PLASTIC INDUSTRIES

Plastic came from the Greek word plastikos, which means moldable or
formable. It consists of long chains of molecules called polymers. The
molecules can be either natural (cellulose, wax, and a natural rubber) or
synthetic (polyethylene or nylon) which are derived from non-renewable
resources oil, coal and natural gas.
Resins in the form of pellets, powder, or solutions serve as the starting
materials and from these the finished plastics are formed. When heated to a
liquid or semi-solid form, plastics can be molded into almost any desired
shape; when cooled they harden into a solid.

KINDS OF PLASTIC
Kindly refer on Shreeves CPI table 34.2 and table 34.3
A. Based on Polymerization Process
1. Addition Polymerization
2. Condensation Polymerization
B. Based on Processibility
1. Thermoplastic
2. Thermosetting
C. Based on Chemical Nature

Manufacturing
Resins

of

Process

Phenol-formaldehyde

Kindly refer on Shreeves CPI fig. 34.7 for the flowchart

Phenolic resins designate a group of synthetic resins that are probably the
most varied and versatile that we know. The may be made from almost any
phenolic body and aldehyde. Phenol-formladehyde resins constitute by far the
greatest proportion of phenolics, and are most widely used in production of
laminates.
BLENDING. The phenol and formaldehyde are placed in reaction kettle with the
catalyst (Sulfuric acid) and heated 3 to 4 hours at temperature of 140 t0 163C.
Polymerization starts to happen here.
CONDENSATION. During condesation , reaction water is eliminated and forms the
upper of two layers. This water of reaction is removed under vacuum without the
addition of heat.
COOLING AND HARDENING.The warm, dehydrated viscous resin is run out of the
kettle into shallow trays and allowed to cool and harden.
CRUSHING AND GROUNDING. The cooled, brittle resin is crushed and finey
ground and becomes the resin binder for molding phenolic resins.
ADDITION OF ACTIVATORS AND ADDITIVES. Fillers, lubricant and plasticizers
are mixed. Hexa is added to convert the thermoplastic resin to thermosetting resin.
STEAM HEATING.The powder mixture is is further reacted on steam heated roll at
35-115C at about 45-75 seconds
COOLING AND GROUNDING. The mixture phenolic moulding compund now goes
to a cooling converyor and then cut by low speed cutter.

Manufacturing of Process of Laminates

A. Raw Materials

Kraft Paper
Phenolic Resin
Decorative Printed Paper
Melamine Resin
Clear Translucent Paper

Manufacturing Process

FIRST SOAKING

The manufacturing process starts by soaking the paper in resins. The brown
paper that is going to form the bottom side or base of the laminate is soaked in
a bath tub that is filled with phenolic resin.

DRYING
This is followed by a drying process in which the soaked papers are
allowed absorbed fully all the phenolic resins.

SECOND SOAKING
The decorative printed paper and the translucent paper is similarly
soaked and saturated with the melamine resin.

DRYING
This is followed again by a drying process in which the soaked papers
are allowed to dry. After the drying is complete, the paper which earlier
was easy to tear acquires new physical properties. It becomes stiff and
brittle.

CUTTING
The hardened rolls of paper are then cut to the desired sizes by the
cutting machines (called cutters).
HIGH PRESSURE PRESSING AND BONDING
The next step in the laminate manufacturing process is to hard press
these papers together under high pressure and temperature. This is
done using hydraulic presses. The papers or sheets are stacked upon

each other.
SANDING
In the final step of the process, the bottom side (non-decorative side) is

uniformly sanded by a sanding machine.

TESTING, PACKING, AND SHIPPING
Samples of the finished products may be subjected to standard quality
tests for laminates as per norms, and these sheets are then packaged
and shipped to the regular distribution channels of the laminate
companies.