DESIGN AND FINITE ELEMENT ANALYSIS (FEA) OF PLASTIC WASTE SHREDDING MACHINE FOR ENVIRONMENTAL SUSTAINABILITY

The rapid increase in plastic waste generation has intensified environmental challenges, necessitating efficient recycling technologies capable of converting discarded plastics into reusable materials. This study presents the design and finite element analysis (FEA)-based evaluation of a plastic waste shredding machine developed for small-scale recycling applications. The machine was designed to reduce plastic waste into smaller fragments suitable for subsequent recycling processes while ensuring structural reliability and operational safety. Mild steel was selected as the primary construction material for the major components due to its favourable mechanical strength, toughness, machinability, weldability, and cost-effectiveness. The shredder components, including the hopper, shredding chamber, shafts, blades, gears, coupling, and support frame, were designed using standard mechanical design principles. Three-dimensional modelling of the machine was developed using SolidWorks, while thermal and structural performances were evaluated using ANSYS finite element analysis. The simulations investigated temperature distribution, heat flux concentration, equivalent von Mises stress, and total deformation under operating conditions. The blade thermal analysis revealed that the highest temperature occurred at the blade–shaft interface, with a maximum temperature of 55 °C, indicating the region of greatest frictional heat generation. The maximum heat flux was concentrated around the shaft and blade contact region due to mechanical interaction during shredding. Structural analysis of the support frame showed a maximum equivalent stress of 6.68 kPa, which was significantly lower than the material yield strength of 293.5 MPa, confirming the structural safety of the design. The maximum predicted deformation was 1.782 × 10⁻⁸ m, demonstrating minimal deflection under applied loading conditions. The developed plastic shredding machine, with a design capacity of 10 kg/h, provides an efficient and sustainable approach for plastic waste reduction and recycling, particularly in environments where low-cost recycling solutions are required. The integration of mechanical design analysis with FEA validation provides a reliable framework for improving the durability, performance, and safety of locally fabricated plastic recycling equipment