INDUSTRIAL TRAINING REPORT

WAN CHENG PLASTIC INDUSTRIES SDN BHD

AMIRUL IZAN BIN MOHD MANSOR

BACHELOR OF CHEMICAL ENGINEERING

(ENVIRONMENT) WITH HONOURS
UNIVERSITI TEKNOLOGI MARA
2017
 INDUSTRIAL SUPERVISORS CERTIFICATION

I declared that Ive read this report and in my point of view this report is qualified in
terms of scope and quality for completion of Industrial Training

Signed :
Date : ..
Industrial Supervisor
Mr. Lim Ti Seng
Assistant Operation Manager,
Wan Cheng Plastic Industries Sdn Bhd
1198, Jalan Maklom, Sungai Dua,
13800, Butterworth, Pulau Pinang

Accepted:

Signed :
Date : ...
Industrial Training Coordinator (EH224)
Norhusna Mohamad Nor
Faculty of Chemical Engineering
Universiti Teknologi MARA
Cawangan Pulau Pinang
13500 Permatang Pauh
Pulau Pinang.
 Acknowledgement

First of all, I felt thankful to Allah for the opportunity to gain working experiences from
this industrial training. I would also like to express my gratitude and appreciation to all those
who gave me the possibility to complete this industrial training report. Special thanks is due to
my supervisor Mr. Lim Ti Seng whose help, knowledge and experience sharing and
encouragement helped me throughout the industrial training period and also to complete this
report.

The experiences from such a huge company like Wan Cheng Plastic Industries Sdn. Bhd.
is very valuable for a graduate that will start working later. Therefore, I would like to thank to
the management of Wan Cheng Plastic Industries Sdn. Bhd. For accepting me as an industrial
trainee at Wan Cheng Plastic Industries Sdn. Bhd.

The supports from Faculty of Chemical Engineering in UiTM Penang is incomparable

as their will in ensuring all the students are able to complete industrial training and study on
time. They tried their best to help and ease the industrial training application process. The
supports from families and friends also appreciated since it become my motivational to complete
my industrial training and study.

I also gratefully acknowledge the assistance of everybody especially my family and my

fellow friends who helped directly and indirectly in the completion of this industrial training at
Wan Cheng Plastic Industries Sdn. Bhd. because without all the helps and supports, I will not
have achieved what I have today.

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 Table of Contents

Acknowledgement ...................................................................................................................... 1
Table of Contents ........................................................................................................................ 2
Executive Summary .................................................................................................................... 3
Chapter 1 : Introduction ..................................................................................................... 4
1.1 Company Background .............................................................................................. 4
1.1.1 Introduction ....................................................................................................... 4
1.1.2 Company Scope ................................................................................................ 4
1.1.3 Company History .............................................................................................. 6
1.1.4 Organization Chart ............................................................................................ 7
1.2 Job Scopes ................................................................................................................ 8
1.3 Industrial Training Gantt Chart ................................................................................ 8
Chapter 2 : Industrial Training Activities .......................................................................... 9
Chapter 3 : The Injection Moulding Process (Mini Project) ........................................... 11
3.1 Introduction ............................................................................................................ 11
3.1.1 Problem Statement .......................................................................................... 11
3.1.2 Objectives ........................................................................................................ 11
3.1.3 Scope of Work................................................................................................. 11
3.2 Literature Review ................................................................................................... 12
3.2.1 Injection Moulding in Plastic Industry ............................................................ 12
3.2.2 Injection Moulding Process............................................................................. 12
3.2.3 Injection Moulding Machine ........................................................................... 13
3.2.4 Injection Moulding Cycle ............................................................................... 16
3.2.5 Material used in Injection Moulding ............................................................... 18
3.3 Results and Discussion ........................................................................................... 20
3.4 Conclusion .............................................................................................................. 20
References ................................................................................................................................. 21
Appendix ................................................................................................................................... 22

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 Executive Summary

Wan Cheng Plastic Industries Sdn. Bhd. is one of the leading plastic company especially
in for injection moulding and blow moulding based products. The humble beginning of Wan
Cheng Plastic Industries Sdn. Bhd. is in 1970 where it all started. After decades of continuous
improvement, Wan Cheng Plastic Industries Sdn. Bhd. has grow and achieved many awards
including the prestigious ISO:9001 certificate in 2001. Wan Cheng Plastic Industries Sdn. Bhd.
also emphasize in ensuring that the latest skills & techniques of plastic manufacturing are
applied to all its manufacturing assignment, and all staff are continually trained on the latest
technical development in the manufacturing process. Enamours production lines in the company
is suitable place for the graduates to learn about the plastic industry.

The candidate was assigned under the engineering department with the supervision of
Mr. Lim Ti Seng, the assistant operation manager. The project that was assigned to the candidate
is the detail literature review on the injection moulding process and the common material used
in the process. In the project, the candidate observe the process of injection moulding at the
injection moulding machine in order to understand how the machine work. The product
condition which indicate the condition of the injection process also collected and observed in
order to study the process.

Based on the project done by the candidate, the candidate has come out with several
factors which must be emphasized during the injection moulding process. The factors are The
material has to be plasticised and injected carefully to avoid negative effects on the material
properties and the process settings such as pressures and temperatures concerning the machine
and mould have to remain constant with the set value, with regard to time and space.

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Chapter 1 : Introduction

1.1 Company Background

1.1.1 Introduction

Wan Cheng Plastic Industries Sdn. Bhd. or also known as Chunbe Sdn.Bhd. is a name
that has been synonymous with the plastic industry. Wan Cheng Plastic Industries Sdn.Bhd. was
founded in 1970 and incorporated under the Companies Act, 1965 on 24 August 1996 as a
private company limited by shares and commenced operations on the same day. It is primarily
engaged in the business of manufacturing of injection moulding and blow moulding based
products. The company is also involve in the manufacturing of shoe care products, adhesive
products, hair care, plastic household products & food packaging products. After years of
continuing improvement, on 4th July 2001, the company were awarded the prestigious ISO 9001
certification, which is the international standard that specifies requirements for a quality
management system (QMS). This means that Wan Cheng Plastic Industries Sdn. Bhd. has
reached the standard to demonstrate the ability to consistently provide quality products and
services that meet customer and regulatory requirements.

1.1.2 Company Scope

Wan Cheng has grown to become one of the leading manufacturers in the industry of
plastic injection moulding and blow moulding product in the country. Plastic injection and blow
moulding based product have become the core business of the company since its humble
beginning. The companys plastic injection product can be summarized as below:

1) OEM plastic casing, plastic cover, plastic toys

2) Household products, container, stationery

3) Industrial parts, machinery hardware

4) Electronic components

While the blow moulding product produced by the company can be summarized as following:

1) Glue bottle, shoe white bottle

2) Hardware products

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 3) Household product

4) Pharmaceutical container and bottles

Besides manufacturing plastic injection and blow moulding based products, Wan Cheng
also expanded its business throughout the years by introducing the thermal forming based
product as one of their main production. The thermal forming machine start operating fully on
March 2016. 17th of July 2017 can be considered as a stepping-stone for Wan Cheng Plastic
Industries, where the sheet extrusion machine starts operating fully on this date. With the
operation of this machine, the company can produce coils, which is the main starting material
for the thermal forming machine, by its own. This means that, the company doesnt has to buy
the coil from another extrusion based company, hence saving a lot of cost. This is an example
of a long-term investment done by the company in order to continue producing quality product
by the most economical way.

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1.1.3 Company History

1970 - Wan Cheng Plastic Industries was founded

24th August 1996 - Incorperated under Companies Act 1965 as a private company limited by
shares

24th August 1996 - Commencing operation

4th July 2001 - Awarded the prestigous ISO:9001 certification as a company that meet the
international standard in quality management system.

April 2015 - Awarded the National Mark of Malaysian Brand Award

2015 - The thermal forming machine started operating fully.

July 2017 -The extrusion sheet machine started operating fully.

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1.1.4 Organization Chart

Mr. Hock Chiang

(Administrative
Manager)

Mr. Ti Huoi Lim Mr. Lim Ti Seng

(Assistant Administrative (Assistant Production
Manager) Manager)

Miss Moly Lim Mrs. Toh Ceng

Mrs Teh Chee Seng Mr. Peter Ooi Miss Ooi Hua
(Human Resource (Administrative (Production (Quality Assurance
Executive) Executive) (Logistic Manager)
Executive) Manager)

Figure 1.1: Organization chart of Wan Cheng Plastic Industries Sdn Bhd

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1.2 Job Scopes

In order to become a competent engineer, process understanding is very important.

Thus, during the internship, the candidate who is under the production department, was
given variety of tasks during the industrial training. The candidate worked together with
other staffs in handling the part or product in the production department. Basically,
production department can be divided into two categories which are on production line
and off production line or also known as online and offline work respectively. On
production line work required the candidate to directly interact with the machine or the
products/parts coming out of the machine. Hence, when doing online work, candidate
must constantly observe the machine and products to ensure that everything works
normally. In the other hand, working off the production line required the candidate in
works such as product packaging process, part, product enhancement and finishing. The
candidate also involved in maintenance work where the candidate work together with
technicians and other worker changing the mould of thermal forming machine.

1.3 Industrial Training Gantt Chart

Table 1.1: Industrial training Gantt chart by week

Week / Activity 1 2 3 4 5 6 7 8
Induction and briefing
Study and understanding the
plastic injection, blow
moulding, thermal forming
and extrusion process
Completing the mini project
assigned
Preparing the presentation
Presentation (visiting lecturer
and industrial supervisor)
Preparing industrial training
report

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Chapter 2 : Industrial Training Activities

During the industrial training, the candidate was assigned under the production
department of the company by Mr. Lim Ti Seng, who is the industrial supervisor, and Mr.
Peter, the production manager for the production department. Mr. Lim Ti Seng is also the
assistant operation manager of the company.On the first day of the industrial training, the
candidate was shown around the company by the industrial supervisor and was briefly
explained about every section and department of the company such as the production,
human resource and quality control department. The candidate was also introduced to
every staff and workers of the company.

In the first two weeks of industrial training, the candidate was explained about the
importance of product quality by manager and staff from the production and quality
control department. The candidate was also explained by managers, enginers and
technicians about the processes of the main production of the company, which is injection
moulding, blow moulding, thermal forming and sheet extrusion. In the coming weeks, the
candidates was tasked by the company on the production line, and off production line type
of works. For on production line type of work, the candidate was trained by the staffs on
how to operate at the injection moulding, blow moulding and sheet extrusion machine.
The candidate also need to screen defective product that come out of the machines.
Candidate also need to regularly observe the machines in order to make sure that the
machines is working normally. For offline production work, most of the time, the
candidate was involved in the packing and packaging of product or plastic parts. Candidate
also involves in product enhancement and finishing work. On and off production line work
were done by trainee by almost every week of the industrial training.

On the third week of the industrial training, mini project was assigned to the
candidate where candidate need to do a detail literature review about the injection
moulding process and the common material used in the process. The project that assigned
to the candidates required regular observation on the injection moulding machine and
plastic parts or products coming out of the machine. The candidate also asked the staff
especially the technician and engineer in order to have a clearer picture on how the
injection moulding machine work.

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 The candidate also worked together with the engineer and technician to do the
maintenance work which is changing the mould of injection moulding machine and
thermal forming machine. Mould changing process of these plastic manufacturing
machines is not a one man job as it require several workers to get the maintenance job
done. Hence, effective and clear communication between workers during the mould
changing process is very important. This is because, safety is the main priority in the
industry and miscommunication, even a little, can lead to accident and disaster.
Maintenance works that done by the general workers on other machines was observed by
the candidates.

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Chapter 3 : The Injection Moulding Process (Mini Project)

3.1 Introduction

During the industrial training, the candidate was assigned to complete a mini
project, which is related to plastic industry. After 3 weeks at Wan Cheng Plastic Industries
Sdn. Bhd. as an industrial trainee, the industrial supervisor, Mr. Lim Ti Seng assigned a
project which is to do a literature review about the injection molding process and the most
common material used in the process.

3.1.1 Problem Statement

Condition of injection moulding based product/parts depends on so many factors.

These factors must be emphasized in order to obtain product that meet the standard before
being sold to customers. For every factor that will be change, there were always producing
a different condition and quality of product in terms of properties. Different
condition/quality of mechanical or physical properties found in producing part by using
injection machine with different value of process properties which is the temperature and
pressure of the process. Hence, deep understanding on the injection moulding process is
very necessary in order to smoothly run the injection moulding process. As a result, good
and quality parts/product can be produced.

3.1.2 Objectives

There are two objectives in this mini project assigned, which are:

a) To understand more about the injection molding process and machinery.

b) To study about the common raw material used in injection molding process.

3.1.3 Scope of Work

The study was done by using the Arburg Allrounder injection moulding machine
number 15. The injection moulding process was observed and monitored by the candidate
in order to have a clear picture on how injection moulding process occur. The observation
was done almost week after the mini project had been assigned to the candidate. The
product produce by the machine is food container. The candidate also observes the product

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constantly because good product quality indicate that the injection moulding process is
running perfectly.

3.2 Literature Review

3.2.1 Injection Moulding in Plastic Industry

Plastics industry is one of the fastest growing industries in Malaysia. To

manufacture finished products, polymers are processed through various types of
techniques namely extrusion, injection moulding, blow moulding and roto moulding.
Injection moulding is one of the most common processes used to produce plastic products
and parts. It is a cyclic process of rapid mold filling followed by cooling and ejection. A
variety of materials both plastic and non-plastic can be used as feedstock. However, the
machine must be configured for the type of material used. Basically, the common material
used in injection molding process, which is generally available as grains or resins, is
plasticized in an injection unit and injected into a clamped mold under high pressure
ranging from 500 to 1500 bar. The main advantage of injection molding is that it is a very
economical method of mass production. Ready parts with tight tolerances can be produced
in one step and completed automatically.

3.2.2 Injection Moulding Process

In injection molding the mold and the plasticizing area are separated from each
other. Temperature of the plasticizing area or the plasticizing cylinder, is kept at the level
of the processing temperature. The mold on the other hand, is kept cold enough for
demolding of the injection molded part. The plasticized material is injected into the
clamped mold. In an injection molding machine, the clamping unit which contains the
mold and the injection unit are integrated. Completely automated production is possible
if the mold is installed with a vertical parting line. This enables the parts to fall down and
out of the mold after demolding. Injection molding machines are typically used for the
processing of thermoplastics. There are two types of injection unit available which are the
piston injection unit and the screw piston injection unit (reciprocating). The reciprocating
screw method is the most common. For the processing of thermosets only screw piston
machines can be used. This is because without the screw, the dwell time would be too

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long and the risk of early crosslinking would be too high. The injection sequence for both
types of machine now follows.

3.2.3 Injection Moulding Machine

For thermoplastics, the injection moulding machine converts resins or pelleted raw
plastic into final moulded parts via a melt, inject, pack, and cool cycle. A typical injection
moulding machine consists of the following major components:

1) Injection system

2) Hydraulic system

3) Mould system

4) Clamping system

5) Control system

Figure 3.1: Arburg Allrounder Injection Moulding Machine at the company

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 Figure 3.2: Major Components in Injection Moulding Machine

For the machine specification, the clamping tonnage and shot size are commonly
used to quickly identify the size of the injection moulding machine for thermoplastics.
Other parameters include injection rate, injection pressure, screw design, mould thickness,
and the distance between tie bars. The major equipment auxiliary to an injection moulding
machine includes resin dryers, materials-handling equipment, granulators, mould-
temperature controllers and several more.

3.2.3.1 The Injection Unit

For a reciprocating screw machine the process cycle can be split into five stages:
1. In stage one, as shown in Figure 3.1, material is injected into the tool.

Figure 3.3: Injection

In stage 2 (Figure 3.2), the screw begins to turn and retract, metering a specified
weight of molten material for the next shot. The previous shot is now cooling in the closed
tool.

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 Figure 3.4: Metering

In stage 3, the injection unit moves back from the clamping unit as shown in Figure
3.3.

Figure 3.5: Injection unit retract

Stage 4 is shown in figure 3.4 below. In this stage the tool opens to reveal a cooled
injection molded component.

Figure 3.6: Mould open

Stage 5 is ejection of the part as shown in Figure 3.5. The injection unit will then
move forward to the clamp unit to start a fresh cycle as shown in stage 1.

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 Figure 3.7: Ejection

3.2.4 Injection Moulding Cycle

A single injection moulding cycle can be broken down into three distinct stages:
plastication, mould filling and cooling with solidification.

3.2.4.1 Plasticization

This stage is carried out in the injection unit and is similar to the process of
extrusion. The polymer flow rate is conducted by the material processing conditions of
the plasticization stage: a combination of material rheology, barrel temperature and shear,
back pressure and screw speed. The basic aim is to produce a homogeneous melt for the
next stage where the material enters the mould. Moulding parameters which control the
plasticization stage are cylinder temperature, screw back temperature and back pressure.

3.2.4.2 Filling

Here the injection unit delivers an amount of molten polymer to the mould tool
that has been set. The parameters of mould filling are of great importance to the end result
especially when considering factors such as orientation effects, or also called as warpage
and surface finish. Filling dynamics are also thought to be the major factor in affecting
the levels of residual stress. It is important that injection speeds are reproducible as slight
changes can cause variations in the end product, hence, reducing its quality. Injection
speeds that are too high can cause jetting and degradation and thus affect mechanical
properties. A low speed may cause an increase in pressure requirements due to a thicker
frozen layer and incomplete filling of the mould. The important thing is that the speeds

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are reproducible from one shot to the next. Important moulding parameters for filling are
the injection speed and injection pressure.

3.2.4.3 Packing and Solidification

Once the material is in the tool, filling must be completed, the part cooled and
finally ejected. The purpose of the packing stage is to add extra material to compensate
for the shrinkage caused by the decreasing density of the solidifying polymer. If the
additional polymer were not injected the component would shrink and warp due to
nonuniform cooling. Ideally the packing and cooling stages should be such that the final
dimensions are maintained as close as possible to design tolerances. Variables during this
stage are packing pressure, packing time and the mould temperature. Bad mould design
can lead to inconsistent cooling along the dimensions of the mould surface which can
cause increased residual stresses. Once the material has cooled sufficiently, the component
can be injected and the injection cycle continues. The cycle does not occur sequentially,
while one part is cooling, plasticization of the next cycle has already begun. Figure below
shows the breakdown of an injection moulding cycle.

Figure 3.8: Breakdown of an injection moulding cycle

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3.2.5 Material used in Injection Moulding

3.2.5.1 Semi-Crystalline Plastic

Semi-crystalline plastics are naturally of a milky opaque colour (thus non-

transparent) as a result of light diffusion at the crystallite borders. Semi-crystalline
thermoplastics as a whole have higher shrinkage values than amorphous plastics between
solidifying and transition temperatures. The risk of overloading is therefore considerably
less; thus ejection difficulties due to this reason scarcely occur in semi-crystalline
components. At the same time increased shrinkage is equalised by favourable antifriction
behavior to give a positive effect. Stated below are the example of semi-crystalline plastic
that can be used in the injective moulding process:

1. Polyethylene (PE)
2. Polypropylene (PP)
3. Polyamide (PA)
4. Polyacetal (POM)
5. Polyterephthalate (PET, PBT)
6. Polyphenylene sulfide (PPS)
7. Polyfluoroolefins (PFA, FEP, ETFE, PVDF)
8. Polyacrylic acid (PM)
However, amongst all of these plastics, the most common plastic used as material
in the injection moulding is the polypropylene (PP) which is in resins form.

3.2.5.2 Polypropylene

One of the most common material used in Wan Cheng Plastic Industries Sdn. Bhd.
is the polypropylene. The way the polypropylene atoms are arranged in the polymer
molecule has a great influence on the properties of a polymer component. This order is
named the tacticity and with polypropylene there are two different arrangements
commonly available isotactic and atactic. The degree of tacticity determines the level of
crystallisation possible. Atactic polymers are those with side groups placed in a random
order. Atactic PP with nonuniformly arranged methyl groups has a density of 0.94 g/cm3.
Isotactic polymers are those whose side groups are all on the same side. Isotactic
polypropylene has a density of 0.90 g/cm3. There are also copolymers with ethylene, to
increase impact resistance below 0 C.
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 The main reason polypropylene is used as the material is because of its
characteristics and application, which will be stated below:

1. Higher rigidity and hardness than PE

2. Impact resistance falls off sharply
3. Upper operating temperature 110C and possibly higher in stabilized types
4. Good electrical properties
5. No tendency to stress crack formation
6. Lower chemical resistance compared to most of other semi-crystalline materials
7. Less opaque than PE
Before injection moulding process starts, the processing data of material used must
be obtained. Table below shows the processing data of polypropylene which is crucial in
running the injection moulding process.

Table 3.1: Polypropylene processing data for injection molding

Pre-drying Not required

Compound temperatures (170 C)-200-270 C-(300 C)
Mold temperatures 50-100 C
Upper temperatures give better surface
gloss, dull points at lower temperatures
Flow behavior Flow better than PE, especially in lower
processing temperature range.
Shut-off nozzles are usually required, if
working without material decompression.
Shrinkage Processing shrinkage in direction of flow
1.3-2%, crosswise to direction of flow
0.8-1.8%.
Injection pressures, holding pressure time 1000-1500 bar
Select sufficiently long holding pressure
time (similar to PE)
Special features PP is suitable for pre-chamber through
injection process.
The plasticising efficiency of the machine
is lower, due to the lower density (only
approx. 70% compared to polystyrene).

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3.3 Results and Discussion

From the mini project done by the candidate, in term of product quality produced
by the injection moulding machine, To guarantee a high quality in the injection moulded
products the following factors have to be considered:

1. The material has to be plasticized and injected carefully to avoid negative effects
on the material properties.

2. The process settings (such as pressures and temperatures) concerning the machine
and mould have to remain constant with regard to time and space.

3.4 Conclusion

The main purpose of this mini project is to understand in detail the injection
moulding process and identifying the factors which need to be emphasized during the
injection moulding process. The methodology of this mini project of this equipment is
simple where the candidate only has to monitor and observe the injection moulding
machine regularly.

From all the result shown above, it shows that in order to obtain quality products
or parts, the temperature of the injection unit and mould must be controlled and set at
desired temperature. This is because, probability of products to become defective is high
when the temperature is unstable or at undesired temperature (too high or too low).
Negative effect is an effect which must be avoided in the injection moulding process. To
prevent negative effect on the material from occurring, the material fed in to the machine
must be plasticized and injected with care.

Overall, the injection moulding process can be considered as the most common
process used to produce plastic parts and products due to the process of plastic injection
moulding is fast, and the ability to produce large quantities of plastic products in a short
time span.

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 References

[1] Wan Cheng Plastic Industries Sdn Bhd, About Us, 2017. [Online]. Available:
https://chunbe.com/about-us /. [Accessed: 27-Aug-2017].

[2] Lee, J. W. "Injection Molding Process Plastics Injection Molding Process: An overview"
pp 67-190

[3] Goodship, V., "Practical Guide to Injection Moulding." pp 1-278

[4] J. Clark, Plastic Industry: Injection Moulding, 2015. [Online]. Available: http://www.
http://easchangesystems.com/application/plastic-injection-molding/ [Accessed: 04-Sep-
2017].

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 Appendix

Worker at blow moulding machine Polypropylene resins

The thermal forming machine

Example of plastic products

The sheet extrusion machine

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