Modeling and Optimization of PET Filament Making Machine Control System Based on Response Surface Methodology
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Dec 31, 2025
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Abstract
This study aims to model and optimize the control system of a PET filament making machine using Response Surface Methodology (RSM). Two main variables, namely extrusion temperature and winding speed, were analyzed through the Central Composite Design experimental design with the help of Design-Expert 13 software. A quadratic model was developed to predict the filament diameter, and the results of the analysis of variance showed that the model was statistically significant and able to represent the nonlinear relationship between variables. Optimization based on the desirability function produced optimum operating conditions at a medium temperature and winding speed range. Experiments showed that the combination of a temperature of 240–245 °C and a speed of 9–12 rpm produced a consistent filament diameter of 1.7 mm with 70–80% flexibility and a smooth surface.
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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
How to Cite
Fauzi, D. N., Kurniawan, P., Junaedi, I., Wicaksono, R. P., & Mahardi, N. B. (2025). Modeling and Optimization of PET Filament Making Machine Control System Based on Response Surface Methodology. Jurnal E-Komtek (Elektro-Komputer-Teknik), 9(2), 709-723. https://doi.org/10.37339/e-komtek.v9i2.3017
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[22] T. K. Trinh and L. S. Kang, ‘Application of Response Surface Method as an Experimental Design to Optimize Coagulation Tests’, Environ. Eng. Res., vol. 15, no. 2, pp. 63–70, Jun. 2010.
[23] V. Aggarwal, S. S. Khangura, and R. K. Garg, ‘Parametric modeling and optimization for wire electrical discharge machining of Inconel 718 using response surface methodology’, Int. J. Adv. Manuf. Technol., vol. 79, no. 1, pp. 31–47, Jul. 2015, doi: 10.1007/s00170-015-6797-8.
[24] J. Yuan et al., ‘Multiple responses optimization of ultrasonic-assisted extraction by response surface methodology (RSM) for rapid analysis of bioactive compounds in the flower head of Chrysanthemum morifolium Ramat.’, Ind. Crops Prod., vol. 74, pp. 192–199, Nov. 2015, doi: 10.1016/j.indcrop.2015.04.057.
[25] S. Ahmadi, A. Khormali, and F. Meerovich Khoutoriansky, ‘Optimization of the demulsification of water-in-heavy crude oil emulsions using response surface methodology’, Fuel, vol. 323, p. 124270, Sep. 2022, doi: 10.1016/j.fuel.2022.124270.
[26] N. El-Gendy, S. Deriase, and A. Hamdy, ‘The Optimization of Biodiesel Production from Waste Frying Corn Oil Using Snails Shells as a Catalyst’, Energy Sources, vol. 36, Feb. 2014, doi: 10.1080/15567036.2013.822440.
[27] P. Biniaz, M. Farsi, and M. R. Rahimpour, ‘Demulsification of water in oil emulsion using ionic liquids: Statistical modeling and optimization’, Fuel, vol. 184, pp. 325–333, Nov. 2016, doi: 10.1016/j.fuel.2016.06.093.
[28] G. Sulochana and s. K. Bhatti, ‘Performance and emission characteristics of a twin cylinder diesel engine blended biodiesel with nano additives using response surface methodology’, Int. J. Mech. Prod. Eng. Res. Dev., vol. 8, pp. 635–646, 2018.
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[2] K. Sandeep Varma, K. Lal Meena, and R. B. R. Chekuri, ‘Optimizing mechanical properties of 3D-printed aramid fiber-reinforced polyethylene terephthalate glycol composite: A systematic approach using BPNN and ANOVA’, Eng. Sci. Technol. Int. J., vol. 56, p. 101785, Aug. 2024, doi: 10.1016/j.jestch.2024.101785.
[3] S. Akhbar, N. S. N. Nik Omar, A. N. Mohd Yusof, S. Mohd Alauddin, and N. Kamarrudin, ‘Preliminary study of melt flow index of recycled Polyethylene Terephthalate/Empty fruit bunch (rPET/EFB) composite as a potential biodegradable 3D printing filament’, Mater. Today Proc., vol. 87, pp. 366–369, Jan. 2023, doi: 10.1016/j.matpr.2023.03.625.
[4] A. Al Rashid and M. Koç, ‘3D-Printed recycled polyethylene terephthalate (PET) sandwich structures – Influence of infill design and density on tensile, dynamic mechanical, and creep response’, Int. J. Lightweight Mater. Manuf., vol. 8, no. 4, pp. 442–452, Jul. 2025, doi: 10.1016/j.ijlmm.2025.03.001.
[5] M. K. J. E. Exconde, J. A. A. Co, J. Z. Manapat, and E. R. Magdaluyo, ‘Materials Selection of 3D Printing Filament and Utilization of Recycled Polyethylene Terephthalate (PET) in a Redesigned Breadboard’, Procedia CIRP, vol. 84, pp. 28–32, Jan. 2019, doi: 10.1016/j.procir.2019.04.337.
[6] G. Kónya, L. Tóth, P. Gerse, F. Palásti, P. Hansághy, and F. Ronkay, ‘Cutting tests and performance evaluation of recycled PET in fused filament fabrication’, Mater. Today Sustain., vol. 31, p. 101126, Sep. 2025, doi: 10.1016/j.mtsust.2025.101126.
[7] M. Nikam, P. Pawar, A. Patil, A. Patil, K. Mokal, and S. Jadhav, ‘Sustainable fabrication of 3D printing filament from recycled PET plastic’, Mater. Today Proc., vol. 103, pp. 115–125, Jan. 2024, doi: 10.1016/j.matpr.2023.08.205.
[8] J. Mesicek et al., ‘Effect of part orientation and thickness on radiation shielding in FDM 3D printing of PET-G composite with tungsten’, J. Mater. Res. Technol., vol. 38, pp. 2886–2891, Sep. 2025, doi: 10.1016/j.jmrt.2025.08.080.
[9] L. Toth, E. Slezák, K. Bocz, and F. Ronkay, ‘Progress in 3D printing of recycled PET’, Mater. Today Sustain., vol. 26, p. 100757, Jun. 2024, doi: 10.1016/j.mtsust.2024.100757.
[10] C. O’Driscoll, O. Owodunni, and U. Asghar, ‘Optimization of 3D printer settings for recycled PET filament using analysis of variance (ANOVA)’, Heliyon, vol. 10, no. 5, p. e26777, Mar. 2024, doi: 10.1016/j.heliyon.2024.e26777.
[11] A. Elik, ‘Response surface methodology based on central composite design for optimizing temperature-controlled ionic liquid-based microextraction for the determination of histamine residual in canned fish products’, J. Food Compos. Anal., vol. 98, p. 103807, May 2021, doi: 10.1016/j.jfca.2021.103807.
[12] D. Alwazeer et al., ‘A Novel Hydrogen-incorporated Carbon Dioxide Supercritical System for Extracting Phytochemicals from Grape Peels: Response Surface Methodology–Based Modeling and Optimization’, Results Eng., vol. 29, p. 109142, Jan. 2026, doi: 10.1016/j.rineng.2026.109142.
[13] N. S. Piro, ‘Predictive modeling and optimization of sustainable ultra-high-performance concrete with response surface methodology’, Prog. Eng. Sci., vol. 3, no. 1, p. 100201, Mar. 2026, doi: 10.1016/j.pes.2025.100201.
[14] L. Xie, F. Wang, Z. Dou, J. Liu, K. Luo, and Y. Li, ‘Modeling and multi-objective optimization of picosecond laser machining of blind holes in 4H-SiC using response surface methodology’, Mater. Sci. Semicond. Process., vol. 206, p. 110419, May 2026, doi: 10.1016/j.mssp.2026.110419.
[15] O. Pektezel and S. N. Ozdemir, ‘Performance optimization of a three-stage cascade refrigeration system using response surface methodology’, Appl. Therm. Eng., vol. 287, p. 129446, Feb. 2026, doi: 10.1016/j.applthermaleng.2025.129446.
[16] L. Alidokht, K. A. Chavarria, and M. Lanzarini-Lopes, ‘Optimizing energy budget for UV driven biofilm prevention using response surface methodology’, Environ. Technol. Innov., vol. 41, p. 104742, Mar. 2026, doi: 10.1016/j.eti.2025.104742.
[17] J. Andraskar and A. Kapley, ‘Optimizing food waste composting with consortium, jaggery, and biochar using response surface methodology’, Bioresour. Technol. Rep., vol. 33, p. 102541, Feb. 2026, doi: 10.1016/j.biteb.2025.102541.
[18] Y. Yang, P. Zhao, L. Yu, J. Jia, and D. Zhu, ‘Optimization of Supercritical CO2 Extraction of Juglone from Waste Walnut Green Husk via Response Surface Methodology’, J. Supercrit. Fluids, p. 106886, Jan. 2026, doi: 10.1016/j.supflu.2026.106886.
[19] A. Mani and J. Sarkar, ‘3D simulation-based multi-objective optimization of segmented thermoelectric coolers using response surface methodology’, Appl. Therm. Eng., vol. 287, p. 129447, Feb. 2026, doi: 10.1016/j.applthermaleng.2025.129447.
[20] R. H. Myers, D. C. Montgomery, and C. M. Anderson-Cook, Response Surface Methodology: Process and Product Optimization Using Designed Experiments. John Wiley & Sons, 2011.
[21] C.-C. Liao and T.-W. Chung, ‘Optimization of process conditions using response surface methodology for the microwave-assisted transesterification of Jatropha oil with KOH impregnated CaO as catalyst’, Chem. Eng. Res. Des., vol. 91, no. 12, pp. 2457–2464, Dec. 2013, doi: 10.1016/j.cherd.2013.04.009.
[22] T. K. Trinh and L. S. Kang, ‘Application of Response Surface Method as an Experimental Design to Optimize Coagulation Tests’, Environ. Eng. Res., vol. 15, no. 2, pp. 63–70, Jun. 2010.
[23] V. Aggarwal, S. S. Khangura, and R. K. Garg, ‘Parametric modeling and optimization for wire electrical discharge machining of Inconel 718 using response surface methodology’, Int. J. Adv. Manuf. Technol., vol. 79, no. 1, pp. 31–47, Jul. 2015, doi: 10.1007/s00170-015-6797-8.
[24] J. Yuan et al., ‘Multiple responses optimization of ultrasonic-assisted extraction by response surface methodology (RSM) for rapid analysis of bioactive compounds in the flower head of Chrysanthemum morifolium Ramat.’, Ind. Crops Prod., vol. 74, pp. 192–199, Nov. 2015, doi: 10.1016/j.indcrop.2015.04.057.
[25] S. Ahmadi, A. Khormali, and F. Meerovich Khoutoriansky, ‘Optimization of the demulsification of water-in-heavy crude oil emulsions using response surface methodology’, Fuel, vol. 323, p. 124270, Sep. 2022, doi: 10.1016/j.fuel.2022.124270.
[26] N. El-Gendy, S. Deriase, and A. Hamdy, ‘The Optimization of Biodiesel Production from Waste Frying Corn Oil Using Snails Shells as a Catalyst’, Energy Sources, vol. 36, Feb. 2014, doi: 10.1080/15567036.2013.822440.
[27] P. Biniaz, M. Farsi, and M. R. Rahimpour, ‘Demulsification of water in oil emulsion using ionic liquids: Statistical modeling and optimization’, Fuel, vol. 184, pp. 325–333, Nov. 2016, doi: 10.1016/j.fuel.2016.06.093.
[28] G. Sulochana and s. K. Bhatti, ‘Performance and emission characteristics of a twin cylinder diesel engine blended biodiesel with nano additives using response surface methodology’, Int. J. Mech. Prod. Eng. Res. Dev., vol. 8, pp. 635–646, 2018.
[29] H. Karazhiyan, S. M. A. Razavi, and G. O. Phillips, ‘Extraction optimization of a hydrocolloid extract from cress seed (Lepidium sativum) using response surface methodology’, Food Hydrocoll., vol. 25, no. 5, pp. 915–920, Jul. 2011, doi: 10.1016/j.foodhyd.2010.08.022.