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CALCUTTA POLYMER
INDUSTRIES

Calcutta Polymer Industries is a 4 years 4 months old

Partnership Firm incorporated on 26-Jul-2019, having its
registered office located at Shed No. 16, Badharghat Industrial
Estate, Badharghat Agartala, Sadar, Nimbark, Agartala, Tripura.

The major activity of Calcutta Polymer Industries is

Manufacturing, Sub-classified into Manufacture of rubber and
plastics products and is primarily engaged in the Manufacture
of ploymer synthetic pvc water storage tanks.
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Calcutta Polymer Industries is classified as Micro enterprise in

the financial year 2023-24. It has its unit situated at
Agartala7, Tripura.
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VISION AND VALUES OF

CALCUTTA POLYMER INDUSTRIES
To become a company that constantly strives for quality and
customer satisfaction by providing best Water Tank and fittings
solutions with global benchmarks. To excel with an emphasis on
best business and ethical practices with strong organizational
values justifying the interests of all our customers.

Work relentlessly towards coming closer to our vision statement

by offering best working environment and training focusing on
integrity and ethics.Company is producing best, Useful, Eco
Freindly, Safe water storage and supply solutions water tanks as
well as HDPE Pipes.
Those HDPE pipes is using in various segments like
underground water boring pipe,Underground wire fittings etc.
Apart that completesprinkler fittings available. Mission of the
company toalways maintain better quality with minimum price.
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PROCESS OF
MANUFACTURING
OF WATER STORAGE
TANKS BY LLDPE
RESIN
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INTRODUCTION
Polyethylene water storage tanks are ideal for economic and
hygienic storage of potable water in residential buildings,
industrial units, business complexes, in fact anywhere and
everywhere. These tanks are moulded in one piece. Water
storage tanks are without any seams, joints or welds.

Because of their light weight, these tanks are easy to install and
are extremely mobile.

LLDPE (Linear Low-Density Polyethylene) water storage tanks

are innovative solutions designed to provide reliable and durable
containment for water in various settings. These tanks leverage
the exceptional properties of LLDPE resin, a robust
thermoplastic material known for its flexibility, strength, and
resistance to corrosion and chemicals.

The versatility of LLDPE resin allows for the creation of water

storage tanks in a range of sizes, shapes, and configurations,
catering to diverse storage needs. Their lightweight yet durable
construction ensures ease of installation while guaranteeing
long-term performance and reliability.
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MATERIALS REQUIRED:
• LLDPE
• Master batch black
• LPG Industrial gas

INTRODUCTION TO LLDPE RESIN

Linear Low-Density Polyethylene (LLDPE) is a type of
thermoplastic polymer widely used in manufacturing due
to its flexibility, toughness, and chemical resistance.

Its properties make it suitable for applications like water

storage tanks where durability and resistance to
corrosion are crucial.

Linear Low-Density Polyethylene

(LLDPE) is a versatile thermoplastic polymer with
exceptional properties, including high tensile strength,
flexibility, chemical resistance, and impact strength.
These characteristics make LLDPE an ideal material for
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producing water storage tanks that require durability and

reliability in various environments.

MANUFACTURING PROCESS:

1. Raw Material Selection and Preparation:

The manufacturing process begins with selecting high-

quality LLDPE resin. Additives like UV stabilizers,
antioxidants, and colorants are incorporated into the
resin to enhance its resistance to weathering, prevent
degradation from sunlight exposure, and provide color
customization
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2. Extrusion:

The prepared resin blend is fed into an extruder, where it

undergoes heating and melting. The molten resin is then
pushed through a die to form continuous sheets or rolls
of specific thickness and width. These sheets will serve
as the primary material for constructing the water
storage tanks.

3. Molding:

The extruded sheets are further processed in a molding

machine. Through a combination of heat and pressure,
the sheets are formed into the desired shape
corresponding to the tank design. This process might
involve various techniques, such as rotational molding or
blow molding, depending on the tank's size and
specifications.
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4. Seam Welding and Assembly:

For larger tanks or tanks requiring multiple sections, the

sheets might be welded together using methods like heat
sealing or extrusion welding. This process ensures a
seamless structure and prevents leakage. Additionally,
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during or after molding, fittings such as inlet, outlet,

drainage, and vent fittings are integrated into the tank
and securely attached to maintain structural integrity.

5. Quality Control and Testing:

Throughout each stage of production, rigorous quality

control measures are implemented. Various tests are
conducted to ensure the tanks meet industry standards
and specifications. This includes tests for structural
integrity, leak resistance, impact resistance, and overall
quality. Non-destructive testing methods might be
employed to detect any potential defects or weaknesses.

6. Finishing and Surface Treatment:

Upon passing quality control checks, the tanks undergo

finishing touches. This might involve trimming excess
material, smoothing rough edges, and applying protective
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coatings or treatments to enhance resistance to

environmental factors and prolong the tank's lifespan.

7. Packaging and Distribution:

Once the manufacturing process is complete, the water

storage tanks are carefully packaged to prevent any
damage during transportation. The tanks are then
distributed to wholesalers, retailers, or directly to
consumers, depending on the supply chain structure.

PROCESS OF MANUFACTURING:
Rotational Moulding is a process for producing hollow
seamless containers of all sizes and shapes. The process
does not involve high injection pressure or high shear
rates.

Black polyethylene powder of 35 mesh is weighed and

charged in the mould. The
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mould is heated while it is being rotated about two

perpendicular axes. Simultaneously

a porous skin is formed on the mould surface which

gradually melts as the heating cycle

progresses. At the end of heating cycle a layer of

homogenous uniform thick wall is

formed. The mould then enters a cooling station where

forced air/water spray cools the

mould. It is then positioned in a work zone where the

mould is opened, the tank is

removed and the mould is recharged for next cycle.

Process:

The rotational moulding process for manufacturing water

storage tank consists of the

following major process steps.

• Loading of raw material

• Moulding of the part

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• Cooling or curing

• Unloading of finished part

Cycle time generally varies from 6 to 10 minutes. Cycle

as low as 2 minutes can be achieved and extremely large
part with heavy wall requires 15 minutes for each

moulding cycle.

• Loading: Raw material in the form of powder (35 to

40 mesh) or liquid state is

loaded into the mould or cavities and mould halves are

mechanically locked

together. Loading is generally accomplished before the

machine has completed its previous cycle and ready to
accept the mould.

• Moulding the part: The prepared mould is next

placed in a closed chamber

where it is subjected to intense heat up to 400oC while

rotating the mould bi-acially. Rotation is at low speed
generally in the range of 1 – 40 rpm on the
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minor axis and 1 – 12 rmp on the major axis. A 4:1 rotation

is common however both variable speeds and variable
ratios are used for moulding unusual

configuration.

• Cooling or curing: The mould containing formed part

is then transferred to a

second enclosed chamber where it is subjected to a

combination of water spray

and forced air cooling while continuing to rotate biaxially.

This causes the part to cure evenly and mould to reach
handlingtemperature.
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• Unloading: Like loading this can be accomplished

manually by simply opening the mould and
physically removing the parts or automatically by
using forced air to facilitate the ejection of the part.

Advantages of LLDPE Water

Storage Tanks:
• Durability and Longevity: LLDPE's inherent
properties make the tanks highly durable,
ensuring a long service life.
• Resistance to Corrosion and Chemicals: These
tanks are resistant to rust, corrosion, and
various chemicals, maintaining the purity of
stored water.
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• Lightweight Construction: Despite their

strength, LLDPE tanks are lightweight,
simplifying handling and installation.
• Versatility and Customization: Tanks can be
manufactured in various shapes, sizes, and
colors to suit specific applications and
aesthetic preferences.
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PROCESS OF
MANUFACTURING OF
HDPE ROLL PIPE BY
HDPE RESIN
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INTRODUCTION

High-Density Polyethylene (HDPE) resin is a

thermoplastic polymer derived from petroleum. It's
known for its strength, toughness, and versatility. HDPE
resin is created through the polymerization of ethylene,
resulting in a material with a high strength-to-density
ratio, making it suitable for various applications. It's
commonly used in manufacturing pipes, bottles,
containers, and other plastic products due to its excellent
chemical resistance, durability, and ease of processing
HDPE roll pipes are flexible, durable, and commonly used
for various applications like water and gas distribution,
drainage systems, and more. These pipes, manufactured
in a coil or roll form, offer easy installation due to their
flexibility and are resistant to corrosion, chemicals, and
abrasion. They come in various diameters and are often
utilized for both underground and above-
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ground purposes High density polyethylene (HDPE)

pipes have a very large market in India, in a broad
variety of applications, like, municipal, industrial,
underwater, mining, landfill gas extraction, cable
duct and agriculture. Out of these, agricultural use
is the most abundant and fastest growing in
developing countries like India. The product is very
popular in the pipes market because of its lowest
repair frequency per km per pipe per year as
compared with all other pipe materials used for
urban water and gas distribution. It has a very low
cost of production. Also, with simple composition
changes, a wide range of chemical and thermal
resistance, strength, ductility and other properties
can be achieved. These are mostly achieved by
slight variation in the quality and proportions of
master-batch(MB). Such a wide use raises the
concerns about its impact onthe environment.
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INTRODUCTION TO HDPE RESIN:

HDPE also known high density polyethylene and made up
from polyethylene which makes largest family of polymer.
It is very important to consider its molecular structure
and polymer chain during polymer synthesis. Structures
are generally found in repeating format. These repeating
chains of units determine how densely it is packed and
the mate-

rials molecular weight, crystallinity depends upon the

bonds between the units of polymers.

HDPE has very good thermal and mechanical properties

which makes it widely selected materials in making of
different product. Compressive tensile strength and
stiffness is very high in HDPE polymers alongside with
high melting and great crystallization point.

Among the polymers HDPE has the high strength for long
term. To produce high quality pipes, high density
polyethylene plastics are considered good in plastic
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industries. HDPE pipes are corrosive free and flexible to

work with, which makes pipes more handy and durable.
HDPE pipe made are lightweight and consumes less
energy while manufacturing.However, there are other
polyethylene that differs in densities, hyper-branched,
crystal-linities to their molecular weight and chain
structure. The processing temperature for HDPE in
general is 160oC -250oC and shrinkage rate is
considered 1.5%-3%. High heat withstand ability,
flexibility and machinability makes HDPE as leading
polymer in making varieties of plastic products. The
products like pipes, detergent bottles, automobile parts
are made from HDPE polymer.
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MANUFACTURING PROCESS:

EQUIPMENTS USED:

• Extruder
• Controller
• Die
• Compressor
• Motor
• Roller
• HDPE resin
• Six-meter water bathtub for cooling
and
• Manual pipe cutter
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EQUIPMENT DESCRIPTION:

Extruder :

Extruder is a wide range production machine used in

manufacturing varieties of products. Any industries
which needs constant and large amount of productions
widely uses extruder machine. Many experiments with
extruders are increasing much-more possibilities day by
days in product making industries. Many companies use
it to get desired products.

The extruders generally consist of feed hopper, a heating

barrel, screw and die. Screw consists of five heating zone
channels, through which raw materials is melted inside
till it is homogeneous in state. When melt mixture
reaches the die, the required product will be produced.
The varieties of die give many different type of product,
however hopper, screw, barrel remains the same in
manufacturing process.
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What Is Extruding?

First resin is chosen for the product and some additives

together needed for desired properties of final product.
Extruder is preheated first and made temperature stable
before pouring the raw materials. When the resin is
added all the materials goes through the feed hopper and
reach the base of barrel by gravity. Then the helical screw
inside the barrel pushed the materials forward to the feed
section where material gets gently heated and massive
amount of pressure is created inside the barrel pushing
the materials towards the melting zone. Screw rotates in
controlled RPM of the motor. In melting section, all the

materials transform from pellets to melted liquid form

and all the materials flows towards the metering section,
in this section melted mixture goes through to get more
homogene-ous in state and thus finally resin moves
towards die and gets in desired shape.
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Feed Hopper:

Feed is considered a mouth of the extruder; all the raw

materials are first poured in feed where they are pre-
heated. All the raw materials pass through feed throat
smoothly and reaches the heating barrel for further
process. Material must reach to the other end of the

barrel starting from feed hopper or also called feeding

zone. Supply of feed in the hopper should be sufficient to
create required pressure to continue the
materials towards other zones of barrel. Therefore, the
design efficiency of hopper also plays the great role in
passing the resins to melt smoothly in the process.
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Barrel :
Extruder barrels are made of Nitriding steels, powder
metallurgy steels or Bi-metals.

Apart from what extruders are made up of, it

can be also grouped according to the external surface
feature. In some extruder, the surface of the barrel can
be machined or smooth. Smoothing or machining the
outer surface of extruder is directly related to the heat
dispersion rate while extruding
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Screw :
An importance of the screw in extruding is the shape of
the screw. The screw used in extruders are helical. Its
unique shape produces much friction and heat required
for melting and pushing raw materials forward. In
general, a long screw inside the extruder can be further
divided into feed section, transition section and metering
section. In feed section, all the raw materials get down
from feed throat by gravity to base of rotating screw and
get in contact with screw and further process of

extruding begins.

Die:

Die plays an important role in determining the shape of

the product. There are various types of dies available for
different products. Some common dies that most of
extruding companies uses are cast film dies, sheet dies,
twin wall dies and more. Flat dies are also
available nowadays
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Water Cooling Tub:

When hot extrudate comes out of the die, it is supposed

to be hot and soft. For cooling process extrudate pipe
further process through long chamber to bath tub. The
specific amount of heat is loss in water which results in
the solidification of profiles. The used or hot water
return water back to the central cooling unit. And this
cooling cycle continues throughout the process of
cooling pipes or plastic profiles.
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METHOLOGY OR PROCESS
OF MANUFACTURING:
The manufacturing process of HDPE (High-Density
Polyethylene) roll pipe typically involves several steps.
Here's a simplified overview:

• Resin Selection: HDPE resin pellets are chosen

based on the desired properties of the final pipe,
such as density, melt index, and molecular weight.

• Extrusion: The chosen HDPE resin pellets are melted

in an extruder at controlled temperatures and
pressures. The molten HDPE is then forced through
a die to form a continuous tube shape.
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• Cooling and Sizing: The extruded pipe is rapidly

cooled using a water bath or air cooling system to
solidify the HDPE material. Sizing devices might be
used to control the diameter of the pipe.

• Ovality Control: To ensure uniformity, the pipe might

undergo a process to control its ovality and maintain
a consistent round shape.

• Printing and Marking: Information like product

specifications, brand logos, or identification codes
may be printed onto the pipe's surface.

• Cutting and Winding: The continuous pipe is cut into

specific lengths and wound onto rolls, hence the
term "roll pipe."
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• Quality Control: Various quality checks and tests,

such as dimensional inspections, pressure testing,
and visual inspections, are performed to ensure the
pipe meets industry standards and specifications.

Throughout the process, manufacturers adhere to strict

quality control measures to produce HDPE roll pipes with
the required strength, durability, and dimensional
accuracy for various applications like water supply,
drainage, gas distribution, and more.
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Winding Process:

As shown in figure above the rolling machine for pipe is

very simple and works manually. A worker in factory
continuously spins the wheel for pipe to get rolled. Little
bit of oil maintenance is done occasionally for smooth
spinning and good efficiency.
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Cutting Process:

Cutting process of the pipe is also done manually,

workers use local cutting tools i.e. Saw instead of
modern cutting laser cutters. Therefor cutting personnel
should be very careful to keep exact dimensions of
profile like pipes.
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Recycle Process:

Recycling system was not in large scale in Calcutta

Polymer Industries. But small recycling was machine was
helping very much to keep local village and environment
cleaner. Below is an image of simple recycling of used
plastics collected locally.
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Results in images of Manufacturing Process :

The following figures show the final products of the

Calcutta Polymer Industries.

Applications of HDPE Pipes:

HDPE pipes are vital on our daily life such as water

supply, irrigation, electric wirings,
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sewage management line and a lot more. Here are

enlisted the major applications of HDPE pipes over the
world:

• Agriculture & Irrigation:

1. Flood Irrigation (Suction & Delivery pipes in pump
sets)
2. Sprinkler Irrigation (Crops, Lawns, Golf course,
Gardens)
3. Drip irrigation (Plantations, Orchards, Nurseries)

• Water Supply:
1. Potable water supply
2. Water mains
3. Distribution
4. Service Pipes

• Sewage & Industrial Effluent Disposal

1. Domestic Sewage System
2. Sanitary System
3. Petrochemical Industry
4. Fertilizer Industry
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• Ducting
1. Air-conditioning & Refrigeration
2. Extraction of Fumes
3. Telecommunication, as conduits for OFC

• Electrical Installations
1. Conduits for Cables

• Drainage Pipes
2. Surface & Rain water
3. Waste Water Mains
4. Sub-soil water (Anon., 2015)
The effective utilization of HDPE Pipes isn't
restricted to the previously mentioned ap-
plications. It has various helpful applications. For
example, when the need to convey wa-
ter over a stream emerges, building a bridge for a
surface pipeline would not be a finan-
cially savvy arrangement. Further a submerged
pipeline of other regular materials would
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be vulnerable to crack on the undulating river

because of saltiness. HDPE channels being
adaptable and chemically inert are the solution. The
pipeline might be amassed, drifted on the water,
adjusted and afterward sunk by only filling it with
water. That is the comfort in establishment no other
pipe can offer. These flexible channels may likewise
be utilized in cooking gas dissemination systems,
transportation of corrosive chemicals, chilled water
and compacted air inside a plant, transportation of
items such as milk, edible oils and so on.
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FUTURE DEVELOPMENTS:

The extruder used in this company seem a bit old fashioned. The
extruder takes lot of energy as the design efficiency is not quite
seen developed comparing European extruders. The use of the
insulation on the barrel are considered as more efficient. If the
barrel could use aluminium or copper block heater including the
glass fibre or carbon fibre insulation it could greatly save power
usage around 75%. Besides the laser cutter could save work
force used. It could increase the speed and help to maintain the
rigid structure of the barrel which can be operated using less
torque on the screw. This also minimizes the wearing and
breaking of the screw as the screw is highly brittle and made
using brass to conduct more heat. Furthermore, the most
important steps to follow during production process must be
strictly following Calcutta Polymer Industries. It’s not mandatory
to pass the quality test from NSTM and PPI however if they ask,
the products must meet the criteria.
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CONCLUSIONS:
HDPE (High-Density Polyethylene) is commonly used to
produce rolls due to its toughness, chemical resistance, and
versatility. It's ideal for applications like packaging, liners, and
industrial purposes. LLDPE (Linear Low-Density Polyethylene)
is preferred for water tanks due to its flexibility, impact
resistance, and ability to withstand stress cracking. Both resins
offer specific properties suitable for their intended applications,
ensuring durability and functionality in their respective
manufacturing processes. Water storage tanks are used across
a variety of applications where water needs to be stored for
ready access. Household water storage, commercial food and
beverage preparation, agriculture and irrigation, fire
suppression, and industrial manufacturing all utilize water
storage tanks to streamline water delivery. HDPE pipe is used
across the globe for applications such as water mains, gas
mains, sewer mains, slurry transfer lines, rural irrigation, fire
system supply lines, electrical and communications conduit, and
storm water and drainage pipes.
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BIBLIOGRAPHY:
References has been taken from the following sources for the
succesful completion of this project report:

• [email protected]
• https://m.indiamart.com
• https://national-plastics.com/
• www.researchgate.com
• www.sciencedirect.com
• www.wikipedia.com

THANK-YOU!
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SUMMERTRAININGREPORT

CALCUTTA POLYMER INDUSTRIES

(AGARTALA SECTOR,TRIPURA)
01.06.2023 to 30.06.2023

NATIONAL INSTITUTE OF TECHNOLOGY

AGARTALA

Submitted by:
SREYASHI DAS (20UCH001)
B.TECH, 6th Semester, 3rd Year
Chemical Engineering Department

DateofSubmission:30.06.2023
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CERTIFICATE

This is to certify that the candidate SREYASHI DAS (20UCH001/2012299)

B.Tech. 6th Semester, 3rd Year of Chemical Engineering Department of
National Institute of Technology,Agartala has satisfactorily completed the
summer training from 01.06.2023 to 30.06.2023 ,under the guidance of Sri
Rafikul Islam Sir, Calcutta Polymer Industries. During her training period
she has submitted a report on “PROCESS OF MANUFACTURING OF
WATER STORAGE TANKS BY LLDPE RESIN AND WATER ROLL PIPES
BY HDPE RESIN”.

During this training she took utmost interest in the assigned work. She is
sincere and completed her training programme at Calcutta Polymer
Industries with utmost dedication. We wish her all success in her
academic endeavors and life.

(Mr. Rafikul Islam)

HR, Calcutta Polymer Industries
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ACKNOWLEDGEMENT

I'm heartily thanking my industry mentor. Sri Rafikul Islam Sir for his
continuous support and guidance during my training. I'm indebted to hím
for providing me with the resources and have learned a lot of things from
him which will surely help me in my near future.

This golden opportunity I had with Calcutta Polymer

Industries,Agartala proved to be a great platform for me to learn that
I can apply in industry. This training helps me to learn about
professional traits one should have. Therefore, I'm grateful that I got
an opportunity to be a part of it. I'm also grateful for having a chance
to meet my mentor through this training period.
Secondly, I would like to thank my parents and
other group members who helped me in successful completion of
training program.This training program helped me in increasing my
knowledge and skills.

Thanking You,
Sreyashi Das
B.Tech ,6th Semester, 3rd Year
Chemical Engineering Department
National Institute of Technology Agartala