Fabrication of Spool using Plastic Waste

Plastic waste is one of the most significant environmental challenges worldwide, with large quantities generated annually and only a small percentage being recycled effectively. In India, improper disposal and inadequate waste management have resulted in serious environmental pollution, affecting landfills, water bodies, and ecosystems. Recycling-based manufacturing offers a sustainable solution by converting waste materials into useful industrial products. Spools are widely used in applications such as 3D printing, textile winding, and electrical cable management; however, they are typically manufactured from virgin plastics, increasing production costs and environmental impact. This project focuses on the fabrication of spools using recycled Polyethylene Terephthalate (PET) through an extrusion-based process. The methodology includes the collection, cleaning, shredding, drying, extrusion, cooling, and assembly of PET waste into functional spool components. CAD modeling is employed to design spools with adequate strength, balance, and dimensional accuracy. Extrusion system components and process parameters are carefully selected to ensure a consistent material flow and high-quality products. The project aims to demonstrate a cost-effective and environmentally sustainable approach to utilizing PET waste, reducing plastic pollution, lowering manufacturing costs, and supporting circular economy practices.