Tribhuvan University

INSTITUTE OF ENGINEERING
NATIONAL COLLEGE OF ENGINEERING
Talchhikhel, Lalitpur

Department of Electronics and Computer Engineering

A Case Study on
Manakamana Plastic Industry
Patan Industrial Area, Lalitpur

Submitted by: Date of submission:

Kasti Nakarmi (078BEI005) 2080-05-03
Kelsan Pradhan (078BEI006)
Paras Gyawali (078Bei007)
Sujin Prajapati (078BEI012)
Sushan Shrestha (078BEI013)
Swostika Dahal (078BEI014)
ACKNOWLEDGEMENT

Firstly, we would like to express our gratitude towards everyone who has been a
part of this case study, for this report is the evident result of all the coordination,
support and guidance of the authorities involved. We are utterly thankful to our
subject teacher of Instrumentation, Er. Suraj Burlakoti, for assisting us with
proper knowledge, support and guidance for the study. We would like to thank our
Head of Department, Er. Anup Shrestha, for the immense support during the
study.
We heartfully thank the officials of Manakamana
Plastic Industry as well for their coordination to feed our curiosity about the
particular subject during our industry visit, and our special thanks to Patan
Industrial Area for letting us through for the visit.

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Table of Contents

ACKNOWLEDGEMENT 1
1. Introduction 3
1.1. Background 3
1.2. Objective 4
1.2.1. Primary Objective 4
1.2.2. Specific Objective 4
1.3. Methodology 4
1.3.1. Primary Sources 4
1.3.2. Secondary Sources 4
1.4. Limitations 5
1.5. Significance 5
2. Main Operation 5
2.1. Injection Molding 6
2.2. Blow Molding 8
3. Daily Production, Cost Estimation and Power Consumption 12
4. Recommendation 12
4.1. Automated Injection Molding 12
4.2. Robotics for Material Handling 12
4.3. Conveyer System 13
4.4. Process Monitoring and Control 13
4.5. IoT and Industry 4.0 13
4.6. Energy Efficiency 13
5. Conclusion 14

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1. Introduction

1.1. Background

Patan Industrial Estate was established in 1962 with the help of India and is
managed by the Industrial Districts Management Ltd, a government undertaking. It
covers an area of 293 ropanies with 220 ropanies leased to industries and 73 ropanies
occupied by the service sector. The estate offers infrastructure like land, electricity,
water, and drainage facilities for a 40-year lease at reasonable fees to support easy
establishment and smooth operations of industries.

Currently, 113 out of 116 industries are operating in the estate, with a combined
private sector investment of over 170 crores and government sector investment of 4.01
crores. It has its electricity distribution network consuming 4600KVA and a water
production capacity of 2 lakh liters per day. The estate focuses on promoting handicraft
and cottage industries, as well as encouraging local entrepreneurship, especially in arts
and crafts like wood, stone, metal, plastics and textiles. It also supports the establishment
of other manufacturing industries to reduce imports and meet local needs.

Manakamana Plastic Industry is one of the 18 plastic industries in the Patan

Industrial Estate, that has been now manufacturing plastic bottles for the drinks and
beverages. The date of establishment and other detailed background of this establishment
has been unknown to us since it can be categorized under a small-scale industry and we
couldn’t get to meet a particular individual for further details with proper knowledge of
the background of this industry.

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1.2. Objective

1.2.1. Primary Objective

The Primary objective of this case study is to visit a particular organization
relevant to the course subject and observe and learn about the operation of the
system involved under the supervision of senior engineers and technicians.

1.2.2. Specific Objective

We have the following specific purposes for the study:
• To observe and learn about the technology used in the industry
• To be familiarized with the operation of the instrumentation system
used for the manufacture
• To study the problems faced by the industry in operation and propose
appropriate designs for automation and improved stability

1.3. Methodology
Over the study period, both primary and secondary sources of information were
employed as hinted below:

1.3.1. Primary Sources

We gathered some raw useful information from these primary sources like the
senior engineers, technicians and the workers employed in the industry. We
observed the operation of machines and visited the prefecture related to the
technology where we were allowed by the authorities. From that we were able
to acquire basics for the block diagram, fundamentals of the operation and
challenges the industry has to face.

1.3.2. Secondary Sources

We roamed around the college library flipping books, visited the internet and
previous reports for reference before and after the industry visit. These
sources of information were truly crucial and only the ones that were
beneficial for us were filtered and hence referred to while preparing the report.

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 1.4. Limitations

We had to face some minor challenges during our study. Firstly, we were unable to
meet the owner of the industry which was really important to achieve some useful
information regarding the background of the industry. Unfortunately, we had to
complete the visit in a very limited amount of time, that led to missing out many
primary information and we ended up relying in secondary sources. Due to their
safety policy, only one person was allowed to observe machines as they were still in
work. We could therefore gather only very limited amount of information, that too in
a very short period of visit.

1.5. Significance

For us, this case study and industry visit had several significant benefits, and not to
mention to the organization involved as well. Here is a short and summarized list of
some of the significances:

• Understanding the manufacturing processes

• Knowledge of technology and machinery
• Quality Control and Standards
• Environmental benefits and drawbacks
• Networking Opportunities
• Building trust and relationships, etc.

2. Main Operation

The main operation of the plastic manufacturing process and mechanisms can be
encapsulated in following points:

• Processing of plastic resins, usually in the form of pellets or granules

• Heating, melting and shaping of plastic in injection molding
• Final shaping and design of plastic bottle in blow molding
• Cooling, trimming and finishing

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These points cover the essential steps involved in plastic bottle manufacture, highlighting
the key stages of processing, molding, and finishing to produce the final product. The
temperature control and time for the mixing of ingredients were crucial for the making of
suitable molds and shapes.
The ingredients and chemicals used during the manufacture are as follows:

• Polyethylene terephthalate (PET) resin: It is the main ingredient used in making

plastic bottles. The chemical composition of PET includes Carbon, Hydrogen and
Oxygen atoms, and it is derived from petroleum.

In addition to the primary ingredient, the manufacturers use various

additives and chemicals as per their requirements to ensure the quality and healthy
products. Some of these additives include:
• Plasticizers
• Colorants
• Stabilizers
• Antioxidants
• Release agents
• Chain Extenders

It’s important to note that the use of chemicals and additives in plastic bottle
manufacturing is subject to strict regulations and guidelines to ensure the safety of final
product and its compliance with food-grade standards. Manufacturers follow these
regulations to ensure that these bottles are suitable for use with food and beverages and
are safe for consumer use.
The following processes and instruments were used for the manufacture of the
plastic bottles from the above-mentioned ingredients:

2.1. Injection Molding:

Injection molding is a manufacturing process for producing parts by injecting

molten material into a mould. Plastic injection moulding can produce a wide variety of
plastic parts, ranging from small, intricate components to large, complex structures. This
process can be used to produce parts for a range of industries, including automotive,
medical, consumer goods, and more.

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Injection moulding uses a special-purpose machine that has three parts:
• The injection unit
• The mold
• The clamp
Parts to be injection-moulded must be very carefully designed to facilitate the
moulding process. The materials used the desired shape and the features of the plastic
bottles to be manufactured and the bottle caps of the corresponding bottles must all be
considered. The injection moulding machine is based on an extruder barrel and screw
assembly which melts the polymers. The molten polymer is fed into a manifold where it is
injected through nozzles into a hollow, heated preform mould (of bottle and bottle caps).

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The preform mould forms the external shape and is clamped around a mandrel (the core
rod) which forms the internal shape of the preform. The preform consists of a fully formed
bottle/jar neck with a thick tube of polymer attached, which will form the body.

Advantages of using Injection Moulding:

• It allows for complex geometries with tight tolerances
• It’s compatible with wide range of materials and colours
• It’s very efficient
• It offers high repeatability and reliability
• The materials can be reused

Disadvantages of using Injection Moulding:

• Start-up costs are high
• Initial lead times are long
• Design changes are expensive

2.2. Blow Molding: “A Manufacturing Process for Hollow Plastic Parts”

Blow molding is a manufacturing process used to produce hollow

plastic parts or containers. It is a popular method for creating various plastic products,
such as bottles, containers, jars, and other hollow shapes. The process involves the
extrusion of molten plastic, followed by the shaping of the plastic into the desired
form using compressed air.

Blow molding is the versatile process that allows for the production of
various sizes and shapes of plastic products. It is widely used in industries such as
packaging, automotive, consumer goods, and medical equipment due to its cost-
effectiveness and efficiency in mass-producing plastic products.

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In general, the main types of blow molding include:

2.2.1. Extrusion Blow Molding (EBM):

This is the most common type of blow molding. It involves melting plastic
resin and extruding it into a hollow tube called a parison. The parison is then clamped
into a mold, and compressed air is used to inflate it to the shape of the mold. After
cooling and solidification, the part is removed from the mold.

2.2.2. Injection Blow Molding (IBM):

This process combines injection molding and blow molding. A preform is
produced using injection molding, which is a solid piece with a small opening called
a neck finish. The preform is then transferred to a blow molding machine, where it is
heated and blown into the final shape using compressed air.

2.2.3. Stretch Blow Molding (SBM):

In this process, a preform is also produced using injection molding. The
preform is then reheated and stretched in the axial direction to orient the molecular
structure. Finally, it is blown into the final shape using compressed air.

2.2.4. Injection Stretch Blow Molding (ISBM):

This is a variation of stretch blow molding where the preform is stretched first
and then blown in the same machine. It is commonly used to produce PET bottles for
beverages and other liquids.
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 2.2.5. Rotational Blow Molding:
In this process, the mold rotates while the plastic is being blown into the mold
cavity. This method is typically used for large, hollow objects like tanks, drums, and
toys.

2.2.6. Compression Blow Molding:

Compression blow molding starts with a heated plastic preform placed in a
mold cavity. The mold is then closed, and compressed air is used to expand the
preform to take the shape of the mold.
Each type of blow molding has its advantages and is suitable for different
applications based on factors like cost, production volume, complexity of the part,
and material used. Manufacturers choose the most appropriate blow molding
technique based on their specific needs and product requirements.

Advantages of blow molding:

• Cost-effective: Blow molding is a cost-effective manufacturing method for producing
plastic parts and containers in large volumes. The process is relatively fast and can
create complex shapes with minimal material wastage.

• Versatility: Blow molding can produce a wide range of products with varying shapes
and sizes, from simple bottles and containers to more complex automotive
components, toys, and medical devices.

• Lightweight: Blow-molded products are generally lightweight, making them ideal for
packaging and transportation, which can reduce shipping costs and carbon emissions.

• Strong and durable: Blow-molded products exhibit good strength and durability,
making them suitable for various applications where impact resistance is essential.

• Consistent quality: The process allows for consistent wall thickness, reducing the risk
of defects and ensuring the uniformity of the final product.

• Customization: Blow molding can be easily customized to meet specific

requirements, such as adding handles, threads, or logos directly during the
manufacturing process.

• Material options: Blow molding is compatible with various plastic materials,

including polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET),

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 and others, providing flexibility in selecting the right material for the intended
application.

• Short lead times: Compared to other manufacturing processes, blow molding can
offer relatively short lead times, allowing companies to respond quickly to market
demands.

• Sustainability: Many blow-molded products are recyclable, contributing to

sustainable practices and reducing the environmental impact of plastic waste.

• Automation-friendly: Blow molding processes can be easily automated, leading to

increased production efficiency and reduced labor costs.

Disadvantages of Blow molding:

• Limited material options: Although blow molding can work with a variety of plastic
materials, it is not suitable for all types of plastics. Some high-temperature
engineering plastics and certain specialty materials may not be compatible with the
blow molding process.

• Design restrictions: The process may have design limitations, particularly in the
complexity of shapes that can be achieved. Certain intricate designs or features may
be challenging to produce through blow molding.

• Initial setup costs: Setting up a blow molding operation can require significant
investment in machinery and tooling, making it more feasible for large production
runs. This can be a barrier for smaller companies or those with lower production
volumes.

• Thin wall limitations: While blow molding can create hollow parts with consistent
wall thickness, extremely thin walls can be challenging to achieve, and it may affect
the overall strength and durability of the final product.

• Long cooling times: The cooling process for blow-molded parts can take time, which
may slow down production cycles. Cooling rates can be affected by the part's
thickness and size.

• Environmental concerns: Blow molding relies on plastic materials, and while some
blow-molded products are recyclable, many single-use plastic items end up in
landfills or contribute to environmental pollution if not disposed of properly.

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3. Daily Production, Cost Estimation and Power Consumption

As per the information provided by the technicians in the industry, there are
currently two injection molding machines and two blow molding machines, in which one
of each are semi-automatic and the other ones are automatic. The average production of
the bottles of 1 liter each is estimated to be about 1500-1800 in each machine per hour,
that makes around 3,000-3500 bottles per hour from both the machines. Total estimation
of defective bottles is reported to be 2% overall in a month.

Talking about the cost estimation and power consumption, the industry alone has
a large electricity bill of NRs.4 lakhs per month from the total Estate electricity. The cost
of and total number of bottles manufactured depend solely on the cost the raw materials
and demand of the customers. The cost for each machine may vary from around NRs.10
lakhs to NRs.16 lakhs, depending on the level of automation and excluding the servicing
and maintenance charges.

As per the power consumption, energy is required in the production of raw PET
material and production of PET bottles, which is provided by various means like gas,
petroleum and local electricity network. As per the power rating of the machines, the
average approximate power a PET blowing machine is 8KW to 12KW depending on the
level of automation.

4. Recommendation
Here are some of the recommendations we could bring up after analyzing the
management and instrumentation in the industry:

4.1. Automated Injection Molding/Blow molding machines:

Use of advanced, computer-controlled machines that can automatically adjust

processes parameters, monitor quality, and optimize cycle times. These machines
reduce human errors and ensure consistency in production.

4.2. Robotics for material Handling:

Use of robotics for material handling decreases the manpower cost and manual
labor and increases the speed and efficiency of work.

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4.3. Conveyer Systems:

Implementation of conveyer systems to transport bottles through different stages

of the manufacturing processes, enabling a smooth, continuous flow, and reducing
the need for manual handling.

4.4. Process Monitoring and Control:

Employment of sensors and data analytics to monitor and control various process
parameters, such as temperature, pressure and cycle times. This helps optimize
production efficiency and identify potential issues before they escalate.

4.5. IoT and Industry 4.0:

Embracement of the principles of Industry 4.0 by integrating IoT (Internet of

Things) devices and smart sensors. This helps in real-time data collection, remote
monitoring, predictive maintenance and data-driven decision making.

4.6. Energy Efficiency:

Implementation of automation strategies that promote energy efficiency, such as

using energy-efficient motors, optimizing heating and cooling processes, and
implementing on-demand power systems.

By implementing these recommendations, the industry can certainly enhance

productivity, quality, and overall competitiveness in the market reducing operational
costs and minimizing the environmental adversities.

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5. Conclusion

Summing up the report, we can conclude by stating the obvious that this case
study has been a vital learning factor for students like us who need to learn about the
instrumentation as our course subject as well.
We were able to get a grasp of the principles and operation of different systems
and procedures. Various aspects of an industry such as production capacity, technology
and management, quality control, workforce, market demand, environmental impact,
business practices, cost considerations, competitiveness and more so were observed and
analyzed.
Overall, visiting the industry allowed us to gather valuable insights of the
operations, processes and dynamics of the industry, helping us make informed decisions
or recommendations based on our common objectives, whether for business purpose,
research or evaluations.
The considerations on our recommendation and evaluations will surely bring upon
some positive changes and ultimate profit to the organization as well. This will help the
industry improve their productivity and reduce errors in the overall production of bottles.

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