Omar Khalid
Building a plastic shredder is a great way to recycle plastic and reduce plastic waste. Precious Plastics, an initiative with the goal of reducing plastic waste, provides a range of open-source tools and machines, including a plastic shredder. The shredder can be built using basic techniques and parts that can be sourced from anywhere in the world. The build requires a motor and gearbox, which provide power to the shredder, as well as blades and a mesh to determine the output size. The Precious Plastics community also provides instructional videos and support for building the shredder. The machine can be purchased fully built or as a kit, with the option to buy parts individually on the Precious Plastic Bazar.
| Characteristics | Values |
|---|---|
| Type of shredder | Small Shredder, Shredder Pro |
| Difficulty level | Shredder Pro is more complex to build |
| Skills required | Advanced tools and skills required for Shredder Pro |
| Materials | Sheet metal, stainless steel |
| Parts | Electric motor, gearbox, shaft, coupling, shredder blades, hand crank |
| Motor specifications | Nominal torque of 1100N.m-2000N.m, 3-phase geared motor, 2kW-16rpm-1200N.m |
| Gearbox specifications | 1:20 ratio |
| Blade specifications | 13 teeth blades on the shaft connected to the motor, 6 teeth blades on the opposite shaft, gap between blades is 0.25mm |
| Other considerations | Clean parts during assembly, tighten nuts to at least 100Nm, weld tubes of the box for faster cleaning |
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What You'll Learn
Choosing the right tools
When it comes to choosing the right tools for building a plastic shredder, there are a few key considerations to keep in mind. Firstly, it's important to decide on the type of shredder you want to build – a small shredder or a Shredder Pro. The Pro version is more robust, advanced, and productive, but it's also more complex to build and requires more advanced tools and skills. However, the tools and techniques for the Shredder Pro are still relatively basic and can be found anywhere in the world.
If you opt for the small shredder, you can source the parts and materials yourself or purchase a ready-to-assemble kit. The small shredder is mostly made out of sheet metal, which can be sourced from any laser shop. You can also find pre-cut parts, bearings, axles, and bolts from suppliers like Precious Plastics. Their Bazar marketplace offers a convenient way to buy parts without having to source them individually.
On the other hand, if you choose to build the Shredder Pro, you'll need to make sure your tools and skills are up to the task. While the techniques are basic, the tolerances are tighter, so precision is key. You'll need to be comfortable with using tools like a lathe to shape the long and heavy shafts, or you may need to order them from a professional. Additionally, you'll want to have a good understanding of motor and gearbox specifications, as these are crucial components for powering your shredder.
Regardless of the type of shredder you choose to build, it's important to follow the instructions and recommendations provided by the designer or manufacturer. This includes paying attention to details like blade spacing, torque requirements, and motor specifications. For example, a nominal torque of 1100N.m is recommended as a minimum for the Shredder Pro, with 2000N.m as a solid goal. Additionally, the service factor, which is the ability of the motor to handle overloading, should be at least 1 for both the gearbox and the motor.
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Blade arrangement
First, it is recommended to use different numbers of teeth on the blades depending on their placement. For the shaft connected to the motor, use 13-teeth blades, and for the opposite shaft, use 6-teeth blades. This arrangement provides a good balance for the shredder's performance. However, it is important to note that blade configuration can be customized based on specific requirements.
The gap between the blades is crucial for effective shredding. A precise gap of 0.25mm between the blades is recommended. To achieve this level of precision, ensure that all parts are clean during assembly. Additionally, the blades should be secured firmly in place with two nuts on each side. Tighten the nuts to at least 100 Nm to prevent plastic from getting stuck between the blades and spacers.
When stacking the blades, follow the provided instructions or manuals. However, keep in mind that the blade arrangement may vary depending on the material being shredded. Different materials might require alternative stack configurations to optimize the shredding process.
For the blade arrangement to function properly, the blades must be attached to a sturdy shaft. If you cannot access a good lathe for this purpose, consider ordering the shafts from a professional. Additionally, order multiple spacers to have adjustment options during assembly.
Finally, safety is a priority when working with blades. Ensure that the blades are securely attached and that there is a screen with specifically sized holes placed below the blades. This screen helps regulate the output size of the shredded plastic and prevents accidental contact with the blades.
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Motor and gearbox
The motor and gearbox are essential components of a plastic shredder, providing the power and torque necessary for effective shredding. When choosing a motor, it is important to consider the type of shredder being built, the desired level of performance, and the specific application.
For a more robust and productive shredder, a higher-powered motor is required. A 3-phase geared motor with a nominal power value linked to nominal current is recommended. This allows for continuous operation at a certain power level, with the ability to deliver higher power for short periods by increasing the current. The service factor, which is the overload capacity within correct voltage tolerances, should also be considered. A higher service factor can provide benefits such as longer insulation life and improved accuracy in predicting system horsepower needs.
The gearbox is another critical component in the shredder's power transmission system. It is responsible for reducing the speed and increasing the torque transmitted from the motor to the shredder blades. A typical gearbox for a plastic shredder may have a 1:20 ratio, resulting in an output speed of 70 rpm. It is important to select a gearbox that matches the motor's service factor or has a higher value to avoid downgrading the motor reductor.
In addition to the motor and gearbox, the shaft connected to the motor plays a crucial role in the shredder's performance. It is recommended to use 13-teeth blades on this shaft, with 6-teeth blades on the opposite shaft, to achieve a good balance. Keeping the parts clean during assembly is essential to ensure precise blade spacing of 0.25mm. The blades should be secured with at least 100 Nm of torque to prevent plastic from entering the spaces between the blades and spacers.
For those seeking a more compact and manually operated solution, a hand-cranked shredder is an option. While it may not require a motor, the hand crank mechanism still needs to be attached to a geared motor with sufficient torque, typically around 2kW, to effectively shred materials.
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Shaft and coupling
To build a plastic shredder, you will need to consider the type of shaft and coupling you will use. The shaft is an important component of the shredder as it is responsible for transmitting power from the motor to the blades.
For a double shaft shredder, it is recommended to use 13-teeth blades on the shaft connected to the motor and 6-teeth blades on the opposite shaft. This configuration provides a good balance between shredding performance and torque. The gap between the blades should be 0.25mm, and to achieve this level of precision, it is important to keep all the parts clean during assembly.
The blades are secured to the shaft with two nuts on each side. These nuts should be tightened to at least 100Nm to prevent plastic from getting between the blades and spacers. If you are unable to use a good lathe, it is recommended to order the shafts from a professional, as they are long and heavy.
The coupling is another critical component that connects the shaft to the motor. You will need to design and build a coupling that fits your specific requirements and type of gearbox. Unfortunately, there are no specific specifications provided for the coupling, as it depends on your individual setup.
Additionally, when selecting a motor, consider a nominal torque of 1100N.m as a minimum and 2000N.m as a solid goal. The service factor, which is the ability of the motor to handle overloading, should be at least 1 for both the gearbox and the motor. A higher motor service factor can be advantageous in terms of predicting intermittent system horsepower needs and prolonging insulation life.
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Assembly
Building a plastic shredder is a complex task that requires careful planning and execution. Here is a step-by-step guide to assembling a plastic shredder:
First, gather all the necessary parts and tools. You can refer to the Precious Plastic Toolbox for a comprehensive list of commercial parts that you need to buy and where to find them. You can also source parts from the Precious Plastics Bazar, a marketplace for parts and materials.
Next, follow the instructions provided by Precious Plastics, which include an instructional video and manual. Before beginning assembly, ensure all parts are deburred and clean. Check for any necessary modifications, such as drilling holes and threading them for attachments.
When assembling the blades, refer to the provided pattern or configuration instructions. Stacking the blades is a crucial step, and you may need to adjust the stack configuration depending on the material you plan to shred. The gap between the blades should be 0.25mm, and they should be fixed to the shaft with two nuts on each side, tightened to at least 100Nm.
The shredder's performance can be enhanced by using 13-teeth blades on the shaft connected to the motor and 6-teeth blades on the opposite shaft. This setup will provide a good balance.
For the motor, a 3-phase geared motor is recommended. Check the nominal power and current to ensure continuous operation. A higher current will deliver more power for a short period. The nominal torque should be a minimum of 1100N.m, with 2000N.m as a solid goal. The service factor, which is the overload capacity within correct voltage tolerances, should be at least 1 for both the gearbox and motor.
Finally, attach the motor to the shredder using a shaft and coupling. You may need to create a custom shaft based on your motor and gearbox specifications.
Always prioritize safety and refer to the provided instructions and videos for a more detailed assembly process.
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Frequently asked questions
Precious Plastics provides open-source tools and instructions for building a plastic shredder. They also have a marketplace called Precious Plastics Bazar where you can buy parts and materials.
There are two types of shredders: the original small Shredder and the Shredder Pro. The Pro version is more robust, advanced, and productive, but it is also more complex to build.
A 3-phase geared motor with a nominal torque of 1100N.m as a minimum and 2000N.m as a solid goal is recommended for a plastic shredder. The motor needs to have low speed and high torque capabilities.
It is recommended to use 13-teeth blades on the shaft connected to the motor and 6-teeth blades on the opposite shaft to achieve a good balance in the shredder's performance. The gap between the blades should be 0.25mm.
A plastic shredder is used to recycle plastic waste and reduce plastic pollution. It can be used to process plastic into smaller flakes or particles that can be reused or recycled.
