INTERNSHIP REPORT on

INCAP LIMITED
Manufacturers of capacitors

An internship report submitted in partial fulfilment of the requirements for the

award of degree of
BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING
BY

K. VISHNU CHAITANYA SIDHARDHA

(22505A0211)

Under the esteemed guidance of

Dr. C. KUMAR
Associate Professor

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

PRASAD V. POTLURI SIDDHARTHA INSTITUTE OF TECHNOLOGY
Autonomous & Permanent Affiliation to JNTUK, Kakinada.
AICTE Approved, NBA & NAAC accredited and ISO 9001-2015 Certified Institution
KANURU, VIJAYAWADA - 520007

JUNE – 2023
 DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
PRASAD V. POTLURI SIDDHARTHA INSTITUTE OF TECHNOLOGY
Autonomous & Permanent Affiliation to JNTUK, Kakinada.
AICTE Approved, NBA & NAAC accredited and ISO 9001-2015 Certified Institution

KANURU, VIJAYAWADA - 520007

CERTIFICATE

This is to certify that the “Internship report on INCAP LIMITED” is submitted by

K.VISHNU CHAITANYA SIDHARDHA (Reg.no :22505A0211) in partial fulfilment of the
requirements for the award of BACHELOR OF TECHNOLOGY in ELECTRICAL AND
ELECTRONICS ENGINEERING, at PRASAD V. POTLURI SIDDHARTHA INSTITUTE
OF TECHNOLOGY, Vijayawada, affiliated to the Jawaharlal Nehru Technological University
(JNTUK), Kakinada. This is a record of bona-fide work carried out by him under our guidance
and supervision.

SUPERVISOR HEAD OF DEPARTMENT

Dr. C. KUMAR Dr. CH. PADMANABHA RAJU
ASSOCIATE PROFESSOR PROFESSOR & H.O.D
 ACKNOWLEDGEMENT

It is my sincere obligation to thank Mr. C. Bhagavantha Rao, managing director, INCAP

LIMITED, Vijayawada for their immeasurable beneficent help with timely suggestions,
insurmountable guidance and constant encouragement given throughout this internship and
philanthropic ideas which wrapped us in an inconceivable complaisance. We are very much
indebted for his valuable suggestions and inspiration he has proffered throughout the course of
my internship.
I wish to record my deep sense of gratitude and profound thanks to my supervisor, guide
Dr. C. Kumar, Associate Professor, Department of Electrical and Electronics Engineering,
PVPSIT for his keen interest, inspiring guidance, constant encouragement with my work during
all stages, to bring this report into fruition.
I am highly grateful and obliged for the most cooperative attitude of Dr. Ch. Padmanabha
Raju, Head of Electrical and Electronics Engineering Department in preparing our internship.

I am thankful to our beloved Principal Dr. K. SIVAJI BABU for his encouragement and the
facilities provided to us.

I am also thankful to all our staff members for their valuable support for the completion of
the Internship.

Finally, I express my thanks to the Personnel officer, Workers and Foremen of INCAP
LIMITED company for providing the required information and clarifying the doubts without
hesitation.

K. VISHNU CHAITANYA SIDHARDHA

(Reg. No: 22505A0211)

 ABSTRACT

This report gives the detailed information of the knowledge and skills that I gained during the
period of the Summer Internship at INCAP LIMITED, Gudavalli, Vijayawada.

I learned what is the actual and practical applications of capacitors in real life, either for the
household or industry usage.

I observed the key processes involved in manufacturing a capacitor from the start to the end. I have
keenly interpreted each and every step that is involved in the manufacturing process. I’ve also
noted the important practical relatable factors that are involved in each step.

I have also visited the power supply and panel rooms of the company to gain the knowledge on
the power supply used for the manufacturing process.

I have noticed the interlinking factors and management tactic that are been used in the company
which helps to improve the overall production and gain.

I have interacted with many of the employees, general managers to know the practical solutions
and the ways to solve any complex problems that occur.

The internship has given a better idea that how there are having an involvement of multi-
disciplinary professional work together to solve a complex problem and helped me to learn the
importance of teamwork. I was able to comprehend how various departments' work is done and
how it relates to the front end.

Finally, this internship has given the confidence and immense knowledge regarding the operation
and management of an industry that would definitely help me to become an industry ready person
with the required skillset.
 ANNEXURE

S. No Name of the topic Page no.

1. INTRODUCTION 1–4
1.1 Profile of the company 1
1.2 Plant and machinery 1
1.3 Product range 2
1.4 Capacitor 3
1.5 Weekly Activity log 4
2. PROCESS OF MANUFACTURING 5–7
2.1 About the Process 5
2.2 Process flow chart 5
2.3 Power supply 6
2.4 Route card 7
3. IMPORTED RAW MATERIAL 8–9
3.1 Paper and Foil 8
3.2 Lead Tabs 8
3.3 Silicon powder 8
3.4 Electrolyte 9
3.5 Rubber bungs and Cans 9
3.6 PVC sleeve 9
4. SLITTING 10 – 11
4.1 Process of slitting 10
4.2 Slit paper and foils 11
5. STITCHING AND WINDING 12 – 13
5.1 Process of stitching 12
5.2 Stitched foils 12
5.3 Process of winding 13
5.4 Wounded elements 13

6. BAKING AND IMPREGNATION 14 – 16

6.1 Process of baking 14
6.2 Process of Impregnation 15,16

7. ASSEMBLING 17 – 18
7.1 Process of assembling 17
7.2 Need for assembling 18
7.3 Assembled Capacitors 18
8. WASHING AND DRYING 19 – 20
8.1 Process of washing 19
8.2 Process of drying 20
8.3 Dried Capacitors 20
 9. SLEEVING 21
9.1 Process of sleeving 21
9.2 Sleeved capacitors 21
10. AGEING AND TESTING 22 – 24
10.1 Dig loading 22
10.2 Process of Ageing 22
10.3 Testing of Capacitors 23
10.4 Types of capacitors produced at INCAP LIMITED 24
11. QUALITY CHECKING 25 – 26
11.1 Process of quality checking and inspection 25
11.2 Storage 26
11.3 Shipment 26
12. INTERPRETATION AND CONCLUSION 27 – 29
12.1 Skills involved 27
12.2 Conclusion 28
12.3 Photos of Internship 29
13. REFERENCES 30

LIST OF FIGURES

Fig.No Name of the Figure Page no.

1.1 INCAP LIMITED 1
1.2 Parts of a Capacitor 3
2.1 Process Flow chart 5
2.2 11 K.V Sub-station 7
2.3 250 KVA Generator 7
2.4 Control Panels 7
2.5 Air Fresheners 7
2.6 Route Card 7
3.1 Paper 8
3.2 Aluminum foil 8
3.3 Lead Tabs 9
3.4 Aluminum Cans 9
3.5 Rubber bungs 9
3.6 P.V.C Sleeve 9
3.7 Polyvinyl Alcohol 9
4.1 Slitting Machine 10
 4.2 Slit Foil rolls 11
4.3 Slit Paper rolls 11
5.1 Stitching Machine 12
5.2 Stitching Process 12
5.3 Winding Machine 13
5.4 Wounded Element 13
6.1 Baking Oven 14
6.2 Impregnation Chambers 16
7.1 Assembling machine 17
7.2 Assembling components 17
7.3 Assembled capacitors 18
8.1 Washing Machine 19
8.2 Process of Drying 20
9.1 Sleeving Machine 21
9.2 Sleeved Capacitor 21
10.1 Dig loading of capacitors 22
10.2 Process of Ageing 23
10.3 Voltage stressing 23
10.4 Process of testing 23
10.5 Different types of Capacitors 24
11.1 Process of Quality check 25
11.2 Storage and shipment of capacitors 26

LIST OF TABLES

Table Name of the Table Page no.

1. Types of Electrolytes 8
2. Time for Baking 14
3. Composition of an Electrolyte 15
4. Impregnation Cycle 16
5. Various types of Capacitors 24
 CHAPTER – 1
INTRODUCTION

1.1 Profile of the company :

INCAP LIMITED a Public Limited Company with ISO 9001:2000 accreditation is managed by
professionally qualified personnel. The company with sound financial discipline, is having its
registered office and manufacturing facility located at Nidamanuru village which is 12 K.M. away
from Vijayawada on N.H. 5 and is accessible by road and rail from different parts of the country.
The company has got an installed capacity of 100 million pcs per annum and was established in
the year 1992 with technical and financial collaboration from M/s. Lelon Electronics Corporation.

1.2 Plant and Machinery :

The Plant is housed in 2.5 acres of land with clean and green atmosphere. We also ensure that the
process followed and waste disposable actions are environmental friendly. Machinery which are
imported from Japan and Taiwan are maintained with meticulous care to ensure improved
productivity of quality products. The performance of the Machine is closely monitored by the team
responsible for Maintenance and Production by analyzing the percentage yield on weekly basis
and making further improvements in the yield by going for innovative techniques.

Fig 1.1 : INCAP LIMITED

1
1.3 Product Range :

The product range covers Radial capacitors of

• Low Voltage (850 C and 1050 C.)
• Medium & High voltage (850 C and 1050 C.)
• Low Leakage
• Long Life & Extended Long Life
• Low ESR (850 C and 1050 C.)
• Low Impedance Long Life
• Bi-Polar, Non-Polar etc.

The Snap-In type capacitors and Lug type capacitors cover a range of capacitance up to 10,000 uF
and a voltage range up to 500 WV. We have satisfactorily developed 1050 C special type Snap-in
type capacitors up to 450WV and are being regularly supplied to OEM’s and Dealers.
Radial Capacitors :
a) Specially designed capacitors for Electronic Ballast and other Lighting
Applications
b) Import substitute capacitors with DOT approval.

Motor Start Capacitors :

c) 230 V AC Motor Start Capacitors (Single Can and Double Can) for local
requirement of single phase pump sets, air conditioners, wet grinders etc.,

d) 110 V AC, 125 V AC , 140 V AC and 150 V AC single can Motor Start Capacitors
meant for export to Singapore, Taiwan, Mexico etc.,

LUG Terminal Capacitors :

Starting from 25 diameter to 45 diameter covering a range of very high CV values in Low
Voltage, Medium and High Voltages.

Professional Screw Terminal Capacitors :

Starting from 35 diameter to 90 diameter covering a wide range of CV values including high
voltage up to 500 WV.

2
1.4 Capacitor :

A Capacitor is a device that stores electrical energy in an electric field by virtue of accumulating
electric charges on two close surfaces insulated from each other. It is a passive electronic
component with two terminals.
The effect of a capacitor is known as capacitance. While some capacitance exists between any two
electrical conductors in proximity in a circuit, a capacitor is a component designed to add
capacitance to a circuit. The capacitor was originally known as the condenser.
Working Principle :
A capacitor consists of two conductors separated by a non-conductive region. The non-conductive
region can either be a vacuum or an electrical insulator material known as a dielectric. Examples
of dielectric media are glass, air, paper, plastic, ceramic, and even a semiconductor depletion region
chemically identical to the conductors. From Coulomb’s law a charge on one conductor will exert
a force on the charge carriers within the other conductor, attracting opposite polarity charge and
repelling like polarity charges, thus an opposite polarity charge will be induced on the surface of
the other conductor. The conductors thus hold equal and opposite charges on their facing surfaces,
and the dielectric develops an electric field.
An ideal capacitor is characterized by a constant capacitance C, in farads in the SI system of units,
defined as the ratio of the positive or negative charge Q on each conductor to the voltage V between
them.
C = Q/V
Parts and Applications :
A capacitor has two outer conducting plates, an inner layer of dielectric material, and external
terminals that connect the two plates to the circuit. These metal plates can be placed close to each
other in parallel combination, or side by side in series combination.
Main parts of a capacitor are :
• Dielectric material
• Conducting plates

Fig 1.2 : Parts of a Capacitor

3
1.5 Weekly Activity log :

WEEK – 1
Date Day Topic learnt / Activity done
15.06.23 Thursday Introduced about the Profile of the company
16.06.23 Friday Known about the process of manufacturing
17.06.23 Saturday Details about the plant and machinery
19.06.23 Monday Known about various raw materials used
20.06.23 Tuesday Understood the operation and working of a Capacitor
21.06.23 Wednesday Familiarized with the parts and Applications of Capacitors

WEEK – 2
Date Day Topic learnt / Activity done
22.06.23 Thursday Learnt about the usage of Route Card
23.06.23 Friday Understood the Process of Slitting
24.06.23 Saturday Learnt about the Preparation of glue
26.06.23 Monday Known about the process of Stitching
27.06.23 Tuesday Understood the process of Winding
28.06.23 Wednesday Familiarized with the process of Baking

WEEK – 3
Date Day Topic learnt / Activity done
29.06.23 Thursday Bakrid – Holiday
30.06.23 Friday Understood the types of Electrolytes and Impregnation process
01.07.23 Saturday Familiarized with the process of Assembling
03.07.23 Monday Learnt about Sleeving and it’s importance
04.07.23 Tuesday Understood the concept of Ageing
05.07.23 Wednesday Known about the Cap-LC-DF testing

WEEK – 4
Date Day Topic learnt / Activity done
06.07.23 Thursday Understood the process of error rectification
07.07.23 Friday Familiarized with the Final Quality Check
08.07.23 Saturday Known about the Process of Storage and Shipment
10.07.23 Monday Interacted with the employees about the industry required skills
11.07.23 Tuesday Taken Photographs and Required information for the sake of report
12.07.23 Wednesday Final draft of the Report on Internship

4
 CHAPTER – 2
PROCESS OF MANUFACTURING

2.1 About the Process :

All products are processed in a controlled and dust free environment where Temperature,
Relative humidity and Human comfort are maintained at the optimum level. The operators are
provided with uniform and it is made compulsory to use chlorine free gloves while handling the
products till it is hermetically sealed. We have provided Air curtains at the entry to the plant to
keep a barrier from outside atmosphere and also to prevent dust coming inside the plant. Operators
are trained specific to the nature of the work carried out including the setting precautions and the
quality norms so that production is never taken on deviation. Besides, petrol inspector collects
samples at regular intervals from all stages of production to see its conformance to the set quality
norms.

2.2 Process Flow Chart :

The following flow chart shows the Step by step process of the manufacturing of the capacitor
of different sizes and rating in the company.

Fig 2.1: Process Flow Chart

5
2.3 Power Supply :
For any industry to manufacture any kind of products, heavy machinery and equipment are used.
They are all run by an electric supply. So to maintain the effective operation of the machines a
highly regulated and efficient electric supply should be used. INCAP LIMITED company
considers the importance of the electric supply and possess the following Power supply equipment
for the manufacturing process to run smoothly.
11 K.V Sub-station :
Regular used power supplies are not meant for the industries as they consist of high power rated
equipment. So, a dedicated 11 K.V feeder is given from NIDAMANURU 33/11 K.V SUB-
STATION (APCPDCL). From the 11 K.V substation the required 3-Phase supply is used
Auxiliary supply :
During the conditions of power cuts, Line Clears or Incoming feeder faults, the power supply to
the industry gets cut-off. It will be a huge impact on the production of the company. So, a backup
auxiliary supply is installed such that it bears the load of the whole company. A 250 KVA A.C
GENERATOR is used as the auxiliary supply and a Change over switch is provided for the
switching the power supply between the Incoming feeder supply and the Generator supply.
Control panels :
A control panel is a flat, often vertical, area where control or monitoring instruments are displayed
or it is an enclosed unit that is the part of a system that users can access, such as the control panel
of a security system (also called control unit). They are found in factories to monitor and control
machines or production lines. Older control panels are most often equipped with push buttons and
analog instruments. The change over switch is also provided in the control panel itself.
Purifiers and Blowers :
During the manufacturing process, as the electrolyte of the capacitor and the paper are temperature
and impurity dependent, moderate and suitable temperature and air are required to flow in the
plant. The purifier is used to absorb the air inside the plant and filters all the impurities. The
blowers reemit the purified air into the plant with moderate cool temperature.

2.4 Route Card :

The Route Card consists of the information regarding the manufacturing details of a particular day
or a session, that goes on in the company. The Route Card provides the details about voltage,
capacitance rating, Lot number, Stage of process, Remarks and the signature of the operator of
each process. This helps in locating the position of a particular lot and also to monitor the regular
working and conditions of the manufacturing.

6
Fig 2.2 : 11 K.V SUB-STATION Fig 2.3 : 250 KVA GENERATOR

Fig 2.4 : CONTROL PANELS Fig 2.5 : AIR FRESHNERS

Fig 2.6 : ROUTE CARD

7
 CHAPTER – 3
IMPORTED RAW MATERIAL

During the manufacturing of the capacitors in the company there is a requirement of some other
materials which helps in the production. Such products cannot be available in the company and all
the required materials cannot be obtained in the company. So they are been imported from several
other industries.
1. Paper and Foil: The capacitor consists of a capacitive element which is a dielectric
material. Here the combination of Paper and foil acts as the dielectric medium. The paper
is made up of wood pulp and resins that act as an insulator between the anode and cathode
foil. Where as the foil is made up of a paper coated with Aluminum Sulphate (AlSo4). The
thickness of paper is more than that of the foil.

Fig 3.1: Paper Fig 3.2: Aluminum Foil

2. Electrolyte: To provide the Capacitance value to the wounded foil element, an electrolyte
is necessary this acts a medium which provides the necessary capacitance value to the foil
element. There are several types of electrolytes that are used based upon the size and rating
of the capacitor.
S. NO SIZE P.O MEAS

1. SL – 24 RM – 34 – 24 30*30*35 Cm.

2. HL – 1C RM – 28 – 22 30*30*35 Cm.

3. YU – 450 RM – 30 – 17 30*35*30 Cm.

Table – 1: Types of Electrolytes

8
3. Lead Tabs : Lead tabs are used as the cathode and anode terminals of the capacitors. They
are generally made up of steel material and they are stitched to the foils with the help of
glue or tape.

Fig 3.3 : Lead tabs

4. Cans and Rubber bungs : As the capacitive element is sensitive to external forces and
impurities, it should be protected. Hence, Aluminum fans are used to protect the element
from the external impact agents. The rubber bungs are tightly fitted to the can edge thereby
closing the can chamber such that no moisture content is allowed.

Fig 3.4 : Aluminum Cans Fig 3.5 : Rubber Bungs

5. PVC Sleeve : The sleeve covers the whole can. It is made up of Poly vinyl chloride. It has
printed details about the capacitor voltage and capacitance rating and also the make symbol
of the company.

6. Silicon Powder : To stitch the lead Tabs to the foil glue or tape is required. The necessary
glue is prepared in the company itself. Silicon Powder is treated with water and external
agent and produces a sticky substance that can be used to stitch the lead Tabs to the foil.

Fig 3.6 : P.V.C Sleeve Fig 3.7 : Polyvinyl Alcohol

9
 CHAPTER – 4
SLITTING

4.1 Process of Slitting:

Slitting is a shearing operation that cuts a large roll of material into narrower rolls. There are two
types of slitting: log slitting and rewind slitting. In log slitting the roll of material is treated as a
whole (the ‘log’) and one or more slices are taken from it without an unrolling/re-reeling process.
In rewind slitting the web is unwound and run through the machine, passing through knives or
lasers, before being rewound on one or more shafts to form narrower rolls. The multiple narrower
strips of material may be known as mults (short for multiple) or pancakes if their diameter is much
more than their width. For rewind slitting the machine used is called a slitter rewinder, a slitter or
a slitting machine – these names are used interchangeably for the same machines. For particularly
narrow and thin products, the pancakes become unstable, and then the rewind may be onto a
bobbin-wound reel: the rewind bobbins are much wider than the slit width and the web oscillates
across the reel as it is rewound. The large roll of capacitor film is unwound and fed into the slitting
machine. The film passes through a series of rollers and tension control devices to ensure smooth
and consistent feeding.
Slitting Blades :
The slitting machine is equipped with multiple circular blades or rotary knives. These blades are
positioned to cut the film into narrower strips. The number and spacing of the blades depend on
the desired width of the final capacitor elements.
Slitting Process:
As the film passes through the slitting machine, the blades rotate and cut the film into narrower
strips. The blades are set to precise dimensions to achieve the desired width and accuracy of the
capacitor elements.

Fig 4.1 : Slitting Machine

10
Winding of Slit Foils : After the slitting process, the narrower strips of capacitor film are wound
onto individual spools or cores. This allows for easy handling and further processing in subsequent
manufacturing steps.
There are several types of capacitors with a wide of diameter starting from 5mm to 5cm. Slitting
is done according to the requirement of the order for a particular diameter of the capacitor.
Overall, the slitting process in capacitor manufacturing plays a crucial role in converting large rolls
of capacitor film into narrower strips or rolls, which can then be used to produce individual
capacitor elements. It requires precision machinery, proper tension control, and quality assurance
measures to ensure the consistent and accurate production of capacitors. By efficiently performing
the slitting process, capacitor manufacturers can produce precise, high-quality capacitor elements
that meet the required specifications for various electronic applications.

4.2 Slit Foil and Paper :

Once the capacitor film is slit into narrower strips, it can be used for various capacitor
manufacturing processes. These may include electrode deposition, lamination, winding, and
assembly to create complete capacitors.
After the Slitting process the different sizes of paper and Foil rolls are stored and used for the
production of the capacitors.
The Slitted Foil and Paper rolls are transferred to the level of process called Stitching and winding.
The Slitted rolls are stored in the stock room and taken out whenever the manufacturing is started.
As the paper and Foil rolls are sensitive to dust and other foreign impurities, touching the foils
with bare hands is prohibited.
The slitting process generates waste material, such as the trimmed edges of the film. Efficient
waste management practices, such as proper collection and recycling, should be implemented to
minimize environmental impact and optimize material usage.

Fig 4.2: Slit Foil rolls Fig 4.3: Slit Paper rolls

11
 CHAPTER – 5
STITCHING AND WINDING

5.1 Process of Stitching :

The stitching process involves in mainly three components – Aluminum foil rolls, lead Tabs and
Glue.
Stitching lead tabs on the foil of capacitors typically involves the following steps:
Placement of Lead Tabs: Position the lead tabs on the designated areas of the capacitor foil. The
number and placement of tabs depend on the capacitor design and requirements. Ensure that the
tabs align correctly with the designated soldering points.
Alignment: Use tweezers to adjust and align the lead tabs precisely. The tabs should be securely
placed and have good contact with the capacitor foil.
Stitching the lead Tabs : The lead Tabs are strongly stickled to the foil by using the glue prepares
from the Silicon Powder (Polyvinyl Alcohol)
Trim Excess Leads: Once all the lead tabs are soldered onto the capacitor foil, use wire cutters to
trim any excess length from the leads. Be careful not to damage the capacitor foil or the soldered
joints while trimming.
It’s important to note that the specific process may vary depending on the type and design of the
capacitor, as well as any industry or company-specific guidelines. Always refer to the
manufacturer’s instructions or established procedures when stitching lead tabs on capacitor foils.

5.2 Stitched Foils :

The foils that are stitched with the Lead tabs are wounded again to rolls and promoted to the next
level of the manufacturing process called winding. The stitched foils are needed to be handled very
carefully as the lead Tabs are sensitive to get detached from the foil.

Fig 5.1 : Stitching Machine Fig 5.2 : Stitching Process

12
5.3 Process of Winding :
The process of winding in a capacitor refers to the construction method used to create the
capacitor's electrode layers and separate them with a dielectric material. Winding is commonly
employed in electrolytic capacitors and some types of film capacitors. Here's a step-by-step
overview of the winding process:
Electrode preparation: The first step involves preparing the electrodes. For electrolytic
capacitors, a thin sheet of aluminum is used as the anode, while for film capacitors, metalized film
or foil is used. The electrodes are typically coated with a conductive material to enhance their
surface area and capacitance.
Dielectric material: A dielectric material, such as a thin layer of oxide for electrolytic capacitors
or a plastic film for film capacitors, is chosen. This dielectric material will separate the electrode
layers and determine the capacitor's electrical characteristics.
Winding process: The winding process begins by interleaving the prepared electrodes with layers
of the dielectric material. The layers are carefully aligned and wound together to form a tightly
packed cylindrical or spiral structure. The winding can be done manually or using automated
machinery, depending on the capacitor's size and production scale.

Fig 5.3 : Winding Machine

5.4 Wounded Elements :

After the process of Winding the combination of paper foil and lead Tabs is called as ‘Element’.
The element gives the basic Structure to the Capacitor starting stage. At this position there is no
capacitance or Voltage value in the element.

Fig 5.4 : Wounded Element

13
 CHAPTER – 6
BAKING AND IMPREGNATION

6.1 Process of Baking :

Baking process is a mandatory one in the manufacturing of capacitors. As the capacitor foils are
stitched with the lead tabs using glue, the moisture content of the glue may cause some unwanted
errors or malfunctions of the capacitor. So the moisture content in the element should be removed.
For this reason, the capacitive elements are baked inside an oven at a preloaded temperature that
depends upon the and rating of the capacitors.
The wounded elements are placed in flat tubs and are placed inside the oven. The oven is closed
and a particular temperature and time limit are set until the moisture inside the capacitor is
removed.
Temperature and time values :
For various sizes and rating of the capacitors, different time limit and temperature values are set
by the baking oven.
S. No Diameter in mm. Time of Baking
1. Upto 22 mm. 2 Hours
2. 25-40 mm. 3 Hours
3. 50 mm. 4 Hours
4. 63 mm.& above 6 Hours

Table – 2 : Time for Baking

All the various diameter elements are baked under a constant temperature of 85°C, During the
moisture condition seasons like winter or rainy, the temperature of baking gets increased to 90°C.

Fig 6.1 : Baking Oven

14
6.2 Process of Impregnation :
To indulge the capacitance value in the element the mandatory process is Impregnation it is the
most important part of the manufacturing process as the capacitance value can be obtained to the
element by the process. It mainly includes in the usage an electrolyte that is being impregnated
into the element.
Electrolyte : An electrolyte is a medium containing ions that is electrically conducting through
the movement of those ions, but not conducting electrons. This includes most soluble salts, acids,
and bases dissolved in a polar solvent, such as water. Upon dissolving, the substance separates into
cations and anions, which disperse uniformly throughout the solvent. Solid-state electrolytes also
exist. In medicine and sometimes in chemistry, the term electrolyte refers to the substance that is
dissolved.
Electrically, such a solution is neutral. If an electric potential is applied to such a solution, the
cations of the solution are drawn to the electrode that has an abundance of electrons, while the
anions are drawn to the electrode that has a deficit of electrons. The movement of anions and
cations in opposite directions within the solution amounts to a current. Some gases, such as
hydrogen chloride (HCl), under conditions of high temperature or low pressure can also function
as electrolytes.
Properties of an Electrolyte : Some of the properties of electrolyte are,
• It conducts electric current as a result of its dissociation into ions.
• It generally ionizes when it is dissolved in a solvent.
• Many salts, such as sodium chloride, behave as electrolytes when melted in the absence of
any solvent.
• Silver iodide (salt) exists as an electrolyte even in the solid state.

Chemical Composition of the Electrolyte :

Ingredient Chemical Formula CAS NO. Content
Ethylene C2H6O2 107-21-7 15 – 60 %
Alcohol
Adipic acid C₆H₁₄N₂O₄ 19090-60-9 5 – 15 %
ammonium
Mannitol C6H14O6 69-65-8 3–5%

Diethylene C4H10O3 111-46-6 10 – 15 %

Glycol
Pure Water H2O 7732-8-15 10 – 65 %

Table – 3 : Composition of an Electrolyte

15
The process of capacitor oil impregnation involves filling a capacitor with a suitable dielectric oil
to enhance its performance and insulation properties. Here are the general steps involved in the
capacitor oil impregnation process:
Preparing the capacitor : Ensure that the capacitor is clean and free from any contaminants. This
may involve cleaning the capacitor with a suitable solvent or detergent to remove any dirt, dust, or
residual substances.
Vacuum drying : Place the cleaned capacitor in a vacuum chamber to remove any moisture or air
trapped within. Applying vacuum helps in drying the internal components and ensures better
impregnation.
Impregnation : Submerge the capacitor in the chosen dielectric oil, making sure it is completely
immersed. The oil can be poured into a suitable container or a vacuum impregnation chamber,
depending on the size and type of capacitor.
Pressurization : In certain cases, pressurization of the impregnation chamber may be employed
to further enhance the penetration of the oil into the capacitor. This helps ensure complete
impregnation and minimizes the presence of any air pockets.
The total impregnation process is carried out in the impregnation chambers in the presence of both
air and vacuum.
Time in minutes
Diameter Air Vacuum Number of Cycles
5 40 10 1
6.3 to 22 40 10 2
22 to 35 40 15 2
40 to 45 40 15 3
50 45 15 4
63 & above 45 15 6
Table – 4 : Impregnation Cycle

Fig 6.2 : Impregnation Chambers

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 CHAPTER – 7
ASSEMBLING

7.1 Process of Assembling :

The bare element cannot be used as a capacitor. So, an outer covering and protection should be
provided to impregnated elements. The main components for the Assembling are Element,
Aluminum can and Rubber bung.
The process of assembling capacitors typically involves several steps. While the specific details
may vary depending on the type of capacitor and the manufacturing process, here is a general
overview of how capacitors are assembled:
Preparation of capacitor plates: The capacitor plates are usually made of conducting materials
such as aluminum or tantalum. These plates are formed into specific shapes and sizes, depending
on the type of capacitor. The plates may undergo processes like cutting, etching, or deposition to
achieve the desired dimensions and characteristics.
Application of dielectric material: The dielectric material is placed between the capacitor plates
to insulate them from each other. The dielectric material is chosen based on the desired capacitance
and other electrical properties of the capacitor. It could be made of materials like ceramic, plastic
film, electrolyte, or tantalum pentoxide.
Connection of leads or terminals: Capacitors typically have leads or terminals that allow for
electrical connections. These leads are attached to the capacitor plates. The method of attachment
can vary, but it often involves soldering or welding the leads to the plates.
Encapsulation: Once the capacitor assembly is complete, it is often encapsulated in a protective
casing. The casing provides mechanical protection and insulation for the capacitor. The casing may
be made of materials like plastic or metal, depending on the application and the desired level of
protection

Fig 7.1 : Assembling Machine Fig 7.2 : Assembling Components

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7.2 Need for Assembling :
Assembling capacitors is a critical process that requires precision and adherence to
quality control measures to ensure that the capacitors perform as expected in various electronic
applications.
Increased capacitance: By connecting capacitors in parallel, their individual capacitances add up,
resulting in a higher overall capacitance. This is useful when a larger capacitance is needed than
what a single capacitor can provide.
Voltage rating: Capacitors have voltage ratings that specify the maximum voltage they can
withstand. By connecting capacitors in series, their voltage ratings add up, allowing for the use of
higher voltage circuits.
Ripple current handling: Some applications require capacitors to handle high ripple currents,
which are alternating current components superimposed on a direct current. Assembling multiple
capacitors in parallel increases the overall current-handling capability.
Customization: Assembling capacitors allows for customization of their electrical characteristics.
For example, combining capacitors with different values and types can create specific frequency
response curves or impedance characteristics.
Size limitations: In some cases, the available space for installing capacitors may be limited. By
assembling capacitors in a compact configuration, the overall size can be reduced while still
achieving the desired capacitance.
Cost considerations: Assembling capacitors can sometimes be a more cost-effective solution than
using a single high-capacity capacitor. This is particularly true when specific capacitance values
are not readily available or are more expensive.
Circuit design requirements: Certain circuit designs may call for specific combinations of
capacitors, such as coupling capacitors, decoupling capacitors, or timing capacitors. Assembling
capacitors allows for precise integration into the circuit layout.

7.3 Assembled Capacitors :

It’s important to note that the assembly of capacitors requires careful consideration of their
electrical characteristics, such as capacitance, voltage ratings, and tolerance. Additionally,
appropriate circuit design and connection methods must be employed to ensure the desired
performance and reliability.

Fig 7.3 : Assembled Capacitor

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 CHAPTER – 8
WASHING AND DRYING

The Assembled Capacitors may have dirt and grease over their Aluminum can surface due to the
processes that are executed before. This may effect the after processes like Sleeving and testing so
the dirt over the aluminum cans should be removed. So washing is a n essential process in the
manufacturing of the capacitor.

8.1 Process of Washing :

Washing capacitors is meant for the parts like Aluminum Cans and Rubber bungs. The steps
involved in washing process are,
• Safety precautions: Before working with any electronic component, ensure you take proper
safety precautions. Disconnect the capacitor from any power source and discharge it to
prevent any electrical shock. Wear appropriate safety gear such as gloves and goggles.

• Assessment: Examine the capacitor carefully to determine the extent of the cleaning
required. If there is visible dirt, dust, or contaminants on the surface, you can proceed with
cleaning. However, if the capacitor has been damaged or exposed to liquids, it is best to
replace it rather than attempting to clean it.

• Cleaning solution: Prepare a cleaning solution suitable for electronic components.

Isopropyl alcohol (IPA) is commonly used for cleaning electronics. Dilute the IPA with
distilled water to achieve a concentration between 70% and 90%. Avoid using strong
solvents or water alone, as they can damage the capacitor.

• Cleaning process: Dip a soft-bristled brush or a lint-free cloth into the cleaning solution.
Gently brush or wipe the exterior surface of the capacitor to remove any dirt or
contaminants. Be careful not to apply excessive pressure or use abrasive materials that
could damage the capacitor's protective coating.

Fig 8.1 Washing Machine

19
8.2 Process of Drying :
After the process of drying, the moisture content remains on the assembled capacitor, which may
lead to impact the next process called applying sleeve. So, the assembled capacitors after drying
must be dried to remove the moisture content.
Drying: After cleaning, you need to ensure the capacitor is completely dry before reconnecting it
to any circuit. The safest method is to leave it to air dry naturally. Alternatively, you can use
compressed air to blow away any remaining moisture, but be cautious not to subject the capacitor
to excessive force or temperature changes.
Testing: Once the capacitor is dry, you can test it using appropriate equipment or multimeter to
ensure it is functioning properly. If there are any signs of damage or malfunction, it is advisable to
replace the capacitor rather than risking its use in a circuit.

8.3 Dried Capacitors :

Electrolytic Capacitors consists of a solid Anode and a liquid cathode. The cathode is the liquid
electrolyte. Sometimes, the electrolyte inside the capacitor evaporates causing the capacitor to
fail.

The drying of the Electrolyte in the electrolytic capacitor can be due to age or high temperature.
Hence, care should be taken to ensure that the capacitors are not operated at temperatures higher
than the rated temperature. The least priced and type of aluminum electrolytic capacitors with non-
solid electrolyte also have the broadest range of sizes, capacitance, and voltage values. They are
made with capacitance values from 0.1 µF up to 2,700,000 µF (2.7 F), and voltage ratings ranging
from 4 V up to 630 V.

The liquid electrolyte provides oxygen for re-forming or “self-healing” of the dielectric oxide
layer. However, it can evaporate through a temperature-dependent drying-out process, which
causes electrical parameters to drift, limiting the service life time of the capacitors.

Due to their relatively high capacitance values aluminum electrolytic capacitors have low
impedance values even at lower frequencies like mains frequency.

Fig 8.2 : Process of Drying

20
 CHAPTER – 9
SLEEVING

9.1 Process of Sleeving :

Sleeving capacitors typically refers to the process of applying a protective sleeve or coating to
capacitors. This protective sleeve helps to insulate the capacitor, provide mechanical protection,
and prevent electrical shorts or damage from external factors. Here's a general overview of the
process:
1. Select the appropriate sleeve material: The choice of sleeve material depends on the specific
requirements of the application. Common materials include heat-shrink tubing, silicone sleeves,
PVC sleeves, or specialized insulating materials designed for capacitors.
2. Prepare the capacitor: Ensure that the capacitor is clean and free from dust, dirt, or any other
contaminants. Wipe the surface of the capacitor using a lint-free cloth or appropriate cleaning agent
if necessary.
3. Cut the sleeve to size: Measure the length of the capacitor and cut the sleeve material
accordingly, leaving some extra length to accommodate any shrinkage or fitting requirements.
4. Slide the sleeve onto the capacitor: Carefully slide the cut sleeve material over the capacitor,
ensuring a snug fit. Take care not to damage the capacitor leads or terminals during this process.

9.2 Sleeved Capacitors :

It's important to note that the specific process may vary depending on the type of capacitor, sleeve
material. The white arrow mark on the sleeve represents the Cathode terminal of the capacitor. .

Fig 9.1 : Sleeving Machine Fig 9.2 : Sleeved Capacitor

21
 CHAPTER – 10
AGEING AND TESTING

10.1 Dig loading :

Before going into the process of Ageing, the capacitors are needed to stack under a single
conducting plate. Because, Ageing process cannot be done on a single capacitor alone. So, the
process will be easier if a group of capacitors are stacked. Capacitors are needed to stacked
correctly to avoid the errors at the time of ageing.

Fig 10.1 : Dig Loading of Capacitors

10.2 Process of Ageing :

The aging process in capacitors typically occurs gradually over time and can be influenced by
several factors.
1. Initial Usage: Capacitors are initially used in electronic circuits, where they perform their
intended function of storing and releasing electrical energy. The aging process begins as soon as
the capacitor is put into operation.
2. Environmental Factors: Environmental conditions such as temperature, humidity, and
exposure to contaminants can accelerate the aging process. High temperatures can lead to faster
breakdown of materials, while moisture and contaminants can °rade the performance of the
capacitor.
3. Voltage Stress: The voltage applied to a capacitor can impact its aging process. Higher voltages
can increase stress on the dielectric material, potentially leading to breakdown and °radation over
time. Operating within the specified voltage ratings helps mitigate this stress.
4. Capacitance Drift: Over time, capacitors may experience a gradual change in their capacitance
value. This capacitance drift can be caused by factors like the breakdown of the dielectric material
or changes in the electrode structure.

22
 Fig 10.2 : Process of Ageing Fig 10.3 : Voltage Stressing

10.3 Testing of Capacitors :

Generally, the Process of testing is known as CAP-LC-DF testing. As the name conveys, the
testing process involves in testing of three parameters – Capacitance, Leakage Current and
Dissipation Factor
1. Capacitance Drift: Over time, capacitors may experience a gradual change in their
capacitance value. This capacitance drift can be caused by factors like the breakdown of
the dielectric material or changes in the electrode structure.

2. Dielectric Absorption: Certain types of capacitors, such as electrolytic capacitors, can

exhibit dielectric absorption or soakage. This effect causes the dielectric material to retain
a charge temporarily after being discharged, resulting in a slow change in the effective
capacitance of the component.

3. Leakage Current: Capacitors have a property called leakage current, which is the current
that flows through the dielectric material. Over time, this leakage current can increase as a
result of the aging process, leading to higher power dissipation and reduced performance.

Fig 10.4 : Process of Testing

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10.4 Types of Capacitors produced at INCAP LIMITED :
There are several types of capacitors that are been manufactured at INCAP LIMITED, the
variations depends upon the usage and applications for several purposes. They are listed below.

SERIES FEATURES OF THE CAPACITOR

IG General Purpose 85 °C
IT General Purpose 105 °C
1H1 Medium & High Voltage 85 °C
1H2 Medium & High Voltage 105 °C
LA1 Lighting Apparatus 85 ° C
LA2 Lighting Apparatus 105 ° C
BP1 Bi-Polar 85 ° C
BP2 Bi-Polar 105 ° C
NP1 Non-Polar 85 ° C
NP2 Non-Polar 105 ° C
IE1 Low ESR 85 °C
1E2 Low ESR 105 °C
LL1 Low Leakage 85 °C
LL2 Low Leakage 105 °C
ST1 Screw Terminal 85 ° C
ST2 Screw Terminal 105 ° C
LT1 Lug Terminal 85 ° C
LT2 Lug Terminal 105 ° C
MS1 Motor Start (Single Can)
MS Motor Start (Double Can)

Table – 5 : Various types of Capacitors

Fig 10.5 : Different Capacitors

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 CHAPTER – 11
QUALITY CHECKING

11.1 Final Quality Check and Inspection :

Quality checks in the manufacturing of electrolytic capacitors involve various inspections and tests
to ensure that the products meet the desired quality standards. Here are some common quality
checks performed during the manufacturing process:
Visual Inspection:
• External Appearance: Capacitors undergo visual inspection to identify any visible defects,
such as physical damage, scratches, cracks, or irregularities in the shape or sealing.
• Labeling and Marking: The labels and markings on the capacitors are checked to ensure
they are accurate, legible, and meet the required standards.
Dimensional Inspection:
• Size and Shape: The dimensions of the capacitors, including length, diameter, and lead
spacing, are measured and compared against the specified tolerances to ensure they meet
the dimensional requirements.
Performance and Reliability Testing:
• Temperature Cycling: Capacitors may be subjected to temperature cycling, where they are
exposed to alternating high and low temperatures to evaluate their performance under
thermal stress.
• Endurance Testing: Some capacitors undergo extended operation under stress conditions,
such as elevated temperature, high voltage, or continuous ripple current. This testing aims
to assess the capacitors’ long-term reliability and stability.
By implementing these quality checks, manufacturers can ensure that the electrolytic capacitors
meet the specified standards, perform reliably, and provide optimal performance in their intended
applications.

Fig 11.1 : Process of Quality Check with Samples

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11.2 Storage :
When it comes to storing capacitors, there are a few guidelines you can follow to ensure their
longevity and performance:
1. Avoid extreme temperatures: Capacitors should be stored in a cool and dry environment, away
from excessive heat or cold. Extreme temperatures can degrade the components and affect their
performance. Ideally, the temperature should be within the manufacturer's recommended range.
2. Protect from humidity: Moisture can damage capacitors, so it's essential to store them in a dry
environment. High humidity can lead to corrosion and the formation of conductive paths on the
capacitor's surface, which can cause malfunctions.
3. Prevent physical damage: Capacitors are delicate electronic components, so it's crucial to
handle and store them with care. Avoid dropping, bending, or subjecting them to any mechanical
stress that may damage their structure.
4. Label and organize: When storing capacitors, it's helpful to label them properly with relevant
information such as capacitance, voltage rating, and date of purchase. Additionally, organizing
them in a way that allows easy access and identification can save time and prevent mishandling.

11.3 Shipment :
Packaging and Labeling: Capacitors should be appropriately packaged to ensure their safe
transportation. This may involve using suitable protective materials, such as anti-static packaging,
to prevent damage during transit. Additionally, proper labeling should be applied to packages
indicating the contents, handling instructions, and any necessary warnings.
Transportation: Selecting the appropriate mode of transportation is important when exporting
capacitors. This can vary based on factors such as the destination, volume of capacitors, and
urgency. Common transportation options include air freight, sea freight, or land transportation. It's
important to consider factors like cost, transit time, and the specific requirements of the capacitors
being shipped.

Fig 11.2 : Shipment of Capacitors

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 CHAPTER – 12
INTERPRETATION AND CONCLUSION

12.1 Skills Involved :

Along with the knowledge about the process going on in the industry, the internship gave a
tremendous chance to learn new skills that are very useful for the industry ready purpose. Some of
them and which I’ve learnt are,

1. Communication Skills: Strong written and verbal communication skills are essential in almost
every industry. Being able to effectively convey information, collaborate with others, and articulate
ideas is highly valued.
2. Technical Skills: Many industries require specific technical skills relevant to their field. For
example, programming languages and software development skills are important in the technology
industry, while engineering fields may require proficiency in CAD software or specific engineering
principles.
3. Analytical and Problem-Solving Skills: The ability to analyze data, identify patterns, and solve
complex problems is valuable across industries. Employers often seek individuals who can think
critically, make sound decisions, and propose innovative solutions.
4. Adaptability and Flexibility: Industries are constantly evolving, and being able to adapt to
change is crucial. Employers value individuals who can quickly learn new skills, embrace new
technologies, and adjust to evolving market trends.
5. Time Management and Organization: The ability to prioritize tasks, meet deadlines, and
effectively manage time is highly valued. Being organized and efficient helps improve productivity
and ensures that work is completed in a timely manner.
6. Creativity and Innovation: Industries often require individuals who can think creatively and
come up with innovative ideas. Employers seek individuals who can bring fresh perspectives, solve
problems in unique ways, and contribute to the growth and development of the organization.
7. Industry-Specific Knowledge: Depending on the industry, employers may require specific
knowledge or experience related to the field. This could include understanding industry
regulations, specialized software, specific methodologies, or relevant industry trends.

It's important to note that these are general skills, and the specific skills required can vary
significantly depending on the industry, job role, and level of experience. It's always a good idea
to research and understand the skills that are in demand within your particular field

27
 CONCLUSION

During my summer internship experience in the INCAP LIMITED has been extremely valuable
and rewarding. Throughout the internship, I have gained practical knowledge and skills that have
enhanced my understanding of the industry and provided me with a solid foundation for my future
career.
During my time at the company, I was able to actively contribute to various machinery, allowing
me to analyze the theoretical concepts I learned in my academic studies. This hands-on experience
has been instrumental in deepening my understanding of the industry’s operations and challenges.
One of the key takeaways from my internship is the importance of effective communication and
teamwork. I had the opportunity to collaborate with professionals from different departments and
levels within the organization. This experience not only improved my interpersonal skills but also
taught me the value of collaboration in achieving organizational goals.
Moreover, the internship exposed me to the more enthusiastic at the machines. I had the chance to
work with tools of making capacitors, which expanded my technical knowledge and increased my
adaptability to rapidly changing environments.
Furthermore, the supportive and encouraging work environment at the company played a
significant role in my growth and development. I received guidance and mentorship from
experienced professionals who were always available to answer my questions and provide valuable
feedback. This nurturing atmosphere fostered my personal and professional growth, making my
internship experience even more fulfilling.
Overall, my internship in the sample industry has been an enriching experience that has helped me
bridge the gap between theory and practice. It has provided me with valuable insights into the
industry’s dynamics, improved my technical skills, and enhanced my ability to work effectively in
a team. I am confident that the knowledge and experience gained during this internship will serve
as a strong foundation for my future endeavors in the industry.
I would like to express my sincere gratitude to the company and all the individuals who supported
and guided me throughout this internship. Their mentorship and encouragement have been
invaluable, and I am grateful for the opportunity to have been a part of their team.

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PHOTOS OF INTERNSHIP

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REFERENCES :

1. www.incap.org
2. www.electricals4u.com
3. www.eletronix.com

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