Design, Fabrication, and Performance Evaluation of an Optimized Thermoplastic Waste-Crushing Machine for Sustainable Recycling Applications

Abstract

The management of thermoplastic waste presents a significant environmental and operational challenge, especially in developing countries where recycling infrastructure is limited. This study presents the design, fabrication, and performance evaluation of a modified thermoplastic waste-crushing machine developed to enhance crushing efficiency, reduce energy consumption, and promote localized plastic recycling. Key innovations in the machine include a redesigned rotor with three sharp-edged blades, optimized blade geometry, improved hopper configuration, and enhanced pulley alignment. The machine was constructed using locally sourced materials and standard workshop tools. Experimental testing was conducted using polyethylene (PE) and polypropylene (PP) at varying feed rates and rotor speeds (1000–1200 RPM). Results showed a maximum crushing efficiency of 88% and a significant reduction in crushing time, up to 194 seconds faster than a conventional design. Crushed particles exhibited consistent size and morphology, and the machine demonstrated high operational repeatability with minimal variance across multiple trials. The modified machine offers a viable and scalable solution for decentralized plastic waste management, particularly in resource-constrained environments. It contributes toward sustainable recycling practices by enabling effective on-site plastic size reduction, reducing logistics costs, and facilitating material reuse in a circular economy.