A MINOR PROJECT REPORT

ON

Fabrication of a Manually Operated Paper-

Recycling Machine

Under the guidance of

Mr. Shobhit Srivastava

Assistant Professor

Department of Mechanical Engineering

Submitted by: -

1. Abhijit Kumar (Roll No. 01)

2. Amrendra Kumar (Roll No. 10)

3. Prakhar Katiyar (Roll No. 59)

4. Shivram Kumar (Roll No. 81)

Faculty of Engineering & Technology

Gurukula Kangri Vishwavidyalaya

Haridwar-249404 (UK)

Session: 2016-17

1

CANDIDATE’S DECLARATION

We here by certify that the work which is being presented in the report entitled “Fabrication of

manually operated paper recycling machine” for the award of the degree of bachelor of

technology in Mechanical Engineering, Faculty of Engineering and Technology, Gurukula Kangri

Vishwavidyalaya, Haridwar, during the year 2016-17 is an authentic record of own work carried

out under the guidance of Mr. Shobhit Srivastava, Assistant professor in Department of

Mechanical Engineering.

The matter presented in the report has not been submitted in part or in full of award of

degree/diploma of other university/institute.

Date - 17/11/2016

Place - Haridwar

1. Abhijit Kumar (Roll No. 01)

2. Amrendra Kumar (Roll No. 10)

3. Prakhar Katiyar (Roll No. 59)

4. Shivram Kumar (Roll No. 81)

2

CERTIFICATE

This is to certify that the minor project report entitled “ Fabrication of manually operated

paper recycling machine” submitted by Abhijit Kumar (Roll No. 01), Amrendra Kumar (RollNo.

10), Prakhar Katiyar (Roll No. 59), Shivram Kumar (Roll No. 81), in partial fulfilment for the

award of the degree of Bachelor of Technology in Mechanical Engineering, Faculty of Engineering

and Technology, Gurukula Kangri Vishwavidyalaya, Haridwar, during the year 2016-17, is a

bonafied record of work carried out under my guidance and supervision.

Mr. Sanjeev Kumar Lambha

Assistant professor & Incharge

Mechanical Engineering

Faculty of Engineering & Technology

Gurukula Kangri Vishwavidyalaya

Haridwar-249404 (UK)

Mr. Shobhit Srivastava

Assistant professor

Mechanical Engineering

Faculty of Engineering & Technology

Gurukula Kangri Vishwavidyalaya

Haridwar-249404 (UK)

3

ACKNOWLEDGEMENT

We wish to express our deep gratitude and thanks to Mr. Shobhit Srivastava, Assistant professor

in department of mechanical engineering, who guide us to successful of this minor project. We

take this opportunity to express our deep sense of gratitude for his invaluable guidance. Constant

encouragement, constructive comments, sympathetic attitude and immense motivation, which has

sustained our effort at all of the project work.

We sincerely thanks to Mr. Sanjeev Kumar Lambha, Assistant professor & Head of Mechanical

Engineering department, for his encouragement. We sincerely appreciate his magnanimity by

taking us into his fold for that we shall remain indebted to him.

We are thankful to all the faculty members for their valuable support and suggestion.

At last but not least, we are thankful to almighty GOD for his mercy and grace upon us for

`carrying out this little piece of work.

Abhijit Kumar (Roll No. 01)

Amrendra Kumar (Roll No. 10)

Prakhar Katiyar (Roll No. 59)

Shivram Kumar (Roll No. 81)

4

CONTENTS

Contents Page No.

CHAPTER 1: Introduction 5

CHAPTER 2: Literature Review 6

CHAPTER 3: Discription 7

CHAPTER 4: Working Principle 9

CHAPTER 5: Design Procedure 13

CHAPTER 6: Advantages & Disadvantages 20

References 21

5

CHAPTER 1: INTRODUCTION

Paper is one of the most important products ever invented by man. The primary raw material for

the paper production is pulps fibres obtaining by acomplicated chemical process from natural

materials, mainly from wood. This fibres production is very energy demanding and at the

manufacturing process there are used many of the chemical matters which are very problematic

from view point of the environment protection. The paper recycling, means the repeated defibring,

grinding and drying, when there are altered the mechanical properties of the secondary stock, the

chemical properties of fibres, the polymerisation degree of pulp polysaccharidic components,

mainly of cellulose, their supramolecular structure, the morphological structure of fibres, range

and level of inter fibres bonds.

Paper recycling saves the natural wood raw stock, decreases the operation and capital

costs to paper unit, decrease water consumption and last but not least this paper processing gives

rise to the environment preservation. A key issue in paper recycling is the impact of energy use in

manufacturing. Paper recycling is the process of recovering waste paper and remaking it into new

paper products. There are three categories of paper that can be used as feedstock for making

recycled paper:- mill broke, pre-consumer waste, and post-consumer waste.

Designing a manually operated paper recycling plant ensures that a cheap and noncomplex

method of production of paper product is guaranteed. Recycling, which is the extraction and

recovery of valuable materials from scrap or other discarded materials, is employed to supplement

the production of paper. The fabricated plant consists of six major component units that include

the disc refiner, the hydropulper, the head box, the felt conveyor, the driers and the rollers. The

invention of paper means that more people would be educated because more books would be

printed and distributed.The primary source of raw material for production of paper is vegetable

fibers, obtained mainly from plants. To ensure that the forest is not depleted of these woods, there

is need to provide alternative source of raw materials, this therefore leads to the invention of the

process of recycling. The designing and fabricating of a used paper recycling plant is a welcome

development as it will ensure that the source of raw material for paper production is multiplied

and also waste paper that could have constituted into wastes are recycled for various productive

purposes.

6

CHAPTER 2: Literature review of Paper Recycling Machine

Carlson W. E. C. (May 6,1991), “The paper recycling, means the repeated defibring, grinding and

drying, when there are altered the mechanical properties of the secondary stock, the chemical

properties of fibres, the polymerisation degree of pulp polysaccharidic components, mainly of

cellulose, their supramolecular structure, the morphological structure of fibres, range and level of

inter fibres bonds.”

Kenneth W.B. (1970), “Designing a manually operated paper recycling plant ensures that a cheap

and noncomplex method of production of paper product isguaranteed. Recycling, which is the

extraction and recovery of valuable materials from scrap or other discarded materials, is employed

to supplement the production of paper.”

Paul, D.R. (1942), “ Paper recycling saves the natural wood raw stock, decreases the operation and

capital costs to paper unit, decrease water consumption and last but not least this paper processing

gives rise to the environment preservation.”

Meyers R.A. (1992), “To ensure that the forest is not depleted of these woods, there is need to

provide alternative source of raw materials, this therefore leads to the invention of the process of

recycling. The designing and fabricating of a used paper recycling plant is therefore a welcome

development as it will ensure that the source of raw material for paper production is multiplied

and also waste paper that could have constituted into wastes are recycled for various productive

purposes.”

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CHAPTER 3: Description of Paper Recycling Machine

1 - Pulp inlet, 2 - Water outlet, 3 – Pickup roller,

4 – Sieve drum, 5 – Drum case, 6 – Felt conveyor,

7 – Idlers, 8 – Power driven roller, 9 – Calendar roller.

The designed of a waste paper recycling plant included the determination of the volume

of the refiner, hydropulper and head box and also the selection of a convenient material

for the construction of the individual units. The bulk of the parts of the plant were

fabricated using mild steel, this is because it is the easiest to be joined among all

1 2

3 4

5

6

7

8

9

Fig. 3.1

8

fabrication of process unit equipment. Apart from its versatility, it is also very cheap

and readily available compared to other metals.

Some basic properties of mild steel :-

Tensile strength: 430KN/mm;

Yield stress: 230KN/mm;

Tensile modulus: 210KN/mm3

The bulk of the parts of the unit were fabricated using mild steel, this is because it is the

easiest to be joined among all other metals. It is a very versatile metal, necessitating its

use by many industries for fabrication of process unit equipment. Apart from its

versatility, it is also very cheap and readily available compared to other metals. The

calculated volume of the refiner, hydropulper and head box is 11795.62cm3,

62930.47cm3 and 60979.096cm3 respectively. The fabricated machine is capable of

producing 7.6 kg of recycled paper from 10 kg of used paper.

The manually operated paper recycling machine unit broadly consists of the following

four systems:-

1. Pulp feeding system: It consists of the sieve drum, drum case and the pickup

roller. Its function is the preparation of pulp slurry and feeding it.

2. Pulp transferring system: It consists of the nylon felt conveyor and the set

of idlers. Its function is to transfer the slurry to the calendaring system.

3. Calendaring system: It consists of two calendar rollers. Here the pulp gets

calendared to paper and then the paper is removed out.

4. Driving mechanism: It consists of an electric motor, a gear box and a pulley-

belt drive.

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CHAPTER 4: Working Principle of Paper Recycling Machine

General Layout:

1 - Pulp inlet, 2 - Water outlet, 3 – Pickup roller,

4 – Sieve drum, 5 – Drum case, 6 – Felt conveyor,

7 – Idlers, 8 – Power driven roller, 9 – Calendar roller.

1 2

3 4

5

6

7

8

9

Fig 4.1

10

Salient Features of Machine Unit:

Size of paper sheets to be made – approx 297 x 210 mm (A4 size)

No. of sheets taken out per batch – 3

Speed of calendar drum from which paper is removed off – 18-20 rpm.

The batch size implies the maximum no. of paper sheets of the given size that can

be taken out in one complete revolution of the calendar drum. The major dimensions

of the various components of the unit are based on these three parameters. The size

of each paper sheet and the no. of sheets per batch give the dimension of the calendar

roller. Correspondingly, the dimensions of the other main rollers (the power-driven

calendar roller, the sieve drum and the pickup roller) have been determined. It is to

be noted that, the thickness of the paper to be obtained is decided by the no. of turns

the calendar drum is allowed to make before peeling off the paper from it (provided

the feed is constant and consistent). Fresh layer of pulp gets coated over the previous

layer with every new turn. Greater the no. of turns given before removing the paper,

thicker is the final paper obtained.

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Preparation of Pulp Slurry:-

The raw material for the paper recycling plant unit is paper pulp slurry. It is a mixture of

approx. 50% pulp and 50% water. Generally, for big paper recycling plants, the source of raw

material is the waste paper pulp from paper industry. But, as the machine unit fabricate under

this project is of small scale and is meant for reusing and recycling the waste paper generated

in a school or college, pulp slurry can be prepared locally.

From Pulp to Paper:

After the preparation of slurry, it is transferred into the sieve drum case. The drum case

consists of a sieve drum. The function of the sieve drum is to transfer the pulp onto the

conveyor belt.

Working of sieve drum - Sieve drum is a hollow cylindrical drum whose entire lateral

surface is covered with a sieve-like mesh. It has rectangular slots cut onto its lateral

surface to allow flowing of water through it. This drum is fitted inside the drum case.

The sieve drum keeps rolling in the drum case continuously at very small speed. The pulp

slurry is fed to the small V-shaped collecting chamber which is a part of the drum case. As the

drum is continuously rolling against the press roller (pickup roller), the pulp gets stuck on the

conveyor belt which is passes between the two drums. The pickup roller is rubber coated to

increase friction on its surface so as avoid slippage of the belt.

Felt conveyor - The felt conveyor assists the flow of pulp. It is made up of nylon. The

conveyor carries the pulp to a set of calendar rollers which comprises of two rollers –

one of diameter bigger than the other. The belt passes between the two rollers and the

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paper gets stuck on the roller which is rolling. The smaller roller is the driven roller i.e.

the electric motor shaft is connected to this roller shaft. This roller drives the other

rollers, the idlers and the sieve-drum. This roller is rubber coated. Pair of arms carrying

the pickup roller. These pivots enable the arms to make small angular motion about the

joint. This flexibility is necessary as these arms have springs hooked to them.

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CHAPTER 5: Design Procedure of Paper Recycling Machine

The Disc Refiner

The unit consists of three main parts:-

1. A hopper for charging in the pulp slurry,

2. A screw type conveyor for moving the slurry to the treating element blade, and

3. A treating element.

Volume of hopper is a frustum of a pyramid and the volume is given by,

V = Ah/3

Where, V = volume,

A = area of base of pyramid and

H = height of pyramid.

Using similar triangle theorem, height:-

h/8 = H/30

But, H = h +29

So, h/8 = h +29/30,

h = 10.545 cm

Total volume of pyramid Vp:

Vp = (1/3) × (300)2 × (10.545 + 29)

= 11863.5 cm3

Volume of truncated pyramid:

Vs = (1/3) × Ah

14

= (1/3) × 8 × 8 × 10.545

= 224.96 cm3

Volume of cylinder enclosing shaft:

Vc = πr2h

r = 2.5

h = 8cm

Vc = 157.08cm3

Total volume of hopper refiner is

V = (Vp - Vs) + Vc

V = (11863.5 - 224.96) +157.080

V = 11795.62cm3

15

The Hydropulper

Assume,

Thickness, t = 0.022cm

Radius, r = 0.95cm

Height, h = 50cm

This is an open cylindrical vessel incorporating one bladed rotating element that serves both to

circulate the slurry and to separate the fibre from each other. It makes the paper source become

disintegrated, transformed and well blended into fibre slurry. This unit is operated manually.

It follows :-

Volume of hydropulper (Vr), it results from its mass and density. Using a scale up factor of 10 (for

the whole plant) mass of pulp slurry leaving hydropulper,

Mass, m = 7.14675×10 Kg

= 71.46750 Kg

= 71467.5 g

h

t

r

16

Density of pulp is 1.172 g/cm3, then volume of pulp slurry (VC),

VC = 60979.096 cm3

Total Volume of Hydropulper:

Vr = VC + 0.032 VC

= 1.032 VC

= 62930.427cm3

Diameter of Hydropulper (a cylindrical vessel) it results from volume of cylinder,

V = Πr2h

Where, h = 50 cm

Radius of circular cylinder: r2 = V/πh

r = (V/π h)1/2

r = (62930.43/π ×50)1/2

r = 400.628

r = 20.016 cm.

Diameter of cylinder

D = 2r

D = 2×20.016

= 40.032 cm.

The total surface area of cylinder,

A = 2πr(h+r)

= 2π× 20.016(50+20.06)

= 8805.51 cm3

17

Circumference of cylinder,

C = 2πr

= 2π×20.016

= 125.764 cm

Head box

This unit is made out of an 18" gauge flat sheet into a square tank. Its purpose is to ensure that a

continuous flow of stock at constant velocity across the width of the machine is provided. Its

principal design involves the use of a single slice to develop a free jet of pulp that is then deposited

onto the moving felt conveyor. It has an inlet medium fitted with a 2" pipe socket that allows for

a continuous flow of pulp slurry. It follows:-

Volume of Head box, using a scale up factor of 10 (for the whole plant) result from mass of slurry

leaving the hydropulper to the head box,

m = 7.14675×10 Kg

= 71.4675 Kg

The density of the pulp = 1.172 g/cm3

Volume of the pulp slurry = mass/density

= 71.4675/1.172

= 60.979096m3

Volume of the headbox = 60979.096cm3

Free jet area = length × breadth

VC = 2.5 × 25.50

VC = 63.75 cm2

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Felt Conveyor:

• The felt is made up of nylon.

• Approx. length - 3.9m to 4m

• Width – 13”

The design of the felt is to serve three main purposes:

1. A conveyor to assist the sheet through the manufacturing process

2. A porous media to provide void volume and channels for effective water removal

3. A texture cushion for passing moist sheet without crushing or significant marking.

As a tension band to maintain sheet felt ness and ultimate contact with followings:

Hot dry surface length of cylinder, l = 50cm

Radius of cylinder, r = 7cm

Circumference of cylinder, C = 2πr

= 43.99 cm

Details of the driving System:

Electric Motor and the integrated Gear Box -

Motor – 1 HP, A.C., 3-phase, 900 rpm

Gear-box – 42:1 speed reduction, attached to motor

Belt and pulleys -

Speed increment ratio – 1:2

Belt – ‘V’ shaped, Leather, B-type, 46 cm long

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Component List of Paper Recycling Machine

S.N. Component Name N.O. of Components Components Material

1 Sieve drum case 1 M.S. Sheet, 2mm thick

2 Sieve drum 1 M.S. 5mm thick

3 Pickup roller 1 M.S. 5mm thick with rubber coat

4 Calendar roller (big) 1 M.S. 5mm thick

5 Calendar drum (small) 1 M.S. 5mm thick with rubber coat

6 Idlers 5 M.S.

7 Felt Conveyor belt 1 Nylon

8 AC Motor with Gear box 1 -

9 Pulleys 2 Cast Iron

10 V-belt (B-type) 1 Leather

20

CHAPTER 6: Advantages & Disadvantages of Paper Recycling-

Machine

Advantages

Low cost of operation

Low cost for development

Easy to transport

Suitable for small industries

Simple operation

Easy maintenance

Recycling saves the Earth.

Recycling conserves energy.

Recycling minimizes waste products placed in landfills.

Recycling can help you save money.

Recycling of waste paper is beneficial not only from economic point of view but also for

the protection of environment.

Disadvantages

Recycling can create more environmental problems, if not done right.

Recycling can increase low quality jobs.

Recycling is not always cost-efficient.

21

REFERENCES

1 Kenneth W.B., Handbook on Pulp and Paper Technology, Second Edition, Van Nostrand

Reinhold Co., New York, 1970.

2 Carlson W. E. C., Recycle Process Inc. USA, PCT/US 91/03084, May 6, 1991.

3 Paul, D.R., Vinson, C.E., and Locke, C.E., Polym. Eng. and Sci., 12, 3 (1972).

4 Flory, P.J., J. Chem. Phys., 10, 51 (1942).

5 Mondragon, I. and Nazabal, J., Polym. Eng. Sci., 32, 6191 (1986).

6 Hills, Richard, "Papermaking in Britain 1488–1988", Athlone Press, 1988.

7 Meyers R.A., Encyclopaedia of Physical Science and Technology, Vol. 9, 14, and 15, Second

Edition, Academic Press, London, 1992.