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International Journal of Manufacturing and Production Engineering Original Research

Design and Development of Extruder for Plastic Wastes

  1. Prafulla Bhatia Department of Mechanical Engineering, Pillai College of Engineering, New Panvel, Navi Mumbai, University of Mumbai
  2. Gajanan Thokal Department of Mechanical Engineering, Pillai College of Engineering, New Panvel, Navi Mumbai, University of Mumbai

Abstract

Plastic waste has become one of the most significant environmental challenges due to its widespread use, non-biodegradable nature, and increasing accumulation in landfills and water bodies. The rapid growth in plastic consumption has created an urgent need for effective recycling technologies that can reduce environmental pollution while recovering valuable materials. Among the various recycling techniques, extrusion is considered an efficient and economical method for converting plastic waste into reusable products. This study focuses on the design and development of a low-cost plastic waste extruder for recycling thermoplastic materials into continuous extruded products. The extruder was designed by considering the major components, including the hopper, screw conveyor, barrel, heating system, die, and drive mechanism, to facilitate material feeding, melting, and extrusion. The fabricated machine was experimentally evaluated using Acrylonitrile Butadiene Styrene (ABS) and Polypropylene (PP) plastic waste. During the experiments, ABS was successfully processed at a barrel temperature of 220–240°C, while PP was extruded at 180–200°C. Under these operating conditions, both materials melted uniformly and produced continuous rope-type filaments with stable material flow and satisfactory surface quality. The successful extrusion of both plastics demonstrated the capability of the developed machine to process different thermoplastic materials effectively. In addition to the experimental work, this study reviews the operating principles of extrusion technology, different types of plastic extruders, recyclable plastic materials, and the factors influencing extrusion performance, including processing temperature, screw design, material properties, energy consumption, and product quality. The findings indicate that the developed extruder is capable of converting plastic waste into reusable products using a simple and cost-effective design suitable for small-scale recycling applications. The proposed system offers an environmentally friendly approach to plastic waste management by reducing plastic pollution, promoting material recovery, and supporting sustainable manufacturing practices. Furthermore, the developed extruder has potential applications in educational institutions, research laboratories, and community-level recycling initiatives, contributing to the circular economy through the effective reuse of plastic waste.

Keywords

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