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Improvement of a Plastic Fiber Production Machine

Thesis · March 2022

DOI: 10.13140/RG.2.2.23108.09607

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Improvement of a Plastic Fiber Production Machine
 Improvement of a Plastic Fiber Production Machine

Submitted by

MD. IMRAN HOSEN JOY MD. SAMS AZIZ

Student ID: 18107029 Student ID: 18107113
Program: BSME Program: BSME

This Thesis is Submitted in Partial Fulfillment of the Requirements for the

Degree of Bachelor of Science in Mechanical Engineering

Department of Mechanical Engineering IUBAT—International

University of Business Agriculture and Technology

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 ACKNOWLEDGEMENT

First of all, praise is due to almighty ALLAH with his compassion and mercifulness to allow
us finalizing this undergraduate thesis. We express sincerest gratitude to our supervisor, Dr.
A.K.M Parvej Iqbal, Associate Professor & Coordinator, Department of Mechanical
Engineering, IUBAT, who has supported us throughout our thesis with his patience and
knowledge. We attribute the level of our Bachelor degree to his encouragement and effort and
without him this thesis would not have been completed and written.

Our special thanks to all the lab assistants of IUBAT who participated in maintenance related
to experimental setup. We are grateful to IUBAT for funding. It would not be possible to
complete this thesis without the financial co-operation of this organization. Finally, we thank
our parents for supporting us throughout all our studies at university. We are also grateful to
our friends for inspiring us in different stages of the thesis work.

The Authors,

Department of Mechanical Engineering,

IUBAT - International University of Business and Agriculture Technology.
Uttara model town, Sector: 10, Dhaka-1230, Bangladesh.
February, 2022.

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 ABSTRACT

This study has been carried out to effectively manage and recycle PET plastic bottles by
identifying practical means and introducing recycling as a cleaner production tool to achieve
sustainable development goals. We have designed and analyzed a PET bottle recycling machine
that turns PET flakes, pellets, granules into the synthetic fiber. PET bottle is a thermoplastic resin
so it can be melted and reshaped repeatedly. Utilizing the plastic extrusion process with our
recycling machine we can melt PET bottle flakes and then air is blown using an air compressor
turning that molten plastic into the continual synthetic fiber. In present years the consumption and
disposal of polyethylene terephthalate (PET) have increased greatly in Bangladesh. After use, PET
products should be disposed of in selective waste collection in order to recycle and reinsert the
plastic into the production chain. We have found out with the abundance of plastic bottles and
PET product waste we can make synthetic fiber at a very cheap price. Compering with the
imported fiber or felt, flock our synthetic fiber costs less than half of the price. This fiber can be
used primarily as a packaging material or stuffing material. It can also be processed at a spinning
mill to turn it into polyester yarn and then into polyester thread. As recycling PET bottle has
commercial value, employment and income can be generated as a result it will help the economy
of our country.

Keywords:

PET recycling: Extrusion, Synthetic fiber, PET bottle, r-pet, plastic recycling, plastic extrusion

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 TABLE OF CONTENTS

ACKNOWLEDGEMENT ....................................................................................................... v
ABSTRACT ............................................................................................................................vii
TABLE OF CONTENTS .....................................................................................................viii
LIST OF FIGURES ................................................................................................................. x
LIST OF TABLES .................................................................................................................. xi
LIST OF SYMBOLS AND ABBREVIATION...................................................................xii
CHAPTER 1: INTRODUCTION ......................................................................................... 13
1.1 Research Background .................................................................................................. 13
1.2 Problem Statement ....................................................................................................... 14
1.3 Problem analysis in Machine…………………………………………………………20
1.4 Objectives…………………………………………………………………..…………21
1.5 Organization of the Report……………………………………………………….….21
CHAPTER 2: LITERATURE REVIEW:……………………………..……………….…22
2.1 Plastic industry in Bangladesh………………………………………………………...24
2.2 PET Recycling methods…………………………………………………………….….24
CHAPTER 3: METHODOLOGY………………………………………………………....25
3.1 Introduction of Extrusion Process…………………………………………………..25
3.1.1 Ram Extrusion……………………………………………………………….…..26
3.1.2 Screw Extrusion……………………………………………………………….…27
3.2 Types of Extrusion Process…………………………………………………………..27
3.2.1 Sheet/Film Extrusion……………………………………………………………..27
3.2.2 Blown Film Extrusion……………………………………………………………27
3.2.3 Over-Jacketing Extrusion………………………………………………………..28
3.2.4 Co-extrusion………………………………………………………………………29
3.2.5 Extrusion Coating……………………………………………………………….29
3.3 Materials Used…………………………………………………………………….….30
3.3.1 Symbols of plastics……………………………………………………………….31
3.3.2 Properties of Polyethylene terephthalate (PET)……………………………….31
3.4 Design of Machine…………………………………………………………………….32
3.4.1 Schematic diagram of Machine………………………………………………….33
3.4.2 Screw Shaft Design………………………………………………………………34
3.4.3 Hopper…………………………………………………………………………….36
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 3.4.4 Pipe Barrel………………………………………………………………………..36
3.4.5 Induction Motor…………………………………………………………………36
3.4.6 Mica Band Heater…….…………………………………………………………37
3.4.7 Temperature Controller…………………………………………………………37
3.4.8 Thermocouple…………………………………………………………………….38
3.4.9 V-Belt and Pulley arrangement………………………………………………..39
3.4.10 Gear train arrangement………………………………………………………..39
3.4.11 Heating coal inside the air heater barrel………………………………………40
3.4.12 Hot Air Blower………………………………………………………………….40
3.4.13 Thermal Insulation Tube………………………………………………………41
3.5 Working principal………………………………………………………………..42
CHAPTER 4: DATA COLLECTION AND CALCULATION………………………….45
4.1 Calculation of Current consumption…………………………………………….45
4.1.1 Electricity consumption of Induction Motor…………………………………....45
4.1.2 Electricity consumption of Barrel Heater……………………………………...46
4.1.3 Hot Air Blower……………………………………………………………………47
4.1.4 Thermal Insulation……………………………………………………………….47
4.1.5 Gear train …………………………………………………………………………48
4.1.6 Shaft expected life………………………………………………………………...48
4.2 Calculation of cost of fiber………………………………………………………...…49
4.3 Result Analysis………………………………………………………...………………50
CHAPTER 5: CONCLUSION……………………………………………………………...58
REFERENCES………………………………………………………………………………59

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 LIST OF FIGURES

Fig 1. 1: Global PET bottle production .................................................................................... 15

Fig 1. 2: Effect of plastic pollution on animals ........................................................................ 16
Fig 1. 3: Global plastic production........................................................................................... 16

Fig 3. 1: Blown film extrusion ................................................................................................. 28

Fig 3.2: Over Jacketing extrusion…………………………………………………………….28
Fig 3.3: Co-extrusion…………………………………………………………………………29
Fig 3.4: Extrusion coating…………………………………………………………………….30
Fig 3.5: Material used…………………………………………………………………………30
Fig 3. 6: Symbol for recyclable plastic container .................................................................... 31
Fig 3. 7: Extrusion Machine..................................................................................................... 33
Fig 3. 8: Actual Image of Machine .......................................................................................... 33
Fig 3. 9: Screw Shaft ................................................................................................................ 34
Fig 3.10: Dimension of hopper ................................................................................................ 36
Fig 3.11: Mica band heater ...................................................................................................... 37
Fig 3. 12: J type thermocouple ................................................................................................. 38
Fig: 3.13: Gear train…………………………………………………………………………..39
Fig 3.14: Hot Air Blower……………………………………………………………………...40
Fig 3.15: Thermal Insulation Tube……………………………………………………………41
Fig 3.16: Flow chart for PET extrusion ................................................................................... 42
Fig 3. 17: Extrusion process..................................................................................................... 44

Fig 4. 1: Flakes input vs Fiber Output before………………………………………………...50

Fig 4.2: Flaks input vs Fiber output after……………………………………………………..50
Fig 4. 3: Fiber Output vs Power Consumption before………………………………………..51
Fig 4.4: Fiber output vs power consumption after……………………………………………51
Fig 4.5 : Shaft expected life after improving shaft design……………………………………52
Fig 4.6: Torque analysis compraison between V-belt pully and the gear train………………. ..53
Fig 4.7: Price point of imported and recycled fiber before……………………………………54
Fig 4.8: Price point of imported and recycled fiber after……………………………………...54
Fig 4. 9: Result analysis before and after insulation………………………………………… ..55
Fig 4.10: Result analysis fiber difference before and after improvement…………..………… 56

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 LIST OF TABLES

Table 3. 1: Properties of PET………………………………………………………………...32

Table 3. 2: Dimension of helical screw shaft…………………………………………………35
Table 3. 3: Specification of Induction Motor…………………………………………………36
Table 3. 4: Specification of Induction Motor before………………………………………….37
Table 3. 4: Specification of Induction Motor after…………………………………………….38

Table 4. 1: Total Electricity Consumed per hour……………………………………………...49

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 LIST OF SYMBOLS AND ABBREVIATION

R-PET= Recycling Polyethylene Terephthalate

PET = Polyethylene Terephthalate
PP= Polypropylene
V = Voltage
R = Resistance
I = Ampere
R.P.M = Revolutions per Minute
KWh= Kilo Watt per Hour

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 CHAPTER 1: INTRODUCTION

1.1 Research Background

Polyethylene terephthalate (PET) is a versatile material and has a broad range of applications

such as food packaging, plastic bottle, beverage bottles, clothing, sportswear, agricultural

equipment’s, nonwovens, sheets and films, straps, resins, packaging materials, reinforcement

in building construction etc. Among these products, bottle grade PET is generally used for

water and beverage packaging due to its lightweight, inexpensive price, resistance to

microorganisms, and light [1]. Bottles of water, soft drinks, and other beverages constitute 83–

84% of global PET resin requirement. Furthermore, the projected demand for PET packaging

materials is forecasted to reach 20 million tons by 2019 with an annual increase of 4.6% [2].

There are two main types of plastics including thermoplastics and thermosets. Thermoplastics

are the plastic materials that can be formed into other products by re-melting or reprocessing

into different shapes by the application of heat and pressure. These are easily recyclable into

other products. These thermoplastics include polyethylene terephthalate (PET), polyethylene,

low and high density (LDPE, HDPE), polypropylene (PP), polyvinyl chloride (PVC),

polystyrene (PS) etc. Thermoset plastic includes components like alkyd, epoxy, ester,

melamine formaldehyde, polyurethane, etc. Which upon applying heat can’t be soften thus will

not allow the formation of different shapes. At present Bangladesh have a very small amount

of work going on about recycling of plastic. There are bulk amounts of plastic wastes and no

orderly process is present to recycle it. If there is a methodological way to recycle that waste

plastic and manufacture different kinds of products it will create more job opportunity and that

it can also help the economy of our country.

So, in this study we are implementing extrusion process to recycle PET bottle into synthetic

fiber as PET bottles are made of thermoplastic resin.

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1.2 Problem Statement

Since plastic is a non-biodegradable product and cannot be dumped in the ground, plastic

recycling is a very important issue in protecting the nature. Use of plastic is increasing and

plastic waste becoming a major obstacle to greener technology. Waste plastic is often the most

visible component in waste dump and landfill. Recent studies say to us that plastic bottle

remains for 450 years long on the earth and since plastic waste is growing rapidly hence the

improper disposal of plastics causes problems as distant as breast cancer, reproductive problems

in humans and animals, genital abnormalities and much more. Plastics wastes are found in

different forms which almost 5% of the municipal solid wastes which is toxic in nature.It is a

common sight in both urban and rural areas to find empty plastic bags and other type of plastic

packing material littering the roads as well as drains. If current trends continue, our oceans could

contain more plastic than fish by 2050.

While the United States, Japan and many European countries generate significant amounts of

plastic waste, they’re also relatively good at managing it. About half of all of the plastic waste

that ends up in the oceans comes from just five countries: China, Indonesia, the Philippines,

Thailand and Viet Nam. These countries are experiencing rapid economic growth, which is

reducing poverty rates and improving the quality of life for hundreds of millions of people. But

as these economies grow, consumption booms — and so does the use of plastic goods [3].

A million plastic bottles are bought around the world every minute and the number will jump

another 20% by 2021, creating an environmental crisis some campaigners predict will be as

serious as climate change. New figures obtained by the Guardian reveal the surge in usage of

plastic bottles, more than half a trillion of which will be sold annually by the end of the decade.

The demand, equivalent to about 20,000 bottles being bought every second, is driven by an

apparently insatiable desire for bottled water and the spread of a western, urbanized “on the go”

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culture to China and the Asia Pacific region. Most plastic bottles used for soft drinks and water

are made from polyethylene terephthalate (Pet), which is highly recyclable. But as their use

soars across the globe, efforts to collect and recycle the bottles to keep them from polluting the

oceans, are failing to keep up.

Fig 1. 1: Global PET bottle production

In the UK 38.5m plastic bottles are used every day – only just over half make it to recycling,

while more than 16m are put into landfill, burnt or leak into the environment and oceans each

day. “Plastic production is set to double in the next 20 years and quadruple by 2050 so the time

to act is now,” said Tag Holm. Animals like birds or fish can mistake plastic in the ocean for

food. In addition, because plastic can come in sizes large or small, even the smallest organisms

like plankton could be affected. When an animal consumes enough plastic, their digestive

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systems could get clogged up, eventually starving them to death. Sometimes, the uneven shape

of plastic pieces could even choke animals, like sea turtles, to death.

Fig 1. 2: Effect of plastic pollution on animals

Fig 1. 3: Global plastic production

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 There has been growing concern about the impact of plastics pollution in oceans around the

world. Last month scientists found nearly 18 tons of plastic on one of the world’s most remote

islands, an uninhabited coral atoll in the South Pacific [4]. Production of Plastic Bottles

Requires Fossil Fuels. One big problem with plastic, of course, is that its production requires

the use of non-renewable fossil fuels. Plastic bottles are no exception to this. Most plastic

bottles are made from a plastic known as PET (polyethylene terephthalate), which is produced

using oil. Worse yet, the production of plastic bottles isn’t the only time when energy is wasted.

In fact, energy is used during the entire lifespan of a plastic bottle: This includes the energy

used for transportation, storage, and the final disposal of the bottle. Plastic bottles are not

biodegradable in order to fully understand what this means, it is important to understand the

difference between biodegrading and degrading.

Biodegrading is when an object gets broken down (digested) by living organisms. This means
that the object can be naturally recycled (by decomposers like bacteria and fungi) into new
organic molecules and new life.

On the other hand, degrading is just the process of breaking down into smaller pieces [4].

So, this paper will concern about, plastic wastes and how plastic waste can be recycled and
utilized.

1.3 Problem Analysis in the Machine

Every machines have the limitation. During analyzing of the machine, we found some limitations
of the machine. We figure out the limitations and work on it to higher the limitation limit to
increase the production capacity of the machine.
 The limitations are:
• Low Production Capacity & high electricity consume
• Vibration in the Machine
• Component of the Machine
• Heat Transfer loss
So, this paper will concern how to increase production capacity and how plastic waste can be
recycled and utilized.
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1.4 Objectives

1. To find out how to exploit PET bottle waste.

2. To find out how PET bottles can be sustained.
3. To pursue PET recycling situation in Bangladesh.
4. To rummage the sectors of Thermoplastic Extrusion.
5. To inquire different PET extrusion process.
6. To assess the need of Human commodities product in Bangladesh.

1.5 Organization of the Report

This thesis is organized with five chapters. First chapter is about research background, Problem

statement and objective of this study. In chapter 2, develop literature review is presented about

injurious effect of plastic pollution and how effectively we can sustain plastic bottle. Chapter

3 contains materials, design of machine and methods for this study with explicit experimental

setup. Chapter 4 includes experimental result, presented with data collection and analysis of

obtained results respectively. Conclusion of this research work is drawn. in chapter5, along

with potential possibilities for further research.

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 CHAPTER 2: LITERATURE REVIEW:

Economic and population growth and industrialization in the world together cause an increase

in the amount of plastic waste. Plastic pollution is the accumulation of plastic objects and

particles (example: plastic bottles, bags and microbeads) in the Earth's environment that

adversely affects wildlife, wildlife habitat, and humans. As a consequence of all these, while the

more intensive use of natural resources is inevitable, the plastic wastes created by the ever-

increasingconsumption tendency have reached the huge amounts that threaten the environment

and human health due to their quantity and harmful contents. For this purpose, plastic waste

policies should be developed and waste management studies should also be carried out,

especially in the field of recycling these plastic wastes, because of long decomposition time of

these wastes in the environment causing landfill and water logging problem. Waste

management system enables collection, categorization, reduction, recycling, and reuse of

plastic waste. At present, countries’ intensive efforts on waste management are striking.

Currently, there is an increasing focus on the importance of recycling and reuse in an effort to

save the environmentfrom the harmful substances that result from plastic waste disposal. Many

cities have created anew system for waste collection where recyclables go in one bin, non-

recyclables in another and food scraps go in a third. Also, in an effort to reduce the disposal of

plastic bottle in landfills the city of Toronto, for example, requested all retailers to charge

customers a fee for these bottles and have been encouraging retailers to use bottles made from

biodegradable material and customers to use reusable bottles. The thought of plastics first came

in the late 1950s and early 1960s. The idea of plastic recycling on the other hand began to take

shape in the 1990s in United States and elsewhere. At that time this process was run only to

destroy the plastic wastes. Between 1960 and 1970, the average person bought between 200

and 250 packaged drinks ever year, Elizabeth Royte reported in her book Bottle mania, citing

data fromthe Container Recycling Institute. Most of those purchases and involved refillable

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bottles. As of 2017, on a global scale a million plastic beverage bottles were purchased every

minute, according to data from Euromonitor International’s global packaging trends report,

published in 2017 by The Guardian. Today, plastic bottles and jars represent about 75 percent

of all plastic containers, by weight, according to the Plastics Industry Association. Now-a-days

many products are coming out of recycling plastic PET bottle. Once bottles have become trash,

entrepreneurs around the world are turning them into printer ink cartridges, fence posts, roofing

tiles, carpets, flooring, and boats, to name only a few items. Even houses have been constructed

from bottles. The latest is a three-story modern on the banks of the Meteghan River in Nova

Scotia, promoted as able to withstand a Category 5 hurricane. It only took 612,000 bottles.

Waste management, which has an important place among environmental protection policies,

should prevent the rapid depletion of natural resources and minimize the potential risks of the

wastes to the environment and human health [8]. With the widespread application of PET, large

quantities of PET waste were inevitably created. PET has no side effects on the human body

and does not pose a direct threat to the environment. On the other hand, it is regarded as a

harmful material because of its high volumetric fraction in the waste stream and high resistance

to atmospheric and biological agents . Due to poor biodegradation of PET bottle, it is difficult

to remove it from our environment. Beverage companies have pledged to use more recycled

bottles in manufacturing, a goal that aims to reduce the production of new resin and boosts

recycling numbers by adding value to bottle recovery. PepsiCo pledged to increase recycled

content in all its plastic packaging 25 percent by 2025. Nestle Waters vowed to make all of its

packaging recyclable by 2025 and increase recycled content in bottles to 35 percent by 2025

globally and to 50 percent in the United States, focusing on Poland Spring. Additionally,

recycled content for European brands will increase to 50 percent by 2025. Coca-Cola pledged

to recycle a used bottle or can for every one the company sells by 2030 and increase recycled

material in plastic bottles to 50 percent by 2030.

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For example, Brazilian team’s total outfit wearing T-shirts made from recycled plastics bottles

in the last world cup. There are two acceptable solutions; burning and recycling. Burning

method arises releasing toxic fumes into the atmosphere, causing environmental pollution and

health risks. As an acceptable solution, the recycling of PET bottles enables the conservation

of natural sources such as fossil fuels and energy, solving landfill problem, reducing

greenhouse gas emission, lowering carbon footprint, creating new business opportunities as

well as a contribution to the national economy. In addition, recycling processes are thebest way

to economically reduce PET waste. With both reduced energy costs and raw material costs,

recycling fiber production has become a form of production with a significant economic

advantage. PET flakes are obtained from PET bottle wastes after a series of procedures such as

sorting, washing, grinding, drying, etc. Most of the recycled PET flakes produced worldwide

are utilized for staple fiber applications in textile sector. Because of environmental reasons

initially, the recycling of PET bottles to textile fibers has now become commercially attractive.

Worldwide, approximately 7.5 million tons of PET were collected in 2011. This gave 5.9

million tons of flake. In 2009 3.4 million tons were used to produce fiber, 500,000 tons to

produce bottles, 500,000 tons to produce APET sheet for thermoforming, 200,000 tons to

produce strapping tape and 100,000 tons for miscellaneous applications . Petcore, the European

trade association that fosters the collection and recycling of PET, reported that in Europe alone,

1.6 million tons of PET bottles were collected in 2011 - more than 51% of all bottles. After

exported bales were taken into account,

1.12 million tons of PET flake were produced. 440,000 tons were used to produce fibers,

283,000 tons to produce more bottles, 278,000 tons to produce APET sheets, 102,000 tons for

strapping tape and 18,000 tons for miscellaneous applications. (Source: PCI for Petcore and

EuPR). In 2008 the amount of post-consumer PET bottles collected for recycling and sold in

the United States was approx. 1.45 billion pounds. In 2012, 81% of the PET bottles sold

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in Switzerland were recycled. In 2018, 90% of the PET bottles sold in Finland were recycled.

The high rate of recycling is mostly result of the deposit system in use. The law demands a tax

of 0.51 €/ for bottles and cans that are not part of a refund system. Thus, encouraged by the

law, products are included to have a 10¢ to 40¢ deposit that is paid to the recycler of the can or

bottle. Increasing prices may increase the volume of recycling PET bottles. In Europe, the EU

Waste Framework Directive mandates that by 2020 there shouldbe 50% recycling or reuse of

plastics from household streams . In the United States the recycling rate for PET packaging was

31.2% in 2013, according to a report from The National Association for PET Container

Resources (NAPCOR) and The Association of Postconsumer Plastic Recyclers (APR). A total

of 1,798 million pounds was collected and 475 million poundsof recycled PET used out of a

total of 5,764 million pounds of PET bottles. Furthermore, as petroleum prices increase,

recycling of PET becomes more financially feasible rather than avirgin PET. It is expected that

the recycling of the PET bottle will be estimated up to annually13 million tons in 2018 and up

to 15 million tons in 2021. The plastic industry in Bangladesh is relatively new compared with

the textile and leather industries. The plastic industry began its journey as a small industry in

1960. The plastic industry in Bangladesh usesimported polymer granules. During the period

1989 to 2007, the import of polymers increasedfrom 10,000 tons to 289,000 tons per year. At

present total consumption of polymers including imported polymers and recycled plastic wastes

is 750,000 tons in 2010-2011. Thiscorresponds to the per capita consumption of plastics in

Bangladesh 5kg per year against the world average 30kg. Per capita consumption in India and

ASEAN countries are 8kg and 17kgrespectively. There are about 3000 manufacturing units in

the plastic sector of which 98% belongs to the Small and Medium Enterprises (SMEs). The

plastic sector contributes 1.0percentof GDP and provides employment for half a million people.

The PET recycling technologyhas been developed better and better across the world. There are

mainly two methods: chemical

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recovery and physical recovery. Compared with the method of chemical recovery, the physical

recovery has made less secondary pollution on the environment. It is easier to implement the

process and start large-scale industrial production. Thus, the method of physical recovery has

been widely applied. In thermoplastics, processing techniques can be classified into either batch

or continuous process. Batch process includes injection molding and roto-molding. Extrusion

of plastics is a continuous process. However, blow molding is available both in batch and

continuous process. Extrusion process is the most commonly used process in the world and

accounts for ~60% of total consumption by downstream plastic processing industries.Injection

molding is the other popular process accounting for ~25% of the consumption. Blow molding is

used for ~5% while Roto molding 1% while the rest of the plastic is processed through other

processes . At present, many developed countries, such as the United States,Japan and Germany,

have made much research on the high-quality precision extrusion recycling technologies like

the automatic sorting technology, efficient cleaning and melting equipment, developing "bottle

to bottle" technique, and made a great achievement. In 2007, the German Battenfeld Extrusion

Technic company developed a new PET single-screw extrusion system. The extruder was

equipped with specially developed planetary geared degassing parts which can be directly

processed without drying materials. The productivity of the system is 800- 1000kg/h . China is

very good at making high-capacity recycling machines like Palletizing Machine, High speed

Single Screw Extruder, Twin Screw Extruder etc. China once bought about 45 percent of the

world’s plastic waste. In 2017, the government started to cut way back on plastic trash imports.

Then the big bombshell: In January 2018, it banned almost all imports. Last year, China took

in less than 1 percent of its 2016 total. That means a huge amount of plastic is looking for a

place to go. So, with rapidly growing textile industry in Bangladesh, recycling plastic bottle into

synthetic fiber is very viable.

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2.1 Plastic Industry in Bangladesh
The plastic industry in Bangladesh is relatively new compared with the textile and leather

industries. The plastic industry began its journey as a small industry in 1960. The plastic industry

in Bangladesh uses imported polymer granules. During the period 1989 to 2007, the import of

polymers increased from 10,000 tons to 289,000 tons per year. At present total consumption of

polymers including imported polymers and recycled plastic wastes is 750,000 tons in 2010-2011.

This corresponds to the per capita consumption of plastics in Bangladesh 5kg per year against the

world average 30kg. Per capita consumption in India and ASEAN countries are 8kg and 17kg

respectively. There are about 3000 manufacturing units in the plastic sector of which 98% belong

to the Small and Medium Enterprises (SMEs). The plastic sector contributes 1.0percent of GDP

and provides employment for half a million people [17].

2.2 PET Recycling Methods

PET recycling technology has been developed better and better across the world. There are mainly
two methods: chemical recovery and physical recovery. Compared with the method of chemical
recovery, physical recovery has made less secondary pollution on the environment. It is easier to
implement the process and start large-scale industrial production. Thus, the method of physical
recovery has been widely applied. In thermoplastics, processing techniques can be classified into
either batch or continuous process. Batch process includes injection molding and roto - molding.
Extrusion of plastics is a continuous process. However, blow molding is available both in batch
and continuous process. Extrusion process is the most commonly used process in the world and
accounts for ~60% of total consumption by downstream plastic processing industries. Injection
molding is the other popular process accounting for ~25% of the consumption. Blow molding is
used for ~5% while Roto molding 1% while the rest of the plastic is processed through other
processes [18].

24
 CHAPTER 3: METHODOLOGY

3.1 Introduction of Extrusion Process

Plastic extrusion is a manufacturing process in which raw plastic is melted and formed into a

continual shape. By feeding plastic material (pellets, granules, flakes) from a hopper into the

barrel of the extruder the process can be started. A cylindrical rotating screw shaft is placed

inside the barrel which forces out molten plastic through a die in our case we blow the molten

plastic with air to make continual fiber. The extruded material takes shape according to the

cross-section of die. The material is gradually melted by the mechanical energy generated by

turning helical screw shaft and by heaters arranged along the barrel. The molten polymer is

then forced into a die, which shapes the polymer into a shape that hardens during cooling. There

are two types of plastic extrusion:

1. Ram Extrusion.

2. Screw Extrusion.

3.1.1 Ram Extrusion

A ram extruder is an extruder where, instead of extrusion screw, a ram or plunger is used and

a plunger goes through a barrel and pushes out the material under pressure. The ram extruder

was the earliest extruder to be used in the plastics industry. This typical process is applied for

producing profiles, sleeves, rod, block, tubing, lining sheet bars, etc. The ram extrusion process

is very effective for specific materials like PTFE which are not extruded successfully using

screw extruder because of its low friction. In this process plastic material in powder form is

gravity fed into a chamber. In the extraditing chamber the resin powder is heated on sintering

temperature. Ultra-high molecular weight polyethylene becomes gelatinous as it melts so it can

be extruded with this type of processes. A hydraulic ram pushes the resin materials like PTFE,

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UHMW, etc. from the chamber to the die. The die actually gives the shape of the desired plastic

like a rod, tube or a profile shape with the requisite internal or outer diameter. When the

material comes out of the die, it moves the length of the conveyor. The profiles can be

manufactured endlessly and cut by the continuous extruding of each length.

3.1.2 Screw Extrusion

Screw extrusion involves a helical feed screw that turns inside a barrel. This is often called the

feed screw or the extruder screw. The screw is a single shaft with helical flights. Sometimes,

when more thorough mixing is needed, two screws are used. The constantly turning screw

moves the resin through the heated barrel where it is heated to proper temperature and blended

into a homogeneous melt. Extrusion screw design has been improving over the years, with new

innovations and ideas. Nowadays, single screws are available that have a secondary flights that

improve speed by enabling faster melting. This process of extrusion serves two functions: it

heats the plastic material above its melting point and puts the melt under pressure. The molten

plastic material can then be forced through an orifice, commonly known as the die. This process

is common to all types of extrusion. Most screws have these three zones, Feed zone (also called

the solids conveying zone): this zone feeds the resin into the extruder, and the channel depth is

usually the same throughout the zone. Melting zone (also called the transition or compression

zone): most of the polymer is melted in this section, and the channel depth gets progressively

smaller. Metering zone (also called the melt conveying zone): this zone melts the last particles

and mixes to a uniform temperature and composition. Like the feed zone, the channel depth is

constant throughout this zone. A great advantage of extrusion is that profiles such as pipes can

be made to any length. If the material is sufficiently flexible, pipes can be made at long lengths

even coiling on a reel. Another advantage is the extrusion of pipes with integrated coupler

including rubber seal.

26
3.2 Types of Extrusion Process

The extrusion process is broadly classified into seven different types depending upon the

specific applications.

3.2.1 Sheet/Film Extrusion

In this extrusion process, the molten plastic material is extruded through a flat die. The cooling

rolls are used to determine the thickness of sheet/film and its surface texture. The thickness of

sheet can be obtained in the range of 0.2 to 15 mm. The thin flat sheet or film of plastic material

can be made. Generally, polystyrene plastic is used as a raw material in the sheet extrusion

process.

3.2.2 Blown Film Extrusion

In the blown film process, the die is like a vertical cylinder with a circular profile. The molten

plastic is pulled upwards from the die by a pair of nip rollers. The compressed air is used to

inflating the tube. Around the die, an air-ring is fitted. The purpose of an air-ring is to cool the

film as it travels upwards. In the center of the die, there is an air inlet from which compressed

air can be forced into the center of the circular profile, and creating a bubble. The extruded

circular cross section may be increased 2-3 times of the die diameter. The bubbles are collapsed

with the help of collapsing plate. The nip rolls flatten the bubble into double layer of film which

is called lay flat. The wall thickness of the film can be controlled by changing the speed of the

nip rollers. The lay flat can be spooled in the form of roll or cut into desired shapes. Bottom

side of the lay flat is sealed with the application of heat, and cut across further up to form

opening; hence it can be used to make a plastic bag. The die diameter may vary from 1 to 300

centimeters. Generally, polyurethane plastic is used in this process.

27
 Fig 3. 1: Blown film extrusion

3.2.3 Over-Jacketing Extrusion

This is also called wire coating process. In this process, a bare wire is pulled through the center

of a die. There are two different types of extrusion tooling used for coating over a wire i.e.

pressure or jacketing tooling as shown in figure 3. If intimate contact or adhesion is required

between the wire and coating, pressure tooling is used. If adhesion is not desired, jacketing

tooling is used. For pressure tooling, the wire is retracted inside the die, where it comes in

contact with the molten plastic at a much higher pressure. For jacketing tooling, the wire will

extend and molten plastic will make a cover on the wire after die. The bare wire is fed through

the die and it does not come in direct contact with the molten plastic until it leaves the die. The

main difference between the jacketing and pressure tooling is the position of the wire with

respect to the die.

In this process, the molten plastic is extruded through a die and hollow cross sections are

formed by placing a mandrel inside the die. Tube with multiple holes can also be made for

specific applications, by placing a number of mandrels in the center of the die.

Fig 3. 2: Over-Jacketing Extrusion

28
3.2.4 Co-extrusion

Co-extrusion is the extrusion process of making multiple layers of material simultaneously. It

is used to apply one or more layers on top of base material to obtain specific properties such as

ultraviolet absorption, grip, matte surface, and energy reflection, while base material is more

suitable for other applications, e.g. impact resistance and structural performance. It may be

used on any of the processes such as blown film, over jacketing, tubing, sheet/film extrusion.

In this process, two or more extruders are used to deliver materials which are combined into a

single die that extrudes the materials in the desired shape. The layer thickness is controlled by

the speed and size of the individual extruders delivering the materials.

Fig 3.3 : Co-extrusion

3.2.5 Extrusion Coating

Extrusion coating is used to make an additional layer onto an existing roll stock of paper, foil

or film. For example, to improve the water resistant of paper polyethylene coating is used. The

applications of extrusion coating are liquid packaging, photographic paper, envelopes, sacks

lining for fertilizers packaging and medical packaging. Generally, polyethylene and

polypropylene are used.

29
 Fig 3.4 :Extrusion coating

3.3 Materials Used

The different types of plastic materials that can be used in extrusion process are Polyethylene

terephthalate (PET), Polypropylene (PP), Acetal, Acrylic, Nylon (Polyamides), Polystyrene,

Polyvinyl Chloride (PVC), Acrylonitrile Butadiene Styrene (ABS) and Polycarbonate.

Fig 3.5 : Material Used

30
3.3.1 Symbols of plastics

There are many kinds of plastics. Some of them are recyclable and some of them are not

properly recyclable. So, when someone knows about the symbol and the number which is on

the products in every item s/he can keep that plastic in right place.

Fig 3. 6: Symbol for recyclable plastic container

3.3.2 Properties of Polyethylene terephthalate (PET)

Polyethylene terephthalate (sometimes written poly (ethylene 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 fibers for clothing, containers for liquids

and foods, thermoforming for manufacturing, and in combination with glass fiber for

engineering resins.

31
 Table 3. 1: Properties of PET

IUPAC Name Poly(ethyl benzene-1,4-dicarboxylate)

Chemical formula (C10H8O4)n

Solubility in water Practically insoluble

Melting point > 250 °C; 482 °F; 523 K

Boiling point > 350 °C; 662 °F; 623 K

3.4Design of Machine

Our extrusion machine has single screw shaft design with Different parts of Machine is

listed below-

1. Screw Shaft Design

2. Hopper

3. Barrel

4. Induction Motor

5. Mica Band Heater

6. Heat Controller

7. Thermocouples

8. Gear Train Arrangement

9. Hot Air blower

10. Thermal Insulation Tube

11. Heating coal

32
3.4.1 Schematic diagram of Machine

Fig 3. 7: Extrusion Machine

Fig 3. 8: Actual Image of Machine

33
 3.4.2 Screw Shaft Design:

The design of screw is important for plastic processing. It has mainly three different functions

namely, feeding mechanism; uniform melting and mixing of plastic and finally it generates the

pressure to push the molten material through die. A screw length (L) is referenced to its

diameter (D) as L/D ratio. Generally, L/D ratio is used as 24:1, but for more mixing and output,

it may increase up to 32:1. The Screw is made of mild steel. There are three possible zones in

a screw length i.e. feed zone, melting zone, and metering zone.

(a) Feed zone: In this zone, the resin is inserted from hopper into the barrel, and the channel

depth is constant.

(b) Melting zone: The plastic material is melted and the channel depth gets progressively

smaller. It is also called the transition or compression zone.

(c) Metering zone: The molten plastic is mixed at uniform temperature and pressure and

forwarded through the die. The channel depth is constant throughout this zone.

Fig 3. 9: Screw Shaft

34
 In addition, a vented (two-stage) screw has:

(a) Decompression zone: In this zone, about two-thirds down the screw, the channel

suddenly gets deeper, which relieves the pressure and allows any trapped gases (moisture, air,

solvents, or reactants) to be drawn out by vacuum.

(b) Second metering zone: This zone is similar to the first metering zone, but with greater

channel depth. It serves to re-pressurize the melt to get it through the resistance of the screens

and the die.

Each zone is equipped with one or more thermocouples in the barrel wall for temperature

control. The "temperature profile" i.e., the temperature of each zone is very important to the

quality and characteristics of the final product.

Table 3. 2: Dimension of helical screw shaft

Previous Dimension New Dimension

Length 2 feet Length 2 feet

Major Diameter 1.5 inch Major Diameter 4 inch

Minor Diameter 1 to 1.4 inch Minor Diameter 3 to 0.5 inch

Pitch 0.4 inch Pitch 1.5 inch

Helix Angle 15° to 25° Helix Angle 20° to 30°

Depth 0.5 to 0.1 inch Depth 2.5 to 0.1 inch

Pulley Diameter 10 inch Pulley Diameter 14 inch

r.p.m 110 r.p.m 100

AISI NO 1060-HR AISI NO 1095-HR

35
 3.4.3 Hopper

Our hopper is a pyramidal shaped device used to feed plastic flakes into the screw shaft.

Fig 3. 10: Dimension of hopper

3.4.4 Pipe Barrel

Barrel houses the screw shaft. The helical screw shaft rotates inside the barrel. The barrel is

made of Mild Steel. Has a length of 22.5 inch.

3.4.5 Induction Motor

The machine uses an induction motor or an AC electric motor in which the electric current in

the rotor needed to produce torque is obtained by electromagnetic induction from the

magnetic field of the stator winding. It is used to rotate the screw shaft that is housed in pipe

barrel.

Table 3. 3: Specification of Induction Motor

Voltage 220 volt

Ampere 4.25 amp

R.p.m 1400

Power 0.935 kW

36
 3.4.6 Mica Band Heater

The Mica band heater is an electrical device that converts an electric current into heat energy.

There is three circular band heaters placed around the pipe barrel. The diameter of the heater

is 2.5 inch and length are 2.8 inch. The resistance of three heater wire is 144 Ω, 136 Ω, 136 Ω

accordingly.

Fig 3. 11: Mica band heater

3.4.7 Temperature Controller

It is widely used for measuring temperature and auto control temperature in different

machinery. We are using one temperature controller for three circular band heaters.

Table 3. 4: Specification of Induction Motor Before

Input signal K type thermocouple

Power supply 110v or 220v

Sensitivity range 50º C to 400º C

Output Relay

37
 Input signal J type thermocouple

Power supply 110v or 220v

Sensitivity range -346º C to 1260º C

Output Relay

Table 3. 5: Specification of Induction Motor After

3.4.8 Thermocouple

A thermocouple produces a temperature-dependent voltage which results in thermoelectric

effect, and this voltage can be used to measure temperature. Thermocouples are a widely used

temperature sensor. We are using J type thermocouple. It has sensitivity range of -346º C to

+1260º C.

Fig 3. 12: J type thermocouple

38
 3.4.9 V-Belt and Pulley arrangement

The belt and pulley arrangement are used to transmit the rotation from motor to helical screw

shaft. We have used two v-belt and three pulleys. The motor pulley has a diameter of 3 inch

and the other two has 12 inch and 10 inches accordingly. The arrangement is made in a way

that it reduces the motor’s 1400 r.m.p into 110 rpm in the screw shaft.

3.4.10 Now we are using Gear Train Arrangement

Gear Ratio- 4:1

Fig 3.13: Gear Train

• We analysis the issue of the belt pulley arrangement. Here is the slip issue of the belt pulley

system.

• So that, if we use gear set arrangement instead of belt pulley there is no chance to slip.

• Another issue of belt pulley is, when we put flex continuously in the hoper it get jam in

the screw shaft.

• So that gear set arrangement is more efficient to increase the production capacity.

39
 3.4.11Heating Coals Inside the Air Heater Barrel

Heating coal and barrel are combinedly used to heat up the air. Heating coal has a

regulating system to control the heating capacity. Air heater coal inside the barrel heats up

the air and gives an air bubble through which the hot molten material is getting through

and gradually the temperature of the expanded synthetic fiber.

3.4.12 Hot Air Blower

Fig 3.14: Hot Air Blower

An air blower is a useful tool that has many domestic and commercial applications. It is a piece
equipment or device that increases the velocity of air when the air is passed through equipped impellers.
You will commonly see these tools used in the manufacturing process, including exhausting, aspirating,
cooling, ventilating, and conveying. They can also be used for any application that requires a controlled
focus of air, whether that application is small or large.

While an air blower is a great tool, it is essential to be aware that there are a few different types

available, and it’s important to learn the difference so that you can find the best type for your

needs. Below, you’ll learn more about the different types available for your consideration.

40
3.4.13 Thermal Insulation Tube

All thermal insulation materials work on a single

basic principle: heat moves from warmer to
colder areas. Therefore, on cold days, heat from
inside a building seeks to get outside. And on
warmer days, the heat from outside the building
seeks to get inside. Insulation is the material
which slows this process. Rigid phenolic, rigid
urethane and extruded polystyrene insulation
materials have tiny pockets of trapped gas. These
Fig 3.15 : Thermal Insulation tube
pockets resist the transfer of heat. They will not
stop the loss or gain of heat completely.

Before dealing with the principles of insulation it is necessary to have an understanding of the
mechanism of heat transfer. When a hot surface is surrounded by an area that is colder, heat
will be transferred and the process will continue until both are at the same

temperature. The heat transfer takes place by one or more of three methods: - conduction,
convection and radiation.

41
3.5 Working principle

Before actual extrusion process can take place, the PET bottle is need to be processed for

extrusion. Flow chart of the process is given below

Fig 3. 16: Flow chart for PET extrusion

WASTE PET BOTTLES → SORTING → SHREDDING TO FLAKES → HOT WASHING

→ VACUUM DRYING → EXTRUSION

There are mostly three important steps to be considered before extrusion process:

• Melting temperature of plastic

• Speed of the screw

• Extrusion pressure required

In extrusion process, plastic in the form of pellets or granules is gravity fed from the hopper

into the barrel. The plastic material enters through the feed throat and comes into contact
42
with the rotating screw, rotating in 110 rpm. The rotating screw pushes the plastic pellets

forward into the barrel. The barrel is heated using the circular band heater up to the melting

temperature of the plastic, which is 260º C. There are three zones in a rotating screw shaft

which are feed zone, melting zone, and metering zone. In the feed zone, the plastic pellets

43
melt gradually as they are pushed through the barrel. In the melting zone plastic pellets are

completely melted. A thermocouple is used to maintain the temperature of the mild steel barrel.

The overheating of plastics should be minimized which may cause degradation in the plastic

properties. At the front of the barrel, the molten plastic leaves the screw shaft and then it is blown

with the help of air compressor to make the continual synthetic fiber.

Extrusion process

Fig 3. 17: Extrusion process

44
 CHAPTER 4: DATA COLLECTION AND CALCULATION

4.1 Calculation of Current consumption

1. Induction Motor
2. Three Barrel Heater
3. Hot Air Blower
4. Thermal Insulation
5. Gear Train
6. Shaft Expected life

4.1.1 Electricity consumption of Induction Motor

From motor specification list we get,

Voltage – 220 v

Current – 4.25 amp

So, Power = V × I =220×4.25 = 935 watt

= (935÷1000) kW

= 0.935 kW

Electricity Consumption = Power × time

= (0.935 × 1) kW h

= 0.935 kW h

45
 4.1.2 Electricity consumption of Barrel Heater
As we have three-barrel heater, measuring heater resistance and ampere with the help of

multimeter we get,

R1 = 144 Ω, I1 = 0.67 amp

R2 = 136 Ω, I2 = 0.56 amp

R3 = 136 Ω, I3 = 0.56 amp

R4= 144 Ω, I1 = 0.67 amp

So, Voltage = I × R

So, V1 = 96.48 v , V2 = 76.16 v , V3 = 76.16 v

Again, Power = V × I

Power consumption of barrel heater B1, B2, B3, B4 is 64.641 watt , 64.641 watt , 42.649

watt, 42.649 wattaccordingly.

So, electricity consumption of barrel heater B1, B2, B3, B4 is 0.65 kW h , 0.65 KW h 0.43 kW

h, 0.43 kWh accordingly.

46
 4.1.3 Hot Air Blower

From Hot Air Blower specification list, we get,

Power – 0.20 kW

Voltage – 220 v

Electricity Consumption = Power × time

= (0.20 × 1) kW h

= 0.20 kW h

4.1.4 Thermal Insulation

r1= 0.019 m
r2= 0.037 m
For Sphere, R- Resistance Thermal Conductivity
K= 39.64 W2/K (Mild steel)
r2 – r1 0.037−0.019
R= = 4∗3.1416∗0.037∗0.019∗39.64
4𝜋 𝑟1 𝑟2 𝐾

= 0.1228 •C/W

Heat Transfer rate

Q = T2-T1/R = 350-4 / 0.1228 = 2817.58 W

47
4.1.5 Gear Train

Here,
tin=10, tout=40
t= Tooth
40 N= rotational speed (rpm)
Gear Ratio=10 =4:1 T= Torque

Nin=150 rpm, Tin=15 Nm

𝑁(𝑖𝑛) 15𝑂
Gear Ratio =𝑁(𝑜𝑢𝑡) = 4=𝑛(𝑜𝑢𝑡)

150
N (out) = =37.5rpm
4

Torque(out) = G.R * Tin = 4 * 15 = 60 N.m

4.1.6 Shaft Expected life

Sut= Tensile Strength = 830 ( AISI 1095- HR)

S’e = .5 *830 = 415 mpa [Sut<1400mpa]

For, Sut =830 mpa, Fatigue strength factor f= .82

a = (.82*830)2 / 415 = 1116.184

b = - 1/3 log (f * Sut /Se)

= -1/3 log (.82 * 830 / 415)
= -.0716

Shaft Expect Life N = ( 𝟑𝟖𝟓

𝒂
) 1/b
= ( 385/1116.184) (1/-.07160)
= 28.5* 105 Cycles

48
 Table 4. 1: Total Electricity Consumed per hour

Electrical Component Electricity Consumed (kW h)

Induction Motor 0.93

Barrel Heater, B1 0.65

Barrel Heater, B2 0.65

Barrel Heater, B3 0.43

Barrel Heater, B4 0.43

Heating Coal 0.25

Hot Air Blower 1

Total 4.35

4.2 Calculation of cost of fiber

Small industry electricity tariff per unit is 7.66/- taka

So, electricity cost per hour to run the machine is = 4.35 × 7.66 = 33.32/- taka per hour
At present, our machine can produce up to 8 KG synthetic fiber per hour.
PET Flakes cost 30/- taka per kg.
Cost for making 8 KG synthetic fiber will be = 33.32+(30*8) = 273 taka
So, per unit production cost is 273/8 = 34.125 taka

As we can see, initially we are making synthetic fiber at a very cheap price excluding any

overhead cost. Compering to other synthetic fiber that we import; we can make our synthetic

fiber for half of the price. As we improve our machine and bulk production of synthetic fiber

will reduce the price furthermore.

49
 4.3 Result Analysis
Analysis Flakes input vs Fiber Output
1000
y = 0.936x
900

800
Fiber output in gramFiber

700

600

500

400

300

200

100

0
0 200 400 600 800 1000 1200
Flakes input gramFiber

Figure 4.1: Flakes input vs Fiber Output before

Flakes input vs Fiber Output After improvement

flakes input vs fiber output

1000 940
Fiber output in gramFiber

900
800
700
600
470
500
fiber output
400
Linear (fiber output)
300
200
94
100
0
0 200 400 600 800 1000 1200

Flakes input gramFiber

Figure 4.2: Flakes input vs Fiber Output after

Comment: Fiber out put incraese From 936 to 940 gram Per hour

50
 Analysis Fiber Output vs Power Consumption

2 1.836
1.8 y = 0.002x - 0.0063

1.6
Power Consumption in kW h

1.4

1.2

1 0.91

0.8

0.6

0.4
0.18
0.2

0
0 100 200 300 400 500 600 700 800 900 1000

Fiber output in gram

Figure 4.3: Fiber Output vs Power Consumption before

Fiber Output vs Power Consumption After improvement

Fiber Output vs Power Consumption

5
4.43
4.5
power consumption in kwh

4
3.5
3
2.5 2.15
2
1.5
1
0.43
0.5
0
0
0 200 400 600 800 1000 1200
Flakes output in gram

Figure 4.4: Fiber Output vs Power Consumption after

Comment: Power Consume less per hour than previous and get more Productivity

51
 Analysis Screw shaft Design effect

Expected life cycle after improvement 2859937.51

Expect life cycle before 670340.76

0 500000 1000000 1500000 2000000 2500000 3000000 3500000

Expect life cycle before Expected life cycle after improvement
Series 1 670340.76 2859937.51

NUMBER OF STRESS CYCLES, N

Figure 4.5: Shaft expected life after improving shaft design

Comment : After development the shaft expected life From Low cycle to High cycle (Finite
Life).

52
 Analysis Design Gear train effect

62

60

58

56
Torque N.m

54

52

50

48

46

44
V-belt pully Gear train

Figure 4.6: Torque analysis compraison between V-belt pully and the gear train

Comment:

• We analysis the issue of the belt pulley arrangement. Here is the slip issue of the belt
pulley system.
• So that, if we use gear set arrangement instead of belt pulley there is no chance to slip.
• Another issue of belt pulley is, when we put flex continuously in the hoper it get jam in
the screw shaft.
• So that gear set arrangement is more efficient to increase the production capacity.

53
 Price point of Imported and Recycled Fiber

Price Comparison
200
200 170
Price in Taka

150

100 50
50

0
Imported Fiber/Felt Recycle Fiber
Series 1 200 170 50
Catagory of Fibers

Imported Fiber/Felt Recycle Fiber

Figure 4.7 : Price point of Imported and Recycled Fiber Before

Price point of Imported and Recycled Fiber After improvement

Price Comparison
250

200
200
170
Price in Taka

150

100

50 34.12

0
Imported Fiber Recycle Fiber

Imported Fiber Recycle Fiber

Figure 4.8 : Price point of Imported and Recycled Fiber After

Comment: Price is significantly less then previous price of certain ammount.

54
 Result Analysis Before and after Insulation

7000
6202
6000

5000
Heat Transfer Rate

4000

3000 2817

2000

1000

Without insulation After Insulation

Figure 4.9: Result Analysis comparison Before and After Insulation

Comment: After thermal insulation heat transfer loss decrease which will improve the Productivity

55
 Fiber Difference Analysis

Figure 4.10: Result Analysis Fiber Difference before and after improvement

Change in Barrel effect

Previously they had used 3mm MS barrel, so that there is some heating issue due to poor
thickness.
We change the barrel with 6 mm MS barrel, so that heat remains same at hole barrel and avoid
the heat loss of the barrel.

Change in Band heater effect

There are two types of band heaters that Thermal Corporation sells: mica band heaters and
ceramic band heaters. There are strong points with each type, and the general differences are laid
out below:

• Temperature
• Heater life
• Watt density
• Insulation option

56
 Vibration in the Machine effect
• During our analysis we found a lot of unnecessary vibrations in the machine.

• It affects the production and decrease the longevity of the machine.

• So that, if we put damping bush rubber under the motor and also under the machine stand

it will damp the vibration and keep the smooth running.

From, above graphs and figures we can see the price of fiber production and comparison of

foreign fiber. At present, Bangladesh imports the felt, flock and synthetic fiber to fulfill the

countries demand. With huge amount of plastic waste already in our environment we can

collect and recycle PET bottle with ease. With the advantage of cheap raw material and labor,

small or medium enterprise can easily open up recycling plant. As we can produce synthetic

fiber for half of price compering to others. Operating a recycling plant will easy and profitable.

Our country has a rapidly growing textile industry. We can process this synthetic fiber to make

polyester yarn to meet the demand of our textile industry. So, we can see that our recycling

machine can help in achieving sustainable environment and also have economic value.

57
 CHAPTER 5: CONCLUSION

Population growth and rapid pace of urbanization pose several environmental challenges for

Bangladesh. One of the challenges is the waste management, and especially plastic waste

management. Mechanical sustainable of PET bottles is the most reposed reclamation path for

comparatively tidy plastic dissipation flow. It has been harmonized for modern wealthy

countries like Bangladesh, moreover, beneficial for cost savvy. Putting all the thrash together

process is the purpose to successfully sustain of PET bottles and plastic waste resources. It lies

on consumers that must become educated and motivated through designed community

educational program so that identification and collection of recyclables containers becomes a

routine activity. Result shows with the abundance of plasticbottle waste we can make synthetic

fiber in reasonable price which compering with the other goods commodities.

Currently expansion the operation of Air blown with the hot air blower which reduce the lack

of production and beneficial to get the Fiber output easy and steadfastly. By using the Thermal

insulation reduce the heat loss and become more productive. Added the Mica band heater, J

type thermos couple for better avail and enlarge the resource of Machine Design. Designing

Gear train to get better output torque and improvement the shaft to Expected High life cycle

shaft.

58
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