Case Study Article: Concept

Recycling plastic the eco-friendly way: A young scientist’s path-breaking

innovation

Abstract

Plastic is a highly versatile, simple, and inexpensive manufacturing material. People

often throw away plastic goods and packaging after a single use, resulting in massive
amounts of plastic pollution. In this way, poor waste disposal is one of the major
problems affecting society.

Plastic bags entering water bodies are a major cause of water pollution. Unknowingly,
animals and marine creatures consume plastic particles in their food, leading to their
premature deaths. These plastics are essentially derived from oil, coal and gas. Mining
these non-renewable resources results in the release of hazardous chemicals, such as
benzene, toluene, carbon monoxide, hydrogen sulphide, ozone and sulphur dioxide.
These toxic chemicals are emitted into the atmosphere, which is hazardous to both
humans and the environment.

Athul Varghese of Grade 9 wants to create a more effective waste management system.
He devised a novel solution to handle some of the activities and procedures associated
with managing plastic waste disposal from its inception to its conversion into a useful 3D
printer filament.

A Sequence of Steps Involved in the Innovation

Step 1: Problem Identification

Athul conducted a survey among his friends, teachers, and parents. He identified that, in
the absence of an adequate waste disposal or collection system, plastic waste is a major
issue that’s plaguing his community.

Here are a few key statistics to put the plastic waste crisis into context:

1. Currently, 300 million tons of plastic waste are produced annually, of which about
60% end up in landfills and the natural environment.
2. The recent COVID-19 pandemic has only worsened this situation with large
amounts of disposable plastic and the medical waste being discarded at rapid
rates.
3. India alone generated 34 lakh tons of waste in 2019–2020, which was an
increase of more than 10 lakh tons compared to 2017–2018.
4. As per data from 2019, metropolitan cities like Chennai, Bengaluru, and Delhi
contribute to more than 50% of plastic waste deposition. (Source: Earth 5R)
Step 2: Research and Development

After research and analysis, he envisioned an idea and named it The Waste Depositor
and Plastic Printer. The idea focuses on recycling all kinds of plastic waste and their
conversion into a filament that can be used in 3D printers, without harming the
environment or other organisms.

The idea consists of five main parts:

1. Hopper Unit
2. Electric Motor 12 V
3. Heating Unit
4. Die Pattern Unit
5. Air-Cooling Unit

Recycling the collected plastic waste into colour filaments for 3D printers involves the
following steps:

1. The collected plastic waste from the desired source goes through the grinding,
washing, and drying process, and then the crushed plastic waste is fed into the
hopper unit manually, which consists of a hopper, screw conveyor, and screw
drive motor.
2. The crushed plastic waste is transported to the heating unit, through the screw-
based mechanism with the help of an electric motor.
3. The heating unit continuously melts the plastic waste at a temperature of around
482 °C (900 °F) and mechanically pushes it through the die pattern unit. This
results in the formation of filaments that match the diameter specifications of the
die.
4. Then this filament is pushed through the air-cooling unit and the formed filament
is tested according to the modulus of elasticity, tensile strength, elongation, and
hardness.

Step 3: Impact

This innovation has multiple benefits. It reduces plastic pollution and its related side
effects. The final product is also significantly useful in 3D printers.

The 3D printer depends on the Fused Deposition Method. This is an additive

manufacturing technology that creates 3D components using a continuous thermoplastic
or composite material thread in filament form. Acrylonitrile Butadiene Styrene (ABS) is
stronger and more durable than Polyvinyl Chloride (PVC) and Polylactic Acid (PLA), the
most commonly used printer materials.
Consequently, the result of this idea indicates that the spooler speed is approximately 3
or 4 rpm and the temperature around 200 °C, which can produce an average filament
diameter of 1.6 mm. However, there’s still scope for improvement.

Therefore, Athul with his mentors is working to make the technology more reliable,
sustainable, simpler, and easier to install. With in-depth analysis and multiple upgrades
to negate the existing flaws, this product can be mass-produced and made mandatory in
public places, so the country could benefit from less plastic waste. The product also
promotes the government’s Swachh Bharat Mission.

While there are comparable technologies currently available in the market, they’re highly
expensive. As a result, the young innovator wishes to develop low-cost manufacturing
techniques and increase the number of small businesses and jobs throughout rural India.
In the coming years, he plans to identify, address and improve project flaws. He also
intends to scale up his projects in the future with the assistance of his mentors.