The document describes the design and fabrication of a machine to manufacture plastic bricks by recycling plastic waste. It includes sections on the aim to reduce plastic waste and make affordable bricks, introduction describing the machine parts and design methodology using finite element analysis, results of testing different plastic to sand ratios in bricks, and conclusions about addressing the problem of plastic waste and limitations of the current design with recommendations for future improvement.

1. Design And Fabrication Of Plastic
Brick Manufacturing Machine
Group Supervisor:
Engr. Ali Raza
Group Members:
Muhammad Saad Arslan (F18602015)
Mateen Ali Akbar (F18602013)
Ali Hamza (F18602006)
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2. Table of contents
• Aim
• Introduction
• Design Methodology
• Results and Discussion
• Conclusion
• Future Recommendations
• References
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3. Aim
• To design and fabricate a machine which converts waste plastic into plastic bricks.
• To make high quality and cost-efficient plastic bricks.
• Reduce Plastic waste
• Economically feasible Production
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4. Introduction
• Attempting to reduce the quantum of plastic wastes that fill our landfills, we decided to
fabricate a Plastic Recycling Machine. In this connection, we also took into consideration the
fact that the demand for bricks for housing and general construction purposes is on the rise.
Thus it was felt that fabrication of a machine for manufacturing bricks by using plastic wastes
as one of its components will reduce plastic waste menace to a great extent and at the same
time we will also get a novel building material for construction purpose. The machine
essentially consists of a cutting unit, recycling unit and a mixing unit. The machine parts are
made of mild steel, because of its availability and versatile machinability. The efficiency of
the machine was established using plastic wastes, cement and other aggregates. Plastic waste,
after chipping into finer granules, was added to cement and aggregates in definite proportion.
Then the mixture is allowed to pass through recycling unit to form a mix, and then packed
into mould box.
• Plastic is a synthetic material made from a wide range of organic polymers such as
polyethylene, PVC, nylon, etc., that can be moulded into shape while soft, and then set into a
rigid or slightly elastic form. Looking seriously at the global issue of environmental pollution
posed by postconsumer plastic wastes, research is being focused indepth on finding out more
ways and means to consume this waste material on a massive scale in an efficient and
environment friendly manner.[1]
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5. Introduction
• Plastic waste dumped in the ocean and land is increasing every year. It takes almost hundreds
of years for plastic to decompose completely. Imagine how many years will it take for plastic
waste of the whole world to decompose. It makes life miserable for the living of the sea as
well as the earth. It has polluted the ecosystem for hundreds of years. Most of the plastic used
by the food industry is dumped instead of re-using or recycling. In this way it was felt that
manufacture of a machine for manufacturing bricks by involving plastic wastes as one of its
parts will decrease plastic waste hazard to an extraordinary degree and simultaneously, we
will likewise get a book building material for development reasons.
• Plastic brick manufacturing machine recycles the plastic and helps us to use in a better and
useful way instead of dumping it. Plastic is shredded by shredder and pushed into mixer
where it is mixed up and heated up in extruder. Melted mixture is poured into mold and
compressed by Hydraulic Press to gain higher strength.
• The machine is designed to approach the limit of possible volume reduction via compaction
methods. The machine contains following parts:
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6. Introduction
Extruder
An extruder is simply the machine used to complete the extrusion process. Using a system
of barrels and cylinders, the machine heats the product and propels it through the die to create the
desired shape.
Shredder
A shredder is a machine or equipment used for shredding. Shredding systems are used to
reduce the size of a given material. shredders designed to support material reduction across a
range of recycling applications.
Mixer
Mixer mix-up the sand with shredded plastic coming from the shredder. When the plastic
and the sand are mixed up completely. It is sent to the extruder then.
Mould
Mixture of sand and plastic both are heated up in an extruder. When plastic is melted completely,
both sand and melted plastic will form a mixture. Now this mixture will be pushed into mould.
Mould is basically of the shape of our desired brick.
Hydraulic Press
• Hydraulic press is used to compress the bricks when melted mixture is poured into mould.
Press is used for compression purpose to strengthen the bricks.
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7. Calculations
• Extruder
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Total Length of Barrel (h) = 0.61 m
Inner radius of barrel (ri) = 0.025 m
Outer radius of barrel (ro) = 0.04 m
Volume of Barrel=VB = π x h x ri
2
VB = π x (0.61) x (0.025)2 = 1.19x10-3 m3
Inner Surface area of barrel = Ai = 2 π ri (ri + h)
Ai = 2 π x 0.025 (0.025 + 0.61) = 0.01 m2
Volume of Helical Screw= VHS = 0.00762 m3
VB – VHS = 0.0004357 m3
Helix Angel = tan−1 𝑃𝑖𝑡𝑐ℎ × 𝑛𝑜 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡𝑠
𝜋 ×𝑃𝑖𝑡𝑐ℎ 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
Helix Angel = tan−1 0.042 × 1
𝜋 ×0.034
Helix Angle = 21.46o
Lead = 0.042 m
Thread thickness = 0.012 m

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Density (ρ) = 1370 kg/ m3
Melt density (ρmelt) = 1200 kg/ m3
Coefficient of viscosity (μ)= 0.15 – 0.25
Melting point = 167o C
Heat Capacity (Cp) = 1.5 KJ/Kg o C
Latent Heat of Fussion = 136 KJ/Kg o C
Ultimate Tensile Strength = 150 MPa
Yeild Strength = 40 Mpa

9. Qmax
=
1
2 π2
× di
2
× 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤 × 𝑁 sin θ cos θ
Qmax
=
1
2 π 2
𝑥 (0.05)2
𝑥0.016𝑥50 sin(21.46) cos(21.46)
Qmax = 6.72 x 10-4 m3 / min
Qoutput = Qmax × 60 × ρmelt = 6.72 x 10-4 × 60 × 1200 = 48.39 kg/hr
Pmotor = 745.5 × 3600 = 2683.8 watt
Eheater = Em = Pheater × t = 1000 x 3600 = 3600 KJ
Energy Consumed by 4 Heater = Eheater × 2 = 7200 KJ
Etotal = E motor + E heater = 2683.8 + 7200 =9883.8 KJ
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10. 𝑄 =
𝐸𝑡𝑜𝑡𝑎𝑙
𝑂𝑢𝑡𝑝𝑢𝑡
=
9838.8
48.39
= 204.2 𝐾𝐽/𝐾𝐺
Qactual = m Cp ∆T + mHF
Qactual = 1 x 1.5 (267-32) + 1(136)
Qactual= 478 KJ
Friction force = 39.2 N
Ʈ=Torque = r × F
Ʈ = 0.025 ×(78.5 + 39.2)
Ʈ = 2.94 Nm
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11. Calculations
• Shredder Calculations:
Ʈmax = 80 Mpa
Factor of safety = 1.5
Fc = Ʈplastic × A
Fc = 120MPa x 2 x 10-6 = 240 N
T = F x r
T = 240 x 0.06
T = 14.4 Nm
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Let’s say we have 1Hp with 1450 rpm motor
HP =
𝑅𝑃𝑀 𝑥 𝑇
5252
T =
𝐻𝑃 𝑥 5252
𝑅𝑃𝑀
Requirement is 14.4 Nm at least
1HP =
𝑅𝑃𝑀 𝑥 14.4
5252
RPM = 364
RPM is 10
T = 525.2 Nm

12. Design Methodology
• Static structural analysis of the blade was done utilizing the finite element analysis approach.
The finite element strategy is a mathematical analysis method for getting approximate
answers for a wide assortment of designing issues, due to its variety and adaptability as an
analysis apparatus. It is getting a lot of consideration in designing school and enterprises. In to
an ever-increasing extent designing circumstances today, we see that it is important to get
inexact answers for issues rather than the accurate shut structure arrangement. The static
structural analysis of the current blade was done utilizing ANSYS workbench to assess the
various anxieties and misshapenness under static loading conditions.
• Finite element analysis includes four fundamental stages to address any material science issue
utilizing ANSYS software.
• 1. Preliminary Decisions
• 2. Pre-processing
• 3. Solution
• 4. Post processing
•  Preliminary decisions include what type of analysis is needed to run in order to analyze the
geometry. The CAD data and element type are also included in this part.
•  Pre-processing is a set of decisions a designer has to make before running the solution.
selection of material for geometry and generating mesh.
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13. Design Methodology
Solution is the next step which includes initializing boundary conditions and selecting the type of
results needed after calculations are complete.
Post processing deals with the graphics of results, their representations, deformations and stresses
etc.
1. Preliminary Decisions:
• Analysis Type: static structural analysis
• CAD data: three-dimensional solid model
• Element type: Solid95
2. Pre-processing:
• Define material: Low Carbon Steel
• Import Geometry
• Mesh geometry: tet10
3. Solution:
• a. Apply load: load and boundary conditions applied as per shredder specification
• b. Solve: linear analysis physics problem
• 4. Post Processing:
• a. Total deformation
• b. Von Mises stress
• c. Shear stress
• d. Equivalent Strain
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14. Design Methodology
4 Post Processing:
• Total deformation
• Von Mises stress
• Shear stress
• Equivalent Strain
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15. Design
• Shredder
Blade
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16. Spacer Hexagonal Shaft Body
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17. Stand Complete Assembly
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18. • Extruder
Outer Body of Extruder Hopper
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19. Extruder Screw
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20. Extruder Complete Assembly
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21. Extruder Cutaway Model
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22. Results and Discussion
Directional Deformation
Extruder
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23. Total Deformation
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24. Shredder
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25. Final Fabricated Model
Shredder Extruder
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26. Plastic : Sand (70 : 30)
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27. Plastic : Sand : Cement (80 : 10 : 10)
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28. Plastic : Sand : Cement (70 : 15 : 15)
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29. Plastic : Sand (80 : 20)
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30. Plastic (100)
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31. 31
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32. Conclusion
• Finding a solution for the plastic waste is one of the most important challenge the world is
facing right now, due to its long life of decomposition plastic stores itself in landfills.
Utilizing plastic waste into some useful product can be a solution for plastic waste, in this
context a two stage machine is designed and fabricated which is a working prototype. First
necessary calculations were done to find the least requirements for the implementation of this
model. Then keeping factor of safety, the final results were evaluated. A 3D CAD model was
designed and analyzed using software to analyze the behavior of critical parts under
operation. The plastic brick manufacturing machine during its first stage, plastic bottles are
shredded (crushed) into small pieces and then mixed with sand. This mixture is then fed into
extruder in which on high temperature a mixture is formed. a die with specified dimensions is
used to form the final shape of the brick. Final brick is light weight and have more strength.
Moreover, the final cost for manufacturing this brick is less than normal paver brick used.
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33. Limitation
• Currently we are constrained by many factors and are continuously working to improvement.
Following are the limitations described below
• The full utilization of plastic into bricks isn’t possible right now because of only one mould. It
takes time to cool down the mixture in the mould while we can’t stop the extruder again and
again to avoid the solidification of plastic into the barrel.
• The flow rate is very less when we use raw untreated recycled plastic because the large chips
of plastic are taken into the mouth of the extruder in very small quantity.
• The mixture of sand and plastic is not very uniform due to the small length of barrel.
• The power transmission losses are very huge in the shredder due to larger component
assembly.
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34. Future Recommendation
• A compression unit after extruder should be installed to avoid the fumes entrapped inside the
brick mould. The limitation of stopping machine is also very easy to overcome once this
compression unit is installed.
• A full scale model of extruder will overcome the flow rate and uniform mixing of plastic and
sand.
• A direct flange coupling can reduce the losses in power transmission. A geared motor can be
used instead of gearbox and pulley.
•
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35. References
• MACHINE, BRICK MANUFACTURING. "DESIGN AND FABRICATION OF A PLASTIC
REINFORCED." (2015).
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