INDUSTRIAL TRAINING AT MASRAY PLASTIK SDN. BHD.

NOOR FAUZANI BINTI AYOPKE09050

BACHELOR OF CHEMICAL ENGINEERING (BIOTECHNOLOGY)

18TH JUNE 2012 UNTIL 7TH SEPTEMBER 2012

BACKGROUND OF COMPANY

• Masray Plastik Sdn Bhd (MPSB) was incorporated on the 13th January 1984, with 100 percent equities belonging to Bumiputera

• The company started by producing polyethylene bags (PE bags) use in agriculture industries at Pandamaran, Klang, Selangor

• In 1986, the operation was shifted to Seri Kelemak Industrial Area, Alor Gajah.

• The encourage by Perbadanan Kemajuan Negeri Melaka offer of two medium size factory lot to house the machinery couple.

• The company expanded by adding a new line of product, known as Woven Polypropylene bags (WPP bags)

• In 2004, the company has invested into new machinery to produce laminate WPP and laminated PE bags

The product quality is our priority to meet customers fulfillment. The quality assurance department is developing to ensure the implementation for quality improvement is done with efficiency. The efficient quality controlled, the company will meet the ISO 9001:2000 standard pushing over limit beyond our competitors.

MPSB VISION

• Masray Plastik Sdn Bhd aim to participate and contribute towards the country by producing product with high-quality for the customers. Therefore, by the usage of the new technology by these day together with edicated and experiences workers, MPSB do an implementation of new ideology that will ensure the sustainability of the competitiveness.

MPSB MISSION

• To achieve market leadership in the production of plastic packaging products

• To ensure the customers' satisfaction through a high standard of product service quality.

MAIN PRODUCT OF MPSB

• The main product of MPSB are woven polypropylene bags (WPP) and polyethylene bags (PE bags). The product produce either laminated or non-laminated.

• Other that, at blowing PE department produce form-fill-seal (FFS) heavy duty roll.

WOVEN POLYPROPYLENE (WPP) PRODUCTS

WPP Department

Food Fertilizer

Petrochemical Feed mill

TASK REPORT

• The task given for first 6 weeks of training is being quality controller (QC) which is the main task is checking all the productions in order to ensure its according to specification given by customers.

• Furthermore, as a QC also make sure the production process is continuous.

• After 6 weeks, the admin was sent to factory 35 for handling the cutting machine for WPP bags.

FFS Heavy Duty Roll

• The production were collected at every 2640 meters at 375 kg.

• There are three type of measurement that has to be done on the FFS bag, which are;– Thickness– Tensile (strengthen of bag)– Coefficient of friction (cof)

FFS Heavy Duty Roll Products

• For every collected FFS production, the operator will cut 2 meter or more for test

• The testing will be done at lab with high technology instrument which is LLYOD instrument.

• The result for tensile strength and cof will appeared at computer

• The thickness of FFS bag was measured using thickness gauge.

Samples From FFS Bag

CUSTOMERS POLYETHYLENE MALAYSIA (PEM) SDN BHD

PETLIN SDN BHD

Target 0.140 0.160

Maximum 0.148 0.170

Minimum 0.132 0.150

Specification for FFS thickness according customers requirement in inch

Measuring The COF

• Coefficient of friction (cof) test is done by LLYOD instrument.

• The test is essential to know the friction occur between the bag’s surface whether greasy or rough because it’s related with the extruding process where the process for melting the materials.

• The result for cof also according to the specification from customers;

Specification For COF

LIMIT INCH

Maximum 0.55

Minimum 0.40

COF Test

Measuring The Tensile Strength

• The tensile strength also tested using LLYOD instrument

• This test is to measure the strength of ffs bags when tension was occurred on the bags until its breaks.

• The test done by two position which are horizontal and vertical

• No specification for this test.

Tensile Strength Test

Yarn Production For WPP Bags

• Production of WPP bag is actually begin with production of yarn.

• The materials that use for yarn production are polypropylene and cc powder

• The yarn will collected at Windsor

Yarn Processes Mixing the materials

The materials melting at extruder at 270oc

With high concentration of liquid, it flow at heat exchanger by using cold water at 20oc

The cold layer flow at cutter and form a tiny layer

An oven was use for minimizing the diameter of layer

The yarn will flow out from the oven to the roller to cold down the temperature, Then the complete yarn can be collected at Windsor. The broken or reject yarn can be thrown at t-die head as the waste site

Extruder

Heat Exchanger And Cutter

Oven

Windsor

Yarn Test

• The specification for denier is 800 mg to 900 mg.

• By randomly, collect 10 samples of yarn from Windsor to measure the denier

• Take 9 X 1 meters for each sample and measure the weight

• The test the yarn at lab using LLYOD instrument for measure the yarn strength.

Yarn Test

Fabric Production At Circular Loom For WPP Bags.

• The yarn was brought to the loom for produce the WPP fabric.

• The fabric width and construction is according to customers specification, examples;

• Total machines for producing wpp fabric is 25 machine at loom.

Type of machine Korea (K-01)

Width 440mm/17’’

Construction 10 x 8.5

Machine At Circular Loom

The Good Fabric From Loom

Cutting The WPP Bags

• This is the final process before insert the PE liner.

• After the fabric was produce from loom, the roll was brought to insert machine for insert the EVA liner

• After that, the EVA liner need to laminate to the bag inner surface by laminate machine

• Next, the laminate roll was bring to printing machine and final go to cutting machine.

Put the printed roll on the right position

By manually, set the length and the line for cutting

Ensure the thread for sewing the bag at right place and on the thread was pour the white oil

At every 25 bag, collect the bags

Remove the rejected bag from loom, laminate, printed and cutting

Process At Cutting Machine

Cutting Machine

Roll place

CUTTERSew machine

COLLECTION AREA

CONCLUSION

• The industrial training is a program that exposed the student into the real situation at industries.

• The student also have a opportunities to learn a various skills and show the capabilities during training.

• The student also able gain knowledge before enter into the real industries field.

RECOMMENDATION

• After 10 weeks experience this industrial training at MPSB, there are many pro and cons that has seen and learn.

• This company has lack of safety at working environment such as wearing the safety shoes, glove, ear plug and mask.

• At PE blowing, the bag thickness is very essential especially at FFS bag, but there has no solution to overcome the problem when the thickness does not achieve the target.

• The compressor always broke down and make a lot of offline roll. Same as at extruder, there was too many broke down and produce 2 or 3 stage of yarn waste.

• During at circular loom, the operators does not aware with the fabric width and does not refer to the specification given.

• At cutting machine, there was many rejected bags from loom and laminate and make abundant of WPP bag waste.

• This company has lack of worker that need to handling the machine and the machines at the factory always broken at make the production stuck.