TECHNOLOGY ANALYSIS OF PLASTIC RECYCLING INDUSTRIES & THEIR PERFORMANCE ENHANCEMENT: A CASE STUDY OF KATHMANDU VALLEY

Abstract

This thesis presents the comprehensive study of the current plastic recycling technologies employed in the industries of Kathmandu valley. The research identified a technological gap that required improvement. To fulfill this gap machines that are being used in plastic recycling industries, with a focus on HDPE, were redesigned as per engineering calculations and then fabricated. Numerical verification of redesigned machines revealed subsequent improvement. It showed that for granulator machine by using the suitable bearing type, the dynamic and static load bearing capacity was increased by 2.13 times and 2.64 times respectively compared to the existing design. Similarly, for dryer machine, using double support instead of single increased critical loading by 1.48 times and combined loading decreased by 1.63 times. Likewise, the mixture machine also achieved significant enhancement, with critical loading increased by 2.53 times and combined loading decreased by 2.95 times. Those newly fabricated machines were then operated on a factory in normal conditions. Detail comparison of the performance of updated machines were then made with the existing ones. Due to the design changes, the production capacity of factory was increased while decreasing the maintenance cost. The machines were locally manufactured, resulting in the lowest manufacturing cost compared to other factories. In addition, the maintenance cost incurred throughout the year on upgraded machines was compared with the existing ones which showed the minimum value on the former case. Furthermore, financial analysis was done to check the feasibility of the factory. For this, Benefit Cost Ratio, Internal Rate of Return (IRR) and Payback period is calculated. In the first one NPV of cost and benefit was duly calculated with reference to the data of miscellaneous costs incurred in the industry. From the result obtained benefit cost ratio is 1.11 which is clearly greater than 1, which confidently shows that the project is feasible. Also, the IRR is obtained to be 18% with a payback period of four years.