Syllabus Structure for Certificate Course in

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1 Syllabus Structure for Certificate Course in Plastic Processing Machine Operations Industry Partner: M/S. Spectrum Polytech Pvt. Ltd, MIDC, Jalgaon W.E.F Year Sr. No Paper Name of Subject Theory/ Practical Teaching Hour Maximum Marks Allotted External (EE) Internal (IE) Total External (EE) Passing Internal (IE) Total Credit 01 Paper-I 02 Paper- II Plastic Processing Machine Operations Plastic Materials and Quality Control Theory Theory Paper- III Industry Training Practical Overall objective of the course: To achieve training in plastic processing operations, develop an understanding of basic engineering skills involved to manage the processing machines. Prepare the trainee to be able to conduct an analysis of defective moulded products and suggest remedial measures. Learning Outcomes: Participants shall be imparted with live hands-on skill training with Plastic Processing Machine Operations followed by Industrial Training; to help them develop necessary skill sets to Operation of plastic processing machines Skills in trouble shooting of defective moulded product along with exposure routine maintenance techniques would develop an operator capable enough to work in any plastic processing facility

2 PAPER-I Plastic Processing Machine Operations COURSE CONTENTS Unit 1 [25 Hrs] Injection Moulding Machine Operation: Introduction to Injection Moulding, Machine construction, Machine Controls & Instrumentation, Work Safety Precautions, Start-up & Shut down Procedures, Moulding Process Parameters, Mould Handling, Auxiliary Equipment Handling, Trouble Shooting Unit 2 [25 Hrs] Extruder Machine Operation: Introduction to Extruder, Machine Construction, Machine Controls & Instrumentation, Work Safety Precautions, Start-up & Shut down Procedures, Extrusion Process Parameters, Die Handling, Recycling of Plastics, Auxiliary Equipment Handling, Trouble Shooting Unit 3 [25 Hrs] Blow Moulding Machine Operation: Introduction to Blow Moulding, Machine Construction, Machine Controls & Instrumentation, Work Safety Precautions, Start-up & Shut down Procedures, Blow Moulding, Process Parameters, Die Handling, Auxiliary Equipment Handling, Trouble Shooting Unit 4 [15 Hrs] Compression Moulding Machine Operation: Familiarize with the process & machine, Work Safety Precautions, Start-up & Shut down Procedures, Mould Handling, Trouble Shooting

3 PAPER-II Plastic Materials and Quality Control Unit 1 [30 Hrs] Introduction to Plastics Materials: Understands the raw materials used in the manufacturing of plastic materials, Differentiate between Thermoplastic & Thermo set material, Understand the relevance of molecular weight & its effect on product properties, Understand various additives & the need for compounding Unit 2 [20 Hrs] Identify the Commodity & Engineering Plastics: Understand the difference between Olefin, PVC, Acrylic, Styrenics, Polyamide, Polyester (PET) Unit 3 [20 Hrs] Conduct inspection of plastic products & material: Understand basic plastics testing for performance evaluation & their identification, ii. Correlate the test results with spec., sheet iii. Correctly prepare samples for tests. iv. Understand operation and handling of testing equipment Unit 4 [20 Hrs] Tests: Study of physical, mechanical, electrical & thermal tests on given samples. Study of measuring instruments: micrometers, calipers, weigh scales, etc., Universal testing machine, Melt flow rate tester, impact tester, density meter and various Plastic product & Material samples

4 PAPER-III: INDUSTRY TRAINING [120 HRS] INJECTION MOULDING [25 Hrs] INJECTION MOULDING cycle from feeding to part ejection, Recognize screw configurations, Multi component moulding Screw & Barrel configuration, Tie-bars, Platens, Clamping mechanism, Ejector system Differentiate between types of heaters, thermocouples & controllers, Understands energy, conservation issues, Cooling water flow to mould and machine, Flow rate controlling devices, Pneumatic line circuit & devices., Trace hydraulic lines w.r.t. process Proper use of personal safety equipment, hot work & cold work permit, Recognizes heater, micro switches and machine guards ii. Power lines & their controls. Adjust temperature from feed zone to injection point, Adjust injection pressure, Identify runner, gate and clamping, Identify two plate, slider mould, hot runner mould, Identify and set up part ejection in the mould Handle air compressor, chiller, generator, Handles air drier for plastics(resin), Recognize the different defects and their causes EXTRUSION MOULDING [25 Hrs] EXTRUSION CYCLE from feeding to stacking of extruded product, Screw configurations, Single screw & Twin screw, Absence of feeding points Screw & Barrel configuration, Screw drives system, Die assembly set-up Differentiate between types of heaters, thermocouples & controllers, Understands energy conservation issues, Cooling water flow to mould and machine, Flow rate controlling devices, Pneumatic line circuit & devices Learn to recognizes machine controls, Identifies power supply sources, adjust temperature from feed zone to metering zone, Uses back pressure Identify breaker plate, mandrel, and torpedo, Identify spider die, coat hanger die Sorting of plastic waste, Crushing of waste, Feeding of recyclate

5 Handle air compressor, chiller, vacuum pump, generator, Handles air drier for plastics(resin) Recognize the different defects and their causes BLOW MOULDING [25 Hrs] BLOW MOULDING cycle from feeding to ejection of product, Extrusion Blow Moulded & Stretch Blow Moulded products e.g., PET, PP HDPE, PVC., Absence of injection points & parting lines, transparency defects Screw & Barrel configuration, Screw drive system, Die assembly set-up Differentiate between types of heaters, thermocouples & controllers, Cooling water flow to mould and machine, Flow rate controlling devices, Pneumatic line circuit & devices. Recognizes machine controls, Identifies power supply sources Learn to adjust temperature from feed zone to metering zone, Uses back pressure Identify mandrel, torpedo, die centering device Handle air compressor, chiller, vacuum pump, generator, Handles air drier for plastics(resin) Recognize the different defects and their causes COMPRESSION MOULDING [25 Hrs] COMPRESSION MOULDING: Identify production cycle from feeding to de-moulding of product. Understand the materials used for moulding. Trainee feeds and removes the products from the Differentiates b/w types of heaters, thermocouples & controllers mould Proper use of personal safety equipment. Hot work permit. Recognizes heater, micro switches and machine guards. Power lines & their controls. Types of fire extinguishers Recognizes machine controls. Identifies power supply & handle hydraulic circuit Assemble the mould & performs die cleaning procedures Recognize the different defects and their causes. Understand the effect of un-melted resin

6 PLASTIC MATERIALS & QUALITY CONTROL [ 20 Hrs] PLASTIC MATERIALS & QUALITY CONTROL: Identify the hydrocarbon structure and source plastics from oil & gas. Identify Crystalline & Amorphous plastics. Understand properties like density, specific gravity, melting temperature etc. Identify performance & cost reducing materials. Differentiate the plastic material w.r.t. application and structural properties Understand basic plastics testing for performance evaluation & their identification. Correlate the test results with spec., sheet. Correctly prepare samples for tests. Understand operation and handling of Testing equipment REFERENCE BOOKS: 1. Polymer Science Gowariker V.R. & others 2. Plastic Materials Hand Book A.S. Athalye 3. Injection Moulding Theory & Practice Rubin, Irvin. 4. Plastics Engineering Hand Book Socity of Plastic Industry Inc. 5. Plastics Processing Data Hand Book D.V. Rosato. 6. Plastics Materials & Processing Brent Strong 7. Text Book on Fundamentals of Plastics Testing - Prof. (Dr.) S.K..Nayak 8. Compression Moulding Iyesaw, A.I 9. Total Quality Process Control for Injection Molding, 2nd Edition, M. Joseph Gordon 10. Manuals on Hydraulics & Pneumatics Vickers 11. Plastics Moulds and Dies, Sors

Section N. Application Information. Thermal Manufacturing Solutions. Extrusion N-1. Injection Moulding N-2 N-3. Other N-4

Section N. Application Information. Thermal Manufacturing Solutions. Extrusion N-1. Injection Moulding N-2 N-3. Other N-4 Thermal Manufacturing Solutions Section N Application Information Extrusion Injection Moulding Other Electrical Heating Of Plastic Injection Molds Heating And Cooling Of Cores Electrically Heated Platens