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Plastic Smelter

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SUMMARY, CONCLUSIONS AND RECOMMENDATIONS

SUMMAR, CONCLUSIONS, RECOMMENDATION

SUMMARY

This research study aimed to develop a Plastic Smelter. Specifically, it aims to accomplish the following objectives: 1). To design and develop a Plastic Smelter; 2). To evaluate the Plastic Smelter in terms of: level of technical soundness, level of technical performance, level of economic viability, and level of acceptability; 3). To prepare an Operation Manual for the Plastic Smelter.

This study used the project-development-descriptive-evaluative design. The Plastic Smelter was developed based on the design prepared by the researchers, after which it was tested. A questionnaire was used to gather data to determine the Plastic Smelter’s level of technical soundness, level of technical performance, level of economic vialbility and level of acceptability.

The findings of this study were as follows: 1). The design and development of Plastic Smelter was developed and constructed based on the design conceptualized by the researcher that the machine is intended for smelting different kinds of plastics. 2). The plastic smelter in terms of its technical soundness with a grand mean 4.65 was excellent which means that the plastic smelter significantly exceeds the condition requirement as expected by the expert evaluators and end users. Along the level of technical performance, the grand mean 4.62 with a descriptive equivalent of excellent shows that the plastic smelter significantly exceeds the performance requirements thus far exceeded expectations due to exceptionally high quality of work performed, resulting in an overall quality performance that was superior. In terms of its level of economic viability, a grand mean of 4.57 means very highly viable. This shows that the plastic smelter is distinctly competitive and marketable, considering the cost of manufacturing, its sale value, and the revenue that will be gained and in terms of level of acceptability, a grand mean of 4.68 which is very highly acceptable came out that it is extremely worthy of being accepted because of its capability to perform its function within acceptability range. 3). The manual of operation was prepared and ready for use.

CONCLUSIONS

Based on the findings, the following conclusions were derived:

1. The Plastic Smelter was design and developed based on the design conceptualized by the researcher.

2. The technical level of technical soundness and the level of technical performance was excellent respectively, in terms of economic viabiltiy is highly viable and the acceptability of the Plastic Smelter was very highly acceptable.

3. The Operations Manual for the Palstic Smelter is ready to be used by the end users.

RECOMMENDATIONS

Based on the conclusions of the study, the following recommendations were given:

1. The design and development of the plastic smelter can be improved by putting additional heater that is needed to stabilize the property of liquefied plastic going to the molder.

2. Attachment of an upgraded plastic smoke filters to further refine the smoke output.

3. Additional plastic molder to produce variety of designs in terms of its output.

4. Development of plastic shredder to be interconnected with the plastic smelter to have a continuous process of plastic smelting.

MANUAL

MANUAL

STARTING THE MACHINE

1. Connect the power.

Before connecting the power cord to the power source see to it that the Plastic Smelter and the Vacuum Cleaner with Smoke Filter are in OFF mode.

2. Adjust the Timer to the required time setting before the electric motor start.

3. Switch ON the breaker.

 See to it that the emergency stop button is ON mode.

 The red light indicator will light up. The machine is still on standby position.

4. Push the upper automatic button to start the heater in heating up.

 PID will trigger the heater to heat up on its pre-set setting.

 Left green light indicator will light up. Indicating that the heaters are heating up.

The red light indicator is still light up indicating that the motor is not yet running

5. Set the proportional–integral–derivative controller to the required setting.

 Refer to the REX-C100 series Instruction Manual.

6. After setting up the PID the machine is now set.

7. Wait for the heater to reach the temperature being set on the PID and the motor will turn on, on the time set on the timer.

8. Switch on the exhaust fan to cool down the control panel box.

9. If motor already turned on, Switch on also the Vacuum Cleaner with Smoke Filter.

 Right green light indicator will light up. Indicating that the electric motor is now running.

 The two green lights will be lighted up.

 Red light indicator will turn off.

10. Use a suitable hand glove and face mask.

11. Put shredded plastic on the hopper.

7. Wait for the heater to reach the temperature being set on the PID and the motor will turn on, on the time set on the timer.

8. Switch on the exhaust fan to cool down the control panel box.

9. If motor already turned on, Switch on also the Vacuum Cleaner with Smoke Filter.

 Right green light indicator will light up. Indicating that the electric motor is now running.

 The two green lights will be lighted up.

 Red light indicator will turn off.

10. Use a suitable hand glove and face mask.

11. Put shredded plastic on the hopper.

12. Set the molder on the plastic smelter to be poured by the melted plastic coming out from the melting chamber of the machine.

13. Manually change the molder if it’s already full.

14. Allow melted plastic to cool down naturally. Then remove it from the molder.

15. Continuously put shredded plastic to the hopper to have a continuous flow out of melted plastic from the heating chamber of the machine.

16. If you want the machine to stop from running, just push the red push button.

 The motor and the heater will turn of simultaneously.

17. If you want to run the machine again, just push one the green push button.

 If you think that the heater is still capable to melt the shredded plastic, push the lower green push button. This is the manual push button of the machine. The motor and the heater will simultaneously turns on.

 If you think that the heater is not yet ready to melt the shredded plastic, set the timer for a certain time to wait for the heater to reach the temperature to melt the plastic before the electric motor will run again.

18. Follow procedure number 7 until procedure number 15 for the whole process of melting shredded plastic.

19. To turn of the machine after using it, push the red push button to simultaneously stop the heater and the electric motor.

 Switch off also the control panel box exhaust fan.

 Then turn off the breaker located at the right side corner of the control panel box.

 Then unplug the machine. Always grasp the plug to remove it from the outlet. Pulling on the cord may damage the cord, or lead to fire or electric shock.

RESULTS AND DISCUSSION

RESULTS

RESULTS

Design and Development of the Plastic Smelter

The Plastic Smelter was developed and constructed based on the design conceptualized by the researcher that the machine is intended for smelting different kinds of plastics. The development was started by sketching the design, the parts and mechanisms of the machine. The Plastic Smelter has three machine elements. These elements consist the: Machine Structural Components, Machine Mechanism Components, and the Machine Control Components.

Description of the Machine Elements

1. Control Element of Plastic Smelter

2. Mechanical Element of the Plastic Smelter

3. Structural Element of the Plastic Smelter

TEST AND REVISIONS

Test and Revisions

EVALUATION

Level of Technical Soundness

Level of Technical Performance

Level of Economic Viability

Level of Acceptability

INTRODUCTION

INTRODUCTION

SITUATION ANALYSIS

The beauties of nature are being lost one after another and environmental destruction is spreading. There were no magic bullets and lots of very smart people have been working the problem over passionately. Pollution is one of the many environmental challenges facing the world today. Handling garbage in urban areas had long become a hot issue in the recent past, due to the inadequate space available and the lack of systematic recycling processes. Plastic is one of the most popular building materials of modern human culture, but its widespread use brought us many problems and caused environmental dangers of unprecedented scale.

The process of recycling plastic is not as simple as recycling paper, glass and metals. By recycling soft plastics from discarded shampoo sachets, candy and junk food wrappers can easily reduce the volume of waste clogging drainage canals and filling the landfills of major towns and cities in the country. Processing the unavoidable plastic wastes into something useful, like school chairs.

In view of the problem situation presented, the researcher was motivated in helping the program of DMMMSU MLUC on Waste Management to systematize their waste management through the development and testing of Plastic Smelter in response to the call for waste reduction particularly in plastic waste.

STATEMENT OF OBJECTIVES

This study aims to develop and evaluate a Plastic Smelter.

Specifically, it aims to accomplish the following objectives:

1. To design and develop a Plastic Smelter.

2. To evaluate the Plastic Smelter in terms of:

a. level of technical soundness,

b. level of technical performance,

c. level of economic viability, and

d. level of acceptability

3. To prepare an Operation Manual for the Plastic Smelter.

TIME AND PLACE OF STUDY

This study was focused on the design and development as well as the evaluation of Plastic Smelter. The activities in this regard were undertaken by the researcher at the laboratory shop of the Bachelor of Science in Electro-Mechanical Technology Department of the College of Technology, Don Mariano Marcos Memorial State University Mid – La Union Campus, City of San Fernando, La Union in the Second Semester, School Year 2016-2017.

SMELTER

Global

Issues

POWER CONSUMPTION

METHODOLOGY

CHAPTER II

METHODOLOGY

Research Design

DESIGN

This study used the project-development type wherein the researcher conceptualized the design and specification of the Plastic Smelter, fabricate and assemble all the parts in conformity to the design. Try-out is undertaken; defects and weakness are corrected until the Plastic Smelter is considered functional.

The descriptive-evaluative research design is also used in this study to determine the level of technical soundness, level of technical performance, level of economic viability and the level of acceptability of the Plastic Smelter.

SUPPLIES AND MATERIALS

LIST

TOOLS AND EQUIPMENT

TOOLS AND EQUIPMENT

TOOLS AND EQUIPMENT

TOOLS AND EQUIPMENT

TOOLS AND EQUIPMENT FUNCTION

Welding Machine Use to join metals

Welding Mask Protects eyes, face, neck from spatter

Hacksaw Use to cut metals

Grinder Use to smoothens rough surface of metal

Drilling Machine Use to drills holes

Lathe Machine Use to turns cylindrical work pieces

Pull Push Rule Use for measuring

Table Vise It grips and holds parts together

Allen Wrench Use loosen and tighten nuts

Hammer Drive metal and nails

Vice Grip Locks object into position

Screwdriver Loosen and tighten screws

Pliers Holds object firmly

Pencil Use to draw lines and points

Riveter Drives blind rivets

PRODUCTION COST

PRODUCTION COST

TOTAL PRODUCTION COST

TOTAL PRODUCTION COST

SOURCES COST

1. Supplies and Materials 32,206.54

2. Labor Cost 12,000.00

3. Other Cost 9,000.00

Overhead Cost 11, 173.38

Total Production Cost 64,379.92

DIRECT MANUFACTURING LABOR COST

Quantity 1

Production Time (Hr.) 240.00

Labor Rate (Hr.) 50.00

Number of Worker 1

Total DMLC 12,000.00

30 days × 8hrs. = 240hrs.

400/day ÷ 8hrs. = ₱50/hr.

50/hr. × 240 hrs. = ₱12,000.00

OVERHEAD RATE

Indirect Cost 9,000.00

Direct Cost 44,206.54

Total Overhead Rate 21%

OHR = Indirect Cost ÷ Direct Cost

= 9000 ÷ 44,206.54

= 0.213 × 100%

= 21%

OVERHEAD COST

Supplies & Materials 32,206.54

Labor Cost 12,000.00

Other Cost 9,000.00

Total Over Head Cost 11,173.38

OHC = SM + LC + Other Cost × OHR

= ₱32,206.54 + ₱12,000 + ₱9,000 × 21%

= 53,206.54 × 21%

= 11,173.38

FLOWCHART

FLOWCHART

CHART

ANALYSIS

DATA ANALYSIS

ANALYSIS

DATA ANALYSIS

The data for this study is collected and processed in response to the objectives posed in Chapter 1. This study used a questionnaire to gather the needed data. The questionnaire is patterned from the Criteria for the Evaluation of Technical Research Projects formulated by Dr. Ismael Gurtiza, et. Al.

This study used frequency counts and weighted mean as measures to determine the level of technical soundness, level of technical performance, level of economic viability and level of acceptability of the Plastic Smelter.

The categorization of data is used to quantity descriptive equivalents to the perceptual evaluation of the expert evaluators and target end users

LEVEL OF TECHNICAL SOUNDNESS

LEVEL OF TECHNICAL PERFORMANCE

LEVEL OF ECONOMIC VIABILITY

LEVEL OF ACCEPTABILITY

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