ME 233

Manufacturing Technology

PLASTIC
MANUFACTURING
INDUSTRIES In
BANGLADESH
Military Institute of Science & Technology
 1 INTRODUCTION

AGENDA 2 INDUSTRIES

3 MANUFACTURED PRODUCTS

4 MANUFACTURING PROCESS

5 MAPING & FLOW CHART

6 DESIGN CONSIDERATIONS

7 SUGGESTIONS

8 CONCLUSION
 OUR TEAM

A.S JAHIN Maliha Farhin Ashef Iftihaj Hasib Ishraq

202218002 202218038 202218012 202218049

Iram Mustavi Jinia Eva Jubaida Ahmed

202218030 202218032 202218033
INTRODUCTION
What is Plastic?
A synthetic material made from a wide range of
organic polymers that can be molded into shape
while soft, and then set into a rigid or slightly
elastic form.

Plastics have a range of unique properties

It is used in numerous packaging applications,

baby products, plastic toys, construction
materials, automotive and electronic parts
 Plastic industry overview in Bangladesh

5000 factories present where 15 lac people works.

142 plastic products are made.

Per capita consumption about 5kg/year.

Market Size: Total market size of US$ 2.9 billion in 2017-18 with a domestic market size of US$1.9
billion with 20% year on year growth.

Plastic manufacture is related to automotive, garments and medical field.

140 metric ton plastics are recycled every day in Bangladesh.

For raw materials mostly dependent on China, India, Thailand.

INDUSTRIES
INDUSTRIES
RFL Plastics Ltd :
There is no doubt that RFL Plastics Ltd. is the
biggest plastic manufacturer in the entire country.

Products:
The company manufacturers a variety of different
plastic products such as baskets, buckets,
containers, dust pans, jugs, kitchen items, racks,
tableware, tiffin boxes, trays, chairs, tables,
crates, and so much more
INDUSTRIES
Gazi Plastics :
Gazi Group was established in 1974 & is one of
the leading rubber and plastic manufacturers in
Bangladesh.

Gazi Tanks is the pioneer in manufacturing

plastic overhead water tanks

Products:
Gazi Tanks, Gazi Toys, Gazi Fittings, Gazi
Pipes, and Gazi Doors.
INDUSTRIES
Bengal Plastics :
Bengal Group of Industries started its journey in
1969.
The company processes more than 3,000 metric
tons of raw materials per month.

Products:
Chairs, Tables, Cabinets, Wardrobes, Garden
ware, Kitchenware, Tableware, Home
organizers, Crates, Mats, Pallets, etc
INDUSTRIES
NAVANA Plastics :
Navana Group is one of the most influential
business entities in Bangladesh

Products:
The company uses its expertise & state of the
art machinery to manufacture Household,
High-Density Polyethylene, UPVC, and PPR
products.
INDUSTRIES
Partex Plastics :
PPL’s policies on environmental, health, safety
and security have been a big indicator of the
company’s dedication to reducing and
minimizing negative impacts

Products:
PPR and PVC products like sockets, plugs,
elbows, tees, valves, pipes, etc. as well as
chairs, tables, stools, and several other kinds
of plasticware
 MANUFACTURING PROCESSES

INJECTION BLOW ROTATIONAL

EXTRUSION MOULDING
MOULDING MOULDING
 MANUFACTURING PROCESSES

INJECTION BLOW ROTATIONAL

EXTRUSION MOULDING
MOULDING MOULDING
 Material Selection
INJECTION Plastic material is supplied in the form of pellets, which are loaded into the
injection molding machine's hopper.

MOULDING Melting & Injection

Plastic pellets are then melted in the machine's barrel & forced into the
mold cavity through a screw or ram under high pressure.
Injection molding is a process used for thermoplastics &
thermosetting plastics. The process involves melting the plastic
material and injecting it into a mold under high pressure.
Cooling & Solidification
The cooling time is determined by the thickness of the plastic part, the
material being used, and the temperature of the mold.

Cooling & Solidification

Once the plastic part has solidified, the mold is opened, & the part is
ejected from the mold using ejector pins

Post Processing
Injection molding is a versatile process that can be used to produce After ejection, the part may require additional post-
complex shapes and geometries with high precision and consistency. processing. such as trimming excess plastic or adding
finishing touches.
 MANUFACTURING PROCESSES

INJECTION BLOW ROTATIONAL

EXTRUSION MOULDING
MOULDING MOULDING

EXTRUSION
Extrusion is a process used for creating long continuous pieces of
plastic with a consistent cross-section. The process involves melting
the plastic material and forcing it through a die, which shapes the
plastic into a specific shape. Extrusion is ideal for creating plastic
tubing, pipes, and sheets.
With a uniform cross-section, a variety of
plastic goods can be made
using this method. The method might not work well for
creating complex geometries or designs that call for
different wall thicknesses.
Material Selection
The plastic material is supplied in the form of pellets or powder, which are
loaded into the extruder's hopper
Melting & Mixing
The plastic material is melted & mixed in the extruder's barrel using a
combination of heat and mechanical action. The molten plastic is then
forced through a die, which shapes the plastic into a continuous profile.
Cooling & Sizing
As the plastic exits the die, it is cooled using a cooling bath or air stream to
solidify the plastic.
Co-Extrusion (Optional)
In some cases, multiple layers of plastic may be extruded simultaneously
using a co-extrusion process. This allows for the creation of products with
different properties or colors.
Finishing
Once the extruded product has been cooled and sized, it
may require additional finishing touches, such as printing,
cutting, or punching.
 MANUFACTURING PROCESSES

INJECTION BLOW ROTATIONAL

EXTRUSION
MOULDING MOULDING MOULDING

BLOW
MOULDING
Blow molding is a manufacturing technique used to create
hollow plastic parts by inflating a heated plastic tube
inside a mold until it forms into the desired shape.
PROCESS
1. Small plastic pellets are melted and formed into a hollow
tube, called the parison or preform (depending on the blow
molding subtype).
2. The parison is clamped into a mold and gets inflated by
pressurized air until it takes the shape of the inside of the
mold.

3. The part cools in the mold until it is solid enough to be

ejected.
 MANUFACTURING PROCESSES

INJECTION BLOW ROTATIONAL

EXTRUSION MOULDING
MOULDING MOULDING
 PROCESS

ROTATIONAL
1. Fill the hollow mold with powdered plastic resin.

MOULDING 2. Initiate bi-axial rotation of the mold.

3. Transfer the rotating mold into an oven.

Rotational molding (also called Roto-moulding) is a process that
involves heating a hollow mold filled with powdered thermoplastic 4. Maintain the rotation while the resin melts and evenly
and rotated around two axes to produce mainly large hollow objects. coats the inner walls of the mold

5. Cool the rotating mold to allow the resin to harden and

take the desired shape.
6. Stop the rotation and open the mold.

7. Carefully remove the finished part from the

mold
 MAPPING PROCESS
Suppliers Input Process Output Customers

Supply Department Production plan Supply materials Materials request Production department

Mixing area Raw materials Mixing process Different types of mixed Compound area
plastic and enhancers

Different types of mixed

Compound area plastic & enhancers Extrusion of plastic strings Plastic sheets Component’s area

Building area Components Shaping Final Shape Curing

Curing Final Shape Curing Process Final Product Finishing Area

Finishing Area Final Product Quality Check Discarded & Marketed Storage
products
 FLOW CHART
Material Preparation
Product Design &
Development
Injection Molding

Blow Molding
Plastic Molding
Processes
Extrusion

Thermoforming
Finishing and
Assembly
Trimming excess materials

Quality Control Assembling components

Post-Production
Processes (if
necessary)
Packaging and Adding labels or decorations
Distribution
 Design Considerations
1 Material Selection:
Choosing the right type of plastic material is crucial. Factors to consider include durability,
flexibility, transparency, chemical resistance, and suitability for the intended application.

2 Functionality :
The design should prioritize the intended function of the product. Considerations include ease
of use, ergonomics, and compatibility with other components or systems.

3 Aesthetics & Branding:

The appearance of the product is important for consumer appeal. Considerations include color,
texture, and the integration of branding elements.

4 Manufacturability
Design should facilitate efficient and cost-effective manufacturing processes. Considerations
include the choice of molding method (e.g., injection molding, blow molding), ease of
assembly, and minimization of complex features that may increase production costs
 Design Considerations
5 Durability & Structural Integrity:
Ensure the product is designed to withstand expected usage conditions. Considerations include
load-bearing requirements, impact resistance, and the prevention of stress concentrations.

6 Cost Efficiency:
Design decisions should take into account the overall cost of production. This includes
material costs, production efficiency, and potential post-processing or finishing requirements.

7 Sustainability:
Increasingly, companies consider the environmental impact of their products. Design for
sustainability involves minimizing material usage, optimizing energy efficiency in production,
& ensuring recyclability or biodegradability where possible.

8 Regulatory Compliance:
Products must comply with relevant industry standards and regulations. Design considerations
should include safety standards, environmental regulations, and any other applicable
guidelines.
 Design Considerations
9 User Safety:
Ensure that the design minimizes potential hazards to users. This includes considerations for
sharp edges, choking hazards, and other safety concerns.

10 Ease of Assembly & Disassembly:

If the product consists of multiple components, the design should facilitate easy assembly.
Considerations for products that may need maintenance or repair include ease of disassembly
and reassembly

11 Adaptability & Customization:

Consider designing products that can be adapted for different purposes or customized
according to user preferences. This can enhance the product's market appeal.

12 Lifecycle Considerations:
Assess the entire lifecycle of the product, including manufacturing, transportation, use, and
disposal. Design for a long lifespan, easy maintenance, and minimal environmental impact.
on,
 SUGGESTIONS
1 Invest in Technology & Automation:
Adopting advanced machinery and automation can significantly increase production efficiency,
reduce labor costs, and enhance overall productivity.

2 Supply Chain Optimization:

Streamline the supply chain to minimize delays and reduce costs. Efficient procurement,
inventory management, and distribution can contribute to overall cost savings.

3 Research and Development:

Invest in research and development to innovate new products or improve existing ones. This
can open up new markets and increase customer loyalty.

4 Energy Efficiency:
Implement energy-efficient technologies to reduce operational costs and contribute to
sustainability. This could involve upgrading machinery or optimizing manufacturing processes.
 SUGGESTIONS
5 Employee Training & Skill Development:
Ensure that employees are well-trained and have the necessary skills to operate and maintain
modern machinery. This can improve overall efficiency and reduce downtime.

6 Quality Control Measures:

Implement robust quality control measures to minimize defects and product recalls. High-
quality products can enhance the brand's reputation and reduce costs associated with rework.

7 Diversification of Product Line:

Consider diversifying the product line to cater to different market segments. This can help
reduce dependency on specific products and mitigate risks associated with market fluctuations.

8 Environmental Sustainability:
Emphasize environmentally sustainable practices. This can not only improve the company's
image but also open up opportunities for accessing markets with environmentally conscious
consumers
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