Habib Ngumar Faruq, Tri Andi Setiawan, Anda Iviana Juniani, Khoirul Amin

Extruder Machine Design as a Facility for Utilization of High Density Polyethylene Waste into Plastic Panels

Introduction

Extruder machine design as a facility for utilization of high density polyethylene waste into plastic panels. Design and develop an extruder machine for recycling HDPE plastic waste into value-added panels. Supports sustainable waste management and reduces environmental plastic threats.

Abstract

Plastic waste is a persistent material that poses a serious environmental threat due to its resistance to natural decomposition. Indonesia generates approximately 27.3 million tons of waste annually, of which 19.8% is plastic, highlighting the urgent need for effective recycling strategies. This study aims to design and develop an extruder machine to recycle High-Density Polyethylene (HDPE) waste into value-added plastic panels. The research methodology comprised literature review, needs identification, concept design development using the Ulrich method, concept selection through the Analytical Hierarchy Process (AHP), fabrication, and machine performance testing. Concept 1 was selected as the best alternative among the three proposed design concepts, achieving the highest Alternative Weight Evaluation score of 35.14, compared to 34.65 for Concept 3. The fabricated machine measures 779.5 mm in length, 610 mm in width, and 689.3 mm in height, powered by a 1 HP electric motor and equipped with four 300 W heaters. Performance tests demonstrated that the machine successfully melted HDPE and produced plastic panels with uniform surfaces, good material density, and minimal voids, although the resulting color tended to be dark. The findings confirm that the developed extruder machine effectively supports HDPE recycling into functional products, contributing to waste reduction efforts and promoting sustainable plastic waste management technologies.

Review

This paper presents a timely and highly relevant study on the design and development of an extruder machine specifically engineered for recycling High-Density Polyethylene (HDPE) waste into value-added plastic panels. Addressing the critical environmental challenge posed by persistent plastic waste, particularly in regions with high generation rates like Indonesia, the project offers a tangible and sustainable solution. The clear objective to transform a prevalent pollutant into a functional product positions this research as a significant contribution to waste reduction efforts and the promotion of a circular economy. The research methodology employed is commendably structured, commencing with a literature review and needs identification, progressing through concept design using the Ulrich method, and culminating in concept selection via the Analytical Hierarchy Process (AHP). The successful fabrication of the machine, with precise dimensions and specifications (779.5 mm x 610 mm x 689.3 mm, powered by a 1 HP electric motor with four 300 W heaters), demonstrates a practical and well-executed engineering endeavor. Performance tests indicate positive outcomes, with the machine effectively melting HDPE and producing panels characterized by uniform surfaces, good material density, and minimal voids. However, the observation that the resulting color tended to be dark warrants further investigation, as it could impact marketability. While AHP was used for concept selection, the abstract highlights a very close score between Concept 1 and Concept 3 (35.14 vs 34.65), suggesting that a deeper articulation of the discriminative criteria leading to Concept 1's selection would strengthen the justification. In conclusion, this study successfully validates the design and development of an extruder machine as an effective facility for repurposing HDPE waste into plastic panels, thereby offering a practical avenue for sustainable waste management. The findings confirm the machine's capability to produce functional products from recycled plastic, which is a crucial step towards mitigating environmental pollution. For future research, it would be highly beneficial to quantitatively characterize the mechanical properties (e.g., tensile strength, flexural modulus, impact resistance) of the produced panels to fully assess their potential applications. Furthermore, exploring strategies to address the dark color, such as pre-sorting of waste, incorporation of pigments, or optimized processing parameters, along with an analysis of the machine's throughput, energy efficiency, and economic viability, would significantly enhance the commercial readiness and impact of this promising technology.

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