FEDERAL UNIVERSITY OTUOKE

BAYELSA STATE

A TECHNICAL REPORT

ON

STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

HELD AT

EBU OIL AND GAS: BAYELSA PLASTIC INDUSTRY. OPOLO-ELEBELE

(AIT) ROAD, ELEBELE, YENAGOA, BAYELSA STATE.

WRITTEN

BY

SELEGHA BLESSING
FUO/17/BCH/6362
DEPARTMENT OF BIOCHEMISTRY

FACULTY OF SCIENCE

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF

BACHELOR OF SCIENCE [B.Sc.] DEGREE IN BIOCHEMISTRY

AUGUST 2021
 DEDICATION
I dedicate this work to my dearest parents Mr. and Mrs. Selegha Francis Igabo whom
through their advice, love, care and financial assistance have made me to be where I am
today, I pray that the good Lord, will continue to keep and guide them for me. Amen
 ACKNOWLEDGEMENT

I sincerely appreciate the Federal Republic of Nigeria, the Industrial Training Fund (ITF)
and all other supervising agencies who ensure the continuity of the SIWES. Indeed, they
have made a tremendous impact in my life.

My utmost gratitude goes to the almighty and ever-living God, for His divine grace from
which I have always benefited from. In Him I live, move and have my being.

My profound gratitude also goes to all members of staff of Ebu Oil And Gas: Bayelsa
Plastic Industry, who gave me an extensive training and provided a conducive
environment for the exercise.
 ABSTRACT

This report is a summary of my industrial work experience gained during my four months
at Ebu Oil And Gas: Bayelsa Plastic Industry. It contains four chapters which include
history of SIWES, description of the company, departments in the company, extrusion
section, Injection section, recycling section and the relevance of BIOCHEMISTRY in
plastic and polymer industry.
 TABLE OF CONTENT

Title page

Dedication

Acknowledgement

Abstract

Table of content

List of figures

List of tables

CHAPTER ONE: INTRODUCTION

1.1 History of SIWES

1.1.1 Objectives of SIWES
1.1.2 Importance of SIWES
1.1.3 The role of student in SIWES
1.1.4 The role of the institution in SIWES
1.1.5 The role of the industry/employers in SIWES
1.2 Brief history of Ayom Integrated Production Limited.
1.2.1 Department in the company
1.2.2 Administrative department
1.2.3 Account/sales department
1.2.4 Production department
1.2.5 Store department

CHAPTER TWO: DIFFERENT PRODUCTION DEPARTMENTS IN EBU OIL

AND GAS: BAYELSA PLASTIC INDUSTRY

2.1 EXTRUSION DEPARTMENT

2.1.1 Plastic Extrusion Process
2.1.2 Extrusion Process Description
2.1.3 The production of PVC pipes using extrusion moulding
2.1.4 Raw materials & Additives used in PVC pipe production
2.1.5 PVC pipes formulation for compounding in Ayom Integrated Production LTD
2.1.6 Terms used in Extrusion moulding process
2.1.7 Defects encountered during production of PVC pipes using Extrusion & its
remedies
2.2 INJECTION DEPARTMENT
2.2.1 Terms used in Injection moulding process
2.2.2 Production process
2.2.3 Raw material & Additives used in plastic production
2.2.4 Defects and corrections in Injection moulding of plastics
2.2.5 Difference between Extrusion and Injection moulding
2.3 RECYCLING DEPARTMENT
2.3.1 Recycling of plastic waste
2.3.2 Recycling process in Injection plant
2.3.3 Recycling process in Extrusion plant
2.4 QUALITY CONTROL/QUALITY ASSURANCE OF PRODUCTS IN AYOM
PLASTICS
2.4.1 Quality control and Quality assurance
2.4.2 Quality control

CHAPTER THREE: RELEVANCE OF THE INDUSTRIAL TRAINING TO MY

COURSE OF STUDY, EXPERIENCED GAINED, PROBLEMS ENCOUNTERED
3.1 Relevance of the Industrial training to my course of study
3.2 Experienced Gained
3.3 Problems encountered
CHAPTER FOUR: CONCLUSION AND RECOMMENDATION
4.1 Conclusion
4.1 Recommendation
References

LIST OF FIGURES

Figure 1: Basic elements of an Extrusion moulding machine

Figure 2: High speed impeller used for compounding/mixing

Figure 3: An Extrusion machine used in Bayelsa Plastics

Figure 4: Trimming machine used in Bayelsa Plastics

Figure 5: Heating and Socketing machine used in Bayelsa Plastics.

Figure 6: Extruder, Extrusion water-bath, Extrusion line.

Figure 7: A Suspension PVC resin

Figure 8: PVC pipes produced in Ebu Oil And Gas: Bayelsa Plastic Industry

Figure 9: An Injection moulding machine used in Bayelsa Plastics.

Figure 10: Different colours of master-batch used in Bayelsa Plastics.

Figure 11: Products of polypropylene from Injection moulding machine in Bayelsa Plts..

Figure 12: Crushing machine used at the Injection plant in Bayelsa Plastics.

Figure 13: Concrete washing basin used in Bayelsa Plastics.

Figure 14: A Drying machine used a.t the Injection plant in Bayelsa Plastics.

Figure 15: A Magnetic sieve.

Figure 16: Recycled polypropylene scraps and lumps.

Figure 17: Crushing machine used at the Extrusion plant in Bayelsa Plastics.

Figure 18: Pulverizing machine in Bayelsa Plastics.

Figure 19: A Vibratory sieving machine.

 CHAPTER ONE

INTRODUCTION

Students Industrial work experience scheme (SIWES) is designed for skill acquisition. It
is designed to prepare and expose students of universities, Polytechnic and College of
Education to the real life situation they would encounter after graduation.

SIWES is a key factor required to inject and engender industrialization and economic
development in our nation through the induction of scientific and technological skills on
students.

1.1 HISTORY OF SIWES

The SIWES scheme was first initiated and funded by the Industrial Training Fund (ITF)
in the year 1973. It was established to solve the problem of lack of adequate practical
skill exposure for employment in industries by Nigerian graduates of tertiary institutions.

As a result of increasing number of students enrolment in higher institutions of learning,

the administration of this function of funding the scheme became enormous, hence ITF
withdrew from the scheme in 1978 and the scheme was taken over by the federal
Government in1979 and handed to both the National University Commission (NUC) and
the National board of Technical Education (NBTE). By 1979, the College of Education
were not part of the scheme and later in 1984, the Federal Government reverted back to
the Industrial Training Fund which took over the scheme officially in 1985 with funding
provided by the Federal Government.

1.1.1 OBJECTIVE OF SIWES

The following are objectives of SIWES:

 To provide an avenue for students in institutions of higher learning to acquire

industrial skills and experience in their course of study.
 Make the transition from school to world of work easier and enhance students
contacts for later job placement.
 Provide students with opportunity to apply their knowledge in real work situation
thereby bridging the gap between theory and practice.
  Prepare students for industrial work situations they are to meet after graduation.
 Expose students to techniques in handling equipment and machinery that may not
be available in the universities.

1.1.2 IMPORTANCE OF SIWES;

 It provides students the opportunities to apply their theoretical knowledge in real
life situations
 It strengthens the links between students, employers, universities and ITF
 It exposes students to more techniques
 It also prepares the students for the labor market after graduation.

1.1.3 The Role of Students in SIWES;

Attend SIWES Orientation program organized by Institution in conjunction with ITF.

 Be obedient to constituted authorities.

 Be regular and punctual to work.
 Avoid change of place of SIWES attachment outside the allowed time frame.

1.1.4 The Role of the Institutions in SIWES

 Establishment of SIWES Units in Institutions and equipping them.
 Appointment of coordinators and supporting Staff.
 Promptly prepare and submit master placement lists to NUC, NBTE, NCCE and
ITF as it concerns each Institution.
 Apply Job Specifications as prepared for all the accredited courses and award
appropriate credit Units to SIWES attachment e.t.c.

1.1.5 The Role of the Industry/Employers in SIWES

 Collaborate with Institutions in the preparation of Job specification.
 Accept students for SIWES attachment.
 Provide welfare services to students on SIWES attachment.
  Participate in training and assessment of students on SIWES attachment.
 Allow students on SIWES attachment access to facilities in their establishments.
 Appoint industry-based supervisor.

1.2 BRIEF HISTORY OF EBU OIL AND GAS: BAYELSA PLASTIC INDUSTRY

The Bayelsa Plastic Industry is an indigenous industry currently overseen by Ebu Oil and
Gas Company Limited which produces Synthetic Polymers (nylon) and Polyvinyl
Chloride (PVC). The Bayelsa Plastic Industry has been closed for a long time which Ebi
Oil and Gas took over it as of January, 2021. The company is headed by Mr. Ebimie
Norman Niweigha as the CEO or Managing Director.

COMPANY’S ORGANOGRAM

1.2.1 DEPARTMENTS IN THE COMPANY.

Ebu Oil And Gas: Bayelsa Plastic Industry, has four major departments namely:

1) Administrative department
 2) Account/Sales department
3) Production department
4) Store department.
1.2.2 ADMINISTRATIVE DEPARTMENT

This department is responsible for the smooth running of the company. It is headed by the
administrative manager who is also the CEO of the company. The administrative
manager performs the following function:

 Supervision of the company’s daily activities

 Ensuring rules and regulations of the company are kept
 Implementation of the company’s policies etc.
 Employment of staff

1.2.3 ACCOUNT/SALES DEPARTMENT

This department manages every aspect of budgeting and expenditures of the company. It
also co-ordinates and supervises all sales activities of the company’s product. The
department is headed by the account/sales manager; he reports directly to the CEO.

1.2.4 PRODUCTION DEPARTMENT

The department oversees the activities of production in the company and ensures quality
processes of various products in the firm are met. The department is headed by the
production manager who reports directly to the CEO and it is divided into four sections
namely:

a) Extrusion Department
b) Injection Department
c) Recycling Plant/Section
d) Quality Control Department
e) Maintenance Department

1.2.6 STORE DEPARTMENT

The store department is responsible for receiving and stocking all raw materials,
packaging materials and finished products as well all other equipment required to serve
manufacturing purposes. It is headed by the Store Manager. They are responsible for
issuing raw materials and packaging materials for production, ensure that the actual
quantity of products produced after a single run tallies with the expected quantity and
also notifies the company when there is need for procurement of raw and packaging
materials.

CHAPTER TWO

DIFFERENT PRODUCTION DEPARTMENTS IN EBU OIL AND GAS:

BAYELSA PLASTIC INDUSTRY
Ebu Oil And Gas: Bayelsa Plastic Industry we have different sections of production.
These various departments include: the extrusion department, the injection department,
the recycling department, the quality assurance department and maintenance department
which maintains everything in the factory for better production.

2.1 EXTRUSION DEPARTMENT

2.1.1 PLASTIC EXTRUSION PROCESS:
Plastics extrusion is a continuous high-volume manufacturing process, in which raw plastic is
melted and formed into a continuous profile. This process starts by feeding plastic material
(pellets, granules, flakes or powders) from a hopper into the barrel of the extruder. The material is
gradually melted.Mechanical energy generated by turning screws and by heaters arranged along
the barrel. The molten polymer is then forced into a die, which shapes the polymer into a shape
that hardens during cooling.
 Fig 1. Basic Elements of an Extrusion Moulding Machine Used in Ebu Oil And Gas: Bayelsa Plastic
Industry

Extrusion process is very common in the plastic industry. It is used for high volume
plastic production. In extrusion process the color pigments along with other performance
enhancing additives are combined with resin which is then pushed through the rotating
screws.

Extrusion is without doubt the most important method of processing in the plastics
industry. This is because it can be adapted to produce a wide variety of finished or semi-
finished product which include pipes, rod, sheet, film, coated wires and cables and other
substrates. It is claim that nearly all thermoplastic pass through an extruder at one stage
of their lives! The most important thermoplastic extruded are poly Vinyl Chloride,
polyethylene, polypropylene, polystyrene, polyamides etc.

Advantages of Plastic Extrusion Process

One of the main advantages of the extrusion process is it can produce pipes of any length.
It is continuous. High production volumes with very low cost per pound. The melting is
very efficient. The mixing of the ingredients is very good. Different types of raw
materials can be used. It uses thermoplastics which can be reused.

Disadvantages of Plastic Extrusion Process

Highly complicated parts are very not suitable for production in extrusion process. It can
only produce the parts which have uniform cross sections. 

2.1.2 EXTRUSION PROCESS DESCRIPTION

In the extrusion of plastics, the raw compound material is commonly in the form of
hurdles (small beads, often called resin) that are gravity fed from a top mounted hopper
into the barrel of the extruder. Additives such as colorants and UV inhibitors (in either
liquid or pellet form) are often used and can be mixed into the resin prior to arriving at
the hopper. The extruder technology though it differs in that it is usually a continuous
process. Extrusion molding is a process of forcing softened plastic through a nozzle or
die extrusion molding is used for continuous molding of thermoplastic material into
article of uniform cross-section example wires, pipes etc.

The extrusion machine has four major zones;

a. The feed zone

b. The compression zone
c. The metering zone and
d. The cooling zone
The Feed Zone: compounded PVC resins in form of powder are feed into an
extruder through the hopper.
The Compression Zone: It consist of a barrel, an electrical heater and a screw for
softening of materials. In this zone the powdered resins undergoes melting
because of heat conducted by the heating bands or the heating elements and is
 compressed by the working of a reciprocating screw. The molten material is then
pushed to the metering zone. The temperature is controlled by thermocouple.
Metering Zone:It is at this point that the polymer melt acquires a constant flow
rate impacted by the helical flight of the screw.the build up pressure and the
shearing action of the screw forces the molten polymer out of the extruder
through the die into the cooling zone,the die shapes the extrudant into the desired
form.
Cooling Zone: the cooling zone contain a water bath that cools the pipe as it
emerges from the die,this is done to prevent deformation and shrinkage of
pipes.the size of the pipes depends on the size of the die.the pipe exist through the
extrusion line and are cut into desired length.

Thermoplastic Material in Extrusion: Typical plastic materials that are used in extrusion
include but are not limited to:

a) Acetal,

b) Acrylic,

c) Acrylonitrile butadiene styrene (ABS)

d) Nylon (polyamides),

e) Polycarbonate (PC)

f) Polyethylene (PE),

g) Polypropylene (PP),

h) Polystyrene (PS),

i) Polyvinyl chloride (PVC),

2.1.3 THE PRODUCTION OF P. V. C PIPES USING EXTRUSION MOULDING

Pipes are first and foremost produced through an extrusion process. The raw material is
feeded into the extruder via a hopper and a gravimetric or volumetric control system.
Inside the extruder barrel the material is heated up to the melting point around 200°C by
electricity and the friction in the screw system. The melted material is pushed through a
cavity, called a die-head and thereby formed into a pipe. The pipe is then calibrated to
correct size in a vacuum box and thereafter cooled by water in spray boxes. Extrusion is a
continuous process and pipes can in principle be produced in infinity lengths. In the end
of the production line pipes are cut into lengths and socketed or coiled according to the
intended use.

PRODUCTION FLOWCHART
DESCRIPTION

VIRGIN MATERIAL MEASUREMENTS: the different raw material are measured

out in adequate quantities using a weighing balance

COMPOUNDING: PVC compounding is a process in which additives are mixed with

the base resin to get a homogeneous mixture. The additives are added to either improve
process ability or enhance. The measured material are compounded here using a high
speed mixer forming a homogeneous mixture

Fig 2 High Speed Impeller Used For Compounding /Mixing

EXTRUDING: Here the compounded material are fed into the hopper of extrusion
machine and extrusion molding take place here

Fig. 3 An Extrusion Machine Used In Ebu Oil And Gas: Bayelsa Plastic Industry
TRIMMING SECTION: The edge of the PVC pipes are trimmed here with the aid of a
trimming machine to give it a round smooth edge.

Fig. 4 a Trimming Machine Used In

Ebu Oil And Gas: Bayelsa Plastic Industry

HEATING AND SOCKETING:

Here the trimmed pipe are heated
and socket using a heating and socketing machine so the pipe can fit into each other.

Fig. 5 a Heating And Socketing Machine Used In Ebu Oil And Gas: Bayelsa Plastic Industry
Pipes are produced by horizontal extruding molten polymer through an annular opening
in to several sizing, cooling devices that stabilize the final dimensions. The elements of
the production line are: Extruder, Die, Sizing device, Cooling bath, Puller, Cutter.

Fig. 6 Extruder, Extrusion Waterbath, Extrusion Line

2.1.4 RAW MATERIALS AND ADDITIVES USED IN PVC PIPE PRODUCTION

The resin commonly

used for the pipe
manufactures
in Ebu Oil And Gas:
Bayelsa Plastic
Industry are: PE, PVC,
PS & ABS. For the
pipe production
the materials may
have to be
compounded. For example, many pipe producers use PVC. The resin is heat sensitive and
under the normal processing conditions, it has high viscosity, thus it can’t be processed-
Its needs compounding. However appropriate grades of other polymers, such as PE or
ABS, can be directly use as supplied by the manufacturer, without compounding. product
performance. The following ingredients are added to PVC for pipe production:

 Plasticizer

 Heat Stabilizer

 Lubricants

 Fillers

 Processing aids

 Colorants

 Flame retardant

 Impact Modifier

PLASTICIZERS: are used to make the resin softer, reduce the viscosity and thus make
process of PVC easier. Epoxy and Di-ethyl hexyl phthalate (DOP) are example of
common PVC plasticizers.

HEAT STABILIZERS: are required to prevent the thermal degradation of PVC at the
process temperatures. The degradation involves resin discoloration and evolution of
HCL, In the process lead stabilizers have been used. Owing to toxicity of PB. Today the
common stabilizers are based on tin viz. di-butyl tin maleate.

LUBRICANTS: are used to reduce friction during processing that may lead to
degradation. Two types of lubricants are used. External and internal. The former viz.
calcium stearate and wax is used to reduce friction on process between metal surfaces to
polymer. The latter stearic acid friction arising out of polymer chain for slippage.

FILLERS AND REINFORCEMENT: are added for cost reduction and improvement
for mechanical properties of product. Both increase rigidity, hardness, and density and
flame retardancy. Typical filler is calcium carbonate, a typical reinforcement are chopped
glass fiber and mica flakes, while such additives as clay, talc and silica are between.

FLAME RETARDING AGENTS: are needed for plasticized PVC. Chlorinated paraffin
oil or waxes, oxide of Sb, Mo, P or B, as well as aluminum oxide have been used.

PROCESSING AIDS: are added to rigid PVC to improve flow through the barrel and
die. In to the group of additives belong polymer and co-polymers miscible with PVC ex.
PMMA, ABS & SAN etc.

IMPACT MODIFIER: are added to improve the impact strength impact modifier are at
least two parts. One that ascertain miscibility with PVC and other elastomeric additives
are used to make stiffing. Example MBS, CSR & NBR.

POLYVINYL CHLORIDE (PVC) RESIN: Polyvinyl Chloride (PVC) is one of the

most commonly used thermoplastic polymers in the world (next to only a few more
widely used plastics like PET and PP). it is a naturally white and very brittle (prior to the
additions of plasticizers) plastic. PVC is produced in two general forms, first as a rigid or
plasticized polymer (RPVC or uPVC), and second as a flexible plastic. Polyvinylchloride
is a white brittle thermoplastic polymer that can be softened on heating, it is produced by
polymerization of vinyl chloride monomer PVC is chemically inert, resistant to water and
environmental corrosion, it's also a good electrical and thermal insulator and still
maintain its properties over a reasonably large temperature range.

SYTHENSIS OF PVC

Structurally, PVC is a vinyl polymer. it’s similar to polyethylene, but on every other
carbon in the backbone chain, one of the hydrogen atoms is replaced with a chlorine
atom. It’s produced by the free radical polymerization of vinyl chloride.

H H H H

C=C free radical vinyl polymerization [ C C ]

H Cl H Cl

Vinyl chloride Poly(Vinyl Chloride)

 There are 4 types of PVC Resin grouped by polymerization method

1. Suspension Grade PVC

2. Emulsion Grade PVC
3. Bulk Polymerised PVC
4. Copolymer PVC’

Fig. 7 a Suspension PVC Resin

PIGMENTS

Pigments again are a vast subject. They can be broadly classified as:

Inorganic Pigments
Organic Pigments
Carbon Blacks.
Inorganic pigments are oxides and salts of metals as well ass complex minerals. The most
important is Titanium Dioxide which is the chief whitening pigment used in Plastics.

2.1.5 PVC PIPE FORMULATION FOR COMPOUNDING IN EBI OIL AND GAS:
BAYELSA PLASTIC INDUSTRY

Pipes Pvc resins Calcium Titanium Stearic acid Carbon Carbon Calcium Stabili- Paraffin
{C2H3Cl} carbonate dioxide {C18H36O2}
products blue black sterate zers wax
{CaCO3} {TiO2}
{C36H70CaO4}
White 75Kg 65kg 1.5Kg 0.5kg _____ _____ 0.5kg 0.2kg 0.5kg
1.5mm

Blue 75kg 65kg ______ 1.5kg 0.10kg ____ ______ 0.3kg 0.5kg
2.5mm

Black 75kg 65kg ______ 1.5kg _____ 0.10kg ______ 0.4kg 0.5kg
2.5mm

2.1.6 TERMS USED IN EXTRUSION MOULDING PROCESS

 Back Pressure – The resistivity of molten plastic material to forward flow.

 Barrel – The part of the extruder encasing the screw or plunger.

 Compound – Any plastic material prepared for subsequent manufacturing

processes, specifically in extrusion, molding or calendaring.

 Cooling Tank – A tank typically containing water through which extrusion is

constantly passed for cooling.

 Die – The component on a plastics extruder affixed to the extruder head through
which the melt is pushed to form the desired profile.

 Dry Blend – A free flowing blend of compound or resin and other ingredients as
prepared for an additional manufacturing operation specifically for extrusion or
molding.

 Extrudate – The product or result of an extrusion process.

 Extrusion - A continuous shaping of plastic material by forcing it under pressure

through a die.

 Haul-off – Also called a “caterpillar,” it is an apparatus used for the continual

removal of extrudate from the die.
 Heat Aging – The unique process of aging a thermoplastic or thermoset product
and examining the percentage of retained physical and chemical properties after
exposure to heat for a prolonged period of time.

 Masterbatch - A compounded resin or additive already optimally dispersed in

concentration and is compatible with the main resin in the process flow.

 Melt – Extrusion material when heated to a molten plastic condition.

 Pellets – Resins or mixtures of resins with compounding additives similar in

shape or size that have been extruded or chopped into short segments to prepare
them for molding operations.

 Post Cure - To continue the cure of a molded article by a subsequent heating

process.

 Processing Aid - An additive or component in a resin to facilitate processing.

 Ram Pressure - Used colloquially for the total force applied by a hydraulic ram,
equal to the hydraulic pressure multiplied by the ram area.

 Resin – Any of several physically similar polymerized synthetics or chemically

altered natural resins, such as thermoplastic materials (polyvinyl, polystyrene,
polyethylene) or thermosetting materials (polyesters, epoxies, silicones used with
fillers, stabilizers, pigments).

 Take-up – An apparatus for reeling extruded material.

 Thermoset – A term that refers to the family of materials that can be melted only
once during the original processing and cannot be reprocessed after the original
part is made.

 Thermoplastic – Any material, such as polyethylene, PVC and ABS, which can
be re-melted and reprocessed without considerable loss of properties or scrap loss.

 Transition Section - The flighted portion of the screw between the feed and
discharge sections in which the extrusion material becomes a melt.

 Travelling Saw - A saw which travels with the extrudate while cutting it to
length. .
 Vinyl – A generic term for PVC, one of various compounds of ethylene that are
polymerized to form resins and plastics (e.g. polyvinyl or polyethylene plastics).
2.1.7 DEFECTS ENCOUNTERED DURING PRODUCTION OF PVC PIPES
USING EXTRUSION AND ITS REMEDIES.

The following are the various defects encountered during production:

1) Blocking

2) Improper System Installation,

3) Improper Operation,

4) Resin Defect,

5) Poor Mixing,

6) Moisture release,

7) Trapped Air Contamination

1. BLOCKING

a) Insufficient bubble cooling

Remedy: Optimize cooling air.

2. IMPROPER SYSTEM ENGINEERING/INSTALLATION

a) Wrong Clamps used or Clamps too tight.

b) Improper die setting
c) Improper alignment of die and
d) Incompatible fire caulk used.
e) Contact of outside of pipe with incompatible material (e.g., solder flux).

Remedies: Adjust the die setting, Check for alignment and check for uniformity in die
heating.

3. IMPROPER OPERATION

a) Exposure to freezing temperatures without freeze protection

b) Over pressurization
c) Pulsating water pressure
Remedies: Use the Digital Pressure gauge and use proper/Digital temperature sensor

4. RESIN DEFECTS

a) Occlusions, char particles, voids

b) Filler/pigment not well distributed
c) Improper mixing of resin and additives
d) Foreign contamination
e) Due to over heating

Remedies: Screening the resin material and exact addition of (Percentage of mixing)
resin material

5. POOR MIXING

This often sets the upper limit for output. The screw cannot be run any faster because the
material is coming out with an “applesauce” surface, with streaks, parabolic ridges, and
perhaps Particles of undispersed additive.

Remedie: Exact addition of (Percentage of mixing) resin material, check for foreign
material and increase rpm back pressure for better mixing.

6. MOISTURE RELEASE

Moisture is absorbed by some plastics. It passes through the extruder and boils when the
pressure is relieved at the die lips. The result is a pattern of dotted lines, long bubbles,
and pits.

Remedies: To remove moisture, the material must be pre-dry and vent must be used in
the extruder.

7. TRAPPED AIR

A trapped-air surface shows bubbles and pits, but little, if any, dotted lines. This is not
common in pelletized material

Remedies: Avoid the over-speed of extrusion.

DEFECTS AND ITS IMPACT ON PRODUCT QUALITY

S/N DEFECTS IMPACT ON QUALITY

1 Improper system installation Centring problem, chatter mark on the

product
2 Improper operation Uneven wall thickness
3 Resin defects Blow hole formation on the product

Fig 8 PVC Pipes Produced In Ebu Oil

and Gas: Bayelsa Plastic Industry

2.2 INJECTION

DEPARTMENT

Injection molding is the most common modern method of manufacturing plastic parts; it
is ideal for producing high volumes of the same object. The Injection molding uses a ram
or screw-type plunger to force molten plastic material into a mold cavity; this solidifies
into a shape that has conformed to the contour of the mold. It is most commonly used to
process both thermoplastic and thermosetting polymers, with the volume used of the
former being considerably higher. Thermoplastics are prevalent due to characteristics
which make them highly suitable for injection molding, such as the ease with which they
may be recycled, their versatility allowing them to be used in a wide variety of
applications, and their ability to soften and flow upon heating. Thermoplastics also have
an element of safety over thermosets; if a thermosetting polymer is not ejected from the
injection barrel in a timely manner, chemical crosslinking may occur causing the screw
and check valves to seize and potentially damaging the injection molding machine.

Fig 9 An Injection Moulding Machine Used In Ebu Oil and Gas: Bayelsa Plastic Industry

2.2.1 TERMS USE IN INJECTION MOLDING.

a. Additive: A substance compounded into a resin to enhance or improve certain

characteristics
b. Back Pressure: The resistance of the molten plastic material to forward flow. In
molding, back pressure increases the temperature of the melt, and contributes to
better mixing of colors and homogeneity of the material. However, as back pressure
increases, so does cycle time.

c. Barrel: The section of a molding machine that contains the feed screw, also the
section where resin heating and mixing occurs.

d. Binder: A resin or other material used to hold particles together. The binder is the
continuous phase in a reinforced plastic, which provides mechanical strength or
ensures uniform consistency, solidification, or adhesion to a surface coating. Typical
binder materials include resin, glue, gum..

e. Compound: A mixture of resin(s) and additives usually formed in a separate machine

downstream from the primary reactor.

f. Cooling Channels: Channels located within the body of a mold through which a
cooling medium is circulated to control the mold surface temperature.

g. Cycle Time: The time required by an injection molding system to mold a part and
return to its original position/state.

h. Cycle: complete, repeating sequence of operations for injection molding a part.

i. Gate: The channel through which the molten resin flows from the runner into the
cavity.

j. Mold (v): To impart shape to a plastic mass by means of a confining cavity or matrix.

k. Pellets: Tablets or granules of uniform size, consisting of resins or mixtures of resins

with compounding additives which have been prepared for molding operations by
extrusion and chopping into short segments.

l. Resin (Synthetic): The term is use to designate any polymer that is a basic material
for plastics. around the core before filling the cavity.
m. Runner: In an injection mold, the feed channel, usually of circular cross section,
which connects the spur with the cavity gate. The term is also used for the plastic
piece formed in this channel.

n. Thermoplastic: material that will repeatedly soften when heated and harden when
cooled.

o. Thermoset: A polymer that doesn't melt when heated. Thermoset polymers "set" into
a given shape when first made and afterwards do not flow or melt, but rather
decompose upon heating. They are often highly cross-linked polymers, with
properties similar to those of network covalent solids, i.e., hard and strong.

p. Virgin Material: Any plastic compound or resin that has not been subjected to use or
processing other than that required for its original manufacture.

2.2.2 PRODUCTION PROCESS

Injection molding is a manufacturing process of producing parts from both thermoplastic

and thermosetting plastic material injection molding is widely used for manufacturing a
variety of part such as customer products, toys etc. Injection molding machine is used in
Ebi Oil and Gas: Bayelsa Plastic Industry to manufacture variety of plastic products, the
products include pipe covers, foot valve, cups bowl ,cloth hangers , toilet seat,
automobile fan belt ,pipe joints.

 CLAMPING: prior to the injection of the material into the mold the two halves of

mold must first securely closed, the mold is made of movable and stationery part .the

stationery part is attached to the injection machine and the movable part is allow to

slide

 INJECTION: the compounded raw material in form of pellet is fed into the injection

machine through the hopper into a cylindrical chamber called the barrel, the barrel

contain a screw and heating bands the material is melted by heat and pressure
 utilizing the friction action of the rotating screw and heating bands, the hot plastic

(molten state) is injected into the mold cavity with the aid of the control switch.

 COOLING: the pasty plastic begins to cool once it is injected into the mold cavity

because of the water hose connected to the mold cavity as the plastic cools it

solidifies into the shape of the mold cavity

 EJECTION: the cooled product is ejected from the mold by pressing a button for

supply of compressed air to allow easy ejection of the product once the product is

removed from the mold the mold is close and the cycle is repeated the cycle time is

10 to12 minutes depending on the type of product to be produced.

2.2.3 RAW MATERIAL AND ADDITIVES USED IN PLASTIC PRODUCTION

USING AN INJECTION MOLDING MACHINE

 PP, Polypropylene: Semi-crystalline material. Wide range of properties, usage,

and cost. Chemical and low- temperature resistant. Difficult to mold to very close
tolerances.
 High Density Polyethylene (HDPE): A high molecular weight polyolefin
material, nontoxic, non-contaminating, and exhibits a high degree of break
resistance. It is lighter than water, easily withstands exposure to a wide variety of
common lab chemicals, and has a milky white translucent appearance.
 Impact Modifiers: Additive used to enhance the material's ability to withstand
the force of impact.
 Light, UV Stabilizers & Absorbers: These additives increase the ability of the
material to withstand the negative effects of light and UV exposure, thus
increasing the service life of the material
 Masterbatch: A concentration of a substance (an additive, pigment, filler, etc.) in
a base polymer.
 Odorants & Deodorants: Odorants are used to add odor to materials, usually for
safety reasons.
POLYPROPYLENE (PP)

Polypropylene (PP) also known as polyprene, is a thermoplastic polymer used in a wide

variety of applications. It is produced via chain growth polymerization from the monomer

propylene Polypropylene is used in both household and Industrial applications. It is white

tough, rigid and crystalline with chemical formula {C3H6}. It has a melting point of160°-

165°with iupac name poly (1 methyl ethylene)

Properties of polypropylene

a) Polypropylene retain mechanical and electrical properties at elevated temperature it

is a water repellant plastic.
b) Polypropylene is highly flammable
c) Excellent chemical resistance

SYNTHESIS OF POLYPROPYLENE

Polypropylene is produced by the chain-growth polymerization of propene

H Polymerization
H2C CH2 CH CH2 CH

CH3 CH3

CH3

Propylene(monomer) Polypropylene(polymer)

In Ebu Oil and Gas: Bayelsa Plastic Industry, POLYPROPYLENE Is used in production

of many plastic products such as foot valve, toilet seat, pipe joints, pipe plugs, helmet,

automobile fan belt, cloth hangers, cups, bowls etc. the type of product produced depends

on the type of mold inserted into injection molding machine

MASTERBATCH: Masterbatch is a solid in form pellet used for coloring plastics and

imparting other properties to plastics it comes in different colors. These masterbatch also

reduces the rate of wears and allows continuous operation of machine element.

Fig. 10 Different Colours Of Masterbatch Used In Ebu Oil And Gas: Bayelsa Plastic Industry
 TABLE CHART SHOWING POLYPROPYLENE PRODUCTS,RATIO OF
POLYPROPYLENE TO MASTERBATCH

S/N PRODUCT RATIO ADDITIVES

1 TOILET SEAT 60.35 White or pink

masterbatch
2 PIPE JOINT 60.30 White,grey or black

masterbatch
3 AUTOMOBILE FAN 60.35 Black or white

BELT masterbatch
4 AUTOMOBILE 60.30 Black, blue or yellow

BRAKE PLUNGERS masterbatch

5 CLOTH HANGER 60.40 Any colour of

masterbatch
6 PLASTIC HELMET 60.35 Yellow,black and

white masterbatch
7 Pipes plugs 60.30 White or black

masterbatch
Trimmed Hangers Pipe Junction Pipe Plugs

Toilet Cover Untrimmed Hangers

Fig. 11 Products Of Polypropylene From Injection Molding Machine At Ebu Oil And Gas: Bayelsa Plastic
Industry

2.2.4 DEFECTS AND CORRECTIONS IN INJECTION MOLDING OF

PLASTICS.

 FLOW LINES

 Flow lines are streaks, patterns, or lines - commonly off-toned in color - that show up on
the prototype part as a consequence of the physical path and cooling profile of the molten
plastic as it flows into the injection mold tooling cavity. Injection molded plastic begins
its journey through the part tooling via an entry section called a “gate.” It then flows
through the tool cavity and cools (eventually hardening into a solid).
Causes: Flow line defects are caused by the varying speed at which the molten plastic
flows as it changes direction through the contours and bends inside the mold tool. They
also occur when the plastic flows through sections with varying wall thickness, or when
the injection speed is too low causing the plastic to solidify at different speeds.

Remedies:

 Increase injection speeds and pressure to the optimal level, which will ensure the
cavities are filled properly.

 Locate the gate at a spot in the tool cavity with thin walls.

 VACUUM VOIDS:

 Vacuum voids are pockets of air trapped within or close to the surface of an injection
molded prototype

Causes: Vacuum voids are often caused by uneven solidification between the surface and
the inner sections of the prototype.

Remedies:

1. Switch to a less viscous plastic. This will ensure that less gas is trapped as air is
able to escape more rapidly.

2. Ensure that mold parts are perfectly aligned.

 SHORT SHOT:

As the term implies, short shots can be described as a situation where a molding shot falls
short. This means that the molten plastic for some reason does not fully occupy the mold
cavity or cavities, resulting in a portion where there is no plastic. The finished product
becomes deficient because it is incomplete.

Causes: Short shots can be caused by a incorrect calibration of the shot or plasticizing

capacities can result in the plastic material being inadequate to fill the cavities.

Remedies:

1. Increase mold or melt temperature so as to increase flow ability.

2. Increase the material feed in the molding machine or switch to a machine that has a
higher material feed in the event that the maximum material feed has been reached. 

 WARPING:

Is the deformation that occurs when there is uneven shrinkage in the different parts of the
molded component. The result is a twisted, uneven, or bent shape where one was not
intended.

Causes: Warping is usually caused by non-uniform cooling of the mold material.

Different cooling rates in different parts of the mold cause the plastic to cool differently
and thus create internal stresses. These stresses, when released, lead to warping.

Remedies:

1. Ensure that the cooling time is sufficiently long and that it is slow enough to
avoid the development of residual stresses being locked into the part.

2. Design the mold with uniform wall thickness and so that the plastic flows in a
single direction.

3. Select plastic materials that are less likely to shrink and deform. Semi-crystalline
materials are generally more prone to warping

 FLASH:

 Flash is a molding defect that occurs when some molten plastic escapes from the mold
cavity. Typical routes for escape are through the parting line or ejector pin locations. This
extrusion cools and remains attached to the finished product.

Causes: Flash can occur when the mold is not clamped together with enough force (a
force strong enough to withstand the opposing forces generated by the molten plastic
flowing through the mold), which allows the plastic to seep through. The use of molds
that have exceeded their lifespan will be worn out and contribute to the possibility of
flash. Additionally, excessive injection pressure may force the plastic out through the
route of least resistance.

Remedies:
Increase the clamp pressure to ensure that the mold parts remain shut during shots.

 Ensure that the mold is properly maintained and cleaned (or replaced when it has
reached the end of its useful lifespan).

 Adopt optimal molding conditions like injection speed, injection pressure, mold
temperature, and proper gas venting.

The following plastic products are gotten through injection molding machine: plate, cup,
spoon Lids of all sorts are made from plastic injection molding. That includes plastic
bottle caps, plastic cup lids and the lids for prescription drug containers (not to mention
the bottles themselves).

2.2.5 DIFFERENCE BETWEEN EXTRUSION MOLDING AND INJECTION

MOLDING

Injection molding machine is similar to Extruder. The main difference between the two
machines is in screw operation. In extruder screw rotates continuously providing output
of continuous long product (pipe, rod, sheet). Screw of injection molding machine is
called reciprocating screw since it not only rotates but also moves forward and backward
according to the steps of the molding cycle.

2.3 RECYCLING DEPARTMENT

2.3.1 RECYCLING OF PLASTIC WASTE

Plastic recycling is the process of recovering scrap or waste plastic and reprocessing the
material into useful products. Before any plastic waste is recycled, it needs to go through
different stage so that it can be further used for making various types of products.

In the industry, deformed pipes, scraps and flashed from product and lumps from
machine are recycled and reuse to manufacture useful products.

2.3.2 RECYCLING PROCESS IN INJECTION PLANT

The process of recycling waste in injection plant includes;

1) Crushing - lumps from machine and scraps from products are crushed in pellet using a
crushing machine.

Fig 12 Crushing Machine Used At The Injection Plant In Bayelsa Plastics

2) Washing - the crushed material is washed in a large cemented basin to remove dirt
and metal chips
 Fig 13 Concrete Washing Basin Used In Bayelsa Plastics

3) Drying - After washing the material is dried using an injection drying machine or by
spreading under sun

Fig. 14 a Drying Machine Used At The Injection Plant In Bayelsa Plastics

4) Sorting - it involves separating different colours to obtain uniform colours

5) Sieving - the dry crushed material is sieve using a magnetic sieve to remove metal
chips this done because these tiny metals can block the nozzle during molding process.
the recycled material loose some of its quality and strength during the first production
and recycling process virgin polymer are added to the recyclate to improve strength.
 Fig 15 a Magnectic Sieve

Fig 16 Recycled Polypropylene Scraps And

Lumps

2.3.3 RECYCLING PROCESS IN

EXTRUSION PLANT

In the extrusion plant ,lumps,

deformed and shrink pipes can still be recycled and reused to produce another PVC's
pipes

The recycling process includes;

1. Crushing: Damaged pipe and lumps are first cut into smaller sizes and poured into the
hopper of a crushing machine for crushing. The crusher reduces the small size pipe to
pellet form the resulting granules called the recyclate .

Fig 17 Crushing Machine Used At The Extrusion Plant In Bayelsa Plastics

2. Pulverizing: the small pellets ‘recyclate’ is grounded into fine powder(pulverized)

using a pulverizing machine.

Fig 18 Pulverizing Machine In Bayelsa Plastics

3. Sieving: the powdered material is sieve using electrical vibratory filtering machine to

get a fine powder, the fine powdered material is compounded with virgin PVC and

additives to increase the quality of the pipe.

 Fig 19 a Vibratory Sieving Machine

2.4 QUALITY CONTROL/QUALITY ASSURANCE OF PRODUCTS IN EBU

OIL AND GAS: BAYELSA PLASTIC INDUSTRY

2.4.1 QUALITY CONTROL AND ASSURANCE

Quality control and assurance (QC&QA) is a process through which a business seeks to
ensure that product quality is maintained or improved with either reduced or zero error.

2.4.2 QUALITY CONTROL

The nature of injection and extrusion molding machines is such that there are bound to be
defects therefore parameters such as temperature, fill speed, clamping force, cooling rate
are monitored so that defects can be minimized and eliminated.

 Formulation Calculation: This is done using international standard for

formulation calculation to achieve Quality products
 Product Inspection: Virgin material are mostly added to recycled thermoplastic
to increase the quality of the products.
 Packaging: Plastics products in the company are usually pack inside sack to
prevent dirt and cracking.
 Storage: The products especially pipes are bundled in desired number as per
consumer’s requirement and stored in cool and dry place store room to prevent
cracking and ensure freshness till delivery.

CHAPTER THREE

RELEVANCE OF MY INDUSTRIAL TRAINING EXPERIENCE TO MY

COURSE OF STUDY, EXPERIENCE GAINED, PROBLEM ENCOUNTERED,

3.1 RELEVANCE OF MY INDUSTRIAL TRAINING TO MY COURSE OF

STUDY
Working at Ebu Oil and Gas: Bayelsa Plastic Industry has given me opportunity of
getting a first hand experience and exposure to some of the practical polymer aspect,
learning to work with various equipment and machinery used in plastic moulding, it has
also provided an avenue for me to acquire industrial skills and experience which is highly
paramount in chemical and other related industries.

One of the experiences is safety management techniques as a result of my training, I can

confidently apply most safety measures I was taught in school such as the use of personal
Protective Equipment (PPE), firefighting, environmental management and pollution
control when the need arises.

Practical application of quality control (QC) which is paramount in every industry, tool
handling, machine operation was also in no small measure added to my experience.

Optimization which is very pertinent to any chemist formed the basis of what we do

every day before engaging in production. Day by day, we find a better way to minimize

cost, wastage and time and maximize yield and still maintain the quality of products. It

was a golden opportunity to build good and lasting human relationship with my

colleagues, staffs and supervisor in the company, all these made me appreciate my course

of study better and as well broadened my knowledge of the course.

3.2 EXPERIENCE GAINED

The Industrial training, I underwent in Ebu Oil and Gas: Bayelsa Plastic Industry as a
student trainee has given opportunity to learn about plastics molding, learning its
fundamental and how to work with various machinery used in the industry, I was able to
apply some theoretical knowledge during my study at the University to real work
situation thereby bridging the gap between school work and actual practice. I also gained
experience in other field of science, I learnt lesson on the code of conduct of the company
and it prepared me for work scenario I am likely to meet after graduation.

My general experiences in Ebu Oil and Gas: Bayelsa Plastic Industry

1) I learnt to how operate the injection and extrusion molding machine.

2) I learnt about the possible defect that occurs during plastic molding and how to reduce
these defects and how difficult task are handled to ensure smooth process of molding.

3) I was able to grasp adequate knowledge and understanding regarding quality assurance
and control in the industry

4) I learnt about PVC resin, polypropylene and additives and their roles and function in
plastic molding I also learnt about recycling process of waste plastic

3.3 PROBLEMS ENCOUNTERED

i. Inadequate equipment to carry out some test in the quality control section limited my
experience.
ii. During the first week, I had difficulties understanding a lot of the term and
terminologies that was used at the company because a lot of them were very new to me.
iii. Lack of residential building and medical facilities in the industry.
iv. Lack of time to train students by Industrial based supervisor.

CHAPTER FOUR

RECOMMENDATIONS AND CONCLUSION.

4.1 CONCLUSION

A journey that started on the 6th of July and ended on the 6th of August at Ebu Oil and
Gas: Bayelsa Plastic Industry was a great source of practical knowledge. During my four
(4) Months Industrial Training in the firm I learnt how well to develop good work
relationship with managers and coworkers. The SIWES program afforded me reason to
appreciate my course “Biochemistry”. In the area of plastic production as I was able to
learn the various steps, test and material needed to produce various plastic products.

4.2 RECOMMENDATION
 1. SIWES should allocate fund to IT students during the process of their SIWES

training

2. SIWES should increase the number of time they visit student in their various place
where they are undertaking their IT.

REFERENCES

1. Agwuna, R.N (2012) Detailed manual on SIWES guidelines and operations for tertiary
institutions
2. J G Khan ,R S Dalu and S SGadekar (2014) Defect in Extrusion process and their Impact
on Product Quality.
3. EngrObassiEttu (2014) The Role And Importance Of Engineering Material Utilization in
Present Day World..
4. L M Galantucci, R spina Journal Of Material Processing Technology 141(2003) 260-275
5. www.wikipedia.org/injection molding.