CHAPTER ONE

1.0 INTRODUCTION
This report is based on the training undergone at Winco foam Nigeria Limited, located at
no 2 Winco avenue Agu-Awka, Anambra State.

The industrial training program lasted in accordance to the duration scheduled by the
student industrial work experience scheme (SIWES) unit.

Winco foam and chemical industry in which I was placed in production department, I
was well exposed in all the procedures which are involved in the production of quality
and flexible foam which includes (i) measuring of chemicals, (ii) proper mixing of
chemicals (iii) reactions that occurs during polymerization i.e foam formation (iv) and
calculating the density of foam and pillow produced

In measuring of chemicals, all the chemicals are measured based on the sizes and quality
of block to be produced. The correct proportion of the various chemicals must be
carefully determined. Too little or too much of any chemical will bring about problems.
During the period, I was exposed to different equipments which I have not been able to
see or use.

Before I continue, I will consider the history of SIWES who gave me the opportunity to
undergo this training.

1.1 BRIEF HISTORY OF SIWES

SIWES is an academic program introduced by Federal Government of Nigeria according

to the decree No. 42 of Education Act of 1973 to solve the problem of lack of adequate
practical skills preparatory for employment in industries by Nigerian graduates of tertiary
institutions.

The program became a reality through the help of Industrial Training Fund (ITF). ITF
was established by decree No. 24 of October 1977 and the aim is to promote and
encourage the acquisition of industry and commercial, and the view of generating the
power at indigenous trained manpower sufficient to meet the need of economy and also

1
finally equip the students who undergo the training so that they will not be financially
handicapped.

Thus, the industrial training is a compulsory course for all students as part of the
fulfillment in Bachelor of Engineering (B.ENG) Degree in Chemical engineering.

SIWES is operated by the ITF with the following stakeholder:

a. Federal Government (Federal ministry of Commerce and Industry)

b. Industrial Training Fund (SIWES Division)
c. Supervising/Regulatory Agencies (NUC, NBTE, NCCE)
d. Industries/Employers (NECA, NACCIMA, MAN, Government Establishments)
e. Tertiary Institution (Universities, Polytechnics, colleges of Education) and
f. Student trainees (Engineering, science, Technology, NCE Technical).

It is funded by the Federal Government of Nigeria. Its beneficiaries are undergraduate

students of the following: Agriculture, Engineering, Technology, Environmental
Sciences, Education, Medical Science and pure and applied science. Duration of the
training is four months for polytechnics and colleges of Education, and six months for the
universities.

1.2 OBJECTIVES OF THE SCHEME

a. To expose students to the industrial environment and skills in there course of study
which can be simulated in the classroom.
b. To expose students to the industrial responsibilities and ethics.
c. To prepare students for the work situation they are likely to meet after graduation.
d. To gain experience from writing reports in Chemical works/projects.
e. Expose students to the work method and techniques in handling equipments and
machinery that may not be available in the universities.

1.3 SCOPE OF INDUSTRIAL TRAINING PROGRAM

a. The main aim of industrial training program is to produce graduates who are ready to
face the working world.

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b. The program also aims to produce knowledgeable, skilled and experience graduates
demanded by employers who are able to apply the knowledge acquired in university
to the working world.
c. The industrial training program provides opportunities for exposure to the working
world, which will make graduates more aware of the hopes and expectations that
industry has of them.
d. The program will also equip students with real work experience.
e. Placing students in industry also increase their chances of employment after
graduation, as there is a strong possibility that they will be offered a job in the same
place where they do their training.

1.4 DURATION OF THE INDUSTRIAL TRAINING

Fourth year (400 Level) chemical engineering students should spend at least six (6)
months on a full-time basis in a governmental organization, a reputable industrial firm, or
a research centre that conducts and/or is involved in chemical activities.

1.5 IMPORTANCE OF THE INDUSTRIAL TRAINING PROGRAM

a. The program gives you that edge in seeking employment when you graduate. Turning
theory into practice helps you apply learning from your degree program into a real
working environment.
b. The program is an exposure to workplace culture and increased career insights.
c. Helps develop work ethic, and professional skills required in the work place.
d. Development of the key employability skills sought by graduate employers.
e. The program helps students to improve in critical analysis, produce good report
writing, and presentation skills, argue logically, human skills and community
expectation, interaction with other professionals and in awareness of contemporary
issues.

1.6 OBJECTIVES OF THE REPORT

a. The report helps the student to cultivate the habit of documenting.

b. It encourages the student to search for details.

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c. It develops own thought process and reasoning abilities.
d. It helps the student to be very adequate in writing and also to be able to make a
purposeful write-up.

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 CHAPTER TWO

COMPANY AND ORGANISATIONAL BACKGROUND

2.1 ORGANISATIONAL HISTORY

The company, founded by Chief G.I. Okafor started as a small scale mattress production
outfit in the 70s. This small scale production involved purchase of foam blocks from
bigger foam manufacturers and processing the foam blocks into mattresses.

This mode of operation continued until 1980 when the company acquired its batch foam
ÒboxÓ machine for in-house block foam production. Then in 1991 the company
acquired its first continuous foam production machine that enabled the company enhance
quality from production. As a result of high market acceptance of the Winco brand of
products, the company established a second foam plant in the eastern part of the country
and a second continuous production machine was purchased and deployed there. In 2000
the company yet acquired a third state-of-the-art continuous production machine to
replace the one in Lagos. That same period the company established another plant in
Abuja to cater for the northern market and then deployed the first machine to this plant.

2.2 ORGANISATIONAL PROFILE

WINCO FOAM Industries Limited is a wholly indigenous private limited company

incorporated on March 18th 1983. The company since 1978 has been operating in
Nigeria as one of the leading commercial organizations involved in so many activities
including foam manufacturing and trading activities. WINCO FOAM Industries Limited
is one of the largest continuous polyurethane foam manufacturers with head office
located in Lagos. The Company is family owned and operated and has been dedicated to
manufacturing high quality polyurethane foam and bedding products for 30 years. Since
its early beginning as a box foam producer in Lagos with a small market presence, the
company has grown and expanded into a continuous foam producer with three large
multi-million naira production plants in Nigeria strategically located to serve all the
markets in the country.

The first production line (Canon Viking, United Kingdom), that is the state-of-the-art
Omega 600 maxfoam, has a capacity of 350 kilos per minute. The second production line
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(CRMTO, Taiwan) has a capacity of 250 kilos/ min and the last production line (Sunkist,
Taiwan) has also a capacity of 250 kilos/ min. Quality control is maintained in the
production process by carrying out physical tests on statistically selected production
samples. Advanced control technology helps assure the highest quality foam products:
viscoelastic, high resilience (HR) and conventional foam cushioning for top-of-the-line
sleeping comfort. Foam is tested in the laboratory for density, firmness, physical strength
and durability. Foam that meets strict quality and performance standards is cut into sheets
and cores for use in WINCO FOAM bedding products.

WINCO FOAM prides itself with the quality of foam products it manufactures to achieve
customer satisfaction. The company is set out to achieve high foam quality from the
beginning to the end of production and to make effort to ensure that it keeps to the
mission of providing excellent products and services and giving consumers value for
money.

WINCO FOAM Industries Limited manufactures foam products for the home and
commercial healthcare industries, furniture and upholstery industries, carpet underlay for
both residential and commercial sectors and other cushioning products for a very wide
range of consumers who have different needs and requirements.

Winco foam has won numerous Awards to show how well the company is going. The
company is a member of Manufacturers Association of Nigeria (MAN) with registration
number MAN/GML/00816.

The company has its head office in Lagos and a sister company in Awka, where I did my
SIWES program.

MISSION OF COMPANY

To offer to our customers’ outstanding products and services that provide total sleep
solutions while creating superior value for consumption.

VISION

To be at the top and remain as the undisputed leader in the industry while searching for
ways to get better every day.

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CORE VALUES

We maintain a set of values we hold to heart as our business guide and philosophy
because we believe in these values. We are not much of a company without these values
because they define standards, beliefs and govern the decisions and actions of the
individuals and the company.

Our core values are

 Accountability- Responsibility of our actions that influence the lives of our

customers and fellow workers

 Commitment-Commitment to roll great product, service and other initiatives that

impact lives both within and outside the organization.

 Community- A sense of responsibility and contribution to society that define our

existence.

 Consistency-Be consistent in offering the best for wonderful experience.

 Efficiency- Being efficient and effective in our approach to give best solution each
time.

 Empowerment- Empowering the employees to take initiative and give the best.

 Innovation- To come out with new creative ideas that have the potential to change
the world

 Integrity-To act with honesty and integrity without compromising the truth.

 Passion-Putting the heart and mind in the work to get the best.

 Quality-Giving the best and unmatched results for all round satisfaction.

 Respect-Giving due respect to self and others and maintain the environment of team
work and growth.

 Safety- Ensuring the safety of people and making sure to give them trouble free
experience.
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2.3 ORGANISATIONAL STRUCTURE AND HIERARCHY

2.4 BOARD OF DIRECTORS AND MANAGEMENT TEAM

Various Unit of Operation

Co-ordination office: In this unit, the coordinator co-ordinates and decides on the
decision to be taken which will help to promote the organization.

Director’s Office: The directors directs and controls the staff on what to do and also
manages the affairs of the organization.

Accounting Unit: This unit keeps all the financial records of the organization, both all
the money that comes in and the ones that goes out, and payment of their worker’s salary.

Managing Unit: Under this unit, we have the production manager and the sales manager.
The production manager is in charge of the production department and manages all the
affairs in the production unit.

The sales manager is in charge of the company’s sales. He directs the sales of the
company’s products.

STAFF: Here, we have the drivers, the sowing department, the quitting department,
slicing department, the cleaners and then the security men.

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2.5 VARIOUS DEPARTMENTS IN THE ESTABLISHMENT AND THEIR
FUNCTIONS

 Production
 Slicing

 Quitting of foam borders

 Sowing

 Store
 Production: This is the section where foam blocks and sheeting are produced.

 Slicing: In this section, the foam blocks are sliced into different sizes using the slicing
machine and shifted to the quality section.

 Quitting Section: This is where the foam covers/boarders are quitted and are used to
cover the foams before taking them to the sowing department.

 Sowing: In this section, the foam boarders are sowed in other to cover the necked
foam before taking them to the store.

 Store: This is the warehouse where the foams are packed and stored before they are
loaded and taken to the various distributors or deports.

2.5.1 PRODUCTION FLOWCHART

2.6 SAFETY RULES AND REGULATION

There are some safety rules and regulation that are observed in the company so as to
ensure works are carried out in orderly manner. Below are the Do’s and don’ts.

a. Do not drink or play inside the production factory to avoid contaminations.

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b. Always sterilize all working equipment before use.
c. Do not enter the factory production department without the lab coat, factory shoes,
cap and gloves so as to avoid contamination as well as a nose mask, so as not to
inhale dangerous chemicals.
d. Proper cleaning of working equipments and machineries should be done at the end of
every production.
e. Loitering is not allowed around the factory production site when production is taking
place.
f. Water should always be made available in case of accidents like burns.
g. Every production worker should make sure that he/she wash his/her hand at the end of
every production.
h. Always remove your shoes, lab coats, hand gloves and nose mask in the production
site before leaving to avoid environmental contamination.

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 CHAPTER THREE

LITERATURE REVIEW

Foam can be defined as a soft light rubber, full of small holes, no matter how tiny they
could be, that has a wide variety of application. Foam has become a very important
material required for a vast production of so many other materials needed for the
satisfaction of human want. These materials include; vehicle seat, mattresses and cushion
to name but a few. Owing to the vast use and need for foams, there is now an increase in
its production across the globe.

Foam production can be said to be the process of manufacturing foam blocks by putting
together some chemicals like polyal, Toluene Disocynate and others in the right
proportion with the right catalyst, which can be used in the manufacturing of some
finished goods like mattresses, pillow, cushion and other foam materials

There are various types of foam, which includes:

 Polyurethane foam:

Used for fill, packing, shipping, mattress topper, dog beds, costumes. Thick pieces will
develop "sink" areas after a short time. Polyurethane foam is really not a high quality of
foam, and will often not return to its original form. Most times, one cannot guarantee the
foam will maintain its original shape during shipping.

 High density foam:

Sold primarily for mattresses, average sofa and chair cushions, baywindows, boats,
camping pads, etc...

 Evlon foam:

Also known as Lux foam. A "good" foam, typically used for upper scale furniture seating
and mattresses. It is very buoyant.

 High resilience foam:

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Used in most types of expensive furniture including yachting and boating Makes for an
excellent mattress, very buoyant and resilient.

 Latex rubber foam:

This is a non-allergenic, first type of foam on market. Longest lasting Used in top of the
line products including mattresses, cushions etc... (Better than High Resilience)

 Supreme foam:

Used primarily for computer and camera cases, packing and shipping, acoustical
dampening and sound proofing. It is charcoal grey/black in color.

 Rebond foam:

Used as carpet padding, weight equipment, outdoor furnishing and other covered
padding, widely used in the hospital. Has very high resiliency and stands up to high
impact/ usage.

 Memory foam:

Also known as NASA foam, miracle foam, wonder foam or Viscolastic foam. Developed
for space shuttle seating and used for mattresses and seating. Very dense, conforms to
shape most unique foam on the market today.

 Closed cell foam:

Non-water absorbent, non-biodegradable, floats, great tensile strength, impervious to

petroleum. Used in exercise mats, high impact aerobic equipment, mechanic's box fining
(25" to 50" thick). Good thermal insulator (hot tub covers)

 Dry fast foam:

Very good for outdoor uses, very resilient and buoyant, open cell structure. Used filtering
or padding that is subject to high amounts of liquid

In all the foam types mentioned above, one thing is common and that is that they all
emanate from the polyurethanes. The difference in each and every one of them, is
dependent on the nature of some other chemical elements added to it in other to give it
the desirable quality.

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WINCO FOAM has polyurethane foam as the basics for their production. Therefore, we
will be going into the production process of polyurethane foam.

3.2 THEORY OF POLYURETHANE FOAM PRODUCTION

Polyurethanes are linear polymers that have a molecular backbone containing carbamate
groups (-NHCO2). These groups, called urethane, are produced through a chemical
reaction between a disocyanate and a polyol. First developed in late 1930s, polyurethanes
are some of the most versatile polymers. They are used in vast foam production building
insulation, surface coatings, adhesives, solid plastics, and athletic apparel.

Polyurethanes, also known as polycarbamates, belong to a larger class of compounds

called polymers. Polymers macromolecules made up of smaller, repeating units known as
monomers. Generally, they consist of a primary long-chain backbone molecule with
attached side groups. Polyurethanes are characterized by carbamate groups (-NHCO 2) in
their molecular backbone.

Synthetic polymers, like polyurethane, are produced by reacting monomers in a reaction

vessel: In order to produce polyurethane, a step-also known as condensation-reaction is
performed. In this type of chemical reaction, the monomers that are present contain
reacting end groups. Specifically, a disocyanate (OCN-R NCD) is reacted with a diol
(HO-R-DH). The first step of this reaction results in the chemical linking of the two
molecules leaving a reactive alcohol (OH) on one side and a reactive isocyanate (NCO)
on the other. These groups react further with other monomers to form a larger, longer
molecule. This is a rapid process which yields high molecular weight materials even at
room temperature. Polyurethanes that have important commercial uses typically contain
other functional groups in the molecule including esters, ethers amides, or urea groups.

3.3 BRIEF HISTORY OF POLYURETHANE

Polyurethane chemistry was first studied by the German chemist, Friedrich Bayer in
1937. He produced early prototypes by reacting toluene diisocyanate reacted with
dihydric alcohols. From this work one of the first crystalline polyurethane fibers, Perlon
U, was developed. The development of elastic polyurethanes began as a program to find
a replacement for rubber during the days of World War II. In 1940, the first polyurethane

13
elastomers were produced. These compounds gave millable gurns that could be used as
an adequate alternative to rubber. When scientists found that polyurethanes could be
made into fine threads, they were combined with nylon to make more lightweight,
stretchable garments

In 1953, the first commercial production of a flexible polyurethane foam was begun in
the United States. This material was useful for foam insulation. In 1956, more flexible,
less expensive foams were introduced. During the late 1950s, moldable polyurethanes
were produced. Over the years, improved polyurethane polymers have been developed
including Spandex fibers, polyurethane coatings, and thermoplastic elastomers.

3.4 THE CHEMISTRY OF POLYURETHANE

Polyurethanes are in the class of compounds called reaction polymers, which include
epoxies, unsaturated polyesters, and phenolics. A urethane linkage is produced by
reacting an isocyanate group, -N=C=0 with a hydroxyl (alcohol) group, -OH.

Polyurethanes are produced by the polyaddition reaction of a polyisocyanate with a

poiyalcohol (polyol) in the presence of a catalyst and other additives in this case, a
polyisocyanate is a molecuse with two or more isocyanate functional groups. R-
(N=C=O)n ≥ 2 and a polyol is a molecule with two or more hydroxyl functional groups, R-
OH) n ≥ 2 . The reaction product is a polymer containing the urethane linkage,
-RNHCOOR-. Isocyanates will react with any molecule that contains active hydrogen.
Importantly, isocyanates react with water to form a urea linkage and carbon dioxide gas,
they also react with polyetheramines to form polyureas. Commercially, polyurethanes are
produced by reacting a liquid isocyanate with a liquid blend of polyols, catalyst and other
additives. These two components are referred to as a polyurethane system, or simply a
system. The isocyanate is commonly referred to in North America as the A-side or just
the iso. The blend of polyols and other additives is commonly referred to as the 'B-side'
14
or as the 'poly. This mixture might also be called a 'resin' or 'resin blend. In Europe the
meanings for "A side' and 'B-side' are reversed. Resin blend additives may include chain
extenders, cross linkers, surfactants, and flame retardants blowing agents, pigments, and
fillers.

The first essential component of a polyurethane polymer is the isocyanate. Molecules that
contain two isocyanate groups are called disocyanates. These molecules are also referred
to as monomers or monomer units, since they themselves are used to produce polymeric
isocyanates that contain three or more isocyanate functional groups. Isocyanates can be
classed as aromatic, such as diphenylmethane diisocyanate (MDI) or toluene disocyanate
(TDI); or aliphatic, such as hexamethylene diisocyanate (HDI) or isopherone disocyanate
(IPDI). An example of a polymeric isocyanate is polymeric phenylmethane disocyanate,
which is a blend of molecules with two, three, and four- or more isocyanate groups, with
an average functionality of 2.7. Bocyanates can be further modified by partially reacting
them with a polyol to form a prepolymer. A quasi prepolymer is formed when the
stoichiometric ratio of isocyanate to hydroxyl groups is greater than 2:1. A true
prepolymer is formed when the stoichiometric ratio is equal to 2:1. Important
characteristics of isocyanates are their molecular backbone, NCG content, functionality,
and viscosity.

The second essential component of a polyurethane polymer is the polyal. Molecules that
contain two hydroxyl groups are called diols, those with three hydroxyl groups are called
trials, et cetera. In practice, polyols are distinguished from short chain or low molecular
weight glycol chain extenders and cross linkers such as ethylene glycol (EG) 1.4-
butanedial (BDO), diethylene glycol (DEG), glycerine, and trimethylalpropane (TMP).
Polyols are polymers in their own right. They are formed by base-catalyzed addition of
propylene oxide (PO), ethylene oxide (EO) onto a hydroxylor amine containing initiator,
or by polyesterification of a di-acid, such as adipic acid, with glycols, such as ethylene
glycol.or dipropylene glycol (OPG). Polyols extended with PO or EO are polyether
polyols. Polyols formed by polyesterification are polyester polyols. The choice of
initiator, extender, and molecular weight of the polyal greatly affect its physical state, and
the physical properties of the polyurethane polymer. Important characteristics of polyols

15
are their molecular backbone, initiator, molecular weight, % primary hydroxyl groups,
functionality, and Viscosity.

PU reaction mechanism catalyzed by a tertiary amine

The polymerization reaction is catalyzed by tertiary amines, such as

dimethylcyclohexylamine, and organometallic compounds, such as dibutyltin daurate or
bismuth octanoate. Furthermore, catalysts can be chosen based on whether they favor the
urethane ligell reaction, such as 1,4-diazabicyclo(2.2.2) octane (also called DABCO or
TEDA), or the urea (blow) reaction, such as bis-(2 dimethylamincethyl)ether, or
specifically drive the isocyanate trimerization reaction, such as potassium octoate.

One of the most desirable attributes of polyurethanes is their ability to be turned into
foam. Blowing agents such as water, certain halocarbons such as HFC-245fa (1,1,1,3.3-
pentafluoropropane) and HFC-194a (1,1,1,2-tetrafluoroethane) and hydrocarbons such as
n-pentane, can be incorporated into the poly side or added as an auxiliary stream. Water
reacts with the isocyanate to create carbon dioxide gas, which fills and expands cells
created during the mixing process. The reaction is a three step process. A water molecule
reacts with an isocyanate group to form carbamic acid, Carbamic acids are unstable, and

16
decompose forming carbon dioxide and an amine. The amine reacts with more isocyanate
to give a substituted urea. Water has a very low molecular weight, so even though the
weight percent of water may be small, the molar proportion of water may be high and
considerable amounts of urea produced. The urea is not very soluble in the reaction
mixture and tends to form separate "hard segment" phases consisting mostly of polyurea.
The concentration and organization of these polyurea phases can have a significant
impact on the properties of the polyurethane foam. Halocarbons and hydrocarbons are
chosen such that they have boiling points at or near room temperature. Since the
polymerization reaction is exothermic, these blowing agents volatilize into a gas during
the reaction process. They fill and expand the cellular polymer matrix, creating foam. It
is important to know that the blowing gas does not create the cells of foam. Rather, foam
cells are a result of blowing gas diffusing into bubbles that are nucleated or stirred into
the system at the time of mixing: in fact, high-density microcellular foams can be formed
without the addition of blowing agents by mechanically frothing or nucleating the polyol
component prior to use.

Surfactants are used to modify the characteristics of the polymer during the foaming
process. They are used to emulsify the liquid components, regulate cell size, and stabilize
the cell structure to prevent collapse and surface defects. Rigid foam surfactants are
designed to produce very fine cells and a very high closed cell content. Flexible foam
surfactants are designed to stabilize the reaction mass while at the same time maximizing
open cell content to prevent the foam from shrinking. The need for surfactant can be
affected by choice of isocyanate, polyol, component compatibility, system reactivity,
process conditions and equipment, tooling, part shape, and shot weight.

Though the properties of the polyurethane are determined mainly by the choice of polyal,
the disocyanate exerts some influence, and must be suited to the application. The cure
rate is influenced by the functional group reactivity and the number of functional
isocyanate groups. The mechanical properties are influenced by the functionality and the
molecular shape. The choice of diisocyanate also affects the stability of the polyurethane
upon exposure to light Polyurethanes made with aromatic diisocyanates yellow with
exposure to light, whereas those made with aliphatic disocyanates are stable.

17
Softer, elastic, and more flexible polyurethanes result when linear difunctional
polyethylene glycol segments, commonly called polyether polyols, are used to create the
urethane links. This strategy is used to make spandex elastomeric fibers and soft rubber
parts, as well as foam rubber. More rigid products resulti polyfunctional polyols are used,
as these create a three dimensional cross-linked structure which, again, can be in the form
of a low-density foam.

An even more rigid foam can be made with the use of specialty trimerization catalysts
which create cyclic structures within the foam matrix, giving a harder, more thermally
stable structure, designated as polyisocyanurate foams Such properties are desired in
rigid foam products used in the construction sector.

Careful control of viscoelastic properties by modifying the catalysts and polyols used
can lead to memory foam, which is much softer at skin temperature than at room
temperature.

There are then two main foam variants: one in which most of the foam bubbles (cells)
remain closed, and the gas(es) remains trapped, the other being systems which have
mostly open cells, resulting after a critical stage in the foam-making process (if cells did
not form, or became open too soon, foam would not be created). This is a vitally
important process if the flexible foams have closed cells, their softness is severely
compromised, they become pneumatic in feel, rather than soft: so, generally speaking,
flexible foams are required to be open-celled.

The opposite is the case with most rigid foams. Here, retention of the cell gas is desired
since this gas (especially the fluorocarbons referred to above) gives the foams their key
characteristic high thermal insulation performance

A third foam variant, called microcellular foam, yields the tough elastomeric materials
typically experienced in the coverings of car steering wheels and other interior
automotive components.

4.4 EQUIPMENTS UTILIZED DURING THE PROGRAM

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a. OHAUS Scale: It is a triple beam scale used for weighing silicone oil. It has a
capacity of 100g and readability of 0.1g.

Fig 3.1

b. DIAMOND SCALE: It is a precision weighing balance used in measuring polyol. It

has a capacity of 150kg 330lb and sensitivity of 500g 1lb.

Fig 3.2

c. AVERY WEIGHING BALANCE: This is used for weighing Toluene-Di-Isocynate

(TDI).
19
 Fig 3.3

d. WAYMASTER WEIGHING BALANCE: This is used for weighing stannous

octate, methylene chloride (MC) and water. It has a capacity of 10kg x 20g.

Fig 3.4

e. SALTER WEIGHING BALANCE: It is used for weighing Amine. It has a capacity

of 5kg x 20g.

20
 Fig 3.5

f. POLYOL POT: This serves as a container where polyol is been poured in before
placing it on the weighing balance. It is also in this pot that all the chemicals
measured are mixed together before it is poured into the board for gellation

Fig 3.6

g. TOLUENE-DI-ISOCYNATE POT: It serves as a container where TDI is been

poured in before placing it on the weighing balance.

21
 Fig 3.7

h. MOULD: It is in this board

that polymerization reaction takes place. It has different sizes (54, 6/6, 7/6). Each size
of the mould is used depending on the size of block to be produced.

Fig 3.8

I. ELECTRONIC COMPACT SCALE: This scale is used when calculating the

density of a foam or pillow. It is used for measuring the mass of the foam sample
and pillow.

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 Fig 3.9

Fig 3.10: sample of product produced

CHAPTER FOUR

4.1 KNOWLEDGE GAINED FROM THE INDUSTRIAL WORK EXPERIENCE

23
As a chemical engineering student, I was placed in production department. There, I
joined in the day to day production of quality and flexible foams and chitins.

The raw materials used in the manufacture of flexible polyurethane foam are as following
in table 4.1:

TABLE 4.1

Main Chemicals Polyol

TDI (Toluene-di-isocyanate)

Activators Amine

Stannous Octoate (Tin II October)

Foam Stabilizer Silicone Oil

Additives Colorants

Fillers

Others Water

Auxiliary Blowing Agent

Each chemical plays different role in the manufacture of foam. Polyol and Toluene-di-
isocyanate are the main chemicals, Amine and stannous octoate are the activators,
silicone oil is the foam stabilizer, colorants and the fillers are the foam additives, and
water generates heat while methylene chloride is a blowing agent.
24
In the production field, I carried out different activities such as; measuring of calcium
carbonate (caco3), Toluene-di-isocyanate (TDI), Polyol, stannous octoate, silicone oil,
amine, water and methylene chloride (MC). I also helped in mixing the measured
chemicals.

4.1.1 FOAM MANUFACTURING:

The manufacture of flexible foam undergoes few steps, which are:

1. Measuring and weighing: The raw materials are measured based on the size and
quality of block to be produced. In measuring the chemicals, the correct proportion of
the various chemicals must be carefully determined. Too little or too much of any
chemical will bring about problems.

2. Mixing of raw materials: The raw materials after it has all been measured are mixed
inside an open vessel and then stirred with a driller. Too little or too much of mixing
brings about problems.

3. Molding: The mixed raw materials are then poured into the molding machine. In the
molder, it undergoes some reaction which results in the formation of foam. Foam
reaction lasts for about 6minutes before it attain its full rising. The foaming reaction
undergoes three stages.
a) Cream Time: This is the first sign that chemical reaction have started. Noticeably,
the chemical mixtures has a slightly white color and it has been determined that this
period lasts for about 12 seconds. As soon as generation of CO 2 gas starts, the cream
time ends. The duration of this cream time is dependent on the amount of amine in
use (high quality and/or high activity of amine shortens the cream time).

b) Rising Time:
This is the period (lasts 60-80 seconds) when all the foam expansion takes place like
formation of cell structure; gas reaction accompanied by generation of CO 2 takes
place and evaporation of auxiliary blowing agent if present in formulation.

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C) Curing Time: When the foam full rise is achieved, the foam is initially a soft
gelatinous mass and the period between attainment of full rise and complete
solidification of foam is the curing time. Curing time is allowed for about 3-5 minutes
before blocks are being discharged.

4. Cooling: The molded foam is pushed out of the molder after it has reached its full
rising time to about 15meters away from the molder to cool so as to avoid over
heating which may lead to fire outbreak.

5. Density Determination: After the mixed chemicals have been poured into the board
and covered so that polymerization reaction can take place, the remnant mixtures in
the pot is left to form into a foam and allowed to cool, then it is brought out and kept
till the following day. The remnant from the pot which formed the foam is sliced into
a square shape then used to calculate the density of all the foams produced the
previous day using an electronic compact scale. The density determined is used to
know the quality of the foam produced.

In formulating, the correct proportions of the various chemicals must be carefully

determined. Too little or too much of any chemical will bring about problems. Some of
the known problems are seen in Table 4.2

4.1.2 PROBLEMS ASSOCIATED WITH CHEMICALS (TABLE 4.2)

CHEMICALS EFFECTS
TOO LITTLE TOO MUCH
TDI Too soft foam Too hard foam

Foam blocks over-heat

Silicone Oil Bubble instability leading to Induces closed cells due to
foam collapse over-stabilization

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 Stannous octoate Side splits of regular Closed cells
interval; if too low may
Foam shrinkage
extend deep into the block
Amine Delayed cream time Foam splits

Unusual very fast reaction

Methylene chloride Hard foam which is
generally accepted
Stirrer speed Presence of air bubbles
Water Insufficient blowing
Too soft foam
Too fine cell structure
leading to splits.
High exotherm

Low block height Risk of fire

Scorching

4.2 CONTRIBUTION OF THE PROJECT TO THE COMPANY

I contributed a lot to the company in so many ways, listed below;

a. I make sure I come as early as possible to work thereby boosting their image about
workers coming early.
b. In production I helped in mixing and measuring of chemicals during production. I
help in controlling the machine used in production.
c. I made sure that every required chemical needed for work is set before production and
I also helped in keeping the equipments used during production clean after every
production.
d. I helped in convincing customers to buy the goods thereby boosting the finance of the
company.
e. I endeavored to keep the surrounding clean.
f. I helped in accounting unit in creating invoice for customers, entering petty cash
account, payment voucher and debtors account book.

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4.3 HOW INDUSTRIAL TRAINING HAS BROADENED MY KNOWLEDGE

The training has helped me in understanding some things I was thought in class better
because I was able to carry out the practical on my own and saw the reactions occur. I
was able to decipherer the reaction that occurs during polymerization reaction which
takes place In two stages; the primary reaction is the addition reaction between the di-
functional isocyanate (TDI) and polyol to form urethane while in the secondary
reaction (which occurs during curing stage) is that between the nitrogen atom of the
urethane and another isocyanate molecule to form an allophanate group.

I was also able to know that when water reacts with toluene-di-isocyanate, it produces
quite a large amount of gas (carbon dioxide) which in turn blows up (expands) the foam
cells.

4.1 PROBLEMS ENCOUNTERED DURING SIWES

There are numerous problems I encountered during industrial training program

The major problems are

1. Problem of securing a place of attachment: I had the problem of searching for a

place of attachment for my industrial training because companies rejected my request
giving one reason or the other that they don’t want an I.T student.
2. Finances: The Company pays little money to I.T students which were not enough for
transport expenses for two weeks.
3. Inaccessible machines: The I.T students were not giving the opportunity to operate
most of their machines, they will rather ask you to watch them and learn.
4. Inadequate facility: The Company did not provide enough facilities equipment
which makes the program to be difficult for me because the company or the
establishment didn’t provide accommodation for their I.T students.

CHAPTER FIVE

SUMMARY, CONCLUTION AND RECOMMENDATION

5.1 SUMMARY

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Student industrial training scheme (SIWES) provides students with appreciable skills
designed to expose or equip them with real life working experience. Students gain
increased maturity and understanding of the workplace and a better understanding of
your own career goals and for the progress of the nation.

The program is an invaluable and worthwhile venture as such should be encouraged by

the federal Government of Nigeria. This implies that more funds facilities and also
trained personnel should be made available to help in the realization of the noble aims
and objectives of the program.

Again it should be given adequate publicity to enable various establishments appreciate

the relevance of (IT) to students and work towards helping the students in achieving their
goals.

This report contains and gives a detailed explanation of all the activities carried out at
Winco foam Limited, Awka production branch.

5.2 CONCLUTION

In conclusion I could say that generally, the SIWES program is very beneficial to
students in preparing them for the future engagement and graduation. It is a sincere
approach to technology growth and development as we are now in technological age.

5.3 RECOMMENDATION

However, every problem has a solution or remedy and even prevention. Therefore I am
recommending the following:-

1. The industrial training fund should compile list of employer’s available training
places for industrial attachment and forward the list to the coordinating agencies.
2. The company should be willing to accept and encourage students that are seeking for
SIWES placement in the company.
3. The company should also grant access to students to make use of their machines.

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4. The company and organization that accepts the (IT) students should be educated on
the benefits of paying the attached students no matter the amount so as to encourage
them and also to help them in solving some of their problems like transportations.
5. The establishment should provide adequate facilities to make the program enjoyable
for students such as accommodation.

REFERENCES

 Buist, J. M. “polyurethane foams, Basic equipments for producing flexible and rigid
foams”; proceedings of the international conference, Washington, D.C., November,
1959; American chemical society. 1959; page 9-20.

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 Buist, J. M.; Hurd, R.; Lowe, A. “Polyurethane foams: Methods of production,
properties and Applications”; Chem. And Ind. 1960, page 1544-1558.

 Scott, G. Atmospheric Oxidation And Antioxidant; Elsevier Publishing: New York,

1965. page 339.

 David D. J.; Stanley, H. B. Analytical chemistry of the polyurethanes; Robert

Krieger: New York, 1979, page 294.

 Kuryla, W. C.; Critchfield, F. E.; Platt, L. W.; Stamberger, P. “Polymer/polyols, a

New Class of Polyurethane Intermediates”; J. Cell. Plast. 1966, page 84-96.

 Pinner, S. H. “Chemistry and Technology of the organic Isocyanate”, Plastics

(London) 1947, 11,Apr./May, page 206-211, page 215.

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