FACULTY OF ENGINEERING, TECHNOLOGY,

APPLIED DESIGN AND FINE ART

DEPARTMENT OF MECHANICAL ENGINEERING

AN INDUSTRIAL TRAINING REPORT HELD AT HENG

CHANG PLASTIC COMPANY LIMITED, NAMANVE.

BY:

MUCUNGUZI BONEVENTURE

2020/A/KME/2129/F

SUPERVISOR: STELLA KIZANYE

AN INDUSTRIAL TRAINING REPORT SUBMITTED TO THE DEPARTMENT

OF MECHANICAL ENGINEERING IN PARTIAL FULFILLMENT FOR THE

AWARD OF BACHELOR OF MECHANICAL ENGINEERING AT KABALE

UNIVERSITY

DATE: 30/02/2024
 DECLARATION
I MUCUNGUZI BONEVENTURE hereby declare that all information in this report is my
original work obtained by my own collection during industrial training and has never been
presented to any Institution for academic purposes.

Sign… ……………………………………………………………………….….

MUCUNGUZI BONEVENTURE

Date…. …………………………………………………………………….…….

ii
 APPROVALS
This is to certify that MUCUNGUZI BONEVENTURE has underwent Industrial Training
with HENG CHANG PLASTIC COMPANY where he was attached to ENGINEERING
SECTION. This is a true record of all the work he was able to do under our supervision and
it is now ready for submission to the Faculty of Engineering-Mechanical department
(KAB).

MR. ANTHONY

FIELD SUPERVISOR

HENG CHANG PLASTIC COMPANY.

Signature…………………………...

Date………………………………...

MRS STELLA KIZANYA

KABALE UNIVERSITY SUPERVISOR

Signature…………………………………

Date………………………………………

iii
 DEDICATION
I dedicate this report to my Parents Mr. MURAMUZI BONEFENCE, Mrs. KYOMUNYAZA
ASUMPTER for the support they rendered to me in all aspects especially financially.

I also extend my Dedication to my friends and people in engineering section at HCPC for
their support, cooperation and advice throughout this period.

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 ACKNOWLEDGEMENT
I thank the Almighty God for the protection, guidance & blessings within my academic struggle
since I started the journey of education. My heartfelt thanks go to my dear parents, guardians for
the great support in terms of financial support, care and their efforts towards my academic
success, without them my academic journey would be a mess

My sincere thanks also go to Kabale University Faculty of Engineering, Technology, Applied

Design and Fine Art administrators for having put this training in place, because it helped me to
attain the practical skills of Engineering and related work environment

I sincerely extend my appreciation and gratitude towards my Industrial supervisors ENG

ANTHONY, ENG DENIS AND ENG ANDREW whose skills, advice, comments and
suggestions greatly helped throughout my training session. Without their guidance,
parental care and Professional advice, it would not have been possible to accomplish my
report.

I honorably express my gratitude to the MANAGER Mr. MOHHAMED who allowed me

to train from this factory. Thank you so much for your kindness, may the Almighty God
bless you abundantly.

Great thanks to the engineering department, Mr. DISSAN, Mr. PATHIUS, Mr. JOVAN
who were so welcoming and helpful and for the advice and guidance they gave me from day
one up to the end of my industrial training.

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 ABSTRACT
The industrial training (BME 3207) is conducted after year three semester two by all
students from all engineering departments i.e., Mechanical, Electrical & Civil just before
joining the next year of their academic journey.

Therefore, it is from this context that I was able to do my industrial training at HENG
CHANG PLASTIC CO. LTD, located in NAMANVE-KAMPALA. The training started
on 4th.Jan.2023 and successfully ended on 25th.Feb.2023.

The training was basically aimed at analysis, practice, repair and servicing of various
blow and injection molding machines which equipped me with practical skills that are
very important to a Mechanical Engineer.

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 TABLE OF CONTENTS
DECLARATION ........................................................................................................ ii
APPROVALS ............................................................................................................ iii
DEDICATION ............................................................................................................iv
ACKNOWLEDGEMENT ........................................................................................... v
ABSTRACT ...............................................................................................................vi
LIST OF FIGURES ..................................................................................................... x
LIST OF ABBREVIATIONS ....................................................................................xi
1.0. CHAPTER ONE: INTRODUCTION. ................................................................ 1
1.0 Introduction ........................................................................................................ 1
1.2 COMPANY’S LOCATION, VISION AND MISSION. ................................... 2
1.3 OBJECTIVES OF HCPC ................................................................................... 2
1.4. Objectives of the industrial training. .............................................................. 3
1.5. HEALTH AND SAFETY ................................................................................. 3
1.5.1. Introduction ................................................................................................. 3
1.5.2. Environmental health .................................................................................. 3
1.6. RULES AND REGULATIONS WHILE IN THE INDUSTRY IN
REGARDS TO HEALTH AND SAFETY. .......................................................... 4
1.7. Personal protective equipments (PPEs) .......................................................... 5
CHAPTER TWO: TOOLS AND EQUIPMENTS USED IN THE INDUSTRY
AND ANALYSIS OF BLOW MOLDING MACHINES. .......................................... 8
2.0 INTRODUCTION. ............................................................................................. 8
2.1 Tools and equipment’s used. .............................................................................. 8
2.2 BLOW MOLDING MACHINES .......................................................................... 9
2.2.1 PARTS OF BLOW MOLDING MACHINES AND THEIR
FUNCTIONS. ...................................................................................................... 12
2.1.1.3) HYDRAULIC SYSTEM ....................................................................... 13
2.1.1.4) PRESSURE SYSTEM ........................................................................... 13
2.1.1.5) HEATING SYSTEM/CHAMBER ........................................................ 14
2.1.1.6) ELECTRICAL SYSTEM....................................................................... 14
2.1.2 PARTS OF BLOW MOLDING MACHINES ........................................... 15
2.1.3 TYPES OF BLOW MOLDING MACHINES. ............................................. 16
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 2.1.4 SEMI AUTOMATIC/SINGLE CAVITY MOLDING MACHINE ............. 16
2.1.5 THREE CAVITY MOLDING MACHINES ............................................. 17
2.1.6 FOUR CAVITY MOLDING MACHINES .................................................. 17
2.1.7 SIX CAVITY MOLDING MACHINES ...................................................... 18
2.1.8 INSERTING OF MOLDS IN BLOW MOLDING MACHINES/ MOLD
CHANGE. .............................................................................................................. 18
2.1.8.1 STEP 1: MOLD REMOVAL .................................................................. 18
2.1.8.2 STEP 2: PLACING OF NEW MOLDS IN THE MOLD SYSTEM ...... 19
2.1.9 THE PLASTIC COVER BOTTLE MOLDING MACHINE. ...................... 20
2.1.10 PARTS OF A PLASTIC COVER BOTTLE BLOW MOLDING
MACHINE .......................................................................................................... 20
2.1.11 REPLACING OF THE SEAL FOR BLOW MOLDING MACHINES .. 21
2.1.12 ANALYSIS OF THE EXHAUST SYSTEMS OF BLOW MOLDING
MACHINES ........................................................................................................... 22
2.1.13 TYPES OF PRODUCT DAMAGES CAUSED BY BLOW MOLDING
MACHINES AND HOW THEY CAN BE OVER COME ................................... 22
CHAPTERTHREE: HIGH-&LOW-PRESSURE COMPRESSORS, INDUSTRIAL
CHILLERS AND INDUSTRIAL AIR DRYERS..................................................... 23
3.1. HIGH- AND LOW-PRESSURE COMPRESSORS ....................................... 23
3.2. PARTS OF A COMPRESSOR. ................................................................... 23
3.3. DIFFERENCE BETWEEN HIGH- AND LOW-PRESSURE
COMPRESSORS. .................................................................................................. 24
3.4. WORKING PRINCIPLES OF HIGH-PRESSURE COMPRESSOR. .......... 24
3.5. MANTAINANCE PRACTICES THAT SHOULD ALWAYS BE CARRIED
OUT COMPRESSORS. ......................................................................................... 25
3.6 INDUSTRIAL CHILLERS .............................................................................. 26
3.6.1 PARTS OF INDUSTRIAL CHILLERS .................................................... 26
3.7. WORKING PRINCIPLES OF INDUSTRIAL CHILLERS ........................... 27
3.8. INDUSTRIAL DRYERS ................................................................................ 28
3.8.1 IMPORTANCE OF AIR DRYERS. ............................................................. 28
3.9. WORKING PRINCIPLES OF REFRIGERANT DRYERS........................... 29
3.9.1. WELDING AND FABRICATION PRACTICE. ........................................ 30
viii
CHAPTER FOUR: PLANT MAINTENANCE ........................................................ 31
CHAPTER FIVE: CONCLUSION, RECOMMENDATIONS AND
REFERENCES. ......................................................................................................... 35
5.1CONCLUSION ................................................................................................. 35
5.3 GENERAL CHALLENGES FACED DURING THE TRAINING ................ 35
5.5. RECOMMENDATIONS ................................................................................ 36
TO KABALE UNIVERSITY .............................................................................. 36
TO THE STUDENTS ............................................................................................ 36
REFERENCES .......................................................................................................... 37
APPENDIX................................................................................................................ 38

ix
 LIST OF FIGURES
Figure 1 Front view of the industry....................................................................................... 1
Figure 2 HELMET .................................................................................................................. 5
Figure 3 welding and grinding googles................................................................................... 5
Figure 4protection gloves........................................................................................................ 6
Figure 5 Safety boot ................................................................................................................ 6
Figure 6 Overall ..................................................................................................................... 7
Figure 7 Nose mask ................................................................................................................ 7
Figure 8 product from blow molding machine ..................................................................... 10
Figure 9 manufacturing of jerry can..................................................................................... 10
Figure 10 materials used to make jerry can(HDPE resin)..................................................... 12
Figure 11 mold cavity ........................................................................................................... 13
Figure 12 pressure system .................................................................................................... 14
Figure 13 SINGLE CAVITY MOLDING MACHINE ........................................................ 16
Figure 14 CHILLERS .......................................................................................................... 27
Figure 15 it shows chillers ................................................................................................... 29
Figure 16 -Opening core side of the mold ............................................................................ 31
Figure 17 cleaning the mold................................................................................................ 33

x
 LIST OF ABBREVIATIONS
FETADFA - Faculty of Engineering, Technology, Applied Design and Fine Art

IT - Industrial Training

I.e. - that is

Feb - February

Jan -January

Fig - Figure

Co. Company

LTD. Limited

HCPC Heng cheng Plastic company

PPE Personal protective measure

xi
 1.0. CHAPTER ONE: INTRODUCTION.
1.0 Introduction

Industrial training is an important phase of a student’s professional career, whereby a well

Planed, properly executed and evaluated industrial training helps a lot in developing a
professional attitude. It gives awareness to industrial approach, problem solving based on a
broad understanding of processes and mode of operation of an organization. The student is
able to receive discipline, acquire skills and learn to work as a team and gain technical
knowledge through a proper training environment. This helps a student in the field of
Mechanical engineering to develop responsiveness to self-disciplinary nature of problems at
work place.

During this period, I personally managed to join HENG CHANG PLASTIC COMPANY
where I had the experience of machine operations, plant maintenance and team working
with various workers in different sections of the factory.
1.1 Brief background of the company.

Figure 1 Front view of the industry

1
This industry basically deals in the manufacturing of plastics such as bottles, jerry cans, plastic
chairs, cups, flasks, and among others.

The company has two branches dealing in the manufacturing of the same products of which
one is in NAMANVE while the other is in BUGOLOBI both in KAMPALA. This company
is under ZHONG'S industries that are operating in UGANDA and across AFRICA.

Majorly there are two sections of mechanical engineering at the industry and these include
blow molding section and injection molding section. However, i was training under the blow
molding section.

HCPC takes professionalism and business ethics standards very seriously in its daily
interaction with customers, principals. Therefore, every team member receives a training
on these standards, and they are implemented strictly company wide.

1.2 COMPANY’S LOCATION, VISION AND MISSION.

1.2.1 Location
HENG CHANG PLASTIC COMPANY is located along Kampala - Jinja highway at
Namanve industrial park in Mukono district.

1.2.2 Vision
To be the leading manufacturer of household plastic products in East Africa

1.2.3 Mission
To supply high products in quality, cast and customer satisfaction through the assimilation
of people, technology and quality systems to maintain sustainable production,
professionalism, integrity, transparency and team work.

1.3 OBJECTIVES OF HCPC

 Commitment to quality and building quality trusted throughout the region.

 Develop new, more effective products.

 Focus on reliable and consistent customer services.

 Partnership with other organizations that share a similar vision.

2
1.4. Objectives of the industrial training.

Objectives of the industrial training were to:

• Enable students appreciate the use of hand tools in workshop and production
engineering.

• Teach students how to operate and maintain heavy machines found in the industry.

• Train a student interacts with different machines, tools and equipment found in
industries.

• Introduce students to basic repair and maintenance of different machines that are
available in industries such as compressors, driers chillers and among others.

• To help a student relate the theory learn in class with the practicals found in the
industry.

1.5. HEALTH AND SAFETY

1.5.1. Introduction

Public health and safety can be defined as the science of the anticipation, recognition,
evaluation and control of hazards arising in the workplace that could affect the health and
well-being of public, considering with the possible impact on the general environment.

While in the industry, health and safety is a major concern because if taken lightly it can
result into accidents, injuries, fire out breaks and death.

1.5.2. Environmental health

a) Also, industries take into consideration the health of the environment and this was
realized by,

b) Ensuring that the area is free from oil spills and metal materials that are always cut.

c) Ensuring that there are trenches that direct used water/waste water

3
d) Ensuring that there is proper ventilation by installing fans in the industry and using
heat extractors and pumps.

1.6. RULES AND REGULATIONS WHILE IN THE INDUSTRY IN

REGARDS TO HEALTH AND SAFETY.
One was to observe the following rules and regulations while in the industry
Always keep tools in proper working order.

❖ Concentration was essential in proper working environment.

❖ Attire, overalls were the appropriate clothes in the workshop (long sleeves are a
source of accidents especially in presence of fast rotating spindles).

❖ Improper belts, loosely worn wrist watches are another recipe for a possible
accident.

❖ Safety shoes or boots were a must to avoid injuries to the feet

❖ checking machine components condition before use and after work was
compulsory.

❖ Alcoholism and any form of drug abuse was strictly prohibited.

❖ Machine operators were not allowed to start machines/run in absence of

engineers.

❖ Machine operators were supposed to clean the machines when the machine is off

first.

❖ In case of power disruptions, it is the role of engineers to switch the breakers off
to avoid machine damage in case power comes.

4
 1.7. Personal protective equipments (PPEs)

Helmet

The helmet was to protect the head against falling objects especially when lifting metal sheets
from shelves

Figure 2 HELMET

❖ Eye and face protection; goggles were to protect eyes while working in the
workshop especially during grinding and welding.

Figure 3 welding and grinding googles

5
 Arm and hand protection; safety gloves were worn to avoid losing fingers at work and
also to avoid shock and injuries while doing operations like welding and grinding.

Figure 4protection gloves

❖ Foot and leg protection; safety shoes (steel-toe shoes) were emphasized to
protect your feet if you accidentally dropped something or even while moving
in the working

Figure 5 Safety boot

6
 ❖ Protective clothing; a fitting overall with proper belt was necessary to avoid
being dirtened by oil soils and effects from flames while welding.

Figure 6 Overall

❖ Mouth and nose protection; A very thick dust mask was emphasized just to
protect the nose since the work environment was dusty.

Figure 7 Nose mask

7
CHAPTER TWO: TOOLS AND EQUIPMENTS USED IN THE
INDUSTRY AND ANALYSIS OF BLOW MOLDING
MACHINES.
2.0 INTRODUCTION.
Under this chapter consists of tools and equipments used in the industry as it is essential
components of any industry. It also contains the analysis of the blow molding machines.

2.1 Tools and equipment’s used.

NO Tools or devices used Purpose/Used

1. Tape measure/measuring For measuring all linear dimensions like height, length
and width
tape.

2. Engineer’s try square For measuring all angular (45◦) and right angles (90◦)
3. Scriber For marking the exact measured dimensions on the
material

4. Hand hacksaw For cutting smaller dimensions of thin material. Like

the bars and other soft materials

5. Cutting disk For cut larger dimensions of the thick metal sheet and
materials.

6. Bench vice For holding the material when cutting using a hacksaw

7. set of Allen keys For putting and removing of screws in the machines

8. Anvil For hammering the burglar bars to the correct shape and
style.

9. welding machine For providing the power needed by the welding rods to
bond joints.

10. Hammer For pounding the burglar bars to correct shape

For adjustments of parts on machines

8
11. Grinding disc For removing protruding sludge to obtain equal flatness
on the different materials.

12. set of spanners for loosening and tightening of nuts

13. thread tape applied on water pipes to prevent leakage

14. Sand paper For scraping the joints having the filler material for
final finishing.

15. Compressors For spraying paint to the entire window

Table 1 Tools and equipment used

2.2 BLOW MOLDING MACHINES

2.3 Introduction: Blowing of jerry can

A Jerry can is a container that is used to store liquid. The

Jerry cans have become a perfect storage container as they are available in different sizes,
shapes, and designs. Additionally, Jerry Cans are also available in several colors which
depict different materials being stored. For example, red color depicts gasoline, yellow is
for diesel and blue color donates kerosene. Plastic gas cans are cheaper, lighter, and less
bulky than metal ones, and more user-friendly. They are constructed from HDPE (Food
Grade) Plastic, so are perfectly safe for storing drinking water. Jerry cans are widely used
for carrying several dangerous goods including chemicals, as well as diesel and petrol fuels
owing to which these cans have to adhere to several regulations and standards laid down by
government organizations across different countries. This project report explains the
manufacturing process for 5Ltr Jerry can having approximate weight of 200gram each. The
project cost may vary with the product variations.

9
Figure 8 product from blow molding machine

2.4 Manufacturing process of jerry can:

Figure 9 manufacturing of jerry can

In plastic jerry can manufacturing, HDPE plastic local authorized vendor and stored in the
inventory. The composition of pellets is 97-98 % pellets are of pure HDPE. In this HDPE
resins, 2-3% resins of the master color of the cans are added to impart the necessary color.
The mixture is rotated at high rpm in the rotary mixer so that it is uniformly distributed and

10
thoroughly mixed. Profile dies are mounted into the molding machine as per the desired
dimension of the jerry can after approval from the production team.
In the next step, the barrel heaters are started and brought to the desired temperature to melt
down the thermoplastic pellets. The resins are added into the hopper of the extruder. From
the hopper, these plastic pellets come into the feed section of the barrel. There is a screw
inside the barrel which rotates about the vertical axis and moves the pellets into the heating
section of the barrel where these plastic pellets melt to a semi-solid state and are ready to be
injected into the mold of the machine.

The molten plastic comes out from extruder at the desired pressure. The profile extruded
is called a parson. In jerry cans, there is a requirement of a equal concentration of material
at the base as compared to the top. The amount of material is precisely controlled by
sensors and controllers. In the next step, when the parson reaches the blowpipe of Blow
Molding Machine, the dies of the machine get closed. Compressed air is blown at desired
pressure through the blowpipe. Under air compression, the parison acquires the desired
shape of the die.

After this, the mold dies are cooled using water flow arrangements for the desired cooling
time cycle. The molten plastic solidifies and gets separated. Excess lines are trimmed off. In
the next step, the jerry cans are inspected for any quality defects. After this, they are packed
and dispatched in the required quantity.

Raw material: Major raw materials are as follows:

1. HDPE Resin
2. Master Color

11
 Figure 10 materials used to make jerry can(HDPE resin)

2.2.1 PARTS OF BLOW MOLDING MACHINES AND THEIR FUNCTIONS.

Blow molding machines have various parts that play vital roles to ensure its efficiency.
These parts can be classified into different systems which include; mold system, hydraulic
system, pressure systems, the heating/baking system and electrical system.

2.2.1.2) MOLD SYSTEM

This system mainly comprises of molds; bottom mold and side mold that form the final
shape of the products needed. it is important to note that a mold is a replica of the final
object required.

These molds can be changed/removed at any time depending on the need of customers.

12
Figure 11 mold cavity

2.1.1.3) HYDRAULIC SYSTEM

Blow molding machines need water in various circumstances;

Water is needed in the mold system to keep the molds cold so that the final product
produced is cool enough since plastics tend to change the size and shape upon cooling.
water is also important in the heating chamber specifically on the cooling bed so that heat

does not affect the bottle necks of preforms.

2.1.1.4) PRESSURE SYSTEM

It is important to note that pressure is an important element in blow molding machines

since it provides the force needed for blowing and the running of machine parts.

Blowing uses high pressure of about 8bars depending on the type of machine whereas
movement of machine parts needs low pressure.

However, it is important to note that air compressed to 500psi is regarded as high pressure.

This pressure is provided by compressors.

13
Figure 12 pressure system

2.1.1.5) HEATING SYSTEM/CHAMBER

Basically, the heating chamber is a very important part of blow molding machines
because it aids in softening preform to allow easy formation of the required size and shape
upon blowing.

This system comprises of filament lamps for heating preform, cooling bed for protecting
the bottle neck from effects of heat and the fan to extract excess heat away from the
chamber.

2.1.1.6) ELECTRICAL SYSTEM

This is an important system of blow molding machines since the electrical force needed
by the machines is controlled by this section. This system comprises of programmable
logic controllers which controls the work of sensors in the machine, the wiring for heating
lamps, wrings for screen and the drive that runs the heating chamber with aid of motors.

More so, this system comprises of voltage regulators that regulate the intensity of voltages
entering the machine, the control panels and the circuit breakers.

14
2.1.2 PARTS OF BLOW MOLDING MACHINES

The following are the parts of blow molding machines;

◼ Motors: these are very important parts of blow molding machines and they play
vital roles to the machines. Basically, motors provide the mechanical force that
is needed for the running of machine parts. The blow molding machines use
more than five motors for it to work efficient and these include; drum motor,
motor for baking, feeding motor, sorting motor and among others.

However, these motors differ in the power consumption in terms of volts that they need
in order to run.

◼ Screen: This is an important part of blow molding machines in that it contains

all the parameters and the settings of the machine. Automatic blow molding
machines are controlled on the screen and the any fault or failure, its easily
identified on the screen.

◼ Pressure cylinders: these are cylindrical in shape and they carry pressure that is
needed in by machine. it is important to note that pressure after being
compressed, it passes into the pressure cylinders before entering the machine.
Also, these pressure cylinders act as pressure reservoirs

◼ Filament lamps: These are found in the heating chamber and they provide heat
that is needed to soften the preform before being slide away to the clamps.

◼ Clamps: these aid in clamping preform upon passing the heating chamber into
the mold section. also, after blowing in the mold section, they are clamped away
to the conveyors.

◼ Spindles: these holds preform when it is passing in the heating chamber.

◼ Sensors: This is an important part of blow molding machine in that they control
the machines in various instances. sensors help the machine components to
connect and communicate so that they can perform their roles efficiently.

15
 ◼ other parts of blow molding machines include; slide plates, exhaust pipes,
cooling bed, drive, voltage zones, seal and among others.

2.1.3 TYPES OF BLOW MOLDING MACHINES.

The following are the types of blow molding machine;

1) Single cavity molding machine/semi-automatic

2) Three cavity molding machines

3) Four cavity molding machines

4) Six cavity molding machines

2.1.4 SEMI AUTOMATIC/SINGLE CAVITY MOLDING MACHINE

➢ This is a type of blow molding machine that is manually operated. this type of
machine requires the machine operator to feed preform in the heating chamber and
also removing it to feed it in mold system.

➢ this type of machine produces a single bottle at a time. it’s called semi-automatic
because it requires the machine operator to do manipulations and has limited
sensors in it.

➢ this machine is applied in the production of five litre bottles and even other bottles
plastic in particular.

Figure 13 SINGLE CAVITY MOLDING MACHINE

16
2.1.4.1 DISADVANTAGES OF THE ABOVE MACHINE

 it is hectic since it requires labor to feed preform in the chamber and in the blowing
system.

 less production since it only produces a single bottle at a time.

 the machine is affected by temperatures/ surrounding temperatures which requires an

operator's regulation.

NB. the semi-automatic blow molding machines have the same parts as for all blow
molding machines. however, it has some limited parts such as clamps, conveyors etc.

2.1.5 THREE CAVITY MOLDING MACHINES

❖ These are blow molding machines that produce three plastic bottles at a time.
These types of machines are automatic in nature and everything happens as a result
of sensors.

❖ three cavity molding machines have the same parts of blow molding machines as
that of six cavity molding machines and they require less work by the machine
operators as well as Engineers.

❖ three cavity molding machines however require regular maintenance by the

engineers and they produce more bottles as compared to semi-automatic blow
molding machines.

2.1.6 FOUR CAVITY MOLDING MACHINES

a) This type of blow molding machines is also automatic in nature and produce for
bottles at a time.

b) the mold systems and the clamping system as well as the stretch rods and the slide
plates are modified to produce four bottles at a time.

17
 c) this type of blow molding machines also requires less operation by the operators
and the Engineers as well. they require less maintenance by the Engineers.

d) they produce a greater number of bottles approximately 36000 bottles per day as
compared to three cavity machines that produce averagely 26000 per day which
increases production.

2.1.7 SIX CAVITY MOLDING MACHINES

i. These types of machines are latest and they are more automatic, produce less noise,
and less heat to the surroundings.

ii. Such types of machines are modified to produce six bottles at a time which
increases the production.

iii. Six cavity molding machines require less labor in maintenance by engineers such
as mold change, parameter settings and among others.

iv. Basically, six cavity blow molding machines are more efficient as compared to
other blow molding machines.

2.1.8 INSERTING OF MOLDS IN BLOW MOLDING MACHINES/ MOLD

CHANGE.
Basically, the company may need to change on the production of products in terms of
size, shape and quality of the products. This is only achieved by mold change.

Mold change requires two main steps i.e.

⚫ Removal of the molds in machine

⚫ Placing of new molds in the mold system of the machine.

2.1.8.1 STEP 1: MOLD REMOVAL

✓ the first step in the removal of molds is to stop the machine and where possibly for
six cavity molding machines you switch it off.

18
 ✓ the second step is loosening the screws using the pair of pliers such as alley keys
6, 10 and 12and removing the screws completely.

✓ also, the bottom mold is loosened using the pair of pliers alley keys 6.

✓ lastly, it is followed by removing of molds with careful attention. it should be noted

that the molds are made of aluminium which is less strong and therefore during
removal serious care and handling is required to prevent mold damage.

2.1.8.2 STEP 2: PLACING OF NEW MOLDS IN THE MOLD SYSTEM

◼ The first step before placing new molds is cleaning of both the side molds and
bottom molds using cotton waste. This is because the molds contain passages for
water which are very important in allowing water flow into the mold system.

◼ Secondly, the side molds are placed in their respective sides and the screws placed
in their respective holes. However, the screws are not tightened.

◼ Using the screen, the side molds are aligned by closing and opening the molds on
screen. and when this is done, then the bottom mold is placed in its position and
tightened.

◼ Finally, the operations such as mold close, inch pressure, spotting, and bottom
mold up are performed to confirm proper working of the mold system to avoid
damage and then the pipes carrying water in and out of the mold system are placed
back in their respective positions.

Challenges/limitations

i. some molds are very heavy to lift into the mold system like those of semi-automatic
molding machines.

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2.1.9 THE PLASTIC COVER BOTTLE MOLDING MACHINE.

a) This is a type of blow molding machine that makes the production of plastic covers
of bottles. it is a modified form of blow molding machine with a hopper, an injector
nozzle, a heating chamber, a cutter and among other parts.

b) it is different from other blow molding machines in that in this machine the
material is injected in the hopper due to pressure effect which is dried enough in it
and then in put in the heating chamber where it is heated to very high temperatures
slightly below the melting temperature of the material.

c) the heated material then through the injector nozzle is injected into the mold system
where it is shaped into the required size and shape. the mold system has a hydraulic
system in which the after molding the cover bottles are cooled since plastics
undergo expansion and contraction upon cooling.

d) The cutter helps to give the exact size and height of the cover bottle that is required
by removing the unnecessary material in the cover bottle.

2.1.10 PARTS OF A PLASTIC COVER BOTTLE BLOW MOLDING

MACHINE

The basic parts of the machine include;

❖ HOPPER: This is a container placed at a higher height than the heating chamber. it
is where the material through the aid of high pressure is inserted and then dried
before it goes to the heating chamber.

❖ HEATING CHAMBER: This contains sections which are at different temperatures

ranging from high temperatures to low temperatures. (heat zones). in this chamber,
the material is heated to high temperatures about melting and then then through
the injector nozzle the heated material passes to the mold section.

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 ❖ MOLD SECTION: This forms the exact shape and size of the required plastic

covers. It has a bottom mold and upper mold running like a cam profile with
equidistant displacements.

❖ COOLING SECTION: Due to the heat obtained from the heating section, this

section caters removes the excess heat in molded covers and cools them to as low
as normal temperatures.

❖ RELIEVE TANKS: These tanks aid in opening and closing of molds so that the

plastic covers can proceed to other units.

❖ Other parts include'; screen, motors, sensors, injector nozzles and among others

2.1.11 REPLACING OF THE SEAL FOR BLOW MOLDING MACHINES

1) A seal is very important to blow molding machines in a way that it prevents air
from escaping during blowing. Once the blowing pressure is not sufficient, then
the bottle can’t be shaped to the exact size and shape depending on customer
requirements.

2) The following procedures were followed in removing and replacing of a seal.

3) The first step was to open the mold on the screen and this was followed by using
alley keys 12 and 14 to remove the screws in the plates.

4) after removal of screws, the plate was analyzed and seal found to be broken.

5) A new seal therefore was obtained from the workshop and then using blade it was
cut to exact dimension and joined using glue.

6) The plate was then placed back and then the screws tightened back.

• NB. it is important to smear lock tight on the screws before placing then back in
their respective holes.

• it is also important to always close high pressure before closing low pressure in
case of power disruptions to avoid seal damage.

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2.1.12 ANALYSIS OF THE EXHAUST SYSTEMS OF BLOW MOLDING
MACHINES
a) it is important to note that any high pressure must have an exhaust system.
therefore, blow molding machines have two exhaust systems i.e. exhaust for
clamping pressure and exhaust for blowing pressure.

b) the exhaust systems conduct the excess air away during and after blowing or
clamping unless the parts of the machine will be damaged or the products would
be damaged.

c) basically, the blowing pressure is high pressure of about 8bars and therefore after
blowing if it is not exhausted away it can cause product damage and damage of
seals and other parts.

d) also, after clamping preform both into the mold and out to the conveyor, the micro
pressure used is high pressure and must be exhausted away in order to avoid
product damage and destruction of clamps.

2.1.13 TYPES OF PRODUCT DAMAGES CAUSED BY BLOW MOLDING

MACHINES AND HOW THEY CAN BE OVER COME
Like any other machines, blow molding machines are not 100% efficient and their

inefficiency is justified by the products they produce.

the following are the damages caused by the blow molding machines on the products and
how they can be solved;

➢ OFF CENTER BOTTLE DAMAGE: often on the bottom side of the bottle, there
is a Centre being not at the right Centre which is normally caused by a number of
reasons such as too much heat that is supplied to preforms, looseness of the bottom
mold and among others.

However, this can be overcome by adjusting on the power setting of heating zones and
checking whether the bottom mold is tight enough and whether the seal is in good
working conditions.

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 ➢ BOTTLE NECK DAMAGE: Often when poor clamping occurs or when the slide
plates are not in the rightful positions, the bottle neck tends to change and tilt to
some shape which is not required. however, this can be overcome by tightening
the clamps and making sure that the slide plates are in their rightful positions
always.

➢ BOTTLE BURST: This is always caused by too much pressure during blowing and
the stretch rods overextending deep in the preforms during blowing. it can as well
be caused by too much heat supplied to preforms which changes its shape.

This can be overcome by adjusting on the stretch rods depending on preform size and
height and also adjusting on the heat zones.

other minor damages and challenges include, poor clamping, too much sound during
blowing, loose preform spindles leading to preform loss in heating chamber.

CHAPTERTHREE: HIGH-&LOW-PRESSURE
COMPRESSORS, INDUSTRIAL CHILLERS AND
INDUSTRIAL AIR DRYERS
3.1. HIGH- AND LOW-PRESSURE COMPRESSORS
A compressor is a mechanical device (engine structured) that in puts air through the air
inlet valve and compresses it to very high temperatures and pressures. it is important to
note that air compressed to 5000psi and above is regarded as high pressure and vice versa.

Compressors are very important to all blow molding machines because they provide
pressure that is needed for running of machine parts as well as blowing.

3.2. PARTS OF A COMPRESSOR.

The parts of compressor and its structure resemble to that of an engine and as well as the
four cycles(strokes) of an engine are very much similar to those of a compressor. The
following are the parts of a compressor;

 Connecting rod: This connects the piston and the crankshaft which is connected to
an electric motor.

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  Crankshaft: As the motor shaft rotates, the crankshaft also performs a rotary
motion which gives the piston the ability to perform a reciprocating motion.

 Air filter: This is at both the inlet and out let valves and allows clean air to enter
and leave the compressor respectively. it therefore provides a cleaning action.

 Compressor pump: This provides the pumping action for air to the pressure
reservoir tanks. it also pumps oil to compressor pumps.

 Pulleys.: These are essential components of any air compressor as they are attached
to the motor and play a critical role in sending pressurized air to the tanks.

 other parts of the compressors include; belt pulley, check valve, pressure switch
and among others.

3.3. DIFFERENCE BETWEEN HIGH- AND LOW-PRESSURE COMPRESSORS.

a) The basic difference between high- and low-pressure compressor is the magnitude
of pressure that they produce. High pressure compressors produce high pressure
that is enough for blowing. however, this high pressure is regulated by regulators
before entering blowing machines since machines require both low and high
pressure for movement of machine parts and blowing respectively.

b) On the other hand, low pressure compressors produce air that is not sufficient for
blowing as well as movement of machine parts. Due to this effect, the machines
are connected to pressure cylinder tanks as well as compressors directly so that
pressure from the compressors can supplement pressure in cylinders so that it’s
enough for blowing.

3.4. WORKING PRINCIPLES OF HIGH-PRESSURE COMPRESSOR.

Basically, high pressure compressors in put the ambient atmospheric pressure through the
inlet valve and compresses it to as high as 6000psi.

As air enters through the air inlet valve, it is filtered through the filter and as air enters
through the multiple stages of compression, it is cooled at each stage.

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Normally, cooling is important to make the compression to these high temperatures and
pressures possible.

After compression is done, air is pumped into the reservoir pressure tanks where it is
stored temporarily for consumption by the blow molding machines. However, it is
important to note that due to multiple stages of cooling during compression, it is important
to pass air into the industrial driers before consumption by the machines since the
machines require only dry air. The four cycles include;

⚫ air input

⚫ power

⚫ compression

⚫ pressure output

3.5. MANTAINANCE PRACTICES THAT SHOULD ALWAYS BE CARRIED OUT

COMPRESSORS.
It is always important to check compressors regularly by engineers in order to keep in
proper working conditions. The following should always be done;

✓ Always clean the compressors with pressure/air to avoid air contamination.

✓ Always check for oil levels in the compressors and if it is less then it is vital to add
oil in the compressors. it is important to note that if compressors are out of oil, then
they can lead to damage of parts through wear, leading to failure.

✓ Remove water from the pressure reservoir tanks regularly. Due to multiple cooling
stages that air undergoes during compression, there is condensation process that
takes place and this water if not removed, pressure can’t be sufficient.

✓ Check for worn out belt pulleys and replace regularly.

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 ✓ Use the right grade of oil for the right type of compressors for the compressors to
work efficiently.

✓ Replace gaskets regularly.

3.6 INDUSTRIAL CHILLERS

These are mechanical devices that cools the water used in the blowing machines and
pumps it back to the machines.

3.6.1 PARTS OF INDUSTRIAL CHILLERS

The following are the basic parts of industrial chillers;

⚫ Condenser: This helps in the elimination of heat from the refrigerant(water) that is
being circulated through the chiller unit. This can be achieved by circulating water
between a cooling tower and the condenser for water cooled variants.

⚫ Motor: This helps to provide the driving unit of any chiller system. It helps to
generate pressure gradient necessary to push the refrigerant around the chiller.

⚫ Evaporators: This is always like a fan. It removes heat from any associated process
into circulating refrigerant.

⚫ Thermal expansion valves: These are placed between the motor and the evaporator
and serve to expand the refrigerant passing through them.

⚫ Pump: This serves to pump refrigerant/water back to the blow molding machines.

⚫ Other parts include; power unit, water boxes, control panels, sensors, throttle valve
and among others.

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Figure 14 CHILLERS

3.7. WORKING PRINCIPLES OF INDUSTRIAL CHILLERS

It is important to note that industrial chillers are very important in that they aid in cooling
of hot water/used water that is exhausted away through the outlet valves of the hydraulic
system of blow molding machines.

According to Engineers in the industry, industrial chillers work on three principles i.e.

1) Phase change: This includes heat flow and boiling point.

2) Heat absorption: Chillers integrate heat ex changers that pull heat away from any
associated processes and dissipate them exteriorly. Heat exchangers are typically
composed of piping that contain water.

3) Vapour compression: Chillers achieve a cooling effect by circulating a coolant in

pipes through the processes requiring cooling. This pulls away heat from any
associated processes into a coolant which is then circulated to a refrigerant system
that cools the chiller fluid and prepares it for a new cycle of process cooling.

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3.8. INDUSTRIAL DRYERS

❖ An air dryer is a system or piece of equipment typically that is used to remove

moisture present in the air, particularly compressed air.

❖ Ambient air typically has a relative humidity of around 30 to 50%. Hence

compressing air packs higher quantities of moisture in a small volume. This
increases the relative humidity to 100% while the excess moisture that cannot be
held condenses.

❖ Often, air undergoes a lot of cooling cycles in a compressor and therefore pressure
may not be dry enough for blowing. its therefore important to pass it into the driers
before going to the pressure tanks.

❖ Industrial driers are very important in a way that they separate the moisturized air
from moisture.

❖ Drying can be defined as vaporization of absorbed moisture from wet materials.

3.8.1 IMPORTANCE OF AIR DRYERS.

a) Removes water contamination. this is a serious problem in industries that use high
purity compressed air such as blow molding machine. water along with other
contaminants can create various effects depending on how the compressed air is
used.

b) Prevents water build up: Usually compressed air is fully saturated with water.
Decreasing its temperature or further compression and pressurization can cause the
diffused water Vapour to precipitate.

c) Abates corrosion: The presence of water into equipment internals can cause
corrosion to steel surfaces, pipes and tanks which can promote corrosion to the
internal surfaces of the blow molding machines and pressure cylinders.

d) Prevents freezing: Precipitated air in compressed air systems can freeze

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Figure 15 it shows chillers

3.9. WORKING PRINCIPLES OF REFRIGERANT DRYERS

Refrigerant dryers are types of dryers that work by cooling the stream of air to temperature
low enough to condense water vapor.

This temperature is usually at or below the dew point temperature. compressed air is
usually at a saturated state which means it is at its maximum capacity of holding moisture.
since air with a higher temperature can hold more water than cold air, cooling removes
water by decreasing the water holding capacity of the air which forces the excess water
vapor to precipitate and condense.

The air circuit is the system that removes water vapor from the air. its process involves
the following operations.

⚫ pre-cooling the stream of incoming hot wet air using the outgoing cool dry air.

⚫ Further cooling the air to temperatures around 3degrees Celsius to condense the
water vapor.

⚫ Heating the cold dry air using the heat of incoming air.

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3.9.1. WELDING AND FABRICATION PRACTICE.

It is very important to a mechanical engineer to master the art of welding and fabrication.
Therefore, I had to do some welding practice at the industries workshop where i was re
sizing and reshaping of the molds for blow molding machine 8.

a) Due to the molds being made of aluminum that is less strong, they are prone to
damage during blowing and improper handling by the engineers especially during
removal and replacing in the mold system.

b) Using a welding machine, a welding torch and a welding rod, the bottom mold was
fitted and the cracks on it removed by welding. It was then made to fit in the side
molds and aligned.

c) It was important to adjust on the power on the welding machine since too much
power was prone to damage. Also, a lot of attention was needed while welding
because to much welding would cause misalignment and damage.

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 CHAPTER FOUR: PLANT MAINTENANCE
4.1 Introduction

This chapter consists of the activities I took part in during the training, the lessons learned
and the skills I acquired.

In this section I leant about the maintenance and lubrication of the drive assembly,
participated in changing molds, assembly of molds, cleaning of the mold cores, repaired
the ball breaker, fixed the retaining ring into the mandrel adapter, replaced the cross bearing
of the male part of propeller shaft and finally participated in servicing the radiator.

4.2 Assembly of the mold

Assembly of the mold refers to the process of putting together individual components or
parts of molds in the order to create a complete and functional mold for use in
manufacturing process. This involves fitting and connecting different molds components
such as cavity, cores, inserts and other necessary parts to form a complete mold assembly
that can be used to shape and produce parts or products.

These ae steps followed in assembly of mold

Figure 16 -Opening core side of the mold

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 We started by assembling cavity side and clean up mold base frame. Put the oil ring for
cooling on the position with grease, clean up the cavity inserts. Install cavity inserts to mold
base, lock them tightly with screw, spray some anti-rust oil on the mold surface. Insert the
sprue and assemble the clamping plate.

After we started to the assembly process for the core side. Insert all injector pin on the right
position as their marks. Assemble ejector supports plate to ejector plate to fix the ejector
and return pin. Lock the supporters to clamping plate. Tight up the screw from base side.
Clean the inserts surface and spray using oil rust to protect the mold. Put some grease on
guide pins to help mold smoothly, then put two halves together

4.3 cleaning of the mold

These are steps followed while cleaning the mold

We opened the mold

We opened the guard which protect water from flowing out

We opened every mold core and cleaned using cotton waste

After cleaning we closed the mold’

4.4 changing of mold

Changing of mold are based on customer’s demand.

These are steps;

We disconnected the pipes for water from the mold and even the pipes for pressure and even
the wire for electricity

We opened bolts that were holding molds in its position and even clamps

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Figure 17 cleaning the mold

We removed the 12g mold using crane and replaced with 15g mold.

New mold (15g) was tightened very well and lined very well on the nozzle side of the barrel.

4.5 opening of the injector pins

Injector pins are always inside the cores. It helps to break off tail of the preform.

These are steps;

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We opened the bolts which holding the mold using allen key and pipe.

We removed the mold from its position using crane and placed it down for cleaning.

We opened the guards that were preventing water to flow out using the allen key

We put some heat to the mold to melt the material such that it allows removal of injector pins

Then after removed it and cleaned

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 CHAPTER FIVE: CONCLUSION, RECOMMENDATIONS
AND REFERENCES.
5.1CONCLUSION

❖ It was a resourceful and a practical hands-on training that enabled me to acquire

hands on skills and experience in various fields like blow molding machines,
industrial chillers, air dryers as well as welding and fabrication.

❖ It also helped me to use the theory work that we studied in lecture room and use it in
practical works.
5.2 GENERAL SKILLS AND KNOWLEDGE ATTAINED DURING

THE TRAINING

❖ A skill in analysis and understanding the working principles of various machines

was achieved.

❖ A skill in identifying and fixing problems resulting from compressor's failure was
attained.

❖ Exposure to various mechanical engineering tools and equipment’s was achieved.

❖ A skill in planning and designing different products was also another benefit.

❖ About all, most of my theory was converted to practical.

5.3 GENERAL CHALLENGES FACED DURING THE TRAINING

❖ Un stable electric power supply during the training.

❖ Limited time for the training.

❖ Limited protective gears such as PPEs provided to Engineers and machine operators
which exposed human life to severe injuries.

❖ Limited access to some newly purchased blow molding machines which limited my
learning.

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5.4 POSSIBLE SOLUTIONS

⚫ The industry needs to improve on the health and safety of workers by proving enough
masks other personal protective equipment’s to its engineers.

⚫ The industry needs to improve on the welfare of its workers by giving out free
holidays to workers, resting periods during lunch hours which will improve worker’s
efficiency.

⚫ The university need to alie with such industries to always allow students train
especially during holidays which can improve students’ skills and experience.

5.5. RECOMMENDATIONS

TO KABALE UNIVERSITY

The training duration should be increased from two months to two and a half months
(10weeks) for better acquisition of skills, new technologies and practical knowledge by
students
Supervisors should always visit the training places to advise or credit the work being
done during the training.
Information about the training program should always be delivered early to students so
that they prepare early.
TO THE STUDENTS
⚫ They should respond quickly and regularly attend to their practical work as these are
meant to prepare them for their future career.
Students should also have extra vigor and morale (willingness) to learn if at all they
are to gain skills and training out of the recess.

⚫ In so doing, they will go an extra mile in learning which will help them gain more
skills and experience.

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 REFERENCES

1. Introduction to Basic Manufacturing Processes and Workshop Technology by Raj

Ender Singh.

2. Whiten KW, Davis RE, Peck LM & Stanley GG 2014, Chemistry, 10th Edition

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APPENDIX

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