BATANGAS STATE UNIVERSITY

College of Engineering, Architecture and Fine Arts

Gov. Pablo Borbon Campus II,
Alangilan, Batangas City, Philippines 4200
www.batstate-u.edu.ph Telefax: (043) 300-4044 locs. 106-108

CHEMICAL AND FOOD ENGINEERING DEPARTMENT

ChE 312:
Chemical Process Industries

Plastic Industry

Pepito, Alyssa C.
ChE - 3301

Dr. Eufronia M. Magundayao

Instructor

July 4, 2017
 PLASTIC INDUSTRIES

INTENTED LEARNING OUTCOMES:

Define Plastics and know its basic raw materials.

Know the different classification of plastics.

Know the different methods of processing plastics.

PLASTICS
A material that contains a polymerized organic substance of large molecular
weight as an essential ingredient; solid in its finished state; and at some stage in its
manufacture or its processing into finished articles can be shaped by flow

Common basic raw materials are:

- Coal
- Petrochemicals
- Cotton
- Wood
- Gas
- Air
- Salt
- Water
Synthetic resins largest source of plastics, with cellulose derivatives ranking
next

HISTORY
Baekland developed a commercial phenolic resin in 1909
His discovery stimulated the search for other plastics and resulted in an
industry that has grown to become one of the nations top ten in size.
Cellulose nitrate (Celluloid) first plastic of industrial significance
First used in 1869 by Hyatt who was searching for an ivory substitute
Cellulose acetate developed in 1984 as a less flammable material
Used extensively as a base for photographic film and as dope for
airplane coverings during WWI

CLASSIFICATION
Plastics are often divided into
- Thermosetting
 - Thermoplastic
- Oil soluble
- Protein products

On the basis of derivation, they may be grouped as:

- Natural resins
- Cellulose derivatives
- Protein products
- Synthesis resins

In general, except where noted;

Thermosetting - synthetic resins formed by condensation polymerization
- Heat curing produces an infusible or insoluble product
Thermoplastic synthetic resins formed by addition polymerization
- Heating softens and cooling hardens

Addition polymerization involves a series of conversions which produce a

polymer having a recurring structural unit identical with that of the monomer
from which it is formed
Condensation polymerization yields polymers whose recurring units lack
certain atoms present in the original monomer
Engineering plastics high strength high-performance materials that can be
substituted for many metal uses
- Show better resistance to wear, impact, and corrosive chemicals and
have excellent electrical properties

USES AND ECONOMICS

Plastics are not interchangeable. Each one has its own individual properties and
characteristics that make it useful for certain applications

Methods of Processing Plastic

There are a variety of methods used to process plastic. Each method has its advantages
and disadvantages and are better suited for specific applications. These methods include:
injection molding, blow molding, thermoforming, transfer molding, reaction injection
molding, compression molding, and extrusion.
Injection Molding

The main method used for processing plastic is injection molding. With this process, the
plastic is placed into a hopper. The hopper then feeds the plastic into a heated injection
unit, where it is pushed through a long chamber with a reciprocating screw. Here, it is
softened to a fluid state.

A nozzle is located at the end of the chamber. The fluid plastic is forced through the
nozzle into a cold, closed mold. The halves of the mold are held shut with a system of
clamps. When the plastic is cooled and solidified, the halves open and the finished
product is ejected from the press.

Thermosetting materials usually are not processed with injection molding because they
will soften, they harden to an infusible state. If they are processed with injection molding,
they need to be moved through the heating chamber quickly so they do not set.

Blow Molding

Blow molding is used when the plastic item to be created needs to be hollow. A molten
tube is created with blow molding by using compressed air, which blows up the tube and
forces it to conform to the chilled mold. Variations of blow molding include injection,
injection-stretch, and extrusion blow molding.

With injection blow molding uses a perform, which is taken to a blow mold and filled
with compressed air. As a result, it conforms to the interior design of the blow mold.
With injection-stretch blow molding, the plastic is stretched prior to being formed.
Otherwise, it is essentially the same as the injection process.
With continuous-extrusion, a molten plastic tube is continuously created. At the
appropriate times, the tube is pinched between two mold halves. Then, a needle or a blow
pin is inserted into the tube and blows compressed air up the part in order to force it to
conform to the mold interior. With accumulator-extrusion, the molten plastic material is
gathered in the chamber before it is forced through a die in order to form a tube.

Thermoforming

Thermoforming uses a plastic sheet, which is formed with the mold by applying air or
through mechanical assistance. The air pressure used can be nearly zero psi, or several
hundred psi. At 14 psi, which is equivalent to atmospheric pressure, the pressure is
created by evacuating the space between the mold and the sheet. This is known as
vacuum forming.

Transfer Molding

Transfer molding is generally used only for forming thermosetting plastics. It is similar to
compression molding because the plastic is cured into an infusible state through pressure
and heat. Unlike compression molding, however, transfer molding involves heating the
plastic to a point of plasticity prior to being placed into the mold. The mold is then forced
closed with a hydraulically operated plunger.

Transfer molding was initially developed as a method for molding intricate products,
such as those with many metal inserts or with small, deep holes. This is because
compression molding sometimes disturbed the position of the metal inserts and the holes
of these types of products. With transfer molding, on the other hand, the liquefied plastic
easily flows around the metal parts without causing them to change position.

Reaction Injection Molding

Reaction injection molding, or RIM, is one of the newer processes used in the plastics
industry. It differs from liquid casting in that the liquid components are mixed together in
a chamber at a lower temperature of only about 75 to 140 degrees Fahrenheit before it is
injected into a closed mold. Here, an exothermic reaction occurs. As a result, RIM
requires less energy than other injection molding systems. Reinforced RIM, or R-RIM,
involves adding materials such as milled or chopped glass fiber in the mixture in order to
increase the stiffness.

Compression Molding

Compression molding is the most common process used with thermosetting materials and
is usually not used for thermoplastics. With this process, the material is squeezed into its
desired shape with the help of pressure and heat. Plastic molding powder and other
materials are added to the mix in order to create special qualities or to strengthen the final
product. When the mold is closed and heated, the material goes through a chemical
change that causes it to harden into its desired shape. The amount temperature, amount of
pressure, and length of time utilized during the process depends on the desired outcome.
Extrusion

The process of extrusion is usually used to make products such as film, continuous
sheeting, tubes, profile shapes, rods, coat wire, filaments, cords, and cables. As with
injection molding, dry plastic material is placed into a hopper and fed into a long heating
chamber. At the end of the chamber, however, the material is forced out of a small
opening or a die in the shape of the desired finished product. As the plastic exits the die,
it is placed on a conveyor belt where it is allowed to cool. Blowers are sometimes used to
aid in this process, or the product may be immersed in water to help it cool.

REFERENCES:

http://www.plasticsindustry.com/plastic-processing-methods.asp

Shreves Chemical Process Industries 5th Ed. by George T. Austin

 BATANGAS STATE UNIVERSITY
College of Engineering, Architecture and Fine Arts
Gov. Pablo Borbon Campus II,
Alangilan, Batangas City, Philippines 4200
www.batstate-u.edu.ph Telefax: (043) 300-4044 locs. 106-108

CHEMICAL AND FOOD ENGINEERING DEPARTMENT

ChE 312:
Chemical Process Industries

Plastic Industry

Pepito, Alyssa C.
ChE - 3301

Dr. Eufronia M. Magundayao

Instructor

July 4, 2017
Narrative Report

I. INTENDED LEARNING OUTCOMES

To be able to know what nuclear industry is.
To have enough knowledge about nuclear industry.
To be able to know the elements involved in nuclear industry.
II. DISCUSSION
The Chemical Process Industry has a wide range of various types of processes
which is necessary to produce things we need in our daily lives. One of the most
common product we see and we need from the process industries are the plastics. For
further knowledge about Plastic Industry, the reporter will discuss the last topic for
the semifinal period.
One in the afternoon, the reporter started by having a quick review about the
plastics which were tackled during the Industrial Chemistry subject. She defined the
plastic as a material that contains a polymerized organic substance of large molecular
weight as an essential ingredient; solid in its finished state; and at some stage in its
manufacture or its processing into finished articles can be shaped by flow. She also
stated the different basic raw materials for plastic production. She also mentioned
about the largest source of plastics which is the synthetic resin and the cellulose
derivatives as the next one. She briefly discussed a bit of the history of plastics which
Leo Baekeland was mentioned and the first use or the development of cellulose
nitrate and cellulose acetate. A table was shown for the early history of polymers
which was dated from the earliest to the latest discovered. Classification of plastics
was then discussed by the reporter. The reporter added additional meaning and
examples for the thermosets and thermoplastics. Two types of polymerization are
mentioned by the reporter, the addition polymerization which involves a series of
conversions which produce a polymer having a recurring structural unit identical with
that of the monomer from which it is formed, and the condensation polymerization
yields polymers whose recurring units lack certain atoms present in the original
monomer.
For the methods of plastic processing, the reporter have chosen 7 methods which
includes the injection molding, blow molding, thermoforming, transfer molding,
reaction injection molding, compression molding, and extrusion. For the first
process, she discussed about the injection molding which is the main method for
processing the plastics. She displayed the diagram or the picture in which the method
was shown. The next one is the blow molding which is is used when the plastic item
to be created needs to be hollow. The diagram was also shown for the blow molding.
Thermoforming was next that uses a plastic sheet, which is formed with the mold by
applying air or through mechanical assistance. Next is Transfer molding which is
generally used only for forming thermosetting plastics. Then the reaction injection
molding which is one of the newer processes used in the plastics industry. The
Compression molding is the most common process used with thermosetting materials
and is usually not used for thermoplastics. The last one discussed is the extrusion
which usually used to make products such as film, continuous sheeting, tubes, profile
shapes, rods, coat wire, filaments, cords, and cables. To further understand the
methods of processing plastics, the reporter showed video having the manufacturing
of plastics with different method. She also showed the class a video of how plastic
bags are made.
In order to test the attentiveness and if the students learned, the reporter prepared
a set of five easy questions but with a twist. The game was entitled WHATS
POPPIN and they need to pop the balloon in order to get the question. As for the
scores, the Group 2 got the highest score of 23 then the Group 3 got 19, and the
Group 1 got the lowest score of 14. As reporter, she can tell that everybody complied
to the game properly and everyone enjoyed the game. The whole reporting and the
OBE was a nice experience to learn and to have fun.
III. TITLE OF THE GAME: WHATS POPPIN
IV. MECHANICS
1. The class should be divided into 3 groups.
2. Each group shall form a straight line.
3. The first member of the group should get the balloon and pass it to next
member.
4. The last member should pop the balloon to get the question and should pass
the answer on the first member.
5. The first member should write the answer in CAPITAL LETTERS.
6. The first group to write the answer correctly shall gain 5 points. The next
group will receive 3 points and the last group will have a point if their answer
is correct.
7. If any of the balloons popped before it reach the last member, the group
will be deducted by 2 points. If any member of group touched the balloon
except for the first and the last member, a point is deducted to the total points.
V. QUESTIONS AND ANSWERS IN THE GAME
Questions:
1. Defined as a material that contains a polymerized organic substance of large
molecular weight as an essential ingredient.
ANSWER: PLASTIC/S
 2. Developed in 1894 as a less flammable material and was used extensively as a
base for photographic film and as dope.
ANSWER: CELLULOSE ACETATE
3. It uses a plastic sheet, which is formed with the mold by applying air or through
mechanical assistance.
ANSWER: THERMOFORMING
4. Yields polymers whose recurring units lack certain atoms present in the
original monomer.
ANSWER: CONDENSATION POLYMERIZATION
5. It is similar to compression molding because the plastic is cured into an
infusible state through pressure and heat.
ANSWER: TRANSFER MOLDING

VI. SCORE SHEET AND ATTENDANCE

NAME SCORE
Aonuevo, Hayley A. 19/23
Aldovino, Jeanel L. 19/23
Alolod, Ronalyn M. 23/23
Aranas, Santa Monica V. 23/23
Badillo, Charlene A. 23/23
Barrion, Annalyn V. 14/23
Bautista, Joel F. 14/23
Cena, Reniel C. 19/23
Claus, Christian M. 19/23
Dimaculangan, Melissa Marie C. 14/23
Espina, Kristian Ronel A. 19/23
Gomez, Kenneth B. 19/23
Hernandez, Ma. Eufracia I. 23/23
Lasi, Jimuel A. 19/23
Latag, Christine Joy M. 23/23
Laylo, Rex Gregor M. 14/23
Maderazo, Aljon Joseph G. 19/23
Magsino, Jhamella A. 23/23
Magsino, Ivee Dyan S. 23/23
Manalo, Sharon V. 23/23
 Marasigan, Maricar C. 14/23
Matira, John Marco I. 23/23
Medrano, Lai Heinrich A. 14/23
Pagsinohin, Kim R. 14/23
Pepito, Alyssa C. REPORTER
Tenorio, Mary Rose B. 23/23
Verano, Reniel D. 19/23
Villanueva, Albert D. 14/23
Villarba, Vaeda Rizelle U. 14/23

VII. DOCUMENTATION

The reporter started to discuss about The sample of what the reporters
her topic. Plastic Industry. PowerPoint Presentation.

The reporter showed videos to the The class listening attentively while
class in order to further understand. the report is ongoing.

GAME TIME Mechanics of the game is introduced.

 Balloons were the material for the The class is listening for the
reporters OBE. mechanics of the game.

The first players of the group waiting for the Go signal of the reporter to start.

Other members of the group passing the balloons to reach the last member.

The last member of the group popped The last member read the question and
the balloon to get the question. passed the answer to 1st member.
The 1st member of the group wrote the The reporter checking the answers of
answer on the board. the groups and showing the answer.

Team Scores:

Group 1 = 14

Group 2 = 23

Group 3 = 19