PLASTIC AND RUBBER

Macaranas, Mark Gabriel M.

Fernandez, Lawrence Christopher M.

History of Plastic
1600 BC - Early plastics were bio-derived materials such as egg and blood proteins, which
are organic polymers.
Middle Ages - Mesoamericans used natural rubber for balls, bands, and figurines. Treated cattle
horns were used as windows for lanterns.
19th century - industrial chemistry developed during the Industrial Revolution, many materials
were reported. Parkesine (nitrocellulose) is considered the first man-made plastic. The plastic
material was patented by Alexander Parkes, in Birmingham, England in 1856
1897 - The Hanover, Germany mass printing press owner Wilhelm Krische was commissioned to
develop an alternative to blackboards. The resultant horn-like plastic made from the milk protein
casein was developed in cooperation with the Austrian chemist (Friedrich) Adolph Spitteler
(1846–1940)
Early 1900s - Bakelite, the first fully synthetic thermoset, was reported by Belgian chemist Leo
Baekeland by using phenol and formaldehyde.
1930s - The earliest examples in the wave of new polymers were polystyrene (PS), first produced
by BASF in the
1920s - Polyvinyl chloride (PVC), first created in 1872 but commercially produced.
1933 - Polyethylene was discovered by Imperial Chemical Industries (ICI) researchers Reginald
Gibson and Eric Fawcett.
In 1954, polypropylene was discovered by Giulio Natta and began to be manufactured in 1957.

Definition of terms
Plastic is material consisting of any of a wide range of synthetic or semi-synthetic organic
compounds that are malleable and so can be molded into solid objects.
Polymer is a large molecule, or macromolecule, composed of many repeated subunits. Due to
their broad range of properties, both synthetic and natural polymers play essential and ubiquitous
roles in everyday life.
Monomer is a molecule that "can undergo polymerization, thereby contributing constitutional
units to the essential structure of a macromolecule".
Thermoplastic is a polymer in which the molecules are held together by weak secondary
bonding forces that soften when exposed to heat and return to its original condition when cooled
back down to room temperature. 

Thermoset is a polymer that solidifies or “sets” irreversibly when heated or cured.

Plastics applications
 Construction
Plastics are used in a growing range of applications in the construction industry. They have great
versatility and combine excellent strength to weight ratio, durability, cost effectiveness, low
maintenance and corrosion resistance which make plastics an economically attractive choice
throughout the construction sector.
 Electrical and electronics application
Electricity powers almost every aspect of our lives, at home and in our jobs, at work and at play.
And everywhere that we find electricity, we also find plastics.
 Plastics packaging
Plastics is the perfect material for use in packaging goods.  Plastics is versatile, hygenic,
lightweight, flexible and highly durable.
 Transport
The cost-effective and safe transportation of people and goods is vital to our economy, cutting
the weight of cars, aeroplanes, boats and trains can cut fuel consumption dramatically. 

Materials
Today most plastic are made from petrochemicals including natural gas. Plastics are organic
materials that contain such elements as carbon (C), hydrogen (H), nitrogen (N), Chlorine (Cl),
and sulfur (S). They are made from raw materials such as oil, natural gas, and coal. The first step
in making plastics is the polymerization of the raw materials, resulting in a product called a
monomer. Hydrocarbons are then heated in a “cracking phase.”

PLASTIC MAKING PROCESS

USING AUTOMATED THE PET IS HEATED AND THE TUBE OF PET, NOW CALLED A
MIXER IT COMBINES THE PLACED IN THE MOLD PARISON, IS THEN TRANSFFERED
PET PELLETS WITH FLAKES WITH 315˚C USING INTO A SECOND BOTTLED-SHAPED
RECYCLE PET. PLASTIC INJECTION MOLD
MACHINE.

USING A REHEAT STRETCH BLOW MODLDER IT A THIN STEEL ROD, CALLED A

HEATS THE PARISON JUST ENOUGH TO MAKE THE MANDREL, IS SLID INSIDE THE
PLASTIC MALLEABLE, THEN INSERTED A ROD TO PARISON WHERE IT FILLS THE
STRECH IT LENGTHWISE AND BLOWING AN AIR PARISON WITH HIGHLY PRESSURIZED
WITH EXTREME HIGH PRESSURE AND FORCES IT AIR AND STRETCH BLOW MOLDING
INTO A BOTTLE SHAPE MOLD. COLD WATER BEGINS
CIRCULATES WITHIN THE MOLD TO COLD THE
PLASTIC INSTANTLY. THE SPEED PRODUCTION OF
THE MACHINE IS 10,600 BOTTLES PER HOUR.

THE CONVEYOR BELT TRANFFERS THE AFTER PACKAGING IT IS READY

FINISH BOTTLE TO THE PACKAGING FOR THE DISTRIBITION.
Different processing
AREA. THE FACTORY PULLS methods
EXAMPLE OF
THE LINE FOR TEST THE THICKNESS FOR
THE QUALITY CONTROLS.
Extrusion - This continuous process is used to produce films, sheet, profiles, tubes, and pipes.
Plastic material as granules, pellets, or powder, is first loaded into a hopper and then fed into a
long heated chamber through which it is moved by the action of a continuously revolving screw.
The chamber is a cylinder and is referred to as an extruder. Extruders can have one or two
revolving screws. 
Film Blowing – This process continuously extrudes vertically a ring of semi-molten polymer in
an upward direction, like a fountain. A bubble of air is maintained that stretches the plastic
axially and radially into a tube many times the diameter of the ring.
Injection Molding - This process can produce intricate three-dimensional parts of high quality
and great reproducibility. It is predominately used for thermoplastics but some thermosets and
elastomers are also processed by injection molding. In injection molding plastic material is fed
into a hopper, which feeds into an extruder. 
Blow Molding - Blow molding is a process used in conjunction with extrusion or injection
molding.  In one form, extrusion blow molding, the die forms a continuous semi-molten tube of
thermoplastic material.
Expanded Bead Blowing – This process begins with a measured volume of beads of plastic
being placed into a mold. The beads contain a blowing agent or gas, usually pentane, dissolved
in the plastic. The closed mold is heated to soften the plastic and the gas expands or blowing
agent generates gas.
Rotational Molding - Rotational molding consists of a mold mounted on a machine capable of
rotating on two axes simultaneously. Solid or liquid resin is placed within the mold and heat is
applied.
Compression Molding – This process has a prepared volume of plastic placed into a mold
cavity and then a second mold or plug is applied to squeeze the plastic into the desired shape. 
Casting – This process is the low pressure, often just pouring, addition of liquid resins to a
mold. Catalyzed thermoset plastics can be formed into intricate shapes by casting.
Thermoforming – Films of thermoplastic are heated to soften the film, and then the soft film is
pulled by vacuum or pushed by pressure to conform to a mold or pressed with a plug into a
mold. 

Maintenance
Mold maintenance has always been considered one of the “black arts” of plastics processing.
That’s because there is little in the way of formalized training programs for mold-repair
technicians or managers. There is no accessible knowledge base of standardized practices and
procedures no mold-maintenance to turn to, for example, when a hot runner begins to ooze
plastic from the top of the electrical box during a critical production run.
Typical mold-maintenance functions such as disassembly; troubleshooting, repair, cleaning,
and assembly can and should be standardized and formalized. A systemized approach can
bring significant benefits:

 Reduced labor hours and spare-parts usage.

 Reduced or eliminated part defects.
 Reduced scrap rates and downtime.
 Improved part quality.
 Improved mold performance and reliability.
 Improved skill levels and morale of repair technicians.

A. HISTORY OF RUBBER
- The first use of rubber was by the indigenous cultures of Mesoamerica. The earliest archeological
evidence of the use of natural latex from the Hevea tree comes from the Olmec culture, in which rubber
was first used for making balls for the Mesoamerican ballgame. Rubber was later used by the Maya and
Aztec cultures – in addition to making balls Aztecs used rubber for other purposes such as making
containers and to make textiles waterproof by impregnating them with the latex sap.
B. DEFINITION
- Rubber is a material which can stretch and shrink. It is a polymer. Sometimes the word means only
natural rubber (latex rubber). Natural rubber is made from the white sap of some trees such as the Hevea
brasiliensis (Euphorbiaceae). Other elastomers, called synthetic rubbers, are made by chemical processes.
- Polymers a substance that has a molecular structure consisting chiefly or entirely of a large number of
similar units bonded together . Many synthetic organic materials used as plastics and resins. Polymer has
the ability to return to its original shape after being stretched or deformed.
- Elastomer is a natural or synthetic polymer having elastic properties.
C. APPLICATION
- Natural rubber forms an excellent barrier to water. This is possibly the best barrier against pathogens
such as the AIDS virus (HIV). That is the reason why latex is used in in condoms and surgical and
medical examination gloves. Natural rubber latex is also used in catheters, balloons, medical tubes, elastic
thread. Other than rayon, it is the sole raw material, which is used by the automotive industry.
- Synthetic rubber can be used in tires, flexible rubber toys, paints, shoe sole, rubber gloves, tube and
hoses.
Advantage of natural rubber:

 less buildup of heat from flexing

 greater resistance to tearing when hot
 good dynamic performance
 low level of damping
Disadvantage of natural rubber:

 get damaged under the action of strong acid, ozone, oils, greases and fats.
Advantages of synthetic rubber:

 being more resistant to oil, certain chemicals and oxygen

 better aging (last longer) and weathering
 resilience over a wider temperature range
Disadvantages of synthetic rubber :

 its tensile effect is relatively poor

 tear and mechanical properties are relatively poor

D. RAW MATERIALS
Natural Rubber - Latex (tree sap)

Synthetic Rubber – secondary raw material, styrene and butadiene. Both made from crude oil.
E. PROCESS

Natural Rubber
- The natural rubber manufacturing process begins with harvesting latex from rubber trees. Harvesting
latex from rubber trees starts with scoring or cutting into the bark of the tree. Latex flows into a cup
attached to the bottom of the cut in the tree it flows about 5-6 hours filling the cup.
After straining the pour rubber sap (latex) into a plastic container. They add formic acid, the acid causes
the sap to coagulate after 15 to 30mins. It thickens to the consistency of a tufo. After a minute sap has a
sticky structure that allows to be rolled like a dough. The rolling machine squeeze out excess water then
they rinse off formic acid.
They hang the rubber sheets to dry for 5hours as they dry, the rubber thickens and become stronger and
the color darkens. The coagulated rubber sap is transformed from liquid to solid. They store the stack
form the warehouse until the new stage of processing. When they ready to move on, the workers pill the
sheet from the stack and soap them from water about 20mins. It washes away the surface contaminants.
The rubber sheets go in the machine with many brushes to remove more dirt.
They hang the sheet on the rack to dip dry. They build a fire in a brick oven and smoke the rubber sheets
in the chamber over head for 5days. Slow and low temperature of smoking that preserve and to prevent
the growth of molds. They grade the rubber sheet by examining them against the bright light. Sheets with
fewer remaining contaminants will receive higher rating and will command in better price. They stack the
sheets according to their grade.
They put the stack in hydraulic baler and press it in cube form. The dimension of the cube confirm from
the national packaging regulations. So they fit neatly in to container for shipping. They spray the rubber
cubes with mix of calcium carbonate and solvent. That prevents molds and keeps them from sticking
together.
Synthetic Rubber
- Synthetic rubber production begin, a mixture of different hydrocarbons like oil and coal should be
created and then refined. One of the by-products, naphtha, is a flammable liquid hydrocarbon mixture
that is used for manufacturing gasoline and plastic.
Naphtha is then combined with natural gases to produce monomers. A monomers is used to bind
molecules together to create polymers.
The chemicals will be bonded together by monomers to create polymers. Common monomers that are
used for synthetic rubber are, styrene-butadiene rubber, nitrile rubber, butyl rubber. Chemical agents are
used to form chains of polymers to form rubber substances.
Rubber substance will then undergo vulcanization to process them into rubber products. Vulcanization is
the process in which polymers are converted into a more durable material by adding Sulphur or other
accelerators.
F. MAINTENANCE
Rolling Machine Daily Maintenance

1. Perform Daily Maintenance Checks

- Completing a brief walk-around of the machine can be an easy way to see if something is off before
you even leave the shop in the morning.

2. Keep the Drum Clean & Lubricated

- During your visual inspection each morning, make sure there are no dings in the drum surface and
that the drum is clean.

3. Check All Fluid Levels 

- From completing the recommended oil change to making sure you have enough coolant, keeping all
fluid in check will help ensure the engine at its full performance level. A brief check of the
maintenance decal on the machine can also ensure that all fluid is at its optimal level.

4. Inspect the Water System

- Always fill the tank with clean water from a known source. Water goes from the tank to the sprinkler
bars and sprays out over the front and rear drum. It serves as a lubricant to prevent asphalt from
sticking to the drum so it’s important that the water you put in it is clean and won’t clog the system.

5. Check Air Filters

- Making sure the air filter isn’t clogged can help ensure that the engine won’t run too hot.

6. Inspect Shock Mounts

- The shock mounts are another important part of the roller to check before you leave the shop. The
shock mounts are the rubber mounts that isolate the vibration of the drum from the operator.  The
energy then is directed from the drum into the mat.

Hydraulic Baler Weekly Maintenance

1. Inspect all nuts and bolts during the first week of use, and then monthly thereafter.
2. Check hydraulic oil reservoir for proper oil level with the cylinder fully retracted. Maintain
proper oil level in the reservoir with a high quality all weather hydraulic oil such as Conoco 5W-20
or equivalent. A “Fill to Here” decal is provided to help maintain the proper level. In addition, check
for any leakage, kinks, or other damage to the hydraulic hoses and replace if necessary.

3. Check the power unit. Keep the power unit clean and free of debris in order to provide a clean
airflow around the unit. Wipe all grease, dust, and dirt from the outside of the control box.
4. Check that all safety guards and access covers are secure and in the proper condition before
operation.