INDUSTRIAL TRAINING REPORT

KANPUR PLASTIPACK LIMITED

(30 May to 1July)

SUBMITTED TO: SUBMITTED BY:

A.K GARG SIR MANAS BHASIN
HR KPL 2ND B.TECH
PLASTIC DEPT
HBTU KANPUR
INDUSTRIAL TRAINING REPORT

KANPUR PLASTIPACK LIMITED

(30 May to 1 July)

SUBMITTED TO: SUBMITTED BY:

PLASTIC TECHNOLOGY DEPATMENT MANAS BHASIN
H.B.T.U KANPUR 2ND B.TECH
PLASTIC TECHNOLOGY
SR NO 17PL13
ROLL NO 170112013
 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude towards “KANPUR

PLASTIPACK LIMITED” for providing me the opportunity
to get trained in their esteemed organisation and extending their facilities for
me which was very beneficial in my learning process.

I would like to thank pradeep sir my mentor for guiding me throughout the
training programme. And I would also like to thanks ravindra sir,sudhir
sir,chandan sir and all the employees of the company for being so supportive
during the duration of training and helping me in the compilation of this
report.
 TABLE OF CONTENTS

1) COMPANY PROFILE
a) About kanpur plastipack limited
b) Manufacturing units and location
c) Products

2) RAW MATERIAL

a) Basic raw material used

b) Properties and applications

3) TAPE PLANT

4) CIRCULAR WEAVING LOOMS

5) LAMINATION UNIT

6) REPROCESSING UNIT

7) QUALITY TESTING
About Kanpur plastipack limited

It was the year 1971 and the city – Kanpur up in North India. An entrepreneur
was looking at setting up a Greenfield
project in a new Industry. Raffia Flat tapes and woven sacks was just beginning
to get an entry into the world of plastics and what then seemed like a great
thing to get into. The transition to FIBCs and Bulk bags took place in the year
1999. The Company Kanpur Plastipack has since then evolved into an Industrial
Bulk Packaging Solution provider. From humble beginnings employing under 50
persons Kanpur Plastipack is now entering into its Fifth decade of service to the
Global Bulk Packaging Industry.

Saga of Success with Three Generations

Three Generations Together

We at Kanpur Plastipack are endowed with three generations of hard word,
professional management coupled with technical expertise results in an
organization providing a superior product and an unparalleled customer
support.
The company has a fully integrated facility and is operating from three
locations all within half a mile of each other in Kanpur. The company is BRC
and ISO 22000 certified for Food Grade and Clean room bags we are one of the
few ones who offer a full range of products and services under one roof. Our
FIBC’s and big bags division is doing over 5 million bags per annum and has an
installed capacity for over 7 Million bags.
Manufacturing Units and Locations
Kanpur Plastipack currently operates from 3 Locations in the city of Kanpur. All
the three facilities are located within half a Mile of each other. We are a fully
integrated company offering end to end solutions for the Bulk bag and FIBC
Industry.

Unit 1
D-19, Panki Industrial Area, Registered Office/Head office
P.O. Udyog Nagar Extrusion and Weaving
Kanpur 208022,
India

Unit 2 Finishing Unit for FIBCs and Big bags

A1/A2 Udyog Kunj, small bags
Panki Industrial Area Site 5, CFG facility
Kanpur 208022, Multi Filament Yarn
India

Unit 3 Extrusion and Weaving unit

Village Shyampur,
Raipur,
Gajner Road, Tehsil Akbarpur,
Kanpur Dehat,
Uttar Pradesh (India) – 209304
Products

1. Flexible intermediate bulk containers(FIBC)

2. PP/HDPE woven bags

3. Woven fabrics

4. Sulzer fabrics

5. Multifilament yarn

6. FIBC woven bags accessories

BASIC RAW MATERIAL USED
1. Polypropylene

2. High density polyethylene

Additional additives
1)Antifabmaster batch:-this additive is used as filler and to
avoid the tape fibrillation

2.Coloured masterbatch:-it is used for colouring the tape

and films

3.U.V Master batch:-Its purpose is to protect the product

from ultraviolet rays during the
storage for long time

4.Reprocess:-It is like resin granules made from wastage

which is generated during the production .it is
actually recycled material of the products
 PROPERTIES OF RAW MATERIAL

1)PROPERTIES OF POLYPROPYLENE
a) Chemical and physical properties
Polypropylene is in many aspects similar to polyethylene, especially in solution
behaviour and electrical properties. The methyl group improves mechanical
properties and thermal resistance, although the chemical resistance decreases.
The properties of polypropylene depend on the molecular weight and molecular
weight distribution, crystallinity, type and proportion of comonomer (if used)
and the isotacticity. In isotactic polypropylene, for example, the methyl groups
are oriented on one side of the carbon backbone. This arrangement creates a
greater degree of crystallinity and results in a stiffer material that is more
resistant to creep than both atactic polypropylene and polyethylene

b)Mechanical properties
The density of (PP) is between 0.895 and 0.92 g/cm³. Therefore, PP is the
commodity plastic with the lowest density. With lower density, moldings parts
with lower weight and more parts of a certain mass of plastic can be produced.
The Young's modulus of PP is between 1300 and 1800 N/mm².
Polypropylene is normally tough and flexible, especially when copolymerized
with ethylene. This allows polypropylene to be used as an engineering plastic,
competing with materials such as acrylonitrile butadiene styrene (ABS).
Polypropylene is reasonably economical.
Polypropylene has good resistance to fatigue.

C) Thermal properties
The melting point of polypropylene occurs in a range, so the melting point is
determined by finding the highest temperature of a differential scanning
calorimetry chart. Perfectly isotactic PP has a melting point of 171 °C (340 °F).
Commercial isotactic PP has a melting point that ranges from 160 to 166 °C
(320 to 331 °F), depending on atactic material and crystallinity. Syndiotactic PP
with a crystallinity of 30% has a melting point of 130 °C (266 °F). Below 0 °C, PP
becomes brittle.
The thermal expansion of polypropylene is very large, but somewhat less than
that of polyethylene.

2)PROPERTIES OF HIGH DENSITY POLYETHYLENE

HDPE is known for its large strength-to-density ratio.The density of HDPE can
range from 930 to 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. The
difference in strength exceeds the difference in density, giving HDPE a higher
specific strength. It is also harder and more opaque and can withstand
somewhat higher temperatures (120 °C/248 °F for short periods). High-density
polyethylene, unlike polypropylene, cannot withstand normally required
autoclaving conditions. The lack of branching is ensured by an appropriate
choice of catalyst (e.g., Ziegler–Natta catalysts) and reaction conditions.
The physical properties of HDPE can vary depending on the moulding process
that is used to manufacture a specific sample; to some degree a determining
factor are the international standardized testing methods employed to identify
these properties for a specific process.

APPLICATIONS

1) APPLICATIONS OF POLYPROPYLENE
Polypropylene is widely used in various applications due to its good chemical
resistance and weld ability. Some common uses of polypropylene include:

1) Packaging application: Good barrier properties, high strength, good

surface finish and low cost make Polypropylene ideal for several
packaging applications.

2) Consumer Goods: Polypropylene is used in several household products

and consumer goods applications including translucent parts,
housewares, furniture, appliances, luggage, toys etc.
 3) Automotive Applications: Due to its low cost, outstanding mechanical
properties and mould ability, polypropylene is widely used in automotive
parts. Main applications include battery cases and trays, bumpers,
fender liners, interior trim, instrumental panels and door trims

4) Fibres and Fabrics: A large volume of PP utilized in the market segment

known as fibres and fabrics. PP fibre is utilized in a host of applications
including raffia/slit-film, tape, strapping, bulk continuous filament, staple
fibres, spun bond and continuous filament. PP rope and twine are very
strong and moisture resistant very suitable for marine applications

5) Industrial Applications: Polypropylene sheets are widely used in

industrial sector to produce acid and chemical tanks, sheets,
pipes, Returnable Transport Packaging (RTP) .

2)APPLICATIONS OF HDPE

1) Plastic bottles: Most people are informally introduced to the durable

plastic through water bottles. HDPE is great for blow-moulding
applications, particularly food and beverage containers because it won’t
leach into the bottles’ contents. In addition, HDPE is recyclable which
makes it a great choice for these highly disposable products.

2) Toys: HDPE is UV resistant which helps keep the toys resistant to the
ray’s damaging and discolouring effects.

3) Chemical containers: With its chemical resistant properties, HDPE is

great for laundry, shampoo, conditioner, household cleaning products,
motor oil, antifreeze and recycling bins. The strength of these bottles is
increased when they’ve been coloured or pigmented.

4) Pipe systems: HDPE pipe grade sheet has a higher molecular weight
compared to the standard HDPE used in the above examples. This
strengthening with its UV-resistance makes it ideal for piping and
outdoor applications. Pipe grade sheet has the ability to withstand -220
to 180 degrees Fahrenheit. It’s durable in most chemical interactions
which make it useful in a lot of industrial applications.
SOURCES PROVIDING RAW MATERIAL

 Reliance Industries Limited

 IOCL (Indian Oil Corporation Limited)
 Lyondell Basell
 Exxon mobil
 Soltex Petro products Ltd
 JJ Plastalloy pvt. Ltd
 ONGC Petro Additions Ltd
 Alok Masterbatches Pvt. Ltd
 TAPE PLANT

INTRODUCTION OF TAPE PLANT

Tape plant department is the first department of production line of woven sack
industries. production process of woven sack industries start from this
department.Their are 2 plant in panki unit .There are 24*7 days working in
tape plant except national holidays and recognised festivals .There are reliving
duty to provide weekly off to all empolyees.24 hours working covered by 3
shifts for 8 hrs and work supervision provided by 3 supervisors.

PRODUCTS MANUFACTURED
Basically the organisation is the manufacture of woven sacks and fabric .Tapes
for fabric and sacks are HDPE & PP and denier of the tapes made as required
by the customer.
The bags are made by weaving of tapes and these bags are very useful in
packaging cement, fertilizers and sugars.
The sacks are produced in following forms :
1) Circular woven fabric and bags
2) Laminated or unlaminated
3) Printed or unprinted
4) All type of small bag
5) FIBC (flexible intermediate bulk containers)
RAW MATERIAL
Basically raw material comes from petro chemical & chemical product and is
found in granules shape with diameter under 5 mm.

Basic raw material:

1) Polypropylene(PP)
2) High density polyethylene(HDPE)

Additional additives:
1) Antifab master batch: This is used as a filler and to avoid the
tape fibrillation
2) Coloured masterbatch: It is used for colouring the tape
3) UV master batch: The purpose to use this is to protect the
product from ultra violet rays during the
storage for long period of time
4) Reprocess: it is just like resin granule made from wastage which
is generated during the production.it is actually the
recycled material of the same products

TERMINOLOGY RELATED TO TAPE PLANT

1. DENIER: It is the weight of 9000 metres of tape in grams

2. TENACITY: The value gram per denier is known as tenacity of the

Tape .some time it is also known as GPD

3.ELONGATION AT BREAK: in a tensile test, the difference between

the length of the stretched specimen at
breaking load and its initial length
expressed as percentage of the latter.
CHARACTERESTIC OF GOOD QUALITY TAPE

1. The tape should not be fibrillated

2. Stretch ratio should be more than 5:1
3. Elongation should be 20-25 in PP and 16-20 in HDPE
4. Tenacity should be more than5.5 (GPD)

DESCRIPTION OF TAPE PLANT

Tape plant may be divided in various segments according to their function as
below:
1. HOPPER FEEDER:
There are equipment known as ARODRY whose function is to feed the raw
material after mixing all additives to hopper feeder.in case of arodry there
are four chambers which is connected with pipe for material suction from
four different drums.
2. EXTRUDER:
In the extrusion ,raw material enter through feed throat and comes into
contact with screw which is mostly barrier type and recommended for tape
deniers used for normal sack application The T-Die features computer
designed flow geometry for optimum mass flow geometry for optimum mass
flow distribution and minimum gauge variation across the width .At the front
of the barrel, melted materials travel through a screen pack to remove any
contaminants in the melt material.
3.AUTOMATIC SCREEN CHANGER:
It is used in place of manual screen changer to minimize stoppages of tape
plant for screen change. Movement of this belt filter is timer controlled and
rate of travel of the same is user adjustable.
The screen also serves to creates back pressure in the barrel. Back pressure
is required for uniform melting and proper mixing of polymers
4.T-DIE:
The specially constructed die has integrated flexible lips with
various opening range .The die has rheological optimized flow
channels with adequate heating zone and temperature controls
5.WATER QUENCH:
The water quench film cooling system has especially designed with
combined suction pipe with wipers and squeeze rubber rollers
 which which ensure absolutely dry the film even at high line
speeds.A temperature controller is provided for maintaining
required temperature of the water in the water bath.
6.HOLDING UNIT:
The holding unit with amply proportioned normal temperature
Godets and positively driven nip rubber roller ensure slip free
7.RECYCLING CUTTER UNIT:
The unit helps in direct return of the both side narrow edge trims
Of non stretched film into extruder .the unit consists of shredder
and blower
8.HOT AIR OVEN:
The hot air oven independent blowers for upper and lower
Tunnels ,with common heating and control mechanism to ensure
uniform temperature over the entire heated surface ,which is
essential for uniform tape quality
9.TAPE EXTRACTION UNIT:
The tape extraction unit with suction nozzle at the exit of holding
unit and annealing unit with piping upto the waste collection box
and with mounted suction blower
10.STRETCHING AND ANNEALING UNIT:
The stretching unit is used to stretch the tape according to the
stretch ratio and annealing is used to cool the tape coming after
the stretching unit
11.WINDERS:
Tape winders is the most appropriate solution for speed winding
of flat/fibrillated tape. Tape winders meets the requirements of
winding quality , reducing energy consumption .there is
a mechanism to adjust the tension of the tape for better winding
and according to this there are few numbers putted on setting
knob and the numbers can be set in respect of tape denier.

EXTRUSION
Extrusion is a process used to create objects of a fixed cross sectional profile a
material is pushed through a die of the desired cross-section. The two main
advantages of this process over other manufacturing process are its ability to
create very complex cross-sections, and to work materials that are brittle,
because the material only encounters compressive and shear stresses. It also
forms parts with an excellent surface finish.
Extrusion may be continuous (theoretically producing indefinitely long material)
or semi-continuous (producing many pieces). The extrusion process can be done
with the material hot or cold. Commonly extruded materials include metals,
polymers, ceramics, concrete, modelling clay, and foodstuffs. The products of
extrusion are generally called "extrudates".

PROCESS:
In the plastics extrusion process, raw thermoplastic material, or resin, is gravity
fed from a top mounted hopper into the barrel of an extruder. Additives, such
as colorants and UV inhibitors, in pellet form are often used and can be
introduced into the resin below arriving at the hopper. The process has much in
common with plastics injection moulding though differs in that the process is
usually continual. While injection moulding can offer many similar profiles in
continuous lengths, usually with added reinforcing, the finished product is
pulled out of a die instead of extruding the fluid resin through a die.
As the material enters the feed throat near the rear of the barrel it comes in
contact with the screw. The rotating screw forces the plastic resin forward into
the barrel that is heated to the desired melt temperature depending on the
resin. In most processes, a heating profile is set for the barrel utilizing five
independent PID (proportional-integral-derivative controller) controlled heat
zones that gradually increase the temperature of the barrel from the rear where
the resin has entered to the front. This allows the plastic resin to melt gradually
as it is pushed through the barrel and lowers the risk of overheating which may
cause degradation in the polymer.
At the front of the barrel, the resin leaves the screw and travels through a
reinforced screen to remove any contaminants. A screen changer generally
reinforces screens because the pressure at this point can exceed 5000 psi (34
MPa). The screen pack/breaker plate assembly also serves to create back
pressure in the barrel. Back pressure is required for uniform melting and proper
mixing of the polymer, and how much pressure is generated can be "tweaked"
by varying screen pack composition (the number of screens, their wire weave
size, and other parameters).
After passing through the breaker plate resin enters the die. The die is what gives
the final product its profile or shape and must be designed so that the molten
plastic evenly flows from a cylindrical profile, to the product's profile shape.
Uneven flow at this stage would produce a product with unwanted stresses at
certain points in the profile. These stresses can cause warping upon cooling.
Almost any shape imaginable can be created so long as it is a continuous profile.
The product must now be cooled which is usually achieved by pulling the
extrudate through a water bath. Plastics are excellent thermal insulators and are
therefore very difficult to cool quickly. Compared with steel, plastic conducts its
heat away 2000 times more slowly. In a tube or pipe extrusion line, a sealed
water bath utilizes a carefully controlled vacuum to keep the newly formed and
still molten tube or pipe from collapsing. A set of cooling rollers is generally used
in the sheet extrusion process to cool sheet as it exits the extruder.
Plastic extruders are also extensively used to prepare recycled plastic
waste and/or raw materials after cleaning, sorting and/or blending into
filaments suitable for blending into the resin pellet stock used by the plastics
industry at large.

SHEET/FILM EXTRUSION
Sheet/film extrusion is used to extrude plastic sheets or films that are too thick
to be blown. There are two types of dies used: T-shaped and coat hanger. The
purpose of these dies is to reorient and guide the flow of polymer melt from a
single round output from the extruder to a thin, flat planar flow. In both die
types ensure constant, uniform flow across the entire cross sectional area of the
die. Cooling is typically by pulling through a set of cooling rolls (calender or "chill"
rolls). In sheet extrusion, these rolls not only deliver the necessary cooling but
also determine sheet thickness and surface texture.
EXTRUDER OUTPUT
Extruder output mainly depends upon the metering section of the screw. The
three sources of extruder output are :-
1. DRAG FLOW: This is the forward motion of the melt arising from the
conveying or pumping action of the screw with no flow restriction
2. PRESSURE FLOW: This means a theoretical back flow or the loss of output
due to restriction in the system such as screen changer, breaker plate and
die
3. LEAKAGE FLOW: This is defined as the flow over the top of the screw flight
into the preceding screw channel because of the presence of melt under
pressure at the gap between the screw flight and the barrel wall

OUTPUT=drag flow-pressure flow-leakage flow

TEMPERATURE REQUIREMENT FOR TAPE

The temperature depends upon the material to be manufactured as well as the
denier of tape which is to be manufactured. The temperature can be controlled
by digital temperature controller.
Temperature range maintained during the production at various stages as below

Barrel temperature --------------230 to 290 degree centigrade

Adapter temperature------------190 to 320 degree centigrade
Die temperature------------------230 to 300 degree centigrade
Quench tank temperature-----25 to 45 degree centigrade
Orientation temperature-------110 to 240 degree centigrade

TAPE PRODUCTION
To calculate the tape production of the tape plant we can use the formula which
is given below:

TAPE PRODUCTION= (no. of tape running*denier*line

speed*60) / (9000*1000) kg/hrs
 CIRCULAR LOOMS

EXISTING LOOM MODELS IN PANKI UNIT

The models & no. of circular loom are given below :-
1. LSL-6-----------------32
2. LSL-620--------------18
3. OMEGA-1000------16
4. OMEGA HD---------1
5. RX 6.0----------------3
There are total of 70 looms in panki unit.

TECHNICAL SPECIFICATIONS

MODEL LSL-6 OMEGA-1000 LSL-620

Working width
Double flat 48-85 cm 48-85 cm 85-135 cm
Possible 85-95 cm 85-95 cm 135-145 cm
No. of shuttle 6 6 6
capacity
Weft insertion 900/minute 1000/minute 700/minute
rate
No of tape 720 576 1296
Warp & weft bobbin
Int. diameter 35mm 35mm 35mm
Length of core 218 mm 218mm 218mm
Creel capacity
Bobbin per m/c 720 576 1296
MACHINE DESCRIPTIONS
The circular loom is especially designed to weave endless tubular or flat cloth
out of PP or other tapes of poly olefins
The warp tape are taken from two creels via rollers to the loom which ensures
uniform warp tension, excellent cloth quality and trouble free handling.
The weft is inserted by six shuttle running in a reed constructed.
The cloth width can be easily modified by changing the weaving ring.
The tubular cloth is taken past a calibrating and spreading system to two
continuously driven haul off rollers and subsequently batched on to a cloth
winder.
CREEL:
Creel is a steel pipe construction with creel stands cross connections spindles
and bobbin diameters. Bobbin diameters are made of plastic pieces. circlip hold
the adapter in their position on the creel spindle. The creel side facing the
machine has creel eyelets to guide the warp tapes. Special drop wise ensure
individual tension to control the each warp tape.

WARP INFEED SYSTEM:

Consisting of inlet and intermediate rollers to insure a smooth inlet and tape
into the machine as well as to maintain uneven warp tension.

WARP BREAK DETECTING SYSTEM

Each warp tape is passing through a compensator which is responsible for tape
length compensation which stop the machine automatically. If a broken tape
makes a contact the warp break is indicated by one of the pilot lamp arranged
in the sector of the loom circumference.

WEFT BREAK DETECTING SYSTEM

The magnetic sensor monitors continuous tape supply in weft direction. In case
eventually broken weft tape the haul of speed of rollers is automatically reduced
to zero to avoid a weft fault due to missing weft. An electronic controller and ac
drive for haul of motor helps to achieve cramming on occurrence of weft
missing.

WEFT AND DETECTING SYSTEMS

To get desired amount of tape on weft bobbin when machine stops from weft
exhaust signal through colour sensor, approximates switch and sensing segment
to sense position of shuttle bobble as the colour sensor sense the difference.
The signal is transferred to a logic card placed in control cabinet to stop the
machine.

MANUAL CONTROL UNIT

Consisting of inch button, stop button and start button. The control units are
easily accessible to the operating personnel from every point
Around the loom.

POWER TRANSMISSION AND SHED CONTROL

The main motor drives v-belt, v-belt pulley and the central main shaft with the
cane. The cane and cane followers build six wavy lined sheds by moving the
heddle belt.
SHUTTLE DRIVE
Six pusher roller driven by the main shaft push their corresponding shuttles
through the shed in the reed ring.

SHUTTLE
The shuttle running in the rollers is lying loose in the reed ring .it carries the weft
bobbins

TAKE-UP
The gear box driven by an A.C. drive motor and machine controller transmit a
desired speed to a pair of take up rollers. This speed can be set by changing the
setting in machine controller

SURFACE WINDER
It is designed for winding up the tabular cloth or flat fabric on cores. the winding
tension can be controlled with infinite variability
STATISTICAL & EVALUATION FEATURES

 Actual machine speed, picks per minute

 Haul off speed in metres per minute
 Actual production of fabric in meters –cumulative as well in each shift
 Actual operating time of machine in minute cumulative as well in each
shift
 Actual warp breaks incident in number cumulative as well in each shift
 Actual weft breaks incident in number cumulative as well in each shift
 Actual weft end incidents in numbers cumulative as well in each shift

TERMINOLOGY RELATED TO LOOM

WARP: The tapes woven length wise in the fabric are known as warp

WEFT: The tape woven width wise in the fabric are known as weft

TENACITY: The value of gram per denier is known as tenacity if tape. It is also
known as GPD

MESH: A term used to indicate the density of weft or warp in woven fabric is
known as mesh.it is actually measured as number of tapes per inch

USEFUL FORMULA

 NO of warp ends =2*width of tabular fabric*warp mesh

 Fabric production =PPM*60/PPI*39.37 MTRS/HRS
 Picks per minute =RPM*no of shuttle
 Fabric GSM =Warp mesh*warp denier+ weft mesh*weft denier/228.6
LOOM CHANGEOVER
There are some steps which should be followed whenever going to start the
machine during changeover or newly start.

PREPARATION OF CIRCULAR LOOM FOR THREADING ON CREEL

After calculating the no of warp ends the corresponding number of warp bobbin
to be mounted on the creel. Now the threading to be done up to the creel
eyelets
After creel threading a regular way of eyelet plate and comb threading has to be
made. The threading of the intake combs has to be worked out to provide for
regular sectioning. the tapes are threaded one by one through thee intake
combs

PULLING UP
Two persons take the steel bar and pull all the tapes from one creel over the let-
off roller under the platform and raise the bar to about 2 metres where it is tried
to the fram.

THREADING INTO EYELET BOW AND COMPENSETOR ARM

After programming a regular way of threading into this machine parts. The
threading can be started from the raised portion. The tapes are cut one after the
other from outside to inside and thread into the eyelet bow and compensator
arm.

HEDDLE BELT & REED RING THREADING

The heddle belt threading has to be started at that side which contains more
tapes. When the no of tapes at each side is same, the threading can be started
at any belt side. The continuation in heddle belt eye threading has to be done
alternately after the heddle belt, the warp tape passes through the reed ring
Important for the reed ring threading is:
1. The tape should be passes straight
2. More than one tape should be never in one space
3. Don’t leave more empty space than necessary after finish threading in
one heddle belt, check your threading

PREPARATION OF SHUTTLE
Check the weft tension and re adjust it if necessary. The weft tension has to be
same for the same size of the weft bobbin. Also the weft bobbin has to be same
on all the six shuttles.
INSERTION OF THE SHUTTLE
The reed ring is constructed with tapered tracks towards the inside. This
construction is made precisely according to the principle of roll kinematics.
These tapered tracks of the reed ring together with tapered shuttle roller ensure
long life of the shuttle rollers.
Insert the shuttle into the tapered track. After positioning the shuttle correctly
in the reed ring the shuttle rollers are set to the track with slight pressure. Thus
the shuttle is fixed in its position.

MACHINE SETTING SKILL & OPERATING SKILL

 Centering of weaving ring is done with respect to reed ring I.D. and height
of the weaving ring could also be adjusted
 After maintaining height ensure that insertion finger is at lower edge of
weaving ring
 Cloth flattener opening should be 25mm more than fabric tube, spring
pressure to be kept accordingly so that both arm are moving freely
 Check no of warp ends used as per fabric specification
 Prior to loading of warp bobbins quality of bobbins to be checked
 Each compensator is fixed with spring and hook on compensator ring
 Tape distribution should be uniform in heddle belt and heddle ring
 Ensure that warp tapes are not overlapping on inlet and guide rollers
 Check weft tension for all shuttles accordingly to weft bobbin winding and
ensure for uniformity
 Set the desired winding tension of the fabric, winder tension can be
increased or decreased by movement of magnetic disc.
 Adjust the warp tension by inlet rollers
 Set the magnetic sensor
 Set the colour sensor
 Ensure the tension wire are put for individual tapes
 Ensure creel adapter movement is free
FABRIC FAULT & PREVENTION
There are many types of fabric faults, but it is clear that machine is capable of
producing perfect fabric and that every fault is curable.

MISSING WEFT:
Usually this is due to main functioning of magnet sensor. A common cause of
this fault is shifting of boom magnet assembly

UNDER WIDTH FABRIC:

Either wrong weaving ring is used or weft tension is too high. It could be due to
higher winding tension of cheese winders.

OVER WIDTH FABRIC:

Either wrong weaving ring is used or weft tension is too low or boom setting in
respect of weaving ring is not proper

HOLE IN FABRIC:
After a warp break, the weaver sometimes pull back the mended tape, it causes
a fault

REMEDY
1. Adjust the warp tension by inlet roller
2. Ensure drop wire/tension wire are put for individual warp tape
3. Don’t use oil on water tray/guide roller before inlet roller
4. Ensure warp’s tape are not overlapping on the inlet and guide roller
5. Ensure single warp tape is passed in individual space of reed ring
6. Ensure creel adapter’s movement is free
7. Ensure tape quality (elongation, breaking load)
 LAMINATION PLANT

INTRODUCTION OF PLANT
Lamination plant department is the intermediate department of production
line of woven sack industries. The laminated fabric mainly used to avoid
moisture, water, dust etc. there is one lamination part in panki unit.
Lamination machine has been developed for lamination for flat and as well as
circular fabric of various size in width. Fabric can be coated in both side of the
tubular fabric in single operation. This high speed coating machine produces
coated fabric with precise film thickness and is the latest development in the
field of coating line technology. There is a system for auto joining of one fabric
roll to another one and automatic unloading of laminated fabric roll during the
production.

PRODUCTS MANUFACTURED
The fabric made by weaving of tape are very useful in packaging like cements,
fertilizers, sugars, chemicals, building material.
There are two types of fabric:-
1. UNLAMINATED FABRIC(UNCOATED): this is the fabric which is only
weaved by tape and direct comes from looms
2. LAMINATED FABRIC(COATED): this is the fabric which is laminated in
lamination plant, the fabric made by HDPE is laminated by LDPE & PP
fabric is laminated by PP.

BASIC RAW MATERIAL

1) POLYPROPYLENE(PP): For lamination of PP fabric uses PP polymers of
lamination grade. PP lamination grade material creates better quality
binding with PP fabric and good quality of lamination never delaminate
2) LDPE (low density polyethylene): For lamination of HDPE fabric uses
LDPE polymers because LDPE creates better binding with HDPE. It is the
reason that its coating never removes from fabric
ADDITIONAL ADDITIVES
1) Anti fab master batch: this additive is used as filler
2) Coloured master batch: It is used for doing colour coating
3) U.V. master batch: its purpose is to protect the product from ultraviolet
rays during the storage for long time
4) Reprocess: it is the recycled material of the same products

TERMINOLOGY RELATED TO LAMINATION PLANT

MESH: Number of tapes in one inch

GSM: Weight of one square meter fabric in grams

GAUGE: It is the unit of thickness and in case of lamination it is the thickness of

the film of lamination.

MICRON: It is the unit of thickness and in case of lamination it is the thickness of

the film of lamination. The relation between micron and gauge is:

25 micron=100 gauge
25 micron=23.4 grams

CHARACTERESTICS OF GOOD QUALITY LAMINATION

1. Uniform thickness of lamination
2. No de lamination
3. Lamination without dust/ contamination
4. There should not be fish eye or any other type of hole in film coating

DESCRIPTION OF LAMINATION PLANT

1. HOPPER FEEDER: There is no auto mixing system of material it is done
manually and also feeded to the hopper manually. All required additives
are also mixed to the material at manually mixing stage.
2. EXTRUDER: The extruder unit is equipped with screw for high output and
excellent melt quality . this uniform melt is achieved by proper mixing of
melt, uniform melt temperature and controlled by heating and cooling
 zone. The extruder and coating die are installed above the laminator and
are automatically withdrawn side wise from their working position
whenever the line stopped
3. MANUAL SCREEN CHANGER: There is a manual screen changer in which
circular screen is used always and screen diameter 75mm while 60 and 40
mesh to be used for lamination but in case of colour lamination screen to
be used 80 ,60 and 40 mesh
4. T DIE: The specially constructed die has integrated flexible lips with
various opening ranges.
The die has rheological optimized flow channels with adequate heating
zone and temperature controls
5. UNWINDING UNIT: The lamination plant is equipped with an unwind
system which has two pneumatic shafts. The fabric rolls are loaded on to
unwind stands which can laterally positioned.
6. AUTOFABRIC JOINTER: Their is auto fabric jointing system when fabric of
one unwinder is going to finish, the fabric of another unwinder joint with
fabric of first unwinder with the help of double sides adhesives tapes and
pneumatic system
7. FABRIC WEB LINER: The unit helps in alignment of the fabric which is
feeded for lamination on correct position. There is sensor fitted on correct
position. There is sensor fitted on one edge of fabric to control the
position of the fabric
8. FABRIC REVERSING UNIT: This unit mainly uses for both side coating.
Turns bar uses to reverse one face of fabric to another face after coating
the first face. The both side fabric coating can be done in one single
operation.
9. PREHEATING UNIT: It consists of large diameter chrome plated roll with
double walled. The hot oil passes through this double walled chamber to
achieve the temperature of the surface of the roller. It is used to require
to heat up the fabric for removing moisture from fabric for better coating.
10.CHILLING UNIT: It also consists of a large diameter hard chrome plated roll
with double walled same as preheater but in this water passes through
this double walled chamber to cool the coating on the fabric
11.SIDE SLITTED FABRIC EXTRACTION UNIT: Their is a system to slit excess
fabric both sides of the fabric to maintain require size of the fabric and
finished the fine edge of the fabric.
12.WINDER: The continuous rewinding system uses for wrinkle free
rewinding of the coating fabric. After completing the fabric roll , the fabric
is automatically cut with the help of a sharp knife
TEMPERATURE REQUIREMENT FOR FABRIC COATING
The temperature depends upon the material which is used for coating. The
temperature can be control by digital temperature controller
Temperature range maintained during the production at various stages are as
below:

Barrel temperature---------------220 to 245 degree centigrade

Adapter temperature------------245 to 250 degree centigrade
Die temperature------------------240 to 255 degree centigrade
Preheating temperature--------30 to 50 degree centigrade

VISUAL INSPECTION OF LAMINATED FABRIC

Visual inspection of lamination plant is too important because appearance of
the fabric should be better and attractive. During the visual inspection following
things should be inspected
1. Lamination should be uniform in thickness
2. Coating film should not be delaminated
3. The dust contamination should not be inside the lamination
 REPROCESSING UNIT

PLASTIC RECYCLING-POLYMER WASTE TO GRANULE

Plastic are used in a wide range of applications and some plastic items, such s
food packaging , become waste only a short time after being purchased.
According to most estimates, 80% of post-consumer plastic waste is sent to
landfill, 8% is incinerated and only 7% is recycled.
In “Kanpur Plastipack Limited(KPL)” waste materials coming from product such
as after cutting, waste fabric is used in reprocessing plant to make granules.

MATERIAL RECYCLED
1. Wastage coming from trimming of film
2. Wastage from quality department
3. Wastage from looms
4. Wastage from unused fabric
5. Wastage from lamination plant
NEW GENERATION RECYCLE(NGR) MACHINE

The newest generation of this high-efficiency recycling technology provides a

significant increase in energy efficiency and additional improvements to output
rate for sustainable plastic waste processing.
S:GRAN is the perfect solution for processing scrap plastic materials of a
variety of types, materials and shapes created by industrial processes. Even
thick-walled scrap plastic materials as well as fibers and textiles can be
processed without additional pre-shredding. The plastic recycling technology of
S:GRAN meets even the highest standards for efficiency and achieves zero-
waste production (all production waste is fed back in) thanks to shredding that
conserves an outstanding amount of material as well as optimally guided
extrusion.
PARTS OF NGR MACHINE
1. CONVEYOR BELT: The conveyor belt transports the feed material
through a metal detector into the feed hopper. The belt is stopped
automatically, if metallic matter is detected in order to remove it.
2. HOPPER FEEDER: Through hopper feeder the recycled material is mixed
and transported further
3. CUTTER: Raw material is cut into very fine pieces with the help of 72
rotatory blades and 6 fixed blades and is pushed into screw with the
help of a pusher.
4. SCREW: After feeding the material when it is passed throw the screw it is
melted into viscous liquid in the heating zone with the help of heater
5. DEGASSING UNIT: Depending on the degree of contamination and
volatile substances in the melt flow, different modular degassing units
are used. Homogeneous melt without entrapped gas is the result.
SINGLE VENTING:-
Designed for light printing and low humidity. The vacuum degassing
system includes a vacuum pump and is connected to two venting ports
on the extruder.
6. FILTER/SCREEN CHANGER: Depending on the application, a variety of
filter systems is used. The melt is cleaned efficiently with low melt loss.
Basically, the appropriate filter is selected in consultation with the
customer. Depending on the degree of contamination, the following
variants are available as standard.
Back-flush screen changer:-
For heavily contaminated materials. The hydraulically operated double-
piston screen changer filters the melt in a process-controlled and
continuous manner. The integrated backwash device automatically
cleans the screens. The number of back-flushes and the related service
life of the screens depend on the degree of contamination of the
material.
7. PELLITIZING UNIT: Due to the modular construction of the recycling
systems, different pelletizer systems can be used in a process-controlled
manner, depending on the plastic processed.
Hot-die Watering Pelletizer (HD):-
For thermoplastics with a higher viscosity. The melt exits through the
wear-resistant die plate, and is knocked off by the pelletizer blades. The
pellets cooled in the water ring are flushed out, dried in the centrifuge
 and discharged. By adjusting the blade pressure, pelletizer blades
provide a long service life; replacement is quick and easy.
8. QUENCHING TANK: Cold water is passed from the chiller to the pellets
formed so that the temperature gets controlled and they get cooled so
that they can be operated easily.
9. IMPELLER: Impeller is used to separate the lumps of granules so formed.
Their is a blade attached to it which cuts the big lumps into small pieces
10.BLOWER: The blower sucks all the moisture from the granules via hot air
and made them dry
11.GRANULE HOPPER: The granules after dried and sucked are fed to a
hopper from where they get weighed and stored in bags and are ready
for use.

TEMPERATURE RANGE
Die temperature---------------------215 degree centigrade

Adapter temperature---------------220 degree centigrade

Zone temperature-------------------225 to 250 degree centigrade

 QUALITY DEMARTMENT
In this department, quality of product is checked by performing various testing
such as MFI test, Tensile testing, U.V. testing, denier testing.

TESTING OF TAPE:
There are various type of testing performed during the production of tape at
various stages to fulfil the required quality of tape.
Testing/inspection of the product divided into 3 parts:-
1. Raw material inspection (pre inspection)
2. Process inspection (in process)
3. Final inspection (pre dispatch inspection)

MELT FLOW INDEX TEST

Melt flow index or MFI is a measure of flow polymer. It is defined as the mass
of polymer, in grams, flowing in ten minutes through a capillary of specific
diameter and length by a pressure applied via prescribed alternative
gravimetric weight for alternative gravimetric weight for alternative prescribed
temperatures.
PROCEDURE:
1) Collect 200 grams of sample of material from store for which MFI is to
be performed
2) Set melt temperature and apply weight(W) according to the material
3) Die should be properly cleaned before putting the barrel
4) When the set temperature of barrel is achieved, put the required load
on the piston in the barrel.
5) Set the necessary time in the timer and measure the weight of the
material cut by the cutter
6) With the help of following formula calculate MFI
MFI=(10*W)/time
7) Similarly test the same material for 5 times and calculate the average
MFI

DENIER TEST
The equipment known as reeling machine which is used to reel the tape and
analytical or electronic balance which used to weight the tape.

PROCEDURE:-
1. Collect 6 bobbins on random basis
2. Prepare 90 metres reels of each collected bobbins with the help of
reeling machine
3. Measure the weight of each sample in grams
4. Take the average weight of all 6 samples by dividing the no of samples
5. Now get the denier by multiplying the average value by 100
TENSILE TEST
This testing is performed through tensile testing machine. During tensile
testing we observe the value of elongation at break thus we cam calculate
elongation percentage of tape.

PROCEDURE:-
1. Collect 6 bobbins on random basis
2. Record the test value of breaking load for each of the collected sample
of tape with the help of tensile tester in newton
3. Take the average of all 6 samples by dividing the no of sample
4. The average tenacity of tape to be calculated by converting the
obtaining average value of breaking load in newton inti kgf divided by
obtained value of denier
Tenacity= (breaking load in newton*0.102*1000)/denier
TESTING OF LAMINATION
Here three tests are performed after lamination:-
1. GSM test
2. Tensile test
3. Visual inspection

GSM TEST
The equipment which uses for measuring the GSM is known as 20*20 cm
template and electronic balance which is used to weight the fabric pieces

PROCEDURE
1. Collect laminated sample fabric whose GSM is to be measured
2. Cut 20*20 cm size fabric with the help of template
3. Weight the sample in gram with the help of electronic balance
4. Calculate the area of sample in meter
5. Calculate the GSM of fabric as below
GSM =weight/area

TENSILE TEST
This testing is performed through tensile testing machine. During tensile
testing we observe the value of elongation at break thus we can calculate
elongation percentage of the tape
PROCEDURE:-
1. Cut the sample of laminated fabric in strip of 5*30 cm in warp and weft
direction
2. Record the test value of breaking load for each sample in warp and weft
direction with the help of tensile tester in newton
3. Record the result of elongation at break
4. Calculate the elongation percentage ads below:
Elongation percentage=(elongation at break*100)/20

VISUAL INSPECTION OF LAMINATED FABRIC

Visual inspector of laminated fabric is too important because appearance of
the fabric should be better and attractive. During the visual inspection the
following things should be inspected.
1. Lamination should be uniform in thickness
2. Coated film should not be delaminated
3. The dust contamination should not be inside the lamination
4. There should not be fish eye or any type of hole
REFERENCES:
 Kanplasa.com
 Wikipedia.ac.in
 Extruderscreens.com
 Ngr.ac.in