UNITED IMPEX LIMITED BARAK WATER TANK Vocational Training Report

Submitted by:
Name - PROMIT CHOUDHURY Registration ID 1021010242

B.Tech, 3rd year Mechanical SRM University Chennai Tamil Nadu

MAY-JUNE

2012

UNITED IMPEX LIMITED, SILCHAR, ASSAM

ACKNOWLEDGEMENT

I owe a great many thanks to a great many people who have helped and supported me during the vocational training and in its completion. Training can never exist and thrive in solitude. Training in an industry like UNITED IMPEX LIMITED is never the work of an individual. It is more a combination of use, suggestions and contributions and work involving many individuals. Thus one of the most pleasant parts of writing this report is the opportunity to thank all those who have contributed towards it. The training report as it stands today is the sincere contributions of a few spirited individuals. I take this opportunity to express my sincere gratitude to respected Mr. Navin Gulgulia (Director) who provided me invaluable help during my training. And I would also like to acknowledge Mr. Himanish Dutta (Sr. Engineer), Mr. Shravesh Rathod (Quality Analyst) without their support and direction I would not have been able to complete this vocational training successfully. I would also like to extend my sincere gratitude towards all the staff members of UNITED IMPEX LIMITED, who cooperated with me, at all level during my training. I also show my indebtedness to my college SRM UNIVERSITY, Chennai & its Training and Placement Department to give such an opportunity to take up this training at UNITED IMPEX LIMITED and my parents, and teachers for their unconditional support.

CONTENTS

SERIAL NO. 1. 2. 3. 4. 5 6. 7. 8.

TOPIC Cover Page Acknowledgment Contents Company Profile Introduction Manufacturing Tank Design (Vertical And Horizontal) Manufacturing Processes: 1. Mixing 2. Compounding 3. Pelletizing 4. Pulverising 5. Rotational Moulding 6. Scrap Grinding 7. Agglomerating Quality Control Tank Longevity Projects Undertaken 1. Life Cycle Approach And Analysis 2. Implementation Of A Hybrid Moulding Concept 3. Developing A Revised Extrusion Flow 4. Design Of Multipurpose Tank For High Altitude And Turbulence Prone Area 5. FEA Of Tank For Quality Improvement Conclusion

PAGE NO. 2 3 4 5 6 7-8 9-24

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25-26 27-32 33-40

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COMPANY PROFILE

At United Impex Group of Companies an ISO 9001:2008 Certified Company and the manufacturer of BARAK WATER TANK have completed 10 years of quest for the best. And during this journey, we have traversed through endless enlightening moments all that has turned into unmatched excellence. This wide span of time and experience has taken us to the top in the industry, spearheading the revolution in water tank manufacturing and multipurpose tanks. Deep understanding of the industry and requirement of the customers, coupled with sound technological expertise and experience, topped with a penchant for giving the best of the products to the customers - all these factors have lead us to today's leading position and a nationwide reputation as a trustworthy company for finest quality products. Currently, we have manufacturing capacity of more than 28-30 tanks per week. Reflecting the requirements of the customers, we have also initiated handling turnkey project across the state. Our manufacturing facilities are spread in an area of 12000 sq.meter. With In-House R&D centre and Versatile machines enabling us to be an ISO 9001:2008 certified company. Finest, well qualified mind power, equipped with state-of-the-art machinery to carry out whatever comes to mind, has ensured that we earn a name for being the most dependable innovators and front runners in the industries. And we are all set, for further advancements in the farthest corners of the world!

INTRODUCTION

Plastic tanks are commonly used on farms, household purposes and by commercial application businesses for efficient storage and transportation of water and other liquids such as pesticides and fertilizers. These polyethylene tanks, called poly-tanks are popular for several reasons: They are available from many suppliers and retailers. They cost significantly less than tanks made from other materials. They are compatible with many liquid products used by farmers and commercial applicators. They offer design flexibility. They are relatively light weight and easy to handle. They are corrosion resistant and relatively impact resistant. They can be designed so that the amount of liquid is easily visible. Complex parts can be moulded without need for post assembly.

Roto moulded plastic water storage tanks are made from Linear Low Density polyethylene. These tanks are light in weight therefore; it is easy to fix them at the place of choice. These tanks require no painting, no rotational moulding, product is formed inside a closed mould rotating biaxial in two plains perpendicular to each other. In batch type Rock and Roll type rotational moulding machines, frame of the machine is turned in a primary axis while mould is rotated in secondary axis. Rotational moulding does not involve any injection pressure and high shear stress rates. These tanks keep water clean, odour free and maintain the quality of water stores intact. These tanks are economical, practical and hygienic alternative of storing potable water in single or multi storied residential units, industrial setups.

MANUFACTURING

Poly tanks are built with highly durable, chemical-resistant resins formulated for todays pesticides and fertilizers. They are built to the internal specifications of the manufacturer, not according to a national standard. The resins used in the manufacture of poly tanks are either high density linear polyethylene (HDLPE) or high density cross-linked polyethylene (XLPE). In general, both materials work well for the storage and transport of most pesticides and fertilizers, but XLPE is more chemical resistant and durable (although generally more expensive) than HDLPE. The LLDPE granules are mixed with granules of black colour concentrates. These a re extruded and strands are chopped as granules so as to achieve uniform distribution of carbon black. The granules are pulverized in a special pulverization system from 30 to 40- mesh powder. This powder is fed in the mould in the required quantity. The burners of the Roto Moulding Machine are fired with the help of LPG or Diesel and the moulds are heated to 300'C. Molten powders when rotated in the heated moulds form hollow storage tank. White inner coating is given for better finish. After proper time when the tank is ready, the mould is cooled and opened and the tank is taken out. Finishing of the tanks is done manually. Roto Moulded Tanks are manufactured as per IS 12701:1989. This standard covers the requirements of materials, dimensions, construction, shape, tolerances, fittings, workmanship, performance, requirement and inspection and testing of rotational moulded polyethylene water storages tanks. This standard is applicable only to water storage tanks subject to the following two conditions: Own hydrostatic head of water Tank with uniform flat base support

The internal and external surface of the water storage tank should be smooth, clean and free from other hidden internal defects, such as air bubbles, pits and metallic or other foreign material inclusions. The mould parting line and excess material near the top rim of the tank should be cut and finished to the required leave Defects like air bubbles and pits at mould parting line and at top rim of the main man hole should be repaired by hot air filler rod welding method. A powdered polymer compound with an ultraviolet (UV) protection package is poured into a two-piece mould. The amount of UV protection varies by tank type and manufacturer. The mould is clamped shut and heated in a hot oven. During the heating process, the mould is tumbled in two directions; as the powered polymer melts, the tumbling causes it to coat the inside of the mould. Once completed, the mould is moved into a cooling chamber where the temperature is slowly decreased. The completed tank is then removed from the mould. This process moulds poly tanks as a single piece. A visible external seam known as the parting line gives the impression that two pieces are joined together. But the parting line is merely an external cosmetic artefact from the manufacturing process; it represents the juncture of the two pieces of the mould, not the tank itself.

TANK DESIGN
VERTICAL STORAGE AND HORIZONTAL TRANSPORT
Poly tanks have two distinct use designs: vertical tanks (also called stationary, upright, or hockey puck tanks) and horizontal tanks (side-to-side, transport, application, or leg tanks). The significant design differences between vertical and horizontal tanks dictate how they should or should not be used. Using a tank outside its design specifications voids the manufacturers warranty and increases the odds of tank deterioration, tank failure, costly cleanup, and lost inventory. Vertical tanks are flat- or cone-bottomed, cylindrical tanks designed and manufactured specifically for stationary placement on a reasonably smooth, level surface. As the tank is filled, the pressure of the liquid forces the wall to flex outward. As the tank is emptied, the walls revert to their original shape. This movement of the tank wall is determined by the depth and specific gravity of the liquid. Manufacturers strengthen tanks by making the plastic thicker where the sidewalls meet the bottom; this is where the pressure is greatest. Vertical tanks are made for stationary use only, but many come with tie-down connectors for anchoring them to the ground; empty tanks can be set askew or blown over during high winds if not tied down. The connectors on vertical tanks are not strong enough to secure loaded vertical tanks to the bed of a truck or trailer for transport. Horizontal tanks are designed for placement on trucks, trailers, and field sprayers, but they also may be used as stationary tanks. Pressure points on horizontal poly tanks are much different than those found on vertical tanks. Liquids move from front to back when the truck stops and accelerates, creating a surging effect that exerts pressure on the front and back walls. The tie-down features on horizontal tanks are more substantial than those on vertical tanks. Horizontal tank tie-downs commonly are pipe hoops or metal bands capable of holding a loaded tank in place if the truck or trailer stops suddenly. The hoops and bands also support the sides of the tank. Both vertical and horizontal tanks should be properly secured in place without bulging or looking deformed. Although tanks are designed to change shape slightly when filled, they must not be squeezed out of shape by straps or tie-downs. A deformed tank indicates too much stress on the polymer, which in combination with UV exposure and the weight of the material contained may cause the tank to fail. Large capacity horizontal tanks greater than 1,000 gallons generally are equipped with internal plastic baffles that reduce the force of liquid as it surges from one end of the tank to the other.

HORIZONTAL TANK

VERTICAL TANK

MANUFACTURING PROCESSES
MIXING
The mixer function as hot mixing [temperature is increased due to friction generated during high speed mixing process.] It offers high speed mixture suitable for polymer resin to mix with additives, pigment paste or powder, for dry blending and granules with master batches.

Features
Capacity 25 to 100 kgs per batch. For granule Capacity 25 kgs to 100 kgs. Per batch for resin with pigment powder Moisture free blending and compounding with additives in different controlled temperatures. Stainless steel inner vessel and graded mild steel outer jacket provided with temperature sensors for monitoring the powder temperature and water jacket to avoid clotting of the resin during process. Process control timer switch to set and monitor the process . Provision for on line additives or pigment adding facility and breather valves on the lid. Pneumatic controlled powder discharge and lid opening arrangement. Digital display of powder temperature and water jacket temperature with hoofer /alarm for process timing indication.

COMPOUNDING
Compounding extrusion is a process that mixes one or more polymers with additives to give plastic compounds. The feeds may be pellets, powder and/or liquids, but the product is usually in pellet form, to be used in other plastic-forming processes such as extrusion and injection moulding. Machine size varies from tiny lab machines to the biggest extruders in the industry, running as much as 20 tons per hour, as used by the chemical companies that make the base resins. Usually twin-screw extruders are preferred because they give better mixing at lower melt temperatures. Most of these have screws and barrels made up of smaller segments (mixing, conveying, venting and additive feeding) so that the design can be changed to meet the production and product needs. Single-screw extruders can be used for compounding as well, especially with appropriate screw design and static mixers after the screw. Selection of the components to be mixed (viscosities, additive carriers) is as important as the equipment.

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PELLETIZING PROCESS
The compounding process is defined as melt mixing different components in either a single or twin screw extruder to form a new material. This can be as simple as mixing a colorant in the form of a liquid, powder, or concentrate into the polymer melt to change the resin colour, or as complicated as blending or alloying two or more different resin systems while adding a filler, reinforcement, colorant, flame retardant, and/or stabilizers to produce a radically different formulation with its own unique properties and end-use performance. Figure 44.1 shows a compounding process with feed system, extruder, strand die, water bath, air knife, and pelletizer. Molten polymer exits the die as a strand approximately 1/8 inch (3.2 mm) in diameter. Strands pass through a water bath to remove the heat and solidify the strand, which will be cut to length in the pelletizer. Between the pelletizer and water bath is an air knife or air stripper to remove any surface moisture attached to the strand. A rougher strand surface makes it more difficult to remove the moisture after the strands exit the water bath. How many strands exit the extruder depends on the extruder size and throughput rate, with larger diameter extruders producing more strands and higher throughput rates. Cold water enters the water bath at the tank bottom farthest from the extruder and exits from the tank top next to the extruder. This allows the warmest water to be removed from the tank. It is common to have the water bath water flow counter current to the strands. This results in the water temperature being hotter at the strand entrance than at the strand exit. If insufficient cold water is supplied to remove the heat, the water bath temperature can build up over the run, necessitating higher water flow to keep the strands cold enough so they can be pelletized.

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PELLETS

FEATURES
Recycling Plant available in standard, vented and High L/D Ratio version, having screw & barrel made out from alloy steel & fully nitriding ,Hard chrome plating. Available with Hydraulic Screen Changer Heavy duty bearing housing with Helical/Worm Gear Box. Drive from main A. C. motor to screw is via rubber belts and pulleys and a Gear unit. Barrel Heating by Power saving heaters/Gas system. Cooling System provided for accurate temperature control . Heating Control by temperature controller. Control Panel Having digital temp controller & accessory Cooling Tank fabricated from S.S. Palletizer / under water pelletizing (Die-face) system to produce Pallets.

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PULVERIZER
Pulverizer machines are used to smash materials into tiny shards or granules. Pulverizer machines can crush all types of items, including plastic, glass, aluminium, concrete, coal, rock, resin, tires, and medical waste. Pulverizer machines come in a number of different forms. Hammer mills, ring mills, double roll crushers, granulators, impactors, and shredders are all forms of pulverizer machines. Pulverizer is used in plastic industry for Plastics Pulverizing Including PVC Recycling, Rotational Moulding, Compounding and Master batching. The Naroto range of pulverizer ensures the production of pulverized material from plastic granules for the manufacturing of high quality final products. Pulverizer can pulverize LDPE, LLDPE, HDPE and various thermoplastic materials and other kinds of pulverize for different materials. Pulverisers have fully automatic operations with predetermined sequence of operations such as Automatic granule lifter, Automatic on and off feeder, Automatic controls of mill temperature etc. The Pulverizer constitutes of high quality, maintenance-free, efficient components. Pulverizers are available in various configurations like Single Mill Pulverizer, Twin Mill Pulverizer (Dual Mill Pulverizer) with various designs, sizes and shapes of pulverizer blades. In Plastic Industry, there are need for advanced technology and improvements, reduced maintenance and higher production rates. We incorporated these requirements into all our pulverizing machines. We are supplying the latest in pulverizing technology and auxiliary equipment to the rotational moulding industry. The steadily increasing demand for powders of plastic, rubber, or minerals of any kind as well as the constantly expanding quality requirements with regards to flow ability, bulk density, and particle size distribution and grain structure, pulverizing systems is the best solution. Pulverizers produce reliable high quality plastic powders for rotation moulding, whirl sintering, coatings, flame spraying processes, carpet backside coatings, extrusion and additional processes. Constructive and process-technological characteristics of Pulverizers are:

Grinding path made of wear resistant, technological optimized key segments Exact, central grinding gap adjustment Housing design for optimized air cooling Broad application field

Salient Features of Pulverizer

By using this machine you can manufacture 30-400 Kgs Master Batches p/h. The power consumption is very less compare to other pulverizing machines. Production cost will be cheaper.

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Low maintenance. Higher production capacity. Minimum man-power for operating the machine. High Quality and lower wastage Economical and cost effective Produces fine micro Powder Gives high output rates A Single person can operate easily

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SINGLE MILL PULVERIZER

Overview The range of pulveriser is available from 30 kgs/hr to 500 kgs/hr. For different application, where ever a powder product is required. Application Pulverisers are the grinding varieties of these granulated materials including high and low density plastics like: Ldpe (16 ma 400 ipcl grade for textile and wire coating), Lldpe, hdpe (26500 reliance grade for master batch) Lldpe (36ra 0345 ipcl grade) Rpvc, pc, abs, eva,ps, etc.

Features Disc & mill body: The disc is made from graded material tested quality and dynamically balanced for smooth running. Inspection windows (2 nos.) Are provided on both side of mill body for visually checking the disk gap and assist the gap setting. Several options are available to simplify the cleaning process. Long service life of the discs between resharpenings. Cooling: For mill body, bearing housing and mill door for better result. Bearing housing: Bearing housing water cooled. Metal detector: High efficiency hopper magnet provide with the m/c. To detect the metallic inclusion parts from the polymer. Optionally, metal detector sensor will be provided on request.

Feeding: Feeding hopper showing low level indicator. Auto tripping system available in case of overload feeding. Main motor ampere and feeding device synchronised to avoid tripping of motor due to over feed Cyclone: Our cyclonic system is well designed for easy cleaning, with bag filter arrangement.

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Hopper loader: Pneumatic hopper loader will provide on request. Performance: Uniform particle size for better distribution Optimum material distribution Homogeneous material in case of coloured powders. Low energy consumption and high throughput. Powder temperature monitoring device.

Plastic Pulverizer or Pulveriser

In plastic reprocessing after the types of plastic separated is a Mechanical processing to run the plastic through the Pulverizer. Pulverizer or Pulveriser crushes the plastic into tiny shreds or granules. Plastic pulverizer is the particular equipment for recycling disused insignificant materials in producing and grinding heat-sensitivity plastic such as PVC. Pulverizer includes high output units which can be equipped with automatic temperature control. The material to be pulverized is fed centrally between a fixed and a high speed rotating pulveriser disc with centrifugal effect carrying the material through the processing zone before being discharged from the machine pneumatically. 16

Several different types of pulverizer machines are used to smash down other materials, such as rock, glass, wood, metals, and cement. When it comes to plastic, the three primary types of pulverizers are granulators, shredders, and ring mills. A granulator operates thousands of evenly spaced blades in order to shred or granule the plastic into finely pulverized objects. After it is pulverized, it can be melted and reformed. A shredder is similar to a granulator in that it contains evenly spaced blades, though these blades cut the plastic into strips. Some cut both vertically and horizontally in order to produce square shaped plastic pieces. A ring mill, on the other hand, has a large, steel rolling blade. This blade chops and grinds the plastic that is placed inside the roller. After it has been ground up to the desired size, it falls through the small holes located beneath the rolling blade. Advantages of Plastic Pulveriser or Pulverizer in engineering reprocessing are as follows: Low residence time means lower thermal stress on the process material Heavy-duty construction for longevity Ease of maintenance Ease of operation Full inventory of replacement parts Can cool the processing of heat- sensitivity materials by water cycle system High through put capabilities Cost effective operation Low specific power consumption Powder quality according to specification The models of pulverizing machine ensure the production of pulverized material from plastic granules for the manufacturing of high quality final products. Pulverizers are available in various configurations like single mill, double mill, horizontals mill with various designs, sizes and shapes of pulverizer blades.

The Pulverizer constitutes of high quality, maintenance-free, efficient components, like the Pulverizer Blade. The Pulverizers have very special designs and are being approved by our in-house quality control and testing departments after going through rigorous tests and routine check-up procedures. The Plastic Granulator The Plastic Granulator is the most universal type of pulverizer used with plastic recycling. It is capable of turning jugs, large bottles, and other plastic products into flakes, which are referred to as granules. These granules are then sold to manufacturers in order to be remoulded into new products.

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Plastic Granulator is basically a large electric motor with a rotor. The motor rotates the rotor, which contains cutting blades. The motor, the rotor and the blades are all located inside a closed chamber in which the plastic is positioned. The blades and the chambers of plastic granulators are accessible in different sizes and shapes with the purpose of assemble different needs. There is also a screen situated inside the chamber of plastic granulator. This screen sifts the plastic in order to ensure all of the parts are small enough to be reprocessed, which normally ranges from .125 to .375 inches. If any parts that are too large to in shape through the screen are processed once more within the plastic granulator. The efficiency of a plastic granulator is based upon how a large amount plastic it can shred in one hour, which is referred to as its pounds per hour rating. For engineering recycling purposes, the plastic granulator needs to be very large to process considerable amounts of plastic. There are, however, smaller plastic granulators available for home utilization. No matter the size, Plastic Granulators can be dangerous. Therefore, it is essential to always follow the manufacturer's instructions when using a plastic granulator. A plastic granulator also must be kept clean to remain capable. Generally, the screen situated inside the chamber of plastic granulator is cleaned out after each large processing. Otherwise, pieces of plastic can get stuck in the screening and stop other granules from falling through. The blades of the plastic granulator also require being wiped dirt free and oiled to maintain plastic granulator running efficiently. Technical Features of Plastic Pulverizer An ideal machine for pulverising Thermoplastics (LLDPE/HDPE/LDPE) Dynamically balanced grinding plates Vibratory feeder with Feed Hopper Electric servo control panel Cyclone controller unit Blower unit with dynamically balanced imp leer Vibratory seiving machine with dust collector Fully automatic electric control panel board

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ROTATIONAL MOULDING
A heated hollow mould is filled with a charge or shot weight of material, it is then slowly rotated (usually around two perpendicular axes) causing the softened material to disperse and stick to the walls of the mould. In order to maintain even thickness throughout the part, the mould continues to rotate at all times during the heating phase and to avoid sagging or deformation also during the cooling phase. The process was applied to plastics in the 1940s but in the early years was little used because it was a slow process restricted to a small number of plastics. Over the past two decades, improvements in process control and developments with plastic powders have resulted in a significant increase in usage. Rotocasting (also known as rotacasting), by comparison, uses self-curing resins in an unheated mould, but shares slow rotational speeds in common with rotational moulding. Spin casting should not be confused with either, utilizing self-curing resins or white metal in a high speed centrifugal casting machine.

Equipment and tooling Rotational moulding machines are made in a wide range of sizes. They normally consist of moulds, an oven, a cooling chamber, and mould spindles. The spindles are mounted on a rotating axis, which provides a uniform coating of the plastic inside each mould. Moulds (or tooling) are either fabricated from welded sheet steel or cast. The fabrication method is often driven by part size and complexity; most intricate parts are likely made out of cast tooling. Moulds are typically manufactured from stainless steel or aluminium. Aluminium moulds are usually much thicker than an equivalent

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steel mould, as it is a softer metal. This thickness does not affect cycle times significantly since aluminiums thermal conductivity is many times greater than steel. Due to the need to develop a model prior to casting, cast moulds tend to have additional costs associated with the manufacturing of the tooling, whereas fabricated steel or aluminium moulds, particularly when used for less complex parts, are less expensive. However, some moulds contain both aluminium and steel. This allows for variable thicknesses in the walls of the product. While this process is not as precise as injection moulding, it does provide the designer with more options. The aluminium addition to the steel provides more heat capacity, causing the melt-flow to stay in a fluid state for a longer period. Standard setup and equipment for rotational moulding Normally all rotation moulding systems have a number of parts including moulds, oven, cooling chamber and mould spindles. The moulds are used to create the part, and are typically made of aluminium. The quality and finish of the product is directly related to the quality of the mould being used. The oven is used to heat the part while also rotating the part to form the part desired. The cooling chamber is where the part is placed until it cools, and the spindles are mounted to rotate and provide a uniform coat of plastic inside each mould.

MOULDING MACHINES
Rock and roll machine
This is a specialized single arm machine. It rotates or rolls the mould 360 degrees in one direction and at the same time tips and rocks the mould 45 degrees above or below horizontal in the other direction. Newer machines use forced hot air to heat the mould. These machines are best for large parts that have large length-to-width ratio. Because of the smaller heating chambers, there is a saving in heating costs.

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Clamshell machine This is a single arm rotational moulding machine. The arm is usually supported by other arms on both ends. The clamshell machine heats and cools the mould in the same chamber. It takes up less space than equivalent shuttle and swing arm rotational moulders. It is low in cost compared to the size of products made. It is available in smaller scales for schools interested in prototyping and for high quality models. More than one mould can be attached to the single arm. Vertical or up & over rotational machine
The loading and unloading area is at the front of the machine between the heating and cooling areas. These machines vary in size between small to medium compared to other rotational machines. Vertical rotational moulding machines are energy efficient due to their compact heating and cooling chambers. These machines have the same (or similar) capabilities as the horizontal carousel multi-arm machines, but take up a much less space.

Shuttle or swing arm machine

This is a single arm turret machine that moves the mould back and forth between the heating and cooling chambers. This machine moves the mould in a linear direction in and out of heating and cooling chambers. It is low in cost for the size of product produced. It is also available in smaller scale for schools and prototyping.

Carousel machine
This is one of the most common machines in the industry. It can have up to 6 arms and comes in a wide range of sizes. The machine comes in two different models, fixed and independent. A fixed carousel consists of 3 fixed arms that must move together. One arm will be in the heating chamber while the other is in the cooling chamber and the other in the loading/reloading area. The fixed carousel works well when working with the same mould. The independent carousel machines are available with more arms that can move separately from the others. This allows for different size moulds, with different heating and thickness needs.

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Production process
The rotational moulding process is a high-temperature, low-pressure plastic-forming process that uses heat and biaxial rotation (i.e., angular rotation on two axes) to produce hollow, one-piece parts. Critics of the process point to its long cycle times only one or two cycles an hour can typically occur, as opposed to other processes such as injection moulding, where parts can be made in a few seconds. The process does have distinct advantages. Manufacturing large, hollow parts such as oil tanks is much easier by rotational moulding than any other method. Rotational moulds are significantly cheaper than other types of mould. Very little material is wasted using this process, and excess material can often be re-used, making it a very economically and environmentally viable manufacturing process. The rotational moulding process consists of four distinct phases: Loading a measured quantity of polymer (usually in powder form) into the mould. Heating the mould in an oven while it rotates, until all the polymer has melted and adhered to the mould wall. The hollow part should be rotated through two or more axes, rotating at different speeds, in order to avoid the accumulation of polymer powder. The length of time the mould spends in the oven is critical: too long and the polymer will degrade, reducing impact strength. If the mould spends too little time in the oven, the polymer melt may be incomplete. The polymer grains will not have time to fully melt and coalesce on the mould wall, resulting in large bubbles in the polymer. This has an adverse effect on the mechanical properties of the finished product. Cooling the mould, usually by fan. This stage of the cycle can be quite lengthy. The polymer must be cooled so that it solidifies and can be handled safely by the operator. This typically takes tens of minutes. The part will shrink on cooling, coming away from the mould, and facilitating easy removal of the part. The cooling rate must be kept within a certain range. Very rapid cooling (for example, water spray) would result in cooling and shrinking at an uncontrolled rate, producing a warped part. Removal of the part.

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Mould release agents

A good mould release agent (MRA) will allow the material to be removed quickly and effectively. Mould releases can reduce cycle times, defects, and browning of finished product. There are a number of mould release types available; they can be categorized as follows: Sacrificial coatings: the coating of MRA has to be applied each time because most of the MRA comes off on the moulded part when it releases from the tool. Silicones are typical MRA compounds in this category. Semi-permanent coatings: the coating, if applied correctly, will last for a number of releases before requiring be re-applying or touching up. This type of coating is most prevalent in today's rotational moulding industry. The active chemistry involved in these coatings is typically a polysiloxane. Permanent coatings: most often some form of PTFE coating, which is applied to the mould. Permanent coatings avoid the need for operator application, but may become damaged by misuse.

SCRAP GRINDER
Overview Scrap grinder machine used for recycling the rejected moulded articles made from lldpe, ldpe, hdpe,p.p, pet, eva, ps,. pc, pvc & rpvc etc. Application Suitable for lldpe, ldpe, hdpe,p.p, pet, eva, ps,. Pc, pvc & rpvc injection /blow/ roto moulded articles. Features Heavy mild steel structure with hopper for easy loading of scraps. Unique design of rotor blades functioning as shredding is our unique design. Sturdy multiple rotary and fix blades of alloy steel for longer services life and efficient grinding. Option for material conveying system after grinding.

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AGGLOMERATOR
Designed for processing plastic waste for reclamation and recycling, LDPE, HDPE, PP, LLDPE, BOPP, HM, Polyester, Nylon, PVC etc. trim scraps, baled or loose film, synthetic fiber and carpet. Agglomerator is ideal to convert plastic waste dense cubes for easy feeding into Extruder. The densifier operates in "batches" and the processing chamber is loaded before and during the process. The high-energy-blades shred the material and press it under the rotor due to its design. The friction heats the material to the processing temperature. At this temperature the material becomes highly viscous. Subsequently cold water is injected into the process which causes the material to densify.

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QUALITY CONTROL
SPECIFIC GRAVITY A tanks specific gravity rating is a measure of its ability to hold materials. The specific gravity of a substance is a comparison of its weight per unit volume to that of water. Manufacturers have designed tanks with specific gravity ratings of 1.0 to 1.9 or more. Higher specific gravity ratings indicate a greater ability to withstand hydrostatic stresses caused by a stored liquid. Understanding the significance of specific gravity to poly tank evaluation begins with the weight of water: 8.334 pounds per gallon. The specific gravity of water is 1.0, and the specific gravity of all other substances is relative to the weight of water. For example, a poly tank with a specific gravity of 1.0 is designed to hold the weight of water or any other liquid that weighs 8.334 pounds (or less) per gallon. A poly tank rated at 1.5 specific gravity is designed to handle the weight of a liquid product 1.5 times the weight of water (1.5 x 8.334 pounds); so a 1.5 specific gravity tank is built to withstand the internal forces of liquids weighing up to 12.5 pounds per gallon. A tank rated at 1.9 specific gravity can store products weighing up to 15.8 pounds per gallon (1.9 x 8.334). In general, the weight of liquid fertilizers ranges from 10 to 12 pounds per gallon. Specifically, 10-34-0 liquid fertilizer weighs 11.67 pounds per gallon, while 28-0-0 liquid fertilizer weighs 10.7 pounds per gallon. Most pesticides weigh slightly below or just above the weight of a gallon of water. At a minimum, fertilizers should be stored and handled in poly tanks with at least a 1.5 specific gravity rating. A good rule of thumb is to purchase a tank with a specific gravity rating at least one increment higher than that of the product you intend to put into it. The specific gravity rating tag may no longer be attached to the tank, and it is impossible to guess it based on the tanks appearance. Ask your dealer for the specific gravity rating of the tank youre considering, review the manufacturers catalogue, or examine the tank specification sheet. In some cases, the specific gravity rating is part of the product code. Some manufacturers stamp information on the side or top of the tank. These variations make purchasing used tanks a real challenge.

THICKNESS Tanks must account for the internal forces required to hold the specific gravity of any given product. Wall thickness is a major factor in the ultimate strength of a tank. Tank wall thickness and overall design are two of the most important factors in determining its specific gravity rating. When purchasing a poly tank, first consider the specific gravity of the heaviest liquid you will put into it; then look for tanks with that specific rating or higher. The manufacturers of poly tanks have determined critical stress points, which are different for transport versus storage tanks, and strengthen those areas during the moulding process.

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EXTREME TEMPERATURES Extreme temperatures usually do not impact good quality polyethylene tanks. Quality tanks are designed to withstand expansion and contraction caused by extreme hot and cold. Results of tanks tested to 40F demonstrate that freezing does not damage poly tanks. Constant, sustained temperatures above 100F may weaken tanks, but this is seldom a factor since our temperatures dont remain above 100F for long periods of time.

WATER DETERIORATION Poly tanks do not decay or rust in standing water or in contact with the ground; and any mould or algae that might develop on the inside is removable with an algaecide

. PRODUCT COMPATABILITY HDLPE tanks are compatible with most pesticides and fertilizers. However, poly tanks manufactured to hold fertilizers and pesticides should not be used for gasoline or diesel fuel because they can break down and soften the plastic. Pure bio fuels such as B-100 can be stored in poly tanks built to American Society for Testing Materials (ASTM) D1988 standards with a 1.9 specific gravity rating. But some manufacturers warranties do not cover tank failure due to 100 percent biodiesel or blended modifications. Petroleum-based oils also permeate and soften plastic, but the process is much slower than with gasoline. Oil should be stored in poly tanks with a 1.9 (or higher) specific gravity rating. Experience has shown the importance of selecting valves, gaskets, and hoses that are compatible with the products to be stored in the poly tank. In certain cases, replacing a gasket with one that will stand up to biodiesel makes an HDLPE tank acceptable. Using compatible equipment prevents component failure and product release.

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TANK LONGEVITY
Tank owners expect their storage, transport, and application tanks to last well beyond the three- to five-year manufacturers warranty. But, how long will a tank last? How old is too old? There are no definitive answers. Keeping a tank under cover as much as possible helps protect the polyethylene from deterioration caused by UV radiation. Most UV damage occurs to the outside of the tank, beginning on the outside wall and spreading inward over a number of years, making the plastic brittle and rigid. An uncovered outdoor poly tank generally can be expected to show signs of UV damage within five to eight years. Colour plays only a very small part in reducing UV breakdown of polyethylene. The colour red, green, black, yellow, blue, or white is added as a dry blended pigment during the moulding process, but it does not add UV protection. Some poly tank manufacturers use colour to separate product lines; e.g., a 1.5 specific gravity tank may be white, and a 1.9 specific gravity tank may be blue. Some use colour as a marketing tool. But you should not rely on tank colour as an indication of specific gravity, especially when comparing tanks made by different manufacturers. The following questions have been raised about what can be done to prevent UV degradation: Can a poly tank be painted to reduce UV penetration? Polyethylene tanks are very similar to Teflon, chemically, so paint does not stick well to the tank surface. However, some paints contain solvents that allow the paint to bite or absorb into the plastic; these solvent paints usually will not weaken the tank. In some cases, paint manufacturers recommend abrading the area to be painted; but while this will help the paint stick to the tank, it will also promote increased deterioration of the plastic. Most paints will crack as the tank flexes during expansion and contraction. There are flexible paints on the market that can build up a membrane over the tank; however, these paints scratch and chip easily and require continual repainting to keep the membrane intact. Another disadvantage to painting a tank is that it prevents visual inspection of the tank when using the black marker; it also prevents viewing the contents through the tank walls. There seems to be little value in painting as a means of reducing UV damage to poly tanks. Does covering the tank with a tarp or black plastic reduce UV damage? Tarps do offer limited UV protection, but even good quality tarps need to be replaced often, due to breakdown from sunlight and rain. Getting tarps to fit over tanks and getting them properly secured is difficult.

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 Does the tank have to be totally enclosed to prevent UV degradation? The best management option is to keep the tank away from direct sunlight when not in use, preferably inside a building with the doors closed. A partially enclosed structure that does not protect the entire tank does not provide sufficient UV protection.

FACTORS THAT INFLUENCE LONGEVITY

The only way to truly assess tank deterioration and damage is to conduct routine inspections each fall and spring. Base your decision to replace a tank on the findings or on the warranty expiration date, if feasible. The following factors contribute favourably to tank longevity: High specific gravity rating Infrequent refilling Protection from UV radiation Stationary placement It is difficult to visually determine a good tank from a bad tank. Three simple inspection techniques writing with water-soluble ink, candling with light, and hitting with a baseball batcan pinpoint weakened walls and stressed areas around the fittings. It is important to know the difference between surface scratches, crazing within the tank wall, and cracks that extend through the tank wall. Crazing is the development of very fine cracks within the tank wall, usually appearing as a network of fine lines that cannot be felt with a fingernail. The tank will still hold liquids, but its structural integrity is significantly reduced. Crazing occurs in both high density and cross linked poly tanks; it can be a sign of serious deterioration within the plastic, which leads to cracks and fractures. Cracks can be felt with a fingernail. It is common for the poly material around the crack to appear whiter than the surrounding polymer. Most scratches displace minute amounts of polymer but remain superficial. Scratches are open to the surface; displaced material is evident on the tanks surface; fingernail catches.

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 Crazing is displayed as a patchwork of fine lines.

Cracking causes no displaced material; very abrupt lines may run parallel or cross at right angles; UV cracking has a dry-rot or alligator-skin look in advanced stages; fingernail may catch.

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MARKING THE TANK WITH A WATER SOLUBLE MARKER

Crazing may signal UV damage. UV crazing, which is very difficult to see, forms in areas where the tank gets maximum sunlight exposure; the lines become more visible when you colour the tank with a water-soluble marker. The inspection is performed by rubbing the marker over several six-inch by six-inch sections on the sides of the tank exposed to sun, on its top, and around fittings. Quickly rub off the ink with a dry cloth or paper towel. The ink left behind has penetrated the surface of the tank. Crazing is one of the first signs of deterioration, so tanks with crazing should be checked often. Consider using crazed tanks for water only. If rubbing the ink off reveals no obvious signs of crazing or cracking, the tank probably is good for another season of use. If the ink reveals cracking or spider webbing where the lines go in all directions, classic UV radiation damage is indicated. Advanced deterioration to the plastic presents a chequered or dry rot appearance, indicating loss of elasticity. A tank displaying such symptoms should be replaced or at least not used for fertilizers or chemicals. The appearance of parallel lines signals early UV damage and the need for continual inspections. Tanks with parallel lines in the plastic around fittings should be replaced immediately or used for water only.

CANDLING: VISUAL INSPECTION WITH A LIGHT

Candling consists of placing a bright, cool light source inside a poly tank while conducting a visual inspection from the outside (do not use a hot lamp, as it could melt the tank). Defects and cracks usually show up as areas or lines of different light intensity. Repeat this procedure with the light on the outside of the tank and someone looking through the fill neck or man way. Do not enter the tank. A camera, camcorder, or other optical device may be helpful in recording the inspection from the top of the tank.

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CANDLING

HITTING AN EMPTY TANK WITH A BAT

An empty tank showing UV cracking can be further evaluated by striking it with a bat. Most people are afraid to hit their tank with a bat, fearing that they might break it, but thats just it: if it breaks, it should not be in service. Cracking an empty tank with a bat is a better option than risking it breaking when filled with fertilizer or pesticide. A good tank has the flexibility to bend outward as it is filled and inward as it is emptied. Tanks that are brittle (i.e., that exhibit excessive or advanced cracking) have lost the ability to flex under pressure and to rebound when impacted. The brittleness of an empty tank can be tested with a solid swing of a baseball bat where signs of cracking were discovered during the water-soluble ink inspection. Hit the tank along the sides and top where they receive the most sunlight; then check the tank for signs of breakage. It is impossible to crack a good tank using this method because the polymer is strong and resilient; if the tank cracks or breaks open when hit by a bat, you may have saved yourself from disaster.

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REPAIR OF POLY TANKS

Most poly tanks with crazing or cracks, and those made from cross linked polyethylene, cannot be repaired. Repair of polyethylene tanks is risky and not recommended. Manufacturers sell kits for repairing small surface scratches or pin holes in high density linear polyethylene tanks. But few adhesives or caulks adhere to polyethylene, and other means such as plastic welding are best left to professionals. Even if a tank can be repaired, there is no guarantee that the repair will hold once the tank is filled. A repaired tank should be used for water only. It is best to replace a damaged tank.

REUSE OR RECYCLE OF OLD TANKS

High density linear polyethylene (HDLPE) can be recycled into other products. Conversely, high density cross-linked polyethylene (XLPE) cannot be remoulded and recycled. All tanks, whether recycled or deposited in a landfill, should be triple rinsed prior to disposal. After rinsing, they should be broken or cut into smaller pieces before being recycled or put in a landfill. Contact your local recycling centre for information on recycling HDLPE tanks.

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PROJECTS UNDERTAKEN
PROJECT MAPPING LIFE CYCLE APPROACH AND ANALYSIS IMPLEMENTATION OF A HYBRID MOULDING CONCEPT DEVELOPING A REVISED EXTRUSION FLOW DESIGN OF MULTIPURPOSE TANK FOR HIGH ALTITUDE AND TUBULENCE PRONE AREA FEA OF TANK FOR QUALITY IMPROVEMENT

LIFE CYCLE APPROACH AND ANALYSIS

Information was gathered on the manufacturing operations involved in producing the concrete, plastic and steel water tanks. The LCA study involved the following steps: Goal definition and scope Definition of system boundaries and functional unit Inventory of material, energy inputs and outputs Quantifying emissions Analysis of impacts The functional unit was simplified by choosing tanks with the same storage capacity of 5,000 litres. The life cycle stages for each type of water tank were grouped in the following categories: Extraction and processing of raw materials, transportation to production site, eg. Steelworks, cement producers etc, and production of materials, eg. Cement, steel and plastic. Transport of materials to tank fabricators and fabrication (the energy associated with the fabrication of the tank is negligible and has not been included in this analysis). Transportation of water tank to customer's site. Tank installation (assumes concrete pad is used as base). Disposal at the end of its operational life, assuming full utilisation of tank materials. The tanks were assumed to be at ground level and would normally require the use of a water pump. Because the operation of the pump is independent of the tank material, this part of the life cycle was excluded from the analysis. Environmental burdens in 33

terms of resource consumption and emissions were obtained from Australian National Greenhouse Gas Inventory and BHP Billiton Minerals Technology database. The total embodied energy and emissions were used to assess the environmental burden of each water tank. This allowed for comparisons of the environmental performance of the different rain water tanks to be made based on embodied energy, water, GGE, SOx and NOx emissions. (The annual environmental burden of a 300W water pump, powered by electricity from a coal fired power station, pumping 140,000 litres of water per year (half of household's annual requirements), equates to around 0.4 GJ of energy, 0.5 t of water, 0.1 t of GGE, 0.61 kg of SOx and 0.27 kg of NOx. Compared to the other life cycle stages in this analysis the annual operation of a rain water tank (pumping of water) produces the largest environmental burden.)

WHAT IS LIFE CYCLE ANALYSIS?

Life cycle analysis is an important tool for both analysing processes to find ways to improve them, and assessing materials and products. LCA consists of two components: inventory analysis and impact analysis. Inventory analysis involves summarising the material and energy flows for a defined system. The system' is the combination of processes and activities that manufacture a product or achieve an outcome. This typically includes all of the processes associated with the extraction of resources, supply of energy, manufacture of the product, use of the product and disposal and recycling. The resultant inventory is a list of the resources consumed and the emissions associated with the system. Impact assessment involves interpreting the significance of the resource consumption and emissions determined in the inventory stage. It should be noted that in life cycle assessment, these are restricted to environmental impacts. The model used for this study examines the material use and emissions in a product, from raw materials through to end of its life. It also assesses the impact of products and processes on the environment from the extraction of the raw materials, through the manufacturing processes, to disposal by processes such as recycling at the end of a product's useful life. It does this by examining such things as: Wastes generated during production. Energy consumed during production and the use of the product. The amount of recycling the product is capable of. Today steel products are being designed to be more environmentally sustainable, enabling easier and faster construction, more efficient utilisation, and ease of recycling of components at the end of their product life.

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PLASTIC TANK
The material used in the fabrication of plastic tanks is High Density Polyethylene (HDPE), derived from fossil fuels. Transportation stages involve delivery of materials and road transport of manufactured tanks to customers. For the purpose of this study it was assumed that the tank fabrication is in Orange, NSW. The total mass of the 5,000 litres HDPE tank is 100kg.The fabricated tank (eight tanks in a medium size truck) is transported to the customer's site at the Central Coast, Gosford and NSW. The useful operational life of the HDPE water tank was taken as 25 years, the same as the manufacturer's warranty. It is assumed that at the end of the tank's useful life the feedstock energy is recovered by combustion. Currently, 100% "virgin" plastic is used in manufacture due to concerns over ultra violet light exposure of used HDPE. The life cycle stages and the environmental burden of the HDPE tank are presented in Figure 1. The largest embodied energy is associated with the production of the HDPE, part of which is recovered by combustion at the end of its useful life, displacing an equivalent amount of fuel oil. However, there is a significant net gain of CO2 emission associated with the combustion of HDPE.

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CONCEPT OF ROTATIONAL MOULDING WITH PULVERISING MACHINE

Rotational Moulding needs resin in pulverized form. The particle size, shape and particle size distribution is measure of powder quality. Powder quality plays a very important role in rotational moulding. Following are the resultant effects of the good quality powder: Optimization of the charge weight to meet rising competition Improved finish and colour of the product Reduced fusion time Multi layered and foamed tanks

To attain the above objective pulveriser must have following features. Ability and control to give uniform and consistent Powder Quality Power required should be low Cooling of grinding element must be sufficient and effective High out put Minimum down time Ability to run the machine un attended All system protections so that down time is Low Easy to clean, user friendly operation

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REVISED EXTRUSION FLOW

Strand throughput is measured in pounds/hour/strand. Typical strand throughput rates range from 25 to 125 pounds/hour for a 1/8 inch (3.2 mm) diameter strand and 12 to 70 pounds/hour for a 3/32 inch (2.5 mm) diameter strand. A given water flow rate is required to remove the excess heat and cool the strands sufficiently for pelletizing. As the throughput rate per die hole increases, strand or water baths have to become longer or a serpentine path is required to ensure sufficient time for cooling the strand. A lower throughput per strand rate requires more strands run at slower speeds to produce the same extruder throughput rate. The time a strand spends in the water bath is easily calculated based on the polymer density and throughput rate. Assume a polycarbonate strand with a density of 1.21 grams/cm3 is running at 100 pounds/hour/hole, and the strand diameter is 1/8 inch. How long does the strand spend in a 50 foot long water bath? The following calculations show how to determine the time in the bath. Equation (1.1) gives the pounds/minute/hole throughput rate. 100 lbs * hour = 1.66 lbs hour- strand 60 minutes minute- strand (1.1)

Using a 1/8 inch diameter (0.125 inch or radius r = 0.0625 inch) and a 1 foot or 12 inch length, Eq. (1.2) calculates the volume of a 1 foot polymer strand. Vol (lft) = pi* r^2* L= 3.1416* 0.0625^2* l2 = 0.147inch^3 (1.2)

With the density, it is possible to calculate the weight of the 1 foot strand, Eq. (1.3). Wt (1ft) = 0.147 inch^3* 1.21 gm/cm^3 * 2.54^3 cm^3/inch^3 = 2.91g (1.3)

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At 1.66 pounds/minute/hole, there are (1.66pounds/minute * 454 grams/pound) equals 753 grams/minute/hole. With each foot of strand weighing 2.91 grams, each strand in the process is running at the rate given by Eq. (1.4). Speed = 753 gm/min * 1ft/2.91 g = 259 FPM (1.4)

In a 50 foot long bath, each strand spends 11.6 seconds in the bath, Eq. (1.5), to cool from a 5900F (3100C) melt temperature to 2000F (930C), which is below the glass transition temperature. Time in Bath = 50 ft * 60 sec/1 min* min/259 ft = 11.6 sec (1.5)

The cooling time required to adequately cool the strand depends on the strand diameter, the water temperature, and the temperature difference between the polymer and the water. The heat required to be removed (Q) is given by Eq. (1.6). Q = m* Cp*T + m * Hfusion Where, m = Mass flow rate in pounds/hour (kg/hr). Cp = Heat capacity of the resin in BTU/pound F (kJ/kg C). T = Temperature difference between the melt temperature exiting the die and the strand temperature at the end of the bath in F (C). Hfusion= Heat of fusion of crystalline polymers as the polymer changes from a liquid to a melt in BTU/pound (kcal/kg). Hfusion of amorphous resins is zero. If the result is calculated in BTUs, to convert this to other units, 1 BTU = 252 calories = 1055 joules, = 0.293 watt hour. In the previous example, the amount of heat (Q) that has to be removed per hour per strand is calculated in Eq. (1.7). The heat capacity of polycarbonate is 0.3 BTU/pound F. Q = 100 * 0.3 * (590-200) = 11,700 BTU/hr (1.7) (1.6)

DESIGN OF MULTIPURPOSE TANK FOR ALTITUDE AND TUBULENCE PRONE AREA

HIGH

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FEA OF TANK FOR QUALITY IMPROVEMENT

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CONCLUSION
High density polyethylene tanks have been used successfully by growers and commercial pesticide application businesses for years. They are less expensive than stainless steel and fibreglass tanks and offer ease of movement when empty, along with rust resistance. Polyethylene tanks are low maintenance and relatively reliable for storing and transporting agricultural and commercial liquids. While the benefits of poly tank ownership are well established, the risk of tank failure is real. Like any piece of equipment, poly tanks need to be inspected and maintained to ensure that the benefits of use outweigh the risk of tank failure and product release. Experience has shown that environmental, management, and design factors determine how long a tank last and those annual or biannual inspections will help prevent the unexpected and potentially catastrophic release of contents due to tank failure. These maintenance strategies help extend a poly tanks useful life: Selection of the right tank for the intended use, based on specific gravity. Use of the tank as intended vertical tanks for storage, horizontal tanks for storage or transportation. Protection from UV radiation. Never purchase a used tank without knowing its history. If you intend to buy a used tank, or an inexpensive one that appears in good operating condition, take the time to conduct a proper inspection; and secure information from the manufacturer if at all possible. Without exercising these precautions, you may encounter sudden tank failure resulting in an expensive spill and cleanup, reporting obligations, and costly downtime. The information in this publication is intended to assist you in making an informed decision on the purchase, maintenance, inspection, and ultimate disposal of poly tanks.

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