MECHANICAL ENGINEERING DEPARTMENT

BACHELOR OF MECHANICAL ENGINEERING

NTA LEVEL 8

SENIOR PROJECT II

PROJECT TITLE: DESIGN AND MANUFACTURE OF EXTRUDING MACHINE

PROJECT TYPE: DESIGN

STUDENT NAME: RAYMOUND RUGARULA

ADMISSION No: 150545402833

CLASS: [Link] 15 ME

July, 2018
 Certification

CERTIFICATION
The undersigned certify that he has read and hereby recommend for acceptance by the Dar es
Salaam Institute of Technology project titled “DESIGN AND MANUFACTURE OF
EXTRUDING MACHINE, in partial fulfillment of Bachelor of Engineering degree in
Mechanical Engineering.

Signature……………………
[Link]
(Project Supervisor)

Date………………………

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 Declaration

DECLARATION
I, RAYMOUND RUGARULA (150545402833) hereby declare to the best of my knowledge
that this project is my original work and it has not been copied from somewhere or someone else.
All the contents found in this project are due to my knowledge in Mechanical Engineering,
Information obtained from my supervisor, literature review as well as different experts in the
Mechanical field.

Signature……………………
RAYMOUND RUGARULA
(Student)
Date…………………………

ii
 Abstract

ABSTRACT
This project work is on the design and manufacturing of an extruding machine. This is the
machine designed to extrude or to force out the various melted plastic waste to give a continuous
profile. Plastic wastes like bags, bottles, buckets, gallon are various categories of plastics which
have also different melting temperatures, it is difficult to work with them especially when
required to mix with other materials like sand, but also sorting method of one type of plastic of
the same melting temperature is a tedious work and time consuming. The profile given out will
have uniform melting temperature. The melted plastic waste will be shielded by using shielded
machine and mixed with sand. The mixture is melted together using pest making machine. The
pest given out will be used to make building materials like roofing tiles when further process
takes place

This report involves introduction, literature review, methodology, data collection, data analysis,
conclusion and recommendation. In introduction, input of the machine which is plastics and
machine in general is explained. Through literature review the currently methods of melting
plastics and different types of extruding machine were reviewed. In methodology various
methods to achieve the project are discussed and through data collection the data were collected
from SIDO, Dar es Salaam city council (DCC) and Silafrica company limited in order to
observe the available extruding machines and types of plastic melted. Various parts were
designed after analyzing the data [Link] conclusion summation has made for all chapters
but also through recommendation opinions and advice are given

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 Dedication

DEDICATION
I would like to dedicate this Project to my Family, Mother, brothers and sisters who supported
me much for the fully support they have towards all my movements, especially in academic and
financial issues, I do appreciate their efforts.
To my friends, and classmates ([Link]. 15 ME) whom we shared all issues especially
academically and socially wise.

iv
 Acknowledgement

ACKNOWLEDGEMENT
I would like to extend my gratitude sincere thanks to those who in one way or another have
contributed to the successful completion of my project (senior project 1),
The DIT Mechanical Engineering staff who through their criticisms, suggestions, comments and
opinions, which stand as a cornerstone of this project work, have successfully raised this project
to this point. I do appreciate their efforts. However, the support and education I have had from
them remains as valuable integrated to my life.
Sincerely thanks prevail to [Link] as project supervisor for all the efforts towards the
accomplishment of senior project one. With his proper guidance all the way long, this project has
become even more feasible. The project coordinator, Dr. Malifedha, J.M. whose challenges,
advice, and supervision, have added a very exceptional value to this work, and Dr. Sanga F.M
the course lecturer and head of the mechanical depatment for his guidance, advice and
encouragement towards the accomplishment of this work.
Special thanks to Machael kilango at SIDO, Jagiri and many others who played a very crucial
role during the data collection procedures in their respective sites.

Lastly, thanks to the class of [Link]. 15 ME and friends for their cooperation especially in
discussion concern academic matters.

v
 Contents

CONTENTS
CERTIFICATION ........................................................................................................................... i
DECLARATION ............................................................................................................................ ii
ABSTRACT ................................................................................................................................... iii
DEDICATION ............................................................................................................................... iv
ACKNOWLEDGEMENT .............................................................................................................. v
LIST OF FIGURES ....................................................................................................................... ix
LIST OF TABLES .......................................................................................................................... x
LIST OF SYMBOLS AND ABRIVIATIONS .............................................................................. xi
CHAPTER ONE ............................................................................................................................. 1
INTRODUCTION .......................................................................................................................... 1
1.1 Back ground .............................................................................................................................. 1
1.2 Categories of plastics. ............................................................................................................... 2
1.3 Problem Statement .................................................................................................................... 3
1.4 Project objectives ...................................................................................................................... 3
1.4.1 Main objective ........................................................................................................................ 3
1.4.2 Specific objectives .................................................................................................................. 3
1.5 Significances of the project ....................................................................................................... 4
1.6 Project scope: ............................................................................................................................ 4
CHAPTER TWO ............................................................................................................................ 5
LITERATURE REVIEW ............................................................................................................... 5
2.1 Introduction ............................................................................................................................... 5
2.2 Extruding machine .................................................................................................................... 5
2.2.1 Features of extruding machine .............................................................................................. 5
2.2.2 Components of the extruding machine ................................................................................... 5
2.2.3 Categories of extruding machine. .......................................................................................... 6
2.2.4 Single-screw extruding machine ............................................................................................ 6
2.2.5 Twin-screw extruding machine .............................................................................................. 7
2.2.6 Ram extruding machine ......................................................................................................... 8
2.3 Input of the machine ................................................................................................................. 9
2.4 Designing of the machine ....................................................................................................... 13

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2.4.1Types of design ...................................................................................................................... 13

2.4.2 Characteristics of designing ................................................................................................ 14
2.5 Manufacture of prototype of extruding machine .................................................................... 15
2.5.1 Classifications of engineering manufacturing processes are follows: ................................ 15
2.5.2 Goals of manufacturing process .......................................................................................... 15
2.5.3 The primary consideration for a manufacturing process .................................................... 15
2.6 To test the prototype of extruding machine ............................................................................ 16
CHAPTER THREE ...................................................................................................................... 17
METHODOLOGY ....................................................................................................................... 17
3.1 Introduction ............................................................................................................................. 17
3.2 literature review ...................................................................................................................... 17
3.3 Data collection ........................................................................................................................ 17
3.3.1 Interviewing ......................................................................................................................... 17
3.3.2 Industrial and Observation ................................................................................................. 18
3.4 Data analysis ........................................................................................................................... 18
3.4.1 Design Alternative for the mechanism ................................................................................. 18
3.4.2 Determination of the machine mechanism parameters ....................................................... 18
3.4.3 Design of the machine mechanism ....................................................................................... 18
3.4.4 Manufacturing the Prototype of extruding machine ............................................................ 18
3.4.5 Report writing ...................................................................................................................... 18
3.4.6 Testing of the Prototype of extruding machine .................................................................... 19
CHAPTER FOUR ......................................................................................................................... 20
DATA COLLECTION ................................................................................................................. 20
4.1 Introduction ............................................................................................................................. 20
4.2 Observation ............................................................................................................................. 20
4.3 Data collected.......................................................................................................................... 22
4.3.1 Properties of mild steel ........................................................................................................ 25
4.3.2 Properties of cotton wool ..................................................................................................... 25
CHAPTER FIVE .......................................................................................................................... 26
DATA ANALYSIS ....................................................................................................................... 26
5.1 Introduction ............................................................................................................................. 26

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 Contents

5.2 Conceptual development ......................................................................................................... 26

5.3 Selection optimum alternatives .............................................................................................. 27
5.3.1 Selection of a suitable design ............................................................................................... 27
5.4 Alternative A: extruding machine using piston mechanism ................................................... 27
5.5 Alternative B extruding machine using single screw mechanism .......................................... 28
5.6 Alternative C: extruding machine using double screw mechanism ........................................ 30
5.7 Determination of the weighting factors .................................................................................. 31
5.8 DESIGN CALCULATIONS .................................................................................................. 32
5.5.1 Machine consists of the following components .................................................................... 32
5.8.1 DETERMINATION OF MACHINE CAPACITY .................................................................. 33
5.6.2 Design calculations of hopper ............................................................................................. 33
5.83 Design calculations of the extrusion screw ........................................................................... 36
5.8.5 Liner speed developed in screw Vs ..................................................................................... 37
5.8.5 Design of Coupling: ............................................................................................................. 38
5.8.6 Design of the heater ............................................................................................................. 39
5.8.8 Design of the shaft ............................................................................................................... 40
CHAPTER SIX ............................................................................................................................. 43
CONCLUSION ............................................................................................................................. 43
6.1 Conclusion .............................................................................................................................. 43
6.2 Recommendation .................................................................................................................... 43
REFERENCES ............................................................................................................................. 44

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 List of figures

LIST OF FIGURES
Figure 2. 1: Single-screw extruder .................................................................................................. 6
Figure 2. 2:Twin-extruding machine .............................................................................................. 8
Figure 2. 3: Ram extruding machine............................................................................................... 9
Figure 3. 1: Extruding machine .................................................................................................... 21
Figure 3. 2: High density plastics ................................................................................................. 22
Figure 5. 1: Ram extruding machine............................................................................................. 27
Figure 5. 2: Single screw extruding machine................................................................................ 29
Figure 5. 3: Double screw extruding machine .............................................................................. 30

ix
 List of tables

LIST OF TABLES
Table 2. 1: Physical properties of plastic ...................................................................................... 11
Table 2. 2: Visual properties of plastic ......................................................................................... 11
Table 4. 1: Solid waste collection per day .................................................................................... 23
Table 4. 2: Waste components ...................................................................................................... 23
Table 4. 3: Shows the existing extruding machine ..................................................................... 23
Table 4. 4: Temperature zones involved in melting plastics ........................................................ 24
Table 4. 5: Parts and proposed materials for extruding machine .................................................. 24
Table 5. 1:Average marks for alternative A.................................................................................. 28
Table 5. 2: Average marks for alternative B ................................................................................. 29
Table 5. 3: Average marks for alternative C ................................................................................. 31
Table 5. 4: Weight factors ............................................................................................................. 31
Table 5. 5: Ranking the design alternative.................................................................................... 31

x
 List of symbols abbreviations

LIST OF SYMBOLS AND ABRIVIATIONS

Dr Doctor of philosophy
Eng Engineer
DIT Dar es Salaam Institute of Technology
[Link] Bachelor of Engineering
mm Millimeter
PDS Product Design Specifications
o
C, Degree Centigrade
TShs Tanzanian Shillings
PET Polyethylene terephthalate
HDPE High-density polyethylene
LDPE Low-density polyethylene
PP Polypropylene
PVC Polyvinyl chloride
PS Polystyrene
etc et cetera

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 Chapter one

CHAPTER ONE

INTRODUCTION
1.1 Back ground
Extruding machine is a machine in which plastic wastes are melted and form continuous profile.
The machine will have segments consist of various temperatures, since these various plastic
wastes have different melting point, then output (product) will have the same melting point when
cooled and melted again. The first thermal plastic extrusion was in 1935by Paul Troester and his
wife Ashley Gershoff in Hamburg, Germany. Shortly after, Roberto Colombo of LMP developed
the first twin screw extruding machine in Italy (Rauwendaal,2001).
In the extrusion of plastics, the raw compound material is commonly in the form of nurdles
(small beads, often called resin) that are gravity fed from a top mounted hopper into the barrel of
the extruding machine. The material enters through the feed throat (an opening near the rear of
the barrel) and comes into contact with the screw. The rotating screw (normally turning at e.g.
120 rpm) forces the plastic beads forward into the heated barrel. The desired extrusion
temperature is rarely equal to the set temperature of the barrel due to viscous heating and other
effects. In most processes, a heating profile is set for the barrel in which three or more
independent PID-controlled heater zones gradually increase the temperature of the barrel from
the rear (where the plastic enters) to the front. This allows the plastic beads to melt gradually as
they are pushed through the barrel and lowers the risk of overheating which may cause
degradation in the polymer. Extra heat is contributed by the intense pressure and friction taking
place inside the barrel. In fact, if an extrusion line is running certain materials fast enough, the
heaters can be shut off and the melt temperature maintained by pressure and friction alone inside
the barrel(Alting,1994).
There are five possible zones in a thermoplastic screw. Since terminology is not standardized in
the industry, different names may refer to these zones. Different types of polymer will have
differing screw designs, some not incorporating all of the possible zones. Most screws have these
three zones: Feed zone (also called the solids conveying zone): this zone feeds the resin into the
extruder, and the channel depth is usually the same throughout the zone. Melting zone (also
called the transition or compression zone): most of the polymer is melted in this section, and the

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 Project Work for Bachelor of Mechanical Engineering Students, DIT

channel depth gets progressively smaller. Metering zone (also called the melt conveying zone):
this zone melts the last particles and mixes to a uniform temperature and composition. Like the
feed zone, the channel depth is constant throughout this zone. In addition, a vented (two-stage)
screw will have decompression zone. In this zone, about two-thirds down the screw, the channel
suddenly gets deeper, which relieves the pressure and allows any trapped gases (moisture, air,
solvents, or reactants) to be drawn out by vacuum. Second metering zone. This zone is similar to
the first metering zone, but with greater channel depth. It serves to repressurize the melt to get it
through the resistance of the screens and the die(Gogos,2006)
Plastic wastes are the wastes that involve plastic materials speeded randomly to the environment
after been used which result into environmental pollution. Plastics may be defined as organic
materials that can be easily molded or shaped by either mechanical or chemical action to give
non-crystalline substance that are solid at ordinary temperature.
Plastics may also defined as materials made up of long –chain molecules based on carbon and
hydrogen .The basic unit of a long-chain molecule is [Link] has two carbon bond unused. If two
more hydrogen atom, methane is produced but by joining it to other mers chain is
created(Shenoy,2016).
Waste is now a global problem, and one that must be addressed in order to solve the world’s
resource and energy challenges. Plastics are made from limited resources such as petroleum, and
huge advances are being made in the development of technologies to recycle plastic waste
among other resources

1.2 Categories of plastics.

Plastics are categorized into varies types, these are:

i. Thermoplastic materials: these are plastic materials which lose their rigidity whenever
they are heated, so they can be molded [Link] materials do not undergo
chemical change when heated, and on cooling their plasticity is retained because the
structure is unchanged. The plastic behavior is dependent on composition and
therefore the structure.A noble feature of these resins is the ability of their scrap or
rejects to be reworked along with the new materials.

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 Chapter one

ii. Some common thermoplastics are Polyethylene, P.V.C, Polystyrene, Polypropylene

and Nylon. These can be further divided into cellulose plastics and non cellulose
plastics.

Example of cellulose plastics are Ethylene cellulose, cellulose nitrate, cellulose acetate and that
of non-cellulose plastics are polystyrene, Vinyl chloride-acetate

ii. Thermosetting materials: these are plastic materials which undergo definite chemical change
during the molding process causing them to become permanently rigid and incapable of being
softened again. Cold-setting plastics which become permanently hard due to a chemical reaction
which occur at ordinary temperature are similar in basic principles. Materials used in conjunction
with glass-fibres for the repair of the body work of descript motor cars fall into this class.
[Link]: these are also virtually thermosetting materials but which are characterized by
very high elasticity but a very low module of elasticityDue to this categorization of plastic
materials they have different melting temperature hence it is difficult to work with them
especially when mixed with other materials like sand for the aim of producing building materials
such as roofing tiles and paving blocks. But also the method of sorting only one type of machine
is heavy work and time consuming. The machine which will make these various plastic wastes to
melt at the same temperature is required

1.3 Problem Statement

Those plastic wastes like bags, bottles, buckets, gallon are various categories of plastics which
have also different melting temperature, it is difficult to work with them especially when
required to be mixed with other materials like sand, but also sorting method of one type of
plastic of the same melting temperature is a tedious work and time consuming

1.4 Project objectives

1.4.1 Main objective

The main objective of this project is to design and manufacture extruding machine for plastic
wastes

1.4.2 Specific objectives

To achieve the above objective, the following tasks must be done:
[Link] study existing methods/technology of extruding machine

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 Project Work for Bachelor of Mechanical Engineering Students, DIT

ii To design extruding machine.

[Link] manufacture a prototype of extruding machine
[Link] test prototype of extruding machine

1.5 Significances of the project

At the end of this project the important outcome will be as follows

[Link] will be conserved

[Link] than the plastics waste going into the landfill or water, it can be used as construction
materials after undergoing certain processes
[Link] will also provide employments opportunity to the people
[Link] will be of good quality

1.6 Project scope:

Project Scope give us a lot of advantages to learn new process to produce this unfinidhed product
and absolutely we could find a lot of advantages either we are realized or not. The scope of this
project extruding machine is the most important part in project. It is important to follow the line
of this project to achieve, what the project need. The scope of work in this project are given
below:

i. Literature review about the design from any possible resources.

ii. Design the model of extruding machine
iii. Fabricate the design using materials that have been selected.
iv. Test the design in demonstration.
v. To design the mechanical part of a extruding machine using CAD software Solid
Work.
vi. To design the extruding machine which takes less effort of the worker
vii. To develop the model of extruding machine using bending , welding , drilling and
cutting processes.
viii. To fabricate the extruding machine which extrude more melted plastic wastes

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 Chapter two

CHAPTER TWO

LITERATURE REVIEW
2.1 Introduction
This is concerned with the description of meaning of different concepts and theories surrounding
the study. It is a body of text that aim to review the critical points of current knowledge and or
methodological approaches on a particular topic. Literature reviews are secondary sources of the
information. Usually literature review precedes a project proposal and results section. Its ultimate
goal is to bring the reader up to date with current literature on a topic and forms the basis for
another goal, such as future project that may be needed in the area.

2.2 Extruding machine

Extruding machine is the machine in which plastics are melted and formed into a continuous
profile. The plastic waste extrusion is well known technic, widely used in polyrimalized
Industry. In the extrusion process various types of plastic waste materials in form of small beads
are feed from top mounted hopper into the barrel of the extruder.( Huang,2001)

2.2.1 Features of extruding machine

It consists of hopper in which plastic wastes are poured, then these materials are transported to
barrel. Barrel consists of three zones of varies temperatures controlled by heaters in which
materials are melted. The melted materials are forced forward and then out by means of rotating
screw shaft.

2.2.2 Components of the extruding machine

i. Three phase. Motor
ii. Reduction gearbox.
iii. Screw fed.
iv. Cyrndrical tube.
v. Heaters.
vi. Bearings.
vii. Control box.
viii. Housing

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 Project Work for Bachelor of Mechanical Engineering Students, DIT

2.2.3 Categories of extruding machine.

It is categorized into three types, these are:

i. Single-screw extruding machine

ii. Twin-screw extruding machine
iii. Ram extruding machine

2.2.4 Single-screw extruding machine

This is a low cost type of operative machine designed to use for simple operation such as
dry extrusion, simple formulations and on-farm processing of farm [Link] operation of
this extruder is simple, it is operated at low moist and generally autogenous This machine is
shown in figure 2..The machine use single screw for extrusion of melted materials

Figure 2. 1: Single-screw extruder(Johnston 1978)

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 Chapter two

Advantages
i. It can be used for processing a variety of plastic products such as blown film,
squeeze tubes, plate and also can be used for melting granulation.
ii. It has good plasticizing function to ensure stable and high speed extrusion
iii. The entire process is involved with involute gear transmission so it causes low
noise.

Disadvantages
i. The transmission of materials in single screw extruding machine is mainly by
friction, the feeding performance is limited.

2.2.5 Twin-screw extruding machine

This type of extruding machine is shown in figure [Link] has more number of possible
configurations given the way for products to attain different shapes with co-rotating screws.
These screw can either intermeshing or [Link] intermeshing can be defined as a
gap between the screw where the material flows and compressed. Since the two screws have
flight configuration in such a way that the natural steam lock is formed which is independent of
the material flow. This formation of natural steam lock makes the extruding machine to run as a
positive [Link] non-intermeshing screw can not achieve the high shear as the channel of one
or both screws may have open segment. This problem can be overcome using mechanical steam
locks. Twin-screw extruding machine can be further subdivided into several classifications, these
are
i. Co-rotating intermeshing,
ii. Co-rotating non-intermeshing
iii. Counter rotating inter-intermeshing
iv. Counter rotating non-intermeshing
v. Conical intermeshing

Advantages of Twin-screw extruding machine

i. Material flow is stable, uneasy happen cut off or billow, productive process is
reliable.
ii. Most heat of twin extruding machine mainly come from mechanical
transmission during operation, small amount of heat comes heat jacket.

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 Project Work for Bachelor of Mechanical Engineering Students, DIT

iii. Time distribution is relative narrow range of materials retained in the

machine, which is easier to control the temperature of the materials; sufficient
energy utilization, yield and quality are very stable.
iv. Twin-screw extruding machine has a screw surface self-cleaning effect, so
that the transportation of material is stable

Disadvantages

i. It has complex structure, hence require high precision maching(Shah,2004)

ii. It is expensive compered to single-screw extruding machine

Figure2.2 extruding machine (Bruins, 1976)

2.2.6 Ram extruding machine

This is a machine where, instead of extrusion screw, a ram or plunger is used.

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 Chapter two

Figure 2. 2 Ram extruding machine(zhengchang 2014)

Advantages

i Extrusion can be carried out at lower temperatures.

i. Difficult compounds can be extruded.
ii. Easy to clean.
iii. Useful to short runs.
iv. Useful for compounds which need to be strained through gauge for quality
products requiring completely contamination free material.
Disadvantages
i. It is very effective for specific materials like PTFE
ii. It has complex system
iii. It is cost fully machine

2.3 Input of the machine.

Input is the materials that poured into the machine in order to make a certain product or semi-
finished product .The input that will be involved is a various plastic west materials.
Plastics are materials that can be easily molded or shaped by either mechanical or chemical
action to give non-crystalline substance that are solid at ordinary [Link] plastics are
man-made; they do not occur in nature. The process of making plastics is usually quite
complicated. Most of the materials that are called plastic are polymers. Polymers are long chains

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of atoms bonded to each other. In most plastics, the long chain is a chain of carbon atoms
(Fenichell, 1996).
Old plastics are usually thrown away and put in landfills. Some plastics release toxic fumes when
burned. Plastics are often recycled so they won't become waste (Hester & Harrison, 2011).
Plastics are mostly petrochemicals, made from natural gas or from petroleum, a type of oil.
Chemical engineers refine the petroleum which goes through a heating process. It
develops ethylene and propylene, which are the chemical building blocks for many plastics.
These chemicals are then combined with other chemicals to produce a polymer (Elias, 2005)
.Plastic is generally categorized into three, these are;

i. Thermoplastic materials:
ii. Thermosetting materials
iii. Elastomers:

Advantages of thermoplastic
i. Recyclable & reusable
ii. Environmentally friendly
iii. More options for sheen, variance, etc.
iv. Chemically retardant options

Disadvantages
i. Do not degrade quickly
ii. They pollute environment when spread randomly
iii. Pose a danger to wildlife

Advantages of thermoset plastics

i. Well established processing and application history
ii. Overall, better economics than thermoplastic polymers
iii. Better high temperature properties
iv. Good wetting and adhesion to reinforcement

Disadvantages of thermoset plastics

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 Chapter two

i. Resins and composite materials must be refrigerated

ii. Moisture absorption and subsequent property degradation
iii. Long process cycles
iv. Reduced impact –toughness
v. Poor recycling capabilities
vi. More difficult repair ability

Table 2. 1 : Physical properties of plastic

Plastic Thermal properties Strength Density

Abbreviation- Tm Tg Td Cte Tensile Compressive
Brand name
˚C ˚C ppm/˚C psi Psi g/cc
PET 245 73 21 65 7000 11000 1.29
265 80 38 10500 15000 1.40
LDPE 98 -25 40 100 1200 0.917
115 44 220 4550 0.932
HDPE 130 79 59 3200 2700 0.952
137 91 110 4500 3600 0.965
PP 168 -20 107 81 4500 5500 0.900
175 121 100 6000 8000 0.910
PVC 75 57 50 5900 8000 1.30
105 82 100 7500 13000 1.58
PS 74 68 50 5200 12000 1.04
105 96 83 7500 13000 1.05
Table 2. 2:Visual properties of plastic

Type Name Properties Common uses Burning

Polyethylene Clear, tough, Soft drink, water Yellow flame
PET terephthalate solvent, barrier bottles, salad little smoke
to gas and domes, biscuit
moisture, soften trays

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at 80˚
High-density Hard to semi- Shopping bags, Difficult to ignite
HDPE polyethylene flexible, resistant freezer bags, smells like
to chemicals and milk bottles, candle
moisture, waxy shampoo, crates,
surface, soften at
75˚
Polyvinyl Strong, tough, Electrical Yellow flame
PVC chloride clear and solvent, conduits, roof green spurts
soften at 60˚ sheeting
Low-density Soften, flexible, Garbage bags, Difficult to ignite
LDPE polyethylene waxy surface, refuse bags, cling smell like candle
scratches easily, wrap
soften at 70˚
Polypropylene Hard but still Dishes, food Blue yellow
PP flexible, waxy containers, ice tipped flame
surface, cream tubes,
translucent, straws, flower
withstand pots
solvent, soften at
140˚
Polystyrene Clear, opaque, CD cases, plastic Dense smoke
PS soften at 95˚ cutlery, brittle
toys, imitation
glass
All other plastics Properties Automotive, All other plastics
OTHER depend on the pe electronics,
of plastic packaging

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 Chapter two

2.4 Designing of the machine

Design is the creation of a plan or convention for the construction of an object, system or
measurable human interaction (Ullman,2009). Machine is a combination of various elements

Arranged to work together to serve specific purpose. Machine design includes designing the
elements and arranging the elements to achieve the need. Then the product must be functional,
safe, reliable, competitive, usable, manufactured, and marketable. Hence, the engineering
designer has to be personally comfortable with a decision-making, problem-solving
role.(Khurmi, 1979).

2.4.1Types of design
i. Original design, also called innovative design,
This form of design is at the top of the hierarchy. It employs an original,
innovative concept to achieve a need. Sometimes, but rarely, the need itself may
be original. A truly original design involves invention. Successful original designs
occur rarely, but when they do occur they usually disrupt existing markets
because they have in them the seeds of new technology of far-reaching
consequences. The design of the microprocessor was one such original design.
ii. Adaptive design .
This form of design occurs when the design team adapts a known solution to
satisfy a different need to produce a novel application. For example, adapting the
ink-jet printing concept to spray binder to hold particles in place in a rapid
prototyping machine.
Adaptive designs involve synthesis and are relatively common in design.
iii. Re-design .
Much more frequently, engineering design is employed to improve an existing
design.
The task may be to redesign a component in a product that is failing in service, or
to redesign a component so as to reduce its cost of manufacture. Often redesign is
accomplished without any change in the working principle or concept of the
original design. For example, the shape may be changed to reduce a stress
concentration, or a new material substituted to reduce weight or cost.

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 Project Work for Bachelor of Mechanical Engineering Students, DIT

When redesign is achieved by changing some of the design parameters, it is often

called variant design.
iv. Selection design.
Most designs employ standard components such as bearings, small motors, or
pumps that are supplied by vendors specializing in their manufacture and sale.
Therefore, in this case the design task consists of selecting the components with
the needed performance, quality, and cost from the catalogues of potential
vendors.
v. Industrial design.
This form of design deals with improving the appeal of a product to the human
senses, especially its visual appeal.
While this type of design is more artistic than engineering, it is a vital aspect of
many kinds of design.
Also encompassed by industrial design is a consideration of how the human user
can best interface with the product.(Robert,20037)

2.4.2 Characteristics of designing

i Creativity

Requires creation of something that has not existed before or has not existed in the
designer’s mind before
ii Complexity
Requires decisions on many variables and parameters

iii Choice

Requires making choices between many possible solutions at all levels, from basic
concepts to the smallest detail of shape

iv Compromise

Requires balancing multiple and sometimes conflicting requirements (Sanga, 2017)

In order to obtain proper design of the extruding machine, the following factors should
be considered, these are:
i. Ergonomic factor.

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 Chapter two

ii. Reliability.
iii. Maintainability.
iv. Productivity.

2.5 Manufacture of prototype of extruding machine

Manufacturing is a process through which raw materials are transformed into final product.
In manufacturing of a prototype, factors like fitness, shape of the product produced as well as
strength of the machine should be much considered. Manufacturing processes have to meet
the following factors:

i. Technologically acceptable.
ii. Technically feasible.
iii. Economically viable.
iv. Eco-friendly.

2.5.1 Classifications of engineering manufacturing processes are follows:

i. Joining process.
ii. Shaping or forming.
iii. Removal process.
iv. Regenerative manufacturing

2.5.2 Goals of manufacturing process

i. Meeting performance requirements (ie. Tolerances, strength, weight etc.)
ii. Meeting cost of production requirements
iii. Ability to reproduce constant quality during mass production
iv. Large manufactured components should have uniform material properties throughout the
component.

2.5.3 The primary consideration for a manufacturing process

When different manufacturing processes and methods are considered, it is fundamental to
develop an understanding of the relationship between the important to know what conditions a
particular process will subject a material to and how different manufacturing materials respond
to different conditions, ie. Stress, heat etc. (Groover, 2010)

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2.6 To test the prototype of extruding machine

This part used by the designer to determine if the designed and manufactured machine has either
meets or not meet the objectives of the project.

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 Chapter three

CHAPTER THREE

METHODOLOGY
3.1 Introduction
Methodology is the systematic, theoretical analysis of the methods applied to a field of study. It
comprises the theoretical analysis of the body of methods and principles associated with a branch
of knowledge. The following methods to be used to accomplish this project:

i. Literature review
ii. Data collection
iii. Data analysis

3.2 literature review

In this area, Literature Review gives an overview of the related topics of the project. It gives the
information on the progress of the various types of the existing extruding machine, Properties of
extruding machine and materials . This information is mainly obtained through browsing various
internet websites, reading related engineering books, through the information obtained the gap is
discovered so correction action can be taken to the gap.

3.3 Data collection

These are the information gathered from different sources which are of more importance of the
developing the project. In data collection there are main three methods of collecting data, these
are:
i. Interviewing method
ii. By observation and industry visitation methods were used to collect data;

3.3.1 Interviewing
In order to get information about design methodology of extruding machine, a survey has been
made to the related firms through which various people were interviewed including artisan,
technician, process artisan machine specialist, maintenance planer and maintenance controller.
Information gathered are; size, length, shape and diameter of extruding machine, maintenance
carried out on extruding machine and materials for making extruding machine

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3.3.2 Industrial and Observation

The surveys were made to Silafrica Company Limited at Buguruni-Dar es salaam, Jambo
Company limited and Small Industrial development organization (SIDO), only these firms were
used to survey, due to easy way to reach them whenever consultation is needed. But also through
observation, those unsuitable method of melting plastic waste are observed clearly and its
difficultness hence it will be left and take the best way of melting plastic wastes.

3.4 Data analysis

The data obtained from various sources will be analyzed in order to achieve the objectives of the
project. Through this analysis the design of specification, development, calculations and
selection of the best alternative will be done.

3.4.1 Design Alternative for the mechanism

One purpose of data collection is to determine Product Design Specifications (PDS), thus from
the collected data, the best solutions will be determined considering the PDS, from which the
optimal design will be determined through analysis of each individual design.

3.4.2 Determination of the machine mechanism parameters

The parameters in consideration are such as Cost, Strength, capacity, weight, etc.

3.4.3 Design of the machine mechanism

Using the data collected from visited areas, and using engineering’s principles of designing
(drawings, calculations & material selection), the paste making machine will be designed
accordingly.

3.4.4 Manufacturing the Prototype of extruding machine

After having the specifications of proposed extruding machine (i.e. size of each component,
shape with respect to one another, means of fitting and joining, materials selected, drawings,
etc.) the prototype will be manufactured.

3.4.5 Report writing

A detailed report which will critically explain all the procedures passed, from the idea
generation, design, manufacture till the testing of the extruding machine, with conclusion and
recommendations.

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 Chapter three

3.4.6 Testing of the Prototype of extruding machine

This part used by the designer to determine if the designed and manufactured machine has either
meets or not meet the objectives of the project

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 Chapter four

CHAPTER FOUR
DATA COLLECTION

4.1 Introduction
Data were collected from various sources through: literature review, interview, and observations.
One of the greatest goal of Data Collection is to look for product design specifications (PDS),
that will meet need of the society in need, in terms of capacity, cost, durability and working
environments, user ergonomics, etc. This information is important and useful during design, and
hence, manufacture of a Small scale extruding machine. Through Interview and Observation,
information was collected in Dar es Salaam, specifically Small industry development
organization(SIDO),Dar es Salaam City council (DCC), Silafrica Company Limited at Buguruni,
and Jambo Company [Link] literature review, information was obtained in different
books for designing, and through internet

4.2 Observation
Observation was done at Silafrica Company Limited, and Small industry development
organization(SIDO) at Dar es Salaam Tanzania as shown in figure 4.1 and and 4.2 to observe
how plastic wastes are recycled and its mechanism. Different types of plastic wastes were also
observed, this help to know the facts and the truth about selection of types of plastic wastes that
are most preferred for recycling. Observation was also done to the plastic waste collectors as
small scale entrepreneurs to observe where they sell their plastic wastes. But also observation of
types of machine were observed

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Figure 4.1: extruding machine (SIDO)

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 Chapter four

Figure 4. 2: High density plastics (SIDO)

4.3 Data collected

i. Data collected from Dar es Salaam City Council

According to DCC, Dar es Salaam is estimated to generate waste 4,252 tons per day. About
40-50% of waste generated in the city is managed. Remaining is left near house premises, in
the open pits, streets, markets or storm water drainage. Table 4.1shows solid wastes collected
per day in 2016

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Table 4. 1: Solid waste collection per day (2016)

Municipality Waste generated per day (tons)

Ilala 1,088
Kinondoni 1,223
Temeke 1,300
Ubungo 828
Kigamboni 210
Total 4,252

In collecting data various waste components were collected in order to know the percentage of
plastic [Link] 4.2 shows the waste components with their percentage

Table 4. 2: Waste components

Components Percentage (%)

Kitchen waste 39
Grass 10
Paper 8
Ceramic and stones 6
Metals 5
Plastics 16
Glass 2
Lather and rubber 6
Textile 5
Other 3
Total 100

Extruding machine extrudes materials accordingly. Table 4.3 shows the capacity of the extruding
machine which extrude during operation.

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 Chapter four

Table 4.3: shows the existing extruding machine at Silafrica Company Limited with the
following classifications

Capacity of the machine production 12 tones per day

Fresh material 48%

Recycled material 50%
Master batch 2%

Since the process needs various temperature in order to get a required melted plastics,table4.4
shows temperature zones.

Table 4.4: Temperature zones involved in melting plastics

Zones Temperature in
Zone one 186
Zone two 205
Zone three 230
Zone four 240

After studying the existing machine, the following are proposed materials for different parts of
the machine to be designed, although is not the final choice.

Table 4.5:Parts and proposed materials for extruding machine

Description Material
Angle 1ron Mild steel
Round bar Mild steel
Pipe Mild steel
Insulator Cotton wool
Sheet metal Mild steel

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4.3.1 Properties of mild steel

i. It has high tensile and impact strength.
ii. It malleability and relative soft.
iii. It has a high resistance to breakage.
iv. It has good weld ability and machinability.
v. It is has less resistance to corrosion.

4.3.2 Properties of cotton wool

i. It is light in weight
ii. Bad conductor of heat
iii. Catch fire easily

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 Chapter five

CHAPTER FIVE

DATA ANALYSIS
5.1 Introduction
The data analysis explain much the procedures which have been taken to choose the optimal
alternatives from designing alternatives while keeping in consideration the data collected and the
literature review covered so as to achieve the project design objectives. In order to obtain to
obtain high efficiency and reliable, the machine was designed based on the following
consideration

i. The machine should be relatively cheap.

ii. The machine should be able to extrude melted material to the required volume
iii. Easy to operate
iv. Safe to operate
v. Durable
vi. The machine should be made with right materials.

5.2 Conceptual development

Design process has some stages to consider. The early stage is conceptual development, this deal
with development of varieties of the design where the optimal solution is found. In this chapter
several designs have been developed and the optimum alternative is selected. The major reasons
for their differences are capacity of the machine, efficiency of the machine and parameters which
will assist in obtaining the optimal solution that will solve the project statement of the design In
order to obtain the optimal design solution of the extruding machine, the following are the
considerations made in order to add major impact so as to achieve optimal solution with optimal
safety, , capacity, cost, durability and factors such as

i. Heating zones
ii. Material to be used
iii. Source of power
iv. Power transmission mechanism
v. Mechanisms of recycling.

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5.3 Selection optimum alternatives

5.3.1 Selection of a suitable design

To get the optimum alternative design of a extruding machine, the following factors are highly
considered during the selection:

i. Performance
ii. Reliability
iii. During
iv. Safety
v. Cost

The following are alternatives selected due to the factors above

Alternative A –extruding machine using piston

Alternative B- extruding machine using single screw

Alternative C- extruding machine using double screw

5.4 Alternative A: extruding machine using piston mechanism

In this machine melted plastic materials are forces out by means of plunger or piston.

Principle of operation of piston extruding machine is that, after all plastics have been melted then
plunger or piston is forcing out those melted plastics by either manually or automatic.

Figure 5. 1: Ram extruding machine

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 Chapter five

Advantages

i. Extrusion can be carried out at lower temperatures.

ii. Difficult compounds can be extruded.
iii. Easy to clean.
iv. Useful to short runs

Disadvantages
i. It is very effective for specific materials like PTFE
ii. It has complex system
iii. It is cost fully machine

Table 5. 1 Average marks for alternative A

Judges Performance Reliability Maintainability Durability Safety Cost

1 3 4 3 2 4 3
2 2 2 4 3 4 1
3 3 3 2 3 2 2
4 4 2 3 4 1 2
5 3 3 3 4 5 4
Average 3.4 2.8 3 3.2 3 2.4

5.5 Alternative B extruding machine using single screw mechanism

Principle of operation of single screw extruding machine
It consists a motor that drives screw, the rotation of screw lead to force out the melted plastics,
hence required shape is obtained.

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Figure 5.2: Single screw extruding machine

Advantages
i. It can be used for processing a variety of plastic products such as blown film,
squeeze tubes, plate and also can be used for melting granulation.
ii. It has good plasticizing function to ensure stable and high speed extrusion
iii. The entire process is involved with involute gear transmission so it causes low
noise.
Disadvantages
i. The transmission of materials in single screw extruding machine is mainly
by friction, the feeding performance is limited.

Table 5. 2:Average marks for alternative B

Judges Performance Reliability Maintainability Durability Safety Cost

1 5 4 3 4 4 3
2 3 5 4 4 4 3
3 4 3 5 3 3 2
4 4 5 3 4 4 3
5 3 5 5 4 3 2
Average 3.8 4.4 3.6 3.8 3.6 2.6

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 Chapter five

5.6 Alternative C: extruding machine using double screw mechanism

This type of extruding machine has more number of possible configurations given the
way for products to attain different shapes with co-rotating screws. These screw can
either intermeshing or non-intermeshing.

The intermeshing can be defined as a gap between the screw where the material flows and
compressed. Since the two screws have flight configuration in such a way that the natural steam
lock is formed which is independent of the material flow

Figure 5. 3: Double screw extruding machine

Advantages

i. Material flow is stable, uneasy happen cut off or billow, productive process is
reliable.
ii. Most heat of twin extruding machine mainly come from mechanical
transmission during operation, small amount of heat comes heat jacket..
iii. Twin-screw extruding machine has a screw surface self-cleaning effect, so
that the transportation of material is stable

Disadvantages

i. It has complex structure, hence require high precision maching

ii. It is expensive compered to single-screw extruding machine

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Table 5.3:Average marks for alternative C

Judges Performance Reliability Maintainability Durability Safety Cost

1 2 4 3 2 3 3
2 3 5 4 1 4 2
3 2 3 2 3 3 3
4 2 2 3 2 2 3
5 3 1 2 2 3 3
Average 2.4 3 2.8 2 3 2.8

5.7 Determination of the weighting factors

This was done by interview different people based on the objective of the project to determine
the weight of each pre-selected factors.

Table 5.4: Weight factors

Judges Performance Reliability Maintainability Durability Safety Cost Total(X)

1 5 4 3 3 4 4
2 3 3 3 4 4 4
3 3 2 2 3 4 3
4 5 3 4 4 3 4
5 4 3 4 3 4 3
Total(y) 20 15 16 17 19 18 101
Weight 0.198 0.149 0.158 0.168 0.188 0.178
factor(F)

Where;

Table 5.5: ranking the design alternative

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 Chapter five

Durability
Reliability

Maintaina
Performa

weight

Order
Safety

Rank
Total
bility

Cost
nce
Alternative

Weighting 0.198 0.149 0.188 0.178

factors 0.158 0.168
A Score 3.4 2.8 3 3.2 3 2.4
Weight 0.507 0.417 0.474 0.538 0.427 0.427 2.790 2
B Score 3.8 4.4 3.6 3.8 3.6 2.6
Weight 0.752 0.656 0.568 0.638 0.677 0.463 3.281 1
C Score 2.4 3 2.8 2 3 2.8
Weight 0.475 0.447 0.442 0.336 0.564 0.498 2.762 3

Therefore from the table above the optimal alternative is ALTERNATIVE B which is the single
screw extruding machine.

5.8 DESIGN CALCULATIONS

Having selected the best alternative (i.e. alternative B), The followings are the Design
Calculations based on the Data Collected, and according to the Principles of Engineering Design,
aimed to properly select size and material of different components of the Extruding Machine.

5.5.1 Machine consists of the following components

i Hopper

ii Cylindrical pipe

iii Screw
iv Frame
v Heates

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5.8.1 DETERMINATION OF MACHINE CAPACITY

From literature review and data collected the capacity of machine was decided to be 120kg/hr.

5.6.2 Design calculations of hopper

It is cut into 2mm thick of MILD STEEL material, constructed into trapezoidal shape and edges
are welded together. A 4mm thick hopper frame will be added at the mouth top to prevent the
sharp edges at hopper opening.

Figure 5.1: hopper

Required to calculate the volume of feed hopper

Volume of hopper V

……………………………………………………………………………………. (5.1)

But A = L×W…………………………………………………………………………………(5,2)

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 Chapter five

Therefore area of the hopper is

Inlet unit:

Let,

L=length of the inlet unit

W=width of the inlet unit

H=height of the inlet unit

A= L×W

From

To get total volume of the hopper

Therefore the total volume of the hopper is

5.8.3 Design of calculations of the cylindrical pipe

The pipe will be made using MILD STEEL. Mild steel has the following characteristics;

 Cheap and readily available.

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 Project Work for Bachelor of Mechanical Engineering Students, DIT

 It has medium carbon content so ease to weld.

 It is ductile.

Figure5.2:Cylindrical pipe

Now let;

L= Length of a Pipe

d= An internal diameter of a pipe

D= An external diameter of a pipe

A= A cross section area of a pipe

V =A×L

But we know that;

( )

But

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 Chapter five

………………………………………………………………………………….(5.2)

From

Volume of a cylindrical pipe will be

5.83 Design calculations of the extrusion screw

The shaft diameter which is 75mm is approximately equal to minor diameter of the screw.

From the table of basis for square threads for coarse series

Figure [Link]

Core diameter (dc) =75mm

Major diameter (do) =80mm
Pitch (Pʹ)
Depth of the thread (h) =5mm
Average diameter (d) =(dc+do)/2
d =(75+80)/2
d =77.5mm
Now, the helix angle(αh) can be

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 Project Work for Bachelor of Mechanical Engineering Students, DIT

determined as follows

tan(αh) =

tan(αh) = , αh =2.4°

Since the load is transported along the length of the screw shaft , it is there assumed to be
conveyed in forward direction. The effort required for this operation is obtained from the
equation below,

P=Wtan(αh+Ø)………………………………………………………………………………(5.5)

Where, P = effort required to convey the load

W = Weight of plastic granule

Ø = Friction angle

The friction angle is related to coefficient of friction by

µ =tanØ

For average quality material, average workmanship and running condition according to khurmi
and Gupta, µ = 0.13

Therefore , Ø =7.41°

W =mg

m =1kg and g =9.81N

W =1×9.81

W = 9.81N

Substitute the values of W,P, αh and Ø into equation

P = 9.81×tan(2.4+7.41)

Hence effort or force required to convey the load is 1.70N

5.8.5 Liner speed developed in screw Vs

The extrusion screw has diameter (do) of 80mm

Then,

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 Chapter five

Ro = = =40mm

Vs =

=(188.5 ×40)/2 =7.54m/s

5.8.5 Design of Coupling:

A coupling is device used to connect two shafts together at their ends for the purpose of
transmitting power .The main purpose of coupling is to join two pieces of rotating equipment
while permitting some degree of misalignment or end movement or both. By careful selection,
installation and maintenance of couplings, substantial savings can be made in reduced
maintenance costs and downtime. Flange coupling consist of two flanges keyed to the shaft and
bolted.

Figure 5.4: Flange coupling

Flange coupling has the following advantages and disadvantages:

i. It is cheap
ii. It is simple
iii. Effective
iv. No maintenance

Disadvantage of flange coupling is that can not be de-engaged in motion.

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5.8.6 Design of the heater

The heat required ,Ǫ to melt the plastic pellets of massˈ mˈfrom their stating temperature
for the plastic temperature Tp taken as 29°C, for this design to the melting temperature Tm is
estimated using using the equation below

Ǫ =Cpm(Tm-Tm)………………………………………………………………………...(5.7)

Where: Cp =specific heat capacity of plastic =1470J/kg°C

For this design, the range of melting temperature is 180°C-260°C

Therefore melting temperature Tm =220°C

Qmelt =561KJ

Thus a 2kw heater is chosen based on availability

5.8.7 Selection of motor

The selected motor is 3Ф of 2hp and with speed of 1360r.p.m

Calculation of the torque

From

…………………………………………………………………………………(5.8)

Where

power of a motor

T =toque of a motor

=angular speed in meter

=2πn/60 =2×π×1360 =188.5rad/s

Hence, =142.4rad/s

Then, =T

T= / =(3×746)/142.4

T = 10.5Nm

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 Chapter five

5.8.8 Design of the shaft

Shaft is a rotating part of machine which used to transmit power from one place to another. The
material used for ordinary shaft is MILD STEEL. It is subject to combined twisting moment and
bending moment .The required diameter of shaft is calculated depending on the load
applied(Gupta et al,2005)

The following are stresses induced in shafts:

i. The stresses due transmission of torque

ii. Bending stresses(tensile or compressive) due to forces acting upon the machine element
like gears couplings
iii. Stresses due to combined torsional and bending loads

According to the maximum shear stess theory:

The maximum shear stress in the shaft, max is given by:

.τ max
=√ …………………………………………………………………………(5.9)

√ =Equivalent twisting moment.

Reaction at the support,

ƩFX =0, HA =0

ƩMA =0,The sum of the moment about point A is zero

-q×0.58×(0.58/2)+RB×0.58 =0

But also

ƩMB =0, The sum of the moment about point B is zero

-RA×0.58+q×0.58×(0.58-0.58/2)

Solving these two equations

RA =2.84N

RB =2.84N

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First span of the beam 0<x<0.58

To determine the equations for the axial force(N)

N(X) =HA

N(0) =0 =0(N)

N(0.58) =0 =0(N)

To determine the equations for shear force(τ)

τ(x) = RA-q×(x-0)

τ(0) =2.84-9.81×(0-0) 2.84N

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 Chapter five

τ(0.58) =2.84-9.81×(0.58-0) =-2.84N

The value of τ on this span crosses the horizontal axis at the point x= 0.29

To determine the equations for the bending moment M

M(x) = RA(X)-q×( /2

M(0) =2.84×(0)-9.81×(0-0)/2 =0N

M(0.58) =2.84×(0.58)-9.81×( /2 = 0Nm

M(0.29) =2.84×(0.29)-9.81×( /2 =0.41Nm

Table 5.1: Operation sequence of the extruding machine

OPERATION COMPONENTS OPERATIONS MACHINES TOOLING TIME

NO. NAME SPENT
1 Hopper Cutting and Granger and Metal rod 8hrs
welding plate of Welding and grander
mild steel to machine
form hopper of
330x330
2 Cylindrical pipe Cutting of Hack saw Hack saw 1hr
cylindrical pipe
with dimension
of 586x Ø100
3 Screw shaft Lathe Turning tool 8hrs
machine
4 Frange Drilling the Drilling Dill bit 8hrs
holes of Ø30 machine
and of Ø10
5 Frame Cutting and Grander and Grander 7hs
joing angle iron welding
of 780 x 320x machine
300

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 Chapter six

CHAPTER SIX

CONCLUSION
6.1 Conclusion
The senior project II has been accomplished and designed machine is obtained which is usefully
for conservation of environment since those plastic wastes around the environment are collected
and turned into usefully products using extruding machine .Various technics were used for the
seak of manufacturing of extruding machine .Such technics are studying of existing machine that
helps to know the standard and manufactured parts ,the designing of the machine based on
necessary calculations of the machine were done which help to meet the quality of the products,
detailed drawings and assembly drawings were prepared. The intended manufactured prototype
is made based on the designing of the machine. Finally the prototype was tested in which
shielded waste plastics were melted through pipe at a temperature of 240°C to 260°C in 6 to
12minutes and continuous profile were given out as expected.

6.2 Recommendation
The extruding machine designed is usefully in conservation of environment since those plastic
wastes around the environment are collected and turned into usefully products using extruding
machine. It should be recommended that:

i. In case of manufacturing this type of machine, the right materials should be used
such as steam pipe instead of other pipes in order to get good melting and flow of
melted plastics
ii. The electric parts should be well connected and controlled to avoid over or under
heating
iii. The screw of the this machine should be well designed in order to force out
enough melted

43
 References

REFERENCES
Ertas.A.(1996).The Engineering Dsign Second [Link] York:John Willey & son,Inc

Ertas,A.,&& Jones,j.(1996).The Engineering Design Process second [Link] York.

Giles, Harold F.; Wagner, John R.; Mount, Eldridge M. (2005), Extrusion: the definitive
………processing guide and handbook , William Andrew, p. 151, ISBN 978-0-8155-
………1473-2.

John Vogler (1984). Small Scale Recycling of Plastics. Intermediate Technology

……...Publication. pp. 6–7.

Johnston. G.L. Technical and Practical Processing Conditions with Single Screw

……..Cooking Extruders: Cooking Extruding Techniques, ZDS, Solingen-Grafeath,

……..Germany, 1978.

Judson M. Harper,Extrusion Texturization of Foods, Food Technology, 1986, 40

…….(5), 70-76.

Rauwendaal, Chris (2001), Polymer Extrusion, 4th ed, Hanser, ISBN 3-44621774-6

Shah, A and Gupta, M (2004). "Comparison of the flow in co-rotating and counter-
……….rotating twin-screw extruders". ANTEC, [Link].

Tadmor and Gogos (2006). ‘’Principles of Polymer Processing’’. John Wiley and Sons.
……….ISBN 978-0-471-38770-1.

Todd, Allen & Alting 1994, pp. 223

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 Appendices

APPENDICES

APPENDIX A

PROJECT COST ESTIMATION

The cost estimation for this project has been divided into categories as follows bellow:

i. Material cost
ii. Labor cost
iii. Machining cost
iv. Overhead cost

MATERIAL COST
The considered cost in this design is roughly estimated based on the construction of the whole
machine. The parts like, coupling, bolt, and nut washers angle iron and mild steel sheets should
be purchased from the dealers and manufacturers according to the design specifications .The
materials cost is approximately based on the datasheet and the cost of the material from the local
markets.
S/N Description Quantity Price Subtotal
1 AngleIron 40xmm x5mm 3 @2600/= 7800/=
2 Mild steel 6 @10,000/= 60,000/=
plate100mmx100mmx2mm
3 Relay 1 @25,000/= 25,000/=
4 Motor with gearbox (3Ф) 1 @320,000/= 320,000/=
5 Screw shaft(Ø75x580mm) 1 @50,000/= 50,000/=
6 Electrical 2 @40,000/= 80000/=
heater(Ø105x120mm)
7 Steam pipe(Ø100x500mm) 1 @40000/= 40,000/=
8 Bolt and nut M10X20 8 @500/= 4000/=
9 Temperature controller 1 @100,000/= 100,000/=
with thermal couple
Total 690000/=

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THE LABOR COST

The labor payment is calculated as;

Labor cost = 30% of material cost

Labor cost =

Labor cost = 207,000/=

Therefore, the labor cost is [Link] 207,000/=

THE FABRICATION AND MACHINING COST

Fabrication and machining cost as taken, payment estimates is calculated as;

Fabrication and machining cost = 20% of material cost

138000/=

The fabrication and machining cost is [Link] 138,000/=

THE OVERALL COST

The overall cost is taken as 40% of the labor cost plus machining and fabrication cost.
Overall cost = 40% x (Labor + fabrication and machining cost)

= 138,000/=
The overall cost is [Link] 1380,000/=
TOTAL COST
The total cost of the animal feed extrusion machine is taken as the summation of material cost,
labor cost, fabrication and machining cost plus overall cost.

Total Cost = (material cost + Labor cost +Fabrication and machining cost + Overall cost)

= 690000 +207000 + 138000 138000 =1,173,000

Therefore, the total cost is [Link] 1,173,000/=

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Appendices
Appendix B

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Appendix C

48
Appendices
Appendix D

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Appendix E

50
Appendices
Appendix F

51