Recycling of Plastic into Fibers Using a Novel Machine Design and Analysis of Fiber Characteristics

Mahmoud Khamees, Production Technology Department, Faculty of Technology and Education, Capital University (Helwan, formerly), Saraya El Koba, El Sawah Street, Cairo 11281, Egypt.
Nasser Ayoub, Production Technology Department, Faculty of Technology and Education, Capital University (Helwan, formerly), Saraya El Koba, El Sawah Street, Cairo 11281, Egypt.
Sabreen Addullah Abdelwahab, Production Technology Department, Faculty of Technology and Education, Capital University (Helwan, formerly), Saraya El Koba, El Sawah Street, Cairo 11281, Egypt.
M. M. Maghawry, Production Technology Department, Faculty of Technology and Education, Capital University (Helwan, formerly), Saraya El Koba, El Sawah Street, Cairo 11281, EgyptFollow

Corresponding Author

M. M. Maghawry

Subject Area

Production Engineering and Mechanical Design

Article Type

Original Study

Abstract

This study presents a modified extrusion-based recycling system with an improved nozzle design and controlled fiber production capability. The machine was conceptualized and fabricated to efficiently process waste plastic and extrude it into fibers of varying diameters. The study focuses on evaluating how fiber diameter influences critical material properties. Microstructural analysis by scanning electron microscopy (SEM) was conducted to investigate the morphology and fiber diameters, while tensile testing provided insights into mechanical performance, including strength and elongation. Moisture absorption tests were also performed to assess durability and environmental resistance. The results demonstrate clear correlations between fiber diameter and the examined properties, with finer fibers exhibiting improved tensile performance and reduced moisture absorption. These findings highlight the potential of the proposed recycling approach as both an environmentally sustainable solution and a means of producing functional fibers for applications in textiles, composites, and construction materials. SEM observation shows large-diameter fibers with a fixed and uniform structure at lower bars, and with the use of a large bar up to 8 bar, the diameters are lowest with partial randomness, reflecting a compromise between structural stability and randomness. These structures at different pressures (6:8) enhance mechanical properties in terms of tensile properties, where the low strength is recorded at 6 bars and the high strength is recorded at 8 bars. In terms of humidity, fibers produced at lower pressures (6 bar) are more suitable for applications requiring dimensional stability in humid conditions, whereas higher-pressure fibers (7-8 bar) may be optimized for strength-driven applications where humidity exposure is less critical.

Keywords

Plastic recycling, Fiber production, Machine design, Fiber diameter, absorption

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 License.

Recommended Citation

Khamees, Mahmoud; Ayoub, Nasser; Abdelwahab, Sabreen Addullah; and Maghawry, M. M. (2026) "Recycling of Plastic into Fibers Using a Novel Machine Design and Analysis of Fiber Characteristics," Mansoura Engineering Journal: Vol. 51 : Iss. 6 , Article 2.
Available at: https://doi.org/10.58491/2735-4202.3492

Download