PMC 1

Course objective: To introduce the various unit operations involved in polymer synthesis at
industrial level by covering various types of polymers. To teach the effect of ingredients and
conditions resulting in various grades of polymers. To highlight the limitations of raw
polymers under various situations and to introduce the wide range of compounding additives
that would be complementary in imparting the additional degree of properties to the
polymers. Also to teach about mixing equipment and mechanism of additive functioning
along with highlights on cost-quality balancing and EHS concerns.
Course Outcomes: After completing this course, students should be able to:
CO1 Identify the suitable ingredients / machinery / procedure for developing a polymer
material / polymer compound.
CO2 Explain the unit operations involved in polymer synthesis / polymer compounding and
the effect of operational conditions on properties of polymer / compound.
CO3 Explain the functioning mechanism of chemical ingredients in polymerization /
compounding.
CO4 Modify the structure / properties of the polymers for suitable end use requirements
through molecular engineering / compounding.
.
Unit Course Content No. of
No. Hours
1 Introduction to Polymer Manufacturing: Polymerization reactors; Unit 10
operations in polymer manufacturing; Manufacturing of following polymers
along with a brief note on chemistry, compounding, properties and
applications:
Polyolefines: HDPE, LDPE, LLDPE, VLDPE, UHMWPE, CPE, CSPE;
isotactic, syndio tactic & atactic isomers of PP; and copolymers of PE
(EVA).
2 Styrenics: PS, HIPS, SAN, SBS, ABS, SMA. 11
Acrylics: PMA, PMMA, PAN.
Engineering plastics: Nylon-6; Nylon-6,6; PET; PBT; PC.
3 Thermosetting Resins: PF, UF, MF, Epoxy Resin, unsaturated polyester 10
resin
Introduction to Polymer Compounding: Limitations of raw polymeric
materials; need for compounding; types, properties and technical
requirements of additives. Compounding machineries based on nature &
form of raw material (plastics / elastomers / latex / other forms) – mixing roll
mills, internal mixers, solution mixers and mixing extruders.
Compounding criteria: quantity of additives, dispersive & distributive
mixing, order of mixing, risk management (EHS concerns), eco-friendly
ingredients, cost - quality balancing.
Role, classification, mechanism and examples of following additives in
polymeric materials:
Process aids: lubricants and heat stabilizers.
4 Mechanical property modifiers: reinforcing fillers, impact modifiers / 10
toughener, plasticizer / softener.
Anti-ageing additives: UV stabilizers, antioxidants, antiozonants.
Surface property modifiers: antistatic agents, antiwear additives, adhesion
promoters / tackifiers, antiblock additives /slip additives, release agents.
Optical property modifiers: colorants, pigments, optical brighteners,
nucleating agents.
5 Additives which reduce formulation cost: extending fillers, regrind plastics / 11
ground crumb rubber, recycled plastics / reclaimed rubber.
Functional / specialty additives: blowing agents, flame retardants, conducting
fillers, odorants, anti-microbial additives.
Additives for elastomers: Peptizers, carbon black fillers (with outline of its
manufacturing); curing system – crosslinking agent (sulphur, peroxides,
metal oxides & resins), accelerator (CV, EV, SEV systems, sulphur donor);
activator, retarder / inhibitor, mineral rubber, factice.
Case studies: compounding of PF, NR, PVC and PS.
Text Books:
1. Brydson, J. A. (1999). Plastics materials. Elsevier.
2. Gächter, R., Müller, H., & Andreas, H. (1993). Plastics additives handbook:
stabilizers, processing aids, plasticizers, fillers, reinforcements, colorants for
thermoplastics. Hanser.
3. Rodgers, B. (Ed.). (2015). Rubber compounding: chemistry and applications. CRC
press.
Reference Books:
9. Smith, W. M. (Ed.). (1964). Manufacture of plastic (Vol. 1). Reinhold Publishing
Corporation.
10. Grossman, R. F., & Lutz Jr, J. T. (Eds.). (2000). Polymer modifiers and additives.
CRC Press.
11. Rubin, I. I. (Ed.). (1990). Handbook of plastic materials and technology (p. 693). New
York: Wiley.
12. C. Blow and C. Hepburn (1971); Rubber Technology and Manufacture, Butter Worth
Publishers London.
13. Barlow, F. W. (1993). Rubber compounding: principles, materials and techniques.
Marcel Dekker, CRC Press, New York.
14. Brydson, J. A. (Ed.). (1988). Rubbery materials and their compounds. Springer.
15. Manas-Zloczower, I. (Ed.). (2012). Mixing and compounding of polymers: theory and
practice. Carl Hanser Verlag GmbH Co KG.
Web Resources:
1. https://www.fostercomp.com/polymer-compounding-basics/
2. http://download.polympart.ir/polympart/ebook/Introduction%20to%20Polymer%20C
ompounding%20Raw%20Materials,%20Volume%201.pdf
3. https://www.bing.com/videos/search?q=Polyethylene+Manufacturing+Process&&vie
w=detail&mid=124B5F0776810E54C8C3124B5F0776810E54C8C3&&FORM=VR
DGAR&ru=%2Fvideos%2Fsearch%3Fq%3DPolyethylene%2BManufacturing%2BPr
ocess%26Form%3DVDRSCL%26%3D0
4. https://www.hardiepolymers.com/knowledge/polymer-manufacturing-processes/
5. https://nap.nationalacademies.org/read/2307/chapter/5
6. https://formlabs.com/blog/guide-to-manufacturing-processes-for-plastics/
7. https://pslc.ws/macrog/level2.htm

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Course objective: To introduce the various unit operations involved in polymer synthesis at

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