ADAMA SIENCE AND TECNOLOGY UNIVERSITY

SCHOOL OF MECHANICA, CHEMICAL AND MATERIAL

ENGINEERING

CHEMICAL ENGINEERING DEPARTMENT

Internship Program

from September 08 - October 08, 2021.

HOSTING ORGANIZATION: -Ethiopian Plastic Industry

EPI Advisor: - Mr. Bantamlak

Program Advisor: - Mr. Eba.A

Submitted by:- ID.No

- Mikiyas Tesfaye...................................A/ur14534/10

- Elizabeth Abraham.............................UGR17032/11

- wendeson Abera..................................UGR17759/11

Submitted Date Oct 22, 2021

 Acknowledgment
First and foremost, we would like to thank our Almighty GOD for helping us throughout our
carrier of Internship practice without any problem and, Again we would like to thank Ethio
Plastic Industry for giving us a chance to practice in the company.

Once again we would like to give a heartfelt gratitude to Ethio Plastic Industry production
operation director, our adviser Mr. Bantamlak and program advisor Mr.Eba.A for their
invaluable advice, new idea and constructive idea which helped me throughout the project.

Also We would like to thanks to our university for giving as the chance to Put into Practice the
problem solving Skill ,Techniques and theoretical knowledge Acquired in University through
Lectures that are Important on participating on the real world and playing our roll on community
problem solving practice using Our Skill and Knowledge.And Important for success in our future
endeavor.

i
 Abstract
The main objective of this work is to develop PVC, PPR and HDPE production method which
can be made from available materials. From the technical point of view, this depends on the raw
materials that are used for sanitation, drainage, irrigation, blade and for electrical conduit.

In poly factory like blowing Extrusion machine operation, printing machine operation and
Cutting and sealing machine operation. The apparatus & accessories needed for daily product
inspection used here are Micrometer, Weighting balance (weight), Meter tape. Mainly poly
factory produces are plastic bags, packing materials and plastic sheets.

Composite factory composite materials are produced; which are a combination of two different
materials that have different properties. A composite material has a unique property related to the
components that are used in the manufacturing process.

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 List of acronyms

 EPI – Ethio Plastic Industry

 PVC- poly vinyl chloride
 PPR- poly propylene random
 HDPE- high density poly ethylene
 LDPE - Low density poly ethylene

iii
 Executive summary

This report is an outcome of the exercises we conducted during our internship period at EPI
specifically in four working section, i.e pipe, poly, injection and composite. This was an
opportunity for us to put in practice the legal knowledge that I had acquired during my four
years’ study of ASTU. The purpose of this report is to put in work experience we had performed
and the learning attained from performing especial tasks while working in professional
environment.

The first part of my report, we briefly described general overview about the internship and
background of the hosting company including mission, vision and its main product and service.

From second to the fifth chapter of my report is briefly explained the overall internship
experience we have gained during our practical period. we started by telling my major duty, in
which section of the company we have been working in and the working piece we have been
executing. we also explained clearly what the general production process of the company.

In our team, we tried clearly to state the overall benefits we have gained from the internship
program in terms of developing our practical skill in Plastic, upgrading our theoretical
knowledge, our interpersonal communication skill and in terms of improving our team playing
skills, leadership skills, understanding about work ethics related issues and in terms of
entrepreneurship skills.

And finally, we have provided the conclusion and recommendation for the company and the use
of the internship for us based on our observations.

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Table of Contents
CHAPTER 1..................................................................................................................................................1
1. INTRODUCTION................................................................................................................................1
1.1. Objectives of internship......................................................................................................................1
1.2. Background of the organization.....................................................................................................2
1.3 Mission and vision of EPI....................................................................................................................2
CHAPTER 2..................................................................................................................................................3
2.1 PIPE FACTORY..................................................................................................................................3
2.2. Raw material.......................................................................................................................................3
2.3 Description of Raw material................................................................................................................3
2.3.1 Additives that are added in the production process...............................................................4
2.4 Methodology........................................................................................................................................5
2.4.1 PVC Production Method...............................................................................................................5
2.4.2 Process Flow Diagram for PVC....................................................................................................6
2.4.3 Production method of PPR and HDPE..........................................................................................6
2.4.4 Process Flow Diagram for PPR and HDPE..................................................................................7
2.4 Problem identification....................................................................................................................8
2.5 Recommendation..................................................................................................................................8
CHAPTER 3..................................................................................................................................................9
3.1 POLY FACTORY................................................................................................................................9
3.2 Raw Material........................................................................................................................................9
3.3 Raw Material Description....................................................................................................................9
2.4 Factory operation process...................................................................................................................11
3.4.1 Process Description.....................................................................................................................11
3.4.2 Main Film blowing process.........................................................................................................12
3.4.3 Cutting and sealing machine operations......................................................................................14
3.4.4 Printing machine operations........................................................................................................14
3.4.5 Poly Products...............................................................................................................................16
3.5 Problem identification............................................................................................................................16
3.6 Recommendation....................................................................................................................................17
CHAPTER 4................................................................................................................................................18
INJECTION AND BLOW MOLDING FACTORY...................................................................................18

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4.1 Introduction........................................................................................................................................18
4.2 Raw materials.....................................................................................................................................19
4.3 Raw material description....................................................................................................................19
4.3.1 HDPE injection grand (High-density polyethylene)...................................................................19
4.3.2. PVC compound for boots...........................................................................................................19
4.3.3 LDPE (low density polyethylene)...............................................................................................20
4.3.4 ABS (acrylonitrile butadiene styrene).........................................................................................20
4.3.5 Poly styrene.................................................................................................................................20
4.3.6 PPR (poly propylene)..................................................................................................................20
4.3.7 PVC granule................................................................................................................................20
4.3.8 HDP blow molding.....................................................................................................................21
4.3.9 Master batch................................................................................................................................21
4.4 Process flow diagram.........................................................................................................................21
4.4.1 Process flow diagram for blow molding machine operation.....................................................22
4.5 Process description.............................................................................................................................22
4.5.1 General process description of the injection machine.................................................................22
4.5.2 General process description for the blow molding machine.......................................................23
4.6 Products..............................................................................................................................................24
4.7 Problem identification........................................................................................................................25
4.8 Recommendations..............................................................................................................................25

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 CHAPTER -1
1. INTRODUCTION

First, Plastic is a material consisting of any of a wide range of synthetic or semi-synthetic

organics that are malleable and can be molded into solid objects of diverse shapes. Plasticity is a
general property of all materials which can deform irreversibly without breaking but, in the class
of moldable polymers, this occurs to such a degree that their actual name derives from this
specific ability. They are typically organic polymers of high molecular mass and often contain
other substance. Most commonly derived from petrochemicals. Due to their low cost, ease of
manufacture, versatile, and imperviousness to water. So it is used in a multitude of product of
different scale including paper clips space craft. There are two type plastic thermoplastics and
thermosetting.

PVC and pipe factory is one of the factories that are found in the Ethiopian plastic industry. This
factory produces different size of pipes and PVC plastics for different purposes like for irrigation
purpose, for sanitation and the like. It produces three types of pipes, using two different factories.
In the first pipe factory there are two types of pipe product HDPE pipes and PPR pipes. In the
other pipe industry produce PVC pipes. Mainly produce PVC pipes for different purpose like
sanitation and drainage systems and other pipes for irrigation and water transportation purpose
plus to that conduit for wiring purposes.

1.1. Objectives of internship

 Expand philosophy and knowledge in the field
 Gain a greater understanding of the duties and responsibilities of a fitness professional
 Identify personal strengths and weaknesses
 Understand and adhere to professional standards in the field
 Relate to, interact with, and learn from current professionals in the field
 Broaden your knowledge and education by continuing to learn
 Put theory into practice
 Develop the initiative and motivation to be a self-starter and work independently

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1.2. Background of the organization

1.2.1 Description of the organization

Ethiopia plastic was established in 1960 by a group of five entrepreneurs. In 1973 the military
government took ownership of 55% of the company, leaving the remaining 45% to the original
owners. Consequently in 1978 the military government nationalized the company. Renamed
Ethiopia plastic industry (EPI) the company was incorporated into the Metal and Engineering
Corporation (METEC) in 2011. The initial capital of the factory was 10 billion birr that contains
more than 600 employers.

1.3 Mission and vision of EPI

1.3.1 Mission

 To Satisfy customers’ needs and to be a competitive Organization by producing good

quality of product with in all aspect of production alongside of creating job opportunities
and professionalism in the field.
 To produce and supply highest quality products by optimizing research and strict quality
assurance, by using the contemporary equipment and the application of Technology and
also by using international measurements at competitive price utility every opportunity
available to use its full production capacity and earn reasonable profit for its sustainable
development in the face of competitions outside the country.
1.3.2 Vision
 Fulfill costumer’s needs and requirements by producing UPVC, PPR, HDPE, pipe and
fittings, irrigation hose, Bus and stadium plastic chairs, PVC profile and ceiling, poly-
products and composite products based on international standard that meet requirement
of pertinent interested parties within its context, statutory and legal requirements.
 Assure costumer expectations by establishing implementing and maintaining
ISO9001:2015 and continually improving the effectiveness of the quality management
system.
 Demonstrate the highest level of commitment for team work, participatory and
decentralization of decision making innovativeness and integrity among our employees
and we shall empower them for their continuous development.

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 CHAPTER -2
2.1 PIPE FACTORY

PVC and pipe factory is one of the factories that are found in the Ethiopian plastic industry. This
factory produces different size of pipes and PVC plastics for different purposes like for irrigation
purpose, for sanitation and the like. It produces three types of pipes, using two different factories.
In the first pipe factory there are two types of pipe product HDPE pipes and PPR pipes. In the
other pipe industry produce PVC pipes. Mainly produce PVC pipes for different purpose like
sanitation and drainage systems and other pipes for irrigation and water transportation purpose
plus to that conduit for wiring purposes.

2.2. Raw material

 PVC risen (poly vinyl chloride) compound

 Resin.............................................................150 kg
 Filler (CaCO3)..............................................8kg
 SMS (stabilizer)............................................4.5 kg
 TiO2..................................................................................................... 0.2 kg
 Lubricant.........................................................0.3kg
 Pigment..........................................................0.02 kg

 PPR (poly propylene random)

 HDPE (high density poly ethylene)
 LDPE (Low density poly ethylene) product scraps

2.3 Description of Raw material

PVC risen-This compound is a very strong temperature resistance compound called poly vinyl
chloride with a good strength. It is a thermoplastic polyolefin which is easy to process into pipes
& fittings with superior chemical & physical properties. They are best carriers of potable water

3
(both Hot and cold) in domestic as well as in industrial application in terms of quality and price.
When long term performance under adverse conditions without deviations in standards is
required. Thermoplastic resins consist of macromolecular chains with no crosslinks between the
chains. The macromolecular chains themselves can have statistical oriented side chains or can
build statistical distributed crystalline phases.

PPR -is a poly propylene compound and a thermoplastic polymer used in a wide variety of
applications including packaging and labeling also to produce plastic parts.

HDPE -is a high density poly ethylene. This is used for production of heavy task films and
materials having high temperature resistivity. It is a polyethylene thermoplastic made from
petroleum. It is sometimes called "alkathene" or "polythene" when used for pipes. HDPE is
known for its large strength-to-density ratio. The density of HDPE can range from 0.93 to 0.97
g/cm3 or 970 kg/m3. Although the density of HDPE is only marginally higher than that of low-
density polyethylene, HDPE has little branching, giving it stronger intermolecular forces and
tensile strength than LDPE.

LDPE -this is a low density poly ethylene which is mainly used for poly sheet and other
materials which require the less density poly ethylene requirement.

2.3.1 Additives that are added in the production process

 Filler (CaCO3): - for increasing strength

 TiO2: -for solar energy resistance
 Steric acid: - for physical appearance
 Lubricant: - for decreasing friction
 Pigment: -for coloring purpose
 SMS stabilizer: - for homogenized those chemicals and for temperature

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 2.4 Methodology

2.4.1 PVC Production Method

In Factory 1: - First the raw materials are mixed using a dry mixer like the profile factory, this
dry mixer has a heating and cooling system consecutively with a turbinate equipment. Then there
is a sucker which guide directly to the Hooper and the Hooper direct the mixed powdered raw
material to the extruder. These extruders have seven temperature zone which are in increasing
order and with extruder inside then after that the die containing a mandrill that the molten
material will pass through to attain the shape in need. The die and mandrel is changed according
to the thickness in need. After passing the die and mandrill there is a vacuum pressure calibration
system used to maintain the shape and size of the pipe. Then after that there is a temperature
cooling system used to lower the high temperature of the pipe. Then there is a haul off machine
used for rolling to the next machine which is auto rotary cutter which is used to cut the pipe in
order of the required meter. The cutter will cut the pipe with the signal from the encoder then the
cutter will cut the pipe or if it is needed to troll the roller will roll the pipe.

The reason we are using two rolling in plastic sheet fabrication is to make flat shape of the
product with the required thickness, also the speed will be adjusted.

PVC are coming in two basic forms rigid and flexible. The rigid form of PVC is used in
construction for pipe and in profile applications such as doors and windows. It is also used for
bottles, other non-food packaging. We use this material for fabrication water hose. We also use
recycled polymer for fabricating conduits. The recycled polymer must be size reduced because
scrub polymers are large in size that cannot under goes extrusion process. And they need to be
sorted depending they physical property. By physical property mean specially their colors. The
other advantage of using this scrub polymer is we will not use master batch. But sometimes we
use a master batch for producing simple decorating belts (Bingo).

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 2.4.2 Process Flow Diagram for PVC

Raw material Mixer Hopper Extruder Trolley

imported mounted Die
head
Trainor/haul off Cooling Cooling Vacuum
unit 2 unit 1 bath Calibrator

Final Product
Cutting unit ROLLER Stored
Inspection

No
Crushing unit

2.4.3 Production method of PPR and HDPE

First we going to mix raw material using a mixer like the profile factory. This dry mixer has a
heating and cooling system consecutively with turbinate equipment with coloring master batch in
the proportion of 25 Kg raw material to the master batch 400g.

There is a screw Conveyor which guide mixed raw material directly to the Hooper then the
Hooper direct the mixed powdered raw material to the extruder.
The main area in this process is the extrusion part, where extrusion line consists of a number of
pieces of equipment. An extruder converts the polyethylene raw material to a continuous tubular
melt by extrusion through an annular die having four different zone with different temperature
about 357oc. The screw in the extruder will rotate and develop sufficient pressure to force
material to go through die and produce products with different geometries. screw, extruder drive,
barrel, feed hopper. The helical structured extruder screw is the heart of an extruder, which
includes transport, heating, melting and mixing functions for plastic. An extruder drive, an
electrical motor, supplies power to rotate the screw. The stability and quality of products is
highly dependent of the design of the screw. The extruder barrel is outside the screw providing
heating and cooling capabilities. There is a feed throat connect feed hopper and barrel. The feed

6
hopper is designed to hold the plastic pellets, and allows plastic pellets flow into the barrel
steadily.
Die is placed at the end of the extruder, and can determine the shape of the product. It has three
temperature zones. The speed of the extrusion polymer raw material is 46.5 rpm.
This product can be fabricating 6 meter pipes with required shape and thickness, 75,63,50, and
5.8,6.8. In 1 hour and 45 minutes.
Products – PPR pipe used for hot water resistance pipe.
HDPE pipe-used for town water pump distribution.

Fig.2 product in factory 2

2.4.4 Process Flow Diagram for PPR and HDPE

Raw
material

Flow chart for

Crushing (Size Flow chart for
Floor tiles
reduction) Conduit Factory

Extrusion

Double rolling Machine Cooling

Rolling Machine Finishing

Storing Storing

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 2.5 Problem identification
 There is diameter, thickness and mass variation
 In the factory we were able to observe that there is leaking of gas in to the vacuum tube
these cause the shape to be deformed.
 Lack of using machinery.
 There is no safety for the workers. This production process required a high temperature
and machine equipment loading that affects the person works on this factory. Also the
machine will break when heavy lifting of machine equipment done by only
 Seeing the current actual situation of Ethiopian plastic industries, most of this industries
import their raw material from foreign countries with high cost and long shipment
procedure.

2.5 Recommendation
 To install stand by generator to prevent power loss defects
 To prevent diameter, thickness and off center variations we should carefully attach die
and mandrill in proper position and attachment and not letting air pass through the
vacuum tube.
 For discontinuity we should be careful of arrangement of temperature and rolling device
speed.
 We recommend using a viscous fluid in leaking areas
 We use new HDPE resin for strengthen for supporting scrub polymer property that will
cost much more. But we can strength our raw material by only using the scrub polymer.
 By mixing raw materials HDPE, LDPE and PP and the scrape too according to the higher
ratio with any proportion that suit for a desired property and strengthen the raw material
then we get the higher specific property.
 There is an excellent potential in the nation to produce ethylene from this source of
ethanol and using long process and procedures it is possible to produce polyethylene and
poly vinyl chloride this procedure will help the country to reduce its foreign currency
plus it will decrease the time delay on shipment and create a sustainable raw material
production opportunity.

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 CHAPTER -3
3.1 POLY FACTORY

There are operations in poly factory like blowing Extrusion machine operation, printing machine
operation and Cutting and sealing machine operation. The apparatus & accessories needed for
daily product inspection used here are Micrometer, Weighting balance (weight), Meter tape.
Mainly poly factory produces are plastic bags, packing materials and plastic sheets for different
purpose.

3.2 Raw Material

1. Low density poly ethylene (LDPE)
2. Linear low density poly ethylene(LLDPE)

3. Film grade plastic materials

 Light duty
 Medium duty
 Heavy duty
4. Master batch (GP and poly)

3.3 Raw Material Description

1. LDPE -Low-density polyethylene (LDPE) is a thermoplastic made from the monomer
ethylene. It was the first grade of polyethylene, produced by Imperial Chemical Industries
(ICI) using a high pressure process via free radical polymerization. It is widely used for
manufacturing various containers, dispensing bottles, wash bottles, tubing, plastic bags for
computer components, and various molded laboratory equipment. Its most common use is in
plastic bags.

2. LLDPE- Linear low-density polyethylene (LLDPE) is a substantially linear polymer

(polyethylene), with significant numbers of short branches, commonly made by
copolymerization of ethylene with longer-chain olefins. Linear low-density polyethylene
differs structurally from conventional low-density polyethylene (LDPE) because of the
absence of long chain branching. The linearity of LLDPE results from the different
manufacturing processes of LLDPE and LDPE. In general, LLDPE is produced at lower
9
 temperatures and pressures by copolymerization of ethylene and such higher alpha-olefins as
butane, hexane or octane. The copolymerization process produces a LLDPE polymer that has
a narrower molecular weight distribution than conventional LDPE and in combination with
the linear structure, significantly different rheological properties. LLDPE has higher tensile
strength and higher impact and puncture resistance than does LDPE, It is very flexible and
elongates under stress. It can be used to make thinner films, with better environmental stress
cracking resistance, It has good resistance to chemicals, It has good electrical properties,
However, it is not as easy to process as LDPE, has lower gloss, and narrower range for heat
sealing.

3. HDPE- High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a

polyethylene thermoplastic made from petroleum. It is sometimes called "alkathene" or
"polythene" when used for pipes with a high strength-to-density ratio; HDPE is used in the
production of plastic bottles, corrosion-resistant piping, geomembranes, and Plastic lumber.
HDPE is commonly recycled, and has the number "2" as its resin identification code
(formerly known as recycling symbol). HDPE is used for cell liners in subtitle D sanitary
landfills, wherein large sheets of HDPE are either extrusion or wedge welded to form a
homogeneous chemical-resistant barrier, with the intention of preventing the pollution of soil
and groundwater by the liquid constituents of solid waste.

4. PVC- PVC was accidentally synthesized by German chemist Eugen Baumann. The polymer
appeared as a white solid inside a flask of vinyl chloride that had been left exposed to
sunlight. Waldo Semon and the B.F. Goodrich Company developed a method in 1926 to
plasticize PVC by blending it with various additives. The result was a more flexible and more
easily processed material that soon achieved widespread commercial use. PVC has high
hardness and mechanical properties the heat stability of raw PVC is very poor, so the
addition of a heat stabilizer during the process is necessary in order to ensure the product's
properties.

5. Film Grade plastic materials

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 a. Light duty/ light duty LDPE- Thin shrink film, lamination film, produce bags, textile
packaging, soft goods packaging, general-purpose bags with good optics and t-shirts
carrier bags
b. Medium duty/Medium duty LDPE- can be used for medium duty bags, shrink films,
shopping bags, lamination films and Frozen food packaging.
c. Heavy duty/Heavy duty LDPE- can be used for Heavy duty bags, Industrial shrink
films, construction and agricultural films.

6. Master batch [GP and Poly]-Master batch is a solid or liquid additive for plastic used for
coloring plastics (color master batch), generally there are 4 main inputs to produce products,
this are man, machine, materials and methods. For poly sheet and poly roll-3%, for poly bags
-8%, Poly bags printed-11%. Production capacity by weight, thickness and width. From 5cm-
150 cm width, From 4 micro (0.004mm)- 45 micro(0.45mm) thickness and From 50 kg-3000
kgs weight/day. 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 into a
granular shape. Master batch allows the processor to color raw polymer economically during
the plastics manufacturing process. Master batches can be used in most processes, except
rotational molding and Plastisol and other liquid resin systems. Additive master batches
modify various properties of the base plastic: ultraviolet light resistance, flame retardant,
anti-fouling, anti-static, lubrication, anti-slip, corrosion inhibitors for metals packaged in
plastic, anti-microbial, anti-oxidants, extrusion aid, and phosphorescence

2.4 Factory operation process

 blowing Extrusion machine operation
 Printing machine operation
 Cutting and
 sealing machine operation

3.4.1 Process Description

First the machine is started by turning on the power button, and then it is lifted to worm up, so
that it can further proceed. After the film blowing machine is ready then the raw material LDPE
will be filled to the Hooper then the Hooper will contain and lead the raw material to the
temperature zones.

11
This temperature zones vary with the type of film blowing machine then there is a screw type
puller inside these temperature zone, which help to move this molten raw material from one zone
to the other then when the temperature in need is reached it will be pulled up ward there are two
blowers the inward and the outward blowers the inward will allow the film to have a balloon
structure guiding to the size of the balloon will determine the size of the film to be produced.

This is done by filling air in or air out. If we want to increase the size will increase the diameter
of the balloon if small we reduce the diameter of the balloon, so by this mechanism we can have
the size in need. The other main thing is the thicknesses hear the thickness is measured by micro
meter. The question is how can one make the thickness in the required size? These is done only
by adjusting the duration of the film that pass through these means if we want high thickness we
will pass the film very fast and the vice versa is true. Even if this method is a trial and error
method it is functional and applicable. If we want to cut one edge the machine can be adjusted to
cut the edge using a cutter. If the order contains a selling or panting the selling and painting
machine will be used. Then there is a roller this roller will roll the film then it will be transported
to the store and ready to transport.

Fig 3.1 pfd of poly production

3.4.2 Main Film blowing process

Feed—Extruder—Die-Bubble—Roller—Rolled Sheet Product

⚫ The mixture is heated and conveyed through the extruder.

12
 ⚫ The melted material is then pumped, under continuous pressure, through a circular,
rotating die (1) that creates a tube of thin polyurethane or other polymer.

As the warm, extruded material is drawn up several stories by nip rollers (2), the tube is
expanded by filling it with air, creating a "bubble" (3) that performs three basic functions:

1. The volume and pressure of air "blown" into the tube causes the material to stretch, there by
determining the overall size of the bubble and the width of the finished sheet

2. This same action, in conjunction with the rate at which the bubble is being pulled upward
away from the die, determines the thickness of the finished film.

3. The bubble begins the air-cooling pro As the bubble enters the nip rollers it is collapsed into a
flat tube (4) cess while traveling up to the nip rollers. Then cools further while it travels back
down the outside of the tower (5) to an additional set of rollers (6).

4. The bubble is pulled continually upwards from the die and a cooling ring blows air onto the
film. The film can also be cooled from the inside using internal bubble cooling. This reduces the
temperature inside the bubble, while maintaining the bubble diameter.

13
The Film Blowing Process

3.4.3 Cutting and sealing machine operations

This machine is applied to manufacturing and printing the uncolored vest bags made of LDPE
roll film. It adopts PLC control, double servo step) motor fixed length and the liquid crystal
touch screen actual display to finish the feeding, sealing, cutting, punching holes and
transporting only in one process. It is of high degree of automation and good economic result.

Loading printed /unprinted roll product — passing b/n pulling roller — sealing heater — cutting
blade — conveyor belts — bag products

1. Machine switch on first based on the given working procedure/ machine manual.

2. Mounting the plastic film role in the carry shaft and passing through guide rollers with proper
arrangement.

3. Setting the temperature according to the product thickness.

4. Setting the appropriate bag length and machine speed.

5. Continuing bag making process.

3.4.4 Printing machine operations

⚫ If the bags are to be printed the roll of film is taken to the printing machine known as a
press.

14
 ⚫ This is usually flexographic printer means that it uses flexible printing plat which are
mounted on to a steel cylinder of the correct diameter to give the repeat length required

⚫ The film is corona discharge treated this device essentially bombards the surface of the
film with high voltage sparks.

Printing machine processes loading roll product—passing b/n pulling roller—printing roller—
printed product

POLY AND PRINTING FACTORY

Receiving poly
production order

LDPE Raw material and master

batch requisition

Mixing LDPE with master

batch

Machine set up

Film Blowing Production

INSPECTION No
Yes Yes
Printing
Rolling of Finished Film Product Cutting and
sealing
Packing and labeling the poly sheet/Tubular
Cutting and product
sealing

Recording of voucher
data
Transporting products

15
Applications-Agricultural fill, Bags, Industry packaging, shrink film, stretch film, Consumer
packaging, food wrap, transport packaging, Laminating film, Barrier film, Multilayer film

3.4.5 Poly Products

Mainly produces plastic bags, packing materials and plastic sheets for different purpose.
 Poly Sheet
 Poly Tubular
 P/Bag & P/Carrier Bag- Thickness Variation, Width Variation, Length Variation,
Shrinking/Folding/, Tearing/Discontinuity/, Color Problem, Improper Sealing

Fig.1 poly products

3.5 Problem identification

 Loss due to scrap: loss of material, labor and overheads on the manufacture of defective
product.

 Loss due to repair and rework: labor for repairing/ rework and overheads on it.

 Other losses: Losses due to discount on second grade quality, Excess inspection costs,
Losses due to delays, stoppages, loss of good will of customers.

 Melt fractures- appear as roughness or wavy lines on the film surface

 Thickness variations in the film

 Die lines on the surface of the film -This defect weakens of mechanical properties such as
tear strength

16
3.6 Recommendation
Every time, we must observe: -

 Follow the right proportion of mixing ratio

 Be sure that they have common understanding while communicate each other,

 Give more emphasis for m/c cleaning before & after operating, and adjust operational
parameters regularly in order to minimize product quality defect. I.e.
Decreasing/increasing the R/M feeding speed or Adjust the Centering bolts
& air ring/tube/ or Adjust the die position, Adjust the temperature of the heating zones
and Practice general safety rules.

 Melt fractures- appear as roughness or wavy lines on the film surface, and can be
eliminated by lowering the viscosity of the polymer melt. This can be done by increasing
the melting temperature or by adding an internal lubricant to the material composition.

 Thickness variations in the film- This can be avoided by centering the die in the
extrusion line before every run, adjusting the air speed of the cooling system, or by using
heated die lips.

 Die lines on the surface of the film -This defect weakens of mechanical properties such as
tear strength. This can usually be avoided by routinely cleaning the inner surfaces of the
die and by refinishing scratched or roughened flow surfaces.

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 CHAPTER - 4
INJECTION AND BLOW MOLDING FACTORY
4.1 Introduction
First, Plastic is a material consisting of any of a wide range of synthetic or semi-synthetic
organics that are malleable and can be molded into solid objects of diverse shapes. There are two
type plastic thermoplastics and thermosetting.

Blow molding and injection factory is one of the main factories from the six factory of ETHIO
PLASTIC INDUSTRY. These factories use two machines which are The Blow molding
machine which mainly use air pressure/ blowing mechanize on the raw material with the
participation of the mold and the injection machine which use the injection of the raw material
to the mold.

Blow molding Process-Accomplished in two steps: Fabrication of a starting tube, called a

parison and Inflation of the tube to desired final shape. Forming the parison is accomplished by
either Extrusion which defined as a manufacturing process (high-volume), in which the raw
plastic / raw plastic material is melted and then formed in a continuous profile, With this process
various products can be manufactured such as pipe/tubing, window frames, weather stripping,
wire insulation, and adhesive tape, Typical extruder screws move the thermoplastic material
through four zones: Feed zone, Transition zone, Mixing zone and Metering zone. The two
principal plastic extraction processes are profile $blow film extraction or injection molding
which utilizes elements of conventional thermoplastic injection molding. This is more
economical than the extrusion process and generally is used for large production quantities of
smaller containers of less than liter size. Basically, the systems include an injection station, a
blow station, and a strip or eject station. Injection blow molding Plastic pellets are heated in the
injection unit and forced through system/gates(s) into a cavity in a mold.

These plant(both)is basically engaged in producing different house hold, different pipe joints and
military materials such as armature handles of different weapons, elbows, water holding
containers for military and house hold purpose and different size liquid containers.

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 4.2 Raw materials
1. HDPE injection grand 6. PPR
2. PVC compound for boots 7. PVC granule
3. LDPE 8. HDP blow molding
4. ABS 9. Master batch
5. Poly styrene

4.3 Raw material description

4.3.1 HDPE injection grand (High-density polyethylene)

It has a variety of advantages over other polymers. HDPE offers low cost, easy processing, a
good moisture barrier, and the ability to produce an opaque packaging product. This is used for
production of production of heavy task film and materials. So it is used as a raw material melted
inside the injector.

Blow mold containers-shampoo bottles, oil bottles, household cleaning bottles, blown mold
drums, flower pots, and more. Clear HDPE containers often have a milky haze color.

Extruded Packaging Films- Many retail bags are made from HDPE extrude polymers. Common
products include grocery bags, packaging films, trash bags, and a large selection of retail
packaging bags.

HDPE offers excellent puncture resistance, low stretch, reduce tearing, and moisture protection.
HDPE film can come in a variety of thicknesses depending on the need. Moat HDPE extruded
films are offered between 2-10 mils in thickness High-Density Polyethylene products are very
safe and are not known to transmit any chemicals into foods or drinks. HDPE products are
commonly recycled. Items made from this plastic include containers for milk, motor oil,
shampoos and conditioners, soap bottles, detergents, and bleaches. It is NEVER safe to reusean
HDPE bottle as a food or drink container if it didn’t originally contain food or drink.

4.3.2. PVC compound for boots

Poly vinyl chloride is the raw material for the production of like floor tiles and boots because of
its high thermal resistance and durability.

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4.3.3 LDPE (low density polyethylene)
it the most common type of compound with HDPE. Both compounds have very different
physical properties. While LDPE compound have melting point of 115oC, HDPE at135oC. LDPE
is more flexible than HDPE, but HDPE have strength than LDPE.

LDPE is mainly used for poly sheets and other materials which require the less density poly
ethylene requirement. Low-Density Polyethylene is sometimes recycled. It is a very healthy
plastic that tends to be both durable and flexible. Items such as cling-film, sandwich bags,
squeezable bottles, and plastic grocery bags are made from LDPE

4.3.4 ABS (acrylonitrile butadiene styrene)

It is a common thermoplastic polymer with a glass transition property with a temperature of
105oC. This compound is an inexpensive resin per unit weight and have a general purpose of this
compound is clearing, hard and rather brittle.

4.3.5 Poly styrene

This is an aromatic polymer made from the monomer of styrene. This compound is an
inexpensive resin per unit weight and have a general purpose of this compound is clearing, hard
and rather brittle.

4.3.6 PPR (poly propylene)

This is a thermoplastic polymer used in a wide variety of applications including packaging and
labeling also to produce plastic parts.

4.3.7 PVC granule

is polyvinyl chloride compound plus dope. PVC comes in two basic forms: rigid (sometimes
abbreviated as RPVC) and flexible. The rigid form of PVC is used in construction for pipe and in
profile applications such as doors and windows. It is also used for bottles, other non-food
packaging, and cards (such as bank or membership cards). It can be made softer and more
flexible by the addition of plasticizers, the most widely used being phthalates. In this form, it is
also used in plumbing, electrical cable insulation, imitation leather, signage, inflatable products,
and many applications where it replaces rubber. PVC Compounds, in general, may be divided
into two groups i.e. Granulated Compound where mix is fused and extruded in pellets form and
Dry Blend where resultant compound is often in free flowing powder form.

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4.3.8 HDP blow molding
is also a high density poly ethylene which is also used for production of heavy task film and
materials in these case it is used as a raw material melted and directed to blowing machine

4.3.9 Master batch

It is a concentrated mixture of pigments and/or additives encapsulated during a heat process into
a carrier resin which is then cooled and cut into a granular shape. It allows the processor to color
raw polymer economically during the plastics manufacturing process.

4.4 Process flow diagram

Fill Hopper Turn on Turn on motor granular
Raw material
with raw heater plastic melted and move
screw thread
Packaging, Labeling and
Transport/shapin
stamping
Mold
Melted
open and
Final Quality plastic
finished
production Yes forced in
product
to mold
taken out

Arrange for reuse No

as raw material Recycled

In short we can see how to recycled

First, Plastic recycling refers to the process of recovering waste or scraps plastic and
reprocessing it into useful products.
Shredding is the first step that is done in the recycling process and these shredded pieces are then
processed to eliminate any impurities, such as paper labels.The pieces are then melted and are

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often extruded into pellet form to be used to manufacture other products. Some plastics are
separated according to their color before the process begins.

4.4.1 Process flow diagram for blow molding machine operation

Position of
Fill Hooper
Raw material Turn on Production the mold
with raw
heater of parison halves to
material
entrap the
parson

Final Forming of
Quality Mold open and
product Yes the neck of
finished product
container
taken out
N
Arrange for
reuse as raw Recycled
material

4.5 Process description

4.5.1 General process description of the injection machine

First the raw material is prepared according to the given ratio from the quality and inspection
workshop. Then the sucker will suck the raw material to the Hooper. In the raw material if there
is a color preference by the customer master batch will be added. Then the Hooper guide the raw
material to the extrude line which have six temperature zones in increasing order and a sensor
attached to each partition of the extruder.

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Then according to the temperature adjustment when the temperature is reached the injector will
move toward the die hydraulically then inject the molten raw material to the mold inside. After
that the shape in need is found depending on the mold or die attached inside the injection
machine, so by changing the die inside the machine we can get different shape and size of
material. Some of the products of the injection machine are cups, fittings and electric monitor
coverage can be mentioned.

Fig.4.1. injection machine

4.5.2 General process description for the blow molding machine

First as the injection machine the raw material is prepared according to the ratio from the quality
and inspection workshop. Then the sucker will suck the raw material to the Hooper. In the raw
material if there is a color preference by the customer Master Bach will be added. Then the
Hooper guide the raw material to the heating zones of the blow molding machine then depending
on the temperature arrangement the raw material will be melted and guide to the vertical
arrangement containing the blow pin the plunger and accumulator die head then the blow pin
will blow the raw material directing vertical and the plunger will help to plug and support the
shape and air escape then tis will directly guide to the mold and most of the time either of the
frame of the mold are movable toward the parison then the molten and molten and air pumped

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raw material will get its shape and the air will give the pumping activity for the shape. Some of
the products in blow molding are chairs, oil cup can be mentioned.

Fig. 4.2. Blow molding machine

4.6 Products
Using both the injection machine and blow molding machine we were able to see the production
of many materials some are military materials like rifle butt house hold equipment’s different
size plastic containers like caps and boots, construction materials like safety hats and fittings and
so on.

Fig.4.1. products of injection and blow molding factory

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4.7 Problem identification

Depending on our observation in this factory we were able to observe that there is too much
scrap inside the factory and also there is no stand by generator. There were no permanent
workers who tell you detail about what we want to know. Workers did their job just simply
without skill; they don’t have enough knowledge about what time, so without order there was no
work there. There were also no orders at any they work.

4.8 Recommendations
 We strongly recommend that by adjusting the temperature which is input temperature we
can lower the scrap and minimize wastage
 We recommend that the factory should install stand by generator to precede the work
when there is a sudden power cut.
 Without order produce material and sell it at the market.

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