Processing System for Plastic Bottle to Obtain Polyethylene

Terephthalate Filament in 3D Printers

RICARDO YAURI1,2, HILCAR BERMEO2, ALEJANDRO LEÓN2, OSCAR LLERENA3

1Facultad de Ingeniería,

Universidad Tecnológica del Perú,

Lima,

PERU

2Universidad Nacional Mayor de San Marcos,

Lima,

PERU

3Seoul National University of Science and Technology,

Seoul,

SOUTH KOREA

Abstract: - Plastic has become one of the most used materials in the world for many uses, especially PET

plastic (polyethylene terephthalate) which is used to make plastic containers and bottles. In addition, in recent

years there has been an increase in pollution due to its waste, which affects the terrestrial, marine, and climatic

ecosystems. Since 2018, in Peru, thousands of tons of PET containers have been produced, of which only

21.9% was recycled. This generates great contamination of waste by plastic bottles that are produced annually.

Therefore, it is important to carry out recycling processes to avoid contamination by PET bottles, which take

more than 500 years to degrade. Therefore, new recycling processes are sought in areas of interest such as 3D

printing technologies. For this reason, the objective of this paper is to implement a system that performs the

recycling of PET bottles for use in 3D printing and thus contributes to reducing pollution. As a result, an

electronic card was obtained for the automation of the foundry machine, cutting processes, casting, extrusion,

and collection of filaments. In addition, a programming algorithm was developed to monitor and display the

temperature based on a closed-loop system and thus obtain a higher performance and quality of PET filament.

Key-Words: - Plastic bottles, system processing, 3D printer, Polyethylene Terephthalate, recycling.

Received: February 21, 2023. Revised: November 22, 2023. Accepted: December 11, 2023. Published: January 17, 2024

1 Introduction

Since plastic was invented, it has become one of the

most used materials in the world since it has many

uses, such as the generation of PET plastic

(polyethylene terephthalate) that is used to

manufacture plastic containers and especially plastic

bottles, [1]. Currently, the production of plastic

bottles has continued to increase since 2018, when

the production of plastics has reached 360 million

tons, [2]. This increases the contamination by its

residues which affects the terrestrial ecosystem,

marine environment, and climate change. In

addition, it has been estimated that in 2015 plastics

were related to the production of CO2 and it is

projected that, this will increase to approximately

6.5 gigatons, [3].

Plastic pollution is a serious environmental

problem, as most plastics are single-use and can

remain in the environment for centuries before

breaking down, [4]. This indicates the great

contamination by waste from plastic bottles that are

produced annually in Peruvian territory. In addition,

in 2016, the Algalita Foundation (USA) announced

that off the coast of Peru and Chile, there is a large

island made of plastic, of which 25% corresponds

mostly to plastic bottles, [5].

For this reason, it is important to take recycling

actions to combat contamination by PET bottles,

since immense amounts of this material are

produced every day. The main problem that arises is

that it needs more than 500 years to degrade, [6]. it

cannot be eliminated so easily, and it continues to

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Ricardo Yauri, Hilcar Bermeo,

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accumulate in different environments, and

ecosystems, among others.

Considering the above, it is necessary to recycle

plastic bottles in technological areas related to 3D

printing, [7], using filaments based on thermoplastic

polymers as raw material. This is a field that is

evolving due to its usefulness in various fields such

as manufacturing, health, education, etc., [8], [9],

and it has gained relevance, where it is commonly

used to manufacture products and prototypes, in the

manufacture of toys or educational material, and

other areas, [10], integrating embedded intelligence

in hardware systems to improve their tasks, [11].

Based on the above, the following research

question is proposed: How is it possible to carry out

the processing of plastic bottles to obtain low-cost

PET filament? Therefore, the objective of the

research is to implement a recycling system for PET

bottles for 3D printing. PET thermoplastic is used

for the majority of plastic bottles used in water

containers, [12], so this research adds value in the

context of reducing plastic bottle pollution. For this

reason, the importance of recycling bottles to

produce filaments in 3D printers is shown, having as

specific objectives we have: Design and implement

a low-cost printed circuit board to automate the

plastic bottle processing system; Develop a

programming algorithm for the printed circuit

board; Design and manufacture the mechanical and

structural parts of the system; Evaluate and analyze

the operation of the system.

This paper has multiple sections which are

organized as follows: Section 2 shows related

works. On the other hand, section 3 describes the

concepts and technologies used in plastic processing

systems. Section 4 describes the implementation of

the system. Finally, the results are shown in section

5, and the conclusions in section 6.

2 Literature Review

Plastic bottle processing systems have been studied

in many investigations. Therefore, this section

describes some of the relevant papers on this topic.

There is a need to educate the consumer about

the importance of recycling plastic bottles and show

how it is used for 3D printing, [13]. The authors

propose the reprocessing and recyclability of PET

from discarded bottles. The solution begins with the

collection of plastic bottles subjected to a process of

washing, cutting, crushing (PET_B) and finally

being extruded in the form of a thin wire, called

"PET SC" or "PET RC" (depending on whether the

wire passed through slow or fast cooling

respectively). The authors used the product of this

process as raw material to 3D print some test pieces,

calling the result PET_3D. All these PET samples

went through several quality tests, including a

mechanical characterization test.

A similar research is carried out in, [14], where a

mechanical process for recycling and large-scale

treatment of plastic water bottles to obtain 3D

printing filaments is shown. Before starting with the

mechanical process (Extrusion of material), the

authors followed some previous steps to condition

the plastic bottles. The collection, washing, drying,

and grinding of the PET bottles with a 12-blade

grinding machine were the steps to obtain the

material to be extruded. For the extrusion process,

an industrial machine was used, and 2 different

diameters of 3D filaments (2.85, 2, and 1.75 mm)

were obtained.

Another similar scientific paper is described in,

[15]. The authors implement a machine capable of

recycling PET plastic bottles to obtain filaments for

3D printers. To do this, they designed the

mechanical parts, most of which were 3D printed.

This system is made up of an extrusion nozzle, a

ceramic heating element, a thermocouple, and a

controller to regulate the temperature. The authors

made a comparison based on 2 experimental tests to

verify the quality of PET compared to other

commercial filaments. It was observed that the PET

was slightly more resistant than the PETG.

The paper developed in, [16], describes the use

of material extrusion (MEX) for additive

manufacturing (AM). However, this process

involves the processing of new plastics using PET

materials that offer high recyclability potential. The

paper reviews how the process of extrusion and

recycling of bottles to obtain PET is based on MEX

processes with tensile tests. In addition, a

complementary thermal and mechanical

characterization of the recycled resin is performed

to provide a comparison with polyethylene glycol-

modified (PETG) material. Their results show the

importance of the drying parameters, which are

adequate for the extrusion and the sensitivity of the

material.

In another paper, [17], the quality control of

products and its importance in food industries are

described, where additional safety standards are

required. Many production processes can be

controlled completely contact-free using machine

vision cameras and advanced imaging. The

advantages of these techniques are fast performance

and robustness in complicated classification

applications. This paper shows a novel data

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preprocessing method using a convolutional neural

network (CNN) for quality control of polyethylene

terephthalate (PET) products in bottle caps. In the

results, a five-fold reduction in the prediction and

training time is obtained in comparison.

In the context of recycling, there are papers, [18],

[19], where it is stated that microplastic particles,

produced by non-degradable waste from plastic

bottles, have an impact on the environment. In this

paper, a multi-scale feature fusion method for

hyperspectral imaging is shown by segmenting

objects by location, using sensor fusion to identify

transparent polyethylene terephthalate (PET). A

near-infrared (NIR) hyperspectral camera is used to

obtain RGB and hyperspectral images. In addition, a

band selection stage that reduces dimensionality is

implemented, ensuring that the proposed fusion

method improves the precision in the classification

of plastic bottles.

On the other hand, due to the importance of the

implementation of printed circuit boards (PCBs), it

contributes to carrying out the integration process

with electronic circuits for temperature, humidity,

and lighting monitoring functions as described in

[20]. The paper discloses the development of a

prototype temperature meter and 2 other

environmental conditions. For this, the authors

designed the schematic of an electronic circuit that

can carry out the census functions of some

environmental conditions with an Arduino

microcontroller that serves as a data processor.

In contrast, the main contribution of this

research, the previously mentioned articles highlight

the importance of educating consumers about

recycling plastic bottles for 3D printing,

incorporating methods such as washing, cutting,

shredding, and extrusion processes to produce PET

filaments. In addition, they present the development

of extrusion machines that emphasize the

remarkable robustness of PET-based filaments. In

contrast, this research provides a comprehensive

low-cost plastic bottle processing system focused on

obtaining polyethylene terephthalate filaments for

application in 3D printers, highlighting the original

procedures and process optimization.

3 Polymers and Plastic Melters

3.1 Thermoplastic Polymers

A polymer is a large molecule made up of repetitive

chains of simple chemical units such as monomers

(Carbon atom as the fundamental element).

Normally these polymers are made up of thousands

of monomers to form plastic materials or tissues of

living beings, [21]. Table 1 shows some examples of

polymers with their respective monomer with which

it was formed.

Thermoplastic polymers are a type of plastic that

can be molded at high temperatures and solidified

when cooled. In addition, due to its interaction with

heat, it is easier to be recycled, [22].Thermoplastics

chemically deteriorate if they are heated and cooled

continuously since the polymers, which make up the

thermoplastic, are susceptible to thermal aging, [21].

In industry worldwide, thermoplastics replace

materials such as metals and glass due to the

versatility and ease with which they can be

manufactured. Among the types of polymers, we

have:

• Polylactic Acid (PLA). It is characterized by

being biodegradable since it comes from

renewable organic sources (corn starch, sugar

cane). These are produced from a lower

consumption of fossil resources unlike other

polymers, [23].

• Acrylonitrile Butadiene Styrene (ABS). Made

up of monomers and have better mechanical and

thermal properties than others, [24].

• Polyethylene terephthalate (PET). It is a

polymer that belongs to the family of polyesters

and is derived from petroleum raw materials. It

is a material like glass and the materials

obtained with PET are characterized by being

hard but the resistance to bending decreases

with increasing temperature.

3.2 Plastic Melting System

A plastic melting system is a set of processes and

equipment that melts and mixes plastic materials

into a molten state, used in applications such as

injection molding, extrusion, and 3D printing.

Through heat and pressure, plastics become

malleable and can be molded into different shapes

and final products according to specific techniques

such as injection molding, extrusion, and 3D

printing.

i) Thermoplastic casting. There are different

types of processes for obtaining plastics such as

extrusion, coating, injection molding,

thermoforming, and casting, among others. These

processes have great commercial and technological

importance due to the materials that are obtained as

a product. In the last 50 years, the applications of

plastics have increased considerably and an example

of this is the replacement of glass containers with

plastic containers or bottles, [21]. There are several

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reasons why plastic-obtaining processes are carried

out: Ease that polymers must obtain an immense

number of plastic parts, Less energy is required to

produce products from plastics compared to metals,

and plastic-obtaining processes are one-step

operations.

ii) Temperature control. There are several units

for a temperature control system and among them

we have: the power supply unit (system power),

sensor unit (detects the temperature), display unit

(shows the temperature status), and control unit.

control. This last unit processes the information so

that the system produces an action either to increase

or decrease the temperature, [25]. Among some

control methods, we have thermostats (Figure 1),

thermistors, and PID control.

Fig. 1: bimetal thermostat, [26]

iii) Plastic Extrusion. Is one of the many basic

processes for the formation of different types of

materials (metallic or ceramic such as polymers). In

general, extrusion compresses a material, in which

the result flows through an orifice, producing a

product whose size depends on the shape of the

orifice, [27]. Figure 2 shows the extrusion process

of a solid-state polymer with a specific thickness.

Fig. 2: Extrusion process for polymers, [27]

4 Proposed System

The methodological research process for the

development of the system is innovative because it

presents a proposed system to transform plastic

bottles into PET filaments for 3D printing, focusing

on automation through a PCB that controls sensors,

actuators, and low cost. The distinctive feature lies

in the integration of a structural design that houses

the electronics and mechanical parts to coordinate

the collection of material.

Its main base is the development of a printed

circuit board (PCB). This PCB will oversee

automating the process for obtaining the filament

and this will be achieved thanks to the control of

sensors, actuators, and peripherals. To contain all

the electronics, the design of structural parts that

build the body of the machine is carried out, and

mechanical parts are designed that work together

with the peripherals that carry out the filament

collection process.

4.1 Stages of System

The proposed system is composed of the

following stages (Figure 3):

• First stage: Cutting and Segmentation of plastic

bottles. Plastic bottles can be cut manually or

with assistance.

• Second stage: Casting and Extrusion. oversees

the casting and extrusion of the plastic threads

obtained from the previous stage.

• Third stage: Filament collection. It consists of

the extraction of the material both to be cut and

to be extruded. This stage is also responsible for

storing the filaments for 3D printing. For this, a

NEMA17-1.5 A stepper motor (PAP) is used,

due to the precision for positioning and speed

control, the torque with which it works, the

weight, dimensions, and the price (Table 1).

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Fig. 3: Block diagram for the system

Table 1. Comparison of three PAP engines

Motor PAP

stepper NEMA

17 1.5 A

Motor PAP

stepper

NEMA 23

1.5A

Motor

Johnson

Electric, 12

Cost S/. 25 S/. 100 S/. 65

Nominal

voltage

4.8 V 4.8 V 12 v

Nominal

current

1.5 A 1.5 A Not indicate

Torque 0.55 N.m 0.7 N.m 0.05 N.m

Weight 350 grams 700 grams 25 grams

4.2 Process Control

The machine to be implemented contains 3 stages

(cutting, casting, and harvesting). A process control

is carried out for monitoring, temperature control,

and the PAP motor. This integrates all the electronic

components, microcontrollers, and drivers necessary

for the control of the necessary processes of the

stages:

• Electronic card design. Controls the foundry

stage and the collection of the designed

machine. It is made up of: Power supply.

Engine control phase. Finally, the temperature

control phase of the casting

• Processing with a microcontroller (Figure 4).

• Calculations of the track widths of the PCB.

Techniques applied for thermal relief.

• Techniques applied for thermal relief in the

PCB.

• Implementation and integration of the PCB.

Using Altium Designer software. Figure 5

shows a 3D view of the integrated PCB with all

the electronic components.

Figure 6 represents the physical part of the PCB

with the necessary symbols to position the

electronic components in the correct place.

4.3 Development of the Pieces

The design and obtaining of the mechanical and

structural parts are shown. To do this, the following

steps are performed:

• 3D design of the pieces. Structural pieces,

which support and coverage to the different

sections of the machine. Figure 7 shows the part

called the Main Base, which contains all the

electronics and devices inside. The front section

of this piece is where printed buttons were

placed to be able to configure and display the

information.

• 3D printing and post-processing. All the designs

were exported in STL format to be able to

proceed with the 3D printing of the pieces.

4.4 Assembly and Integration

• After 3D printing and post-processing of all the

parts, the assembly, and integration of devices

were carried out to complete the development of

the foundry machine. In Figure 8, you can see

all the 3D-printed parts and accessories (screws,

filming, metal supports, etc.). While in Figure 9,

the total of all the electronics used (PCB,

sensors, and actuators) is presented.

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Fig. 4: Design stages

Fig. 5: 3D simulation view of the PCB

Fig. 6: Implementation of the PCB

Fig. 7: Main base

Fig. 8: 3D printed parts and accessories of the

foundry machine

Fig. 9: Electronics used in the foundry machine

With the electronics assembled, the filament

collection system is placed. Subsequently, the gears

are placed, both the Pinion and the gear (Figure 10).

The view of the foundry machine has the piece Belt

Aligner on the left side.

5 Results

5.1 Foundry Machine

To conduct the tests, the machine is first prepared,

connecting the power supply to the machine. The

plastic tape was prepared by feeding it through the

tape aligner piece. Once the connections were made,

the machine was turned on. A green LED is the

indicator that the machine is on and working

properly. Values are shown on the 7-segment

display, as can be seen in Figure 11.

5.2 Performance Evaluation

For the evaluation of performance, an exhaustive

analysis of each of the three fundamental stages of

the casting process of the machine is carried out.

This verification was carried out through a series of

meticulous specific evaluations at each stage of the

casting machine process. Multiple replicate tests

were performed under controlled conditions to

ensure consistency and reliability of results. In

addition, through visual observations, the filaments

produced in each stage were evaluated.

Fig. 10: Assembled foundry machine

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Fig. 11: Starting the casting machine

Each of the 3 stages of the foundry machine is

analyzed. To do this, at each stage an evaluation of

its operation is carried out to analyze its behavior as

described below:

• First stage: The system uses a wound tape

obtained from the bottle (Figure 12).

• Evaluation of the Second stage: foundry and

Extrusion. A temperature value close to the

melting point of the PETG material (265°) was

entered (Figure 13).

• Evaluation of the Third stage: Collection of

filaments. A section of the material is placed at

the tip of the spool, which will collect the

filament.

5.3 Analysis of the Filament Obtained

The shape of the filament and its consistency were

verified. The filament obtained maintains a

cylindrical shape, while the consistency is resistant

and flexible. These characteristics have been

equated to a commercial filament (Figure 14) where,

on the left side, there is commercial filament while

on the right side is the filament obtained by the

foundry machine. The diameter of the material was

measured with a digital vernier. The diameter

obtained is 1.7mm, although this is an approximate

value because the instrument only has 1 decimal

place. The value of the diameter is related to the

speed of extraction of the filament from the machine

and the faster this action is performed; the filament

tends to be thinner.

In addition to shape and diameter, Figure 14

reveals other key aspects of the filament produced

by the casting machine. The robust and flexible

consistency of the filament is evident in the image,

suggesting adequate homogeneity in the distribution

of the molten material during the extrusion process.

A uniform surface free of irregularities in the

filament is also observed, indicating a coherent

extrusion and an effective control of the process

conditions.

Fig. 12: Collection of the tape obtained

Fig. 13: Filament foundry process

Fig. 14: Comparison of shape and consistency with

a commercial filament

6 Conclusions

An essential achievement of the system lies in the

incorporation of a sophisticated electronic card,

meticulously designed for the integral automation of

all the stages and operations related to the casting

machine. The careful planning of the phases of

cutting, casting, extrusion, and collection of

filaments by segments generates an advanced level

of specialization and optimization of their respective

functions.

Highlighting the electronics, it displays its

functionality by processing the temperature data

captured by the sensors in real-time, exercising

crucial control over the quality of the PET filaments

obtained in the casting process. The execution of

control algorithms allows the supervision,

regulation, and display of the temperature. This

control, anchored in a closed-loop system,

culminates in an amplified level of performance and

quality.

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The design and manufacture of mechanical and

structural parts are integrated into the process of

generating PET filaments from plastic bottles,

which provide protection, support, and structuring

of the different stages of the machine. The quality of

these filaments was verified by comparing them

with another commercial filament through 3D

printing of the same piece. The results show a visual

understanding of filament quality, supported by

precise measurements, thus cementing the

effectiveness and viability of the casting system in

producing high-quality filament.

In future research, new process control and

monitoring strategies could be explored, such as

more advanced programming algorithms for the

closed-loop system, which allow more precise

control of temperature and other parameters. These

improvements would contribute to the reduction of

contamination by PET plastic bottles.

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