NATIONAL TEXTILE UNIVERSITY, FAISALABAD

SCHOOL OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MATERIALS

LAB REPORT NO. 5

SUBMITTED BY: NOOR FATIMA

REG. NO. 19-NTU-PE-1030

COURSE TITLE: POLYMER PROCESSING

COURSE CODE: PE-4103

SEMESTER: 5th

SUBMITTED TO: Engr. AYESHA AFZAL

DATE OF PERFORMANCE 12th November 2021

SUBMISSION DATE: 19th November 2021.

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Objective:
Production Of Small Recycled Thermoplastic Bottle of LDPE Using
Manual Blow Molding Machine.
Abstract:
In this experiment we use the recycled LDPE as a raw material for the manufacturing of
small recycled thermoplastic bottle through manual blow molding machine. Then evaluate
the defects in the bottle and find the reason due to which the defects have been prominent in
the final product. Then suggest the possible solutions to overcome the defects. At the end
calculate the price of one sample piece and also its waste.

Introduction:
The material which is used in this experiment to manufacture the thermoplastic bottle is
Recycled Low Density Polyethylene made from the ethylene monomer as shown in figure 1.
LDPE (low density polyethylene) is a soft,
flexible, lightweight plastic material.
Recycled LDPE melting temperature is
105°C - 115°C. LDPE is noted for its low
temperature flexibility, toughness, and
corrosion resistance. LDPE is defined by a
density range of 917-930 kg/m3.
Its intermolecular forces (instantaneous- Figure 1: Polyethylene Structure
dipole induced-dipole attraction) are weaker
so, molecules are less tightly packed and less crystalline due to the side branches that’s why
its tensile strength is lower, and its resilience is higher.
The machine which is used for this experiment is Manual Blow Molding Machine as shown
in figure 2. The blow molding process begins with melting down the plastic and forming it
into a parison. The parison is a tube-like hollow molten piece of plastic with a hole in one end
through which compressed air can pass. The parison is then clamped into a mold.

Figure 2: Manual Blow Molding Machine

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Experimental Procedure:
 The temperature of the barrel was 100℃-105℃ by heating it with external heaters.
 The mold was placed under the centre of the nozzle of barrel.
 Then hopper was filled with recycled pellets of LDPE.
 Then the knot of the plunger was turned by hand which rotated the wheel of the
plunger and the molten raw material from the nozzle came out in the form of parison
and filled the mold melting of resin took place in barrel.
 Then the mold was closed and preform was blown with pressurized air from blowing
unit (compressor). After few seconds mold was opened, and bottle was taken out.
Observation and calculation:
Troubleshooting Table:
Problem Causes Possible Solutions

Uneven wall ø Heating uneven.  Check heaters and controllers,

thickness. ø High melt temperature. adjust in the way so that
ø Insufficient back. pressure. temperature is in the
recommended range.
 Set melt temperature.
 Raise back pressure.

Excessive flash ø Melt too hot.  Decrease melt temperature.

ø Blowing air pressure too  Decrease back pressure.
high.  Decrease pre-blow air pressure.
ø Excessive material being  Decrease pre-blow time.
forced into mold.

contamination ø Dust.  Install filters or do regular

ø Dirty regrind. cleaning / purging.
ø Contaminated resin.  Keep contaminants out of
regrind isolate regrind.

Weld lines ø Low melt temperature.  Check heater and controllers,

ø Damaged die or mandrel adjust so that stock temperature
is in the recommended range.
 Replace tooling if scratches or
nicks are present.

Black specks ø Overheating of the  Purging of the equipment to

processing resin causing remove degraded parts.
degradation.  Proper controlling of heaters.
ø Excessive shearing of the
resin caused by back
pressure. incorrect screw
surface speeds
ø Too much residence time in
the barrel resulting in
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 degradation.
ø presence of a former resin
that is heat sensitive
degrading within the
processing resin.

Mathematical Calculations:
Weight of bottle with waste g
Weight of bottle without waste g
Time required to form 1 article 150s
Price of Recycled material (LDPE) per kg 350Rs/kg
Price of material (LDPE) per g 350Rs / 1000g → 0.35Rs/g
Price of material (LDPE) for 3.476g bottle (0.35Rs/g) * ( g) → Rs
Electricity Cost per minute 100Rs/100 → 1Rs.
Labour Cost 25Rs. /100 → 0.25Rs
Overheads per piece 1/100 → 0.01Rs.
Total cost of Cost of material + Electricity cost ( )+1+0.25+0.01 → 3.04Rs
a bottle + Labour cost + Overheads
Cost of Wt. of waste *price of material/g
waste
Cost of Total cost of a bottle – cost of () - () → Rs
bottle waste material
Result:
Small recycled thermoplastic bottle was formed, it contained defect due to poor controlling of
temperature and pressure.
Discussion:
It has been discussed that there are some benefits as well as draw backs of manual blow
molding. It is an economical process as less energy is consumed, smaller products can be
formed these are some advantages of manual blow molding. Basically, manual BM is used
for smaller scale production and its disadvantage include there is more risk of defects,
temperature and pressure control is difficult and low strength product is formed. The defects
appeared in the sample were basically due to poor controlling of temperature and pressure
like rough surface, uneven wall thickness and rocker bottom.
Conclusion:
In this experiment it has been concludes that it took a little longer to form the sample due to
resin association and poor handling of temperature. The bottle(sample) formed by manual
blow molding had defects associated with poor handling of temperature and pressure.

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