DEPARTMENT OF CHEMICAL ENGINEERING

KKEK3192: INDUSTRIAL TRAINING

SEMESTER 3 2016/2017
19TH JUNE 2017 25TH AUGUST 2017

FINAL REPORT

UNIGEL COMPOUNDS SDN BHD

(SUBSIDIARY OF OPCOM HOLDINGS BERHAD)
11, JALAN UTAS 15/7,
SHAH ALAM, 40200 SELANGOR DARUL EHSAN

NAME: MUHAMMAD SYUKRI BIN ABD RAHMAN

MATRIC NUMBER: KEK140024

SUPERVISOR: DR. MAHAR DIANA HAMID

COORDINATOR: ASSOCIATE PROF. DR. NGOH GEK CHENG
Disclosure

This is to confirm that I have read the report and that the information enclosed is
correct and contain no confidential information.

Company: ____________________________________
Supervisors Name: ____________________________
Supervisors Signature and Stamp:

Date: ____________________

1
Acknowledgement

I would like to express my utmost gratitude to everyone in Unigel Compounds Sdn.

Bhd. for their dedications in teaching and assisting me throughout the whole duration
of my industrial training here in this company. Their magnanimous contributions in
term of knowledges and skills had made my internship experience so much more
valuable that I had anticipated. A very incomparable and unique experience I believe
I would never get elsewhere.

Likewise, I would like to thank Associate Prof. Dr. Ngoh Gek Cheng who has been
there from the start and still all the way till now helping and assisting me to solve all
the problems emerged from this course. Subsequently, much thanks to Dr. Mahar
Diana for allocating time to visit and supervise my progress here in Unigel while
sharing engaging insights that helps me to connect the experience here with my
classroom learning, hence, making my internship here much more fulfilling.

Last but not least, undivided trust, understanding and helps from my family, friends,
course mates, seniors and intern mates are very much appreciated. Without them, this
internship would not be as meaningful as it feels right now.

Thank you and god bless.

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Table of content

Content
Disclosure 1
Acknowledgement 2
Abstract 4
1. Learning outcomes 5
2. Company overview
2.1 Company profile 6
2.2 Policy statement
2.2.1 Quality commitment 7
2.2.2 Vision 7
2.2.3 Objectives 7
2.2.4 Customers and product quality 7
2.3 Quality objectives 8
2.4 Organization chart 10
3. Overall system
3.1 System overview 11
3.2 Product overview
3.2.1 Thixotropic gel 12
3.2.2 Product classification and comparison 13
4. Laboratory
4.1 Laboratory overview 14
4.2 Research and development (R&D) 15
4.3 Quality assurance 16
4.4 Tests used for quality assurance
4.4.1 Visual test and flash point test 17
4.4.2 Viscosity test 18
4.4.3 Drop point test 19
4.4.4 Oil separation and volatile loss test 20
4.4.5 Cone penetration test 21
4.4.6 Oxidation induction time test 22
5. Production
5.1 Production overview 23
5.2 Material management
5.2.1 Petroleum-based oil 24
5.2.2 Thermoplastic rubber 25
5.3 Process control 26
5.4 Assisting in maintenance 27
5.5 Product labelling 28
6. Warehouse
6.1 Warehouse overview 29
6.2 Logistics 30
6.3 Packaging 31
6.4 Product labelling 32
7. Skill acquired 33
8. Conclusion 34
9. References 34

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Abstract

As a third-year student pursuing a bachelor degree in Chemical Engineering, I am

obligated to go for an industrial training to complete one of the prerequisite of this
course in the third semester, specifically from 19th June 2017 to 25th August 2017. This
program was meant to help in exposing myself to the real working life of chemical
engineer and any working scopes that are related to this course. Thus, I will be
equipped with hands-on experiences and new skills that I could use to polish my
understandings while expand my awareness towards the engineering industries. My
placement was a company that specialized in the production of thixotropic gel for optic
fibre cable filling and flooding compound, Unigel Compounds Sdn Bhd. This
company whom is a subsidiary of OPCOM Holdings Berhad, an optic fibre
manufacturing company, assigned Mr. Shamsul Amri Abdul Manaf to supervise me
for the whole internship period while Dr. Mahar Diana was assigned by Associate Prof.
Dr. Ngoh Gek Cheng to be my supervisor from the Chemical Engineering Department
of Engineering Faculty, University of Malaya. My generalized job scope in this
company was to be involved in the whole production process of the gel, starting from
the raw materials handling until the final product packaging. Along the way, I was
exposed in quality assurance, process control, logistics and a lot of related hands-on
experiences, valuable in every way, regardless of their respective fields. Thus, all the
information and knowledge gained during my internship here in Unigel and how the
new experience in this industry had help me for my own self development and future
preparation are shared in this report.

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1. Learning outcomes

At the end of the course, the student will be able to:

1. Apply ethics and professional engineering practice in working environment.
2. Investigate engineering issues in related field towards lifelong learning.
3. Identify public health and safety issues in relevant engineering working
environment.
4. Display team working spirit.
5. Demonstrate industrial related communication and presentation skills.
6. Formulate solutions for industrial related problems.
7. Examine the impact of engineering solution towards sustainable environment.

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2. Company overview

2.1. Company profile

Figure 1: Overview of Unigel Compounds Sdn. Bhd. principal and subsidiary companies.

Unigel Compounds Sdn. Bhd. or used to be known as OPCOM Niaga Sdn. Bhd. is one
of the subsidiaries of OPCOM Holdings Berhad and a partial owner of Unigel (UK)
Limited and Unigel IP Limited.
OPCOM Holdings Berhad whom entirely owns Unigel Compounds Sdn. Bhd. works
on building renting, provision of management services to subsidiaries and investment
holding.
Subsequently, the principal activities of Unigel Compounds Sdn. Bhd. is
manufacturing and sales of cable filling and flooding compounds while Unigel (UK)
Limited whom 40% owned by the former focuses on the same activities with addition
of associated pumping and delivery equipment. Likewise, Unigel IP Limited whom
also 40% owned by Unigel Compounds Sdn. Bhd. focuses on investment holding for
the company. The approximate share value owned by Unigel Compounds Sdn. Bhd.
for Unigel (UK) Limited is around RM11.65 million.
Unigel (UK) Limited and Unigel IP Limited are both incorporated in United Kingdom
and Hong Kong respectively. The current Chief Executive Officer for the company is
Mr. Eric Chhoa Kwang Hua.

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2.2. Policy statement

2.2.1 Quality commitment

Everyone in Unigel is 100% committed towards the quality and the customer service.
Moreover, quality is not just another goal, instead, it is a basic strategy for survival
and sustainable growth while moving forward to being the best in the industry as a
team.

2.2.2 Vision

Unigel embraces Total Quality Management (TQM). Pledging to satisfy the

customers requirement through continuous improvement process. Understanding that
TQM is long term commitment that aims to improve working methods while educating
and training people, providing safer workplace, managing the business processes and
selection and retention of supplier. Unigel also aims to expand the market to improve
job security and better quality of life for all.

2.2.3 Objectives

Unigel focuses to supply high quality products, right on time and at the lowest cost
possible for the customers. Also, Unigel will continue to improve each time an
objective is achieved to stimulate further quality improvement once recognized and
reset. Full dedication, commitment and teamwork will be instilled to maintain a
constant focus on quality while reaching for the objectives.

2.2.4 Customers and product quality

Unigel knows the identity of the customers and their needs and will always try to meet
and exceed their expectation. If any requirements are unclear, Unigel will try to gain
better understanding at any mean necessary. If failure occurred, Unigel must determine
the roots of the problem and ensure none of the problems will repeat themselves again.
Quality comes first before cost and schedule. Peers or superiors actions or decisions
can be questioned if they are somehow leading to reduction in quality of the products.

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2.3 Quality objective

There are total of eight measurable quality goals and objectives that concur with the
quality policy and overall needs of the organization which help in the efforts of
continuous improvement and enhancing customer satisfaction.

1. Delivery precision

The department of supply chain must ensure that the products shall always be
delivered precisely on time. Any delay must be kept as minimum as possible.

2. To improve customer satisfaction

Marketing department must measure the levels of customer satisfaction toward

the products and services. They also must ensure that the feedback forms are
prepared, distributed and collected by March 2018 and summarized by end of
April 2018.

3. Customer complaints handling

Marketing department and quality assurance department must keep the number
of complaints on delivered products physical defects as minimum as possible
during financial year. They also must ensure that the time taken from when a
complaint is received until a written acknowledgement is sent to the costumer
is within a working day.

4. To enhance supplier reliability

Supply chain department must ensure that there is zero stock out on delivery
precision of all supplied material, calculated as on time delivery.

5. Continuous improvement and innovation

Human resource and administration department must provide training session

for employees to upgrade their competence levels. This shall be done once a
year for each employee.

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6. Meet customer specification

Production department must ensure to achieve entirely against Purchase Order.

7. Minimize scrap

Excess material remaining after the manufacturing process including unviable

defect product must be kept as minimum as possible by the production
department.

8. To provide good quality service to support production

Engineering department must ensure seldom machines breakdown and totally

commit to the scheduled preventive maintenance.

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2.4. Organization chart

Figure 2: Organization chart for Unigel Compounds Sdn. Bhd. as of July 1, 2017.

Based on this chart which was created on July 1, 2017 and approved on July 11, 2017,
shows the overall institutional structure of Unigel Compounds Sdn. Bhd.
As of the later date, there were 16 people working under this company as direct
employees along with four support employees. However, from all of them, there were
around ten people I had worked with during my internship, excluding my fellow
industrial training students.
Furthermore, I was placed under the supervision of Operations Manager, Encik
Shamsul Amri Abdul Manaf whom would give out task order during daily roll call
early in the morning. Subsequently, I would be by then placed either under production,
warehouse or laboratory department for the rest of the day.

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3. Overall system

3.1. System overview

Figure 3: Department based flowchart for production of thixotropic gel.

The plant operates from 8:30 a.m. until 5:30 p.m. on weekdays and from 9:00 a.m.
until 1:00 p.m. every first week Saturday each month.
The whole production process of thixotropic gel only involves in physical reaction
instead of chemical reaction where the raw materials are heated up and mixed until
entirely homogenize.
The raw materials import and product exports are both locally and globally bound.
They are, however, required to undergo quality assurance tests before being proceeded
to the next assigned process. This is to ensure that only the best quality is received and
sold.
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3.2. Product overview

3.2.1 Thixotropic gel

Figure 4: Location of gel filling and flooding inside a fibre optic cable. (Loose Tube Fibre Optic Cable, A Furukawa
company, 2015)

So far, the only product made by Unigel Compounds Sdn. Bhd. is thixotropic gel.
However, this product is made using different formulations of which led to different
grades with different properties and is produced only upon customers demand for
their own specialize purpose based on the properties.
Thixotropic gel is a non-Newtonian pseudo plastic liquid with time-dependent shear
thinning property. It is highly viscous and exhibit few properties that are highly
beneficial for optic cables. These properties assist in ensuring the safety and working
efficiency of the optic cables.
These gels are produced as a filling and flooding compound inside a fibre optic cable.
Filling and flooding have a rather the same kind of function but differs in term of
location. Filling gel is applied in the cable core, meanwhile, flooding gel is applied
between the core wrap and the outer protective casing or housing. They are specifically
made to provide water and gas tightness for the cable in a wide range of temperature,
location and environment.

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3.2.2 Product classification and comparison

The formulations of the thixotropic gel are differentiated based on the petroleum-based
oil, antioxidant and antirust used for each formulation while are mixed along with
sustained type of material used for thickener and de-crystallizer. Different formulation
will be graded differently and will be produced solely based on customers demand.
However, under the same grade, there are also different formulations which are
differentiated by the materials used. Currently, these differences focused on the type
and percentages of antirust mixed in the formulation.

Table 1: Example of different formulations under same thixotropic gel grade.

Grade A
F-A F-B Tolerances
Oil X1A X1B 0.5 w%
Thickener X2A X2B 0.5 w%
De-crystallizer X3A X3B 0
Antioxidant X4A X4B 0
Antirust 1 X5A X5B 0
Antirust 2 - X6B 0
Total 100 100 -

Based on latest R&D, only petroleum-based oil was determined suitable to be mixed
with thixotropic gel and able to maintain it needed characteristics. The thickener is
used to turn the mixture into gel-like liquid and is made of polymer under category of
thermoplastic rubber. Antioxidant is used to prevent or retard the degradation of
material caused by ozone specialized for plastics and rubber. It is a derivative of
aniline. Antirust was added so that the cable metals that will be in contact with the gel
will not corrode.
Once the products are made, two samples of the gel are taken for testing before being
either approved or rejected for loading. Each sample is approximately 1 litre of gel
taken in metal tub.
The samples are tested based on the viscosity. If the viscosity is in the given range
provided by the company, the whole batch of the gel is approved. However, if the
viscosity is out of range, the whole batch of the gel will be reworked until the new
sample tested is within the needed viscosity range.

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4. Laboratory

4.1. Laboratory overview

Figure 5: Two ways of obtaining sample. Processing line 1 uses the first method (left picture) meanwhile
processing line 2 and 3 use the second method (right picture).

Laboratory mainly focuses on the enhancement of the product quality or maintaining

the ideality of the existing formulations. These are all can be achieved all the way from
conducting research and development process to the sample testing for quality
assurance.
This department also handles the complaint received from the buyers by retesting the
sample and hands the result over to the production and logistics departments for further
action.

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4.2. Research and development (R&D)

Figure 6: Mixer (left) and vacuum (right) used during research and development process.

Research and development process was done with purpose to keep up with the latest
technology in fibre optic elements and to find better formulation for thixotropic gel
using new and better oil available in the market.
If the new formulation created seems to be effective and economically sustainable after
a wide range of quality tests, the formulation will be drafted to undergo further
evaluation and consideration by the higher management.
Other than different type of oil, different percentage of oil used in formulation also
was done in R&D process as part of the same purpose.
The type of oil ranges all the way from oleo to petroleum-based oil. As far as these
processes go, it can be concluded that the petroleum-based oil is the most suitable oil
to produce thixotropic gel while oleo is the least one due to certain defectiveness
occurred such as oil separation at room temperature.

15
 4.3. Quality assurance

Table 2: Re-illustration and combination of two technical data sheets for different grades of gel.

Grade B Grade C
Properties Specifications Test Method Specifications Test Method
Appearance Translucent Visual White Visual
Color stability, 130 , 120 hrs < 2.5 ASTM D127 - -
Density, 25 (g/ml) 0.8 - 0.9 ASTM D1475 0.45 0.025 ASTM D1475
Flash point () 200 ASTM D92 > 200 ASTM D92
Drop point () 150 ASTM D 566-93 > 190 ASTM D 566
Cone penetration, 25 (dmm) 350 ASTM D 217 401 20 ASTM D 217 (M)
Cone penetration, -40 (dmm) 230 ASTM D 217 > 160 ASTM D 217 (M)
Viscosity, 50 s-1, 25 (Pa.s) 4.3 - 6.3 CR Ramp 0-100 s-1 35 - 55 UNIGEL CR Ramp 0-12 s-1
Oil separation, 150, 24 hours (Wt %) 0.8 FTM 791(321) Zero FTM 791-321 (M)
Volatile loss, 150, 24 hours (Wt %) 1.0 FTM 791(321) < 1.0 FTM 791-321 (M)
Oxidation OIT, 190 (min) 30 ASTM D3895 > 30 ASTM D3895
Acid value (mg KOH/g) - - < 0.3 ASTM D974-85
H2 generation, 80, 24 hours (l/g) 0.1 UNIGEL 0.02 UNIGEL
Water resistance, 20, 7 days - - Pass SH/TO453
Fungal growth Nil BS 5980 Nil BS 5980
Relative permittivity, 1 MHz, 25 - - 0.8 ASTM D150
Volume resistivity, 23 (ohms.cm) - - 19x1014 ASTM D257
Dissipation factor, 1 MHz - - 4.4x10-4 ASTM D924

Table 2 illustrates some kind of quality benchmarks for two of their products which
were drafted by the laboratory for quality assurance purposes.
Upon receiving the sample from the intended processing unit, this sample will be tested
and compared according to their specifications. If the result lies within the needed
range, the product will be a go for packaging and export. However, if not, the gel will
need to be reworked until it reaches the desired properties.
Sample testing for approval can either be instantaneous or delayed. This may be caused
by the procedure needed for each test or it necessity in the production itself. All of
which affected from buyers demand and process economy.
So far, most prominent test is the determination of product viscosity. This test is also
the only instantaneous test that decides if the product is ready to be discharged for
packaging or in need for reworking. The rest however, due to their procedures or/and
necessity in the production, will be ran later or upon which they are critically needed.
E.g.: upon receiving complaint.

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4.4 Tests used for quality assurance

4.4.1. Visual test and flash point test

Figure 7: Equipment used to determine the flash point of newly arrived oil.

Flash point test is run each time new petroleum-based oil arrives. Apart from visual
test using evaluator owns naked eyes, this is one of the compulsory procedures to
determine whether the oil is suitable for production or the other way around. If the test
gives a positive result, the oil is then ready to be discharged from the oil tank into the
designated containers. Meanwhile, if the result is negative, the oil will be sent back to
the supplier and a new batch of oil will be delivered as earliest possible to avoid any
delay in the production.
The benchmarks for visual test consist of the colour of the oil and the presence of any
unwanted debris inside the liquid whilst for flash point test, the most common and
averaged benchmark would be the temperature where the oil started to burn,
approximately at least at 220.

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4.4.2. Viscosity test

Figure 8: Rheometer used to run the viscosity test.

Viscosity test is considerably the most crucial test of all the tests during production
process. This test is the ultimate go or no for the production process of the gel and
the discharging process of the gel into designated containers. This property correlates
itself to other properties that the viscosity test itself is enough to be the one who speaks
first for the whole production process before other tests provide more detailed
information on the gel produced.
As exampled in the table 2, if the viscosity of the gel produced falls into the provided
range, the process is a go and the gel is ready to be discharged. Meanwhile, if it is the
other way around, the gel need to be reworked until its viscosity falls into the range.

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4.4.3. Drop point test

Figure 9: Depiction of ongoing drop point test process.

Drop point test aims to determine the melting point of the gel. This was done by filling
the gel into a small semi-sphere container with holes at the larger part of the semi
sphere and another at the tip of the container. The gel is formed into a cone shape and
placed inside a test tube. The test tube is then submerged inside silicone oil placed
inside a larger beaker. Two thermometers are used in this process. One is placed inside
the test tube, slightly above the gel container, meanwhile, another one is submerged
into the silicone oil.
The silicone oil is then gradually heated with help from magnetic rotator to
homogenize the heat distribution through the oil and to increase the efficiency of heat
transfer from the silicone oil to the gel container. Once the gel melt and drop through
the hole at the tip of the cone, both reading of the thermometers are taken and the
average is calculated.
+
=
2
Where,
Tdp = drop point temperature,
Ttt = test tube temperature,
Tso = silicone oil temperature.

The averaged drop point temperature for these gels would usually be around 200. If
the gels started to drop below their own specific temperature, the gels are presumably
considered as failed products.

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4.4.4. Oil separation and volatile loss test

Figure 10: Depiction of the apparatus coordination. Before test (left), the oven used (middle) and after test (right).

This test determines whether the gel produced will discharge oil under extreme
condition. Referring to table 2, a sample with amount between 9.8 to 10.2 grams will
undergo 24 hours heating process at temperature more than 100. Subsequently, the
quality of the sample will then be evaluated visually to determine oil separation while
physical evaluation was done to determine volatile loss.
Visual evaluation consists of checking whether there is a present of yellow liquid at
the bottom of the beaker or/and any leakage from the porous cone occurred after the
process. If there is a leakage occurred as depicted in figure 10, the test is still
considered pass but this shows that the gel is not at its highest quality. However, if
there is a yellow liquid discharged at the bottom of the beaker, the gel is considered a
failed product due to the occurrence of oil separation.
For volatile loss test, the weight of the gel along with the apparatus are weighted for
before and after test. If there is a weight differences, this shows that the gel had
evaporated during the heating process. However, if the evaporation amount is still
below the specified maximum value, the gel is still considered an ideal product to sell.

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4.4.5. Cone penetration test

Figure 11: Depiction of a tub containing thixotropic gel undergoing cone penetration test.

To be working at full capacity, the gel must withstand any harsh condition including
cold weather. Thus, due to this factor, the gel is formulated with antifreeze to stop it
from turning solid under cold weather of which can cause the fibre optic cable to break
easily. To test the probability of this condition to occur on the gel, cone penetration
test is done to every batch of gel produced by the company.
The gel is placed inside a designated tub and stored in a freezer for 24 hours at the
temperature approximately around -40. The tip of the cone is then placed slightly
above the gel before the whole cone is released and fell into the liquid.
The best indication on the quality of the gel would be when the cone falls as low as it
can be. This shows that there is not much of resistance caused by the frozen gel and
the gel manages to stay in liquid phase even after undergoing extremely cold
temperature exposure.
This test is also done at room temperature (25) to make sure that the gel is behaving
ideally at the particular condition and also to act as a benchmark used to be compared
with the test at the extreme condition. The gel at the normal condition must never be
defrosted or heated before this test is done.

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4.4.6. Oxidation induction time test

Figure 12: Equipment used for oxidation-induction time test.

Oxidation of the gel can cause severe deteriorations toward the mechanical strength
and electrical properties of the fibre optic cable. Hence, this negative perpetration need
to be detected and contained before any unwanted effect happened.
This detection process can be done by running an oxidation induction time test using
equipment as in figure 12. This equipment works by heating a sample with weight
between 9.5 mg to 10.5 mg under Nitrogen atmosphere at temperature of 190. The
atmosphere is then changed to Oxygen. Upon this change, the time from the gas change
to the observed exothermic peak is observed. During this brief, the oxidation time is
measured.
This process runs for 100 minutes with both Oxygen and Nitrogen flow at the rate of
50 ml/min.

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5. Production

5.1 Production overview

Figure 13: Simplified illustration of the common pathways for the whole production process.

Production department involves mainly on the formulation of thixotropic gel.

Handling materials starting from their raw and unmixed conditions until the formation
of the final product. This department need to make sure that the product produced
follows the formulation provided by the company and any other production standards
and regulations set by the law. This department is also in charge in minimizing cost,
safety regulations and any other task that helps to ensure the plant wellbeing along
with its workers.

5.2 Material management

When it comes to raw materials, some of them can be stored inside common containers
and can be easily handled as usual. However, there are also some of the raw materials,
which will be specified below, need to be stored inside their own specialize container
or be prepared for production differently from their own consanguine due to certain
factors.

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5.2.1 Petroleum-based oil

Figure 14: Storage tanks (left) is used to store Korean oil while IBC container (right) is used to store Qatar oil.

Currently, there are two main petroleum-based oils used in the formulation of Unigels
products of which both are stored in different type and size of containers due certain
factors. The two oils are represented as Qatar oil and Korean oil.
The storage tanks that store Korean oil are made of metal and large in capacities.
Meanwhile, the IBC containers that store Qatar oil are made of plastic-polymer type
of compounds and critically smaller than the storage tanks.
Although around 15 IBC containers are used to store Qatar oil for each batch arrived.
The factor on the bulkiness of oil ordered for production can still be included as part
of storage selection factor and furthermore be considered as the main factor due to the
summation of all the IBC containers capacities used for Qatar oil is still way less than
a storage tank for Korean oil. One IBC container can hold around 500+ kg liquid,
while, one storage tank can hold around 24000 litres of liquid with weight
approximately around 24 metric tons.
Other factors that can be considered are the composition of oils that affect their
physical and chemical properties and the quality of oil.

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5.2.2 Thermoplastic rubber

Figure 15: Grinding process of thermoplastic rubber.

Thermoplastic rubber is a type of polymer used as a thickener to turn the mixture into
a gel. There are two brands used by Unigel for thickener, of which both are made from
the same compound.
However, the polymer from one of the brand need to be grinded first before being
loaded into the processing tank. This is because the polymer from that particular brand
are somehow harder and more compact than the other one.
Potential reasonings of this condition could be due to the packaging of the polymers
and their qualities. Polymer that needed grinding is packed using plastic while the other
brand is packed using paper. These packaging may cause different electrostatic
interaction between the polymer particles of which the plastic packaging might has
higher attractive electrostatic force, hence, making it more compact and harder to
break.
Difference in the quality of the polymer from both brands, undetermined which one is
better or lesser, could also be a considering factor of why one brand is harder while
the other is softer.

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5.3 Process control

Figure 16: A re-illustrated image of the storage tank system for Korean oil.

Supervisory control and data acquisition (SCADA) software is used for the whole
production process. Starting from Korean oil storage tank to the final gel discharging
process into the drum barrels or IBC containers. The software controls most physical
properties such as volume, temperature, pressure and weight.
However, as the storage tanks in figure 17 are located outside of the plant, while the
control room is in the inside, manual control had to be implemented in the time of
short-staffed. One way is that, a translucent pipe was installed on each tank to
determine that the lower tank is about to overflow. Once the pipes indicate the said
situation, the valve above the lower tank is closed so the oil can be filled inside the
higher storage tank. Optimum volumetric usage for each tank is around 95% to avoid
overflow and over-pressurized tank conditions.

26
5.4 Assisting in maintenance

Figure 17: Maintenance on air spray gun piping system.

As according to the eighth 2.3 Quality objective, maintenance is critically needed to

be at constant alert to avoid any machine breakdown that can adversely affects the
production process. Thus, scheduled maintenance is set up to prevent such problem
from having any fortuity to occur.
Maintenance also helps in making ease of the production process by providing easier
and user-friendly system for the workers in the plant. Thus, this inadvertently helps in
increasing the efficiency of the production process.
Being a part of this task somehow gave me a chance to correlate the smaller details
into a bigger picture. It also made me realise that everything matters even to the
smallest feature and helps to complete each other in ways that are systematic and
organize.

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5.5 Production labelling

Figure 18: The position of labels for both production and warehouse departments on a re-illustrated drum
barrel.

Figure 19: Re-illustrated and generalised version of production labelling.

Production labelling solely focus on the product details. This helps to avoid reopening
of the barrel drum in case of product confusion occurred after packing. The labelling
process usually was done after the product is loaded into the drum barrels or IBC
containers or before the lid of the drum is sealed and locked.
QR code printed along with the label directs the scanner to the batch number of the
product when scanned. In a way, this feature provides confirmation and security for
the customers while inadvertently, makes their logistics procedure much easier.

28
6. Warehouse

6.1 Warehouse overview

Figure 20: Depiction of oil discharging process. The cable is disconnected from the hose that is used as an inlet
to storage tanks.

Warehouse mainly focuses on pre-and post-production process. They are usually

involved partially in documentation and entirely in physical work for raw materials
import and product exports.
For pre-production process, upon receiving the raw materials, especially, the
petroleum-based oil, warehouse will start to discharge the oil to the designated
container (IBC or storage tanks) once the laboratory has proven the quality of the oil
to be satisfying. If not, they will need to send back the oil to the supplier and arrange
for new oil arrivals at the earliest.
Meanwhile, for post-production process, warehouse would pack the barrel drums or
IBC containers and load them into the container lorry for global export. They would
also put another label on those products that specify mainly on the export process and
comply to the regulations made by the customers, company and the Malaysian
customs.

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6.2 Logistics

Logistics mostly handle the documentations of the raw materials import and products
export. Both of which are connected globally and locally toward this company.
The raw materials are commonly imported from Korea, China and USA for petroleum-
based oil and thermoplastic rubber. Meanwhile, the products are exported to fibre optic
cable manufacturing companies nationwide. Some of the countries Unigel had their
exports to are Indonesia, India, Australia, Russia, United Emirates Arab and USA.
Locally, these gels are mainly ordered by the sister company, OPCOM Cables Sdn.
Bhd., and a cable company in Penang.
Even before the products are packed and until to the extent of products loading into
the container, logistics must make sure that the warehouse labelling is tally to the
product being produced (grade, batch number etc) by the production department while
getting up to date with the requirements and changes made by the company, customers
and the Malaysian customs.
In any case of error in this section, the products will be barred from shipping by the
customs and the products will be subjected to complex procedures for passing process.

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6.3 Packaging

Figure 21: Completely packaged barrel drums ready to export (left) and the arrangement of the drums inside
the container lorry(right).

Before export, product packaging is one of the most important processes and need to
be attended with careful manners. This procedure ensures the safety and security of
the product during shipment.
Compared to IBC containers, barrel drums have a far more complicated packaging
procedure as depicted in figure 22. This is due to the complex approach needed to
make sure that the barrel drums stay together on the pallet without sliding through or
getting apart during travel.
The procedure starts with the metal straps are strapped around the drums horizontally
while the drums are then strapped to the pallet vertically using a specialize tool. This
procedure is used to bring the drums closer to each other and in the meanwhile, helps
to lock the drum to the pallet respectively.
Next, after ensuring that the warehouse labelling is pasted onto the drums, the strapped
drums are then wrapped using a translucent plastic wrapper as final protective layer.
This somehow helps to keep the metal straps from getting loose in the case of
unexpected turbulence and to prevent the drums from getting scratched during
delivery.
Finally, the fully packed drums can now be loaded into the container lorry and ready
to be exported nationwide.

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6.4 Product labelling

Figure 22: Re-illustrated example of warehouse labelling.

Warehouse labelling solely focus on the logistics of the product. The details of the
label usually consist of what already is inside the production labelling but added with
buyers details and demanded amount of barrel drums or IBC containers. Analysis of
these labels can generate so much information such as potential market and
optimisation of future productions.
The labelling process usually was done after the product is loaded into the warehouse
or before the drums are wrapped for export.

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7. Skill acquired

I. Self-discovery initiative

Inquiring direct employees and text book learning can only go so far. Thus,
due to these limitations, I started to develop a self-discovery initiative in search
of ways to fill in the gap between information so that I could gain complete
understand of the system I was aiming to learn. E.g.: checking the control
system myself to understand the whole production process of the gel and
correlate them to the lab scale gel making process (R&D process).

II. Adaptive work skills

Adaptive work is the change in method or strategy when the existing one is
unfitting to the current situation. This requires problem analysis on the existing
solution which lead to new learning. I gain quite an increment in this skill when
I was working the warehouse where my capability to do the physical work was
limited. Thus, some of the works were made easier after certain levels of
observation and try and error analysis.

III. Basic laboratory analysis grasp

When I was assigned in the laboratory, I was introduced with several

equipment and laboratorial procedures in an instant. This situation was very
different as compared to what I had faced in university where I was given time
to study only an equipment each time and yet was further familiarized by the
technician through assisted learning. However, during this internship, I
somehow gain better efficiency in grasping information related to laboratory.
This would surely benefit in a long run especially during my final year research
project period.

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8. Conclusion

In conclusion, this 10 weeks of internship provides me with such an eye-opening

experience and a highly valuable insight of what I might face in my future career as a
chemical engineer. To quote Rita Mae Brown, an Emmy-nominated screenwriter,
Good judgment comes from experience, and experience comes from bad judgment.
I believe that experience truly is the best teacher of all no matter how they came or
from who they came from. Thus, from this experience, it made me realizes that
everyone must equip themselves with a bit of everything when running something as
huge as a chemical plant. This is considerably important to avoid delay or malfunction
in the system or organization when a sudden uncertainty comes unsuspecting.
Consequently, it made me more appreciative toward every knowledge that I gained
during internship regardless whether they are a part of chemical engineering or any
other fields. Undoubtedly, a knowledge today could become a valuable experience
tomorrow.

9. References

[1] Cable Filling / Flooding Compounds. (n.d.). Retrieved August 1, 2017, from
http://www.marcusoil.com/product/cable-filling-flooding-compounds/
[2] Guillaume-Koene, E. (2016, November 1). Six Principles for Leading
Adaptive Work. Retrieved August 05, 2017, from
http://network.crcna.org/classis/six-principles-leading-adaptive-work
[3] Lakshmanan, P. R., & Tayebianpour, A. (June 5, 1995). U.S. Patent No. 5 728
754. Washington, DC: U.S. Patent and Trademark Office.
[4] Malaysia's Opcom to buy 40% stake in UK supplier Unigel. (2014, July 31).
Retrieved August 02, 2017, from
http://www.thestar.com.my/business/business-news/2014/07/31/opcom-to-
buy-strategic-stake-in-supplier/
[5] Organisation Structure. (n.d.). Retrieved August 2, 2017, from
http://www.opcom.com.my/corporate-information/corporate-
information/corporate-structure
[6] Oxidation Induction Time Measurements by DSC [PDF]. (1988, October).
Tokyo: Hitachi High-Tech Science Corporation.
[7] Technical characteristics of fiber optic cable [PDF]. (2015). Ofs Sviazstroy- 1
Fiber Optic Cable Company.
[8] Unigel Compounds Sdn Bhd: Company Profile - Bloomberg. (n.d.). Retrieved
August 02, 2017, from
https://www.bloomberg.com/profiles/companies/1359964D:MK-unigel-
compounds-sdn-bhd

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