1. MARDEC PROCESSING SDN. BHD,
BATU 5, JALAN KARAK,
PETI SURAT NO. 6,
28407 MENTAKAB, PAHANG.
WAN NUR FARAH AZLIN BINTI WAN OTHMAN
AA130075
SEMESTER 1 / SESI 2015/2016
Department Faculty evaluation Approval by supervisor
Department of
Science and
Mathematics
1. Pn. Aida Binti Mohamad
Signature and official
stamp :
2. ACKNOWLEDGEMENT
First and foremost, I would like to thank to my lab manager as supervisor during my internship,
En. Mohd Marzwan Rashidi Bin Marzuki for the valuable guidance and advice. He inspired me
greatly to work with other members and his willingness to motivate me contributed
tremendously to my training. Besides, I would also like to thank to Mrs. Sabariah Binti Ariffin as
operation supervisor for laboratory because provided me valuable information about SMR
testing as the guidance to complete my internship. In addition, I would like to take this
opportunity to thank to Miss Norhasikin Binti Kamarudin as the lab personnel effluent for
teaching and leading me to do various tasks related to effluent management. It gave me an
opportunity to participate and learn more about the chemical application for testing effluent.
Finally, an honorable mention goes to all lab teammates for sharing their knowledge and always
supports me to do better in my work. Last but not least, special thanks to staffs, lecturer and
beloved families for their understandings and supports on me in completing this internship.
Without helps of the particular that mentioned above, I would face many difficulties while doing
this training. Thanks for all for your kindness. I really appreciate it.
3. ABSTRACT
MARDEC Berhad is a Malaysia – based integrated investment holding company that is
involved in processing, trading and marketing of Standard Malaysia Rubber (SMR), SIR, SVR,
ISNR graded and Natural Rubber Latex concentrate known under the brand names of MARUB
and MATEX. Moving towards product diversification, MARDEC Berhad also manufactures
value added rubber and polymers based products through its subsidiary Mardec Industrial Latex
Sdn. Bhd.(MIL) and Mardec Polymers Sdn. Bhd. (M-Pol). With operations in Malaysia,
Indonesia, Thailand, and Vietnam, Mardec Berhad commits to quality excellence to meet the
standards and needs required by its clients.
To date, Mardec Berhad has received certifications in relations to quality management
system and environmental management system for its processing centers. As subsidiary of
Tradewinds Plantation Berhad, Mardec Berhad has the advantage to supplement its vast
processing experience of more than 40 years with the assured consistent and quality supply of
NR as Tradewinds Plantation Berhad expands its rubber plantation ownerships.
4. CHAPTER 1:
BACKGROUND OF COMPANY
1.1 History
MARDEC Processing Sdn Bhd (MPSB) Mentakab was located at Batu 5, Jalan Karak, 28407
Mentakab, Pahang, which was about 10km from Mentakab town. It was established in 1969 to
improve the quality of the rubber produced by Malaysia’s smallholders, and to recognize its
marketing by buying cup lump-based raw rubber and process this material into technically
specified rubber (SMR 5, 10, 20) and compounded rubber products.
The natural rubber (NR) products are mostly supplied to major type manufacturing companies
such as Continental, Goodyear, Kumho, Hankook, and Michelin and other clients in more than
90 countries worldwide. MPSB invest in the latest technology in NR processing to continuously
improve the quality of its products. With its commitment to excellence in quality, service and
consistency, the company was awarded SIRIM’s ISO 9001:2000 QMS certification in 2002.
Table 1.1: Group structure of MARDEC around worldwide
Processing Trading/ overseas invest Manufacturing
Mardec Processing Sdn Bhd
(MPSB)
Mardec International Sdn Bhd
(MISB)
Mardec Polymers Sdn
Bhd (M-Pol)
Baling, Kedah
Bota, Perak
Kuala Berang, Terengganu
Mentakab, Pahang
Mardec Saigon Rubber
Co. Ltd, Vietnam
Mardec Yala Co. Ltd,
Thailand
PT. Mardec Siger Way
Kanan, Indonesia
PT Mardec Musi
Lerstari, Indonesia
M-Pol Procession
Products Sdn. Bhd,
Pulau Pinang
Mardec Industrial Latex Sdn
Bhd
Alfagomma Mardec
Sdn Bhd
Tapah, Perak
Ulu, Ara Negeri Sembilan
5. Figure 1.1: MARDEC processing centres in Malaysia
1.2 Organization structure of company
Figure 1.2: Organization chart of MPSB Mentakab
6. 1.3 Company area
Figure 1.3: Overall view of MPSB Mentakab
1.4 Main product of company and marketing
MARDEC is an investment holding company with activities in rubber processing, trading and
manufacturing of value added rubber and polymer products and is a fully owned subsidiary of
Tradewinds Plantation Berhad a member of Tradewinds (M) Berhad. Mardec began, when
primary concerned to increase the quality of rubber produced by Malaysia’s smallholders and to
reorganize its marketing efforts .Then, Mardec transform to be global with technology to ensure
that the products meet international standard. Their subsidiaries custom-make rubber products
and components according to specifications from buyers who came from all over the world .As a
global business, Mardec also interfered in several joint ventures with other foreign partner.
Furthermore, with emphasis on total quality management in all their operations Mardec ensure
that their products same level with the most stringent standards and meeting their customer’s
7. specification. Their commitment to quality excellence has earned them the MS ISO 9001:2008
certifications for them subsidiaries and factories. Continued efforts to ensure that their meet strict
environment standards has earned Mardec the MS ISO 14001:2004 certificates for their
subsidiaries and factory
1.5 Procedures in rubber processing
a) Purchasing of raw material (cup lump)
Figure 1.4: Recording at guard house
Figure 1.5: Weighing gross weight (lorry + rubber)
8. Figure 1.6: Unload rubber at CL bin
Figure 1.7: Checking / segregate / picking contaminants
Figure 1.8: Pushing rubber for blending
9. Figure 1.9: Weighing empty lorry weight
Figure 1.10: Chemical malodour (fresh cup lumps are sprayed with malodours chemical to
reduce the smell)
10. CHAPTER 2: BACKGROUND OF LABORATORY
2.1 Description
Figure 2.1: The view of laboratory
MARDEC Rubber and effluent testing laboratory consist of two divisions in conducting
experiment which are for effluent and other one is SMR testing. Effluent personnel testing will
conduct any effluent testing either samples from MPSB Mentakab itself (internal) or sample
from external in effluent test room. Then, for SMR personnel testing will conduct SMR testing in
milling room, balancing room, plastimeter room, oven drying and ageing room, nitrogen/dirt
room and ash room based on certain parameters. All laboratory personnel are suitably qualified
and fully trained so that they can perform their assigned tasks with competency and efficiency to
maintain a high standard of laboratory performance and integrity at all times.
11. 2.2 Title and position
Figure 2.2: Title and position in laboratory
Factory Manager
En. Mohd Arif Bin Ashaari
Laboratory Manager
En. Mohd Marzwan Rashidi
Bin Marzuki
Admin
Pn. Masni Binti Mohamed Sani
Operation Supervisor
Pn. Sabariah Binti Ariffin
Effluent Personnel
Testing
Norhasikin Binti
Kamarudin
SMR Personnel Testing
Norhafizah Binti
Shahidan
SMR Personnel Testing
Narayani A/P Marutan
SMR Personnel Testing
Khuzaimah Binti Zakaria
SMR Personnel Testing
Muhd Afiq Bin Romli
SMR Personnel Testing
Anis Syuhada Binti Omar
Hamdan
12. 2.3 Work schedule
Table 2.1: Work schedule for MPSB Mentakab staffs
Department Office Production
Lab
SMR Effluent
Work day
Monday -
Friday
Saturday -
Thursday
Saturday -
Thursday
Monday –
Saturday
Work hour 8am – 5pm
7am – 4pm
10am - 7pm
7am – 4pm
8am – 5 pm
10am - 7pm
8am – 5pm
Scope of work
All the
main HR
Purchasing
Process
main
product
Testing on
rubber
quality
Testing on
effluent
from
production
Off day
Saturday &
Sunday
Friday Friday Sunday
Break hour
I hour and 30
minutes
1 hour 1 hour 1 hour
13. CHAPTER 3: TRAINING CONTENTS
3.1 Effluent treatment system
Period of training: 7 September 2015 – 14 November 2015
There are seven parameters in testing effluent as follow:
Table 3.1: Parameter limits for effluent discharge
Parameter effluent Unit Standard result effluent
Biochemical oxygen demand (BOD3) mg/l 100 (50)
Chemical oxygen demand (COD) mg/l 250
Total solid mg/l -
Suspended solid mg/l 150 (100)
Ammoniacal nitrogen mg/l 40
Total nitrogen mg/l 60
pH - 6 – 9
Six effluent samples are collected for full testing (only on Monday and Wednesday) and only
two samples for daily testing for another days. Samples are collected at raw, v-notch, outlet 1,
outlet 2, outlet 3 and final discharge.
14. Figure 3.1: MPSB Mentakab effluent treatment system
Raw effluent
from factory
ST
T
RT1
RT2
AP
ARP
SP
FP
X X
X X
FD
FM
BH
15. i. Sand trap (ST)
Figure 3.2: Sand trap management
Function:
Used to trap dirt or sand
Necessary to be dredged and disposed for every hour
ii. Rubber trap (RT1 & RT2)
Figure 3.3: Rubber trap with 10 plots
16. Function:
Used to trap waste and scrap of rubber that come from the factory
Disposed 2 times every day for every plot (morning and evening)
Figure 3.4: Rubber trap with 28 plots
Function:
To trap waste and scrap of rubber that come from the factory
Soil need to be disposed once per week
iii. V-notch
Figure 3.5: V-notch area
Function:
Measure raw effluent flowrate discharge
17. iv. Anaerobic pond (AP)
Figure 3.6: Anaerobic pond with algae
Fuction:
Anaerobic bacteria play role in converting organic matter to biogas (methane/
carbon dioxide)
The depth should exceed 3 metres
Oxygen and sunlight are not required
v. Outlet 1 and aeration pond (ARP)
Figure 3.7: Outlet 1 Outlet 3.8: Aeration pond
Function:
Nutrient was given at this pond for aerobic bacteria
Aerobic bacteria can help organic waste change to biogas (gas methane or carbon
dioxide)
Aerobic bacteria need oxygen and sunlight
The depth should exceed 3 metres
18. vi. Settling pond and facultative pond
Figure 3.9: Settling pond Figure 3.10: Facultative pond
vii. Final discharge
Figure 3.11: Location for taking final sample
3.1.1 Effluent testing
i. Determination of pH
Objective: To determine of pH in rubber effluent.
Equipment: pH meter consist of potentiomer, glass electrode, a reference electrode, and a
temperature-compensating device.
19. Figure 3.12: pH meter
Procedure:
1. The pH meter is switched on.
2. Glass electrode is put in the standard potassium chloride in the beaker.
3. Then, make sure the glass rod is washed with distilled water and wipe it with tissue.
4. After that, the glass rod is put into the beaker that had a test sample and wait until the
meter gave the reading result.
5. Next, the glass rode is washed again with distilled water followed by wiping it with
tissue.
6. Procedure no 4 and 5 are continued for another sample.
7. Take the reading and write in the data sheet.
8. The glass rode is washed with distilled water and then immersed in the standard
potassium chloride after be used.
9. The reading of ph is recorded in the attachment as below.
20. Table 3.2: Example of attachment for pH test
No. Sample reference Time Temperature pH
ii. Determination of ammoniacal nitrogen (AN)
Objective: To determine of ammoniacal nitrogen in rubber effluent by acid digestion followed by
steam distillation and titration method.
Apparatus and reagent: K-jeldhal tube, K-jeltec 1002 Distillation unit, Magnesium oxide, and
phenolphthalein
Figure 3.13: K-jeltec 1002 Distillation unit
Procedure:
1. The apparatus was set up.
2. The tested sample about 25ml was poured into the K-jeldhal tube.
21. 3. 0.5g of magnesium oxide was added into the tube and continued by 2 drops of
phenolphthalein.
4. Check the result by enters the sample into K-jeltec distillation unit.
5. The result was recorded in the attachment.
Calculation:
Ammoniacal nitrogen (mg/l) =
(A−B)×C ×28000 ×D
S
Where:
A = ml of standard H2SO4 0.01 m solution in titrating sample
B = ml of standard H2SO4 0.01 m solution used in titrating the blank
C = actual molarity of H2SO4 0.01 m solution
D = dilution factor
S = mL of sample used
Attachment:
Table 3.3: Example of attachment for ammoniacal nitrogen test
No Sample reference Dilution S A B A - B
Ammoniacal – N
(mg/L)
iii. Determination of total nitrogen (TN)
Objective: To determine of total nitrogen in rubber effluent by acid digestion followed by steam
distillation and titration method.
22. Apparatus and reagent: Digestion system, distillation unit, digestion tube, standard sulphuric acid,
catalyst, sodium hydroxide, boric acid, phenolphthalein, and glass beads.
Figure 3.14: Phenolphthalein indicator
Procedure:
1. 25ml of sample was poured into the digestion tube.
2. 10ml of H2SO4 was added and followed one Kjeltab M/35 tablet (catalyst).
3. The digestion tube was placed in the digestion block in preheated (420ºc) and put the
exhaust unit on the top of the tube.
4. The sample was digested about 30 minutes until the colour change into colorless.
5. Then cooled the tube to room temperature and added about 40 ml of distilled water to
each tube. Mix well and the sample ready to steam distillation.
6. Steam distillation:
Place the digestion tube and receiver flask in their proper position. Pull down the
safety window.
Open the steam.
State the method : No7- Choose the method (TN)
Enter No 1: (Determination) – no of tube –wait until 2 times of beep sound
Calculation:
Total nitrogen (mg/l) =
(A−B)×C ×28000 ×D
S
23. Where:
A = ml of standard H2SO4 0.01 m solution in titrating sample
B = ml of standard H2SO4 0.01 m solution used in titrating the blank
C = actual molarity of H2SO4 0.01 m solution
D = dilution factor
S = mL of sample used
Attachment:
Table 3.4: Example of attachment for total nitrogen test
No Sample reference Dilution S A B A - B Total – N (mg/L)
iv. Determination of chemical oxygen demand (COD)
Objective: To determine of chemical oxygen demand (COD) in rubber effluent by open reflux,
titrimetric method.
Apparatus: Digestion tube, reflux condenser, digestion block.
Reagents: Std. Potassium dichromate, Sulphuric reagent, Std. Ferrous ammonium sulphate titrant
(0.1m), Ferroin indicator solution (orthophenanthroline ferrous), silver sulphate, and potassium
acid phthalate.
Procedure:
1. The apparatus was set up.
24. 2. 20ml of each sample was poured into the tube of COD and added 10ml of potassium
dichromate and followed by added 30ml of concentrate sulphuric acid that mix with the
silver sulphate by slowly swirling while added the mixture acids.
3. Molarity of Fe(NH4)2(SO4)2 was prepared by added 100ml of distilled water
continued by added 10ml of potassium dichromate and 30 ml of H2SO4 followed cooled .
4. Blank of COD prepared by using same procedure with the sample but using 20ml of
distilled water.
5. Standard of COD was prepared by using potassium acid phthalate. These potassium
acid phthalate was prepared one day before because the potassium phthalate must be
weighed about 0.45251g followed dried in oven about an hour and dilute in 1000ml of
distilled water of volumetric flask.
6. These tubes were connected with reflux condenser and place it’s into the digestion
block.
7. The digestion tube was ready heated at 150ºC ±2ºC and wait about 2 hours.
8. After refluxing for 2 hours, the tube took out from the digestion block and cooled with
room temperature followed by washed the condenser with distilled water.
9. Then continued by titration method.
Figure 3.15: Preparation for COD titration
25. Figure 3.16: Before titration Figure 3.17: After titration
Calculation:
COD (mg/l) =
(A−B)×C ×8000 ×D
S
Where:
A = ml of Fe(NH4)2(SO4)2 ml used for blank
B = ml of Fe(NH4)2(SO4)2 ml used for sample
C = molarity of Fe(NH4)2(SO4)2
D = dilution factor
S = volume of sample taken (ml)
Attachment:
Table 3.5: Example of attachment for COD test
No Sample reference Dilution S A B A - B Total – N (mg/L)
26. v. Determination of biochemical oxygen demand (BOD)
Objective: To determine of biochemical oxygen demand (BOD3) in rubber by dissolved oxygen
(DO) meter alternative method.
Apparatus: BOD bottles, incubator (temperature 30ºC ±1ºC) and DO meter.
Reagents: Ferric chloride, calcium chloride, magnesium sulfate, phosphate buffer stock solution,
manganese sulfate and sodium alkaline axide solution
Procedure:
A. Preparation of dilution water
1L of distilled water: 1ml of chemical solution (Ferric chloride, calcium chloride, magnesium
sulfate, and phosphate buffer stock solution (aquarium) and subjecting the stream of air through
a filter of :
i. Soda lime (non-deliquescent;4-10 mesh)
ii. Activated charcoal (for gas absorption passed an mesh sieve)
iii. Cotton (to remove any particle in their stream)
Figure 3.18: Solutions used to make dilution water
27. Figure 3.19: Set up for aeration of dilution water
B. Pretreatment of sample
Temperature of the sample should be such that when diluted the mixture would be at room
temperature. The pH of the sample should be between 6.5 and 8.2; acid being added if necessary
to bring it to within this pH range.
C. Preparation of sample
1. BOD had tested at Monday and Wednesday while Thursday and Saturday testing BOD when
after 3 days in incubator.
2. The sample was poured in range dilution 10ml, 10ml, 20ml, 50ml, 100ml and 100ml and
mark up with distilled water until reach calibration mark using 1000ml of volumetric flask.
Table 3.6: Dilution factor for each type of sample
Types of sample Dilution (ml)
Raw 10
v-notch 10
Outlet 1 20
Outlet 2 50
28. Outlet 3 100
Final discharge 100
3. The sample was shaken and then poured into BOD bottle.
4. Divide the Bottle with two parts:
i. Daily (DO)
ii. After 3 days (DO3)
5. For DO was testing in that day, while for DO3 will testing after 3 days in incubator.
6. Then poured about 2ml of manganese sulfate (pink colour) followed by sodium alkaline axide
iodide about 2ml (clear solution). These two mixtures change the colour of BOD to brown colour.
7. After that, 2ml of sulphuric acid was added slowly to the BOD bottle and the colour change
to the brown red.
8. Titration method was conducted.
Figure 3.20: Preparation for BOD titration
29. Figure 3.21: Manganese sulfate (pink colour) and sodium alkaline axide iodide (clear solution).
Calculation:
(A-(B+C) x D x E
Where,
A = the initial dissolved oxygen content of the diluted sample (DO)
B = the final dissolved oxygen content of the diluted sample (DO3)
C = the blank value (DO – DO3)
D = the dilution factor
E = 1.014
Attachment:
Table 3.7: Example of attachment for BOD test
No Sample reference Dilution A B C BOD3 (mg/L)
30. vi. Determination of total solids (TS)
Objective: To determine of total solid in water and industrial effluent including rubber
processing effluent by drying at 103-105ºC
Apparatus: Drying oven, desiccator, analytical balance and evaporating dishes made up from
porcelain with 90mm diameter.
Procedure:
A. Preparation of evaporating dish.
i. Clean dish was heated at temperature 105ºC for 1 hour.
ii. Dish was stored in desiccator until needed.
iii. Then weighed before use.
B. Preparation of evaporating dish.
i. Crucible was heated after weighed it.
ii. Crucible was after drying.
iii. The sample was poured about 20 ml.
iv. Process of dry was going about an hour.
v. Then took the crucible out and cooled in the desiccator.
vi. The crucible was weighed followed by final dry.
vii. After cooled, continued by final weighed.
Calculation:
Total solids (mg/l) =
(A2−B2)×106
S
Where,
A = weight of dried residue and dish (g)
31. B = weight of dish (g)
S = volume of sample taken (mL)
Attachment:
Table 3.8: Example of attachment for total solids test
Crucible no Sample
reference
S
(ml)
A1
(g)
A2
(g)
B1
(g)
B2
(g)
Total solids
(mg/L)
vii. Determination of suspended solids (SS)
Objective: To determine suspended solid in rubber processing effluent.
Apparatus: glass microfiber filters, filtration apparatus (filter holder or gooch crucible), suction
flask, drying oven, desiccator and analytical balance.
Figure 3.22: Glass microfiber filters are placed in crucible
Procedure:
1. The crucible were rinsed and followed dry into oven at temperature 105ºC ±1ºC. Then,
continued cooling in the desiccator about 30 minutes.
32. 2. The crucible was weighed at initial with filter paper and followed dry again in the
oven and then continued cooling in the desiccator about 30 minutes.
3. The test samples about 25 ml were poured into the crucible through vacuum pump.
4. Arranged and dry again in the oven about an hour. After that, continued by cooling in
desiccator.
5. The crucible was weighed with residue. Then, continued final dry and followed by
cooling in the desiccator.
6. The weighing recorded in the attachment.
Calculation:
Suspended solids (mg/l) =
(A2−B2)×106
S
Where,
A = weight of gooch crucible with filter and residue (g)
B = weight of gooch crucible with filter (g)
S = volume of sample taken (mL)
Attachment:
Table 3.9: Example of attachment for suspended solids test
Crucible no Sample
reference
S
(ml)
A1
(g)
A2
(g)
B1
(g)
B2
(g)
Suspended
solids (mg/L)
33. 3.1.2 Scrubber system at MPSB Mentakab
As for block rubber processing factories, malodour originates from volatile organic compounds
produced from the microbial breakdown of non-rubbers during storage of the field-grade
materials or thermal degradation during processing. The malodorous vapours from natural rubber
processing factory found it consists mainly of water vapours, ammonia, fatty acids of low
molecular weight, alkenes, ketones, ester and hydrogen sulphite. These can be eliminated by
condensing the hot malodorous vapours at 35oC followed by water scrubbing. The system
normally consists of a cylindrical column with one or more layers of packing materials which act
as filter. Tellerettes, spiral or any other types of packing materials function to enhance the
scrubbing surface activities which subsequently reduce the concentration of odour.
Figure 3.23: The water scrubber system at MPSB Mentakab
34. Figure 3.24: Schematic diagram of water scrubber system
Theoretically, water scrubber plays an important role in reducing odour concentrations from the
factory. The exhaust odours from the dryer are directed upwards by suction fan to pass through
the packing materials as a filter. Packing materials are inert solid material that produces large
surface areas were stacked as double, triple or quadruple layered, to increase the surface
activities and consequently enhance the performance of scrubber. Volatile fatty acids and volatile
organic compounds were detected as abundance of compounds released from the scrubber. These
obnoxious water soluble compounds travel through the packing material to have their
concentrations reduced considerably and would be discharged to the atmosphere. The present
ofacetic, propanoic, isobutaric, isovelaric and velaric acids are compounds identified by literature
previously.
36. 3.2 Standard Malaysian Rubber (SMR)
Period of training: 16 November 2015 – 8 January 2016
3.2.1 SMR processing
This processing is categorized into 6 sections as follows:
i. External line
Figure 3.26: Cup lumps from the supplier Figure 3.27: The cup lumps are put into the
external slab cutter using a loader
Figure 3.28: Water is sprinkled onto the
conveyors to remove any dirt and
contaminants
Figure 3.29: Vibrating the screen
37. Figure 3.30: Picking on contaminants Figure 3.31: Blending after external slab cutter
ii. Pre-cleaning line
Figure 3.32: Blended cup lumps is put into the
soaking tank 1
Figure 3.33: Bucket into internal slab cutter
and sprinklers are used to remove dirt and
contaminations
Figure 3.34: After internal slab cutter Figure 3.35: Cup lumps that come out from the
internal slab cutter go into soaking tank 2
38. Figure 3.36: Bucket into pre-breaker Figure 3.37: Small cup lumps from the pre-
breaker go into the vibrating screen
Figure 3.38: Conveyor into bleading trough 1
iii. Intermediate line
Figure 3.39: The cup lumps are further
blended in the blending trough 1
Figure 3.40: Picking of visible contaminants at
belt 1
39. Figure 3.41: Picking of visible contaminants at
belt 2
Figure 3.42: Small cup lumps are further
blended in the blending trough 2
Figure 3.43: Small cup lumps are crept into a
thick blanket at creeper 1
Figure 3.44: The rubber blanket is creped
thinner at creeper 2
Figure 3.45: The rubber blanket is cut into
coarse crumbs at the shredder 1
Figure 3.46: Blending trough 3
40. iv. Final line
Figure 3.47: Bucket into creeper 3 Figure 3.48: The coarse crumbs are crept into a
rubber blanket at creeper 3
Figure 3.49: Creeper 4 Figure 3.50: Creeper 5
Figure 3.51: Creeper 6* Figure 3.52: Creeper 7*
41. Figure 3.53: Creeper 8* Figure 3.54: Creeper 9*
* Diamond creeper is used reduce the blanket thickness
Figure 3.55: The thin rubber blanket is cut into
fine crumbs at the shredder 2
Figure 3.56: The fine crumbs is mixed with the
lime solution in the final trough to prevent
agglomeration
42. v. Drying line
Figure 3.57: Vibrating the screen Figure 3.58: Trolley feeding
Figure 3.59: Dryer
Figure 3.60: After heat, rubber takes out from
dryer A and B (biscuit)
vi. Packing line
Figure 3.61: Press area Figure 3.62: Weighting biscuit
43. Figure 3.63: Compressing process Figure 3.64: Quality control (QC) checking at
conveyor to remove white spots
Figure 3.65: Bale cutter for center inspection Figure 3.66: Wrapper
Figure 3.67: Metal detector unit Figure 3.68: Cross checking for
reconfirmation of weight
44. Figure 3.69: Packing for shipment process
Shipment process:
1. Arrange bale in the box followed the categories:
a) MB 5: SMR 10
b) WOODEN : SMR 20
2. Pending check
3. PDI (PRE DELIVERY INSPECTION)
4. Wrapping
5. Lorry
Time table for shipment planning:
Shipment schedule Time arrive Place
ETD (Estimate time departure) 18/every month/every year Klang
ETA (Estimate time arrived ) 20/every month/every year Abroad
45. 3.2.2 SMR testing
Table 3.10: Definition for routine sampling technique
Lot Sample Piece Test piece
A quantity of bales of the
same type and grade,
from the same source
Forming one
consignment
Not exceeding 50 tonnes
A collection of
bales
Represent the
lot or
consignment
Rubber taken
from a bale to
represent the
bale
Rubber taken
from the piece
for testing
i. Taking piece for lab testing
Figure 3.70: Technique for taking sample (50x50x140)
ii. Homogenization of test piece
Objective: to homogenized the sample and segregate it for each test
Procedure:
1. The roller is cleaned with dummy sample by passing the sample six times through lab
mill (nip set at 1.65 0.16mm).
2. After each pass, the sample is rolled into cylinder and introduced it endwise. Any
rubber is collected from the sample after each passes.
3. After 5th pass, the sample is folded and then be passed lengthwise through the mill.
4. The sample should be folded and be cut into six pieces for:
50 mm
50 mm
140 mm
50 mm
140 mm 50 mm *Total weight: 360 g
46. Table 3.11: Approximate weight of sample for each test
Testing Weight (g)
Dirt 20 - 30
VM 20 - 30
PRI 15 - 25
VR 25
N2 10
Ash 25
*Test piece must be wrapped to prevent contamination
Figure 3.71: Lab mill
iii. Determination of dirt
Objective: To determine the amount of foreign matter in natural rubber that fails to pass a sieve
off 44m side-square aperture.
Apparatus: Conical flask (500ml), thermometer (100oC – 200oC), sieve (44m side-square
aperture), heating unit, analytical balance, drying oven, ultrasonic bath, drying cabinet,
desiccators, sieve holder.
Reagent: Mineral turpentine, rubber peptizing agent (xylyl mercaptan).
Procedure:
47. 1. 25g of the homogenized rubber is taken and passed twice through a lab mill at room
temperature with nip set at 0.33 0.05mm.
2. 10g of sample portion is weighted and then cut into small strips and be placed in a
500 ml conical flask containing 250 ml of mineral turpentine and about 1 ml of
rubber peptizing agent, then placed it on the heating unit for 2 hours.
3. The hot solution is filtered through a previously weighted, clean and dry sieve, any
dirt remaining in the flask is transferred by means of a jet of of turpentine and the
washing be poured through the sieve; finally inside the walls of the sieve are rinsed
with 20 ml of turpentine.
4. The sieves are dried in the oven at 100oC for 1 hour, and then be weighted to the
nearest 0.1 mg after the sieve cool to room temperature.
Figure 3.72: Filtering dirt by using sieve
Calculation:
Percentage of dirt (%) =
D
A
× 100
Where:
A = the weight of the clean dry sieve
B = the weight of the sieve plus dirt
C = the weight of test portion
48. Attachment:
Table 3.12: Example of attachment for dirt test
No.
Lot
no.
Sample
no.
Flask
no.
Sieve
no.
A B C D=B-C D/Ax100
Wt of
sample
(g)
Wt of dirt
+ sieve
(g)
Wt of
sieve (g)
Wt of
dirt (g)
Dirt (%)
iv. Determination of ash
Objective: To determine the amount of ash in natural rubber that represents the amount of
mineral content in natural rubber.
Equipment and apparatus: Crucible (50 ml) muffle furnace, ashless filter paper, vacuum
desiccator, tong for handling hot crucibles, furnace.
Procedure:
1. 5.0g of homogenized sample is cut and be weighted.
2. The sample is wrapped with ashless filter paper and put into weighted and marked
crucible.
3. The crucible is introduced into furnace at temperature 550 oC 20 oC for 4 hours.
4. The crucible is removed from furnace and let it cool in desiccator. Then, the crucible
is weighted to the nearest 0.1mg.
49. Figure 3.73: Cooling hot crucibles in desiccator
Calculation:
Percentage of ash (%) =
A−B−C
D
× 100
Where:
A = the weight of crucible + ash
B = the weight of empty crucible
C = the weight of ash from filter paper
D = the weight of sample taken
Attachment:
Table 3.13: Example of attachment for ash test
No. Lot no.
Sample
no.
Crucible
no.
A B A - B D
(A-B-C) /D
x100
Wt after
(g)
Wt
before (g)
Wt of
sieve (g)
Wt of
ash (g)
Ash (%)
50. v. Determination of volatile matter
Objective: To determine the moisture or any other material in rubber is volatile at 100 oC.
Apparatus and materials: Lab mill, polythene bags, analytical balance, aluminium tray, clip,
drying oven.
Procedure:
1. 10g of the homogenized sample is cut and weighted immediately.
2. The test portion is passed twice through lab mill with a nip setting of 0.5 0.05mm.
3. The test portion is placed on aluminium tray and then be placed in the oven at 100
oC 3oC for 4 hours.
4. The tray is removed from oven and the sample is put into polythene bag quickly. The
wrapped sample is placed in the labeled perforated sample tray.
5. The sample is allowed to cool for about 30 minutes, and then sample is removed from
bag to be weighted.
Calculation:
Percentage of volatile matter (%) =
A−B
A
× 100
Where:
A = the weight of test portion before drying
B = the weight of test portion after drying
Attachment:
51. Table 3.14: Example of attachment for volatile matter test
No. Lot no.
Sample
no.
Tray no.
A B (A-B) /A x100
Wt before
(g)
Wt after
(g)
VM (%)
vi. Determination of nitrogen
Objective: To determine the percentage of nitrogen that can be used to provide indication of the
protein content.
Apparatus:
Micro-kjeldahl digestion and distillation unit, kjeldahl flask (30ml), rack for kjeldahl flasks,
spatula and analytical balance.
Reagents:
a) Catalyst; mixture of anhydrous potassium sulphate, copper sulphate pentahydrate and
selenium powder in the ratio 15:2:1
b) Concentrated sulphuric acid
c) Sodium hydroxide
d) Boric acid. Dissolve about 40g of boric acid in distilled water, make up the volume to 2
litres.
e) Indicator solution. Dissolve about 0.1g of methyl red and about 0.05 of methylene blue in
100ml of ethanol.
Procedure:
1. 0.1g of homogenized rubber sample is weighted and be put into Kjeldahl flask.
2. 0.65g of catalyst is added into flask and be followed by 2.5ml of concentrated
sulphuric acid. Then, the flask is introduced into digestion unit and heated for 1 hour.
52. 3. The digested solution be cooled at room temperature and be added with 2 drops of
indicator solution before being introduced into distillation unit for distillation and
titration process.
Figure 3.74: Digestion of sample
Calculation:
Percentage of nitrogen (%) =
(V1−V2)N ×0.014
W
× 100
Where:
V1 = the volume of H2SO4 required for titration of the contents of the receiving flask
V2 = the volume of H2SO4 for titration of the blank
N = the normality of the H2SO4
W = the weight of sample
Attachment:
Table 3.15: Example of attachment for nitrogen test
No. Lot no.
Sample
no.
W V1 V2
Nitrogen (%)Wt of
sample (g)
Volume of
titrate (ml)
Volume of
blank (ml)
53. vii. Determination of plasticity (P0) and plasticity retention index (PRI) of the sample
Objective: To determine the plasticity retention index (PRI) of the sample.
Equipment and apparatus:
Lab mill, dial thickness gauge, aluminium tray, PRI oven, cigarette paper, Wallace plastimeter
with steam generator.
Procedure:
1. A sample size is cut of about 25g from the homogenized sample.
2. The nip setting is adjusted with thickness is between 1.6 to 1,8mm and then the
sample is passed for twice.
3. The sheeted sample is folded and then the thickness is checked with the Dial
Thickness Gauge, to be between 3.2 to 3.6mm. The sample is retaken if the thickness
is not obtained.
4. Six test pellets are punched out from the sample using the PRI sample cutter with
diameter is approximately 13mm.
5. The six test pellets are divided into two sets. One set is used to measure the initial
plasticity (P0) and the other set is used to measure the plasticity retention index (PRI).
6. For PRI set of test pieces, three test pieces are put into the allocated aluminium tray
and then be put into the PRI oven at 140oC 0.5 oC for 30 minutes.
7. The test pieces are then cooled at room temperature for about 20 minutes.
8. The steam pressure from steam generator must be ensured at between 0.5 to 1.0 psi
(35 to 70mbar). The test pellet is introduced sandwiched between two cigarette papers
into the parallel platens of the Wallace plastimeter.
9. The test pellet should be punched in at the centre when the lever of the Wallace
plastimeter is clamped down
54. 10. The reading is recorded right before the ‘click’ sound is heard.
11. Step 8 to 10 is then repeated for the other two test pieces, to obtain the mean value of
the aged plasticity (P30) reading.
Figure 3.75: The sample after being punched
out about 6 pellets
Figure 3.76: Wallace plastimeter
Calculation:
PRI (%) =
P30
P0
× 100
Attachment:
Table 3.16: Example of attachment for P0 and PRI test
Oven No: __________________ Plastimeter No: _________________
Lot
no.
Sample
no.
Initial plasticity, P0
Tray
no.
Aged plasticity, P30 (P30/ P0 X 100)
1 2 3 P0 1 2 3 P30 PRI
55. viii. Measuring the thickness of the sample using the dial thickness gauge
Scope: To check the thickness of the sample when the thickness of the sample is between 0.01 to
10.00 mm.
Equipment:
Dial thickness gauge
Procedure:
1. The platen is clean where the sample should be placed.
2. The origin of gauge is checked to be at zero.
3. The platen is lifted up gently by pressing the lever on the gauge.
4. The small scale is 0.01 mm per unit measurement, while the big scale is 1 mm per
unit measurement.
5. The sample should be placed parallel and flat to the plate when measuring the sample.
Figure 3.77: Dial thickness gauge
ix. Determination of Mooney viscosity
Objective: To determine the torque necessary to rotate a disc in a cylindrical chamber filled with
rubber using the Mooney viscometer.
Equipment:
56. Mooney viscometer
Procedure:
1. The temperature of viscometer must be ensured at 100oC 1 oC and the rotor is placed
in the lower die cavity.
2. The homogenized test piece is cut (~25g) into two equal portions, then the hot rotor
from die cavity is removed and one portion be placed through the stem of the rotor
and whole combination is returned to the die cavity. The second portion is placed on
the top of rotor.
3. The die is closed immediately by pressing and holding the two top panel green
buttons until amber light appears. The buttons are released and the timing is started
for 1 minute. The motor is started and initial gauge maximum reading is recorded
immediately.
4. The reading at 3
1
2
and 4 minutes are recorded continuously and the reading at 4th
minute is taken as the rubber viscosity.
Figure 3.78: Mooney viscometer
57. Attachment:
Table 3.17: Example of attachment for Mooney viscosity
Viscometer Platen Temperature (oC)
Top
Button
Producer/client/grade: _______________ Lot No: _____________
Sample no. VR reading at Corrected VR
0’ (max) 3 1/2’ 4’
x. Determination of dry rubber content (DRC)
Objective: To measure the dry factor in determining the dry rubber content of the sample.
Equipment:
Analytical balance, memmert oven, lab mill, dial thickness gauge
Procedure:
1. For the scrap sample, the crepe factor must be known prior to determining the dry
factor and for blanket sample, there is no crepe factor.
2. In determining the crepe factor, the raw rubber is passed through the creeper 12 times
with water and 3 times without water to get clean raw rubber which is the wet sample.
3. The crepe factor is (creped rubber weight / raw rubber weight) x 100%
4. Wet sample must be checked to not contain any dirt and contamination. The wet
sample size in determining the dry factor is normally 20 to 50g. The wet sample
weight is measured with the analytical balance.
58. 5. The wet sample is dried in the memmert oven at 140oC±5oC for 1 hour.
6. The sample is checked for any white spots and then the sample is passed 5 times
through the lab mill to achieve a thickness of 3.2 to 3.6 mm.
7. The sheeted sample is dried in the memmert oven at 140oC±5 oC for another 15
minutes.
8. The dried sample is weighted immediately from the oven with analytical balance.
9. The lab factor is (dried sample weight / wet sample weight) x 100%.
10. The dry rubber content is (crepe factor x lab factor x 1/100).
Figure 3.79: The wet samples are cut approximately 40g
Figure 3.80: The dried samples
59. 3.2.3 SMR specification and customer aspects specification
Table 3.18: SMR specification
Parameter
SMR
CV
50
SMR
CV
60
SM
R L
SMR 5 SMR GP
SMR
10
CV
SM
R 10
SMR
20
CV
SM
R 20
LATEX
Sheet
materia
l
60% Flx
coagulatio
n
40% CL
BLEND
FIELD GRADE
MATERIAL
DIRT 0.02 0.02 0.02 0.05 0.08 0.08 0.08 0.16 0.16
ASH 0.50 0.50 0.50 0.60 0.75 0.75 0.75 1.00 1.00
NITROGEN
0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60
0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15
0.55 0.55 0.55 0.55 0.55 0.55 0.55 0.55 0.55
V.
MATTER
0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80 0.80
0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50
PO (MIN) - - 35 30 - - 30 - 30
PRI (IND.)
(**) MEAN
60 60 60 60 50 50 50 40 40
70 70 70 70 60 60 60 50 50
V.R.
(**)
50
(± 5)
60
(± 5)
- - 65(+7 -5) - - - -
50
(± 5)
60
(± 5)
- - 65 (± 5)
60
(± 5
)
-
65
(± 5
)
-
RHEO R R R - R R - R -
61. 3.2.4 Procedure of packing samples to Mech. Chem. Laboratory
Figure 3.81: The procedure of packing sample
After the sample is sent to Mech. Chem. Laboratory, they will give COA (Certificate of
Analysis) to MPSB Mentakab, and then the rubber that had been processed will get the
permission for shipment to the customers.
Checking on P0/PRI result
of sample
It is passed?
Retest
Writing cover note
Getting permission from lab manager
(signature) to proceed packing sample
Wrapping and weighing the sample and then
ABX serving post will take the sample
No
Yes
62. CHAPTER 4: TRAINING SCOPE
4.1 Experiences
About four months to complete my internship, there were many things I had learned and I was
really glad to have such precious experience in improving my knowledge and skill to become a
future engineer. I got the opportunity to handle many kinds of experiments either effluent or
SMR testing during my training and also be familiar with all procedures and apparatus that being
used. Besides, I could apply my basic knowledge that had been learned in university such as
molarity, dilution and many more and it was not a waste thing at all to have my training here.
Since I already learned wastewater treatment process in the university, but the real experience to
handle experiment was very valuable and truly improved my skill to handle all parameters based
on the methods given. I also could learn the management for effluent treatment for rubber
processing and deal with some problems related with it.
Although I never learn precisely about natural rubber, but it was really great to work and deal
with it. Other than that, I learned in a good way how to take any responsibility by exposing
myself to the real workplace environment. Handling any testing or work already taught me to
become honest, punctual and always give the best commitment although had to face some
problems as long as the result was always precise and accurate. Furthermore, I was able to
increase my self-confidence day by day as I had to deal many people and works every day and it
was a good way to get along better in workplace. Although this training was not a real work for
me but it was much enough to get me through the real world of work life one day and I was very
glad to had great and precious time with other lab teammates that always help and support me as
a big family.
4.2 Problem faced during internship
For the first two months in effluent, I could notice some misunderstanding between lab personnel
and manager in handling some problems especially related to the effluent treatment when there
were some chaos happened with other workers that responsible to take sample, checking on
63. flowrates, filling nutrients and scrubber management. But after some discussion and tolerance
between both sides, most of problems finally can be solved properly.
Then, next two months in SMR also faced some miscommunication between the lab worker and
worker from the production when there were some mistakes happened about lot order and
untrustworthiness among other workers on testing that had been conducted by lab assistant when
certain results were not satisfied. After the lab manager conducting meeting among lab assistants,
all problems can be solved immediately without more chaos.
Besides, the laboratory also faced problem because of lack of workers especially in SMR testing.
The lab manager and supervisor had to plan schedule by involving only five workers at the
beginning and after the discussion with assistant factory manager, a worker from the production
was taken to work in laboratory to handle SMR testing which required a lot of works every day.
Since then, all works included housekeeping activities looked more systematic and organize
because all lab assistants were able to do work productively than before.
4.3 Recommendation
Having internship at MPSB Mentakab was such a precious experience for me a diploma student.
There were many new things I had learned here and as engineering student, I wish to improve
myself better with all knowledge I gained from testing on effluent and SMR. As a student, I wish
more industries will let students to have their training like this in their factory and should not be
too picky especially on diploma student. For MPSB Mentakab as rubber processing industry, it
was really good for this industry to give opportunity to any universities or academic institutes to
have a visit for the students to learn and get know more about natural rubber instead of learning
theoretically in the classroom.
4.4 Conclusion
Learning about testing on effluent and Standard Malaysian Rubber (SMR) during this internship
given me a lot of knowledge and skills to be applied in the future. As the result from my training,
64. all objectives that had been targeted by me and UTHM were achieved successfully. I managed to
handle effluent and SMR testing based on their parameters properly and familiar with some
solutions and chemicals that seldom to be handled practically during study. I also was able to
handle any chemical preparation and it was really great experience for me. Moreover, I got the
opportunity to see overall production of natural rubber in MPSB Mentakab and at the same time,
I could learn more about it since I not learned about it precisely in the class.
MBSB Mentakab was a great place for a student to learn and apply basic knowledge here since it
was industry with processing as major and has received certifications in relations to quality
management system and environmental management system for its processing centers.
65. REFERENCES
PRIM Test Methods for Standard Malaysian Rubbers, 1973, SMR Bulletin No 7,
Akademi Hevea Malaysia, Selangor.
Dr. Zaid Isa, 2013, Determination of pH in water and industrial effluent by American
Public Health Association (APHA) Standard Methods. Mardec, MPSB. Malaysia
Dr. Zaid Isa, 2013, Determination of ammonical nitrogen in rubber by steam distillation
and titration. Mardec, MPSB. Malaysia
Dr. Zaid Isa, 2013, Determination of suspended solid in rubber. Mardec, MPSB.
Malaysia
Dr. Zaid Isa, 2013, Determination of total solid in rubber. Mardec, MPSB. Malaysia
Dr. Zaid Isa, 2013, Determination of total nitrogen in rubber followed by steam
distillation and titration method. Mardec, MPSB. Malaysia
Dr. Zaid Isa, 2013, Determination of biochemical oxygen demand (BOD) by dissolved
oxygen (DO) meter. Mardec, MPSB. Malaysia
Dr. Zaid Isa, 2013, Determination of Chemical oxygen demand (COD) in rubber by open
reflux and titrimetric method. Mardec, MPSB. Malaysia
Zaid I., 1993, Control of Malodour in SMR Factories. RRIM Planters'Bull., Second
Quarter, 56-63.
Zaid I., 2005, Malodour Control in Rubber Processing. Proc. Rubb. Plrs' Conf. 2005.
Kuala Lumpur.
Zaid I., Hidayaty N.K., Zairossani M.N., 2008, Malodour Assessment and Control from
Standard Malaysian Rubber Processing Factories. International Rubber Conference, 20-
23, Kuala Lumpur.
