CHAPTER 1: INTRODUCTION

1.1 PROJECT BACKGROUND

The number of fast food restaurants has increases every year. Therefore, the
amount of trash product by the restaurants is increasing. The amount of trash also
growing due to the growing number of customers.
Most of trash produced by fast food restaurant is made of paper. Paper is widely
used among fast food restaurant because it is cheap and easy for waste
management. However, with the enormous amount of trash, the workers of the
restaurants are struggling to handle it.
They usually run of space to put the trash and need to spend money to buy
plastic bags to throw away the trash. Huge amount of trash also can make the
restaurant hygiene become worse as the leftover of the food stuck to the trash
become smelly and attracts pests.
That is why our team decided to make our project “Paper trash Compactor”.
With our creation, the huge pile of paper trash can be compressed into small size
bricks. That way the restaurant can save many space and spend less money to buy
plastic bags. By compressing the trash also means the bad smell will not escape
from the trash.
Our team decided to use 2 pneumatic cylinders as our compression tool.
Pressured air is used because it operates with less energy and produce less noise
during operation. In addition, pressured air produces enough energy to compress
trash made by paper.
1.2 PROBLEM STATEMENT
In fast food restaurant, the restaurant worker compact all trash manually.
Sometimes he workers forgot to compress the trash thus make the bin become
full faster. Manual compaction requires a lot of energy. The workers will
exhausted themselves from doing another task in the restaurant. When the
workers feel exhausted, the works will be done slowly.

1.3 PROJECT OBJECTIVE

1. To design a trash compactor system

2. To integrate PLC with pneumatic cylinder and sensors
3. To program the system using CP1E PLC
1.3 PROJECT OVERVIEW
A trash compactor can reduce the workforce required for compacting trash. Trash
compactor not only able to provide more space for collecting trash but can reduce the
cost for recycling.

This project named “Paper Trash Compactor” was inspired from the use of personal
trash compactor that can be install in kitchen, which is popular in Western countries.
From that, the idea of trash compaction into a smaller size and more simple design
for non-industrial place.

The system consists of several major parts, 2 double acting cylinders for the actuator
for compaction, a 5/2-way valve for mechanical control of the cylinders and a PLC
for controller, a limit switch and 4 reed switches as sensor.

Our problems mostly cause by the lack of material to fulfill the original design. Also
our testing in the project meet with failure because the wooden part is easily broken
with the lack of material also mean our program need to be modified from original.
Our solution is following the original design and scale down most of the dimension
and measurement to make our project smaller. In addition, we reduce the compaction
power to minimize the damage done onto the wood.

We eventually able to finish our project and fulfill the requirements needed. After
several testing us able to design a program suitable for our project.
 CHAPTER 2: LITERATURE REVIEW
2.1 INTRODUCTION
Waste compaction is the process of compacting waste, reducing it in size. Garbage
compactors and waste collection vehicles compress waste so that more of it can be
stored in the same space. Waste is compacted again, more thoroughly, at the landfill
to conserve valuable airspace and to extend the landfill's life span. A side effect of
this is that important items, like evidence in a crime, may be difficult to recover from
the garbage. Due to reduced oxygenation, biodegradation of organic waste is also
slowed.
 HOW COMMON RECYCLING PROCESS WORKS

Trash contains many Trash that was

elements such as collected in dumpsite
paper, plastic, metal will be compacted to
and glass give more space

The trash will then be transferred to recycling

center

Trash will then be separated by its

elements.
 WHAT WILL HAPPEN IF WE SEPARATE THE TRASH AND THEN
COMPACT THEM?

The trash are separated

The trash can directly sent to recycling center

for further process

By dividing trash into their types and compacting each one of them separately by
ourselves, we can directly send them to recycling center. This method eliminates the
compaction and separation process when they are mixed. Thus, we can reduce the
cost of recycling.
 Compactor
A compactor is a machine or mechanism used to reduce the size of material such as
waste material or biomass through compaction. A trash compactor is often used by a
home or business to reduce the amount of trash. A baler-wrapper compactor is often
used for making compact and wrapped bales in order to improve logistics.

Normally powered by hydraulics, compactors take many shapes and sizes. In landfill
sites for example, a large tractor (typically a converted front-end loader with some
variant of a bulldozer blade attached) with spiked steel wheels called a landfill
compactor is used to drive over waste deposited by waste collection vehicles
(WCVs).

WCVs themselves incorporate a compacting mechanism, which is used to increase

the payload of the vehicle and reduce the number of times it has to empty. This
usually takes the form of hydraulically powered sliding plates, which sweep out the
collection hopper and compress the material into what has already been loaded.
Different compactors are used in scrap metal processing, the most familiar being the
car crusher. Such devices can be of either the "pancake" type, where a huge
descending hydraulically powered plate flattens a scrap automobile, or the baling
press, where the automobile is compressed from several directions until it resembles
a large cube.
2.1 EXAMPLE OF WASTE COMPACTORS
BigBelly

BigBelly is a solar powered, rubbish-compacting bin, manufactured by U.S.

Company BigBelly Solar for use in public spaces such as parks, beaches, amusement
parks, and universities. The bin was originally designed and manufactured in
Needham, Massachusetts by Seahorse Power, a company set up in 2003 with the aim
of reducing fossil fuel consumption.

It has capacity of 600 liters and automatically starts the compaction when full allows
5x capacity of standard 120L wheelie bins. The flagship hopper design also keeps
waste contained while deterring pest access and preventing waste overflow and
wind-blown litter. It had been proven to reduce street bin collections by an average
86% (Average taken from installations with remote rural and heavy urban councils)
BigBelly also customizable with Options such wraps, stickers, side panels, ashtray,
security shield, foot pedal. The internal compactor increases the litter capacity by 6 -
8 times that of a normal street bin.

Each BigBelly sends an email & text when the bin is 85% full to BigBelly company
server so the management and operatives can view, on desktops and smartphones,
the real time fill levels of all bins, eliminating “milk round” type collection rounds
The usage of BigBelly is proven to eliminate overflowing bins, weekend collections
and birds/vermin scattering rubbish across streets, parks & beaches
 PRESTO waste compactor

PRESTO Wet waste compactors are used to dispose of large quantities of moist or
very wet residual waste or commercial waste that is similar to household waste. As in
all other systems, the PRESTO wet waste compaction container is firmly attached to
the container. The material is compacted by a pendulum compaction plate with an
electro-hydraulic drive system.

All hydraulic cylinders, aggregate and the electrical control are located outside the
intake opening. It an important feature of the PRESTO wet waste compactor. This
way, liquids and waste cannot damage the cylinders. Furthermore, a cleaning
opening for this product can be completely omitted.

PRESTO has particularly low feeding opening and the foldable hook (PHR version)
offer maximum feeding comfort. Its drive elements and bearings are located on the
outside and do not get into contact with the waste material. Low-maintenance
operation is ensured.

The plunger swings in its bearing and is self-cleaning. A cleaning opening is not
necessary. Also PRESTO has a large aggregate cabinet ensures service-friendly
access. Since PRESTO’ s design is absolutely water-tight the installation site cannot
be soiled by any leaking liquids. The central locking system is operated from one
side, so the emptying hatch can be opened safely and quickly.
2.6 DIFFERENCE BETWEEN THE EXAMPLE AND “PAPER TRASH
COMPACTOR”

Difference between BigBelly and “Paper Trash Compactor”

Elements BigBelly Paper Trash Compactor
Size (mm) 1281 X 672 X 660 950 X 450 X 300
Weight (kg) 136 20
Volume 120 17
(Liter)
Compaction 570 100
force (kN)
Actuator Electric motor and chain 2 pneumatic cylinders with
pressured air
Body Galvanized sheet metal steel None
material (outer and interior)
Polyethylene plastic (interior)
Controller IC processor Programmable logic controller
Location Everywhere Fast food restaurant
Type of trash Anything Paper
Energy Solar power 24Vdc electrical supply
supply
 Difference between PRESTO and “Paper Trash Compactor”
Elements PRESTO Paper Trash Compactor
Size (mm) 3830 X 2040 X 2500 450 X 300
Weight (kg) 2750 20
Volume 2000 17
(Liter)
Compaction 2400 100
force (kN)
Actuator Electric motor 2 pneumatic cylinders with
pressured air
Body Welded steel Transparent Perspex
material
Controller Manual Programmable logic controller
Location Waste compaction side Fast food restaurant
Type of trash Anything Paper
Energy Electric power supply 4 bar pressured air + 20Vdc
supply electrical supply
 CHAPTER 3: METHODOLOGY
3.1 INTRODUCTION
Methodology is the systematic analysis of the methods and rules that have been used
in the project in order to find the suitable software. This systematic study focused more
on the programing part. This chapter will describe more about the project
programming from beginning and to the end and describe the suitable software used
to program the controller.

3.2 FLOW CHART

Start

The cylinder immediately

retracted

Reed switches 1 and 3 detects

Cylinder 1 and 2 retracted

Limit switch turned ON

A
 No Reed switches 1
and 3 detects
cylinder retracted
Cylinder 1 and 2 will not
extend
Yes

Cylinder 1 and 2 will

extend

Reed switch 2 and 4 detects

the Cylinder 1 and 2 extended

No Reed switches 2
and 4 detects
cylinder extended
Timer will not start
counting
Yes

Timer will start counting

for 10 seconds

A
Cylinder 1 and 2 will
retracted

End
3.3 BLOCK DIAGRAM

Inputs Controller Pre- actuator Actuator

Start button PLC CP1E 5/ 2 way 2 double

OMRON double acting acting
Stop button solenoid valve cylinder
Limit switch
4 reed switches
24Vdc power 4 bar
supply compressed air
 HARDWARE DEVELOPMENT
Design

Figure 3.4.1.1

In this process, several designs were involved to determine the most suitable design.
Each design was being discussed with supervisor for advisory session. Finally, the
right design has been selected and agreed by both side. At this point, the fabrication
process can be start. The process will go on based on the drawing of design selected.

Project layout
 Fabrication
This is the final design of this project. This project is been developed and fabricated
according to this design.

Figure 3.4.3.1
Figure 3.4.3.1: This first step in fabrication process is to fabricate the project body.
The body is fabricated with aluminum profile. Its material is strong enough to
support the compression force that will be carried out by the double acting cylinder.
 Figure 3.4.3.2
Figure 3.4.3.2: Then the double acting cylinder is attach at the right height for the
compression process. The cylinder is then supported by a pair of aluminum profile.

Figure 3.4.3.3

Figure 3.4.3.3: The solenoid valve is put between the double acting cylinder. The
solenoid valve is supported by a modified base perspex to hold the valve between the
double acting cylinder.
 Figure 3.4.3.4

Figure 3.4.3.4: For the compression baseboard, this project used a thick wood
material. The board is been resizing by modifying the board by pairing a pair of
wood with an iron plate to satisfy the actual size ratio.

Figure 3.4.3.5

Figure 3.4.3.5: The limit switch is put at the bottom right of the body with the right
height so that the trash box can triggered the limit switch. The limit switch is
supported by the modified Perspex to hold the limit switch.
 Figure 3.4.3.6

Figure 3.4.3.6: The paper trash box is then fabricated with wood material that is
strong enough to withstand the compression process.

Figure 3.4.3.7
All the parts and component that needs wiring is been connected. All wires is
connected to the PLC through terminal block. In addition, for the cylinder, the tube is
connected through the valves.
 Figure 3.4.3.8

Figure 3.4.3.8: The PLC, valves, power supply and wire is placed on top of the body
beside the double acting cylinder. The power supply is supported by aluminum
profile while a metal rail supports the PLC.

Figure 3.4.3.9

Figure 3.4.3.9: The program then been transfer into the PLC for wiring testing and
adjustment. During this process, the reed switch is adjusted to a suitable position on
the double acting cylinder for it to function. The speed of the actuator is controlled
using flow control valve.
Pneumatic diagram

Figure 3.4.4.1 Turn ON right solenoid

Figure 3.4.4.2 Turn ON left solenoid

PLC input and output list
Input list
Component Symbol Address
Normally open start St I0.00
push switch
Normally close stop Sp I0.01
push switch
Reed switch 1 R1 I0.02
Reed switch 2 R2 I0.03
Reed switch 3 R3 I0.04
Reed switch 4 R4 I0.05
Limit switch L1 I0.06

Output list
Component Symbol Address
Cylinder 1 extend C1 100.00
Cylinder 2 extend C2
Cylinder 1 retract C3 100.01
Cylinder 2 retract C4
PLC input and output wiring
Input wiring
28

0 24V 0 1 2 3 4 5 6 Com

10 11 12 13 14 15 16

17 18 19 20 21 22 23

St Sp R1 R2 R3 R4 L1

Output wiring
29

0 24V 2 3 Com

24 25

C1 C3 C2 C4

26 27
SOFTWARE DEVELOPMENT
Ladder diagram using CX- Programmer
Figure 4 CX- Programmer
Instruction list
Operand Address Description
LD I0.00 START
OR 16.00 -
AND LD I0.01 STOP
OUT 16.00 -
LD 16.00 -
AND I0.02 REED SWITCH 1
DIFU 17.00 -
LD 17.00 -
LD I0.03 REED SWITCH 2
KEEP 18.00 -
LD 16.00 -
AND I0.03 REED SWITCH 2
DIFU 17.01 -
LD 17.01 -
LD I0.02 REED SWITCH 1
KEEP 18.01 -
LD 16.00 -
AND I0.04 REED SWITCH 3
DIFU 17.02 -
LD 17.02 -
LD I0.05 REED SWITCH 4
KEEP 18.02 -
LD 16.00 -
AND I0.05 REED SWITCH 4
DIFU 17.03 -
LD 17.03 -
LD I0.04 REED SWITCH 3
KEEP 18.03 -
LD 16.00 -
AND I0.06 LIMIT SWITCH
 OR 19.00 -
AND LD 18.00 -
AND 18.02 -
AND NOT T000 -
OUT 19.00 -
LD 19.00 -
LD 0.03 REED SWITCH 2
AND 0.05 REED SWITCH 4
KEEP 20.00 -
LD 18.01 -
AND 18.03 -
OR 19.01 -
AND LD 16.00 -
AND I0.06 LIMIT SWITCH
OUT 19.01 -
LD 20.00 -
AND 16.00 -
TIM 001 #50 -
LD T001 -
OUT 100.02 CYLINDER 1 AND
CYLINDER 2 EXTEND
AND 19.01 -
AND NOT 20.00 -
AND I0.06 LIMIT SWITCH
TIM 000 #100 -
LD 16.00 -
AND NOT I0.06 LIMIT SWITCH
LD T000 -
AND NOT I0.02 REED SWITCH 1
AND NOT I0.04 REED SWITCH 3
3.6 PROJECT PLANNING

Gantt chart

30-Sep-167-Oct-1614-Oct-1621-Oct-1628-Oct-164-Nov-1611-Nov-16
18-Nov-16

1 Proposal Stage 1
1.1 Project title selection
1.2 Project research
1.3 Discussion with supervisor about project
1.4 Project proposal preparation
1.5 Project proposal submission
2 Stage 2
2.1 Feasibility study
2.2 Data collection
2.3 Research the detail about project
2.4 Research the programming that use
2.5 Prepare the material that use during the…
2.6 Complete the final report
2.7 Presentation for the project
 20-Nov-1627-Nov-164-Dec-16 11-Dec-1618-Dec-1625-Dec-16 1-Jan-17

3 Result & Analysis

3.1 Design & testing

3.2 Result & analysis

3.3 Applications

4 Prototype Preparation

4.1 Purchasing

4.2 Model preparation

4.3 Design final testing

5 Report Writing Stage

5.1 Complete the final report

5.2 Preparing for final report submission

6 Presentation Project

6.1 Prepare the material that use during the…

 Work Breakdown Structure

Automatic
Paper Trash
Compactor

Design Programming

Solidwork Testing
program
Sketch
PLC

Brainstorming
Instruction
list

Ladder
Main diagram
structure
Brainstorming

Framework Cylinders Reed Wooden Compaction

switches box base

Buying
Buying Buying Building Building
Cutting
Combining Installation Installing
Building

Testing Testing

Power Testing
supply

Wiring

Testing
 Total cost

1. 2 double acting cylinder

2. 1 double solenoid 5/2-way valve
3. 3 meter 20mm X 20mm aluminum profile
4. 1 limit switch
5. 1 CP1E PLC
6. 24 half round nuts
7. 24 screws
8. 8 aluminum profile caps

Equipment Amount Cost for a single unit(RM)

Double acting cylinder 2 85
Double solenoid 5/2-way 1 90
valve
3 meter 20mm X 20mm 3 meter 40
aluminum profile
Limit switch 1 -
CP1E PLC 1 -
Half round nuts 24 5
Screws 24 3
Aluminum profile caps 8 2
470mm X 120mm X 300 1 70
mm wooden box
Total RM626
 CHAPTER 4: RESULT
4.1 INTRODUCTION
To completed this project there are several method or process to achieve the
objectives of this projects. In this chapter, we will explain methods that have
been applied to diagnose and troubleshoot the problem theoretically and
practically to find a solution for each problem that occurs during the
development of this project. The data that be collected and result also being
explained in this chapter.
 RESULT AND TESTING
Input wiring testing
1. Continuity

Figure 1
Figure 1: we check the continuity of input wiring using a multimeter. If the
multimeter sounds then the wiring connected perfectly.
 2. PLC

Figure 2
Figure 2: Then we connect the PLC to power supply, if the PLC inputs light on, then
input components connects with the PLC.

3. Programming

Figure 3
Figure 3: we connect the PLC to our computer and transfer the program to PLC.
We check the wiring by observing the green color of the program. If the inputs in
the program gives green color, then the program and wiring works.
 Ouput wiring testing
1. Continuity

Figure 4
Figure 4: We check the continuity of output wiring using a multimeter. If the
multimeter sounds then the wiring connected perfectly.
 2. PLC

Figure 5
Figure 5: Then we connect the PLC to power supply, if the PLC inputs light on, then
input components connects with the PLC.

3. Programming

Figure 6
Figure 6: We connect the PLC to our computer and transfer the program to PLC. We
FORCE ON the output and observe. If the cylinders extend then the programming
and wiring work
 Overall testing

Figure 7
Figure 7: We test our project by providing power supply to electrical components
and compressed air to valve. Then we transfer the PLC program to the PLC, we press
the start button and limit switch. We observe both the project and the programming.
Project is successful and works

PROBLEMS AND SOLUTIONS

List of problems
1. Wooden box is too fragile
2. The compactor is too small to fill many trash
3. Requires an air compressor for air supply

List of solutions
1. Replace wooden box with metal for stronger compaction.
2. Build taller compactor to increase the volume of trash can be filled in the
compactor
3. Install a mini portable air compressor into the compactor as a single unit
 CHAPTER 5: CONCLUSION
5.1 Conclusion
The project as a whole was very successful in designing a “Paper Trash Compactor”
by considering necessary thing ensuring it could meet the needed capabilities and
objectives. most difficulties happen in mechanical sector. We were short of time
and money to fill the requirements.

Improvements to the compactor majorly can be achieved from mechanical aspects.

Most compactors do not have a complicated program installed in them. However,
more programs can be install such as reading of trash amount and location of
compactor can be done if multiple sensor and GPS are installed with the compactor.

In conclusion, has achieved its objectives. we were able to design a paper trash
compactor. We also able to install sensors and PLC with it and we program the
system using PLC programmer