Subject Code & Name: PT25405 – Plastics Processing – I
Regulation: R-2025
Semester: IV (Fourth Semester)
Branch: B.Tech. Plastics Technology (Plastics)
Credits / L-T-P: 5 Credits | L-T-P: 3-0-4
Course Objectives
- To understand various processing techniques of plastic materials.
- To learn the fundamentals of compression molding and transfer molding of thermoset plastics.
- To learn the basic processing of thermoplastics by injection molding, extrusion and blow moulding.
Full Unit-wise Syllabus
Unit I – Compression moulding
Basic principles of compression and transfer moulding- Meaning of terms-Bulk factor and flow properties as applied to moulding materials-The methods adopted for estimating these properties and their limitations Process variables- Inter relation between flow properties-Curing time-Mould temperature and Pressure requirements-Preforms and preheating-Techniques of preheating- Machines used- Types of compression mould-Common moulding faults and their correction- Finishing of mouldings.
Practical: Study of Hand compression M/c, Operating Principle of Hand Compression Press, mould setting procedure & parameter setting, operation practice on different compression moulds, M/c specification observations and recording
Activities: Analysis of relationship between flow properties and moulding conditions.
Unit II – Transfer moulding
Fundamental principles of transfer moulding-advantages over compression moulding- Equipment used-Press capacity-Integral moulds and auxiliary ram moulds-Moulding cycles-Tool costs- Moulding tolerances-Materials Theoretical calculation of pressures- Line pressures- Injection ram pressure-clamping-Heating requirements-Finishing of moulded parts—Moulding faults – causes and remedies.
Practical: Technical specification of M/c, Mould clamping on M/c, Parameter setting, operation- practice on different Transfer Moulds, Cycle-time analysis, observation & Procedure of start-up & shut down of M/c.
Activities: Identification of parts used in transfer moulding operations.
Unit III – Injection moulding
Principles processing outline - Process variables - Mould cycle - Machinery used – Parts and functions –Specifications - Construction and maintenance - Start-up and shut down procedures - Cylinder nozzles - Press capacity projected area - Shot weight Basic theoretical concepts and their relationship to processing - Interaction of moulding process aspect effects in quoted variables - Introduction to trouble shooting.
Practical: (i) Injection Moulding Semi-Automatic -Study of Semi-Automatic Injection Moulding M/cs of all types in IRO. Comparative study of Pneumatic type & Hydraulic type of M/cs, Operating Principle of M/cs. Line diagrams of M/cs with nomenclature of parts, M/cs specifications. (ii) Injection Moulding M/c.- Automatic- Study of M/c Parts & function, Study of clamping systems in M/cs, Technical spec. of M/c, study of process sequence in Machine, Study & definitions of terms related to M/c operation e.g. M/c Day light, Locating Ring Dimensions, ejector-stroke, Tie- Bar distance, M/c Platen sizes & mould clamping arrangements. Definitions of all Processing Parameters & study of controls in M/cs.
Activities: Study of injection moulding machine parts, functions, and specifications.
Unit IV – Extrusion
Basic principles of extrusion – Types of extruders, general features of extruders viz. barrel, screw, types of screws, drive mechanism, specifications, heating & cooling systems, flow mechanism, die entry effects and exit instabilities. Melt fracture & Bam- booing. Factors affecting the output of an extruder, process variables in extrusion Extrusion processes and the downstream equipments for the production of films, blown film, cast film/slot film, BO film, coextruded film. Tube/pipe-sizing take off equipment, extrusion coating, wire & cable covering –pretreatment of conductor, cooling, takeoff equipment constructional features of dies for the above processes and trouble shooting. Applications of extrusion and new developments.
Practical: (i) Study of Extruders in IRO, Free sketch of machines, their parts and parts-function, List of products manufactured by Extrusion-Process. Study of different types of extrusion process. (ii) Operation-Practice by Trainee on setting up of Process parameter to produce Blown-Film on Film-plant, observations on extruder output, size of film produced and technical specifications of machines to be recorded.
Activities: Identification of downstream equipment used in film and pipe extrusion lines.
Unit V – Blow Moulding
Basic principles and definitions- Processer – viz, Injection Blow moulding, extrusion blow moulding, Accumulation blow moulding, Merits & Demerits - Development of blow moulding industry Processing Parameters-Temperature-Pressure and cycle time Components – Materials requirements related to process and product performance- Materials used-Limitations in product design presented by process characteristics- Design guide lines for optimum product performance and appearance- Equipment used- Hand and power operated equipment. Screw and Plunger Systems- Cross head and die design-Blow moulding machine features and operation including hydraulic and electrical control systems-faults, causes and remedies. Parison programming, blow mould construction, cooling methods, mould venting, blow moulding of difficult articles like fuel tanks, odd shaped containers with handles, limitation in blow moulding, decoration of blow moulding products, hot stamping-multi colour printing- faults, causes and remedies.
Practical: (i) Study of Hand Blow Moulding, Free-sketch of M/c with parts & study of part-function, Specification of M/c, Study of Parison-die with sketch. (ii) Die-centering practice by Trainees, operation of Hand Blow Machines, to produce components observations, cycle time analysis Procedure of operation and observations
Activities: Study of materials used in blow moulding and their performance requirements.
Course Outcomes (COs)
- CO1: Explain the principles, process parameters, equipment, and applications of plastic processing techniques such as injection moulding, extrusion, and blow moulding.
- CO2: Apply and analyze compression moulding and transfer moulding processes for thermoset plastics and evaluate their suitability for different product applications.
Assessment Pattern (Quick Note)
- Weightage: Continuous Assessment 50% | End Semester Examinations 50%
- Internal methodology: Theory (30%), Practical (10%), Activities (10%)
Source: Official Anna University – B.Tech. Plastics Technology R-2025 Syllabus
Last Updated: October 2026
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