Recycled Plastic Film Batching for Contamination-Controlled Extrusion
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Solution Overview
Problem
Existing plastic recycling processes lack real-time monitoring and automation for quality control, leading to inefficiencies and human error, which affects product quality and customer satisfaction, especially in the extrusion of recycled plastic films.
Innovation Solution
A method and system for determining the level of contamination in recycled plastic using analytical techniques like GC-MS and FTIR, combined with automated batching systems, to optimize the ratio of virgin and recycled plastic in the extrusion process, ensuring high product quality and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual quality control inspection is used in the recycling process, then operational flexibility is maintained, but productivity is reduced and human error increases
Solution Approach 1:
The patent replaces manual visual inspection with automated optical detection systems including cameras and image processing algorithms. The system captures images of recycled plastic materials and automatically analyzes them for contamination, defects, and quality parameters, eliminating the need for manual inspection while improving both productivity and accuracy.
Solution Approach 2:
The system enables self-inspection of recycled materials through automated image capture and analysis. The inspection system independently evaluates material quality without human intervention, making the process self-sufficient and eliminating dependency on manual labor for quality control.
2Manufacturing precision
If real-time monitoring and automated batching systems are implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system integrates multiple functions into a single automated platform that combines image capture, image processing, contamination detection, quality assessment, and batching control. This multi-functional approach improves manufacturing precision while managing device complexity by consolidating operations rather than adding separate systems.
Solution Approach 2:
The system implements real-time feedback loops where image analysis results immediately inform batching decisions and process adjustments. The automated system continuously monitors material quality and adjusts parameters accordingly, improving precision through dynamic control while the integrated feedback mechanism manages complexity through systematic information flow.
3Measurement precision
If comprehensive analytical techniques like GC-MS and FTIR are used for contamination detection, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The system applies a two-stage inspection approach: first using rapid optical imaging for initial quality assessment and obvious defect detection, then applying sophisticated analytical techniques like GC-MS and FTIR only when needed for specific contamination cases. This partial application of comprehensive analysis maintains measurement precision for critical cases while reducing overall inspection time through selective detailed analysis.
Solution Approach 2:
The system performs preliminary screening using fast optical detection methods before committing to time-consuming analytical techniques. By pre-identifying materials that require detailed analysis and filtering out those that don't, the system maintains high measurement precision for problematic cases while minimizing time loss through early elimination of materials needing extensive testing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides real-time quality control, reduces human error, and ensures consistent product quality by automating the identification and correction of defects, maximizing the use of recycled materials while meeting regulatory standards.
Implementation Method 1
gas chromatography (GC-MS)
Implementation Method 2
gas chromatography (GC-MS)
Implementation Method 3
liquid chromatography (LC-MS)
Implementation Method 4
liquid chromatography (LC-MS)
Implementation Method 5
thermogravimetric analyses such as TGA
Implementation Method 6
thermogravimetric analyses such as TGA, DSC
Implementation Method 7
spectroscopic techniques such as FTIR
Data Source
Figure 1
Figure 2
Figure 3.1
AI summary
The method comprises determining the level of contamination, in a particular embodiment, by sequentially executing the following steps: (a) characterizing the recycled input material; (b) calculating the level of contamination (LC) from the characterization data of the material and/or images; and (c) calculating the percentage of recycled material to be introduced into the batching system of a plastic material extruder; and wherein image capturing may be performed, for the manufacture of a recycled plastic film with a known LC.