WELCOMEWELCOME

A STUDY REPORT ON PRODUCTION ANALYSIS OF PVC PIPES

ABSTRACTABSTRACT

COMPANY PROFILE Sri S.P.Y.REDDY B.E(Mec) the founder and chairman of Nandi group of companies. Initially he started a small unit for manufacturing of L.D.P.E (Low Density Poly Ethylene pipe), Later he developed the business by manufacturing of PVC pipes in the name of M/S Sujala pipes pvt.Ltd. At Nandyal in the year 1978 Soon,the company has become a prestigious Nandi Group and has earned a high reputation in the terms of producing and supply of most comprehensive range of quality PVC pipes suitable for water transportation,irrigation,Drinage,electrical,plumbing pipes in the last two decades. Sri S.P.Y.REDDY B.E(Mec) the founder and chairman of Nandi group of companies. Initially he started a small unit for manufacturing of L.D.P.E (Low Density Poly Ethylene pipe), Later he developed the business by manufacturing of PVC pipes in the name of M/S Sujala pipes pvt.Ltd. At Nandyal in the year 1978 Soon,the company has become a prestigious Nandi Group and has earned a high reputation in the terms of producing and supply of most comprehensive range of quality PVC pipes suitable for water transportation,irrigation,Drinage,electrical,plumbing pipes in the last two decades.

INTRODUCTIONINTRODUCTION In this company the pipes are manufactured by the extrusion process. Extrusion is a continuous process of converting the suitable raw material into a product of specific cross section by forcing the material through an orifice or by under controlling conditions. In this company the pipes are manufactured by the extrusion process. Extrusion is a continuous process of converting the suitable raw material into a product of specific cross section by forcing the material through an orifice or by under controlling conditions.

The company will manufacture the following types of pipes Electrical pipes Electrical pipes Plumbing pipes Plumbing pipes Casing pipes Casing pipes HDPE pipes HDPE pipes Agricultural pipes Agricultural pipes SWR pipes and fittings SWR pipes and fittings Submergible Submergible

The industry may include different streams like 1.Production 2.Maintanance 2.Maintanance 3.Quality control 3.Quality control

ProductionProduction Production can be as the transformation of raw material by manufacturing methods into useful and variable things needs to this society. Production planning is very basic step of manufacturing. Production can be as the transformation of raw material by manufacturing methods into useful and variable things needs to this society. Production planning is very basic step of manufacturing.

MaintananceMaintanance “A professional Maintenance can be stated as keeping the machines running safely and reliable and also always trying constantly to improve the Efficiency of the equipment”. “A professional Maintenance can be stated as keeping the machines running safely and reliable and also always trying constantly to improve the Efficiency of the equipment”.

Quality Control Quality Control is a process employed to ensure a certain level of quality in a product or service. Quality Control is a process employed to ensure a certain level of quality in a product or service.

Fig 1.1: PLANT LAYOUT Plant Layout

Extrusion Process Extrusion process is used for manufacturing long and straight metal parts. Extrusion is done by squeezing the metal in a die by using a mechanical or hydraulic press. Extrusion process is used for manufacturing long and straight metal parts. Extrusion is done by squeezing the metal in a die by using a mechanical or hydraulic press.

Types of Extrusions  Hot Extrusion  Cold Extrusion  Hot Extrusion  Cold Extrusion

Injection Moulding There are six major steps in injection moulding process. They are Injection Moulding There are six major steps in injection moulding process. They are Cooling Cooling Mold opening Mold opening Ejection Ejection Clamping Clamping Injection Injection Dwelling Dwelling

ClampingClamping An injection molding machine consists of three basic parts; the mold, the clamping and the injection units. The clamping unit is what holds the mold under pressure during the injection and cooling. Basically, it holds the two halves of the injection mold together. An injection molding machine consists of three basic parts; the mold, the clamping and the injection units. The clamping unit is what holds the mold under pressure during the injection and cooling. Basically, it holds the two halves of the injection mold together.

InjectionInjection

Dwelling Dwelling

CoolingCooling The plastic is allowed to cool to its solid form within the mold using water. to maintain the required temperature difference between the mold the plastic material, water is circulated through holes and channels within the mold. The plastic is allowed to cool to its solid form within the mold using water. to maintain the required temperature difference between the mold the plastic material, water is circulated through holes and channels within the mold.

Mold Opening After the cooling is completed, the clamping unit is opened, which separates the two halves of the mold. After the cooling is completed, the clamping unit is opened, which separates the two halves of the mold.

EjectionEjection When a mould cools, it contracts by an amount depending on material being processed. For a solid rectangle block the molding will shrink away from the walls of cavity. When a mould cools, it contracts by an amount depending on material being processed. For a solid rectangle block the molding will shrink away from the walls of cavity.

PRODUCTION PROCESS

RAW MATERIAL The main components of preparing pipes are: The main components of preparing pipes are: Poly vinyl chloride (Resin) [CH2=CHCL] Poly vinyl chloride (Resin) [CH2=CHCL] Master batch [This is combination of both Titanium dioxide, Carbon black and CA] Master batch [This is combination of both Titanium dioxide, Carbon black and CA] One pack stabilizer [this consist of lead, wax, steric acid. One pack stabilizer [this consist of lead, wax, steric acid.

Heating Mixture And Cooler

HopperHopper

ExtruderExtruder It is used to extrude the pipe. They are two types of extruders It is used to extrude the pipe. They are two types of extruders 1. Single screw extruder 2. Double screw extruder 1. Single screw extruder 2. Double screw extruder

 The Zones of screws are as follows 1.Feeding Zone 2.Compressing Zone 3.Decompressing Zone 4.Degassing Zone 5.Mixing Zone

DIESDIES

VACCUM CALIBRATORS&SPRAY BATHS

Cooling Towers In Pipe manufacturing plant water from the spay bath is cooled in cooling tower. So, that it can be reused in spay bath for cooling purposes

HAUL–OFF-DEVICE

Sensor/CutterSensor/Cutter A sensor is a device which senses the changes in the physical quantity which is to be measured. A sensor is a device which senses the changes in the physical quantity which is to be measured.

SocketingSocketing HEATING COIL MANDREL

REUSABILITY OF THE SCRAP If any product does not satisfy the standard of the company (defective or damaged) then it is termed as scrap. If any product does not satisfy the standard of the company (defective or damaged) then it is termed as scrap.

Reasons for Formation of Scrap Improper mixing of raw material. Improper mixing of raw material. Speed variation between Extruder unit and Haul off unit. Speed variation between Extruder unit and Haul off unit. Discontinuous supply of cooling water. Discontinuous supply of cooling water. Fluctuations in power supply. Fluctuations in power supply.

Scrap can be reproduced by passing them through the grinders, pulverize.SCRAPSCRAP

GRINDERGRINDER

PULVERIZERPULVERIZER

Advantages of PVC pipes Pipe is lighter in weight & easy for installation Pipe is lighter in weight & easy for installation Non corrosive, non toxic & chemical resistance in nature Non corrosive, non toxic & chemical resistance in nature Better resistance of water hammer & surge pressure Better resistance of water hammer & surge pressure Uniform pipe dimension & threading with smooth inner diameter Uniform pipe dimension & threading with smooth inner diameter Non conductivity of electricity Non conductivity of electricity

CONCLUSIONCONCLUSION

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