This document discusses sources of technical knowledge for the plastics industry, focusing on classifications of plastics, important properties for designers, manufacturers and customers, materials and manufacturing methods, strategies for improvement, basic economics, and case studies of high-return plastic projects. It provides information on plastic consumption trends, commodity vs engineering plastics, important design and manufacturing properties, manufacturing methods like injection molding and rotational molding, standards, design for manufacturing strategies, project cost estimation, basic economic analysis, and examples of profitable plastic product lines.

1. Sources for Technical Know –howSources for Technical Know –how
- Focus on Plastics Industries- Focus on Plastics Industries
Dr. K. Padmanabhan FIIPE, FIEDr. K. Padmanabhan FIIPE, FIE
ProfessorProfessor
Mechanical EngineeringMechanical Engineering
SVCE, Sri PerumbudurSVCE, Sri Perumbudur

2. ContentsContents
 Plastics, Classifications, ConsumptionPlastics, Classifications, Consumption
 Important Properties:Important Properties: Designer, Manufacturer, CustomerDesigner, Manufacturer, Customer
 Materials and Manufacturing MethodsMaterials and Manufacturing Methods
 Strategies for ImprovementStrategies for Improvement
 Basic EconomicsBasic Economics
 High Flying Projects- Case StudiesHigh Flying Projects- Case Studies
 TANSTIA FNF Service CentreTANSTIA FNF Service Centre

3. ProductsProducts
 Consumer ProductsConsumer Products
 Engineering ProductsEngineering Products
Metal based productsMetal based products
Ceramic based productsCeramic based products
Polymer based productsPolymer based products

4. Polymer and PlasticPolymer and Plastic
 A Plastic should be aA Plastic should be a
Solid in finished formSolid in finished form
Should be organic in structureShould be organic in structure
Must have been capable of flow atMust have been capable of flow at
some stage in processingsome stage in processing
(ASTM Definition)(ASTM Definition)

5. Focus on PlasticsFocus on Plastics
 Plastics and Reinforced PlasticsPlastics and Reinforced Plastics
 The Rising ImportanceThe Rising Importance
 Present ConsumptionPresent Consumption
 StatisticsStatistics
 ScopeScope

6. Indian Plastics ConsumptionIndian Plastics Consumption

7. World Plastics ConsumptionWorld Plastics Consumption

8. Plastic ProductsPlastic Products
 Commodity PlasticsCommodity Plastics
TypesTypes
ApplicationsApplications
Consumption and DemandConsumption and Demand
 Engineering PlasticsEngineering Plastics
TypesTypes
ApplicationsApplications
Consumption and DemandConsumption and Demand

9. Plastic ProductsPlastic Products
 Properties important to theProperties important to the
DesignerDesigner
ManufacturerManufacturer
Customer/ UserCustomer/ User

10. Design PropertiesDesign Properties
 Strength, Stiffness, Toughness, Fatigue,Strength, Stiffness, Toughness, Fatigue,
Creep and ImpactCreep and Impact
 Dimensions, Weight, TolerancesDimensions, Weight, Tolerances
 Judicious use of drafts, radii, fillets, webs,Judicious use of drafts, radii, fillets, webs,
ribs, blends, chamfers and curves forribs, blends, chamfers and curves for
specific propertiesspecific properties
 Ease of assembly, disassembly andEase of assembly, disassembly and
serviceservice
 Aesthetics, colouring and texturingAesthetics, colouring and texturing

11. Manufacturing PropertiesManufacturing Properties
 Forming temperature, Glass transition, MeltingForming temperature, Glass transition, Melting
point, Rate of solidificationpoint, Rate of solidification
 Energy required to form, Whether batch processEnergy required to form, Whether batch process
possible? , Pressure requiredpossible? , Pressure required
 Flow behaviour, Viscosity, Melt flow indexFlow behaviour, Viscosity, Melt flow index
 Mouldability and Castability, WorkabilityMouldability and Castability, Workability
 Fabrication of Complex Parts, TimeFabrication of Complex Parts, Time
 Curing/Solidification Shrinkage in the MouldCuring/Solidification Shrinkage in the Mould
 Materials properties, Availability, ToxicityMaterials properties, Availability, Toxicity

12. Customer/User RequirementsCustomer/User Requirements
 Quality, Cost, Durability ( low moistureQuality, Cost, Durability ( low moisture
absorption), Reliability ( low degradation ofabsorption), Reliability ( low degradation of
properties with time)properties with time)
 Efficiency : Better properties at lighterEfficiency : Better properties at lighter
weight and less money, Valueweight and less money, Value
 Flexibility : Multi functionalityFlexibility : Multi functionality
 Low maintenance costLow maintenance cost
 Aesthetics, textures in DesignAesthetics, textures in Design

13. Material CostsMaterial Costs
 An OverviewAn Overview
 Commodity thermoplastics are the cheapest.Commodity thermoplastics are the cheapest.
Commodity thermosets are costlierCommodity thermosets are costlier
 Entry level engineering thermoplastics areEntry level engineering thermoplastics are
cheaper than advanced engineeringcheaper than advanced engineering
thermoplasticsthermoplastics
 High end blends, alloys and IPNs ofHigh end blends, alloys and IPNs of
thermoplastics and thermosets are expensivethermoplastics and thermosets are expensive
( used in aircrafts, marine industry, luxury /sports( used in aircrafts, marine industry, luxury /sports
cars, Sports equipment etc.)cars, Sports equipment etc.)

14. Manufacturing MethodsManufacturing Methods
 For Plastics and Reinforced PlasticsFor Plastics and Reinforced Plastics
Calendaring, Autoclave vacuum bagging,Calendaring, Autoclave vacuum bagging,
Vacuum resin infusion moulding,Vacuum resin infusion moulding,
Reinforced reaction injection moulding,Reinforced reaction injection moulding,
Casting, Pultrusion, Extrusion, Hand layCasting, Pultrusion, Extrusion, Hand lay
up contact mouldingup contact moulding

15. Blow MouldingBlow Moulding

16. Injection MouldingInjection Moulding

17. Compression MouldingCompression Moulding

18. Resin Transfer MouldingResin Transfer Moulding

19. ThermoformingThermoforming

20. Rotational MouldingRotational Moulding

21. Relative Margins in ManufacturingRelative Margins in Manufacturing
 Injection moulding and compression mouldingInjection moulding and compression moulding
are efficient as batch fabrication is possibleare efficient as batch fabrication is possible
 Extrusion is also efficientExtrusion is also efficient
 Blow moulding, Thermoforming , Resin transferBlow moulding, Thermoforming , Resin transfer
moulding and Rotational moulding are alsomoulding and Rotational moulding are also
economicaleconomical
 Room temperature thermosets and casting themRoom temperature thermosets and casting them
is cheapis cheap
 Other techniques described are high endOther techniques described are high end

22. Choice of Manufacturing MethodChoice of Manufacturing Method
 Shape, Size, Finish and Design complexityShape, Size, Finish and Design complexity
 Desired mechanical propertiesDesired mechanical properties
 Materials selectionMaterials selection
 Batch processing requirementBatch processing requirement
 Tooling, fixturing requiredTooling, fixturing required
 Cost per pieceCost per piece
 Demand and local availabilityDemand and local availability
 Overall reliability and durability of the methodOverall reliability and durability of the method
 SafetySafety

23. Plastics and StandardsPlastics and Standards
 Raw Materials, semi finished and finishedRaw Materials, semi finished and finished
materials/productsmaterials/products
 Processes, methodsProcesses, methods
 Testing , specimen dimensionsTesting , specimen dimensions
 Voluntary consensus standards, industryVoluntary consensus standards, industry
standards, company standardsstandards, company standards
 Standards making bodiesStandards making bodies
ASTM, ASC, ISO,BIS,ISI, DIN….ASTM, ASC, ISO,BIS,ISI, DIN….

24. Design for ManufacturingDesign for Manufacturing
 A practice for designing products, keepingA practice for designing products, keeping
manufacturing in mind.manufacturing in mind.
 Minimise the number of parts through aMinimise the number of parts through a
more compliant designmore compliant design
 Multifunctional partsMultifunctional parts
 Minimize part variationsMinimize part variations
 Ease of handling, assembly and repairEase of handling, assembly and repair
 Optimum design for manufactureOptimum design for manufacture

25. Single Minute Exchange of DieSingle Minute Exchange of Die
 A Japanese concept by Shigeo ShingoA Japanese concept by Shigeo Shingo
 Quick change of die for a different partQuick change of die for a different part
Design for clampabilityDesign for clampability
Use of same machine for different partsUse of same machine for different parts
 Switching Resins, transferring resins inSwitching Resins, transferring resins in
tankstanks
 SMED reduces costsSMED reduces costs

26. Other Productivity StrategiesOther Productivity Strategies
 Computer Aided Design, ManufacturingComputer Aided Design, Manufacturing
and Engineering (CAD/CAM/CAE)and Engineering (CAD/CAM/CAE)
 Product design validation through finiteProduct design validation through finite
element analysiselement analysis
 Feed back FEA results to design stagesFeed back FEA results to design stages
 Iterative design process, avoid overIterative design process, avoid over
designdesign
 Cost effective design optimizationCost effective design optimization
 First attempt at production- to be aFirst attempt at production- to be a
success !success !

27. Estimated Cost of the ProjectEstimated Cost of the Project
 Land and BuildingLand and Building
 Plant and MachineryPlant and Machinery
 Erection and CommissioningErection and Commissioning
 Office EquipmentOffice Equipment
 Pre-operative ExpensesPre-operative Expenses
 Working Capital for Three MonthsWorking Capital for Three Months
 Identification of Clients, CustomersIdentification of Clients, Customers

28. Basic EconomicsBasic Economics
 Working CapitalWorking Capital
 Cost of the ProjectCost of the Project
 Net Profit Per YearNet Profit Per Year
 Net Profit RatioNet Profit Ratio
 Rate of Return on Total InvestmentRate of Return on Total Investment
 Breakeven PointBreakeven Point

29. High Flying ProjectsHigh Flying Projects
 High Returns/Profit ProjectsHigh Returns/Profit Projects
Compression moulded plastic goodsCompression moulded plastic goods
Blow moulded containersBlow moulded containers
FRP Products- Helmets and PanelsFRP Products- Helmets and Panels
Automatic injection moulded industrialAutomatic injection moulded industrial
componentscomponents
PTFE bushesPTFE bushes
Reprocessing of plasticsReprocessing of plastics
(contd…)(contd…)

30. High Flying ProjectsHigh Flying Projects
Keyboard switchesKeyboard switches
Plastic flash light torch casesPlastic flash light torch cases
Nylon zip fastenersNylon zip fasteners
Fevicol type adhesivesFevicol type adhesives
PET bottles from preformsPET bottles from preforms
Rigid PVC pipesRigid PVC pipes
PP/HDPE woven sacksPP/HDPE woven sacks

31. Present Status and FuturePresent Status and Future
Prospects of PlasticsProspects of Plastics
 Production and demand patternProduction and demand pattern
 Imports and exportsImports and exports
 Application areasApplication areas
Electronics and telecommunication, Consumer goods,Electronics and telecommunication, Consumer goods,
Automobile industry, Structural Engineering, EnergyAutomobile industry, Structural Engineering, Energy
Sector, Sports and leisure, Medicine and MarineSector, Sports and leisure, Medicine and Marine
 Scope for innovationScope for innovation
 Manpower and employment potentialManpower and employment potential
 Future prospectsFuture prospects

32. TANSTIA-FNF Service CentreTANSTIA-FNF Service Centre
www.tanstiafnf.comwww.tanstiafnf.com,, www.tanstia.org.inwww.tanstia.org.in
 Tamil Nadu Small and Tiny IndustriesTamil Nadu Small and Tiny Industries
Association-Friedrich Naumann FoundationAssociation-Friedrich Naumann Foundation
(Germany) Service Centre, Estd 1992(Germany) Service Centre, Estd 1992
 Situated at Guindy Indl. EstateSituated at Guindy Indl. Estate
 Offers services in information, consultancy,Offers services in information, consultancy,
training programmes, seminars, studies andtraining programmes, seminars, studies and
publicationspublications
 Assists to obtain subsidies, concessions andAssists to obtain subsidies, concessions and
benefits of various schemes by the governmentbenefits of various schemes by the government

33. Thank youThank you
Questions ?Questions ?