A TECHNICAL REPORT ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

APACO FOAMS, AGBOR, DELTA STATE

BY

OTUAGA PROMISE EFEZIN O

FOS/18/19/254338

SUBMITTED TO THE DEPARTMENT OF CHEMISTRY,

FACULTY OF SCIENCE, DELTA STATE UNIVERSITY ABRAKA,
DELTA STATE

IN PARTIAL FUFILMENT OF THE REQUIREMENTS FOR THE

AWARD OF BACHELOR OF SCIENCE (B.Sc.) DEGREE IN
INDUSTRIAL CHEMISTRY.

JANUARY 2022

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 ABSTRACT
It is a great privilege for me to work in Apaco Foams and Chemical Industry
Limited. Sincerely this has really helped to boost my understanding of the way
things operate and also has given me a first-hand experience hereby arming me
for a proficient service delivery in any foam making and related company
worldwide.

Apaco Foams and Chemical Industries Limited boasts of a great variety of

equipment that is pivotal to the effective production of quality foams. I will be
discussing certain of these equipment in this report as I have been privileged to
understand the dynamics and operations of these equipment during the period
of my industrial attachment.

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 ACKNOWLEDGEMENTS

First of all, I want to thank God almighty for this opportunity and for granting
me the grace to successfully complete this program.

I want to also specially appreciate the management and staff of Apaco Foams
and Chemical Industries Limited for allowing me to undergo my Industrial
Training at the company and also for showing me immense support all through
the period of my training with them. A massive shout out to the managing
director, in person of ENGR. ANTHONY OKECHUKWU MOUBUIKE.

I would also use this medium to celebrate and appreciate my own dear parents
MR. AND MRS. OTUAGO for their continual support in my educational
pursuit and also during this period of my industrial attachment.

Lastly, I would love to appreciate everyone who contributed in one way or the
other in ensuring that the success of this program is a reality.

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 TABLE OF CONTENT

Title Page - i

Abstract - ii

Acknowledgement - iii

Table of Content - iv

CHAPTER ONE

1.1 Introduction - 1
1.2 Students Industrial Work Scheme (SIWES) - 1
1.3 Objectives of SIWES - 2
1.4 Scope of Industrial Training Program - 2

CHAPTER TWO

2.1 Company’s Organizational Background - 3

2.2 Organizational Structure of the company - 4

2.3 Departments in the Company - 4

2.4 Safety Rules and Regulations - 6

CHAPTER THREE

3.1 Equipment Utilized during the Program - 7

CHAPTER FOUR

4.1 Knowledge Gained from Industrial Work Experience - 13

4.2 Raw Materials Used - 13

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 4.3 Foam Manufacturing - 14

4.4 Problems Associated with the Chemicals - 16

4.5 My contribution to the company - 17

4.6 How Industrial Training has Broaden my Knowledge - 17

CHAPTER FIVE

5.1 Summary - 18

5.2 Conclusions - 19

5.3 Recommendation - 19

5.4 References - 20

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 CHAPTER ONE
INTRODUCTION
This report is based on the training undergone at Apaco Foam and Chemical
Industry, Asaba, Delta State. The industrial training lasted for six (6) months in
accordance with the duration recommended by the Student Industrial Work
Scheme (SIWES).

STUDENT INDUSTRIAL WORK SCHEME (SIWES)

The Student Industrial Work Scheme (SIWES) is a skill training programme

designed to prepare and expose students of universities, polytechnics, colleges of
technology, colleges of agriculture and colleges of education for the industrial
work situation they are likely to meet after graduation. The scheme affords
students the opportunity of familiarizing and exposing themselves to handling
equipment and machinery that are usually not available in their institutions.

Before the establishment of the scheme, there was a growing concern that
graduates of our institutions of higher learning lacked adequate practical
knowledge and that the theoretical education in higher institutions was not
responsive to the needs of the employers’ of labour.

It is against this background that the Industrial Training Fund (ITF) initiated,
designed and introduced SIWES scheme in 1973 to acquaint students with the
skills of handling industrial equipment and machinery

The Industrial Training Fund (ITF) solely funded the scheme during its formative
years. However, due to the financial constraints, the Fund withdrew from the
scheme in 1979. The federal government, who noted how significant this program

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was, handed the management of SIWES to National University Commission
(NUC) and the National Board for Technical Education (NBTE) in 1979.

In November, 1984 management and implementation of the scheme was again

reverted to the ITF with the funding be solely borne by the Federal Government.

OBJECTIVE OF SIWES

Specifically, the objectives of the Students Industrial Work Experience Scheme

(SIWES) are to:
1. Provide avenue for students in institutions of higher learning to acquire
industrial skills and experience in their course of study.
2. Prepare students for the industrial work situation they are to meet after
graduation.
3. Expose students to work methods and techniques in handling equipment
and machinery that may not be available in their institutions.
4. Make the transition from school to the world of work easier, and enhance
students’ contacts for later job placement.
5. Provide students with an opportunity to apply their knowledge in real work
situation, thereby bridging the gap between theory and practice.
6. Enlist and strengthen employers involvement in the entire educational
process and prepare students for employment after graduation.

SCOPE OF INDUSTRIAL TRAINING PROGRAM

 The main aim of industrial training program is to produce graduates who
are ready to face the working world.

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  The program also aims to produce knowledgeable, skilled and experience
graduates demanded by the employers who are able to apply the knowledge
acquired in the university to the working world.
 The industrial training program provides opportunities for exposure to the
working world, which will make graduates more aware of the hopes and
expectation that industry has for them.
 The program will also equip students with real work experience.
 Placing student in an industry also increase their chances of employment
after graduation, as there is strong possibility that they will be offered a job
in the same place where do their training.

CHAPTER TWO
COMPANY AND ORGANIZATIONAL BACKGROUND
Apaco Foam and Chemical Industries is a limited liability company registered
under the Companies and Allied Matters Act with registration number 73,372 on
October 16, 1985. The main business of the company remains the manufacturing
and sales of foams, soaps and other chemical related businesses.

Apaco Foam and Chemical Industries Limited has been an household name in
foam production in Nigeria for quite a number of years now. Having been actively
involved in the Nigerian market for over 40 years, the company is a leading
manufacturer of flexible block, mattresses of different sizes, pillows, underlays,
sheeting and orthopedic foams.

Apaco Foam and Chemical Industries Limited was officially commissioned on the
18th of April 1985 with the aim of delivering quality foams to within and outside
the shores of Nigeria.

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This great company is currently located at 12, Owa Ekei Road Oppositee Kezaih
Hotel, Agbor, Delta State, Nigeria.

ORGANIZATIONAL STRUCTURE OF THE COMPANY

Every organization has its own typical management structure that defines and
governs the relationship between the various employees, the tasks that they
perform, and the roles, responsibilities and authority provided to carry out
different tasks.
An organization that is well structured achieves effective coordination, as the
structure delineates formal communication channels, describes how separate
actions of individuals are linked together
The success of Apaco Foams and Chemical Industries Limited can be linked also
to their exceptional management structure that has helped synergize every
worker’s ability towards achieving the main aim of the company.

DEPARTMENTS IN THE COMPANY

1. Administration/Accounting Department: This department ensures the

efficient dispatch of duties in all the other department of the company. They
are also in charge of all financial matters as regarding the company. The
administrative department daily supervises all other departments and ensure
all necessary needs that are meet so the other departments can effectively
carry out the function assigned to them. This department is made up of the
Executive Director, Managing Director, Chief Accountant and other
accounting officers

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2. Quality Control Department: The quality control department is
responsible of monitoring and ensuring that each stage of production is
followed by all the necessary procedures for safe use of machinery and that
each product coming out of the production process complies with all
standards and specification defined so as to ensure a trouble free operations.
To ensure this, at certain times a labouratory test is usually carried out on the
sample by the quality control department to ensure that proper standard is
upheld.

3. Production Department: The production department is responsible for

converting raw materials and other inputs into finished goods or service. In
between the processes of production, the department works to improve the
efficiency of the production or assembly line so that it can meet the output
targets set by company management and ensure finished products offer
customers the best value and quality
4. Conversion Department: They are involved in the conversion of products
produced to their required finished product using the rotary and vertical
cutting machines
5. Maintenance Department: This department is saddled with the
responsibility of conducting routine checks, servicing, repairing and
replacing of necessary equipment. The goal of this department is to ensure
that all machineries are functioning effectively.
6. Sales/Marketing Department: This department is responsible for deciding
where the company should sell, setting prices for various products and
engaging actively in the sales of the products
7. Store Department: They are involved in the storage of the products before
they are delivered to the buyers. They also ensure safe guarding of raw

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 materials and deliver them to the production department on request during
production time.
8. Tailoring and Quilting/Pillow Department: They are responsible for
determining. Producing and also sewing the coverings and packaging for
the product before they are finally delivered to the buyers.
9. Carriage Crew: They ensure proper delivery/carriage of products. Their
job includes from carrying raw materials from one department to another,
delivering the finished products to dealers and wholesales etc.

SAFETY RULES AND REGULATION

Safety has always posed a major problem among workers in various industries. Year in
year out, various deaths and accidents have been recorded in factories across the world
and these could have been prevented if workers had fully followed the laid down safety
precautions. In order to safeguard lives and also equipment, it is mandatory for workers
to imbibe the culture of following safety rules and regulations in their workplace. There
are some safety rules and regulation that are observed in the company so as to ensure
works are carried out in orderly and safe manner. Below are the Do’s and Don’ts:

a. Do not drink or play inside the production factory to avoid contaminations.

b. Always sterilize all working equipment before use.
c. Do not enter the factory production department without the lab coat, factory shoes,
cap and gloves so as to avoid contamination as well as a nose mask, so as not to
inhale dangerous chemicals.
d. Proper cleaning of working equipment and machineries should be done at the end of
every production.
e. Loitering is not allowed around the factory production site when production is taking
place.
f. Water should always be made available in case of accidents like burns.

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g. Every production worker should make sure that he/she wash his/her hand at the end of
every production.
h. Always remove your shoes, lab coats, hand gloves and nose mask in the production
site before leaving to avoid environmental contamination.

CHAPTER THREE

EQUIPMENTS UTILIZED DURING THE PROGRAM

OHAUS Scale: It is a triple beam scale used for weighing silicone oil. It has a
capacity of 100g and readability of 0.1g.

DIAMOND SCALE: It is a precision weighing balance used in measuring polyol.

It has a capacity of 150kg 330lb and sensitivity of 500g 1lb.

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AVERY WEIGHING BALANCE: This is used for weighing Toluene-Di-
Isocynate (TDI).

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WAYMASTER WEIGHING BALANCE: This is used for weighing stannous
octate, methylene chloride (MC) and water. It has a capacity of 10kg x 20g.

SALTER WEIGHING BALANCE: It is used for weighing Amine. It has a

capacity of 5kg x 20g.

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POLYOL POT: This serves as a container where polyol is been poured in before
placing it on the weighing balance. It is also in this pot that all the chemicals
measured are mixed together before it is poured into the board for gellation.

TOLUENE-DI-ISOCYNATE POT: It serves as a container where TDI is been

poured in before placing it on the weighing balance.

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MOULD: It is in this board that polymerization reaction takes place. It has
different sizes (54, 6/6, 7/6). Each size of the mould is used depending on the size
of block to be produced.

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ELECTRONIC COMPACT SCALE: This scale is used when calculating the
density of a foam or pillow. It is used for measuring the mass of the foam sample
and pillow.

SAMPLE OF THE
PRODUCT

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 CHAPTER FOUR

KNOWLEDGE GAINED FROM THE INDUSTRIAL WORK

EXPERIENCE

As a student of industrial chemistry, I was placed in production department.

Although I functioned mainly in the production department, I was also given a tour
round all the other departments in the company. The raw materials used in the
manufacture of flexible polyurethane foam are listed in the table below

RAW MATERIALS USED

Main Chemicals Polyol

TDI (Toluene-di-isocyanate)

Activators Amine
Stannous Octoate (Tin II October)

Foam Stabilizer Silicone Oil

Additives Colorants
Fillers

Others Water
Auxiliary Blowing Agent

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Each chemical plays different role in the manufacture of the foam. Polyol and
Toluene-di-isocyanate are the main chemicals, Amine and stannous octoate are the
activators, silicone oil is the foam stabilizer, colorants and the fillers are the foam
additives, and water generates heat while methylene chloride is a blowing agent.

In the production field, I carried out different activities such as; measuring of
calcium carbonate (caco2), Toluene-di-isocyanate (TDI), Polyol, stannous octoate,
silicone oil, amine, water and methylene chloride (MC). I also helped in mixing the
measured chemicals.

FOAM MANUFACTURING:

The manufacture of flexible foam undergoes few steps, which are:

1. Measuring and weighing: The raw materials are measured based on the
size and quality of block to be produced. In measuring the chemicals, the
correct proportion of the various chemicals must be carefully determined.
Too little or too much of any chemical will bring about problems.
2. Mixing of raw materials: The raw materials after it has all been measured
are mixed inside an open vessel and then stirred with a driller. Too little or
too much of mixing brings about problems.
3. Molding: The mixed raw materials are then poured into the molding
machine. In the molder, it undergoes some reaction which results in the
formation of foam. Foam reaction lasts for about 6minutes before it attain its
full rising. The foaming reaction undergoes three stages.
a) Cream Time
This is the first sign that chemical reaction have started. Noticeably, the
chemical mixtures has a slightly white color and it has been determined that
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 this period lasts for about 12 seconds. As soon as generation of CO2 gas
starts, the cream time ends. The duration of this cream time is dependent on
the amount of amine in use (high quality and/or high activity of amine
shortens the cream time).
b) Rising Time
This is the period (lasts 60-80 seconds) when all the foam expansion takes
place like formation of cell structure; gas reaction accompanied by
generation of CO2 takes place and evaporation of auxiliary blowing agent if
present in formulation.
c) Curing Time
When the foam full rise is achieved, the foam is initially a soft gelatinous
mass and the period between attainment of full rise and complete
solidification of foam is the curing time. Curing time is allowed for about
3-5 minutes before blocks are being discharged.

4. Cooling: The molded foam is pushed out of the molder after it has reached
its full rising time to about 15meters away from the molder to cool so as to
avoid over heating which may lead to fire outbreak.

5. Density Determination: After the mixed chemicals have been poured into
the board and covered so that polymerization reaction can take place, the
remnant mixtures in the pot is left to form into a foam and allowed to cool,
then it is brought out and kept till the following day. The remnant from the
pot which formed the foam is sliced into a square shape then used to
calculate the density of all the foams produced the previous day using an
electronic compact scale. The density determined is used to know the quality
of the foam produced.
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In formulating, the correct proportions of the various chemicals must be carefully
determined. Too little or too much of any chemical will bring about problems.

PROBLEMS ASSOCIATED WITH CHEMICALS

CHEMICALS EFFECTS
TOO LITTLE TOO MUCH
TDI Too soft foam Too hard foam
Foam blocks over-heat
Silicone Oil Bubble instability leading Induces closed cells due
to foam collapse to over-stabilization
Stannous octoate Side splits of regular Closed cells
interval; if too low may Foam shrinkage
extend deep into the block
Amine Delayed cream time Foam splits
Unusual very fast reaction
Methylene chloride Hard foam which is Too soft foam
generally accepted
Stirrer speed Presence of air bubbles Too fine cell structure
leading to splits.
Water Insufficient blowing High exotherm
Low block height Risk of fire
Scorching

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 MY CONTRIBUTION TO THE COMPANY

I contributed a lot to the company in so many ways, for instance;

a. I make sure I come as early as possible to work thereby boosting their image
about workers coming early.
b. In production I helped in mixing and measuring of chemicals during
production. I help in controlling the machine used in production.
c. I made sure that every required chemical needed for work is set before
production and I also helped in keeping the equipment used during
production clean after every production.
d. I helped in convincing customers to buy their goods thereby boosting their
finances.
e. I endeavored to keep the surrounding clean.
f. I helped in accounting unit in creating invoice for customers, entering petty
cash account, payment voucher and debtors account book.

HOW INDUSTRIAL TRAINING HAS BROADENED MY KNOWLEDGE

The training has helped me in understanding some things I was taught in class
better because I was able to carry out the practical on my own and saw the
reactions occur. I was able to decipherer the reaction that occurs during
polymerization reaction which takes place In two stages; the primary reaction is
the addition reaction between the di-functional isocyanate (TDI) and polyol to
form urethane while in the secondary reaction (which occurs during curing stage)

17
is that between the nitrogen atom of the urethane and another isocyanate molecule
to form an allophanate group.

I was also able to know that when water reacts with toluene-di-isocyanate, it
produces quite a large amount of gas (carbon dioxide) which in turn blows up
(expands) the foam cells.

CHAPTER FIVE

SUMMARY, CONCLUTION AND RECOMMENDATION

SUMMARY

Student industrial training scheme (SIWES) provides students with appreciable

skills designed to expose or equip them with real life working experience. Students
gain increased maturity and understanding of the workplace and a better
understanding of your own career goals and for the progress of the nation.

The programme is an invaluable and worthwhile venture as such should be

encouraged by the federal Government of Nigeria. This implies that more funds
facilities and also trained personnel should be made available to help in the
realization of the noble aims and objectives of the programme.

Again it should be given adequate publicity to enable various establishments

appreciate the relevance of (IT) to students and work towards helping the students
in achieving their goals.

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This report contains and gives a detailed explanation of all the activities carried out
at Apaco foam and Chemical Industries, Agbor.

CONCLUSION

In conclusion I could say that generally, the SIWES programme is very beneficial
to students in preparing them for the future engagement and graduation. It is a
sincere approach to technology growth and development as we are now in
technological age.

My industrial training was very educative and enjoyable because the programme
exposed me to learn many things and to be self-reliant without depending on
anybody.

RECOMMENDATION

However, I think if certain things are done, it could help boost the efficiency of the
program and make it even more enjoyable for students and companies as well.
Therefore I am recommending the following:-

1. The industrial training fund should compile list of available training places
for industrial attachment and forward the list to the coordinating agencies.
2. The company should be willing to accept and encourage students that are
seeking for SIWES placement in the company.
3. The company should also grant access to students to make use of their
machines under strict supervision.

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 4. The company and organization that accepts the (IT) students should be
educated on the benefits of paying the attached students no matter the
amount so as to encourage them and also to help them in solving some of
their problems like transportations and feeding during the period of their
industrial attachment.
5. The establishment should provide adequate facilities to make the programme
enjoyable for students such as accommodation.

REFERENCES

Buist, J. M. “polyurethane foams, Basic equipments for producing flexible and

rigid foams”; proceedings of the international conference, Washington, D.C.,
November, 1959; American chemical society. 1959; page 9-20.

Buist, J. M.; Hurd, R.; Lowe, A. “Polyurethane foams: Methods of production,

properties and Applications”; Chem. And Ind. 1960, page 1544-1558.

Scott, G. Atmospheric Oxidation And Antioxidant; Elsevier Publishing: New

York, 1965. page 339.

David D. J.; Stanley, H. B. Analytical chemistry of the polyurethanes; Robert

Krieger: New York, 1979, page 294.

Kuryla, W. C.; Critchfield, F. E.; Platt, L. W.; Stamberger, P. “Polymer/polyols, a

New Class of Polyurethane Intermediates”; J. Cell. Plast. 1966, page 84-96.

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Pinner, S. H. “Chemistry and Technology of the organic Isocyanate”, Plastics
(London) 1947, 11,Apr./May, page 206-211, page 215.

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