A TECHNICAL REPORT

ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME

(SIWES)
UNDERTAKEN AT
FOAMING SECTION OF MOUKA LIMITED,

IKEJA, LAGOS STATE.

BY

AZUKA IFESINACHI SUCCESS

(2019214062)

DEPARTMENT OF CHEMICAL ENGINEERING,

FACULTY OF ENGINEERING
NNAMDI AZIKIWE UNIVERSITY, AWKA, ANAMBRA STATE.

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR

THE AWARD OF BACHELOR OF ENGINEERING (B.ENG.)
DEGREE IN CHEMICAL ENGINEERING

JANUARY, 2024

i
 DEDICATION

I dedicate this project to God Almighty our creator, author and finisher of our faith, our source of

inspiration, wisdom, knowledge and understanding. He has and is still the source of our strength

throughout this field study.

ii
 ACKNOWLEDGEMENT

I give thanks to God for his grace and strength given to me all through the SIWES program. He is

and has been faithful to me during the course of searching and working in my place of attachment.

I just can’t thank my parents enough who have always been there for me, spiritually, financially,

mentally and morally. I greatly appreciate my siblings who have supported me with ideas on how

to make the best of my SIWES program.

Also, I wish to appreciate Mr Emeka who took time to find a place of attachment even after

informing him of my ordeal late.

I cannot fail thank Engr. Chimezie, for putting in good words for me at the company. I could not

have asked for more!

To Mr and Mrs Mbamala for accepting me into your family – for the accommodation, the feeding,

the prayers, and care I received. It really helped me stay strong throughout the program.

I wish to thank the Head of Department and the entire staff of Chemical Engineering Department,

Nnamdi Azikiwe University for giving me this ample opportunity to go out there to experience

engineering in real life thereby increasing my knowledge.

My appreciation goes to all the people who imparted knowledge in me in Mouka; my industry

based supervisors - Engr. Obinna, Engr. Christian, and Engr. Casmir. To Engr. Emeka, thank you

for the teachings in all aspect of learning. Your notes has helped me in getting understanding in

polymer section.

I am grateful to the plant manager for reconnecting me to Laplace and Fourier series. To Mr.

Afolabi, Mrs Juliet, Mr. Segun, thank you for the diligent training.

I also appreciate my fellow interns and friends, Falilat and Taiwo, for making the journey

interesting and lively.

iii
I can”t fail to acknowledge the workers in the foaming section most especially Mr Ibrahim and Mr

Dare for making the job a stress free one for me.

To Mr Moses, Mr Osas, Miss Grace, Miss Abigail, and the entire staff of Mouka, big thanks for

your encouragement and intellectual support.

Finally, to all who ensured that I was always safe, I appreciate you all.

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 ABSTRACT

This technical report is based on the experiences gained during my five months of industrial

training at Mouka Limited, Ikeja, Lagos. This report highlights the activities engages in the

Foaming Department, the raw materials used for the production of polyurethane foam, the

chemistry behind the formation of semi-rigid foam, the reasons for box foaming, the production

of viscoelastic and reconstituted foams and the different machines used for all.

It also details the activities engaged in the quality assurance department, duties and responsibilities,

the different tests carried out on the manufactured foam including Density Test, Tensile Strength

Test, Ball Rebound Test, Compression Load Test, Inflection Load Test and more. Other sections

in the company were also included and explained briefly including photos for better experience.

Most importantly, this report clearly describes the activity and the experience gained during the

period of training. Also, it stated the problems encountered and gave recommendations for

improvement of the scheme and students.

v
 TABLE OF CONTENTS

Content Page

TITLE PAGE i

DEDICATION ii
ACKNOWLEDGEMENT iii
ABSTRACT v
TABLE OF CONTENTS vi
LIST OF TABLES viii
LIST OF FIGURES ix
CHAPTER ONE 1
INTRODUCTION 1
1.0 About SIWES 1
1.1 Scope of SIWES 2
1.2 Objectives of SIWES 3
CHAPTER TWO 4
ABOUT MOUKA LIMITED 4
2.0 BRIEF HISTORY OF MOUKA LIMITED 4
VISION 5
MISSION 5
VALUES – PIIPE 5
2.1 OBJECTIVES OF MOUKA LIMITED 5
2.2 DEPARTMENT AT MOUKA INDUSTRIAL PLANT LAGOS 6
2.3 ORGANOGRAM OF MOUKA LIMITED 8
2.4 INDUSTRIAL HARZARDS AND SAFETY PRECUATIONS 8
2.5 MOUKA’S PRODUCTS 9
CHAPTER THERE 12
TECHNICAL EXPERIENCE GAINED 12
3.0 THE FOAMING DEPARTMENT 12
3.1 THE FOAMING PROCESS 12
3.1.1 POLYURETHANE FOAM 12
3.1.2 VISCOELASTIC FOAM 22
3.1.3 RECONSTITUTED FOAM (SUPER DELUXE MATTRESS) 24
3.1.4 CHEMISTRY OF POLYURETHANE FOAMS 27

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 3.1.5 FOAM FORMULATION 29
3.1.6 DATA 34
3.1.6.1 CALCULATION 37
3.2 HANDLING AND STORAGE OF CHEMICALS 39
3.3 APPLICATIONS OF POLYURETHANE FOAMS 39
CHAPTER FOUR 40
4.0 QUALITY ASSURANCE (QA) DEPARTMENT 40
FUNCTIONS OF THE QA LABORATORY 40
4.1 PHYSICAL TEST AND LABORATORY TESTS DESCRIPTIONS FOR FOAM 41
4.2 CONVERSION AND FINISHING 45
4.3. SALES OF FOAM BLOCKS AND DISTRIBUTION 46
4.3.1. SALES OF MATRESSES 47
CHAPTER FIVE 49
CONCLUSION AND RECOMMENDATION 49
5.0 PROBLEMS ENCOUNTERED DURING SIWES 49
5.1 CONCLUSION 50
5.2 RECOMMENDATION 51
5.3 REFERENCES 54

vii
 LIST OF TABLES

Table 1 Formulation Chart for Density 16kg/m3 32

Table 2 Formulation Chart for Density 22kg/m3 33

Table 3 Formulation Chart for Density 22kg/m3 33

Table 4 Formulation Chart for Density 30kg/m3 34

Table 5 Sample Foam Formulation for 22kg/m3 38

viii
 LIST OF FIGURES

Figure 2.0: The Ikeja Plant Site Layout. 7

Figure 2.1: Organogram of Mouka Limited 7

Figure 3.0: Chemical structure showing 2,4-TDI and 2,6-TDI. 13

Figure 3.1: A tank where solid calcium and polyol and bended 17

Figure 3.2: Stainless steel TDI Storage tanks 17

Figure 3.3: The cream period of flexible polyurethane foam. 18

Figure 3.4: The product of the production of flexible foam 19

Figure 3.5: Viscoelastic flexible polyurethane machine 21

Figure 3.6: Viscoelastic Foam 22

Figure 3.7: Reconstituted Foam Machine 24

Figure 3.8: Orthopedics Mattress 25

Figure 3.9: The two primary chemical reactions and three secondary

reactions involved in polyurethane foam production. 26

Figure 4.0: Porosity Meter 38

Figure 4.1: Miniflex CLD Foam Hardness Tester 39

Figure 4.2: Constant Force Fatigue tester 40

Figure 4.3: Ball Rebound Tester 41

ix
Figure 4.4: The Vertical Cutting Machine 43

Figure 4.5: The Carousel Cutting Machine 43

Figure 4.6: The Quilting Machine 45

Figure 4.7: The Packaged Mattresses and Machine. 45

Figure 5.0: A figure of me at the Temporary Storage Area for Polyol 48

x
 CHAPTER ONE

INTRODUCTION

1.0 About SIWES

Students’ Industrial Work Experience Scheme (SIWES) was established by Industrial Training

Fund (ITF) in 1973 with the headquarters in Jos, Nigeria. The Scheme started in 1974 in 11

institutions of higher learning with 748 participants. By 1978, it has widened in scope to about

5,000 participants from 32 different institutions in the country and has continually continued its

spread.

It is a skill development program primarily aimed at building technical skills and experience for

professional development of students in their course of study. According to Nse (2012), the scheme

is a planned, supervised training and intervention programme based on stated and specific learning

and career objectives, leading to the development of occupational competencies of the participants.

It also serves to prepare students in higher institutions for the conditions they would meet when

they eventually venture into the industry after graduations. This serves to ensure that not only does

the students learn most of the work processes that take place in the industry but also gives them an

avenue to practice it under supervised conditions.

SIWES is also an effort to bridge the existing gap between theory and practice and expose students

to necessary skills for smooth transition from the classroom to the world of work. It enables

students to acquire technical skills and experience for professional development in their study.

The scheme acts as a catalyst for industrial growth and productivity through professional

development as the students will have acquired some work experience while in school and will

have adequate practical background experience necessary for employment.

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In Nigeria SIWES is financed by the Federal Government (through the ministry of commerce and

industry) and managed by the Industrial Training Fund (ITF) aiming at making education more

relevant and also to bridge the yearning gap between theory and practice of Engineering,

Technology and other related disciplines in tertiary institutions in Nigeria.

The bodies involved in SIWES operation are known as the stakeholders and they are; the Federal

Government of Nigeria (through the Ministry of Commerce and Industry), Industrial Training

Fund, NUC/NBTC/NCCE, the institution, the industries or employers and the students.

SIWES is a form of cooperative industrial internship programme among all its stake holders. Mafe

(2009) stated that all stakeholders are involved in the operation of SIWES but that students are the

key actors that are directly involved in its implementation, all other stakeholders have lesser role

to play in the actual training process. Mafe (2010) citing Crag (1987) stated that, SIWES is generic

because it cuts across more than 60 programmes in the universities, over 40 programmes in the

polytechnics and about 10 programmes in the colleges of education. Students who participate in

this training programme include those studying Library and Information Science, Engineering,

Vocational, Technological and related courses in higher institution of learning. Other courses

involved in SIWES include Agricultural science, Forestry, Industrial Chemistry, Microbiology,

Geology and Mineral Science, Physics and Mineral Science, Plant and Environmental Biology,

Computer Science, Tourism and Hospitality, Business Education, Industrial Engineering,

Enterprise Creation and Management.

1.1 Scope of SIWES

Practical knowledge relates to doing which involves hand on activities included in learning without

which mastery of an area of knowledge would come with some difficulties. It also involves

developing skill through the use of tools or equipment to perform tasks that are related to a field

2
of study. SIWES is a skill development program designed to prepare students of universities,

polytechnics/monotechnic and college of education for transition from college environment to

work. This work experience scheme gives two thing. The opportunity to be part of an actual work

situation outside the classroom.

SIWES is a corporate industrial internship program that involves institution of higher learning,

industries, the federal government of Nigeria, industrial training fund (ITF), Nigerian Universities

Commission (NUC) and NBTE/NCCE in Nigeria. Students that participate in this Work

Experience program includes Science, Engineering, Vocational, Technological and related courses

in institutions.

1.2 Objectives of SIWES

Specifically, the objectives of the Students Industrial Work Experience Scheme (SIWES) are to:

∑ Provide avenue for Students in Institutions of higher Learning to acquire industrial skills

and experience in their course of study;

∑ Expose Students to work methods and techniques in handling equipment and machinery

that may not be available in their Institutions;

∑ Make the transition from school to the world of work easier, and enhance Students contacts

for later job placement;

∑ Provide Students with an opportunity to apply their knowledge in real work situation

thereby bridging the gap between theory and practice; and

∑ Enlist and strengthen Employers involvement in the entire educational process and prepare

Students for employment after graduation.

3
 CHAPTER TWO

ABOUT MOUKA LIMITED

2.0 BRIEF HISTORY OF MOUKA LIMITED

About half a century ago, MOUKA LIMITED opened up its doors to the Nigerian Market as a

family owned business in Kano. It was pioneered by the children of the late Mr. Faiz Moukarim.

In 1959, the company was incorporated under the name Moukarim Metalwood Factory Limited.

Operations started with the production of furniture and allied metal products, providing a major

portion of the market in Northern Nigeria with quality furniture. Mouka Foam and Mouka Pipe,

both a part of MOUKA LIMITED, were established in 1972 respectively. Thereafter, the two

companies separated and Actis, a leading private equity investor company acquired 66%

ownership of the company in 2007.

For over five decades, MOUKA have consistently strived to be the leading manufacturer of top

quality Mattresses, Sheetings, Pillows, Polyurethane blocks and other foam materials for industrial

use. The MOUKA promise is to deliver durable and quality products for the West African market.

Research into the needs of comfort seekers over the last five decades has led MOUKA into the

creation of their adequate range of products designed to meet various needs. To ensure customer

satisfaction, MOUKA also custom produce to any size, shape or density specification.

MOUKA LIMITED delivers on high comfort and high quality products, in line with keeping to

their promise of innovation. MOUKA LIMITED currently have three factories; the Head Office

at Plot ‘M’ Awosika Avenue, Ikeja Industrial Estate, Lagos; the second plant at Km 12, Benin-

Lagos Express Road, By Okhun Road Benin City, Edo State; and the latest and third plant at No.

6, Inuwa Abdul Kadir Street, Industrial Estate, Behind PAN Kakuri, Kaduna South, Kaduna.

4
MOUKA LIMITED Lagos factory is equipped with a state of the art continuous production line

(Ladderberg) with a capacity of hundreds of kilos of Polyurethane foam per minute supplied with

a continuous CO2 line, which is the first in Nigeria. Complementing the high capacity recycling

plant is a semi-automatic block foam processing machine and several cutting and converting

machines which allow MOUKA LIMITED to meet all the requirements of its customers.

VISION

To be the clear market leader in the bedding and foam business by building high quality brands

that deliver profitable growth.

MISSION

To add comfort to life.

VALUES – PIIPE

PASSION

INTEGRITY

INNOVATION

PERFORMANCE

EXCELLENCE

2.1 OBJECTIVES OF MOUKA LIMITED

MOUKA LIMITED is committed to the following objective

To meet and exceed customers’ expectations by prompt delivery of orders and reduction in rejects

and returns.

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 1. Comply with legislative, statutory and regulatory requirements, preventing any actions that

may lead to violations or contravention.

2. Provide appropriate and safe work environment to foster safe practices.

3. Establish and operate hazard identification and risk management processes in order to

eliminate or mitigate safety risks resulting from our activities.

4. Ensure employees well-being through routine health surveillance and provision of quality

health support services.

5. Liaise with host communities, stakeholders, and customers to identify ways of improving

work relations, safe environment and enhancing development.

6. Prevent pollution, preserve and protect the environment through proper waste

management.

2.2 DEPARTMENT AT MOUKA INDUSTRIAL PLANT LAGOS

1. Foaming department.

i. Curing section

ii. Block hall section

2. Conversion department.

i. Foam Lamination section

ii. Spring section.

3. Quilting section

4. Tape Edge Department

5. Packaging section

6. Storage department

7. Marketing department

6
8. Sales and customer service department

Figure 2.0: The Ikeja Plant Site Layout

7
2.3 ORGANOGRAM OF MOUKA LIMITED

Managing
Director

Operations
Director

Research and Quality

Plant Manager Development Assurance
Manager Manager

Foam Foam
Processing Processing Quality Officers
Engineers Engineer

interns Interns Lab Personnel

Junior Staff Interns

Contract Staff Junior Staff

Figure 2.1: Organogram of Mouka Limited

2.4 INDUSTRIAL HARZARDS AND SAFETY PRECUATIONS

Industrial activities always go along with discharge of effluents that are harmful to the

environment. MOUKA LIMITED as a chemical processing industry has its own hazards. A

hazard is a situation that poses a level of threat to life, health, property, or environment.

Safety precautions are preventive measures, taken to prevent the occurrence of these hazards. This

is better than curing them when they occur.

The following are the HSE Department (Health, Safety and Environment Department) Risk

Assessment and Control Measures:

8
 1. FOAM DUST INHALATION: Wear dust mast and factory eye googles, ensure

foam samples are properly cut free of dust particles.

2. FIRE HAZARD/ALARMS RESPONSE: Availability of fire control team always. Walk

quickly to the nearest fire muster point and adhere to all HSE protocols before returning to the

factory.

3. HEAT EMISSION: Availability of heat extractors and fans. Factory doors are left open.

4. NOISE GENERATION: Regular maintenance of machine, use of ear plugs/muffs.

5. CHEMICAL FUMES INHALATION: Strict adherence to all safety requirements for

chemical offloading, transportation/storage, and usage. Ensure functional fumes extractors

always. Regular health surveillance. Wear Gas Respirator always.

6. CHEMICAL SPILLAGE: Concertizing of chemical storage area, ensure chemical samples

are collected without spillage to prevent environmental pollution and slip/fall in the factory.

Wear right PPEs (Personal Protective Equipment’s- chemical hand gloves, apron, safety boot,

lab coat, and eye googles).

7. MACHINE CUTS: Always wear safety hand gloves. Ensure careful handling of machines.

8. PSYCOLOGICAL HAZARD: This is also referred to as human hazard because it has to

do with the state of mind of the workers. This includes poor welfare, bad news, poor health,

terrorism, excessive alcohol or drugs, uncontrolled stress, poor rest periods, and so on. This

requires prompt monitoring, instructing and assessment of workers by the HSE personnel.

2.5 MOUKA’S PRODUCTS

1. POLYURETHANE FOAM BLOCKS: MOUKA LIMITED produces four different

polyurethane foam blocks based on density and hardness, namely;

9
(A) D13- Ultra Low Density Foam (ULDF)

(B) D16- Low Density Foam (LDF)

(C) D22- Medium Density Foam (MDF)

(D) D30 (Regina or Semi- Orthopedic) - High Density Foam (HDF)

2. SDM (Super Deluxe Mattress): This is the highest foam in MOUKA LIMITED based on

hardness and density. It has a density of 100g/cm3 made from reconstituted foam. It is called D100-

Ultra High Density Foam (UHDF). It’s also known as Orthopaedic or Regal mattress.

3. F.R (Fire Retardant foam): These are special Polyurethane Foams of different densities and

hardness which does not light fire.

4. VISCO ELASTIC FOAM BLOCKS: They are also called memory foam. These are foam

blocks produced from polyol and diisocyanate. Viscoelastic foam has wide spread use in pillows,

toppers, and mattresses.

4. PILLOWS: MOUKA LIMITED has different brands of pillows of high standard, quality and

comfort delivery. Mouka Pillows include; Crown, Comfy, Classic, Cozy, Bio crystal Pillows

5. MATTRESSES: MOUKA LIMITED has varieties of mattress brands of which some have

quilted textile coverings while some have plane textile coverings. Namely;

(a) Comfy, Koko, and Dreamtime (water resistant) and so on-D16

(b) Flora, Super-Flora, Mondeo, Fantasia, Exquisite, Super-Mondeo and so on-D22 foam.

(c) Regina/ Semi-orthopaedic- D30

10
(d) Orthopaedic/Regal- D100

(e) Spring Mattress: Spring metal support with foam.

11
 CHAPTER THERE

TECHNICAL EXPERIENCE GAINED

3.0 THE FOAMING DEPARTMENT

This is the engine room of the factory. It is the department where the main chemical process in the

factory takes place, from the actual Foam Production, Box Foaming to test formulation and

chemicals to the Production of Viscoelastic Foam. The Super Deluxe Mattress Department is also

under the foaming department where the production of Reconstituted foam takes place.

3.1 THE FOAMING PROCESS

Many parameters are involved in the making of polymeric foams, some of which include; the raw

materials, foam formulations, chemistry of polyurethane foams and others all of which are

highlighted later in this paper. The three major types of foaming process utilized by MOUKA are

polyurethane foaming process, viscoelastic foaming process and reconstituted foam process all of

which are carefully explained in details.

3.1.1 POLYURETHANE FOAM

Foam can best be defined as a dispersion of gases in a liquid phase or medium or we can say that

foam is any substance with gas bubbles enclosed in a liquid or a solid. In summary, polyurethane

foam can best be defined as any product that has been produced by the internal generation or

liberation of carbon dioxide (gases) in a urethane medium (liquid phase) that is simultaneously

polymerizing while expanding in volume. Foams are grouped majorly into two, namely; rigid

and flexible foams.

FLEXIBLE POLYURETHANE FOAM: This type of PU foam can be defined as open cell

urethane foam having the property of complete recovery immediately after compression.

12
RIGID POLYURETHANE FOAM: They are hard foams having low flexibility and show

permanent deformation after compression. They have high cross linked chemical structure and

higher percentage of closed cell. They are mostly used as insulators in refrigerators.

3.1.1.1 RAW MATERIAL USED IN THE PRODUCTION OF POLYURETHANE FOAMS

MAIN CHEMICALS Polyol, Toluene Di isocyanate (TDI)

BLOWING AGENTS Water (H2O), Methylene Chloride

FOAM Silicone oil

STABILIZERS/SURFACTANTS
CATALYST Amine, Stannous Octate
ADDITIVES Color, Calcium carbonates

1. POLYOL

These are polymeric compounds having at least two hydroxyl groups e.g. polyether polyol,

polyester polyol etc. Polyether polyol is the major polyol for preparing various urethane foams.

Polyester polyol is formed by the process known as Alkoxylation.

ALKOXYLATION

This is a chemical reaction that involves adding epoxide to another compound. The usual

manifestation of this reaction is the ethoxylation of alcohols (ROH) in which case ethylene oxide

is the alkoxylating Agent.

Industrially, the epoxide used is propylene oxide (PO)CH3CHCH2) is used as the alkoxylating

agent to produce polyether polyols. The alkoxylation process is shown below;

ROH + C2H4O ROCH2 CH2CH3

Alcohol ethylene oxide Propylene oxide

13
These polyols are used in large scale to produce polyurethane foams. It is the main chemical that

forms the backbone of the polymer chain.

2. TOULENE DIISOCYANATE (TDI)

This is a toxic and unstable chemical used in foam production. It is the most commonly used

isocyanate in production of polyurethane foam, others are methylene di phenyl diisocyanate

(MDI). TDI has two isomers that are commercially important; 2,4-TDI and 2,6-TDI.

Figure 3.0: Chemical structure showing 2,4-TDI and 2,6-TDI.

Manufacture do vary the ratio of the isomers blend but the most çommonly used is the 80:20 (2,4_ TDI &

2,6 _ TDI) blend. For higher load bearing foams however the blend ratio of the 65:35 is recommended,but

it should be noted that the 2,4_ isomer is more relative than 2,6 isomers.

3. WATER (primary blowing agent)

Water reacts with isocyanate that produces carbon dioxide that eventually fills the cell and foams

the polymer. Increasing water content influences both cell structure and the solid-state

morphology of the foam. Most foams with densities lower than 15kg/m3 are blown with water

and a non-reactive blowing agent because low density water blown foam can self-ignite.

4. METHYLENE CHLORIDE (auxiliary blowing agent)

14
Methylene dichloride (MeCl2) is an auxiliary blowing agent used to bring about an increased

blowing effect during foaming. When in use, lighter foam density can be achieved without

increasing the water level and also helps to cool foam mixture.

5. SILICONE OIL

Flexible polyurethane foam production relies greatly on the performance of non-ionic silicone

based surfactants which is added to realize a variety of functions. Some of the main functions are

reducing surface tension, emulsifying incompatible ingredients, promoting bubble nucleation

during mixing, stabilization of the cell walls during foam expansion and reducing the defoaming

effect of any solid added.

6. TERTIARY AMINE:

Tertiary amine compounds contain a nitrogen atom having three substituent groups and a free

pair of electrons.

Amine is introduced to speed up and maintain the reaction between TDI and water. They are

blowing catalysts and also a gelation reaction catalyst which its activity is determined by the

availability of a free electron pair complexation. The catalytic mechanism involves the donation

of these electrons by the tertiary catalyst of nitrogen to the isocyanate group leading to the

formation of an intermediate complex. The availability of the electrons is a function of both

steric hindrances caused by the subsequent groups, as well as electron withdrawing or electron

releasing nature of the substituent group (electronic effect) which are the main factors

influencing the relative catalytic activity of the various amine.

7. STANNEOUS OCTOATE (Tin-2-ethyl hexanoate)

15
Tin-2-2ethylhexanoate [CH3(CH2)3CH(C2H5)COO]2Sn is a cross linking agent which has a

powerful influence on cohesion and hardening of the foam. Tin compound are widely used for

the gelation reaction between the isocyanates and a polyol it act as acid and are to function by

interacting with basic site in the isocyanate and polyol compound. For flexible foam stannous

octoate (TinII 2- ethyl hexoate) is the preferable gelling catalyst.

Effect of increasing stannous octoate catalyst: foam split occur when there is in sufficient

gellation to balance the blowing or gas evolution reaction . The motive force of the expanding

gas bubbles exceed the tensile strength of the polymer matrol and a physical separation (a split)

occurs. A small increase in stannous octoate concentration will give a good open foam with some

relaxation or sigh back, further increase in catalyst will eventually prevent the relaxation and the

foam will become progressively tighter. At higher tin level, slight to severe shrinkage result as

the foam begins to gel faster, giving stronger cell windows that are more difficult to burst.

Factors affecting catalyst selection include balancing three reactions: urethane

(polyol+isocyanate, or gel) formation, the urea (water + isocyanate, or “blow”) formation, or the

isocyanate trimerization reaction (e.g., using potassium acetate, to form isocyanurate rings). A

variety of specialized catalysts have been developed.

NOTE: Catalyzing a polyurethane foam involves choosing a catalyst package in such a way that

the gas produced becomes sufficiently entrapped in the polymer.

8. CALCIUM CARBONATE

Calcium Carbonates are fillers used in flexible polyurethane foam production to modify the

materials properties such as dimensional stability, density and retraction from the mold. Also they

reduce the resiliency and contribute to the increase in permanent deformation by serving as a

16
hardening agent when mixed with polyol in order to speed up the reaction time which will give a

positive development.

9. COLORANTS:

Colorants are introduced in foam formulation in order to identify various foam grades, to conceal

yellowing of manufacturing foam. Ordinarily, a colorant do not interfere with the main chemical

reactions during foaming. If special care is not taken to ensure the inertness of the colorant, it can

bring about more instability, foam scorch or abrasive action on the pump and mixer. So suitability

of colorant should be confirmed before formal introduction into the production line. Typically,

inorganic colorants are titanium dioxide, iron oxide, chromium oxide. Organic pigments are made

from azo or diazo dyes and carbon black. But the most convenient colorants to use are those that

are either soluble in water or polyol.

3.1.1.2 FLEXIBLE FOAM BLOCK PRODUCTION PROCESS

The processes involved in the production of flexible polyurethane foams includes:

v Pumping and conditioning of the raw materials.

v Preparation of the foaming machine.
v Foaming.
v Curing of the foam blocks.

Pumping and conditioning of the raw materials.

Firstly, some of the chemicals are blended with polyol while others are directly pumped into large
stainless steel tanks. The purpose of blending with polyol is to minimize cost.

Calcium Carbonate, which is in solid form cannot be pumped into the tank directly, hence it is
blended with polyol in a pit before it is sent to the tank where mixing continues. TDI is another
chemical mixed with polyol before foaming in order to reduce it’s effect as it is a very hazardous
and flammable chemical. Other chemicals blended with polyol before production includes

17
stannous octate, amine and color. The tank contains a stirrer which stirs the chemicals in it
continuously to avoid coagulation or caking of the chemical before production.

Figure 3.1: A tank where solid calcium and polyol and bended

The tank is made up of three parts; the inner part, the intermediate part, and the outer part. The
inner part is where the chemical is pumped into. The intermediate part is where the cooling process
occurs. A water tank is connected to a chilling machine which is connected to the tank and
connected back to the water tank. Water moves from the water tank to the chiller where it is chilled,
sent to the tank to chill the chemicals in it and sent back to the water tank, while checking the
temperature of the chemicals in the tank subsequently. This process is known as the COOLING
PROCESS and it continues until the chemicals have reached the desired temperature. The
outermost part is covered with foam which is used to retain the temperature of the chemical inside
the tank.

18
Figure 3.2: Stainless steel TDI Storage tanks

NOTE: Methylene Chloride is the only chemical that is not cooled because it already has a low
temperature and is cold, hence cooling is not necessary. It also serves as a cooling agent during
production by reducing the temperature of the production process to avoid inflammation of the
foam.

Preparation of the foaming machine and foaming

The mixing head is taken to be heart of any polyurethane of any dispensing machine. Success or

failure with a given chemical system can often be influenced by the adequency of mixing. Mix

head can be classified as recirculatory or non-recirculatory. In a recirculatory head, the component

are circulated from the feed tank through the head and back to the tank. As soon as reaction

becomes visible, the material is said to be creaming and the cream line is the distance from the

head to the start of creaming. The creaming liquid layer is about ¾ inch thick within 1-2 minutes

it will rise to a height of about 40-50 inches as the foam begins to rise the side wall exerts a

frictional drag on the foam, an extra polyethylene film is added between the side wall paper and

foam.

19
 Figure 3.3: The cream period of flexible polyurethane foam

During the foam rise, the film is pulled upward. The film is parallel to the foam surface and prevent

the foam from sticking to the side paper, by eliminating friction at the sidewall, a post cure time

of at least 24hrs is required for the foam to reach its ultimate hardness. As the foam mixture leaves

the mixing head, it is clear or slightly cloudy when conventional polyol are used. The mixing head

or dispensing hose is traversed across the conveyor to distribute material as uniformly as possible.

The conveyor and side support walls are lined with paper or plastic film moving at the same speed

of the conveyor.

Figure 3.4: The product of the production of flexible foam

Curing of the foam blocks.

20
The blocks are transferred to the block curing hall and are positioned at least five (5) meters from

each other. At this point the temperature of the individual blocks will continue to rise. This is

where the need for probing comes in. Probing is done with a probe stick and a meter which is used

to check the temperature of the blocks, the temperature is checked every ten minutes and is

recorded. The temperature for any normal foam block is meant to rise to a point where it becomes

stagnant also known as the peak point and then it starts to drop till it gets to room temperature and

that is when the block is fully cured. If the block temperature continues to rise above a certain

temperature, then there is a high risk of fire, and the peak temperature also has a range. As shown

below.

After the blocks are fully cured which usually takes a minimum of twenty-four hours then the

blocks can be transferred to the block hall.

3.1.1.4 BOX FOAMING

This is a batch process of producing polyurethane foam using a foaming mould. It is carried out

for various reasons;

∑ Evaluating raw materials in existing formulation

∑ Checking the approximate cream and rise time of a formulation before a large machine run

is made

∑ Determine the level of catalyst, additives, blowing agents etc in a new formulation

∑ Checking the efficiency of silicone surfactants

∑ Checking catalyst stability and activity

∑ Checking for suspected contamination of raw materials

∑ Training new personnel

21
 ∑ Testing out new chemicals before usage.

3.1.1.4.1 PROCEDURE FOR BOX FOAMING

∑ Weigh out the polyol

∑ Weigh out the required amount of isocyanate into a different beaker

∑ Weigh your calcium and add to your polyol, mix for about 10- 30 second

∑ Add your weighed water + silicone + amine and mix together

∑ Add your methylene chloride

∑ Add your catalyst and mix for about 6-7 seconds

∑ Add isocyanates and mix for about 3- 5 seconds

∑ Pour mixture into the foaming mould

∑ Record cream, rise and gel times

∑ Clean stirrer with methylene chloride

Note your stannous is to be the last catalyst added before toluene di-isocyanates because it is a

catalyst and start reacting immediately when its poured into the other component.

3.1.2 VISCOELASTIC FOAM

Viscous means a material is thick and (reluctantly) runny—treacle, for example, or

thick lubricating grease. The more viscous something is, the longer it takes to flow from one place

to another. Elastic means something will stretch or deform but return exactly to its original shape

and size when you take away the stretching force. A viscoelastic material is both viscous (changes

shape slowly) and elastic (it returns to its original shape). Briefly, it deforms and returns to shape

very slowly. Viscoelastic foam is another term for memory foam. It is a blend of polyurethane

foam that was developed for airplane cushions by a NASA contract in the 1970s.

22
Viscoelastic (memory) foam technology represents an alternative to conventional and HR flexible

polyurethane foams.Visco elastic foam is a polymer created during a chemical reaction between

polyol and diisocyanate (two chemicals created from organic compounds). The ratio of polyol to

diisocyanate is 2:1 to form polyurethane, though there may be other compounds that are added to

create just the right amount of elasticity and density for each piece of foam. This hot mixture is

then placed in a mold, dried, cooled, and cut for the use in mattresses.

Figure 3.5: Viscoelastic flexible polyurethane machine

Viscoelastic materials also respond differently according to how you apply forces. They're stiffer

(change shape more reluctantly) if you apply a force quickly than if you apply it slowly, which

makes them very useful both for cushioning and absorbing impacts. There's also a significant lag

between when you deform a viscoelastic material and when it returns to shape (a typical memory-

foam mattress takes 5–10 seconds to flex back to shape when you get off it—much longer than,

for example, a foam sponge). That can be very useful for cushioning things, because energy is

effectively absorbed and dissipated during the time lag (a phenomenon known as hysteresis)

23
 Figure 3.6: Viscoelastic Foam

The foam bubbles or ‘cells’ are open, effectively creating a matrix through which air can move.

Higher-density memory foam softens in reaction to body heat, allowing it to mold to a warm body

in a few minutes.The difference between viscoelastic foam and other types of polyurethane foam

is its slow response and low resistance. Its soft surface allows for contouring and its slow response

lowers bounce.

Though viscoelastic foam is an industry buzzword, it is usually found only in the top layer of

viscoelastic foam mattresses. Other layers of 'viscoelastic foam' mattresses are usually a blend of

polyurethane foams with less elastic attributes and spring.

3.1.3 RECONSTITUTED FOAM (SUPER DELUXE MATTRESS)

Polyurethane Flexible Foam is classified as thermostat polymer, and thermoset polymers

historically have not generally been associated with recycle activities, in reality, a great deal of

recycling does occur. As with all scrap recycle processes, the first step in the re- use of flexible

foam scrap is the separation of the foam from any contaminants such as wire, fabrics and any other

debris, the foam is then chopped into pieces of suitable sizes and coated with binder, steam is

added, the foams crumb is then tightly compressed and bonded together in order to form a new

product and leave to cure before usage.

24
Reconstituted foam sometimes called (Crumbs foam or recon foams) unlike many other types of

foam is a recycled product made up of piece of leftover polyurethane e.g. (off cut and remnants

from cutting different densities like the low density foam, medium density foam, high density

foam, viscoelastic foam and the crumbs gotten from the reconstituted foam itself) the end result is

surprisingly resilient and firm product with a long life span.

Various grades of foam off cuts are fed through a shedding machine which turn it into crumbled

foam of various sizes and shape, the crumb foam is then passed into the silos where its been stored

and transfer to either pillow storage tank which serve as a storage for filler of pillow or the

weighing tank, the grams of crumbs used per 72 inches block is 130kg. the weighed crumbs is

been transferred to the mixer where the crumbs comes in contact with voramer of 19kg allowed

to mix for 15 minutes before passing it into a mould.

Voramer is a moisture curing, solvent free, very low viscosity and high process ability prepolymer

based on MDI. It is specifically used as moisture curing binder for rebounding of flexible foam

scraps for the manufacture of foam composite with high viscosity property.

Steam is later added to the whole process after it has been compressed to a certain height of 20

inches. The steam is applied for 15 minutes to ensure proper steaming of the foam and the covalent

bond holding the foams together is firm enough to avoid deformation. It is generally considered

best for application, such as orthopedic mattress, pub seating, public transport seating, gym mats,

crashmats.

Reconstituted foam can comes in different weight / sizes usually in 75*72*20 or 75*84*20 or 75*

54*20 inches. Visually it looks multi colored and marbled due to all different piece of foam used

to make it which can varies with sizes and color.

25
Being a recycled product means it is also cost effective, it is good to know that the foam industry

is able to make such good use of leftover foam pieces and off cuts rather than just throwing it

away.

Figure 3.7: Reconstituted Foam Machine

An orthopedic mattress is a type of mattress that offers support to the joints. Orthopedic mattresses

are typically recommended for people who sleep with pain, people who are in active recovery from

injury, seniors, and athletes. The word orthopedic was derived from a medical study that focuses

on disorder or deformities of spine and joints. This mattress is usually recommended by doctors to

persons with chronic back, neck and joint pains cause reconstituted foam is a foam that support

the joint firmly having a strongly bonded covalently properties, density above 80kg/m3 with

hardness above 800N enough to support the joint.

26
 Figure 3.8: Orthopedics Mattress

3.1.4 CHEMISTRY OF POLYURETHANE FOAMS

The chemistry of this foam’s process can be divided into two parts:

• Gelation (Polymerization) reaction

• Blowing reaction

GELATION (POLYMERIZATION) REACTION

This involves the reaction between polyol and isocyanate which is identified as gelling, one

which forms the backbone urethane group. This reaction leads to the formation of a cross-linked

polymer. The reaction occurs at a temperature range of 19oc – 22oc. The basic reaction is as

shown below:

Stannous octate catalyzes the above reaction

BLOWING REACTION

27
The blowing reaction involves two stages, first is the reaction between water and isocyanate, one

which forms the unstable carbamic acid which composes an amine and carbon dioxide gas in the

form of bubbles. Next, the formed amine group reacts with another isocyanate group to give a

distributed urea. The second part of the blowing reaction contributes to the chain extend the

aromatic groups of the isocyanate molecules to form linear hard segments.

Figure 3.9: The two primary chemical reactions and three secondary reactions involved in

polyurethane foam production

28
3.1.5 FOAM FORMULATION

Foam formulation can simply be defined as a data or list which gives the percentage of various

chemical used in the flexible foam production relative to parts per hundred percent (ppp) by

weight of polyol. From the above definition, it means that formulating a specific grade of

polyurethane foam is the process of determining the proportion of various chemicals for foam

production. In deriving formulation for the production of flexible polyurethane foam, the

following factors have to be considered.

1. Basic foam chemistry

2. Chemicals and functions

3. Density and hardness

4. Effects of formulation variables

5. Catalysis of Reaction

DENSITY

The density of foam produced ranges from 12-40kg/m3. A definite density of about 20kg/m3 should
be picked at the start of the formulation.

TOULENE-DI-ISOCYANATE (TDI)

TDI is used at three different stages of the foaming process;

1. Reaction between TDI and water

2. Curing of Polyether
3. Hardening of the foam
a. Amount of TDI required to react with water

= (part of water) * 9.67

b. Amount of TDI required to cure the polyether

= (Hydroxyl no of polyol) * 0.52

29
Theoretically, the exact amount of TDI required = a + b, using the exact theoretical amount, it
would cause the foam to come out too soft, hence to harden the it, extra amount of TDI would be
added. It is assumed that the exact theoretical amount of TDI is equivalent to an index of 100. If
an index of 105 is 105/100, hence the total amount in formulation = 105/100 * (a + b)

The formulation variables are:

1. BLOW INDEX

This term describes the blowing effect of water and the auxiliary blowing agent in a formulation.

This is defined for water/methylene chloride formulation as;

Blow index = pph% water + pph%MC/7.0

Note that blow index determines the density of the foam. By this, an increase or decrease in either

water or m/c level have effects on the density of the foam produced. For example, using a 22kg/m3

density foam whose blow index is about 4.45, different qualities of the same density can be

produced.

• 4.45 pph% of water without MC

• 4 pph% of water with 3.15 pph% of MC

• 3 pph% of water with 10.15 pph% of MC

This variation of methylene chloride/ water ratio enables foam of various hardness to be produced

at the same density. However, there is a limit to the use of MC as it should not be more than seven

(7) times the amount of water.

2. TDI INDEX

30
This is a measure of the extra TDI used required for the reactions (Covalent Cross-linking) in

polyurethane foam reactions. TDI index can be defined as the amount of Isocyanate used relative

to theoretical equivalent amount. It is expressed as

TDI Index = Actual TDI used * 100

Theoretical amount of TDI

In Flexible foam production, it is advisable to fluctuate within the range of 105%-116% for safety.

Variation in TDI Index has a remarkable effect on the hardness of the product. Increasing the index

will increase the product hardness. There is however a point beyond which hardness does not

increase and other physical properties are highly affected. An increase in TDI index will lower.

• Tear strength

• Tensile strength and

• Elongation at break

3. WATER LEVEL

Water is the primary blowing agent in flexible foam production, this is the reason why the more

the water in a formulation the lower the density of the foam produced. Recall that the gas formation

reaction is exothermic hence there is a limit to the amount of water to be used as a sole blowing

agent for flexible foam products as stated before in the heat of the reaction. As increase in water

level at fixed m/c level will lower density but if density is held constant, by decreasing the m/c to

give constant blow index, then increase in water level will increase;

• Hardness

• Tear strength

• Tensile strength and

31
• Elongation at the break.

4. METHYLENE CHLORIDE LEVEL

The m/c functions by heat absorption from the exothermic reacting of TDI and water leading to its

consequent vaporization and provision of some additional gas utilized in the expansion of the foam

to a lower density, since they contribute nothing to the polymer structure, and do not participate in

the foam reaction, they induce softness in foam.

An increase in the m/c level will lower foam density but if the density does not the density is kept

constant by using the same blow index increasing the m/c level will lower hardness and tear

strength but will increase tensile strength and elongation at the break.

5. CATALYST LEVEL

The catalyst used are the stannous octoate which catalysis the polymer formation and the amine

compound (DMEA) which gives rise to the gas formation reaction. Although the two reactions

must be keenly balanced for a good quality foam produced, each catalyst influence the two

reactions in the foaming sequence. The use of low stannous octoate causes side splits which occurs

at irregular intervals but promotes softness of foam, porosity and resilience while too high level of

stannous octoate leads to coarse cells, tight foam and shrinkage during cure. For amine catalysts,

using very low levels promote the following; Closed cells, Entrapped air bubbles, Delayed cream

time and rising time which are vital in foam production and max product profile.

On the contrary, high level of amine encourages foam splits and very fast reaction which affects

the rise time of formulation thereby causing serious processing problems.

6. SILICONE OIL LEVEL

32
In foam production, a minimum level of silicone oil is required to produce an acceptable product.

When the level drops lower than the minimum level, an event referred to as boiling occurs.

Increasing the level of surfactant improves the foam stability and cell size control. At a high level,

the cell walls become over stabilized, and the resulting foams are tighter with reduced

performance. The reduction of foam density, using water, attracts higher surfactant level in order

to determine the theoretical surfactant requirement. About0.8 parts of surfactant is required for

every 100 parts of polyol copolymer and an additional 0.1 parts of surfactant for every 0.5 parts of

water above 3.5 parts of water. Also, introduction of m/c leads to an increased surfactant level.

Conventionally, for each part of m/c used, 0.06-0.1 parts of silicone is needed in addition to that

used for a non m/c blown foam.

7. ALTITUDE

Weight of objects vary from place to place due to the difference in gravitational pull. This therefore

will affect mostly the water level which will eventually affect other parameters. This is why a

formulation balanced on sea level may fail in higher altitudes.

8. REACTION TEMPERATURE

Because the gas formation reaction is exothermic and high reaction temperatures favor the gas

formation reaction, the temperature of the chemicals at the mixing point become crucial. This is

because processing problems occur when chemicals are either too cold (below 20°C) or too hot

(above 25°C).

The reaction is very vital as variation in reaction temperature could lead to some inconsistencies

in the formulated foam recipes. As component or ambient temperatures are increased, the cream

time and gel time are lowered. The load bearing properties of the foam decreases as the temperature

of the system increases.

33
Reaction temperatures of between 20°C – 24°C for TDI – Polyol is recommended for optimal

results. Although a slight variation as high as 27°C and not lower than 18°C can be accommodated.

It is not advisable as the physical properties of the foam will be affected. Therefore, for a consistent

foam quality, a particular range in reaction temperature, must be maintained.

9. METERING AND MIXING COMPONENT

In a continuous foam machine, all components are metered to the mixing head separately through

their respective feed lines. The accuracy of the pumps is an essential factor to the efficiency of the

foam formulations. In practice; air in the lines, the shape. The cleanliness of the nozzles can affect

the reactant ratio of the formulation. Constant calibration of the component streams is a

considerable way of ensuring the efficiency of metering. Outside efficient metering of formulation

components, the efficiency of the mixer is also an important factor to be considered. Mixing of

formulation components can be used to control cell foam size. If the energy input of the mixer is

too low, the resultant foam will be coarse and if otherwise, the cell size becomes finer. On extreme

cases, high energy input from the mixer leads to splits. The energy input from the mixer in both

cases manifests as heat which in turn alters the balance of the blow and gelation of the produced

foam. However, energy input is a function of stirrer speed, mixing time and mixer design. All these

are the reasons why it is difficult to run exactly the same formulation with different mixing

conditions.

3.1.6 DATA

Table 1: Formulation Chart for Density 13kg/m3

34
Formulation For Density 13kg/m3 Output factor: 0.85 Color: Light Blue

Table 2: Formulation Chart for Density 16kg/m3

Formulation For Density 16kg/m3 Output factor: 1.20 Color: Claret

Table 3: Formulation Chart for Density 22kg/m3

35
Formulation For Density 22kg/m3 Output factor: 1.60 Color: Olive Green

Table 4: Formulation Chart for Density 30kg/m³

36
Formulation For Density 30kg/m3 Output factor: 1.90 Color: Grey

3.1.6.1 CALCULATION
The calculation for a foam formulation is straight forward, all recipes and calculation are based on

100 total part by weight of polyol. There may be more than one polyol in a recipes but conventional

dictates that the sum of all polyol add up to 100 parts.

It is calculated using the PART PER HUNDRED POLYOL by first determine the part of each

polyol. Total polyol should equal 100 and determine the part of other component per part polyol

= ∗ OR Output = input * output factor

37
Table 5: SAMPLE FOAM FORMULATION FOR 22kg/m³

Output factor – output (kg) polyol / pph of polyol

5000/100 = 50

20 = (4.8 ∗ 50) = 240kg

= (60.5 ∗ 50) = 3025

= (0.15 ∗ 50) = 7.5

7.5kg for raw and for the blended amine;

Amine : Polyol = 1:4,

Therefore, if 7.5kg of Amine is been consumed, 30kg of polyol will be blended alongside with the

amine giving 37.5kg as the overall amine consumed.

38
 = (0.2 ∗ 50) = 10

Stannous : Polyol = 1:4, therefore if 10kg stannous is been consumed, 40kg of polyol will be

blended alongside with the stannous giving 50kg as the overall stannous consumed.

= (1.1 ∗ 50) = 55

In the preparation using blended additives, the amount of polyol is carefully calculated due to the

amount used for blending.

3.2 HANDLING AND STORAGE OF CHEMICALS

Each chemical used in the foam factory has its hazard profile and recommended safety

precautions. Users are advised to contact their suppliers for specific instruments for the safe

handling, use, storage and disposal of each chemical. It is generally advised that when handling

each of the chemicals, workers should wear their complete personal protective equipment (PPE).

If any of the chemicals comes in contact the eye, the eye should be half open while flushing with

a continuous low pressure. If it comes in direct contact with the skin, wash the affected area

thoroughly using plenty of water and a mild soap for at least 15 minutes, depending on the

degree of water, further medical care may be required. None of the chemicals should be stored

under the direct glove of the sun. Storage temperature is best between 18-24oc. Low boiling

methylene chloride must be stored below 24oc, higher temperature may cause pressure build up

leading to the container’s rupture. Polyol has no known explosive potential, but TDI has.

3.3 APPLICATIONS OF POLYURETHANE FOAMS

1. Apparels: They are used in making high weight stretchable wears e.g. sport wears.

2. Medicals: They are used in a number of medical applications e.g. general purpose tubing,

hospital beds (orthopaedic beds), surgical drapes, and wound dressings.

3. Furniture: They are used mostly at home for beddings, carpet underlying, cushions, etc

39
4. Packaging: They are used to protect items that need to stay in place during

transportation.

5. Appliances: Rigid polyurethane foams are used as insulators in refrigerators and freezers

as thermal insulating system.

6. Automotive: They are used to make car seats, bumpers, doors, and windows.

CHAPTER FOUR

4.0 QUALITY ASSURANCE (QA) DEPARTMENT

The QA department of MOUKA LIMITED is divided into two units, QA department factory unit

and QA laboratory. Both have similar but varying KPI’s (Key Performance Indicators) and

functions.

FUNCTIONS OF THE QA LABORATORY

ÿ The QA laboratory personnel carries out the following functions.

ÿ Analysis and certification of production raw materials – chemical and non-chemicals

ÿ Prompt monitoring and quality control of polyurethane foam production processes.

ÿ Preparation and testing of produced polyurethane foam during and after production using

American Standard Method (ASTM) developed by ANSI (American Standard Institute)/

International Organization for Standardization (ISO)/ Standard Organization of Nigeria

(SON) certified processes.

ÿ Analysis and certification of textiles and threads used in pillows and matrasses productions.

These analysis and tests are all carried out based on ISO/SON guidelines.

ÿ Analysis and certification of Orthopaedic/Regal foam productions based on ISO/SON

guidelines.

ÿ Analysis and checking of returned products.

40
 ÿ Preparation of a well-documented daily/weekly/monthly product analysis report.

ÿ Preparation of a well-documented raw-materials analysis report.

4.1 PHYSICAL TEST AND LABORATORY TESTS DESCRIPTIONS FOR FOAM

The following tests are carried out by the QA Department Laboratory to ensure MOUKA’s

objectives and standards are met.

1. POROSITY TEST

This task description is applicable to cured and uncured (green) foam samples to ascertain that the

openness or breathability of the foam structure met customers specifications, establish control

measures and effect possible improvement. Breathability is a method for determining the

resilience of flexible polyurethane foams. A porosity meter is placed onto a foam sample of

specified dimension. Fixed air pressure (Pi) is passed through the sample and the back pressure

(Po) is measured. The back pressure (Po) is divided by the original pressure (Pi) to give a

percentage of the openness of the foam network.

Inlet pressure= Pi

Outlet pressure= Po

%Porosity= Po/Pi x 100%

Figure 4.0: Porosity Meter

41
2. COMPRESSION LOAD DEFLECTION, RECOVERY, HYSTERESIS, GUIDE

FACTOR AND SAG FACTOR

The Indentation/Compression Hardness of flexible cellular material is a measure of their load-

bearing properties. It is to determine the hardness, resilience, longevity, sag/guide factor and

fatigue conformance of the foam to customers’ specifications.

The test apparatus used is the Calibrated Miniflex CLD Foam Hardness Tester

Figure 4.1: Miniflex CLD Foam Hardness Tester

3. CONSTANT LOAD FATIGUE TEST

Fatigue is a measurement of the loss in load bearing capability and is expressed as a percentage

load loss. Constant Force Fatigue tester is used to fatigue the sample for 8,000 cycles for two

hours. This determines the loss in thickness and loss in hardness of flexible cellular materials

intended for use in the load-bearing applications. The sample dimensions are a standard-sized

square of length side 100mm with a thickness of 50mm.

IFD Hardness values at 40% deflection are compared before and after fatiguing and the percent

load loss is calculated.

42
 Figure 4.2: Constant Force Fatigue tester

4. COMPRESSION SET

Compression set is the difference between the initial thickness and the final thickness of a test

piece of the cellular material after compression by 75% of its thickness and maintained under this

condition for 72hours at a given temperature and after a given recovery time of few minutes, the

difference being referred to the initial thickness.

It is a measure of the permanent deformation of foam after it has been compressed between two

metal plates for a controlled time and a temperature condition. It measures the durability of the

foam sample.

TO == thickness before compression

Tr= thickness after compression.

Compression set = (TO – TR/TO) x 100%

5. DENSITY TEST

43
Density is the mass of a substances divided by its volume it is expressed in kilogram per cubic

meter, it is a measure of firmness, stiffness or load bearing capacity. High densities generally

results in higher cost and improved load – bearing properties. Initial density is evaluated during

foaming while final density is evaluated after proper curing of the foam usually at about

24hours or more after production.

Mass (m) = reading on the scale (Kg)

Volume (V) = length x width x height (m3)

Density (p) = m/V (kg/m3)

6. BALL REBOUND TEST

The test involves dropping a steel ball of known mass from a predetermined height onto

a foam sample. The rebound height attained by the steel ball, is expressed as a percentage

of the original drop height, is the ball rebound resiliency value. It is used to measure the

surface resiliency of flexible polyurethane foam.

Apparatus used is the Calibrated Cell Flex Ball Rebound Resilience tester with its steel ball

and magnetic rod.

44
 Figure 4.3: Ball Rebound Tester

7. WHOLESOMENESS

The blocks must be inspected individually for wholesomeness (void of splits, cracks,

partial collapse, etc.) Any unwholesome block must be assigned a percentage depending

on the usefulness. The number of affected block and the percentage usefulness is recorded

in the report.

4.2 CONVERSION AND FINISHING

Foam blocks are the products of foaming process and the come in various sizes depending on the

machine setting during foaming in a continuous plant or mould type.

Ordinarily, a mature foam block is of no use until it is cut and shaped into pre-determined units.

It is this process of cutting and shaping that is referred to as foam conversion. It should be noted

that foam conversion is certainly one of the most critical operations in the foam factory.

The foam blocks are converted into slabs with the help of the following machines:

v The Vertical machine

v Carousel cutting machine

The Vertical Cutting Machine

After curing, the foam blocks are manually transferred to the conversion section using a trolley. In
the conversion section, the foam blocks are firstly trimmed to a required dimension with the aid of
a vertical cutting machine having an electrically driven blade motor. After, the trimmed foam
blocks are transferred to the boarding section.

45
Figure 4.4: The Vertical Cutting Machine

The Carousel Cutting Machine

The carousel cutting machine is an automatic horizontal slitter with a rotating table. Using the
carousel cutting machine, while the foam blocks are in a spin, they are cut into different heights,
depending on the dimension of foam to be produced.

Figure 4.5: The Carousel Cutting Machine

4.3. SALES OF FOAM BLOCKS AND DISTRIBUTION

46
The foam block that passes through the curing stage only is sent to another section of the

company where it is sorted according to the densities and stamped with the company's logo

before sent out for deliveries.

Foam blocks like that are mostly sold to furniture manufacturing companies and require little or

no processing.

4.3.1. SALES OF MATRESSES

After the foams have been cut into different dimensions in the conversion section, the foams are

clothed with fabric. The clothing of foam slabs is carried out in the tailoring section and the

process involved includes:

1. Production of Quilted Cover Using the Quilting Machine

The quilting machine is a machine used to produce quilted cover for foam.

2. Quilting

The quilting comprises of several parts including mechanical and electrical parts, both working

simultaneously. The quilted cover is made up of a backing net, foam linen and a fabric. It is

produced by sewing these three parts together by the help of the automatic sewing process of the

quilting machine.

3. Clothing with Tape Edge Machine

4. The tailors use the tape edge machine to seal up the edges of the foam slabs with the

quilted fabric.

5. Sealing of mattress with nylon (packaging)

The mattresses are sealed up in transparent nylons to prevent dust and transported to the

warehouse for storage or loaded in a van for delivery to customers.

47
 Figure 4.6: The Quilting Machine

Figure 4.7: The Packaged Mattresses and Pillows

48
 CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.0 PROBLEMS ENCOUNTERED DURING SIWES

There were challenges I faced during the SIWES program. Most of them were not major

problems but it is something that should be looked at.

ABSENCE OF STOPWATCH: The recording of cream and rise time was not done the proper

way. For every visco-elastic foam production and sample box foam production, we had to use

our mobile phones for time recording. It was unsafe and also distracting.

USING OF THE RESPIRATOR FOR LATE PRODUCTION: Another was the use of the

full and half-face respirators. Although, it should be used but it gets suffocating while using it

most especially when the production is usually done during the afternoons. There wasn’t stand-

ins in case one wants to go out to remove the respirator and take in fresh air.

49
OVERWORKING: During the course of my IT, I didn’t have enough time to make in-depth

study of other important sections of the company because the amount of work to be done in the

foaming section.

5.1 CONCLUSION

The five months SIWES program has enable me to bridge the gap between Chemical Engineering

Processes taught in university and the commercial Chemical Engineering of real life in the

industry. During the cause of my industrial training, I gained practical experience and explanation

of numerous theories and principles I am learning in my discipline. I have been exposed to the

intricate functioning of an actual business environment. It also gives me clues as to my

responsibilities in industries and prepares me for actual job experience after school.

The Industrial Training was a huge eye opener for me as I was exposed to the theoretical and

practical aspect of polyurethane foam production. I learned a lot of things, from the different

chemicals used to their functions and importance in foam production. I was also able to witness

the production processes first hand from start to finish for a good number of times. In conclusion,

the training was very educative and enlightening.

Industrial Training is a program with a lot of value and there is need for students to harness it in

order to develop potentials deposited throughout their educational pursuit.The initiation of SIWES

program is without doubt a milestone in the development of academic activities in the National

University System. The benefits derivable by employers, the university, and the student alike are

immense and will go a long way to move the country forward.

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Figure 5.0: A figure of me at the Temporary Storage Area for Polyol

5.2 RECOMMENDATION

Based on my five months of attachment, I would recommend the following to better improve the

SIWES experience:

1. The government should establish more quality relationship with companies, industries, and

agencies where student could be attached for their industrial training.

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2. The supervision of the student by the ITF officials and the institution base supervisor should

be done at regular intervals.

3. Government should always encourage individuals and cooperation to build industries and

company so that student could have choice of place of attachment.

The Students also have roles to play to ensure they gain the required knowledge during their

Industrial training.

1. They should seek organizations, industries or organizations that are in their field of studies or

related to that

2. Report punctually for work every day and continue working until closing time.

3. Participants should have it in mind that good experience is the sole aim of the program.

4. Be disciplined and take instructions from your supervisor, observe the rules and regulations of

the organization to which you are attached.

5. Be humble, honest, decent, and respectful. Humility during my SIWES Program went a long

way in helping me achieve quality training, love and support from my supervisors.

6. Identify and documents your experience.

7. SIWES students should be polite to their co-workers and maintain cordial relationship with

each other.

8. Individual participant should not personally or cooperatively protest the administration of the

establishment.

9. They should use every opportunity to learn all that is carried out in the industry as no

knowledge is waste.

10. Participants should take whatever information or skills they stand to gain serious as it could

pave way for a career path development.

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5.3 REFERENCES

Beckerdite, J., Herrington, R., Hock, K., & Dow Chemical Co. (1991). Flexible polyurethane

foams. Midland, Mich: Dow Chemical Company.

Class note on polyurethane foam production

Dounis DV, Wilkes Gl:Proc 1995 (353-361): Polyurethane

Danielle Williams Mchem: Chemistry of polyurethane

ISO/ANSI/SON Standards for Polyurethane Foam Test and Analysis.

Makanjuola. D. (1999), Handbook of Flexible Foam Manufacture. Temm Consulting Ltd, Nigeria.

Meier-Westhues, H.-U., Danielmeier, K., Kruppa, P., & Squiller, E. (2019). Polyurethanes:

Coatings, Adhesives and Sealants. Hannover: Vincentz Network.

Mouka Limited QA Task Descriptions.

SIWES website (www.siwesdata.org)

University SIWES handbook

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