Diseño, construcción y evaluación experimental de un prototipo de trituradora de botellas de vidrio para procesos de reciclaje

Abstract

This technical project presents the design, construction, and experimental evaluation of a hammer type glass bottle crusher prototype aimed at supporting small and medium scale recycling operations. Given the critically low glass recycling rates across Latin America, a cost-effective mechanical solution was developed to reduce glass bottles into cullet with an average particle size of 4.77 mm. The crushing power was calculated using Bond's method, which determined the need for a 3 HP electric motor running at 1800 rpm with a nominal torque of 11.86 N·m. Key mechanical components including shafts, hammers, discs, and a belt driven transmission system were analytically dimensioned and validated through SolidWorks finite element simulations using Von Mises stress, displacement, and safety factor criteria. Material selection was technically driven: A36 steel with INDURA Overlay 60 abrasion-resistant coating for hammers, AISI 4340 steel for the secondary shaft, and AISI 1018 for the primary shaft. Experimental testing confirmed continuous operation over 8-hour shifts without jamming or motor overheating. Granulometric analysis showed that 70% of the crushed output met the target aperture of 4.77 mm, demonstrating effective size reduction for recycling applications. The resulting prototype is portable, economically viable, and easy to maintain, representing a practical solution for decentralized glass waste processing.