Gujarat Technological University

Chandkheda, Ahmedabad
L. D. College of Engineering
Navrangpura, Ahmedabad
(Affiliated with GTU)

A Summer Internship Report on

“To study about Injection Molding Machine Working and Production”
At the industry or company
Varmora Plastech Plastech Pvt. Ltd.

Under the subject

Summer Internship (3170001)

Submitted By

Aman Mandal 190280123017

Academic Year
(2022-2023)

CERTIFICATE

I
 This is to certify that the project report submitted along with the project
entitled “To study about Injection Molding Machine Working and
Production” has been carried out by Aman Mandal, Enrollment Number
190280123017, under my guidance in partial fulfilment for the degree of
Bachelor of Engineering in Plastic Technology Branch, 7th semester at L. D.
College of Engineering of Gujarat Technological University (G.T.U.),
Ahmedabad from 22/06/2022 to 09/07/2022.

Date : 11th July 2022

Place : Ahmedabad

Guided By :

Prof. B. G. Basantani Dr. R. K. Gajjar

(Internal Guide & Head of Department) (Principal)
Plastic Technology L. D. College of Engineering

Gujarat Technological University

L. D. College of Engineering
Navrangpura, Ahmedabad – 380015.

II
III
 Acknowledgement

The Industrial Training is the most important and essential part of the study
of engineering. An engineering student is incomplete without the industrial
training.

We thank Varmora Plastech Pvt. Ltd. for providing us this opportunity of

gaining knowledge enriching industrial experience.

We are also thankful Mr. Amar Rout and Mr. Sailesh Patel for continuously
supporting us throughout the process.

We would like to express our sincere gratitude to Mr. Rishabh Jaiswal and
Mr. Kapil Patel for their valuable guidance, suggestions and coordination
during the internship.

Last but not the least; we would like to thank all operators, run-off engineers
and staff members of Varmora Plastech India Pvt. Ltd. for their throughout
support and guidance.

Thank You.
Aman Mandal

IV
Table of Content Page No.

V
Cover Page I

Certificate II

Summer Internship Completion Certificate III

Acknowledgement IV

Table of Contents V

1. INTRODUCTION TO THE COMPANY

1.1 Vision of company 1

1.2 Mission of company 1

1.3 Introduction to Varmora 1

1.4 Department of company 2

2. MACHINES AVAILABLE
2.1 Injection Moulding 3

2.2 Injection Blow Moulding 4

2.3 Extrusion Blow Moulding 5

2.4 PU Foaming 6

3. TRAININGS AT COMPANY
3.1 Quality Control 8

3.2 Production Unit 21

3.3 Tooling 24

VI
4. CONCLUSION 29

5. REFERENCES 29

VII
VIII
 1. Introduction to the Company

1.1 Vision of company:

Vision is diversification and to expand the wings into international
market.”
Presently, Varmora Group includes:
1. Varmora Granito
2. Varmora Sanitaryware
3. Varmora Home ware
4. Varmora Furniture
5. Varmora InfoTech
6. GRV Spinning Mill
7. Arya Green (flex material production)
8. Sunshine Fastners
1.2 Mission of company:
To create value & build better lifestyle for our customers by providing
world-class products with superior quality.

1.3 Introduction to Varmora:

Varmora Plastech Pvt. Ltd. is a leading manufacturer and exporter of
houseware products. We are a successful brand in the plastic industry with
wide range of innovative and attractive products. This range of products
from Varmora Plastech comes with its unique and user-friendly designs. The
products include – bottles, tiffins, dinner sets, dry storage and others kitchen
products. Made from 100% virgin and food grade plastic, our products are
completely healthy and safe.

1.4 Department of the company:

 Machines
 Assemblys
 Maintenance department
 Stores & inspection department
 Testing department
 Purchase & Administrative department
 Company sales department

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  Other departments:

 Design department
 Sales department
 Account department
 Customer service department
 Personal & Administrative department
 Material procurement of purchase department
 Quality control department
 Production planning and control department
 Electronics data processing department
 Production, planning and control department
 Industrial engineering department

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 2.Machines Available in Varmora Plastech:-
2.1:-Injection Moulding Machine:-
1.)

Armour 450-900 T
Winfit – RPVC
Winfit – CPVC
Armour – 2C

Toggle Injection Moulding Machines

Armour Series Toggle Injection Moulding Machines are designed with CAD
optimized high speed, five point twin toggle locking mechanism using
graphite impregnated bushes & high tensile chrome plated tie bar for fast and
precise mold closing and opening system.

A toggle machine line, the Armour series is built for faster clamp movement,
robust performance, higher energy efficiency and greater productivity.

Automatic mold height & tonnage setting through Sun gear mechanism with
rotary encoder enables easy operation of mold setting, resulting in
advantages like positive drive, no backlash, high rigidity, increased mold
safety and longer life.

Armour series machines are available with Servo technology as a standard

feature and with VDP & VDP/VFD systems as an optional feature.

3
Armour series ranges from 450 to 900 ton clamping force capacity

2.)

Toggle Injection Moulding Machines

Armour series Toggle Injection Moulding Machines are designed with CAD optimized
high speed, five point twin toggle locking mechanism using graphite impregnated bushes
& high tensile chrome plated tie bar for fast and precise mold closing and opening
system.

A toggle machine line, the Armour 2C series is built for faster clamp movement, robust
performance, higher energy efficiency, greater productivity.

Automatic mold height & tonnage setting through Sun gear mechanism with rotary
encoder enables easy operation of mold setting, resulting in advantages like positive
drive, no backlash, high rigidity, increased mold safety and longer life.

Armour 2C series machines are available with Servo technology as a standard feature and
with VDP & VDP/VFD system as an optional feature. Armour 2 color machines are
available with Head Mixing and Barrel Mixing versions to help produce various patterns.

Armour 2C series ranges from 450 to 900 ton clamping force capacity.

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2.2)

The ASB-70DP Series are mid-sized one-step injection stretch blow

molding machines offering a perfect balance of productivity & flexibility
that are available in two main variants, the “H” and the “W” model. Both
models share a common overall size and structure, that contributes to
simplified factory layout, faster operator training and reduced cost of
maintenance. Whereas the “H” model provides extremely wide versatility for
bottles and large mouth jars in up to 12 cavities, in the “W” variant the
container molding portion - including the rotary table, stretch-blow unit and
eject station - are re-engineered to enable double row molding of smaller
containers with thread sizes up to 57mm diameter. This dramatically
increases the potential productivity for bottles up to 1 liter capacity as
available cavitation is doubled with up to 24 cavities being possible for
containers up to 100ml capacity resulting in a machine that can produce up
to 8,000bph* in an extremely compact floor area. * Subject to container
specification

2.3)

5
A standardized design and the simple layout of the POLYMAMIX enables
Polycraft-puf Machine to build a custom machine while meeting the
requirements of each application. Outputs are available for various ranging.
Ratio’s range from 1:5 to a 5:1.
Standard features include 170 Lit. rated day tanks, strainers, axial piston
pumps, and low-pressure circulation. Each machine can be equipped with
either a straight type or an L-type mix head.
Specially engineered to produce molded products such as toys, PU panel
and sporting equipment, the POLYMAMIX provides advanced Reaction
Injection Molding technology in a compact, economical package.

6
2.4)

3.)Trainings at the company:

7
3.1 Quality Control:-
(This training was conducted by Mr.Rishabh Jaiswal)

Importants test Done in the company:-

1.)

Bottles and Containers Leak Testing

Bottle leak testing is what guarantees container quality. Some of

the most common bottles are for juices, milk and dairy products,
carbonated soft drinks, water, energy drinks, dressings, sauces,
oils, household cleaning products and much more. In order to
ensure the quality of these products bottle leak testing is performed
to check that each bottle will not leak.

8
2.)

Melt flow index

Test Procedure:
Approximately 7 grams of the material is loaded into the barrel of
the melt flow apparatus, which has been heated to a temperature
specified for the material. A weight specified for the material is
applied to a plunger and the molten material is forced through the
die. A timed extrudate is collected and weighed. Melt flow rate
values are calculated in g/10 min.

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3.)

Plastic compression test

Testing is done by placing a small specimen of plastic (typically a
prism 0.5 by 0.5 by 1 in. or a cylinder with a diameter of 0.5 in.
and a length of 1 in.) between two hardened blocks and slowly
compressing it until the point of fracture.

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4.)

Hot Water Bath

As plastics are affected by the temperature, Hydrostatic Pressure
tests for HDPE, R-PVC, C-PVC, U-PVC, MDPE and lateral pipes
test specimens are suppose to be tested either at room temperature,
at higher temperature or lower temperature in water bath as per
national & international standards

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Defects found in the products and how to fix
them:-
Flow Lines

Description: Flow lines are streaks, patterns, or lines - commonly off-

toned in color - that show up on the prototype part as a consequence of
the physical path and cooling profile of the molten plastic as it flows into
the injection mold tooling cavity. Injection molded plastic begins its
journey through the part tooling via an entry section called a “gate.” It
then flows through the tool cavity and cools (eventually hardening into a
solid).

Image From DieNamic.com

Causes: Flow line defects are caused by the varying speed at which the
molten plastic flows as it changes direction through the contours and
bends inside the mold tool. They also occur when the plastic flows
through sections with varying wall thickness, or when the injection speed
is too low causing the plastic to solidify at different speeds.

Remedies:

1. Increase injection speeds and pressure to the optimal level, which

will ensure the cavities are filled properly (while not allowing the
molten plastic time to start cooling in the wrong spot). The
temperature of the molten plastic or the mold itself can also be
elevated to ensure the plastic does not cool down sufficiently to
cause the defect.

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 2. Round corners and locations where the wall thickness changes to
avoid sudden changes in direction and flow rate.

3. Locate the gate at a spot in the tool cavity with thin walls.

Sink Marks

Description: Sink marks are small craters or depressions that develop

in thicker areas of the injection molded prototype when shrinkage occurs
in the inner portions of the finished product. The effect is somewhat
similar to sinkholes in topography, but caused by shrinkage rather than
erosion.

Image From PlasticTroubleshooter.com

Causes: Sink marks are often caused when the cooling time or the
cooling mechanism is insufficient for the plastic to fully cool and cure
while in the mold. They can also be caused by inadequate pressure in
the cavity, or by an excessive temperature at the gate. All else being
equal, thick sections of the injection molded part take longer to cool than
thin ones and so are more likely to be where sink marks are located.

Remedies:

1. Mold temperatures should be lowered, holding pressure

increased, and holding time prolonged to allow for more adequate
cooling and curing.

2. Reducing the thickness of the thickest wall sections will also

ensure faster cooling and help reduce the likelihood of sink marks.

13
Vacuum Voids

Description: Vacuum voids are pockets of air trapped within or close to

the surface of an injection molded prototype.

Causes: Vacuum voids are often caused by uneven solidification

between the surface and the inner sections of the prototype. This can be
aggravated when the holding pressure is insufficient to condense the
molten plastic in the mold (and thereby force out air that would
otherwise get trapped). Voids can also develop from a part that is cast
from a mold with two halves that are not correctly aligned.

Image from PlasticTroubleshooter.com

Remedies:

1. Locate the gate at the thickest part of the molding.

2. Switch to a less viscous plastic. This will ensure that less gas is
trapped as air is able to escape more rapidly.

3. Increase holding pressure as well as holding time.

4. Ensure that mold parts are perfectly aligned.

Surface Delamination

Description: Surface delamination is a condition where thin surface

layers appear on the part due to a contaminant material. These layers
appear like coatings and can usually be peeled off (i.e. “delaminate”).

14
 Image From PlasticTroubleshooter.com

Causes: Foreign materials that find their way into the molten plastic
separate from the finished product because the contaminant and the
plastic cannot bond. The fact that they cannot bond not only has an
affect on the appearance of the prototype, but also on its strength. The
contaminant acts as a localized fault trapped within the plastic. An over-
dependence on mold release agents can also cause delamination.

Remedies:

1. Pre-dry the plastic properly before molding.

2. Increase the mold temperature.

3. Smooth out the corners and sharp turns in the mold design to
avoid sudden changes in melt flow.

4. Focus more on the ejection mechanism in the mold design to

reduce or eliminate the dependence on mold release agents.

Weld Lines

Description: Weld lines are actually more like a plane than a line that
appears in a part where molten plastics meet each other as they flow
from two different parts of the mold.

15
 Image From PlasticTroubleshooter.com

Causes: Weld lines are caused by the inadequate bonding of two or

more flow fronts when there is partial solidification of the molten plastic.

Remedies:

1. Raise the temperature of the mold or molten plastic.

2. Increase the injection speed.

3. Adjust the design for the flow pattern to be a single source flow.

4. Switch to a less viscous plastic or one with a lower melting

temperature

Short Shot

Description: As the term implies, short shots can be described as a

situation where a molding shot falls short. This means that the molten
plastic for some reason does not fully occupy the mold cavity or cavities,
resulting in a portion where there is no plastic. The finished product
becomes deficient because it is incomplete.

16
Causes: Short shots can be caused by a number of things. Incorrect
calibration of the shot or plasticizing capacities can result in the plastic
material being inadequate to fill the cavities. If the plastic is too viscous,
it may solidify before fully occupying all the cavities and result in a short
shot. Inadequate degassing or gas venting techniques can also result in
short shots because air is trapped and has no way to escape; plastic
material cannot occupy the space that air or gas is already occupying.

Remedies:

1. Select a less viscous plastic with higher flowability. This plastic will
fill the hardest-to-reach cavities.

2. Increase mold or melt temperature so as to increase flowability.

3. Account for gas generation by designing the mold so that gas is

not trapped within the mold and is properly vented.

4. Increase the material feed in the molding machine or switch to a

machine that has a higher material feed in the event that the
maximum material feed has been reached.

Warping

Description: Warping (or warpage) is the deformation that occurs when

there is uneven shrinkage in the different parts of the molded

17
component. The result is a twisted, uneven, or bent shape where one
was not intended.

Causes: Warping is usually caused by non-uniform cooling of the mold

material. Different cooling rates in different parts of the mold cause the
plastic to cool differently and thus create internal stresses. These
stresses, when released, lead to warping.

Remedies:

1. Ensure that the cooling time is sufficiently long and that it is slow
enough to avoid the development of residual stresses being
locked into the part.

2. Design the mold with uniform wall thickness and so that the plastic
flows in a single direction.

3. Select plastic materials that are less likely to shrink and deform.
Semi-crystalline materials are generally more prone to warping.

Burn Marks

Description: Burn marks are discolorations, usually rust colored, that

appear on the surface of the injection molded prototypes.

Image From ParallelDesign.com

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Causes: Burn marks are caused either by the degradation of the plastic
material due to excessive heating or by injection speeds that are too
fast. Burn marks can also be caused by the overheating of trapped air,
which etches the surface of the molded part.

Remedies:

1. Reduce injection speeds.

2. Optimize gas venting and degassing.

3. Reduce mold and melt temperatures.

Jetting

Description: Jetting refers to a situation where molten plastic fails to

stick to the mold surface due to the speed of injection. Being fluid, the
molten plastic solidifies in a state that shows the wavy folds of the jet
stream on the surface of the injection molded part.

Image From ParallelDesign.com

Causes: Jetting occurs mostly when the melt temperature is too low and
the viscosity of the molten plastic becomes too high, thereby increasing
the resistance of its flow through the mold. When the plastic comes in
contact with the mold walls, it is rapidly cooled and the viscosity is
increased. The material that flows through behind that viscous plastic
pushes the viscous plastic further, leaving scrape marks on the surface
of the finished product.

Remedies:

1. Increase mold and melt temperatures.

19
 2. Increase the size of the gate so that the injection speed becomes
slower.

3. Optimize gate design to ensure adequate contact between the

molten plastic and the mold.

Flash

Description: Flash is a molding defect that occurs when some molten

plastic escapes from the mold cavity. Typical routes for escape are
through the parting line or ejector pin locations. This extrusion cools and
remains attached to the finished product.

Image From Paulsontraining.com

Causes: Flash can occur when the mold is not clamped together with
enough force (a force strong enough to withstand the opposing forces
generated by the molten plastic flowing through the mold), which allows
the plastic to seep through. The use of molds that have exceeded their
lifespan will be worn out and contribute to the possibility of flash.
Additionally, excessive injection pressure may force the plastic out
through the route of least resistance.

Remedies:

1. Increase the clamp pressure to ensure that the mold parts remain
shut during shots.

2. Ensure that the mold is properly maintained and cleaned (or

replaced when it has reached the end of its useful lifespan).

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3.2 PRODUCTION UNIT:-
(This training was conducted by Mr.Lalit)

1.)

Working Principle of Injection Moulding

Machine:
 The reciprocating screw rotates by means of a motor and
its reciprocating motion is provided by the hydraulic system.
 The Plastic granules are to be poured into the hopper and
they will be passed through the chamber due to the rotation
of the screw.
 The Heater heats the granules to their critical temperature.
 The thermoplastic molten liquid is pressurized (by the
hydraulic system) outside the Assembly and allowed to
travel through a nozzle of small diameter(Dn)[injector]
with high velocity and low pressure into the space
between the molds.
 The liquid will fill the mold with uniform compaction among
the atoms and thereby density is uniform.
 After filling the liquid in the mold, by the cooling process, it
will be solidified.

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  Any shape and any size of the component can be produced
with uniform density.
 Density can be controlled by varying the pressure in the
pressure line and thereby production rate is high and
wastage is recyclable.
 The component can be produced any number of times till it
achieves the required shape.

2.)

Working Principle of Blow Moulding

Blow moulds were relatively simple in design and construction. The
predominant blow moulded products are thin walled plastic parts, such as
bottles and containers. Blow moulding process is classified into three types.

 Injection Blow Moulding

 Extrusion Blow Moulding
 Stretch Blow Moulding.

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Over the three processes, the injection blow moulding is commonly used a blow
moulding process. In injection blow moulding, a preformed shape emerged
from extrusion called parison is fitted in the nozzle and the compressed air will
be blown into it which forms a thin walled parts.

3.)

Working principle of polyurethane foaming machine

Polyurethane foam machine is inserted into the industrial vat equipped with components A
and B through two lifting pumps, and the materials come out of the lifting pump. As the feed
pipe enters the main machine, it is mixed and output at a certain volume ratio 1: 1 in the main
machine.
After the material is output, it passes through the thermal insulation hose to reach the spray
gun. After pulling the trigger, it passes through the filter in each direction through the high-
pressure impact mixing in the mixing chamber, and then sprays out at a high speed. Upper
curing molding.
According to the function of polyurethane spraying machine, it has sprayability and perfusion
type:

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The sprayable polyurethane foaming machine is mainly used in the construction industry,
specifically for large-scale thermal insulation equipment such as polyurethane foam
insulation of exterior walls of buildings, integration of roofing polyurethane foam insulation
and waterproofing, and cold storage polyurethane foam insulation lamps.
The perfusion type polyurethane foaming machine is mainly suitable for the filling and filling
of the interlayer thermal insulation layer of the solar water heater barrel, the thermal
insulation water tank, the car portable refrigerator and other small thermal insulation tools.

3.3 TOOLING:-
(This training was conducted by Mr.Jojo)

Tooling is divided into three cells:

 Platen cell
 Turn cell
 Manifold cell

1. Platen cell:
 In platen cell machining of various platens take place.
 Clamp platens like moving, stationary and die head and injection
unit platens like traverse and stationery are machined here.
 General procedure for platen machining is as follows:
i. Clamping of platen on a fixture
ii. 1st set up of platen in which machining of 4 sides of
platen takes place in HMC machine.
iii. 2nd set up of platen which includes following machining
processes:
 Casting checking
 Facing
 Rough boring
 Cut Centre for drilling
 Final facing
 Boring

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  Finish bore
 Final size cut by finish cutter
 Cut Centre
 Drilling
 Chamfering
 Tapping
 Checking all operation

iv.3rd set up of platen which include following machining

processes:
 Parallel groove
 Final facing size
 Drilling
 Rough boring
 Finish boring
 Cut Centre
 Drilling
 Chamfering
 Tapping
 Check all operation
 Material for platen: GGG 50 casting

2.)Turn cell:

 In turn cell machining of tip seat valve, barrel adaptor and

split nut is done.

Tip seat valve:

 Material of tip seat valve is H13(Hot Work Tool Steel).

 Following is the procedure for machining of tip:

 Raw material cut

25
  1st set up in which turning operation of back end of
tip take place.
 2nd set up in which turning and milling operation for
front end of tip takes place.
 Buffing
 Hardening
 Turning all over the part
 3rd set up in which threading at back end of the tip.
 Grinding of OD.
 Nitriding of tip.
 Grinding
 Inspection
 Dipping of tip in wax.
 Packaging

 Following is the procedure for machining of seat:

 Facing
 Centering
 Drilling
 Boring
 1st set up in which ID is made through turning
 Chamfering
 Hardening
 2nd set up in which facing and turning takes place.
 Following is the procedure for machining of valve:
 Facing
 Centering
 Drilling
 Boring
 1st set up in which ID is made through turning
 Chamfering
 Hardening
 2nd set up in which facing and turning takes place.
 Accuracy is checked by micrometer.
 Types of tips:

26
  FME
 PC
 Global
 Pin type
 Screw type

3.)Manifold cell:
 In this cell machining of manifold blocks take place on CNC
machine.
 Drilling and tapping of holes of manifold is done here.
 Checking of critical holes is done by using bore gauge.
 Deburring of blocks is done for removing burrs by means of
manual tools.
 Surface grinding of all faces of manifold block is done on the
surface grinding machine.
 Blocks are dipped in oil and then placed in flushing tank for
cleaning purpose.
 Packing of block & make ready for outside vendor for
phosphating process.
 After phosphating again visual inspection takes place.
 Block is dipped in oil before packing.
 Final packing of manifold block.

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Career Prospects for Young Engineers in Plastic Processing
Company:-
 This training was conducted by Mr. Shailesh Patel
 Contents of training:
 Why to choose Processing sector?
 Career Vs Job
 Manage your career-Continuous process
 Functions: Management of Processing Industry
 Departments
 Sales and Marketing
 Design Engineering and R&D
 Operation Planning
 Purchasing and Supply Chain
 Production and Warehouse management
 IT
 Finance
 HR and Admin
 Maintenance

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4.Conclusion:

 Through this industrial internship we have enhanced our competencies

and knowledge related to our field. With hands on training experience, we
learned the required skills for the respected areas of industry. We have
received practical and theoretical understanding concepts that were new to
us.. With support of staff; we got to learn about the future in
manufacturing and how to proceed further to make it as a career. At the
end this internship has bridged the gap between academic theory and
practical application of it throughout building a good quality product.
Indeed, it has built the confidence, making us future ready for upcoming
adventures.

5.References:

 Notes made by Self

 Google
 Wikipedia

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