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Industrial Automation on Manufacturing of Plastic Products

Technical Report · August 2023

DOI: 10.13140/RG.2.2.15007.53924

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Industrial Automation on Manufacturing of Plastic
Products
Aakar saini**, Aditya Chaudhary**, Abhiyant Singh**, Deepak Kumar**
*
Department of Electrical Engineering
**
Gurukula Kangri (Deemed to be University), Haridwar”
DOI: DOI[Numbret]
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Abstract- In the modern world, industrial automation has
revolutionized the manufacturing sector by reducing the need for
manual labor, increasing efficiency, and improving quality. The
manufacturing of plastic products is no exception, as automation
has played a significant role in increasing production rates,
reducing costs, and improving the overall quality of the products.
This paper aims to provide an in-depth analysis of the use of
industrial automation in the manufacturing of plastic products.
The paper begins by discussing the history and development of
industrial automation, followed by an overview of the plastic
manufacturing industry. The paper then goes on to describe the
different types of industrial automation technologies used in the
plastic manufacturing industry, such as robots, programmable
logic controllers, and sensors. Furthermore, the paper discusses
the advantages and disadvantages of using industrial automation
in the plastic manufacturing industry. Finally, the paper
concludes with future perspectives on the role of industrial
automation in the manufacturing of plastic products.
INTRODUCTION
The manufacturing of plastic products is an essential industry
that produces a wide range of products, including packaging
materials, toys, automotive parts, and medical devices. However,
the manufacturing process of plastic products is complex,
time-consuming, and labor-intensive. Traditionally, the
manufacturing process involved manual labor, which was prone
to errors, inconsistent quality, and safety risks. In recent years,
industrial automation has emerged as a game-changer in the
manufacturing sector, and the plastic industry is no exception.
Industrial automation has transformed the manufacturing of
plastic products by reducing the need for manual labor,
improving product quality, and increasing production rates.
Industrial automation has revolutionized the manufacturing
sector by reducing the need for manual labor, increasing
efficiency, and improving quality. The manufacturing of plastic
products is no exception, as automation has played a significant
role in increasing production rates, reducing costs, and
improving the overall quality of the products. The use of
industrial automation in the manufacturing of plastic products
has transformed the traditional manufacturing process by
automating repetitive tasks, reducing the need for manual labor,
and improving the consistency and accuracy of the
manufacturing process. In this paper, we will provide an in-depth
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analysis of the use of industrial automation in the manufacturing
of plastic products. The paper will discuss the history and
development of industrial automation, an overview of the plastic
manufacturing industry, the different types of industrial
automation technologies used in the plastic manufacturing
industry, the advantages and disadvantages of using industrial
automation in the plastic manufacturing industry, and future
perspectives on the role of industrial automation in the
manufacturing of plastic products. Overall, this paper aims to
provide an informative and comprehensive analysis of the use of
industrial automation in the manufacturing of plastic products,
highlighting the benefits and challenges of this technology in this
industry.
I. HISTORY AND DEVELOPMENT OF INDUSTRIAL AUTOMATION
The history of industrial automation can be traced back to the
early 20th century, when the first mechanical systems were
developed to replace manual labor. The first programmable
automation system, the Numerical Control (NC) machine, was
developed in the 1940s. The NC machine used a set of
instructions to control the movement of machine tools, allowing
for the production of complex shapes and parts. In the 1950s and
1960s, the first computer numerical control (CNC) machines
were developed, which used computer programs to control the
movement of machine tools.
Over the years, industrial automation has evolved significantly,
with the development of more sophisticated technologies such as
programmable logic controllers (PLCs), robots, and sensors. The
modern industrial automation system uses a combination of
hardware and software to control and monitor the production
process. The use of industrial automation has resulted in
improved efficiency, reduced production costs, and increased
product quality.
Fig 1.1
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According to a report by MarketsandMarkets Shown in fig 1.1,
the global industrial automation market size was valued at USD
153.83 billion in 2020 and is projected to reach USD 269.5
billion by 2025, at a CAGR of 10.7% from 2020 to 2025. The
report cites several factors contributing to the growth of the
industrial automation market, including the increasing need for
cost-effective and energy-efficient automation solutions, growing
demand for mass production, and advancements in Industry 4.0
technologies such as the Internet of Things (IoT), artificial
intelligence (AI), and machine learning.
II. OVERVIEW OF THE PLASTIC MANUFACTURING INDUSTRY
Fig 2.1
As Shown in the Fig 2.1 , The plastic manufacturing industry is a
critical sector of the economy that produces a wide range of
products, including packaging materials, toys, automotive parts,
and medical devices. The plastic manufacturing process involves
a series of complex and interconnected steps, including material
handling, compounding, molding, and finishing. Each step of the
manufacturing process requires precision, consistency, and
accuracy to produce high-quality plastic products.
The plastic manufacturing industry is a significant contributor to
the global economy. It involves the production of various plastic
products used in various applications, including packaging,
automotive, construction, and consumer goods. According to a
report by Research and Markets, the global plastic manufacturing
industry's market size was valued at USD 522.66 billion in 2020
and is projected to reach USD 685.35 billion by 2028, growing
at a CAGR of 3.4% during the forecast period.
However, the plastic manufacturing industry faces several
challenges, including environmental concerns, stringent
regulations on plastic product usage and disposal, and the
increasing competition from substitutes such as biodegradable
plastics. To address these challenges, industry players are
focusing on innovation and adopting sustainable manufacturing
practices.
The industry's growth is attributed to several factors, including
increasing demand for lightweight and durable plastic products,
rising adoption of plastic products in various end-use industries,
and technological advancements in plastic manufacturing
processes. Additionally, the industry's growth is driven by the
availability of raw materials at lower costs, expanding
distribution networks, and favorable government policies. Light
Weight Material Market Data avaliable on fig 2.2 source:
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precedenceresearch..
Fig 2.2 Source: Precedenceresearch
III. TYPES OF INDUSTRIAL AUTOMATION TECHNOLOGIES USED
IN THE PLASTIC MANUFACTURING INDUSTRY
The plastic manufacturing industry has been utilizing various
types of industrial automation technologies to improve
productivity, reduce costs, and enhance product quality. The
following are the most commonly used types of industrial
automation technologies in the plastic manufacturing
industry:The plastic manufacturing industry has been utilizing
various types of industrial automation technologies to improve
productivity, reduce costs, and enhance product quality. The
following are the most commonly used types of industrial
automation technologies in the plastic manufacturing industry:
1. Robotics and automation systems: The use of robotics
in the plastic manufacturing industry has been on the
rise in recent years. Robots are used for a variety of
tasks, including material handling, assembly, packaging,
and quality control. Industrial robots can work
continuously and accurately, which results in increased
efficiency, reduced downtime, and improved product
quality.
2. Programmable Logic Controllers (PLCs): PLCs are
computer-based control systems that can automate the
operation of manufacturing processes. They are used to
control various manufacturing processes such as
mixing, molding, and extrusion. PLCs are flexible and
can be easily programmed to adapt to changes in the
manufacturing process.
3. Computer Numerical Control (CNC) Machines:
CNC machines are automated machine tools that use
computer programs to control the movement of the
cutting tools. They are widely used in the plastic
manufacturing industry to produce high-quality plastic
parts with high precision and accuracy. CNC machines
can produce complex parts that would be difficult or
impossible to produce manually.
4. Automated Guided Vehicles (AGVs): AGVs are
automated vehicles that are used to transport materials
and products between different locations in the
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manufacturing plant. They are equipped with sensors
that allow them to navigate through the manufacturing
plant without human intervention. AGVs can help to
reduce the need for manual labor, increase efficiency,
and improve safety.
5. Vision Systems: Vision systems use cameras and image
processing software to inspect and monitor the
manufacturing process. They can be used to detect
defects, measure dimensions, and ensure the quality of
the finished product. Vision systems can improve
product quality, reduce waste, and increase efficiency.
IV. MONITOR PLASTIC MANUFACTURING USING PLC AND SCADA
Monitoring plastic manufacturing using PLC and SCADA
involves the use of advanced control and monitoring
technologies to optimize the production process. PLC
(Programmable Logic Controller) is a digital computer that is
used to control industrial processes, such as manufacturing lines,
robotic devices, and other automated systems. It can be
programmed to execute various functions, including reading and
interpreting data from sensors, executing logic commands, and
controlling actuators. PLCs are often used to automate repetitive
industrial processes in manufacturing plants, such as assembly
lines, packaging lines, and conveyor systems. They are designed
to operate in harsh industrial environments and are programmed
using ladder logic or other specialized programming languages.
Fig 4.1 Source: Dpstele
SCADA (Supervisory Control and Data Acquisition) is a
software system that is used to control and monitor industrial
processes. It can be used to manage and control PLC systems” as
the structure shown in Fig 4.1 Source: Dpstele”, allowing
operators to view and control industrial processes in real-time.
SCADA systems can also be used to collect and analyze data
from different sensors, providing insights into the manufacturing
process and identifying areas for improvement.
In the plastic manufacturing industry, PLC and SCADA systems
can be used to monitor and control the production process,
ensuring that the manufacturing process runs smoothly,
efficiently, and effectively. This can include monitoring the
temperature of injection molding machines, managing the flow
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of raw materials, tracking the quality of finished products, and
controlling robotic arms and other automated systems.
By using PLC and SCADA systems, plastic manufacturing
companies can improve their production processes, increase
efficiency, reduce downtime, and improve product quality. It also
enables them to quickly identify and respond to any issues or
problems that arise during the manufacturing process, reducing
waste and improving profitability.
Monitoring plastic manufacturing using PLC and SCADA is an
effective way to optimize the production process, improve
efficiency and quality, and maintain a competitive edge in the
plastic manufacturing industry.
Fig 4.2 Source: Tcagurgaon
When it comes to monitoring plastic manufacturing using PLC
and SCADA, the PLCs are used to control the manufacturing
processes as Shown in Fig 4.2 Source: Tcagurgaon, such as
extrusion, injection molding, and blow molding. The PLCs
receives inputs from sensors and other input devices, and use this
information to control the output devices, such as motors, valves,
and actuators. The SCADA system is used to monitor the
processes, collect data from the sensors, and provide operators
with real-time information about the processes. The SCADA
system can also be used to adjust the manufacturing processes as
needed, based on the data collected from the sensors.
V. ADVANTAGES AND DISADVANTAGES OF USING INDUSTRIAL
AUTOMATION IN THE PLASTIC MANUFACTURING INDUSTRY
The use of industrial automation in the plastic manufacturing
industry offers several advantages, including:
1. Increased Efficiency: Automated processes can operate
24/7, which improves overall efficiency and
productivity.
2. Improved Quality: Automation eliminates the potential
for human error, which improves the quality of the end
product.
3. Cost Savings: Automation reduces labor costs and
waste, which leads to significant cost savings in the
long run.
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4. Flexibility: Automated systems can be programmed to
perform a variety of tasks, which allows for greater
flexibility in the manufacturing process.
5. Enhanced Safety: Automated systems can handle
dangerous tasks, such as working with hazardous
materials, which reduces the risk of accidents.
Disadvantages of Using Industrial Automation in the Plastic
Manufacturing Industry:
1. Initial Cost: Implementing automated systems can be
expensive, and may require significant capital
investment.
2. Maintenance: Automated systems require regular
maintenance to ensure they operate correctly, which can
add additional costs.
3. Dependence on Technology: Relying heavily on
automation can leave a company vulnerable to
technological malfunctions and downtime.
4. Lack of Human Interaction: Automation can
eliminate jobs and reduce human interaction in the
manufacturing process, which can lead to potential
social and economic consequences.
5. Skill Requirements: Implementing automation systems
requires skilled technicians and engineers, which can be
difficult to find and expensive to hire.
VI. APPLICATIONS OF INDUSTRIAL AUTOMATION IN THE
PLASTIC MANUFACTURING INDUSTRY
Industrial automation has a wide range of applications in the
plastic manufacturing industry. Some of the key applications
include:
1. Injection Molding: Injection molding is a popular
method of manufacturing plastic products. Industrial
automation can be used to automate the injection
molding process, which can increase efficiency and
reduce the number of errors.
2. Blow Molding: Blow molding is another popular
method of manufacturing plastic products. Industrial
automation can be used to automate the blow molding
process, which can increase efficiency and reduce the
number of errors.
3. Extrusion: Extrusion is a method of manufacturing
plastic products by pushing the plastic through a die.
Industrial automation can be used to automate the
extrusion process, which can increase efficiency and
reduce the number of errors.
4. Quality Control: Industrial automation can be used to
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automate the quality control process in the plastic
manufacturing industry. This can help ensure that the
products meet the required standards and specifications.
5. Material Handling: Industrial automation can be used
to automate the material handling process in the plastic
manufacturing industry. This can help reduce the
number of errors and increase efficiency.
6. Packaging: Industrial automation can be used to
automate the packaging process in the plastic
manufacturing industry. This can help increase
efficiency and reduce the number of errors.
7. Thermoforming: Thermoforming is the process of
heating a plastic sheet and shaping it into a desired
form. Industrial automation can be used to control the
heating and shaping process, leading to a more efficient
and precise process.
8. Assembly: Industrial automation can be used to
assemble plastic products, reducing the need for manual
labor and increasing production rates.
The applications of industrial automation in the plastic
manufacturing industry can help increase efficiency, reduce the
number of errors, and improve the quality of the products.
VII. CASE STUDIES OF SUCCESSFUL IMPLEMENTATIONS OF
INDUSTRIAL AUTOMATION IN THE PLASTIC
MANUFACTURING INDUSTRY
1. Bosch Rexroth: Bosch Rexroth implemented an
automation solution in the production of plastic bags.
The solution included an intelligent conveyor system
that sorted the bags based on their size and weight. This
solution helped Bosch Rexroth to increase its
production efficiency and reduce its operating costs.
2. Braskem: Braskem, a Brazilian petrochemical
company, implemented an automation solution in the
production of plastic resins. The solution included a
control system that monitored and optimized the
production process. This solution helped Braskem to
increase its production capacity and reduce its energy
consumption. Samsung Engineering:
3. Samsung Engineering: a South Korean engineering
company, implemented an automation solution in the
production of plastic pipes. The solution included a
robotic system that automated the welding process. This
solution helped Samsung Engineering to improve the
quality of its products and reduce its production costs.
4. Tupperware: Tupperware, a global manufacturer of
plastic containers, implemented an automation solution
in the production of its products. The solution included
a molding machine that produced the containers
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automatically. This solution helped Tupperware to
increase its production capacity and reduce its labor
costs.
All of these case studies demonstrate the successful
implementation of industrial automation in the plastic
manufacturing industry, resulting in increased efficiency,
productivity, and cost savings.
VIII. CHALLENGES AND FUTURE TRENDS IN THE USE OF
INDUSTRIAL AUTOMATION IN THE PLASTIC
MANUFACTURING INDUSTRY
Challenges: Despite its many benefits, the implementation of
industrial automation in the plastic manufacturing industry
comes with its own set of challenges. Some of the key challenges
include:
1. High initial investment: Industrial automation requires
significant capital investment upfront, which can be a
barrier for small and medium-sized businesses. The cost
of equipment, software, and implementation can be
substantial and may take several years to recoup.
2. Need for skilled workers: Industrial automation
requires specialized skills and knowledge to design,
install, and maintain the systems. Finding and training
the right personnel can be a challenge, especially in
areas with limited access to skilled labor.
3. Integration with legacy systems: Many manufacturing
plants have legacy systems in place, which may not be
compatible with new automation technologies.
Retrofitting or replacing these systems can be costly and
time-consuming.
4. Cybersecurity risks: Industrial automation systems are
vulnerable to cyber attacks, which can have serious
consequences for both the plant and the environment. It
is essential to implement robust cybersecurity measures
to protect these systems.
Future Trends: Despite the challenges, the use of industrial
automation in the plastic manufacturing industry is expected to
continue to grow in the coming years. Some of the key trends to
watch include:
1. Increased use of collaborative robots: Collaborative
robots, or cobots, are designed to work alongside human
workers, rather than replace them. These robots can be
programmed to perform repetitive or dangerous tasks,
freeing up workers to focus on more complex jobs.
2. Adoption of artificial intelligence and machine
learning: AI and machine learning technologies are
being used to improve the efficiency and productivity of
manufacturing processes. These technologies can be
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used to optimize production schedules, predict
maintenance needs, and reduce waste.
3. Expansion of the Internet of Things (IoT): The IoT
allows for real-time monitoring and control of
manufacturing equipment, providing valuable data on
production processes. This data can be used to identify
inefficiencies and make improvements to the
manufacturing process.
4. Focus on sustainability: There is an increasing focus on
sustainability in the manufacturing industry, and
industrial automation can play a key role in reducing
waste and improving energy efficiency. Automated
systems can be designed to minimize material waste and
optimize energy usage.
the use of industrial automation in the plastic manufacturing
industry has significant advantages, including increased
efficiency, improved quality, and reduced labor costs. However,
there are also challenges to consider, including high initial costs
and the need for skilled workers. Looking ahead, emerging
technologies like collaborative robots, AI, and IoT are expected
to play an increasingly important role in the industry, while
sustainability will continue to be a key focus.
IX. CONCLUSION
In conclusion, industrial automation has become a game-changer
in the plastic manufacturing industry. It has brought significant
advantages such as improved efficiency, increased production
capacity, and reduced labor costs. Automation technologies such
as robotics, sensors, and IoT have made it possible to achieve
higher levels of precision and accuracy in manufacturing
processes. Case studies of successful implementations of
industrial automation in the plastic manufacturing industry have
shown how automation can revolutionize the industry.
However, there are also challenges that come with implementing
industrial automation, such as the high cost of initial investment,
the need for skilled workers to operate and maintain the systems,
and the potential for job displacement. Future trends in the use of
industrial automation in the plastic manufacturing industry
include the use of artificial intelligence, machine learning, and
advanced robotics.
In light of these findings, it is recommended that the plastic
manufacturing industry consider implementing industrial
automation to remain competitive in the market. Further research
is needed to explore the full potential of automation technologies
and to address the challenges associated with their
implementation.
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ACKNOWLEDGMENT
We would like to express our sincere gratitude to all those who
have contributed to the completion of this paper. Firstly, we
would like to thank our supervisor for providing us with
guidance and support throughout the research process. We would
also like to thank the participants of the case studies for their
cooperation and willingness to share their experiences.
Additionally, we would like to extend our appreciation
to the staff of the plastic manufacturing companies who have
generously provided us with information and insights on the use
of industrial automation in their operations.
Finally, we would like to thank our families and friends
for their unwavering support and encouragement throughout this
journey. Their support has been invaluable in keeping us
motivated to produce a high-quality paper.
[10] Kumar, A., & Srivastava, A. (2018). Automation in manufacturing industry:
Review and recommendations. Materials Today: Proceedings, 5(2),
4705-4712.
[11] Gao, R. X., Cao, Y. J., & Helander, M. G. (2014). Handbook of
manufacturing engineering and technology. Springer.
AUTHORS
Aakar saini
Department of Electrical Engineering
Gurukula Kangri (Deemed to be University), Haridwar.
Aditya Chaudhary
Department of Electrical Engineering
Gurukula Kangri (Deemed to be University), Haridwar.

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