Design and Fabrication of waste compactor System

ii
For the requirement of the Bachelor’s Degree
In
MECHANICAL ENGINEERING
This report is submitted to
Department of Mechanicacal Engineering,
University of Engineering and Technology, Lahore
I do hereby declare that the work submitted in this report is my own, and any work
that is not mine has been quoted and acknowledged in reference.
(Imtaiz Ahmad, Syed Wasif Ahmad,
Muzammil Arfat Khan and Adnan Ahmad)
Approved on………………….
Internal Examiner: Engr. Nauman Javed
Signature……………………..
External Examiner: Name:……………………..
Signature…………………….
Department of Mechanical Engineering,
University of Engineering and Technology, Lahore

iii
ACKNOWLEDGEMENT
First of all thanks to Almighty Allah, who gave us courage to complete this project. We want to
dedicate our efforts to our parents and worthy teachers.
Alhamdulillah, we have done this project in the best interest of people of Gujranwala. Our
objective was to provide best technological solution to clean Gujranwala.
We are extremely thankful to our project advisors; Engr. Nauman Javed and Engr. Uzair
Arsam (Gujranwala waste management company) who guided us throughout this project.
their instructions and suggestions enabled us to successfully accomplish the task.
Adnan Ahmad
Imtaiz Ahmad
Wasif Ahmad
Muzammil Arfat

iv
ABSTRACT
Waste compactor is a machine which is used for the compaction and easy transportation of
municipal waste. Compactors were already functional in (Gujranwala waste management
company) but they were suffering bending of shovel plate under severe pressure, high
maintenance cost and less internal volume for compaction.
After examining all these problems we were designed a new compaction mechanism according
to the specifications of a Bradford chess which was given to us by GWMC. 3D Model is made
on PRO-E wildfire 4.0. Shovel plate thickness was increased by 1 mm. An Ejection plate was
made at an angle of 70 with best supporting features. Sliding mechanism was replaced by roller
bearings so we have minimum friction and maintenance problems. 3 Ribs were inserted in shovel
plate to strengthen it.
Seizer plunger was replaced by telescopic plunger which led towards volume enhancement of
0.35 3
m . New designs of shovel plates and ejection mechanism were analyzed in ANSYS.
Results showed that the new designs were stable.

v
Table of Contents
ACKNOWLEDGEMENT ..............................................................................................................iii
ABSTRACT....................................................................................................................................iv
CHAPTER 1 ................................................................................................................................... 1
INTRODUCTION .......................................................................................................................... 1
1-1 Overview of waste compactor:............................................................................................. 1
1-2 Review of existing vehicles in GWMC ............................................................................ 1
1-2-1 Truck mounted vacuum sweeper:.................................................................................. 1
1-2-2 Mini tipper with compaction arm:................................................................................. 2
1-2-3 Procured Sewer Suction Machine: ................................................................................ 2
1-3 Hydraulic mechanism:.......................................................................................................... 3
1-3 Major components of waste compactor:............................................................................... 3
1-3-2 Telescopic plunger: ....................................................................................................... 3
1-3-3 Ejection plate:................................................................................................................ 3
1-3-4 Hopper:.......................................................................................................................... 3
1-3-5 Shovel plate:.................................................................................................................. 3
CHAPTER 2 ................................................................................................................................... 5
POWER TAKE OFF AND HYDRAULIC PUMPS ...................................................................... 5
2-1 Power takes off (PTO):............................................................................................................. 5
2-2 Power required to run the pump: .......................................................................................... 5
2-3-1 Advantages of accurate power take off:........................................................................ 5
2-3-2 Function of the superstructure:...................................................................................... 5
2-3-3 Technical variables:....................................................................................................... 6
2-4 Clutch independent take off:................................................................................................. 6
2-4-1 Clutch Independent Power Take off for Manual Gearboxes: ....................................... 6
2-4-2 Clutch Independent Power Take offs for Automatic Gear Boxes:................................ 6
2-5 Clutch dependent take off:.................................................................................................... 6
2-6 Advantages of clutch dependent power takeoff: ................................................................ 6
GLOBAL EFFORTS FOR WASTE COMPACTION ................................................................... 7
3-1 History: ..................................................................................................................................... 7
CHPTER 4 ...................................................................................................................................... 8

vi
GEOMETRICAL MODEL............................................................Error! Bookmark not defined.
4-1 Design Consideration: .......................................................................................................... 9
4-3 Modeling of Geometry: ...................................................................................................... 10
CHAPTER 5 ................................................................................................................................ 15
RESULTS and ANALYSIS.......................................................................................................... 15
Chapter 6....................................................................................................................................... 16
Optimization and improvements................................................................................................... 16
6-1 Improvements ..................................................................................................................... 16
6-1-1 Hydraulic telescopic plunger:...................................................................................... 16
6-1-2 reduced friction with roller bearings:.......................................................................... 17
6-1-3 Overall cost reduction: ................................................................................................ 18
6-1-4 Strengthen the shovel plate: ........................................................................................ 18
6-1-4Reducing wall thickness:.............................................................................................. 18
CHAPTER 7 ................................................................................................................................. 19
APPENDEX A.............................................................................................................................. 19
REFERENCES ............................................................................................................................. 20

vii
LIST OF FIGURES
Fig.1-1 Truck mounted vacuum sweeper…………………………………………………………7
Fig. 1-2 Mini tipper with compaction arm...................................................................................... 2
Fig. 1-3 procured Sewer Suction Machine ..................................................................................... 2
Fig 1.4 schematic daigram of waste compactor.............................................................................. 4
Fig.3-1 Thorneycroft’s steam dust cart........................................................................................... 7
Fig.3-2 Dumpsters invented by George Dumpster .......................Error! Bookmark not defined.
Fig. 3-3 covered trucks...................................................................Error! Bookmark not defined.
Fig.3-3(a) external hopper introduced by Heil in 1929 Fig.3-3(b) external hopper introduced
by Heil in 1929...............................................................................Error! Bookmark not defined.
Fig.4-1 Design of waste compactor on P-roe................................................................................ 10
Fig 4.2: rearview design of waste compactor ............................................................................... 11
Fig.4-3 Shovel plate of compactor................................................................................................ 11
Fig .4-4: Shovel plate.................................................................................................................... 12
Fig.4-5: Ejection plate of compactor........................................................................................... 12
Fig.4-6: Pro-e model of hopper.................................................................................................... 13
Fig.4-7 Sliding plate plunger ........................................................................................................ 13
Fig.4-8 Hopper lifting plunger...................................................................................................... 13
Fig.4.9 Garbage lifting plunger..................................................................................................... 14
Fig.4.10 Shovel plate plunger ....................................................................................................... 14
Fig.5.1 (a) pressure distribution on shovel plate ........................................................................... 15
Fig.5-2(b) pressure distribution on shovel plate ........................................................................... 15
Fig. 6-1 Telescopic Plunger .......................................................................................................... 16
Fig.6-2 Extended form of Telescopic Plunger.............................................................................. 17
Fig.6-3 Roller bearing................................................................................................................... 17

1
CHAPTER 1
INTRODUCTION
1-1 Overview of waste compactor:
Waste compactor is the device which is used to reduce
the size of the waste material and also for the purpose of compaction of the biomass. In this way
we compact the materials and there is more place for the material in the container. It is also used
for the compaction process of trash of homes. Another process, in practice, is the baller-wrapper
compactor which is used to compact we well as wrap the bales to improve the logistics
processes.
In most of the cases the waste compactor is powered by hydraulic mechanism. Compactor which
has different sizes and shapes like bulldozer with spiked wheels called landfill compactor. Waste
compactor vehicles which are working on the hydraulic mechanism to increase the payload of
vehicle but on the other hand it reduces the number of items it has to empty in this case.
Hydraulic mechanism is used in the Waste compactor .In this mechanism sliding plate moves in
the outer body. Shovel plate is used to compact the material.
1-2 Review of existing vehicles in GWMC
1-2-1 Truck mounted vacuum sweeper:
In fig 1-1 Truck mounted vacuum sweeper is shown which is used to clean the roads
automatically. In this mechanism Hydraulic mechanism is used to rotate the fan .In this way fan
is rotated and used for cleaning the roads.
Fig.1-1 Truck mounted vacuum sweeper

2
1-2-2 Mini tipper with compactionarm:
In fig 1-2, Mini tipper with compaction is used to carry the garbage at minimum level. It carry
garbage and compact it but the amount of garbage carried in the mini tipper is very low .
Fig. 1-2 Mini tipper with compaction arm
1-2-3 ProcuredSewerSuction Machine:
In Fig 1-3, Procured Sewer suction machine is shown which is used for pumping the
water in which one centrifugal pump is used to create vacuum and a power take off
(PTO) also attach with it. When the vacuum is created then in the centrifugal pump the
water is pump in the container. In this way water is collected through centrifugal pump.
Fig. 1-3 procured Sewer Suction Machine

3
1-3 Hydraulic mechanism:
A hydraulic mechanism is the transmission process which uses pressurized fluid to activate
hydraulic machinery. System operates on the basis of Pascal law. Pascal’s law or the principle of
transmission of fluid-pressure (also Pascal’s Principle) is a principle in fluid mechanics that
states that a pressure change occurring anywhere in a confined incompressible fluid is
transmitted throughout the fluid such that the same change occurs everywhere.
1-3 Major components of waste compactor:
Floor of the waste compactor is used to carry garbage. Its is inclined to collect water in the water
storage tank.
1-3-2 Telescopic plunger:
Telescopic plunger is used for the movement of the ejection plate in this way when the plunger
is moved forward then the ejection plate is moved towards the hopper on the other hand when
plunger moved backward then ejection plate also moved backward.
1-3-3 Ejectionplate:
Ejection plate is used when the shovel plate is compacted the garbage then it is used to place this
garbage on the ejection plate. In this way it continues to do this same work and ejection plate is
moved backward with the help of telescopic plunger.
1-3-4 Hopper:
Hopper is used to carry garbage from the storing garbage box, than shovel plate is used to pic the
garbage and then compact it.
1-3-5 Shovel plate:
The main purpose of the shovel plate is that to carry the garbage, compact it and then it placed to
the ejection plate. Shovel plate is the most crucial part of compactor.

4
Fig 1.5 schematic daigram of waste compactor

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CHAPTER 2
POWER TAKE OFF AND HYDRAULIC PUMPS
2-1 Power takes off (PTO):
Power take off is the gearbox which operates mechanically and attached to the vehicle engine to
the auxiliary components e.g. hydraulic pump. With the help of hydraulic pump hydraulic flow
are generated and then directed to the cylinders.
Some applications of PTO are pneumatic blowers, liquid transfer pumps,
Generators and air compressors. The main purpose of the PTO is to provide power in the form of
a rotating shaft directly to the driven components.[1]
2-2COMPLETE HYDRAULIC SYSTEMS:
There are also complete hydraulic systems for the power take-off, with hydraulic pumps, tanks,
pipes, connections and suspension parts.
2-3Power required to run the pump:
Power required running the pump needs to be determined. Pump will transfer its pressure to the
plunger which will further lift it up and down.
2-3-1 Advantages of accurate powertake off:
There are many reasons why it is important to specify the power take off according to the
chassis. The most important are as follows.
 Optimal operation (noise level, fuel consumption & emission level) can be guaranteed
 Better scope for quality assurance.
 Sealing and cleanliness can be guaranteed
 Reduced lead time
 Reduced total cost
2-3-2 Function of the superstructure:
The power take off is often used to run the hydraulic pump which is the part of the hydraulic
system and also used for the function of the super structure. The selection of power take off
depends upon the shape of the super structure of the vehicle. The selection of the super structure
is determined by the customer needs.

6
2-3-3 Technicalvariables:
Following variables are calculated when power takeoff is to be determined
• Required hydraulic flow
 Location of the power take-off
 Maximum hydraulic system pressures in different circuits
 Location of the power take-off
 Requirements for clutch dependent power take-offs
 Working speed of the engine
2-4 Clutch independent take off:
There are several alternatives of clutch independent power take off. This clutch independent
power takes off can be used for both driving and when the vehicle is stationary. It is also useful
for the engagement and disengagement from outside of vehicle.
2-4-1 Clutch Independent PowerTake offfor Manual Gearboxes:
The power take off is determined by the flywheel of the engine which is fitted between the gear
box and engine. In this case the power and speed is governed by the engine and power takeoff
has an electro-pneumatic hydraulic engagement system in the form of disc clutch.
2-4-2 Clutch Independent PowerTake offs for Automatic GearBoxes:
The power take off is mounted on the outer side of the upper part of the gear box. This is driven
by the flywheel of the engine and also with the support of sturdy pinion. Hence it is affected by
the speed of the engine. With the help of electrical and hydraulic system power take off is
engaged and also allows it to be engaged when the vehicle is moving.
2-5 Clutch dependent take off:
Clutch dependent power take is also fitted on manual gear
box, including I-Shift. This is only used when the vehicle is stationary. It is simple to install and
used for the light weight units.
It is fitted on the rear end of the gear box, the power take off is driven by the gear box. In this
case the rotation speed and power output are determined by the engine revolution and also the
gearbox ratio.
2-6 Advantages of clutch dependent power takeoff:
A clutch dependent power takes off is lightweight as compared with a
clutch independent one. In this case, the design is simple and requires minimum maintenance.
And also the cost is very low. It is safe as well.

7
CHPTER 3
GLOBAL EFFORTS FOR WASTE COMPACTION
3-1 History:
Waste compactors are being used from centuries. Forest waste compactor was made by the steam
wagon and carriage company in 1897. The company described it as a steam motor tip-car as
shown in fig. 3.1. This design of the body was specific for the house refuse and the collection of
dust.[3]
Fig.3-1 Thorneycroft’s steam dust cart
with the passage of time more advanced invented. In 1920 the use of open-topped trucks
began. But the main problem was its foul odor and spreading of waste during vehicle movement.
To overcome this problem, covered vehicles were introduced.
. North America and Europe used closed trucks for the first time in history.

8
While designing a waste compactor main problem was to lift it at shoulder height. To overcome
this problem round compartments were built with massive cork screws More efficient model
known as Hopper was developed in 1922. In Hopper, there was a mechanism of cables that
pulled waste into the truck.
In 1937 Dumpster-Dumpster system was invented by George dumpster. In this system wheeled
waste containers were mechanically tipped in to the truck. His containers were known as
Dumpsters.
In 1938, Garwood Load Packer revolutionized the industry when he made a compactor in the
truck. by using the compactor the capacity of truck was doubled. he used the hydraulic press for
the compa

9
CHPTER 4
DESIGHNING OF WASTE COMPACTOR
Power take-off and pressure of hydraulic pump were calculated using the method described by
the calculations were based on hydraulic approach. The method used for the calculations were
taken from the principle of Volvo Company and Study, Design, Analysis and Manufacturing of
Garbage Compactor by Surag Gavali (IET Maharashtra India). The model of compactor was
prepared in PTC Pro-E 4.0.
4-1 Design Consideration:
The design of waste compactor is designed by considering reference area approach. Following
results were obtained after calculations:
Nomenclature:
Flow rate=Q
Pressure=P
Revolution=N
Displacement=D
Q = 95 liter/min
P = 250 bar
engineN = 1000 rpm
reqD = 50
rev
cm3
permM
= 198.4 Nm
P = 41.5 kW

10
4-3 Modeling of Geometry:
The geometry based on the calculations is modeling in PTC Pro-e 4.0. we design the outer body,
hopper plate, Shovel plate and plungers of the compactor. The geometry of waste compacter is
shown in Figures below. [5]
In Fig 4-1 design of waste compactor is shown. In this figure all the components of waste
compactor are labeled
Fig.4-1 Label all the components in Pro/E.
In Fig 4-2 compactor with lifted hopper is shown. It can be seen that hopper lifting plungers
have lifted the hopper to its extreme.

11
Fig 4.2: Compactor with lifted hopper
In Fig 4-3 shows shovel plate and sliding plate mechanism. The main purpose of the shovel plate
is to carry the garbage, compact it and then placed to the ejection plate. Now the sliding plate is
used to move shovel plate.
Fig.4-3 Shovel plate of compactor

12
In Fig 4-4 shows shovel plate which is used to collect garbage and compact it.
Fig .4-4: Shovel plate
In Fig 4-5 shows ejection plate the shovel plate compresses the garbage on the ejection plate. In
this way it continues to do this same work and ejection plate is moved backward with the help of
telescopic plunger.
Fig.4-5: Ejection plate of compactor

13
In fig 4-6 hopper is shown . Hopper is used to carry garbage storing boxes from the shovel plate
is used to pick the garbage and compact it.
Fig.4-6: Pro-e model of hopper
In Fig 4-7, 4.8, 4.9 and 4.10 show the plungers which are used to lift the sliding plate , hopper
plate , hopper, garbage lifter and shovel plate lifter respectively.
Fig.4-7 Sliding plate plunger
Fig.4-8 Hopper lifting plunger

14
Fig.4.9 Garbage lifting plunger
Fig.4.10 Shovel plate plunger

15
CHAPTER 5
ANALYSIS AND RESULTS
In fig 5-1 (a) Pressure and Temperature distribution were obtained from ANSYS.
Fig.5.1 (a) pressure distribution on shovel plate
In fig 5-1 (b) Pressure distribution on a shovel plate while applying 110 bar pressure
Fig.5-1(b) pressure distribution on shovel plate
Shovel plate plays a vital role in compaction of garbage. Since compactors we are designing are
clutch dependent so driver has no information about what type of waste is being compressed. If
in any case, hard material comes in the way of shovel plate; it can bend and fail the shovel plate.
We decided to increase its thickness to avoid its failure during operation. Shovel plate thickness
was increased by 1mm. we analyzed after increasing its thickness while applying same pressure
of 110 bars on shovel plate in ANSYS results show that the shovel plate with increased thickness
is stable against this pressure.

16
Chapter 6
Optimization and improvements
6-1 Improvements
Following improvements were suggested to GWMC to optimize the design of waste compactor
 Hydraulic Telescopic plunger
 Reduced friction with roller bearings
 Strengthen the shovel plate
 Overall cost reduction
 Quantity Enhancement
 Reducing wall thickness
6-1-1 Hydraulic telescopicplunger:
The use of hydraulic telescopic plunger increases the internal storage area.. In this way, we
replaced the bulky mass plunger seizer mechanism by telescopic plunger.
In Fig 6-1 and 6-2 contraction and expansion form of Telescopic plunger are shown.
Fig. 6-1 Telescopic Plunger

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Fig.6-2 Extended form of Telescopic Plunger
6-1-2 reduced friction with roller bearings:
In this mechanism we used roller mechanism because when the roller mechanism is used then
friction is reduced. On the other hand when using sliding mechanism in the slots then the friction
is too much .Therefore by using roller mechanism friction is reduced to great extent.
Fig.6-3 Roller bearing

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6-1-3 Overall costreduction:
The use of telescopic plunger and reduced wall thickness of outer body, the overall cost of
compactor has been reduced.
6-1-4 Strengthen the shovelplate:
GWMC was receiving complaints about shovel plate bending due to high pressure. Ribs were
added in the shovel plate to provide reinforcement. Shovel plate was strengthened using this
approach..
6-1-4Reducing wallthickness:
The thickness of the outer body was ____ mm which was too high. Safe working of outer body
was ensured by reducing the thickness to ___mm. It was therefore suggested to reduce the
thickness of the outer body to ____mm for new models..

19
CHAPTER 7
Conclusion AND FUTURE RECOMMENDATION
From this work followings conclusions can be deduced.
After installation of telescopic plunger, we are able to increase the compaction area which leads
towards quantity enhancement of compactor by 0.35 m3
. Use of roller bearings in sliding plate
reduces the friction as well as maintenance cost.
ANSYS results show that shovel plate strength is enhanced by inserting ribs and increasing
thickness by 1 mm.
GWMC has its own workshop and talented workers for maintenance. However, if GWMC
establishes a research and development department, it will reduce its dependency on other
companies. It will enable GWMC to even generate revenue.

20
REFERENCES
(1)Power take off and hydraulic pumps by VOLVO technologies (a field of application
calulations guide)
(2)Design, construction and evaluation of hydraulic powered PTO winch by Joey McKee
(3)Design, Analysis and Manufacturing of Garbage compactor
- a Review by Suraj gavali (Student) , Dr DY Patil Institute Of Engineering And Technology
Pune,Maharashtra,India Email:suraj.gavali@gmail.com Dr.R.J.Patil (Principal)
(4) Understanding Power take off system sixth edition by dodge builder.com
(5) "Motor-Cars for Dust Collection", The Automotor and Horseless Carriage Journal, February
1897, p192
(6)http://www.tigerdude.com/garbage.

21
APPENDEX ‘A’
reqD =
engnz
Q

1000
engn  z
permM =
63
PD
permM  2
P =
000,30
14.3100024.198 

Design and Fabrication of waste compactor System

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