Development of Small-Scale PETE Plastic Bottle

Shredder with Electronic Sensor Controls for Cap

Separation: Basis for Reverse Vending Machine
Alec Christian M. Cervantes1, Ace Vann Cardiff T. Aleria1, Christian Carlo B. Taer1
1
Mechanical Engineering Students, University of Mindanao
Matina, Davao City, Philippines
1
alec.pimple@gmail.com
acealeria@gmail.com
christiantaer4@gmail.com

Abstract – Most institutions no matter how big or small
encounter problems in solid waste management, such as
mismanagement of plastic bottle wastes. PETE plastic is the
common raw material for manufacturing plastic bottles for
beverages that are usually improperly disposed after
consumption. This study aims to provide a new approach to
managing plastic bottle waste by using a plastic shredder which
reduces the volume of the solid waste to maximize storage space,
while utilizing electronic control features to separate the caps
from its bottles before shredding since they have different plastic
composition. Different sizes of PETE plastic bottles were tested,
and results show that 300 to 500 mL bottles have achieved
average volume reduction percentages of 50 – 65% after
shredding. 300 – 400 mL bottle sizes had high shredding success
rate of about 92%, and the cap detection feature has acquired an
average accuracy rating of 90%.
Index Terms— PETE bottles, Plastic shredder, Reverse vending
machine, Arduino Uno, Plastic waste
I. INTRODUCTION
The use of plastic is unarguably in demand by many. In
the Philippines, plastic use has widely been welcomed not
only by industries but also by educational institutions. In fact,
Asian countries contribute a large share to the total amount of
plastic wastes floating in the world’s oceans estimated to be at
around 12 million tons in 2010 [1]. This is supported by a
similar study [2] stating that the Philippines generate about 3
million tons of plastic waste annually, and 20 per cent of that
leaks into the oceans. As per report of the United Nations
Environment Program (UNEP) on World Environment Day
2018, data from a 2015 research suggest that the Philippines
wastes 6, 237, 653 kilograms (6875.84 tons) of plastic per
day, of which 81% is mismanaged. With this, it could be said
that the bulk of plastic waste in the country calls for
minimization. It is in this case that a machine needs to be
designed which will aid in lessening the plastic waste
produced in the country, most specifically in academic
institutions, where a lot of plastic wastes are also produced by
the school community.
Multiple literature regarding the design and testing of
small-scale polyethylene terephthalate (PETE) plastic bottle
shredders are available in the web. The “rotary blade against a
fixed blade” design is more favoured by previous studies due
to its simplicity and effectiveness [3], [4]. The materials used
for the blades however are varying from carbon steel to alloy
steel, depending on different cost-effectiveness considerations
by previous researchers [3]–[5]. A simple crank-rocker
mechanism may also be implemented but it is jerkier and
more unstable [5]. Plastic recycling facilities who purchase
and use used plastic for mixing and re-melting are more
commonly found in progressive foreign countries [6]. So far
only one such facility is present within Davao City – Winder
Recycling Company – who manufactures armchairs and other
common home furniture from plastic wastes in landfills and
donates them to schools and less-privileged communities. The
plastic wastes are turned into plastic lumber composites,
which are made of a mixture of plastic, plant fiber, wood
flour, and binders [7].
Despite the presence of already-existing small-scale
plastic bottle shredders, only a few, if none, have electronic
sensor controls that facilitate the segregation of the cap from
its bottle. The implementation of plastic shredders in reverse
vending machines for plastic bottles is also not yet common.
If such features are integrated into small-scale plastic
shredders, people especially students could be more
encouraged to properly dispose plastic bottles in school. These
are the inspirations for this proposed project title.
In the light of the premise for a need of a machine to
address the issue at hand, the researchers target to achieve the
following objectives: (1) to develop and fabricate a small-
scale PETE plastic shredder for reverse-vending machine; (2)
to integrate electronic sensor-control features in the machine
to provide a machine process that separates bottle caps from
the PETE plastic bottles before disposal; and (3) test the A. Conceptual Framework
machine’s functionality.
Input Process Output
This machine innovation will be of great benefit to the
following: school administration, school community, and Small-Scale
Design PETE Plastic
Physical Plant Office. First, this design will be of significance
Constraints; Design and Bottle
to the school administrators as they could be provided with a
Material Fabrication Shredder basis
solution to the long-existing problem on plastic waste for Reverse
Selection; of the
management. Through this machine, the production of plastic Vending
Design Machine
waste in the school could be lessened; and the disposal of such Machine
Concepts
will be more cost-efficient and strategic. Second, this design
could benefit entire school community comprised of the
students and workforce. As this design features a reward Fig. 1. Conceptual Framework
system, the active participants in the recycling process could
also receive something in return out of their conscious efforts Fig. 1 shows the conceptual framework which the
in helping with the prime purpose of the machine design, that researchers are going to follow in conducting this study. The
is waste reduction and recycling. Lastly, the Physical Plant input consists of the following: design constraints, material
Office of the identified locale will benefit as the office will selection, and design concepts. The proponents must process
not need to extend its waste management facilities to cater to these inputs in order to successfully design and fabricate the
the increasing number of wastes in the community. Also, a machine according to the specified requirements. Lastly, the
strategic waste management system could be implemented in output is to a fully working small-scale PETE plastic bottle
lieu of the traditional waste management system. shredder compatible for reverse vending machine
applications.
The design for this machine project shall be delimited to
only considering the implementation of the machine in the
University of Mindanao campus only as the researchers
envision that this initiative shall first help their own school in
solid waste management. And although the purpose of this
project is for reverse vending machine application, the
researchers only aim to focus on designing and fabricating the
shredder unit and its controls, and not including the reward
system for the reverse vending machine. Also, the electronic
control functions for this machine shall only include plastic
cap recognition, plastic cap acceptance and/or rejection, and
time-delayed switching of components. Any other advanced
functional and security features in reverse vending machines
will not be included, such as image processing, among others.
Furthermore, the machine shall be limited to the recycling of
PETE plastic bottle wastes in sizes that are available in food
stalls inside the university (500 mL and less). Any other size,
form, or type of plastic wastes shall not be covered by this
machine design.

II. MATERIALS and METHODS

In this chapter, the considerations on how the shredder

was made and the employed testing methods are described.
The design procedure, material selection, and fabrication of
the actual shredder machine are tackled in detail. The course Fig. 2. Process Flowchart
of the function testing, the means for evaluation of
performance parameters, and the statistical tools to be used are For the machine itself, the process flow for its operation
also discussed. is shown in Fig. 2. First, the sensor detects if a legitimate
bottle cap is placed in the cap passage. Next, the
microcontroller assesses the conditions and then triggers relay
switches to accept or reject the inserted cap, and then turns on
the actuator and the shredder for a specific amount of time.
After the process, bits of shredded PETE plastic will be
collected and stored in a container.
B. Design Procedure
The proponents started the design process by defining the
main design constraints in building this machine. These are
noise control, aesthetics, and compatibility for reverse
vending machine applications. It must be a well-enclosed
machine with minimal moving components to minimize the
noise, as in commercial vending machines. It should also be
aesthetically finished and presentable to encourage the public
to use it as a means for disposal for their plastic bottle waste.
And since it is deemed to be applied to reverse vending
machines, it should have components compatible with
electronic controls for it to be smart and independent in doing
the shredding process.
In the design process, the proponents planned to adopt
design from existing plastic bottle shredders and then test it if
it is suitable for shredding PETE bottles. This was done
through Solidworks stress simulation for the shredder
components. The proponents specifically planned to adopt the
rotor-stator design where rotating toothed blades shred against
stationary knives. This design was chosen due to its simplicity
since it involves only few parts, thus reducing the sources of
noise. This design is shown in Fig. 3.
Fig. 3. Rotor-Stator Shredder Design
The necessary force to shred PETE bottles was also
calculated by knowing the tensile properties of the material
and then incorporating it to the Maximum Principal and Shear
Stress Theory equations shown below. From this process, the
required torque and power were eventually calculated.
σ σ 2 2 σ 2 2
σ max= +
2 √( )
2
+τ (1)τ max=
(2)
√( )
2
+τ
Where:
σ max = Maximum Tensile Stress
τ max = Maximum Shear Stress
σ = Principal Tensile Stress
τ = Principal Shear Stress
The design of power transmission elements from the
motor to the shredder was carried out by referring to standard
mechanical engineering tables for selection and use of
different machine elements such as belts and pulleys. For the
design of the machine frame, it was based on common
dimensions of medium-sized vending machines. At the same
time, it was designed to accommodate dimensions and load of
the components to be mounted on them.
C. Materials and Fabrication
For this machine, an AC motor will be needed as a
power unit to drive the shredder. The proponents were able to
acquire a 1.5 HP single phase AC motor and plastic shredder
with hopper from a former undergraduate thesis in the
University with consent from its proponents who are now
successful UM graduates [8]. This shredder had the same
rotor-stator design that the proponents desired. The
innovation added to this shredder for this study were the
design and fabrication of its drivetrain, frame, and electronic
control system to make it fit to the design constraints
determined by the proponents. For the drivetrain, a gear box
reducer was used to achieve necessary speed reduction while
occupying minimal space. For the framework, small-sized
steel tubes were a good choice for more stiffness and easier
machinability.
For the electronic controls, usage of Arduino
microcontroller was the preferred choice for the smart control
functions necessary in this machine. For cap detection and
recognition, the proponents opted to use color sensor system
for simplicity. The color values of the caps of commonly
purchased plastic-bottled beverages were pre-recorded by the
proponents. Any color value reading that does not match with
these recorded color values are considered invalid and will be
rejected by the machine.
In the fabrication stage, the proponents had high
involvement in the cutting and welding of the rigid frame.
However, most of the moving machine components were sent
for machining work in machine shop services, such as in
adjusting the bore of the coupling and pulleys, in fabricating
the adjustable motor base, and in the proper alignment and
assembly of these components. The proponents faced greater
challenge in setting up the electronic components and in A. Design of Shredder Machine
programming, since it is not their field of expertise. 1) Motor Power: The acquired AC motor already has 1.5
HP rating, so what remains for the proponents is to determine
if this rating is suitable for their application. To verify, the
proponents calculated the required power that is needed to
shred a PETE bottle one at a time. The calculation was based
D. Testing and Statistical Methods upon the nature of the blades’ shredding action which was
modelled as a punching press and a guillotine equipment as
Once finished, function testing was done on the machine. well [5]. The main parameters considered in solving the
It was tested according to its shredding performance and required motor power were the ultimate strength of PETE
sensor accuracy. bottles, the estimated stress area (Fig. 4), the body thickness
of the plastic bottle to be shredded, and the presumed
Evaluation of shredding performance was further rotational speed of the shredding shaft. Data collected on
subdivided into two aspects: shredding capability and volume dimensions of PETE plastic bottle commonly found in the
reduction. The machine’s shredding capability was tested by University are shown in TABLE I. The largest value for
repeatedly putting bottles under the shredding process, and thickness of PETE material on bottles – 2.1 mm – was used in
then counting the number of instances that successful the calculations. The average ultimate tensile strength of
shredding occurs out of the set total number of trials. PETE plastic was found to be 55 MPa [9].
Shredding was considered successful when the entire bottle
was consumed and shredded by the machine without any TABLE I
DIMENSIONS OF SAMPLE PETE BOTTLES (MM)
problems. Unsuccessful shredding on the other hand was
recorded when the machine fails to shred the bottle and gets
stuck, or when the bottle was only partially but not completely Max. Max. Min.
shredded. Success rate of shredding was then recorded by Beverage Height
Diameter Thickness Thickness
dividing the number of successful shredding instances to the
total number of trials. Consequently, the approximate volume Nature’s
reduction was evaluated by roughly measuring the volume of Spring 60 210 2 0.3
the shredded output per bottle using a beaker. The output (500 mL)
volume was then compared to the bottle’s initial volumetric
capacity to calculate the percent volume reduction. Coca-Cola
55 200 1.4 0.7
(300 mL)
The sensor accuracy was evaluated by testing the caps for
validity using the sensor in repeated trials. The accuracy of the Real Leaf
66.2 211 2.1 0.8
sensor was mathematically represented by dividing the (500 mL)
number of the sensor’s correct detections to the total number
of trials.

For the interpretation of these data, simple comparative

and inferential statistics are necessary. Basic statistical tools
such as mean (the average of a set of data) and standard
deviation (the most commonly used measure of the spread or
dispersion of data around the mean) were employed.

III. RESULTS AND DISCUSSIONS

This chapter shows results of the design and machine

testing processes. Discussion of the results on the design of
the shredder machine are sub-divided into the following
topics: Motor Power, Drivetrain, Sress Analysis, and Machine
Frame and Covering. On the other hand, function testing
results were also sub-divided into Shredding Performance and
Sensor Accuracy, in which Shredding Performance was
further sub-divided into Shredding Capability and Volume
Fig. 4. Stress Area of PETE Plastic during Shredding (shown as PLANE 1)
Reduction.
 Upon using the Maximum Principal and Shear Stress
Theory equations along with these presented data, an effective
shredding force of about 4502 N was calculated, which
resulted to a required torque of 270.12 Nm after multiplying
to the radius of the rotating blades. The proponents agreed that
the ideal rotational speed for the shredder should be around 30
– 40 rpm. The shredding speed was set be this low to
minimize operating noise, and to provide better chances of
shredding action to happen. Considering how light empty
PETE bottles are, there are better chances of shredding action
to happen without human assistance by feeding the bottles to
the hopper when the shaft is in low speed. The resulting motor
horsepower from using these values was at about 1.14 HP.
This value is well within the 1.5 HP rating of the acquired
motor, making it applicable for use in this study.
3) Stresses Analysis: The proponents utilized the help of
SolidWorks software to simulate and show the von Mises
stresses induced on the machine members during machine
operation. For the simulation, AISI 1023 carbon steel sheet
was set as the material for the components, with a yield
strength of 2.827 x 108 Pa., and ultimate tensile strength of
4.25 x 108 Pa. based on the Solidworks database. The
calculated effective force for shredding PETE plastic was used
as input force. The simulation was done on the blades which
are the most critical parts that experience most stress during
operation.

2) Drivetrain: For the power transmission from the motor,

a compact worm gear speed reducer was used to achieve the
desired operating speed of the shredder. Usage of compact
worm gear speed reducer saves space, and more importantly it
reduces noise levels since it involves less parts that are well-
sealed compared to multi-stage gear-drive or chain-drive
speed reduction that produce more noise. The worm gear type
was chosen over other speed reducer types due to local
availability reasons. A variant with 60:1 speed ratio was
purchased. The motor and the worm of the reducer are
connected through belt drive. Two Type A V-belts were used
on two 3.5-inch pulleys mounted on the motor and the worm,
respectively. Then the worm gear and the shredder are
connected through a roller chain coupling. Selection of Fig. 6. Stress Simulation Results on Rotating Blades
suitable roller chain coupling was guided by standard charts
Fig. 6 shows the von Mises stress distribution one of the
on RC coupling ratings available online, with which it was
rotating blades during shredding action. The highest stress
found that a 4016 chain coupling suits best for the application
recorded in this simulation is at 132 MPa, which is less than
and was purchased. The configuration of the drivetrain from
half of the material yield strength, resulting to a factor of
the motor to the shredder is shown in Fig. 5.
safety that is slightly greater than 2. This high stress occurs on
areas of stress concentration at the apexes of the hexagonal cut
and on the blade surface normal to the plastic being shredded.

Fig. 5. Drivetrain Configuration

 Fig. 7. Stress Simulation Results on Stationary Knives PVC Board because it is easy to handle, lightweight, and good
for outdoor use and for advertising. This material provided
Fig. 7 shows the von Mises stress distribution on a set of
convenience in fabrication, and an ideal surface for putting
stationary knives during shredding action. The highest stress
informative and decorative labels commonly placed on
recorded in this simulation is at 30.49 KPa, which occurs on
vending machines. An actual image of the shredder machine
the inside corners which are stress concentration areas. It can
with its covers and labels is shown below in Fig. 9.
be seen that the stationary knives experience dramatically
lower stress values compared to the rotating blades.
B. Electronic Control Features
For the needed smart features of the shredder, a
microcontroller is employed. The proponents used Arduino
Uno microcontroller, which controls the motor for the
shredder, the sensor for cap detection, a servo motor, and a
linear actuator. An RBG sensor was used for the cap
detection. RGB sensor which sorts objects based on three-
color approach is advantageous in sorting plastic cap from
foreign objects. The servo motor serves as the sorting
mechanism which accepts valid caps and rejects foreign
objects. A linear actuator is placed above the shredder hopper
to push the bottle down the blades during shredding.

Fig. 8. Stress Simulation Results on Shredder Assembly

Fig. 8 shows the von Mises stress distribution on the

whole shredder assembly during shredding action. The highest
stress recorded in this simulation is at 140 MPa, which again
occurs on the inside corners which are areas of stress
concentration. This maximum stress value is still halfway to
the material’s yield strength, resulting to a factor of safety of
2.
It can be seen from these simulation results that the von
Mises stresses on the critical components are well below the
yield strength of the material. The high stress values were
recorded only on small localized areas of stress concentration. Fig. 9. Actual Front Image of Shredder Machine
But for most areas, the machine components experienced low
B. Shredding Performance
stress levels. The subsequent factors of safety were equal to or
greater than 2, which makes it a sufficiently safe design for The results of testing on the two aspects of shredding
shredding PETE bottles. performance: Shredding Capability and Volume Reduction,
are discussed below.
4) Machine Frame and Covering: The materials used for
the framework are rectangular and square tubes, 1.5mm thick. 1) Shredding Capability: A total of 102 trials were done
Hollow tubes were chosen for they provide the necessary for testing the shredding capability, wherein: there were 20
stiffness for the machine frame at a lower weight than angle trials for bottles with 200 mL capacity; 52 trials for bottles of
bars. Outside dimensions of the frame were at 30 in. x 29 in. various brands within 300 to 350 mL capacity; and 30 trials
x 68 in. Stresses on the machine frame were expected to be for bottles of various brands within 400 to 500 mL capacity.
low due to the nature of the shredding operation which During initial testing trials, the proponents found that a higher
produces only light intermittent loading. Hence, the stress on shredding success rate can be achieved when the bottles are
machine frame was no longer critically analysed. For the shoved into the hopper with its head first, instead of bottom
covering on the machine frame, the researchers used Sintra first. And so, such configuration was maintained by the
proponents throughout the entire data recording procedure.
Summary of results for the testing on shredding capability is
shown in Fig. 10.
In the results shown in the figure, a lower shredding
success rate is recorded for 200 mL bottles which are only at
60%. This higher instance of failure is due to the geometry of
the bottles; their smaller height and diameter sometimes
causes them to be awkwardly positioned within the hopper
where they only get squeezed in a spot where the rotating
blades cannot clench them well. A slightly lower success rate
is also recorded on 500 mL bottles. The shredding failure for
the bottles under this capacity is due to some instances of belt
slip caused by overloading in the shredder, which happens
when shredding the mouth and neck part of the bottles. 500
mL bottles have greater material thickness in their mouth and
neck area, which is difficult to shred. Overall, a high
shredding success rate is achieved, especially in bottles within
300 to 400 mL capacity, reaching up to 92%.
100
92.3
80
(Success Rate)
Fig. 11. Volume Reduction Graph
The average volume reduction results mostly lie around
50 to 65 percent. Less volume reduction is recorded in 200
mL bottles, which can be attributed to the fact that their initial
capacity is already small. But overall, the shredder showcases
sufficient volume reduction, which can reduce the volume of
the plastic bottle waste to more than half of its initial size.
The green standard deviation caps indicate the range of
±1 standard deviation from the mean value. A significantly
greater dispersion of data can be seen on percent volume
reduction of 200mL bottles, with standard deviation of ±9.6%
from the mean. For the remaining bottle sizes, the percent
Shredding Capabilities
volume reduction per bottle was stable with low standard
92.3 deviations calculated to be within ±5% from the mean.
86.67
E. Sensor Accuracy
An RGB sensor was used to detect and test the

60
60
validity of inserted PETE bottle caps. Sample bottle caps of
commonly purchased PETE bottled beverages that are
40
available within the school premises were initially collected.
The respective color values of the bottle caps were pre-
20
recorded by the proponents with added tolerance. The sensor
accuracy is evaluated by testing the caps for validity using the
0
200 300 400 500
sensor in repeated trials. The accuracy of the sensor can be
Bottle size (ml) calculated by dividing the number of the sensor’s correct
detections to the total number of trials. The results on this
Fig. 10. Shredding Success Rate Graph
accuracy test are shown in TABLE II.

TABLE II
2.) Volume Reduction: For the trials with successful SENSOR ACCURACY
shredding result, the approximate volume reduction was
recorded by the proponents after each shredding process was Bottle Total Correct Incorrect
finished. This was done one at a time, separately measuring Accuracy
Cap Trials Detection Detection
the output volume per bottle. The results on the average
volume reduction per bottle capacity are shown in Fig. 11. Sprite 10 9 1 90%

Real Leaf 10 7 3 70%

Volume Reduction
70 Avg. Vol. Reduction Gatorade 10 10 0 100%
60 Nature’s
10 10 0 100%
Percent Vol. Reduction

Spring
50
Coke 10 9 1 90%
40
30 58.9 63 64.8 Royal 10 9 1 90%
51
20
32.1 From the results shown on the accuracy test, the sensor
10
and its set-up exhibit high accuracy, reaching up to 100% on
0
200 300 350 480 500
Bottle Size (mL)
some cap variants, with 70% as the lowest accuracy
percentage on a certain beverage brand. These high accuracy
values signify that the cap separation process of the shredder
is reliable and effective.
IV. CONCLUSION AND FUTURE WORKS
From the results, it can be said that the proponents have
successfully developed a small-scale PETE plastic bottle
shredder that is compatible for reverse vending machine
application. Following the well-defined guidelines and
procedure in the Materials and Methods, the proponents have
successfully fabricated an aesthetic shredder machine that can
effectively shred medium-sized bottles. The Process
Flowchart has also provided a definitive guide in effectively
incorporating electronic controls to the shredder machine
which resulted to achieving a reliable separation process
between the bottle cap and body, and has added considerable
independence in the operation of the shredding machine. The
Results and Discussion has proven that the design of the
shredder allows it to resist material stresses during operation
and is safe. The tabulated data show that the shredder can
effectively shred PETE plastic bottles, reaching up to 92%
shredding success rate on 300 – 400 mL sizes. The sensor set-
up for cap detection was also found to be highly accurate,
garnering an average of 90% accuracy rating across multiple
cap variants after multiple trials.
The proponents highly suggest that this study would be
further developed towards the completion of a reverse vending
machine where rewards would eventually be given to the
users for disposing their PETE plastic bottle wastes into the
shredder. The proponents envision that the said further
development would encourage more students and staff to
properly dispose of their trash, leading to a healthier school
community and a safer environment. Additionally, the
proponents suggest adding safety features to the shredder to
counteract belt-slip if overloading occurs. A specific
suggestion would be adding an automatic momentary reverse
drive when the machine gets stuck, which automatically
reverts to forward drive when the load returns to normal.
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