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A STUDY REPORT ON A STUDY REPORT ON PRODUCTION PRODUCTION

ANALYSIS OF PVC ANALYSIS OF PVC PIPESPIPES

A STUDY REPORT ON A STUDY REPORT ON PRODUCTION PRODUCTION

ANALYSIS OF PVC ANALYSIS OF PVC PIPESPIPES

ABSTRACTABSTRACTABSTRACTABSTRACT

COMPANY PROFILECOMPANY PROFILECOMPANY PROFILECOMPANY PROFILE

Sri S.P.Y.REDDY B.E(Mec) the founder and chairman of Sri S.P.Y.REDDY B.E(Mec) the founder and chairman of Nandi group of companies . Initially he started a small unit Nandi group of companies . Initially he started a small unit for manufacturing of L.D.P.E (Low Density Poly Ethylene for manufacturing of L.D.P.E (Low Density Poly Ethylene pipe), Later he developed the business by manufacturing of pipe), Later he developed the business by manufacturing of PVC pipes in the name of M/S Sujala pipes pvt.Ltd. At PVC pipes in the name of M/S Sujala pipes pvt.Ltd. At Nandyal in the year 1978 Soon,the company has become a Nandyal in the year 1978 Soon,the company has become a prestigious Nandi Group and has earned a high reputation prestigious Nandi Group and has earned a high reputation in the terms of producing and supply of most in the terms of producing and supply of most comprehensive range of quality PVC pipes suitable for comprehensive range of quality PVC pipes suitable for water transportation,irrigation,Drinage,electrical,plumbing water transportation,irrigation,Drinage,electrical,plumbing pipes in the last two decades .pipes in the last two decades .

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

In this company the pipes are manufactured by In this company the pipes are manufactured by the extrusion process . Extrusion is a continuous the extrusion process . Extrusion is a continuous process of converting the suitable raw material process of converting the suitable raw material into a product of specific cross section by forcing into a product of specific cross section by forcing the material through an orifice or by under the material through an orifice or by under controlling conditions. controlling conditions.

The company will manufacture the The company will manufacture the following types of pipesfollowing types of pipes

The company will manufacture the The company will manufacture the following types of pipesfollowing types of pipes

Electrical pipesElectrical pipes Plumbing pipesPlumbing pipes Casing pipesCasing pipes HDPE pipesHDPE pipes

Agricultural pipesAgricultural pipes SWR pipes and SWR pipes and

fittingsfittings SubmergibleSubmergible

The industry may include different The industry may include different streams likestreams like

The industry may include different The industry may include different streams likestreams like

1.Production1.Production

2.Maintanance 2.Maintanance

3.Quality control3.Quality control

ProductionProductionProductionProduction

Production can be as the transformation of raw Production can be as the transformation of raw material by manufacturing methods into useful material by manufacturing methods into useful and variable things needs to this society. and variable things needs to this society. Production planning is very basic step of Production planning is very basic step of manufacturing.manufacturing.

MaintananceMaintananceMaintananceMaintanance

““A professional Maintenance can be stated A professional Maintenance can be stated as keeping the machines running safely and as keeping the machines running safely and reliable and also always trying constantly to reliable and also always trying constantly to improve the Efficiency of the equipment”.improve the Efficiency of the equipment”.

Quality ControlQuality ControlQuality ControlQuality Control

Quality Control is a process employed to Quality Control is a process employed to ensure a certain level of quality in a ensure a certain level of quality in a product or service. product or service.

Fig 1.1: PLANT LAYOUT

Plant LayoutPlant LayoutPlant LayoutPlant Layout

Extrusion ProcessExtrusion ProcessExtrusion ProcessExtrusion Process

Extrusion process is used for manufacturing long and Extrusion process is used for manufacturing long and straight metal parts. Extrusion is done by squeezing the straight metal parts. Extrusion is done by squeezing the metal in a die by using a mechanical or hydraulic press. metal in a die by using a mechanical or hydraulic press.

Types of ExtrusionsTypes of ExtrusionsTypes of ExtrusionsTypes of Extrusions

Hot ExtrusionHot Extrusion

Cold ExtrusionCold Extrusion

Hot ExtrusionHot Extrusion

Cold ExtrusionCold Extrusion

Injection MouldingInjection Moulding

There are six major steps in injection There are six major steps in injection

moulding process. They aremoulding process. They are

Injection MouldingInjection Moulding

There are six major steps in injection There are six major steps in injection

moulding process. They aremoulding process. They are CoolingCooling Mold openingMold opening EjectionEjection

ClampingClamping InjectionInjection DwellingDwelling

ClampingClampingClampingClamping

An injection molding machine consists of An injection molding machine consists of three basic parts; the mold, the clamping three basic parts; the mold, the clamping and the injection units. The clamping unit and the injection units. The clamping unit is what holds the mold under pressure is what holds the mold under pressure during the injection and cooling. Basically, during the injection and cooling. Basically, it holds the two halves of the injection it holds the two halves of the injection mold together.mold together.

InjectionInjectionInjectionInjection

Dwelling Dwelling

Dwelling Dwelling

CoolingCooling CoolingCooling

The plastic is allowed to cool to its solid The plastic is allowed to cool to its solid form within the mold using water. to form within the mold using water. to maintain the required temperature maintain the required temperature difference between the mold the plastic difference between the mold the plastic material, water is circulated through holes material, water is circulated through holes and channels within the mold.and channels within the mold.

Mold OpeningMold OpeningMold OpeningMold Opening

After the cooling is completed, the After the cooling is completed, the clamping unit is opened, which separates clamping unit is opened, which separates the two halves of the mold.the two halves of the mold.

EjectionEjectionEjectionEjection

When a mould cools, it contracts by an When a mould cools, it contracts by an amount depending on material being amount depending on material being processed. For a solid rectangle block the processed. For a solid rectangle block the molding will shrink away from the walls of molding will shrink away from the walls of cavity.cavity.

PRODUCTION PRODUCTION PROCESSPROCESS

PRODUCTION PRODUCTION PROCESSPROCESS

RAW MATERIALRAW MATERIALRAW MATERIALRAW MATERIAL

The main components of preparing pipes The main components of preparing pipes are:are:

Poly vinyl chloride (Resin) [CH2=CHCL]Poly vinyl chloride (Resin) [CH2=CHCL] Master batch [This is combination of both Master batch [This is combination of both

Titanium dioxide, Carbon black and CA]Titanium dioxide, Carbon black and CA] One pack stabilizer [this consist of lead, One pack stabilizer [this consist of lead,

wax, steric acid.wax, steric acid.

Heating Mixture And CoolerHeating Mixture And CoolerHeating Mixture And CoolerHeating Mixture And Cooler

HopperHopperHopperHopper

ExtruderExtruder ExtruderExtruder It is used to extrude the pipe . They are It is used to extrude the pipe . They are

two types of extruders two types of extruders

1. Single screw extruder 1. Single screw extruder 2. Double screw extruder2. Double screw extruder

The Zones of screws are as followsThe Zones of screws are as follows

1.Feeding Zone 1.Feeding Zone 2.Compressing Zone 2.Compressing Zone

3.Decompressing Zone 3.Decompressing Zone 4.Degassing Zone 4.Degassing Zone

5.Mixing Zone5.Mixing Zone

DIESDIESDIESDIES

VACCUM CALIBRATORS&SPRAY BATHS

VACCUM CALIBRATORS&SPRAY BATHS

Cooling TowersCooling Towers Cooling TowersCooling Towers

In Pipe manufacturing plant water from the spay bath is cooled in cooling tower. So, that it can be reused in spay bath for cooling purposes

HAUL–OFF-DEVICEHAUL–OFF-DEVICE

Sensor/CutterSensor/Cutter Sensor/CutterSensor/Cutter A sensor is a device which senses the changes in A sensor is a device which senses the changes in

the physical quantity which is to be measured.the physical quantity which is to be measured.

SocketingSocketingSocketingSocketing

HEATING COIL HEATING COIL MANDREL MANDREL

REUSABILITY OF THE SCRAPREUSABILITY OF THE SCRAPREUSABILITY OF THE SCRAPREUSABILITY OF THE SCRAP

IIf any product does not satisfy the f any product does not satisfy the standard of the company (defective or standard of the company (defective or damaged) then it is termed as scrap.damaged) then it is termed as scrap.

Reasons for Formation of Reasons for Formation of ScrapScrap

Reasons for Formation of Reasons for Formation of ScrapScrap

Improper mixing of raw material.Improper mixing of raw material. Speed variation between Extruder unit and Speed variation between Extruder unit and

Haul off unit.Haul off unit. Discontinuous supply of cooling water.Discontinuous supply of cooling water. Fluctuations in power supply.Fluctuations in power supply.

Scrap can be reproduced by passing them through the grinders, pulverize.

SCRAPSCRAPSCRAPSCRAP

GRINDERGRINDERGRINDERGRINDER

PULVERIZERPULVERIZER PULVERIZERPULVERIZER

Advantages of PVC pipesAdvantages of PVC pipesAdvantages of PVC pipesAdvantages of PVC pipes

Pipe is lighter in weight & easy for Pipe is lighter in weight & easy for installationinstallation

Non corrosive , non toxic & chemical Non corrosive , non toxic & chemical resistance in natureresistance in nature

Better resistance of water hammer & Better resistance of water hammer & surge pressuresurge pressure

Uniform pipe dimension & threading with Uniform pipe dimension & threading with smooth inner diameter smooth inner diameter

Non conductivity of electricityNon conductivity of electricity

CONCLUSIONCONCLUSIONCONCLUSIONCONCLUSION

Thank YouThank YouThank YouThank You