Sources for Technical Know –howSources for Technical Know –how

- Focus on Plastics Industries- Focus on Plastics Industries

Dr. K. Padmanabhan FIIPE, FIEDr. K. Padmanabhan FIIPE, FIEProfessor Professor

Mechanical EngineeringMechanical EngineeringSVCE, Sri PerumbudurSVCE, Sri Perumbudur

ContentsContentsPlastics, Classifications, ConsumptionPlastics, Classifications, Consumption Important Properties: Important Properties: Designer, Manufacturer, CustomerDesigner, Manufacturer, Customer

Materials and Manufacturing MethodsMaterials and Manufacturing MethodsStrategies for ImprovementStrategies for ImprovementBasic EconomicsBasic EconomicsHigh Flying Projects- Case StudiesHigh Flying Projects- Case StudiesTANSTIA FNF Service CentreTANSTIA FNF Service Centre

ProductsProductsConsumer ProductsConsumer ProductsEngineering ProductsEngineering Products Metal based productsMetal based products Ceramic based productsCeramic based products Polymer based productsPolymer based products

Polymer and PlasticPolymer and Plastic A Plastic should be a A Plastic should be a Solid in finished formSolid in finished form Should be organic in structureShould be organic in structure Must have been capable of flow at Must have been capable of flow at some stage in processingsome stage in processing (ASTM Definition)(ASTM Definition)

Focus on PlasticsFocus on PlasticsPlastics and Reinforced PlasticsPlastics and Reinforced PlasticsThe Rising ImportanceThe Rising ImportancePresent ConsumptionPresent ConsumptionStatisticsStatisticsScopeScope

Indian Plastics ConsumptionIndian Plastics Consumption

World Plastics ConsumptionWorld Plastics Consumption

Plastic ProductsPlastic ProductsCommodity PlasticsCommodity Plastics TypesTypes Applications Applications Consumption and DemandConsumption and DemandEngineering PlasticsEngineering Plastics TypesTypes ApplicationsApplications Consumption and DemandConsumption and Demand

Plastic ProductsPlastic ProductsProperties important to the Properties important to the DesignerDesigner

ManufacturerManufacturer

Customer/ UserCustomer/ User

Design Properties Design Properties Strength, Stiffness, Toughness, Fatigue, Strength, Stiffness, Toughness, Fatigue,

Creep and ImpactCreep and ImpactDimensions, Weight, TolerancesDimensions, Weight, TolerancesJudicious use of drafts, radii, fillets, webs, Judicious use of drafts, radii, fillets, webs,

ribs, blends, chamfers and curves for ribs, blends, chamfers and curves for specific propertiesspecific properties

Ease of assembly, disassembly and Ease of assembly, disassembly and serviceservice

Aesthetics, colouring and texturingAesthetics, colouring and texturing

Manufacturing PropertiesManufacturing Properties Forming temperature, Glass transition, Melting Forming temperature, Glass transition, Melting

point, Rate of solidificationpoint, Rate of solidification Energy required to form, Whether batch process Energy required to form, Whether batch process

possible? , Pressure requiredpossible? , Pressure required Flow behaviour, Viscosity, Melt flow indexFlow behaviour, Viscosity, Melt flow index Mouldability and Castability, WorkabilityMouldability and Castability, Workability Fabrication of Complex Parts, TimeFabrication of Complex Parts, Time Curing/Solidification Shrinkage in the MouldCuring/Solidification Shrinkage in the Mould Materials properties, Availability, ToxicityMaterials properties, Availability, Toxicity

Customer/User RequirementsCustomer/User RequirementsQuality, Cost, Durability ( low moisture Quality, Cost, Durability ( low moisture

absorption), Reliability ( low degradation of absorption), Reliability ( low degradation of properties with time)properties with time)

Efficiency : Better properties at lighter Efficiency : Better properties at lighter weight and less money, Valueweight and less money, Value

Flexibility : Multi functionalityFlexibility : Multi functionalityLow maintenance costLow maintenance costAesthetics, textures in DesignAesthetics, textures in Design

Material CostsMaterial Costs An OverviewAn Overview Commodity thermoplastics are the cheapest. Commodity thermoplastics are the cheapest.

Commodity thermosets are costlierCommodity thermosets are costlier Entry level engineering thermoplastics are Entry level engineering thermoplastics are

cheaper than advanced engineering cheaper than advanced engineering thermoplasticsthermoplastics

High end blends, alloys and IPNs of High end blends, alloys and IPNs of thermoplastics and thermosets are expensive thermoplastics and thermosets are expensive ( used in aircrafts, marine industry, luxury /sports ( used in aircrafts, marine industry, luxury /sports cars, Sports equipment etc.)cars, Sports equipment etc.)

Manufacturing MethodsManufacturing Methods For Plastics and Reinforced PlasticsFor Plastics and Reinforced Plastics

Calendaring, Autoclave vacuum bagging,Calendaring, Autoclave vacuum bagging, Vacuum resin infusion moulding, Vacuum resin infusion moulding, Reinforced reaction injection moulding,Reinforced reaction injection moulding, Casting, Pultrusion, Extrusion, Hand lay Casting, Pultrusion, Extrusion, Hand lay up contact mouldingup contact moulding

Blow MouldingBlow Moulding

Injection MouldingInjection Moulding

Compression Moulding Compression Moulding

Resin Transfer MouldingResin Transfer Moulding

ThermoformingThermoforming

Rotational MouldingRotational Moulding

Relative Margins in ManufacturingRelative Margins in Manufacturing

Injection moulding and compression moulding Injection moulding and compression moulding are efficient as batch fabrication is possibleare efficient as batch fabrication is possible

Extrusion is also efficientExtrusion is also efficient Blow moulding, Thermoforming , Resin transfer Blow moulding, Thermoforming , Resin transfer

moulding and Rotational moulding are also moulding and Rotational moulding are also economicaleconomical

Room temperature thermosets and casting them Room temperature thermosets and casting them is cheapis cheap

Other techniques described are high endOther techniques described are high end

Choice of Manufacturing MethodChoice of Manufacturing Method

Shape, Size, Finish and Design complexityShape, Size, Finish and Design complexity Desired mechanical propertiesDesired mechanical properties Materials selectionMaterials selection Batch processing requirementBatch processing requirement Tooling, fixturing required Tooling, fixturing required Cost per pieceCost per piece Demand and local availabilityDemand and local availability Overall reliability and durability of the methodOverall reliability and durability of the method SafetySafety

Plastics and StandardsPlastics and StandardsRaw Materials, semi finished and finished Raw Materials, semi finished and finished

materials/productsmaterials/productsProcesses, methodsProcesses, methodsTesting , specimen dimensionsTesting , specimen dimensionsVoluntary consensus standards, industry Voluntary consensus standards, industry

standards, company standardsstandards, company standardsStandards making bodiesStandards making bodies ASTM, ASC, ISO,BIS,ISI, DIN….ASTM, ASC, ISO,BIS,ISI, DIN….

Design for ManufacturingDesign for ManufacturingA practice for designing products, keeping A practice for designing products, keeping

manufacturing in mind.manufacturing in mind.Minimise the number of parts through a Minimise the number of parts through a

more compliant designmore compliant designMultifunctional partsMultifunctional partsMinimize part variationsMinimize part variationsEase of handling, assembly and repairEase of handling, assembly and repairOptimum design for manufactureOptimum design for manufacture

Single Minute Exchange of DieSingle Minute Exchange of DieA Japanese concept by Shigeo ShingoA Japanese concept by Shigeo ShingoQuick change of die for a different partQuick change of die for a different part Design for clampabilityDesign for clampability Use of same machine for different partsUse of same machine for different partsSwitching Resins, transferring resins in Switching Resins, transferring resins in

tankstanksSMED reduces costsSMED reduces costs

Other Productivity StrategiesOther Productivity Strategies Computer Aided Design, Manufacturing Computer Aided Design, Manufacturing

and Engineering (CAD/CAM/CAE)and Engineering (CAD/CAM/CAE) Product design validation through finite Product design validation through finite

element analysiselement analysis Feed back FEA results to design stagesFeed back FEA results to design stages Iterative design process, avoid over designIterative design process, avoid over design Cost effective design optimizationCost effective design optimization First attempt at production- to be a First attempt at production- to be a

success !success !

Estimated Cost of the ProjectEstimated Cost of the ProjectLand and BuildingLand and BuildingPlant and MachineryPlant and MachineryErection and CommissioningErection and CommissioningOffice EquipmentOffice EquipmentPre-operative ExpensesPre-operative ExpensesWorking Capital for Three MonthsWorking Capital for Three Months Identification of Clients, CustomersIdentification of Clients, Customers

Basic EconomicsBasic EconomicsWorking CapitalWorking CapitalCost of the ProjectCost of the ProjectNet Profit Per YearNet Profit Per YearNet Profit RatioNet Profit RatioRate of Return on Total InvestmentRate of Return on Total InvestmentBreakeven PointBreakeven Point

High Flying ProjectsHigh Flying Projects High Returns/Profit ProjectsHigh Returns/Profit Projects

Compression moulded plastic goodsCompression moulded plastic goods Blow moulded containersBlow moulded containers FRP Products- Helmets and PanelsFRP Products- Helmets and Panels Automatic injection moulded industrial Automatic injection moulded industrial componentscomponents PTFE bushesPTFE bushes Reprocessing of plastics Reprocessing of plastics

(contd…)(contd…)

High Flying ProjectsHigh Flying Projects

Keyboard switchesKeyboard switches Plastic flash light torch casesPlastic flash light torch cases Nylon zip fastenersNylon zip fasteners Fevicol type adhesivesFevicol type adhesives PET bottles from preformsPET bottles from preforms Rigid PVC pipesRigid PVC pipes PP/HDPE woven sacksPP/HDPE woven sacks

Present Status and Future Present Status and Future Prospects of PlasticsProspects of Plastics

Production and demand patternProduction and demand pattern Imports and exportsImports and exportsApplication areasApplication areas Electronics and telecommunication, Consumer goods, Electronics and telecommunication, Consumer goods, Automobile industry, Structural Engineering, Energy Automobile industry, Structural Engineering, Energy Sector, Sports and leisure, Medicine and MarineSector, Sports and leisure, Medicine and Marine

Scope for innovationScope for innovationManpower and employment potentialManpower and employment potentialFuture prospectsFuture prospects

TANSTIA-FNF Service CentreTANSTIA-FNF Service Centrewww.tanstiafnf.comwww.tanstiafnf.com, , www.tanstia.org.inwww.tanstia.org.in

Tamil Nadu Small and Tiny Industries Tamil Nadu Small and Tiny Industries Association-Friedrich Naumann Foundation Association-Friedrich Naumann Foundation (Germany) Service Centre, Estd 1992(Germany) Service Centre, Estd 1992

Situated at Guindy Indl. EstateSituated at Guindy Indl. Estate Offers services in information, consultancy, Offers services in information, consultancy,

training programmes, seminars, studies and training programmes, seminars, studies and publicationspublications

Assists to obtain subsidies, concessions and Assists to obtain subsidies, concessions and benefits of various schemes by the governmentbenefits of various schemes by the government

Thank youThank you

Questions ?Questions ?