Internship Report

Chapter 1

INTRODUCTION

1.1 Company Profile

Company Name : Mangalore Pipe Industries

Location : Kamblapadavu, Near Mangalore University, BantwalTaluk

The company was established in the year 2000. Like every other beginner, they too had a humble
beginning, weighing every opportunity making the best of whatever came in their way. But they
had a dream that was big, a restless urge to grow and a determination that was as strong as steel.

Their factory and office is situated at kamblapadvu near Mangalore University ,BantwalTaluk all
the manufactured products are stored in the warehouse. The sales and marketing jobs are carried
out here. PVC pipes manufactured here.

The main focus of the company is to manufacture and maintain always the best quality PVC and
UPVC pipes ranging from 0.5 inches to 6.0 inches. Company is manufacturingtwo layered pipes
available in three different colours, White , blue. The quality is the key that differentiates them
from others to maintain leadership in the market.

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1.2 Organizational Structure

Proprietor

Factory Supervisor Three Workers

Three Workers One Helper

Two Helpers

Proprietor: Mr. Ameer Ali is the owner of the business and the company. He looks after the
whole organization.

Three workers: Three workers in the warehouse take care of the sales.

One Helper: Helper maintains and cleans the whole warehouse.

Factory Supervisor: The supervisor is in charge the factory and supervises the work in the
factory.

Three workers: The workers operate machineries and manufacture the pipes.

Two Helpers: Helpers assists the workers and maintain the cleanliness of the factory.

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1.3 Vision and Mission

Vision

To become a company that constantly strives for quality and customer satisfaction by providing
best PVC pipes and fitting solutions with global benchmarks.Focus the organization on the
execution of its strategy.

Mission

To deliver water and energy to the world in the most efficient way.

1.4 Policies

1.4.1 Quality Policy

Quality is an integral part of their commitment to top-class product and customer service.At
Mangalore Pipe Industries, they practice continual improvement to achieve customer delight by
providing customer-centric, cost-effective, timely and qualitative PVC pipes.

1.4.2 Safety Policy

 Personal hygiene: Be fit for the job, through good healthy habits, cleanliness
 Know your job responsibilities
 Wear protective goggles to prevent any possibility of eye contact especially when cutting.
 Standard industrial protective clothing should be utilized.
 Provide adequate general and local exhaust ventilation.
 Gloves should be worn if edges are sharp where pipes have been broken.
 Keep equipment’s, tools, materials and work area clean and orderly
 Any machine that has exposed hazardous parts must be properly guarded
 Employees are not to use equipment or machinery that is not adequately guarded
 Fire and emergency preparedness

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1.4.3 HR Policy

1. Development of superior workforce

2. Safety of the workforce
3. Development of an employee oriented company culture that emphasizes quality
4. Development of the human resources department
5. Personal ongoing development

1.5 Products

The products available at Mangalore Pipe Industry are PVC pipes and UPVC pipes ranging from
0.5 inches to 6.0 inches.

PVC pipes : These are used in variety of applications in buildings and construction, healthcare,
electronic, automobile and other sectors, in products ranging from piping and sidings, wire and
cable insulations. There are available in many sizes. Plumbers use several types of pipes to
construct underground service and water lines, including synthetic and metal pipes. Because
climate and site conditions often affect a pipes performance, it’s best to consult local codes or a
building professional before installing an underground water supply line

Fig 1.1: PVC pipes

UPVC Pipes: UPVC stands unplasticized polyvinyl chloride is a rigid chemically resistance form
of PVC used for pipe works, window frames.It is incredibly strong ,stiff and cost effective, and so
is often used for sewage lines and exterior drainage pipes.

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Fig 1.2: UPVC pips

1.6 Customers

The customers of Mangalore Pipe Industries are:

 For domestic use in households

 Construction contractors (whose details could not be disclosed)

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Chapter 2
TASK PERFORMED
2.1 Introduction

PVC pipe which is made from polymerized vinyl chloride, a synthetic resin, which when
plasticized or softened with other chemicals has some rubber like properties. Derived from
acetylene and anhydrous hydrochloric acid.PVC pipe nominal sizes that are to be used with PVC
socket fitting (schedule 40) and PVC socket or threaded fittings (schedule 80).

PVC pipe and fittings have got tremendous demand in India as well as abroad. To manufacture
this, all the machinery and raw materials are available indigenously. A polyvinyl chloride (PVC)
pipe is made from a plastic and vinyl combination material. Thepipes are durable, hard to damage
and long lasting.

A PVC pipe does not rust, rot or wear over time. For that reason, PVC piping is most
commonly used in water systems, underground wiring and sewage lines. PVC was first developed
in 1925 when a BF Goodrich employee, Dr.Waldosemon, attempted to invent a method for
bonding metal and rubber. After blending materials together to create a strong and flexible
material, semon discovered PVC.

Nonetheless, the product remained virtually useless for another decade. In the late 9030’s PVC
was found to have Great shock absorbing abilities. This discovery led to the creation of long
lasting PVC tire threads, which were created with flexible forms of PVC.

PVC pipes and fittings exhibit excellent resistance to aggressive environment both naturally
occurring and as a result of industrial activity. They are resistance to almost all types of corrosion,
either chemical or electrochemical in nature. Since PVC is a non-conductor, galvanic and electro
chemical effects do not occur in PVC pipes.

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PVC compounds, in general, may be divided into two groups, i.e. Granulated compound where
mix is fused and extruded in pellets form and Dry Blend where resultant compound is often in
free flowing powder flow.

2.1.1 PVC PIPES

Polyvinylchloride(PVC) pipe is made from a plastic and vinyl combination materials. The pipe
are durable, hard to damage and long lasting. They do not rust, rot or wear overtime. PVC is a
polar polymer with strong intermolecular forces therefore it is rigidat room temperature. On other
hand when a plasticizer is depend upon fabrication flexible PVC product are obtained. This
versatility is a major advantages of PVC.

PVCis a common, strong but lightweight plastic used in construction. It is made softer and

more flexible by the addition of plasticizers. If no plasticizers are added, it is known as u PVC
(unplasticized polyvinyl chloride) or rigid PVC. In the U.S. and Canada it is known as vinyl or
vinyl siding.

PVC is undoubtedly a very versatile thermoplastic material commercially available in variety

of compound form to cover a wide range of flexibility and hardness for host of applications. Its
physical strength and resistance to water and most of chemicals makes it popular plastic for wide
variety of products polyvinyl chloride, or PVC is a synthetic material that has been used to make
pipes since the early 20th century. It has become an increasingly popular substances foe builders
and plumbers because of its resistance to corrosion. In additionto varying by size, thickness is a
chemical composition, PVC pipes can be color-coded by function (e.g., blue for water main, red
for fire main).

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Fig.2.1 PVC pipes

2.1.2 Manufacturing
Because of its rigid properties once it’s formed, manufacturers frequently blend additional
plasticizing polymers into PVC. These polymers make PVC pipe are more bendable and
generally, easier to work with than if it remains unplasticized. PVC andU-PVC are largely made
of the same material. Polyvinylchloride is a polymer that can be heated and molded to create very
hard, strong compounds such as piping those plasticizing agents are left out when is nearly as

rigid as cast iron pipe.

2.1.3 Handling
For installation purposes, PVC and U-PVC pipe are generally handled in the same fashion. Both
can be easily cut with plastic-cutting hack saw blades or power tools designed to cut PVC pipe
and both are joined using gluing compounds rather than through soldering. Because U-PVC pipe
doesn’t contain the plasticizing polymers that make PVC slightly flexible, it must be cut perfectly
to size because it doesn’t allow for give.

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Fig. 2.2 Plumbing Tools

2.1.4 Advantage of PVC pipe

 Resistance to Corrosion
 Lightweight
 Toughness
 Rigidity
 Economical in laying, joining and maintenance
 Ease of fabrication

2.1.5Applications

It’s durable product to use in plumbing systems. It’s easily cut and its joints don’t require
soldering, fastening with glue instead, and offers a little amount of give when pipes aren’t sized
perfectly, so PVC pipe is frequently chosen by handymen as an easier-to-use alternative to metal
piping. PVC pipe is used as a replacement for copper and aluminum piping on non-portable
water, replacing metal piping in waste lines, irrigation system and pool circulation system.
Because it resist corrosion and degradation from biological sources.

The use of U-PVC isn’t quite as widespread in plumbing in America, through its durability has
helped it to become the material of choice for plumbing sewage lines, replacing cast iron pipe. It’s

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also frequently used in manufacturing exterior drainage system such as rain gutter downspouts.
The only type of plastic pipe that should be used for transmission of drinking after is C-PVC pipe.

2.1.6 Types of PVC pipe

There are many types of PVC pipes. Some of the main pipes which we will be discussing are

 PVC
 CPVC
 UPVC
 OPVC
 MPVC

2.1.6.1 PVC (Polyvinyl Chloride)

PVC pipes will cause them to lose some of their integrity.Cheap,light and resistance to
corrosion,PVC became an obvious solution to many of the problems faced by plumbers,builders
and city planners. It gained popularity in the United States in the 1940s, and has since become a
mainstay for many uses, including irrigation, sanitary sewer collection and electrical
communications. Because it is a thermostatic plastic,PVC can only be melted and moulded once.
A second melting to re-shape.

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2.1.6.2 CPVC and UPVC

CPVC stands for chlorinated PVC pipe. Suitable for a variety of applications, CPVC has
higher chlorine content than regular PVC, which means it can withstand a broad spectrum of
temperatures. CPVC isideal for use with hot water heaters.UPVC stands for unplasticized PVC
pipe. This type of material is more rigid than traditional PVC material, and is commonly used for
water waste transport. It can also be used to make siding materials for construction and remodel
purposes.

Fig. 2.4 CPVC and UPVC

2.1.6.3 MPVC and OPVC

UPVC pipes have thicker walls than regular PVC pipes. This modification enables them to
withstand more internal pressure .MPVC and OPVC pipes are newer versions of the UPVC. If
you see PVC with a dash after it, the subsequent character has something to do with the thickness
of the pipe walls through they have thinner walls than the traditional UPVC,MPVC and OPVC
pipes are specially designed for high levels of internal pressure as well.

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Fig. 2.5 MPVC Pipes

Fig .2.6 OPVC

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2.2 First Week

Fig 2.6: Manufacturing Unit

 learnt about the company and listed other manufacturers in the market
 learnt about the process of PVC pipe extrusion machine , injection moulding , blow
moulding and various other process of moulding
 learnthow polyvinyl chloride manufactured and it is the most versatile thermoplastics
with a wide range of application than any other plastics..
 learnt about the various process parameters that determine the quality of the product
 learnt about the safety requirements needed while carrying out the process to avoid
injuries.

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2.3 Second Week

Fig 2.7: Equipments unit

 Learnt about the following equipments.

 High-speed mixer, die size 20,25,45,63,75mm and mandrel size 2.5kg/cm2 ,4kg/cm2 ,6
kg/cm2, 10 kg/cm2.
 Scrapper , grinder , heavy duty fitted with electric motor , overhead water tank and
recycling pump unit.
 learnt about the weighing balance , pipe storage , racks , maintainance of small hand
tools , greasing , oil equipment’s and so on.
 we were asked to watch and understand the process of manufacturing which was done
by their experienced workers.

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2.4 Third Week

 we were assisting the workers in the process of manufacturing

 understood how and when to add raw materials after the process starts to obtain
optimum quality and thickness
 learnt about the controller used there
 learnt to operate the controller which controls the manufacturing process

Fig 2.8 : Sizing Unit

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Fig 2.9: Traction Unit

2.5 Fourth Week

 we involved in the manufacturing of PVC , UPVC ourselves under the supervision of

experienced personnel.
 We performed cutting, printing, shaping operations.

 The last operation is cutting. There are basically two cutting techniques for rigid PVC
pipes, manual and automatic. The pipes are then tested for ISI marks.
 In printing unit company logo trademarks are printed on the pipe.

 In shaping unit the pipe sides are enlarged for connecting purposes.

 Conducted quality checks by visual inspection to ensure quality.

 Listed out various possible defects that may occur.

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Fig 2.10 :Cutting operation Fig 2.11 : Printing Operation

Fig 2.12:
Shaping Operation

Chapter 3

OUTCOMES

 Learnt how the raw materials are converted into a finished product.
 Learnt about the PVC extruding process in the manufacturing of the PVC pipe.
 learnt how to control the various process parameters using a controller
 learnt to perform quality checks by visual inspection

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Chapter 4

CONCLUSION
Internship in MANGALORE PIPE INDUSTRIES for a period of 28 days was very useful where I
could able to gain lots of information about PVC pipe industry

Internships are very necessary for an individual in understanding the working of Industries and
the application of theoretical knowledge gained in college. Internship is necessary to bridge the
gap between theoretical knowledge from the classroom and the real world application of this
knowledge. In addition it helps us to understand the subject better.

In our internship we learnt how a small-scale factory operates. We had hands on experience on
manufacturing PVC pipes. We understood what common problems that are faced by an industry
are and how to overcome it. We understood the importance of time and how to manage it well.
We understood that safety is one of the most important factor in any industry.
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By this internship a great deal of practical knowledge was gained. We came to know that
theoretical knowledge alone is not sufficient to be a good engineer at any company. We had
opportunity to work with experienced personnel who were more than happy to share their
knowledge and experience with us.

REFERENCES

1. Rosato, D. V. - “Extruding Plastics- Practical Processing Handbook”, First edition, Thomson

Science Publication, New York, (1998).
2. Farshad, M. - Polymer Testing 23, p.967-972 (2004).
3. Titow, W. V. - “PVC Technology Handbook”, Elsevier Applied Science Publications, London,
(1984).
4. McCauley, J. C.; Heald, R. &Hussain, I. M. - “Machinery’s Handbook”, Industrial Press Inc,
New York, (2000).
5. Sarvetnick, H. - Polyvinyl chloride, Polytechnical services, New York, (1979).
6. Blackburn, M. - “Global PVC Market”, in: Anais do 2° CongressoBrasileiro do PVC, São
Paulo Jun (2007).

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7. Thiehi, C. - “South American PVC Market”, in: Anais do 2° CongressoBrasileiro do PVC, São
Paulo Jun (2007).

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