Industrial Attachment of AGPFT plc

2013 e.c.

BAHIR DAR UNIVERSITY

COLLEGE OF SCIENCE

DEPARTMENT OF INDUSTRAIL CHEMISTRY

INDUSTRAIL ATTACHMENT (Iche 4111)

HOSTING COMPANY – AMHARA GOLDEN TRUST

PIPE FITTING TECHNOLOGY PLC (AGPFT)

Prepared By ID number

Submitted To:
Submission Date:

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Declaration
We declare, here by this final internship report on Amhara golden trust pipe fitting
technology plc (AGPFT) and our project entitled on the production of cornice from
HDPE and west is our original work and performed by our effort with the will of
GOD during the internship period. During the time we have improved our practical
skills, theoretical knowledge that we have so far, enter personal communication skills,
work ethics and entrepreneurial skills in it. We assure that the report contains actual
events and facts that were observed performing during the internship period, all
sources of material used for this report work has been fully acknowledged.

Approved by:

Student name signature date

Advisor name signature date

Mr.

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ACKNOWLEDGEMENT

First and foremost, we would like to acknowledge the almighty GOD for giving the
strength to accomplish this work and to perform the internship practice with in a
stipulated time. We want to give a compliment to the company for giving us an
opportunity of passing the internship program under the company and enable us to know
what we should have to know related to the theoretical parts what we have learnt
formerly, and we would like to provide a great thank for our company quality control
technicians ( lab technicians) Mr. Tayachew Takele, Mr. Masresha, Mr. Mengstu, and
Mr. Worku for his unstoppable support in the production process and quality control
section and all AGPFT operators (Mr. Seid (operator), Mr. Qelemwork (coordinator) and
the production manager Mr. esunew assefa) for their willingness to tell us whatever
anything we ask them concerning internship time activities.

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EXCUTIVE SUMMARY

This report contains the internship report that we have performed in AG pipe fitting
technology P.L.C from September 08/2013 – November 08/2013 E.C. It includes the
historical background about Amhara golden trust pipe fitting technology(AGPFT),
its main services, customers ,over all organization structure and work flow of each
section, raw materials, products and the main machines with their operating
mechanisms used in AGPFT. This report also includes our overall internship
experience, our work tasks and benefits that we have got from our hosting company,
the challenge that we have been faced and the measures we have taken to overcome those
challenges. In this internship program we have been involved in all section of plastic
processing that is extrusion, injection and fiber glass work.

This internship report has four chapters including project which is the

Production of cornices and partition from HDPE and west. During our internship time
in addition to academic knowledge, we have gained an important experience in
terms of social interaction, team work, punctuality, leadership that may be very
important for our life. Since AG pipe is recent company at Bahir Dar and due to
low workers performance and the effect of other process parameters, generation of
product scrap becomes a big issue for the company and also there is a lot of waste
HDPE during extrusion. Thus engineering solutions that we have chosen to solve
those problems was reusing the HDPE waste as a raw material for the production of
cornices and room partition.

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SYMBOLS AND ABBREVIATIONS

PPR…………………………..polypropylene random

PE……………………………..polyethylene

UPVC …………………………..un plasticized polyvinyl chloride

FGRP…………………………....fiber glass reinforced polymer

AWWCE………………………..Amhara water works construction

enterprise ADWCE…………………………Amhara design works
construction enterprise AGPFT…………………………..Amhara
golden trust pipe fitting technology

POM……………………………..polyoxy methylene
RPM……………………………...revolution per meter
PLC……………………………....private limited company
ANOVA………………………….analysis of variance
Tm…………………………………melting temperature
Ph…………………………………...holding pressure

Content

DECLARATION................................................................................
ACKNOWLEDGEMENT ................................................................. ii

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EXCUTIVE SUMMARY .................................................................. iii

SYMBOLS AND ABBREVIATIONS ................................................ iv
L IST OF TABLE ................................................................................. vii
LIST OF FIGURES ................................................................................ viii
CHAPTER ONE ........................................................................................ 1
1. BACKGROUND OF AMHARA GOLDEN TRUST PIPE FITTING
TECHNOLOGY (AGPFT) ......................................................................1
1.1 Brief history ..............................................................................................1
1.2 Vision, Mission and Objective of the company.....................................2
1.2.1 Vision.....................................................................................................2
1.2.2 Mission ................................................................................................ 2
1.2.3 Objective of the company .................................................................... 2
1.2.4 Core values of the company ................................................................. 2
1.3 Raw materials .......................................................................................... 3
1.6 End users of AGPFT .............................................................................. 7
1.7 Organization structure of AGPFT ........................................................... 7
1.9 Main tasks of each department ................................................................ 9

List of Tables

Table 1 experimental data’s for pp....................................................39

Table 2 Experimental data for HDPE ......................................................... 41

Table 3 R^2 test for regression model ........................................................ 42

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Table 4the ANOVA result for polypropylene (PP) .................................... 43

Table 5the ANOVA result for HDPE ........................................................ 44

Table 6 optimization result.......................................................................... 45

LIST OF FIGURES

Figure 1 Main product of factory ................................................................. 6

Figure 2 work flow the company ................................................................. 8

Figure 3 over view of injection molding machinery at AGPFT ………………11

Figure 4 Typical injection molding machinery parts .................................. 12

Figure 5 general process flow diagram of injection molding process ......... 14

Figure 6 the movement of screw with time............................................... 16

Figure 7 Hopper machine.......................................................................... 17

Figure 8 mixer machine............................................................................. 17

Figure 9 Cooling tower............................................................................ 18

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Figure 10 Water cooled chiller ................................................................... 19

Figure 11 major product defects ................................................................ 22

Figure 12 percentage contribution of each parameter ................................ 44

Figure 13 estimated HDPE and PP shrinkage in regard injection pressure and

cooling time…………………………………………………………………………………………... 45

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CHAPTER ONE
BACKGROUND OF AG PIPE FITTING
TECHNOLOGY (AGPFT)
1.1 Brief history
Amhara Golden trust pipe fitting technology (AGPFT) was established in 12/05/14 by
the joint venture company with the Amhara region development enterprise and part of
the golden trust capital group; its source of capital is from the share holders’ contribution
with initial capital of 19 million birr in which the golden trust group accounts 60% and
40% the regional government. When the company established since there it primarily
aims to bring technological transformation in the region, to develop modern agricultural
facilities like irrigation dams and construction. But unfortunately the golden trust groups
are no eligible to do so and the government took an immediate action to hold the share
contribution of the golden trust group in collaboration with Amhara water works
construction enterprise (AWWCE) and Amhara design works enterprise (ADWE). Now
its capital becomes 244 million birr in which the government accounts 95.4% and the rest
4.6% by the golden trust group. At the company there are 78 permanent, 9 contracts and
totally 87 workers. AGPFT acquires for 47000 sq. meters in the industrial belt of Bahir
dar town just 565 km from Ethiopian capital city Addis abeba. This company is the only
pipe fitting technology in the nation having expected annual capacity of producing more
than 250 parts of pipe fittings and 18 part of bucket and various related products.
Offering the most complete line of manufacturing and locally produced HDPE, PP, PPR,
UPVC pipe fitting and different fiber glass products delivered in the region and anywhere
in Ethiopia. The main aim of the company is to solve regional plastic fitting related
problems by manufacturing locally. Until the new injection molding machines become
installed and commissioning, the company tried to substitute some of imported fittings by
butt welding fabricated manufacturing. Even though the company is committed to
improve its production system by deliver products to customer, and regarding their
feedback to build workers capacity by learning by doing, on job training approach. But
concerned governmental sectors are not keen customer for local regional product. The

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total annual demand request and their interest become shift to private sector suppliers.
The best solution for all these and others are fulfilling budget design, construct,
workshop, procure machines, molds and raw materials at least to start in its opening
capacity. This year plan contains how to solve primary problems to achieve our vision,
mission and objectives of annual plan.

1.2 Vision, Mission and Objective of the company

1.2.1 Vision
Aspiring to see AGPFT plc in 2025 E.C. as one of the leading and competent plastic pipe
fittings, buckets, and seats manufacturing industry in Africa.

1.2.1 Mission
To manufacture quality fittings fiber water tanker, transparent Ega sheet sanitary
materials and related fiber glass products to meet customer requirement and expectation,
in addition increasing the company market share by distributing all over Ethiopia and
Africa; and creating job opportunity and professionalism on the field.

1.2.3 Objective of the company

 To provide the best engineered suitable, quality, efficient products and solution
for customers

 To delivery on time and quick reply to consumer inquiries

 To delivery on time and quick reply to consumer inquiries

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 To offer customer information, technical support and customer service that meet
and exceed their requirement

1.3 Core values of the company

 Meets customer needs and requirement.

 Quality, reliability and social responsibility.

 Even profit though customer satisfaction.
 Culture of team spirit and intensity.
 Genuine tax payer for national development.
 Save customer expenses by prefight and delivery time.
 Provide quality local products.
 Apply daily kaizen and ISO principles, tools and standards.

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1.4 Main product of the company

Flanges

PPR and PP elbows

Stadium chairs

Buckets

Elbow (22.5, 45 and 90 )

Gaskets

Straight reducers

Fig, 1.1 Main product of factory

1.5 Key stake holders of the company

 Amhara region joint venture sectors

 Golden trust capital group

1.6 End users of AGTFP

 Amhara water works construction enterprise (AWWCE)
 Amhara region water office

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 Amhara region agricultural and rural development

office
 Individual farmers and private construction companies

1.7 Organization Structure of AGPFT

A functional organization structure is mainly aims to organize workers. They are grouped
based on their specific skills and knowledge. It vertically structures each department with
their duty from the general manager to finance and sales departments, to customer
service, to employees assigned to one product or service.

1.8 Work flow of the company

General manager

Marketing Finance and Purchasing and

Human property
departiment budget
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Production
Quality control
Maintainance and safety manager
departiment manager

Production
Quality control team manager
and assurance
Maintainance team leader
and repair team
leader

Laboratory
Tools and technician
utility
operator

Fig,1.2 Work flow of company

1.9 Main tasks of each department
1.9.1 GENERAL MANAGER

Control, follow up and lead over all the company, apply yearly plan and occupational
program.
Generally control all over working process of the company.
1.9.2 PRODUCTION DEPARTMENT
 On the basis of marketing strategy and sales plan prepare production plan and
manage the production process according to the plan

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 Controlling and monitoring the production process

 Increase collaborations with reverse department ensure that the right quality and
quantity of raw materials and man power are available for the production
function.
 Receiving job order

1.9.3 QUALITY CONTROL DEPARTMENT

 Ensure inspection and testing is carried out in accordance with plan

documented plan.
 Monitor the performance of production machines preservation and production
process.
 Conduct laboratory experiments to insure the virginity of raw materials and to
check the quality of the final product.
 Ensure that non-conforming products are handled according to the procedure
and criteria document.
 Coordinate quality management system audit to confirm compliance
requirement.
1.9.4 MAINTANANCE DEPARTMENT
 Plan preventive maintenance parts and major laws.
 Carry out preventive maintenance based on pre-planned program.
 Evaluate machinery performance and suggest equipment that need mass
disposal.
 Prepare maintenance schedule tooth for machinery and vehicles.
 Advice and assist the deputy general manager on technical matters related
maintenance.

1.9.5 MARKETING DEPARTMENT

 Developing and designing price policy promotional strategy distribution

mechanisms and implementing after approval by the general manager.

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 Ensuring that effective customer service is produced at all levels.

 Strategic thinking, planning and implementing of the marketing function of
the company
1.9.6 HUMAN RESOURCE
 Carry out proper manpower planning to ensure supply of man power in
terms quality and quantity.
 Carry out recruitment and selection of employers based on the man power
plan.
 Carry out induction and orientation program for newly recruited staffs.
 Design and developing trained and developed policies and procedures.

1.9.7 FINANCE AND BUDGET DEPARTMENT

 Ensure that the company has adequate financial policies and procedures.
 Develop financial strategies and policies that make the company competitive and
profitable.
 Manage working capital cash receivables internal payables

1.9.8 PURCHASING AND PROPERTY ADMINSTRATION

 Provide proper purchasing policy and procedure for the wellbeing of the
company.
 Basically purchasing the acquisition of materials and services from suppliers
 Support and facilitate the company operation with uninterrupted flow by
supplying materials and services at the right time, right price, and right place
from the right source.

1.10 GENERAL SPECIFIC OBJECTIVES

1.10.1 General objectives
The general objectives of this report paper are to evaluate the knowledge that we
have obtained through the industrial internship/ attachments, and to documentaries
descriptions about AG pipe fitting technology plc.

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1.10.2 Specific objectives

The specific objectives of the paper include the following points;
 To know the overall process of injection molding, extrusion
molding, injection blow molding and fiber glass production.
 To have practical training in real plastic and fiber plants.
 To know the process description of each process(injection molding,
extrusion molding, injection blow molding and fiber glass)
 To know the phenomenon hold in each unit operations and to know
the function of each equipment

CHAPTER TWO
RAW MATERIALS OF AGPFT

2.1 Introduction

The AGPFT plc uses many different raw materials to produce different desired
products. These raw materials or resources get from different foreign countries.

2.2 Raw Materials and Their Properties

Raw materials are the inputs or resources that the company used to manufacture
its finished product.

2.2.1 Raw Materials

The main raw materials used in the AGPFT plc. Are:

 HDPE
 PP
 PPR

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 Master batch
 HDPE pipe from APF(amhara pipe factory)
 U-PVC
 Filler
 Wax
 PVA (poly vinyl acetate/alcohol)
 Gel coat
 Risen
 Pigment
 Gypsum
 Silicon dioxide (SiO2)
 Titanium dioxide (TiO2)
 Hardener (catalyst)
 Fiber glass
 Woven

2.2.2 Properties of Raw Materials

A. HDPE: High–density polyethylene (HDPE) or polyethylene high-density (PEHD)

is a thermoplastic polymer produced from the monomer ethylene. HDPE is a cost
effective thermoplastic with linear structure and no or low degree of branching. The
monomer ethylene is produced by cracking higher hydrocarbon of natural gas or
petroleum olefins means oil forming. Historically given to ethylene because oil was
formed when ethylene was treated with Cl. Polyethylene discovered around 1900,
though using an expensive process. C2H4 has the general formula of crude oil of
97% polyethylene. In 1953, Karl Ziegler and Erhard holzkamp invented HDPE.

PE density is divided into three main groups or grades according to their crystalline
structure percent.
Type 1: (branched) low density of 0.910-0.925 g/cm (PE-63%)
Type 2: medium density of 0.926-0.940 g/cm (PE-80%)
Type 3: high density of 0.941-0.959 g/cm (PE-100%)
HDPE can be made in various colors. The majority of HDPE is available in either black
or white. The AGPFT mainly used these types of HDPE products to manufacture
different types of products. HDPE properties include:
1. Resistance to chemicals
2. Low weight: HDPE has less weight than other types of materials.
3. High strength and flexibility and tensile strength
4. Impact resistance
5. Abrasion resistant
6. Resistant to attack of rodents and microorganisms
7. No need for cathodic protection because resistant to corrosion and rust
8. Having a long life

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9. Resistant to organic solvents

10. Resistant to uv-rays
11. Resistant to cold extreme heat
12. Resistant to chemicals
13. Cheap price
14. Thermal insulation
15. Improved toughness and
16. High viscosity
B. PP (Polypropylene/(C3H6)n): This also known as polypropene is a
thermoplastic polymer used in a wide variety of applications. It is produced via
chain-growth polymerization from the monomer propylene. PP is from the
polyolefin group. It is a semi rigid translucent polymer with good toughness and
weather resistance properties low water absorption and is easily molded to desired
shapes. PP is a largely non polar, partially crystalline thermoplastic with a
crystalline of 60 – 70 % and a density of 0.90 to 0.91g/cm which is among the
lowest for all plastics. Prior to 1954 most attempts to produce plastics from
polyolefin had little commercial success. PP invented in 1955 by Italian scientist
F.J. Natta by addition reaction of propylene gas with a stereo specific catalyst
titanium trichloride. PP is similar in manufacturing method and in properties to PE.
PP produced with low pressure process (ziegler) and with linear chains. PP is
similar in manufacturing method and properties to PE.
C. PP-R (Polypropylene-Random): Random copolymer polypropylene is a
clear, semi crystalline polymer which exhibits;
Properties of PP-R
 High stiffness
 High resistant to chemical substances
 It is durable
 Brilliant and smooth inner surface
 Provide heat and sound insulation
 Environmentally friendly
 Better impact strength
 Good electrical insulation properties
 Other options in PP include fire retardant and
electro-conductive grades.
 PP can also be UV-stabilized.

D. Master batch (concentrate): It is a concentrated mixture of pigments or

additives encapsulated during a heat process in to a carrier resin which is then
cooled & cut in to granular shape. It allows the process or to color raw polymer
economically during the plastics manufacturing process. But it should be added at
the correct dosing levels.

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E.Fiber Glass: The primary function of the fibers is to carry the loads along their
longitudinal directions. A fiber glass is a form of fiber –reinforced plastic where glass
fiber is the reinforced plastic. This is the reason perhaps why fiberglass is also known as
glass reinforced plastic or glass fiber reinforced plastic. The glass fiber is usually
flattened into a sheet, randomly arranged or woven into a fabric.

Fiberglass is lightweight, strong and less brittle. The best part of fiberglass is its
ability to get molded into various complex shapes. This is why fiberglass is widely
used in boats, aircraft, and water tankers.

Properties of fiberglass

 Mechanical strength: Fiberglass has a specific resistance greater than steel. So, it
is used to make high performance.
 Electrical characteristics: Fiberglass is a good electrical insulator even at low
thickness.
 Incombustibility: Since fiberglass is a mineral material, it is naturally
incombustible. It does not propagate or support a flame exposed to heat.
 Thermal conductivity: Fiberglass has low thermal conductivity making it highly
useful in the building industry.

F. Resin: Primary Function “To transfer stress between reinforcing fibers and to
protect them from mechanical and environmental damage” Attaches the fiber glass with
the gel coat . Types:
1. Thermoset Resin
2. Thermoplastic Resin
G. Wax: Is used to polish the mold and lubricant it by removing unwanted parts from
the mold.
H. Gel coat: This is evenly spread on the mold for the purpose of holding the required
color and shape.
I. Pigment: Varnished at the end to prevent bacteria and germs in the stored water.
J. Woven: Required for strengthen the fiber glass.
K. Hardner (Catalyst): It’s used to for drying purpose. If quick order is coming
from end users, then to get the product fast harder is used.

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L. U-PVC (un-plasticized polyvinyl chloride): are excellent resistance to

aggressive or destructive environment both naturally occurring as the result of industrial
activity. U-PVC is used for the plastic pipe and fittings in the world as it is resistant to
chemical erosion and has smoother inner walls that help to encourage water flow it also
functions well in a wide range of temperature and operating pressure. The main
properties of are;

 It is incredibly strong
 It is highly stiff
 It also costly effective
 Excellent resistant to aggressive or destructive environments.

2.3 Application Of Raw Materials

A. HDPE: HDPE is used for the manufacture of elbows, reducers, flanges and etc
because of the above mentioned properties. In AGPFT it is widely used in water related
applications. Some of these are;

1. Packaging applications; HDPE is used in several packaging applications such as;

bottles, jerry cans industrial bulk containers.

2. Consumer goods; Low cost and easily processibility make HDPE a material of choice
in several household /consumer goods like garbage containers.

3. Pipe and fittings; due to its excellent resistance to chemicals and hydrolysis.

4. Fibers and textiles; due to high tensile strength, HDPE is used in fishing and sport
nets, nets for agricultural use.

B. PP : It is a thermoplastic polymer in a wide variety of applications. In AGPFT it is

used for many different applications. Some of these are;

1. Packaging applications; such as buckets ;

2. Consumer goods; like stadium chairs ;house wares;

3. Industrial applications; used to produce acid and chemical tanks, sheets, pipes.

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C. PP-R: It is a combination of propene and ethane the monomer of PPR raw material
creates random chain and takes under protection.The use of plastic materials in pipe
fitting applications is well established because of the lightweight, high performance, and
excellent corrosion performance they can offer compared with metallic materials such as
iron and copper. There fore, PPR is specially designed PPR copolymer (PP-R, natural
and synthetic colored) that features excellent long-term hydrostatic pressure resistant and
heat stability. It is suitable for hot & cold water supply pipes and fittings as well as
radiator connecting pipes. Applications of PPR in AGPFT are;

Pipe fitting and PP-R ball valve

For potable water supply and food liquids

For hot & cold water supply
For boiler connection
For compressed air system (air condition)
Agricultural (watering system for green house and garden
For manufacturing of PPR ball valve

D. Master batch: master batch is a concentrated mixture of pigments and/or

additives encapsulated used in plastic industries to modify various properties of the base
plastic or plastic polymers. Generally master batch are used in plastic manufacturing
process. In AGPFT plc. master batch pellet form have the application to uniformity in
melting point of fed raw materials and colorant agent. In AGPFT plc.there are seven
different master batch used for manufacturing of products. These master batches are;

 Green master batch

 Yellow master batch
 Red master batch
 White master batch
 Purple master batch
 Black master batch
 Green master batch

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E. Fiber Glass Mat: Materials with high-temperature insulation provide an

effective thermal barrier for industrial gaskets. Since fiberglass is durable, safe and offers
high thermal insulation, fiberglass is one of the widely preferred materials in industrial
gaskets. They not only provide a better insulation but also help in protecting machinery,
conserving the energy and ensure the safety of the professional workforce. This is the
reason why fiberglass is widely used in industries below:

Cooling towers: Since cooling towers are always wet, they have to be protected from
rust, corrosion, and other safety issues. Due to the excellent properties of fiberglass, it is
used in these towers as screening to keep people and animals away from the danger
zones.
 Power generation: many areas of the power generation industry like tank farms,
scrubbers, and others use fiberglass. The reason for this the non –conductive
property of fiberglass.
 Chemical industry: In this industry, the fiberglass grating is used for anti –slip
safety feature of the embedded grit surface and the chemically resistant feature of
different resin compounds. The chemicals being used are matched with the resins.
 Car washes: fiberglass grating is greatly used for rust resistance and to give a
contrast color to areas that previously looked forbidden. It brightens the inside of
the carwash tunnel making the car look cleaner than it was.

F. Resin: In AGPFT plc. to produce a desired product of fiber glass the poly ester
resin used. MEKP (methyl ethyl ketone peroxide ) is the catalyst added to
polyester resin. It is clear and colorless solution. Poly ester resins are the most
commonly used matrix in the marine and composite industry. Polyester film is
useful for making sheet. Polyester film is reusable. Plain fiberglass sheet’s
production starts with polyesterfilm.

G. Wax: In AGPFT plc. wax application is for unpair of product from the mold.
H. Gel coat: Gel coat in AGPFT plc. used for external body and application of
water cooling in the tanker.

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I. Pigment: pigment in AGPFT plc. used for internal body and have an
application of to prevent algea formation inside the tanker.

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