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Design, Analysis and Fabrication of Automatic Plastic Shredder Machine

Preprint · November 2022

DOI: 10.13140/RG.2.2.31808.20482

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Foysal Ahmed Neerob Md. Al-Shahriar Islam Ziko

Bangladesh University of Engineering and Technology Bangladesh University of Engineering and Technology
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Dhananjoy Banik Joy Pratic Sarker

Bangladesh University of Engineering and Technology Bangladesh University of Engineering and Technology
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 Design, Analysis and Fabrication of
Automatic Plastic Shredder Machine
Foysal Ahmed Neerob, Dhananjoy Banik Joy, Pratic Sarker, Md Al-Shahriar Islam Ziko
Bangladesh University of Engineering and Technology
Abstract: Plastic pollution has become one of the most
burning issues due to rapid increase in production of
disposable plastic products. Plastic recycling aims to
reduce plastic pollution and plastic shredder plays an
important role in the recycling plants. Existing shredding
technology requires continuous power consumption and
contains complicated gearbox with belt pulley system. We
have designed and fabricated a shredder which can
overcome these problems to some extent. The shredder
has some unique features such as it starts rotating the
blades automatically if it detects any object at a certain
distance from the blades. The blades also stop rotating
after a certain time if the machine does not detect any
object in proximity. This functionality was developed
using a micro-controller and it reduces the electric power
consumption. The shredder can also rotate in reverse
direction which is quite advantageous in a way that if any
plastic gets stuck, it can be pulled from the shredder
easily. Altogether our shredder is an energy efficient
design, easily mountable and scalable. The machine can
shred PVC sheets, disposable cups, plastic bottles with
this customized shredder and the chips we found were
mainly rectangular in shape. Then chips can be further
used for value added plastic products.
1. Introduction
Plastic is a non-biodegradable material which is of
high demand in our modern life. Plastics are used as
they are very easy and cheap to make and they can
last a very long life due to its chemical properties. In
the last decade plastics have affected human health
and life very badly by polluting the environment.
Plastic pollution is caused by the accumulation of
plastic objects and particles in the environment.
Since the industry began, annual global plastic
production has exploded from some 1.5 million
metric tons in 1950 to 359 billion metric tons in
2018. The cumulative production of plastic has
already surpassed eight billion metric tons
worldwide, with further increases expected in the
coming decades. The global production of plastic
was about 359 million metric ton according to a
report published by Ian Tiseo in September 2020 [1].
In Bangladesh plastic consumption rate is about 5 kg
per capita ton per year. According to a study
conducted by Waste Concern, a Bangladeshi social
business enterprise that promotes resource recovery
From waste, concluded that approximately 0.8
million tons of plastic waste is generated per year in
Bangladesh [2]. The large amount of dumped unused
plastics accumulates at different places and
adversely affects human life and other elements of
the environments. Plastic recycle is a process that
aims to reduce high rate of plastic pollution by
putting less pressure on virgin materials to produce
plastic products. In plastic processing recycling
industries, plastic shredder plays an indispensable
role as they recoup plastic wastes and size reduction.
No matter whether it is plastic container, PVC, PET
bottle, the shredder gets it down into reusable
shapes. Our shredder is no different from the usual
plastic shredder machines rather it has some benefits
in certain cases. Our shredder does not require
continuous power consumption and does not have
any complicated gear box which makes it more
economical, handy and compact in size than the
conventional shredders. The blades start rotating if
it detects an object in proximity and stop after a
certain time if it does not detect anything. This
characteristic feature lessens unnecessary power
usage and is helpful where less power consumption
is required. Rotating the blade in reverse direction is
also a characteristic feature of our shredder that aids
in pulling plastics that get stuck.
According to Shiri et al [3] a combined washing and
shredding machine is developed in a single chamber.
The design consists of only a belt drive for the
operation of the rotary blade shaft. Ravi [4] gives
importance in improving the performance of the
shredding machine by optimizing the design of the
blade. The modified blade has two cutting edges,
unlike the conventional shredders.
2. Materials & Methodology
2.1 Materials and Components:
Components Specification
1. Blades Ferritic Stainless Steel
(Diameter 155+.5mm)
2. Shafts Stainless Steel (Diameter
29±.5 mm)
3. Motor 24V DC motor (Torque
11.5 Nm, 15 rpm)
 4. Bearing DG3258-X1 Blades: We choose stainless steel material
5. Frame Mild steel to make cutter blades of the shredder. All
6. Base Wood of the blades were cut identically from a
7. Electric Microcontroller, servo round disk using wire cutting operation.
Components motor, sonar sensor, Then a key hole was made in each blade for
custom switch system, assembling with shafts using milling
breadboard operation.

Shafts: Material of each shaft was mild

steel. Turning and taper operations was
done by Lathe machine to achieve
necessary dimensions. Each of the shafts
contains two beatings to support the
assembly and for smooth motion transfer.

Support Box: Support box was made of

mild steel which makes the machine rigid
during cutting operation.

Automated System: Micro-controller was

introduced for making the machine self-
working. Ultrasonic sensor was used to
sense object in proximity. This system
allows to start shredding after sensing
object and stop shredding after completion.

Electronic Circuit: Electric power is used

to operate the machine. Two individual
voltage sources were used to give DC
power to motors. Electronics system
controls the power consumption of the
motors. We also used DPDT switch for
altering between manual reverse rotation
and automated system of forward rotation.
Reverse rotation is required to pull out the
chips from the blade gaps if the blades get
stuck while operating.

Miscellaneous: Two keys were used in the

shafts so that the blades and shafts rotate
simultaneously without any relative
motion. A wooden base is used to support
whole assembly. There is a cavity in the
wooden base to accumulate the chips after
shredding.

Fig 2.1: (a) Blade (b) Shaft (c) Frame

2.2 Methodology

The shredder machine consists of blades, shafts,

body, automated system, electronic circuit etc. The
machining processes done for making the
components are discussed below:

Figure 2.1: Flowchart of Fabrication.
3. Result & Discussion
3.1 Blade
Blades: We used 8 identical blades. All of the blades
are made of Stainless steel and each shaft carries
four
blades. The consecutive blades are positioned in a
way that the angle between two cutting edges remain
at a certain angle to maintain gradual shredding
operation. These blades are hold tight with shaft by
a keyhole system. Each blade has 3 teeth and the
shape was formed by wire cutting operation.
Fig 3.1: Cutting Blade
Force Calculation (for a single motor):
Motor Torque = 11.5 Nm
Motor Torque = Blade Torque
Mass of the blade = 1291.53 grams = 1.29
kg
Volume= 164526.49 mm3
Average cutting diameter, davg = (160-15)
= 145 mm
Average cutting radius, ravg = 72.5 mm
Exerted Force by Blade, F= T/ravg =
11.5/72.5*10-3 = 158.62 N
3.2 Shaft
The shaft was made of mild steel. Each shaft carries
four blades and contributes in motion transfer from
motor to cutting blades. A key hole system is
implemented to attach the blades with shaft to
impede relative velocity
Fig 3.2: Shaft
When the shaft remains in static condition, it holds
four blades and four rings between the blade. Each
shaft is supported by two ball bearings with MS
support.
Fig 3.3: FBD of Shaft
Fig 3.4: (a) Shear Force Diagram of Shaft; (b)
Bending Moment Diagram of Shaft
3.3 Electronics and Automated System
In this machine we use some electronic components
to make an automated system. An ultrasonic sensor
is used here to sense objects at a distance about 20
centimeters. After detecting objects, an automatic
switch completes the circuit and transmit power to
the motors. Two DPDT switches are used to rotate
the motors in reverse direction and also supply
voltage to the micro-controller. The automated
switch is built based on servo motor which works
mechanically as a switch. Here two different voltage
sources are used to driver two motors separately.
The motors receive 12V as DC power which is
converted from 220V-50 Hz AC power through a
AC-DC converter.

Fig 3.5: Chips After Shredding.

Machine assembly and the sequence of the

Fig 3.5: Circuit Diagram. operation is given below:
3.4 Other Components

Motors: Two motors were used to rotate the blades

in opposite direction on the shafts. These motors
have gear functionalities so we didn’t need any
additional gear box or belt pulley system and can
save some space. The torque of the motor is very
high compared to its speed to shred the plastics
smoothly.
MS Support: These are used to support the shafts so Fig 3.6: Schematic Diagram of Shredding
that it doesn’t get inclined with the motor attachment Operation.
line. This component helps to reduce collision 3.6 Static Analysis
between the blades’ tips and enables a swift shred.
Wooden Base: This part provides rigidity to the
whole machine. It has a cavity through which the
chips can be collected. It helps to carry the machine
from one place to another place easily.
Bearing: We have used two bearings in each shaft to
decrease frictional loss and smooth power transport
to the blades.

3.5 Chips

After shredding operation, rectangular chips are

formed which are accumulated in the box cavity,
then collected from it. The length of the chips is
around 10mm to 35mm, the width of the chips is 5
mm to 10 mm with thickness around 5 mm to 10
mm.

Fig 3.7: Total Deformation for (a) 3003 Al-Alloy

(b) Plain Carbon Steel (c) Ferrite Stainless Steel
(d) Brass
 an automatic switch which is much reliable
than existing models.
• Chip size is satisfactory due to the
convenient blade design.
• low manufacturing cost and functionality
makes it a good choice for recycling plant.
• Additionally, an increased torque can shred
much harder plastics and increased rpm can
make chip formation faster.
5. References
1. Plastic Waste Worldwide - Statistics &
Facts | Statista
2. Plastic pollution in Bangladesh: A
review on current status emphasizing the
impacts on environment and public
health (eeer.org)
Fig 3.8: Equivalent Elastic Strain for (a) 3003 Al-
Alloy (b) Plain Carbon Steel (c) Ferrite Stainless
Steel (d) Brass
Equivalent Equivalent
Total
Elastic von-Mises
Material Deformation
Strain Stress
(mm)
(mm/mm) (MPa)
3003 Al-Alloy 0.12276 0.00288 198.9
Plain Carbon Steel 0.04727 0.00115 234.21
Ferritic Stainless
0.04963 0.00117 234.21
Steel
Brass 0.09529 0.00199 198.9
Table 1: Comparison of Total Deformation, Strain,
Stress of Different Materials

In this study, for static analysis, we calculated force

and line pressure considering the safety factor 4 and
simulated in ANSYS platform.

We used ferritic stainless steel as blade material

considering availability, comparatively easy
machining process and also no heat treatment is
needed for this material. Similar operation can be
obtained by using other cheap materials such as
brass as strain is almost similar to ferritic stainless
steel. Brass can be a good choice to manufacture low
cost shredder blade since stress is lower than
existing blade material.

4. Conclusion

The following important point drawn from our

project work as follows:

• The shredder is compact, easy to build and

reassemble, easy maintenance.
• Easy to manufacture and sustaining to
objects to be shred.
• Motor is positioned in a way that makes it
easy to replace.
• Risk for human operation as well as power
consumption are minimized by installing

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