An

Industrial Training Report

Submitted to

GUJARAT UNIVERSITY

For the degree of

MASTER OF SCIENCE
In

ORGANIC CHEMISTRY
By

DESAI PRATIK THAKARSHIBHAI

University. No. __________, Roll No.: 49 (HPP)

Under the supervision of

Dr. Nikita Mishra

Department of Chemistry
School of Science
Gujarat University

APRIL 2023

1
 DECLARATION

I DESAI PRATIK THAKARSHIBHAI, hereby declare that the Industrial training was

completed at CHEMIERESIN INDUSTRIES PVT. LTD. from 04-01-2023 to 25-01-2023

under the supervision of Dr. Nikita Mishra. I also hereby declare that this industrial

training report is original and written by me and has not been previously submitted for

the award of Master of Science in any other University or examining body in India or in

other country.

Date: DESAI PRATIK T.

Place: Ahmedabad M.Sc.-SEM-IV
University
No._____________
Roll No.49, HPP

Department of
Chemistry, School of
Sciences, Gujarat
University,
Ahmedabad-380009
Gujarat, India

2
INDUSTRIAL CERTIFICATE SCANNED COPY

3
DEPARTMENT OF CHEMISTRY Telephone No.: 079-26300969
SCHOOL OF SCIENCES
GUJARAT UNIVERSITY Ref. No.: CHEM/
AHMEDABAD - 380009
GUJARAT, INDIA Date:

CERTIFICATE

This is to certify that the industrial report is a bonafide record of independent training

work done by Mr. DESAI PRATIK THAKARSHIBHAI (Exam No.: _______ M.Sc.- IV Roll

No.: 49 HPP) under my supervision and submitted to the Gujarat University in partial

fulfillment for the award of the Degree of Master of Science (M.Sc.). The industrial

report is original and no part of the report has been submitted previously to this

university or to any other university.

Supervised by: Forwarded by:

Dr. Nikita Mishra Dr. Pranav Shrivastav

Teaching Associate Professor and Head
Department of Chemistry Department of Chemistry
School of Sciences, School of Sciences,
Gujarat University, Gujarat University,
Ahmedabad-380009 Ahmedabad-380009
Gujarat, India Gujarat, India

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 ACKNOWLEDGEMENT

I would like to express my deepest gratitude and heartfelt thanks to all

those who helped me in the completion of Industrial training work without
which this work would not reach its destination.

It gives great pleasure to express my gratitude with respect to my esteemed

guide Dr. Nikita Mishra, Department of Chemistry, School of Science, Gujarat
University who has been a constant source of encouragement. Its discipline
guidance and perfection throughout the work offered me interest and courage
to sustain the efforts to complete my Industrial training work.

Most importantly I would like to thank Mr. PRAFULBHAI S. VAHOLIYA

CHEMIERESIN PVT. LTD. for permitting me for Industrial training and good
support.

I am also thankful to technical lab, non-teaching staff, lab assistants,

administration, peon and security that helped me especially in odd times.

I am extremely indebted to my parents for all the required help and spirit of
enthusiasm they provide me. I appreciate the co-operation offered by my
friend Brijesh during critical period of my Industrial training work.

Desai Pratik T.

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 INDEX

Sr.No. CONTENT Page No.

1. Introduction
1.1 Company profile 07
1.2 Company overview 08
1.3 Resin profile 11
1.4 Departments 14

1.5 Fire Safety 19

2. Instruments 20-28

- pH meter
- Digital weight balance
- Viscometer
- Steamer Machine
- Hot Air oven
- Cooling Tower
- Electronic Thermometer
- Electronic Stirrer
3. Manufacturing Process of Resin 29
4. Conclusion 39
5. Reference 40

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 Chapter -1
Introduction
1.1 Company Profile

Name of the Company

CHEMIERESIN PVT. LTD.

Address Plot No. 901/A, Gayatri mandir road,

Phase-4, Naroda GIDC, Naroda, Ahmedabad.

Phone No. 9879550065

E-mail chemieresin@gmail.com

Website https://chemieresin.com/

Nature of the organization Engaged in manufacturing of reactive

Resin and exporting
for textile applications, Paints Chemical,
Epoxies & Amine hardeners/adducts has
depended their roots in the market.
Functional Area Manufacturing and supply of epoxy resin
and epoxy hardeners
Founder Prafulbhai s. Vaholiya

Founded in 2001
Number of employees 40
Branch Office Plot No. 901/A, Gayatri mandir road,
Phase-4, Naroda GIDC, Naroda, Ahmedabad

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 1.2 Company Overview
Chemieresin is ISO 9001:2015 Certified Company located at Naroda, Gujrat in
Western India.

Started to create milestones, we, Chemieresins marked our presence in the

year 2001 and operate in the manufacturing of epoxy resin, epoxy hardener
and polyamide resin since 15 years.

Since last 5 year we developed and introduced ourselves as producer of

modified epoxies, specialty amine hardeners and epoxy amine adducts require
for floor coating, putties, grouts, mortars.

Our organization is well developed in manufacturing and exporting our

products by utilization of high grade raw materials, we are enabled to
formulate highly efficient chemicals. Being a quality committed organization
we offer flawless range of products and we are able to gain good position in
both national and international market.
Our present capacity to produce different amine based hardener, modified
epoxies and polymers is more than 500 tons per month.

Our quality services/products have been always appreciated by our clients.

Our spontaneous attitude and confident approach in offering an excellent range
of mould release agent, textile chemical, paints chemicals, epoxies and amine
hardeners/adducts has deepened our roots in the market. We, Chemieresins
breathe with the aim of fully satisfying our clients with our high quality
products/services.

We are a unit of highly experienced professionals, all of them contributing at

the best of their potentials to offer the highest degree of efficiency and client
satisfaction.

Vision
The company sees itself becoming one of the branded resin frontrunners in India
and a producer with international standing.

Mission
The company is dedicated towards cultivating relationships with customers by
providing quality products and solutions that match their needs in every aspect.

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 Industries served by
epoxy resin

BACKGROUND

Over the past two years there have been several regulatory developments in Europe
affecting Bisphenol A, a key starting material of epoxy resin. As a result of a first evaluation
by the European Chemicals Agency (ECHA), German authorities requested further
information about skin absorption and environmental exposure to Bisphenol A and its
applications. In response to this request, the Epoxy Resin Committee commissioned an
independent agency to perform a series of studies on the life cycle of epoxy resins used in
water pipes, flooring, marine coatings, automotive and wind rotor blade applications.

Product Range of epoxy resin

Product Purpose
code
Epoxy CR Epoxy resin based on Bisphenol A and Epichlorohydrine.
110
Epoxy CR CR 112 is an unmodified, medium viscosity, liquid epoxy resin
112 based on Bisphenol-A.
When it is used with an appropriate epoxy curing agent, it
provides an excellent
combination of mechanical, thermal, chemical and physical
properties.
Epoxy CR Medium molecular weight solid epoxy resin solution for
1075X coatings.

Epoxy CR Suitable for Acid resistant paints, durable metal coating, Aircraft
767 finishes, fiber glass components / Boats, plastics

Epoxy CR Highly reactive low temperature cross-linking resin.

301 MF

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Organization structure

10
 1.3 Epoxy resin profile

 What is Epoxy resin?

Epoxy is the family of basic components or cured end products

of epoxy resins. Epoxy resins, also known as polyepoxides, are a
class of reactive prepolymers and polymers which contain
epoxide groups. The epoxide functional group is also collectively
called epoxy. The IUPAC name for an epoxide group is an
oxirane.

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 1.3.1 Epoxy Resin Overview

Fig.2: Epoxy resin

 Type of Resin

Natural Resins
It’s the first used and appeared type of resins, that formulated by the nature without any
human interaction, natural resins are complicated more than the synthetic ones, in fact the
human body can be consider as a plant of many natural resins such as proteins, beside
existence of DNA and RNA in human bodies, also the nature produce natural polymers
such as; cellulose, and natural rubber.
Industrial (Synthetic) Resins
In-Organic Resins
The first appearance of using inorganic resins has been in 12000 BC, when Egyptians
used alkaline silicate glass to make shapes of animals, and birds which is considered now
high value exceed the it cost in money.
Like ability of organic elements such as ethylene to react with similar elements or
different ones to form a polymer or a resin in specific characteristics. In-organic elements
can also form resins have many applications in our life and a clear example is the; cement,
and concrete.

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Organic Resins
It’s the most common resins and most of them come from polymerization of
compounds come from distillation of crude oil, such as ethylene and propylene. The
organic resins can be employed in several applications in our life such as; paints, plastics
products, foams, and many other uses.
Thermoset Resins
It’s a type of organic resins distinguished by its high aromatic content such
polycarbonates, and Epoxies which give it high strength, make it suitable to be used in
application that require high mechanical properties.
Thermoplastic Resins
Type of organic resins that contains high aliphatic content, which decrease its
mechanical properties, making it suitable only for applications that require low
mechanical properties, such as; poly ethylene and poly propylene.

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 1.4 Departments

1.4.1 Research and development department

 We have set up a modern, well-equipped Research & Development Centre

which has earned the recognition of Department of Science & Technology,
Naroda GIDC, Ahmedabad Chemieresin Research & Development.
 At Chemieresin, quality is a religion. Besides the everyday job of maintaining
the sanctity of every process, there is also an ongoing commitment to best-in-
class equipment. Our Quality Assurance and R&D lab is furnished and
regularly upgraded with systems and devices from world-renowned names:

- Viscometer
- stirrer
- Laboratory Oven
- Digital Single Pan Balance
- Other equipment like Digital pH Meter.

 Personnel at our Quality Assurance division act like fierce watchdogs,

merciless in rejecting batches that do not measure up. They also test some of
these against the demanding parameters of world-class labels and brands.
R&D initiatives at the lab include new product development, new applications
and customizing our products to suit processes at the client’s end.

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1.4.2 Quality control department

Quality control is a procedure or set of procedures intended to ensure that a

manufactured product or performed services adheres to a defined set of quality
criteria or meets the requirements of the clients and customers.

Thus, it is a system for verifying and maintaining a desired level of quality

in a product by careful planning, use of equipment and corrective action required.

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1.4.3 QA Department

QA Department: Quality Assurance Department

Responsibilities:

 Release and reject of finished product

 Packing monitoring of samples
 Internal Audit
 Quality system and document control
 Approval of master document
 Records
 Change of control
 Stability study
 Product quality review
 Handling of customer complaints
 Handling of returned and recalled products
 Periodic monitoring of plant act.
 In-process check

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 1.4.4 Production Department
1.4.5

 The entire production process of Epoxy resin is carried out in six steps:

- Polymerization Process

- Dumping Process

- Distillation

- Condensation

- Separation

- Blending

Epoxy resins are created by mixing BPA and epichlorohydrin (ECH), which are then reacted so
as to create the basic monomer unit of epoxy resin called BADGE or DGEBA. The properties of the
cured epoxy resins are determined by a chemical process called curing or hardening. It involves
mixing the resin with (poly)amines, aminoamides, phenolic compounds or other reactive
substances. This curing process will determine many properties of the cured epoxy resin, like, its
adhesion to other materials, durability, resistance and versatility. The ratios of BPA and ECH also
contribute to determine the epoxy’s final properties.

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 Residual BPA content :

Epoxy can be used either in solid (SsER) or liquid (LER) form depending on the applications.
Thus, the amount of unreacted BPA in final applications would also depend on the type of epoxy
resin used. Although lots of factors indicate that the values usually are much lower, according to
literature LER can contain a maximum of 10 ppm of residual (unreacted) BPA. For SsER the
maximum amount is 65 ppm of BPA. This analysis assumed the highest estimate for both type of
epoxy resins; hence the final amount of residual epoxy per step of the life cycle of epoxy resin is
likely to be lower in reality. Unreacted BPA could potentially leave the epoxy matrix and enter the
environment but there are no available scientific studies specifying in what quantities and how it
would be further degraded in the environment.

Potential BPA release :

BPA may be released when BADGE is washed during manufacturing of epoxy resin. BPA
dissolved in water is assumed to be disposed of via the sewages. ERC Members indicated that
between 5 and 19 g of BPA per produced ton of epoxy resin was released after on-site and
municipal waste water treatment in the past ten years, with an efficiency BPA removal rate of
80% to 90%. Assuming a highest estimate scenario (highest BPA quantity and lowest removal
rate), it has been estimated that a total of 572 kg of BPA per year could leave the wastewater
treatment plant in the whole of Europe and enter water bodies, possibly being removed due to
bacteria and other biological means or degradation as well as UV-light.

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 1.5 Fire Safety

Fire extinguishers must be tested and inspected regularly. Automatic sprinkler systems
that are properly installed and maintained greatly enhance workplace fire safety. Total fire
suppression devices should be installed where necessary. Clear warning signs and alarms
must be installed to warn employees.

Chapter -2
Instruments
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  pH meter

 pH: potential of hydrogen

 Make: Systronics
 Principle: The working principle of the pH meter depends upon the exchange
of ions from sample solution to the inner solution of glass membrane.
 A pH meter is an electronic instrument used for measure hydrogen – ion
activity (acidity or alkalinity) in water – based solutions indicating its
alkalinity expressed as pH
 pH is the negative logarithm of concentration of hydronium ions in the solution.

 A pH meter consists of a voltmeter attached to a pH responsive

electrode(glass) and a reference electrode (silver – silver chloride
electrode).

 For the calibration of pH meter, we use 7.0 pH, 4.01 pH and 9.18 pH buffer solution.

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  Weight balance

 Make: Scale – Tec

 Range: 0 to 200 mg.

 Principle: It is based on principle that ‘electromagnetic force balance’.

 A balance is a class of balance designed to measure small mass in milligram range.

 It can produce an electrical signal when a sample is placed on the weighing

pan, the magnitude of which is related to sample’s weight.

 To convert electrical signal into a weight value, balance compares the

electrical signal from the sample to the signal from a standard of the
known weight.

 The basic tool in all quantitative analyses is the balance.

 It is use for the accurate weight of samples.

 Calibration frequency: once in a month

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 Viscometer

 Make: BIKER
 Principle : Capillary viscometers measure the flow through a capillary tube. The
flow is compared with a reference liquid and a relative viscosity is obtained. A
simple flow technique is to measure the time required for a known sample volume
to flow through an orifice such as the Ford cup.
 A viscometer is an instrument used to measure the viscosity of a fluid For liquids
with viscosities which vary with flow conditions, an instrument called a rheometer
is used. Thus, a rheometer can be considered as a special type of viscometer.
Viscometers only measure under one flow condition. The viscosity of the resin is the
thickness of the liquid and is typically measured in units called centipoise(cP).LV
Resin has a viscosity similar to honey (1,000 cP).

 Steamer machine
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 Make: RBE
 Hot gases are produced by burning fuel in the furnace. These hot gases are
made to come in contact with the water vessel where the heat transfer takes
place between the water and the steam. Therefore, the basic principle of the
boiler is to convert water into steam by using heat energy.

The use of steam boilers in HVAC systems include water heating, sanitation,

cooking, waste energy utilization, and central heating. Fire-tube boilers are used

to warm the air which is transferred to the rooms of a house or warehouse.

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 Hot air oven

 Principle: Sterilizing by dry heat is accomplished by conduction. The heat is

absorbed by the outside surface of the item, then passes towards the center of
the item, layer by layer. The entire item will eventually reach the temperature
required for sterilization to take place.
 Dry heat dose most of the damaged by oxidizing molecules. The essential cell
constituents are destroyed and the organism dies. The temperature is
maintained for almost an hour to kill the most difficult of the resistance
spores.
 The temperature required for sterilization to take place.
 Hot air ovens are electrical devices which use dry heat to sterilize. They were
originally developed by Pastcur. Generally, they can be operated from 50 to 300
oc, using a thermostat to control the temperature.
 A hot air oven is used to sterilize equipment and materials used in the medical
field. A hot air oven is a type of dry heat sterilization.
 The commonly used temperatures and time that hot air ovens need to sterilize
materials is 170 oc for 30 minutes, 160 oc for 60 minutes, and 150 oc for 150
minutes.
 Uses:
- These are widely used to sterilize articles that can with stand
high temperature and not get burnt, like glassware and powders.

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Cooling tower :

Principle : Air enters the tower beneath the fill and is drawn up vertically into
the tower. Above the fill, hot water is introduced through low pressure spray
nozzles to divide the hot water over the surface of the fill in fine droplets. The
cooling air draws heat from the water as it progresses to the bottom of the
tower.
The cooling tower are classified according to the means by which air is supplied
to the tower
(A)Natural draft tower
(B) Forced draft tower
(C) Induced draft tower.

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Electronic Thermometer :

Principle :
Digital thermometers contain a small computing mechanism and a resistor.
A change in temperature causes the sensor to notice a change in resistance. The
computer converts the difference in resistance into a difference in temperature
and offers a digital readout in degrees.
Depending on the curing agent, epoxy resins can be used over the temperature
range − 50 to 260 °C. Epoxy adhesives based on multifunctional resins can be
used up to ~ Shear strengths will typically be between 35 and 70 MPa. Epoxy
resins are generally limited to temperatures no higher than 175 °C.

26
Electromagnetic stirrer :

Principle :
The electromagnetic stirrer utilizes the principle of a linear motor and
differs from the conventional mechanical and decompression types as it is a
noncontact stirrer in which no part touches the molten metal.
The primary use of magnetic stirrer or hot plate with magnetic stirrer is to
conduct biological and chemical experiments by mixing two components. It is
equally suitable for solids or liquid samples to obtain a consistent liquid
mixture. Examples include media for bacterial growth and chemical synthesis.

27
 Chapter -2
Manufacturing process
of Resin

 Resin name: Epoxy Resin

 Batch name: LAB EXPERIMENT
 Molecular formula: C21H25ClO5
 Molecular weight: 392.9 gm/mole
 Molecular structure:

2-(chloromethyl)oxirane;4-[2-(4-hydroxyphenyl)propan-2-yl]phenol;prop-2-enoic acid
Acrylic acid bisphenol A epichlorohydrin polymer

Production of Resins

Polymers Reactions

Resins formulated by reacting of monomers, and this can be done in two types of
polymerization process. The first one is the homogeneous reactions which contain bulk
and solution polymerization, and the second type is heterogeneous reactions which
contains; emulsion, suspension, Interfacial, and precipitation polymerization process.
Table (1.1) shows the characteristics, advantageous, disadvantageous and examples of
each polymerization process, [3].
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Polymerization Reactors
It's the first and important machine used in production of resins, its importance
introduced in its effect on effluent molecular weight and distribution of this molecular
weight, beside percentage of monomer conversion. Three types of reactors used in the
production; batch reactor, plug flow reactor, continuous stirred reactor. Table (1.2)
shows each type characteristics, suitable polymerization reactions and process, beside
some of products, [3].

Case study

Production of Polycarbonates by interfacial polymerization

A presentation of number of students in department of chemistry(Gujarat
University), under supervision of Dr. Nikita Mishra in 2023 provided a description of
process flow sheet of manufacturing polycarbonate by interfacial polymerization.
Production of polycarbonate pass through three stages; starting from reaction of bis-
phenol A and phosgene, then separation process until

Figure (1.2): Process flow sheet for manufacturing of Bis-Phenol A

Polycarbonates by interfacial polymerization

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Table(1.1):Polymerization processes,[3]

31
Table(1.2):Polymerization reactors,[3],[4]

32
 getting polycarbonate powder and finally drying of polycarbonate paste extrusion
and getting of PC-pellets and packaging it. Figure (1.2) shows process flow sheet for
that.
In production of polycarbonate by interfacial polymerization method these raw
materials are required; Solution of Bis-Phenol A and methylene chloride, phosgene in
liquid form at 8.2°C, phenol in liquid form at 4°C, which used as molecular weight
regulator, to inactivate some carbonate oligomer ends to get required weight,
triethylamine added in liquid form at 20°C used as catalyst to prevent revere of
reaction, and sodium hydroxide is added in solid form to get sodium salt of bis-phenol A.
(1) Reaction
The interfacial polymerization done in patch reactor on two steps;

❑ first bis-phenol A reacts with sodium hydroxide to get sodium salt of bis-phenol A at
25-30°C in average time 25 minute as shown in equation (1).

❑ after that and at same temperature phosgene react with sodium salt of bisphenol A
to get polycarbonate as shown in equation (2).

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 (2) Separation
The separation process done through passing the effluent of reactor to a
scrubber, where the effluent of the reactor washed with water to get rid of any
miscellaneous attached in polycarbonate solution, after that the solution is fed to
solvent recovery unit, where the solvent is extracted and recycled again to the reactor.
(3) Drying, Extruding, Pelletizing & Packaging
The product of solvent recovery unit is a paste need to be dried by using a dryer
at 120°C for three or four hours to get rid of humidification, and after that powder is fed
to an extruder, it may be single or twin-screw extruder, and since extruder work with
direct extrusion technique talk powder added to reduce friction, poly carbonate melted
at 250°C so through group of parallel heaters. The extruder used is German-made
Werner which is twin screw extruder which are capable of rotating between 146 rpm
and 172 rpm the extruder has eleven zone polymer powder passes through it to be in
molten shape until it reaches to head of extruder (die), a solid steel plate with 986 holes
in it to form the molten powder into ribbons.
After extruding molten ribbons pass through tank of water supplied with water
pump to cool these ribbons, after that cooled ribbons cut with blades set at axis it may
be 16, 20, 24 knifes, the pelletizer rotates with 600 to 850 rpm. After that
polycarbonates pellets are charged to silos to be packaged, [5].

Processing of Resins
The term of processing resins to get final products used in our life is used for
organic resins through several processes which will be discussed in some details in the
next sections.
Processing tools
The tools are used for defining the shape of plastic products, as seen in our life such as
bottles of water. They categorized into main two categories; die, and mold. The typed
will be discussed in next sections.

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Die
A tool used in extrusion, thermoforming, and pultrusion. It produces 2
dimensional shapes, and the third dimension, which usually length or thickness be
controlled by other processes such as pressing. Dies can be classified according to
products (films, sheets, etc.) but each of them consists of main parts that are; steel
structure, heaters, melt pressure sensors, parting line, and die swell compensation, [6]
Mold and Molding

The molds classified into two main types; single cavity, and multiple cavity,
which showed in figure (1.2). Table (1.3) shows each type characteristics.

Table (1.3) Characteristics of mold types, [6]

Type of mold Characteristics

Single cavity mold Simplest type of molds, allow to small
volume production, and large parts design
Multiple Cavity mold
A) Dedicated multiple Popular due to; easy balancing of molten
cavity mold plastic flow, and establishing a controlled
process

B) Family multiple Allow to produce a shape with different

cavity mold parts, historically it avoided due to
difficulty in filling the mold uniformly, but

Figure (1.3): types of molds; (a) single cavity mold, (b) dedicated multiple
cavity mold, (c) Family dedicated cavity mold, [6]

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 The molding process is classified to transfer molding and compression molding,
each class of them have number of types, that will be discussed in table (1.4)
Table (1.4): Compression and transferee molding ,[6]

35
Processing Techniques
Converting the polymeric raw materials into final products its importance in our
daily life, done by number of processes which enable us to have; bottles, hoses, tubes,
hollow products, and etc. Processes such as; extrusion, injection molding, below
molding, and etc. Table (1.5) Shows those processes, their description, suitable resins,
and examples of products for each process, [3]

36
Table (1.5): Description, suitable resins, and products of polymer processing,
[3]

Process Description Suitable resins products

Extrusion A process used for PE, PVS, PP, PS Pipes, garden
manufacturing hoses, and foam
intermediate length sheets
products and const.
cross section area, for
thermo plastics

Injection A process suitable for All thermoplastics, Automobile

molding high speed and low- and thermoset parts, camera
cost production, also cases
for high volume
production

Blow molding A process suitable Thermo plastics, PS, Bottles,

for making hollow PP, ABS hollow toys
parts and thin
walls

Rotational A process used for PE, PP, PVC Hollow balls,

molding production of storage tanks
hollow parts
with thick walls

Thermoforming A process used for Polycarbonates, refrigerator

forming complex Acrylics liners, freezer
shapes that not stand panels;
with rotational packaging
molding trays for meat
packing

casting Process used for Polyesters, poly Electrical

converting urethane connectors,
liquid resins into rigid and radio
shapes cases

37
 Conclusion

 Epoxy rein concrete has high strength, good durability, fast growth strength,
good toughness, forming time is short, and the advantages of easy
construction,etc. As a high performance material, it is applied in many fields
such as machinery, construction, chemical industry,etc.
 Experimental conclusion-
- It is concluded that epoxy polymer concrete has higher mechanical
properties compared with the ordinary cement concrete when it
exposed to the temperature below 250 ° C.

38
 Reference

https://chemieresin.com/

https://www.youtube.com/

https://www.wikipedia.org/

https://www.google.co.in/

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