Design and Analysis of a Dual-Shaft Shredder Machine for Thermoplastic Recycling

Year 2025, Volume: 1 Issue: 2, 60 - 67, 28.11.2025

Mustafa Öncül , Keziban Fidan , Emre Sığırcı

Abstract

This study presents the design and structural analysis of a dual-shaft plastic shredding machine developed for small-scale enterprises involved in thermoplastic processing. The aim was to recycle off-cuts and defective parts generated during production, which are typically unsuitable for direct reuse, thereby enhancing material efficiency and promoting environmental sustainability. Mechanical analyses were performed using ANSYS Workbench to evaluate the structural integrity of critical components. The blade, made of DIN 1.2379 tool steel with a yield strength of 2120 MPa, experienced a maximum equivalent (von Mises) stress of 323.3 MPa, while the shaft, also fabricated from DIN 1.2379, was subjected to a maximum stress of 90.935 MPa. Both values were well below the material yield limit, confirming the mechanical reliability of the design under expected operational conditions. A helical gearbox was selected for its quiet and efficient performance, suitable for businesses operating in confined or residential environments. The compact and cost-effective design of the machine ensures ease of use and long-term durability with minimal maintenance. Overall, the developed system effectively supports the recycling of thermoplastic waste, contributing to reduced raw material consumption and sustainable production practices.

Keywords

Thermoplastic recycling , Dual-shaft shredder , Finite Element Analysis (FEA) , Sustainable waste management

Ethical Statement

This article does not require ethics committee approval. This article has no conflicts of interest with any individual or institution.

Thanks

We would like to thank Prof. Dr. Mehmet Çevik for his support in analyzing the critical parts with ANSYS, and Alperen Akbaş, the owner of Born Material, for sharing useful information about the needs of small-scale businesses, which helped make the study more focused and practical.

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