Szymon Berdak – an integrated line for processing plastic waste

In an era of rising ecological awareness and growing emphasis on sustainable development, innovations that address plastic waste management are more important than ever. Industry increasingly faces the challenge of reducing waste and using resources efficiently. The solution proposed by our guest today – Szymon Berdak, a student at the Lublin Centre for Vocational and Continuing Education (LCKZiU) – holds promising practical potential not only for everyday life, but also for businesses and industrial facilities generating large quantities of plastic waste.

Projects like this one show that innovation can go hand-in-hand with care for the planet, offering real solutions for both industry and local communities – read on to find out more!

Where did your interest in technology come from?

I’ve been interested in technology  – especially electronics, mechanics, and machine construction  – since I was a child. It all started with taking apart broken electronic devices to see what was inside. Not long after, my father gave me an Arduino microcontroller board, and I started building my own small, simple circuits. The knowledge I gained during the first months of technical school allowed me to move on to more advanced projects.

What was your first technical project?

At first, my projects were quite simple  – based on the Arduino board with very basic programs, usually involving a few LEDs or simple sensors. My first more advanced project was a power supply with adjustable output current and voltage. It could be used to test individual electronic components or power prototypes.

Tell us about your main completed project.

The final version of the project is designed as a full processing line. It starts with a shredder for plastic waste, which breaks the material into small pieces. These are then transported to a washing and drying station to remove contaminants and dry the plastic as thoroughly as possible. At the end of the line, there’s an automated injection moulding machine that melts the plastic and injects it into any desired mould. The end product can be virtually anything  – provided the right mould has been made in advance. The plastic would most likely be transported between stages via air tunnels.

Currently, the shredder has been completed, and we have a manually operated injection moulding machine that will be adapted and upgraded to become part of the automated version.

Which stage of building the solution was the most difficult, and why?

The biggest challenge is always making the metal components  – mainly because achieving precise and complex parts is very time-consuming. Sometimes, it takes multiple machines (a lathe, CNC milling machine, surface grinder) just to produce a single part. I worked on these components together with my teammates and some of the teachers in our school’s workshops.

How did work on each stage of the project progress?

Originally, the injection moulding machine was a group project involving four people. I was the main originator, so I designed it in CAD software and supervised each stage of the build. The shredder was mostly handled by one of my teammates. Structurally, it’s simpler, but making it work required getting a CNC plasma cutter back into working order first. We worked on the project outside of class time  – sometimes on weekends or even during the holidays.

In your opinion, what’s most important when carrying out an innovative technical project? What skills are key to making it a success?

In my view, the most important thing is creating a detailed design in the right software and researching all the components to make sure everything fits and works together. Experience from smaller projects is helpful, and if you don’t have the necessary knowledge in a certain area, it’s important to get support from teachers or even university lecturers. The internet and modern AI tools are also extremely helpful.

These days, ecology and sustainable development are often cited as essential to business growth. Do you think your solution could be realistically implemented in companies?

I think similar solutions  – or at least parts of this kind of line  – could be implemented in some businesses or industrial plants that generate significant amounts of plastic waste. Even just the shredding stage brings benefits by reducing the volume of waste for transport. One company that collaborates with my school wanted a similar device built for that very purpose. Some facilities could also make use of the injection moulding machine to produce small components for the production line or office use.

You mentioned that the project was built in the school’s workshops. Do you think that equipment is sufficient for students who want to explore their technical interests more deeply?

The workshops in my school are well-equipped in terms of machine variety, but many are outdated and don’t offer the precision of newer models. Wear and tear also makes them harder to use. As for the electronics lab, the equipment is quite modern, though a few devices for more advanced testing are still missing.

Are you working on any other projects right now? Tell us more.

My newest project is a racing game steering wheel setup, complete with a gear stick and pedals. Among my earlier builds, the Tesla coil definitely stands out  – it can generate high-voltage discharges from 400 kV up to 1 MV. I’m also working on an electric-assist bicycle, but I’ll continue testing it after winter.

If you could name one external factor that would make your work easier, what would it be?

In my opinion, the biggest barrier for young inventors is funding. There are very few programs offering financial support, and if you want to build something independently (without entering a competition), the only real option is cooperation with companies. I think the city could help by organising contests where the most talented students receive funding to complete their projects.

Are local Lublin companies open to working with young talent?

I’m currently helping a friend with a robotic arm project, which is being supported by two companies from Lublin. So it is possible to get that kind of backing  – but unfortunately, not every project has the chance. If a company doesn’t see a direct benefit, the project might not get support  – even if the idea itself is strong.

Do you feel the knowledge and skills you’re gaining in school meet the expectations of employers? What was your experience?

Yes  – during my internship, the skills I learned in school proved very useful in understanding machine construction and performing equipment repairs. I also worked with industrial PLC controllers, which I only got to know in more detail later on.

How would you rate your internship experience with Lublin-based companies?

Very positively. I got to see what it’s like to work in a production plant’s maintenance department, solving everyday machine issues and carrying out maintenance. I also learned more about electric motor manufacturing and how the entire production line operates.

Thank you for the conversation  – and we’re rooting for your continued success!