Turning Plastic Waste into Opportunity: A Small-Scale Recycling Solution in Bali
A small-scale recycling project in Bali exploring the Precious Plastic Injection Machine to transform plastic waste into marketable products, empowering local communities.
Project types:
Context
product Development
Client:
Kopernik, Bali
Year:
2018
Tools
Injection Machine, Fusion 360, Adobe
Recognition
Background
Bali faces a significant waste management challenge, with plastic waste being one of the most pressing issues. While numerous private and public organizations are implementing various waste disposal models, there is still a need for accessible, small-scale solutions that empower local communities.
In collaboration with Kopernik, this project explores the potential of low-cost, small-scale plastic recycling technology. Our focus is on testing the Precious Plastic Injection Machine, an open-source recycling system designed by Dutch product designer Dave Hakkens. This machine enables individuals and communities worldwide to transform plastic waste into valuable products, providing both an environmental and economic opportunity.
As a product designer, my role in this project was to develop market-driven, feasible products that could be manufactured using the Precious Plastic machine. By aligning product ideas with local market demand and ensuring practical production methods, we aimed to create a sustainable, community-based recycling model that turns waste into new opportunities.
Approach
Our approach followed a structured market research framework, incorporating:
Observation & Definition – Understanding market needs and user behaviors.
Ideation & Prototyping – Generating product ideas and creating rapid prototypes.
User Testing – Conducting qualitative research (in-depth interviews, focus groups) to refine designs.
Market Validation – Using quantitative methods to assess consumer reactions and product feasibility.
The insights were then translated into potential business models, leading to design requirements, concept development, 3D modeling, and production feasibility tests. Finally, user testing with behavioral, attitudinal, and classification data provided valuable feedback for future design iterations.
Insights
The Recycling Trend
With increasing eco-awareness, plastic is being redefined from a disposable material to a valuable resource through innovative sourcing and experimental manufacturing techniques. According to Stylus, an innovation research and trend firm, companies are shifting towards collaborative alternatives to virgin petroleum-based plastic, reducing environmental impact while driving innovation.
Stylus highlights three key trends:
Process-Driven Products – Advances in 3D printing and experimental casting are pushing plastic manufacturing to new frontiers.
Sustainable Innovation – Businesses adopting alternative plastic solutions are gaining recognition for their eco-friendly efforts.
Refined Aesthetic – Once overlooked, plastic products are now designed with sophisticated finishes, subtle color palettes, and combinations with natural materials, enhancing their appeal.
This evolution in plastic recycling is paving the way for a more sustainable and design-forward future.
Precious Plastic in Indonesia
Since the rise of Dave Hakkens’ Precious Plastic project in Indonesia, many individuals and communities have refined and adapted his open-source plastic recycling machines. Hakkens’ blueprints are freely available, allowing anyone to establish their own plastic recycling workshop.
The project features four core machines:
Shredder – Breaks plastic into smaller pieces.
Extrusion Machine – Creates long plastic filaments.
Injection Machine – Molds plastic into new products.
Compressor – Produces larger, more solid objects.
These machines, built using locally sourced materials, cost between €120-192 ($133-213) each, making them affordable and accessible. As a pioneering open-source initiative, Precious Plastic fosters creativity, shared knowledge, and community-driven solutions, empowering local changemakers to reduce pollution, educate others, and drive global-local impact.
Design Challenge
We identified plastic waste recycling in Indonesia as an emerging market with limited competition and untapped product opportunities. To address the key challenge—"Who needs plastic waste products?"—we conducted exploratory research.
Result
After going through countless challenges, failures, and refinements, we gained valuable insights throughout the process. Early trials were met with setbacks, revealing the machine’s limitations and areas for improvement in both the process and technology.
Through persistent trial and error, we successfully produced a product using the machine—one that featured a unique, gemstone-like pattern. While our initial goal was to develop six different products, we ultimately focused on two designs, ensuring quality and feasibility. Despite the hurdles, this achievement marked a significant milestone in transforming plastic waste into valuable products.
Reflection
(and feedback)
Challenges & Considerations
Throughout the project, we encountered several limitations in resource collection (plastic waste) and the mold-making process. Key challenges included:
Size limitations – Constraints in product dimensions due to machine capacity.
CNC machine limitations – Restrictions on precision and complexity in mold fabrication.
Plastic waste variability – Inconsistent material quality, including color variations.
Melting temperature differences – Different plastics require specific processing conditions.
Resource availability – Difficulty in sourcing suitable plastic waste and mold materials.
Machine operation – Ensuring proper usage and maintenance for optimal performance.
These factors influenced our design and production decisions, requiring careful adaptation to maximize feasibility and product quality.