EXTRUSION MACHINE OPERATOR (PLASTICS)

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1 Syllabus for the trade of EXTRUSION MACHINE OPERATOR (PLASTICS) Under APPRENTICESHIP TRAINING SCHEME Government of India Ministry of Labour & Employment (D.G.E.&T.) CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN Block, Sector V, Salt Lake City Kolkata

2 List of the Trade Committee Members designed and approved the syllabus for the trade of EXTRUSION MACHINE OPERATOR (PLASTICS) under Apprenticeship Training Scheme. Shri S.D. Lahiri Director C.S.T.A.R.I. Kolkata SL. NO. NAME & DESIGNATION ADDRESS REMARKS 1 Shri L.K. Mukherjee C.S.T.A.R.I. Kolkata Chairman Deputy Director 2 Shri J.S. Jain M/s. Jain Irrigation systems Member Production Manager ltd. Jalgaon 3 Shri D.G. Desuza M/s Supreme Industries Ltd. Member Works Manager Jalgaon. 4 Shri DF.P. Kelkar M/s. Winley Polymers, Member Jalgaon 5 Shri Ajanadkar Vinod M/s. Soham Electroplast, Member Jalgaon 6 ShriA.R. Deshpande M/s Supreme Industries Ltd. Member Dy. Manager Jalgaon. 7 Shri K.K. Kharul M/s. Jain Irrigation systems Member Manager Extrusion ltd. Jalgaon 8 Shri Harish Yadav M/s. Shaguan Ployplast, Member Partner Jalgaon 9 Shri B.J. Patil I.T.I. Jalgaon Member Principal 10 Shri T.G. Milmile B.T.R.I. Member Jr. Surveyor I.T.I. Jalgaon 11 Shri S.B. Sardar C.S.T.A.R.I. Kolkata Member Training Officer 12 Shri R.N. Manna Training Officer C.S.T.A.R.I. Kolkata Member

3 General information Name of the designated trade : Extrusion Machine Operator (Plastics) N.C.O. Code No. : Qualification Duration of the Apprenticeship Training Rebate in Apprenticeship Training : Passed 10 th class under 10+2 system of education or its equivalent. : Two years : One year & six months Broad Based Basic Training in Plastic Processing Sector under Centre of Excellence Scheme and Advanced module of Centre of Excellence Scheme in Extrusion Process. Ratio of Apprentice to Workers: : 1:3 Terminal Behavior: : On completion of the training the trainee is able to work as an operator in any Plastic Processing Industries. Course Outline The training shall comprise of - a) On the job training The actual training shall be depended on the facilities available in the establishment, with an idea to expose the trainees to as many activities as possible. The trainees shall maintain a daily work diary for the on job training, which shall be periodically authenticated by the supervisor. b) Project Group / Individual apprentice shall under take a project in any of the areas depending on his/her interest and facilities available in the establishment. The duration of the project shall be four weeks.

4 Syllabus for the Trade of EXTRUSION MACHINE OPERATOR (PASTICS) Under Apprenticeship Training Scheme (ATS) Practical Training: SIX-MONTH DURATION SL NO SHOP FLOOR SKILLS RELATED INSTRUCTIONS 1 SAFETY AT WORK: - Carry out safe working practices on the shop floor. Demonstrate the use of safety devices. Occupational Hazards and safety measures related to the trade. Introduction about environment and environment management system. Environment pollution and mechanics role in minimising the same. INTRODUCTION Trade development and roll of trade in plastic industries. Importance of the trade in the development of industrial economy in the countrywide and worldwide. SAFETY & PRECAUTION: - Safety at work Accident do not happen, they are caused. Fire precaution. Causes and type of fires. Precaution against outbreak of fire. Fire extinguisher, type and uses. Rules and safety precaution related to plastic processing machinery and equipments. Occupational Hazards and safety measures related to the trade. Introduction about environment and environment management system. Environment pollution and mechanics role in minimising the same. Revision of the work of previous year. 2 EXTRUSION PROCESS: - EXTRUDER: - Study of extruder machine, lay outing sketch, main parts and respective functions to be observed. Operation & controls of extruder machine in IRO Operation and controls of extruder machine in TRO using various plastic. PLASTIC MATERIAL: - Today s and in future development in plastic material field. Common plastic used in extrusion process wise grades and behaviors. Common acronyms in the plastic field likes materials and compound, additives, processing. Designing and tooling, testing and quality control trade name etc. Definitions and terms used in plastic process.

5 3 BLOWN FILM EXTRUSION PLANT :- Installation and commissioning of blown film extrusion plant. Lay out and line diagram. Setting up of process parameter to produce blown film and observation to be recorded likes Different zone temperatures, screw speed, nip roller speed, winder speed, blow ratio, bubble cooling air pressure, etc. Methodology and practice by trainees to fix the blown film die on extruder machine. Procedure of replacement of screw and cleaning. Procedure of die setting on the machine. Dismantling and assembling practice of die. Procedure for setting up parameter and operation. Practice in running the machine in TRO to produce various sizes of blown film using various grades of plastic. Processibility of plastic material Processing techniques of plastic material. EXTRUSION PROCESS. EXRTUDER :- Working principle, design construction fundamentals. Classification of extruder; specification rating and selection. EXTRUDER SCREW GEOMETRY :- Extruders designed for different plastic raw material. Type of screw according to required single thread screw, double thread screw(barrier), Maddox screw, twin screw, vented screw. Single screw extruder :- Design sketch, Technical specification, different temperature zone, barrel, simple screen pack Automatic hydraulic operated screen pack, breaker plate, die design, extrudate swell, melt fracture, etc. Twin screw extruder :- Types of TSE main features of TSE, performance advantages over other screw. Concept of counter rotating non intermeshing ( CRNI ), intermeshing counter rotating ( ICRR ), co rotating intermeshing (CORI) related to twin screw extruder. 4 EXTRUDER DIE: - Introduction, development latest technology. Design view, their parts and functions. Classification of die; comparison between single layer and multi layer extrusion die.

6 5 6 PIPE / TUBE EXTRUSION :- Study to layout sketch and entire line diagram. Setting up process parameter and controls. Practical exposure of die setting and precautions. Replacement and cleaning procedure of pipe die. Practice and produce various sizes of pvc pipes / tubes. MAINTENANCE OF EXTRUDER DIE AND PLANT :- Study to check point extruder machine and Auxiliary equipments. Starting and shut down procedure daily and periodical checkups. Faults, causes and remedies in entire plant. Preventive maintenance. Break down maintenance and precautions. Die head, automatic hydraulic operated screen changer, die heater / barrel heater types, cooling methods used. DIFFERENT EXTRUSION PROCESS PLANT :- Introduction repaid development. Technology to days & tomorrow, various type of extrusion process. Pellet sing line with water ring die face cutter. Vented extruder line with die face cutter. Vented extruder line with air ring die face cutter. FILM EXTRUSION :- Types & specification requires. Blown film, Flat film, cast film, tubular quench film ( TQ ), expanded film, co extruded film & sheet etc. Die used according to process and sizes. Material used, specification, Maintenance, handling and precautions. Orientation of film, corona treatment, printing cutting, sealing & decoration. Processing parameters, operating controls. Process faults, causes and remedies. PIPE / TUBE EXTRUSION PROCESS. :- Introduction, development different features. Construction & operation Pipe extrusion line according to various material & sizes. Sizing method, take off method & post operation method. Pipe extruder die, constructive feature, size and specification. Latest development in die technology. Process fault, causes and remedies Maintenance programmes.

7 7 RECYCLING PROCESS OF PLASTIC WASTE: - Study different method & machinery uses for recycling process of plastic waste material. Machine study in IRO, specification, main parts and function. Line diagram of machine Daily start up and shut down procedure, precautions. Operation procedure & process techniques of recycling of various plastic waste materials. Output study for different plastic waste. Testing & quality control: - Testing of mechanical properties Electrical / thermal / chemicals. Identification of various plastic in relation to properties. handling unit etc. 8 TESTING & QUALITY CONTROL: - Testing method, testing equipments, product dimensions. Finishing, Statistical process control (SPC) Statistical quality control (SQC), ISO, ISI. TQM, TPM, Process record 9 Entry and upkeep of log sheet, trouble log. Review and case study. Examination. GENERAL MACHINERY 1. Pipe extrusion machine 2. Extrusion for Blow film single layer 3. Printing Machine with oxidizing Treatment nut 4. Moulds/die and accessories SPECIAL EXTRUSION PROCESS. Introduction technology development. Corrugated pipes. Double walled corrugated pipe products. Reinforced flexible hosepipes. Tapes, woven sack, monofilamentmanufacturing process. REPROCESSING CYCLE: - Introduction, Technology development. Preprocessor plant location. Method of reprocessing. Over view on advance method precautionary measures in reprocessing cycles at different level. UTILITY: - Agglomerator, pulveriser, low speed / high mixer, grinder, cutter, chilling unit, material up keeping. Review and case study. Examination.

8 Examination Scheme for EXTRUSION MACHINE OPERATOR (PLASTICS) S.No Title Total Marks Minimum Marks PRACTICAL 1 Project work based on Practical Training in respective Industry Marks Obtained Practical Test /Viva based on Practical training in Respective Industry Theory Total

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