MERU UNIVERSITY OF SCIENCE AND
TECHNOLOGY
SCHOOL OF EDUCATION TECHNOLOGY
FABRICATION OF SIMPLE MILLING PET
PLASTIC BOTTLE WASTE MACHINE FOR
RECYCLING
BY
MUUO JOB MUSYOKA
EG205/103738/20
AND
PATRICK KIPKOSGEY KIPLAGAT
EG205/103738/20
The report submitted in partial fulfilment of requirements for award in degree of bachelor of
education technology (mechanical engineering) in Meru University of Science and Technology.
To be submitted before: 22nd April 2025
©2025
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DECLARATION
We hereby affirm, with absolute certainty, that the work contained within this project report is
entirely our own original work. It has not been previously submitted or presented at Meru
University of Science and Technology. Furthermore, no portion of this proposal shall be
reproduced or duplicated without my explicit prior authorization.
NAME: Patrick Kipkosgei Kiplagat : Muuo Job Musyoka
REG. NO.: EG205/103738/20 : EG205/103738/20
SIGN…………………………. ………………………
Date………………………………. ………………………
This project report has been submitted for examination with our approval as university
supervisors:
Sign………………………………. Date…………………………….
Name KINUTHIA MUGI CHARLES
Supervisor:
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EXECUTIVE SUMMARY
University studies is one of the bridges towards achieving the four national agendas in our nation
Kenya. Education is for sure the mirror of the society. Having gone through various units,
satisfying the requirements for award of bachelors of education technology in mechanical
engineering, research project was among them. This report hereby aims at clarifying our project
idea, findings as well as conclusions. Fabrication of simple milling machine for pet plastic waste
recycling came as a result of the burden in us of seeing how many water and soda plastic bottles
waste were everywhere around major streets of our institution. The scope of this machine was
from the corona hand grain milling machine used mostly in small scale. We were aiming at a
simple machine just as the title suggests that can be used at a small scale to help curb the mess of
pet plastic waste. The fabrication took stages of activities as elaborated very well inside this
report. From buying of required materials to assembling of fabricated parts to painting of the
maching as well as testing the functionality of the machine. Essentially, we were aiming at how
this machine can reduce the pet plastic waste bottles into pellets which can be used
constructively in places like construction or even innovations of valuable resources which are
eco-friendly. The machine was to basically crush the waste pet bottle at first stage by the help of
screw conveyors and resistors. The crushed parts were then to be directed to the grinding discs
which could achieve the goal of pellets. As mentioned earlier, this project aimed at converting
unvaluable waste product polluting the environment into valuable substances that are eco-
friendly. The fabrication process took place at Meru university metal sheet engineering
workshop. We faced challenges starting with finances to even health challenges for instance
sleepless nights crying throughout the night due to welding side effects. We courageously report
that this experience, helped us to gain the hand skill hence we are now well equipped for any
welding operation. We highly recommend to everyone doing a fabrication project to be first be
familiarized with the safety and precaution measures on welding. We did our best and the
machine functioned though not fully to our expectations due to some few errors which we
recommended on consideration this machine is one of the best as far as recycling of pet waste
bottles in small scale is concerned.
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CHAPTER ONE: INTRODUCTION
This chapter is the opening of the idea that was implemented. Seeks to response what was the
idea how it was executed and why, who excited the idea and when and where was the idea
executed. It gives the bigger picture of the entire project process and through it one can to the
clear understanding of the project idea.
1.1 PURPOSE
The rising consumption of Polyethylene Terephthalate (PET) bottles has triggered a mounting
ecological crisis due to improper waste handling. Renowned for their affordability and resilience,
PET bottles dominate beverage packaging, particularly in most institutions, towns and cities.
Unfortunately, PET’s resistance to decomposition causes these plastics to linger for centuries in
landfills and natural ecosystems, where they disrupt biodiversity. Additionally, research
conducted by scientist, shows that burning PET waste emits 3.5 kg of CO₂ per kilogram,
intensifying global warming and releasing toxic pollutants that threaten human and wildlife
health. This highlights the pressing need for innovative strategies to counteract the environmental
hazards of plastic pollution.
Transforming PET waste into functional products presents an eco-friendly and economically
viable solution. By leveraging accessible, low-cost machinery to grind PET into reusable pellets,
local communities can reclaim waste and create items such as planters or furniture. This initiative
fosters environmental stewardship while unlocking entrepreneurship opportunities, particularly
for underserved populations. Empowering communities through sustainable recycling practices
reduces plastic pollution and promotes a shift towards a circular economy, where waste becomes
a resource. This project seeks to close critical knowledge gaps, offering practical solutions to
manage PET waste while creating green jobs and advancing climate resilience.
1.2 IMPLEMENNTORS
One among many things we have learned through our course work in management skills. This
entails team work, unity and collaboration. This is one of the most crucial aspects in real life
situation and so we worked as a group of two personals (Patrick and Job) as introduced earlier.
This helped in exchanging of ideas, nurturing each other in the technological field and even in
the general aspect of life.
1.3 IMPLEMETATION TIMELINE AND PLACE OF THE PROJECT
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Started working on the project the previous semester of study whereby we proposed the idea
through research and presented it to our supervisor as a research proposal for approval and
consent.
Early the last semester of our study the month of February started working on the fabrication
process of the machine.
The first step was to buy and the materials to work with and secure safety tools and outputs like
overalls gloves and glasses et cetra.
The timeline of the fabrication process approximately was three- four weeks translating to one
month.
The whole process took place at Meru university of science and technology engineering metal
sheet workshop.
1.4 PROJECT GOALS AND OBJECTIVES AS OUTLINED IN THE INITIAL
PROPOSAL
1. Designing a simple pet milling machine
2. Fabrication of the designed pet milling machine
3. Testing of the fabricated simple pet milling machine
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CHAPTER TWO: ACTIVITIES DONE
This chapter seeks to delve deeper into the actual activities that took place to the actualization of
the machine. Its more concerned on the fabrication part to even the presentation of the project
before supervisors for awarding of marks.
It is divided into sub topics so as to cover fully each activity in a comprehensive and more
clearly way in a sequential order.
2.1 PROCUREMENT AND PREPARATION OF PROJECT MATERIALS
Visited Meru red flag scrap yard located at Meru town where we secured most of our project
work. Engineering entrepreneurship states that its more economical and reasonable for a
technologist to utilize and recycle waste products and transform them into useful end products.
From the itemized budget and the design, we had, we procured good number of project materials
as well as purchasing of essential for instance welding electrodes and cutting and grinding discs.
After purchase these materials were transported to school’s engineering metal workshop waiting
for the awaited task to commence
2.2 PRESICION CUTTING AND MEASUREMENT OF MATERIALS FOR COMPONET
FABRICATION
Metrology is the science of measurement and during this stage we really appreciated the
knowledge gained from the subject as we now practically gained the skills. Were keen on
tolerance as well as the dimensional analysis of the materials so as to achieve a smart final
product. We were keen at attaining the diagonal accuracy of the stand.
Accuracy was our aim as we understood that for the grinding discs to effectively mesh, we ought
to have achieved accuracy from the word go.
2.3 FABRICATION OF MACHINE HOUSING AND STRUCTURAL FRAMEWORK
The fabrication involved folding metal sheet using a manual sheet metal break. The shape of the
machine from design work was supposed to be hollow cylinder of Ø260mm. so we were to
convert the flat sheet by calculating the circumference and the folding it into cylindrical form of
length 400mm
circumference=∏ ❑ d
=π*26o
Welding was the technique we used to make the cylinder from rectangular sheet in which
afterwards, the housing was divided into two as per the design. This to allow room for fitting the
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inner parts of the machine as well as to ensure that the servicing of the machine during operation
time was at ease.
The front end of the machine it was also covered using a circular metal sheet of Ø262mm hence
making the cylinder semi-hollow as the other side it was to be covered by the grinding discs as
per design.
2.4 PRESICION ENGINEERING IN CONVEYOR SYSTEMS.
This involved several steps. One, the shaft was to be machined into Ø20 mm of length 555 mm.
Secondly, the screw conveyors of Ø 250 mm were to be designed then fabricated into belt from
individual circular discs.
Finally, the screw conveyor belt now formed was fixed onto the shaft. With the help of resistors,
this conveyor was to initiate the crushing effect onto the plastic alongside propelling it forward
towards the grinding plates. There were welded at an angel of 35.
2.5 SHAFT BEARING INSTALLATION AND ALINGMENT
A bearing helps parts move smoothly and efficiently, especially when there's rotation or
movement involved. Since the shaft will be moving at a high speed. It was very wise to mount
the bearings and Alling then for smooth movement. We as well mounted bearing housing to
provide extra support so as to withstand the vibrations.
A total of two bearings were used of Ø20mm mounted on both sides on top of the housing frame.
After fixing we oiled so as to ensure efficiency required is achieved.
2.6 DISK INSTALLATION AND ALLINGMENT
Involved a couple of activities which were done following a certain procedure to achieve the
objective.
First the flat brake disks were converted into grinding disk through shaping the teeth pattern. The
fixed grinding disc with female teeth pattern was mounted firmly onto the housing of the
machine. This was achieved through intense arc welding using shielded metal arc welding
machine.
The driven disk was mounted onto the shaft which could rotate and with the help of the fixed
disk initiate a grinding effect. Accuracy in alignment was very critical at this stage so as to
ensure there is minimal wear and tear as well as to reduce the heat effect due to the high melting
point of the plastic material being machined. We used the spirit level to attain to the perfect
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alignment of the two disc. This also ensured they well meshed so as to achieve a nearly uniform
pellet.
2.7 SURFACE FINISH FOR SAFETY AND FUNCTIONALITY
Surface finish refers to the texture, smoothness, or roughness of a surface after a manufacturing
process like machining, grinding, or polishing. This reveals the physical appearing of the
machine as attractive and appealing to the eyes.
Above that surface finish is a critical aspect in fabrication as it ensures safety in such a way that
it reduces accidents. The sharp edges should be trimmed to avoid any injury.
Surface finish again ensures that the efficiency of the functionality of the machine is achieved.
This is through ensuring moving parts are well equipped and positioned.
We spend quality time in ensuring all welded parts were at good state, polishing any fractures
using the sandpapers procured the first day as well as painting the machine for good appeal.
2.8 MOUNTING OF THE MOTOR.
From our design, the motor was to provide the driving force to the shaft that could initiate the
machining process. For our case, we improvised the angel grinder. So as to achieve the torque
required in the machining process as per the design calculations, we reduced the speed by the
help of gears. The small gear had 11 teeth while the big gear had 52 teeth. Normally a grinder is
run by electricity, so also in our case we used electricity to run the angel grinder.
2.9 TEST RUNNING OF THE MACHINE.
This involved three major steps;
1) Connecting the motor to power source and test running the machine without anything in
it. This was to ensure that all parts of the machine are well fixed ready for the machining
process. This also helped us to rectify any error with ease.
2) After the first step was successful, we then proceeded to the next step of measuring. In
this we used hard manila papers. This was to re-prove our idea and the machine using a
soft material first so as to be sure of the functionality and again predict ant improvement
if any. This was a success giving us a go ahead to the next and final step.
3) This was the final step. We used the pet plastic bottle waste as per the designed and
evident in our proposal.
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This activity led us to achieving our third objective and hence seeing the success of our project
work. We were then to present to our supervisors for marks awarding and further advice on the
subject matter for improvements.
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FINANCIAL REPORT
Itemized budget
.
item Description/quantity price
Metal sheet 2 (2 mm thick) 1800
Circular-hollo-metal bars 2(21 x 1.5 mm) 2000
Circular-hollow metal bar (42 x 1.5 mm) 800
Welding rods 2 packets 700
Cutting disks 2 pieces 1000
Grinding disks 2 pieces 800
Metal sheet 1(5 mm thick) 3600
cement 3 bags 1800
Ceiling board 3 pieces 1200
Reinforcement bars 2 pieces 500
paints 4 liters 1500
sandpapers - 500
transportation 1200
TOTAL 17400
TOTAL AMOUNT COLLECTED
Contributed a total of KSH 10,000 from individual savings and HELB loan funds.
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EXPENDITURES
.
item Description/quantity price
Circular-hollow metal discs 2 in number 1000
Solid metal bar I meter long 200
Metal sheet Re-used scrap metal sheet 400
Lunch allowances During fabrication 2000
Welding rods 5kgs 1000
Cutting disks 2 pieces 360
Angel grinder Re-cycled 2000
Grinding disks 1 piece 180
Reinforcement bars 2 pieces 100
paints 1 liter 1000
sandpapers - 500
transportation 1200
Transaction costs Daily 100
TOTAL 10,040
RECOMMENDATIONS
Having achieved and gained some experience on project work. We would highly recommend for
one to always have a strategic plan on what is required before working on the project. This will
save on extra cost on transport as well as avoid buying the wrong thing.
CONCLUSIONS
For a project to thrive, more than finances it needs commitment and application of technological
skills to solve both minor and major problems as we have explored through our project.
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