Introduction:

A 20mm paper cup crusher and waste compactor is an automated mechanical system designed to crush, flatten, and reduce the volume of used or defective 20mm paper cups and small beverage containers. Built using a low-cost motorized drive mechanism or manual lever compression, it transforms bulky cup waste into flattened profiles to optimize storage space. It serves as an accessible mechanical engineering project for exploring basic structural design, cost-effective power transmission, and low-budget prototyping under ₹6,000.

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EXISTING SOLUTIONS & LITERATURE REVIEW

1. Dedicated Paper Cup Wastage Crusher System

Description: This video demonstrates a compact machine built specifically for paper cup waste processing, showing how hollow disposable containers are crushed and compacted into smaller fragments to save storage space.

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2. Low-Cost Wiper Motor & Small DC Motor Setup

Description: This setup illustrates how repurposing affordable small DC motors or drill attachments can provide sufficient rotational force for light-duty crushing applications on a budget.

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3. Compact Cup Shredding Mechanism Layout

Description: A specialized machine layout built for handling small disposable beverage cups and board scrap, minimizing space requirements efficiently using economic components.

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4. CAD Modeling & Structure Planning

Description: A technical walkthrough using 3D modeling tools to plan out compact frames, guide plates, and clearance gaps tailored for small cups.

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5. Budget Prototype Integration

Description: A complete project integration showing the fabrication of side plates, housing frames, and drive assemblies using cost-effective scrap metals and basic workshop tools.

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Complete Bill of Materials (BOM) & Budget Estimate: 20mm Paper Cup Crusher Project (Under ₹6,000)

1. Electrical & Electronic Components

Sr. No.	Component Description	Specifications / Model	Qty	Unit Price (INR)	Total Cost
1	Standard DC Geared Motor	12V, 30–60 RPM High Torque	1	₹1,200	₹1,200
2	Power Supply Adapter	12V 5A SMPS Power Supply	1	₹350	₹350
3	Control Switch & Rocker Switch Panel	SPST On/Off Toggle Switch	1 Set	₹100	₹100
4	Connecting Wires & Heat Shrink Tubes	Copper Core, 1.5 sq mm	1 Set	₹150	₹150
Subtotal					₹1,800

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2. Mechanical & Structural Components

Sr. No.	Component Description	Specifications / Model	Qty	Unit Price (INR)	Total Cost
1	Custom 20mm Pitch Crushing Rollers / Press Plate	Mild Steel / Aluminum Stock	1 Set	₹1,100	₹1,100
2	Hardened Mild Steel Drive Shafts	10mm–12mm Diameter Rods	2	₹300	₹600
3	Ball Bearings with Pillow Block Mounts	UCP000 / KP08 Type	4	₹125	₹500
4	Feed Chute & Collection Tray Housing	Galvanized Sheet Metal / Acrylic	1 Set	₹500	₹500
5	Structural Frame & Support Chassis	Mild Steel Angle Iron (1 inch)	1 Set	₹800	₹800