Plastic is a synthetic or semi-synthetic material made from polymers that can be molded. The first man-made plastic was Parkesine created in 1862, while celluloid was invented in 1868. Common plastics include polyethylene, polyvinyl chloride, and polyurethane. Plastics are made through polymerization of monomers and may contain additives. They are manufactured through processes like injection molding, blow molding, and extrusion. Major plastic products include packaging, bottles, fibers, sheets, and pipes.

1. industryPlastic

2. TOPICS TO BE
COVERED
Introduction
History of Plastic
Composition & Synthesis
Types of Plastic & Their Uses
Plastic Resin codes
Advantages
Industrial Manufacturing Of Plastics
Chemicals in Plastic
Processing Of Plastics
Polyethylene terephthalate (PET)
Manufacture of PVC

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)
- Food packaging
Polyethylene (PE) - Wide range of inexpensive
uses including supermarket bags, plastic bottles.
Polycarbonate/Acrylonitrile Butadiene
Styrene (PC/ABS) - Car Interior and exterior parts
Chemicals in Plastic

7. TYPESOF
❖Plastic bags
❖Plastic coatings
❖Plastic furniture
❖Plastic sheets
❖Plastic fittings
❖Plastic tanks
❖Plastic toys
❖Plastic buckets
❖Plastic sanitaryware
❖Plastic stationery
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
Condensation polymerization 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. CONCLUSION
1. INTRODUCTION OF PLASTIC
2. AWARENESS OF ADVANTAGES AND DISADVANTAGES
3. TYPES OF PLASTIC
4. SOME MANUFACTURING PLANTS.
5. TYPES & METHODS OF MOULDING.