FABRICATION OF COMPOSITE GEAR DIE USING

DISCARDED PLASTICS

A MINI PROJECT REPORT

Submitted by

PERSIN C (210519114037)
SUJITH KANNAN B (210519114058)
VIJIN R (210519114063)

in partial fulfillment of the requirements for the degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

DMI COLLEGE OF ENGINEERING

ANNA UNIVERSITY: CHENNAI 600 025
JUNE 2022

i
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “FABRICATION OF COMPOSITE

GEAR DIE USING DISCARDED PLASTICS” is a bonafide work of

PERSIN C (210519114037), SUJITH KANNAN B (210519114058), VIJIN R

(210519114063) who carried out the project under my supervision.

SIGNATURE SIGNATURE
Dr. T. SENTHIL KUMAR M.E., Ph.D Dr. A. AMALA MITHIN M.E., Ph.D
HEAD OF THE DEPARTMENT SUPERVISOR
ASSOCIATE PROFESSOR
DEPARTMENT OF MECHANICAL DEPARTMENT OF MECHANICAL
ENGINEERING ENGINEERING
DMI COLLEGE OF ENGINEERING DMI COLLEGE OF ENGINEERING
PALANCHUR, CHENNAI 600 123 PALANCHUR, CHENNAI 600 123

Certified that the candidates were examined in the viva voce examination held on
………………………….

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT

First, we thank the God Almighty for blessing us with the knowledge and
skills to carry out the project successfully.
We wish to record our deep sense of gratitude and profound thanks to our
beloved Founder and Chairman the most Rev. Fr. Dr. J. E. Arulraj, for providing
us the immense facilities in this Institution.
We are extremely indebted to our Correspondent Rev. Sr. M. K. Teresa,
Administrator Rev. Sr. P. Pradeeba for their valuable suggestions and supports
throughout our study in this Institution.
We are happy to extend our sincere thanks to the Principal
Dr. N. Azhagesan, M.Tech., Ph.D. for his continuous motivation and support
towards successful completion of our project work.
We are grateful to our Head of the Department Dr. T. Senthilkumar, M.E.,
Ph.D. for his keen interest, inspiring guidance, constant encouragement during all
stages of our study.
We express our thankfulness to our project guide Dr. A. Amala Mithin
Minther Singh, M.E., MBA., Ph.D. and our project coordinator
Mr. R. Venkatesh, M.E., (Ph.D) for their valuable technical guidance and
cooperation, which helped us to complete the project work successfully.
We also extend our sincere thanks to all the Teaching and Non Teaching
staff off the Department of Mechanical Engineering for the valuable support
throughout our course of study and accomplishment of project work.
Finally, we are grateful to our beloved parents and friends for their
continuous support and encouragement to complete the project successfully.

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 ABSTRACT

Nowadays the discarded plastics are dumped in the earth and spoil the

quality of soils and reduce the absorption capacity of the rain water into the earth.

So, the collection and recycling of glass bottles made up of plastics is now widely

practiced and various methods have been utilized. The recycling of plastic presents

shows greater difficulties, however, owing to the need to separate the principal

polymers with a high degree of precision. To avoid the dump age of these bottles,

we can recycle these bottles into a useful product.

The present work is to recycle the discarded plastic bottles into useful

product as gear die. The discarded plastic bottles were collected from the various

dumped areas and sized into small pieces. These sized bottles were melted in the

furnace and converted into semi liquid state. Once it is cooled these plastics were

synthesized with the manual hand method still to obtain the required size as

microparticle. The microparticle plastic powder is then mixed with the polyester

resin and hardener still it mixes. The prepared composites were sized according to

ASTM standards to perform mechanical behaviors like tensile, flexural, impact,

Brinell and Rockwell hardness. The results obtained from the above mentioned test

depict with higher strength in TiO2 incorporated composites and utilization of these

composites gives more strength as well as eco- friendly to the environment due to

the binding nature of matrix.

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 TABLE OF CONTENTS

CHAPTER
TITLE PAGE NO
NO
ABSTRACT iv
LIST OF TABLES vii
LIST OF FIGURES viii
1 INTRODUCTION 1
1.1 HISTORY OF PLASTIC 2
1.2 TYPES OF PLASTICS 3
1.2.1 Polyethylene Terephthalate (PETE or PET) 4
1.2.2 High-Density Polyethylene (HDPE) 4
1.2.3 Polyvinyl Chloride (PVC) 5
1.2.4 Low-Density Polyethylene (LDPE) 6
1.2.5 Polypropylene (PP) 7
1.2.6 Polystyrene or Styrofoam (PS) 7
1.3 WASTAGE OF PLASTIC 8
1.4 SURVEY OF PLASTIC 9
1.5 MOTIVATION OF THE PROJECT 10
1.6 OBJECTIVES OF THE PROJECT 11
1.7 OVERVIEW OF THE PROJECT 12
2 LITERATURE REVIEW 14
3 MATERIALS, FABRICATION AND 26
TESTING
3.1 MATERIALS 26
3.1.1 Plastic 26

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 3.1.2 Resin 26
3.1.3 Polyester Resin 27
3.1.4 Accelerator 28
3.1.5 Catalyst 29
3.1.6 Wax 31
3.1.7 Mould 31
3.2 FABRICATION METHOD 32
3.2.1 Melting of Plastics 32
3.2.2 Synthesis of plastic 33
3.2.3 Hand Layup method 34
3.3 TESTING OF MATERIALS 38
3.3.1 Tensile Test 38
3.3.2 Flexural Test 38
3.3.3 Impact Test 39
3.3.4 Brinell Hardness Test 40
3.3.5 Rockwell Hardness Test 41
4 RESULT AND DISCUSSION 43
4.1 TESILE TEST 43
4.2 FLEXURAL TEST 44
4.3 IMPACT TEST 46
4.4 BRINELL HARDNESS TEST 47
4.5 ROCKWELL HARDNESS TEST 48
5 CONCLUSION 50
REFERENCES 51

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 LIST OF TABLES

TABLE NO TITLE PAGENO

4.1 Tensile Strength 43

4.2 Flexural Strength 45
4.3 Impact Strength 46
4.4 Brinell Hardness Number 48
4.5 Rockwell Hardness 49
Number

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 LIST OF FIGURES

FIGURE NO TITLE PAGENO

1.1 Plastics 1
1.2 Plastic Wastages 8
1.3 Work Flow Chart 13
3.1 Polyester Resin 28
3.2 Hardener 29
3.3 Accelerator (Cobalt) 30
3.4 Wax 31
3.5 Wooden Mould 32
3.6 Melting of Plastics 32
3.7 Making plate before synthesis 33
3.8 Plastics after Melting 33
3.9 Synthesis of Plastics 34
3.10 Hand Lay-up Method 35
3.11 Applying Wax 35
3.12 Mixing plastics with resin 35
3.13 Placing the composite in die 36
3.14 Final Product in Die 36
3.15 Composite Gear Die 37
3.16 Plastic with TiO2 Specimen 37
3.17 Tensile Testing Machine (UTM) 38
3.18 Flexural Testing Machine (UTM) 39
3.19 Impact Testing Machine 40

viii
3.20 Brinell Hardness Testing Machine 41
3.21 Rockwell Hardness Testing Machine 42
4.1 Tensile Specimen 43
4.2 Tensile Strength 44
4.3 Flexural Specimen 44
4.4 Flexural Strength 45
4.5 Impact Specimen 46
4.6 Impact Strength 47
4.7 Hardness Specimen 47
4.8 Brinell Hardness Number 48
4.9 Rockwell Hardness Number 49

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 CHAPTER 1
INTRODUCTION

Plastic is material consisting of any of a wide range of synthetic or semi-

synthetic organic compounds that are malleable and so can be molded into solid
objects.Plasticity is the general property of all materials which can deform
irreversibly without breaking but, in the class of moldable polymers, this occurs
to such a degree that their actual name derives from this specific ability. Plastics
are typically organic polymers of high molecular mass and often contain other
substances. They are usually synthetic, most commonly derived
from petrochemicals, however, an array of variants are made from renewable
materials such as polylactic acid from corn or cellulosics from cotton
linters.Due to their low cost, ease of manufacture, versatility, and
imperviousness to water, plastics are used in a multitude of products of different
scale, including paper clips and spacecraft. They have prevailed over traditional
materials, such as wood, stone, hornand bone, leather, metal, glass, and ceramic,
in some products previously left to natural materials.

Figure 1.1 Plastics

In developed economies, about a third of plastic is used in packaging and

roughly the same in buildings in applications such as piping, plumbing or vinyl

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siding.Other uses include automobiles, furniture, and toys. In the developing
world, the applications of plastic may differ. 42% of India's consumption is used
in packaging. Plastics have many uses in the medical field as well, with the
introduction of polymer implants and other medical devices derived at least
partially from plastic. The field of plastic surgery is not named for use of plastic
materials, but rather the meaning of the word plasticity, with regard to the
reshaping of flesh.
1.1 HISTORY OF PLASTIC

The development of plastics has evolved from the use of natural plastic
materials to the use of chemically modified, natural materials and finally to
completely synthetic molecules. Early plastics were bio-derived materials such
as egg and blood proteins, which are organic polymers. In around 1600
BC, Mesoamericans used natural rubber for balls, bands, and figurines. Treated
cattle horns were used as windows for lanterns in the Middle Ages. Materials
that mimicked the properties of horns were developed by treating milk-proteins
with lye. In the nineteenth century, as industrial chemistry developed during
the Industrial Revolution, many materials were reported. The development of
plastics also accelerated with Charles Goodyear's discovery of vulcanization to
thermoset materials derived from natural rubber.

Parkesine is considered the first man-made plastic. The plastic material was
patented by Alexander Parkes, in Birmingham, England in 1856 It was unveiled
at the 1862 Great International Exhibition in London Parkesine won a bronze
medal at the 1862 World's fair in London. Parkesine was made
from cellulose treated with nitric acid as a solvent. The output of the process
could be dissolved in alcohol and hardened into a transparent and elastic
material that could be molded when heated By incorporating pigments into the
product, it could be made to resemble ivory.In 1897, the Hanover, Germany
mass printing press owner Wilhelm Krische was commissioned to develop an

2
alternative to blackboards The resultant horn-like plastic made from the milk
protein casein was developed in cooperation with the Austrian chemist Adolph
Spitteler The final result was unsuitable for the original purpose. In 1893,
French chemist AugusteTrillat discovered the means to insolubilize casein by
immersion in formaldehyde, producing material marketed.In the early
1900s, Bakelite, the first fully synthetic thermoset, was reported by Belgian
chemist Leo Baekeland by using phenol and formaldehyde.After World War I,
improvements in chemical technology led to an explosion in new forms of
plastics, with mass production beginning in the 1940s and 1950s. Among the
earliest examples in the wave of new polymers were polystyrene (PS), first
produced by BASF in the 1930s,] and polyvinyl chloride (PVC),first created in
1872 but commercially produced in the late 1920s In 1923, Durite Plastics Inc.
was the first manufacturer of phenol l-furfural resins In 1933, polyethylene was
discovered by Imperial Chemical Industries (ICI) researchers Reginald Gibson
and Eric Fawcett

In 1954, polypropylene was discovered by Giulio Natta and began to be

manufactured in 1957. In 1954, expanded polystyrene was invented by Dow
Chemical Polyethylene terephthalate discovery is credited to employees of
the Calico Printers' Association in the UK in 1941; it was licensed to DuPont for
the US and ICI otherwise, and as one of the few plastics appropriate as a
replacement for glass in many circumstances, resulting in widespread use for
bottles in Europe.

1.2 TYPES OF PLASTICS

 Polyethylene Terephthalate (PETE or PET)
 High-Density Polyethylene (HDPE)
 Polyvinyl Chloride (PVC)
 Low-Density Polyethylene (LDPE)
 Polypropylene (PP)

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  Polystyrene or Styrofoam (PS)

1.2.1 Polyethylene Terephthalate (PETE or PET)

Polyethylene terephthalate commonly abbreviated PET, PETE, or the obsolete

PETP or PET-P, is the most common thermoplastic polymer resin of
the polyester family and is used in fibres for clothing, containers for liquids and
foods, thermoforming for manufacturing, and in combination with glass fibre
for engineering resins.The majority of the world's PET production is for
synthetic fibres with bottle production accounting for about 30% of global
demand. In the context of textile applications, PET is referred to by its common
name, polyester, whereas the acronym PET is generally used in relation to
packaging. Polyester makes up about 18% of world polymer production and is
the fourth-most-produced polymer after polyethylene (PE), polypropylene (PP)
and polyvinyl chloride. PET consists of polymerized units of the monomer
ethylene terephthalate, with repeating (C10H8O4) units. PET is
commonly recycled, and has the number "1" as its resin identification
code (RIC). Depending on its processing and thermal history, polyethylene
terephthalate may exist both as an amorphous (transparent) and as a semi-
crystalline polymer. The semi crystalline material might appear transparent or
opaque and white depending on its crystal structure and particle size.The
monomer bis(2-hydroxyethyl) terephthalate can be synthesized by
the esterification reaction between terephthalic acid and ethylene glycol with
water as a byproduct, or by transesterification reaction between ethylene
glycol and dimethyl terephthalate (DMT) with methanol as a byproduct.
Polymerization is through a polycondensation reaction of the monomers with
water as the byproduct.
1.2.2 High-Density Polyethylene (HDPE)

High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is

a thermoplastic polymer produced from the monomer ethylene. It is sometimes

4
called "alkathene" or "polythene" when used for HDPE pipes. With a high
strength-to-density ratio, HDPE is used in the production of plastic bottles,
corrosion-resistant piping, geomembranes and plastic lumber. HDPE is
commonly recycled, and has the number "2" as its resin identification code.In
2007, the global HDPE market reached a volume of more than 30 million tons.

HDPE is known for its large strength-to-density ratio. The density of HDPE can
range from 930 to 970 kg/m3 Although the density of HDPE is only marginally
higher than that of low-density polyethylene, HDPE has little branching, giving
it stronger intermolecular forces and tensilestrength than LDPE. The difference
in strength exceeds the difference in density, giving HDPE a higher specific
strength. It is also harder and more opaque and can withstand somewhat
higher temperatures High-density polyethylene, unlike polypropylene, cannot
withstand normally required autoclaving conditions. The lack of branching is
ensured by an appropriate choice of catalyst and reaction conditions.The
physical properties of HDPE can vary depending on the molding process that is
used to manufacture a specific sample; to some degree a determining factor are
the international standardized testing methods employed to identify these
properties for a specific process. For example, in Rotational Molding, to
identify the environmental stress crack resistance of a sample, the Notched
Constant Tensile Load Test (NCTL) is put to use. Owing to these desirable
properties, pipes constructed out of HDPE are ideally applicable for potable
water, and waste water.
1.2.3 Polyvinyl Chloride (PVC)

Polyvinyl chloride colloquial: polyvinyl, vinyl; abbreviated: PVC, is the

world's third-most widely produced synthetic plastic polymer,
after polyethylene and polypropylene. About 40 million tonnes are produced per
year.PVC comes in two basic forms: rigid and flexible. The rigid form of PVC
is used in construction for pipe and in profile applications such as doors and

5
windows. It is also used in making bottles, non-food packaging, and cards). It
can be made softer and more flexible by the addition of plasticizers, the most
widely used being phthalates. In this form, it is also used in plumbing, electrical
cable insulation, imitation leather, flooring,
signage, phonograph records,inflatable products, and many applications where
it replaces rubber. With cotton or linen, it is used to make canvas. Pure
polyvinyl chloride is a white, brittle solid. It is insoluble in alcohol but slightly
soluble in tetrahydrofuran.
1.2.4 Low-Density Polyethylene (LDPE)
Low-density polyethylene (LDPE) is a thermoplastic made from
the monomer ethylene. It was the first grade of polyethylene, produced in 1933
by Imperial Chemical Industries (ICI) using a high pressure process via free
radical polymerization. Its manufacture employs the same method today.
The EPA estimates 5.7% of LDPE is recycled. Despite competition from more
modern polymers, LDPE continues to be an important plastic grade. In 2013 the
worldwide LDPE market reached a volume of about US$33 billion. LDPE is
defined by a density range of 0.917–0.930 g/cm3. It is not reactive at room
temperatures, except by strong oxidizing agents, and some solvents cause
swelling. It can withstand temperatures of 80 °C continuously and 90 °C
(194 °F) for a short time. Made in translucent or opaque variations, it is quite
flexible and tough.

LDPE has more branching (on about 2% of the carbon atoms) than HDPE, so
its intermolecularforces are weaker, its tensile strength is lower, and
its resilience is higher. Also, because its molecules are less tightly packed and
less crystalline due to the side branches, its density is lower.

When exposed to ambient solar radiation the plastic produces

two greenhousegases, methane and ethylene. Due to its low density properties it
breaks down more easily over time, leading to higher surface areas. The

6
production of these trace gases from virgin LDPE increase with surface
area/time, with rates at the end of a 212-day incubation of 5.8 nmol. g-1 d-1 of
methane, 14.5 nmol. g-1 d-1 of ethylene, 3.9 nmol. g-1 d-1 of ethane and 9.7
nmol. g-1 d-1 of propylene. When incubated in air, LDPE emits gases at rates 2
times and 76 times higher in comparison to water for methane and ethylene,
respectively.
1.2.5 Polypropylene (PP)

Polypropylene (PP), also known as polypropene, is

a thermoplastic polymer used in a wide variety of applications. It is produced
via chain-growth polymerization from the monomer propylene.

Polypropylene belongs to the group of polyolefins and is partially

crystalline and non-polar. Its properties are similar to polyethylene, but it is
slightly harder and more heat resistant. It is a white, mechanically rugged
material and has a high chemical resistance.Polypropylene is the second-most
widely produced commodity plastic and it is often used in packaging and
labeling. In 2013, the global market for polypropylene was about 55
million tonnes
1.2.6 Polystyrene or Styrofoam (PS)

Styrofoam is a trademarked brand of closed-cell extruded polystyrene

foam (XPS), commonly called "Blue Board" manufactured as foam
continuous building insulation board used in walls, roofs, and foundations
as thermal insulation and water barrier. This material is light blue in color and is
owned and manufactured by The Dow Chemical Company.

In the United States and Canada, the colloquial use of the word styrofoam refers
to another material that is usually white in color and made of expanded
polystyrene foam (EPS). It is often used in disposable coffee cups and coolers,
and as cushioning material in . The trademarked term is used

7
generically although it is a different material from the extruded polystyrene
used for Styrofoam insulation.

The Styrofoam brand polystyrene foam, which is used for craft applications, can
be identified by its roughness and the "crunch" it makes when cut Additionally,
it is moderately soluble in many organic solvents, cyanoacrylate, and the
propellants and solvents of spray paint

1.3 WASTAGE OF PLASTIC

Plastic pollution is the accumulation of plastic objects in the

Earth's environment that adversely affects wildlife, wildlife habitat, and
humans. Plastics that act as pollutants are categorized into micro-, meso-, or
macro debris, based on size. Plastics are inexpensive and durable, and as a result
levels of plastic production by humans are high. However, the chemical
structure of most plastics renders them resistant to many natural processes
of degradation and as a result they are slow to degrade.Together, these two
factors have led to a high prominence of plastic pollution in the environment.

Figure 1.2 Plastic Wastages

Plastic pollution can afflict land, waterways and oceans. It is estimated that 1.1
to 8.8 million metric tons (MT) of plastic waste enters the ocean from costal
communities each year. Living organisms, particularly marine animals, can be
harmed either by mechanical effects, such as entanglement in plastic objects or
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problems related to ingestion of plastic waste, or through exposure to chemicals
within plastics that interfere with their physiology. Humans are also affected by
plastic pollution, such as through disruption of various hormonalmechanisms.

1.4 SURVEY OF PLASTIC

Response of Shopkeeper: 30% shopkeepers have understood that plastic usage
is harmful for environment and now they are using eco-friendly bags like paper
bag, cloth bag etc. 20% shopkeepers think Charging people for bags will cause
a lot of inconvenience. We can‟t use paper bags as they tend to tear easily and
jute bags are not very handy.” 50% shopkeepers prefer plastic bags because
they are cheap and readily available and also easy to carry
Preference of Shopkeepers: Majority of shopkeepers (80%) preferred plastic
bags as they are cheap and easily available. The customers also demand for the
poly bags so to fulfill their demand shopkeepers have to buy the plastic bags.
On the other hand some shopkeepers were in favor of usage of paper or cloth
bag.Response of customers In some areas customers were satisfied by the
Usage of plastic bags as according to them Plastic bags are cheap and readily
available and convenient to use On the other hand some were not satisfied and
they preferred cloth bags and find it convenient to use.
Preference of Customers What About Less Educated Customer? Majority of
customers prefer plastic bags as they are very easy to handle. can be brought at
very cheap rates. Don‟t know about harmful effects of using plastic. What
about educated customer? the educated and wise people preferred the cloth
bags because they last for a longer time. can be used again and again they are
biodegradable do not have any adverse effect on the environment.Suggestion to
consumers stop using plastic straws, even in restaurants. Use reusable produce
bag. Give up gum. Gum is made of a synthetic rubber, aka plastic. Buy boxes
instead of bottles. Often, products like laundry detergent come in cardboard
which is more easily recycled than plastic. Purchase food, like cereal, pasta, and

9
rice from bulk bins and fill a reusable bag or container. You save money and
unnecessary packaging. Reuse containers for storing leftovers or shopping in
bulk. Use a reusable bottle or mug for your beverages, even when ordering from
a to-go shop Bring your own container for take-out or your restaurant doggy-
bag since many restaurants use styrofoam. Use matches instead of disposable
plastic lighters or invest in a refillable metal lighter. Avoid buying frozen foods
because their packaging is mostly plastic. You save money and Avoid
unnecessary packaging!
Plastic Usage In Industries: 75% industries use non-biodegradable
packaging Only 25% industries use biodegradable packaging. Future Scenario
Now The Future Is In All Our Hands For All New Generations.”Feedback Of
Survey Feedback Of Survey:"Some are offering more environmentally friendly
alternatives like cloth bag or jute bag some have removed bags from the counter
and won't give them at any cost.
Facts on Plastic:Recycling plastic saves twice as much energy as burning
it in an incinerator. Today, Americans generate 10.5 million tons of plastic
waste a year but recycle only 1 or 2 % of it. An estimated 14 billion pounds of
trash, much of it plastic is dumped in the world‟s oceans every year. The
worldwide fishing industry dumps an estimated 150,000 tons of plastic into the
ocean each year, including packaging, plastic nets, lines, and buoys. About
1,200 plastic soft drink and salad dressing containers could carpet the average
living room.
1.5 MOTIVATION OF THE PROJECT

In India, 70 percent of total plastic consumption is discarded as waste.

Around 5.6 million tonnes per annum (TPA) of plastic waste is generated in
country, which is about 15,342 tonnes per day (TPD).Delhi produce 40% more
plastic waste than Mumbai. Around 60% of Indian plastic waste is recycled.

 Delhi - 690 tonnes

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  Chennai - 429 tonnes
 Kolkata - 426 tonnes
 Mumbai - 408 tonnes
 Benguluru - 314 tonnes
Rise of plastic consumption in india (per year):
 1996 - 61,000 tonnes
 2000 - 300,000 tonnes
 2001 - 400,000 tonnes
 2007 - 8500,000 tonnes
 2017 - 17,800,000 tonnes

These are the basic survey that we saw before start the project , This survey
motivates us to do this project . Because the plastic consumption in india is
increasing day by day. There are some number of recycling process but we just
have to recycle the plastic and use for automobile accessories.

1.6 OBJECTIVES OF THE PROJECT

1. To represent and promote the recycling industry for the benefit of all
Members of the Association.

2. To promote the individual and collective services of Members.

3. To represent the interests of Members at local, national and European

Government level with direct contact and through Government agents.

4. To be a principal voice for the recycling industry.

5. To develop best practice in the recycling industry by promoting:

 Health & Safety standards

 Legal and Regulatory compliance

11
  Operational standards

6. To provide a source of information for Members on matters relating to the

waste and recycling industry, including:

 Health & Safety

 Current legislation and regulation
 Industry benchmarking
 Technical developments
 Training & education
7. To explore group purchasing schemes for the benefit of Members.
8. To organise networking and social fellowship events in order to improve
communication between Members.

9. To promote and communicate the best interests of the Association and its
Members to the trade and general media and public.

1.7 OVERVIEW OF THE PROJECT

1. Collect the waste plastic bottles and melt the bottles.

2. After melting powder the plastic.
3. Mix the powder plastic and titanim oxide.
4. Add polysterresine with the above plastic and titanim oxide mixture and
pore it to the molde.
5. Then wait for an hour or two and take it from the moulde
6. Cut the out product as per the ASTM standard
7. Identify the characterization using EDAX, Tensile, and flexural.
8. Analyse the obtain result and compare with the convensional result

12
 Collection of waste plastic bottles.

Melting of collected plastic bottles

Cool the molten plastic in to solid state

Then powder the cooled plastic.

Mix the resin with catalyst and accelerator

Add powdered plastic with the resin

Add titanium oxide with the above resin plastic

mixture

Then poured the mixture in the mould mixture

Obtained the Required specimen

Figure 1.3 Work Flow Chart

13
 CHAPTER 2
LITERATURE REVIEW
D.A. Wahab et.al (2007)This study presents the findings from a study on
the consumption of recycled materials and recycling practices in the plastics
manufacturing industry and recycling companies in Malaysia. The findings
were obtained from a survey conducted in twenty plastic manufacturing
companies and detailed case studies in three recycling companies. The survey
conducted in the plastic manufacturing companies‟ shows that the consumption
rate for poly-olefins (PP and PE) is the highest among the resin types and the
industrial sector that consumes the most plastic materials is the electrical and
electronics sector. The consumption of recycled materials is high among the
local manufacturing companies (80%) which are largely due to cost savings;
about 20% of these companies conducted in-house recycling. The study has also
shown that the medium scale industry consumes the most recycled materials as
compared to the large and small scale industry. The rate of disposal for plastic
materials in the local industry is approximately 5%. The detailed case studies
conducted in the recycling companies have successfully identified the main
processes involved in plastic recycling namely manual sorting, cleaning, drying,
meshing/pelletising and packaging. These recycling companies obtained
recycled materials from various sources including industrial scrap, dumping
sites, local producers as well as imported sources. Pricing of recycled materials
were based on classification according to grade and quality of the recycled
materials. The study has reflected the extent of in-house recycling trends in the
local plastic manufacturing companies and their dependency on the supply from
the local recyclingcompanies. In Malaysia, one of the prime movers for the
expansion of the plastics industry is the plastic recycling companies. Findings
from the study indicated that 19% of the plastics materials used are recycled
materials and their supplies are either from in-house or local recycling
companies. This study found that 20% of the manufacturing companiesrecycled

14
their own materials as well as hiring external recycling companies to mesh their
products into flake-forms. The material flow pattern within the plastics
manufacturing company enables the re-use of materials of the same grade. Ten
percent of the manufacturing companies purchased second grade materials in
the form of pellets or flakes. Three possible reasons were cited i) the lack of
facilities for recycling, ii) high demand for recycled materials causing
manufacturers to be incapable of recycling their own material, or iii) the need to
develop products of a higher quality by using second grade materials that has
been pelletized; pellets are deemed better than meshed materials.
S.M. Al-Salem et.al (2009)Plastic solid waste (PSW) presents challenges
and opportunities to societies regardless of their sustainability awareness and
technological advances. In this paper, recent progress in the recycling and
recovery of PSW is reviewed. A special emphasis is paid on waste generated
from polyolefinic sources, which makes up a great percentage of our daily
single-life cycle plastic products. The four routes of PSW treatment are detailed
and discussed covering primary (re-extrusion), secondary (mechanical), tertiary
(chemical) and quaternary (energy recovery) schemes and technologies.
Primary recycling, which involves the re-introduction of clean scrap of single
polymer to the extrusion cycle in order to produce products of the similar
material, is commonly applied in the processing line itself but rarely applied
among recyclers, as recycling materials rarely possess the required quality. The
various waste products, consisting of either end-of-life or production waste, are
the feedstock of secondary techniques, thereby generally reduced in size to a
more desirable shape and form, such as pellets, flakes or powders, depending on
the source, shape and usability. Tertiary treatment schemes have contributed
greatly to the recycling status of PSW in recent years. Advanced thermo-
chemical treatment methods cover a wide range of technologies and produce
either fuels or petrochemical feedstock. Nowadays, non-catalytic thermal
cracking is receiving renewed attention, due to the fact of added value on a

15
crude oil barrel and its very valuable yielded products. But a fact remains that
advanced thermo-chemical recycling of PSW still lacks the proper design and
kinetic background to target certain desired products and/or chemicals. Energy
recovery was found to be an attainable solution to PSW in general and
municipal solid waste (MSW) in particular. The amount of energy produced in
kilns and reactors applied in this route is sufficiently investigated up to the point
of operation, but not in terms of integration with either petrochemical or
converting plants. Although primary and secondary recycling schemes are well
established and widely applied, it is concluded that many of the PSW tertiary
and quaternary treatment schemes appear to be robust and worthy of additional
investigation. The various recycling technologies of PSW presented in this
paper, have contributed greatly to the eco-image of waste management and
particularly to PSW recycling, treatment and recovery. Re-using and decreasing
single-life polymeric materials will certainly benefit the current situation. By
initiating the loop of recycling in a processing line, one can integrate it with the
proces scrap re-extrusion occurring at different scales with different
thermoplastics. Certain disadvantages appear when mechanical recycling is
chosen as a route of recycling. The types of the polymer based plastic, its
condition and suitability as well as the intense energyconsumption involved are
all major issues concerning PSW.
John N.Hahladakis et.ai (2018)The European Commission (EC)
recently introduced a „Circular Economy Package‟, setting ambitious recycling
targets and identifying waste plastics as a priority sector where major
improvements are necessary. Here, the authors explain how different collection
modalities affect the quantity and quality of recycling,using recent empirical
data on household (HH) post-consumer plastic packaging waste (PCPP)
collected for recycling in the devolved administration of England over the
quarterly period July-September 2014. Three main collection schemes, as
currently implemented in England, were taken into account: (i) kerbside

16
collection (KS), (ii) household waste recycling centres (HWRCs) (also known
as „civic amenity sites‟), and (iii) bring sites/banks (BSs). The results indicated
that: (a) the contribution of KS collection scheme in recovering packaging
plastics is higher than HWRCs and BBs, with respective percentages by weight
(wt%) 90%, 9% and 1%; (b) alternate weekly collection (AWC) of plastic
recyclables in wheeled bins, when collected commingled, demonstrated higher
yield in KS collection; (c) only a small percentage (16%) of the total amount of
post-consumer plastics collected in the examined period (141 kt) was finally
sent toreprocessors (22 kt); (c) nearly a third of Local Authorities (LAs)
reported insufficient or poor data; and (d) the most abundant fractions of
plastics that finally reached the reprocessors were mixed plastic bottles and
mixed plastics. The present research has focused on evaluating the effect that
different collection schemes have on the quantity of PCPP waste collected for
recycling, using empirical serial data from HH dryrecyclables collection in
England, in 2014. Three main collection schemes were analysed.
Bupe G Mwanza et.al (2016)Waste recycling is a livelihood for the
marginalized society in the developing economies and it is not surprising to find
recycling of municipal solid waste (MSW) been carried out. Plastic waste is a
waste type in MSW yet a numberof challenges still exist in managing this waste
type. A literature review was conducted to identify the key drivers to
sustainable development of post-consumer packaging plastic waste recycling
systems in developed and developing economies. A number of articles focusing
on drivers or factors influencing sustainable management and recycling ofsolid
waste and municipal solid waste were reviewed. Further analysis of the results
indicated a number of drivers from the economic, environmental and social
aspect as drivers to sustainable development of recycling systems for post-
consumer packaging plastic solid waste. Sustainable recycling of post-consumer
packaging plastic solid waste provides opportunities to reduce oil usage, carbon
dioxide emissions and quantities of waste requiring disposal. As a

17
resultrecycling of plastic waste is considered sustainable in manufacturing as
new products are manufactured without utilizing new materials hence
contributing to sustainable development. Economic, environmental and social
drivers in development of SW or MSW systems were identified both at
community and household levels. The drivers identified are applicable to the
sustainable development of post-consumer packaging plastic waste recycling
systems since plastics are a waste type in municipal solid waste. However, an
empirical study should be conducted to statistically analyse the impact each
driver has on sustainable development of recycling systems. Further the
researchers identified that the major way forward is how to apply these drivers
at different contexts both in developed and developing economies.
Charles Mbohwa et.al (2018)despite these positive aspects of plastics,
plastic industries have continued to face a number of challenges into the
recovery and recycling of plastic for waste reduction and resource utilization.
The study assessed the strategies that would positively influence plastic
manufacturing and recycling companies to recover and recycle plastic solid
wastes. A total of 15 plastic manufacturing and recycling companies were
investigated in Zambia and the results showed favourable The study analyzed
and identified the most critical strategies in the recovery and recycling of PSW
from the plastic manufacturing and recycling companies‟ perspective. These
strategies are relevant for implementation in the recovery programs for
sustainable manufacturing and resource utilization of PSW in Zambia. However
if applied in the context of any developed or developing nation, they are likely
to work. From the technological, economical, market, social and environmental
concerns and legislations; the following were identified as the most critical in
the recovery and recycling of PSW in Zambia. Ensuring material applicability
in manufacturing processes The cost of alternative acceptable forms of disposal
compared to recycling Creating closer engagements of recyclers with one
another along the supply-chain. Efficiency of the municipality, private waste

18
contractors or informal waste collectors in waste collection Enforcement of
producer responsibility regulations to encourage collection of plastic wastes.
Adil Koç et.al (2013)The rapid increase in the use of plastic materials in
the recent years led to the accumulation of excessive amounts of plastic waste.
The so-called thermoplastics such as PE, PP, PS, PVC and PET as well as
materials that are derived from these are the type of plastic that is most used and
consequently creates most of the waste. In this study, the original and waste
forms of PE and PP plastic types have been chosen for thermal and catalytic
degradation. As process parameter, 410˚C - 450˚C temperature interval and 600
mL/min constant flow rate nitrogen gas have been chosen as the carrier gas and
the reaction time was considered to be 90 minutes for all experiments. Liquid
products collected in experiments were separated by means of fractioned
distillation process. For purposes of determining product distribution, the
fractions, which were separated by distillation, were diluted in an appropriate
solution for analysis of GC/MS. In the study conducted, it has been observed
that the liquid product distribution obtained mainly consists of a mixture of
saturated and unsaturated (heptane, heptane, octane, nonane, dodecane, etc.)
hydrocarbons. The catalytic degradation of HDPE and PP shows us that in
different catalyst/plastic ratios the amount and structure of liquid products are
different. So the iodine number is an interesting parameter for unsaturated
compounds determination. In this study, the unsaturated products are important
part of the degradation products. In our later studies, the evolution of
unsaturated product which they obtained in thermal or catalytic degradation
processes will be investigated.
Mats Zackrisson et.al (2014)The main driver for recycling cable wastes
is the high value of the conducting metal, while the plastic with its lower value
is often neglected. New improved cable plastic recycling routes can provide
both economic and environmental incentive to cable producers for moving up
the “cable plastic waste ladder”. Cradle-to-gate life cycle assessment, LCA, of

19
the waste management of the cable scrap is suggested and explained as a
method to analyze the pros and cons of different cable scrap recycling options at
hand. Economic and environmental data about different recycling processes and
other relevant processes and materials are given. Cable producers can use this
data and method to assess the way they deal with the cable plastic waste today
and compare it with available alternatives and thus illuminate the improvement
potential of recycling cable plastic waste both in an environmental and in an
economic sense. The methodology applied consists of: cradle-to-gate LCA for
waste material to a recycled material (recyclate); quantifying the climate impact
for each step on the waste ladder for the specific waste material; the use of
economic and climate impact data in parallel; climate impact presented as a
span to portray the insecurities related to which material the waste will replace;
and possibilities for do-it-yourself calculations. Potentially, the methodology
can be useful also for other waste materials in the future. This paper suggests
cradle-to-gate life cycle assessment as a method to analyze the pros and cons of
differentcable scrap recycling options at hand. Economic and environmental
data about different recycling processes and other relevant processes and
materials have been collected and are presented. Cable producers could use this
data and the proposed method to assess the way they deal with the cable plastic
waste today and compare it with available alternatives and thus illuminate the
improvement potential of recycling cable plastic waste both in an environmental
and in an economic sense.
AnkeBrems et.al (2013)The disposal of plastic solid waste (PSW) has
become a major worldwide environmental problem. New sustainable processes
have emerged, i.e. either advanced mechanical recycling of PSW as virgin or
second grade plastic feedstock, or thermal treatments to recycle the waste as
virgin monomer, as synthetic fuel gas, or as heat source (incineration with
energy recovery). These processes avoid land filling, where the non-
biodegradable plastics remain a lasting environmental burden. Within the

20
thermal treatments, gasification and pyrolysis gain increased interest.
Gasification has been widely studied and applied for biomass and coal, with
results reported and published in literature. The application to the treatment of
PSW is less documented. Gasification is commonly operated at high
temperatures (>600˚C to 800˚C) in an airlean environment (or oxygen-deficient
in some applications): the air factor is generally between 20% and 40% of the
amount of air needed for the combustion of the PSW. Gasification produces
mostly a gas phase and a solid residue (char and ashes). The use of air
introduces N2 in the product gases, thus considerably reducing the calorific
value of the syngas, because of the dilution. The paper will review the existing
literature data on PSW gasification, both as the result of laboratory and pilot-
scale research. Processes developed in the past will be illustrated. Recently, the
use of a sequential gasification and combustion system (at very high
temperatures) has been applied to various plastic-containing wastes, with
atmospheric emissions shown to be invariably below the legal limits. Operating
results and conditions will be reviewed in the paper, and completed with recent
own lab-scale experimental results. These results demonstrate that gasification
of PSW can be considered as a first order reaction, with values of the activation
energy in the order of 187 to 289 kJ/mol as a function of the PSW nature. The
gasification of PSW can certainly be developed into a valid recycling route for
PSW, producing a syngas, rich in H2 and CO. Although references of industrial
scale application are given in the literature, the future breakthrough of the
process will require further experimental work to improve the equipment design
and product optimisation. Advances in that area will aid in the improvement and
more widespread use of gasification reactors.
Heinz Langhals et.al (2014)Technical polymers could be identified by
means of their remarkably strong auto fluorescence. The time constants of this
fluorescence proved to be characteristic for the individual polymers and can be
economically determined by integrating procedures. The thus obtained

21
unequivocal identification is presented for their sorting for recycling.
Furthermore, polymeric materials were doped with fluorescent dyes allowing a
fine-classification of special batches. The unequivocal identification of
technical polymers by means of their time constants of auto fluorescence decay
is a promising method for their sorting for recycling. Time constants can be
economically determined by phase-shifted integration of the fluorescence
response of pulsed optical excitation. The auto fluorescence of polymers can be
applied for the identification of the basic material where a doping with
fluorescent dyes allows the further fine-classification of special batches. A
binary coding of the doping with n fluorescent dyes results in 2n − 1
possibilities for the labelling of batches.
Masakazu Yamashita et.al (2012)This study examined the effect of
reducing disposable plastic checkout bags used in supermarkets, convenience
stores, and so on in Japan. Considering that even when these checkout bags are
abolished, alternative waste bags should be newly produced, because these
checkout bags have been reused as household waste bags so far, and the
corresponding amount of oil is still necessary to produce them, the amount of
oil saved by this bag reduction was found to be 0.2 L/person/year at most.
Further, it was demonstrated that the necessity to purchase substitute bags may
increase the household and financial burden on consumers. As previously
discussed, the effect of checkout bag reduction may not be significant.
Particularly, from an economic aspect, such a campaign may have a negative
impact on consumers. On the other hand, the appropriate use of checkout bags
may be more beneficial to both consumers and the environment than their
reduction. In addition, checkout bag reduction inevitably involves the problem
of necessary substitutes. Considering that checkout bags are currently reused for
diverse household purposes, this study examined the necessity of substitutes,
limiting them to household waste bags; however, if checkout bags are entirely
cut, a significantly negative effect may be expected. In contrast, if such bags

22
with multiple functions are actively reused for a broader range of purposes,
further products may be spared.
Yash Menaria et.al (2015)Wrappers of betel nuts, chocolates, chips,
hand bags, cold drink bottles and all other forms of plastic create significant
environmental and economic problem. They consume massive energy and other
natural resources, depleting the environment in various ways. In manufacturing
firms, construction industries and products delivery services, use of plastic is a
priority to handle and pack things comfortably due to its light weight, cost
effectiveness and strength. Plastics cannot be banned as it will result in usage of
natural resources like paper, wood at a great extent. It is made up of various
chemical elements and is regarded as a highly pestilent material which does not
easily degrade in the natural environment after its usage. Waste plastics are
made up of Polyethylene, Polystyrene and Polypropylene. Temperature varying
between 120˚C - 160˚C gives the softening point of these plastics . They do not
produce any toxic gases during heating but the softened plastics have tendency
to form a lamination or coating over the aggregate, when it is sprayed over the
hot aggregate at 160˚C. The main objective of this paper is to discuss the
significance of plastic in terms of cost reduction, increase in strength and
durability when these plastics are heated and coated upon the aggregates
(160˚C) to compensate the air voids with plastic and binds with aggregate to
provide stability.
Surabhi Srivastava et.al (2012)This paper presents substitute for non-
biodegradable plastic packed material which comes as a part of municipal solid
waste and becoming global problem due to its overuse. The plastic as packaging
material has its advantages but also have more disadvantages because of its
durability that it does not degraded. If the packaging material is made up of
natural fibres it has more effect on local ecosystem. This paper provides the
solution that use of natural fibres as packaging due to its light weight, high
strength to weight ratio, corrosion resistance and other advantages are useful for

23
the industry as well as commercially availability for the markets. The
investment for an on-site waste management system in an individual health care
setting is very high. In contrast, an integrated common treatment & disposal
facilitycost a maximum of Rs. 3 to 15/kg/day with an added benefit of no
capital investment being required. The company could have profit about 35%
making it a sustainable venture if they use natural fibres as packaging material
instead of plastic. The natural fibres are environmentally sound it will also give
good market cost to the farmers.
Irene S. Fahim et.al (2011)Plastic wastes are a major environmental
concern that needs to be dealt with to minimize the amount of municipal solid
waste and depletion of natural resources thus enhancing the sustainability
concept for future generations. The objective of this study is to enhance the
properties of plastic products using plastic wastes reinforced with treated natural
fibers such as rice straw as well as carbonized rice straw, using a simple and
efficient technology. The mechanical properties of RLDPE increased three
times due to the reinforcement with chemically treated rice straw. This
composite can be used in several applications due to durability, environmental
friendliness, ease of processing, high strength and flexibility. The effect of
increasing the fiber concentration to 6% and decreasing it to 2% lowered both
tensile and flexural thus 5% is the optimum fiber content. Moreover, the
treatment of rice straw through carbonization was addressed as the tensile
properties of the composite were enhanced by 9 times. The chemical treatment
contributed to the formation of fibers with higher values of surface area and
micro porosity. This carbonization enhanced the environmentally utilization of
undesirable cellulosic wastes.
Syed Shahan Ali Shah et.al (2016)About 1.3 billion tons of waste is
being generated in the world annually. This waste is a cause of various diseases.
Open dumping of waste also destroys valuable agricultural land. Various
researchers have beneficially used plastic waste in cement concrete and asphalt

24
concrete in the past. This study aims at the use of aggregates, made from
different types of plastic waste, as partial replacement of coarse aggregates in
asphalt mixes. For this purpose waste is collected from different hospitals of the
city. Sorted plastic from the waste consists of 64% low density polyethene, 32%
high density polyethene and 4% of polypropylene. Plastic waste is shredded,
heated and after cooling, pulverizes manually and mechanically. Specific
gravity of plastic aggregates is 0.96. Water absorption and soundness values are
4.68% and 7.68% respectively. Impact, crushing and Loss Angeles values of
plastic aggregates are 0.7%, 0.5%, and 1.1% respectively. Replacement of
natural aggregates by plastic aggregates in asphalt mixes is done up to 25% with
5% incremental increase. Density of asphalt mixes decreases to 2060 kg/m3.
Consequently flow increases to 5.73 mm. Maximum stability is at 20%
replacement i.e. 34.57 KN. Cost analysis of the study indicates that 205%
increase in stability are observed with 219% increase in cost. There is no proper
solid waste management system for Peshawar city. Mostly people throw the
waste in their streets, In relatively developed areas of the city, scavengers
collect the waste and dump it in an open area usually at a distance from densely
populated area. Existing landfills of the city are not well designed. Open
burning of waste on the dumpsites is observed. Major portion of the waste
generated by the city is plastic. Plastic waste can be converted to aggregates by
proper manufacturing setup. After performing different aggregates tests, it is
found that plastic aggregates used in this research are exceptionally strong in
impact, crushing and abrasion. Due to higher porosity of aggregates, soundness
values are little higher. In asphalt mixes, density and percent voids increased
with increasing plastic aggregates content. Stability and flow also increase with
increasing plastic aggregate content. But for this increasein stability, cost also
increases. After 25% replacement, stability decreases while cost keeps on
increasing. Therefore up to 20% of natural aggregates can be replaced by plastic
aggregates.

25
 CHAPTER 3
MATERIALS, FABRICATION AND TESTING
3.1 MATERIALS
3.1.1 Plastic
Plastic is material consisting of any of a wide range of synthetic or semi-
synthetic organic compounds that are malleable and so can be molded into solid
objects. Plastics are typically organic polymers of high molecular mass and
often contain other substances. They are usually synthetic, most commonly
derived from petrochemicals, however, an array of variants are made from
renewable materials such as polylactic acid from corn or cellulosics from cotton
linters.
3.1.2 Resin
The primary functions of the resin are to transfer stress between the
reinforcing fibers, act as a glue to hold the fibers together and protect the fibers
from mechanical and environmental damage. Resins are divided into two major
groups known as thermoset and thermoplastic. Thermoplastic resins become
soft when heated and may be shaped or molded while in a heated semi-fluid
state and become rigid when cooled. Thermoset resins are cured by the use of a
catalyst heat or a combination of the two. Once cured solid thermoset resins
cannot be converted back to their liquid form. Unlike thermoplastic resins cured
thermosets will not melt and flow but will soften when heated and once formed
they cannot be reshaped. Heat distortion temperature and the glass transition
temperature is used to measure the softening of a cured resin. Both test methods
measure the approximate temperature where the cured resin will soften
significantly to yield under load,The most common thermosetting resins used in
the composites industry are unsaturated polyester, epoxies, vinyl ester and
phenolic. There are differences between these groups that must be understood to
choose the proper material for a specific application.

26
3.1.3 Polyester Resin
Polyester is a type of Thermoset resin. Thermoset resins are used to make
most composites. They‟re converted from a liquid to a solid through a process
called polymerization, or cross-linking. When used to produce finished goods,
thermosetting resins are “cured” by the use of a catalyst, heat or a combination
of the two. Once cured, solid thermoset resins cannot be converted back to their
original liquid form.
Unsaturated polyester resins (UPR) are the workhorse of the composites
industry and represent approximately 75% of the total resins used. A range of
raw materials and processing techniques are available to achieve the desired
properties in the formulated or processed polyester resin. Polyesters are
versatile because of their capacity to be modified or tailored during the building
of the polymer chains. They have been found to have almost unlimited
usefulness in all segments of the composites industry. The principle advantage
of these resins is a balance of properties (including mechanical, chemical, and
electrical) dimensional stability, cost and ease of handling or processing.
Polyester producers have proved willing and capable of supplying resins with
the necessary properties to meet the requirements of specific end user
applications. These resins can be formulated and chemically tailored to provide
properties and process compatibility.
Thermoset polyesters are produced by the condensation polymerization of
dicarboxylic acids and difunctional alcohols (glycols). In addition, unsaturated
polyesters contain an unsaturated material, such as maleic anhydride or fumaric
acid, as part of the dicarboxylic acid component. The finished polymer is
dissolved in a reactive monomer such as styrene to give a low viscosity liquid.
When this resin is cured, the monomer reacts with the unsaturated sites on the
polymer converting it to a solid thermoset structure. Unsaturated polyesters are
divided into classes depending upon the structures of their basic building
blocks. Some common examples would be orthophthalic (“ortho”), Isophthalic

27
(“iso”), dicyclopentadiene (“DCPD”) and bisphenol A fumarate resins. In
addition, polyester resins are classified according to end use application as
either general purpose (GP) or specialty polyesters such as fire retardant (FR).

Figure 3.1 Polyster Resin

Advantages
1. Adequate resistance to water and variety of chemicals.
2. Adequate resistance to weathering and ageing.
3. Low cost.
4. Polyesters can withstand a temperature up to 80°C.
5. It has good wetting to glass fibres.
6. Relatively low shrinkage at between 4-8% during curing.
7. Linear thermal expansion ranges from 100-200 x 10^-6 K^-1.
3.1.4 Accelerator(Methyl Ethyl Ketone Per Oxide)
In the present work Hardener (araldite) HY 951 is used. This has a
viscosity of 10-20 poise at 2500C. Butanone, also known as methyl ethyl ketone
(MEK), is an organic compound with the formula CH3C(O)CH2CH3. This
colorless liquid ketone has a sharp, sweet odor reminiscent of butterscotch and
acetone. It is produced industrially on a large scale, and also occurs in trace
amounts in nature. It is soluble in water and is commonly used as an industrial
solvent.

28
 Butanone is an effective and common solvent and is used in processes
involving gums, resins, cellulose acetate and nitrocellulose coatings and in vinyl
films. For this reason it finds use in the manufacture of plastics, textiles, in the
production of paraffin wax, and in household products such as lacquer,
varnishes, paint remover, a denaturing agent for denatured alcohol, glues, and as
a cleaning agent. It has similar solvent properties to acetone but boils at a higher
temperature and has a significantly slower evaporation rate. Unlike acetone, it
forms an azeotrope with water, making it useful for azeotropic distillation of
moisture in certain applications. Butanone is also used in dry erase markers as
the solvent of the erasable dye.

Figure 3.2 Hardener (Methyl Ethyl Ketone)

3.1.5Catalyst (Cobalt)
Cobalt is a chemical element with symbol Co and atomic number 27.
Like nickel, cobalt is found in the Earth's crust only in chemically combined
form, save for small deposits found in alloys of natural meteoric iron. The free
element, produced by reductive smelting, is a hard, lustrous, silver-
graymetal.Cobalt-based blue pigments (cobalt blue) have been used since
ancient times for jewelry and paints, and to impart a distinctive blue tint to
glass, but the color was later thought by alchemists to be due to the known
metal bismuth. Miners had long used the name kobold ore (German for goblin
ore) for some of the blue-pigment producing minerals; they were so named
because they were poor in known metals, and gave poisonous arsenic-

29
containing fumes when smelted. In 1735, such ores were found to be reducible
to a new metal (the first discovered since ancient times), and this was ultimately
named for the kobold.
Today, some types of cobalt are produced specifically from one of a
number of metallic-lustered ores, such as for example cobaltite (CoAs S). The
element is however more usually produced as a by-product of copper and nickel
mining. The copper belt in the Democratic Republic of the Congo (DRC),
Central African Republic and Zambia yields most of the global cobalt
production. The DRC alone accounted for more than 50% of world production
in 2016 (123,000 tonnes), according to Natural Resources Canada.

Figure 3.3Accelerator (Cobalt)

Cobalt is primarily used in the manufacture of magnetic, wear-resistant
and high-strength alloys. The compounds cobalt silicate and cobalt(II)
aluminate (CoAl2O4, cobalt blue) give a distinctive deep blue color to glass,
ceramics, inks, paints and varnishes. Cobalt occurs naturally as only one stable
isotope, cobalt-59. Cobalt-60 is a commercially important radioisotope, used as
a radioactive tracer and for the production of high energy gamma rays.Cobalt is
the active center of a type of coenzymes called cobalamins. vitamin B12, the
best-known example of the type, is an essential trace mineral for all animals.
Cobalt in inorganic form is also a micronutrient for bacteria, algae, and fungi.
Several cobalt compounds are oxidation catalysts. Cobalt acetate is used
to convert xylene to terephthalic acid, the precursor of the bulk polymer

30
polyethylene terephthalate. Typical catalysts are the cobalt carboxylates (known
as cobalt soaps). They are also used in paints, varnishes, and inks as "drying
agents" through the oxidation of drying oils. The same carboxylates are used to
improve the adhesion between steel and rubber in steel-belted radial
tires.Cobalt-based catalysts are used in reactions involving carbon monoxide.
Cobalt is also a catalyst in the Fischer–Tropsch process for the hydrogenation of
carbon monoxide into liquid fuels. Hydroformylation of alkenes often uses
cobalt octacarbonyl as a catalyst, although it is often replaced by more efficient
iridium- and rhodium-based catalysts, e.g. the Cativa process. The
hydrodesulfurization of petroleum uses a catalyst derived from cobalt and
molybdenum. This process helps to clean petroleum of sulfur impurities that
interfere with the refining of liquid fuels.
3.1.6 Wax
Wax is a substance used to remove the composite plate and the mould
easily. The enough amount of wax applied between the composite plate and the
mould.

Figure 3.4 Wax

3.1.7 Mould
Mould is a substance which is used to make a composite required shape.
Here we using the mould dimension is 30mm× 22mm.

31
 Figure 3.5 Wooden mould
3.2 FABRICATION METHOD
3.2.1 Melting of Plastics
Collect the plastic bottles and melt them using gas stove and aluminium vessel.
At the temperature of 260oC the plastic will melt. We melt approximately melt
3kg of waste plastic.

Figure 3.6 Melting of Plastics

32
 Figure 3.7 Making plate before synthesis
3.2.2 Synthesis of plastic
The combining of the constituent elements of separate material or abstract
entities into a single or unified entity the separating of any material or abstract
entity into its constituent elements. a complex whole formed by combining.We
manually synthesis the melted plastic.

Figure 3.8 Plastics after Melting

33
 Figure 3.9 Synthesis of Plastics
3.2.3 Hand Layup method
Hand lay-up is an open moulding method suitable for making a wide variety of
composites products from very small to very large. Production volume per
mould is low; however, it is feasible to produce substantial production
quantities using multiple moulds. Hand lay-up is the simplest composites
moulding method, offering low cost tooling, simple processing, and a wide
range of part sizes. Design changes are readily made. There is a minimum
investment in equipment. With skilled operators, good production rates and
consistent quality are obtainable.

34
 Figure 3.10Hand Lay-up Method

Figure 3.11 Applying Wax

Figure 3.12Mixing plastics with resin

35
Figure 3.13 Placing the composite in die

Figure 3.14 Final Product in Die

36
 Figure 3.15 Composite Gear Die

Figure 3.16 Plastic with TiO2 Specimen

There are two specimens were prepared
 Plastics with resin
 Plastics and TiO2 with resin

37
3.3 TESTING OF MATERIALS
3.3.1 Tensile Test
Tensile test also known as tension testing, is a fundamental materials science
and engineering test in which a sample is subjected to a controlled tension until
failure.The test process involves placing the test specimen in the testing
machine and slowly extending it until it fractures. During this process, the
elongation of the gauge section is recorded against the applied force. The data is
manipulated so that it is not specific to the geometry of the test sample. The
value measurement is calculated by using of formulations.

Figure 3.17 Tensile Testing Machine (UTM)

Tensile strength at yield and at break of 16 layers of glass fiber

composites and partially substituted used fish net in glass fiber composites were
measured by using a Universal Testing Machine. This test was conducted as per
the ASTM D 638 specifications. The specimens were cut by using circular saw.
The gauge length was set at 100 mm and testing speed was 5 mm/min.

3.3.2 Flexural Test

The flexural test provides values for the modulus of elasticity in bending,
flexural stress, flexural strain and the flexural stress-strain response of the

38
material. The main advantage of a three point flexural test is the esae of
specimen preparation and testing. The test method for conducting the test
usually involves a specified test fixture on a universal testing machine. Details
of the test preparation, conditioning, and conduct affect the test results. The
sample is placed on two supporting pins a set distance apart.

Figure 3.18 Flexural Testing Machine (UTM)

The flexural tests were performed according to ASTM D 790 using

Universal Testing Machine at a cross head speed of 5 mm/min. Test specimens
were made to 191×13 mm

3.3.3 Impact Test

The Charpy impact test, also known as the Charpy V-notch test, is
a standardized high strain-rate test which determines the amount
of energy absorbed by a material during fracture. This absorbed energy is a
measure of a given material's notch toughness and acts as a tool to study
temperature-dependent ductile-brittle transition. It is widely applied in industry,

39
since it is easy to prepare and conduct and results can be obtained quickly and
cheaply. A disadvantage is that some results are only comparative.

Figure 3.19 Impact Testing Machine

Impact test were carried out on composite specimens in accordance with

ASTM D 3029. Specimen was fixed in the slot and impact load was applied, by
releasing pendulum. Load required to break specimen was noted down and
procedures was repeated for different trials.

3.3.4 Brinell Hardness Test

Material having too coarse or rough surface, the hardness was
measured using the brinell method and the test is performed according to the
ASTM E10 standard. The Brinell hardness testing machine is shown in
Figure 3.18.

40
 Figure 3.20 Brinell Hardness Testing Machine
The indenter used was 10 mm in diameter with hardened steel or
carbide ball and a load of about 2500 kgf was applied to the material surface for
a duration of 10 seconds. For soft materials the load can be applied between
155Kg to 500Kg to avoid excessive indentation. The diameter of the indentation
on the tested materialwas measured with low powered microscope. Thismethod
is used to achieve bulk or macro hardness of material, particularly with
heterogeneous structures. The BrinellHardness number is calculated using the
formula
2𝐹
BHN = 0.102 x (3.1)
𝜋𝐷 (𝐷− 𝐷 2 −𝑑 2

where F – Test force in N,

D- Diameter of the ball in mm and
d- Mean diameter of the indentation in mm.
3.3.5 Rockwell hardness test
Rockwell hardness was measured by the depth of penetration of an
intender under minor load and major load conditions. The test is performed
according to the ASTM E18 standard with a ball indenter of 1.6 mm in dia and
a load of 100 kgf was applied to the material surface for a dwell time of 10

41
seconds. The Rockwell hardness machine is shown in Figure 3.18. The
Rockwell hardness test method consists of indenting the test material with a
diamond cone or hardened steel ball indenter. The indenter is forced into the test
material under a preliminary minor load and then with major load. The
permanent increase in depth of penetration and removal of the additional major
load is used to calculate the Rockwell hardness number.
ℎ
RHN = 𝑁 - (3.2)
𝑠

where N– No of Specific Rockwell Hardness Scale (100 units for diamond

indenter and 130 units for steel ball indenter),
h – Permanent depth indentation in mm under removal of test force
applied and
s – Scale unit (0.002mm for A,B,C,D,E,F,G,H,K and 0.001mm for
15N, 30N, 45N, 15T, 30T, 45T).

Figure 3.21 Rockwell Hardness Testing Machine

42
 CHAPTER 4
RESULTS AND DISCUSSIONS
Mechanical properties was performed to determine the specific
characteristics of a material and to identify the assets occurred during
deformation under the influence of externally applied load. In general the
properties like strength, hardness, impact, roughness, ductility, fracture etc.
were measured. However, in this section the Tensile, Flexural, Impact, hardness
measurements like Brinell, Rockwell were reported.

4.1 TENSILE TEST

Figure 4.1 Tensile Specimen

Table 4.1 Tensile Strength

Tensile Strength (kgf/cm2)

Composites Trial 1 Trial 2 Trial 3
Plastics 132.45 132.34 132.89
Plastics with TiO2 138.23 137.98 138.31

43
 Figure 4.2 Tensile Strength
From the Figure 4.2 and Table 4.1, it is obvious that the composites
plastics with the addition of 10% TiO2 give more tensile strength than the pure
plastics composites due to the presence of hardest materials Titanium. So the
utilization of plastics incorporated TiO2is possible and it is recyclable.
4.2 FLEXURAL TEST

Figure 4.3 Flexural Specimen

44
Table 4.2 Flexural Strength

Flexural Strength (kgf/cm2)

Composites Trial 1 Trial 2 Trial 3
Plastics 489.42 489.63 489.57
Plastics with TiO2 510.00 510.56 510. 23

Figure 4.4 Flexural Strength

From the Figure 4.4 and Table 4.2, it is obvious that the composites
plastics with the addition of 10% TiO2 give more flexural strength than the pure
plastics composites due to the presence of hardest materials Titanium. So the
utilization of plastics incorporated TiO2 is possible and it is recyclable.

45
4.3 IMPACT TEST

Figure 4.5 Impact Specimen

Table 4.3Impact Strength

Impact Strength (Joule)

Composites Trial 1 Trial 2 Trial 3
Plastics 55.5 55 55.5
Plastics with TiO2 57.5 57 57.5

46
 Figure 4.6Impact Strength

From the Figure 4.6 and Table 4.3, it is obvious that the composites
plastics with the addition of 10% TiO2 give more impact strength than the pure
plastics composites due to the presence of hardest materials Titanium. So the
utilization of plastics incorporated TiO2 is possible and it is recyclable.
4.4 BRINELL HARDNESS TEST
Material having too coarse or rough surface, the hardness was
measured using thebrinell method and the test is performed according to the
ASTM E10 standard. The ball indenter used was 10 mm in dia and a load of
about 2500 kgf was applied to the material surface for a duration of
10 seconds.

Figure 4.7 Hardness Specimen

47
 Table 4.4 Brinell Hardness Number
Brinell Hardness (HBW)
Composites Trial 1 Trial 2 Trial 3
Plastics 142 141 141
Plastics with TiO2 144 143 144

Figure 4.8 Brinell Hardness Number

From the Figure 4.8 and Table 4.4, it is obvious that the composites
plastics with the addition of 10% TiO2 give more Brinell Hardness strength than
the pure plastics composites due to the presence of hardest materials Titanium.
So the utilization of plastics incorporated TiO2 is possible and it is recyclable.
4.5 ROCKWELL HARDNESS TEST
Rockwell hardness was measured by the depth of penetration of an
intender under minor load and major load conditions. The test is performed
according to the ASTM E18 standard with a ball indenter of 1.6 mm in dia and
a load of 100 kgf was applied to the material surface for a dwell time of 10
seconds.

48
 Table 4.5 Rockwell Hardness Number

ROCKWELL HARDNESS (HRB)

Composites Trial 1 Trial 2 Trial 3
Plastics 71 70 71

Plastics with TiO2 72 71 72

Figure 4.9 Rockwell Hardness Number

From the Figure 4.9 and Table 4.5, it is obvious that the composites
plastics with the addition of 10% TiO2 give more Rockwell Hardness strength
than the pure plastics composites due to the presence of hardest materials
Titanium. So the utilization of plastics incorporated TiO2 is possible and it is
recyclable.

49
 CHAPTER 5
CONCLUSION
Plastics were recycled and new composites were fabricated. Few
investigations were made and following conclusions were obtained.
 From the Figure 4.2 and Table 4.1, it is obvious that the composites
plastics with the addition of 10% TiO2 give more tensile strength
(138.31Kgf/cm2) than the pure plastics composites due to the presence
of hardest materials Titanium. So the utilization of plastics incorporated
TiO2 is possible and it is recyclable.
 From the Figure 4.4 and Table 4.2, it is obvious that the composites
plastics with the addition of 10% TiO2 give more Flexural strength
(510.56Kgf/cm2) than the pure plastics composites due to the presence
of hardest materials Titanium. So the utilization of plastics incorporated
TiO2 is possible and it is recyclable.
 From the Figure 4.6 and Table 4.3, it is obvious that the composites
plastics with the addition of 10% TiO2 give more impact strength
(57.5J) than the pure plastics composites due to the presence of hardest
materials Titanium. So the utilization of plastics incorporated TiO2 is
possible and it is recyclable.
 From the Figure 4.8 and Table 4.4, it is obvious that the composites
plastics with the addition of 10% TiO2 give more Brinell
hardnessstrength (144HBW)than the pure plastics composites due to the
presence of hardest materials Titanium. So the utilization of plastics
incorporated TiO2 is possible and it is recyclable.
 From the Figure 4.9 and Table 4.5, it is obvious that the composites
plastics with the addition of 10% TiO2 give more Rockwell hardness
strength (72HRB)than the pure plastics composites due to the presence
of hardest materials Titanium. So the utilization of plastics incorporated
TiO2 is possible and it is recyclable.
50
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