FEDERAL UNIVERSITY OTUOKE

BAYELSA STATE

A TECHNICAL REPORT

ON

STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

HELD AT

AYOM INTERGRATED PRODUCTION LIMITED. NO 32 STAMFORD ROAD NEAR

ARROMA FEED, ARROMA JUNCTION AWKA.

WRITTEN

BY

EKWELI OVERCOMER ABUMONYE

MATRIC NO: FUO/16/CHM/4075

DEPARTMENT OF CHEMISTRY

FACULTY OF SCIENCE

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF

BACHELOR OF SCIENCE [B.Sc.] DEGREE IN CHEMISTRY

DECEMBER 2019

1
 DEDICATION

I dedicate this work to my dearest parents Mr. and Mrs. OSITA and NGOZI
EKWELI whom through their advice, love, care and financial assistance have
made me to be where I am today, I pray that the good Lord, will continue to keep
and guide them for me. Amen

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 ACKNOWLEDGEMENT
My utmost gratitude goes to the almighty and ever-living God, for His divine grace from which I
have always benefited from. In Him I live, move and have my being.
My profound gratitude also goes to all members of staff of AYOM INTEGRATED
PRODUCTION LIMITED AWKA, who gave me an extensive training and provided a
conducive environment for the exercise.
Many thanks to my parents, Mr. and Mrs. OSITA and NGOZI EKWELI for their selfless support
throughout the period of my training.
I also wish to express my gratitude to my supervisor, Mr. Godwin okonkwo, for all his help
before, during and after the exercise.
I sincerely appreciate the Federal Republic of Nigeria, the Industrial Training Fund (ITF) and all
other supervising agencies who ensure the continuity of the SIWES. Indeed, they have made a
tremendous impact in my life.

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 ABSTRACT

This report is a summary of my industrial work experience gained during my six months at
Ayom integrated production Limited. It contains five chapters which include history of SIWES,
description of the company, departments in the company, extrusion section, Injection section,
recycling section and the relevance of CHEMISTRY in plastic and polymer industry.

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 TABLE OF CONTENT

Title page

Dedication

Acknowledgement

Abstract

Table of content

List of figures

List of tables

CHAPTER ONE: INTRODUCTION

1.1 History of SIWES

1.1.1 Objectives of SIWES
1.1.2 Importance of SIWES
1.1.3 The role of student in SIWES
1.1.4 The role of the institution in SIWES
1.1.5 The role of the industry/employers in SIWES
1.2 Brief history of Ayom Integrated Production Limited.
1.2.1 Department in the company
1.2.2 Administrative department
1.2.3 Account/sales department
1.2.4 Production department
1.2.5 Store department

CHAPTER TWO: DIFFERENT DEPARTMENTS IN AYOM INTEGRATED

PRODUCTION LTD

2.1 EXTRUSION DEPARTMENT

2.1.1 Plastic Extrusion Process

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2.1.2 Extrusion Process Description
2.1.3 The production of PVC pipes using extrusion moulding
2.1.4 Raw materials & Additives used in PVC pipe production
2.1.5 PVC pipes formulation for compounding in Ayom Integrated Production LTD
2.1.6 Terms used in Extrusion moulding process
2.1.7 Defects encountered during production of PVC pipes using Extrusion & its remedies
2.2 INJECTION DEPARTMENT
2.2.1 Terms used in Injection moulding process
2.2.2 Production process
2.2.3 Raw material & Additives used in plastic production
2.2.4 Defects and corrections in Injection moulding of plastics
2.2.5 Difference between Extrusion and Injection moulding
2.3 RECYCLING DEPARTMENT
2.3.1 Recycling of plastic waste
2.3.2 Recycling process in Injection plant
2.3.3 Recycling process in Extrusion plant
2.4 QUALITY CONTROL/QUALITY ASSURANCE OF PRODUCTS IN AYOM
PLASTICS
2.4.1 Quality control and Quality assurance
2.4.2 Quality control

CHAPTER THREE: RELEVANCE OF THE INDUSTRIAL TRAINING TO MY

COURSE OF STUDY, EXPERIENCED GAINED, PROBLEMS ENCOUNTERED
3.1 Relevance of the Industrial training to my course of study
3.2 Experienced Gained
3.3 Problems encountered
CHAPTER FOUR: CONCLUSION AND RECOMMENDATION
4.1 Conclusion
4.1 Recommendation
References

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 LIST OF FIGURES

Figure 1: Basic elements of an Extrusion moulding machine

Figure 2: High speed impeller used for compounding/mixing

Figure 3: An Extrusion machine used in AYOM plastics

Figure 4: Trimming machine used in AYOM plastics

Figure 5: Heating and Socketing machine used in AYOM.

Figure 6: Extruder, Extrusion water-bath, Extrusion line.

Figure 7: A Suspension PVC resin

Figure 8: PVC pipes produced in Ayom Integrated Production Ltd

Figure 9: An Injection moulding machine used in AYOM.

Figure 10: Different colours of master-batch used in AYOM.

Figure 11: Products of polypropylene from Injection moulding machine in AYOM.

Figure 12: Crushing machine used at the Injection plant in AYOM plastics.

Figure 13: Concrete washing basin used in AYOM.

Figure 14: A Drying machine used a.t the Injection plant in AYOM plastics.

Figure 15: A Magnetic sieve.

Figure 16: Recycled polypropylene scraps and lumps.

Figure 17: Crushing machine used at the Extrusion plant in AYOM plastics.

Figure 18: Pulverizing machine in AYOM plastics.

Figure 19: A Vibratory sieving machine.

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 CHAPTER ONE

INTRODUCTION

Students Industrial work experience scheme (SIWES) is designed for skill acquisition. It is
designed to prepare and expose students of universities, Polytechnic and College of Education to
the real life situation they would encounter after graduation.

SIWES is a key factor required to inject and engender industrialization and economic
development in our nation through the induction of scientific and technological skills on
students.

1.1 HISTORY OF SIWES

The SIWES scheme was first initiated and funded by the Industrial Training Fund (ITF) in the
year 1973. It was established to solve the problem of lack of adequate practical skill exposure for
employment in industries by Nigerian graduates of tertiary institutions.

As a result of increasing number of students enrolment in higher institutions of learning, the

administration of this function of funding the scheme became enormous, hence ITF withdrew
from the scheme in 1978 and the scheme was taken over by the federal Government in1979 and
handed to both the National University Commission (NUC) and the National board of Technical
Education (NBTE). By 1979, the College of Education were not part of the scheme and later in
1984, the Federal Government reverted back to the Industrial Training Fund which took over the
scheme officially in 1985 with funding provided by the Federal Government.

1.1.1 OBJECTIVE OF SIWES

The following are objectives of SIWES:

 To provide an avenue for students in institutions of higher learning to acquire industrial

skills and experience in their course of study.
 Make the transition from school to world of work easier and enhance students contacts
for later job placement.
 Provide students with opportunity to apply their knowledge in real work situation thereby
bridging the gap between theory and practice.
 Prepare students for industrial work situations they are to meet after graduation.

8
  Expose students to techniques in handling equipment and machinery that may not be
available in the universities.

1.1.2 IMPORTANCE OF SIWES;

 It provides students the opportunities to apply their theoretical knowledge in real life
situations
 It strengthens the links between students, employers, universities and ITF
 It exposes students to more techniques
 It also prepares the students for the labor market after graduation.

1.1.3 The Role of Students in SIWES;

Attend SIWES Orientation program organized by Institution in conjunction with ITF.

 Be obedient to constituted authorities.

 Be regular and punctual to work.
 Avoid change of place of SIWES attachment outside the allowed time frame.

1.1.4 The Role of the Institutions in SIWES

 Establishment of SIWES Units in Institutions and equipping them.
 Appointment of coordinators and supporting Staff.
 Promptly prepare and submit master placement lists to NUC, NBTE, NCCE and ITF as it
concerns each Institution.
 Apply Job Specifications as prepared for all the accredited courses and award appropriate
credit Units to SIWES attachment e.t.c.

1.1.5 The Role of the Industry/Employers in SIWES

 Collaborate with Institutions in the preparation of Job specification.
 Accept students for SIWES attachment.
 Provide welfare services to students on SIWES attachment.
 Participate in training and assessment of students on SIWES attachment.

9
  Allow students on SIWES attachment access to facilities in their establishments.
 Appoint industry-based supervisor.

1.2 BRIEF HISTORY OF AYOM INTEGRATED PRODUCTION LIMITED..

Ayom Mother Company was registered in 1989 under the name Komadin Integrated Limited
as a freight forwarding and general merchandise organization.
By 1995, another entity sprang up as a father company to Komadin integrated Limited. It was
called Odum Okwuonu Co.Ltd which is a transport company of goods, haulage, warehousing
and operates in the West Coast.
These two companies mentioned above then gave rise to the baby company called Ayom
Industries which is a manufacturing industry. Ayom industries are comprised of two
companies which are; Ayom Integrated Production Ltd which is a polymer processing
company and Ayom foams which is based on the production of all kinds of foams from
upholstery and cushions to auto mobile seats.
The head office of Ayom Industries is situated in Lagos at 16/18 Babare Yusuf
Street.Ishasho,Okomaiko in Ojo Local Government Area.It has two branches which are
located at Nnewi L.G.A and Awka L.G.A in Anambra State
It can be said that Ayom is a group of industry with very long history and operates from the
South East down to Mali.

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 COMPANY’S ORGANOGRAM

GODWIN N.N OKONKWO

CHAIRMAN/MANAGING
DIRECTOR/CEO
UWAEZUOKE
UCHECHUKWU
CONFIDENTIAL
GODWIN C. OKONKWO SECRETARY
GENERAL
MANGER/ACCOUNTANT

OMOLAYO PHILIP EKRIKPO LOUIS C. OKEKE CAPT

OLATUNBOSUN OGBONNAYA
HEAD PRODUCTION ACCOUNT
FACTORY MANAGER OFFICER(INJECTION) SUPERVISOR/STORE HEAD OF
OFFICER SECURITY

DAVID EKEZE
DRIVER
CHIBUZOR OBI ACCOUNT
OLAWALE HITMAN ASSISTANT
HEAD
HEAD MAINTENANCE/SUPERVISOR
PRODUCTION/QUALIT ELECTRICAL SETION
Y CONTROL/SALES
(EXTRUSION)
CHARLES UZUH
ELECTRICIAN
ABRAHAM AGBOR UNYIME ETOK
OPERATOR/SUPER OPERATOR/SUPE
VISOR RVISOR

JOHN JOHNO.ALFRED
OKECHUKWU
MIXER
MIXER

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1.2.1 DEPARTMENTS IN THE COMPANY.

Ayom Integrated production limited, Have four major departments namely:

1) Administrative department
2) Account/Sales department
3) Production department
4) Store department.
1.2.2 ADMINISTRATIVE DEPARTMENT

This department is responsible for the smooth running of the company. It is headed by the
administrative manager who is also the CEO of the company. The administrative manager
performs the following function:

 Employment of staff
 Supervision of the company’s daily activities
 Ensuring rules and regulations of the company are kept
 Implementation of the company’s policies etc.
1.2.3 ACCOUNT/SALES DEPARTMENT

This department manages every aspect of budgeting and expenditures of the company. It also co-
ordinates and supervises all sales activities of the company’s product. The department is headed
by the account/sales manager; he reports directly to the CEO.

1.2.4 PRODUCTION DEPARTMENT

The department oversees the activities of production in the company and ensures quality
processes of various products in the firm are met. The department is headed by the production
manager who reports directly to the CEO and it is divided into four sections namely:

1) Extrusion department
2) Injection department
3) Recycling plant/section
1.2.6 STORE DEPARTMENT

The store department is responsible for receiving and stocking all raw materials, packaging
materials and finished products as well all other equipment required to serve manufacturing

12
purposes. It is headed by the Store Manager. They are responsible for issuing raw materials and
packaging materials for production, ensure that the actual quantity of products produced after a
single run tallies with the expected quantity and also notifies the company when there is need for
procurement of raw and packaging materials.

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 CHAPTER TWO

DIFFERENT DEPARTMENTS IN AYOM INTEDGRATED PRODUCTION LTD

In Ayom Integrated Production Ltd we have different sections of production. These various
departments include: the extrusion department, the injection department and the recycling
department.

2.1 EXTRUSION DEPARTMENT

2.1.1 PLASTIC EXTRUSION PROCESS:

Plastics extrusion is a continuous high-volume manufacturing process, in which raw plastic is melted and
formed into a continuous profile. This process starts by feeding plastic material (pellets, granules, flakes
or powders) from a hopper into the barrel of the extruder. The material is gradually melted.Mechanical
energy generated by turning screws and by heaters arranged along the barrel. The molten polymer is then
forced into a die, which shapes the polymer into a shape that hardens during cooling.

FIG 1. BASIC ELEMENTS OF AN EXTRUSION MOULDING MACHINE

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Extrusion process is very common in the plastic industry. It is used for high volume plastic
production. In extrusion process the color pigments along with other performance
enhancing additives are combined with resin which is then pushed through the rotating screws.

Extrusion is without doubt the most important method of processing in the plastics industry.
This is because it can be adapted to produce a wide variety of finished or semi- finished product
which include pipes, rod, sheet, film, coated wires and cables and other substrates. It is claim that
nearly all thermoplastic pass through an extruder at one stage of their lives! The most important
thermoplastic extruded are poly Vinyl Chloride, polyethylene, polypropylene, polystyrene,
polyamides etc.

Advantages of Plastic Extrusion Process

One of the main advantages of the extrusion process is it can produce pipes of any length. It is
continuous. High production volumes with very low cost per pound. The melting is very
efficient. The mixing of the ingredients is very good. Different types of raw materials can be
used. It uses thermoplastics which can be reused.

Disadvantages of Plastic Extrusion Process

Highly complicated parts are very not suitable for production in extrusion process. It can only
produce the parts which have uniform cross sections. 

2.1.2 EXTRUSION PROCESS DESCRIPTION

In the extrusion of plastics, the raw compound material is commonly in the form of hurdles
(small beads, often called resin) that are gravity fed from a top mounted hopper into the barrel of
the extruder. Additives such as colorants and UV inhibitors (in either liquid or pellet form) are
often used and can be mixed into the resin prior to arriving at the hopper. The extruder
technology though it differs in that it is usually a continuous process. Extrusion molding is a
process of forcing softened plastic through a nozzle or die extrusion molding is used for
continuous molding of thermoplastic material into article of uniform cross-section example
wires, pipes etc

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The extrusion machine has four major zones;

1. The feed zone

2. The compression zone
3. The metering zone and
4. The cooling zone
 The Feed Zone: compounded PVC resins in form of powder are feed into an extruder
through the hopper.
 The Compression Zone: It consist of a barrel, an electrical heater and a screw for
softening of materials. In this zone the powdered resins undergoes melting because of
heat conducted by the heating bands or the heating elements and is compressed by the
working of a reciprocating screw. The molten material is then pushed to the metering
zone. The temperature is controlled by thermocouple.
 Metering Zone:It is at this point that the polymer melt acquires a constant flow rate
impacted by the helical flight of the screw.the build up pressure and the shearing action
of the screw forces the molten polymer out of the extruder through the die into the
cooling zone,the die shapes the extrudant into the desired form.
 Cooling Zone: the cooling zone contain a water bath that cools the pipe as it emerges
from the die,this is done to prevent deformation and shrinkage of pipes.the size of the
pipes depends on the size of the die.the pipe exist through the extrusion line and are cut
into desired length.

Thermoplastic Material in Extrusion: Typical plastic materials that are used in extrusion
include but are not limited to:

 Polyethylene (PE),

 Polypropylene (PP),

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  Acetal,

 Acrylic,

 Nylon (polyamides),

 Polystyrene (PS),

 Polyvinyl chloride (PVC),

 Acrylonitrile butadiene styrene (ABS)

 Polycarbonate (PC)

2.1.3 THE PRODUCTION OF P. V. C PIPES USING EXTRUSION MOULDING

Pipes are first and foremost produced through an extrusion process. The raw material is feeded
into the extruder via a hopper and a gravimetric or volumetric control system. Inside the extruder
barrel the material is heated up to the melting point around 200°C by electricity and the friction
in the screw system. The melted material is pushed through a cavity, called a die-head and
thereby formed into a pipe. The pipe is then calibrated to correct size in a vacuum box and
thereafter cooled by water in spray boxes. Extrusion is a continuous process and pipes can in
principle be produced in infinity lengths. In the end of the production line pipes are cut into
lengths and socketed or coiled according to the intended use.

PRODUCTION FLOWCHART
PVC
PVC
PIGMENT HEATING AND
RESINS
AND SOCKETING PIPES
ADDICTIVES
FORMULATION AND
COMPOUNDING TRIMMING

HOPPER
CUTTING

MELTING
PULLING
17
 FORMED
EXTRUDING INTO A
COOLING
TUBE

DESCRIPTION

VIRGIN MATERIAL MEASUREMENTS: the different raw material are measured out in

adequate quantities using a weighing balance

COMPOUNDING: PVC compounding is a process in which additives are mixed with the base
resin to get a homogeneous mixture. The additives are added to either improve process ability or
enhance. The measured material are compounded here using a high speed mixer forming a
homogeneous mixture

FIG 2 HIGH SPEED IMPELLER USED FOR COMPOUNDING /MIXING

EXTRUDING: Here the compounded material are fed into the hopper of extrusion machine and

extrusion molding take place here

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FIG 3 AN EXTRUSION MACHINE USED IN AYOM INTEGRATED PRODUCTION LTD

TRIMMING SECTION: The edge of the PVC pipes are trimmed here with the aid of a
trimming machine to give it a round smooth edge.

FIG 4 A TRIMMING MACHINE USED

IN AYOM INTEGRATED PRODUCTION

LTD

HEATING AND SOCKETING: Here the

trimmed pipe are heated and socket using a
heating and socketing machine so the pipe
can fit into each other.

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FIG 5 A HEATING AND
SOCKETING
MACHINE USED IN AYOM
INTEGRATED PTD
LTD

Pipes are produced by

horizontal extruding molten
polymer through an annular
opening in to several sizing,
cooling devices that
stabilize the final dimensions.
The elements of the production line are: Extruder, Die, Sizing device, Cooling bath, Puller,
Cutter.

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FIG 6 EXTRUDER, EXTRUSION WATERBATH, EXTRUSION LINE

2.1.4 RAW MATERIALS AND ADDITIVES USED IN PVC PIPE PRODUCTION

The resin commonly used for the pipe manufactures are: PE, PVC, PS & ABS. For the pipe
production the materials may have to be compounded. For example, many pipe producers use
PVC. The resin is heat sensitive and under the normal processing conditions, it has high
viscosity, thus it can’t be processed-Its needs compounding. However appropriate grades of other
polymers, such as PE or ABS, can be directly use as supplied by the manufacturer, without
compounding. product performance. The following ingredients are added to PVC for pipe
production:

 Plasticizer

 Heat Stabilizer

 Lubricants

 Fillers

 Processing aids

 Colorants

 Flame retardant

 Impact Modifier

 PLASTICIZERS: are used to make the resin softer, reduce the viscosity and thus make
process of PVC easier. Epoxy and Di-ethyl hexyl phthalate (DOP) are example of common
PVC plasticizers.

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 HEAT STABILIZERS: are required to prevent the thermal degradation of PVC at the
process temperatures. The degradation involves resin discoloration and evolution of HCL, In
the process lead stabilizers have been used. Owing to toxicity of PB. Today the common
stabilizers are based on tin viz. di-butyl tin maleate.

 LUBRICANTS: are used to reduce friction during processing that may lead to degradation.
Two types of lubricants are used. External and internal. The former viz. calcium stearate and
wax is used to reduce friction on process between metal surfaces to polymer. The latter
stearic acid friction arising out of polymer chain for slippage.

 FILLERS AND REINFORCEMENT: are added for cost reduction and improvement for
mechanical properties of product. Both increase rigidity, hardness, and density and flame
retardancy. Typical filler is calcium carbonate, a typical reinforcement are chopped glass
fiber and mica flakes, while such additives as clay, talc and silica are between.

 FLAME RETARDING AGENTS: are needed for plasticized PVC. Chlorinated paraffin
oil or waxes, oxide of Sb, Mo, P or B, as well as aluminum oxide have been used.

 PROCESSING AIDS: are added to rigid PVC to improve flow through the barrel and die.
In to the group of additives belong polymer and co-polymers miscible with PVC ex. PMMA,
ABS & SAN etc.

 IMPACT MODIFIER: are added to improve the impact strength impact modifier are at
least two parts. One that ascertain miscibility with PVC and other elastomeric additives are
used to make stiffing. Example MBS, CSR & NBR.

 POLYVINYL CHLORIDE (PVC) RESIN: Polyvinyl Chloride (PVC) is one of the most
commonly used thermoplastic polymers in the world (next to only a few more widely used
plastics like PET and PP). it is a naturally white and very brittle (prior to the additions of
plasticizers) plastic. PVC is produced in two general forms, first as a rigid or plasticized
polymer (RPVC or uPVC), and second as a flexible plastic. Polyvinylchloride is a white
brittle thermoplastic polymer that can be softened on heating, it is produced by
polymerization of vinyl chloride monomer PVC is chemically inert, resistant to water and
environmental corrosion, it's also a good electrical and thermal insulator and still maintain
its properties over a reasonably large temperature range.

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SYTHENSIS OF PVC

Structurally, PVC is a vinyl polymer. it’s similar to polyethylene, but on every other carbon in
the backbone chain, one of the hydrogen atoms is replaced with a chlorine atom. It’s produced by
the free radical polymerization of vinyl chloride.

H H H H

C=C free radical vinyl polymerization [ C C ]

H Cl H Cl

Vinyl chloride poly(vinyl chloride)

There are 4 types of PVC Resin grouped by polymerization method

1. Suspension Grade PVC

2. Emulsion Grade PVC
3. Bulk Polymerised PVC
4. Copolymer PVC’
FIG 7 A SUSPENSION PVC RESIN

 PIGMENTS

Pigments again are a vast subject. They can be broadly classified as:

1. Inorganic Pigments
2. Organic Pigments
3. Carbon Blacks.
Inorganic pigments are oxides and salts of metals as well ass complex minerals. The most
important is Titanium Dioxide which is the chief whitening pigment used in Plastics.

2.1.5 PVC PIPE FORMULATION FOR COMPOUNDING IN AYOM INTEGRATED

PRODUCTION LTD

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Pipes Pvc resins Calcium Titanium Stearic acid Carbon Carbon Calcium Stabilizers Paraffin
{C2H3Cl} carbonate dioxide {C18H36O2}
products blue black sterate wax
{CaCO3} {TiO2}
{C36H70CaO4}

White 75Kg 65kg 1.5Kg 0.5kg _____ _____ 0.5kg 0.2kg 0.5kg
1.5mm

Blue 75kg 65kg ______ 1.5kg 0.10kg ____ ______ 0.3kg 0.5kg
2.5mm

Black 75kg 65kg ______ 1.5kg _____ 0.10kg ______ 0.4kg 0.5kg
2.5mm

2.1.6 TERMS USED IN EXTRUSION MOULDING PROCESS

 Back Pressure – The resistivity of molten plastic material to forward flow.

 Barrel – The part of the extruder encasing the screw or plunger.

 Compound – Any plastic material prepared for subsequent manufacturing

processes, specifically in extrusion, molding or calendaring.

 Cooling Tank – A tank typically containing water through which extrusion is

constantly passed for cooling.

 Die – The component on a plastics extruder affixed to the extruder head through
which the melt is pushed to form the desired profile.

 Dry Blend – A free flowing blend of compound or resin and other ingredients as
prepared for an additional manufacturing operation specifically for extrusion or
molding.

 Extrudate – The product or result of an extrusion process.

 Extrusion - A continuous shaping of plastic material by forcing it under pressure

through a die.

24
  Haul-off – Also called a “caterpillar,” it is an apparatus used for the continual removal
of extrudate from the die.

 Heat Aging – The unique process of aging a thermoplastic or thermoset product and
examining the percentage of retained physical and chemical properties after exposure to
heat for a prolonged period of time.

 Masterbatch - A compounded resin or additive already optimally dispersed in

concentration and is compatible with the main resin in the process flow.

 Melt – Extrusion material when heated to a molten plastic condition.

 Pellets – Resins or mixtures of resins with compounding additives similar in shape or size
that have been extruded or chopped into short segments to prepare them for molding
operations.

 Post Cure - To continue the cure of a molded article by a subsequent heating process.

 Processing Aid - An additive or component in a resin to facilitate processing.

 Ram Pressure - Used colloquially for the total force applied by a hydraulic ram, equal to
the hydraulic pressure multiplied by the ram area.

 Resin – Any of several physically similar polymerized synthetics or chemically altered

natural resins, such as thermoplastic materials (polyvinyl, polystyrene, polyethylene) or
thermosetting materials (polyesters, epoxies, silicones used with fillers, stabilizers,
pigments).

 Take-up – An apparatus for reeling extruded material.

 Thermoset – A term that refers to the family of materials that can be melted only once
during the original processing and cannot be reprocessed after the original part is made.

 Thermoplastic – Any material, such as polyethylene, PVC and ABS, which can be re-
melted and reprocessed without considerable loss of properties or scrap loss.

 Transition Section - The flighted portion of the screw between the feed and discharge
sections in which the extrusion material becomes a melt.

 Travelling Saw - A saw which travels with the extrudate while cutting it to length. .
 Vinyl – A generic term for PVC, one of various compounds of ethylene that are
polymerized to form resins and plastics (e.g. polyvinyl or polyethylene plastics).

25
2.1.7 DEFECTS ENCOUNTERED DURING PRODUCTION OF PVC PIPES USING
EXTRUSION AND ITS REMEDIES.

The following are the various defects encountered during production: Improper system
Installation, Improper Operation, Resin defect, poor mixing, , Moisture release, Trapped air
contamination and blocking

 BLOCKING

1. Insufficient bubble cooling

Remedy

 Optimize cooling air.

 IMPROPER SYSTEM ENGINEERING/INSTALLATION

1. Wrong Clamps used or Clamps too tight.

2. Improper die setting
3. Improper alignment of die and
4. Incompatible fire caulk used.
5. Contact of outside of pipe with incompatible material (e.g., solder flux).

Remedies

 Adjust the die setting

 Check for alignment
 Check for uniformity in die heating

 IMPROPER OPERATION

1. Exposure to freezing temperatures without freeze protection

2. Over pressurization
3. Pulsating water pressure

Remedies

 Use the Digital Pressure gauge.

 Use proper/Digital temperature sensor

26
 RESIN DEFECTS

1. Occlusions, char particles, voids

2. Filler/pigment not well distributed
3. Improper mixing of resin and additives
4. Foreign contamination
5. Due to over heating

Remedies

 Screening the resin material

 Exact addition of (Percentage of mixing) resin material

 POOR MIXING

This often sets the upper limit for output. The screw cannot be run any faster because the
material is coming out with an “applesauce” surface, with streaks, parabolic ridges, and perhaps
Particles of undispersed additive.

Remedies

 Exact addition of (Percentage of mixing) resin material.

 Check for foreign material.
 Increase rpm back pressure for better mixing.
 MOISTURE RELEASE

Moisture is absorbed by some plastics. It passes through the extruder and boils when the pressure
is relieved at the die lips. The result is a pattern of dotted lines, long bubbles, and pits.

Remedies

 To remove moisture, the material must be pre-dry.

 Vent must be used in the extruder.

 TRAPPED AIR

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 A trapped-air surface shows bubbles and pits,
but little, if any, dotted lines. This is not common
in pelletized material

Remedies

 Avoid the over-speed of extrusion.

DEFECTS AND ITS IMPACT ON
PRODUCT QUALITY

S/N DEFECTS IMPACT ON QUALITY

1 Improper system installation Centring problem, chatter mark on the

product
2 Improper operation Uneven wall thickness
3 Resin defects Blow hole formation on the product

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FIG 8 PVC

PIPES

PRODUCED IN AYOM INTERGRATED PRODUCTION LTD

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2.2 INJECTION DEPARTMENT

Injection molding is the most common modern method of manufacturing plastic parts; it is ideal
for producing high volumes of the same object. The Injection molding uses a ram or screw-type
plunger to force molten plastic material into a mold cavity; this solidifies into a shape that has
conformed to the contour of the mold. It is most commonly used to process both thermoplastic
and thermosetting polymers, with the volume used of the former being considerably higher.
Thermoplastics are prevalent due to characteristics which make them highly suitable for injection
molding, such as the ease with which they may be recycled, their versatility allowing them to be
used in a wide variety of applications, and their ability to soften and flow upon heating.
Thermoplastics also have an element of safety over thermosets; if a thermosetting polymer is not
ejected from the injection barrel in a timely manner, chemical crosslinking may occur causing
the screw and check valves to seize and potentially damaging the injection molding machine.

FIG 9 AN INJECTION MOULDING MACHINE USED IN AYOM INTEGRATED PRODUCTION LTD

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2.2.1 TERMS USE IN INJECTION MOLDING.

 Additive: A substance compounded into a resin to enhance or improve certain

characteristics

 Back Pressure: The resistance of the molten plastic material to forward flow. In molding,
back pressure increases the temperature of the melt, and contributes to better mixing of
colors and homogeneity of the material. However, as back pressure increases, so does cycle
time.

 Barrel: The section of a molding machine that contains the feed screw, also the section
where resin heating and mixing occurs.

 Binder: A resin or other material used to hold particles together. The binder is the
continuous phase in a reinforced plastic, which provides mechanical strength or ensures
uniform consistency, solidification, or adhesion to a surface coating. Typical binder
materials include resin, glue, gum..

 Compound: A mixture of resin(s) and additives usually formed in a separate machine

downstream from the primary reactor.

 Cooling Channels: Channels located within the body of a mold through which a cooling
medium is circulated to control the mold surface temperature.

 Cycle Time: The time required by an injection molding system to mold a part and return to
its original position/state.

 Cycle: complete, repeating sequence of operations for injection molding a part.

 Gate: The channel through which the molten resin flows from the runner into the cavity.

 Mold (v): To impart shape to a plastic mass by means of a confining cavity or matrix.

 Pellets: Tablets or granules of uniform size, consisting of resins or mixtures of resins with
compounding additives which have been prepared for molding operations by extrusion and
chopping into short segments.

 Resin (Synthetic): The term is use to designate any polymer that is a basic material for
plastics. around the core before filling the cavity.

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 Runner: In an injection mold, the feed channel, usually of circular cross section, which
connects the spur with the cavity gate. The term is also used for the plastic piece formed in
this channel.

 Thermoplastic: material that will repeatedly soften when heated and harden when cooled.

 Thermoset: A polymer that doesn't melt when heated. Thermoset polymers "set" into a
given shape when first made and afterwards do not flow or melt, but rather decompose upon
heating. They are often highly cross-linked polymers, with properties similar to those of
network covalent solids, i.e., hard and strong.

 Virgin Material: Any plastic compound or resin that has not been subjected to use or
processing other than that required for its original manufacture.

2.2.2 PRODUCTION PROCESS

Injection molding is a manufacturing process of producing parts from both thermoplastic and
thermosetting plastic material injection molding is widely used for manufacturing a variety of
part such as customer products, toys etc. Injection molding machine is used in Ayom Integrated
Production Ltd to manufacture variety of plastic products the products include pipe covers ,foot
valve, cups bowl ,cloth hangers , toilet seat, automobile fan belt ,pipe joints.

 CLAMPING: prior to the injection of the material into the mold the two halves of mold

must first securely closed, the mold is made of movable and stationery part .the stationery

part is attached to the injection machine and the movable part is allow to slide

 INJECTION: the compounded raw material in form of pellet is fed into the injection

machine through the hopper into a cylindrical chamber called the barrel, the barrel

contain a screw and heating bands the material is melted by heat and pressure utilizing

the friction action of the rotating screw and heating bands, the hot plastic (molten state) is

injected into the mold cavity with the aid of the control switch.

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  COOLING: the pasty plastic begins to cool once it is injected into the mold cavity

because of the water hose connected to the mold cavity as the plastic cools it solidifies

into the shape of the mold cavity

 EJECTION: the cooled product is ejected from the mold by pressing a button for supply

of compressed air to allow easy ejection of the product once the product is removed from

the mold the mold is close and the cycle is repeated the cycle time is 10 to12 minutes

depending on the type of product to be produced.

2.2.3 RAW MATERIAL AND ADDITIVES USED IN PLASTIC PRODUCTION USING

AN INJECTION MOLDING MACHINE

 PP, Polypropylene: Semi-crystalline material. Wide range of properties, usage, and cost.
Chemical and low- temperature resistant. Difficult to mold to very close tolerances.
 High Density Polyethylene (HDPE): A high molecular weight polyolefin material,
nontoxic, non-contaminating, and exhibits a high degree of break resistance. It is lighter
than water, easily withstands exposure to a wide variety of common lab chemicals, and
has a milky white translucent appearance.
 Impact Modifiers: Additive used to enhance the material's ability to withstand the force
of impact.
 Light, UV Stabilizers & Absorbers: These additives increase the ability of the material
to withstand the negative effects of light and UV exposure, thus increasing the service
life of the material
 Masterbatch: A concentration of a substance (an additive, pigment, filler, etc.) in a base
polymer.
 Odorants & Deodorants: Odorants are used to add odor to materials, usually for safety
reasons

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POLYPROPYLENE (PP)

Polypropylene (PP) also known as polyprene, is a thermoplastic polymer used in a wide variety

of applications. It is produced via chain growth polymerization from the monomer propylene

Polypropylene is used in both household and Industrial applications. It is white tough, rigid and

crystalline with chemical formula {C3H6}. It has a melting point of160°-165°with iupac name

poly (1 methyl ethylene)

Properties of polypropylene

1. Polypropylene is highly flammable

2. Excellent chemical resistance

3. Polypropylene retain mechanical and electrical properties at elevated temperature it is a

water repellant plastic.

SYNTHESIS OF POLYPROPYLENE

Polypropylene is produced by the chain-growth polymerization of propene

H Polymerization
H2C CH2 CH CH2 CH

CH3 CH3 CH3

Propylene(monomer) Polypropylene(polymer)

In Ayom integrated production LTD, POLYPROPYLENE Is used in production of many plastic

products such as foot valve, toilet seat, pipe joints, pipe plugs, helmet, automobile fan belt, cloth

hangers, cups, bowls etc. the type of product produced depends on the type of mold inserted into

injection molding machine

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MASTERBATCH: masterbatch is a solid in form pellet used for coloring plastics and imparting

other properties to plastics it comes in different colors. These masterbatch also reduces the rate

of wears and allows continuous operation of machine element.

FIG 10 DIFFERENT COLOURS OF MASTERBATCH USED IN AYOM INTEGRATED

PRODUCTION LTD

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 TABLE CHART SHOWING POLYPROPYLENE PRODUCTS,RATIO OF
POLYPROPYLENE TO MASTERBATCH

S/N PRODUCT RATIO ADDITIVES

1 TOILET SEAT 60.35 White or pink

masterbatch
2 PIPE JOINT 60.30 White,grey or black

masterbatch
3 AUTOMOBILE FAN 60.35 Black or white

BELT masterbatch
4 AUTOMOBILE BRAKE 60.30 Black, blue or yellow

PLUNGERS masterbatch
5 CLOTH HANGER 60.40 Any colour of

masterbatch
6 PLASTIC HELMET 60.35 Yellow,black and white

masterbatch
7 Pipes plugs 60.30 White or black

masterbatch

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Fig Trimmed Hangers Fig Pipe Junction Fig Pipe Plugs

Fig Toilet Cover Fig Untrimmed Hangers

FIG 11 PRODUCTS OF POLYPROPYLENE FROM INJECTION MOLDING MACHINE AT AYOM

INTEGRATED PRODUCTION LTD

2.2.4 DEFECTS AND CORRECTIONS IN INJECTION MOLDING OF PLASTICS.

 FLOW LINES

 Flow lines are streaks, patterns, or lines - commonly off-toned in color - that show up on the
prototype part as a consequence of the physical path and cooling profile of the molten plastic as

37
it flows into the injection mold tooling cavity. Injection molded plastic begins its journey
through the part tooling via an entry section called a “gate.” It then flows through the tool cavity
and cools (eventually hardening into a solid).

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

Remedies:

 Increase injection speeds and pressure to the optimal level, which will ensure the cavities
are filled properly.

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

 VACUUM VOIDS:

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

Causes: Vacuum voids are often caused by uneven solidification between the surface and the
inner sections of the prototype.

Remedies:

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

2. Ensure that mold parts are perfectly aligned.

 SHORT SHOT:

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

38
Causes: Short shots can be caused by a incorrect calibration of the shot or plasticizing capacities
can result in the plastic material being inadequate to fill the cavities.

Remedies:

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

5. Increase the material feed in the molding machine or switch to a machine that has a
higher material feed in the event that the maximum material feed has been reached. 

 WARPING:

Is the deformation that occurs when there is uneven shrinkage in the different parts of the molded
component. The result is a twisted, uneven, or bent shape where one was not intended.

Causes: Warping is usually caused by non-uniform cooling of the mold material. Different

cooling rates in different parts of the mold cause the plastic to cool differently and thus create
internal stresses. These stresses, when released, lead to warping.

Remedies:

4. Ensure that the cooling time is sufficiently long and that it is slow enough to avoid the
development of residual stresses being locked into the part.

2. Design the mold with uniform wall thickness and so that the plastic flows in a single
direction.

3. Select plastic materials that are less likely to shrink and deform. Semi-crystalline
materials are generally more prone to warping

 FLASH:

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

39
Causes: Flash can occur when the mold is not clamped together with enough force (a force
strong enough to withstand the opposing forces generated by the molten plastic flowing through
the mold), which allows the plastic to seep through. The use of molds that have exceeded their
lifespan will be worn out and contribute to the possibility of flash. Additionally, excessive
injection pressure may force the plastic out through the route of least resistance.

Remedies:

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

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

 Adopt optimal molding conditions like injection speed, injection pressure, mold
temperature, and proper gas venting.

The following plastic products are gotten through injection molding machine: plate, cup, spoon
Lids of all sorts are made from plastic injection molding. That includes plastic bottle caps, plastic
cup lids and the lids for prescription drug containers (not to mention the bottles themselves).

2.2.5 DIFFERENCE BETWEEN EXTRUSION MOLDING AND INJECTION MOLDING

Injection molding machine is similar to Extruder. The main difference between the two machines
is in screw operation. In extruder screw rotates continuously providing output of continuous long
product (pipe, rod, sheet). Screw of injection molding machine is called reciprocating screw
since it not only rotates but also moves forward and backward according to the steps of the
molding cycle.

2.3 RECYCLING DEPARTMENT

2.3.1 RECYCLING OF PLASTIC WASTE

40
Plastic recycling is the process of recovering scrap or waste plastic and reprocessing the material
into useful products. Before any plastic waste is recycled, it needs to go through different stage
so that it can be further used for making various types of products.

In the industry, deformed pipes, scraps and flashed from product and lumps from machine are
recycled and reuse to manufacture useful products.

2.3.2 RECYCLING PROCESS IN INJECTION PLANT

The process of recycling waste in injection plant includes;

1) Crushing - lumps from machine and scraps from products are crushed in pellet using a
crushing machine.

FIG 12 CRUSHING MACHINE USED AT THE INJECTION PLANT IN AYOM PLASTICS

2) Washing - the crushed material is washed in a large cemented basin to remove dirt and metal
chips

41
FIG 13 CONCRETE WASHING BASIN USED IN AYOM PLASTICS

2) Drying - After washing the material is dried using an injection drying machine or by
spreading under sun

FIG 14 A DRYING MACHINE USED AT THE INJECTION PLANT IN AYOM PLASTICS

4) Sorting - it involves separating different colours to obtain uniform colours

5) Sieving - the dry crushed material is sieve using a magnetic sieve to remove metal chips this
done because these tiny metals can block the nozzle during molding process. the recycled

42
material loose some of its quality and strength during the first production and recycling process
virgin polymer are added to the recyclate to improve strength.

FIG 15 A MAGNECTIC SIEVE

FIG 16 RECYCLED POLYPROPYLENE

SCRAPS AND LUMPS

43
2.3.3 RECYCLING PROCESS IN EXTRUSION PLANT

In the extrusion plant ,lumps, deformed and shrink pipes can still be recycled and reused to
produce another PVC's pipes

The recycling process includes;

1. Crushing: Damaged pipe and lumps are first cut into smaller sizes and poured into the hopper
of a crushing machine for crushing. The crusher reduces the small size pipe to pellet form the
resulting granules called the recyclate .

FIG 17 CRUSHING MACHINE USED AT THE EXTRUSION PLANT IN AYOM PLASTICS

2. Pulverizing: the small pellets ‘recyclate’ is grounded into fine powder(pulverized) using a
pulverizing machine.

FIG 18 PULVERIZING MACHINE IN AYOM PLASTICS

44
3. Sieving: the powdered material is sieve using electrical vibratory filtering machine to get a

fine powder, the fine powdered material is compounded with virgin PVC and additives to

increase the quality of the pipe.

FIG 19 A VIBRATORY SIEVING MACHINE

45
2.4 QUALITY CONTROL/QUALITY ASSURANCE OF PRODUCTS IN AYOM
INTEGRATED PRODUCTION LTD

2.4.1 QUALITY CONTROL AND ASSURANCE

Quality control and assurance (QC&QA) is a process through which a business seeks to ensure

that product quality is maintained or improved with either reduced or zero error.

2.4.2 QUALITY CONTROL

The nature of injection and extrusion molding machines is such that there are bound to be defects

therefore parameters such as temperature, fill speed, clamping force, cooling rate are monitored

so that defects can be minimized and eliminated.

 Formulation Calculation: This is done using international standard for formulation

calculation to achieve Quality products

 Product Inspection: Virgin material are mostly added to recycled thermoplastic to

increase the quality of the products.

 Packaging: Plastics products in the company are usually pack inside sack to prevent dirt

and cracking.

 Storage: The products especially pipes are bundled in desired number as per consumer’s

requirement and stored in cool and dry place store room to prevent cracking and ensure

freshness till delivery.

46
 CHAPTER THREE

RELEVANCE OF MY INDUSTRIAL TRAINING EXPERIENCE TO MY COURSE OF

STUDY, EXPERIENCE GAINED, PROBLEM ENCOUNTERED,

3.1 RELEVANCE OF MY INDUSTRIAL TRAINING TO MY COURSE OF STUDY

Working at AYOM INTEGRATED PRODUCTION LIMITED popularly called Ayomplastics

has given me opportunity of getting a first hand experience and exposure to some of the practical

polymer aspect, learning to work with various equipment and machinery used in plastic

moulding, it has also provided an avenue for me to acquire Industrial skills and experience which

is highly Paramount in chemical and other related industries.

One of the experience is safety management techniques.as a result of my training, I can

confidently apply most safety measures I was taught in school such as the use of personal

Protective Equipment (PPE), firefighting, environmental management and pollution control

when the need arises.

Practical application of quality control (QC) which is Paramount in every industry, tool handling,

machine operation was also in no small measure added to my experience.

Optimization which is very pertinent to any chemist formed the basis of what we do every day

before engaging in production. Day by day, we find a better way to minimize cost, wastage and

time and maximize yield and still maintain the quality of products. It was a golden opportunity to

build good and lasting human relationship with my colleagues, staffs and supervisor in the

company, all these made me appreciate my course of study better and as well broadened my

knowledge of the course.

47
3.2 EXPERIENCE GAINED

The Industrial training, I underwent in Ayom Integrated production limited as a student trainee

has given opportunity to learn about plastics molding, learning its fundamental and how to work

with various machinery used in the industry, I was able to apply some theoretical knowledge

during my study at the University to real work situation thereby bridging the gap between school

work and actual practice. I also gained experience in other field of science, I learnt lesson on the

code of conduct of the company and it prepared me for work scenario I am likely to meet after

graduation.

My general experience in Ayom Integrated production limited

1) I learnt to how operate the injection and extrusion molding machine.

2) I learnt about the possible defect that occurs during plastic molding and how to reduce these
defects and how difficult task are handled to ensure smooth process of molding.

3) I was able to grasp adequate knowledge and understanding regarding quality assurance and
control in the industry

4) I learnt about PVC resin, polypropylene and additives and their roles and function in plastic
molding I also learnt about recycling process of waste plastic

3.3 PROBLEMS ENCOUNTERED

i. Inadequate equipment to carry out some test in the quality control section limited my
experience.
ii. During the first week, I had difficulties understanding a lot of the term and terminologies that
was used at the company because a lot of them were very new to me.
iii. Lack of residential building and medical facilities in the industry.
iv. Lack of time to train students by Industrial based supervisor.

48
 CHAPTER FOUR

RECOMMENDATIONS AND CONCLUSION.

4.1 CONCLUSION

A journey that started on the 8thof July and ended on the 20th of November at Ayom integrated
production Ltd. was a great source of practical knowledge. During my six (6) Month IT in the
firm I learnt how well to develop good work relationship with managers and coworkers. The
SIWES program afforded me reason to appreciate my course “Chemistry”. In the area of plastic
production as I was able to learn the various steps, test and material needed to produce various
plastic products.

4.2 RECOMMENDATION

1. SIWES should allocate fund to IT students during the process of their siwes training

2. SIWES should increase the number of time they visit student in their various place where
they are undertaking their IT.

49
 REFERENCES

1. Agwuna, R.N (2012) Detailed manual on SIWES guidelines and operations for tertiary
institutions
2. J G Khan ,R S Dalu and S SGadekar (2014) Defect in Extrusion process and their Impact
on Product Quality.
3. EngrObassiEttu (2014) The Role And Importance Of Engineering Material Utilization in
Present Day World.
4. Director, Ayom integrated production limited.
5. L M Galantucci, R spina Journal Of Material Processing Technology 141(2003) 260-275
6. www.wikipedia.org/injection molding.

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