Central Institute of Plastics Engineering and Technology (CIPET)

KORBA
(Dept. of Chemicals & Petrochemicals, Ministry of Chemicals & Fertilizers, Govt. of India)

PLASTIC PROCESSING
Today’s Reality
Plastic products have become an integral part
of all our lives, and play an irreplaceable role
in our day-to-day activities.
What is Plastic ?
A plastic is a kind of wonder material that is
made by people
(not available naturally)
and can be formed into almost any shape.
Most plastics are strong, long-lasting, and
lightweight.
They resist damage by water, heat, chemicals,
and electricity.
In addition, plastics can be made in many
colors.
 INTRODUCTION TO
PLASTICS PROCESSING
 INTRODUCTION
Plastics – The unique class of wonder materials – came into existence by virtue of
their superior performance and cost effectiveness over to conventional materials.

Every day newer and newer application are being promoted in all the key sectors
of Indian Economy viz, Automobiles, Agriculture, Aerospace. Building &
Construction, Infrastructure, Telecommunication, IT, Medical & Bio Medical
engineering, Packaging, etc.

This in turn necessitates the need for different types processing methods and
machinery to produce quality plastics products at affordable cost
 DEFINITION:

Plastics Processing – in a simple layman’s language – can be defined as

the process of converting the plastic raw materials into Semi-finished
or finished products.

Processing Semi-finished
Raw Materials
(Powder/granules) or
Finished Products

In a more technocrate way we may say “Get the Shape and set the Shape”.
Technique to get the shape and Set the shape varies depending on Process and
Material employed.
CLASSIFICATION OF PROCESSING METHODS

1. Primary Processing Methods:

u More importance by virtue of

o Extent of utilization for Varied applications

o Growth Potential

Ex: Injection Moulding, Extrusion, Blow Moulding, Compression / Transfer Moulding,

2. Secondary Processing Methods

u Lesser extent of utilization

u Acts as supplementary to primary operation

Ex: Roto Moulding, Thermoforming, Coating, Casting, FRP Fabrication Methods, Calendaring, etc.,
 PROCESSING FUNDAMENTALS

Performance Requirements

Practical Engineering
Approach Approach

Material Selection

Properties Process Cost

Ideal Choice

Product Manufacture : A Simplified Flow Diagram

The process selection depends on several interrelated factors:

(1) Designing a part to meet performance and manufacturing requirements at the

lowest cost;

(2) Specifying the plastic;

(3) Specifying the manufacturing process, which requires

 Designing a tool ‘around’ the part,

 Putting the ‘Proper Performance’ fabricating process around the tool,

 Setting up necessary auxiliary equipment to interface with the main processing

machine

 Setting up ‘Completely integrated’ controls to meet the goal of zero defects;

(4) Purchasing equipment's and materials, and warehousing the materials.

 COMPETITIVE PROCESSES

S. Comp./
Inj. Thermo Blow Roto
N Product Extrusion Transfer
Moulding forming Moulding Moulding
o Moulding
1 Narrow neck - - - 1 - -
container

2 Oil Barrels - - - 1 - 1
Upto (200 ltrs)
3. Tanks (20000 - - - - - 1
ltrs)
4. Films,Profiles, - 1 - - - -
Pipes
5 Housing, Auto 1 - 2 2 2 -
parts
6. Wider Neck 1 - - - - -
parts
7. Hallow - - - - - 1
Containers
1. Best Process 2. Supplementary Process
Parameters that help one to select the right options are

1. Setting up specific performance requirements;

2. Evaluating material requirements and their processing capabilities;

3. Designing parts on the basis of material and processing characteristics, considering

part complexity and size as well as a product and process cost comparison

4. Designing and manufacturing tools (Moulds, Dies, etc) to permit ease of

processing;

5. Setting up the complete line, including auxiliary equipment;

6. Testing and providing quality control, from delivery of the plastics, through
production, to the product

7. Interfacing all these parameters by using logic and experience and / or obtaining a
required update on technology.
 PROCESSABILITY :

Processability means generally the ease or difficulty with which a plastic can be
handled during its fabrication into film, molded products, pipe, etc.

A plastic with good processability possesses the properties necessary to make it easy
to process the plastics into desired shapes.

The main characteristics or properties which determine a plastic’s processability are

molecular weight, uniformity, additive type and content, and plastic feed rates.
 PROCESSING METHODS:

The type of process to be used depends on a variety of factors, including product shape
and size, plastic type, quantity to be produced, quality and accuracy (Tolerances)
required, design load performance, cost limitation, and time schedule.

Each of the processes provides different methods to produce different products. As an

example, extrusion with its many methods produces films, pipe, sheet, profile, wire
coating, etc.

Almost all processing machines can provide useful products with relative ease, and
certain machines have the capability of manufacturing products to very tight dimensions
and performances. The coordination of plastic and machine facilities these processes.
 PROCESSING METHODS – An Overview:
Depending upon the configuration of the part, economic viability and the
part tolerance, etc the process can be selected.

Machine Operation Terminology

Terminology in the plastics industry regarding the operation of machinery is as
follows:
 Manual Operation
Each function and the timing of each function is controlled manually by an operator.
 Semiautomatic Operation
A machine operating semi automatically will stop after performing a complete cycle
of programmed molding functions automatically. It will then require an operator to
start another complete cycle manually.
 Automatic Operation
A Machine operating automatically will perform a complete cycle of programmed
moulding functions repetitively; it will stop only for a malfunction on the part of the
machine or mould, or when it is manually interrupted.
BLOW MOULDING :

Description :
An extruded parison tube of heated thermoplastic is positioned between two
halves of an open split mould and expanded against the sides of the closed
mould via air pressure. The mould is opened and the part ejected. Low tool and
die costs, rapid production rates, and ability to mould fairly complex hollow
shapes in one piece.

Limitations:

Generally limited to hollow or tubular parts; some versatile mould shapes, other
than bottles and containers.
BLOW MOULDING
INJECTION MOULDING :

Description

Very widely used. High automation of manufacturing is standard practice.

Thermoplastic or thermoset is heated to plasticate in cylinder at controlled
temperature, then forced under pressure through a nozzle into sprue, runners,
gates, and cavities of mould. The resin undergoes solidification rapidly. The
mould is opened, and the part ejected, Injection Moulding is growing in the
making of glass-reinforced parts. High production runs, low labour costs, high
reproducibility of complex details, and excellent surface finish are the merits.

Limitations:
High initial tool and die costs; not economically practical for small runs.
INJECTION MOULDING
EXTRUSION :
Description :

Widely used for continuous production of film, sheet, tube, and other profiles;
also used in conjunction with blow moulding. Thermoplastic moulding
compound is fed from a hopper to a screw pump where it is heated to plasticate
then pumped out through the shaping orifice (die) to achieve desired cross
section. Production lines require input and takeoff equipment that can be
complex. Low tool cost, numerous complex profile shapes possible, very rapid
production rates, can apply coatings or jacketing to core materials (Such as
wire).

Limitations:

Usually limited to sections of uniform cross section.

EXTRUSION
COMPRESSION MOULDING :

Description :
Thermoset compound, usually preformed, is positioned in a heated mould
cavity; the mould is closed (heat and pressure are applied) and the material flows
and fills the mould cavity. Heat completes polymerization and the part is ejected.
The process is sometimes used for thermoplastics, e.g. Vinyl phonograph
records. Little material waste is attainable; large, bulky parts can be moulded;
process is adaptable to rapid automation.

Limitations:
Extremely intricate parts containing undercuts, side draws, small holes, delicate
inserts, etc.; very close tolerances are difficult to produce. Time consuming
process.
COMPRESSION MOULDING :
TRANSFER MOULDING

Description :
Widely used to produce Thermoset products with part complexity. Thermoset
moulding compound is fed into transfer chamber where it is then heated to
plasticate; it is then fed by a plunger through sprues, runners, and gates into a
closed mould where it cures; mould is opened and part ejected. Good
dimensional accuracy, rapid production rate, and very intricate parts can be
produced.

Limitations:

High mould cost; high material loss in sprues and runners; size of parts is
somewhat limited.
TRANSFER MOULDING
CALENDERING :

Description :

Dough-consistent thermoplastic mass is formed into a sheet of uniform thickness

by passing it through and over a series of heated or cooled rolls. Calenders are
also utilized to apply plastic covering to the backs of other materials. Low cost,
and sheet materials are virtually free of moulded-in stresses.

Limitations:

Limited to sheet materials and very thin films are not possible.
CALENDERING :
ROTATIONAL MOULDING

Description :
A predetermined amount of powdered thermoplastic material is poured into
mould; mould is closed, heated, and rotated in the axis of two planes until
contents have fused to the inner walls of mould; mould is then opened and part
is removed. Low mould cost, large hollow parts in one piece can be produced,
and moulded parts are essentially isotropic in nature.

Limitations:

Limited to hollow parts; production rates are usually slow.

ROTATIONAL MOULDING
THERMOFORMING

Description :
Heat-softened thermoplastic sheet is positioned over male or female mould; air
is evacuted between sheet and mould, forcing sheet to conform to contour of
mould. Variations are vacuum snapback, plug assist, drape forming, etc. Tooling
costs are generally low, large part production with thin sections possible, and
often comes out economical for limited part production.

Limitations:

Limited to parts of simple configuration, high scrap, and limited number of

materials from which to choose.
THERMOFORMI
NG
CASTING

Description :
Liquid plastic which is generally thermoset except for acrylics is poured into a
mould without pressure, cured, and taken from the mould. Cast thermoplastic
films are produced via building up the material (either in solution or hot-melt
form) against a highly polished supporting surface. Low mould cost, capability
to form large parts with thick cross sections, good surface finish, and convenient
for low-volume production.

Limitations:

Limited to relatively simple shapes. Most thermoplastics are not suitable for this
method. Except for cast films, method becomes uneconomical at high volume
production rates.
CENTRIFUGAL CASTING:
Description :
Reinforcement is placed in mould and is rotated. Resin distributed through pipe;
impregnates reinforcement through centrifugal action. Utilized for round objects,
particularly pipe.

Limitations:
Limited to simple curvatures in single axis rotation. Low production rates.

COATING
Description :
Process methods vary. Both thermoplastics and thermosets widely used in
coating of numerous materials. Roller coating similar to calendaring process.
Spread coating employs blade in front of roller to position resin on material.
Coatings also applied via brushings, spraying, and dipping.
Limitations:
Economics generally depends on close tolerance control.
FILAMENT WINDING :
Description :

Excellent strength-to-weight. Continuous, reinforced filaments, usually glass, in

the form of roving are saturated with resin and machine-wound onto mandrels
having shape of desired finished part. Once winding completed, part and
mandrel are cured; mandrel can then be removed through porthole at end of
wound part. High-strength reinforcements can be oriented precisely in direction
where strength is required. Good uniformity of resin distribution in finished part;
mainly circular objects such as pressure vessels, pipes, and rocket cases.

Limitations:

Limited to shapes of positive curvature; openings and holes can reduce strength
if not properly designed into moulding operations.
LAMINATING :

Description :

Material, usually in form of reinforcing cloth, paper, foil, metal, wood, glass
fibre, Plastic etc., preimpregnated or coated with thermoset resin (sometimes a
thermoplastic) is moulded under pressure greater than 1000psi (7Mpa) into
sheet, rod, tube, or other simple shapes. Excellent dimensional stability of
finished product; very economical in large production of parts.

Limitations:

High tool and die costs. Limited to simple shapes and cross sections.
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