Plastic

Plastic Pipeline

Our pipeline begins at the three major campsites in the Simien Mountains National Park, where we will install designated receptacles for plastic bottle collection in collaboration with the Ethiopian Wildlife Conservation Authority. Park authorities will transport the receptacles, once full, to the recycling workshop at Debark University. Workshop employees and volunteers will clean the plastic and feed the bottles into the shredder, which pelletizes bottles into small shards. These shards will then be fed into the injection molder, which melts the shards with heat and injects the liquified plastic into one of a set of pre-fabricated molds, each of which renders a different product. Local residents in Debark will be able to buy the products at a low price, customize the products by adding paint, magnets, hooks, or other alterations, and will sell the final customized products to tourists for a profit.

Products

Despite its status as a UNESCO World Heritage Site and one of Ethiopia’s most visited tourist attractions, there are virtually no souvenirs for sale in the areas surrounding the park. Our student team has worked with community members in Debark, the gateway town for visiting the Simien Mountains, to design items that capture unique elements of the local flora and fauna. We have designed an additional suite of children’s toys that can be made for sale in the local market– another open niche that will have a positive impact on the lives of people living in and around the Simien Mountains.

While PET plastic is the most ubiquitous form of plastic, it is also among the most difficult forms to work with. The chemical and physical limitations of PET plastic constrain the type of items that we can produce; for example, making recycled PET plastic food-grade requires an additional cost-prohibitive step. However, as our project expands and we aim to scale up, we intend to incorporate the production of food-grade items (e.g., plates, bowls, and cups to be sold in local markets) made from recycled plastic bottles.

Collection

Despite its status as a UNESCO World Heritage Site and one of Ethiopia’s most visited tourist attractions, there are virtually no souvenirs for sale in the areas surrounding the park. Our student team has worked with community members in Debark, the gateway town for visiting the Simien Mountains, to design items that capture unique elements of the local flora and fauna. We have designed an additional suite of children’s toys that can be made for sale in the local market– another open niche that will have a positive impact on the lives of people living in and around the Simien Mountains.

While PET plastic is the most ubiquitous form of plastic, it is also among the most difficult forms to work with. The chemical and physical limitations of PET plastic constrain the type of items that we can produce; for example, making recycled PET plastic food-grade requires an additional cost-prohibitive step. However, as our project expands and we aim to scale up, we intend to incorporate the production of food-grade items (e.g., plates, bowls, and cups to be sold in local markets) made from recycled plastic bottles.

Shredding

Once plastics are collected and transported to the recycling workshop, they are sorted, cleaned, and sent through the plastic shredder. The plastic shredder is based off of the open source plans from Precious Plastic, and consists of a 3hp (2.2kw) motor, a 30:1 gearbox, and a shredding box made from high-strength steel. Plastics are loaded into the machine via a hopper with a 36 in² (232 cm²) throat into the 13 spinning blades, and are shredded with varying sizes between ¼ in to 1in. Subsequent passes through the shredder guarantee a more uniform flake of around ¼ in. These flakes are then loaded into the injection molding machine.

Injection Molding

The injection molding machine heats the flaked plastic and pushes it into a mold under high pressure. The machine is simple in concept, but with a variety of molds, it can accommodate hundreds of different end products.

A steel barrel (~1in in diameter) is heated by six electrical band heaters. Once the barrel reaches the plastic melting point (>200 ℃), the plastic is held for 10 minutes to allow a uniform melt. A human-powered metal plunger is used to press the molten plastic into a metal mold attached to the base of the barrel, which settles the product's shape. The two-part mold and plastic are allowed to cool, after which the product is removed and the process repeated to create additional products.

Product Sales & Marketing

Our project aims to cultivate an alternate revenue stream in the areas surrounding the Simien Mountains National Park in order to increase the number of people that can profit from tourism, which is currently limited in a saturated market of tour guides and ancillary workers. Anyone in the surrounding communities will be able to purchase items from our workshop in bulk at a low cost, customize the items, and sell them at a profit to tourists.

We will work closely with the Ethiopian Wildlife Conservation Authority and local tour operators to promote people and businesses selling these goods to visitors.