REPORT ABOUT BLOWN FILM EXTRUSION PRODUCTION PROCESSES AT LUUKA PLASTICS LIMITED PDF

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KYAMBOGO UNIVERSITY FACULTY OF ENGINEERING DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING THIRD YEAR INDUSTRIAL TRAINING REPORT BY SEMATA PETER 14/U/8558/IEE/PE SUPERVISED BY MR. SSEMPIJJA DEO THIS REPORT IS SUBMITTED TO THE DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING IN PARTIAL FULFILM...

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REPORT ABOUT BLOWN FILM EXTRUSION PRODUCTION PROCESSES AT LUUKA PLASTICS LIMITED Peter Semata

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KYAMBOGO

UNIVERSITY

FACULTY OF ENGINEERING DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING THIRD YEAR INDUSTRIAL TRAINING REPORT

BY SEMATA PETER 14/U/8558/IEE/PE

SUPERVISED BY MR. SSEMPIJJA DEO

THIS REPORT IS SUBMITTED TO THE DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING IN PARTIAL FULFILMENT FOR THE AWARD OF A BACHELOR OF ENGINEERING IN INDUSTRIAL ENGINEERING AND MANAGEMENT.

MAY-AUGUST 2017

DECLARATION I declare and confirm solemnly that this report is the original copy of my work and has not been submitted anywhere by any other person to any institution of learning.

SIGNATURE: ................................................ DATE..................................................... SEMATA PETER 14/U/8558/IEE/PE

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APPROVAL This is to certify that SEMATA PETER with registration number 14/U/8558/IEE/PE had a period of ten week industrial training at Luuka Plastics Limited along KalerweTtula road. This is a true record of work he has been able to do under our supervision and it is now ready for submission to the board of examination and Senate of Kyambogo University with our approvals.

INDUSTRIAL SUPERVISOR SIGNATURE: ................................................... DATE..................................................... MR. BULIMBO USAAMA (THE TECHNICAL DIRECTOR)

UNIVERSITY SUPERVISOR SIGNATURE: ............................................. DATE............................................................ MR. SSEMPIJJA DEO

DEPARTMENT OF MECHANICAL & PRODUCTION ENGINEERING FACULTY OF ENGINEERING KYAMBOGO UNIVERSITY

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PREFACE With the engineering profession, students must be able to supplement their theoretical knowledge with practical skills. Industrial training is basically designed to provide these skills needed. In addition, it exposes the student to working environment thus giving them an opportunity to learn and understand how to work with others who may or may not share their opinion or views. This encourages the development of profession ethics. The training therefore paves a way to any student pursing a bachelor of engineering in industrial engineering and management at the faculty of engineering in Kyambogo University towards success in today's engineering fraternity. Therefore this document gives a detailed account of a 10 week industrial training at Luuka Plastics Limited between May and August, 2017. It is therefore my duty to inform whoever reads this report that the information in here is basically about Blown film Extrusion, Printing, Lamination, Slitting, Bag making, Quality control, and Maintenance done in the PE section at Luuka Plastics Ltd. This has provided me with knowledge and skills of team working and it has also helped me in developing practical skills.

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ACKNOWLEDGEMENT It is of great importance to forward my appreciation to the almighty God who enabled me to complete this training without disturbances. I would like to take this opportunity to thank the entire management of Luuka Plastics Limited for allowing me carryout my industrial training at their organization. It is a truly a matter of grate pleasure to express my sincere thanks and gratitude to Mr. Bulimbo Usaama for his supervision, knowledge and encouragements throughout the training period. I am immensely indebted to Mr. Ssempijja Deo, the university supervisor for his effort and time spent towards my training period. I also send my sincere thanks to my father Mr. Musoke Corney, my mum Miss Najjemba Juliet and other relatives for supporting me both financially and the piece of advice they owe to me. Lastly, I thank the all the workers of Luuka Plastics Limited for the love and co-operation they showed me during the training period.

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ABSTRACT This report was produced as a part of the university requirement after first semester of my third academic year 2016/2017. It was compiled basing on the different activities done during my industrial training done at Luuka Plastics Limited located along Kalerwe-Ttula road. The information in this report is based on Blown film Extrusion, Printing, Lamination, Slitting, Bag making, Quality control, and Maintenance done in the PE section at Luuka Plastics Ltd. This has provided me with knowledge and skills of team working and it has also helped me in developing practical skills. Most of the pieces of work in this report were done practically and successfully under supervision of the supervisors of different departments of PE section at Luuka Plastics Ltd.

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TABLE OF CONTENT DECLARATION ..................................................................................................................i APPROVAL ........................................................................................................................ii PREFACE...........................................................................................................................iii ACKNOWLEDGEMENT ..................................................................................................iv ABSTRACT.........................................................................................................................v CHAPTER ONE ..................................................................................................................1 INTRODUCTION ...............................................................................................................1 1.1. Company Background...............................................................................................1 1.2. Location.....................................................................................................................1 1.3 Management ...............................................................................................................1 1.4 Vision .........................................................................................................................2 1.5 Mission .......................................................................................................................2 1.6 Objectives...................................................................................................................2 1.7. Purpose of industrial training: ...................................................................................3 CHAPTER TWO .................................................................................................................4 PRODUCTION....................................................................................................................4 2.1 INTRODUCTION......................................................................................................4 2.1.1 General safety precautions...................................................................................4 2.1.2 Rules and Regulations .........................................................................................4 2.2 BLOWN FILM EXTRUSION ...................................................................................5 2.2.1 Introduction..........................................................................................................5 2.2.2 Materials for blown film......................................................................................5 2.2.2.1 Polymers ...........................................................................................................5 2.2.2.2 Additives...........................................................................................................6 2.2.3 The Extruder ........................................................................................................7 2.2.3.1 Purpose of the extruder.....................................................................................7 2.2.4 Hardware for blown film ...................................................................................10 2.4.5 Process variables used to determine the bubble diameter .................................11 Types of bubbles.........................................................................................................12 2.2.6 The Film Blowing Process.................................................................................14 2.2.7 Advantages of Blown film Extrusion ................................................................15 2.2.8 Disadvantages of blown film extrusion .............................................................15 2.2.9 Optimization of the Process...............................................................................16 vi

2.2.10 Applications of Blown Film Extrusion............................................................16 2.2.11 Procedures for start-up and shutdown of a blown film extruder .....................17 2.2.11.1 Start-up of a blown film extruder .................................................................17 2.2.11.2 Shutdown Procedure for Blown Film Extruders ..........................................19 2.2.12 Blown Film properties .....................................................................................20 2.2.13 FILM EXTRUSION TROUBLESHOOTING GUIDE...................................21 2.3 PRINTING SECTION .............................................................................................25 2.3.1 Introduction........................................................................................................25 2.3.2 Printable Substances ..........................................................................................25 2.3.3 Types of printing................................................................................................25 2.3.3.1 FLEXOGRAPHIC PRINTING..........................................................................25 2.3.3.1.1 Introduction..................................................................................................25 2.3.3.1.2 Process Overview ........................................................................................26 2.3.3.1.3 Basic sections of the press ...........................................................................27 2.3.3.1.4 Basic components of each colour station.....................................................27 2.3.3.1.5 Types of Flexographic printing Presses.......................................................28 2.3.3.1.6 Kinds of artwork used in flexographic printing...........................................30 2.3.3.1.7 Flexographic inks.........................................................................................31 2.3.3.1.8 Applications of flexographic printing..........................................................32 2.3.3.1.9 Advantages of Flexographic printing ..........................................................32 2.3.3.1.10 Limitations of Flexographic printing.........................................................32 2.3.3.2 ROTOGRAVURE PRINTING ..........................................................................33 2.3.3.2.1 Introduction..................................................................................................33 2.3.3.2.2 Basic components of the gravure printing unit............................................33 2.3.3.2.3 Features........................................................................................................34 2.3.3.2.4 Process overview .........................................................................................35 2.3.3.2.5 Advantages of gravure system.....................................................................35 2.3.3.2.6 Disadvantages of gravure system ................................................................36 2.3.3.2.7 Applications of Gravure printing.................................................................36 2.3.4 Reverse Vs Surface Printing..............................................................................37 2.3.4.1 Reverse printing..............................................................................................37 2.3.4.2 Surface printing ..............................................................................................37 2.4 ROLL SLITTING & LAMINATION......................................................................38 vii

2.4.1 ROLL SLITTING..............................................................................................38 2.4.1.1 Definition........................................................................................................38 2.4.1.2 Types of slitting ..............................................................................................38 2.4.1.3 Main sections of the Slitter (Slitting machine) ...............................................38 2.4.1.4 Process overview ............................................................................................39 2.4.1.5 Industry usage.................................................................................................39 2.4.2 LAMINATION SECTION................................................................................40 2.3.2.1 Introduction.....................................................................................................40 2.4.2.2 Reasons for Flexible Packaging Lamination: .................................................40 2.4.2.3 Types of laminating techniques ......................................................................40 2.4.2.4 Advantages of Lamination..............................................................................43 2.4.2.5 Applications of Flexible Packaging Laminates ..............................................43 2.5 PLASTICS BAG MAKING.....................................................................................44 2.5.1 Introduction........................................................................................................44 2.5.2 Basic functions of the machine..........................................................................44 2.5.3 Machine parts.....................................................................................................45 2.5.4 Setting the sensitivity of printing photo cell......................................................48 2.5.4.1 Description of the operation ...........................................................................48 2.5.4 Machine Formats ...............................................................................................48 2.5.4.1 Side Seal machine...........................................................................................48 2.5.4.2 Bottom Seal ....................................................................................................49 2.5.4.3 Pouch type ......................................................................................................50 2.5.4.4 Bag & Roll......................................................................................................51 2.6 RECYCLING ...........................................................................................................52 2.6.1 Procedure ...........................................................................................................52 CHAPTER THREE............................................................................................................53 GENERAL MAINTENANCE...........................................................................................53 3.1 Maintenance concepts; .............................................................................................53 3.2 Safety precautions ....................................................................................................53 3.3 Engineering hand tools.............................................................................................54 3.4 Safety equipments ....................................................................................................54 3.5 Extruder Maintenance ..............................................................................................54 3.5.1 How to disassemble Extruder ............................................................................54 viii

3.5.2 Preventive maintenance on the Extruder parts ..................................................55 3.6 Preventive Maintenance in bag making section .......................................................55 3.7 Trouble shooting and corrective maintenance of bag making machine ...................56 CHAPTER FOUR..............................................................................................................58 RECOMMENDATIONS AND CONCLUSION...............................................................58 4.1 RECOMMENDATIONS. ........................................................................................58 4.2 CONCLUSION ........................................................................................................59 REFERENCES...................................................................................................................60

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CHAPTER ONE INTRODUCTION

1.1. Company Background The organization was initially established in 1986 as a general trading company. Later in 1993, the company concentrated on dealing on a variety of flexible packaging bags in polythene (PE) and polypropylene (PP) that were in a finished form. Luuka plastics Limited was there after established as a factory in 2002 and now is engaged in production of films and fabrics from basic raw materials consisting of granules, that is, polyethylene and polypropylene raffia. The packaging materials produced in a variety of sizes and types range from plain to printed films for polythene and polypropylene bags. The factory also has machinery for laminating films which was installed in 2008. In 2016, the company installed machinery for injection and blow moulded products mainly for domestic and industrial applications e.g. cups, plates, jugs, crates, basins, buckets, baskets, jerry cans, chairs, among others. Luuka plastics Limited is ISO 9001-2015 certified, and therefore focuses on meeting customer expectations delivering customer satisfaction (Quality Management System).

1.2. Location Business name:

Luuka Plastics Limited

Business type:

Limited Company

Registration Number: Telephone:

+256 414 566665

Email:

[email protected]

URL:

www.luukaplastics.com

Physical Address:

Plot 375 Kalerwe-Ttula Road

Postal Address:

P.O Box 30525 Kampala, Uganda

1.3 Management The operations of the company are run by a team of reputable Directors, Line managers, Supervisors and team leaders.

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The company employs highly motivated and specialized staff from diverse professional backgrounds and this has contributed to professionalism and thrift necessary for the success of the company.

1.4 Vision To be the leading manufacturer of high quality flexible packaging materials and plastic products in East Africa by 2020

1.5 Mission To continuously increase the market share and provide quality goods and services for our clients through a quality based approach that also meets the expectations of our employees, shareholders, suppliers, customers, community as well as conserving the environment.

1.6 Objectives 1) To address the needs of our clients by providing the right packaging materials 2) To enhance shareholders returns through maximizing efficiency and reliability. 3) To create awareness of our customers with regards to varieties of packaging materials that can be manufactured for their specific needs. 4) To minimize the cost to our customers of packaging...