REPORT ON STUDENT INDUSTRIAL WORK

EXPERIENCE SCHEME (SIWES)

TRAINING PROGRAMME

JULY 2018 TO DECEMBER 2018

AT

DEPHGHALIN VENTURES

BY

Name

Mat Number

A REPORT SUBMITTED IN PARTIAL FUFILLMENT OF THE

REQUIREMENT FOR THE AWARD OF THE BACHELOR OF

ENGINEERING (B.ENG) DEGREE IN CHEMICAL ENGINEERING

UNIVERSITY OF BENIN, BENIN CITY

NIGERIA.

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 DECLARATION

I, name hereby declare that the presented report of the students Industrial Work Experience

Scheme (SIWES) which started on the 31st of July 2018 and ended on the 31st of December

2018, was compiled and completed by me. I therefore, submit the report as a partial fulfillment

of the requirement for the Student’s Industrial Work Experience Scheme of the University of

Benin.

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 ACKNOWLEDGEMENT

I express my immense gratitude firstly to God for making it possible that I secure a placement in
Depghalin Ventures LTD. Also for his grace, guidance and protection during my industrial
training period.
Special thanks to my industry based supervisor, Engr Emeka Anyanwu who ensured in his every
possible best that I learn and get as much knowledge I can. Many thanks to the staffs at
Depghalin Ventures LTD who were welcoming made my stay a productive one.
I also would like to appreciate my family for their care, support and understanding shown during
my internship period. To my lecturers who through their various lectures and teaching made me
appreciative in the industry. Finally I would also want to appreciate my friends who one way or
the other were very support during and after my internship and even in the finalizing of this
report.

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 DEDICATION

This industrial Training Report is dedicated to God Almighty for his grace and guidance over me
during my industrial training at Depghalin Ventures Ltd.

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 ABSTRACT

This report is centered on a six months Student Industrial Work Experience Scheme (SIWES)

training program with Depghalin Ventures Ltd, located at 15, redemption close Ikotun, Lagos

state, with an highlight on polythene production and recycle giving a full enlightenment on

equipments used in polythene production, as well as the components, the production steps and

control processes, giving a clear idea of student involvement in all operational activities that took

place in the polythene production factory.

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 TABLE OF CONTENTS

Title Page……………………………………………………………………………

Abstract……………………………………………………………………………...

Acknowledgement…………………………………………………………………...

Dedication……………………………………………………………………………

Table of Content……………………………………………………………………..

CHAPTER ONE

Introduction………………………………………………………………………….1

Students Industrial Work Experience Scheme (SIWES)…………………………….1

Aims and Objectives of SIWES……………………………………………………...2

Introduction to Depghalin Ventures Ltd……………………………………………..2

Organogram of Dephghalin Ventures ltd…………………………………………….3

Functions of various department……………………………………………………..4

Summary of Intern’s role and activities……………………………………………...5

Skills and knowledge acquired during the period of internship……………………...6

CHAPTER TWO

Detailed Internship Roles and daily Activities………………………………………9

Work place Orientation………………………………………………………………15

Safety Precaution……………………………………………………………………..16

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Roles performed during internship…………………………………………………….18

CHAPTER THREE

Discussion, Analysis and Evaluation…………………………………………………...24

Production of polythene bags using blown film extrusion process……………………..28

Recycling of polythene Waste…………………………………………………………..33

Introduction to polythene……………………………………………………………….34

Description of Tools and Equipment used in Production………………………………36

CHAPTER FOUR

Conclusion………………………………………………………………………………37

Limitation……………………………………………………………………………….38

Recommendation……………………………………………………………………….39

REFERENCES…………………………………………………………………………40

APPENDICES………………………………………………………………………….42

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 CHAPTER ONE

1.1 INTRODUCTION

The Students Industrial Work Experience Scheme (SIWES) is a skill acquisition program designed
for the students of tertiary institutions as a complimentary program to the knowledge gained through
theoretical education, laboratory and workshop practice engaged in by students, in partial fulfillment
of the requirement for the award of degree in Bachelor of engineering to students of the department of
chemical engineering, University of Benin, Benin City.
Practical experience are improvised for students to discover the working environment, students of
400 level in Universities are opportune to use this privilege provided by the federal government
through its parastatal (Industrial Trust fund) ITF, for the period of six (6) months.
The program also exposes the students to real life experiences situations, It prepares the students for
life after school since the whole process is far from the normal academic, laboratory and workshop
practices.

1.2 AIMS AND OBJECTIVES OF SIWES

 To create an avenue for students to apply learnt theories in solving problems encountered at
their places of attachment.
 To enable the student gain knowledge that is not obtainable in the classroom.
 To serve as an avenue for building relationships that could help career wise after their years of
undergraduate study.
 To focus and re-focus students on how their field of study can build up and develop various
fields of human endeavors.

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1.3 BRIEF HISTORY OF SIWES

The introduction of the Industrial (ITF) program otherwise called Students Industrial Work
Experience (SIWES) in 1994 by the military government of Gen. Babagida was an on the overall
technological advancement of our country. The Students Industrial Work Experience Scheme is the
accepted skills training program, which forms part of the approved minimum academic standards Sin
the various degree program for all Nigerian universities. It is an effort to bridge the gap between
theory and practice of engineering and technology, science, agriculture, media, management, and
other professional educational program in the Nigeria Tertiary institutions. It is aimed at exposing
students to the machines and equipment’s, professional work methods and ways of safe guarding the
work areas and workers in industries and other organization.

1.4 HISTORY OF DEPHGHALIN VENTURES LTD

Depghalin Ventures Ltd is located in Lagos, Nigeria. It is a subsidiary of Rapolans International

Mine Resource and Co Ltd. It deals with the manufacturing and producing of Polythene
(LDPE/HDPE/PP) Products of high quality shrinks Nylon Wrapper in all Categories and sizes for
both Table waters, all kinds of beverages bottles and Cans Products, and all kinds of industrial Usage,
sea food nylon packages, waste disposal Nylon bags e.t.c.

It was founded and established by Mr Raphael Gbenga in 2009 as a subsidiary of Rapolans

International Mine Resources. It has it’s head office and factory located at 15, Redemption Close, off
Ikotun, Idimu Road, College bus/stop, Ikotun, lagos Nigeria. With over 50,000 different sizes of
polythene bags, Depghalin Ventures Ltd can solve any packaging problem it’s customers may have.
By providing so many options it can accommodate our customer’s specific needs. It can serve a
variety of industries including agricultural, apparel, automotive, banking, clean room, consumer
process, electrical, food, house wares, laboratory, medical, devices, pharmaceutical, security and
transportation. With so many bag options and uses in a wide variety of industries, it has a trusted
name in polythene bags over the years.

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 1.5 ORGANOGRAM OF DEPGHALIN VENTURES LTD

Depghalin Ventures Ltd is made up of different departments all functioning in their various
capacities in ensuring the success of the organization.

CENTRE MANAGER

PLANNING ADMINISTRATION ACCOUNTS AND TECHNICAL SECURITY

COMMERCIAL AND HUMAN FINACE DEPARTMENT DEPARTMENT
DEPT RESOURCES DEPARTMENT

MARKETING
DAPARTMENT

Figure 1: Organogram of Dephghalin Ventures ltd

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 1.6 FUNCTIONS OF VARIOUS DEPARTMENTS

 Administrative Section: The section oversees and monitors the day to day running of the
centre and is also in charge of admission of prospective and innovative entrepreneurs into
the centre.
 Accounting Section: this section is in charge of issues relating to funds, record keeping,
finances, budgets and so on.
 Management Section: this section consists of the office of the general manager, assistant
general manager, head of department and others. It deals with the general management of
the centre.
 Operation/technical Section: This section is in charge of operation, processing, process
control and other technical issues.
 Security Section: This section is in charge of general and environmental safe guarding of
the environment and other security related matters.
 Marketing Section: this section is responsible for the marketing strategies and marketing
the organization’s products.

1.7 SUMMARY INTERNS ROLE AND ACTIVITIES

During my period of Industrial training in Depghalin Ventures Ltd, I was assigned to the carried
out. I also worked with the recycling team, who were in charge of recycling waste polythene
products into polythene granules for polythene production and also the packaging and marketing
team who were in charge of packaging and sealing the polythene products into their various
specifications.

1.8 SKILLS AND KNOWLEDGE ACQUIRED DURING MY PERIOD OF INTERNSHIP

The remarkable practical training I have undergone and acquired at Depghalin Ventures are
highlighted below.

 Production of Polythene bags using blown film Extrusion Process

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 Process control and regulation of blown film Extrusion Process
 Operation of the Extrusion machine
 Right selection of materials
 Recycling of polythene waste
 The use of sealing and cutting Machine
 The use of thickness gauge
 The use of the weighing scale.

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 CHAPTER TWO

2.1 DETAILED INTERNSHIP ROLE AND DAILY ACTIVITIES

These five months of industrial training at Depghalin ventures ltd especially in the operations section
where I primarily did my training was full with lots of experiences and practical knowledge for me
that I can confidently say, it was indeed an industrial training for me.

2.2 WORKPLACE ORIENTATION

The first few weeks of my industrial training was spent receiving orientation on Depghalin Ventures
Ltd ; orientation, rules and regulation, getting familiar with the working environment, introduction
and establishing relationships with staffs, employees and members of the organization.

2.3 SAFETY RULES AND PRECAUTION

I was introduced and given an intensive training on safety rules and precaution not just in the working
and operation environment alone but in the factory as a whole. I was also given some safety
equipment’s called for my personal use to ensure I adhere to the safety rules and precautions. Some
safety tips that I learnt and was given are below:

1. The use of protective Clothing (personal protective equipment, PPE): Always wear protective
clothing when in the operation or working environment. Such includes safety boots, overall,
earmuffs, gloves, goggles etc.

2. Inform Supervisors of Unsafe Conditions : If you see something that could potentially hurt
someone, remove the object or clean the area if you can do so safely. Otherwise, inform your
supervisor.

3. Use Equipment, Machines, and Tools Properly: Misusing tools and machines is the most
prevalent cause of workplace injuries. When using equipment, make sure that you are using each
piece of equipment for its intended purpose and are using it correctly. Furthermore, regularly clean
and inspect equipment to ensure that it is safe.

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4. Prevent Slips and Trips: As the second most prevalent cause of nonfatal occupational injuries, it
is vital to ensure that aisles are clear and spills are cleaned to prevent employees from tripping or
slipping

5. Keep Work Areas and Emergency Exits Clear: Make sure to remove any clutter blocking
emergency exits, equipment shutoffs, and areas that you are working. A cluttered work area can lead
to not having enough space to use tools and pick up heavy objects properly.

6. Avoid Tracking Hazardous Materials: To ensure that hazardous materials are not accidentally
tracked into other areas, make sure that work area mats are maintained and kept clean. Prevent cross-
contamination by using different cleaning materials—such as mops—for various spills, and change
clothes if you spill toxic materials on them. Also, if you work with toxic materials, do not wear your
work clothes home.

7. Prevent Objects from Falling: To keep objects from falling, use protections such as nets, toe
boards, and toe rails. In addition, stack boxes straight up and down, and place heavy objects on lower
shelves. Furthermore, keep stacked objects out of the way of aisles and work areas.

8. Use Correct Posture when Lifting: To avoid injuring your back when you are trying to pick up
an item, keep your back straight, use your legs to lift, and pick up the item without stooping or
twisting. Whenever possible, use mechanical aids such as a conveyor belt, wheelbarrow, or forklift.

9. Take Work Breaks From Time to Time: Many work-related injuries occur when a worker is
tired and cannot adequately observe dangers in their surroundings. By taking regular breaks, you are
able to stay more alert when working.

10. Protect your ears against noise: prolonged exposure to loud noise can cause impairment or loss
of hearing. A suitable hearing protective device such as earmuffs or ear plugs should be worn to
protect against objectionable or uncomfortable loud noises.

11. Eliminate Fire Hazards: If you are using combustible materials in the work environment, only
keep the amount you need for the task at hand. When you are not using the flammable material, store
the chemical in an assigned safe storage area away from sources of ignition. Also, store combustible
waste in metal receptacles and dispose of it daily.5 percent or more of a room’s surface being covered

14
at 0.8 millimeters of dust—about the width of a dime—can cause an explosion if the dust catches on
fire. To prevent dust accumulation, use industrial vacuums to frequently

12. Handle volatile liquids carefully: handle volatile liquids, compressed gases etc. with care
because it is highly inflammable.

2.4 ROLES PERFORMED DURING MY INTERNSHIP

During my period of attachment, I was assigned to various roles as the need may be. These roles
include:

 Cutting and opening of the bags of polythene granules

Before the polythene granules are loaded in the hopper, the bags containing the polythene granules
are cut open in preparation for processing.

 Production of polythene bags -Blown Film Extrusion Process

Polythene bags production is done every day the quantity produced vary depending on demand.
Polythene bags are produced in the factory through a process called blown-film extrusion process,

 Positioning the polythene product on the core roller

The flattened polythene after it emerges from the nip roller goes through the idler roller then it is
properly positioned on the core roller.

 Putting and loading the recycle drum with polythene waste for recycling: Polythene waste
majorly from the factory is shredded before being loaded into the recycle drum. The recycle drum

15
 is powered on, which converts the polythene waste into polythene granules called resins. The
resins which can then in turn be processed into useful polythene products.

 Process control of the blown film extrusion process: During production process certain
conditions and factors such as temperature, length, thickness, weight and others are taken into
consideration and hence they are regulated and controlled to get the desired result.

 Cutting and sealing the polythene films into bags: Rolls of tubing or sheeting are fed through a
manual sealing and cutting machine that draws material out to the proper length. The machine then
cycles to place a seal on the material and it is cut off to make individual bags.

 Bagging and packaging of polythene bags: After production and the polythene bags have been
weighed, they are bagged and packaged for distribution.

 Weighing and scaling of polythene bags: After production and the polythene bags are ready, they
are weighed and scaled for accounting and record purposes.

 Regulating the compressor and air in the blown film during production required: During
production, the compressor which regulates the air inside the bubble is being regulated as

 Clearing the polythene waste products during production: After production polythene waste
are cleared off the production site for tidiness and conducive working environment.

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 CHAPTER THREE

DISCUSSION, ANALYSIS AND EVALUATION.

3.1 PRODUCTION OF POLYTHENE BAGS USING BLOWN FILM EXTRUSION

PROCESS

The blown-film extrusion process is a technology that is the most common method to make
polythene films. The first stage in this process is to make polythene film. We take the polythene
granules; blend them with coloring agents (known as master batch) and other additives if required.
This mixture of cold polythene granules is then conveyed to a blown film extruding machine, in
which the granules are heated until they are molten and again forced through a die - but in this case,
of an annular shape (circular) with about a 1mm gap between the inner and outer parts of die, so a
molten tube of polyethylene emerges vertically with a wall thickness of 1mm and a diameter the
same as that of the die.
This molten tube has air pumped into it, so that it inflates like an elongated balloon. This stretches
the tube outwards, whilst at the same time the tube is being pulled by a pair of nip rollers, which
stretch it the other direction. This process is known as biaxial orientation, as it causes the molecular
chains to orientate both crossways and lengthways, thus giving it strength.
The tube is cooled by cold air blowing onto it; it emerges beyond the nip rollers, still as a flattened
tube, but now of a much larger diameter. This flattened tube is then wound on to a cardboard or
plastic tube (known as a core roller).
The finished rolls of film are removed for the next stage. Polyethylene bags are made by heat sealing
and cutting rolls of film.

If the bags are to be printed, the roll of film is taken to the printing machine known as a 'press'. This
is usually a flexographic printer, which means that it uses flexible printing plates which are mounted
on to a steel cylinder of the correct diameter to give the repeat length which will subsequently
determine the size of bags made.

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 Figure 3.1

18
 Figure 3.2: Diagram showing a blown film being extruded

Advantages of Blown Film Extrusion over Others

Blown film generally has a better balance of mechanical properties than cast or extruded films
because it is drawn in both the transverse and machine directions. Mechanical properties of the
thin film include tensile and flexural strength, and toughness. The nearly uniform properties in
both directions allow for maximum toughness in the film.

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Blown film extrusion can be used to make one large film, two smaller ones, or tubes that can be
made into bags. Also, one die can make many different widths and sizes without significant
trimming. This high level of flexibility in the process leads to less scrap material and higher
productivity. Blown films also require lower melting temperatures than cast extrusion. at the die
opening, the temperature of cast film is about 220°C, where as the temperature of blown film is
about 135°C. Furthermore, the cost of the equipment is approximately 50% of a cast line

3.2 RECYCLING OF POLYTHENE WASTE

Recycling polyethylene is a vital process for our environment considering over 60 million metric
tons of it is produced annually for use in packaging and containers, including plastic bags and
bottles—the kinds of ordinary products consumers encounter every day. Higher densities of this
kind of plastic are also frequently used in many industrial applications.

Recycling polyethylene is essential because in most cases, it isn’t biodegradable and can
accumulate in landfills for decades when the plastic waste is discarded. That being said, recycling
of polyethylene is fairly easy to carry out. Because of its composition, the polythene wastes are
shredded and reshaped or extruded as polythene granules, by the recycling machine. This makes it
reusable. Recycling polyethylene can therefore lead to the creation of new, durable products that
are also cost effective and environmentally friendly.

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 Figure 3.3: Diagram showing a recycling machine

3.3 INTRODUCTION TO POLYTHENE

Polyethylene or polythene (abbreviated PE; IUPAC name polyethene or poly(methylene)) is the

most common plastic. As of 2017, over 100 million tonnes of polyethylene resins are produced
annually, accounting for 34% of the total plastics market. Its primary use is in packaging (plastic
bags, plastic films, geomembranes, containers including bottles, etc.). Many kinds of polyethylene
are known, with most having the chemical formula (C2H4)n. PE is usually a mixture of similar
polymers of ethylene with various values of n. Polyethylene is a thermoplastic; however, it can
become a thermoset plastic when modified (such as cross-linked polyethylene).

Figure 3.4: Skeletal formula of a polyethylene monomer

21
 Figure 3.5: Spacefill model of polyethylene

Figure 3.6: Sample of granulated polyethylene

PROPERTIES

Chemical formula (C2H4)n

Density 0.88–0.96 g/cm3[2]

Melting point 115–135 °C (239–275 °F; 388–408 K)[2]

1.02620[3]
log P

Magnetic susceptibility (χ) −9.67×10−6 (HDPE, SI, 22°C) [4]

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 Except where otherwise noted, data are given for materials in their standard state (at 25 °C [77
°F], 100 kPa).The repeating unit within polyethylene in the most stable staggered conformation

PROPERTIES
The properties of polyethylene can be divided into mechanical, chemical, electrical, optical, and
thermal properties.

MECHANICAL PROPERTIES OF POLYTHENE

Polyethylene is of low strength, hardness and rigidity, but has a high ductility and impact strength
as well as low friction. It shows strong creep under persistent force, which can be reduced by
addition of short fibers. It feels waxy when touched.

THERMAL PROPERTIES
The commercial applicability of polyethylene is limited by its comparably low melting point. For
common commercial grades of medium- and high-density polyethylene the melting point is
typically in the range 120 to 180 °C (248 to 356 °F). The melting point for average, commercial,
low-density polyethylene is typically 105 to 115 °C (221 to 239 °F). These temperatures vary
strongly with the type of polyethylene.

CHEMICAL PROPERTIES
Polyethylene consists of non-polar, saturated, high molecular weight hydrocarbons. Therefore,
its chemical behavior is similar to paraffin. The individual macromolecules are not covalently
linked. Because of their symmetric molecular structure, they tend to crystallize; overall
polyethylene is partially crystalline. Higher crystalline increases density and mechanical and
chemical stability. Most LDPE, MDPE, and HDPE grades have excellent chemical resistance,
meaning they are not attacked by strong acids or strong bases, and are resistant to gentle oxidants
and reducing agents. Crystalline samples do not dissolve at room temperature. Polyethylene
(other than cross-linked polyethylene) usually can be dissolved at elevated temperatures in

23
aromatic hydrocarbons such as toluene or xylene, or in chlorinated solvents such as
trichloroethane or trichlorobenzene.

ELECTRICAL PROPERTIES
Polyethylene is a good electrical insulator. It offers good electrical treeing resistance; however, it
becomes easily electro statically charged (which can be reduced by additions of graphite, carbon
black or antistatic agents).

OPTICAL PROPERTIES:
Depending on thermal history and film thickness PE can vary between almost clear (transparent),
milky-opaque (translucent) or opaque. LDPE thereby owns the greatest, LLDPE slightly less and
HDPE the least transparency. Transparency is reduced by crystallites if they are larger than the
wavelength of visible light.

MANUFACTURING PROCESS OF POLYTHENE OR POLYETHYLENE

E
Figure 3.7: Ethylene skeleton

24
 Figure 3.8: Ethylene (3D model)

ETHYLENE (ETHENE)

The ingredient or monomer is ethylene (IUPAC name ethene), a gaseous hydrocarbon with the
formula C2H4, which can be viewed as a pair of methylene groups (–CH2–) connected to each
other. Typical specifications are <5 ppm for water, oxygen, and other alkenes. Acceptable
contaminants include N2, ethane (common precursor to ethylene), and methane. Ethylene is usually
produced from petrochemical sources, but also is generated by dehydration of ethanol.

POLYMERIZATION
Ethylene is a rather stable molecule that polymerizes only upon contact with catalysts. The
conversion is highly exothermic. Coordination polymerization is the most pervasive technology,
which means that metal chlorides or metal oxides are used. The most common catalysts consist of
titanium(III) chloride, the so-called Ziegler–Natta catalysts. Another common catalyst is the
Phillips catalyst, prepared by depositing chromium(VI) oxide on silica. Polyethylene can be
produced through radical polymerization, but this route has only limited utility and typically
requires high-pressure apparatus.

CLASSIFICATION
Polyethylene is classified by its density and branching. Its mechanical properties depend
significantly on variables such as the extent and type of branching, the crystal structure, and the
molecular weight. There are several types of polyethylene:

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 Ultra-high-molecular-weight polyethylene (UHMWPE)
 Ultra-low-molecular-weight polyethylene (ULMWPE or PE-WAX)
 High-molecular-weight polyethylene (HMWPE)
 High-density polyethylene (HDPE)
 High-density cross-linked polyethylene (HDXLPE)
 Cross-linked polyethylene (PEX or XLPE)
 Medium-density polyethylene (MDPE)
 Linear low-density polyethylene (LLDPE)
 Low-density polyethylene (LDPE)
 Very-low-density polyethylene (VLDPE)
 Chlorinated polyethylene (CPE)
 With regard to sold volumes, the most important polyethylene grades are HDPE, LLDPE, and
LDPE.

MOLECULAR STRUCTURE OF DIFFERENT POLYTHENE TYPES

The diverse material behavior of different types of polyethylene can be explained by their
molecular structure. Molecular weight and crystallinity are having the biggest impact, the
crystallinity in turn depends on molecular weight and degree of branching. The less the polymer
chains are branched, and the smaller the molecular weight, the higher the crystallinity of
polyethylene. The crystallinity is between 35% (PE-LD/PE-LLD) and 80% (PE-HD). Within
crystallites polyethylene has a density of 1.0 g·cm−3, in the amorphous regions of 0.86 g·cm−3.
Thus, an almost linear relationship exists between density and crystallinity.[13]

CHAIN BRANCHES

The properties of polyethylene are highly dependent on type and number of chain branches. The
chain branches in turn depend on the process used: either the high-pressure process (only PE-LD)
or the low-pressure process (all other PE grades). Low-density polyethylene is produced by the
high-pressure process by radical polymerization, thereby numerous short chain branches as well as

26
long chain branches are formed. Short chain branches are formed by intramolecular chain transfer
reactions, they are always butyl or ethyl chain branches because the reaction proceeds after the
following mechanism.

Mechanism for the emergence of side chains during synthesis of polyethylene (PE-
LD)Polyethylene is produced from ethylene, and although ethylene can be produced from
renewable resources, it is mainly obtained from petroleum or natural gas. Moreover, the widespread
usage of polyethylene poses difficulties for waste management if it is not recycled. Polyethylene is
not readily biodegradable, and thus accumulates in landfills. Incineration may result in harmful
gaseous emissions.

BIODEGRADABILITY

Polyethylene is not readily biodegradable, and thus accumulates in landfills. However, there are a
number of species of bacteria and animals that are able to degrade polyethylene.In May 2008,
Daniel Burd, a 16-year-old Canadian, won the Canada-Wide Science Fair in Ottawa after
discovering that Pseudomonas fluorescens, with the help of Sphingomonas, can degrade over 40%
of the weight of plastic bags in less than three months. The thermophilic bacterium
Brevibacillusborstelensis (strain 707) was isolated from a soil sample and found to use low-density
polyethylene as a sole carbon source when incubated together at 50 °C. Biodegradation increased
with time exposed to ultraviolet radiation. Acinetobacter sp. 351 can degrade lower molecular-
weight PE oligomers. When PE is subjected to thermo- and photo-oxidization, products including
alkanes, alkenes, ketones, aldehydes, alcohols, carboxylic acid, keto-acids, dicarboxylic acids,
lactones, and esters are released.

27
 3.4 ANALYSIS AND DESCRIPTION OF TOOLS AND EQUIPMENT USED.

 Blown film extrusion machine: This machine carries out the basic process of blown film
extrusion which is a high-volume manufacturing process in which raw plastic is melted and
formed into a continuous profile. This process starts by feeding plastic material (pellets, granules,
flakes or powders) from a hopper into the barrel of the extruder. The material is gradually melted
by the mechanical energy generated by turning screws and by heaters arranged along the barrel.
The molten polymer is then forced into a die, which shapes the polymer into a shape that hardens
during cooling.

28
 Figure 3.9: Diagram of showing a blown film extrusion process

 Thickness guage: This helps in determining and regulating thickness of the polythene
film during production,

29
 Figure 3.91: Diagram of a thickness guage

 WEIGHING SCALE: This is used for weighing the various required quantity of
polythene bags that have been produced for sales and distribution.

30
 Figure 3.92: Diagram of weighing Scale

 Packaging bags: These are the bags used in bagging and packaging the produced
polythene bags for sales and distribution.

31
 Figure 3.93: Diagram of a polythene packaging bag

 Industrial knives and scissors: During production process the industrial knives and
scissors comes in handy when the need to cut or tear arises. For example the knives are
used in cutting a roll of polythene film during production and the scissors are used for
cutting or tearing the sacks of polythene resins before they loaded into the hopper.

32
 Figure 3.93: Diagram of a scissors

Figure 3.94: Diagram of an Industrial Knife

33
  Wheelbarrow: This comes handy when bulky materials need to be moved or transported
from one location to another in the factory.

Figure 3.95: Diagram of a wheelbarrow

 Measuring tape: This is used for measuring the length of the polythene in order to inline
with the desired specification.

34
 Figure 3.96: diagram of a measuring tape

 Recycling Machine: Polythene waste to be recycled into the are shredded manually and
kept into the machine. The machine in turn shreds them better and extrudes them out as
polythene granules which can now be processed into useful polythene products.

35
 Figure 3.97: Diagram of a recycling machine

Personal protective equipment (PPE): The importance of personal protective equipment cannot
be over emphasized, the various PPE are described below:

 Coveralls: Worn over the body to protect it from injuries.

 Hard hat: It protects the head from objects falling from a height.
 Ear muffs/plugs: Protects the ears from noise pollution
 Eye goggles: Protects the eyes from harmful substance and from intense sun rays from entering.
 Safety boots: Protects the leg from injuries that may arise from heavy and sharp falling objects
and from hitting against an object.
 Hand gloves: Worn to protect the hand from cut and from harmful chemicals.
 Body harness: It is worn over the personnel from falling when working at heights.

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 3.5 ANALYSIS OF PROBLEMS ENCOUNTERED AND SOLUTION

 Air entrapment between film layers and rollers – this may cause film scratching or wrinkling,
or processing problems when winding up the film due to reduced friction. Possible solutions to
this is using a vacuum to remove entrapped air or by using winding rolls with a diamond shaped
groove in the rubber cover to increase surface area and decrease amount of entrapped air in the
film.
 Large output fluctuations from the die – this causes thickness variations, and can be prevented
by keeping the extruder clean and by using more consistently shaped pellets in the extrude.
 Melt fractures – these appear as roughness or wavy lines on the film surface, and can be
eliminated by lowering the viscosity of the polymer melt. This can be done by increasing the
melting temperature or by adding an internal lubricant to the material composition.
 Thickness variations in the film – this can be avoided by centering the die in the extrusion line
before every run, adjusting the air speed of the cooling system, or by using heated die lips.
 Die lines on the surface of the film – this defect reduces the aesthetic appeal of the film, reduces
optical properties, and weakens mechanical properties such as tear strength. This can usually be
avoided by routinely cleaning the inner surfaces of the die and by refinishing scratched or
roughened flow surfaces.
 Gels – these defects are small, hard globules encapsulated in the film or stuck on the film surface
and reduce the aesthetic appeal of the film and cause stress concentration points which may result
in premature failure. These are caused by overheating to the point of polymer degradation in the
die, and can therefore be avoided by cleaning the inner surfaces of the die on a regular basis.

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 CHAPTER FOUR

CONCLUSION, LIMITATIONS AND RECOMMENDATIONS

4.1 CONCLUSION

My five months industrial training at Dephghalin Ventures Ltd was an enlightening and
interesting experience for me. It was an opportunity for me to learn, acquire practical skills and
experience. I was also able to relate and appreciate the theoretical knowledge I have acquired
(such as mass transfer, heat transfer, process control) and also see their practical applications in
the industry.

I was enlightened and exposed to how an industrial working environment looks like,
administration, working codes and conducts, team work, structures, good and cordial relationship
with the factory staffs and managements. In all it was a great and e4nlightening experience for
me.

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4.2 RECOMMENDATION

 Students find it difficult in getting good placements with companies hence constraining
their options and having them to settle for late or no reasonable placements. There should
be a mandate or law enforced on companies to take a given number of students according
to the operation and structure of the company.
 All staffs in every organization should be ever willing and ready to accept students and
also free and ready to share their knowledge without withholding some as they tag them
as trade secrets.
 The training Organization should encourage students inform of allowances during the
training period to help students handle isssues as regards feeding, transportation,
accommodation e.t.c.
 I recommend that the training program should be taking serious by students as it is a very
great opportunity to learn a lot practically and be exposed to real life situations.

39
 REFERENCES

1. Chanda, Manas and Roy, Plastica Technology Handbook, 4 th ed. Massachusetts: john
Wiley & Sons Inc, 2003.
2. Van, Der Molen Theodorus Jacobu. ”Process for the preparation of blown film and
oriented film” European Patent EPO156130. September 1991.
3. Callister, William D. Jr. Materials science and Engineering “An Introduction. 6 th ed.
Massachusetts: John wiley & Sons Inc 2003.
4. Dyson, R.W. Engineering Polymers. New York: Chapman and Hall, 1990.
5. Cantor, kirk, Blown Film Extrusion: An introduction. Ohio: Hanser Publishers, 2006.

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APPENDICES

41
 Front View of the production and work area .

Side view of the production and working area

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