The document generally relates to a method and system for crushing fibres. More particularly the document relates to a method and system for crushing natural fibres for their use in manufacture of natural fibre reinforced thermoplastics composite.

BACKGROUND

Fibre reinforced thermal plastics are finding application in a number of fields. Generally fibre reinforced thermoplastic composites are made by adding artificial fibres such as glass fibres to plastic polymers. Use of such artificial fibres is expensive and causes environmental pollution.

Natural fibres such as jute, cotton, coconut fibres and hemp fibres can be used for reinforcing thermoplastic composites in place of artificial fibres. In order to make natural fibre reinforced thermoplastic composites, natural fibres such as jute, cotton, hemp etc are added to molten polymers in an extruder, in the desired ratio. For example a plastic compound having 40 percent by weight of fibres may be required. Natural fibres are typically available as bales having long fibre lengths, and having large specific volume. The large specific volume of such fibres, makes it very difficult to feed natural fibres into the extruder, often causing jamming or burning problems. Such difficulties are compounded when a specific feed rate of such fibres is required in the mixing operation.

Accordingly, in order to make the addition of natural fibres manageable, the length of the fibres is to be reduced. Studies have shown that fibre length of substantially 1.5 to 3mm, and preferably 2mm exhibits better end results when used for reinforcing thermoplastic composites. Traditionally the length of the fibres is reduced by either manually cutting the natural fibres, or by using bale cutting machines. However, bale cutters do not give a uniform fibre length and a subsequent sieving is required to obtain natural fibres within a specific range. Bale cutters also do not have a large capacity, and to meet the requirements of a plastic mixing process, multiple bale cutters may be required.

Therefore, there is a requirement to obtain natural fibres of desired length to enable them to be conveniently added to plastics.

SUMMARY

The invention relates to a fibre crushing system including a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore, an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres, a shaft located within each bore, each shaft configured for rotation in the same direction, and a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including a receiving zone configured for receiving and separating fibres, a crushing zone configured for crushing the fibres received from the receiving zone, and a conveying zone configured for conveying crushed fibres to the outlet.

The invention also relates to a method for crushing fibres including feeding fibres into a fibre crushing system, the fibre crushing system including a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore, an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres, a shaft located within each bore, each shaft configured for rotation in the same direction, and a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including a receiving zone configured for receiving and separating fibres, a crushing zone configured for crushing the fibres received from the receiving zone, and a conveying zone configured for conveying crushed fibres to the outlet, the method including feeding fibre into the receiving zone through the inlet of the fibre crushing system, crushing the fibres received from the receiving zone by passing them through the crushing zone, and conveying the crushed fibres received from the crushing zone to the outlet.

The invention also relates to a method for manufacturing a natural fibre reinforced thermoplastic composite including crushing the natural fibres including feeding the natural fibres into a fibre crushing system, the fibre crushing system comprising a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore, an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres, a shaft located within each bore, each shaft configured for rotation in the same direction, and a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including a receiving zone configured for receiving and separating fibres, a crushing zone configured for crushing the fibres received from the receiving zone, and a conveying zone configured for conveying crushed fibres to the outlet, the method including feeding fibre into the receiving zone through the inlet of the fibre crushing system, crushing the fibres received from the receiving zone by passing them through the crushing zone, and conveying the crushed fibres received from the crushing zone to the outlet and adding the crushed fibres received from the fibre crushing system to a thermoplastic polymer to obtain a natural fibre reinforced thermoplastic composite.

BRIEF DESCRIPTION OF ACCOMPANYING FIGURES

The accompanying drawing illustrates the preferred embodiments of the invention and together with the following detailed description serves to explain the principles of the invention.

Figure 1, illustrates a natural fibre crushing system in accordance with an embodiment.

Figure 2, illustrates a screw shaft of the fibre crushing system in accordance an embodiment.

Figure 3, illustrates a screw shaft of the fibre crushing system in accordance an alternate embodiment.

Figure 4, illustrates the fibre length distribution for a sample of a bale of jute fibres passed through the fibre crushing system.

Figure 5, is a magnified image of a sample of crushed jute fibres obtained by passing a bale of jute fibres through the fibre crushing system.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

A system and method for crushing natural fibres is disclosed. More particularly a system and method for crushing natural fibres for their use in manufacture of natural fibre reinforced thermoplastics composite is disclosed.

The fibre crushing system comprises of an inlet hopper configured to receive a fibres to be crushed, a twin screw system configured for crushing the fibre and an outlet for passing the crushed fibre from the system. The fibre crushing system comprises of a receiving zone configured for receiving and separating the fibres to be crushed fed from the inlet hopper, a crushing zone configured for crushing the fibres received from the receiving zone and a conveying zone configured for conveying the crushed fibres from the crushing zone to the outlet.

With reference to figure 1, the fibre crushing system is illustrated. The fibre crushing system comprises of a co-rotating twin screw system (10) comprising of a long barrel (12) having two parallel bores (14) that intersect each other. Two parallel shafts (16) and (18) that are both driven in the same direction are placed in the bore (14). Processing segments (20) are mounted one after the other in a continuous chain on the shaft (16) and (18) that transmits the rotary motion without slippage to the processing segments (20).

As illustrated in figure 1, 2 and 3, the fibre crushing system comprises of three regions, the receiving zone (22) configured for receiving and separating the fibres to be crushed fed from the inlet hopper (28), a crushing zone (24) configured for crushing the fibres received from the receiving zone (22) and a conveying zone (26) configured for conveying the crushed fibres from the crushing zone (24) to the outlet (30).

In the embodiment illustrated in figure 2, C0 is the receiving zone (22), C1 forms the crushing zone (24) and C2 and C3 form the conveying zone (26). The lengths of the zones may be determined based on the length and the nature of the fibres to be crushed and on the required length of the end product.

In accordance with an aspect, the length of the receiving zone (22) is in the range of 2 to 5 times the barrel diameter. The length of the crushing zone (24) is in the range of 1 to 7 times the barrel diameter and the length of the conveying zone (26) is in the range of 1 to 10 times the barrel diameter. In the embodiment illustrated in figure 2, the length of the receiving zone (22) is approximately 5 times the barrel diameter, the length of the crushing zone (24) is approximately 2 times the barrel diameter and the length of the conveying zone (26) is approximately 9 times the barrel diameter.

The processing segments (20) provided in each zone are configured for that zone. By way of a specific example, suitable available extruder elements may be provisioned in each zone.

In accordance with an aspect the processing elements (20) are twin screw extruder elements. The twin screw extruder elements may be completely intermeshing elements.

In accordance with an aspect, the receiving zone (22) is provided with processing segments (20) configured for receiving and separating the fibres to be crushed received from the inlet hopper (28) and for conveying the fibres to be crushed to the crushing zone (24). By way of specific example the processing segments (20) provided in the receiving zone (22) are extruder conveying elements.

The extruder elements that may be provided in the receiving zone (22) include but are not limited to a SchubKanten Elements or Regular Flighted Shovel element or their combination. In the embodiment illustrated in figure 2, the receiving zone (22) is provided with three SchubKanten Elements having a 90mm pitch and a 90mm length (SKE90/90). In the embodiment illustrated in figure 3, the receiving zone (22) is provided with two SKE90/90 elements.

In accordance with an aspect, the crushing zone (24) is provided with crushing elements configured for crushing natural fibres. By way of specific example, the crushing elements provided in the crushing zone (24) are extruder kneading elements.

The crushing zone (24) comprises of at least one extruder kneading element. Various known extruder kneading elements may be used in the crushing zone (22). The extruder kneading element that may be provided in the crushing zone (22) include but is not limited to right handed kneading blocks, neutral kneading blocks, left handed kneaded blocks, eccentric kneading blocks, fractional lobed kneading blocks or their combination.

In the embodiment illustrated in figure 2, the crushing zone (22) is provided with a single right handed bi-lobed kneading block having a length of 40 mm with 5 disks that are offset at 45 degree angle from each other (RKB 45/5/40) and a neutral kneading block having a length of 40mm with 5 disks that are offset at a 90 degree angle from each other.

In accordance with an aspect, the crushing zone (24) may comprise of a plurality of kneading blocks positioned such that kneading blocks are placed in alteration with other processing segments (20).

In the embodiment illustrated in figure 3, the crushing zone comprises of three right handed bi-lobed kneading block having a length of 40 mm with 5 disks that are offset at 45 degree angle from each other (RKB 45/5/40), a neutral kneading block having a length of 40mm with 5 disks that are offset at a 90 degree angle from each other (NKB 90/5/40) , a eccentric tri-lobed kneading block having 5 having a length of 40 mm with 5 disks that are offset at 45 degree angle from each other (3KB 45/5/40) and two normal bi-lobed right handed screw elements having a 90 mm pitch and a 90mm length (RSE90/90). The two RSE90/90 elements are positioned between a RKB 45/5/40, NKB 90/5/40 and 3KB 45/5/40, RKB 45/5/40 elements.

In the embodiments where SchubKanten element is provided in the receiving zone (22) the receiving zone (22) is further provided with a transition element, the transition element having a SchubKanten profile at one end and a normal profile at the other end. The transition element allows for a smooth connection between SchubKanten element and the elements having a normal or Erdmender profile in the crushing zone (24). In the embodiment illustrated in figure 2 and 3, a SchubKanten normal element having a pitch of 90 mm and a length of 45mm (SKN90/45) is provided between the SchubKanten Element in the receiving zone (22) and the right handed bi-lobed kneading block in the crushing zone (26).

The conveying zone (26) is provided with processing segments (20) configured for conveying the crushed fibre from the crushing zone (24) to the outlet (30). By way of specific example the processing segments (20) provided in the conveying zone (26) are extruder dispersive elements. The conveying zone (26) elements may also serve to separate the crushed fibres and to limit agglomeration of crushed fibres. The conveying zone (26) elements are also configured to separate the longer fibres received from the crushing zone (24) and to crush the longer fibres before conveying them to the outlet (30).

In accordance with an aspect, the processing segments (20) that may be provided in the conveying zone (26) include but are not limited to the normal bi-lobed right handed screw element, screw mixing element or their combination. In the embodiment illustrated in figure 2, the conveying zone (26) is provided with three normal bi-lobed right handed screw elements having a 90 mm pitch and a 90mm length (RSE90/90), three screw mixing elements having a 75 mm pitch and a 75 mm length (SME90/90) and one normal bi-lobed right handed screw elements having a 60 mm pitch and 60 mm length (RSE 60/60). In the embodiment illustrated in figure 3, the conveying zone (26) is provided with a RSE90/90 element, three SME 75/75 elements and a RSE 75/75 element.

A method for crushing fibres is also disclosed. The method comprises of feeding fibres to be crushed into a fibre crushing system through an inlet hopper, allowing the fibres to be crushed to pass through a receiving zone of the fibre crushing system that receives fibre to be crushed fed through the inlet hopper and crushing the fibres received from the receiving zone by passing them through a crushing zone of the fibre crushing system, configured for crushing the fibres. The crushed fibres received from the crushing zone are then conveyed to the outlet by a conveying zone. The receiving zone is configured to receive and separate the long length natural fibre strands.

In accordance with an aspect the fibres to be crushed may be fed in the fibre crushing system in the form of bale of fibres.

By way of a specific example, the bale of jute was fed into a twin screw system having a barrel diameter of 60mm, a screw diameter of 59.7mm and aDo/Diratio of 1.71, a flight depth of 12.3 mm, and a screw configuration as illustrated in figure 2. The twin screw system is run at a screw speed of 600RPM to get an output of 200Kg/hr of crushed jute fibres having length substantially in the range of 1.5 mm to 3 mm.

In accordance with an aspect, any fibre may be crushed using this method and device. Such fibres include natural fibres including but not limited to jute, cotton, hemp, flex or coconut fibres. In accordance with a preferred embodiment the fibre is jute.

In accordance with an aspect, the fibres are crushed such that the length of crushed fibres is in the range of 1 to 5mm. In accordance with a preferred embodiment the fibres are crushed such that the length of a substantial portion of fibres is less than 3 mm, and a large portion of such fibres is substantially 2mm. Figure 4, illustrates the tabulation of experimental data for a sample of a bale of jute fibres passed through the natural fibre crushing system, and analyzing the length of crushed fibres. A magnified image of a sample of crushed jute obtained by passing the bale of jute fibres through the natural fibre crushing system is illustrated in Figure 5.

However, the length of fibres may be adjusted by adjusting the configuration of the crushing zone. By use of different screw configuration the size of the crushed natural fibre achieved may be varied. By way of a specific example, smaller fibres are obtained by increasing the number of crushing elements in the crushing zone.

By way of a specific example, fibres having length less than 2 mm may be obtained by using a fibre crushing system having a configuration illustrated in figure 3. In the embodiment illustrated in figure 3 the crushing zone comprises of four crushing elements.

A process for manufacturing a natural fibre reinforced thermoplastic composite is disclosed. The process comprises of crushing the fibres to a desired length by passing fibres to be crushed through a fibre crushing system to obtain crushed fibres of desired length, the fibre crushing system comprising of a receiving zone for receiving and separating the fibres fed through the inlet hopper, a crushing zone for crushing the fibres received from the receiving zone and a conveying zone for conveying the crushed fibres to the outlet, adding the crushed fibres obtained from the twin screw system to a thermoplastic polymer to obtain a natural fibre thermoplastic composite.

In accordance with an aspect the process further comprises of passing the natural fibre thermoplastic composite through a pelletizing system to obtain pellets of natural fibre reinforced thermoplastic composite.

In accordance with an aspect the natural fibre reinforced thermoplastic composite may also be used directly for forming other structures including tubes and sheets using suitable molds and dies.

The fibres used for the manufacture of natural fibre reinforced thermoplastic include but not limited to jute, cotton, hemp, flex or coconut fibres or a combination therefore. In accordance with a preferred embodiment the fibre is jute.

In addition to natural fibres the natural fibre reinforced thermoplastic may also contain manmade fibres including but not limited to fibre glass, carbon fibres.

In accordance with an aspect, the fibres have a length in the range of 1 to 5 mm.

Preferably the range of length of a substantial portion of fibres is less than 3 mm, and a large portion of such fibres is substantially 2mm.

The amount of natural fibres that may be added to the natural fibre reinforced thermoplastic is in the range of 5 to 30 weight per cent.

The thermoplastic polymer that may be used for the manufacture of natural fibre reinforced thermoplastic includes but is not limited to polypropylene, polyethylene, polyamides, polyamines, polycarbonate, polystyrene, styrene-acrylonitrile copolymers, acrylonitrile-butandiene-styrene terpolymers, polysulphones, polyesters, polyurethanes, polyphenylene sulfides, polyphenylene ethers or their combinations.

Specific embodiments are described below:

A fibre crushing system comprising a barrel having two parallel bores of equal diameter,
the centre distance between the two bores lesser than the diameter of the bore, an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres, a shaft located within each bore, each shaft configured for rotation in the same direction, and a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including a receiving zone configured for receiving and separating fibres, a crushing zone configured for crushing the fibres received from the receiving zone, and a conveying zone configured for conveying crushed fibres to the outlet.

Such fibre crushing system(s), wherein the processing elements are twin screw extruder elements.

Such fibre crushing system(s), wherein the twin screw extruder elements are completely intermeshing elements.

Such fibre crushing system(s), wherein the processing elements in the receiving zone are any of SchubKanten Elements or Regular Flighted Shovel element or their combination.

Such fibre crushing system(s), wherein at least one processing element in the crushing zone is an extruder kneading element.

Such fibre crushing system(s), wherein the extruder kneading elements provided in the crushing zone are any of right handed kneading blocks, neutral kneading blocks, left handed kneaded blocks, eccentric kneading blocks, fractional lobed kneading blocks or their combination.

Such fibre crushing system(s), wherein the processing element in the conveying zone is any one of normal bi-lobed right handed screw element, screw mixing element or their combination.

Such fibre crushing system(s), wherein the length of the receiving zone is in the range of 2 to 5 times the barrel diameter, the length of the crushing zone is in the range of 1 to 5 times the barrel diameter and the length of the conveying zone is in the range of 1 to 5 times the barrel diameter.

Further specific embodiments are described below:

A method for crushing fibres comprising feeding fibres into a fibre crushing system, the
fibre crushing system comprising a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore, an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres, a shaft located within each bore, each shaft configured for rotation in the same direction, and a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including a receiving zone configured for receiving and separating fibres, a crushing zone configured for crushing the fibres received from the receiving zone, and a conveying zone configured for conveying crushed fibres to the outlet, the method comprising feeding fibre into the receiving zone through the inlet of the fibre crushing system, crushing the fibres received from the receiving zone by passing them through the crushing zone, and conveying the crushed fibres received from the crushing zone to the outlet.

Such process(s), wherein the fibres are separated in the receiving zone using any one of SchubKanten Elements or Regular Flighted Shovel element or their combination.

Such process(s), wherein the fibres are further crushed in the conveying zone using any one of normal bi-lobed right handed screw element, screw mixing element or their combination.

Such process(s), wherein the fibre crushing system is operated at a speed of 600 RPM.

Such process(s), wherein the output of the fibre crushing system is 200 kilograms per hour.

Such process(s), wherein the fibre is any one of jute, hemp, flex or coconut.

Such process(s), wherein the length of the crushed fibre is in the range of 1.5mm to 3mm.

Further specific embodiments are described below:

A method for manufacturing a natural fibre reinforced thermoplastic composite
comprising crushing the natural fibres comprising feeding the natural fibres into a fibre crushing system, the fibre crushing system comprising a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore, an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres, a shaft located within each bore, each shaft configured for rotation in the same direction, and a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including a receiving zone configured for receiving and separating fibres, a crushing zone configured for crushing the fibres received from the receiving zone, and a conveying zone configured for conveying crushed fibres to the outlet, the method comprising feeding fibre into the receiving zone through the inlet of the fibre crushing system;

crushing the fibres received from the receiving zone by passing them through the crushing zone, and conveying the crushed fibres received from the crushing zone to the outlet and adding the crushed fibres received from the fibre crushing system to a thermoplastic polymer to obtain a natural fibre reinforced thermoplastic composite.

Such method(s), wherein the fibre is any one of jute, hemp, flex or coconut.

Such method(s), wherein the thermoplastic polymer may be any one of polypropylene, polyethylene, polyamides, polyamines, polycarbonate, polystyrene, styrene-acrylonitfile copolymers, acrylonitrile-butandiene-styrene terpolymers, polysulphones, polyesters, polyurethanes, polyphenylene sulfides, polyphenylene ethers or their combinations.
Such method(s), wherein the length of the crushed fibre is in the range of 1.5mm to 3mm.

Such method(s), wherein the process further comprises of passing the natural fibre reinforced thermoplastic composite through a pelletizing system to obtain pellets of the fibre reinforced thermoplastic composite.

Such natural fibre reinforced thermoplastic(s) obtained by any such process(s).

Such natural fibre reinforced thermoplastic(s), wherein the natural fibre reinforced thermoplastic is the form of pellets.

INDUSTRIAL APPLICABILITY

The device and method as disclosed above provides for a simple and efficient device and method for crushing the natural fibres to obtain short length natural fibre. The crushed natural fibres obtained are within a small length range. Moreover the length of the fibers obtained by the system and method as dislosed may be adjusted by adjusting the configuration of the system. . Moreover, the device and method as disclosed allows for crushing of natural fibres in an energy efficient manner.

The crushed fibres so obtained by using the device and method as disclosed above may be used for the manufacture of natural fibre reinforced thermoplastic.

Reduction in the length of fibres increases its density and reduces its specific volume, allowing the addition of the natural fibre in the desired rate. The crushed natural fibres are suitable for use in manufacturing natural fibres reinforced plastics.

We claim:

1. A fibre crushing system comprising:

a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore;

an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres;

a shaft located within each bore, each shaft configured for rotation in the same direction; and

a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including

a receiving zone configured for receiving and separating fibres;

a crushing zone configured for crushing the fibres received from the receiving zone; and

a conveying zone configured for conveying crushed fibres to the outlet.

2. A fibre crushing system as claimed in claim 1, wherein the processing elements are twin screw extruder elements.

3. A fibre crushing system as claimed in claim 2, wherein the twin screw extruder elements are completely intermeshing elements.

4. A fibre crushing system as claimed in claim 1, wherein the processing elements in the receiving zone are any of SchubKanten Elements or Regular Flighted Shovel element or their combination.

5. A fibre crushing system as claimed in claim 1, wherein at least one processing element in the crushing zone is an extruder kneading element.

6. A fibre crushing system as claimed in claim 5, wherein the extruder kneading elements provided in the crushing zone are any of right handed kneading blocks, neutral kneading blocks, left handed kneaded blocks, eccentric kneading blocks, fractional lobed kneading blocks or their combination.

7. A fibre crushing system as claimed in claim 1, wherein the processing element in the conveying zone is any one of normal bi-lobed right handed screw element, screw mixing element or their combination.

8. A fibre crushing system as claimed in claim 1, wherein the length of the receiving zone is in the range of 2 to 5 times the barrel diameter, the length of the crushing zone is in the range of 1 to 7 times the barrel diameter and the length of the conveying zone is in the range of 1 to 10 times the barrel diameter.

9. A method for crushing fibres comprising feeding fibres into a fibre crushing system, the fibre crushing system comprising

a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore;

an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres;

a shaft located within each bore, each shaft configured for rotation in the same direction; and

a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including

a receiving zone configured for receiving and separating fibres;

a crushing zone configured for crushing the fibres received from the receiving zone; and

a conveying zone configured for conveying crushed fibres to the outlet; the method comprising

feeding fibre into the receiving zone through the inlet of the fibre crushing system;

crushing the fibres received from the receiving zone by passing them through the crushing zone; and

conveying the crushed fibres received from the crushing zone to the outlet.

10. A process as claimed in claim 9, wherein the fibres are separated in the receiving zone using any one of SchubKanten Elements or Regular Flighted Shovel element or their combination.

11. A process as claimed in claim 9, wherein the fibres are further crushed in the conveying zone using any one of normal bi-lobed right handed screw element, screw mixing element or their combination.

12. A process as claimed in claim 9, wherein the fibre crushing system is operated at a speed of 600 RPM

13. A process as claimed in claim 9, wherein the output of the fibre crushing system is 200 kilograms per hour.

14. A process as claimed in claim 9, wherein the fibre is any one of jute, hemp, flex or coconut.

15. A process as claimed in claim 9, wherein the length of the crushed fibre is in the range of 1.5mm to 3mm.

16. A method for manufacturing a natural fibre reinforced thermoplastic composite comprising crushing the natural fibres comprising feeding the natural fibres into a fibre crushing system, the fibre crushing system comprising

a barrel having two parallel bores of equal diameter, the centre distance between the two bores lesser than the diameter of the bore;

an inlet configured for receiving the fibres to be crushed and an outlet for the crushed fibres;

a shaft located within each bore, each shaft configured for rotation in the same direction; and

a plurality of processing segments removably mounted on each shaft, forming three zones within the barrel, the zones including

a receiving zone configured for receiving and separating fibres;

a crushing zone configured for crushing the fibres received from the receiving zone; and

a conveying zone configured for conveying crushed fibres to the outlet; the method comprising

feeding fibre into the receiving zone through the inlet of the fibre crushing system;

crushing the fibres received from the receiving zone by passing them through the crushing zone; and

conveying the crushed fibres received from the crushing zone to the outlet; and
adding the crushed fibres received from the fibre crushing system to a thermoplastic polymer to obtain a natural fibre reinforced thermoplastic composite.

17. A method as claimed in claim 16, wherein the fibre is any one of jute, hemp, flex or coconut.

18. A method as claimed in claiml6, wherein the thermoplastic polymer may be any one of polypropylene, polyethylene, polyamides, polyamines, polycarbonate, polystyrene, styrene-acrylonitrile copolymers, acrylonitrile-butandiene-styrene terpolymers, polysulphones, polyesters, polyurethanes, polyphenylene sulfides, polyphenylene ethers or their combinations.

19. A method as claimed in claim 16, wherein the length of the crushed fibre is in the range of 1.5mm to 3mm.

20. A method as claimed in claim 16, wherein the process further comprises of passing the natural fibre reinforced thermoplastic composite through a pelletizing system to obtain pellets of the fibre reinforced thermoplastic composite.

21. A natural fibre reinforced thermoplastic obtained by a process as claimed in any of claims 16 to 20.

22. A natural fibre reinforced thermoplastic as claimed in claim 21, wherein the natural fibre reinforced thermoplastic is in form of pellets.

23. A fibre crushing system substantially as herein described with reference to and as illustrated by the accompanying figures.

24. A method for crushing fibres substantially as herein described with reference to and as illustrated by the accompanying figures.

25. A method for manufacturing a natural fibre reinforced thermoplastic composite substantially as herein described with reference to and as illustrated by the accompanying figures.

26. A natural fibre reinforced thermoplastic substantially as herein described with reference to and as illustrated by the accompanying figures.