FORM 2

The Patent Act 1970

(39 of 1970)

&

The Patent Rules, 2005

COMPLETE SPECIFICATION
[See Section 10 and Rule 13]

A PROCESS AND A SYSTEM FOR

MANUFACTURING OF TILES/BLOCKS
FROM WASTE PLASTICS

HINDURA INFRASTRUCTURE PVT.

LTD., A COMPANY INCORPORATED
UNDER THE COMPANIES ACT, 1956,
WHOSE ADDRESS IS 721/16
SENADATTA PETH, NEAR KALE
MOTOR SCHOOL, PUNE - 411030,
MAHARASHTRA, INDIA

THE FOLLOWING SPECIFICATION

PARTICULARLY DESCRIBES THE
INVENTION AND THE MANNER IN
WHICH IT IS TO BE PERFORMED.

1
 TECHNICAL FIELD OF THE INVENTION

The present invention relates to a system and process for manufacturing

tiles/blocks materials for construction purposes.

5 BACKGROUND OF THE INVENTION

Cement bricks, fly ash bricks, pavement blocks of cement, mud bricks are
available in the market which are normally manufactured by mixing sand, cement,
water and other ingredients followed by pouring in different moulds of required
shapes and sizes. Blocks manufactured by such processes are costly and easily
10 breakable.

There are several drawbacks of manufacturing tiles or blocks by above mentioned

processes and raw materials. Raw materials such as stone, sand, clay, etc are
obtained by digging the earth that causes soil erosion. Large quantity of water is
needed for manufacturing, construction and utilization of the cement. Further, the
15 kiln process may cause air pollution. Thus, soil, water, air, vegetation and human
health are adversely affected by using the conventional processes for
manufacturing bricks or tiles.

The current state of art includes the bricks or tiles manufactured by using specific
waste plastics as additives to stone or asphalt or any solid waste like raw
20 materials. It is required to have specific collection of the individual material or
sort the desired material from the generally collected plastic waste. The process of
collecting specific plastic or sorting the desired type from collected plastic adds to
cost. Furthermore, also such efforts do little to solve the problem of utilization of
vast unsorted, unsortable or unclassified bulk mixtures of plastic waste.

25 Accordingly, there is a need of a process for manufacturing tiles or blocks using

the waste material that overcomes above mentioned drawbacks.

2
 SUMMARY OF THE INVENTION

The present invention relates to a system and a process for manufacturing of

tiles/blocks from waste plastics. The system includes a first conveyor, a second
5 conveyor line, a mixing unit, a hot stock chute and a moulding station. The first
conveyor line is used for conveying and processing of a first raw material. The
first conveyor line includes a first feeder for delivering the processed first raw
material. The second conveyor line is used for conveying and processing of a
second raw material. The second conveyor line includes a second feeder for
10 delivering the processed second raw material. The mixing unit is used for heating
the processing of raw materials received from the first feeder and the second
feeder thereby forming a hot mix stock. The mixing unit includes a burner for
mixing and heating the processed raw materials from about 180 degrees to about
200 degrees. The hot stock chute is used for transferring the hot mix stock
15 received from the mixing unit, the hot stock chute having a vibrating unit attached
thereto. The molding station form converting hot mix stock to tiles/ blocks by
application of pressure, wherein the pressure ranges from about 40 tones to about
50 tones.

20 The present invention provides a process for manufacturing of tiles/blocks from

waste plastics comprises. Initially, the first raw material is processed through a
first conveyor line and the second raw material is processed through a second
conveyor line. In next step, the first and second raw materials are mixed and
heated with each other and other additives and fillers in a mixing unit at a
25 predefined temperature thereby obtaining a hot mix stock. In the next step, the hot
mix stock is transferred to a multi station hydraulic moulding machine through a
hot stock chute using the vibrating unit. In the next step, the hot mix stock is
molded in the multi station hydraulic moulding machine under a predefined
hydraulic pressure thereby forming blocks/tiles
30

3
 BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a system and process for manufacturing tiles/blocks from stone
aggregates and waste plastics in accordance with a preferred embodiment of the
present invention.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing objects of the present invention are accomplished and the problems
and shortcomings associated with the prior art, techniques and approaches are
overcome by the present invention as described below in the preferred
10 embodiments.

All materials used herein were commercially purchased as described herein or

prepared from commercially purchased materials as described herein.

Although specific terms are used in the following description for sake of clarity,
these terms are intended to refer only to particular structure of the invention
15 selected for illustration in the drawings and are not intended to define or limit the
scope of the invention.

References in the specification to “preferred embodiment” means that a particular

feature, structure, characteristic, or function described in detail thereby omitting
20 known constructions and functions for clear description of the present invention.

In general aspect, the present invention provides a process and a system for
manufacturing tiles/blocks from stone aggregates and waste plastics.

The present invention is illustrated with reference to the accompanying

25 drawings, throughout which reference numbers in brackets indicate
corresponding parts in the various figures.

4
 Referring to FIG. 1 a system for manufacturing tiles/blocks from waste plastic
(herein after “the system (100)”) in accordance with an embodiment of the present
invention is shown. The system (100) includes a plurality of conveyor lines, a
mixing unit (138), a hot stock chute (140), a moulding machine (142), mould
5 ejector (148), delivery conveyor (144), a pallet stacker (150) and a packing area
(152).

In accordance with this one embodiment, the plurality of conveyor lines include a
first conveyor line (I) and a second conveyor line (II). However, it is understood
10 here that the number of conveyor lines may vary in alternative embodiments of
the present invention. The first conveyor line (I) includes a bucket elevator (104)
connected to a rotary sieve (106). The rotary sieve (106) includes a first conveyor
(108) attached thereto at first end of the first conveyor (108). Second end of the
first conveyor (108) connected to a first storage yard (110). The first storage yard
15 (110) includes a bucket elevator (112) that conveys material from the first storage
yard (110) to a heating unit (116). The heating unit (116) includes at least one
burner (114) positioned therein. The heating unit (116) has a first feeder (118)
attached thereto.

20 In accordance with an embodiment of the present invention, the first conveyor

line (I) is used for conveying and processing of a first raw material i.e. stone
aggregates (102). However it is understood here that any other raw material may
be conveyed and processed through the second conveyor line (II) in alternative
embodiment of the present invention.
25
In this one embodiment, the stone aggregates (102) are passed through the bucket
elevator (104) to a rotary sieve (106) for sieving. The rotary sieve (106) converts
stone aggregates (102) into dust fine particle (DF). In this one embodiment, the
size of the obtained clean stone aggregates ranges from 4 mm to 13.5 mm. The
30 sieved stones are moved through the first conveyor (108) to the storage yard
(110). The sieved stones are further conveyed to the rotary heating unit input

5
 hopper (116) for heating. In this one embodiment, the heating unit (116) includes
a burner (114) that heats the sieved stones by an open flame thereby converting
dust particles into hot clean stone aggregates (102). The hot clean stone
aggregates are then transferred to the first feeder (118).
5
In accordance with this one embodiment of the present invention, the second
conveyor line (II) includes a second conveyor (122) that passes sequentially
through a rotary washer (124), a rotary dryer (126), a second storage yard (128),
a feed shredder (130) and a third storage yard (132). The third storage yard (132)
10 includes a bucket elevator (134) that carries a material from the third storage yard
to a second feeder (136).

In accordance with this one embodiment, the second conveyor line (II) conveys
and processes a second raw material i. e. waste plastic (120). However it is
15 understood here that any other raw material may be conveyed and processed
through the second conveyor line (II) in alternative embodiment of the present
invention.

The waste plastic (120) includes waste plastic bottles or other plastic goods such
as carry bags, cups, thermocoles, multi and mono layered waste plastics, plastic
20 film packaging materials of thickness ranges from 2 mm to 4mm. The waste
plastics used in present invention works a binder. PET bottles are used as filler
that are added at the mixing stage of two raw materials in the mixing unit (138).

The waste plastic (120) is sorted and passed through the second conveyor (122) to
25 the rotary washer (124). The rotary washer is equipped with water flushed in (WI)
in the rotary for washing and cleaning of the sorted waste plastics (120) and
excess water is flushed out (WO). The cleaned waste plastic is transferred into
the rotary dryer (126) through the second conveyor (122) for drying. In this one
embodiment, the washed plastic is dried by air drying technique. The air dried
30 sorted waste plastic is further transferred to the second storage yard (128) and
then send to a feed shredder (130) through the second conveyor (122) for

6
 shredding of the air dried sorted waste plastic. In this one embodiment, the feed
shredder includes three rotary knives and two stationery knives placed in a
predefined configuration. The shredded sorted waste plastic is further send to the
third storage yard (132) and further transfer to the second feeder (136) through the
5 bucket elevator (134).

In this one embodiment, the first feeder (118) and the second feeder (136) are
connected to the mixing unit (138). The hot clean stone aggregates and the
shredded plastic are fed into the mixing unit (138) through the first feeder (118)
10 and the second feeder (136) respectively. In this one embodiment, a proportion of
mixture second raw material is 40% to the weight of the first raw material. The
hot stone aggregates and the obtained shredded waste plastics are mixed together
along with fillers and other additives in the mixing unit (138) under a predefined
temperature to obtain a hot mix stock. The hot mix stock is transferred to the
15 molding machine (142) through a hot stock chute (140). The hot mix stock is
subjected to a predefined pressure by using prefixed hydraulic pressure thereby
forming mould of blocks/tiles (146) of a predefined size. The mould of
blocks/tiles (146) are transferred are ejected to a delivery conveyor (144) for
curing and settling of the blocks/tiles. The mould of blocks/tiles (146) are further
20 delivered to the mould ejector (148), stacked on the pallet stacker (150) and are
transported to a packing area (152) thereafter.

In this one embodiment, molding of the hot mix stock is carried out in the multi
station hydraulic moulding machine (142). The multi station hydraulic machine
25 (142) includes a plurality of moulds of predefined size placed in a rotary table
(Not Shown). The hot mix stock is poured from the hot stock chute (140) into the
moulds (146) of desired shape and size with a vibrating unit. In next step, the hot
mix stock is subjected to a predefined hydraulic pressure forming pressed
blocks/tiles. In this one embodiment, the hydraulic pressure used for pressing the
30 hot mix stock into the moulds ranges from 40 to about 80 tones.

7
 In the last step, the pressed blocks/tiles are allowed to get dried and cool and
further subjected to forced air cooling for a predefined time. In this one
embodiment, the tiles/ blocks are allowed to cool from about 15 minutes to about
30 minutes. It is understood here that the cooling techniques and time required for
5 cooling and drying may vary in alternative embodiments of the present invention.
It is understood here that the blocks/tiles may be dipped into a suitable color, to
produce a colored block/or polished smoothly using a granite polishing machine.

The present invention provides a process for manufacturing tiles/blocks from

10 waste plastics comprises. Initially, the first raw material is processed through a
first conveyor line (I) and the second raw material is processed through a second
conveyor line (II). In next step, the first and second raw materials are mixed and
heated with each other and other additives and fillers in a mixing unit (138) at a
predefined temperature thereby obtaining a hot mix stock. The maximum
15 temperature of the mixing unit is 250 0C. In the next step, the hot mix stock is
transferred to a molding machine (142) through a hot stock chute (140) using the
vibrating unit (Not Shown). In the next step, the hot mix stock is molded in the
multi station hydraulic molding machine (142) under a predefined hydraulic
pressure thereby forming blocks/tiles (146).

20 In this one embodiment of the present invention, processing of the second raw
material includes the steps of: In first step, the waste plastic materials are sorted
and passed to the rotary washer (124) through the second conveyor (122). In the
next step, the sorted waste plastic raw material is washed in the rotary washer
(124). The washed and cleaned sorted waste plastic is transferred to the rotary
25 dryer (126) through the second conveyor (122). In this step, the washed sorted
waste plastic is air dried in the rotary dryer (126). In this one embodiment, the
plastic is washed by water. However, it is understood here that some cleansing
agent may added to the water as per the requirement. In the next step, the air dried
sorted waste plastic is transferred to the feed shredder (130) through the second
30 conveyor (122) to obtain shredded clean and sorted waste plastic of a predefined

8
 size. In this one embodiment, the size of shredded plastic ranges from about 2 mm
to about 4 mm.

The blocks/tiles as manufactured using the method in accordance with an

embodiment of the present invention have high compression strength, flexural
5 strength malleability and ductility. In accordance with the present invention, the
conveyors belts, mixing units, elevators are driven by geared motors. However, it
is understood here that some other power mechanism may be used in alternative
embodiments of the present invention.

10 EXAMPLES

Only a few examples and implementations are disclosed. Variations,

modifications, and enhancements to the described examples and implementations
and other implementations can be made based on what is disclosed.

Examples are set forth herein below and are illustrative of different amounts and
15 types of reactants and reaction conditions that can be utilized in practicing the
disclosure. It will be apparent, however, that the disclosure can be practiced with
other amounts and types of reactants and reaction conditions than those used in
the examples, and the resulting devices various different properties and uses in
accordance with the disclosure above and as pointed out hereinafter.
20
During mixing step the predefined quantity of obtained hot clean stone
aggregates used is approximately 4 kg and the predefined quantity of shredded
clean and sorted waste plastics used is 1.2 kg to 1.6 kg. The quantity depends
upon the size of the obtained tile/block. For 1 x 1 foot block requires 4 kg of stone
25 aggregate and 1.2 kg to 1.6 kg of shredded waste plastics.

The foregoing description of specific embodiments of the present invention has

been presented for purposes of illustration and description. They are not intended
to be exhaustive or to limit the present invention to the precise forms disclosed,

9
 and obviously many modifications and variations are possible in light of the
above teaching.

The embodiments were chosen and described in order to best explain the
principles of the present invention and its practical application, to thereby enable
5 others, skilled in the art to best utilize the present invention and various
embodiments with various modifications as are suited to the particular use
contemplated.

It is understood that various omission and substitutions of equivalents are

contemplated as circumstance may suggest or render expedient, but such are
10 intended to cover the application or implementation without departing from the
spirit or scope of the present invention.

10
 We Claim:

1. A system for manufacturing of tiles/blocks from waste plastics, the system

comprising:
5 a first conveyor line for conveying and processing of a first raw
material, the first conveyor line having a first feeder, the first feeder
delivering the processed first raw material, the first conveyer line having a
first conveyor belt, the first conveyer belt carrying the first raw material
sequentially through a rotary sieve, a heating unit and the first feeder;
10 a second conveyor line for conveying and processing of a second raw
material, the second conveyor line having a second feeder for delivering
the processed second raw material, the second conveyor line having a
second conveyor belt, the second conveyer belt carrying a second raw
material sequentially through a rotary washer, a rotary dryer, a feed
15 shredder and the second feeder;
a mixing unit attached to the first feeder and the second feeder, the
mixing unit receiving processed first and second raw materials therein, the
mixing unit having a burner positioned at a predetermined position
therein, the mixing unit facilitating mixing and heating of the processed
20 first and second raw materials at a temperature from about 180 0C to about
200 0C to form a hot mix stock;
a hot stock chute connecting to the mixing unit, the hot stock chute
receiving the hot mix stock from the mixing unit, the hot stock chute
having a vibrating unit attached thereto; and
25 a molding station connecting to the hot stock chute, the molding station
applying a predetermined pressure in a range from about 40 tones to about
50 tones for converting the hot mix stock to form tiles/ blocks.

11
 2. The system for manufacturing of tiles/blocks from waste plastics as
claimed in claim 1, wherein the first raw material includes stones, sand,
bricks, crushed rock and the like.

5 3. The system for manufacturing of tiles/blocks from waste plastics as

claimed in claim 1, wherein the second raw material includes plastic
bottles, plastic carry bags, cups, thermocoles, multi layered and mono
layered waste plastics, plastic film packaging materials and the like.

10
4. A process for manufacturing tiles/blocks from stone aggregates and waste
plastics as claimed in claim 1, the process comprising the steps of:
(a) processing a first raw material through a first conveyor line;
(b) processing a second raw material through a second conveyor line;
15 (c) mixing and heating the first and second raw materials in a mixing
unit at a predefined temperature thereby obtaining a hot mix stock;
(d) transferring the hot mix stock obtained in step (c) to a multi
station hydraulic moulding machine through a hot stock chute; and
(f) moulding the hot mix stock in the multi station hydraulic moulding
20 machine under a predefined hydraulic pressure thereby forming
blocks/tiles.

5. The process for manufacturing tiles/blocks from stone aggregates and

waste plastics as claimed in claim 4, wherein the temperature of the
25 mixing unit is from about 1800 to about 2000 C.

6. The process for manufacturing tiles/blocks from stone aggregates and

waste plastics as claimed in claim 4, wherein the pressure applied for
moulding is from about 40 tones to about 80 tones.
30

12
 7. The process for manufacturing tiles/blocks from stone aggregates and
waste plastics as claimed in claim 4, wherein the proportion of the second
raw material is 40% by weight as that of the first raw material.

Dated this 06th day of August, 2018

5 FOR HIDURA INFRASTRUCTURE PVT. LTD.
By their Agent

(Anand Gopalkrishna Mahurkar) (IN/PA- 1862)

Krishna & Saurastri Associates LLP
10

13
 ABSTRACT

A PROCESS AND A SYSTEM FOR MANUFACTURING OF TILES/BLOCKS

FROM WASTE PLASTICS

5 The present invention provides a system and process for manufacturing of

tiles/blocks from waste plastics comprises. The system (100) includes a plurality
of conveyor lines for processing of raw materials. The second raw material and
the preheated first raw material are mixed and heated with each other and other
additives and fillers in a mixing unit (138) at a predefined temperature thereby
10 obtaining a hot mix stock. The hot mix stock is transferred to a molding machine
(142) through a hot stock chute (140) using the vibrating unit. The hot mix stock
is molded in the molding machine under a predefined hydraulic pressure thereby
forming blocks/tiles (146).

FIG. 1 for publication

14