This document describes a project report on plastic recycling using a hand-operated injection molding machine. A group of students designed and built the machine to reuse scrap plastic into new products. The machine uses a mechanically-operated process where shredded plastic is heated and injected into a die mold of the final product shape. The report provides details on the machine design and construction, injection molding process, materials used, total costs, advantages and limitations. The students concluded the machine can be built inexpensively and operated with basic skills to produce small plastic parts from recycled materials.

2. VISVESVARAYA TECHNOLOGICAL UNIVERSITY
Jnana Sangama, Belgavi - 590018, Karnataka, India
A Project Phase 02 Report on
“PLASTIC RECYCLING BY HAND OPERATED INJECTION MOLDING MACHINE”
Submitted in the partial fulfillment of the requirements for the award of
BACHELOR OF ENGINEERING in MECHANICAL ENGINEERING
Submitted by
SALEEMHUSSAIN 3PG17ME029
SUNIL KUMAR.BA 3PG17ME034
MOHAMMAD MUSTAQ 3PG17ME017
MOHAMMED MALIK AYOUB 3PG17ME018
Under the Guidance of
Prof. Murthy S L
Professor
Dept. of Mechanical Engineering, PDIT Hospete
BELLARY V.V. SANGHA S
PROUDADEVARAYA INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
T.B. DAM, HOSAPETE - 583 225
2020-21

3. “PLASTIC RECYCLING BY HAND
OPERATED INJECTION MOLDING
MACHINE”

4.  Plastic waste is one of the greatest source of waste which has been increasing since the
plastic was first used as a daily need product.
 But, most danger property of plastic is that is does not degrade with time which makes it
difficult to dispose.
 A good quality of plastic is that it can be Recycled or Reused.
 We can reuse some of the products, like plastic bottles, Chairs, etc,
(We are using thermoplastic polymers for molding)
 Plastic recycling is the process through which we can use these plastic to create new
products.
 Plastic Injection Molding Process is one of the most used manufacturing process.
 So, we decided to make a plastic recycling machine that can reuse scrap plastic to make
useful product and at a cheaper cost.

5.  In our project we are going to carry out recycling using Injection process. Injection
molding machine is a mechanically operated mechanism in which the shredded plastic
is heated to change its state from solid to semi liquid and then injecting (pushing) it
into a die, that has an cavity of shape of our final product.
 This machine is made at least possible cost and is capable enough to start a business
from home and commercialize it. Products formed can also be made into combination
of colors.
 Injection machine is flexible enough to create different product just by changing the
die.

6. CLAMPING
HEATING
INJECTING
MATERIAL
SOLDIFY
MOLD
OPENING
EJECTION
MOLD
CLOSING
INJECTION
MOLDING
PROCESS CYCLE

7. PID CONTROLER BAND HEATERS K-TYPE THERMOCOUPLE
SOLID STATE RELAY WOOD DIE STEEL DIE

9. P
r
o
c
e
s
s
Injection molding process can be performed in
following four Steps :-
Step-1: DIE CLOSING
The process starts with Closing the die
and clamping the die to vice.
Step-2: HEATING AND INJECTING
The heated Plastic is injected into a
Mould Cavity.
Step-3: COOLING
Once the mould cavity is filled, the part
is allowed to Cool.
Step-4: EJECTION
After cooling, the final product is taken
out from the mold.

11. Molding Temp (in oC)
80 -120 oC
110 -120 oC
50 -120 oC
20 -70 oC
100 -110 oC
30 -60 oC
80 -90 oC
Molding Temp (in
oC)

12.  Plastic Injection Molding Process is one of the most used manufacturing process
capable of producing flexible and economical parts at a large scale.
 Evaluate current industry processing standards and determine what practices are
beneficial and sustainable.
 Demonstrate a recognition of alternate methods of injection molding.
 Recognize commonly used terminology and componentry utilized in injection molding.
 Determine how properly manage, prepare and cool plastic materials throughout the
injection molding process.
 Analyze the phases of the injection molding process and determine the appropriate
machine setting are for each phase
 Evaluate if an injection mold is a good match for an injection molding machine.

13. Sl.
NO PARTICULARS QUANTITY
RATE/
UNIT
ESTIMATED
AMOUNT
ACTUAL
AMOUNT
1 PID controller 1 2800 2800/- 2300 /-
2 SSR 1 600 600/- 420 /-
3 MCB 1 180 180/- 180 /-
4 Band heaters 3 800 2400/- 2400/-
5 Hollow rod 1 300 300/- 500 /-
6 Solid rod 1 400 400/- 400/-
7 Nut & bolts 10 5 50/- 50 /-
8 Wires 3m 50/m 150/- 150 /-
9 Spray Paint 1 190 190/- 200 /-
10 Plywood 1 500 500/- 500 /-
11 Dies 2 500 1000/- 1000 /-
Total - - 10,000 /- 8,100 /-
Before the machine is actually manufactured. Thus, the calculation of probable
cost of project is as follows :

14.  Labour cost is low.
 It is easy in construction.
 Fast production & Low waste.
 Material and color flexibility.
 It can be operated by even an unskilled person.
 It can be developed further to make it more efficient and make it automatic.
 To this mechanism there is low maintenance.
 Any required shapes and sizes are can be required with the help of the die.
 This also helps to clean up our surrounding and help in recycling and reusing the
already used plastic.

15.  Accuracy is comparatively less.
 High initial cost if automation is done.
 Limited size objects only can be created.
 Accurate costing may difficult.

16.  These are useful for recycling thermoplastics by suitable product.
Small objects can be manufactured.
 Mechanical part can be made.
 Injection machine is cheap enough to build at home.
 Simple jobs can be made according to die.
 Using this machine many useful products can be manufactured and can be
commercialized to make profit.
 The raw material required is free of cost and easy to find because we are
recycling the plastic.

17. [1] www.preciousplastic.com
[2] Elements of workshop Technology-Volume I & II
[3] Production Technology Volume- I & II by O. P. Khanna & Lal
[4] A text book of Foundry Tech. by O.P. Khanna
[5] www.thelibraryofmanufacturing.com
[6] International Research Journal of Engineering and Technology (IRJET)

18.  After completing our project we can conclude that the plastic injection machine can be
constructed in less cost. If any part in our project breaks or gets damaged then we can
replace it easily.
 It does not require any special skills to operate the machine, except for the electronic
connections included in the project. The Electronics circuit is easy to understand and
anyone that can understand the given circuit diagram, the person can without any
difficulty assemble the electronics.
 All the parts that have been fabricated require only basic fabrication skills, and no
special purpose machines are required to perform these.
 All the equipments can be found in any basic workshop.
 This machine is hand operated so it does not require any prime mover, only electrical
supply is given to the band heaters to heat it.