Duflon Industries Private Limited

established in 1988
Industrial training under the guidance of
Mr. Prashant More
Submitted By:
Ukaye Maaz M. Saleem
Name of the institute:
Lonere
Dr Babasaheb !mbed"ar #echnological
$niversity
1
IND%&
1 IN#'(D$)#I(N (* #+% )(,P!N-
. /!'I($S D%P!'#,%N#S
a0 ,($LDIN1 S+(P
b0 ,!)+ININ1 S+(P
c0 2$!LI#- )(N#'(L D%P!'#,%N#
d0 )L%'I)!L D%P!'#,%N#
e0 P!)3!1IN1
f0 DIS#'IB$#I(N
g0 ,!N!1%'I!L 4('3S
5 IN#'(D$)#I(N #( P#*%
a0 #-P%S (* P#*%
b0 P'()%SS%S IN/(L/%D IN P#*% P'(D$)#S
c0 !D/!N#!1%S
2
d0 DIS!D/!N#!1%S
6 #'!ININ1 4('3 %&P%'I%N)%
7 )(N)L$SI(N
IN#'(D$)#I(N
Duflon Industries Private Limited8
)91:18 ,ID)8,ahad 9 6:. 5:98 ,aharashtra8 India
Duflon is one the ;orld<s leading fluro=olymer =rocessers and
su==lier of com=onents in P#*% In addition to P#*%8 Duflon is also a
=remium su==lier of com=onents in other =olymers8 rubber moulding8
metal casting8 metal turning as ;ell as semifinished materials
Duflon has its main site in India and dedicated sales and
distribution centers in $S! and $3 In addition to that Duflon has sales
re=resentatives all over the ;orld to service its e>isting client base
consisting of blue chi= cor=orate
Duflon has a ?uality system certified to IS( 9::1 : .:::8 as ;ell as
many individual a==rovals by various =arties and detailed audits @
accreditations from customers Duflon also runs S!P through its
organiAation In addition to that8 Duflon has a $3 based bes=o"e
soft;are to oversee the efficient sam=ling8 develo=ment and '@D
=roBects
Duflon =roducts are used in the ;ide range of mar"ets throughout
the ;orld such as )hemical =rocessing8 (il and gas and =etrochemicals8
electrical8 medical @ =harmaceutical8 food @ beverage8 4ater and
%nvironmental8 automotive8 hydraulic8 laboratory e?ui=ments8 =ul= @
=a=er mining8 general engineering
#he obBective of com=any is =rocessing fluro=olymers #hese
fluro=olymers include P#*%8 P*!8 *%P8 %#*% and other =lastics such
as $+,4P%8 P/D*8 PP @ Nylon etc
3
Initially the su==lies ;ere focused at the s;itchgear industry8 then
gradually develo=ed into the chemical industry ;ith su==lies of vital
com=onents of use in =um=s and valves8 =roduction of castings in
various metals and alloys as ;ell as elastomers ;hether they are
su==lied inde=endently or lined8 coated or bonded ;ith fluro=olymers
Duflon is the leading manufacturer of fluro=olymer and
engineering com=onents for various industries
/!'I($S D%P!'#,%N#S
a0 ,($LDIN1 S+(P:
#he moulding sho= includes P#*% moulding and P*! moulding
=rocesses )onventional P#*% moulding is done using hydraulic
=resses #hese hydraulic =resses are of different ca=acities such as .7
tonne8 7: tonne8 C7 tonne and u=to .7: tonnesInBection moulding is also
used for critical materials li"e butterfly valve =arts
/arious heat treatment techni?ues are also used in lining of P*!
material Sintering =rocess is done for conventional P#*% material
=roducts such as =lug valve8 ball valve =arts
4
5
+ydraulic =ress for com=ression moulding of P#*% is sho;n
Sim=le semi automatic +ydraulic =ress
6
#he various P#*% =roducts made from the above =resses are sho;n
belo;
#he holes8 grooves and chamfer etc =resent in above P#*% =roduct are
made in ,achine Sho=
7
b0 ,!)+ININ1 S+(P:
,achining sho= includes various =rocesses such as threading8
milling8 drilling8 facing8 and many other machining o=erations
#he moulded =roduct is e>ceeds the dimensions #he =roduct
should be machined to its =erfect dimensions as =er customer
re?uirement and Bob dra;ings
P#*% is the very tough material and it can be machined easily as
=er the dimensions But the machining should be done at s=ecific
tem=erature to maintain the dimensional accuracy #he machining
tem=erature for machining of P#*% is maintained by air conditioners
or refrigerators #he maintained tem=erature is about .:9.7
o
)
/arious machining e?ui=ments are used for machining such as
conventional lathes8 )N) machines and /,) machines #he sim=le
lathes are used for the small o=erations li"e facing as ;ell as for
removing e>cess materials
)N) lathes are used for different mechanical o=erations li"e
threading8 chamfering etc
8
Lathe machine used for these =rocesses is sho;n belo;
)N) lathes are used for accurate machining of the =roducts #he
;or"er has to feed the =rogram of the machining =rocess in the
com=uter attached to the )N) machine #he =rogram is in the form of
19code and ,9code 4hen machine is started8 the =rogram runs and
machining is done on the Bob ;hich is to be machined #he machine
sto=s automatically after the machining is done #he )N) machine is
sho;n belo;
9
/ertical ,achining )entre ie /,) machines are also used no;adays
for easy machining #he com=uter integrated manufacturing reduces
the machining time /,) machines are e?ui==ed ;ith ne; technology
;here machining can be done using 7 a>es ;hich is faster than )N)
machines /,) ,achine is sho;n belo;
10
c0 2$!LI#- )(N#'(L D%P!'#,%N#
2uality )ontrol De=artment is the most im=ortant de=artment of
any industry of this era #his de=artment decides the ?uality of the
=roduct manufactured after the moulding or machining
#his de=artment includes various tests and chec"s of the =roduct
after the moulding and machining #he =roduct is sold or for;arded to
the customer only if the ?uality control de=artment a==roves the
=roduct ?uality
#he various tests done in the ?uality control de=artment are listed
belo;
/isual #est: #his test is done by carefully observing the =roduct
in a D:4 bulb #his test is done to chec" any contamination8
crac"8 damage or fla;s #his is the sim=lest test in the
de=artment
Dimension )hec": In this chec" the dimensions of the =roduct
are chec"ed ;eather they are meeting the s=ecification given by
the customer or not Different tools such as /ernier )ali=er8
surface finish tester8 scre; gauge8 height gauge8 run9out tester etc
Eyglo #est: #his test is done to chec" very minute crac"s ;hich
are develo=ed on the surface In this test a florescent li?uid called
=enetrant is a==lied on the =roduct and is visualiAed in $/ light8
the crac" gets dar"ened in the light
S=ar" #est: #his test is
,echanical #ests: #hese include a series of tests ;hich are
listed as follo;sF
10 S=ecific gravity G!S#, DC9.0
.0 Durometer +ardness9Shore G!S#, D..6:0
50 #ensile strength G!S#, D68960
60 %longation G!S#, D68960
70 Dielectric strength G!S#, D1690
#hese tests are discussed in detail in the follo;ing lines
11
S=ecific gravity G!S#, DC9.0:
#he test =rocedure for this test includes ;eighing the s=ecimen in
air and ;eighing the same s=ecimen in ;ater again #here is digital
calculator for calculating s=ecific gravity #he s=ecific gravity tester is
sho;n belo;
#he s=ecific gravity of P#*% is .1 to .6
Durometer +ardness9Shore G!S#, D..6:0:
In this test the s=ecimen is first =laced on the hard =arallel
surface8 and then the indenter of the instrument is =ressed on the
s=ecimen It must be ensured that the surface of the instrument is
=arallel to the indenter #he hardness is read in one second on the
digital dis=lay #he testing machine is sho;n belo;
#he shore hardness of P#*% is 7:9D:
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#ensile Strength G!S#, D68960:
#his test is done to chec" the tensile strength of the P#*%
material #he =rocedure includes cutting the test s=ecimen8 clam=ing it
in machine8 increasing the =ulling force in terms of load @ note do;n
the load at brea"ing of the s=ecimen #he tensile strength can be
calculated by follo;ing formula
#ensile strength H LoadIarea
#he machine for testing tensile strength is sho;n in belo; diagram
#he usual tensile strength value for a P#*% article rangees from 187::9
58::: lbIs? in
%longation G!S#, D68960:
#his is measured by the same =rocedure as that of tensile strength
it is measured in terms of =ercentage GJ0 #he formulae for measuring
elongation is
%longation H Gfinal length K initial length0
L1::
*inal length
#he machine used for this test is same as that of tensile strength P#*%
has a ;ide range of elongation value ;hich varies from 7:J to D7:J
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Dielectric Strength G!S#, D1690:
!s P#*% is also very ;idely used in electrical a==lication such as
soc"ets8 circuit brea"ers etc this test is also very im=ortant to conduct
In this test the P#*% material is =laced in bet;een t;o electrodes8 and
voltage is increased from Aero to brea"do;n voltage at a constant rate
#he rate of voltage rise is determined by the time it ta"es the sam=le to
reach dielectric brea"do;n ! s=ar" in the dielectric medium usually
transformer oil indicates the brea"do;n of the s=ecimen
#he s=ar" after failure loo" li"es the belo; figure
P#*% has a very good dielectric strength range ie 1891:7 "/Imm
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Introduction to *luoro=olymers
*luorine is one of the most reactive elements in nature and is even
more reactive than its halogen relatives such as chlorine8 bromine and
iodine Gthese are all 1rou= 1C elements or8 if you =refer the older
notation8 1rou= /II0 #his high8 and sometimes e>=losive8 reactivity
delayed research on the material for a long time because scientists
sim=ly couldn<t find any material to contain elemental fluorine8 not to
mention that it ;as difficult doing research under those conditions #;o
of the first researchers of fluorine chemistry ;ere 'uff and
Bretschnieder of 1ermany in the 195:s8 first synthesiAing the gas
tetrafluoroethylene #his ;as considered to be a to=ic of =urely
academic concern and fe; =eo=le =aid much attention to their ;or" It
;as also in 1ermany that the first of the fluoro=olymers ;as created
and the I1 *arben conglomerate =atented P)#*% in 1956
Des=ite this8 it ;as the discovery of P#*% that accelerated the
develo=ment of the fluoro=olymers !s mentioned in a =revious
ne;sletter GM*ocus on: P%%3N08 the discovery of P#*% ;as =urely
accidental In 19588 'oy Plun"ett and his team at DuPont ;ere ;or"ing
on the chemistry of tetrafluoroethylene and noticed that a Ofull< cylinder
of the gas a==eared to have nothing in it ;hen the valve ;as o=ened
Intrigued by the missing tetrafluoroethylene8 they cut the cylinder o=en
and a ;hite residue GPolytetrafluoroethylene0 ;as found on the inside of
the cylinder P#*% ;as bornP P#*% may have remained a laboratory
curiosity e>ce=t for the onset of 4orld 4ar II
*luorine chemistry in all its forms suddenly became a vital to=ic of
research across the ;orld in the race to build the first atomic bomb
)oncentration of the fissile com=onent G$ranium9.570 from natural
uranium re?uired the =re=aration of uranium he>afluoride gas K ;hat
had once been of sim=le academic interest suddenly had the attention of
the ;orld and almost unlimited finance and =ersonnel
#he =olymer chemists ;ere a little faster in attem=ting to develo=
useful =olymers from the basic structure and )ar others carried out
some of the first ;or" in the develo=ment of nylon in the 195:s #his
basic research continued8 and in the 19C:s8 'ose and his team at I)I
began constructing =olymers almost from the first re=orted =rinci=les
#heir ;or" ;as based on =reviously successful materials such as the
15
=olysulfones8 and one of their first =roducts ;as the aromatic =olyether
"etone family
#he result ;as that a small amount of ;hite residue in a gas
cylinder suddenly found itself the center of considerable scientific
attention as researchers attem=ted to find out more about this ne;
material *or a ne; and accidental material8 P#*% had remar"able
=ro=erties It ;as resistant to almost every "no;n chemical8 had
e>cellent heat and electrical resistance =ro=erties8 an e>tremely lo;
coefficient of friction8 and a surface energy so lo; that it ;as almost
im=ossible to get anything to stic" to it ! fortuitous set of circumstances
for the birth of the fluro=olymers family
#he high thermal stability of the fluorine9carbon bond and
e>cellent chemical resistance of the fluoro=olymers means that the
P#*% and P)#*% =olymers have uni?ue =ro=erties Polymer
technologists have continued to develo= the fluoro=olymer family to
im=rove melt =rocess ability8 reduce cost and im=rove other =ro=erties
#oday the fluoro=olymer family consists of a range of
homo=olymers and co=olymers to meet the demands of the industry
16
#+% *L$('(P(L-,%' *!,IL-
+omo=olymers and co=olymers G4hat<s the differenceQ0
+omo=olymers consist of a single monomer G!0 that is re=eatedly Boined
together to form the long chain of the =olymer molecule:
! K ! K ! K ! K ! 9 !
)o=olymers consist of t;o different monomers G! and B0 that are
alternated ;hen Boined together to form the long chain of the =olymer
molecule:
! K B K ! K B K ! K B 9 !
1raft co=olymers are co=olymers ;ith a branched structure in the long
chain of the =olymer molecule:
9 ! 9 ! 9 ! 9 ! 9 ! 9 ! 9 ! K ! 9

B B B
#er=olymers consist of three different monomers G!8 B and )0 that are
alternated ;hen Boined together to form the long chain of the =olymer
molecule:
9 ) K ! K B K ) 9 ! K B 9 ! K B 9
17
Semi )rystalline Polymers
#he fluoro=olymers also have ty=e called semi9crystalline high
=erformance thermo=lastics #his means that they have a random
molecular orientation ;hen in the molten =hase but have densely
=ac"ed crystallites in the solid =hase #he degree of crystalliAation
varies ;ithin the fluoro=olymer family but all semi9crystalline =lastics
have some general common =ro=erties
P'(P%'#I%S
#he high =erformance semi9crystalline thermo=lastics tend to have the
follo;ing =ro=erties Gin com=arison to amor=hous =lastics0:
R +igher s=ecific gravity
R +igher tensile strength and tensile modulus
R Lo;er ductility
R #end to be translucent or o=a?ue rather than trans=arent
R +igher fatigue resistance
R ,ore difficult to bond using adhesives and solvents
#hese =lastics also tend to have the follo;ing =ro=erties Gin com=arison
to other =lastics0:
R (utstanding tem=erature resistance
R (utstanding electrical =ro=erties
R (utstanding chemical resistance
R Lo;er coefficient of friction
R Better toughness
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#-P%S (* *L$('(P(L-,%'S K
P#*% K Polytetrafluoroethylene
P#*% is one of the fe; fully fluorinated =olymers and is made by
=olymeriAing #*% P#*% ;as the first fluoro=olymer to be
manufactured and used by both 1ermany and the $S during 4orld
4ar II P#*% ;as used e>tensively in the ,anhattan ProBect to handle
corrosive com=ounds such as uranium he>afluoride Due to its full
fluorination8 it still has some of the best =ro=erties of the family today
#he maBor disadvantage ;ith P#*% is the very high melt viscosity that
ma"es =rocessing difficult by the normal methods of e>trusion and
inBection molding Processing technologies have more similarity to those
of =o;der metallurgy than those of traditional =lastics =rocessing #his
led to a search for melt9=rocess able fluoro=olymers and the
develo=ment of other members of the family
P)#*% K Polychlorotrifluoroethylene
P)#*% is a =artially fluorinated =olymer and is made by =olymeriAing
)#*% monomer in a very similar manner to that for P#*% #he
introduction of the )hlorine atom distorts the symmetry of the crystal
=ac"ing and leads to a lo;er softening =oint and reduced electrical and
chemical resistance =ro=erties It also results in a harder =olymer ;ith
higher tensile strength P)#*% is melt9=rocess able but it is still difficult
to =rocess because of the high melt viscosity Gbrand names are 3el9*S
and NeoflonS0
19
P/D* K Polyvinylidene fluoride
P/D* is a =artially fluorinated homo=olymer and is made by
=olymeriAing vinylidene monomer P/D* is a high molecular ;eight
fluoro=olymer that has better mechanical =ro=erties and ;ear and
cree= resistance than the maBority of the family It is melt9=rocessable
and is some;hat less e>=ensive than many other fluoro=olymers #he
first use of P/D* ;as in architectural coatings a==lications GPennsalt
discovered it in 19D: but sold the rights to the com=any that is no;
!r"ema8 brand name 3ynarS08 and the e>cellent ;eather resistance
=ro=erties resulted in many a==lications in cars and electrical =roducts
in e>=osed situations
#he co=olymers of *louro=olymers:
*%P K *luorinated ethylene =ro=ylene
*%P is a fully fluorinated co=olymer made by =olymeriAing #*% and
he>afluoro=ro=ylene *%P ;as first =roduced by DuPont in 197D
G#eflonS *%P0 and ;as the first commercially =roduced material to
attem=t to combine the uni?ue mechanical and chemical =ro=erties of
P#*% ;ith the melt9=rocessability of more conventional =olymers *%P
has very similar mechanical and chemical =ro=erties to P#*% but better
im=act strength )om=ared to P#*%8 *%P has a ma>imum service
tem=erature that<s a==ro>imat1::o* lo;er and a slightly higher
coefficient of friction
20
%#*% K %thylene tetrafluoroethylene
%#*% is a =artially fluorinated co=olymer made by =olymeriAing #*%
and ethylene8 and %#*% ;as first =roduced by DuPont in 19C:
G#efAelS0 and is another melt9=rocess able fluoro=olymer %#*% has
mechanical =ro=erties that a==roach those of the fully fluorinated
=olymers but has a lo;er ma>imum service tem=erature Des=ite this8
%#*% e>cels in s=ecific a==lications because of greatly increased cut
through and abrasion resistance and im=act strength
%)#*% K %thylene chlorotrifluoroethylene
%)#*% is a =artially fluorinated co=olymer made by =olymeriAing
chlorotrifluoroethylene and ethylene8 %)#*% ;as first =roduced by
!llied )hemicals G+alarS0 at the same time as %#*% and the
mechanical =ro=erties are very similar to those of %#*% %)#*% also
has mechanical =ro=erties a==roaching those of fully fluorinated
=olymers8 ;ith a lo;er ma>imum service tem=erature and the lo;est
density !s ;ith %#*%8 %)#*% has e>cellent cut through and abrasion
resistance and im=act strength
P*! K Perfluoroal"o>y
P*! is a =artially fluorinated co=olymer made by =olymeriAing #*%
and Perfluoroal"o>y P*! ;as first =roduced by DuPont in 19C.
G#eflonS P*!0 and is also melt9=rocessable In many ;ays P*! is
similar to *%P but generally has better mechanical =ro=erties at
higher tem=eratures and a ma>imum service tem=erature very similar
to that of P#*% It is considered by some to be the best melt9=rocessable
fluoro=olymer alternative to P#*%
21
1%N%'!L P'(P%'#I%S (*
P#*%
1 #ensile strength
. #ensile ,odulus
5 ,a>imum Service #em=erature
6 Lo; )oefficient of friction
7 +igher melt #em=eratures
D +igher density
C /ery good #hermal resistance
8 %>cellent )hemical resistance
9 /ery good +ardness and toughness
1: 4ide range of Dielectric Strength
22
!PPLI)!#I(N (* P#*%
!utomotive K
P#*% is used as a com=onent in vehicles ;here over9braided hose
constructions are used for air bra"e systems P#*% has a high9
tem=erature tolerance8 so it is im=lemented into the outlet side of air
com=ressors In addition8 the fluoro=olymer hel=s to minimiAe the
carbon =article de=osition
!ircraftI!eros=ace K
P#*% is used for aircraft fuel8 hydraulic hose8 and tubing hoses over
braided ;ith 3evlar In addition8 it is im=lemented to facilitate medium
=ressure and to tem=er heat in fuel8 oil8 and ;aterIalcohol in hydraulic
and =neumatic systems
)hemical =rocessing K
P#*% is used in relation to chemical transfer hoses8 fle>ible connectors8
=roduct interchange lines8 and fle>ible hoses for =rocess lines8 steam
lines8 and refrigeration systems In this industry the fluoro=olymer8
P#*%8 is recogniAed as an advantage over stainless steel8 corrugated
hoses
Pharmaceuticals K
Su==lied ;ith an over braid8 P#*% offers a strong and easy =urging and
cleaning system to meet those im=erative demands of the industry
)ryogenic K
P#*% stays tenacious under cryogenic conditions8 so it is celebrated in
the industry P#*% is an o=timal fluoro=olymer to use in li?uid air
systems8 fuel lines8 hydraulic hoses in Bet aircraft8 and in =iston rings
23
Some of the Products made from P#*% are sho;n belo;

24