Plastics

Importance of plastics manufacture

Plastics make our modern world possible. Without the cheap durable
components that plastic makes possible, many of our modern
conveniences would not be possible.
Plastics can be mass manufactured like no other material type.
Plastic controversy
Plastics have been frowned upon for the last decade due to their
durable nature. Due to the fact that they are cheap and durable it
creates a problem with waste.
However plastics are on the whole easy to dispose of. Either by
recycling or incineration.

The big problem is responsible disposal procedures. Make sure your

plastics are disposed of in eco friendly ways.
Most used plastics
1.Polyethylene (PE) - Approximately 34% of global plastic production
2.Polypropylene (PP) - Approximately 23% of global plastic production
3.Polyvinyl Chloride (PVC) - Approximately 16% of global plastic production
4.Polyethylene Terephthalate (PET) - Approximately 10% of global plastic production
5.Polystyrene (PS) - Approximately 6% of global plastic production
6.Polyurethane (PU) - Approximately 5% of global plastic production
7.Other types of plastics - Approximately 6% of global plastic production
1. Polymethyl Methacrylate (PMMA)
2. Polycarbonate (PC)
3. Polyamide (PA or Nylon)
4. Acrylonitrile Butadiene Styrene (ABS)
5. Poloxymethylene (POM or Acetal)
6. Polyethylene Naphthalate (PEN)
7. Ethylene Vinyl Acetate (EVA)
Recyclable plastics
1.Polyethylene Terephthalate (PET): Widely recycled and used in bottles, food
containers, and textiles.
2.High-Density Polyethylene (HDPE): Commonly recycled and used in milk jugs,
detergent bottles, and shopping bags.
3.Low-Density Polyethylene (LDPE): Recyclable, used in plastic bags, films, and food
packaging. Recycling rates are generally lower than PET and HDPE.
4.Polyvinyl Chloride (PVC): Recyclable but not as widely accepted as PET and HDPE. It is
used in construction materials, pipes, and vinyl products.
5.Polypropylene (PP): Recyclable and used in food containers, bottle caps, and
automotive parts.
6.Polystyrene (PS): Recyclable, but not widely accepted due to its low density and
difficulty in transportation. It is used in foam packaging, disposable cutlery, and cups.
Making plastics
Steam cracking, also known as pyrolysis, is a process used in the petrochemical industry to break
down large hydrocarbon molecules from crude oil or natural gas into smaller, more valuable
molecules, such as ethylene, propylene, and other olefins. The process involves the use of high
temperatures, pressure, and steam to initiate the chemical reactions.
1.Feedstock preparation: The feedstock, which can be naphtha derived from crude oil, natural gas
liquids (NGLs), or other hydrocarbon sources, is first treated to remove impurities, such as sulfur
compounds. This is important because impurities can deactivate the catalysts used in
subsequent processes and produce undesirable byproducts.
2.Preheating: The purified feedstock is mixed with steam and preheated in a series of heat
exchangers, typically to a temperature of around 500-700°C (932-1292°F).
3.Cracking furnace: The preheated feedstock and steam mixture is then introduced into a cracking
furnace, where it is heated further to a temperature of approximately 750-900°C (1382-1652°F)
or even higher, depending on the feedstock and the desired products. The high temperatures
cause the large hydrocarbon molecules to break down (crack) into smaller molecules.
4. Quenching: The cracked hydrocarbon mixture is rapidly cooled, or quenched, to stop the cracking
reactions and prevent further reactions that could lead to unwanted byproducts or coke formation.
This is typically done by introducing a quench oil or water stream into the cracked mixture.
5. Fractionation: The cooled mixture is then sent to a fractionation column, where it is separated into
different components based on their boiling points. The lighter components, such as ethylene and
propylene, rise to the top of the column, while heavier components, such as naphtha and gas oils,
remain at the bottom.
6. Product purification: The separated components are further purified to remove impurities and any
remaining byproducts. For example, ethylene and propylene may undergo additional distillation,
scrubbing, or adsorption processes to remove trace amounts of acetylene or other unwanted
compounds.
7. Recovery and recycling: Some byproducts, such as hydrogen and fuel gas, can be recovered and
used as fuel in the cracking furnaces or other processes. Unreacted feedstock and other valuable
components can be recycled back into the process to improve overall efficiency and yield
How to make Polyethylene
1.Raw material extraction: Ethylene is obtained from the steam cracking of hydrocarbons, such as
natural gas liquids (NGLs) or naphtha from crude oil. The hydrocarbon feedstock is heated at high
temperatures, causing the molecules to break down into smaller components, including ethylene.
2.Polymerization: Ethylene molecules are polymerized to form polyethylene chains. This reaction takes
place in a high-pressure or low-pressure reactor, depending on the desired type of polyethylene.
1. High-Density Polyethylene (HDPE): HDPE is produced using low-pressure polymerization in the presence of a
catalyst, typically a Ziegler-Natta catalyst or a metallocene catalyst. The low-pressure process allows for more
controlled polymerization, resulting in a more linear polymer structure with fewer side branches.
2. Low-Density Polyethylene (LDPE): LDPE is produced using high-pressure polymerization (up to 2,000-3,000
atmospheres) and high temperatures (up to 200-300°C) without the use of a catalyst. The high-pressure process
results in a more branched polymer structure, which gives LDPE its characteristic flexibility and lower density
compared to HDPE.
3.Post-polymerization processing: Once the polymerization reaction is complete, the resulting
polyethylene mixture is separated from any unreacted ethylene, catalyst residues, and other
byproducts. The mixture is then cooled, and the polyethylene is solidified and cut into pellets or
granules.
How to make polypropylene
1.Raw material extraction: Propylene is obtained from the steam cracking of
hydrocarbons, such as natural gas liquids (NGLs) or naphtha from crude oil. The
hydrocarbon feedstock is heated at high temperatures, causing the molecules to break
down into smaller components, including propylene.
2.Polymerization: The propylene molecules are polymerized to form polypropylene
chains. This reaction takes place in a reactor, typically under low pressure and
moderate temperature. The polymerization process uses a catalyst, most commonly a
Ziegler-Natta catalyst or a metallocene catalyst, which controls the reaction and
influences the properties of the resulting polymer.
3.Post-polymerization processing: After the polymerization reaction is complete, the
resulting polypropylene mixture is separated from any unreacted propylene, catalyst
residues, and other byproducts. The mixture is then cooled, and the polypropylene is
solidified and cut into pellets or granules.
Types of processes
1.Injection Molding
2.Extrusion
3.Blow Molding
4.Thermoforming
5.Compression Molding
6.Rotational Molding
7.Additive Manufacturing (3D Printing)
Plastic injection molding
• This was covered in casting and will not be covered again. It is a very
important process
Plastic extrusion
Plastic extrusion is a manufacturing process used to create continuous, uniform plastic profiles or products with a
consistent cross-sectional shape. This process involves melting raw plastic materials, usually in the form of pellets
or granules, and forcing them through a shaping die to create the desired profile. Extrusion is commonly used to
produce items such as plastic pipes, tubing, films, sheets, rods, and profiles like window frames or siding.
Here's an overview of the plastic extrusion process:
1.Raw material preparation: The raw plastic material, usually in the form of pellets or granules, is mixed with any
required additives, such as colorants, stabilizers, or fillers, to achieve the desired properties for the final product.
2.Feeding: The prepared plastic mixture is fed into the extruder's hopper, a funnel-shaped container that holds the
plastic materials before they enter the extrusion process.
3.Extruder barrel and screw: The plastic materials move from the hopper into the extruder barrel, which houses a
rotating screw. As the screw turns, it conveys the plastic materials along the barrel, generating heat through
friction and external heaters along the barrel, which causes the plastic to melt gradually. The screw also mixes
the plastic materials and additives, ensuring a consistent and homogenous melt.
4.Melt compression: As the molten plastic reaches the end of the barrel, the screw's compression zone forces the
melt through a small opening, called the extrusion die, which is specifically designed to create the desired cross-
sectional shape or profile.
5. Shaping die and extrusion: The molten plastic exits the extruder through the shaping
die, which determines the final product's cross-sectional shape. The continuous plastic
profile is then cooled, typically by air or water, to solidify and maintain its shape.
6. Cooling and sizing: After extrusion, the plastic profile is passed through a series of
cooling and sizing equipment, such as calibrators or vacuum sizing tanks, to ensure
that the product maintains its shape and dimensions while cooling.
7. Cutting or winding: Once the plastic profile has been cooled and solidified, it is either
cut to the desired length (for items like pipes, rods, or profiles) or wound onto a roll
(for films or sheets).
8. Inspection and packaging: The finished products are inspected for quality, such as
dimensions, surface finish, and color consistency, before being packaged for shipment
or storage.
Blow molding
• Blow molding is a manufacturing process used to produce hollow
plastic products with a uniform wall thickness. It involves inflating a
molten plastic tube, called a parison or preform, inside a closed mold
cavity to create the desired shape. Blow molding is commonly used to
make items like plastic bottles, containers, toys, automotive parts, and
fuel tanks.
• There are three main types of blow molding: extrusion blow molding,
injection blow molding, and stretch blow molding. While the specific
steps may vary slightly between these methods, the general principles
remain the same. Here's an overview of the blow molding process:
1.Raw material preparation: The raw plastic material, typically in the form of pellets or granules, is
mixed with any required additives, such as colorants, stabilizers, or fillers, to achieve the desired
properties for the final product.
2.Plastic melting: The prepared plastic mixture is fed into the barrel of an extruder or injection
molding machine, where it is heated and melted using a combination of friction and external
heaters. The molten plastic is then conveyed to the molding stage by a rotating screw.
3.Parison or preform formation: In extrusion blow molding, the molten plastic is extruded through
a die to form a hollow tube called a parison. In injection blow molding and stretch blow molding,
the molten plastic is injected into a preform mold to create a preform, which is a partially
shaped, solid piece that will be later inflated to form the final product.
4.Inflation and molding: The parison or preform is placed inside a two-part mold cavity that
defines the final product's shape. Pressurized air is introduced into the parison or preform,
inflating it against the mold cavity walls. This step is known as blowing, and it forms the hollow
shape of the final product.
5. Cooling and solidification: The inflated plastic is allowed to cool and solidify while
still inside the mold. Cooling can be achieved through direct contact with the mold
walls or by using additional cooling methods, such as water or air circulation.
6. Ejection: Once the plastic product has cooled and solidified, the mold is opened, and
the finished item is removed, typically by an ejection mechanism or manually.
7. Trimming and finishing: Any excess material or flash, which may have formed at the
mold's parting lines, is trimmed from the product. Additional finishing steps, such as
labeling, decoration, or assembly, may also be performed as needed.
8. Inspection and packaging: The finished products are inspected for quality, such as
dimensions, wall thickness, and surface finish, before being packaged for shipment
or storage.
Thermoforming
Thermoforming is a manufacturing process used to create plastic parts
and products by heating a flat plastic sheet and forming it into a desired
shape using a mould. The process involves heating the plastic sheet
until it becomes pliable, placing it over or into a mold, and applying
pressure or vacuum to form the desired shape. Thermoforming is
commonly used to produce items such as packaging, trays, containers,
automotive parts, and appliance components.
1.Raw material preparation: The raw plastic material, typically in the form of flat sheets or rolls, is
selected based on the desired properties of the final product. Commonly used plastics for
thermoforming include polystyrene (PS), polyethylene (PE), polypropylene (PP), polyvinyl chloride
(PVC), and acrylic.
2.Heating: The plastic sheet is heated using infrared heaters, hot air, or contact heating until it
reaches its forming temperature, which is the point where the plastic becomes soft and pliable.
The heating process must be carefully controlled to ensure the sheet reaches a uniform
temperature without overheating or degrading the material.
3.Forming: The heated plastic sheet is placed over or into a mold, and pressure or vacuum is applied
to conform the sheet to the mold's shape. There are several forming methods used in
thermoforming, including:
1. Vacuum forming: The heated sheet is placed over the mold, and a vacuum is applied to draw the plastic
against the mold surface, forming the desired shape.
2. Pressure forming: The heated sheet is placed over the mold, and positive air pressure is applied to force the
plastic sheet against the mold surface, forming the desired shape.
3. Drape forming: The heated sheet is draped over the mold, and gravity or a slight vacuum is used to help the
plastic conform to the mold surface.
4. Plug-assisted forming: A mechanical plug is used to push the heated sheet into the mold before vacuum or
pressure is applied, improving material distribution and detail reproduction.
5. Cooling and solidification: Once the plastic sheet has conformed to the mold's
shape, it is allowed to cool and solidify, typically through contact with the
mold or by using additional cooling methods, such as air or water circulation.
6. Trimming and finishing: After the formed plastic part has cooled and
solidified, it is removed from the mold, and any excess material or flash is
trimmed away using cutting tools or automated trimming machines.
Additional finishing steps, such as drilling, painting, or assembly, may also be
performed as needed.
7. Inspection and packaging: The finished products are inspected for quality,
such as dimensions, surface finish, and detail reproduction, before being
packaged for shipment or storage.
Compression moulding

Compression molding is a manufacturing process used to form plastic

or composite materials into a desired shape by applying heat and
pressure. It involves placing a preheated, pre-measured amount of
material, called a "charge" or "preform," into an open mold cavity and
then closing the mold, applying pressure, and maintaining heat until
the material has cured, hardened, or solidified. Compression molding is
commonly used to produce items such as automotive parts, electrical
components, and composite materials, like sheet molding compounds
(SMC) and bulk molding compounds (BMC)
Rotational moulding

Rotational moulding, also known as rotomoulding or rotocasting, is a

manufacturing process used to produce hollow plastic products with a
uniform wall thickness. It involves heating a plastic material, usually in
the form of powder or granules, inside a rotating mould to form a
seamless, one-piece product. Rotational moulding is commonly used to
make items such as large storage tanks, containers, playground
equipment, and furniture.
Blown film extrusion
Plastic bags, specifically thin-film bags, are typically made using a
process called "blown film extrusion." This process is used to create
continuous, thin plastic film, which can be used to manufacture plastic
bags, packaging materials, and other similar products. The most
common material used for plastic bags is low-density polyethylene
(LDPE), though other materials like high-density polyethylene (HDPE) or
linear low-density polyethylene (LLDPE) can also be used.
1. Raw material preparation: The plastic material, usually in the form of pellets
or granules, is mixed with any required additives, such as colorants,
stabilisers, or slip agents, to achieve the desired properties for the final film.
2. Plastic melting: The prepared plastic mixture is fed into the barrel of an
extruder, where it is heated and melted using a combination of friction and
external heaters. The molten plastic is then conveyed towards the die by a
rotating screw.
3. Film formation: The molten plastic is extruded through a circular die,
forming a thin-walled tube called a "bubble." The bubble's size and wall
thickness are controlled by the extrusion rate, die gap, and the rate at which
the bubble is pulled away from the die.
4. Blowing and cooling: Air is blown into the bubble, inflating it and
increasing its diameter, while simultaneously cooling and solidifying the
plastic film. The bubble is carefully controlled to maintain a consistent
diameter and wall thickness throughout the process.
5. Collapsing and winding: As the plastic film cools and solidifies, the
bubble is collapsed into a flat, two-layer film using a set of rollers. The
flattened film is then wound onto a roll, forming a continuous sheet of
plastic film.
6. Conversion into bags: The plastic film rolls are sent to a converting
process, where they are cut, sealed, and printed as needed to create
the final plastic bags.