INDIAN INSTITUTE OF INFORMATION
TECHNOLOGY DESIGN AND MANUFACTURING
(IIITD&M)
KANCHEEPURAM

GARBAGE SORTER

Submitted by

R Subhashini

IIITDM KANCHEEPURAM
JAN-MAY 2011

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INDEX
Chapter no

Contents

Pg No

Abstract

4

1

Mission statement

5

2

QFD

7

3

Existing products

9

4

Concept generation and selection

12

Phase 1

Segregating lighter and heavier material

13

Phase 2

Segregating sand from heavier materials

15

Phase 3

Crusher

16

Phase 4

Metal detector

14

Phase 5

Segregating plastics

20

Phase 6

Segregating glass

28

5

Pro e models

31

6

Specifications

33

7

Block diagrams

35

8

PLM

37

9

Conclusion

42

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References

43

List of figures

1

Quality function deployment

8

2

Manual sorter

9

3

Garbage sorter in Malaysia

10

4

Separation of metal by eddy current technique

16

5

Identification of plastics based on wavelength

20

6

(a) Plastic identification by spectroscope

22

(b) Plastic identification by laser diode

22

7

Identification of plastics

24

8

Separation of glass

25

9

Block diagram of garbage sorter

31

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Abstract
In recent years, environmental issues have drawn more attention and a wide
Variety of regulations and measures are being enforced all over the world.
Waste disposal is one of the biggest concerns for the environment today; we are facing a serious problem as a consequence of growing mass production and mass consumption. In the near future, a recycling process should be developed as well as a production process to realize this growing recycling-based society in accordance with the concept of ‘inverse manufacturing’

Today in the day to day life, for the survival of every human, natural resources are vital. As the earth is dominantly inhabited by the humans,the depletion of the resources is happening at a faster rate. Hence, the need for alternate source of energy began to gain its importance and so many manmade materials were invented on the objective to fulfil the needs.
Maximum percentages of the man made materials are harmful and are hazardous to the environment and the living beings. Hence the man made materials have to be reused in order to maintain the balanced environment.
Therefore, the need to sort out useful materials from the garbage started gaining importance.

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This project garbage sorter concentrates on the segregation of plastics, metals and glass from the garbage debris. The first step is to segregate lighter and heavier materials and then to remove the sand from the heavier materials and finally to sort out the metals, glass and plastics.

1. MISSION STATEMENT

Product description
An efficient, durable ,environmental friendly ,user friendly debris sorting machine/system.

Primary market
• Residential apartments.
Secondary market
• Small scale industries.
• Residential colonies.
• Hotels, schools etc.
Assumption
• Sorting out the non degradable debris.

CUSTOMER REQUIREMENTS
The goal of identifying the customer needs is to understand the customer requirements and to effectively communicate them to the development team.

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The process of identifying the customer needs is an integral part of the larger product development process and is most closely related to the concept generation, concept selection, competitive benchmarking, and the establishment of the product specifications.
• Durability
• Hygiene
• Safety
• Environmental friendly
• Odourless
• Ease of cleaning
• No noise
• Portable
• Compactness
• Overload indicator
• Aesthetics
• storage

ENGINEERING SPECIFICATIONS
The following are the engineering specifications for the garbage sorter
• Power consumption
• Portability mechanism
• Encasing
• Dimensions
• Airlock
• Material
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• Alarm
• Acoustics
• Battery backup
• Safety mechanism
• Ventilation.

2. QUALITY FUNCTION DEPLOYMENT

Quality function deployment is the structured approach to define customer needs or requirements and translating them into specific plans to produce products to meet those needs. The voice of the customer is captured in a variety of ways direct discussions or interviews,

survey, focus groups,

customer specifications, observation, warranty data, field reports etc. This understanding of the customer needs is then summarized in the product planning matrix or house of quality. These matrices are used to translate higher level whats or needs into lower level hows or product requirements or the technical characteristics to satisfy these needs.

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Fig1.quality function deployment
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3. EXISTING PRODUCTS
Currently in the world the nations successfully using the garbage recycling methods are Japan, China, Malaysia and Singapore. But the major drawback of the systems currently in use is that they do not operate on segregating more than one material (say for example metal)

Manual Sorter

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Fig (2) manual sorter
The above picture shows a manual garbage sorter that is used in Alaska, United
States currently. The bin was given to the houses in the apartment that consists of separate chambers as shown in figure. Later it was individually collected from the houses when it is full.
However, the method was not effective as it has to be done manually. The same method can not be implemented on a larger scale as it involves more manual work. Also the bin has to be emptied frequently and the labour involved is expensive. The same process is being done by the company called EXNORA, an NGO in India, though they are not concentrating in segregating the elements. Garbage Sorter in Malaysia

Fig(3) garbage sorter in Malaysia

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The above picture shows the garbage sorter in Malaysia. This is currently being used to sort out plastics. The big cylinder seen in the figure is the chamber for segregating heavier and lighter materials. The lighter materials are removed from the debris and the heavier materials are taken to the cubical chamber where the plastics are segregated from the heavier materials. The average percentile of plastics from the garbage debris of Malaysia is 8.04. The entire segregating unit was set up by the government of Malaysia to bring down the usage of plastics after the United Nations suggestions
Possible components present in the garbage

1. Plastic
2. Metal
3. Rubber
4. Glass
5. Ceramic
6. Polythene (bags ,covers, etc)
7. Paper
8. Household wastes
9. Clothes
10. Electrical items
11. Thermocol

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4. CONCEPT GENERATION AND SELECTION

Phases of the system
1. Segregating lighter and heavier materials
2. Vibrating belt
3. Crusher
4. Segregating metals
5. Segregating plastics
6. Segregating glass

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Phase 1
Segregating lighter and heavier materials
Concept 1
Air suction
The garbage debris is collected in a huge cylinder. A 3 phase AC motor driven fan is placed on the top of the cylinder. When the fan starts rotating the lighter materials are sucked up. The fan has a mesh arrangement for its protection. The fan is run for a particular duration and is then turned off to remove the lighter materials collected. Simultaneously when it is turned off a metal plate pops out in the cylinder and acts as a separator between the fan and the debris at the bottom. Now the lighter materials sucked up due to the rotation of the fan falls down under gravity and are collected in the metal plate and heavier particles are collected in another chamber separately.
The entire operation is repeated. A timer circuit controls the rotation of the fan. Also the cylinder where in the debris is placed is also rotated so that the lighter materials that are stuck under the heavier materials comes up during the rotation. Concept 2
Segregating lighter and heavier materials – Air blower
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From the debris the lighter and heavier materials have to be separated so that from the heavier materials plastics, metal and glass can be separated.
The entire debris is made to fall from a height under gravity. On the sides three high voltage heavy fans run by AC motors are operated. Hence during the fall the lighter materials are flown away for a small distance and are collected separately. The heavier materials fall down without being disturbed by the fans and are collected separately.
Concept selected – Air blower
Reasons
1. The energy consumed by air suction is more than the air blower
2. The space occupied by air suction is more than the air blower.
3. Maintenance and installation of air suction is more expensive.
Hence air blower was selected.

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Phase 2
Segregating the sand from the heavier materials
A vibrating arrangement is used to segregate the sand. The arrangement consists of a series of rods. The heavier materials collected are placed in the vibrating rods. The vibrating movement is given by moving the rods in a sequential order.
A timing and control circuit is designed to control the sequential order in order to obtain the vibration in the rods. The time interval between the movements of consecutive rods is in the order of micro seconds.

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Phase 3
Crusher
The entire heavier materials segregated are now moved into the crusher. The crusher has a hammering mechanism implemented into it. There are two hammers hammering at the point where the heavier materials are placed. The heavy materials are hammered inside the crusher till each and every single particle size is obtained as one and a half inch. The final vent where the crushed materials need to pass through is of the same size and hence allows only particles of its size or lesser than its size to pass through it else they are sent back to the crusher.

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Phase 4
Metal detector

Concept 1
Electronic metal detector
Electronic metal detector has two distinct coils:

•

Transmitter coil - This is the outer coil loop. Within it is a coil of wire.
Electricity is sent along this wire, first in one direction and then in the other, thousands of times each second. The number of times that the current's direction switches each second establishes the frequency of the unit.

•

Receiver coil - This inner coil loop contains another coil of wire. This wire acts as an antenna to pick up and amplify frequencies coming from target objects in the ground.

The current moving through the transmitter coil creates an electromagnetic field, which is like what happens in an electric motor. The polarity of the magnetic field is perpendicular to the coil of wire. Each time the current
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changes direction, the polarity of the magnetic field changes. This means that if the coil of wire is parallel to the ground, the magnetic field is constantly pushing down into the ground and then pulling back out of it.

As the magnetic field pulses back and forth into the ground, it interacts with any conductive objects it encounters, causing them to generate weak magnetic fields of their own. The polarity of the object's magnetic field is directly opposite the transmitter coil's magnetic field. If the transmitter coil's field is pulsing downward, the object's field is pulsing upward.

The receiver coil is completely shielded from the magnetic field generated by the transmitter coil. However, it is not shielded from magnetic fields coming from objects in the ground. Therefore, when an object giving off magnetic fields passes over the receiver coil, a small electric current travels through the coil. This current oscillates at the same frequency as the object's magnetic field.

Concept 2
Detecting metals using eddy current method

The setup has a strong magnet, vibrating belt and a magnetic rotor. The heavier crushed materials are made to fall from a height. The ferrous metals get attracted by the magnets and falls into the ferrous chamber as shown in the figure. The non ferrous metals and the other heavier materials pass on to the vibrating belt. The vibrating belt is rotated by a magnetic rotor. Hence the materials passing on the vibrating belt are under a magnetic field. The field sets
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up an emf on the metals in the mixer. Hence the metals alone develop a repulsive force and fall on the chamber placed at a distance from the belt but the non metallic materials fall directly on the chamber immediately placed next to the belt

Fig(4) separation of metal by eddy current technique

Concept selected – Eddy current method
Reasons
1. Eddy current method is more accurate.
2. As the materials are crushed the particles are very small in size and hence the current generated in the receiver coil is very small and at times is not sufficient for the device to positively confirm that the material is a metal
3. The metal detector can determine the object based on the distance. The closer to the surface an object is, the stronger the magnetic field picked
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up by the receiver coil and the stronger the electric current generated. The farther below the surface, the weaker the field. Beyond a certain distance, the object's field is so weak at the surface that it is undetectable by the receiver coil.

Phase 5
Segregating plastics
Concept 1
Hyper spectroscopy
The principle of hyper spectroscopy is currently used in cameras to monitor precious monuments and to protect them from robbery. The cameras show the infra red images. The entire room is maintained in a very low temperature (say
9 degree Celsius). The cameras can hence very easily spot humans as the body temperature on an average is always in the order of 30 to 38 degree Celsius.

The above camera principle can be applied to detecting plastics. The hyper spectroscopy involves the identification of the materials based on the reflectivity of the materials. The hyper spectral camera emits infra red radiation. The radiation is allowed to pass through the material to be identified.
As the absorbivity of heat of every material is unique, the wavelength of the infra red radiation reflected from the materials is also unique. Hence by analyzing the reflected infra red radiation the identification of the material is obtained. The identification is done by hyper spectral camera. When the

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wavelength of the reflected wave matches the predetermined value of the plastics reflectivity then the particular material is identified as plastic

Concept 2
Segregating plastics using laser diodes and photo diodes

With critically limited natural resources, the recycling-based society cannot be realized without a well-balanced recovery system .To achieve this, sensing technology plays a significant role in the production/recycling processes.

Conventionally, sensing technology has been used in the production process to detect the presence of a certain material, and to measure the dimension, color and electrical characteristics of material before assembling. Consequently, a wide range of sensing equipment has been in place, which aims to set up a higher level of automated system. On the other hand, in the recycling process, the product is disassembled into pieces, which are then to be identified as specific materials. To this day, there are a limited number of sensors to identify a particular substance among assorted mixture of a variety of materials.

Here, in particular, we address plastic identification, which is a major concern in the current recycling system. Today, it is common to use equipment applying near-infrared spectroscopic analysis with a diffraction grating, acoustic-optic tunable filter or an optical filter.
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These equipment offer high accuracy, but they are not always suitable for the current recycling system from the view point of cost-efficiency and handling.
As the awareness and need for recycling system is increased, an adequate and cost-efficient plastic identification technology is demanded. In order to meet the growing demand of this recycling-based society, sensors applicable to the current recycling system must be developed and manufactured. This report introduces a plastic identification technique using the InGaAsP laser diode
Near-infrared absorption spectrum of plastic
There are several methods for plastic identification such as a near-infrared spectroscopic analysis, a FTIR and equipment adopting Raman spectroscopy. In fact, near-infrared spectroscopic analysis is a widely used method for on-line process, which measures a spectrum of the absorption in the wavelength of
800–2500 nm in the near-infrared region
The following presents the characteristics of each sample including thickness and color.
1. High density polyethylene (HDPE): 0.85 mm, white.
2. Low density polyethylene (LDPE): 1 mm, semi transparent and colorless.
3. Polycarbonate (PC): 2.8 mm transparent and colorless.
4. Polyethylene terephthalate (PET): 2 mm, transparent and colorless.
5. Polypropylene (PP): 1.4 mm, semi transparent and colorless.
6. Polystyrene (PS): 2 mm, transparent and colorless.
7. Polyvinyl chloride (PVC): 2 mm, transparent and colorless.

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Fig(5) identification of plastics based on wavelength
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In addition, an interesting tendency is observed, in which all samples show the absorption peaks in the wavelength of approximately 1700 nm. This is attributable to a stretching vibration of the C-H bond that is commonly found in all plastics.

Comparison of the plastic identification techniques
As for an optical system for plastic identification, there are two optical measurement approaches:
1. Transmittance-based
2. Reflection-based.
We selected the transmittance-based approach

Plastic identification by a near-infrared spectroscope
The near-infrared spectrometer is large piece of equipment with measurement and analysis functions.

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Fig 6(a) plastic identification by spectroscope (b)plastic identification by laser diode As shown in Fig 6(a), it consists of a light-transmitting part including a lamp and condenser lens, and a light-receiving part including a grating, a spatial filter as a slit and a photo detector. As a result, it requires large, complex optical and control systems, leading to approximately 400×300×200 mm3 at minimum through 1000×1000×500 mm3 at maximum. The near-infrared spectrometer is
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suitable for off-line process such as detailed analysis because it offers high precision. On the other hand, for on-line process, there are disadvantages as follows. 1. Frequent replacement is inevitable because a lamp is used as light source.
2. An experienced operator is required due to complicated handling and adjustment of the equipment.
3. Response time of the measurement for the plastic identification is not fast enough because it takes about 10 ms or more to analyze the spectrum pattern.

Plastic identification by the proposed method using the LD

The plastic identification technology using the LD is developed based on the principle in which all plastics have the absorption peaks at approximately 1700 nm as shown in Fig. 6(b). By applying this method, a simple optical system is possible, which uses the InGaAsP LD at a wavelength of approximately 1700 nm . The structure of the equipment is that a laser beam radiated from the LD passes through the lens at the light transmitter and the sample is then finally detected by the photodiode. An amount of the laser beam transmittance depends on a characteristic of the plastic, which enables to identify the plastic material.

InGaAsP laser diode

The InGaAsP LD, used as the light source in this experiment, has been primarily developed for optical glass fiber communication systems. The material of the LD, a compound semiconductor, is mixed crystal composed of two or more elements. The relation between the energy gap, Eg, of the valence

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band and a filled band of direct band gap compound semiconductor and luminous wavelength is given by
Eg (eV)=1239.8/(nm)
Particularly, in case of an In1-x Gax Asy P1-y mixed crystal semiconductor, the energy gap Eg can be controlled in the range of 0.73 Eg

1.25 eV through

changing the composition ratio of x and y within the range 0 x 1.0 y 1.

Concept selected – Segregating plastics using laser diodes and photo diodes
Reasons
A plastic identification is accomplished mainly by a spectrometer that recognizes a near-infrared spectrum of each plastic. This method offers higher accuracy but disadvantages in cost-efficiency, maintenance, and so on.

Fig(7)identification of plastics
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Phase 6
Segregating glass
The arrangement of the glass segregator setup consists of a spherical container which is rotated using an AC motor. The outer spherical container is bombarded with ions to make it electro statically charged. The spherical container is grounded. The container has an electrode at the centre. When the container is rotated, due to centrifugal force, the other materials move to the edge of the container while the glass particles get attached to the electrodes. Later the glass is removed from the electrode.

Fig(8) Separation of glass

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Concept generation

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Concept selection

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5. PRO-E MODELS

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6. SPECIFICATIONS
CRUSHER
Output size

: less than 15 mm

Power

: 11kw

Weight

: 200-300kg

Pressure

: 100mpa

Capacity

: 600kg/hr

ELECTROMAGNET SPECIFICATIONS
Max load taken

: 200 kg

Electromagnet

: flat faced electromagnet

Thickness/height

: 0.04m

Outside diameter

: 2.54m

Dc power

: 214v

Feature

: continuous duty cycle

EDDY CURRENT SPECIFICATIONS
Magnet rotor diameter

: 0.3 m

Magnet roller

: 0-3000rpm

Belt width

: 450mm-0.45mm

Belt speed

: 0-1m/s

Handling capacity

: 900kg/hr

Drive motor power

: 3kw

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VIBRATOR
Centrifugal force

: 400N

Frequency

: 20 Hz

Power consumptions

: 2kw

Maximum vibratory mass

: 200kg

Power input

: 415v 3 phase A.C motor

CONVEYOR BELT
Load

: 200 kg

Speed

: 1 m/sec

Conveyor length

: 20m

Drive

: 3phase gear motor
440v/50Hz

Belt

: twin-laminate polyester covered with pvc

Running of the belt

: on plastic coated chip board

Side guides

: 200mm

GLASS DETECTOR

Weight

: 30 kg

Drum diameter

: 1 metre

Electrode motor speed

: 8 revolutions per minute

DC voltage to ionizing electrodes

: 25 KV

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7. BLOCK DIAGRAMS

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8. PLM - GARBAGE SORTER

Various materials used in the product
Vibrating belt
Motors
Roller
Metallic belt
Vibrating mechanism
Containers
Metal
Crusher
Hammer – iron
Pricking mechanism
Metal rods
Pneumatics
Conveyor belt
Roller
Rubber belt
Metal detector
Magnet
Plastic detector
Electronic components
Picking mechanism
Glass detector
Cylindrical vessel
Electrodes
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Motors

Grouping of materials
Electronic components
Diodes, resistors, capacitors, transformers, etc
Batteries
Wires
Motors
Magnet
Electrodes
Metals (from containers and mechanical components like screws, gears, etc) Aluminum
Iron
Rubber (from belt)
Plastic (from roller)

Key challenges for disposal phase
Materials that can be recycled
• Aluminum
• Iron
• Plastic
• Wires
• Rubber
Materials that can be sent back to the manufacturer
• Electronic components
• Motors
• Magnet
Materials that can be disposed
• Batteries
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• Hazardous electronic components

Different phases of PLM
PHASE

Concept phase

DELIVERABLES

• Concept document
• Time frame and cost estimation

Design phase

• Design document
• Prototypes
• CAD drawings

Manufacturing phase

• Production document
• Product satisfying space constraints

Sales & Service phase

• User manual
• Specifications (Electrical ratings, maximum load, etc. )

Disposal phase

• Materials that can be recycled, reused, disposed
• Auditing report stating if every phase met the disposal standards (WEEE, demolition debris, etc.) 39 | P a g e

Gateway checks
DELIVERABLE ITEMS

YES / NO

Is the plastic used degradable?

Yes

Are the paints used non-hazardous?

Yes

Is the batteries used leakage proof?

Yes

Is the composition of the alloys used fulfilling the reusable

Yes

standards?
Is the rubber used reusable / recyclable?

Yes

Are the chemical compositions of all the materials used non-

Yes

hazardous?

PLM Conclusion
The system satisfies all the disposal standards requirements. Thus, the system can be disposed off safely after its service life is completed.

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9.CONCLUSION
Thus, for designing the garbage sorter the existing products are studied based on which concepts are generated. The most appropriate and advantageous concepts are selected, according to which the product specifications are calculated. Thus, the product is ready for prototyping and modelling.

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REFERENCES
1. United states patents web
2. Elseiver-Identification of plastics using infra red absorption using
InGaAsP laser dode
3. http://cdsweb.cern.ch/record/911388/files/0511212.pdf
4. http://eprintweb.org/S/article/physics/0511212
5. http://www.axmannfs.com/gurtfoerderer_gurtfoerderer_93_00_eur_en.html
6. http://www.engineeringtoolbox.com/young-modulus-d_417.html
7. http://www.hammercrusher.org/hammer-crusher/hammer-crusher-pc800-600.html
8. http://www.globalspec.com/SpecSearch/PartSpecs?partId={561CFB99297B-41C4-979FE4DB5FFAA3BF}&vid=112652&comp=3094&qid=20667314
9. http://permanent-magnet.en.hisupplier.com/product-493097EddyCurrent-Separator.html
10. http://www.magneticequipments.com/eddycurrentseparator.html
11. http://www.magneticequipments.com/heavydutyvibratoryscreeningmachi ne.html 12. http://www.saideeponline.com/vibromoter.htm

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13. http://www.magneticequipments.com/heavydutyvibratoryscreeningmachi ne.html 43 | P a g e