The crusher disk in lamp recovery device used for crushing aluminum end caps is breaking while crushing for unknown reasons. Therefore it is important for design engineers to be able to find out the possibilities of fracture failure and also provide prevention methods for it during design proposals. The scope of this thesis is to find out the reason for failure, solution and prevention methods of the crusher disk in a lamp recovery device. Hence the experiment will include theoretical modeling followed by experimental work. Theory of essential work, experimental and finite element methods using ABAQUS, INVENTOR were used for analysis. Dynamic simulation in Autodesk Inventor was performed to find the startup force. A finite element analysis in ABAQUS was made in order to show stress concentration on the disk. It provides effective method for experimentation. During experimentation it is found that the failure occurs due to improper design. It was Re-designed to prevent the problem.