COLLEGE OF ENGINEERING

ROORKEE

SESSION: 2O23-2024
SUMMER TRAINING
AT
Prince Pipes and Fittings, Haridwar

TRAINING DURATION: 12.07.2023- 04.08.2023

SUBMITTED BY-:
Name- Ritik Chauhan
Course - BTECH(ME)
4rd Year (7th Sem)
 ACKNOWLEDGEMENT

“Inspiration and motivation have always played a key role in the success of any
venture.”

Success in such comprehensive report cannot be achieved single handed. it is

the team effort that sail the ship to the coast. So, I would like to express my
sincere thanks to my mentor MR. Avneesh chauhan Sir.

I am also grateful to the management of PRINCE PIPES AND FITTINGS LTD. for
permitting me to have training during the time frame.
It gives me immense pleasure to express my gratitude to the department of
Mechanical Engineering for their prudent response in course of completing my
training report. I am highly indebted to Dr. Nitish Dutt (HOD) Sir, their guidance
and whole hearted inspiration. It has been a greatest help in bringing out the
work in the present shape. The direction, advice, discussion and constant
encouragement given by them has been so helpful in completing the
work successfully.
Content: -
 Introduction
o PPH1
o PPH2
o PPH3
o PPH4
 Molding
o Injection molding
 Key Components
 Advantages
 Disadvantages
o Products
 Extrusion Process
o Key Steps
o Advantages
o Disadvantages
 CNC Machining
o CNC Lathes and Turning Machines
o CNC Electric Discharge Machines

 Recycling Process
o Grinding Process

 Maintenance
o Preventive Maintenance
o Autonomous Maintenance

 Conclusion
 INTRODUCTION
Prince Pipes and Fittings Ltd. Located in the industrial area of Haridwar known
as SIDCUL is one of the leading suppliers, manufacturer of Pipes and Fittings.
This industry manufacture around 3500 products and well known for its world
class quality and performance. Prince Pipes supplies to industries and have a
great grip in the market as well.

Different blocks in the plant: -

1. PPH-1

This section comprises various injection moulding machines of horizontal

types. The raw materials used in this section are UPVC, CPVC, PPR etc.
Some of the products which are manufactures here are fittings like elbow,
union, tee etc.

2. PPH-2:
This section is totally for the extrusion process of material like PPR and
HDPE. This section uses only the high-density material to make pipes
which have good thermal properties like low thermal conductivity which
helps in areas with critical temperatures and in Thermal Power Plants.

3. PPH-3
This section is also for the Injection Molding but the material used here is
of only one type that is SWR or UPVC this section manufactures fittings for
industrial and agriculture use only.

4. PPH 4: -
This section is much similar like the PPH2 but the materials used here are
different. Materials used here are CPVC and UPVC. In this section pipes are
manufacture on a large scale.
 Molding

Injection molding
Injection molding is a manufacturing process widely used for producing parts
and products in large volumes, especially from thermoplastic and thermosetting
polymers. The process involves injecting molten material into a mold cavity,
where it solidifies and takes the shape of the Mold. It is a versatile and highly
efficient method that can produce complex and detailed parts with high
precision. Here is a step-by-step overview of the injection molding process.
1. Material Selection:
 Thermoplastics, thermosetting polymers, and elastomers are common
materials used in injection molding. The material is chosen based on the
desired properties of the final product.
2. Melting:
 The selected material is heated to a high temperature until it becomes
molten and can flow easily.
3. Injection:
 The molten material is injected into a mold cavity at high pressure. The
mold is typically made of two halves: the cavity (which defines the outer
shape of the part) and the core (which shapes the inner features of the
part).
4. Cooling:
 The molten material is allowed to cool and solidify within the mold,
taking the shape of the cavity.
5. Mold Opening:
 Once the material has solidified, the mold opens, revealing the finished
product.
6. Ejection:
 The moulded part is ejected from the mold, and the process is ready
to start again.
Key Components of the Injection Molding Process:
 Injection Molding Machine:
 The machine is responsible for melting and injecting the material into
the mold.
 Mold:
 The mold is a custom-designed tool that shapes the material into the
desired form. It consists of two halves: the cavity and the core.
 Clamping Unit:
 This unit holds the mold in place during injection and cooling.
 Cooling System:
 Cooling channels help control the temperature of the mold and the
material during the process.
 Injection Unit:
 The injection unit is responsible for melting and injecting the
material into the mold.
 Control System:
 Modern injection molding machines are equipped with sophisticated
control systems to regulate and monitor the various parameters of
the process.

Advantages of Injection Molding:

1. High Efficiency:
 Fast production rates, especially for large quantities.
 High precision and repeatability.
2. Complex Geometry:
 Can produce intricate and complex shapes with tight tolerances.
 3. Material Variety:
 Works with a wide range of materials, including various plastics and
some metals.
4. Low Scrap Rates:
 Minimal material waste compared to other manufacturing processes.
5. Automation:
 Suitable for automation, reducing labour costs.
6. Surface Finish:
 Can achieve smooth and polished finishes on moulded parts.
7. Cost-Effective for Mass Production:
 Economical for large production runs.

Disadvantages of Injection Molding:

1. High Initial Tooling Cost:

 The cost of designing and creating Molds can be expensive, making it
less practical for small production runs.
2. Lead Time:
 Developing Molds can take time, leading to longer lead times for
production.
3. Material Limitations:
 Limited to materials that can be melted and injected, excluding
materials with high melting points or certain additives.
4. Design Constraints:
 Design changes can be costly once the mold is created.
5. Environmental Impact:
  Some materials used in injection molding are not easily recyclable,
contributing to environmental concerns.
6. Not Suitable for Low-Volume Production:
 Economically viable for large production runs but less so for small
quantities.
7. Part Size Limitations:
 Limited to relatively small to medium-sized parts compared to other
manufacturing methods.
.
SOME OF THE PRODUCTS ARE-:
1) PLUMBING & INDUSTRIAL
o Smartfit (CPVC Plumbing Systems)
o Easyfit (UPVC Plumbing Systems)
o Greenfit (PP-R Plumbing Systems)
o Blue Greenfit (PP-R Industrial Piping Systems)

2) SWR
o Silentfit (Low Noise SWR Piping Systems)
o Ultrafit (SWR Systems with World-class Seals)
o Rainfit (Roof water Systems)

3) UNDERGROUND
o Foamfit (Underground Drainage Piping Systems)
o Drainfit (UPVC Underground Drainage Piping Systems)
o Corfit (Underground Double Wall Corrugated Pipes & Fittings)
o Durafit (Manhole & Chamber Covers)

4) AGRI
 Aquafit (Agri-pressure & Non-pressure Pipes & Fittings)
 Safefit (Borewell Systems)
 Extrusion Process
Extrusion is a manufacturing process used to create objects with a fixed cross-
sectional profile. The process involves forcing material, often a plastic or metal,
through a shaped opening in a die. Extrusion is commonly used to produce a
wide range of products with consistent cross-sections, such as pipes, tubing, and
various profiles.

Extrusion Process Steps:

 Material Preparation:
o The raw material, typically in the form of pellets, granules, or
powder, is fed into a hopper.

 Melting and Heating:

o The material is melted and heated to a suitable temperature in an
extruder. The extruder is a machine that consists of a rotating screw
within a barrel. The screw compresses and melts the material as it
moves along the barrel.

 Formation of a Continuous Profile:

o The molten material is forced through a shaped opening in a die. This
die gives the extruded material its desired cross-sectional shape. The
material emerges from the die as a continuous profile.

 Cooling:
o The extruded material is cooled using air or water to solidify its
shape. Cooling is crucial for maintaining the desired dimensions and
properties of the extruded product. It uses multiple cooling
chambers to cool it down. In case pf PPR and HDPE it uses more
cooling chambers because of the low thermal conductivity.

 Cutting and Finishing:

 o The extruded product is cut to the desired length. Additional
finishing processes, such as surface treatments or coatings, may be
applied depending on the specific requirements.

Advantages of Extrusion:

1. High Efficiency:
 Continuous or semi-continuous production allows for high efficiency

and lower production costs.

2. Consistent Cross-Section:
 Extrusion produces products with consistent cross-sectional profiles

and dimensions.

3. Versatility:
 Suitable for a wide range of materials, including plastics, metals, and

rubber.

4. Complex Shapes:
 Can produce complex shapes with the use of intricate dies.

5. Minimal Waste:
 Generates less waste compared to other manufacturing processes.

Disadvantages of Extrusion:
1. Initial Tooling Costs:
 Designing and manufacturing the extrusion die can be expensive,
especially for complex profiles. This cost can be a significant factor,
particularly for small production runs.
2. Limited Material Range:
  Extrusion is most used with materials that can be softened or
melted, such as plastics, metals, and rubber. Some materials,
especially those with high melting points or unique properties, may
not be suitable for the extrusion process.

3. Limited Thickness Control:

Achieving precise control over the thickness of certain sections in an
extruded profile can be challenging. This limitation may affect the
dimensional accuracy of the final product.
4. Surface Finish Issues:
 Extruded products may have a characteristic surface finish that might
require additional finishing processes to meet specific quality
requirements. High-quality surface finishes may be challenging to
achieve directly from the extrusion process.
5. Weld Lines:
 Weld lines or knit lines can occur in the extruded product, especially
in complex shapes. These lines are areas where the flow of material
rejoins after passing through different channels in the die, potentially
leading to weaker points in the structure.
 CNC Machining

Computer Numerical Control machines are automated machines, which are

operated by computers executing pre-programmed sequences of controlled
commands. CNC machines are essentially the opposite of “old-school” devices
that are manually controlled by hand wheels or levers, or mechanically
automated by cams alone. Today’s modern CNC machines understand and
function using CNC machining language – called G-code – which tells them
precise measurements for production, like feed rate, speed, location, and
coordination.
Today’s design and mechanical parts for CNC systems are highly automated –
unlike the old, dangerous, factory machines you’d think of back in the day. The
parts’ mechanical dimensions are defined using computer-aided design (CAD)
software, and then translated into manufacturing directives by computer-aided
manufacturing (CAM) software. Therefore, it is important to have
knowledgeable CNC machinists and programmers in the industry to operate this
high-tech machinery.

CNC Lathes and Turning Machines

Operated with Computer Numerical Control (CNC) systems and provided with
precise design instructions, CNC Lathes are machine tools where the material or
part is clamped and rotated by the main spindle, while the cutting tool that
work on the material, is mounted and moved in various axis.
CNC Lathes are normally used for machining parts, where the material / part is
clamped and rotated whereas the cutting tool is stationery mounted for OD
(Outer Diameter) and ID (Inner Diameter) operations, e.g. shafts and pipes. They
are ideal for parts that have same symmetry around an axis that could be
chucked up (i.e. radially clamped) in the spindle.
A simple CNC Lathe operates on 2-axis and the tool is located in a fixed position
at 8 to 24 station turret. The rotating action of the part is called “turning”,
hence certain types of CNC Lathes are called CNC Turning Machines.
Milling (cutting tool moves around stationery workpiece), boring and tapping (a
tool that cuts threads inside hole) tools are normally driven by a separate drive
system inside the turret. Depending on the application, the life tools (i.e. active
tool) are mounted for axial or radial operational directions. These could be
found in 3-axis CNC Lathes or CNC Turning Machines.

Lathe machines with additional options such as Y-axis, sub-spindles, or specific

selected options for automation are commonly called Turning Centres. These
sophisticated machine tools are capable of machining complex parts – these go
beyond standard OD & ID turning operations and may incorporate milling,
drilling and tapping operations to complete the part in one setting. Taking a
piece from raw part to finished product, such all-in-one machine tools
significantly improves productivity. Operated with Computer Numerical Control
(CNC) systems and provided with precise design instructions, CNC Lathes are
machine tools where the material or part is clamped and rotated by the main
spindle, while the cutting tool that work on the material, is mounted and moved
in various axis.

CNC Lathes are normally used for machining parts, where the material / part is
clamped and rotated whereas the cutting tool is stationery mounted for OD
(Outer Diameter) and ID (Inner Diameter) operations, e.g. shafts and pipes. They
are ideal for parts that have same symmetry around an axis that could be
chucked up (i.e. radially clamped) in the spindle. A simple CNC Lathe operates
on 2-axis and the tool is located in a fixed position at 8 to 24 station turret. The
rotating action of the part is called “turning”, hence certain types of CNC Lathes
are called CNC Turning Machines.

Milling (cutting tool moves around stationery workpiece), boring and tapping (a
tool that cuts threads inside hole) tools are normally driven by a separate drive
system inside the turret. Depending on the application, the life tools (i.e. active
tool) are mounted for axial or radial operational directions. These could be
found in 3-axis CNC Lathes or CNC Turning Machines.
Lathe machines with additional options such as Y-axis, sub-spindles, or specific
selected options for automation are commonly called Turning Centres. These
sophisticated machine tools are capable of machining complex parts – these go
beyond standard OD & ID turning operations and may incorporate milling,
drilling and tapping operations to complete the part in one setting. Taking a
piece from raw part to finished product, such all-in-one machine tools
significantly improves productivity.
CNC Electrical Discharge Machines (EDM)
EDM machining is a contemporary machining method based on the removal of
material from a part using thermal energy. The material is removed by local
melting or vaporizing small areas on the surface of the part being machined.
This is done by a series of repeated electrical sparks between tools that are
called electrodes and the work piece in the presence of a dielectric fluid.
Electrical discharge machining is also known by several names, which are: spark
eroding, spark machining, burning, wire burning, die sinking, or wire erosion.
Working Principle of Electrical Discharge Machining
 It consists of an electric power supply, the dielectric medium, the tool,
workpiece, and servo control.
 The workpiece is connected to the positive terminal and the tool is
connected to a negative terminal of the DC power supply.
 An air gap of 0.005 to 0.05 mm is maintained between the tool and the
work.
 The die electric fluid which is non-conductor of electricity is forced under
pressure through the gap.
 When a DC power is supplied, the fluid in the gap gets ionized and
produces a spark between the tool and workpiece, causing a local rise in
temperature at about 1000 degrees Celsius, when melts the metal in a
small area of the workpiece and vaporizes.
 The DC supply generates a pulse between 40 to 3000 V and the frequency
of spark at the rate of 10000 sparks per second can be achieved.
 The electric and magnetic fields on heated metal cause a compressive
force which removes the metal from the work surface.
 The die electric fluid acts as a coolant carry the cooled metal from the
work surface.
 The die electric fluid acts as a coolant carries the eroded metal particles
which are filtered regularly and supplied back to the tank.
 A servomechanism is used to feed the tool continues to maintain a
constant gap between two electrodes.
 The accuracy of about 0.005 mm can be achieved in this process.
Applications of Electro Discharge Machining
 Drilling for micro holes in the nozzle.
 This is used in thread cutting.
 Used in wire cutting.
 Rotary form cutting.
 Helical profile milling.
 Curved hole drilling.
 Engraving operation on harder materials.
 Cutting off operation.
 The shaping of alloy steel and tungsten carbide dies.
 Recycling Process

Grinding
In the piping industry, grinding processes are commonly employed as part of
recycling efforts, especially when dealing with materials like plastic pipes or
metal pipes. The goal of the grinding process is to reduce the size of waste
materials, making them easier to handle, transport, and recycle. Here is how the
grinding process is typically applied in the piping industry for recycling:
Grinding Process in Piping Industry for Recycling:
1. Material Preparation:
 Gather and collect used or waste pipes for recycling. These pipes
may be made of various materials, such as plastics (e.g., PVC, HDPE).
2. Sorting:
 Separate different types of pipes based on material composition.
Sorting is essential for effective recycling since different materials
require distinct processing methods.
3. Cleaning:
 Remove contaminants, such as dirt, labels, or adhesives, from the
collected pipes. Clean pipes ensure a more efficient grinding process
and improve the quality of the recycled material.
4. Grinding:
 The pipes are fed into grinding machines or shredders designed to
break them down into smaller pieces. The grinding process may
involve different types of equipment, including granulators, crushers,
or shredders.
5. Size Reduction:
 The grinding process reduces the size of the pipes into smaller, more
manageable particles. The size reduction facilitates downstream
processing and recycling.
 6. Separation:
 After grinding, separation processes may be employed to isolate
different materials or components. For example, in the case of mixed
materials, magnets can be used to separate ferrous metals.
7. Quality Control:
 The ground material may undergo quality control measures to
ensure that the particle size meets specifications for recycling and
processing. This step is crucial for maintaining the desired material
characteristics.
8. Pelletization or Compounding (Optional):
 In some cases, the ground material may be further processed
through pelletization or compounding. This involves melting and
reforming the material into pellets or other forms suitable for reuse
in the manufacturing of new pipes.
9. Reuse or Resale:
 The recycled material can be used for producing new pipes or sold to
manufacturers for various applications. Recycling reduces the need
for virgin raw materials and contributes to sustainability in the
industry.

Advantages of Grinding in Pipe Recycling:

1. Resource Conservation:
 Recycling pipes through grinding conserves natural resources by
reducing the demand for virgin materials.
2. Waste Reduction:
 Grinding reduces the volume of waste pipes, making them easier to
handle and transport.
3. Environmental Benefits:
 Recycling reduces the environmental impact associated with the
extraction and production of new materials.
 4. Cost Savings:
 Using recycled materials in pipe manufacturing can be cost-effective
compared to using virgin materials.
5. Energy Efficiency:
 Recycling processes, including grinding, are generally more energy-
efficient than producing materials from raw sources.
The grinding process in the piping industry plays a crucial role in sustainable
waste management, resource conservation, and the circular economy by
transforming used pipes into valuable recycled materials.
 Maintenance
Maintenance is crucial for ensuring the efficient and reliable operation of
injection molding machines. Proper maintenance helps prevent breakdowns,
reduces downtime, and extends the lifespan of equipment. Here are some key
aspects of maintenance in injection molding:
Regular Maintenance Tasks:
1. Check and Lubricate Moving Parts:
 Regularly inspect and lubricate all moving parts of the injection
molding machine. Lubrication helps reduce friction, wear, and
ensures smooth operation.
2. Inspect and Replace Filters:
 Check and replace filters in hydraulic systems, cooling systems, and
air vents to prevent contamination. Clean filters contribute to better
system performance.
3. Examine Hydraulic Systems:
 Monitor hydraulic fluid levels and condition. Regularly check for
leaks, and replace or top up hydraulic fluid as needed. Keep hydraulic
systems clean and free of contaminants.
4. Inspect Electrical Components:
 Examine electrical components, such as switches, relays, and
connectors, for signs of wear or damage. Tighten loose connections
and replace faulty components promptly.
5. Check and Calibrate Sensors:
 Verify the accuracy and functionality of sensors used in the injection
molding process. Calibrate sensors to ensure precise control over
temperature, pressure, and other critical parameters.
6. Clean and Inspect Barrel and Screw:
  Clean the barrel and screw regularly to remove any residue or
contaminants. Inspect for wear and tear, and replace parts as
necessary. This is crucial for maintaining product quality.
7. Inspect Nozzles and Hot Runners:
 Check and clean nozzles and hot runners to ensure proper material
flow. Inspect for any blockages or degradation.
8. Monitor Cooling Systems:
 Ensure that the cooling systems, including water lines and
temperature control units, are functioning correctly. Regularly clean
and flush cooling channels to prevent mold overheating.
9. Check Safety Features:
 Regularly test and check safety features, such as emergency stops,
guards, and interlocks, to ensure they function properly. Safety is a
critical aspect of injection molding machine operation.
10. Inspect Clamping Unit:
 Check the clamping unit for any signs of wear, misalignment, or
damage. Lubricate and adjust as necessary to maintain proper
alignment.
11. Review Control System:
 Regularly update and review the control system software. Check for
any error messages or abnormal behaviour. Keep backups of
essential settings.
Preventive Maintenance (PM):
Establishing a preventive maintenance schedule is crucial to staying on top of
maintenance tasks. This schedule should include daily, weekly, monthly, and
annual checks, depending on the machine's usage and manufacturer
recommendations.
Autonomous Maintenance (AM)
Autonomous Maintenance (AM) is a key concept in Total Productive
Maintenance (TPM), a systematic approach to equipment maintenance that
aims to maximize the effectiveness of manufacturing equipment. Autonomous
Maintenance involves operators taking responsibility for routine maintenance
tasks to prevent equipment deterioration and breakdowns

Conclusion
Gone through rigorous four weeks training under the guidance of capable
engineers and workers of Prince Pipes and Fittings Limited headed by
Production Head Mr. Ashok and Maintenance Engineer MR. Avneesh Chauhan. I
came to know about the Injection Molding, Extrusion Processes, Grinding, CNC
machining, Quality and Maintenance which were shown on heavy to medium
machines. The training brought to my knowledge the various machining and as
well as manufacturing.