DESIGN AND DEVELOPMENT OF PLASTIC BOTTLE RECYCLER FOR ROPE

PRODUCTION

An Undergraduate Thesis Presented to the Faculty of the School of

Engineering and Computer Studies
Divine Word College of Legazpi
Legazpi, City

In Partial Fulfillment
of the Requirements for the Degree of
Bachelor of Science in Electrical Engineering

FRANK ERWIN BORLAGDAN

WILLIAM BURCE
 CHAPTER 1

INTRODUCTION AND ITS BACKGROUND

INTRODUCTION
The use of plastic bottles is growing day by day. Plastics are cost-effective,

lightweight, durable, and corrosion-resistant materials with excellent thermal and

electrical insulation properties, according to Andrade et al. (2006). Polyethylene

terephthalate (PET), high-density polyethylene (HDPE), polyvinyl chloride (PVC), and

low-density polyethylene (LDPE) are plastics commonly used in making water, oil, and

other liquid bottles, found in various forms in our daily lives. As stated by Lin (2016),

PET bottle waste, including 78% of priority pollutants, clogs drainage systems, mixes

with river water, and eventually enters the ocean, posing a significant threat to marine

life and ecosystems. China's Operation National Sword in 2018 banned the import of

certain waste products, including plastics, affecting the recycling industry globally, as

China is the world's largest importer of hard-to-recycle plastics and processed them for

the West. (Bbrooks et al. 2018). Thus, result of the restriction, the recycling industry has

been severely impacted worldwide. As per the findings of Rochman et al. (2019), 70.9

percent of pet bottles find their way into the environment and cause pollution. In their

study Saikia and Brito's study reveals that most plastic recycling occurs at the industry

level, with PET bottles being a highly recyclable option due to their non-toxic melting

process and their ability to survive underwater for longer periods compared to other

polymers.

A recycling machine is a tool used in environmental engineering to melt plastic

materials into granules for new products, focusing on developing technically reasonable

solutions to environmental problems by designing, building, and maintaining systems to

control waste produced by municipalities and private industries. (O.K. Lhesiulor et al.)

Since plastics do not decompose, the accumulation of plastic waste after use poses an

environmental concern. The production of pure plastic raw materials requires significant

amounts of energy. Recycling is often cheaper than creating goods from scratch and
addresses the growing issue of trash disposal. Expanding the recycling program and

requiring less expensive machinery are necessary to address recycling-related issues.

Recycling systems collect waste, divert it from landfills or hazardous disposal, and

process it for recycling. Their performance is characterized by environmental and

economic efficiency. The need to recycle plastics is crucial, especially in developing

countries due to economic and environmental issues caused by plastic use. The

growing plastic waste in landfills is causing serious problems due to its inert nature,

resistance to bio-degradation, and potential hazards such as fires, long-lasting burns,

and pollution. Therefore, proper disposal and recycling are crucial for reducing plastic

waste.

Promoting plastic recycling can save production costs, conserve resources, and

reduce environmental pollution, as waste equipment volume increases in both

industrialized and industrializing nations. To address these issues, a machine

specialized in plastic recycling was developed using locally available materials.

Apparently, Malaka (2020) highlights the growing concern for plastic pollution and

climate change, prompting artists to create visually appealing artworks that highlight the

environmental impact of waste, emphasizing the importance of recycling for sustainable

solutions. Therefore, rope is a popular, high-demand product made from PET bottles,

with concerns about quality and safety due to the sharpness of the bottle strips.

Accordingly, Sattar highlighted the practicality of recycling waste plastics to improve the

environmental performance of the polymer business. This small arrangement can create

high-quality rope and reduce plastic bottle usage. Thus, this study aims to improve

recycling machine technology, create job opportunities, and ensure efficient waste

management. It also recommends supporting PET bottle recycling, promoting

environmental and economic efficiency, producing less energy-consuming plastic

bottles, and producing high-quality ropes. To address this study in the development of

recycling machines for rope production, the purpose of rope will be used in making

things like fish nets, fishing hooks without rads, crab traps, and docking lines for building
small fishing boats and other rope users. The recycling machine will need to be able to

test the strength of rope under UTM (Universal testing machine) to ensure the

production of high-quality ropes.

STATEMENT OF THE PROBLEM

The primary aim of this study is to design and develop a plastic bottle recycler

which transforms plastic bottles into rope. Specifically, this research seeks to answer

the following questions:

1. What is the design of the plastic bottle recycler for rope production?

2. What is the level of performance of the device in terms of:

2.1 Time of production per bottle:

2.2 Length of produced rope per bottle:

2.3 Rate of production: and

2.4 Strength of rope produced?

3. What is the user’s acceptability of the device in terms of:

3.1 Ease of use

3.2 Maintainability

3.3 Functionality: and

3.4 Cost?

SIGNIFICANCE OF THE STUDY

 This research is intended to provide important knowledge and information related

to the selected topic, existing studies and related websites needed and also this study

would be beneficial to the following:

Junk Shops. Junkshops stand to benefit significantly from this research as it

would offer them access to a recycling apparatus capable of processing their

accumulated plastic bottles.

Roper. This research assists them in creating a new version of their product.

Rope Users. This research offers them a fresh outlook on a new high-quality

rope product.

Community. This study would be beneficial to the community since it is eco-

friendly.

Researcher. This study would help the researcher to enhance their knowledge

about the chosen topic.

Future Researchers. The result of this study will serve as a guide to future

researchers who wish to conduct the same or related to this research.

SCOPE AND DELIMITATION

The study aims to develop a recycling device that utilizes a melting process to

turn plastic bottles into rope. It specifically targets junk shops and rope users in Tabaco

City and nearby municipalities who will participate as respondents. The researcher will

create a sample design to be tested, record the results, and also provide a survey about

the acceptability of the device to the users.

The study does not address the country’s recycling rate or waste reduction,

focusing solely on the device’s performance and user acceptance. The study will only

use 7L PET plastic bottles to ensure consistent measurement when it comes to the rate

testing which involves the length of rope and time used to produce. The researcher will
focus exclusively on the population of Tabaco City and neighboring municipalities due to

limited time and financial resources.

SYNTHESIS OF THE STATE-OF-THE-ART

The prior literature and research examined have furnished the researchers with

foundational knowledge, insightful perspectives, and crucial background information,

enriching the groundwork for the current investigation. For instance, Sattar et al.'s

(2022) exploration concentrated on transforming cut and melted PET bottles into a

singular, high-quality rope strip measuring 10mm in width and 0.5mm in thickness,

capable of bearing a maximum load of 64.1kg. Building upon this, the current study

aims to enhance load-bearing capacity by introducing a new machine capable of

producing two separate strips, which will then be intertwined, thereby increasing the

load-bearing potential.

DEFINITION OF TERMS
This study made use of some terms enumerated below which are defined

operationally and conceptually for clearer understanding.

Polyethylene Terephthalate (PET). Recognized as a type of clear, durable, and

versatile plastic, and is a synthetic resin derived from the copolymerization of ethylene

glycol and terephthalic acid.

High - density Polyethylene (HDPE). Is a hydrocarbon polymer prepared from

ethylene/petroleum by a catalytic process. It is a kind of thermoplastic which is famous

for its tensile strength. Its unique properties can stand high temperatures.

Polyvinyl chloride (PVC). An economical and versatile thermoplastic polymer. It is

widely used in the building and construction industry to produce door and window

profiles.
Low - density Polyethylene. (LDPE). Is a flexible, odorless, transparent, 100%

recyclable thermoplastic polymer popular in products like grocery/garbage bags, juice

containers, and cling wrap.

Persistent, bioaccumulative, and toxic (PBT). Chemicals are a class of chemicals

that resist degradation and persist in the environment for extensive periods.

Plastic Recycling. Process of turning used plastic into new products to reduce waste

and environmental harm.

Carbon emissions. Released during the combustion of fossil fuels, such as coal, oil,

and natural gas, to produce electricity.

Universal Testing Machine (UTM). is a type of mechanical testing equipment that is

utilized for determining the mechanical properties of various materials, such as tensile

strength, compressive strength, bending strength, and shear strength.

RELATED LITERATURE

Foreign Studies

Up-recycling has emerged in various sectors to address the challenges of plastic

waste pollution, leading to the creation of a creative movement called recycled artwork.

This movement inspires artists to address excessive consumption and environmental

issues. Recycled art transforms waste into art, using materials like plastic, paper,

cardboard, wood, glass, metals, and rubber. This approach goes beyond traditional

recycling by creating products that exceed their financial, cultural, and social costs.

(Hamid, 2016).

According to Sattar et.al 2022, in their study entitled “Low-Cost consumer level

plastic bottles recycling for rope”, stated that Recycling waste plastics improves the

polymer industry's environmental performance, allowing for self-sufficiency in household

bottle recycling. This process produces high-quality rope and prevents large amounts of

plastic bottles from entering the environment. The study suggests that improving the
performance and minimizing flaws of a plastic recycling machine can help combat

global warming and carbon emissions. The machine is portable, cost-efficient, and

energy-efficient, and could be made at a low cost. The government should support this

project with financial and technical support. A pilot project could be started to test the

machine's performance, as the study successfully produced high-quality ropes.

Moreover, the study by O.k Ihesiulor about “Optimization of the developing of a

plastic recycling machine” which involves the design and construction of a plastic

recycling machine.” A low-tech, low-cost machine is designed for recycling low-density

polyethylene in specific applications, where contamination may be overlooked. It

performs well, is efficient, cheap, easy to operate, and maintains. Experimental analysis

shows that 200°C is required for each piece of used plastic to melt. The machine uses

conveying and heating to shred and melt materials, requiring only two people to

operate. It's designed using locally available raw materials, making it cheap and easy to

maintain. The machine has a high finishing recycling efficiency of 97%, takes 2 minutes

to recycle a batch of plastics, and has a recycling capacity of about 265 kg/hr. It's cost-

and energy-efficient, with a specific mechanical energy consumption of 30.23 kJ/kg.

Local Studies

The absolutely astonishing amount of plastic bottles that everyone uses and

throws into the garbage can every day is truly impressive. This represents an economic

waste since the plastic in bottles is a commodity that is worth money and can be

reused. Also, from an ecological perspective, this poses several problems. Even when

sent for recycling, the volume of plastic bottles makes it challenging to transport and

accommodate them efficiently. According to the 1000KV Technologies Project, by using

mechanical structure, motor alignment, and a structured design, this kit produces the

flat rope by extracting the plastic bottles.

Engr. Santos, Leah et.al. (2021), studied about “Design and Development of a

bottle semi - automated plastic bottle and plastic waste” This research aims to design a
semi-automated machine for producing ecobricks using PET bottles and sachets. The

machine uses Arduino-controlled shredding and compacting mechanisms, with a load

sensor and limit switch for notification. After tests, the machine achieved 100%

functionality and 86.67% reliability, demonstrating its potential for efficient ecobrick

production.

The machine produces ecobricks with no significant difference in weight or production

time compared to manual methods. It is functional in shredding, compacting, and

weighing processes, reliable for two to five continuous working hours, and accurate,

offering a minimum of 525 grams of fillers.

As stated by De Alday, Jhonvher L., et.al (2022), in their study entitled “Design

and Fabrication of Vending Machine with Shredding System” PET bottles are crucial in

the food and manufacturing industry, but they contribute significantly to environmental

waste. A study aimed to promote recycling through a vending machine, integrating a

PET bottle shredder with beverages. Future research could improve the machine's

design and features to reduce environmental waste.

For instance, a study conducted by Lecera Teresa et.al (2020), entitled

“Effectiveness of making an Eco-friendly Chair by using recyclable plastic bottle for

Grade 12 ABM Students in Bestlink College of the Philippines” emphasize that plastic

bottles are constructed from high-density plastic. Plastic bottles are now one of the top

problems not only in the country but also worldwide. Plastic bottles are a huge barrier to

the canals because they cause flooding. Thus, the researchers had an idea to make an

eco-friendly chair by using plastic bottles. The study comprised all students who

presented facts regarding the nature and status of anything. This study was concerned

with the circumstances of the relationship. The results of the study strongly agreed that

making an eco-friendly chair by using waste plastic bottles is effective because it turns

plastic bottles into useful things in our community and helps the students to be more

creative and disciplined.

 CHAPTER 2

RESEARCH DESIGN AND METHODOLOGY

This chapter presents the methodological procedures by which the data pertinent

to the research problems were collected. It presents the research method, design,

frameworks, and sampling techniques or the instrument that is used in the study.

RESEARCH METHOD

Considering the developmental focus of this study, we opted for a quantitative

research design to ensure a methodical and focused investigation. By utilizing

standardized procedures and numerical data, quantitative research enhances objectivity

and reproducibility. This approach involves the quantification and analysis of variables

to derive precise outcomes, making it ideal for our research objectives.

This approach involves the use and analysis of numerical data through

specialized statistical methods to answer critical questions such as who, how much,

what, where, when, how many, and how (Apuke, 2017). Utilizing numerical data during

the testing and evaluation phase demonstrated significant advantages for data

collection. The quantitative research design provided an objective basis for

measurement and evaluation, particularly in tests of the level of performance and

acceptability. Furthermore, numerical data facilitated easier manipulation for the

creation of tables and graphs, enhancing the clarity and precision of our findings.
RESEARCH DESIGN

In this study, the developmental research approach was used. The

developmental research involves situations in which the product-development process

is analyzed and described where the final product is evaluated. Additionally, it focuses

more on the impact of the product on the learner or the organization and imposes a

general analysis of design development or evaluation processes as a whole or as

components

This study aims to determine the performance level of the device by assessing

the strength of the rope through tensile strength tests conducted using a Universal

Testing Machine (UTM). Tensile strength machines, as highlighted in the research by

Wang et al. (2018), are crucial for evaluating the tensile mechanical properties of

various wire ropes, strands, connectors, and other relevant rigging components. These

machines provide detailed insights into the tensile strength and durability of materials,

which is essential for ensuring their reliability and safety in practical applications.

In addition to evaluating tensile strength, this study will also measure the

production rate by calculating the average length and time required for the device to

produce high-quality rope. By examining both the mechanical properties and production

efficiency, this research will offer valuable insights into the overall performance and

potential improvements for the device in rope manufacturing.

Furthermore, the study will also determine the user’s acceptability of the device

to the users in terms of ease of use, functionality, maintainability, and cost.

The following research instrument will be used to obtain the information needed.

First are the materials needed to build the device such as PET plastic bottles, sharp

blades, rope pulleys, electric motors, flat bars, angle bars, and steel tubes.

To ensure that all the information needed is obtained, the data collection

procedures will be followed. This will be done in the form of an experimental study. This
data collection procedure will be investigated by using tables containing the results and

supported with other related studies to better understand the results with the help of

other experts.

Therefore, the observations gathered will lead to a conclusion that will be derived

from the data gathered from testing the device and the observations of the researcher.

The researcher will be conducting a survey to determine the acceptability of the device.

CONCEPTUAL FRAMEWORK

INPUT
 PET plastic bottle
PROCESS OUTPUT
 AC-DC rectifier
 Arduino Uno Survey Development of a
 Sharp Blade questionnaire recycling device that
(Cutter) utilizes a melting
Data gathering process to turn plastic
 Heater Cartridge
Series of test, bottles into rope.
 Belt Pulleys
including strength of
 Gears rope, and efficiency
 Electric Motor of the device

FEEDBACK

Figure 1. Conceptual framework

Figure 1 is the framework of the study. The researcher used input, process, and

output to demonstrate the conceptual framework of the study. As stated in the input, the

materials needed to construct the device. The researcher should execute procedures

that will illustrate the step-by-step procedures for the development of a recycling device
that utilizes a melting process to turn plastic bottles into rope and the gathering of data

and a survey questionnaire to complete this study project and obtain the desired output.

STATISTICAL TREATMENT OF THE STUDY

Statistical treatment of data is essential to make use of the data in the right form.

Raw data collection is only one aspect of any experiment. After the collection and

gathering of data, the results gathered from the survey questionnaire will be interpreted,

This statistical approach facilitated the researchers in drawing conclusions based

on the data, known as the sample mean method:

M=∑
❑x
❑
n
M = mean
x = data acquired
n = total number of terms

Level of Performance Test

The researchers plan to perform a series of performance evaluations on the

device, including rope strength tests and production rate assessments, to collect

essential information about the device's capabilities. The item below shows the test and

trials conducted on the device in terms of:

a. Production Rate Assessment. The researchers elected to conduct a series of ten

(10) tests aimed at determining the average production rate, quantified in meters per

second. This procedure involves inserting a 7-liter PET bottle into the device and

measuring the length of the product generated from a single bottle. Following this, the

researchers will record the time taken to produce a rope from one 7-liter PET bottle, and

get the total and average length to get the average rate of production. By calculating the

production rate, they seek to gather precise and valuable data on the device’s efficiency
and output capabilities, which will be crucial for a comprehensive evaluation of its

overall performance. The table below shows the tests conducted and the parameters

considered for the tests.

TRIAL LENGTH (meters) TIME (seconds) RATE (meter per second)

Trial 1

Trial 2

Trial 3

Trial 4

Trial 5

Trial 6

Trial 7

Trial 8

Trial 9

Trial 10

TOTAL

MEAN

Table 1: Production Rate Trial

b. Rope Strength Test. A critical component of this assessment involves determining the

tensile strength of the product which is ropes using a Universal Testing Machine (UTM).

This machine precisely identifies the breaking point of an object by measuring its tensile

strength, providing objective and reliable data. The results from this conclusive test will
be meticulously documented by the researchers, ensuring comprehensive and accurate

reporting of the device's performance characteristics.

Acceptability Test

The researchers would like to determine the acceptability of the device, in terms

of ease of use, maintainability, functionality, and cost. The researchers prepared an

evaluation form that will be rated by 15 participating respondents which are chosen

through convenience sampling. The data is measured using a five (5) point Likert scale,

a system that analyzes the perspective, or level of agreement of the respondents to a

survey question. The test is composed of fifteen (15) statements to rate from 1 to 5

interpreted by the table below.

RATING INTERPRETATION

5 Strongly Agree

4 Agree

3 Neutral

2 Disagree

1 Strongly Disagree

Table 2: Acceptability Test Score

To interpret the data after getting the average value of the ratings answered by

the respondents, the researchers used a different scale to evaluate the results which is

shown in the table.

SCALE EVALUATION

5.00 – 4.20 Highly Acceptable

 4.19 – 3.40 Moderately Acceptable

3. 39 – 2.60 Acceptable

2.59 – 1.80 Fairly Acceptable

1.79 – 1.00 Poorly Acceptable

Table 3: Acceptability Scale\

The table below shows the questions the researchers used to evaluate the acceptability of the

device in terms of:

A. Ease of Use

Questions Strongly Disagree Neutral Agree Strongly

Disagree Agree
(2) (3) (4)

(1) (5)

The device is user-friendly

The device's operating

instructions are

understandable and

beneficial.

Operating the device

requires minimal physical

effort.

The device enhances the

user’s experience.
 Compared to similar

devices, this device is easier

to use.

Table 4: Ease of Use Survey Datasheet

B. Maintainability

Questions Strongly Disagree Neutral Agree Strongly

Disagree Agree
(2) (3) (4)

(1) (5)

The maintenance tasks can

be performed without the

need for specialized

training.

It is easy to diagnose

problems that occur with the

device.

The design of the device

allows for easy access to

components that need

maintenance

I am confident in my ability

to maintain the device over

the long term.

 I am satisfied with the

overall maintainability of the

device.

Table 5: Acceptability Scale

C. Functionality

Questions Strongly Disagree Neutral Agree Strongly

Disagree Agree
(2) (3) (4)

(1) (5)

The device effectively

converts plastic bottles into

rope.

The device's design

supports its functional

capabilities effectively.

The device's operation is

smooth and reliable.

The device's output meets

industry standards for rope

production.

The device's controls are

responsive and easy to

adjust during operation.

Table 6: Acceptability Scale

D. Cost
Ethical Considerations

The researchers properly informed the respondents regarding the purpose,

procedures, potential risks, and benefits of the research before they agreed to

participate. Respondents were under no obligation or pressure to participate in testing

the device if they felt they were not capable of doing so. The researcher chose an

alternative where providing one's name is not mandatory, aimed to create a comfortable

environment for respondents to answer the survey. The collected data was solely

utilized for research objectives, and measures were taken by the researchers to

dissociate responses from individuals to reduce the likelihood of identification. The

researchers upheld the rights and well-being of the respondents and ensured the

integrity and credibility of their research findings.