IN- PLANT TRAINING REPORT ON THE BASIS

OF OBSERVATION AT
CHINA BANGLA PLASTIC INDUSTRIES
LIMITED (CBPL)

Submitted to

Professor Dr. Sharif Md. Al-Reza

Chairman,
Department of Applied Chemistry And Chemical Engineering
Islamic University Kushtia, Bangladesh

Submitted by

Farzana Mahumda
Roll no: 211344
Reg no:1055
Session: 2021-2022
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19 October, 2024
To,
Professor Dr. Sharif Md. Al-Reza
Chairman,
Department of Applied Chemistry And Chemical Engineering
Islamic University Kushtia, Bangladesh

Subject: Submission of In-Plant training report.

Dear Sir,
At first, we the trainees of CHINA BANGLA PLASTIC INDUSTRIES
LIMITED(CBPL) would like to relay our deepest gratitude to you for providing us
with the opportunity to attend in our in-plant training program from 10 September
to 25 September, 2024 in a renowned company as per our academic requirement.
We take great pleasure in informing you that we have successfully completed the
training program and as a part of it we have tried to prepare a comprehensive report
which will illustrate our observations on various aspects of CHINA BANGLA
PLASTIC INDUSTRIES LIMITED(CBPL).

We, therefore, will be much obliged to you if you will be kind enough to accept the
report and also would be kind enough to forgive our mistakes that might have taken
place unintentionally.

Yours sincerely,

Student Name Roll No

Shohan Ali 211310
Amir Hossain 211328
Md. Maidul Islam 211330
Ahsan Shahriar Asif 211333
Rifat Al Prince 211329
Mst. Nusrat Zahan Sumi 211340
Farzana Mahumda 211344
Sumaiya Khatun 211351
Mst. Su Maia Akter 211339
Sabiha Islam 211353
Md. Sohan Hossain 211316

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Fig: In front of industry with MD

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Objective
For the last years, we went through several courses to complete our post-graduation.
We studied many topics theoretically and have also done our practical classes with
some basic equipment and machines but could not see their implementation in
industries. So far the enrichment of our theoretical knowledge we are here in your
pvc industry and our objectives are,

For the development of our practical skills and techniques which are directly
applicable to our careers.

❑ To realize and know how a pvc company runs.

❑ To know how its departments are interlinked and work together.
❑ To identify how GMP or cGMP is applied in the plant.
❑ To have an idea about Standard Operating Procedure (SOPs).
❑ To get information about how a product runs smoothly and be a quality based
product.
❑ To see how quality is assured as well as controlled.
❑ To learn about the documentation record practices.
❑ To get general ideas about corporate environment and activities of an
organization.

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ACKNOWLEDGEMENT

First of all I would like to express my deepest gratitude to ALLAH, the Almighty
for his mercy extended to me this “Internship Report”, manages each and everything
soundly. To perform any kind of job perfectly, there should be a proper theoretically
knowledge about it. Based on this, the “Internship Report” is including in the
syllabus of our M.Sc. (Eng.) Doubtlessly it is a timely and prudential stay of our
most respectable teachers and well are grateful to them for this.

At first, we wish to express our sense of gratitude to Professor Dr. Sharif Md. Al-
Reza, chairman dept. of Applied Chemistry & Chemical Engineering, IU.

We would like to express our gratitude to CBPL Ltd Authority especially Mr. Md.
Nurujjaman. I must also express my heartfelt thanks to the officers of the
administration, Chemist and Worker of those industries for their act of kind co-
operative that made us possible to have a clear and accurate concept and to
understand all the acclivities within those industries. During our two weeks of
training in CBPL. we have got lots of generous cooperation from every people at
every sector. We are really thankful to all the officers and workers.

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Table of contents

Title Page no
❖ Company Profile 07
• Overview
• Mission
• Vision
• Products
❖ Human Resource Department 08

❖ Environmental Health & Safety 11

❖ Production 12
• Raw Material Selection: 12
• Extrusion 12
• Molding and Fitting Production 15
• Quality Control 17
• Finishing and Packaging 20

❖ Process description 21
• Process Flowchart 22
❖ Learning Experiences 24

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Company Profile:
Company Name: China Bangla Plastic Industries Limited
Founded: 2017
Industry: Manufacturing
Products: PVC and uPVC Pipes and Fittings

Overview:
China Bangla Plastic Industries Limited is a leading manufacturer of high-quality
PVC and uPVC pipes and fittings, established in 2017. With a commitment to
excellence and innovation, we have rapidly grown to become a trusted supplier in
the plumbing, construction, and irrigation industries.

Mission:
Its mission is to provide durable, reliable, and cost-effective piping solutions that
meet the diverse needs of our customers. They strive to enhance infrastructure
development while ensuring environmental sustainability in our manufacturing
processes.

Vision:
To be the preferred choice for PVC and uPVC piping solutions globally, recognized
for our quality, integrity, and customer service.

Products:
• PVC Pipes: Ideal for various applications, including plumbing, drainage, and
irrigation, our PVC pipes are designed for durability and high performance.
• uPVC Pipes: Their unplasticized PVC pipes are perfect for pressure
applications and offer excellent resistance to chemicals and corrosion.
• Fittings: They provide a wide range of fittings, including elbows, tees,
connectors, and more, ensuring seamless integration with our pipes.

Sustainability:
They are committed to sustainable practices. They implement eco-friendly
manufacturing processes and focus on recycling materials to minimize
environmental impact.

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Customer Commitment:
They prioritize customers' needs by offering exceptional service and technical
support. Their experienced team is dedicated to providing solutions tailored to
specific requirements, ensuring satisfaction at every step.

Human Resource Department:

Functions of Human Resource Department

CBPL is one of the leading corporate houses of the country. It has a handsome
amount of work force led by the HRD. Different jobs are done by this department
for a smooth running of the industry.

Functions of Human Resource Department can be outlined as followed:

• Ensure Compliance with Labor Laws
The department has to know and comply with that state's particular set of rules
employment regulations. This includes such issues as the number of breaks given
per number of hours worked and the number of hours and the age in which an
individual can become employed.
• Recruitment and Training
Recruiting and training new employees are primary responsibilities of the human
resources team. This part of the job often entails advertising open positions,
interviewing and hiring candidates and setting aside hours devoted to training the
new recruits.
• Record Keeping
Company should keep records regarding income, expenses, purchases and a
summary of business transactions. The human resources department should also, of
course, maintain employees' records including their individual tax forms. The
company's business license, inventory statistics, insurance records and ail other
pertinent business information should also be on file.
• Payroll and Benefits
Payroll often exists as a separate division in large companies, in small businesses; it
is generally handled by a small human resources staff. Health care benefits are also
handled by the human resource department.
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 • Employee Relations
When there is a dispute or misunderstanding between employees or between
employees and a manager, it is the human resource officers who mediate the
situation. Employees are encouraged to bring relational problems to the attention of
the human resources staff for resolution.
• Employee Performance Improvement Plans
The human resources department is often instrumental in setting up performance
improvement plans commonly called PIPs. In general, these are written proposals
designed to help struggling employees improve their work to raise it to a certain
expectation level of the company. The PIP includes a description of the behavior or
performance that needs attention, objectives to be met within a certain time period,
a plan for accomplishing the improvement along with support resources and detailed
consequences if the improvement does not occur.
• Prepare HR inventory report monthly
It includes daily labour (DL) to the Director of the company and also prepares the
Daily manpower statement.
• Inform Managers and Employees
Inform Managers and Employees regarding personnel policies and procedures of the
company.
• Deals with industrial related issue
HR department deals with negotiation with employee’s union; ensure the labor rights
deals with labor demand.
Thus their activities Include:
1. Maintain liaison with Government Regulatory bodies.
HRD assess the training needs of personnel in light with cGMP & others related to
HRD issues. The training includes:
a. GMP
b. Safety
c. Training on performance appraisal management
d. SOP for HR & Administration
e. Labor standard & work place environment in pharmaceutical
industry.
2. Monitor leaves of plant employees. Each employee has a leave file which
integrate the all kinds of leaves like- v AL (Annual leave)
❖ ML (Medical leave)
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 ❖ CL (Causal leave)
❖ Other leaves- Special leave
• Maternity leave
• Leave without pay etc.
3. Ensure safety of all employees and company assets.
4. Ensure proper securely management of the plant.
5. Handle external visitors & arrange necessary uniform and other accessories.
6. Supervise overall cleaning service of the plant (housekeeping, gardening etc.)
7. Supervise washing facility to provide proper clean dress as per departmental
daily requirement.
8. Supervise transport pool (Distribution, repair, maintenance).
9. Supervise canteen management.
10. Supervise overall services and washing facility of the plant (housekeeping,
gardening etc.) as per department daily requirement.

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Environmental Health & Safety

The Safety Department of CBPL (HPL) is concerned with Personal Safety, that
is, safety of the employees. They arrange annual check-up for the existing
employees and pre medical check-up for the newly joined employees. This
check-up is required for the regular audit and satisfaction of the employees.

Activities of Safety Department

• Collection of Material Safety Data Sheet (MSDS)

• Taking preventive action for fire.
• Identification of hazardous area and taking preventive measures
• Preparation of SOPs for handling chemicals
• Identification of criticalities of machineries and providing awareness &
safety
• Providing Personnel Protective Equipment (PPE)
• Providing First Aid & it’s using procedure
• Arranging yearly Medical Checkup program
• Identification of pipelines by using different colors on them according
to the standards
• Identification of dangerous goods by using different symbols on them
according to the standards
• Providing Automatic Fire Alarming System with smoke & heat
detector
• Providing training for using alternative exit way in case of any type of
emergencies

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Production

Products: PVC Pipes, uPVC Pipes, and Fittings

Production Overview:
It specializes in the manufacturing of high-quality PVC and uPVC pipes and fittings.
Our production facility employs advanced technology and adheres to strict quality
control standards, ensuring that our products meet the highest industry
specifications.

Manufacturing Process:
1. Raw Material Selection:
We source premium-grade PVC and uPVC resins from trusted suppliers to
ensure durability and performance.

Fig: PVC Pellet

2. Extrusion:
Our state-of-the-art extrusion machinery transforms raw materials into pipes
of various sizes and specifications. The process is carefully monitored to
maintain consistent quality and dimensions.

The extrusion process in the PVC pipe manufacturing industry begins with the
preparation of raw materials. PVC resin is mixed with additives, such as stabilizers,

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lubricants, and colorants, to enhance the properties of the final product. This mixture
is then fed into an extruder, a machine that consists of a long heated barrel and a
rotating screw.

As the screw turns, it moves the material through the barrel, where heat and
mechanical shear cause the PVC to melt and become a viscous fluid. The
temperature is carefully controlled to ensure that the PVC is fully melted without
degrading. Once the material reaches the desired consistency, it is forced through a
die, which shapes the molten PVC into the desired pipe profile.

After exiting the die, the newly formed pipe is cooled, often using a water bath or
air cooling system, to solidify its shape. This cooling process is crucial to
maintaining the dimensional accuracy of the pipe. Once cooled, the pipe is cut to
length and may undergo additional processes, such as trimming or surface finishing,
to meet specific requirements.
Finally, the pipes are packaged and prepared for shipment. Throughout this process,
quality control measures are implemented to ensure that the final product meets
industry standards for strength, durability, and performance. The efficiency of the
extrusion process and the properties of the PVC used play significant roles in the
overall success of the manufacturing operation.

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Fig: Extrusion Equipment
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3. Molding and Fitting Production:

Fittings are produced using injection molding technology, allowing for precision and
versatility in design. Our product range includes elbows, tees, connectors, and more.

Injection molding is a widely used manufacturing process in companies that produce

a variety of plastic products. The process begins with the heating of plastic pellets
until they become molten. These pellets are typically made from thermoplastic
materials, allowing them to be remolded.
Once the plastic reaches the appropriate temperature, it is injected into a mold under
high pressure. The mold is designed to shape the molten plastic into the desired final
product, whether it’s a small component or a larger assembly. After the injection,
the material is allowed to cool and solidify, taking on the precise shape of the mold.
Cooling time varies depending on the thickness of the part and the material used, but
once solidified, the mold opens to release the finished product. The efficiency of the
injection molding process allows for rapid production and high levels of precision,
making it ideal for manufacturing everything from automotive parts to consumer
goods.

Companies that utilize injection molding benefit from its ability to produce complex
shapes with consistent quality. Additionally, the process allows for the integration
of various features, such as threads or snap-fits, directly into the molded parts,
reducing the need for secondary operations. Overall, injection molding plays a
crucial role in the production capabilities of many manufacturing companies.
Injection molding is a manufacturing process used to create parts by injecting molten
material into a mold. This technique is particularly popular for producing plastic
products, but it can also be applied to metals and ceramics. The process begins with
the heating of plastic pellets until they become liquid. This molten plastic is then
injected into a precisely designed mold under high pressure. Once it cools and
solidifies, the mold opens, and the finished part is ejected.
The uses of injection molding are extensive. It’s commonly employed in various
industries, including automotive, consumer goods, medical devices, and electronics.
Products made through this process range from simple components, like bottle caps,
to complex assemblies, such as automotive dashboards.

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The advantages of injection molding are significant. Firstly, it allows for high
production rates, making it efficient for mass manufacturing. The precision of the
molds enables tight tolerances, ensuring consistent quality across batches.
Additionally, the ability to create complex shapes and integrate features reduces the
need for secondary machining processes, saving both time and costs.

Another advantage is material versatility; a wide range of thermoplastics,

thermosets, and elastomers can be used, allowing for tailored properties such as
flexibility, durability, or resistance to chemicals. Furthermore, injection molding
supports sustainability, as many materials used are recyclable, and advancements in
technology have improved energy efficiency.

Overall, injection molding is a highly effective process that meets the demands of
various industries, combining speed, efficiency, and versatility.

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 Fig: Injection molding equipment

4. Quality Control:
Every stage of production undergoes rigorous testing. We conduct physical and
chemical tests to ensure our products meet national and international quality
standards.

The quality control (QC) department in the PVC or uPVC pipe manufacturing
industry plays a crucial role in ensuring that the final products meet the required
standards for safety, durability, and performance. This department is responsible for
monitoring the entire manufacturing process, from raw material selection to the final
inspection of finished pipes.

The QC department typically starts its work by assessing the quality of raw
materials. This involves testing the PVC pellets and additives for their chemical

17
composition, physical properties, and compliance with industry standards. Only
materials that meet stringent criteria are approved for production.
During the manufacturing process, the QC team conducts regular inspections at
various stages. This includes monitoring the mixing of raw materials to ensure
uniformity and consistency. They also oversee the extrusion process, checking
parameters such as temperature, pressure, and flow rates. Any deviations from
established norms can lead to defects in the final product, so real-time monitoring is
essential.

Once the pipes are extruded and cooled, the QC department carries out thorough
inspections. This includes dimensional checks to ensure that the pipes meet specified
measurements and tolerances. Visual inspections are also performed to identify any
surface defects, such as scratches or irregularities.
In addition to visual and dimensional inspections, the QC department often conducts
a series of mechanical and performance tests. These may include pressure testing to
evaluate the pipes' ability to withstand internal pressures and stress tests to determine
their structural integrity. In some cases, the QC team may also perform
environmental tests to assess the pipes' resistance to various chemicals or weather
conditions.

Documentation is a key aspect of the QC department's responsibilities. They

maintain detailed records of all inspections, tests, and outcomes, ensuring
traceability and compliance with regulatory requirements. This documentation can
be critical in identifying trends, investigating issues, and providing accountability.
The QC department also collaborates closely with production teams to address any
quality issues that arise. If defects are identified, the QC team works to identify the
root cause, whether it be a material issue, a problem with the machinery, or a process
error. This proactive approach helps to minimize waste, reduce rework, and enhance
overall product quality.

Training and continuous improvement are essential components of the QC

department's function. The team stays updated on industry standards and best
practices, ensuring that the company remains competitive and compliant with
regulations. Regular training sessions for staff on quality standards and procedures
help foster a culture of quality throughout the organization.

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QC Parameters
❖ Raw Material Quality: Assessing the checical composition, physical properties,
and specifications of PVC pellets and additives to ensure they meet industry
standards.
❖ Dimensional Accuracy: Measuring the length, diameter, and wall thickness of
the pipes to ensure they adhere to specified tolerances and dimensions.
❖ Surface Quality: Inspecting the exterior of the pipes for defects such as
scratches, dents, or irregularities that could affect performance.
❖ Mechanical Strength: Conducting tests such as tensile strength, impact
resistance, and flexural strength to evaluate the durability and reliability of the
pipes.
❖ Pressure Resistance: Performing pressure tests to determine the pipes' ability to
withstand internal pressure without failure.
❖ Thermal Stability: Assessing how the material behaves under varying
temperature conditions, ensuring it maintains integrity during use.
❖ Chemical Resistance: Testing the pipes for their resistance to common
chemicals and environmental factors they may encounter in their applications.
❖ Visual Inspection: Conducting thorough visual checks throughout the
manufacturing process to identify any immediate defects or inconsistencies.
❖ Consistency of Production Parameters: Monitoring the extrusion process
parameters, such as temperature, pressure, and flow rates, to ensure they remain
within specified limits.
❖ Documentation and Traceability: Maintaining detailed records of all
inspections, tests, and results to ensure compliance and facilitate accountability.

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5. Finishing and Packaging:
After quality checks, products are finished and packaged to prevent damage
during transport. We prioritize eco-friendly packaging solutions to minimize our
environmental impact.

Fig: Finished Product

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Process description;
1. Raw Material Preparation
o PVC/uPVC Pellets
o Additives (stabilizers, lubricants, colorants)
2. Mixing
o Combine pellets and additives in a mixer
o Ensure uniform distribution
3. Extrusion
o Feed mixed material into the extruder
o Heat and melt the material
o Use a screw to convey molten PVC to the die
4. Molding
o Shape the molten PVC using a die to form the pipe profile
5. Cooling
o Pass the shaped pipe through a cooling system (water bath or air
cooling)
o Solidify the pipe
6. Cutting
o Cut the cooled pipe to specified lengths
7. Finishing
o Trim and inspect for quality
o Apply any additional surface treatments
8. Quality Control
o Test for dimensional accuracy, strength, and other specifications
9. Packaging
o Package the finished pipes for shipment

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Raw Material Mixing Extrusion
Preparation

Cutting Cooling Molding

Finishing Quality Control Packaging

Fig: Process Flowchart

The manufacturing process of PVC or uPVC pipes begins with the preparation
of raw materials, primarily PVC pellets. These pellets are often combined with
various additives, such as stabilizers, lubricants, and colorants, to enhance the
properties of the final product. This mixture is then placed in a high-capacity
mixer, where it is thoroughly blended to ensure an even distribution of the
additives throughout the PVC.

Once the mixing is complete, the blended material is fed into an extruder. This
machine consists of a long barrel equipped with a rotating screw. As the screw
turns, it moves the material forward while simultaneously applying heat. This
heat, generated both by the friction of the screw and external heating elements,
causes the PVC to melt into a viscous fluid. The temperature is carefully
controlled to achieve the optimal melting point without degrading the material.
After the PVC has reached the desired consistency, it is forced through a die,
which shapes the molten material into the specific profile of the pipe. The design
of the die is crucial, as it determines the dimensions and characteristics of the

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finished pipe. Upon exiting the die, the newly formed pipe is in a soft, malleable
state and requires cooling to solidify its shape.

The cooling process typically involves passing the extruded pipe through a water
bath or subjecting it to air cooling. This step is vital for maintaining the
dimensional accuracy of the pipe and ensuring it retains the desired properties.
Once the pipe has cooled and solidified, it is cut to the specified lengths using
automated cutting equipment.

Following cutting, the pipes may undergo a finishing process where any rough
edges are trimmed, and the surface is inspected for quality. This quality control
phase is essential to ensure that the pipes meet industry standards for strength,
durability, and dimensional accuracy. Various tests, such as pressure testing and
visual inspections, may be performed during this stage.

Finally, the finished pipes are packaged and prepared for shipment. They are
typically bundled and labeled according to specifications, ready to be transported
to customers. This entire process, from raw material preparation to final
packaging, reflects the efficiency and precision of modern PVC pipe
manufacturing, ensuring high-quality products that meet diverse application
needs.

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Learning Experiences:

During our internship at the PVC or uPVC pipe manufacturing company, we gained
valuable insights and hands-on experience that significantly enhanced our
understanding of the industry. One of the primary learning outcomes was an in-depth
comprehension of the manufacturing processes involved in producing high-quality
pipes. We observed each stage, from raw material preparation and mixing to
extrusion and cooling, gaining practical knowledge about the equipment and
techniques used.

We also developed a strong appreciation for the importance of quality control

throughout the production process. By participating in quality inspections, we
learned how to assess raw materials and finished products against established
standards. This experience underscored the critical role of QC in maintaining
product integrity and safety, and we became familiar with various testing methods
and the parameters that must be monitored.

Additionally, our internship provided opportunities to collaborate with different

departments, allowing us to understand the importance of teamwork in a
manufacturing setting. We learned how communication and coordination among
production, QC, and logistics teams are essential for efficient operations.
Furthermore, we gained insights into the challenges and innovations within the
industry. Engaging in discussions with experienced professionals gave us a broader
perspective on market trends, sustainability practices, and advancements in
technology that are shaping the future of pipe manufacturing.

Here are the learning outcomes from our internship at the PVC or uPVC pipe
manufacturing company presented in bullet points:
• Understanding Manufacturing Processes: Gained in-depth knowledge of the
entire pipe production process, including raw material preparation, mixing,
extrusion, cooling, and cutting.
• Hands-On Experience: Observed and participated in the operation of various
machinery and equipment used in manufacturing.

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• Quality Control Insights: Learned about the importance of quality control in
maintaining product integrity through inspections and testing.
• Familiarity with Testing Methods: Gained experience in various quality
testing methods, including dimensional checks, pressure testing, and visual
inspections.
• Collaboration and Teamwork: Worked alongside different departments,
enhancing our understanding of how communication and coordination are
crucial for efficient operations.
• Exposure to Industry Challenges: Engaged in discussions about current
challenges, trends, and innovations in the PVC pipe manufacturing industry.
• Sustainability Awareness: Learned about sustainability practices and the
importance of environmentally friendly manufacturing processes.
• Professional Development: Developed practical skills and a deeper
understanding of the engineering and manufacturing sectors, preparing us for
future careers.
• Networking Opportunities: Built relationships with industry professionals,
providing valuable contacts for future career opportunities.

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