FEDERAL UNIVERSITY OF TECHNOLOGY OWERRI

SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

A TECHNICAL REPORT:

ON SIX MONTHS INDUSTRIAL TRAINING WORK

EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

INNOSON TECHNICAL AND INDUSTRIAL COMPANY LIMITED

PLOT W/L EMENE INDUSTRIAL LAYOUT ENUGU

P.O.BOX 1570

BY: ANUKWUOCHA NNAEMEKA PAUL

REG NO: 20151010243

INDUSTRIAL TRAINING REPORT PRESENTED TO THE DEPARTMENT OF

CHEMICAL ENGINEERING (F.U.T.O) IN PARTIAL FULFILLMENT OF THE
REQUIREMENT FOR BARCHELORS DEGREE IN CHEMICAL
ENGINEERING
FEBRUARY 2020
i
 DEDICATION

This SIWES report is dedicated to God Almighty who made it a success, To my family

for their support up to this moment. I am happy to have you people, Thanks to you all for

always being there for me.

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 ACKNOWLEDGEMENT

I express my sincere appreciation to Chief Dr. Innocent Chukwuma, the

CEO/Founder of Innoson Technical and Industrial company Limited, for the

opportunity to intern at his firm. Also, to my workstation supervisor Mr. Okafor

Chukwuka for the lessons he thought me during the period and also to my ever

hardworking lecturers for the knowledge they impacted on me before going for the

training, you all made my stay in the industry worthwhile.

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 ABSTRACT

This Technical report is based on a six months’ student’s industrial work

experience scheme (SIWES) training program which was undertaken at Innoson

Technical and Industrial Co. Nig. Limited. With highlights on Thermoplastics and

thermosets mainly plastic production such as Seats, bowls, cups, plates, Nylon and lots

more. Giving a full enlightenment and knowledge on the materials such as

homopolymer, copolymer, master batch, reprocess and many others and machines such

as injection molding machine, Compression molding machine and others used in plastic

production, as well as the components of plastics and the production /post-production

steps and processes. Giving a clear idea of my involvement in all operational activities

carried out in the plastic factory.

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TABLE OF CONTENTS

DEDICATION... ........................................................................................................................................................... .. ii

ACKNOWLEDGEMENT ... .......................................................................................................................................... iii

ABSTRACT ... .............................................................................................................................................................. . iv

1.0 CHAPTER ONE ... ................................................................................................................................................. .. 1

1.1 BRIEF HISTORY OF SIWES ... ................................................................................................................................. 2

1.1.1. AIMS AND OBJECTIVES OF SIWES ... .............................................................................................................. . 3

1.2 HISTORICAL DEVELOPMENT OF INNOSON TECHNICAL AND ... ................................................................. 3

1.3. ORGANIZATIONAL CHART ... .............................................................................................................................. . 5

1.4 PICTURES OF SOME OF INNOSON’S PRODUCT ... .............................................................................................. 6

CHAPTER TWO ........................................................................................................................................................... . 7

2.0 DESCRIPTION OF POLYMERS ... ....................................................................................................................... .. 7

2.1 CLASSIFICATION OF POLYMERS ... ..................................................................................................................... .. 9

2.3 TYPES OF POLYMERISATION ... .......................................................................................................................... 10

2.3.1 ADDITION POLYMERIZATION ......................................................................................................................... 10

2.3.2 CONDENSATION POLYMERIZATION ... ....................................................................................................... ... 10

2.4.1 SAFETY IN INNOSON TECHNICAL ... ................................................................................................................ 11

2.4.2 SAFETY KITS USED IN PLASTIC PRODUCTION ... ....................................................................................... ... 11

2.4.3 COMMON CAUSES OF INJURY IN THE FACTORY ... ...................................................................................... 12

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 2.4.5 MAINTENANCE OF THE MACHINES IN THE FACTORY ... .................................................................. 12

CHAPTER THREE ... ................................................................................................................................................ ... 14

3.0 DESCRIPTION OF INJECTION MOULDING AND MATERIAL MIXING ... ........................................................... 14

3.1 THE INJECTION MOULDING PROCESS ... ........................................................................................................ 14

3.1.1 PROCESS CYCLE ... ....................................................................................................................................... ... 15

3.2 POSSIBLE DEFECTS ON PLASTIC PRODUCTS .................................................................................................. 16

3.3 GENERAL DESCRIPTION OF THE INJECTION MOULDING... ....................................................................... ... 25

3.4 PARTS OF INJECTION MOULDING MACHINE. .. ........................................................................................... ... 27

3.5 MATERIAL SELECTION AND MIXING ................................................................................................................. 32

3.5.1 MATERIAL SELECTION ... ............................................................................................................................. ... 32

3.5.2 MIXING PROCESS IN INJECTION MOULDING SECTION ... ............................................................................. 39

3.6 PRODUCTS AND MATERIAL RATIO ... ............................................................................................................... 40

CHAPTER FOUR ... ..................................................................................................................................................... 42

COMPRESSION MOULDING ... ............................................................................................................................. ... 42

4.1INTRODUCTION ................................................................................................................................................... 42

4.2 MATERIALS FOR COMPRESSION MOULDING AT INNOSON ....................................................................... ... 44

4.3 STEPS OF PRODUCTION OF CUSTOMIZED PLATE ............................................................................................ 44

4.4 SUB SECTIONS OF PLATE DEPARTMENT AT INNOSON... ................................................................................ 45

4.4.1 MOULD SECTION ...................................................................................................................................... ... 45

4.4.3 AIR BORNE SECTION ... ................................................................................................................................... 48

4.4.4 POLISHING SECTION ... ................................................................................................................................ ... 48

4.4.5 PACKAGING SECTION ... ............................................................................................................................. ... 49

4.5 ADVANTAGES OF COMPRESSION MOULDING ... ............................................................................................ 49

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4.6 MATERIAL MIXING DEPARTMENT: ... ................................................................................................................ 50

CHAPTER FIVE ... .................................................................................................................................................... ... 52

5.1 QUALITY OPERATION ......................................................................................................................................... 52

5.2 NIGERIA STANDARD ON PLASTIC PRODUCTS MADE FROM ........................................................................... 52

5.3 DEFINITION OF TERMS ... ................................................................................................................................... 52

5.4 QUALITY CONTROL PARAMETERS AND REQUIREMENT ................................................................................. 53

5.4.1 REVISION TEST ... ............................................................................................................................................. 53

5.4.2 SURFACE TEST ... .......................................................................................................................................... ... 53

5.4.3 DISTORTION TEST ... ........................................................................................................................................ 54

6.1 CONCLUSION ... ................................................................................................................................................... 55

6.2 CHALLENGES FACED ... ................................................................................................................................... ... 56

7.0 RECOMMENDATIONS ... ................................................................................................................................ ... 57

REFERENCES ... ...................................................................................................................................................... ... 58

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 1.0 CHAPTER ONE

INTRODUCTION OF SIWES

The Student Industrial Work Experience Scheme (SIWES) is a program designed

to mainly bridge the gap between classroom theoretical learning and industrial
practical experience. The Scheme was first initiated and founded by the Industrial
Training Fund (ITF) during the formative years 1973/1974. It is a tripartite
program involving the government through the industrial Training Fund (ITF), the
student and the institution. The Students Industrial Works Experience Scheme;
SIWES as it implies is an initiative of the Federal Government of Nigeria with the aim
of providing adequate practical skills to students in higher institutions; University,
Polytechnic and Colleges of Education so as to bridge the gap between lecture classes and
the ideal field work. Knowledge is not by paper, it is by action; action within prescribed
norms and laid down effective principles.

Sequel to this initiative, the training was set up and is mandatory especially for all
students of Engineering in order to acquire more knowledge and practical skills in
their various fields and disciplines keeping in mind that experience(s) obtained
would help assure a sound technological background for future career practice.

This full semester industrial participation has helped me to be familiar with current
updates in Engineering particularly owing to the fact that Engineering is dynamic and
because technology advances every time as researchers dig deep.

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Industrial Principles and practical processes are expected to be learned during the
cause of training coupled with the ability to be able to apply what has been taught to
real and ideal situations; judging aright and facing responsibilities.

1.1 BRIEF HISTORY OF SIWES

The 1988 SIWES/ITF national conference Jos mandate all collaborating agency (NUC
NBTE and NCCE) to draw up job specification for all degree program including the
Students Industrial Work Experience Scheme (SIWES). The job specification would
guide the industrialist and institutional supervisor in the placements of the students
such that they would meet the expected requirement of minimum industrial exposure
preparatory to employment.

The national university commission, recognizing importance of job specification in

SIWES did set the necessary machine in motion soon after the resolution was taken in
1988. However, from 1989 to 1993 the drawing of the minimum academic standards
documents (a major statutory function of the commission), secretariat to Abuja did not
leave sufficient time to actualize this goal. It was not until January 1996, at a 3 days’
national workshop in Jos, when job specifications were drawn for all those who had
industrial attachments components in their minimum academic standards documents.

Participants were drawn from senior academic from the universities across the
country, SIWES coordinators official of ITF headquarter and NUC academic
planning officers. In all, nine panel and headed by a senior academician were
constituted for all the forty-six programs. The panel draws up the Job specification,
however a one-day meeting was head at which five invited paper were presented

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and the procedure, content and format for presentation of the job specification
documents were decided.

1.1.1. AIMS AND OBJECTIVES OF SIWES

Provide students with an opportunity to apply their theoretical knowledge in
practical situations thus bridging the gap between theory and practice.
To expose student to industrial norms and culture.
0000000To provide students with fundamental and basic knowledge needed
in inspection, installation, maintenance, operations and processes, designing,
constructions and fabrications and repairs of industrial equipment as
machines.
To imbibe the act of creativity in the hearts of potential industrial workers as
well as to appreciate the extent of growth in technological advancements.
To be able to take full responsibilities in proffering solutions to problems.
Expose student to professional work methods and techniques in handling
equipment’s and machines that may not be available in the institutions.
Ascertain the ultimate role which they are expected to play in the industrial
sector on completion of their present course of study.

1.2 HISTORICAL DEVELOPMENT OF INNOSON TECHNICAL AND

INDUSTRIAL COMPANY (ITICL)
Innoson technical and industrial company limited is owned by Chief Dr. Innocent
Chukwuma, a subsidiary of INNOSON group of companies was incorporated in
2002 with full manufacturing activities commencing same year at its head
office/factory situated at plot w/L industrial layout, Emene, Enugu state Nigeria.

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Innoson technical is very strategic in Innoson group’s commitment to improving the
quality of life of Nigeria citizens. It is an indigenous blue chip company engaged
in the manufacturing of plastic products that meet the highest global industry
standards.

With a work force of about 2000 Nigerians and technical support from Chinese
expatriates, Innoson technical is the biggest plastic industry in Nigeria with
products portfolio (more than eighty 80 different plastic products that covers a
wide range of items including chairs, crash helmets (for motor cycle riders,
construction workers, and factory workers), melamine wares, as well as jerry cans
of various sizes (some of which are rated the most reliable by exporters of
chemical products). Innoson technical also customize products to suit the tastes and
needs of its wide clientele.

The expansive factory has the capacity for the production of more than 10,000 plastic
chairs per day, courtesy of the recent state of the art injection mold. An effective
backward integration has been achieved by Innoson technical and industrial
company limited ability to provide its sister companies (Innoson Nigeria ltd and
Innoson vehicles manufacturing company ltd) with vital plastic requirements
needed for its productions. this effort was in direct response to the federal government
policy direction towards encouraging indigenous private sectors as an engine of
growth for the economy.

OUR VISION
To be a dominant player in the plastic industry producing products of first choice in
Nigeria.

OUR MISSION
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To satisfy the industry and household plastic requirement of our clients using the
highest standard of automation and technology with well-motivated and trained
indigenous work force.

OUR COMMITMENT

To have a devoted management team that have wealth of experience in all area and are
able to make fast decisions on new developments which always puts the group one step
ahead of its competitor.

1.3. ORGANIZATIONAL CHART

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1.4 PICTURES OF SOME OF INNOSON’S PRODUCT

FIG 1.4.1 MELAMINE TABLE WARE

FIG 1.4.2 STADIUM SEAT

FIG 1.4.4 ROUND SEAT OF EIGHT

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CHAPTER TWO

2.0 DESCRIPTION OF POLYMERS

A polymer is a substance composed of macromolecules. A macromolecule is a
molecule of high relative molecular mass, the structure of which essentially
comprises the multiple repetition of units derived, actually or conceptually, from
molecules of low relative molecular mass. They are both naturally and synthetic
polymer. Among naturally occurring polymers are protein, starch, cellulose and
latex. Synthetic polymers are produced commercially on a large scale and have a wide
range of properties and uses. The materials called plastics are all synthetic polymers.
Polymers are joined by chemical reactions in which small number of molecules
called monomers are joined sequentially, forming a chain. In many polymers only
one monomer is used.

In others, two or three different monomers may be combined. Polymers are

classified by the characteristics of the reaction by which they are formed. If all
atoms in the monomers are incorporated into the polymer, the polymer is called
addition polymers. If some of the atoms in the monomers are released into small
molecules, the polymer is called a condensation polymer. Polymers occur in nature and
can be made to serve specific needs.

Manufacturing polymers can be a three dimensional network that do not melt and
formed. Such networks are called THERMOSET POLYMERS.

THERMOSET POLYMER

Thermoset materials are those materials that are made by polymers joined together
by chemical bonds, acquiring a highly cross-linked polymer structure. The highly
cross-linked structure produced by chemical bonds in thermoset materials, is

7
directly responsible for the high mechanical and physical strength (high strength to
support high stress or load temperature.) compared with thermoplastics or
elastomers materials. One of the characteristic parameter of thermosets materials
are gel point, which refers to the time when the material changes from an
irreversible way-viscous liquid state to solid state during the curing process.

Polymers abound in nature. The ultimate nature polymers are the deoxyribonucleic
acid(DNA) and ribonucleic acid (RNA) that define life. Spider silk, hair and horn are
protein polymer. Starch can be a polymer as in cellulose in wood.

Rubber tree latex and cellulose have been used as raw material. It makes
manufactured polymeric rubber and plastics. The first synthetic manufactured
plastic was Bakelite, created in 1909 for telephone casing and electrical
components. The first manufactured polymeric fiber was rayon, cellulose in 1901.
Nylon was inverted in 1938 while pursuing a synthetic spider silk.

Plastic can also be safely land fill, although the valuable energy resource of the
plastics would then be lost for recycling or energy capture.

In 2005, 54.3% of municipal solid waste was land filled. Polymers affect every day of our
life. These materials have so many varied characteristics and application that their
usefulness can only be measured by air imagination. Polymers are the materials of
past, present and future generation.

Polymers abound in nature. The ultimate nature polymers are the deoxyribonucleic
acid(DNA) and ribonucleic acid (RNA) that define life. Spider silk, hair and horn are
protein polymer. Starch can be a polymer as in cellulose in wood.

Rubber tree latex and cellulose have been used as raw material. It makes
manufactured polymeric rubber and plastics. The first synthetic manufactured
8
plastic was Bakelite, created in 1909 for telephone casing and electrical
components. The first manufactured polymeric fiber was rayon, cellulose in 1901.
Nylon was inverted in 1938 while pursuing a synthetic spider silk.

Plastic can also be safely land fill, although the valuable energy resource of the
plastics would then be lost for recycling or energy capture.

In 2005, 54.3% of municipal solid waste was land filled. Polymers affect every day of
our life. These materials have so many varied characteristics and application that their
usefulness can only be measured by air imagination. Polymers are the materials of
past, present and future generation.

2.1 CLASSIFICATION OF POLYMERS.

Natural and Synthetic polymers

2.2 POLYMERISATION

Is a process of reacting monomer molecules together in a chemical reaction to

form a polymer chain.

Hompolymer

Z+Z+Z+Z+Z+Z... ZZZZZZ...

Copolymer

Z+M+Z+M ... ZMZM...

In polymerization, alkenes which are relatively stable due to sigma bonding

between carbon atoms, form polymers through relatively simple radical reactions.
Polymerization that is not sufficiently moderated and proceeds at a fast rate can be
very hazardous. This phenomenon is known as hazardous polymerization and can
cause fire and explosion.
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2.3 TYPES OF POLYMERISATION

There are two types of polymerization: -

▪ Addition polymerization(chain-growth).

▪ Condensation polymerization(step-growth).

Most addition polymer are made from monomers containing double bonds
between carbon atoms. Such monomers are called Olefins and most commercial
addition polymers are polyolefin.

2.3.1 ADDITION POLYMERIZATION

It is a polymerization technique where unsaturated monomer molecules add

onto the site of a growing polymer chain one at a time. Growth of the polymer
occurs only at one (or possibly more) ends. Addition of each monomer unit
regenerates the active site.
Polyethylene and polypropylene are common types of plastics made by
chaingrowth polymerization.
They are the primary components of four of the plastics specifically labeled with
recycling codes and are extensively ibn packaging.

2.3.2 CONDENSATION POLYMERIZATION

A condensation polymerization is a form of step-growth polymerization. Small

molecules react with each other to form larger structural units while releasing
smaller molecules as a byproduct, such as water or methanol. A well-known
example of a condensation reaction is the esterification of carbolic acids with
alcohol’s. If both moieties are tri-tetra-functional, the resulting polymer is a cross-
linked polymer (i.e. a three dimensional network). Adding monomers with only
one reactive group will terminate a growing chain, and consequently lower the
average molecular weight thus, the average molecular weight and the crosslink
10
density will depend on the functionality each monomer involved in the
condensation polymerization and on its concentration in the mixture.

2.4.1 SAFETY IN INNOSON TECHNICAL

1. industrial safety is needed to check all the possible chances of

accidents for preventing machine and permanent disability of any
industrial employee, any damage to machine and material as it leads to
the loss to the whole establishment.

2. It is needed to eliminate accidents causing work stoppage and

production loss.

3. it is needed to prevent accidents in industry by reducing any hazard

to minimum.

4. it is needed to reduce workman’s compensation, insurance rate and

all the cost of accidents.

5. it is required to educate all members regarding the safety principles

to avoid accidents in industry.

6. it is needed to achieve better morale of the industrial employees.

7. it is required to have better human relations within the industry.

8. it is needed to increase production means to a higher standard of
living.

2.4.2 SAFETY KITS USED IN PLASTIC PRODUCTION

Safety Overall

Foot Wear

Safety Helmet

Ear Muff
11
 Face Mask

Safety Hand Glove

2.4.3 COMMON CAUSES OF INJURY IN THE FACTORY

An industrial accident is an accident that occurs when an employee is at work. It

includes any type of accident or injury caused from a person’s workplace.
Industrial accidents are unforeseen incidents that are not scheduled or planned
and cause injuries to employees. The results of a workplace accident can be
minimal or tragic, causing minor injury, damage to equipment or even in some
cases, major injury or death. A host of causes created industrial accidents, and
those causes can be placed into different categories. The common causes of these
accidents include:

Tiredness

Overexertion

Carelessness:

Improper Techniques

Manufacturing Defects:

Maintenance:

2.4.5 MAINTENANCE OF THE MACHINES IN THE FACTORY

Regular preventive maintenance is to protect the machines to work as an

effective way. The so-called preventive maintenance is a series of prevention and
inspection. In order to achieve the best performance and extend the life of
machines, the machine is regularly checked by the factory engineers.

Preventive maintenance carried out are:

12
 Reduce downtime and maintain normal operating speed can improve
production efficiency.

Timely replacement of worn or worn parts can maintain the level of

machine precision.

Frequent inspection of the major electrical components.

Lubricating of all movable pars to prevent stick up of parts.

Adhering strictly to the machine operation manual.

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CHAPTER THREE

3.0 DESCRIPTION OF INJECTION MOULDING AND MATERIAL MIXING

3.1 THE INJECTION MOULDING PROCESS

Injection molding is a process of forming an article by forcing molten plastic
material under pressure into a mold where it is cooled, solidified and subsequently
released by opening the two halves of the mold. It is a major technique in plastic
processing and is used for the processing of thermoplastic materials into all sorts of
products. Thermosets can all be processed using this technique but with the
complete modification of some features of the machine

Injection molding process can be summarized into three main stages:

1. Plasticizing of the plastic material into a melt; the material is melted

primarily by turning of the screw which converts mechanical energy into
heat. It also picks up some heat from the heater bands on the extruder barrel
or cylinder. As the material melts, it moves forward along the screw flights
to the front end of the screw.

2. Injection (transferring of the molten plastic into a cool mold; the moves
forward injecting (pushing) the plasticized material (melt) in front of it
though the nozzle sprue brush and runners into the mold.

3. Extraction (ejection) of the article or molding from the mold. When the
molding i.e. article is sufficiently cooled, the mold opens and the ejector
mechanism (pins, rods, bars or air) pushers out the article from the mold.

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3.1.1 PROCESS CYCLE
The process cycle for injection molding is very short, typically between two
seconds to the minutes and consists of the following four stages

1. Clamping: Prior to the injection of the material into the mold, the two
halves of the mold must first be securely closed by the clamping unit. Each
half of the mold is attached to the injection molding machine and one half is
allowed to slide. The hydraulically powered clamping unit pushes the mold
halves together and exerts sufficient force to keep the mold securely closed
while the material is injected. The time required to close and clamp the mold
is dependent upon the machine - larger machines (those with greater
clamping forces) will require more time. This time can be estimated from the dry
cycle time of the machine.

2. Injection: Plastic pellets are fed by means of a hopper into the injection
molding machine. These pellets move towards the mold by the injection
unit. The heat surrounding the barrel and the pressure serve to melt the
pellets. The volume of material injected is called the ‘shot’. This injection
time finished when 95%-99% or the mold is filled. It is hard to calculate
exactly the injection time because the flow of the plastic is always changing
and dynamic. Injection time can be estimated by other factors such as
injection pressure, power and shot volume. The injection pressure can range
from 35-140 MPa. The rate of injection and the pressure which can be
reached are determined and controlled by the hydraulic system in the
machine.

3. Cooling: The cooling process involves the plastic inside the mold beginning
to cool after it makes contact with the interior mold. As the plastic cools

15
 when it hardens it will take the desired shape. The part may shrink slightly
during cooling. Only when the cooling period has elapsed can the mold be
opened. It is from the wall thickness of the part and the thermodynamic
properties of the plastic that the cooling time can be estimated.

4. Ejection: After sufficient time has passed, the cooled part may be ejected
from the mold by the ejection system, which is attached to the rear half of
the mold. When the mold is opened, a mechanism is used to push the part
out of the mold. Force must be applied to eject the part because during
cooling the part shrinks and adheres to the mold. In order to facilitate the
ejection of the part, a mold release agent can be sprayed onto the surfaces of
the mold cavity prior to injection of the material. The time that is required to
open the mold and eject the part can be estimated from the dry cycle time of
the machine and should include time for the part to fall free of the mold.
Once the part is ejected, the mold can be clamped shut for the next shot to be
injected.

5. Dwelling - once the molten plastic is injected into the mold, more pressure
is exerted to make sure all the mold’s cavities are filled, using hydraulic or
mechanical pressure.

6. Opening - the movable platen is separated from the fixed platen to separate
the mold.

3.2 POSSIBLE DEFECTS ON PLASTIC PRODUCTS

A. Flow line

Description: Flow lines are streaks, patterns, or lines - commonly off-toned in

color that show up on the prototype part as a consequence of the physical path and

16
cooling profile of the molten plastic as it flows into the injection mold tooling
cavity. Injection molded plastic begins its journey through the part tooling via an entry
section called a “gate.” It then flows through the tool cavity and cools (eventually
hardening into a solid).

Causes: Flow line defects are caused by the varying speed at which the molten
plastic flows as it changes direction through the contours and bends inside the
mold tool. They also occur when the plastic flows through sections with varying
wall thickness, or when the injection speed is too low causing the plastic to solidify at
different speeds.

Remedies:

1. Increase injection speeds and pressure to the optimal level, which will
ensure the cavities are filled properly (while not allowing the molten plastic
time to start cooling in the wrong spot). The temperature of the molten
plastic or the mold itself can also be elevated to ensure the plastic does not
cool down sufficiently to cause the defect.

2. Round corners and locations where the wall thickness changes to avoid
sudden changes in direction and flow rate.

3. Locate the gate at a spot in the tool cavity with thin walls.

FIG 3.2.1 FLOW LINE

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B. Sink Marks

Description: Sink marks are small craters or depressions that develop in thicker areas
of the injection molded prototype when shrinkage occurs in the inner portions of
the finished product. The effect is somewhat similar to sinkholes in topography, but
caused by shrinkage rather than erosion.

Causes: Sink marks are often caused when the cooling time or the cooling
mechanism is insufficient for the plastic to fully cool and cure while in the mold. They
can also be caused by inadequate pressure in the cavity, or by an excessive temperature
at the gate. All else being equal, thick sections of the injection molded part take longer to
cool than thin ones and so are more likely to be where sink marks are located.

Remedies:

1. Mold temperatures should be lowered, holding pressure increased, and

holding time prolonged to allow for more adequate cooling and curing.

2. Reducing the thickness of the thickest wall sections will also ensure faster
cooling and help reduce the likelihood of sink marks.

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FIG 3.2.2 SINK MARK

C. Vacuum Voids

Description: Vacuum voids are pockets of air trapped within or close to the
surface of an injection molded prototype.

Causes: Vacuum voids are often caused by uneven solidification between the
surface and the inner sections of the prototype. This can be aggravated when the
holding pressure is insufficient to condense the molten plastic in the mold (and
thereby force out air that would otherwise get trapped). Voids can also develop
from a part that is cast from a mold with two halves that are not correctly aligned.

Remedies:

1. Locate the gate at the thickest part of the molding.

2. Switch to a less viscous plastic. This will ensure that less gas is trapped as
air is able to escape more rapidly.

3. Increase holding pressure as well as holding time.

4. Ensure that mold parts are perfectly aligned.

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 FIG 3.2.3 VACUUM VOID

D. Surface Delamination

Description: Surface delamination is a condition where thin surface layers appear on the
part due to a contaminant material. These layers appear like coatings and can usually be
peeled off (i.e. “delaminate”).

Causes: Foreign materials that find their way into the molten plastic separate from
the finished product because the contaminant and the plastic cannot bond. The fact
that they cannot bond not only has an effect on the appearance of the prototype, but
also on its strength. The contaminant acts as a localized fault trapped within the
plastic. An over-dependence on mold release agents can also cause delamination.

Remedies:

1. Pre-dry the plastic properly before molding.

2. Increase the mold temperature.

3. Smooth out the corners and sharp turns in the mold design to avoid sudden
changes in melt flow.

20
 4. Focus more on the ejection mechanism in the mold design to reduce or
eliminate the dependence on mold release agents.

FIG 3.2.4 SURFACE DELAMINATION

E. SHORT SHOT

Description: As the term implies, short shots can be described as a situation where a
molding shot falls short. This means that the molten plastic for some reason does not
fully occupy the mold cavity or cavities, resulting in a portion where there is no plastic.
The finished product becomes deficient because it is incomplete.

Causes: Short shots can be caused by a number of things. Incorrect calibration of

the shot or plasticizing capacities can result in the plastic material being inadequate
to fill the cavities. If the plastic is too viscous, it may solidify before fully
occupying all the cavities and result in a short shot. Inadequate degassing or gas
venting techniques can also result in short shots because air is trapped and has no
way to escape; plastic material cannot occupy the space that air or gas is already
occupying.
21
Remedies:

1. Select a less viscous plastic with higher flow ability. This plastic will fill the
hardest-to-reach cavities.

2. Increase mold or melt temperature so as to increase flow ability.

3. Account for gas generation by designing the mold so that gas is not trapped
within the mold and is properly vented.

4. Increase the material feed in the molding machine or switch to a machine

that has a higher material feed in the event that the maximum material feed
has been reached.

FIG 3.2.5 SHORT SHOT

F. Burn Marks

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Description: Burn marks are discolorations, usually rust colored, that appear on the
surface of the injection molded prototypes.

Causes: Burn marks are caused either by the degradation of the plastic material due
to excessive heating or by injection speeds that are too fast. Burn marks can also be
caused by the overheating of trapped air, which etches the surface of the molded
part.

Remedies:

1. Reduce injection speeds.

2. Optimize gas venting and degassing.

3. Reduce mold and melt temperatures.

FIG 3.2.6 BURN MARK

G. Flash

23
Description: Flash is a molding defect that occurs when some molten plastic
escapes from the mold cavity. Typical routes for escape are through the parting line
or ejector pin locations. This extrusion cools and remains attached to the finished
product.

Causes: Flash can occur when the mold is not clamped together with enough force (a
force strong enough to withstand the opposing forces generated by the molten plastic
flowing through the mold), which allows the plastic to seep through. The use of
molds that have exceeded their lifespan will be worn out and contribute to the
possibility of flash. Additionally, excessive injection pressure may force the plastic
out through the route of least resistance.

Remedies:

1. Increase the clamp pressure to ensure that the mold parts remain shut during
shots.

2. Ensure that the mold is properly maintained and cleaned (or replaced when it
has reached the end of its useful lifespan).

3. Adopt optimal molding conditions like injection speed, injection pressure,

mold temperature, and proper gas venting.

24
 FIG 3.2.7 FLASH

A large number of the defects mentioned above can be prevented in the design
process by incorporating proper tooling design into the iterative process. Using
mold flow software like Solid works plastics will help you identify ideal gate
locations, anticipate air pockets, flow or weld lines, and vacuum voids. Most
importantly, it will help you design solutions to these problems ahead of time, so that
when it comes to production you do not have to worry about the defects costing
you money.

3.3 GENERAL DESCRIPTION OF THE INJECTION MOULDING

Injection molding is a manufacturing process for producing parts by injecting

material into a mold. Injection molding can be performed with a host of materials
mainly including metals, (for which the process is called die-casting), glasses,
elastomers, confections, and most commonly thermoplastic and thermosetting
polymers. Material for the part is fed into a heated barrel, mixed, and forced into a
mold cavity, where it cools and hardens to the configuration of the cavity.

After a product is designed, usually by an industrial designer or an engineer, mold

are made by a mold-maker (or toolmaker) from metal, usually either steel or
aluminum, and precision-machined to form the features of the desired part.
Injection molding is widely used for manufacturing a variety of parts, from the

25
smallest components to entire body panels of cars, plastics and other product can
be produce by this means. Advances in 3D printing technology, using
photopolymers which do not melt during the injection molding of some lower
temperature thermoplastics, can be used for some simple injection molds.

FIG 3.3.1 DIAGRAM OF INJECTION MOULDING M

26
3.4 PARTS OF INJECTION MOULDING MACHINE.
production of different kinds of plastic products are being carried out using
different kinds of injection molding machines of various types based on their
tonnages with respect to the kind of products and machine slot weight. the
injection molding machines are made up of the following parts;

Hopper Loader: This involves connecting the hopper and the ground
material drum with a hose tube of considerable diameter through which the
material is sucked into the hopper.

Electronic Control Panel (Monitor): This is a computer screen panel

which displays all the variable of control (setting) to ensure injection and
clamping are properly done for successful production.

FIG 3.4.1 DIAGRAM OF CONTROL PANEL(MONITOR)

27
Feed Hopper: A large container in which raw material is sucked into before
going into the barrel

FIG 3.4.2 DIAGRAM OF A FEED HOPPER

Barrel: This is where the raw material into molten form before injecting
into mold.

28
 FIG 3.4.3 THE BARREL

A Reciprocating Screw: This moves the material forward by both virtues of

rotation and sliding axially being powered by hydraulic or electric motor.

FIG 3.4.4 RECIPROCATING SCREW

Nozzle: This ushers the melted material into the mold cavity

29
 FIG 3.4.5 THE NOZZLE

Mold: The mold receives the plasticized material, shapes the product and cools
it to solidify.

FIG 3.4.6 THE MOULD

30
A Ram Injection: This forces the material forward through a heated section.

A Ram Plunger: This is usually hydraulically powered to force molten

material through the nozzle.

Water Manifold Valves: This pumps or sprays cooling water (24oc ushers the
molten material into the mold cavity 28oc) to cool the machine. It aids the
solidification of the final part.

Proportional Valve: This uses variable voltage values for instance; it could be
powered by 10v and 15v in respective applications, while the process of
production continues to run. The speed and the pressure vary as the voltage is
being changed depending on the type of product to be produced.

Heat Exchangers: This introduce cooling water to the machine and absorb hot
water from the machine to the factory water outlet line at the inlet and at the
outlet.

CADS: The modern injection molding machine uses single input/output

computer aided drive (CAD) for carrying out operations unlike old machines
with 2-4 CADS for their operation.

Limit Switch: This switch is located inside the injection molding machine and
it actuates after forwarding takes place.

Actuating Switch: This switch is located outside the machine. It is a key lock
switch which stops the movement of the barrel, the movement of the barrel rod
presses the switch downwards.

31
3.5 MATERIAL SELECTION AND MIXING

3.5.1 MATERIAL SELECTION

Selection of materials is a very vital and indispensable stage in plastic production. The
selection of material may not be as difficult as it may appear to be but it requires
awareness on the general behavior of plastics, as well as familiarity with the
characteristics with individual plastics. The first point to note is the need for the plastic
and subsequently the production procedure and required mechanical properties,
the best plastics are polypropylene (PP) - used in Stallion and ethylenepropylene
copolymer.

Based on the products application: chair production, transparent and

nontransparent household material production, we have the following material:

(i) Polypropylene: Polypropylene, a synthetic resin built up by the

polymerization of propylene. One of the important family of polyolefin
resins, polypropylene is molded or extruded into many plastic products in which
toughness, flexibility, light weight, and heat resistance are required. It is also spun
into fibers for employment in industrial and household textiles. Propylene can
also be polymerized with ethylene to produce an elasticethylene-propylene
copolymer. Propylene is a gaseous compound obtained by the thermal cracking of
ethane, propane, butane, and the naphtha fraction of petroleum. The chemical
structure of the propylene molecule is CH2=CHCH3. Under the action of
polymerization catalysts, however, the double bond can be broken and
thousands of propylene molecules linked together to form a chainlike polymer.

The molecule consists of a backbone of carbon atoms with attached hydrogen

atoms; attached to every other carbon atom is a pendant methyl group (CH3).
32
Properties of Polypropylene:
a. Polypropylene is normally tough and flexible, especially when
copolymerized with ethylene

b. Melting point of polypropylene is 160oC. Therefore, unlike other polymers

like polyethylene, it is capable of being operational at a very high
temperature.

c. Its tensile strength is quite high. It shows strong resistance towards stress
and cracking.

d. Polypropylene is crystalline in nature and possesses a regular geometric

shape.

e. It acts as an excellent insulator. That means, it prevents flow of electricity

through it.
f. This polymer remains unaffected when it comes in contact with chemicals
such as alkaline substances, acids, de-greasing agents, electrolytic attacks,
etc. however, its resistance towards aromatic or aliphatic hydrocarbons,
chlorinated solvents and ultraviolet radiation is not very strong.
g. It can retain its stiffness and flexibility intact even at very high temperatures.

The three types of polypropylene - homopolymers, random copolymers and impact

copolymers - exhibit distinctly unique ‘strong-points’

a. Polypropylene Homopolymers (Homo PP): Homo PP is the most widely

utilized. Homo PP offers a high strength to weight ratio and is stiffer and
stronger than copolymer, this combined with good chemical resistance allows
this material to be used in many corrosion resistant structures. Polypropylene
Homo Polymer (Homo PP) is a colorless, non-flammable, non-reactive solid
with no odor. It is non-reactive with environment.

33
 Homo Polypropylene is widely used in plastic processing industry to make
variety of products such as Packaging Films, sheet, Boxes, containers, bags,
FIBC, home ware, home care, personal care and Hygiene combs, brushes,
Medicals and Surgery equipment’s, appliances, Automotive Furniture,
industrial products and article of day to day usage. There are four primary
criteria to consider when selecting a grade of polypropylene:

1. The process to be used

2. The aesthetic requirements of the application.
3. The mechanical function of the part
4. Special additive requirements

b. Impact Polypropylene Copolymer: Polypropylene (PP) impact copolymers

are thermoplastic resins produced through the polymerization of propylene
and by introducing a heterophasic structure inside a semi-crystalline PP
homopolymers matrix.

Impact copolymer polypropylene is a crystalline polymer which exhibits high

stiffness, excellent impact strength at temperatures well below freezing, and good
electrical insulation properties. The commercial grades of polypropylene impact
copolymer are available in a wide range of melt flows, impact strengths and
molecular weight distributions. Special additive packages are available to meet the
needs of your individual application.

The wide range in physical properties, relative ease of processing and low
density make impact copolymer polypropylene an extremely attractive
material capable of competing with more expensive resins in a number of
demanding applications.

34
c. Random Polypropylene Copolymer: Random Copolymer Polypropylene is
thermoplastic material produced through the polymerization of propylene,
with ethylene links added to the polymer chain. Typical characteristics of
Random Copolymer Polypropylene are excellent transparency and gloss, and
aesthetics, radiation resistance, a low melting point and seal initiation
temperature (SIT).

Random copolymer polypropylene is a clear, semi-crystalline polymer which

exhibits high stiffness, better impact strength than homopolymers at room
temperatures, and good electrical insulation properties. The commercial
grades of polypropylene random copolymer are available in a wide range of
melt flows and molecular weight distributions. Special additive packages,
including clarifiers, are available to meet the needs of your individual
application. Random copolymer grades of polypropylene are available to meet
the needs of various fabrication processes such as injection molding, blow
molding, sheet and thermoforming. The wild range in physical properties,
good clarity, relative ease of processing and low density make random
copolymer polypropylene and extremely attractive material capable of
competing with more expensive resins in a number of demanding
applications.

ii. High Density Polyethylene: High-density polyethylene (HDPE) or

polyethylene high-density (PEHD) is a polyethylene thermoplastic made
from petroleum. Known for its large strength to density ratio, HDPE is
commonly used in the production of plastic bottles, corrosion-resistant
piping, geomembrances, and plastic lumber. HDPE is commonly recycled.

35
MASTER BATCH

FIG 3.5.1 MASTER BATCH

Master batch is a solid or liquid additive for plastic used for coloring plastics (color
master batch) or imparting other properties to plastics (additive master batch).
Master batch is a concentrated mixture of pigments and/or additives encapsulated
during a heat process into a carrier resin which is then cooled and cut a granular
shape. Master batch allows the processor to color raw polymer economically
during the plastics manufacturing process.

A master batch is a solid concentrate of color and/or performance enhancing

additives such as anti-static, UV stabilizer, metal deactivator that is added to a base
polymer to impart these attributes. It usually supplied in granular form, either as
pellets similar in size to most polymers or as miniature pellets, known as micro
granules. Alternatively, master branch can be delivered in ‘rough cut’ form, a
mixture of small shreds and chunks.

Two main types are offered - polymer specific and universal. Polymer specific
master batch is produced using the same base polymer group as the type being
used by the processor. Universal master batch employs a carrier system that is
capable of carrying the high quantities of additives necessary to deliver that end

36
use properties required as well as affording the essential compatibility required
across a broad range of polymers.

Manufacturing is a two-stage process: gathering ingredients and then mixing them

together by applying heat and shear to produce a homogenized pellet. Generally,
high and low speed mixers are used to produce a pre-mix of the additives which is
then compounded on roller mills, kneaders, single or twin screw extruders. Even
distribution (dispersion) and development (breaking down) of the additives
throughout the carrier are essential. This processing depends on several key
elements: formulation, quality of raw materials and quality of mixing and
compounding plant. Finally, the finished master match is pelletized (die-face or
stand cut) or ground.

FILLER:

FIG 3.5.2 FILLERS

37
Fillers are defined as materials that are added to a polymer formulation to lower
the compound cost or to improve properties. Such materials can be in the form of
solid, liquid or gas. By the appropriate selection of these materials, not only the
economics but also the other properties such as processing and mechanical
behavior can be improved. Although these fillers retain their inherent
characteristics, very significant differences are often seen, depending on the
molecular weight, compounding technique, and the presence of the other additives
in the formulation.

The additives of fillers also require a balance of formulation for optimum

processing properties. Therefore, before making a final decision on a filled
compound, it is critical to establish the following:
1. Optimum loading for property and benefit.
2. Optimum formulation for processing and production output
3. Economics of filled formulation.

The common observation is that the finer the particle sizes the higher the
values of the tensile strength, modulus and hardness. Coarser particles will
tend to give less strong compounds than the virgin material (i.e. materials
without the filler), but if the particle size is fine there is an enhancement of the
mechanical properties and the phenomenon is called as reinforcement.
Impurities in the fillers can have serious effects on the polymer compound.
Coarse particles lead to points of weakness in soft polymers and will therefore
fall under stresses below that which might be expected. In general, the
phenomenon of reinforcement appears to depend on three factors:

38
 An extensity factor - the total amount of surface area of filler per unit volume in
contact with the polymer.

An intensity factor - the specific activity of the filler - polymer interface

causing chemical and/or physical bonding.

Geometric factors such as structure and porosity of the particles.

3.5.2 MIXING PROCESS IN INJECTION MOULDING SECTION

This is a very important subsection in Innoson Technical; it consists of the mixing

machines (mixers) which are of different sizes and configurations. The primary
work done in the mixing section is to combine the various materials used in
production in their correct proportion to enhance quality product. At INNOSON,
the mixing section which is located at a corner inside the new injection factory
carries out the mixing of all the materials required in the production of injection
molded products. The products include; pallet, chairs of different sizes and shapes,
table tops and legs, baskets. The mixing is done in charges. A charge contains all
the basic materials needed by the product, the quantity of mixed material supplied
to the machines for the production of a particular product depends on the quantity
of products required at such time, this is usually measured in multiple of charges.

REGRIND:

The regrind are materials obtained from damaged products. At Innoson Technical,
due to some mechanical or material error, some products are deformed and as a
result are substandard. Such products are termed “damages” which ordinarily
would amount to waste, but due to the unique nature of polymer, such products are
grinded and reused for production. They are mixed with virgin materials in a ratio

39
that will increase quantity of products and retain quality. At Innoson Technical, not all
the products require regrind for its production; it is the product specification such as
strength, color, that determines the addition of regrind. Basically, all white products do
not require regrind.

All damaged thermoplastic products are sent to the grinding section where they are cut
and grinded; they are then packaged in empty raw material bags. From here, it is sent to
the mixing section where they are combined in the right proportion with virgin
materials for the production process.

REPROCESS

These are materials made from scraps, they are made from a mixture of scraps with a
compound ‘Ravia’. The additions of these materials to the scraps, make it useful in a
production process. They increase the quantity of products and at the same time
maintain the quality of such products.

It comes in different colours; brown used for mixing beige, black used for mixing night
blue, etc. at Innoson, they have a material reprocessing section and they also obtain such
materials within the country.

3.6 PRODUCTS AND MATERIAL RATIO

The various products of new injection molding section have its specific material
mixing ratio and it is the duty of the mixing section to ensure this is done. This
ratio is color dependent as the color of a product alters a material ratio, for all
white coloured product regrind and reprocess are not added. Here is a breakdown
of the breakdown of the major product of injection molding section and their
40
mixing properties ratio. N/B: The products are named after their mold
configuration and the quantity is measured in ratio.

41
CHAPTER FOUR

COMPRESSION MOULDING

4.1INTRODUCTION

Compression molding is the oldest method of molding polymers being first used to
produce molded articles from phenol formaldehyde. It is now used for other classes of
polymers and remains today the major technique for converting thermosets into
molded products. Thermoplastics are not usually compression molded because they
require alternate heating and cooling of the mold hence molding cycles may be long
and production slow which is not economical. PVC is the only important proceed by
compression molding in the production of long playing gramophone records.
Thermosets and elastomers can be removed from the mold while hot once is complete.
Therefore, when compression molding thermosets and elastomers, the mold remains
heated to cure the mouldings and the production rate is determined by the kinetics of
the curing process. Production rates are usually increased by multi-cavity molds.
The temperature of the mold are usually in the range of 127C-
129C while the pressure is between 7 and 40 Mpa and it is normally applied slowly at
first, giving time for the material to soften.

42
FIG 4.1.1 COMPRESSION MOULDING MACHINE

43
4.2 MATERIALS FOR COMPRESSION MOULDING AT INNOSON
In innoson plastics company, compression molding is used for plate production of
different weights, sizes and shapes. There are two materials/chemicals used in plate
production section and they are melamine formaldehyde and melamine resin.

a) Melamine Formaldehyde (MF): Melamine formaldehyde is a thermosetting

plastic that strengthens as it is heated during its preparation. Once set, it cannot be
remolded. Melamine formaldehyde is made from polymerization of formaldehyde
(CH2O) with melamine (C3H6N6).

CH2O + C3H6N6 C4H6N6O (Melamine formaldehyde)

Melamine formaldehyde is hard, rigid material with good abrasion resistance and its
mechanical characteristics are sufficiently good for continuous use at moderate
temperatures (up to 100°C). And it has lower water absorption and improved
temperature and chemical resistance. It is typically used for tableware, laminated
worktops and electrical fittings.

b) Melamine Resin (MR): Melamine resin popularly known as shiner is the same
material with/ gotten from melamine formaldehyde. Purification of melamine
formaldehyde (high density) gives melamine resin (low density). NB: ‘MF’ is used for
plate production while ‘MR’ is used for shine the paper design of the plate. ‘MR’
can’t replace ‘MF’ because of its low density.

4.3 STEPS OF PRODUCTION OF CUSTOMIZED PLATE

1. The graphic designed paper including write-ups and pictures are sent to the
paper section where it is being cut to the desired shape.

44
2. The choice mold is being fixed manually at the compression molding
Machine (Yihao machine).
3. Measure or weigh the melamine formaldehyde at the weighing balance
depending on the weight of the plate or tray to be produced.
4. The weighed powdered melamine formaldehyde is poured into the lower
part of the mold the machine and “operate one’’ from the control is pressed to
meet the upper part of the mold.
5. After some seconds, the plate is formed and the customized paper designed
is placed on the plate.
6. Melamine resin (shin shin) is sprinkle around the paper on the formed plate
and “operate three’’ is pressed to meet the upper mold to complete the work.
7. The final plate is sent for polishing to remove rough surface.

4.4 SUB SECTIONS OF PLATE DEPARTMENT AT INNOSON

4.4.1 MOULD SECTION

Mold are sometimes fitted with ejection mechanisms to save time and damage no
parts. Complicated mold is often split vertically and horizontally and have heating
and cooling channels thus removing reliance on conduction from the platens.
Using electric heaters to heat the platen rarely gives uniform temperatures.
Temperature differences at various points on the platens are known to be as large
as ten degrees. Temperature of the upper platen is always higher than the lower
platen.

Types of Mold

45
a) Positive mold: In positive mold, the top force (or male die) acts as a positive
plunger and impinges directly on the material. There is no provision for gas or
excess material to escape and consequently the correct quantity of material must be
introduced into the mold for close dimensional control. It is not suitable for free
flowing materials. It is, however, used for dough molding compounds (DMC) and cloth
or fabric filled thermosets.

b) Semi-positive mold: is the most widely used type of compression mold. The
molded area is surrounded by a land area or step which limits the travel of the
plunger thus controlling the thickness of the molding. Excess material or gas can
escape into the flash space provided, hence unlike the positive mold, the quantity
of material introduced into this type of mold need not be very accurately measured.

c) Open-flash mold: is the cheapest and simplest mold. It has no loading chamber - a
cavity is simply machined into the bolster. Excess material is squeezed out by the time
the mold is finally closed but the resulting flash requires additional operation to
remove. This mold is used for making flat articles or where greater depth is not
required, e.g. ash trays and plates.

46
FIG 4.4.2 COOLING TOWER

At innoson plastic company, cooling tower is use as an example of a heat

exchanger. Cold water is being pumped from the reservoir tank via metallic pipes
across the

whole compression molding machine in the factory. There is a counter flow heat
exchanger that occurs in the machine where the cold water from the pipes flows in

opposite direction with the hot hydraulic oil from the machine. The hot oil
becomes cold and enters the oil tank of the machine after contact with the cold
water, while the

47
cold water becomes hot by convection. The hot water is sent to the cooling tower
where it will have cooled and goes back to the reservoir tank. The process is a
recycling process

and it helps the compression molding machine not to be hot because the hydraulic oil is
always cooled.

4.4.3 AIR BORNE SECTION

This section is in charge of supplying air to the factory to remove dust and
powered materials that was not used during production of plate which saturate the
atmosphere.

This chemical when inhaled can cause cancer in human body. Screw Air
Compressor machine is used to generate air then sent it to the pressure tank.
Metallic pipes are

connected to the factory through the pressure tank

4.4.4 POLISHING SECTION

In this section is where the rough edge plate produced from the compression
molding machine is sent to for finishing touches. Filing machine is used to
smoothing the rough surfaces of the plate making it attractive. The fan beside the
machine is used to blow out dust particles generated. From the polishing section goes
to the packaging section.

48
 FIG 4.4.4 FILLING MACHINE

4.4.5 PACKAGING SECTION

All the smoothed plate being filed at the polishing section is sent to the packaging
section where it will be packaged in cartons depending on the number of plates
produced waiting for the owner to carry them.

4.5 ADVANTAGES OF COMPRESSION MOULDING

a. Waste of material is minimal about 2 - 5% scrap; but the scrap cannot be

recycled.
b. The finishing costs are low as there are no gate marks, etc. to remove;
c. There is little or no orientation in the molding hence the associated problems
are avoided;

49
d. Relatively low capital and tooling costs because the equipment is less complex
and the molds are very simple;
Against these is the inability to produce intricate mouldings with undercuts,
delicate inserts and internal holes with very close tolerances. Closing the press on
molding material which is unplasticised can damage or break inserts, core pins, etc.
in the cavity.

4.6 MATERIAL MIXING DEPARTMENT:

In this department, materials are being mixed with master batches and fillers for
production in both injection molding and blow molding departments.

For blow molding, the materials used is high density polyethylene(HDPE), it was
mixed with master batch in the ratio of 1:100 i.e. master batch that weighs 250grams
was mixed with a neutral material that weighs 25kg per bag.

For injection molding, the material and master batch are also mixed in the same
ratio. But when palletize materials are used then the mixing ratio changes to 2:100,
i.e. master batch of 500grams with neutral material of 25kg. it was so because
palletize material is coloured and will overshadow or kill the master batch if added in a
little quantity, so to avoid an error in color for the production, there was an increase in
master batch.

50
FIG 4.6.1 MIXING MACHINE

51
 CHAPTER FIVE

5.1 QUALITY OPERATION

This involves the checking of the final products to ensure its quality and to satisfy
customer’s desires.

QUALITY CONTROL
It is the measure of quality of the product. Tests are being carried out on the
plastics which confirm the quality of the plastic that the plastic industries
produced. The following requirements are being set out for plastics by
standard organization of Nigeria: Revision, splitting, surface, distortion and
overload tests.

5.2 NIGERIA STANDARD ON PLASTIC PRODUCTS MADE FROM

POLYETHYLENE
▪ SCOPE: This Nigeria standard specifies requirements and tests method for
the quality of buckets made from polyethylene for domestic use.
▪ DESCRIPTION: Buckets shall be described by their capacity in liters.

5.3 DEFINITION OF TERMS

✔ DELAMINATION: Separation into constituent layer.
✔ FISSURE: A narrow opening or crack of some length and considerable
depth occurring from some breaking, rending or parting.

52
 ✔ SPRUE: The waste plastic piece formed in the hole through which
molten plastic flows into the gate of the mold cavity.
✔ FLASHES: Thin plastics of larger molecules from smaller one.

5.4 QUALITY CONTROL PARAMETERS AND REQUIREMENT

TEST METHOD/PROCEDURES
TEST APPARATUS/EQUIPMENTS
The apparatus used in the quality control laboratory are as follows:
⮚ Vernier caliper
⮚ Test tube(16x450mm)
⮚ Water bath (14 liters)
⮚ Retort stand and clamp
⮚ Electro thermal heating mantle ⮚
Micrometer screw gauge
⮚ Meter rule
⮚ Cutler (sharp knife)

5.4.1 REVISION TEST

TEST SPECIMENS: A specimen of dimension 50mm×2.5mm is cut from the
base of the bowl such that its main axis is radical to the sprue. Five (5) specimens
of the same dimensions from separate sectors of the side are examined in ease case.

PROCEDURE: The specimens are immersed in water at 100oC ±2 o C for

30minutes. On removal they are allowed to cool for one (1) hour after which the
length is measured. Revision is the reduction in length expressed as a percentage of the
initial length of the specimen.

5.4.2 SURFACE TEST

53
The specimen is exactly similar to those employed in revision test but cut from the base
of the bowl so that the center point is 75mm from the sprue.

PROCEDURE

Four (4) specimen are immersed in carbon tetrachloride at 40 o C for four (4) hours. The
solvent is immersed in water bath at 40 o C ± 5 o C. At the end of four (4) hours, the
specimens are allowed to dry for one (1) hour. The extent of declamation
produced is recorded.

5.4.3 DISTORTION TEST

The distortion test is carried out by suspending the bowl filled with water at 60 oc for
5minutes in a special apparatus and then determining the defection of the top rim and
bottom of the bowl.

PROCEDURE: The bowl is suspended by the handlers or by its rim using sturdy
metallic hooks having 20mm diameter flat plates at its ends. The thickness of the plates
shall not be less than 2mm after 5minutes, the between pairs of the hooks and the
bottom of the bowl at the centre is measured.

The following dimension shall be measured.

a) The top of the rim of the bowl midway between the pairs of the hooks.
b) The bottom of the bowl at the centre.

Changes in dimension shall be expressed as percentage of the initial dimensions. The

result from each test are recorded in SON analysis report and presented to SON’S

official when they come for quality control inspection.

54
 6.1 CONCLUSION

Among the many things I learnt as reported in the preceding chapters, I will
conclusively state that relevance of the training exposed me to the working
principle in plastic industry and the control needed. it also exposes me to necessary
requirement in setting up a plastic industry (the plant layout design).

The training also helps me to come in contact with people who have a lot of
working experience, and are professional in handling some sophisticated machine.
Indeed, the scheme is really a wonderful and success in my career as I learnt a lot just
within the few months of training; and I was able to apply the theoretical
knowledge into practical and analyzed its workability.

I want to use this medium to commend the federal government of Nigeria through
the office of the students’ industrial work experience scheme (SIWES) for their
initiative in coming up with this noble scheme, that expose students to obtain the
relevant industrial-based training and experience necessary in their chosen
profession before leaving the higher institution. This scheme is a welcome idea that
equipped students practically in all the skills needed in other to excel in his/her
chosen career.

However, regardless of the gains there were times when it looks stopping the
SIWES programme would have been a better option. Many of the major problems
encountered could have been averted, and hence save the students the unwanted
stress, if the polity was better. But as the time goes I took it as part of the
experience that will be beneficial in one way or the other. Am grateful to the ITF and
the school management for the initiative and the opportunity. God made it a success at
the end may this name be praised.

55
6.2 CHALLENGES FACED

However, I see the need to outline the challenges I faced before and during the period
of my attachment. It will give an insight into the ordeals of students on internship to
ITF, SIWES coordinators and the school management. It will also prepare prospective
students ahead of time. Concerned establishments will by this gain knowledge of what
their custodians find unfavorable but weren’t courageous to relay it directly to them.
1.Getting a place for my IT was a problem because of the economic state of the country
some of the company stopped taking IT students and even if the will agree the will place
you at that section they are having vacancy without considering whether it has to do
with your course of study.
2.There are only few establishments who have in their possession the upgraded
relevant techniques or the practical experience needed.
3.The IT students are not given the opportunity to operate the machines in the
industry, because the works do not understand what the IT is all about. They see us as free
laborers.

56
 7.0 RECOMMENDATIONS

Throughout the six months’ period of my industrial training, there are some
necessary factors that need to be tackled for the good and clear understanding of an IT
student. I do humbly recommend as follows:

1. The industry-based I.T. coordinator/officer should try and ensure that functions ae
carried out in the various departments where IT students is posted to work and also
enlighten the student in carrying out their duties most especially when the student
needs his/her clear explanation.
2. The Institution-based Supervisor that will be visiting and monitoring of the
industrial training students where they are working should be a lecturer from the
student’s department (field of study). He will be able to know if the student is
adequately exposed, if the experience is standard and relevant. Then, he will advise the
student based on the main areas to get proper information.
3. The industry-based I.T Coordinator/officer should try and partner with some of these
big companies so that they will give the students the opportunity to use their machine
that are spoilt for practical and learning.
4. The industry-based I.T coordinator/officer should try to know if they can make
it possible for each institution to have some companies that they will be posting
their students for training and lecturer in charge of the students in that company,
who will be there permanently to supervise the students and help them achieve and
solve problems in the company related to their course of study to enhance their
project work during their final year.
57
 REFERENCES

American Chemical Society National Historic Chemical Landmarks.

http//www.earthday.org>uploads>plastics

www.toxicslink.org>docs>fully reports plastic//

ec. europa.eu>plastic

www.wikihow.com

www.wikipedia.org

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