Development of an Optimized Shredding System for Enhanced Plastic Recycling Efficiency

Abstract

Inefficient shredding processes and inadequate waste management practices lead to environmental hazards, increased waste volumes, and economic losses. Existing shredder machines often suffer from limitations such as high energy consumption, low throughput, and inadequate shredding quality, hindering effective waste reduction and recycling. There is a pressing need for the development of an efficient shredder machine that addresses these challenges, minimizes environmental impact, and optimizes waste processing for various industries. This research concentrated on creating an effective machine for shredding polyethylene terephthalate (PET) plastic. The approach taken includes choosing materials, performing design calculations, building the machine, and evaluating its performance. The machine’s construction used mild steel for the hopper unit, high carbon steel for the blade, chrome steel for the bearings, alloy steel for the shaft, a V-belt, and a 1.3055 kW geared electric motor. The results from the design calculations and performance tests indicated that the shredder had a volume of 0.0117m³, could handle 1.5 kg/hr, transmitted a torque of 61.528 Nm through its shaft, produced a shear force of 3,715.2 N, rotated at a speed of 450 rpm, experienced a shear stress on the blade of 4.02 MPa, dealt with a torque stress on the shaft of 39.165 N/mm², fed material at a rate of 1.55 kg/hr, consumed energy at a rate of 2.611 kW, and operated with an efficiency of 88%. It was concluded that this research met its goals and highlighted that an efficient plastic shredder is vital for cutting down plastic waste and supporting sustainability efforts. By transforming plastic waste into useful resources, environmental pollution can be reduced, natural resources can be saved, and economic issues caused by plastic waste can be addressed. Therefore, it is suggested that establishing effective recycling systems worldwide can greatly help create a cleaner and greener future.