Viability of Establishing a Paper Recycling Machine in the Fablab at the College of Science

and Technology.

Introduction to Research (PRW301)

Project Guide: Mrs. Pema Zangmo.

Project Co-guide: Mr. Shankar Raj Giri

BE Third Year Electronics and Communication

Submission Date: 9th March 2024

Group members:

Penjor Namgay Tamang (02200181)

Narapati Khatiwara (02210175)

Jigme Sherab Phuntsho (02210168)

 1. Acknowledgement(S)

We extend our heartfelt gratitude to Madam Karma Kelzang Eudon for providing us with the idea of paper recycling,
Madam Passang, and the Store Incharge for their invaluable support and assistance in providing with all the necessary
data. Additionally, we express our sincere appreciation to our guides, Mrs. Pema Zangmo and Mr. Shankar Raj Giri,
for their guidance and support.

2. Abstract

This study examines the feasibility of introducing a paper recycling machine into the College of Science and
Technology's Fablab, emphasizing sustainability in educational settings. It explores the benefits and economic viability
of implementing this method. Through a comprehensive review of literature, the environmental impact, operational
requirements, and cost-effectiveness of paper recycling machines are analyzed. Using a mixed-methods approach,
including surveys and financial analyses, the research assesses faculty, staff, and student attitudes towards recycling
initiatives and evaluates the potential financial implications. The study aims to provide insights to decision-makers
within the college, offering recommendations for integrating recycling infrastructure into campus facilities. By
fostering environmentally responsible practices, this initiative contributes to the broader discourse on sustainability in
educational institutions.

3. Introduction

Paper recycling involves decomposing and reusing discarded paper to create new products, aligning with global efforts
to minimize environmental impact. Recycling positively affects nature by reducing pollution and promoting
sustainability. Recycled paper stands out as one of the most effectively managed secondary materials, boasting high
recovery and recycling rates worldwide (Miranda et al., 2010; Ristola, 2012). It serves as a technically and
environmentally sound raw material, crucial in the global paper and board industry. However, despite its benefits, the
demand for paper has surged dramatically, leading to a 400% increase in worldwide consumption over the past four
decades. This surge has contributed to deforestation, with 35% of harvested trees used for paper manufacturing
(Cheung & Pachisia, 2015). In the United States alone, waste paper constitutes approximately 40% of total waste,
equivalent to nearly 72 million tonnes annually.

These statistics underscore the urgent need for sustainable waste management practices, highlighting the importance
of initiatives like paper recycling in mitigating environmental degradation, particularly in light of the challenges posed
by accumulating paper waste from exams at institutions such as the College of Science and Technology. To mitigate
this, a cost analysis is proposed to assess the viability of installing a recycling machine. This analysis will evaluate
initial investment, operational expenses, potential savings from reduced paper usage, and overall return on investment.
Through this approach, informed decisions can be made to address the paper waste issue sustainably and economically.

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 1.1 Research Questions
i. How much kilograms of semester end exam paper waste were generated annually for the past 10 years?
ii. How has paper usage within CST changed in the past 10 years, and what factors or events have influenced
these changes?
iii. What are the anticipated trends in paper consumption within the college (CST) for the next 5 years?
iv. Is it viable to establish a paper recycling infrastructure within CST, and what are the associated benefits and
challenges?
v. What are some effective machines for recycling paper waste that could be implemented within the FabLab at
the College of Science and Technology?

1.2 Aim: To assess the feasibility of establishing a paper recycling machine within the Fablab of the College of
Science and Technology through cost analysis.

1.3 Objectives:
● Determine the quantity of answer sheets used per year.
● To conduct a comprehensive financial evaluation for the acquisition of a paper recycling machine.
● Investigate the disparity in revenue generated from direct paper sales versus paper recycling initiatives.
● Analyse historical trends in paper usage over the past decade and project future paper consumption patterns
for the next five years.

1.4 Expected Outcomes:

● Demonstrate the superiority of investing in paper recycling machines over alternative methods.
● Recommendation of the paper recycling machine.

1.5 Significance of Study.

This study investigates the feasibility and cost-effectiveness of recycling answer sheets within the College of Science
and Technology. By analysing the costs of recycling equipment, it aims to promote sustainable waste management on
campus. Additionally, it compares the financial benefits of selling used paper directly versus selling recycled products,
potentially identifying cost-saving opportunities for the college.

4. Literature Review

Paper production and paper waste have a significant environmental impact and are among the leading factors
contributing to pollution. In recent studies, it has been determined that the production of 1 ton of virgin fiber paper,
including types such as art paper, book covers, glossy paper, and high-absorption papers, requires 33 million BTUs of

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energy. Furthermore, this process results in the consumption of 24 trees, the release of 5601 pounds of greenhouse
gases, 22853 gallons of wastewater, and the generation of 1922 pounds of solid waste (Chaudhary et al., 2024). To
tackle this concerning issue, numerous methods are being implemented, including landfilling, incineration, and
recycling. Despite being economical, landfilling requires a large amount of land and generates greenhouse gases, which
pollute the land and water. Although incineration produces energy and reduces waste volume, it has drawbacks
including high upfront costs, emissions of air pollutants, and few contributions to resource conservation. Recycling,
on the contrary, proves to be the most environmentally friendly choice.

The research analysis done by Senarathna et al. (2023) underscores that high-quality paper is produced through the
extensive recycling of paper in large industries, which includes steps like pulping, cleaning, screening, deinking,
dispersion and kneading, and bleaching. These steps are included in various recycling machines to increase the quality
of paper depending upon the raw materials used. In line with Sathish et al. (2018), the conventional manual paper
recycling machine addresses the growing accumulation of waste paper by employing common household appliances,
such as a mixer grinder, for pulp creation, and executing processes like deinking and paper forming. Experimental
components include a screw press and drying, with chemicals like bleach and starch aiding the process but posing
limitations to paper scalability and environmental concerns. Alternatively, the PaperLab A-8000 distinguishes itself
from traditional industrial machines through its utilization of advanced dry fibre technology. This innovation represents
a significant advancement in paper recycling, as it securely transforms waste paper into new products without the need
for water, thereby eliminating the pulping process. (PaperLab A-8000 In-office Dry Papermaking System Epson
Europe, 2016). Despite its notable features and a high production capacity of 720 sheets per hour, the substantial initial
and operational costs totalling 6.5 million Ngultrum preclude its suitability for college settings characterized by
budgetary constraints. Hence, among the aforementioned two satisfactory machines, the subsequent option, namely
the PaperMek IV, proves superior.

The PaperMek IV is a paper recycling machine characterized by its compact design and capability to process 15 kg of
paper daily (Automation Grade: Automatic Waste Paper Recycling Machine, Capacity, 2015). In addition to its
environmental responsibility, the machine consumes 800 liters of water, offering a sustainable approach to paper
recycling. Its compact footprint, spanning 450 square feet, optimizes space utilization without compromising
functionality. Illustrated in Figure 1 are the machine's four primary components: the Univat, ensuring uniform
thickness of paper sheets; the hydra pulper, responsible for pulp production from raw paper waste; the screw presser,
eliminating excess water from wet sheets; and the calendaring machine, designed for polishing and maintaining the
thickness of recycled paper. Operating on a single-phase power supply and requiring four workers, the PaperMek IV
guarantees uniformity and reliability in pulp processing, thereby enhancing productivity, cost efficiency, and
environmental sustainability. Furthermore, the machine yields A3 paper with a thickness of 0.3 mm per sheet,
representing a notable improvement due to the addition of chemicals like rosins and alum (Sathish et al.,2018). These
additives contribute to the paper's enhanced stickiness and compactness, thereby improving its overall quality. Despite
the comprehensive comparison of various paper recycling machines, it is noteworthy that none of the existing research
conducts a detailed cost analysis of the selected machine, representing a significant gap in the literature. Therefore,
addressing this gap will contribute to a more thorough understanding of the economic implications and feasibility of
implementing the chosen machine in various settings.

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 Figure 1: Different parts of PaperMek IV Recycling Machine

5. Method of Investigation.

5.1 Study area and Research Focus

The research focus of this study is exclusively centered on the analysis of answer sheets excluding the supplementary
paper utilized during the semester examinations conducted over the past decade, spanning from 2013 to 2023. The
study area is confined to the College of Science and Technology, with particular emphasis on examining the trends
and patterns in the utilization of answer sheets during these examination periods.

5.2 Research Design.

Participants

Figure 2: Research design overview

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The research design in Figure 1 explored the feasibility and cost-effectiveness of a paper recycling machine called the
PaperMek IV in the College of Science and Technology's Fablab. It consists of combined qualitative insights from
interviews with fablab manager, quantitative data on student enrolment, and paper procurement records from the exam
cell. Data cleaning was done in Excel and analysed using RStudio, including regression analysis. The collected data
exhibit interrelatedness, indicating that changes in one variable correspond with changes in another. To ascertain these
relationships, regression analysis is employed.

5.3 Participants

The participants in the research encompassed various stakeholders within the college. Personnel from the exam cell,
Mrs. Passang Dema who has ten years of working experience as Administration Assistant, keeps the record of all the
data including the total number of students and the number of courses in each year. The college store in charge Mr.
Tenzin Dorji keeps the record of imported answer sheets and its cost from external companies. Mrs. Karma Kelzang
Eudon, the Fablab manager has the experience of paper recycling using traditional method. Mr. Dhan Bdr. Subba
and the Himalayan scrap dealer collect the waste paper at reasonable rate and sell to the recycling units.

5.4 Procedures and Instruments

By following a semi-structured method, the data about the number of total students and courses were collected from
the exam cell of the college, along with information on how many answer sheets constitute 1 kilogram. Data collection
from the store involved gathering details on the quantity and rate of answer sheet booklets procured from external
companies. The information was obtained on the rate at which paper waste is sold to scrap dealers, and insights into
the existing manual pulping recycling method were gathered from Fablab manager. The comparison will mostly be
done in terms of Kilogram unit and the paper size of A4 which is same as the answer sheet. After the completion of
data acquisition, the feasibility of establishing the machine will be analysed within the study period by comparing the
procurement expenditure of the answer sheet and the production of paper from the machine.

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 5.5 Description of Data and Analysis Techniques.
Table 1: Annual Data Summary and conversion factors (2013-2023)

Year No. of No. of Total Total no Total no Annual

Courses Students no of of of paper scrap sales
Conversion
in a / modules Students each revenue
Semester Semester each year(kgs) (in Factors Equivalent
/ total
(SS/AS) Year Ngultrum)
no. of 11 pages (1
students answer sheet
1 module
4 601 3005 1319 273.84 2190.72 booklet = 11
2013 4 718 3590 pages)
2014 5 687 3435 1457 302.89 2419.12
8 Nu. = 265
5 770 3850 papers
2015 5 711 3555 1575 326.88 2615.04 1 Kg
(measured
5 864 4320 manually)
2016 5 805 4025 1750 363.2 2905
5 945 4725 Affected by
2017 5 817 4085 1736 360.29 2882.32 COVID
5 919 4595 Average
2018 5 876 4380 1843 382.5 3060 5
Module
5 967 4835
2019 7 938 4690 1924 399.31 3194.48 Total no of
Total no of
7 986 4930 Students X
modules
2020 7 925 4625 1916 397.5 3181.2 Average Module
7 991 4955
2021 7 502 2510 1637 339.75 2717.92 Total no of Total no of
7 1135 5675 paper(kgs) modules X 11
2022 9 979 4895 2209 458.12 3664.96
9 1230 6150
2023 9 1190 5950 2313 480.05 3840.4 Annual
Total no of
9 1123 Scrap
5615 paper(kgs) / 265
Deals
Total 19679 4084.33 32671.16

The table 1 shows the mixed-method data from the exam cell which was formatted and analysed using excel sheet. In
2021, the total number of students during the spring semester decreased due to the impact of COVID-19. Only 502
students were present on campus during that period. The average module was calculated by taking the average of the
modules present in different courses. The total paper usage for each year was determined by multiplying the total
number of modules by the number of answer sheets utilized per module. Each module corresponds to 11 pages, as the
answer sheet booklet for semester-end exams typically contains 11 pages, excluding any supplementary papers. One
kilogram of paper was equivalent to 265 papers, measured manually, set at a cost of 8 Nu. This rate was obtained from
the scrap dealer.

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 Table 2: Procurement of Paper
Total
Rate(in Quantity(1
expenditure(in
Year ngultrum) booklet=11 pages)
ngultrum)
2013 6 10000 60000
2014 7 10000 70000
2015 7 10000 70000
2016 7 10000 70000
2017-2018 7 12000 84000
2019-2021 7 20000 140000
2022-2023 15 20000 300000
Total 92000 794000
Table 2 presents the procurement data obtained from the college store, detailing the quantity and cost of answer sheet
booklets acquired during the study period. This information highlights the procurement process wherein the college
bought the paper from external companies.

Figure 3:Specifications and Cost Calculation for PaperMek IV (Automatic Grade: Automatic Waste
Paper Recycling Machine, capacity (2015)

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Figure 2 presents key specifications and costs associated with the PaperMek IV Waste Paper Recycling Machine. It
details the machine's capacity (15 kg/day), water usage (800 L/day), power (4 horsepower), and required manpower
(4 persons). The total machine cost is Rs. 695,000, with additional expenses for labour, water, and power consumption.
Water costs Nu. 3.48 for 800 litres, and power usage is estimated at Nu. 3.98 for 4 horsepower, (Tariff Determination
Regulation of 2016, 2017). The operational hours are from 9 AM to 5 PM, four times a month, with a labour cost of
Nu. 1840 for four persons.

Figure 4: Sequential Stages of Manual Paper Recycling Process in Fablab

The manual recycling process, as illustrated in Figure 3, involves three main steps: pulping, framing, and drying.
According to insights gathered from Fablab members, approximately 50 sheets of A5 paper are produced daily using
4kg of paper waste. However, the production rate and paper quality are hindered by inefficient drying methods and
inadequate equipment and materials. The resulting A5 paper size is attributed to the dimensions of the framing
apparatus, which closely resemble that of an A4 sheet.

5.6 Data Limitation

The research study faced several data limitations which impacted the accuracy and analysis of the data:

1. The exact number of students in each department was unavailable, necessitating the use of an average module. This
approach impacted the overall accuracy of the amount paper waste produced.

2. Supplementary answer sheets were not factored into the calculation of total paper consumption during the study
period, potentially leading to an underestimation of paper usage.

3. Information regarding repeaters or students on medical leave retaking exams was not accessible, which could have
influenced the analysis of student enrollment trends.
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 6. Results

Figure 5: Relation between Number of Course and Number of Students

The figure above illustrates the positive correlation between the total number of students and the number of courses.
The regression analysis reveals a coefficient of determination of approximately 0.4642, indicating that the model
effectively explains 46.42% of the variation in the total number of students based on the number of courses offered.
This suggests that changes in the number of courses significantly influence the total number of students, thereby
impacting paper generation.

Figure 6: Relation between the Year and Number of Students

The figure demonstrates a consistent upward trend in student enrollment over the past decade, supported by a positive

regression line slope. An R-squared value of approximately 56% suggests that a significant portion of the variation in

enrollment can be explained by the linear relationship with the year. This correlation implies a likely increase in paper

usage over time, directly influenced by student enrollment.

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 Figure 7: Forecast of the increase in the paper waste

The figure above illustrates the correlation between annual paper production over the past decade and forecasts for the
next five years. A 95% confidence interval ensures forecast accuracy, alongside a MAPE value of 3.47, indicating
minimal error. This data facilitates predicting resource availability, crucial for future planning. Consequently, it enables
understanding the trend of paper resources in the coming years and planning accordingly.

Results by usage of PaperMek IV: The analysis of the machine is done by taking the paper size in A4 same as the
answer sheet and also by decreasing the working period due to the data limitations which is such that the working hour
is for 8 months in a year, 4 times a month, and 8 hours a day even though the machine can function 12 hours of work
load every day. To create a cost comparison, let’s take the study period of 10 years. In line with the operational capacity
of the recycling machine, the calculated production output was determined based on the assumption of a full
operational schedule of 8-hour shifts, conducted 4 times per month. This yielded a monthly production of 8,400 A4
paper sheets. With an envisaged working period of 8 months, the projected total production equates to 67,200 A4 paper
sheets in a year. Over a 10-year period, the total estimated production reaches 672,000 A4 paper sheets.

To compare the cost effectiveness of machine, the expenditure of procured paper is compared with the production of
machine. Table 2 gives the total expenditure and the rate at which the answer was procured. As the recycled paper has
a good quality of paper, the rate of the recycled paper is at Nu. 15. The machine produces 576,000 divided by 11 which
is approximately 61,090 booklet equivalents to a revenue of Nu. 916,350 when multiplied by the rate of Nu. 15 without
including the factors such as labor cost, water and electric bill and the cost of chemicals used.

The expenditure of utilizing the machine are firstly, there will be an investment cost of Nu. 695000 to buy the paper
recycling machine called the PaperMek IV. It consumes 800 liters of water daily to facilitate pulp production, incurring
a daily expense of Nu. 3.48. Over the course of the study period, spanning 10 years, the cumulative water bill is
calculated as follows: 3.48 (daily cost) * 4 (monthly frequency) * 8 (working period) * 10 (study period), resulting in

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a total expenditure of Nu. 1113. The machine's daily power consumption is 2.98 kW, equivalent to Nu. 3.81 in daily
expenses. Thus, over a span of 10 years, the total power cost incurred by the machine amounts to Nu. 1219.2. The
number of people working is 3 where each person has a pay of Nu. 460, which then equals to Nu. 441,600 expense for
the total labor cost. Additionally, in the 10-year operational span of the recycling machine, the consumption of Rosin
and Alum, essential chemicals for the recycling process, has been carefully analyzed. Each day, 0.09 kg of Rosin and
Alum are utilized, totaling 1.35 kg daily. The unit cost of Rosin is Nu. 80 per kilogram, resulting in a daily expense of
Nu. 7.20, while Alum costs Nu. 20 per kilogram, with a daily cost of Nu. 1.80. Over the course of 10 years, the
cumulative expenditure on Rosin amounts to Nu. 2304, and for Alum, Nu. 576, summing up to a total of Nu. 2880 for
both chemicals combined. Therefore, the table 3 shows the financial aspect if the recycled paper is sold at the rate of
15 Nu.

Table 3:Financial Comparison of Scrap Sales and Recycling Revenue over 10 Years

Financial Aspect Amount (in Ngultrum)

Investment Cost (Machine) 695,000
Water Bill 1,113
Power Cost 1,219.2
Labor Cost 441,600
Rosin Cost 2,304
Alum Cost 576
Total Expenditure 1,141,812.2
Revenue from Scrap Sales 32,761
Revenue from Recycling 916,350
Net Profit (Revenue - Expenditure) -225,701.2

7. Discussion

The research, fortified by pertinent literature, delves into the critical analysis of paper production and recycling,
particularly within the context of environmental sustainability. Chaudhary et al. (2024) underscore the substantial
environmental toll of paper production, emphasizing its resource-intensive processes and detrimental contribution to
pollution. In response to these challenges, various methods such as landfilling, incineration, and recycling have been
employed. However, Senarathna et al. (2023) and Sathish et al. (2018) highlight the significance of high-quality paper
production through extensive recycling processes, emphasizing the need for sustainable alternatives. Among these
alternatives, innovative technologies like the PaperLab A-8000 have emerged as promising solutions. These
advancements offer a more environmentally sustainable approach to paper recycling, providing a viable alternative to
traditional methods.

Within institutional contexts, the analysis of student enrollment and paper production yields valuable insights into
resource management dynamics. The observed upward trend in student enrollment, as evidenced by regression
analysis, shows a corresponding escalation in paper usage over time. Furthermore, the correlation between paper
production and forecasts for future resource availability underscores the pivotal role of predictive analytics in resource
planning. Consequently, there exists a compelling need for future research to bridge existing gaps in the literature,
especially concerning detailed cost analyses and feasibility studies of paper recycling technologies. Such endeavors
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are crucial for fostering informed decision-making and implementing sustainable resource management practices
across diverse settings.

8. Conclusion
In conclusion, the examination of paper production, recycling, and resource management within educational
institutions underscores the pressing need for sustainable waste management practices. Existing literature provides
evidence of the significant environmental impact of paper production and the importance of recycling technologies.
However, challenges in cost and feasibility persist, particularly in budget-constrained educational settings. Therefore,
smaller-scale machines like the PaperMek IV may offer a more practical solution due to its lower cost.

Moreover, the analysis of student enrollment, paper production, and resource availability provides valuable insights
into resource management practices within colleges. Despite encountering data limitations, such as the unavailability
of exact student enrollment figures for each course and the exclusion of students on medical leave or repeating courses,
positive trends in paper usage over the past decade were identified. This underscores the potential influence of student
enrollment on resource consumption, emphasizing the interconnectedness of these factors in educational resource
management.

Therefore, with access to more authentic and comprehensive data, we can progress further in addressing the gaps in
the literature. Detailed cost analyses and feasibility studies of recycling technologies are essential for informed
decision-making and sustainable resource management practices. Future research endeavors should prioritize
overcoming data limitations and exploring the economic viability and practicality of innovative paper recycling
technologies in educational settings. By doing so, educational institutions can significantly contribute to environmental
sustainability efforts while meeting their resource management needs effectively.

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 9. References

Automation Grade: Automatic Waste Paper Recycling Machine, Capacity: (2015)

https://m.indiamart.com/proddetail/waste-paper-recycling-machine-21382481097.html

Chaudhary, U., Gusain, R., Dev, A., & Rana, V. (2024). PAPER WASTE RECYCLING IN INDIA: CURRENT SCENARIO

AND FUTURE PROSPECTS. ResearchGate.

https://www.researchgate.net/publication/377815373_PAPER_WASTE_RECYCLING_IN_INDIA_CURRENT_SC

ENARIO_AND_FUTURE_PROSPECTS

Cheung, W. M., & Pachisia, V. (2015). Facilitating waste paper recycling and repurposing via cost modelling of machine

failure, labour availability and waste quantity. Resources, Conservation and Recycling, 101, 34–41.

https://doi.org/10.1016/j.resconrec.2015.05.011

Ervasti, I., Miranda, R., & Kauranen, I. (2016). A global, comprehensive review of literature related to paper recycling: A

pressing need for a uniform system of terms and definitions. Waste Management, 48, 64–71.

https://doi.org/10.1016/j.wasman.2015.11.020

PaperLab A-8000 in-office dry papermaking system | Epson Europe. (2016). https://www.epson.eu/en_EU/paperlab

Sathish, T., Karuppaiyah, M., & Kumar, B. P. (2018). A study on making of compact manual paper recycling plant for

domestic purpose. ResearchGate.

https://www.researchgate.net/publication/330998752_A_study_on_making_of_compact_manual_paper_recycling_pl

ant_for_domestic_purpose

Senarathna, C., Sulaksha, T., Maneth, D., & Perera, D. (2023). Paper Recycling for a Sustainable Future: Global Trends.
ResearchGate.
https://www.researchgate.net/publication/372365680_Paper_Recycling_for_a_Sustainable_Future_Global_Trends

Tariff Determination Regulation 2016. (2017, July). moenr.gov.bt. Retrieved May 9, 2024, from

https://www.moenr.gov.bt/wp-content/uploads/2017/07/dhps2-1.pdf
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