Design and Implementation of an Effective Screw Conveyor Machine for Improved Plastic Recycling Applications

Abstract

Existing conveyor systems struggle to handle varied plastic material properties, causing frequent jams and operational downtime. There is a need for a reliable screw conveyor machine that ensures smooth material flow, minimizes waste, and boosts recycling efficiency. This study outlines the development and implementation of a designed screw conveyor machine for efficient plastic recycling, featuring a 0.58m shaft length and powered by a 120W electric motor. The machine incorporates an A39 pulley (1.015m length, 0.0125m diameter) and a hexagonal bolt assembly with a 0.3302m length. A 2mm mild steel sheet was cut to the required size to form the screw conveyor hopper with a 0.0006m³ and the hopper seams were welded using the Oxy-acetylene technique. The screw conveyor unit features dual 1.2kW band heaters, totaling 2.4kW of heating power to ensure optimal plastic melting. The screw conveyor cylinder has a diameter of 0.12m. The hopper was further attached to the screw conveyor frame, ensuring proper alignment and secure attachment using the oxy-acetylene technique. A shaft and support were further attached to the screw conveyor with proper precision and alignment. A die was created at the end of the pipe to facilitate the easy flow of molten plastic using a machining process. A hand grinding machine was employed to smooth out rough edges or surfaces. Paint was further applied to prevent rust and corrosion. Performance results indicate a drive force of 11.88N, velocity of 0.042m/s, and a mass of molten plastic of 4.55kg. The screw conveyor capacity is 0.1912kg/s, demonstrating effective plastic processing capabilities. The developed machine offers improved material handling, reduced energy consumption, and enhanced recycling efficiency, contributing to sustainable plastic waste management practices.