj of materials in the hopper section is 40N. Assume weight of
section of four blades on the main shaft to be Ww= 80N altogether. Therefore, different forces acting on the main shaft are
as analysed above in figure 9.
Shear force and bending moment diagram are as in figure 7 below.
Figure 10: Shear Force and Bending Moment Diagram
3.6.7. Transmission Shaft Design
Shaft design consists primarily of the determination of the correct shaft diameter to ensure satisfactory strength
and rigidity when the shaft is transmitting power under various operating and loading conditions. Shafts are usually in
cross-section, and may be either hollow or solid. The shaft considered for design in this technical report is solid cylindrical
shaft. See figure 8 below for details.
Figure 11: Shaft Design Section
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The ASME code equation for solid shaft diameter is as given in equation in equation 10 below.
=
{()+()} ……………………………………… (10) (Hall etal, 1973)
Mb = bending moment
Mt = Torsional Moment
Kb = combined torque and fatigue factor applied to bending moment
Kt = combined torque and fatigue factor applied to torsional moment
From ASME code, Ss = 40MN/m2 for shaft with key
Also, Kb = 1.5, Kt = 1.0
From the bending moment calculation above, Mb = 39.58Nm. Torsional moment, Mt = 502.66Nm (See equation 13 for
details of the value)
Mb = 39.58Nm (see bending moment diagram for details)
=16
4010{(1.539.58)+(1.0502.66)}
=16
4010{3524.80 + 252667.1}
=16
4010√256191.9
d = ∛{0.0000644455} m
d = 40.09 ≈40 . Therefore, the minimum diameter that can be chosen as transmission shaft diameter for the crushing
chamber is 40mm.
3.6.8. Shaft Design for Torsional Rigidity
Rigidity is based on the permissible angle of twist. The amount of twist permissible depends on the particular
application, and varies about 0.30 / m for machine tool shafts to about 30 / m for line shafting.
According to SAME on solid circular shaft,
= 584/ ……………………………………………………………… (12)
= angle of twist (degree)
L = length of shaft (m) = 800mm - designed
Mt =torsional moment (Nm) = 11.13 Nm - calculated
G = torsional modulus of elasticity (Nm2) = 80 x 109Nm2 - standard
d = shaft diameter = 40mm - Assumed value.
R = D/2 = 40/2 = 20mm = 0.02m ={584502.660.8}
{801040. 010}={234842.752}
204800
=1.150. Since the value is less than 30 / m (30 / m >>> 1.430/m), angle of twist of the 0.8m long transmission shaft is
within permissible range.
Torsional moment, Mt = {}
……………………………………………………. (13)
Where J is Polar Moment of inertia of a circular solid shaft, Ss is maximum shear stress and R the radius of the shaft.
=
2=20
1000
2= 2.513310
Since Ss = 40MNm2, therefore:
Mt = .
.
Mt = 502.66 Nm
3.7. Experimental Procedure
The description of a typical experiment was used to explain the experimental procedure. Plastic crusher uses
impact principle to crush plastic fed into it. During working process, its prime mover drives the transmission shaft of the
machine with a high-speed and strong impact force. This speed is then transmitted to the rotating blade cutter head which
in turn forms the relative movement trends cooperated with fixed blade. However, utilizing the gap between rotating
blade and fixed blade gives rise to cutting edges of plastic grinding and cutting, thereby crushing the large pieces of plastic.
Lastly, the broken plastic is filtered and outputted according to particles sizes of plastic through the screen sieve provided
at the peripheral of the machine.
3.8. Materials for Evaluation and Variables Considered
Materials used for plastic crusher evaluation are HDPE, LDPE, PET Bottle and PVC, Sensitive measuring
scale, stop watch and recording materials. Variables considered during evaluation are blade clearance, screen size,
material throughput, machine capacity, polymer type and efficiency.
3.9. Method of Analysis of Results
Null hypothesis for variables considered is Ho: 0.5 ≤ r ≤ 1; while alternative hypothesis is H1: r < 0.5. For Ho in the
range of values stated above, it means there is a strong relationship between the dependent variable and independent
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variable. If the correlation coefficient is not within acceptable region, alternative hypothesis is accepted. The implication of
this is that the relationship between them is weak.
a = ȳ - bẍ ………………………………………………………………………...................…..(14)
From equation 14 above, regression line ‘y = bx + a’ can be determined. Relationship between the observed variables and
the predicted variables was established through statistical instrument (see the annex of this report for details of the
calculation).
3.10. Cost Estimation of Plastic Crusher
Cost of engineering products like newly developed plastic crusher can broadly be grouped under direct or indirect
cost (Haslehurst, 1981). Direct cost is the cost of factors which are directly attributed to the manufacture of a specific
product (i.e. materials and labour costs). Indirect cost on the other hand is that indirectly attributed to the manufacture of
a specific product, such as overhead cost (usually expressed in percentage of direct labour cost) (Ajav et al, 2018).
The costing of the newly designed and fabricated plastic crusher was based on the detailed factorial estimate method
(Sinnot, 1993). This is because fabrication of the machine is complete and detailed breakdown and estimation of
component parts is possible. The cost analysis of the machine is shown in table 2 below.
Qty.
Material Specifications
Rate
(₦)
Amount
(₦)
3
Angle Iron One Length, 70mm x 70mm
7,500
22,500
1
Mild Steel Solid Shaft 1m long,
ϕ
40mm
10,000
10,000
20
Mild Steel Bar 20mm x 5mm x 1m
250
5,000
2
Flange bearing
ϕ
25mm
3,500
7,000
2
Mild Steel
Figure 1
22mm x 244mm x 10mm
30,000
60,000
2
Pkt. Mild Steel Electrode Gauge 12
4,000
8,000
1
Mild Steel Plate 60mm x 80mm x10mm thickness
7,000
7,000
36
Bolts & Nuts M10Hcx. 13mm
50
1,800
2
Cutting Stones
ϕ
230mm size 2.5mm
500
1,000
3
Grinding Stones
ϕ
180mm thickness 5mm
500
1,500
2
Hack Saw Blades 320mm long
75
150
2
Drill Bits 13mm &
14mm
250 & 300
550
1
Counter Balance Weight (5kg)
5,000
5,000
6
Blade 269/74mm
80,000
80,000
1
Electric motor 10Hp
80,000
80,000
-
Transport
7,000
7,000
Sub Total = ₦ 226,520
DIRECT LABOUR COST
Machining of Main Shaft Worms and Spiral Blade 5,000
Fabrication (Bending, Rolling, Shearing, welding, painting) 10 ,000
Sub Total = ₦15,000
INDIRECT/OVERHEAD COST
1. Over head of direct material cost = 20% of ₦15,000 = ₦3,000
2. Over head of direct labour cost = 20% of ₦226,520 = ₦45,304
Sub Total = ₦48,304
TOTAL =
₦226,520 + ₦15,000 + ₦48,304 = ₦289,824
Table 2: Bill of Engineering Measurement and Evaluation (Beme) of the Plastic Crusher
Mechanical Components (Direct Material Cost)
4. Results and Discussion
4.1. Result
Plastic Crushing is the process of transferring an impact force amplified by a mechanical advantage to a material
made of molecules that are bond together more strongly and as well resist deformation. In the evaluation process, large
materials were fed into the machine for crushing exercise. The machine mainly consists of a cutter whose principle is to
destroy the plastic into granules depending on the shear force and impact strength applied. The essence of crushing is to
reduce large solid material object into a smaller piece. It is usually used to reduce size and shape of materials so that it can
be efficiently used for the purpose intended. The results from evaluation work are as shown in tables 3, 4, 5 and charts 1, 2,
3 and 4below. The recyclable polymers used to test the efficiency; material throughput and versatility of the machine are
low density polyethylene (LDPE), high density polyethylene (HDPE), polyethylene terephthalate (PET) bottles and
polyvinyl chloride (PC). Variables evaluated are material throughput, blade clearance, size of screen, nature of materials
processed and efficiency.
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S/N
Polymer Type
Weight of Crushed
Polymer (Kg)
Time
Taken
(Hr.)
Material
Throughput
(Kg/Hr.)
Tonnage/day
(tonnes/day)
W
1
W
2
W
avg.
1
HDPE
76.5
78.8
77.70
1
77.70
0.622
2
LDPE
62.4
62.7
62.60
1
62.60
0.501
3
PC
41.5
41.8
41.70
1
41.70
0.334
4
PET
2.1
2.2
2.15
1
2.15
0.017
Table 3: Result from Crushing Exercise Using Different Polymer Type (2mm Crushing Blade Clearance)
S/N
Rotary to Stationary
Blade Clearance (mm)
Material Throughput
(Kg/Hr.)
Tonnage/
Day
(tonnes/day)
1
1.0
84.2
0.6736
2
1.5
79.6
0.6368
3
2.0
73.3
0.5864
4
2.5
49.8
0.3984
5
3.0
21.56
0.1725
Table 4: Result from HDPE Crushing with Varied Crushing Blade Clearance
S/N
Screen
Clearance (mm)
Material Throughput
(Kg/Hr.)
Tonnage/day (tonnes/day)
1
8.0
78.9
0.6312
2
6.0
67.6
0.5408
3
4.0
50.4
0.4032
4
2.0
30.5
0.244
Table 5: Result from HDPE Crushing with Varied Screen Clearance (1.5mm Crushing Blade Clearance)
Figure 12: Relationship between the Polymer Type and Efficiency of Crushing
Figure 13: Plastic Crusher Capacity Based on Polymer Type Processed
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Figure 14: Relationship between Machine Capacity and Blade Clearance
Figure 15: Relationship between Material Throughput and Screen Sizes
4.2. Discussion
Plastic crusher was designed, developed and subjected to performance evaluation in Agricultural and
Bioenvironmental Engineering Department, FPI, Ilaro, Ogun State, Nigeria. The test result is as shown in tables 3 to 5 and
Charts 1 to 4. The sectioned view of the developed plastic crusher is as shown in Figure 16. The view shows the shaft
section, spiral blade, stationary blade, pillow bearings, pulley and the counter weight. Once the machine is powered with a
3-phase electric motor at a medium speed of 1440 rpm, the spiral blade rubs the plastic to be crushed against the
stationary blade through impact force to crush the plastic.
Results in Figure 12 and 2 above show that the machine is more versatile for HDPE crushing as compared to other
types of polymer as both efficiency (90%) and materials throughput (above 600kg/day) for the polymer are the highest.
This could be due to hardness of the material. Efficiencies of various type of polymers processed are 90% for HDPE, 68%
for LDPE, 45% for PVC and 10% for PET bottles. When PET bottles were processed, the machine capacity was 17kg per
day of 8 hours operation. This could be due to soft nature of the material as it tends to draw instead of braking at strong
impact force. Direct implication from this is that the machine is not suitable for pet bottles crushing. Shredder should
rather be used by processor for materials of that nature.
A plastic shredder is a machine used to cut plastic into smaller pieces for granulation. In the process, large plastic
items are fed into the shredder which moves at a slower speed than a granulator or crusher. The blades arranged on the
transmission shafts rotating in an interwoven manner break the plastic down into smaller chunks. The shredder can tear
up and recycle waste recyclable resources such as waste PET bottles, waste rubber and wastes tires as against crusher
which uses strong impact force to brake hard plastic materials.
In Figure 14, the clearance between the stationary and rotary blade was adjusted at various intervals between
1mm to 3mm to determine if the adjustment has effect on material throughput - the clearance can be adjusted to suit
crushing condition needed. It was observed that if the clearance is too low (below 1mm); it can lead to clogging of parts
and eventual machine seizure. For too large clearance, the impact force needed for effective material crushing will not be
attained. The minimum clearance for smooth running of the machine should be in the range of 1mm and 2mm; above
2mm, material throughput will take a downward trend. R-squared of the regression line for this case is 0.8861, meaning
there is strong relationship between observed variable(machine capacity) and predicted variable (blade clearance).R-
squared is a statistical measure of how close the data are to the fitted regression line – R2 quantifies the degree of linear
correlation between observed value and predicted value.
The screen size provided for crushed material flow into outlet provided at the peripheral of the machine is in the
range of 8mm to 2mm. It was observed that the size of screen has impact on material throughput since measure of the
degree of linear correlation between the two variables is high (R² = 0.9858). The bigger the screen size the higher the
material throughput in an hour (see Figure 15 and table 5 for details). The machine capacity is above 600kg in a day of 8
hours operation for 8mm screen size with HDPE crushing and a bit above 200kg for 2mm screen size - the bigger the size
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of screen, the higher the material throughput. Figure 17 shows the picture from the crushing exercise and the sizes of
crushed plastic observed varied from 8mm to a granular size of particulate matter.
It appears the screen size used for the crusher design is small since materials above 8mm cannot flow easily
through it. This in turn affects the feeding rate of plastic into the machine. The processing time for certain kilogram of
plastic to be crushed can be increased if the screen directly under the crushing chamber is changed to the type in the range
of 12mm to 20mm.
When the machine is in operation, all parts are set in motion due to vibration of major parts like the transmission
shaft. The vibration of parts brings about spill of materials under process out of the machine through the hopper. Lid can
be provided for the hopper to prevent material flow out of the machine through the hopper section.
The medium speed (1440 rpm) electric motor used can also be changed to high speed (2900 rpm) motor. This will
make the impact force on the machine to be high enough to crush the type of polymer under process. In good turn, the
machine throughput will be high.
Figure 16: Section View of the Plastic Crusher with the
Shaft and the Spiral Blade
Figure 17: Plastic Crusher during One of the
Crushing Exercises
5. Conclusions and Recommendations
5.1. Conclusions
The plastic crusher is widely used in industries for plastic waste management. By using this plastic crushing
machine, the overall costing of recycling process is reduced and labour work becomes less. To recycle waste plastic into
other forms of plastics, the following machines are involved: Plastic crusher/shredder, extruder, granulating machine,
washing machine, bale breaker, plastic melting and moulding machine etc. This technical brief focused on plastic crusher.
The following are the conclusions from the evaluation work carried out on the machine:
The plastic crusher is not a suitable machine for PET bottle recycling.
The screen size used for the crusher design is small since materials above 8mm cannot flow easily through it. This
in turn affects the feeding rate of plastic into the machine.
When the machine is in operation, all parts are set in motion due to vibration of major parts like the transmission
shaft. The vibration of parts brings about spill of materials under process out of the machine through hopper. Lid
can be provided for the hopper to prevent material flow out of the machine.
The plastic crusher can only be used for small scale recycling of plastic.
The efficiencies of various type of polymers processed are 90% for HDPE, 68%for LDPE, 45% for PVC and 10% for
PET bottles. Direct implication from this analysis is that the machine is not suitable for crushing PET bottles.
Shredding machine should rather be used for materials of that nature by processors in the industry.
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5.2. Recommendations
The processing time for certain kilogram of plastic to be crushed can be increased if the screen directly under the
crushing chamber is changed to the type in the range of 12mm to 20mm.
The medium speed (1440 rpm) electric motor used can also be changed to high speed (2900 rpm) motor. This will
make the impact force on the machine to be high enough to crush the type of polymer under process. In good turn,
the machine throughput will be high.
The machine versatility for other waste materials like paper waste, tin can, etc., should be tested.
The speed of the electric motor should be increased and the material should be exposed to sunlight radiation for a
long time before they are processed.
Thorough evaluation can be carried out on the machine as data from it will assist in optimization of its process
efficiency.
The machine can be adopted for commercialization if modification work aforementioned is carried out on it.
The plastic of the same materials should be crushed to make materials processed per time attract high market
value.
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