DESIGN AND FABRICATION OF SHREDDER MACHINE AND

FURANCE FOR PLASTIC RECYCLING FOR ITS

UTILIZATION
Project Reference No.: 42S_BE_3127

College : Biluru Gurubasava Mahaswamiji Institute of Technology, Mudhol

Branch : Department of Mechanical Engineering
Guide : Dr. H. V. Mulimani
Students : Mr. Siddappa M. Kumkale
Mr. Kiran R. Ghorpade
Mr. Chandan A. Anagal
Mr. Shrishail V. Hiremath

Abstract:
In all developed and developing countries, the plastic usage is very high. Plastic is non-
biodegradable and also burning of plastic which produces toxic products affects the human
beings and environment. One of the major challenges to human being is how to dispose this
plastic without affecting the environment. This project mainly concentrates on recycling and
utilizing the plastics. This reduces its affect on environment. This project uses the shredder
machine which converts the waste plastic bottles into small pieces; these pieces are converted
into molten plastic in furnace and then injected into moulds to converts this molten plastic into
useful products such as plastic bricks, writing pad Etc.
The overall objective of the project is to reduce plastic in waste streams. These waste
plastics are converting useful products. These products can be used in day to day life.

Introduction:
Today, plastics are indispensable in homes, offices, and industry. The most commonly
used plastics are PET, HDPE, LDPE, PS, PP, and PE. But PET is one of the most common
consumer plastic used. Plastic bottles something that most of us use every day as water
containers. But there are many ways of giving a plastic bottle a second life.
In this process we are using plastic shredder machine. Plastic shredder is a machine used
for cutting the waste plastic in small pieces to make waste management easier. Benefits of this
machine are the reduction of labor work, which results in cost reduction. So we are going to
design this for shred the plastic waste, with the help of blades. The small pieces of plastic bottles
are fed into the Furnace and come in molten state.
In this process we are using the molding. Molding is the process of manufacturing by
shaping the liquid plastic material using rigid frame called mold or matrix for producing the
different products like plastic plates, cups, bricks...etc. Here, we are using injection molding.

Objectives:
The main objective of this project is to convert waste plastic to useful products.
To achieve this main objective we have designed shredder machine and a furnace,
shredder machine which cuts waste plastics into small pieces and furnace is to converting plastic
pieces into molten state. The molten plastic injected in molds for producing the useful products.
  The overall objective of the project is to reduce plastic in waste streams.
 To create the awareness on effective use of plastic materials.
 This project gives the effective way of transporting the waste plastic materials.
 We have designed the shredder machine in low cost, which converts the plastic bottles
into the small plastic pieces.
 Use the waste plastics which effect the environment in proper way by recycling them to
make different useful products.
 By recycling of waste plastic bottles, major problems like global warming and green
house effect can be reduced
Methodology:
This project uses shredding machine which converts plastic bottles into the small pieces,
these pieces are converted into molten plastic in furnace & then injected into the moulds to
convert this molten into useful product such as plastic sticks, bricks…etc. These products can be
used in day to day life.

Waste Plastic Bottles

(PET,PE,HDPE,LDPE)

Shredding

Drying to remove
moisture content

Heating in Furnace

Molding

Useful plastic products such

as plastic sticks, bricks….etc
Design of shredder machine:

Assembly of shredder machine:

Design of furnace:
Parts, cost and materials of the shredder machine and furnace:

1. Shredder machine

Sl no Part name Quantity Material

1 Rotary blade 7 High carbon steel
2 Stationary blade 7 High carbon steel
3 shaft 2 EN8 material
4 plate 4 Mild steel
5 Bearing 4 Chrome steel
6 Washer 4 Mild steel
7 Key 2 Mild steel
8 bush 4 bronze
9 Spur gear 2 Stainless steel

Sl no Part name Operations Cost

1 Rotary blade CNC cutting, Hardening. 1890
2 Stationary blade Cutting, Hardening, welding. 750
3 Shaft Turning, Step turning. 300
4 Plate Turning, Tapping. 2300
5 Key Turning 120
6 Bush, screw Turning. Slot. 240
7 Bearing, washer 320
8 Stand Bending, Welding 1800
9 Spur gear 750

Fabrication of shredder machine:

Parts of shredder machine

2. Furnace

Sl no Part name Quantity Material

1 Hallow pipe
2 Mica sheet
3 Nichrome
wire(500W)
4 hopper
5 Rods for stand
6 Injector
1 Steel
2 Mica
1 Nichrome
1 GI
3 Mild steel
1 Mild steel

Sl no Part name Operations Cost

1 Hallow pipe Cutting, Welding. 220
2 Mica sheet 950
3 Nichrome wire(500W) 180
4 Hopper Welding 250
5 Rod for stand Cutting, welding 210
6 Injector, washer, nuts Welding 190
Fabrication of furnace:
Mould:

Outcomes of projects:
 Design and fabrication of shredder machine in low cost for cutting the waste plastic
bottles to small pieces.
 We are also designed and fabricated of furnace to convert small pieces of plastics to
molten state.
 Our project is helps to convert waste plastic bottles to useful products like plastic sheets,
plastic decorative items.
 We also conducting an experiment on bricks with plastic material for various percentage
of plastic with sand.
  The main aim of project is to make useful products from waste plastics and avoid the
plastic decomposition.

Future scope:
 In future we are planning to use band heater for the heating of plastic pieces instead of
mica sheet and nichrome wire.
 We have also planned to implement automated operation of shredder machine with a help
of 1HP motor instead of manual operation to shred the plastics.
 We are also conducting experiment on molten plastic with different percentage of sand.

Applications:
 Convert the waste plastic into products like plastic sticks, sheets, decorative items.
 Producing plastic bricks with various percentage of sand.
 Producing the Plastic writing pads.
 Effective way of transporting the waste plastic materials after shredding of plastics.

Fabricated products: