AKNOWLEDGEMET

I own a deep sense of gratitude to our guide Mr. Alok . who wholeheartedly supported and
encouraged me throughout the completion of this project. His valuable guidance,
suggestions, and continuous motivation helped me to successfully complete this project
work.

I take great pleasure in expressing my sincere thanks to Mr. Alok for his constant
encouragement and kind cooperation from the initial stage to the successful completion of
this project.

Lastly, I would like to thank all the staff members and the Cordinator and Teachers of
Aligarh Muslim University Department for their sustained efforts, cooperation, and
support during the project work.

Submitted By;

[Link]( Polymer and Coating Technology) Students

 HISTORY OF MOLDING

Molding is one of the oldest manufacturing techniques used by human civilization to give shape to
different materials. The basic concept of molding is to pour or force a material into a cavity or mold so
that it takes the desired shape after solidification.

In ancient times, molding was first used with natural materials such as clay, wax, and metal. Early
civilizations like the Egyptians and Mesopotamians used clay molding to make pots, utensils, and
decorative items. Metal molding was also practiced for making tools, weapons, and coins.

With the development of glass technology, glass molding and glass blowing techniques were
introduced. These techniques later became the foundation for modern blow molding processes used
in the plastic industry.

The real growth of molding technology started during the Industrial Revolution (18th–19th century).
During this period, metal molds and machines were developed, which allowed mass production of
identical components with better accuracy and speed.

The invention of synthetic plastics in the early 20th century completely changed the molding industry.
In 1872, the first injection molding machine was developed to process celluloid. Initially, molding
processes were simple and manually operated, but with time they became fully automatic and highly
efficient.

After World War II, the demand for plastic products increased rapidly. This led to the development of
advanced molding processes such as Injection Molding, Blow Molding, Compression Molding, and
Extrusion Molding. These processes made it possible to manufacture complex, lightweight, and low-
cost plastic products on a large scale.

Today, molding is a highly advanced and automated process used in almost every industry, including
packaging, automotive, medical, electrical, and consumer goods. Modern molding machines use
precise control systems, high-quality molds, and advanced polymers to produce products with
excellent strength, accuracy, and surface finish.
 TYPES OF MOULDING
Moulding is a manufacturing process used to shape plastic and polymer materials by applying
heat and pressure. Different moulding techniques are used in the polymer industry to produce a
wide variety of products depending on their shape, size, and application. The main types of
moulding processes are explained below:

1. Injection Moulding
2. Blow Moulding
3. Transfer Moulding
4. Extrusion Moulding
5. Rotational Moulding
6. Thermoforming
7. Compression Moulding

1. Injection Moulding
Molten plastic is injected into a mould under high pressure to form solid products.
2. Blow Moulding
Hot plastic is expanded with air inside a mould to make hollow products.
3. Transfer Moulding
Heated plastic is transferred into a closed mould cavity using pressure.
4. Extrusion Moulding
Molten plastic is forced through a die to produce continuous shapes.
5. Rotational Moulding
Heated mould is rotated so plastic coats the inside evenly.
6. Thermoforming
Heated plastic sheet is shaped over a mould using vacuum or pressure.

[Link] Moulding

Plastic material is compressed in a heated mould to get the final shape.

 INJECTION MOULDING
Injection moulding is one of the most commonly used plastic processing methods in
manufacturing industries. It is a process in which molten plastic material is injected into a
mould cavity under high pressure to produce products of desired shape and size. This
technique is mainly used for producing components with complex geometry, high
accuracy, and smooth surface finish.

In injection moulding, plastic granules or pellets are fed into the barrel of an injection
moulding machine, where they are heated and melted. The molten plastic is then forced
into the closed mould through a nozzle. After cooling and solidification, the mould is
opened and the finished product is ejected.

Injection moulding is highly suitable for mass production because it ensures uniform
quality, high production rate, and minimum material wastage. Due to these advantages,
this process is widely used in industries such as automobile, electrical and electronics,
medical devices, packaging, and household products manufacturing.
 INJECTION MOUlDING

1. INJECTION UNIT
**Hopper

**Hopper Throught

** Nozzel

**Barrel

**Screw

**Heater

**Thermocouple

2. Clamping Unit
**Fixed platen

**Moving Platen

**Tie Bar

**Ejector Plate
 **Ejector Rod

**Hydraulic Cylinder

**Guid Bush & Guid Pillar

**Clamping Mechnism

** Safety Door / Safety Interlock

Mould

A mould (also called a die) is one of the most important components of the injection
moulding process. It is a specially designed metal tool used to give the final shape, size, and
surface finish to the plastic product. The molten plastic material is injected into the mould
cavity, where it cools and solidifies to form the desired component.

Injection moulds are generally made of hardened steel, stainless steel, or aluminium,
depending on production quantity and product requirements. A mould mainly consists of two
halves: the fixed half and the moving half. When the mould is closed, molten plastic is injected
into it, and after cooling, the mould opens to eject the finished product.
The core is the part of the mould that forms the internal shape of the plastic product. It is
usually fixed on the moving half of the mould. Core is made of hardened steel to withstand
high pressure and temperature.

2. Cavity

The cavity forms the outer shape of the product. It is generally fixed on the stationary side of
the mould. The final appearance and surface finish of the product depend on the cavity.

3. Guide Pillar

Guide pillars are cylindrical rods fitted on one half of the mould. They help in proper alignment
of the core and cavity during mould closing.

4. Guide Bush

Guide bushes are fitted on the opposite mould half and work together with guide pillars. They
ensure smooth movement and accurate alignment of the mould halves.

5. Locating Ring

The locating ring is used to align the mould correctly with the nozzle of the injection moulding
machine. It ensures proper entry of molten plastic into the sprue.

6. Gate

The gate is a small opening through which molten plastic enters the mould cavity from the
runner. It controls the flow, pressure, and filling of plastic into the cavity.

7. Sprue

The sprue is the main channel through which molten plastic flows from the machine nozzle
into the mould. It connects the nozzle to the runner system.

8. Runner

The runner is a passage that distributes molten plastic from the sprue to the gates of one or
more cavities.

9. Ejector Pin

Ejector pins are used to push the solidified product out of the mould after cooling. They are
located on the moving side of the mould.

10. Back Plate

The back plate provides support to the mould assembly. It helps in holding the ejector system
and maintaining mould strength.

11. Ejector Plate

The ejector plate holds the ejector pins and moves forward to eject the finished product from
the mould cavity.
 Electrical Unit
The electrical unit of an injection moulding machine is responsible for controlling,
monitoring, and operating all electrical and electronic functions of the machine. It
ensures accurate control of temperature, pressure, time, and movement of different
machine parts. Modern injection moulding machines use advanced electrical systems
to achieve high precision, safety, and energy efficiency.

Parts of Electrical Unit

1. PLC (Programmable Logic Controller)

PLC is the brain of the injection moulding machine. It controls and monitors all machine
operations such as injection, clamping, cooling, and ejection. PLC helps in automation,
process accuracy, and repeatability.

2. Electrical Circuit

The electrical circuit provides power to all electrical components of the machine. It
includes relays, contactors, breakers, and switches that control the flow of electricity
and ensure safe operation.

3. Electrical Wiring

Electrical wiring connects all electrical components like motors, heaters, sensors, and
control panels. Proper wiring ensures smooth power transmission and safe functioning
of the machine.

4. Heater

Heaters are used to melt the plastic material inside the barrel. Heater bands are
mounted around the barrel to maintain the required processing temperature.

5. Thermocouple

A thermocouple is a temperature-sensing device used to measure and control barrel

temperature. It sends temperature signals to the controller, which helps in maintaining
accurate heating conditions.
Hydraulic System (Injection Moulding Machine)

The hydraulic system of an injection moulding machine provides the required force and
motion for machine operations such as clamping, injection, screw rotation, and ejection.
It works on the principle of fluid power, where pressurized hydraulic oil is used to transmit
energy. The hydraulic system ensures smooth, powerful, and controlled movement of
machine components.

Parts of Hydraulic System

1. Hydraulic Motor

The hydraulic motor converts hydraulic energy into mechanical energy. It is mainly used to
rotate the screw during the plastic melting and injection process.

2. Hose Pipe

Hose pipes carry pressurized hydraulic oil from one component to another. They are
flexible and designed to withstand high pressure and temperature.

3. Oil Tank (Hydraulic Reservoir)

The oil tank stores hydraulic oil required for the system. It also helps in cooling, filtering,
and removing air bubbles from the oil.

4. Hydraulic Pump

The hydraulic pump is the heart of the hydraulic system. It draws oil from the oil tank and
supplies pressurized oil to the system for machine operations.

5. Heat Exchanger

The heat exchanger is used to control the temperature of hydraulic oil. It removes excess
heat generated during machine operation, ensuring proper oil viscosity and system
efficiency.
Cooling System (Injection Moulding Machine)

The cooling system in an injection moulding machine is used to remove heat from the mould
and hydraulic system. Proper cooling is essential to reduce cycle time, improve product
quality, and prevent defects such as warpage and shrinkage. Water is commonly used as the
cooling medium because of its high heat absorption capacity.

Cooling System Components

1. Chiller

A chiller is a cooling device used to supply chilled water at a controlled temperature to the
injection mould. It works on a refrigeration principle and removes heat from water before
sending it to the mould. Chillers help in accurate temperature control, faster cooling, and
improved product quality.

2. Cooling Line

The cooling line consists of pipes or hoses that carry cooling water from the chiller or cooling
tower to the mould and back. It helps in removing heat from the mould during the cooling
stage of injection moulding. Proper cooling lines reduce cycle time and prevent product
defects.

3. Cooling Tower

A cooling tower is used to cool hot water by releasing heat into the atmosphere. Hot water
from the mould and machine system is sent to the cooling tower, where it is cooled and then
reused. Cooling towers are economical and suitable for large-scale cooling requirements.
 Blow Moulding
. Introduction
Blow moulding is an important plastic processing technique used for manufacturing hollow
plastic products. In this process, heated plastic material is expanded with the help of
compressed air inside a closed mould to obtain the desired shape. Blow moulding is mainly
used for making bottles, containers, tanks, and other hollow items with uniform wall
thickness.

This process is widely used in packaging, food and beverage, pharmaceutical, chemical,
and automotive industries because it allows high production rate, low material wastage,
and economical manufacturing of hollow products.

2. Principle of Blow Moulding

The working principle of blow moulding is based on the expansion of heated plastic under
air pressure. First, plastic material is heated until it becomes soft and flexible. This molten
plastic is formed into a hollow tube called parison or preform. When compressed air is
blown into it, the plastic expands and takes the shape of the mould cavity. After cooling, the
mould is opened and the finished hollow product is removed.
3. Types of Blow Moulding

3.1 Extrusion Blow Moulding (EBM)

Extrusion blow moulding is the most commonly used blow moulding process. In this
method, molten plastic is extruded in the form of a hollow tube called a parison. The mould
closes around the parison, sealing the bottom. Compressed air is then blown inside the
parison, forcing it to expand against the mould walls.

Applications:

Milk bottles

Shampoo bottles

Oil containers

Chemical cans

Advantages:

Suitable for large hollow products

Simple and economical process

3.2 Injection Blow Moulding (IBM)

In injection blow moulding, the process starts with injection moulding of a preform. The
preform is then transferred to a blow mould where compressed air is used to form the final
shape. This method provides excellent control over neck finish and wall thickness.

Applications:

Small pharmaceutical bottles

Cosmetic containers

Advantages:

Accurate dimensions

Good surface finish

Blow Moulding Machine – Main Parts

Extruder / Injection Unit

Melts and supplies plastic material.

Parison / Preform

Hollow plastic tube used for blowing.

Mould (Die)

Gives final shape and surface finish to the product.

Blow Pin / Air Nozzle

Supplies compressed air into the parison.

Clamping Unit

Holds mould halves tightly during blowing.

Cooling System

Removes heat and solidifies the product.

Materials Used in Blow Moulding

The materials used must have good melt strength and flexibility.

Common materials include:

HDPE (High Density Polyethylene)

LDPE (Low Density Polyethylene)

PP (Polypropylene)

PET (Polyethylene Terephthalate)

PVC (Polyvinyl Chloride)

7. Advantages of Blow Moulding

Ideal for hollow products

High production rate

Low material wastage

Uniform wall thickness

Smooth surface finish

Cost-effective for mass production