JSPM’S
Imperial College of Engineering and Research, Wagholi, Pune.
[Approved by AICTE Delhi and Govt of Maharashtra, afillated to Savitribai Phule Pune University]
GAT.NO.720, PUNE-NAGAR ROAD, WAGHOLI, PUNE 412207.
DEPARTMENT OF MECHANICAL ENGINEERING
A Internship Report On
“Plastic Injection Moulding ”
Under
AN INTERNSHIP REPORT
Submitted in partial fulfillment for the Internship work
SAVITRIBAI PHULE PUNE UNIVERSITY, PUNE
Submitted By
Name: Pankaj Ramesh Kale
Seat No: T400510190
PRN: 72245634E
Under The Guidance of: Prof. N. P.Patil
JSPM’S Imperial College of Engineering & Research
Wagholi, Pune-412207
CERTIFICATE
This is to certify that the internship work in title “Plastic Injection Moulding’’ at
JSPM’S ICOER submitted by Mr. Pankaj Ramesh Kale is a record of the Bonafide work
carried out by her, under my guidance and it is approved for the partial fulfillment of
requirement of Savitribai Phule Pune University for the Internship work.
Internship Guide Head of Department
Internship Coordinator Principle
Company Overview
Legal Name: Sanika Plast Pvt.Ltd
Incorporation Date: 5 Dec 2018
CIN: U25209PN2018PTC180565
Company Type: Private, non government
Industry: Plastic Manufacturing
Directors: Poonam Nanaso Deokar
📍 Registered Address: Gat No 565/2A, Ground Floor Gavhane Shed, Behind Wable Signage, Koregaon
Bhima, Pune Nagar Road Pune , Haveli, Maharashtra, India - 412216.
📞 Contact Information
Email: info@rsaglobal.in
Proprietor (for retail arm): Mr. Sanjay Petkar
Retail Location:Gat No.565/2A Koregaon Bhima Taluka Shirur Pune
ABSTRACT
Plastic injection moulding is a highly versatile and widely used manufacturing process for producing complex
plastic components with high precision and repeatability. This technique involves injecting molten
thermoplastic material into a mould cavity, where it cools and solidifies into the desired shape. The process is
characterized by its efficiency, scalability, and ability to produce intricate parts with tight tolerances and
minimal waste. This abstract outlines the fundamental principles of injection moulding, including the stages of
the process, the types of materials used, and the design considerations for moulds and products. It also
highlights recent technological advancements in automation, mould design, and material science that have
expanded the applications of injection moulding in industries such as automotive, medical, consumer
electronics, and packaging.
INDEX
Sr. no. Content Page no
1 Introduction 5
2 Objective 6
3 Purpose of internship 7
4 Training program 8
5 Skill gained 32
6 Lesson learned 34
7 Outcomes 35
8 Benefits of training program 36
9 Limitation 38
10 Conclusion 39
INTRODUCTION
Plastic injection moulding is one of the most commonly used manufacturing processes for
producing plastic parts in large volumes. It involves melting plastic material and injecting it
under high pressure into a mould cavity, where it cools and hardens to the shape of the
mould. This method is highly efficient for creating complex and detailed components with
consistent quality, making it ideal for mass production.
The origins of injection moulding date back to the late 19th century, but the process has
significantly evolved with advances in materials, machinery, and automation. Today, it plays
a vital role in numerous industries, including automotive, electronics, consumer goods,
medical devices, and packaging. The appeal of injection moulding lies in its ability to
produce high-strength parts with minimal waste and low per-unit cost at high production
volumes.
Understanding the principles, equipment, material selection, and design aspects of injection
moulding is essential for optimizing product development and manufacturing efficiency.
This technique is particularly popular in industries such as automotive, electronics, medical
devices, and consumer products due to its ability to produce large volumes of complex and
detailed components at a low cost per unit. It offers advantages such as fast production
cycles, minimal material waste, and high repeatability.
As technology advances, injection moulding continues to evolve, incorporating automation,
advanced materials, and sustainability practices to meet the growing demands of modern
manufacturing.
OBJECTIVES
1. Achieve Mass Production – Enable the rapid manufacturing of identical parts in large volumes with
minimal human intervention.
2. Ensure Precision and Consistency – Produce parts with complex geometries and tight tolerances, ensuring
uniformity across batches.
3. Minimize Material Waste – Optimize material usage by recycling excess plastic and reducing scrap.
4. Reduce Production Costs – Lower the cost per part by using automated systems and high-speed production
cycles.
5. Support Design Flexibility – Allow for a wide range of shapes, sizes, and surface finishes to meet diverse
design and functional requirements.
PURPOSE OF INTERNSHIP
1.Skill development - Acquire and enhance specific skills relevant to the field of study or the
industry. Gain hands-on experience and practical knowledge that complements theoretical
learning.
2.Professional Exposure: Gain insight into the day-to-day operations of a professional
environment. Understand the organizational structure and culture of the company.
3.Application of Knowledge: - Apply academic knowledge to real-world situations and
problem-solving. Gain a deeper understanding of how theoretical concepts are implemented
in a practical setting.
4.Project Work: Contribute to ongoing projects or work on specific assignments that add
value to the organization. - Develop a portfolio of work that can be showcased for future career
opportunities.
5.Feedback and Evaluation: -Receive constructive feedback on performance to identify
strengths and areas for improvement.
- Understand how to adapt and thrive in a professional environment.
TRAINING PROGRAM
1. Internship Title: - Intern (Mechanical Department Design and Development)
2. Role Description: - Assisting with project planning and execution. - Collaborating with
team members on various tasks. - Learning and applying industry-specific skills.
3. Duration: Internship start at 03 Jan 2025 and End at 02 Feb 2025.
Parts of Plastic Injection Moulding Machine:
A. Injection Unit
Hopper: Holds and feeds plastic pellets.
Barrel: Heats the plastic.
Screw: Rotates to melt and push plastic forward.
Heaters: Surround the barrel to melt plastic.
Nozzle: Injects molten plastic into the mould.
B. Clamping Unit
Clamps: Hold the mould tightly shut during injection.
Tie Bars: Guide and support moving platens.
Moving & Fixed Platens: Hold the mould halves.
Hydraulic or Toggle Mechanism: Generates clamping force.
Control Unit (Electronic controls and interface)
1. PLC (Programmable Logic Controller)
Brain of the machine, executing programmed injection cycles.
2. Operator Interface / HMI (Human-Machine Interface)
Touchscreen or control panel to operate and monitor the machine.
3. Sensors & Switches
Monitor pressure, temperature, position, etc.
Base & Frame (Structural support)
1. Base Frame:
The main body of the machine holding all other components.
2. Guarding & Safety Doors:
Enclosures and interlocks to protect operators from moving parts.
Specification
Plastic Injection Moulding Machine Starting Procedure
1. Pre-Start Checks:
Check power and air supply – Ensure main power and compressed air are available and stable.
Inspect machine – Look for oil leaks, loose wires, or obstructions.
Check oil level and temperature (for hydraulic machines).
Ensure safety guards and emergency stops are in place and functional.
Load raw materials (plastic granules) into the hopper.
2. Turn on the Machine:
Switch on the main power supply and machine control panel.
Allow the control system (PLC/HMI) to boot up.
3. Heat Up the Barrel:
Set barrel heating zones to the desired temperature (based on material spec).
Wait until all zones reach set temperature (typically 30–60 minutes).
Ensure screw rotation is locked during heating (to avoid damage).
4. Purge the Barrel:
After the barrel is fully heated:
Manually run the screw to purge old/degraded material.
Use proper purging compound if changing materials.
5. Check Clamping System:
Close the mould (dry run) and check for proper clamping action.
Set mould opening/closing speeds and pressures.
6. Set Parameters:
Set injection pressure, speed, hold pressure, back pressure, and cooling time.
Set screw speed and injection time based on your part design and material.
7. Mold Setup:
Mount the mould securely using clamps/bolts.
Connect water lines for cooling.
Check ejector pin alignment and stroke.
8. Trial Run:
Perform a few manual cycles (semi-auto mode).
Check for:
Proper material flow
Flash or short shot
Cooling and ejection issues
9. Switch to Automatic Mode:
Once settings are verified, run in auto cycle.
Monitor for at least 10 cycles to ensure consistent part quality.
BENEFITS OF TRAINING PROGRAMME
Up-to-Date Technical Knowledge : A comprehensive training program ensures that engineering professionals
are equipped with the latest technical knowledge and advancements in their respective domains. This exposure
to cutting-edge technologies enables engineers to remain competitive and contribute effectively to projects,
fostering innovation within the industry.
Skill Enhancement : Training programs are designed to address specific skill gaps within the engineering
workforce. Whether it be mastering new software tools, refining problem-solving abilities, or developing
effective communication skills, these programs contribute significantly to the overall skill enhancement of
engineers.
Adaptability to Industry Changes : The engineering landscape is subject to constant Changes driven by
technological breakthroughs and industry trends. Training programs empower engineers to adapt seamlessly
to these changes, ensuring that they can navigate new challenges and contribute meaningfully to their projects
and teams.
Team Collaboration and Communication : Effective collaboration is fundamental to successful engineering
projects. Training programs often include modules on teamwork, communication, and project management,
fostering a collaborative mindset among engineers. Improved interpersonal skills contribute to streamlined
workflows, reduced errors, and enhanced project outcomes.
Safety and Compliance : In engineering, particularly in sectors like construction and manufacturing, safety
and compliance are paramount. Training programs address these crucial aspects, ensuring that engineers are
well-versed in industry regulations and safety protocols. This not only mitigates risks but also contributes to
the overall well-being of the workforce.
Career Development and Motivation : A well-structured training program provides engineers with
opportunities for career development. Continuous learning fosters a sense of professional growth and
motivation, leading to increased job satisfaction and a more committed and engaged workforce
Outcome
1. High-Quality Parts: Produces consistent, precise, and high-strength components with tight tolerances.
2. Mass Production Efficiency: Ideal for large production runs due to fast cycle times and repeatability.
3. Cost Efficiency (at Scale): Although setup is expensive, unit costs drop significantly with high-volume
production.
4. Complex Geometries: Allows the production of complex and detailed shapes that would be difficult or
expensive to make with other methods.
5. Wide Material Selection: Supports a broad range of thermoplastic materials with various properties (rigid,
flexible, UV-resistant, etc.).
6. Low Waste: Excess material can often be reused or recycled, making it more material-efficient than some
subtractive methods.
Limitation
1. High Initial Costs: The design and manufacture of moulds are expensive and time consuming, making it
less suitable for low-volume production.
2. Design Restrictions: Parts must be designed with certain geometrical rules in mind (e.g., draft angles, wall
thickness) to ensure proper mould filling and ejection.
3. Material Limitations: Not all plastics are suitable for injection moulding. Some high-performance or
thermoset materials may require different processes.
4. Long Lead Times: Mould design and testing can add significant time before production can begin.
5. Part Size Limits: Very large parts may be impractical due to machine size constraints and material flow
limitations.
6. Environmental Concerns: Though recyclable, plastic usage and energy consumption in the process can raise
sustainability issues.
7. Difficult to Prototype: Creating a mould just for prototyping is expensive and time-consuming; alternative
methods like 3D printing are often preferred for early design validation.
8. Flash Formation: Excess material can seep out between the mould halves (called flash), requiring secondary
trimming operations if the mould isn’t perfectly aligned or maintained.
9. Degassing Issues: Trapped air or gases during injection can lead to voids or burn marks if venting is not
properly designed.
10. Long Setup Time: Machine setup—including mould mounting, material loading, and process calibration—
can be lengthy, especially when switching between jobs.
Skills and Techniques learned during Internship
An internship assists with career development by providing real work experiences that provide students with
opportunities to explore their interests and develop professional skills and competencies. During internships,
we are provided with opportunities to apply what We learned in classes to actual practice. It is expected that
we will also be challenged to examine how our attitudes, beliefs, and values influence the process. We learnt
about the leadership & Team work to do an effective work
