Extruder Machine Design as a Facility for Utilization of High Density Polyethylene Waste into Plastic Panels

Abstract

Plastic waste is a persistent material that poses a serious environmental threat due to its resistance to natural decomposition. Indonesia generates approximately 27.3 million tons of waste annually, of which 19.8% is plastic, highlighting the urgent need for effective recycling strategies. This study aims to design and develop an extruder machine to recycle High-Density Polyethylene (HDPE) waste into value-added plastic panels. The research methodology comprised literature review, needs identification, concept design development using the Ulrich method, concept selection through the Analytical Hierarchy Process (AHP), fabrication, and machine performance testing. Concept 1 was selected as the best alternative among the three proposed design concepts, achieving the highest Alternative Weight Evaluation score of 35.14, compared to 34.65 for Concept 3. The fabricated machine measures 779.5 mm in length, 610 mm in width, and 689.3 mm in height, powered by a 1 HP electric motor and equipped with four 300 W heaters. Performance tests demonstrated that the machine successfully melted HDPE and produced plastic panels with uniform surfaces, good material density, and minimal voids, although the resulting color tended to be dark. The findings confirm that the developed extruder machine effectively supports HDPE recycling into functional products, contributing to waste reduction efforts and promoting sustainable plastic waste management technologies.