NicaraguA Bottle Upcycling

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NABU

P18433

Agenda

BackgroundProblem StatementPhase I Follow-up ActionsMarket AnalysisEngineering Requirements

System AnalysisUpdated HOQ DiagramFunctional Decomposition &

sss AnalysisBenchmarking

System Level ProposalSystem Architecture

Concept & Architecture Development

Morphological ChartEngineering Analysis

Environmental AnalysisRisk AssessmentEconomic FeasibilityPhysical Feasibility Research TopicsUpdated Project Plan

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Objective Statement

To upcycle plastic bottles creating a valuable end product, generating employment, and stimulating the economy of

El Sauce, Nicaragua

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Problem Statement● There is lack of proper recycling methods for plastic bottles in El Sauce,

Nicaragua○ Currently trash is being burned or dumped

● Our goal is to design a plastic bottle recycling process that creates jobs and a valuable end product ○ Considering a gutter for water systems, such as irrigation and water

collection○ Connectable, easily expandable

● We aim to design a robust manufacturing process that can accommodate low resource availability and a sparse skilled workforce

● The manufacturing process consists of melting and forming PET plastic chips into a valuable product

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Phase 1 Follow Up Actions

● Based on feedback from our phase 1 problem definition, we have ○ Solidified a product for our molding process○ Updated our engineering and customer requirements so they are quantifiable and relate

directly to each other○ Rebuilt our house of quality to more accurately show the relationships

■ Separated house of quality into final product and process○ Continued benchmarking to include other processes and mechanisms we aim to include in our

process○ Final Product Decision (Gutter) ○ Shredder Status Analysis:

■ Conclusion: Not immediate priority, highly resource intensive

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Engineering Requirements

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HOQ - Product Design

Legend

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HOQ - Equipment

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Phase 2 AchievementsAdam Santagata - Benchmarking, Morphological Chart, Engineering Requirement Values

Vikas Patel - Functional Decomposition, Plastic research, Draft mold design, Risk mitigation

Kyle Appleman - PET Melting feasibility, Concept Generation, Pugh Chart

Ignacio Martos - Set Up Dynamic Tool for Project Management, Economical Analysis, HOQ Equipment Updates, Market Analysis

Pierce Scroggins - Possible solution descriptions, Contributed to Pugh Charts, System architecture, Risk mitigation, Update HOQ’s, Update ER’s & CR’s

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Functional Decomposition

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Functional Decomposition

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Market Analysis

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BenchmarkingPlastic Material Properties

Melting Point Young's Modulus Impact Strength Density Standard

Applications[°F] [GPa] [ft-lbs/in] [lbs/in^3]

Polyethylene

Terephthalate (PET)480-500 2.76 0.7 0.0499 Beverage Bottles

High Density

Polyethylene (HDPE)259-267 1.55 1.3 0.03465

Storage Bins,

Industrial Tubing

Low Density

Polyethylene (LDPE)230 0.29 No Break 0.03321

Plastic Bags &

Bottles

Polyvinyl Chloride

(PVC)320 2.83 0.4-22 0.051 Piping

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BenchmarkingPlastic Melting Machines

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BenchmarkingElectrical Resistance Heating Element

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BenchmarkingCompression Method

Product

AutoCraft 2-Ton Trolley Jack with 2-Ton Jack Stands Combination

Craftsman 2-1/2 Ton Floor Jack, Low Profile

Alltrade Tools 4000LB TRPL LFT JACK

HYDRAULIC SHOP PRESS HSP-10H

Hydraulic Press, 10t, Manual Pump, 36 In

Buffalo Black Bull Fully Automatic Electric Car Jack

Cinva-Ram / Ceta-Ram

Description Car Jack Car Jack Car Jack Hydraulic Press Hydraulic Press Car Jack Custom Press

Max Weight 2 [Tons] 2.5 [Tons] 2 [Tons] 10 [Tons] 10 [Tons] 1 [Tons] ??

Lift Range 5.5 - 13.375 [inches]

14 [inches] 5.5 - 17.5 [inches] 4.33 - 14.33 [inches] 10 [inches] 5 - 14 [inches] 8 [inches]

Power Manual Manual Manual Manual Manual Electric Manual

Price $40 $60 $150 $300 $337.50 $60 Home Made 16

Morphological Chart

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Morphological Chart-Analysis of Components

Green = Practical Solution Components

Orange = Low Budget Solution Components

Red = Impractical / Non-beneficial Components

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First DesignCons: Complexity of molten plastic transfer into mold

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Concept - Previous vs CurrentPrevious Design:

● Two part system with heating and molding accomplished with different mechanisms

● Mold would be contained within an oven and compressed to melt and shape plastic

Current Design:

● Integrated heating and molding into a single unit

● Mold is heated internally and pressured

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Reasoning for Changing Design

After meeting with HARBEC we decided to update our design based on the following criteria

● Lower energy use- don’t have to heat an entire oven● Lower heat loss- mold doesn’t have to cool completely to be re-used● Increased production rate- with multiple molds in use in a series, there will be no down time where

workers are waiting for an oven to heat the mold or to cool down● Decreased materials needed to build system- Aluminum block and resistance heaters● Decreased size of total system- a single mold should only be as large as a shoe box

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System Level Proposal● Plastic is compressed and heated within the mold to increase energy● Plastic has to exceed glass transition temperature to be shaped into the mold (approximately 67 -

81°C)● Force requirement depends on mold shape and temperature and must be determined through

testing● Includes ejector pins to easily remove molded part

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System Level Proposal Schematic

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Draft of Gutter Mold Design (System Level Proposal)

● Current design for gutter mold

● 12” x 6” x 3” (LxWxH) outside gutter dimensions and ⅛’’ thickness

● Resistant heating elements will run through bottom of mold

● Conductive grout will secure the rods and assist heat transfer

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System ArchitectureSystem Inputs:● Energy input● Human input

Failure Modes:● Melting plastic timing● Melting temperature regulation● Applying insufficient compression forces● Product damage during extraction● Product deformation from insufficient

cooling time● Personal injury from operation● Equipment wear from regular use

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Pugh Chart

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Screening Matrix

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Engineering Analysis

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Environmental Analysis● Effects of sun exposure on PET

○ Little to no change in water quality during short exposure periods

○ High temperatures and CO2 presence increased release of formaldehyde and acetaldehyde during long exposure periods

● Recommend not to consume water collected by gutters until further studies are conducted

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Economic FeasibilityObjective:

Payment processed by production: $x for one gutter, quality standards would be important

Desired payback period: 3 ← → 6 months at 0% profit

Desired machine cost: < $500

Average salary range in El Sauce, Nicaragua:

● $0/month, some percentage of the population● $100/month, high percentage of the population● $200/month, some percentage of the population● $400/month, very low percentage● $500+/month, extremely low

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Economic Feasibility Cont.

Hypothesised production scenarios:

● Number of workers: 2 ← → 6● Number of work hours: 8 ← →16● Number of products per mold: 1 ← → 5● Number of molds per batch: 1 ← → 3● Time per batch: < 1hr

○ Length of a single gutter: 1 foot○ Weight of a single gutter (quality): tbd grams (g)

● Price of each foot of gutter: $0.30 ← → $1.00 ● Number of workdays: 25 ← → 30● Monthly salary for operators: <= $100● Cost of plastic chips per liter: $ 0.05 ← → 0.08 (Team 18434 suggestion)

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Physical Feasibility Research Topics● Plastic mold design and methods of molding● Liquid plastic flow mechanics● Required pressure to form plastic at different temperature ranges ● Plastic cooling (rate and how to)● PET & HTP plastic qualities● Liquid plastic feed systems, dripping, injecting, etc● Plastic cooling rate and cooling systems● Handling of hot plastic molds (Leather, can we get it?)● Gas emissions of molten plastics, rate, toxicity, and ppm● Mold clogging scenarios

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Risk AssessmentHigh Importance (9)

● R2: The heater could break down and malfunction○ Mitigation ➜ repeatedly testing the heating element prior to installation

● R3: Inconsistent temperature regulation in the plastic melter○ Mitigation ➜ measuring temperature gradients in different regions of melter

● R8: Insufficient funds to purchase all the required design materials○ Mitigation ➜ research multiple vendors and compare prices

A full list of current project risks can be found on our team edge page

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Risk Assessment Cont.Medium Importance (6)

● R5: We are unable to fill the mold using the plastic melting process○ Mitigation ➜Plastic melted inside the mold, eliminates molten plastic transfer

● R7: System inconsistently produced the plastic product○ Mitigation ➜Measure dimensional variation, adjust molds

● R10: No facilities for us to safely test a moderately large furnace○ Mitigation ➜Locate usable lab with ventilation

● R13: Initial benchmarking machines require salvaged items that may be difficult to acquire○ Mitigation ➜Salvage parts from old, free, or cheap appliances

A full list of current project risks can be found on our team edge page 34

Project Plan - Phase 3

● Finalize mold design including connectability and strength of product● Acquire materials for building mold and product (aluminum, plastic chips,

heating coil, electronics, controls, insulation, compression method)● Create a test plan for initial molding prototype● Risk mitigation analysis

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Management Platform: Dapulse

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Current Direction

● Finish research and designing of mold

● Analyze benchmarked solutions for most viable option

● Start acquiring materials to build prototype

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Questions

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