Design, Fabrication, and Performance Evaluation of Shredding
Machines for Shredding Plastic Bottles and Cups Waste
Frans Mangngi
a
, Aris, Arianto B. Ama and Yudith E. Mase
Mechanical Engineering, State Polytechnic of Kupang, Indonesia
Keywords: Shredding Machine, Plastic Waste, Plastic Bottle, Plastic Cups.
Abstract: Plastic's function in human lifestyles is expanding. This boom is because of the truth that plastic is light-
weight, realistic, and reasonably priced and can replace other objects features. Plastic use is hastily increasing
in East Nusa Tenggara Province, especially in Kupang town, as evidenced by the enormous use of plastic
gadget. Some people in Kupang town see this problem as a possibility and opportunity to create jobs and a
generate of income by gathering plastic waste to be sold and despatched to some other island to be recycled.
Therefore, this study focused on designing and fabricating a low-cost plastic shredding machine that will
assist plastics collectors as small and medium-scale entrepreneurs in the city of Kupang in chopping plastic
waste i.e. bottles and cups into small fragments, making it easy to pack and ship it. The plastic shredder
machine is made up of four major parts: the hopper, the shredding unit, the power unit, and the machine frame.
The design parameters, such as hopper capacity, shaft diameter, reducer ratio, and required power, have been
calculated. The result of the calculated design parameters was being used for fabrication. The uniqueness of
this plastic shredder machine lies in the uniqueness of its design where at the bottom of the shredding unit
there are a metal sieve with the geometric shape of arc that allows the recirculation of crushed plastic not
conforming to the appropriate size to reintegrate it in the shredding process. This metal sieve will ensure the
chopped plastic are uniform in size. The performance evaluation of the machines was determined in terms of
the machine efficiency and the production rate. Following the successful completion of the fabrication, the
shredder machine is tested using 4500 gr of the plastic bottle and 2600 gr of plastic cups as a sample, with the
succeeding results obtained: At a machine speed of 135 rpm, the plastic bottle was shredded to an average
particle size of 30 mm
2
in 840 sec, and plastic cups was shredded to an average particle size of 28 mm
2
in 400
sec. The average machine efficiency was 98% for plastic cups, and 94% for plastic bottle.
1 INTRODUCTION
Plastic's use in human existence is expanding by the
day. Plastic is being used more because it is light,
practical, and affordable, and it may replace the
function of other goods. Because of their practical and
affordable character, plastics are frequently utilized
as disposable objects, increasing plastic waste as
more equipment made of plastic materials is used.
This is what causes the amount of plastic waste to
continue to rise, causing major environmental issues.
Plastic trash is an environmental issue that the people
of Indonesia and the rest of the globe face. The use of
non-environmentally friendly plastic products
generates a variety of major environmental issues.
Plastic garbage is one sort of waste that is extremely
a
https://orcid.org/0000-0003-0882-615X
difficult to degrade in the soil, taking decades or even
hundreds of years to completely decompose in nature.
Plastic garbage dumped directly into the final
disposal site will cause complications if not properly
managed (L. Habib, et all, 2018). The dumping of
plastic waste is one of the sources of environmental
damage that remains a significant concern for the
Indonesian people. The plastic trash takes tens.
However, the negative impact of plastic waste is
proportionate to its usefulness. Thus, if the trash is not
eliminated, it will pose a major hazard
In the city of Kupang, particularly in the sub-
district of Kelapa Lima, the usage of plastic is fast
increasing, as seen by the prevalence of plastic-made
equipment. This is exacerbated by the public's lack of
awareness regarding proper waste disposal, so in
several locations along the coast in Kupang City, such
82
Mangngi, F., Aris, ., Ama, A. and Mase, Y.
Design, Fabrication, and Performance Evaluation of Shredding Machines for Shredding Plastic Bottles and Cups Waste.
DOI: 10.5220/0011712900003575
In Proceedings of the 5th International Conference on Applied Science and Technology on Engineering Science (iCAST-ES 2022), pages 82-88
ISBN: 978-989-758-619-4; ISSN: 2975-8246
Copyright © 2024 by SCITEPRESS – Science and Technology Publications, Lda. Under CC license (CC BY-NC-ND 4.0)
as Pasir Panjang beach and Oesapa Beach, there is a
great deal of plastic waste that pollutes the
environment and will undoubtedly have further
repercussions if not addressed immediately.
The issue of plastic trash is not just an
environmental concern, but also an opportunity for
commercial growth. Therefore, several residents of
Kupang city view this opportunity as a source of
income-generating employment opportunities. The
scavengers will begin to collect and sell plastic waste
to plastic collectors, who will subsequently ship and
sell the plastic waste to the island of Java to be
converted into plastic raw materials.
Based on the preliminary study conducted by the
author in Kupang Regency of East Nusa Tenggara
Province, at various plastic collection sites run by
local citizens in the Kupang City, the collected plastic
was sent directly to the main island of java in
Surabaya without further processing. If the plastic has
been treated (crushed into shreds), it will be
significantly easier to pack and ship. In addition, the
selling price will be more than that of plastic garbage
sold in its entirety.
According to the findings of interviews with a
number of plastic collectors, there is hope that the
community will process the plastic waste into small
pieces before sending it to Java for recycling, but due
to the high cost of the chopper machine and
technological limitations, all plastics collector in
Kupang city continue to operate under the current
conditions. Seeing the data and the reality on the
ground, the author attempts to design and fabricate a
Shredding Machines for Shredding Plastic Bottles
and plastics cups with a simple cutting process so that
it can be more effective in packing and shipping
plastic waste than shipping plastic waste in its intact
form, which is deemed inefficient.
The objective of this research is to design a Plastic
Shredding Machine to obtain small plastic waste in
such a way that it enables recycling industry
professionals to obtain waste automatically and is
also very useful for reducing plastic pollution in the
environment.
2 RELATED WORKS
Plastic waste shredding machines are extremely
important, as a number of studies have demonstrated
as follows;
(A. Waleola Ayo, et all, 2017) recognized that
when disposable plastic is shredded, the small pieces
can be used to create new plastic products.
Accordingly, they proposed the development of a
plastic waste shredding machine. The machine's
performance is 27.3 kg/h and its efficiency is 53% for
all types of plastic and 95% for polyvinyl chloride
plastic, concluding that the machine could be very
useful in situations where large quantities of plastics
need to be crushed and is also effective in crushing
large sizes.
(Nuri Aryani et al., 2019) conducted a study to
design and fabricate a plastic shredder machine using
the Pahl and Beitz method, which consists of
designing and describing the job, designing the
product concept, constructing the machine, and
designing the details. The plastic shredder machine
consists of blades or a cutter, a spur gear-shaped
transmission element, an electric motor, and a
machine body. The types of plastic waste to be
shredded are LDPE, HDPE, PP, and PS Based on its
design, a plastic shredder machine can produce small
flakes measuring approximately 10 mm in length and
1 mm in width.
(Witman Alvarado-Diaz, 2021), conducted a
study to design a plastic shredding machine to obtain
small plastic waste to assist people in being dedicated
to the recycling industry in an automated way, it
would also generate jobs because it requires a staff in
charge of the machine, and it will also be extremely
useful in reducing plastic pollution in the
environment, which is increasing due to COVID-19
The plastic will be selected by color and type of
plastic composition, whether it is Polyethylene
Terephthalate (PET), High Density Polyethylene
(HDPE), Low Density Polyethylene (LDPE),
Polychloride vinyl (PVC), or Others (Plastic Mix),
then it will go through the shredding process to
become small plastic waste, which could be turned
into filament for 3D printers, using the design of the
plastic waste shredding machine.
Jaypalsinh Rana, (2020), Conduct a study to
design and construct a lightweight and inexpensive
plastic shredder machine. So, the goal of this project
is to process plastic garbage as cheaply as possible by
cutting where it is made to reduce labour work, which
results in cost savings. This project describes the trial
with plastic bottle cutting machines as well as the
examination of the machine's mechanism. A plastic
bottle cutter is a machine that cuts plastic into little
pieces to facilitate waste management. We are
developing this project model to be used for the
recycling of plastic waste in the home, industries, and
scrap collectors. This machine is a solution to the
space problem.
Adepo, S. O, and Obanoyen, N. O. (2017),
conducted a study to design and construct a plastic
shredding machine, which is an integral part of plastic
recycling process. By crushing used plastic bottles,
the plastic bottle crushing device assists in the
management and disposal of municipal waste. Due to
the use of readily available local raw materials during
Design, Fabrication, and Performance Evaluation of Shredding Machines for Shredding Plastic Bottles and Cups Waste
83
construction, the machine requires little upkeep and
maintenance. The performance test analysis, which
shows that the machine operates effectively and
efficiently to complete its task at a high level of
finished shredding efficiency of 97% at a speed of
11.5 m/s, defines the characteristics of the machine.
3 MATERIAL AND METHODS
During the design and material selection process, the
following elements were considered: locally
available, safety, strength, reliability, stability, size
and shape, power consumption, ease of maintenance,
and ease of operation. The shredding machine
represented in figure 1 was made up of the following
components: a hopper, a shredding unit, a power unit,
a machine frame, and a discharge chute. The
uniqueness of this plastic shredder machine lies in its
design, which includes a metal sieve with the
geometric shape of an arc at the bottom of the
shredding unit, allowing the recirculation of crushed
plastic that does not conform to the appropriate size
to be reintegrated in the shredding process. This metal
filter ensures that the chopped plastic is uniform in
size.
4 DESIGN CALCULATIONS
The design parameters, such as shredder hopper,
Shredder cutter, blade cutting force, required power,
shaft diameter, shredder machine capacity,
supporting frame have been calculated. The result of
the calculated design parameters was being used for
fabrication
4.1 Shredder Hopper
The shredder hopper is a pyramid with a truncated
rectangular base that is positioned on the shredder
chamber. The volume of the shredder hopper (VH)
through which recyclable plastics are fed is
determined by the equation (1).
𝑉𝐻
1
3
𝐵𝐻 𝑏ℎ
(1)
Where: B = the area of the rectangular base for the
big pyramid (mm), H = the height of the big pyramid
(mm), b = the area of the rectangular base for the
small truncated pyramid (mm), and h = is the height
of the small truncated pyramid. It is hoped that 75
percent of the hopper's volume will be occupied by
recyclable PET/PET plastic due to the spacing
between individual plastic elements.
Volume of PET bottle (Aqua Botle) in the shredding
chamber: Area × height = = (πd4/4) × h; No of bottle
to fill the hopper = volume of hopper/ volume of PET
Bottle
4.2 Shredder Cutter
The cutting system of the plastic shredder machine
employs two shafts with chopping blades placed
alternately and moving in opposite directions to work
by chopping, squeezing, and crushing the plastic
trash. Each shredder knife is made up of 5 cutting
blades with the design depicted in figure 1. The
following is the shredder blade design data: blade
diameter (𝐵
)= 100 mm, inner blade diameter 𝐵
=
80 mm, blade thickness 𝐵
) = 3 mm, blade length
𝐵
) = 10 mm, blade material = SC45 Carbon Steel,
blade cross-sectional area = 30 mm², total number of
blades = 72, modulus elasticity of plastic (PPT) = 2,76
GPA = 281,4 Kgf/mm², planned knife rotation (n):
135 rpm, the initial rotation of the electrical motor:
3600 rpm
Figure 1: Blade Geometric.
4.3 Finding Blade Cutting Force (F
blade
)
The blade cutting force (F
blade
) can be found using the
equation:
𝐹𝑏𝑙𝑎𝑑𝑒
𝐴
.𝐹
(2
)
Where: A = blade cross-sectional area, F
t
= modulus
elasticity of plastic. By getting the cutting force, the
Torque (T) on the blade can be found using the
equation:
𝑇
𝐹
𝑏𝑙𝑎𝑑𝑒
.𝑟
(3
)
Where: r = The blade diameter, T = Torque
iCAST-ES 2022 - International Conference on Applied Science and Technology on Engineering Science
84
4.4 Required Motor Driver Power
The driver motor or provides power to the machine.
There are two types of motor driver can be used to
provides the rotational motion and power needed to
rotate the shaft through belt and pulley which is the
electrical motor, or gasoline motor. The horsepower
of the motor driver needed can be calculated as follow
[7].
𝑃 𝑇
2
.𝑛
60
.
(4)
Where: n = The rotation of planned knife mounted on
the shaft
4.5 Shaft Diameter
The shredder shaft is a revolving component located
in the shredder chamber, and it is fitted with rings
bearing knife-edged teeth. As it rotates against
another stationary shaft in the chamber, this knife-
edge ring enables the shredding of waste plastic
materials. As its near end is supported by two
bearings, the shredder shaft is designed to endure both
torsional and bending loads that it is subjected to
during operation. Consequently, the shredder shaft
diameter (d
s
), can be calculated using equation
𝑑
5,1
𝐾
𝐶
𝑇
/
.
(4)
Where: n = The planned knife rotation
ds = shaft diameter, 𝑇 = Torque, 𝐾
= Torsional
moment correction factor vallue 1,0 – 1,5, 𝐶
=
flexural factor value 1,2 – 2,3,
= allowed shear
stress. The allowed shear stress (
) can be found
using equation
𝑆
𝑓
𝑥𝑆
𝑓
(5)
Where:
= tensile strength, 𝑆𝑓
= first safety factor,
𝑆𝑓
= second safety factor. The tensile strength value
for machine construction carbon steel (S45C) is 58
kg/mm2
4.6 Power Transmission
In order to transport power from the electric motor to
the shaft of the plastic shredded machine, a V-belt and
pulley system is utilized. Principal transmission
parameters can be calculated as follows:
𝐷
𝑁
𝑥 𝐷
𝑁
(6)
Where: D
2
= diameter of the pulley connected to the
gear box (mm), D
1
= diameter of the pulley connected
to the electric motor, N
1
= speed of gasoline motor
(Rpm), and N
2
= speed of the pulley connected to the
gear box (Rpm).
Equation (7) can be used to determine the length of
the belt.
𝑡 2𝐶 1,257
𝐷
𝐷
)
(7
)
Where: t = belt length (m), C = centre distance
between pulley (m), D
1
= pitch diameter of the pulley
connected to the motor (m), D
2
= pitch diameter of
the pulley connected to the gear box.
The transmission utilized is a WPA 70 with a 1:20
ratio. The gearbox is linked to the rotation of the
electric motor, which has been reduced from N
1
to N
2
.
In order to calculate the output rotation of the gearbox
(N
3
), it is determined by the equation as follows.
𝑖
); 𝑖=20
(8
)
Where 𝑖=Gear box ratio = 20, 𝑁
= speed of the
pulley connected to the gear box (Rpm), 𝑁
= rotation
of the gearbox shaft that connected to the machine
shaft.
Figure 2: Power Transmission Design.
The belt speed is calculated uses eq. (9)
𝑉
.𝐷
.𝑁
60
.
000
(9
)
Where: V = belt speed (m/s), D
1
= diameter of the
pulley connected to the electric motor (m), and N
1
=
speed of the pulley connected to the shaft (Rpm).
4.7 Supporting Frame
A frame is a freestanding framework designed to hold
all of the plastics shredder machine's components.
The constructed frame should be capable of bearing
the machine's complete weight without collapsing.
The most important requirement for the design of the
machine frame is that it retains the correct relative
position of the units and parts installed on it during an
extended period of service. The stand structure should
be capable of supporting the machine without
Design, Fabrication, and Performance Evaluation of Shredding Machines for Shredding Plastic Bottles and Cups Waste
85
Figure 3: The Design of Shradding Maching.
collapsing. The frame is composed of 75 x 75 x 8 mm
angle iron manufactured of low carbon steel.
4.8 Finding Machine Capacity
Theoretically the machine capacity is estimated based
on the cutting area of each cutter that mounted on the
shaft, it is assumed that all cutting tips on each cutter
will be cutting perfectly.
The cutting area calculated using equation (10);
𝐴
ℎ 𝑥 𝐷
𝐷
(10)
Where: A = The Cutting Area (m
2
), h = Cutting tip
height, D
1
= cutter outer diameter (m), D
2
= cutter
inner diameter (m)
The cutting volume calculated using equation (11);
𝑉
𝐴
𝑥𝐿
(11)
Where: V
c
= cutting volume, A = cutting area, L = Tip
length.
If each cutter consists of 5 cutting tips; therefore, each
cutter will cut 5 x Vc. Since the total number of
cutters mounted on the two shafts are 76 cutters;
therefore, the volume of plastics chopped by the
shredding machine is 5 x V
c
x 76 m
3
for each shaft
revolution. If the planed shaft revolution is 135 RPM,
then the volume of plastics shredded become 135 x 5
x V
c
x 76 m
3
per minute = 135 x 5 x V
c
x 76 x 60 m
3
per hour. Since the plastic density for PET = 138000
Kg/m3, then the Shredding machine capacity can be
calculated as 135 x 5 x V
c
x 76 x 60 m
3
x 138000
Kg/hour. This theoretical calculation of machine
capacity is an ideal calculation with the assumption
that all blades mounted on the shaft are able to chop
plastic waste perfectly, which in reality is not possible
because during operation there are a number of blades
that cannot chop because of the position of plastic
waste that enters through the machine. the hopper is
still spinning and hasn't had time to touchthe cutting
edge
5 PRINCIPAL OPERATION OF
THE MACHINE
The plastic garbage to be chopped is gathered in a
container and positioned close to the shredder. To
start the engine, a gentle press of the on/off button is
required. When the drive motor is activated, its
rotation and power are sent via pulleys and belts to
the gear box, which is then transmitted to two shafts
that revolve in opposing directions in the counter
space. Due to the movement of the two shafts, the
blades connected to the shafts will also revolve. The
processed plastic garbage is then put into the
machine's hopper with the assistance of an operator.
When the waste plastic contacts the chopping knife
linked to the two shafts that move in opposing
directions, the waste plastic will be severed owing to
the sharp edge of the blade tearing and tearing the
waste plastic.
The plastic waste fragments will then fall into the
half-round filter part and accumulate in the filter. If
the chopped plastic granules reach a size smaller than
the filter's hole, the results will exit out the outlet.
Nevertheless, if the size of the chopped plastic is still
greater than the filter hole, the plastic waste will be
brought back by the chopping knife and chopped
iCAST-ES 2022 - International Conference on Applied Science and Technology on Engineering Science
86
again until its size is smaller than the filter hole.
Figure 2. Shows the final design of the Plastics
shredding machines
6 DESIGN CALCULATION
RESULTS
The outcomes of the calculated procedure are
presented in Table 1. All calculations are obtained
from equations 1 through 11, as described in the
section on design calculations.
Table 1: This caption has one line so it is centered.
Design Parameters Value
obtaine
d
Shredder ho
pp
er Volume 0,011m
3
Plastic Bottle Volume
(
A
q
ua 600ml
)
0,0006 m
3
Number of bottles filled in the hopper
for 1 batch
(
75% of ca
p
acit
y)
13 pcs
Wei
g
ht of 13
p
cs
p
lastic botles 2,6 K
g
Plastic cu
p
s volume
(
a
q
ua 240 ml
)
0,00024 m
3
Number of plastic cups filled in the
ho
pp
er for 1 batch
(
75% of ca
p
acit
y)
30 pcs
Wei
g
ht of 30
p
cs
p
lastic cu
p
s 4,5 K
g
b
lade cuttin
g
force
5148 N
Torque on the blade (T)
257,4 Nm
The horsepower of the motor
driver (P)
5 Hp
shaft diameter (d
s
)
31 mm
allowed shear stress
diameter of the pulley connected
to the
g
ear box (D
1
)
100 mm
diameter of the pulley connected
to the electric motor (D
2
)
80 mm
b
elt speed (V)
18,4 m/s
output rotation of the gearbox
(N
3
)
135 Rpm
speed of
g
asoline motor (N
1
)
3600 Rpm
speed of the pulley connected to
the
g
ear box (N
2
)
2700
the len
g
th of the bel
t
cuttin
g
area
30 mm
2
Cuttin
g
Volume
180 mm
3
Theoretical Machine Capacit
y
73,4 Kg/Hour
7 PERFORMANCE EVALUATION
Performance evaluation is a crucial element in the
machine development process. After the design,
fabrication, and assembly processes, testing is
required to identify the machine's performance,
uncovered issues, and improvement opportunities.
The intended evaluation was of the machine's
production rates and its efficiency.
The following procedures were used for the
performance test: (1) the dry plastic waste test
materials in the form of plastic bottles and plastic
cups packaged of mineral water are weighed; (2) the
shredding machine is turned on by turning on the
gasoline motor as the prime mover; (3) waste plastic
material is fed into the machine's hopper; (4) the time
is monitored using a stop watch during the
enumeration process; (5) collect and re-weigh the
chopped results from the outlet;
7.1 The Production Rates
Equation (12) may be used to calculate the machine's
production rate.
𝑃
𝑇𝑊
𝑇
(12
)
Where: P
r
= production rate (Kg/hour), TWo = weight
of waste plastics discharge from the hopper (Kg), T
o
= time needed to shredded the plastics (Hour)
7.2 Shredding Machine Efficiency
The efficiency of the shredding machine can be
evaluated uses equation (13)
𝑇
𝑇
(13
)
Whwre: = machine efficiency (%), T
wi
= total
weight of plastics fed in to the hopper (Kg), and T
wo
= total weight of plastics discharge from the cute
(Kg).
8 RESULTS AND DISCUSSIONS
Functional test is the latest form of testing of a waste
chopper design which aims to determine whether the
results of the design can function in accordance with
the expected design. If the design is not suitable,
modifications must be made to improve its
performance. The Test results can be seen in table 2
Table 2: Shredding machine test results.
Types of
Plastic
Waste
T
wi
(gr)
T
wo
(gr)
T
o
(sec)
average
particle size
(mm
2
)
PET Glass 2600 2550 400 28
PET Botle 4500 4250 840 30
Design, Fabrication, and Performance Evaluation of Shredding Machines for Shredding Plastic Bottles and Cups Waste
87
Remarks: T
wi
= total weight of plastics fed in to the
hopper (Kg), and T
wo
= total weight of plastics
discharge from the cute (Kg); T
o
= time needed to
shredded the plastics (hour)
The production rates and machine efficiency may
be expressed using equations (12) and (13), as shown
in table 3.
Table 3: The production rates, and the machine efficiency.
Types of
Plastic
Waste
Production rates
(Kg/Hour)
Machine
efficiency (%)
PET Glass 22,95 0,98
PET Botle 18,21 0,94
The trial machine's capacity is 18.21 kg/hr for
mineral water bottle packaging and 22.95 kg/hr for
plastic glass packaging. When compared to the 73.4
kg/h theoretical engine capacity, the test results
appear to be very low. This means that the plastic
shredding machine needs to be redesigned, including
the blades that cut the plastic, since the knives on the
machine tend to break.
9 CONCLUSIONS
The optimization of the machine designed and made
capable of shredding mineral water packaging waste
in the form of glass up to 22.95 kg/hour, and 18.21
for plastic waste mineral water packaging in the form
of bottles. Because the size of the shredded results is
an average of 30 mm
2
for plastic bottle and 28 mm
2
for plastic cups this machine may be more effective
and efficient in the process of enumerating plastic
glass trash and plastic bottle waste, reducing the
requirement for space for packaging rubbish. This
machine is ideal for first-level collectors because it is
simple to operate with maximum capacity, with a
counting efficiency of 0.98% for chopping plastic
glass waste and 0.94% for chopping plastic bottle
trash. The construction is also quite basic and can be
done in small-scale workshops, thus the prices to
build it are affordable. This machine design may
assist and have a favourable and effective impact on
the effectiveness of waste collectors' packaging and
shipping activities.
ACKNOWLEDGEMENTS
This study was funded by State Polytechnic of
Kupang through its annual research program of 2022;
thus, we would like to express our appreciation to the
director of State Polytechnic of Kupang for providing
the funding for this study. In addition, I appreciate the
support of the head of the mechanical engineering
workshop during the creation and fabrication of the
needed technology, and it gives me great pleasure to
recognise my researcher team's contribution to the
completion of this project
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