Design and Development of Waste Compactor for Plastic

Bottles, Metal Cans, and Papers

Charlton S. Inao1 , Alleson Herman V. Corey2, and Antehun Mekonnen3

1
Professor, Production Department, Defense University, Engineering College, Debrezeit,
Ethiopia
2
Professor, Metallurgical and Materials Engineering Department, Defense University,
Engineering College, Debrezeit, Ethiopia
3
Researcher, Center for Research and Development, Defense University, Engineering
College, Debrezeit, Ethiopia

ABSTRACT – A hydraulic waste compactor for compressing solid wastes such as paper,
PET bottles, tin and aluminum cans was designed and developed to alleviate the worsening
condition of waste management in Addis Ababa and the major cities in Ethiopia. The
compactor which compressed the waste into a final cubical form of 190 mm (L) x 190 mm
(W) x 160 mm (H), with a compression density of 1,500 kg/m3 includes three major
operations namely 1) compacting, 2) the lifting, and 3) unloading, all of which were driven
by cylinders and directional control valves.

Structural and material analyses were conducted for the whole structure to become robust.
Electro-pneumatic, electrical, and relay ladder logic diagram was designed to optimize the
whole operations of the compacting system. A Programmable Logic Controller (PLC)
Siemens LOGO was used to control the overall sequence and operations of the machine so
that it will become user friendly to the operator.

Keywords: compactor, PET, compression density, electro pneumatic, ladder diagram, PLC

INTRODUCTION has been taken from studies that were

conducted long time ago.
Waste generation rates are affected by
socioeconomic development, degree of This proposal was developed to conduct a
industrialization, climate, frequency of study on how to reduce solid waste volume
collection, population characteristics, in major cities like Addis Ababa and
recycling extent, and the existence of recommend a solution by designing and
disposal regulation of specific materials. developing an equipment to facilitate
recovery resource and recycling processes.
Generally, greater economic prosperity and
higher urbanization percentage leads to more PROBLEM STATEMENT
solid waste amount produced.
Amid increasing volume of solid waste due
The dearth of reliable data and information to urbanization, poor and ineffective waste
on solid waste is generally lacking in management (collection, segregation, and
developing countries. Information of solid disposal) system exits in every city, town, or
waste generation in Addis Ababa is not municipality in Ethiopia.
reliable and the little available information

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 Wastes are not segregated and were simply • Domestic Solid Waste .............. 0.2 – 0.8
scattered in open dump sites leading to kg/capita/day
environmental degradation and high risk • Commercial Solid Waste ….….. 0.1 – 0.2
exposure and dangers to peoples’ health. kg/capita/day
• Street Sweepings …….…….... 0.05 – 0.2
Design and development of low cost waste kg/capita/day
compactor usable by municipality, city, or • Institutional Solid Waste ........... 0.05 – 0.2
town or any organization can alleviate these kg/capita/day
problems.
Solid waste generation rate for some countries
OBJECTIVES are given below:

• Reduce waste volume before subjecting

it to secondary/recycling process.
• Waste volume reduction and increase the
recovery or reuse to avoid rapid loss of
environmental resources.
• Reduce waste exposure to environment
through better waste materials handling
and storing to diminish the possibility of
spreading diseases.
• Recover resource from waste by effective
segregation and volume reduction as a
preparatory activity before recycling
processes.

LITERATURE REVIEW Average Percentage of Waste Composition

and Rank
Ethiopia is facing a big problem in waste
management system. Every city or town
practically has no systematic waste collecting,
treating or disposal system. People relentlessly
throw garbage anywhere which leads to harmful
effects like diseases, illnesses, and etc. Better
waste management system and waste
segregation is important to be strictly
administered by local authorities. Volume
reduction also plays an important role, since
wastes are compacted and piled, not scattered,
which makes recycling process easily managed.

Quantity and Composition of Solid Waste in

Different Countries

Domestic solid waste generation rates vary from Waste Generation Rates by Different Studies
0.2 kg/capita/day in developing countries to
about 1.6 kg/capita/day. Typical estimates of The reliable data on waste volume and weight
generated and collected in Addis Ababa is rather
urban solid waste generation in less developed
countries are as follows: limited. Quantity of waste generation units was
very much unclear until 1987 when a Nor
Consult, a private consultant company on waste

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management from Norway, first published its households, 6% by street sweeping, 9% by
findings. Some other limited surveys have been commercial facilities, 5% by industries, 3% by
carried out by Lois Berger Company (by Gordon hotels and 1% by hospitals.
Stury in June 1994 and November 1995) and
French Mission in 1986. In different estimates, the share of compostables
has been assumed that 50% of the weight and
All of these indicate waste generation rates that 70% of the volume of the solid waste would be
are very low in international comparison. Waste compostable. The recyclable material (metals,
volume and weight generated varies from 0.40 to glass, plastics, paper, wood, rubber, etc.) is
1.23 liters/capita/day and from 0.11 to 0.25 estimated to be 15% of the weight and volume of
kg/capita/day. Waste density varies from 205 to the municipal solid waste.
370 kg/m3 in different surveys.
Physical Composition of Addis Ababa Solid
Generation Rates by different studies in Wastes
Addis Ababa

Currently, the estimated waste generation rate MATERIALS AND METHODS

used for calculation are:
MATERIALS
Generated solid waste by weight ............. 0.221 • MS Steel plates
kg/cap/day • Ribs and support plates
• Hydraulic cylinders/ram cylinders
Generated solid waste by density ............. 333 • Directional Control Valves
kg/m3 (average of wet and dry seasons) • Pressure relief valve
• Pressure gauge
This waste generation rate by weight is about 1/3 • Hydraulic hoses
of figures found in literature for the lower limit • Hydraulic Reservoir/Power pack (electric
range of generation rate in lower income motor, hydraulic pump, check valve, etc.)
countries. The density of the solid waste is rather • Welding Rods
high, as it varies from 205 to 370 kg/m3 (average • Bolts and Screws
being 333 kg/m3). • Siemens LOGO PLC,8 inputs, 4 outputs,
According to Nor Consult (1982), about 76% of 220V/24V DC
Municipal solid waste is generated by the

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 • Electrical wires, limit switches and
sensors, push buttons • Force developed by Ram:
Relevant Equations:
METHODOLOGY
σ= F
A⊥
→ F = σ(A ⊥ )
Study the existing waste handling practice in
the industry especially the compacting aspect d
or volume minimization.
d = 2r → r = 2
Material selection and characterization. For Ram: Circular cross–section
Design calculations for material and part 2 πd 2
dimension. A = πr = 4
Modeling of the system using software Conversions:
(CATIA, AutoCAD, or Solid Works). 1 bar = 100 KPa or KN/m2
Design review for tolerance analyses, 1 kg = 9.81 N
manufacturability, and assembly. 1 m = 1,000 mm
Selection of electric motor, tank, cylinder,
directional control valves, frame and rib Base on above equations:
thickness. • At 6 bars (600 KPa): F = 1,178 N or
Procurement of materials. 120 kg.
Fabrication of the machine. • At 8 bars (800 KPa): F = 1,571 N or
Reviewing with safety and health, standards. 160 kg.
Testing and debugging. • At max. 10 bars (1,000 KPa): F = 1,964
Document Preparation/final Terminal Report. N or 200 kg.

ANALYTICAL CALCULATIONS Compressive Stress developed inside the

Compaction Chamber:
Material Properties: • Compaction Chamber dimensions 190
• Aluminum Cans (metal): mm by 190 mm by 160 mm
For Aluminum: ρAl = 2.7 g/cm3 or 2,700
kg/m3
Compressive Properties: E = 70 GPa
σult. = 310 MPa
• PET (polyethylene terepthalate) bottles
(plastic):
For PET (polyethylene terepthalate):
ρPET = 1.37 g/cm3 or 1,370 kg/m3
Compressive Properties: E = 4 GPa
σult. = 100 MPa F
• Paper (bond papers, packaging boxes): Relevant Equation: σ= A⊥
For Paper: ρpaper = 0.25 – 1.5 g/cm3
For Compaction Chamber: Square Area
or 250 – 1,500 kg/m3
2
Compressive Properties: E = 2 – 4 GPa A=s
σult. = 150 – 475 KPa (0.15 – 0.475 MPa)
Base on above equations:
• At F = 1,178 N (120 kg) force developed
Pneumatic Cylinder:
• Specifications: by Ram (at 6 bars): σ = 32.63 KPa
Ram Diameter d = 50 mm Very small (insufficient) compressive
Stroke Length L = 120 mm force.
Air Pressure Capacity P = 6 – 8 bars
(600 – 800 KPa), max. 10 bars (1,000 KPa)
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 • At F = 1,571 N (160 kg) force developed REFERENCES
by Ram (at 8 bars): σ = 43.52 KPa
Can compact PAPER waste at 3 to 5 1. Rebullida, Maria Lourdes, Resource
compression stroke repetition of Recovery in Solid Waste Management:
Ram. Strategies, Initiatives, Policy Issues, Center
for Integrative and Development Studies,
• At F = 1,964 N (200 kg) force developed
University of the Philippines, Diliman,
by Ram (at max. 10 bars): σ = 54.40 KPa Quezon City, Philippines; Copyright 2000.
Pneumatic cylinder (seals and
gaskets) will have Pressure Overload 2. United Nations Commission on Human
as Ram rebounds (recoils) during Settlements, UNCHS Promotion of Waste
compression (air is compressible). Recycling and Reuse in Developing
Countries, Manila, January , 1993, pp.1-8.
• Recommendations:
Use 8 bars (air pressure) for safe 3. Technical Studies on Generation of Waste in
continuous operation of pneumatic Addis Ababa by Nor Consult and Gordon;
cylinder. 1982, 1984, 1995.
Use 3 to 5 repetitions of Ram
compression stroke for better
compaction of waste PAPER. Appendix A – Electro–Pneumatic Diagram of
Waste Compactor
CONCLUSION

The use of hydraulic force is very suitable to

reduce the volume of solid waste whether it is
plastic, paper, or metal (aluminum and tin cans).
Due to unavailability of the necessary materials
in this country, the research team still manages
to do actual fabrication and prototype using
pneumatics (compressed air) instead of
hydraulics (compressed oil).

The volume reduction of waste will be helpful in

the subsequent processes of waste treatment and
management process of every municipalities and
cities in Ethiopia.

RECOMMENDATIONS

Based on this study, owing to the large force

requirements to compress the solid waste, it is
therefore recommended that hydraulic system
must be used instead of pneumatics. The use of
pneumatics proved to be costly in the long term
operation since it requires multiple pounding
(several ram strokes) of materials before the
necessary compression density can be achieved,
penalizing the productivity and efficiency of the
waste compaction system.

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Appendix B – Assembly Drawings of Waste
Compactor