CEP

MAN UFA CT URING OF P LAST I C WATE R TANKS

Submitted By:
Fasih Ur Rehman
(19JZMEC0309)

Dated: Feb 3, 2022

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Table of Contents
Manufacturing Processes ......................................................................................................... 1
Blow Molding............................................................................................................................ 1
Manufacturing Steps for Blow Molding .......................................................................... 2
Roto Molding ........................................................................................................................... 3
Manufacturing Steps for Roto Molding .......................................................................... 4
Comparison Of the Processes(Advantages & Disadvantages) ....................................... 5-6

Report Submission……………………………………………………………………………………………7

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Manufacturing Processes:
The two most common techniques used in manufacturing of plastic water tanks
are as follows;

1) - Blow Molding

2) - Roto Molding (Rotational molding, also known as Roto molding)

1)-Blow Molding
It is fully mechanized manufacturing process for the production of plastic water
tanks, it uses pet blow machine with its auxiliaries. This plastic water tanks are
made of food grade material. It helps in providing better & sophisticated look &
it is purest in form.

In blow molding, hollow plastic components are formed through a process

categorized into three steps, Injection, extrusion and injection stretch blow
molding. The blow molding essentially starts with melting down the plastic grains
and rolling it immediately using an injection known for extrusion. It is extruded in
a tube-like plastic that has a hole that serves as a passage way for compressed
air. Next, this material is clamped into a mold and then blown by air. The
pressure will push the plastic out so it can match the mold. Once it has cooled
down and hardened, the mold would open up to eject the part.

Using Blow molding the water tanks can be made up to 100-2000gallons

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 Manufacturing Steps for Blow Molding

1. The grains are well mixed with dies.

2. When the grains are perfectly mixed then it is merged into hopper.
3. The Blow molding machine perform The Following operation on the grains:
4. Working of Blow Molding Machine: An extruder uses a rotating screw to
force the molten plastic through a die head that forms the parison around
a blow pin.
5. The parison is extruded vertically so they can close the parison and blow
pin.
6. Pressurized air flows through the blow pin to inflate the parison.
7. When the Mold is inflated from pressurized air, then the parison take the
shape of mold.
8. Duly after a while the mold opens & the water tank container is removed.

The Grains are dumped The Hopper supplies the It follows strech extrusion The molten metal is then
into hopper . grains into the spiral blow molding. blown according to the
injection. mold implanted as per its
dimensions & volume.

•Hopper is just like turret
where it is mounted
with grains in order to
feed to the exturuder.
•The grain is then •This stretching provides
changed into molten greater strength to the
form & then it is extrude plastic. Stretch blow
through a section of molding is typically
the bet blow, where as used to create parts
it is extruded in a hollow that must withstand
soft molten state. some internal pressure
or be very durable,
such as soda bottle
•The molten metal is
then blown in a mold of
specific dimensions.
later after 7,8 minutes
the mold is the again
opened.

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2)-Roto Molding
It is a very fine old manufacturing processes for making vessels, similarly it is also
widely used in manufacturing of plastic water tanks.

It have a mold like containers where the plastic meshed grains are dumped
accordingly in definite proportion to the volume of the tank. In order to have a
fine oriented & polished water tank the plastic grains must be meshed to fine-
powder. Jurisprudentially in the Rota-molding process, the mold like container is
dumped with fine-powder in definite proportion to the volume of mold,
spontaneously it is heated & rotated wisely over a stranded wheel that rotates
the whole structure causing the softened material to disperse & stick to the walls
of the mold.

Roto molding is often used for parts that require high quality finishes, uniform wall
thicknesses, & high stability. Features such as inserts can be directly incorporated
into the rotomold & foaming can be used to create thermal insulation & stiffness.

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 Manufacturing Steps for Roto Molding
1. Initially mesh the plastic grains into fine powder.
2. Fill the container mold with the fine powder.
3. Add die color in appropriate proportion into the fine powder.
4. Mold container is rotated & heated. It is heated by gas furnace.
5. After 20min of heating & rotating the mold is then sprinkled with cold
water.
6. The manufactured water tank is then removed from the container.

Mold Container is
Platics Grain Mesh Filling the mold The Mold is then
Heated &
into Powder sprinkled with cold
Rotated(Shacked)
water

•It is meshed into •The hollow mold •It is heated so •It is done so that
powder in order is filled with that the powder the water vessel
to inhance the powdered is melted & it is is solidfied as it is
quality of the plastic esins rotated both taken out of the
product. symmetrically & mold. It helps the
unsymmetrically water tank
so that the solidifies ASAP.
molten plastic
with holds the
whole mold
container.
•The Mold
continues to
rotate until the
rezin melts &
coats the walls
of the mold.

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Advantages Of Blow Disadvantages Of
Molding Blow Molding

Time efficient: Its cycle time is

Price: It requires large invest on
8minutes. It means that per
pet blow machine. Initial
water tank manufacturing it
investment is upto 1crore.
requires 8minutes.

Blow molding is energy

It comes with limited uses: Blow
effiecent process. It uses
molding is limited to hollow
electic heater to melt & it also
forms like bottles & plastic
have pressurized injection to
containers.
feed the molten material.

As duely noted that fuels are

costly & they aren't available: It Will experience difficulties
So Blow molding machine is with wall thickness.
performed by electrictiy. As Poor surface finish.
electricity is not that costly.

The accuracy of material

creating waste: More material
It is limited that thickness
is wasted as a result of blow
should be exact.
molding but sooner or later it is
recycled.

While using this technology

uses automation to produce Containers produced by blow
great quantities of molding are light weight due
products..In short it helps to thin wall of containers.
promote productivity.

Its products are low in cost

because it dosent consume
fuel & its per water tank Due to thin walls of containers
production time is very less as there is stress concentration at
compared. the corners.

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Advantages Of Roto Disadvantages of Roto
Molding Molding

It is time consuming: initially

It is cost effective: It means
we have to prepare the
that it is effective in its intial
meshed powder for the
price because it only cost for
mold, & then we have to stir
the mold.
& rotate the mold.

Constant Wall thickness: The

constant rotation of the mold
coats the wall evenly. In rota molding we use
natural gas to heat the mold
Double Wall & convert the grain powder
construction:Complex to molten state.
double wall contatiners can
be produced.

High Strenght: Rotomolding After the process of rota

creates thicker molding we use cold water
corners,reducing the risk of sprinkler to cool down &
failures in these stress solidify. It is timely expensive
concentration points. because it have to solidfy.

High Labour Cost: It require

Thicker walls: Thicker walls greater labor intensity in
means heavier weight. manufacturing processes
.

Limited Material Options :

Raw material used in
rotomolding must be readily
It is simple to generate a converted from granules to
variety of shapes. fine powder with high
thermal stability.
High cost of raw material

Mold must be refurbished or

replaced: After a while the
mold must be replaced due
to the direcdt heating under
furnance.

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Report Submission
I prefer to use automated blow molding machine for manufacturing of plastic
water tanks if initial capital cost is neglected. However the cycle time for blow
molding process is effectively less than traditional roto molding process & thus
results in high mass production in less time. Similarly the Labor cost of roto
molding process is submerged & result in high prices in term of total cost per
product batch. Similarly also the blow molding process is bit cheaper than roto
molding in terms of fuel consumption literally blow molding is fully automated
machine while the roto molding is a traditional process and consumes natural
gas.

Characteristics Blow Molding Process Roto Molding

Labour Cost Low High

Fuel Cost Low High

Labor Hard Work Low low

Enviromentally Friendly Highly Low

Thickness Of Water tank thin thick

Material Option Arbitary Limited

So From above discussion it is concluded that blow molding process is far better
for mass production.

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