School of Engineering and Technology

Department of Industrial and Manufacturing Engineering

A report submitted in partial fulfilment of the requirements for
HIT 200 Team project

Title: Design of a Composite brick making machine.

Submitted by:
Keith T. Magaka H160203W

Talent Mukome H160269Q

Newton Takawira H160424R

Calton Magonde H160107M

Neddy Tanga H160128Z

Robin Nyamindi H160340J

Supervisors: Eng. E Maputi, Eng A. Nhidza

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Declaration

We, Keith Magaka, Talent Mukome, Newton Takawira, Calton Magonde, Neddy Tanga and
Robin Nyamindi, hereby do declare that this work has not been previously accepted in
substance for any degree and is not being concurrently submitted in candidature for any
degree or course

Students signature Date

(Group Leader)
Students signature Date

Students signature Date

Students signature Date

Student signature Date

Students signature Date .

Proposed supervisors signature.Date..

Abstract

To design and optimize a machine which mixes sand and plastic to produce paste used to
make bricks. The project was designed in order to utilize plastics which are being disposed
in the streets by the populous and put the plastics to good use at the same time helping reduce
pollution. The research methods to be used by the researchers are a case study of the project,

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observations of how the process is carried out by existing brick makers in order to identify
the problems they face so as to improve on that problem, journals for more in depth
information of the design and requirements, the internet and also carry out interviews in order
to acquire firsthand knowledge from experienced individuals. The expected results from this
project is to have a fully functional prototype that is able to produce a strong high quality
brick which will be commercialized and the target markets will be the manufacturing and
production industry and SMEs.

CHAPTER 1

1.1 Introduction

Excessive littering has become a big problem in Zimbabwe. This has resulted in piling up of
waste material in the streets and all over the town areas which has brought about an unclean
and unhygienic environment. Reducing the pollution is of relative importance in order to
maintain a cleaner environment which benefits the society. Making use of the disposed
plastics to produce bricks will be a smarter way of putting the plastic waste to good use. Also

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to compliment the efforts of cost reduction, the raw materials used to produce the brick are of
no cost. The project will be the best tool in helping the Environmental Management Agency
(EMA) in reducing land pollution in Zimbabwe.

1.1 Background to the problem

In Zimbabwe majority of the population is improperly disposing their waste materials

especially plastics mainly due to the lack of proper waste collection system and also
ignorance. This negatively affects the environment by that there is land pollution. This results
in the blockage of drainage systems. Some of the waste materials are non-bio degradable
which results in untoward garbage piling in different corners across the city.

Fig 1.1 Vendors sell their wares at Seek (Copa Cabana) commuter omnibus rank oblivious of
the uncollected garbage. (The Herald, May 19 2017)

1.2 Problem statement

Unsafe disposal of plastic material in the environment.

1.3 Aim

To design and optimize a cost effective composite brick making machine that utilizes waste
plastics as a useful resource.

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1.4 Objectives

To design the plastic sand mixing chamber.

To design a pumping system.
To design the heating system that is able to melt the plastics at 135C.
To design electrical control unit that is able to monitor the machine.

1.5 Justification
The project is a convenient way of disposing plastic waste by making use of the plastic waste
as a raw material in producing paste that is used for making bricks. It is a safer way of
disposing plastic material and also use those plastics to make bricks which are a value to the
society. The brick which will be produced is non corrosive thus it will last for a prolonged
period of time.
Most organizations in Zimbabwe do this process manually so the machine will make work
easier. An automated plastic sand mixer improves productivity by producing more paste in a
given period of time compared to the manual worker.

Fig 1.2 Credit to www.operation-boost.com

An automated plastic sand mixer is more effective compared to the manual worker for it is
not affected by fatigue and does not need breaks. There is improved quality of the paste
produced by the machine. Commercialization of this machine promotes indigenization in
Zimbabwe for there is no need to import the produce hence it makes it more affordable. Since

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this machine requires any type of plastic, the collection of plastics from the streets reduces
pollution. The use of the machine it reduces the health hazards of the workers by that they are
not directly exposed to the fumes and heat of the mixing sand and plastic and also no long
term skeletal disorders. The project benefits the researchers as they gain the technical ability
to properly design a working prototype and also improves on teamwork.

1.6 Scope

The project focuses on mixing granules of plastic and sand and then heating the mixture to
produce the paste.

1.7 Research questions

Why did the researchers use plastics?
What is the type of plastic used?
What are the challenges faced by already existing brick making processes?
What kind of material is best suited for the mixing chamber?
What is the ideal temperature for the mixing chamber?
What is the innovation of the project?

1.8 Methodology

The research is a case study which mainly focuses on the effects of land pollution on the
environment in the streets. A literature review shall be carried out to access the qualitative
information of the problem and the intended solution to the given problem. To interview
some employees at brick making companies to gain an in depth knowledge of the
brickmaking process. An observation will be carried out on one of the local companies on
how they carry out their brick making process in order to gain more insight of the qualitative
impact of the problem on the workers. Engineering tools which are AutoCAD, Autodesk
inventor, Solid works and Pro engineer will be used.

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 Gantt Chart For Plastic Sand Brick Making Machine
21-Aug-17 10-Oct-17 29-Nov-17 18-Jan-18 9-Mar-18 28-Apr-18

Proposal

Presentation

Literature review

Methodologies

Findings

Concept development

Design and calculations

Prototype

Model testing

Final presentation
Final Concept
Model Design and Methodolo LiteraturePresentatio
presentatio Prototype developme Findings Proposal
testing calculations gies review n
n nt
Start date 9-Apr-18 1-Mar-18 25-Sep-17 16-Oct-17 25-Sep-17 9-Sep-17 8-Sep-17 25-Aug-17 3-Sep-17 21-Aug-17
Duration 4 37 196 25 25 14 14 227 4 14

Fig 1.3 Gantt chart for sand plastic brick making machine

1.9 Literature Review

The issue of plastic-sand bricks has been considered in some of the developed countries such
as India, and was successfully implemented. Although this has been done manually, the
researchers focus on improving the manufacturing process by automating it. On Literature
review analysis, related literature is being investigated to have an overview of components,
concepts, previous research work and related materials which can aid the projects success.

There are several ways of disposing plastic waste materials which are already in existence.
These are
Recycling

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This is the process whereby the plastics are collected and are reused for other purposes. This
process is a good method of waste disposal but it has not been fully utilized in Zimbabwe
mainly due poor waste management facilities. (The Herald, Thursday 24 August 2017)

Burning
This is when the waste materials are disposed by that they are gathered up and then they are
set ablaze. This is the most widely used method of waste disposal in Zimbabwe mainly
because of the poor waste management facilities so most residents are forced to burn the
plastic waste. This method is not the most efficient way for it could result in the destruction
of the land and the soil could lose its qualities and also could result in accidents.

The researchers used plastics because it is the most disposed resource in Zimbabwe because
most packaging materials are made of plastic hence it is the resource which is in most
abundance.

The most suitable type of plastic for this project is high density polyethylene (HDPE). The
researchers chose this type of plastic due to various numbers of reasons. This type of plastic
is the most used type of plastic in Zimbabwe for it is used to make plastic bags, bottle drinks,
cosmetics etc. thus it is widely available. This type of plastic has high tensile strength, does
not chemically react with most solvents and relatively stiff materials with useful temperature
capabilities HDPE have reduced plastic shrinkage cracks and are water proof(International
Research Journal of Engineering and Technology (IRJET)) All these properties are necessary
and ideal for producing a strong high quality brick.

The researchers discovered that most brick making organizations manually produce the
bricks by that they burn the sand and the plastics and then they would manually mix the
molten sand and plastic to produce the paste. There are several challenges faced by this type
of process. The workers suffer from fatigue from continuously mixing the sand and plastic
thus there is reduced work output. The continuous exposure to the heat fumes can result in
long term lung problems which results in the incompetence of the workers. The continuous
mixing could also result in long term muscle skeletal disorders which could limit the
workers work rate as well. Also another issue was that there was less productivity due to the

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time taken to produce the paste which was affected by the workers capabilities which were
inconsistent over the period of observation.

Fig 1.4 effectiveness-efficiency matrix

The researchers chose silicon dioxide as the material best suitable for the heating chamber.
This is mainly due to the very high melting point of silicon oxide and its hardness therefore it
is not affected by the heating elements inside the chamber. In addition it does not react with
the sand and plastics being mixed. This material is readily available and very cheap.

The recommended temperature for the mixing chamber is 180 degrees Celsius, this is because
the melting point of HDPE is 180 degrees Celsius therefore it is the most suitable temperature
for the mixing chamber.

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As researchers we discovered that these processes exist though the processes of making paste
is done manually hence our innovation is making a good working automated prototype
machine which does the mixing of the plastic and sand.

1.10 Expected results

The prototype should be able to properly mix the plastic and sand in order to produce
a homogenous aggregate
The brick produced will be of high quality and strong
The work task of the machine must be able to limit exposure to ergonomic risk
factors.
The prototype is to be commercialized in order to mass produce the product which
will bring in high returns
Estimated cost of the prototype will be $150.

1.11 Conclusion

This project effectively converts waste plastics into useful building materials like building
bricks and floor interlocks which can effectively reduce environmental pollution and further
decreases the problem of waste plastics in the society. Rather than the waste plastics going
into the landfill or incinerators, it can be used as construction materials at a much lower cost
after undergoing certain specific processes.

References
1. Plastic Packaging Facts,https://www.plasticpackagingfacts.org/plastic-
packaging/resins-types-of-packaging/, Resins and types of packaging, Date accessed :
23 August 2017, Date modified: May 2017.
2. The Herald, Kawadza S, http://www.herald.co.zw/from-sunshine-city-to-garbage-
town/, From Sunshine city to cabbage town, Date accessed: 21 August 2017, Date
modified: May 19 2017.

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3. The Herald, Tsiko S, http://www.herald.co.zw/recycling-could-be-the-answer/,
Recycling could be the answer, Date accessed: 22 August 2017, Date modified:1 may
2013
4. Hopewell, J., Dvorak, R., & Kosior, E. (2009). Plastics recycling: challenges and
opportunities. Philosophical Transactions of the Royal Society B: Biological
Sciences, 364(1526), 2115-2126.
5. North, E. J., & Halden, R. U. (2013). Plastics and Environmental Health: The Road
Ahead. Reviews on Environmental Health, 28(1), 18.
6. Occupational Safety and Health Administration,
https://www.osha.gov/SLTC/ergonomics/controlhazards.html
7. Nitin Goyal, Manisha, CONSTRUCTION STRUCTURES USING ECO-BRICKS
International Journal of Recent Trends in Engineering & Research, ISSN 2455-1457.

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