The Plastic Factory is a full-service plastics distributor and fabrication company offering a full range of plastic materials and accessories for all your engineering and construction needs. Since the start of its mass production in the 1940s, plastic has become a ubiquitous part of human life. As of 2017, the global production of plastics had increased to nearly 350 million metric tons. By the year 2050, plastic production is expected to have tripled and will account for a fifth of global oil consumption.

1. Plastic
Industry

2. TOPICS TO BE
COVERED
Introduction
History of Plastic
Composition & Synthesis
Types of Plastic & Their Uses
Plastic Resin codes
Advantages
Industrial Manufacturing Of Plastics

3. Theword plastic isderived from the Greek(plastikos)
meaning capable of being shapedor molded.
❖Plastics are arange of synthetic or semi-synthetic polymerization
products that can be molded into a permanent object having the
property of plasticity.
Properties of Plastics
Resistant Durable Insulator Inexpensive
Easy to
produce

4. • The first man-made plastic was created
by Alexander Parkes who publicly
demonstrated it at the 1862 Great
International Exhibition in London.
• The material called Parkesine was an
organic material derived from cellulose.
• Celluloid is derived from cellulose and
alcoholized camphor. John Wesley
Hyatt invented celluloid in 1868. He
created celluloid in a strip format for
movie film.
• By 1900, movie film was an exploding
market for celluloid.
History of Plastic

5. Ethene
Oxygen,200 °C
Polythene (LDPE)
(CH2=CH2) 2000 atm ([-CH2-CH2-]n)
Most plastics contain organic polymers.Thevast majority of these polymers are basedon
chains of carbon atoms alone or with oxygen, sulfur,or nitrogen aswell.
➢ Most plastics contain Additives (0 to 50%). The average content of additives is20%
by weight of the polymer.
➢ Fillers are used to improve performance and to reducecosts.
➢ Stabilizers like fire retardants are used to lower the flammability of thematerial.
SYnthesis
COMPOSITION

6. Polyamides (PA)
(Nylons) - Fibers,
toothbrush bristles,
fishing line, under-
the-hood car engine
mouldings Poly(vinyl chloride)
(PVC) - Plumbing
pipes and guttering,
shower curtains,
window frames,
flooring.
Polyurethanes (PU)
- cushioning foams,
thermal insulation
foams, surface
coatings, printing
rollers.
Polycarbonate (PC) -
Compact discs,
eyeglasses, riot
shields, security
windows, traffic
lights, lenses.
Polyvinylidene
chloride (PVDC)
(Saran)
Chemicals in Plastic

7. TYPESOF
Plastic
bags
Plastic
coatings
Plastic
furnitur
e
Plastic
sheets
Plastic
fittings
Plastic
tanks
Plastic
toys
Plastic
buckets
Plastic
sanitary
ware
Plastic
statione
ry
PLASTIC PRODUCTS

8. ADVANTAGES OF PLASTIC:-
LIGHT DURABLE TRANSPARENT VERSATILE ODORLESS
NON-
CONDUCTIVE
CHEAP

9. 80% of the plastics produced are thermoplastics and of these Polyethylene, Polypropylene,
Polystyrene and Polyvinylchoride (PVC) are most commonly used (70%)
Thermoplastic
Thermosetting
• Plastics that do not undergo
chemical change in their
composition when heated and can
be molded again and again.
• Thermosets are permanently "set"
once they're initially formed and
can't be melted.

10. Expansion Uses
HDPE
PVC
LDPE
PP
PS
Poly Ethylene Pterephthalat
High-density polyethylene
Polyvinyl chloride
Low-density polyethylene
Polypropylene-P
Polystyrene
Fizzydrink bottles andoven-
ready meal trays
Bottles for milk andwashing-up
liquids.
Food trays, bottles forsquash,
mineral water and shampoo.
Carrier bagsand bin liners.
Microwaveable mealtrays,
margarine tubs
Pots, trays, boxes ,cartons,cups,
plastic cutlery, packaging ,toys
Type
PEPT

11. Polyethylene terephthalate (PET)
Raw- materials
 Most plastic water bottles are made from
 Pet bottles are replacing glass bottles because of the high rate of
breakage and the inconvenience of returning the empty bottle
after consumption.
 Polymer derived from oil that adds flexibility, color, and strength
to plastic.
 It is impermeable to carbonation. It is strong, light, impact
resistant, naturally transparent, and completely recyclable.
 Some other raw -materials are polyethylene, High-density
polyethylene(HDPE).
 Some plastic bottles contain small amount of Bisphenol A (BPA).

12. Synthesis route
(PET)
An “ester”
is the
reaction
product of
an organic
acid and an
organic
base.
PET formed
by reacting
ethylene
glycol (base)
and
terephthalic
acid
Condensatio
n
polymerizati
on reaction
Largest use
in injection
blow
molded

14. Manufacture of PVC
 It involves two methods:
 Manufacture of vinyl chloride monomer from
Acetylene, Ethane,Ethylene.
 Polymerisation of vinyl chloride monomer to form
poly vinyl chloride.

15. Manufacture of vinyl chloride
 Manufacture Methods
 Ethylene ( obtained from thermal cracking)
 Direct Chlorination & oxychlorination.
 PROPERTIES: VCM is a gas with molecular
 weight of 62.5 & boiling point of -13.9℃ and hence has a
high vapour at ambient temperature.

16. STEP1: PRODUCING ETHYLENE
DICHLORIDE
 Chlorine is extracted from sea salt via electrolysis.
 Ethylene is derived from hydrocarbon
 Raw Materials.
 • They are reacted to produce ethylene
 dichloride (1,2- di chloro ethane)
 C2H4 + Cl2 →C2H4Cl

18. STEP 2: PRODUCING VINYL
CHLORIDE MONOMER
 1. BY ETHYLENE (THERMAL CRACKING)
• The ethylene dichloride is thus decomposed by heating in a
high temperature
C2H4Cl2 → C2H3Cl + HCl
 The hydrogen chloride is reacted with more ethylene in the
presence of oxygen. This produces further ethylene
dichloride.
 The resultant ethylene dichloride is decomposed and
hydrogen chloride is again returned for oxychlorination.
2HCl + C2H4 + ½ O2 → C2H4Cl2+ H2O →C2H3Cl + H2O

19. STEP 2: PRODUCING VINYL CHLORIDE
MONOMER
 2. DIRECT CHLORINATION AND OXY CHLORINATION
 ethylene & chlorine react within a catalyst containing reactor to form
intermediate material EDC .
 EDC is thermally cracked to yield VCM at a few hundred ℃.
 When HCl obtained as by-product from above method
 reacts with ethylene in the presence of catalyst & air.
 EDC is obtained again( called oxychlorination).
 When EDC from oxychlorination is dehydrated & then
 thermally cracked , VCM is obtained

21. STEP 3: MANUFACTURING OF
POLYVINYL CHLORIDE
 • PVC is made using a process called addition
polymerization.
• This reaction opens double bond in vinyl chloride
monomer
(VCM) allowing neighbouring molecules to join together
creating long chain molecules.
• nC2H3Cl →( C2H3Cl)n

23. PROCESSING OF PLASTICS: -
1.COMPRESSIONMOULDING
2. TRANSFERMOULDING
3. INJECTIONMOULDING
4. EXTRUSIONMOULDING
5. BLOWMOULDING
6. CALENDARING
7. THERMOFORMING
8. ROTATIONALMOULDING
9. LAMINATING

24. 1. COMPRESSION MOULDING : -
➢Compressionmouldingistheforming process.
➢Compressionmouldingprocessisfollowedbytwostepfirstonepreheating
andpressurizing.
➢Measuredchargeofcompoundplacedbetweenhalvesofsplitmold
➢Pressureisappliedsothatcompoundflowstofillmoldcavity
➢ Compressionmouldingisgenerallyusedforthermosettingplastic.
➢ Example:-ureaformaldehydeandphenolformaldehyde.

25. PROCESS DESCRIPTION

26. 2. TRANSFER MOLDINGS : -
➢ Itissimilartocompressionmoulding.
➢ Thermosetpolymerscanbeformedwhenapresetamountofmaterialisplacedina
separatecavityandheated.
➢ Aplungermovesthematerialintotheshapedmouldwithhighpressure.

27. 3. INJECTION MOULDING : -
➢Itisamanufacturingtechniqueformakingpartsfrom
thermoplasticandthermosetmaterials.
➢Injectionmouldingisahighlyautomatedproductionprocessforproducinglarge
quantitiesofidenticalitems.
➢Ameasuredamountofmoltenthermoplasticisdrivenbyarampasta
heatingsystemintothemould.
➢Themouldissplittoallowfinishedobjecttoberemovedafter cooling.
➢Example:- Polystyrene,Nylon,Polypropylene,PVC, Acrylonitrile
ButadieneStyrene

29. 4. EXTRUSION MOULDING: -
➢ Continuousprocessusedtoproducebothsolidandhollowproductsthathavea
constantcross-section.
➢ Ex:- Windowframes,hosepipe,curtaintrack,gardentrellis.
➢ Thermoplasticgranulesarefedfromahopperbyarotatingscrewthroughaheatedcylinder.
➢ Thetaperedscrewcompactstheplasticasitbecomeselasticised.Thediewhich isfittedtotheendofthe
extruderbarrel determinesthecross-sectionofthe extrusion.
➢ Thicker cross-sections are extruded more slowly as more time is required for the initial heating and
subsequentcoolingofthelargerquantitiesofmaterialwhich areinvolved.
➢ Astheextrusionleavesthedieitiscooled bypassingthroughacoolingtrough containing
coldwater.

31. 5. BLOW MOULDING:-
➢ BlowMouldingis anautomated processthatisusedextensivelytomake
bottlesandotherlightweight,hollowpartsfromthermoplasticmaterials.
➢ Ahollowlengthofplastic,calledaparison,isextrudeddownbetweenthe twohalvesofthe
mould.
➢ Themouldcloses
➢ Compressedairisblownintotheinsideoftheparisonwhichinflatesit, pushingthesoftplastic
hardagainstthecoldsurfacesofthemould.
➢ Themouldisthenopenedthemouldingejectedandthewaste(called
flash)istrimmedoffwithaknife.
➢ Example:- highdensitypolytheneandlowdensitypolytheneareused.

32. 1. 2.
3. 4.

33. Blow Moulding Process
Extrusion
Blow
Moulding
Injection
Blow
Moulding
StretchBlow
Moulding

34. 6. CALENDARING : -
➢ Itisaintermediateprocesswheretheextrudedplasticsectionsarereducedto sheet.
➢ Onlyusedforthermoplastics.
➢ Involvesrollingoutamassofpremixedplasticsmaterialbetweenlargerollersto formacontinuousand
accuratelysizedfilm.
➢ Theprocessbeginswiththeingredientsbeingblendedandfluxedinamixingmill
atapprox.100°c.
➢ Niprollerscontrolthethicknessofthesheetmaterialcanbegraduallyreducedin thickness.
➢ Rollsofsemi-rigidPVCwhichwillbeusedtomanufacturetransparentA4folder
'pockets'.

35. Example:-
1. FlexiblePVC:- Rainwear,Showercurtains,Tapes,etc.
2. RigidPVC:- Creditcards,Lamination

36. 7. THERMOFORMING: -
➢ Processusedtoshapethermoplasticsheetintodiscreteparts.
➢ Basicprinciples:-
i. Heatathermoplasticsheetuntilitsoftens.
ii. Forcethehotandpliablematerialagainstthecontoursofamoldbyusing eithermechanical,air
orvacuumpressure
iii.Heldagainstmoldandallowtocool,andplasticsretainsitsshape
➢ Thiscanbedoneby:-vacuumandpressureforming.
➢ Lowerpressuresarerequiredtothermoform.

38. 8. ROTATIONAL MOULDING : -
➢ Rotationalmouldingisaprocessusedforproducinghollowplasticproducts.Such
asroadconesandstoragetanksupto3m³capacity.
➢ Ameasuredweightofthermoplasticisplacedinsideacoldmould.
➢ Heatedtoatemperatureof230-400cwhilstbeingrotatedaroundbothvertical andhorizontalaxes.
➢ Themouldmovesintoacoolingareaorchamberwhereitiscooledbyairor waterjets.
➢ Thehollowmouldingcanberemovedassoonasitiscoolenoughtoholdits
shape.

39. Therotationalmolding (roto-
moldingorroto- casting)
process. Trash
cans,buckets,andplastic
footballscanbemadeby this
process.
90%ofrotational mouldingsare
madefrom polyethylene

40. 9. LAMINATING: -
➢ Layersofmaterialsarebondedwitharesinintoastrongsolidstructure,often
withheatandpressure.
➢ Thiscanbedoneinfollowingways:-
▪ Gravurecoating
▪ Wetbondlaminating
▪ Drybondlaminating
▪ Solventlesslaminating
▪ Extrusionlaminating
➢ Example:-Foil,Snackfoodbag,Saran-coatednylon,Metallizedpropylene,etc.

41. Substrate A
Extrusion die
Substrate B
Strip-off roll
Nip roll
Extrudate
Pressure
roll
Three ply
laminate
Extrusionlaminating Drybondlaminating
Gravurecoating

42. ANY QUESTION