Plastic press, The flipflopi project
We developed a recycling solution for plastic woven bags in Lamu, Kenya, where their film-like material caused issues at nearly every recycling stage. The bags were difficult to clean, clogged shredders, and trapped air in extruded beams. Using a simplified sheet press, we produced solid sheets as a proof of concept and explored scaling the process for full-sized panels. Working in an unfamiliar environment, we stayed flexible, listened closely to locals, and relied on visuals when words fell short.
The problem
Plastic woven bags (Gunia) are very difficult to recycle due to their blend of different types of plastics and it's filmy material, clogging machines. The bags des-integrates fast into microplastics under the African sun.
In addition to that, there is almost no waste management system in Kenya, leading people to burn, bury, or discard trash anywhere. This requires many local and customized solutions, making interventions challenging to implement.
Blend of different plastic types
Filmy material, clogs machines
Des-integrate fast
Dirty
No waste management system
The in-between solution
Currently àgglomeration is necessary before shredding to get the bags to more handalable sizes. However it is noisy, dusty, and requires skilled operators. Output from the agglomerator often have air pockets, reducing quality and blending all colours to one, unaapealing colour.
Possible to process
Cheap
Unpleasant work
Does not preseve color
Air pockets
Proof of concept
By removing steps from the production process and directly press the bags in a sheetpress a lot of struggles could be skipped and the colour of the plastic could be maintained. To test this we made a press from locally available materials. Next to developing a physical solution and proof of concept, our task was to analyze Flipflopi's work as an outsider and map out what exactly they were doing and where gaps existed. This involved much more systemic and stakeholder thinking. To provide Flipflopi with a clear overview, we mapped out different scenarios.
We envision a scaled up sheet press featuring a preparation stage, hot press, and cold press stages. Ideally it t produces 1 x2.2m sheets using 34kg of gunia, costing €12.40 each, improving recycling and efficiency. The prototypes and final design had to utilize local resources and be maintainable with the skills and interests of the local community, ensuring sustainability and long-term usability. There is a big difference between the hard plastics and the soft plastic bags in a sheetpress. Due to the big volume we concluded that flanges are necesairy to keep the gunia in its place during the first stage of the heating process.
Vil du lære mer?
Because of the positive results and the proof of concept, the FlipFlopi project proceeded to continue and actually fabricate a full scale press. This press is now in use. Look at those beautiful colourfull sheets!
