Nwachukwu Precious - Siwes Report

SIWES REPORT Nov 13, 2023
FEDERAL UNIVERSITY, OTOUKE

P.M.B 126 BAYELSA STATE
DEPARTMENT OF CHEMICAL ENGINEERING

A SIX MONTHS REPORT ON STUDENTS INDUSTRIAL
WORK EXPERIENCE SCHEME (SIWES)
AT
BLUEWATER ECO LIMITED
NO 108 AKER ROAD, OFF IWOFE PORTHARCOURT
RIVERS STATE
BY
NWACHUKWU PRECIOUS CHIBUZOR
FUO/18/CME/7467
SIWES SUPERVISOR: DR. MOHOK
NOV, 2023.
1
Certification
I hereby confirm and certify that the contents of this report are the Students’ Industrial Work
Experience of NWACHUKWU PRECIOUS CHIBUZOR of the Department of Chemical
Engineering whose matriculation number is FUO/18/CME/7467
Name: ______________________________________
Signature: ______________________________________
2
ABSTRACT
This report details on the activities performed by me during my (SIWES) training programme at Bluewater Eco
Limited. The following practical experience were acquired in (1) Recycling of PETs bottles into reusable
products (2). Production of cold washed flakes from post consumer PETs bottles (3) Crushing Techniques, use
of blades and their cutting angles (4) Practical guide on inventory management control, packing and storage of
cold washed flakes (5) Fault diagnoses
3
DEDICATION
My profound gratitude goes to God Almighty for his endless love and protection throughout
my (SIWES) training programme.
4
ACKNOWLEDGEMENT
For instilling in me the virtues of hard work and a sense of achievement, I humbly dedicate
this technical report to my parents, Mr and Mrs Nwachukwu Ignatiuos amd my lovely wife. I
also wish to acknowledge the contributions of my (SIWES) Technical Director and (SIWES)
Supervisor ENGR. SOLOMON ETUK for his guidance and high sense of discipline.
Finally, I wish to remember on this occasion the contributions of my lecturers who taught me
the beauty and fascinations of Engineering as the all-embracing field of study. You continue
to spur me on.
5
TABLE OF CONTENTS
Title page Pages
Certification - - - - - - - - - I
Abstracts - - - - - - - - - ii
Dedication - - - - - - - - - iii
Acknowledgement - - - - - - - - iv
Table of Contents - - - - - - - - v-vi
CHAPTER ONE
Introduction to SIWES - - - - - - - 1-2
Objective of SIWES - - - - - - - - 2
Introduction to PETs recycling and its processes - - - - 3
Areas of service and division - - - - - - - 4-6
CHAPTER TWO
General experience on industrial training - - - - - 7
Induction to the company and job - - - - - - 7-11
Introduction to basic engineering - - - - - - - 12-14
Introduction to Inventory department - - - - - 15
Inventory log and others - - - - - - 16
Production Processes - - - - - - - - 17-21
Description of crusher 1 - - - - - - - 22-25
6
Pictorial representation of work done - - - - - - 26-27
CHAPTER THREE
New skills acquired - - - - - - - - 28
Safety skills - - - - - - - - - 28
Inventory control management - - - - - - 28
Use of crushing machine - - - - - - - 28
Quality control and its processes - - - - - - - 28
Fault diagnoses on PETS recycling plant - - - - - 28
Challenges - - - - - - - - 28
CHAPTER FOUR
Conclusion - - - - - - - - - 30
Recommendation - - - - - - - - 31
Reference - - - - - - - - - 32
Appendix
7
CHAPTER ONE
INTRODUCTION
The student industrial work experience scheme (SIWES) was established in 1973 by the
federal government of Nigeria and is jointly coordinated by the industrial training fund (ITF)
and the national university commission (NUC)
The scheme helps to bridge the gap between theory and industrial based practical, hence it
affords students of tertiary institution the opportunity of being familiarized and exposed to
the needed experience in handling machineries and equipment’s which are usually not
available in the educational system.
The scheme also has become a precondition for the award of Diploma and Degree certificates
in the various field of discipline in higher institute of learning in the country, which is in
accordance with the federal government directive.
BODIES INVOLVED IN THE MANAGEMENT OF SIWES PROGRAMME
The following bodies have specific roles assigned to them in the administration and
management of SIWES
The Federal Government of Nigeria
The Industrial Training Fund (ITF)
National University Commission (NUC)
National Board for Technical Education (NBTE)
National Commission for College of Education (NCCE)
Institute of Higher Learning; and
The Employers of Labour.

8
FUNDING;
The Federal Government of Nigeria is to provide adequate funding to the Industrial Training
Fund through the Federal Ministry of Trade & Investment for the scheme.
BENEFICIARIES;
The following field of discipline are the beneficiaries of SIWES; Agriculture, Engineering,
Technology, Environmental science, Medical science, Pure & Applied science.
OBJECTIVE OF SIWES
The objectives of SIWES according to Industrial Training Fund (ITF) are;
1 To prepare students for the industrial work situation they are to meet after graduation.
2 To expose student to work methods and techniques in handling equipment’s and
machineries that may not be available in their institutions.
3 To promote industrialization in Nigeria.
4 To enhance the transition from school to the world of real work easier, and also
enable students make contact for later job placement.
5 To provide students the opportunity to apply their knowledge in real work situation
thereby bridging the gap between theory and practical.
9
PLACE OF ATTACHMENT
Bluewater Eco Limited is a company based in portharcourt who’s activities is solely
on recyling of PETs bottles into cold washed flakes for export sales. They have one
of the finest recyling plant in portharcourt and have earned their integrity over the
years as the elephant of recycling
Bluewater Eco was established mainly targeting the core recycling industrialist who
reform waste into usable products such as fibres, foams ete. With the goal of
enabling our clients have prompt access to constant raw materials.
AREAS OF SERVICES AND DIVISIONS
• Providing cold wash PETs products for recycling companies abroad
• Inventory Management control
• Granulation processes
• Receiving of raw materials
• Waste evacuation (cleaner portharcourt city goals)
Training Program
Bluewater Eco ensures that their trainees gain on field experience in industrial based
operation with their (80%) practical oriented training program
They offer the following courses:
• Inventory Management and control
• Plant Processes and maintenance
• Production work flow and damage control mechanism
10
BLUEWATER ECO LIMITED
PROFILE/ORGANOGRAM
11
CHAPTER TWO
GENERAL EXPERIENCE ON INDUSTRIAL TRAINING
INDUCTION TO THE COMPANY AND JOB
HEALTH AND SAFETY RULES
Your safety is the constant concern of Bluewater Eco Limited. Every precaution has been to
provide a safe workplace. It is the policy of Bluewater Eco Ltd to insist that an employee,
trainees and subcontractors understand and strictly adhere to the provisions, Occupational
Health and Safety Policy and all applicable regulations
Common sense and personal interest in safety are still the greatest guarantees of your safety
at work. We take your safety seriously and any willful or habitual violation of safety rules
will be considered cause for dismissal or suspension. The cooperation of every staff member
is necessary to make our workplace a safe place in which to work. Begin right by always
thinking of safety as you perform your job, or as you learn new one.
Reporting Injuries and Accidents/Incidents
All injuries and accidents/incidents, no matter how minor, must be reported in an
incident/accident report form immediately to the supervisor. The supervisor will conduct his
investigation and report it to management.
Safety equipment
Your supervisor will see that you wear the protective clothing and equipment required for
your job. Use them as instructed and take care of them. You will be charged for loss or
destruction of these personal protective equipment (PPEs) only when it occurs through
negligence.
12
Foot protection
Under no circumstances will a trainee be permitted to work in sandals or open-toes shoes into
the workshop or operation site. Safety shoes with toes and sole protection must be worn at all
times when you are on the work floor.
Eye protection
The use of safety glasses by all employees and trainees when on the operation site is
mandatory. Safety glasses (goggles) or prescription eyeglasses coupled with side shields shall
be worn at all times when on the work floor. Additional face shield protection shall be worn
for activities where welding, grinding, radiant heat, chemical exposure or similar risks exist.
Head protection
Hard hats shall be worn on the job by all personnel where a hazard exists and when instructed
to do so.
Skin protection
Appropriate work clothing must be worn when handling and using tools and materials which
may cause injuries to the skin
Clothing
For your clothing on the job,
DO NOT WEAR:
• Loose clothing or cuffs
• Greasy or oily clothing, gloves or boots
• Torn or ragged clothing
13
• Finger rings, bracelets or neck chains
Other Personal Protective Equipment
Other equipment, such as safety belts, full-body harnesses, respirators, reflective vests
floatation vests, ear protection devices, etc. must be worn when required by the policy and
your supervisor.
Seat belts
All employees, volunteer staff and trainees must use seat belts and shoulder restraints (if
available) whenever they operate a company vehicle. The drivers are responsible for seeing
that all passengers in front and rear seats are buckled up.
Drug, & Alcohol Policy
It is an offence for any employee, contractors or trainee of Bluewater Eco, to be under the
influence of, or in possession of alcohol, any non-prescription drug such as cocaine,
amphetamine, marijuana or other illegal substances that may result in impairment to health
and behavior, judgement or job performance while working or residing on any job site,
including water borne operations or properties under the control of Bluewater Eco
Reporting unsafe practices and conditions
If you should notice any unsafe practice or condition on the job, you are obligated by law and
by this company to report the situation immediately in an unsafe acts report form so that
corrective action can be taken.
Heavy lifting
Always seek assistance or use mechanical lifting devices when attempting to lift heavy
material. Avoid awkward positions and always lift with the legs, not your back. Your back is
very susceptible to injury in a bent position.

14
Horseplay
Do not engage in any prank, contest, feat of strength, unnecessary running or boisterous
conduct.
Machinery and equipment
• No tool shall be used for any purpose rather than that intended. All damaged or worn
parts shall be promptly repaired or replaced.
• Do not operate machine or equipment until you are properly trained, instructed and
authorized to do so by your supervisor
• Only authorized personnel shall operate a power tools with guard furnished by the
manufacturer in place.
• Do not temper with electric control or switches.
• All electrical hand tools shall be grounded or double insulated.
Tool maintenance
It is the management’s responsibility to supply and maintain shop tools and other power
equipment in good repair. It is the workers responsibility to use such tools properly and to
report any defect to the supervisor.
NO SMOKING POLICY
Bluewater Eco prohibits smoking by all personnel on all project sites and offices. Visitors
who smoke must do so outside the work areas and offices.
Compressed gas cylinder
• All cylinders shall be transported, stored and secured in an upright position.
• When transporting or lifting any cylinders the regulators and hoses are to be removed
and the protective cap installed.

15
Access to fire extinguishers
• Do not block access route to fire extinguisher
Ladder
Ladders should be set up on a firm level surface
Good housekeeping
Work location must be kept clean and orderly. Keep machines and other objects
(merchandise, boxes, shopping
carts, etc.) out of the center of aisles. Clean up spills, drips, and leaks immediately to avoid
slip and falls. Place trash in the proper receptacles. Stock shelves carefully so merchandise
will not fall upon contact. Waste material and debris must be removing from work and access
areas on a regular basis or at least once a day
DESCRIPTION OF ACTUAL WORKDONE
Introduction to Inventory Management Department
The inventory department is sadled with the core responsibility of receiving unprocessed
PETs materials, received materials are stored in the warehouse through a process called
stacking. This materials are later sent to the sorting unit for removal of labels and PP (covers)
before they are finally sent to the production hall for processing/shredding. The final outcome
of the processing is what we call cold wash PETs flakes
In this department I was trained on how to receive PETs materials, inspect and weigh them
with the use of a digital scale to ascertain the weight of the material supplied by the vendor,
document every product received and report the dialy inflow of materials into the facility.
16
In this unit also, I was trained on proper record keeping, since inventory overses all
companys liquid assets. We take stock of incoming materials, sorted materials from the
sorting unit, then transfer them to the production hall for shredding/crushing into flakes
All processed flakes (cold washed PETs) are stored and stacked in the warehouse after
packaging into 50kg bags respectively before they are exported in containers to clients either
within the country or abroad based on purchase order received by the company
Daily/weekly reporting of all materials received, product processed and sales made
17
Fig. 2.0 See next page for inventory log
Material Sheet. September, 2023
Date Product Type Weight (kg) Weight After Ded. (kg) Average Rate Amount(Naira) Remark
09/01/2023 Lose (Unsorted PETs) 2,985 100 299,485
09/02/2023 Lose (Unsorted PETs) 702 100 70,200
09/03/2023 Lose (Unsorted PETs) 0 0 0
09/04/2023 Lose (Unsorted PETs) 1,531 102 156,162 Completed
09/05/2023 Lose (Unsorted PETs) 1,902 1,708 102 174,045 Completed
09/10/2023 Lose (Unsorted PETs) 0 Completed
09/12/2023 Lose (Unsorted PETs) 765 100 76,500 Completed
09/16/2023 Sorted PETs 10,294 162.38 1,671,540 Completed
09/17/2023 Unwashed PETs Flakes 1,343 180 241,740 Completed
09/18/2023 Lose (Unsorted PETs) 1,772 111.6 197,755 Completed
09/24/2023 Lose (Unsorted PETs) 0 Completed
09/29/2023 Lose (Unsorted PETs) 968 97.1 93,993 Completed
09/30/2023 Lose (Unsorted PETs) 3,394 111.63 378,872 Completed
18
63,343 6,685,471
Avg bottle price 105.5439618
Introduction to Production department
This was my core place of assignment, this department is sadled with the responsibility of
converting Plastic PETs bottles into cold washed flakes before they are packaged and stored
in the warehouse for export.
We have the following machines and systems here to make the crushing/shredding operatons
possible
⚫ Crusher 1
⚫ Cruhser 2
⚫ Screw conveyors
⚫ Blower and dryer
⚫ Water system/ channel
Crusher 1 comprises of the rotary shaft, 37.5kw electric motor, 10 blades (4 stationary and 6
rotary,control panel, 4 belts that drives the shaft conneted to the motor. It also has the inlet
and exit funnel for material input and output of shredded flakes before they are conveyed to
the blower and drier unit.
Crusher 2 is same as crusher 1 the only difference here is the capacity of the electric motor
which is 18.5kw
The conveyors carrys the crushed flakes into the blower and dryer where they are spin clean
and dry and passes them out through its funnel for bagging and storage
19
The blower and dryer as the name implies, spins and dry wet crushed flakes before they are
bagged and stored for export
The water system is connected to the crushing machines, this allows water to get into the
machines as it crushes the PETs bottles, washing also happens silmultaneously. The waste
water after crushing is channeled into a near by soak away, once it get filled the water is
pumped out into the drainage and the cycle continues
Firstly, before crushing commence the crushers are made ready after a previous work. In
achieving this, you sharpen and set the blades to match different cutting angles, ensure badly
worn blades are totally replaced to avoid breaking during the process of shredding/crushing
In this department I leanrt so much about process flow and how it practiaclly works in real
life starting from the power system to the panels that controls the crushers, the conveyors, the
blowers and dryers, the crushing sequence and finally to the packing of the products before
export.
Daily/weekly reporting of all production activities including the challenges recorded and
solution proffered
20
Fig. 3.0 See table below for sample production report. (daily/Monthly)
Bluewater Eco Recycling. September, 2023 Production Data
Date Production Output(kg) Product Type Challenges
Week 1
09/01/2023 1,161.50 Green PETs Non, available quantity proccessed
09/02/2023 0 Maintenance of washline area
09/05/2023 679 Cold washed PETs Maintenance of washline area
09/06/2023 3,048 Cold washed PETs None
09/10/2023 Cold washed PETs
09/14/2023 1,768 Cold washed PETs Circuit breaker failure
09/15/2023 1,130 Cold washed PETs Circuit breaker failure & Gen overheat
09/18/2023 2,993.50 Cold washed PETs None
09/19/2023 2,372 Cold washed PETs & Green None
09/20/2023 2,700 Cold washed PETs & Green None
09/21/2023 2,447 Green PETs None
09/22/2023 1,834 Cold washed PETs Radiator failure from generator
09/24/2023 None
21
57,107.00
22
Fig. 4 crushing machinem and blower machine
23
24
25
Introduction to quality control Unit.
This unit is saddled with the most simplest task in the facility yet the most complex, because
it requires high level of dedication. This unit ensures that the quality of material purchased is
of standard, the sorted PETs bottles are well checked, labels and PP covers removed before
sending the materials to the production hall for processing.
After processing the quality of flakes produced is also examined in terms of the flakes size
which must be 14mm, the colour of flakes must be checked, its moisture content must be
checked, also the packing process of the products must be equally inspected to meet export
standard.
Then during export loading, this unit also ensures that the loading is well carried out and all
details of the loadng is well documented. For example during loading operation, once the
container arrives site you do a 30 seconds video showing when the container is empty, you
also capture the container number. After that you video again at 30% completion, 50%
completion, 70% completion and finally 100%
Afer the loading is completed, this unit raises waybill for the driver and also the packing slip
for the client abroad.
I spent one week in this department, so much knowledge was acquired within the shortest
possible time
Introduction to Power house/Generator Unit
I spent one week in this department/unit, the following task were taught and performed daily
⚫ Check oil level
⚫ Check diesel level and daily diesel consumption
⚫ Check water level

26
⚫ Check the panels to see oil pressure, voltage reading, temperatures etc before powering
ON your generator
⚫ Daily routine check as the generator runs, here I was taught the basis on how to manage a
plant
⚫ Daily/weekly reporting
27
Fig 5.0 Generator unit
28
CHAPTER THREE
NEW SKILLS ACQUIRED
In the course of my six (6) months industrial training, and upon completion made me to
acquire the following skills;
Safety Skills: Working in the company’s safety department has exposed me to a whole lot of
information about safety as regard our everyday work practice, I was made to understand that
safety practice is the duty of every employee and for any company to strife high they must
have a good safety state of consciousness.
Cutting and Grinding operations: Before now I had no prior knowledge on how to remove
and fix the cutting and grinding disc, but today I can confidently carryout maintenance on it.
Running and maintenance of crushers and blower machines
Packaging of cold washed PETs flakes to meet export standard
Fault diagnoses on PETs recycling plants, panels etc
Inventory management and control
Quality control
29
CHALLENGES
Student Industrial Work Experience Scheme (SIWES) comes with a lot of responsibilities
and challenges, the following are some of the challenges I encountered;
Lack of Facilities: The Company where I served, did not make provision for enough
tools/equipment and these made most of the task/operation more difficult and time
consuming.
Inaccessible Machines: Students are mostly not given the opportunity to operate
machineries and this also retarded their speed in learning.
Finance: Companies/establishment did not make provision for payment of IT students.
Power Failure: Most of our operations were never completed due to power failure from
the generator, government should provide steady power supply
Problem of Securing A Place of Attachment: This happens to be the most challenging
aspect of the training programme.
30
CHAPTER FOUR
CONCLUSION
It is pertinent to mention that the much desired technical competence for effective and
efficient operation of the Nigerian industries could be actualized with the current
revitalization of SIWES training programme in all the polytechnics/universities around the
country, at this point I therefore wish to thank the management of SIWES programme and
similarly, I do hope that this programme amongst others will surely develop the much needed
highly skilled labour force required to build the indigenous self-reliant economy envisaged by
this current administration for Nigeria.
My few months of industrial training was very educative and enjoyable, this scheme indeed
has exposed me to a lot of problem solving ranging from;
Safe working awareness
Inventory Management and control
Use of crushing machine and blower machine
Production process for (Cold wash flakes)
Quality control and its processes
SOLUTION TO THE PROBLEMS HIGHLIGHTED IN CHAPTER THREE
Lack of Facilities: Companies/establishments should be able to provide enough facilities for
any available work or project at hand.
Inaccessible Machine: Companies/establishment should give students more room to access
their equipment’s and they should also endeavor to teach them how to operate them.
Finance: Industrial training allowance should be paid to students to enable them meet up
with their transportation fare.
31
Power Failure: The management should ensure they review the power sector, so as to
maintain steady power supply. This will aid businesses to thrive better and meet up their
routine obligation
RECOMMENDATION
I wish to recommend that SIWES programme for university students should be extended
to a period of one year to enable the students acquire more practical experience that will
prepare them ready-made for the industrial upon graduation.
Securing of industrial place of attachment should not be left completely for the students,
also I want to commend the SIWES coordinator department of chemical engineering for
his effort during the period of students’ attachment.
Students should be paid their industrial training allowance on time so that they can be
motivated.
32
References;
COREN (1991). Supervised Industrial Training Scheme in Engineering (SITSIE). Council of
Registered Engineers of Nigeria.
ITF (1973). Policy Document No 1. Industrial Training Fund, Jos, Nigeria.
Industrial Training Fund, Federal Republic of Nigeria (2008) Students Industrial Work
Experience Scheme.
33

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SIWES REPORT Nov 13, 2023

FEDERAL UNIVERSITY, OTOUKE

DEPARTMENT OF CHEMICAL ENGINEERING

Experience of NWACHUKWU PRECIOUS CHIBUZOR of the Department of Chemical

Engineering whose matriculation number is FUO/18/CME/7467

cold washed flakes (5) Fault diagnoses

my (SIWES) training programme.

Table of Contents - - - - - - - - v-vi

Introduction to SIWES - - - - - - - 1-2

Introduction to PETs recycling and its processes - - - - 3

Areas of service and division - - - - - - - 4-6

General experience on industrial training - - - - - 7

Induction to the company and job - - - - - - 7-11

Introduction to basic engineering - - - - - - - 12-14

Introduction to Inventory department - - - - - 15

Inventory log and others - - - - - - 16

Production Processes - - - - - - - - 17-21

Description of crusher 1 - - - - - - - 22-25

Pictorial representation of work done - - - - - - 26-27

New skills acquired - - - - - - - - 28

Inventory control management - - - - - - 28

Use of crushing machine - - - - - - - 28

Quality control and its processes - - - - - - - 28

Fault diagnoses on PETS recycling plant - - - - - 28

and the national university commission (NUC)

available in the educational system.

accordance with the federal government directive.

BODIES INVOLVED IN THE MANAGEMENT OF SIWES PROGRAMME

The Federal Government of Nigeria

The Industrial Training Fund (ITF)

National University Commission (NUC)

National Board for Technical Education (NBTE)

National Commission for College of Education (NCCE)

Institute of Higher Learning; and

The Employers of Labour.

Technology, Environmental science, Medical science, Pure & Applied science.

The objectives of SIWES according to Industrial Training Fund (ITF) are;

2 To expose student to work methods and techniques in handling equipment’s and

machineries that may not be available in their institutions.

3 To promote industrialization in Nigeria.

enable students make contact for later job placement.

thereby bridging the gap between theory and practical.

Bluewater Eco Limited is a company based in portharcourt who’s activities is solely

years as the elephant of recycling

enabling our clients have prompt access to constant raw materials.

AREAS OF SERVICES AND DIVISIONS

• Providing cold wash PETs products for recycling companies abroad

• Inventory Management control

• Receiving of raw materials

• Waste evacuation (cleaner portharcourt city goals)

operation with their (80%) practical oriented training program

They offer the following courses:

• Inventory Management and control

• Plant Processes and maintenance

• Production work flow and damage control mechanism

BLUEWATER ECO LIMITED

INDUCTION TO THE COMPANY AND JOB

HEALTH AND SAFETY RULES

Health and Safety Policy and all applicable regulations

Reporting Injuries and Accidents/Incidents

All injuries and accidents/incidents, no matter how minor, must be reported in an

investigation and report it to management.