The document is an internship report submitted by Shravan Kumar Pathak summarizing their two week internship at AA VASANI POLY PIPE LLP in Talod, Gujarat, India. It provides an overview of the company and details of its various departments including production, testing, quality assurance, and mixing. It describes the extrusion process for pipe production and the skills learned by the intern such as operating extruders and testing machines, quality control, and teamwork. The internship provided valuable hands-on experience in different areas of the plastic pipe manufacturing plant.

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Gujarat Technological University, Ahmedabad
An Internship Report on
“ Over View Of Extrusion Process (Pipe Plant)”
Submitted in partial fulfillment for the award of degree of
Bachelor of Engineering
in
Plastic Technology
Submitted By,
Shravan Kumar Pathak
(180520123045)
Internship carried out at
AA VASANI POLY PIPE LLP,
GIDC,TALOD
Internal Guide External Guide
Dr. Neelmani Srivastava Mr.Amit Tripathi
Assistant Professor HOD, QC
Dept. of Plastic Technology GIDC ,Talod
CIPET,Ahmedabad
Department of Plastic Technology
Central Institute of Petrochemicals Engineering & Technology,Ahmedabad
2021-2022

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Gujarat Technological University
Central Institute of Petrochemicals Engineering &
Technology,Ahmedabad
Department of Plastic Technology
Certificate
Certified that the internship work entitled “Over View Of Extrusion
Process (Pipe Plant)” is a bonafide work carried out by Shravan Kumar
Pathak (180520123045) of CIPET,Ahmedabad ,and this report is
submitted in partial fulfillment for the award of Bachelor of engineering
in Plastic Technology Of Gujarat Technological University,during the
year 2021-2022.
Signature of Internal Guide Signature of External Guide
Dr. Neelmani Srivastva Mr.Amit Tripathi
Assistant Professor HOD, QC
Dept. of Plastic Technology GIDC ,Talod
CIPET,Ahmedabad
Signature of HOD Signature of Principal
Dr.Anshuman Barman Mr. Ratan kumar
Prof.& HOD Principal
Dept.of Plastic Technology CIPET,Ahmedabad
CIPET,Ahmedabad
EXTERNAL VIVA
Name of the examiner; Signature

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Acknowledgement
I am very thankful to AA VASANI POLY PIPE LLP Company for giving me the
opportunity to undertake my summer internship program at their prestigious
company. It was a very good learning experience for me to have worked at this
site.
I would like to convey my heartiest thanks to Mr. Raj Kapoor ,HR Manager ,who
heartily welcomed me for the internship, Mr.Amit Tripathi HOD of QC/QA who
guided and encouraged me all through the summer training and imparted in-
depth knowledge of the programme. I would like to thank all the staff of AA
VASANI POLY PIPE LLP for giving their precious time and valuable guidance
during my internship programme.
I am extremely thankful to Dr. Anshuman Barman,Head of Department of
Plastic Technology,CIPET,Ahmedabad for providing me facilities to work
in,without which this work would not have been possible.

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Preface
Every student of Bachelor of Engineering in Plastic Technology, has an essential
requirement to do Two weeks time of internship in any of the well reputed
organization. The purpose of this programme is to acquaint the students with
practical applications of theoretical concepts taught to them during conduct of
their course.
Really, it was a nice opportunity to have a close comparison of theoretical
concept in practical field.This report may depict deficiencies on my part but still
it is an output of a student's efforts, for which I beg pardon.
The output of my analysis is summarized in a shape of internship the contents of
the report shows the detail of sequence of these.

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Abstract
The report covers the following aspects of internship;
 Table of content.
 Introduction of AA VASANI POLY PIPE LLP.
 Departments of AA VASANI POLY PIPE LLP.
 Description of processing techniques.
 Schedule of Internship.
 Skills learned
 My role as an trainee
 conclusion

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Table of Contents
Acknowledgement ......................................................................................04
Preface ........................................................................................................05
Abstract… .....................................................................................................06
Introduction of Company.............................................................................08
Departments In Company............................................................................09
 Marketing Department ...................................................................09
 Store...............................................................................................10
 Production Department ..................................................................10
 Testing Department( Laboratory) ....................................................13
o Density test.......................................................................13
o Ash content ......................................................................13
o Reversion test ..................................................................13
o VST test ...........................................................................13
o Hydrostatic Pressure test................................................13
o Impact test .....................................................................14
o MFI test..........................................................................14
 Quality Assurance/Quality Control… ..................................................14
 Mixer Department… ...........................................................................14
Internship Rotational Plane.............................................................................14
Skills & Techniques learned during internship .................................................15
Role of internee During Internship ..................................................................15
Conclusion ........................................................................................................16
References…....................................................................................................16

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Introduction
AA VASANI POLY PIPE LLP
This is a largest HDPE, PVC and DWC Pipe Manufacturer company , Started in
1996. This is Located in Special Economic Zone in Gujarat ,India. Being the
industry leader Vasani has the daily production capacity of 100 metric tons to
fulfil industry demand. The manufacturing plants of Vasani are spread across a
43000 square metre large infrastructre in GIDC Talod. To fulfill the ever
increasing demands of top quality PVC,HDPE pipes in market ,Vasani has more
than 1000 across india. Government organization such as SSNL,GIRDA are also
customer of Vasani.
Vasani is to provide integrated solutions and services to the polymers industry of
Vibrant Gujarat, designed to redefine the peasants' satisfaction, rationalize cost
and a bridge the gap between the Indian requirement and International practice
& farmers standard availing neck to neck support to agriculture and irrigation
industries of our beloved nation.
Vasani is enormously trying to achieve complete customer satisfaction by
continuously improving its quality. Vasani determined to be an innovative and
responsive manufacturer and supplier of best quality products through:
 Improvement of quality control system by giving proper training to our staff and
trainees.
 Conducting internal auditing for better result in the whole system.
 Delivering best quality products to the customer with an affordable price.
 Continuously updating and implementing products and process innovation to
reach towarda best quality with optimum sustainability.
 Keep researching product development to fulfill customer satisfaction.
 Smooth up gradation in our operation and processing system.

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Products:
 RRJ pipes
 Selfit pipes
 Upvc plumbing pipe
 Casing pipes
 HDPE pipes
 SWR pipes
 DWC pipes
 UGDS pipes
 Sprinklers
Departments In Company
o Marketing Departments
o Store
o Training Departments
o Production Departments
o Testing Departments (Laboratory)
o Quality Assurance/Quality Control
o Mixer Department
Marketing Department
Marketing departments fulfill the marketing needs and work to ensure the
progress-
 Market research
 Product development
 Sales support

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Store
Major functions :
 Receipt of Incoming goods
 Inspection of all receipts
 Storage and preservation
 Identification of all materials stored
 Material handling
 Packaging
 Issue & Dispatch
 Maintenance of stock records
 Stores accounting
 Inventory control
 Stock taking
Production Department
Extrusion process
The process itself is highly technical. However, it can be summed up in just five
steps.
Step 1: Raw plastic materials like granules, pellets, or powder are loaded into a
hopper and then fed into a long heated cylindrical chamber called an extruder. It
is moved through this chamber by a revolving screw. Some extruders can have
either one or two revolving screws.
Step 2: The raw materials flow from the hopper down through the feed throat
and onto a large spinning screw operating within a horizontal barrel.
Step 3: Not all materials have the same properties, so the raw material is
processed by a heating temperature specific to the type of raw material being
passed through. At the end of the heated chamber, the molten plastic is forced
through a small opening called a die to form the shape of the finished product.
Step 4: As the plastic is extruded from the die, it is fed onto a conveyor belt for
cooling. Cooling can happen by air or water. The process is similar to the
injection moulding process except that the melted plastic is forced through a die
instead of into a mould.

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Step 5: The die for an individual plastic profile is designed so that the plastic
flows smoothly and evenly from the cylindrical profile of the extruder into the
final profile shape. Consistency in this flow is critical to achieving an end product
with integrity
Pipe Plant
We move toward production section ,where various machine fitted with
different outputs-
Hasmukh Engineering Extruder - 350-500 kg/hour
Kabra - 150 kg/hour
Panchveer-250kg/hour
Rolepal- 800kg/hour

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These machines are specially use for production of pipes from ranging 40mm-
400mm.They were consist of extruder,cooling section,haul off unit and cutter
section. During the production of pipes contol the various troubleshooting which
occurs on the pipes.
 Extruded pipe cooled in cooling section.
 Haul – off unit is used to pulling the pipe from extruder.
 Cutter section is used to cut the pipe on required dimensions.
Troubleshooting:
S.N. PROBLEM CAUSES REMEDIES
1. Water mark  Excess water level in
cooling channel
 Increases water
temperature
 Reduce water level
 Decreases water
temperature
2. Rough surface  Improper compounding of
material
 Improper melting of
material in barrel
 Proper
compounding of
material
 Increase the
temperature of
barrel
3. Pin hole  Improper compounding of
material
 Improper melting of
material in barrel
 Proper
compounding of
material
 Increase the
temperature of
barrel
4. Cut mark  High haul-off speed
 Less dosing
 Reduce the amount
of dosing

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Testing Department
Performed various test in testing departments;
 Density test
 Ash content
 Reversion test
 VST test
 Hydrostatic Pressure test
 Impact test
 MFI test
 Density test
Find out the density of PVC and HDPE material by following the IS standard,and
find the amount of filler in the material.
 Ash content
An Ash test is used to determine if a material is filled. The test will identify the
total filler content.
 Reversion test
Reversion Test is a method of determining the level of internal stresses in
pipes,and to know the percentage of shrinkage.
 VST test
To find out the softening temperature of the material by applying the load.
 Hydraustatic pressure test
The vessel is filled with a nearly incompressible liquid-usually water or oil-
pressurised to test pressure, and examined for leaks or permanent changes in
pipe.

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 Impact test
In the impact test use a swinging pendulum to strike a notched bar; heights before
and after impact are used to compute the energy required to fracture the bar.
 Melt Flow Index
Determines the melt flow properties of a material at a specific shear stress and
temperature.
Quality Assurance/Quality Control
Production of pipes requires high end quality assurance which is a part and parcel of
the activity.We got exposed to a well defined quality system,consisting of in process
and in final inspection which ensure 100% inspection for the entire die & mould parts
and also sampling inspection for pipes to meet the customer requirements.
In this section we got basic knowledge of measuring equipments like Digital
Micrometer & Vernier calipers,Pie tape,Ultra frequency thickness gauge.
Mixer Department
In this department material compounded with various additives like
Caco3,Tio2,carbon,One pack stabilizer,Stearic& wax etc in mixer to enhance the
property of the pipes.
Internship Rotational Plane
Production section 1 Week 3 /06/ 21……….9/06/ 21
Testing section 1 Week 10/06/21……...16/06/21
Quality Assurance section 1Day 17/06/21………18/06/21
Mixer section 2 Day 18/06/21……….19/06/21

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Skills & 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
internship ,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
It was valuable time here in AA VASANI POLY PIPE LLP and we learn
unlimited here are a few point I have summarized.
 We learned about the leadership & teamwork to do an effective work.
 We learned about tactics to maintain discipline & How to deal with
workers.
 We learned How to control quality problems,defects in
material,Laboratory Tests.
 We have learnt how to make a powerfull team and achieve goal.
 We learned How to operate extruder machines and testing machine.
Role Of Internee during Internship
I learned how to adjust myself in the work environment,how to deal with
people at work from the boss to the janitors. It’s a good quality
experience.The necessary kind of experience as it helps you realize what you
want in future,also got the opportunity to evaluate myself under these stressful
conditions.

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Conclusion
It was a wonderful learning experience at AA VASANI POLY PIPE LLP for two
weeks in Talod. I gained a lot of insight regarding almost every aspect of
plant. I was given exposure in almost all the departments at the plant. The
friendly welcome from all the employees is appreciating,sharing their
experiences and giving their peace of wisdom which they have gained in
long journey of work. I am very thankful for the wonderful facility from
VASANI. I hope this experience will help me in my future and also in
shaping my career.
I am preety sure that this facility has ability to achieve its goal as stated in
vision statement by following their quality statement.
We are commited to comply with customer requirements and Quality
Management System requirements and shall strive to continually improve
the effectiveness of our Quality Management System to exceed customer
expectations.
References
 http://vasanipolymers/about us.html
 http://www.slideshare.net
 www.google.com