DESIGN OF WASTE PAPER BALER MACHINE

Authors
ETSEGENET ABERA
BIRUK ESHETU
TAMIRU KASSA

Advisor: NETSANET AYELE

In Partial fulfillment of Bachelor of Science Degree with Mechanical

Engineering
Arba Minch University

Arba Minch Institute of Technology (AMiT)

Faculty of Mechanical& Production Engineering
JAN10/2021
 CERTIFICATION

The undersigned certify that they have read and hereby recommend for acceptance by
Arba Minch University a thesis entitled:DESIGN OF WASTE PAPER BALER MACHINE,
in fulfillment of the requirements for the bachelor of science degree in Mechanical Engineering
of Arba Minch University.

Advisor:

Name: ………………………

Date: ………………………

Signature……………………

Dean of the Faculty:

Name: AtkiltMulu (M.Sc.)

Date: ………………………

Signature……………………

i
 DECLARATION

We, BIRUK ESHETU,ETSEGENET ABERA,TAMRU KASSA, declare that this thesis is our
own original work and that it has not been presented and will not be presented to any other
University for a similar or any other degree award.

1. Name: ETSEGENET
ABERA………………………………………

Signature……………………………………

2. Name:BIRUK ESHET………………………………………

Signature……………………………………

3. Name: TAMIRU KASSA………………………………………

Signature……………………………………

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 ACKNOWLEDGEMENT
First of all we would like to thank the almighty GOD for giving us the pertinence to start
andFinalize this project work and thank our instructor Mr.NetsanetAyele. For his patient, talent
andHelping us during those remarkable times. Secondary we are deeply extending our sincere
application to our friends. For them available advice constant support, commitments, dedication,
encouragement and precious guidance creative suggestions, information’s and critical comments
with his being everlasting enthusiastic from the beginning to the end of the project without then
urge, no doubt, this work would nothave been possible at all.Last, but not the least we would like
to thank our family, for their love, encouragement, patienceand support throughout the under
graduate study work.

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 ABSTRACT

Industries and companies are facing a lot of problems in storing and handling the waste paper. A
large amount of space is required to store the waste paper. In order to overcome these problems
the waste paper can be compressed and stored in a brick form. Today, all the modern
manufacturing enterprises are trying to develop best optimized reduced weight and cost effective
products that meet the intended design functionally and reliably. In this scenario, structural
optimization tools like topology and shape optimization with manufacturing simulations are
becoming attractive in product design processes. These tools also aid in reducing product
development times. In last few years, shape optimization has emerged as the valuable tool to
develop new design proposals especially in paper industries. Structural optimization tools have
gained paramount importance in industrial applications. In this project, topology optimization
has been applied on various components of 5Ton hydraulic paper baling press.

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 TABLE OF CONTENT

1 INTRODUCTION........................................................................................................................1

1.1 BACKGROUND............................................................Error! Bookmark not defined.

1.2 PROBLEM STATEMENT............................................................................................6

1.3 OBJECTIVE....................................................................................................................7

1.3.1 General objective.....................................................................................................7

1.3.2 Specific objective......................................................................................................7

1.4 SCOPE AND LIMITATIONS.......................................................................................7

1.4.1 Scope.........................................................................................................................7

1.4.2 Limitations................................................................................................................7

CHAPTER TWO...........................................................................................................................8

2. LITERATURE REVIEW........................................................................................................8

1.5 MATERIALS AND METHODOLOGY.....................................................................12

1.6 MATERIALS................................................................................................................17

1.7 METHODOLOGY........................................................................................................20

CHAPTER FIVE...........................................................................................................................26

5. CONCLUSIONS AND RECOMMENDATIONS................................................................26

5.1 Conclusions......................................................................................................................26

5.2 Recommendations............................................................................................................26

4. REFERENCES....................................................................................................................28

5. APPENDIX...........................................................................................................................28

v
LIST OF FIGURES

vi
LIST OF TABLES

vii
 ABBREVIATIONS

E = Young’s modulus
Allowable tensile stress for mild steel

viii
 CHAPTER ONE
1. INTRODUCTION
Manufacturing industries are facing several problems in storing and handling Waste,
because a large amount of space is required to store this Waste paper. In order to conquer these
problems, the Waste can be compressed and stored in a block form. Today, all the modern
manufacturing enterprises are trying to develop best optimized reduced weight and cost-effective
products that meet the intended design functionally and reliably.

Waste is defined as any material that is considered to be of no further use to the owner
and is hence, discarded. Paper is a thin material mainly used for writing, printing, and drawing
upon and for packaging. It is produced by pressing together moist fibers, typically cellulose pulp
derived from wood, and drying them into flexible sheets. Honestly, any business in Nigeria
generates a mountain of paper, from manufacturers, offices, schools and even retail locations like
supermarkets and bookshop. This mountain of paper is also something that can be heavily
recycled. Increasing pollution regulations make incinerating paper waste an issue, so it increases
the need to produce easy movable and transportable paper waste. So baling waste paper is the
best way to handle this massive amount of waste.

A baling machine is one that compresses waste paper materials into compact defined
shapes, usually cubes or cuboids, making it easier to store, handle and transport for recycling.
Waste paper baling machine would definitely improve waste paper recycling which has a
positive effect on the growth of the economy.

Hydraulic ram is a mechanical actuator that is used to give a unidirectional force through
a unidirectional stroke. Hydraulic actuators are the end result of Pascal’s law. This is where the
hydraulic energy is converted back to mechanical energy. This can be done through the use of a
hydraulic cylinder which converts hydraulic energy into linear motion and work. Hydraulic
Cylinder that was chosen was good for the compressing of waste papers which is the double
acting type. Cylinders are applied based on force and speed of actuation. Cylinders are sensitive
to force media viscosities and performed it tasks effectively and efficiently

Today’s hydraulic fluids serve multiple purposes. The major function of a hydraulic fluid
is to provide energy transmission through the system which enables work and motion to be
accomplished. Hydraulic fluids are also responsible for lubrication, heat transfer and

1
contamination control. Selecting a lubricant, viscosity, viscosity index improver, anti-wear agent,
anti-foam agent, seal compatibility, base stock and the additive package was considered. Three
common varieties of hydraulic fluids found on the market today are petroleum-based, water-
based and synthetics. Since the fluid power industry is standardized on mineral oil based
hydraulic fluids. So, Mineral-based fluids will be used for this waste papers baling machine since
it offers a low-cost, high-quality, readily available selection.

The hydraulic pump transmits mechanical energy into hydraulic energy. This is done by
the movement of fluid which is the transmission medium. All hydraulic pumps work on the same
principle, which is to displace fluid volume against a resistant load or pressure. There are several
types of hydraulic pumps including gear, vane and piston. The gear pump which is the external
gear pump will be the right choice. A gear pump produces flow by carrying fluid in between the
teeth of two meshing gears. One gear is driven by the drive shaft and turns the idler gear. The
chambers formed between adjacent gear teeth are enclosed by the pump housing and side plates.

A partial vacuum is created at the pump inlet as the gear teeth unmeshed. Fluid flows in
to fill the space and is carried around the outside of the gears. As the teeth mesh again at the
outlet end, the fluid is forced out. Volumetric efficiencies of gear pumps run as high as 93%
under optimum conditions. External-gear pumps are comparatively immune to contaminants in
the oil, which will increase wear rates and lower efficiency that is the reason the pump must be
taking suction form a reservoir through a filter, but sudden seizure and failure are not likely to
occur. In most catalogs Gear pumps are rated at 1,200RPM to 1800RPM.

A centrifugal pump used rotating impeller to create flow by adding energy to the fluid.
Centrifugal pumps are commonly used to move liquids through pipes. The fluid enters the pump
impeller along or near to the rotating axis and is accelerated by the impeller, flowing vertically
outwards into a diffuser or volute chamber (casing), from where it exits into the downstream
piping. A shaft is a rotating machine element which is used to transmit power from one place to
another. The shaft is the connection between impeller and driver unit which is in most cases is an
electric motor but can also be a gas turbine.

2
 Machining is the process of removing precise amount of material from the work piece to
attain the desired shape. Machining is one of the important aspects during developing the paper
bailing machine. The different component has to be determined during the machining operation
in other to avoid the corrosion, vibration, and to produce good quality component.

Furthermore, the accomplishments of various researchers’ efforts related to the current

study have been reviewed in the previous subsections of this work. The aim of this project is to
develop horizontal waste paper baling machine with high local content, which will reduce cost of
transportation of waste product, global warning and will also enhance the recycle industry.

Vertical Waste Cardboard Hydraulic Balers can be used to press and bale many kinds of
recyclable material, including cotton, Cardboard, aluminum cans, waste paper, waste plastics,
etc. , can also be used for garbage baler. It is an essential production tool for the cardboard
paper-producing areas

The Cardboard Baler can make the volume reduction be nearly 3:1 or 5:1 when pressing
plastic film or cardboard/paper waste, which will reduce waste storage area, streamline overall
waste processing operations and save transportation and labor costs.

It can help you select the equipment appropriate for your application. We have a large
selection of cardboard bailers ranging from small portable models to automation baling systems.

1. This machine uses the hydraulic transmission; with cylinder operate, durable and powerful.

2. It uses the button common control which may realize the many kinds of work way.

3. The machine working pressure traveling schedule scope can be adjusted according to the
material bale size.

4. Special feed opening and automatic output package of equipment.

5. The operation is simple. The feed opening install the interlocking device which will be safe
and reliable.

6. The Pressure force and packing size may design according to customer’s requirement.

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Paper recycling is a rapidly expanding because of the need to reduce the amount of waste sent to
landfill.A baling machine is a device used to compress materials into a bale for storage,
transport, or handling. Several types of machines exist for this purpose, as some are designed
specifically for one material, while others may be able to handle various materials. Hydraulic
scrap baling presses are machinery that finds usage to compress different types of scraps into
bale forms using hydraulic power [1]. These presses are used in different ways to compress light,
thin as well as soft materials. With several kinds of balers available for different
materials/applications, these Balers are also used in material recycling facilities. There is also a
provision of tying bales manually with help of provided grooves, thus helping in saving much
cost of transportation.
Hydraulic scrap bailing presses are designed for:
 Paper scrap
 Plastic scrap
 Cotton waste
All these can be formed into cuboids bales. Further, as the density of bales is high, these are also
convenient to store, transport and used in metallurgy. Featuring complex electrical-hydraulic
control has two working modes viz.
Auto & Inching, these come with pressure adjustable facility that make these Hydraulic scrap
baling presses best in performance as well as easy in working and high in productivity. Since
high degree of compaction is achieved, it helps in saving expensive storage space as well as
allows making transport and handling more easily. These balers are made of steel with hydraulic
Ram for compressing the material loaded. Some balers offered are simple and labor-intensive,
but suitable for smaller volumes.
1.1 BACKGROUND
The first recycling baler was born from hay balers used in the farming industry since the
1930s. Automatic hay balers were designed to help compress hay into easily transportable bales.
Baling hay also helped to reduce the amount of space required to store it and made stacking of
bales easier.

From these early hay balers, different types of machines were developed to determine how
hay was baled. Some balers roll the hay into circular shapes and then secure it in place using

4
twine or netting. Other balers cut and compress the hay into rectangular shapes, after which it is
also secured together using twine or netting

The compactor has always been used with hydraulics, since 1941, when MS Wells
patented the first commercial model. The hydraulics relied first on water, but were eventually
modified to use electricity. Before the compactor was invented, trash and recyclables were often
mixed together, and it required multiple trips to load and unload them from industrial facilities.

Once the compactor was created, companies were able to divide their recyclables from
their trash and reduce the number of loads it took to remove all of their waste and recyclable
material. In fact, some compactors are “portable” and can sometimes compact and store the
waste.

The baler and the commercial waste compactor have both revolutionized the way that
waste is managed. They both save companies time and money, but they also make recycling
more feasible since it is easier to separate the recyclables from the waste. All in all, they have
changed the way that companies view and use their waste. If your company is in the market for
either of these versatile waste management solutions, feel free to reach out to Global Trash
Solutions today at 866-760-8194

Paper recycling is a rapidly expanding because of the need to reduce the amount of waste
sent to landfill. A baling machine is a device used to compress materials into a bale for storage,
transport, or handling. Several types of machines exist for this purpose, as some are designed
specifically for one material, while others may be able to handle various materials. Hydraulic
scrap baling presses are machinery that finds usage to compress different types of scraps into
bale forms using hydraulic power [1]. These presses are used in different ways to compress light,
thin as well as soft materials. With several kinds of balers available for different
materials/applications, these Balers are also used in material recycling facilities. There is also a
provision of tying bales manually with help of provided grooves, thus helping in saving much
cost of transportation.

Hydraulic scrap bailing presses are designed for:

 Paper scrap
 Plastic scrap
5
  Cotton waste

All these can be formed into cuboids bales. Further, as the density of bales is high, these
are also convenient to store, transport and used in metallurgy. Featuring complex electrical-
hydraulic control has two working modes viz.
Auto & Inching, these come with pressure adjustable facility that make these Hydraulic scrap
baling presses best in performance as well as easy in working and high in productivity. Since
high degree of compaction is achieved, it helps in saving expensive storage space as well as
allows making transport and handling more easily. These balers are made of steel with hydraulic
Ram for compressing the material loaded. Some balers offered are simple and labor-intensive,
but suitable for smaller volumes

1.2 PROBLEM STATEMENT

Generally on the land there are a lot of waste papers without any usages therefore, our
problemStatement is concerned on purpose how to use this wasted papers in a new recycling
matter to reduce the amount of waste papers on the landfill. Also recycling the waste papers for
different Purposes such as wall Insulation, paper, heat source, cardboard (boxes, tubes,), cartoon,
and Commercial causes for close hanging. After our initial survey, we found that most of
theindustries are using the traditional way to store the scraps. Due to the excess of paper waste it
requires lot of time for filling the waste in the transporting vehicle and it more tedious work.
These paper baling machines, hydraulic operated machines are costlier which is not affordable
for some small scale industries.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.

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 1.3OBJECTIVE

Objective of this design is to overcome the problem of statement

1.3.1 General objective

 Design of vertical waste paper baler machine

1.3.2 Specific objective

 Design 3d model
 Design analysis
 Select material
 Cost analysis
 Design calculation
 Result
 Discussion
 Conclusion
 recommendation

1.4SCOPE AND LIMITATIONS

1.4.1 Scope

This project is about the designinga vertical waste paper baler machine in this project we
are going to design baler machine as it’s more reliable and easier to operate in order to develop
new concept of thewaste paper baler machine design.the scope of the project where on the
designing 5-ton maximum baling capacity ofbaler machine by using optimization concept

1.4.2 Limitations

Add limitation here..

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 CHAPTER TWO

2. LITERATURE REVIEW

Agricultural Baler (Arsene Roth) This research relates to an agricultural baler which includes
substantially a pickup element, a conveyor which transports a harvested product stream picked
up from a field, and a transferring device which conveys the collected product stream in direction
toward a bailing chamber. In the known balers the transferring device is composed of several
profiled disks Which are fixedly mounted on a cylinder, the baler has sensors Which areformed
as pilot able sensing brackets located between the pressing chamber for detecting the harvested
product stream over the Width, an evaluating device connected With the sensors, and adjusting
means connected With the evaluating device. Basically this kind of device can only be used in
making bales in agricultural field. [2]

Baler Machine and Method of Baling (Roman Schmaltz, Robert J. Wolf, and Enrich E.
Salzmann) they carried out that that baler machine including a charging chamber for receiving
material to be baled. The charging chamber has a charging passage through which material is
forced into a baling compression chamber by a compression ram to thereby form a bale in the
compression chamber. An ejection ram is provided for forcing the compressed material out of
the baling compression chamber through an exit passageway. A movable decompression wall
functions as one wall of the baling compression chamber. Such wall is located opposite and
spaced from the charging passage through which material is forced from the charging chamber.
A power cylinder is provided to move the decompression wall in a horizontal direction to
effectively increase the volume of the baling compression chamber which, at the same time,
increases the size of the exit passageway to thereby permit ejection of an oversized bale from the
compression chamber. [3]
Horizontal baling apparatus (Wright Colin S.)Baling apparatus for scrap materials, such as
paper, cardboard and the like which is of the so-called high capacity" type capable of producing
relatively large, high-density bales, and baling a large tonnage in a given time period are usually
of two types, vertical or horizontal. Vertical baling equipment employs a compression chamber
which is vertically disposed, and the horizontal type balers use a compression chamber
horizontally disposed. Large vertical chamber balers receive the material to be baled within the

8
compression chamber and a ram, either hydraulic or mechanical, is moved vertically, usually
upwardly, to compress the material at an end region of the chamber. After several compression
strokes, with additional material being introduced into the chamber between strokes, a bale is
formed in the end portion of the chamber and strapping of the bale occurs while it is located
within the compression chamber. This arrangement has the disadvantage of rendering the baler
inactive while strapping of the bale occurs. Additionally, vertical chamber baling devices have
relatively small compression chamber loading openings due to the constructional limitations of
this type of baler. [4]
Round baler machine (Werner Konekamp, Horst Harig, Heinrich Isfort) Round baler for
windrowed fibrous agricultural materials in which the bales are formed by a two-part frame
having a generally cylindrical baling zone therein defined by side wall members on the frame
and roller members extending between the side wall members and distributed around the frame.
The frame includes a conventional pickup and conveying apparatus to move the agricultural
materials from the ground into the entrance of the cylindrical baling zone. The baler includes an
improvement of hollow roller members formed of sheet metal rolled into a cylindrical form with
intermediate supporting discs distributed across the interior of the cylindrical form and seal
plates at the ends of the cylinder which mount stub shafts for journaling the roller members. Seal
members are mounted on the side walls and these seal members project into the ends of the roller
members to coach with the seal plates to insure that the materials in the baling zone do not enter
the area between the roller members and the side walls. In an alternate embodiment of the
invention, the baler is modified by a special conveying means having oscillating tines driven
with the roller members to advance materials from the pickup into the baling zone.

9
 Figure: - 2 Round baler

Wind guard for round baler (Kevin M Smith and Levi Taylor) Pickup for an agricultural
implement, the pickup including dual floating wind guards that pivot and float causing the tines
to maintain contact with the crop at all times as it moves over the pickup and across the stuffer.
The present invention relates generally to hay balers, and more particularly to an improved wind
guard system for the crop pickup and feeder assembly of a round baler. For many years

Agricultural balers have been used to consolidate and package crop material so as to facilitate the
storage and handling of the crop material for later use therefore wind guard in installed in the
baler machine. [5]
Method for compacting material using a horizontal baler with movable bottom support
ejector (James K. Robbins) Horizontal baler has a longitudinally extending generally
rectangular frame assembly defining a receiving chamber and an adjacent aligned compaction
chamber. Each of the chambers has a top, a bottom, and sides. A ram is mounted for
reciprocation within the receiving chamber so that material therein may be transferred to the
compaction chamber and compacted therein by reciprocation thereof. A first cylinder and piston

10
assembly is longitudinally disposed within the frame assembly and is operable associated with
the ram for causing reciprocation thereof. A door defines one of the sides of the compaction
chamber. The door is selectively securable and movable relative to an opening communicating
with the compaction chamber. [6]
Baler machine with a bale transfer conveyor (Wilbur Van Ryswyk) Here cylindrical bale
forming machine has a bale transfer unit yieldable maintained in a transport or rest horizontal
position located below the bale discharge gate to receive a bale discharged from the machine for
transfer to a ground location rearward clear of the discharge gate. The transfer unit is operated in
response to the movement of the discharge gate into its open or bale discharge position and is
returned to its rest position in response to movement of the discharge gate out of the open
position therefor. [7]

Figure: - 3 Baler machine with a bale transfer conveyor

For many years agricultural balers have been used to consolidate and package crop material so as
to facilitate the storage and handling of the crop material for later use. Using baler machine in
this industry waste handling will become very efficient and their transportation cost will also be
reduced. From study we can say that large or small square bales are easy for handling and require

11
less space as compared to current method. Currently this method is used more in agricultural
field but by implementing this method in industries will be more convenient than any other waste
handling system. This system can be used in paper recycling industries, packaging industries,
plastics and glass industries, etc.
 Round bales
 large square bales
 small square bales

Round bales have the ability to shed water much better than square bales,which can allow
roundbales to be stored more easily in the field and forlonger periods of time at a lower cost (Liu
et al. 2013). Large square baleshave a greater bulk density and are easier to transport and move
than roundbales. They also have higher field efficiency because square bales can beejected from
the baler without stopping during operation (Liu et al., 2013).Large square balers have a higher
upfront cost than round balers, whichmakes purchasing them more difficult for smaller scale
operations (Remoue,2007). Storage of square bales is more difficult than round bales
becausethey must be under a structure or out of the weather to decrease mass lossdue to
weathering.square bales can come in two forms, either large or small square bales.

Small square bale technology was developed long before large square balersand is often used by
smaller farmers in certain specialty areas, such as horseoperations. Shinners et al. (1995)
explains that one of the major differencesbetween small square balers and larger square balers is
the pre-compressionchamber. Crop is fed into this chamber where it is compressed slightly untila
relatively large amount of crop is accumulated. Once thishas occurred, the crop flake is pushed
from the pre-compression chamberinto the main chamber and added to the main bale. Because of
thisdifference, a higher bale density can be achieved with a largesquare baler, as compared toa
small square baler.

The forces inside a large square baler can be extremely large, and previousstudies have found
that these forces often change depending on the croptype.

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2.2. Baler types
Balers can be divided into 3 types:

1. Horizontal Waste Paper Baling Press

2. Vertical type Waste Paper Baling Press
3. Double Box Waste Paper Baling Machine

Horizontal Waste Paper Baling Press

Horizontal Waste Paper Baler from SHLOK also known as Semi-Automatic Horizontal
Balers are used for Pressing various material including both solid material and hollow plastic
material.

This machine is a good option for facilities that handle no more than 2 tons volume of
waste per hour and also with relatively low labor cost. Except for manual tying, all other
processes are automatic such as material feeding with a conveyor, compressing, bale outlet door
opening and closing, and bale ejecting.

Applications:

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  Paper/cardboard recycling facilities
 Carton manufacturers
 Printing facilities
 Textile waste recycling installations
 Distribution centers
 Pet bottle recycling plants
 Fiber processing facilities and packaging factories.

Features of a Horizontal Waste Paper Baling Press:

1. Electric Controlled

For easy operation, simply by operating on buttons and switches to fulfill platen moving
and bale ejecting

2. Hydraulic Lifting Chamber Door

For automatically lifting up to let the bales come out, which promotes operation
efficiency and increase output

3. Automatic Feeding Conveyor is Optional

For continuous feeding material, and with the help of sensors and conveyor will
automatically start or stop when the material below or certain position on hopper. This
Enhances feeding speed and maximize throughput

4. Horizontal Cutter on Feeding Mouth

For cutting off the excessive material to prevent it from being stuck feeding mouth

5. Automatic Bale Ejecting System

Enables labor-free bale ejecting

6. Close-end Design

Ensures dense bales especially for hollow products

7. Bale Guide Island

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 Allows bale to be easily removed with forklift

8. PLC Control System

Automates the Operation and promotes accuracy

Vertical type Waste Paper Baling Press

Vertical Waste Paper Baler are one of the SHLOK’s most popular down stroke balers, are
standalone vertical baling machines which are put to great use in the disposal of
cardboard/carton, ideal for waste recycling facilities, cardboard/paper manufacturing units,
supermarkets, department stores, grocery stores, drug stores, printing facilities, and others that
generate massive waste cardboard/paper.

They can strap hundreds of cardboards into a bale up to 600kg with largest bale size of
1520*760*1220mm. The volume reduction is approximately 12:1 when pressing plastic film or
cardboard waste. For recycling centres, this will mean reduced waste storage area, streamline
overall waste processing operations and savings on transportation and labour costs.

Application areas:

15
i

The bi-task ability of Double Boxer Waste Paper Baler greatly increases the working
efficiency, and especially suitable for clothing recycling facilities that have to bale clothes in
large volume every day.

Application areas:

 Used to Bale:
 Waste Paper
 Paper Trims
 Paddy Straw
 Used Clothing
 Rags
 Textile Fiber and Other Textile Waste

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 3. CHAPTER THREE
3.1 Materials and methodology
3.1.1 Materials
Material selection is essential that a designer should have through knowledge of the propertiesof
the materials and their behavior under considerations of the material. Some of the important
characteristics of the materials are strength, durability, flexibility, weight, resistance to heat and
corrosion, ability to cast, welded or harder, machine ability and others. Also material selection is
a matter of quality and cost. The procedure for material selection of machine component should
include consideration of the following points.
 Mechanical properties
 tensile strength, bending strength, bearing strength, compression strength, torsion
Strength, sheer strength
 physical properties
 wear resistance, harden ability, rust and corrosion
 coefficient of thermal efficient expansion
 specific gravity, thermal conductivity
 Technological properties
 machine ability , weld ability, cast ability, mall ability form ability

Material selection is an important process in design processes. Selecting materials is a process

that is design-led in that the material selection process uses the design requirements as the input
so as to come up with materials that have the desired properties for the part to be designed to
function well.

Engineering Materials for Components

The common engineering materials used in making machine components include;

 Cast iron,
 Steel (all types of steel),
 Copper and its alloys,

17
  Aluminum and its alloys,
 Plastics.

Therefore, the right materials for the design of the baler machineparts should be selected.
Selection requires one to consider the following factors which give the best material fit for the
design job:

 Specific strength and mass. It is preferable to select a material of high yield stress with
ability to carry the load without failure and low density in order to realize a pistonrod of
high strength and larger mass. Therefore, the material selection process should aim to
maximize the quantity termed as the specific strength.
 Resistance to abrasive wear. Most of engineering materials in contact with one another
are subjected to surface wear due to relative motion. It is therefore desirable to select a
material from the candidate materials with low wear rate or capacity to resist abrasive
wear at the cylinder bore part surfaces.
 Resistance to buckling. Heavy loads may cause the piston rod to buckle once the critical
load is exceeded. It is preferable to select a material with high resistance to buckling of
the piston rod, that is, excellent elasticity and deflection behavior in response to
application of an external load.
 Availability, Cost and Affordability. It is also preferable to choose a material with the
high Stafford ability rating. Relative cost of the materials is used in finding or calculating
the affordable rates. Therefore, the availability of the material and the cost of processing
the material in to the finished product need to be taken into account and considered as
supporting information when making the final choice of the material.

 Other relevant properties include; resistance to corrosion, electrical and mechanical

properties, heat transmission properties etc.

3.1.2 STEPS FOR SELECTION OF MATERIALS

For Components Selection of materials in engineering design involves the following steps:

 Translation of design requirements in to specifications for a material.

18
  Screening out those materials that do not meet the specifications in order to leave
only the viable candidates.
 Ranking of the surviving materials to identify those that have the greatest potential.
 Using supporting information to finally arrive at the choice of material to be used.

The first three steps involve mathematical analysis, use of various charts and graphs of
specific property such as specific strength, wear resistance, buckling resistance and
affordability. The materials are compared, ranked as per the indices of merit and
available supporting information is used to reach the final decision (Ashby, 2005).In this
project, information from case studies on previous designs of similar products is used in
material selection for the baler machine components/parts. However, other factors such
as availability of the candidate materials, purchase price of the candidate materials,
manufacturing processes and properties, forms and sizes in which the materials are
available are also considered

3.1.3 COMPONENTS AND THEIR SPECIFIC MATERIALS

Selected the goal of material selection is to come up with an appropriate material that best meets
the design requirements. The approach is to identify the connection between functional
requirements and the material properties so as to help us reduce the number of
candidatematerials from which to select from. The following are components and materials
required in the design of a power screw (screw jack):

Frame (Body)

the frames is 600*600*600 dimension box shape and hollow internally to accommodate both the
movable plate and hydraulic cylinder assembly. The frame works to ensure that the baler is safe
and has a complete rest on the base. The purpose of the frame is to support the compressed paper
and enable it to with stand compressive load exerted on it. The frame is a square and thus
requires casting as a manufacturing process. For this reason, grey cast iron as a material is
selected for theframe.

This is also evident from the case study on previous design of the same product (Nyangasi,18
December,2006). Cast iron is cheap and it can give any complex shape without involving costly

19
machining operations. Cast iron has higher compressive strength compared to steel. Therefore, it
is technically and economically advantageous to use cast iron for the frame. Graphite flakes cast
iron with an ultimate tensile strength of 220MPa is considered suitable for the design of the
frame. The graphite flakes improve the ability to resist compressive load. Mechanical properties
British Standard Specification Tensile strength (MPa) 220 Compressive strength (MPa) 766
Shear strength (MPa) 284 Endurance limit (MPa) 96 Young’s modulus (GPa) 89 – 114 Modulus
of rigidity (GPa) 36 – 45 Hardness number (HB) 196.
Mechanical properties of cast iron
Mechanical properties British Standard Specification

Compressive strength (MPa) 766

Shear strength (MPa) 286

Endurance limit (MPa) 96

Young’s modulus (GPa) 89-114

Modulus of rigidity (GPa) 36-45

Hardness number (HB) 196

Tensile strength (MPa) 220

3.2 METHODOLOGY
To achieve the objectives, the following methodologies are used in the experimental and
theoretical investigations.

The purpose of this study is to report on waste paper baling machine which is used to make a
Briquettes product. According to the information gathering process by observation methods, that

20
we have collected data as a sample data collections. From this information in AMU main
campus of three dormitory blocks we made a daily record of waste paper from this we get
average of 1, 1, 1.5 kg wasted papers per day respectively from the selected 3 dormitory blocks.

From this data again we take the average of the three block and we got 1.166kg of waste paper
per day from each dormitory block of AMU
no Monday (in Wednesday (in Friday (in Saturday (in block
kg kg) kg) kg

1 1 2 1 1.5 1

2 1 0.5 0.5 1.5 2

3 1.5 1 2 0.5 3

That means in our campus an average of kg are wasted paper per day only from all (26)
dormitory blocks. From this data we can get an amount of kg wasted papers per month in
A campus and six hundred kg wasted papers per month.

21
 I. Literature review
In order to design this palletizing machine continuous investigation of the past projects are made
basically there analysis and there investigation, from internet and text books.

II. Data collection

Gathered a necessary data for this project from company by;

 Direct measuring of required parameters.

 Gathering standard dimension from internet and from company machine manuals.

III. Design Analysis

Depend on the project profile and given data analysis and necessary design requirement will be
made to know the design is safe or not according to the application area and to know the
effectiveness of the projects.

IV. Result and discussion

Put design analysis result relating to the standard dimension.

V. Project modeling

Make the project modeling by solid work software and assemble each fabricated and purchased
components of a machine.

3.2.1 Procedure in Flow Chart Form

The flow chart below shows the methodology that used to design the machine for Ethiopian
farmers.

22
 3.2.2 Detail the Procedure
In the 1st step, to understand problem area and identifying the gap reading more related literature
is mostly useful. Because of it gives more information about the machine. In the 2 nd step, in order
to design the parts of the machine mathematical and engineering analysis is necessary. This
analysis is done by using different equations. After analysis well done the next step should be
continued which is called modeling by using SOLIDWORK software to show the sample of the
machine. In the 4th step, the designed parts are assembled as engineering drawing. Materials that
used to design the machine should be selected under 5 th step depending up on their nature. After
materials are selected prototype can be developed in order to show how the machine works, and
the material and equipment used to join the components of the machine to make functional like
welding, fastener, riveted ways of joining the components and the place where this joining
methods are done under the 6th and 7th steps respectively. All the necessary steps are done before
and then the next step should be continued which is called manufacturing procedure or process.
All the procedure and necessary steps that should be followed to produce the machine are
sequentially described in this step. And finally testing the mechanism is necessary to make
machine is workable and if it doesn’t work identifying the problem is done under this procedure.

23
 4 .CHAPTER FOUR
4.1 DESIGN AND CALCULATION
4.1.1Specifications
This vertical waste paper baler machine is limited to briquette dimension of 600mm x 600mm x
600mm. Briquette dimension is the dimension of the block of the output or result compressed
Waste paper.
 Bale size = width * height * length
= 600*600*600

The design specification of this project is:-

 Application area of the machine is in every Paper Company and small private
paper
 Company.
 The size of the machine
 Types of paper to be balled
 Mostly this design concern on office paper

3.2.3 Design Considerations

The design considerations of waste baler paper machine are as follows;

 Compacted time of the baler machine

 The cost of the machine with respect to production quality, speed and amount.
 Safety for the operator and others.
 The size and shape of machine
 Alternative waste management option.
 To minimize waste paper quantity.
 To maximize reuse recycling and material recovery are the consideration area.
 In the design of this machine for the purpose of compacting waste papers;

 Machine factors such as tangential load, durability, rigidity, deflection wear, corrosion and
shaping of the various machine components are considered.

24
 Design of Waste Paper Baler Machine
 The overall cost was considered through critical value analysis in the
phase of design.
 From the point of view of cost consideration, the size of the machine to
design and
 through critical value analysis in the phase of design, we select the
following
 Compacted briquette dimensions.
 (W∗H∗L) = [210mm∗90mm∗300mm]
 Compaction pressure, P =30MPA
 Hopper capacity = 20x10
 Position of the machine: vertical position

4.2 Materials:

4.2.1 Material used for various components

Engineers are faced with the dilemma of choosing materials for their everyday design as a result
of the vast production of materials available. A wrong choice will be definitely reduced the value
placed on the product. Therefore, understanding the process of selection is needed. Our thesis
tends to highlight the basic steps in choosing material for the product design and necessary
calculations were done to determine and analyze possible design stresses.
Material as selected on the basis of strength requirement of various components of the
mechanism. The machine is expected to be constructed from locally available materials;
The component of the machine will be: -
1. Engine with support frame 2. Hydraulic cylinder

3. Piston rod. 4. Forward and Return stroke

5. Motor 6.Body Frame structure

7. Door 8. Bolt and nut

The materials include standard parts and manufactured parts used in the above component the
machines.

25
The generalized adapted design procedure for waste paper baler machine is to bale a 5 ton of
cube shaped of 600*600*600-dimension compressed waste paper.

4.3 DESIGN PROCEDURE FOR THE HYDRAULIC CYLINDER

A hydraulic cylinder (also called linear hydraulic motor) is a mechanical actuator that is used to
give a unidirectional force through a unidirectional stroke. it has many applications, notably in
construction equipment (engineering vehicles), manufacturing machinery, and civil engineering.

Hydraulic cylinders get their power from pressurized hydraulic fluid, which is typically oil. The
hydraulic cylinder consists of a cylinder barrel, in which a piston connected to a piston rod
moves back and forth. The barrel is closed on one end by the cylinder bottom (also called the
cap) and the other end by the cylinder head where the piston rod comes out of the cylinder. The
piston has sliding rings and seals. The piston divides the inside of the cylinder into two
chambers, the bottom chamber and the piston rod side chamber (rod end) A hydraulic cylinder is
the actuator or
"motor" side of this system. The "generator" side of the hydraulic system is the hydraulic pump
which delivers a fixed or regulated flow of oil to the hydraulic cylinder, to move the piston. The
piston pushes the oil in the other chamber back to the reservoir. If we assume that the oil enters
from cap end, during extension stroke, and the oil pressure in the rod end / head end is
approximately zero, the force F on the piston rod equals the pressure P in the cylinder times the
piston area A.

Design criteria in hydraulic cylinders

There are so many factors involved in sealing elements working principle. Ignoring these factors
could increase the possibility of design mistake. Hydraulic cylinders have different working
conditions.

For main variables should be taken in to account while choosing a sealing element.

1. Temperature

Media and working condition temperature should be considered when choosing suitable sealing
element.

2. Pressure

System pressure and pressure type should be considered when choosing suitable sealing element.

26
3. Sliding speed

System sliding speed should be considered when choosing suitable sealing element.

4. Media

Media type should be considered when choosing suitable sealing element.

There are other variables which also affect the working of hydraulic cylinders.

5. Working conditions

This is one of the most important variables for hydraulic cylinders design .there are so many
factors on this stage which deserve attention.

V.1 Working in an open or closed area and dirty working conditions are most important
criteria for choosing a wiper. it may be necessary to use an ice scraper in winter for
cylinders in outside working conditions.
V.2 Radial loads and working positions that affect hydraulic cylinders should be taken in
to consideration when deciding on the hydraulic cylinder on the hydraulic cylinder
design. For example; rain drops should be prevented from entering in to the vertical
functioning hydraulic cylinders that are in outside working conditions.

4.2.1 to find diameter of bore

 Capacity of the machine to compress at ones = 5ton
Which is49.05 in Kilo Newton
 And working pressure taking fore this design is 115 bar
P =115 bar
=11.5 N/mm2
=1665.5 psi
 to find the diameter of bore we can use the formula

F
A=
P

Where, length of the bore is 500mm

27
 π 2 F
D =
4 P

π 2 500 x 9.81
D =
4 11.5

D = 73.69mm
D=80mm

4.2.2 Thickness of the cylinder body

 t= ( di2 ) {( s+s−((1−2 µ) P
1+ µ ) P 1
)
1/2
-1}

t=(
2
){
(
80 165+ (1−2 x 0.3 ) 20
165−( 1+ µ ) 20 ) 1/2
-1}

t= 3.55
For safe taking double = 7.5mm

4.2.3 To find outer diameter

 Do = Di +(2t)
 Do = 80 + (2*75)
Do = 95mm
The hydraulic cylinder is 95/80 mm is used

4.2.4 Piston rod design

Piston rod materials are hardened steel and can include metal spray in packing areas to extend
rod life. Piston materials can be steel, cast nodular iron, or aluminum. The most common being
cast iron durability.
Force
 F = AP
π 2
F = d ∗P
4
π 2
F= ∗63 ∗11.5
4
F = 57805.3N

28
 Di
Taking =1.27
d
80
55=1.27
d
D = 62.9mm
D = 63mm

4.2.5Volume of cylinders
 Bore side
π 2
Vb= D *L
4
π 2
Vb = 80 *500
4
Vb = 2.513*106 mm3
 Ram side
π 2
Vr = D *L
4
π 2
Vr = 63 *500
4
Vr= 1.55*106mm3

4.2.6 Time required for Forward and Return stroke

v
 T=
FR
 V = volume
 FR = flow rate
 We assume time for each stroke = 30 seconds
6
2. 51× 10
 F¿
80
mm3
= 837766.66
sec
mm3
 W.K.T = 1 = 0.00006 LPM
sec
 FR = 5.026 LPM

29
  Select Q = 5 LPM gear pump for operation
Time for return
6
1 . 55 ×10
T = 5 .026
( )
0 . 00006
T = 18.5 sec

4.2.7 Motor power selection

Motor required HP
Hydraulic pump rating =1407W
Since the machine designed for Small and medium scale enterprise, a single phase electric
motor is desirable to power the pump. Assuming power transmission of 95%, power rating
of electric motor is therefore
 HP = flowratel( LPM )× pressure ¿ ¿
5.026× 125
HP =
442

HP = 1.307 was selected.

4.2.8 Thickness of cylinder end cover

 F = π∗Di∗tc∗σ a
 tc= Thickness of end cove
 σ a = Allowable tensile stress for mild steel
= 165Mpa
F = 57805.3N

√
 tc = 80*
0.1875× 11.5
165
tc = 9.14mm
=2×9.14
Tc = 18.29mm
Tc = 20mm

30
4.2.9 To check buckling of piston rod
 Rankine formula for induced stress
2
F
σ c= [1 + a lc ]
A n k

Where,

 K= Radius of gyration =
√ l
A

 σ a = compression stress

 Le = Effective length

 a = Rankine constant for mild steel 1/7500

 n = End constant for one end fixed and other end free 0.25

 Le = effective length 2L

 L = 600mm

 Le = 1200 mm
 dp = 63 m

π 2
A= D
4
π 2
A= 63
4
A = 3117.2mm2
π 4
 I= D
64
π 4
I= 63
64
I = 773.27*106 mm4

31
  K=
√ I
A

√
6
K = 773.23∗10
3117.2
K = 15.75

3 N
 E = Young’s modulus 207 * 10 2
mm
F
 σc = ¿
A
F
320 = ¿]
A
F = 243.5KN
Since the critical load for buckling is 243 KN and load applied is 57.8 KN which is less
and hence design is safe.

4.3 Body frame design

4.3.1 Base

4.3.2 Structure

32
4.3.3 Door
The door hinges resist the force of the ram head against the papers to effect baling. The worst
loading a hinge will resist is when its bears the whole force. The hinge is likely to fail due to
tension.
The door is model as a simply supported beam with a central point load
Moment of inertia of the door section

I= 34
Where, b = thickness of the door is 4mm, d = depth of the door is 400mm, I = moment of
Inertia of the door

Therefore, = = 21333333 mm4

The maximum deflection of the door

y
Where, yc = deflection of the door at its center, w = maximum force on the door is 10000N
E = modulus of Elasticity is 200GPa = 200N/mm2 for steel, I = moment of inertia of
the door section is 21333333mm4

33
Therefore,

= 0.003125mm

34
4.3.4 Side Plate

4.4 .Design of machine Operations

A. Amount of Scrap Material Required

Required bale size = 203.2 mm × 203.2 mm × 101.6 mm Density of loose scrap 150 kg/ 3

After compression density increases to 12 times of loose scrap.

Then density of compressed material = 1800 kg / 3

Mass of material required = volume after
compression × density of compressed bale
= 0.00419 3
× 1800 kg / 3

= 7.54 kg

B. Determination of Size of Cavity

Cavity volume × Density = mass of material

35
 L × B × H × 150 kg/ 3
= 7.54 kg
L × 0.2032 m × 0.3048 × 150 kg/ 3 = 7.54 kg

C.Calculation for Total Cycle Time

Total cycle time = time for loading of material + time for forward stroke of upper cylinder + time
for forward stroke of lower cylinder + Time for door opening + time for return stroke of upper
cylinder + Time for return stroke of lower cylinder

= 45 sec + 18.90 sec + 48.27 sec + 25 sec + 12.8 sec +

33.23 sec
=183.2 sec = 3 min 3 sec

4.5 Theoretical Stresses on Different Machine Component

A. Theoretical Stress on Bottom Plate

Total area of base plate = (500 + 102.5 × 4) × 243.2 + (450

× 343.2)
= 37575.2 mm2
Force exerted by upper cylinder = 36 ton = 353160 N
Stress on bottom plate = 353160/37575.2
= 9.398N/mm2

B. Theoretical Stress on the Front Door

Total area of front door = (2 × 37.5 + 334.49) × (269.8 + 2

× 37.5)
= 3635.65 mm2
Force exerted by bottom cylinder = 50 ton = 490500 N
Stress = 490500/3635.65
= 134.91 N/mm2

4.5 Main Machine Components

36
A. Hydraulic Cylinders

1. Bottom cylinder
2. Upper cylinder

B. Fabricated structure

1. Base plate
2. Side walls
3. Upper pressing plate
4. Upper cylinder supporting structure

III.CONSTRUCTION AND WORKING

A. Working Principle

A simple hydraulic system consists of hydraulic fluid, pistons or rams, cylinders, oil reservoir, a
complete working mechanism, and safety devices. Transmission of force is carried by the
hydraulic fluid, in a confined medium. Modern developments in hydraulics have involved many
fields in engineering and transportation. These systems transfer high forces rapidly and
accurately even in small pipes of light weight, small size, any shape, and over a long distance.

Pascal’s law:- Pascal's Law, framed by Blaise Pascal, states that “Pressure applied to any part of
a confined fluid transmits to every other part with no loss. The pressure acts with equal force on
all equal areas of the confining walls and perpendicular to the walls." This is the basic principle
for any hydraulic system.

A hydraulic scrap baling machine is used to compress small chips (such as boar, blanks, and
turning) into compact size bundle that is easy to handle, transport, and store.
37
B. Construction

The hydraulic scrap baling machine consists of fabricated structure hydraulic cylinders, opening
doors, and Hydraulic power pack with hydraulic valves, etc. The fabricated structure includes
cavity base plate two side wall plates which are supported with rigid support of the C-channel
structure. Also, consist of an upper cylinder supporting structure which is welded to the bottom
and side walls of the machine the fabricated structure also consists of upper compressing which
is hinged between side walls. The machine is working with two hydraulic cylinders one is at the
bottom in the horizontal direction and other is at the top in an inclined position which is mounted
with intermediate turn-on mounting to cylinder supporting structure. There are two doors. One
closes from the front due to engagement in the slot provided on the side door. The hydraulic
power pack consists of the 300-liter oil tank, pressure gauge, hydraulic valves, etc. The two side
walls one bottom plates creates a cavity for pressing scrap.

C. Working

The machine works on the simple hydraulic Pascal’s law. The total compressing process is of
two steps one is with upper hydraulic cylinder and other is with a lower horizontal cylinder. The
operation starts with the pouring of turning scrap into the cavity provided in the machine after
that with the lever operated valve the upper cylinder is actuated which pushes the upper
compressing plate into the cavity till stoppers provided to the upper plate rests on the cavity side
wall. After that second horizontal lower cylinder gets actuated with the lever operated valve it
compresses the material inside the cavity to its limit then the lever moves to cutoff position. The
door is opened manually and again lower cylinder is actuated with the lever valve which pushes
the ball to the out of the machine.
A hydraulic scrap baling machine is used to compress small chips (such as boar, blanks, and
turning) into compact size bundle that is easy to handle, transport, and store

38
 CHAPTER FIVE
5. CONCLUSIONS AND RECOMMENDATIONS
5.1 Conclusions
The bales formed by this machine helps in easy handling, storage and transportation. The
maneuverability of the device is quite good and the handling is quite simple. Optimization design
is compared to the actual part design that is being manufactured for the scrap baling press and
hydraulic press. It is inferred that under the same loading conditions, constraints and intended
design purposes, shape optimization results in better and more reliable design. The cost of the
machine is low compared to market product

5.2 Recommendations
Periodic inspection and (Placeholder1) maintenance of the equipment and safe guarding device
that must be conducted to ensure the proper orientation and safe performance.

If the paper company uses this baler, their profit is increase because it decreases costs

39
40
 6. REFERENCES

1. Write your references here according to the proper way of writing references…
2. Sssssss
3. Ddddddd
4. Ggggggg

7. APPENDIX
List and attach here if you use other authors or text book tables & figures, and your
drawings (part, assembly and exploded) according to their proper order.

41