INTERNSHIP REPORT (Repaired).docx

BAHIR DAR UNIVERSITY
BAHIRDAR INSTITUTE OF TECHNOLOGYFACULTY OF CHEMICAL AND FOOD
ENGINEERING DEPARTMENT OF CHEMICAL ENGINEERING4TH YEAR INTERNSHIP
REPORT AND PROJECT
TOPIC: PRODUCTION OF FIBER MAT FROM SISAL PLANT
HOSTING COMPANY: AGPFT
PREPARED BY:
NAME ID NO
PAWULOS MEKURIA………………………………………………………………. BDU1011281
TESHOME MENGESHA……………………………………………………………. BDU1011643
ADDISU LINGEREW…………………………………………………………………BDU1011492
ADVISOR’S NAME
MAHLET
MELAKU
SUBMISSION DATE 19/06/2014 E.C
BIT, BDU, BAHIR DAR, ETHIOPIA

BAHIR DARUNIVERSITY 𝟒𝑻𝑯
YEAR CHEMICAL ENGINEERING
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INTERNSHIP REPORT
DECLARATION
We declare, hereby this internship report on Amhara golden trust pipe fitting technology plc
(AGPFT) and project entitled production of fiber mat from sisal fiber extracted from sisal plant is
our original work and performed by our effort with the will of GOD during the internship period.
We have improved our practical skills, theoretical knowledge that we have so far, enter personal
communication skills, work ethics and entrepreneurial skills in it. We assure that the report
contains actual events and facts that were observed and performed during the internship period.
Name Signature Date
Pawulos Mekuria ………….. ……………..
Teshome Mengesha ……………. …………………
Addisu Lingerew …………... …………………
Advisor approval
This is to certify that the above statement made by the student is correct to the best of my
knowledge and belief. This project work has been submitted for presentation with my approval.
Name of advisor Signature Date
Mahlet
Melaku

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ACKNOWLEDGEMENT
First and foremost, we would like to thank the almighty GOD for giving the strength to accomplish
this work and to perform the internship practice with in a stipulated time. We want to give a
compliment to the company for giving us an opportunity of passing the internship program under
the company and enable us to know what we should have to know related to the theoretical parts
what we have learnt so far.
Next, we would like to express our sincere gratitude for Mr. Melaku and Mrs. Mahlet for their
academicals; comments and recommendations for successfully accomplish our project. In other
side, we would like to give thank Mr. Yirga and other laboratory assistances for their permission
to do laboratory tasks.
Finally, we would like to provide a great thank for our company advisor Mr. Tayachew Takele,
Mr. Maseresha, Mr. Abirham and Mr. Worku for their continuous support in the production
process, quality control section and all AGPFT operators for their willingness to tell us whatever
anything we ask them concerning internship time activities.

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DECLARATION ...................................................................................................................I
ACKNOWLEDGEMENT ....................................................................................................II
LIST OF FIGURES ...........................................................................................................VII
LIST OF TABLES.............................................................................................................VII
ACRONYMS...................................................................................................................... IX
EXECUTIVE SUMMARY ..................................................................................................X
CHAPTER ONE ................................................................................................................... 1
1. BACKGROUND OF AMHARA GOLDEN TRUST PIPE FITTING TECHNOLOGY (AGPFT) 1
1.1 Brief history ................................................................................................................................ 1
1.2 Objectives of the company.......................................................................................................... 2
1.3 Vision of the company................................................................................................................ 2
1.4 Mission of the company.............................................................................................................. 2
1.5 Core values of the company........................................................................................................ 2
1.6 Quality, reliability and social responsibility ............................................................................... 2
1.7 Main products of the company ................................................................................................... 2
1.8 Main customers/end users of the company’s products ............................................................... 3
1.9 Key stake holders of the company .............................................................................................. 3
1.10 Overall organization and work flow of the company ............................................................... 4
1.11 Main tasks of each department.................................................................................................. 5
1.11.1 General Manager................................................................................................................ 5
1.11.2 Production Department ...................................................................................................... 5
1.11.3 Quality Control Department .............................................................................................. 5
1.11.4 Maintenance Department ................................................................................................... 5
1.11.5 Marketing Department ....................................................................................................... 5

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1.11.6 Human Resource................................................................................................................ 5
1.11.7 Promotion, Finance and Budget Department..................................................................... 5
1.11.8 Purchasing and Property Administration ........................................................................... 6
CHAPTER TWO .................................................................................................................. 7
2. OVERALL PROCESS DESCRIPTION........................................................................................... 7
2.1 Raw materials and their properties.............................................................................................. 7
2.1.1 Raw materials....................................................................................................................... 7
2.1.2 Properties of raw materials .................................................................................................. 8
2.2 Overall production process of extrusion molding machine ...................................................... 11
2.2.1 The three different zones of extrusion molding are:.......................................................... 12
2.3 Overall production process of injection molding machine ....................................................... 13
2.3.1 The injection molding machine units................................................................................. 13
2.3.2 Injection molding machine components ............................................................................ 15
2.4 Overall production process of blow molding............................................................................ 16
2.5 Overall production process of fiber technology........................................................................ 17
2.6 Manufacturing process of fiber glass........................................................................................ 17
2.7 Utility in the company .............................................................................................................. 18
2.7.1 Cooling tower..................................................................................................................... 18
2.7.2 Chiller................................................................................................................................. 19
2.7.3 Compressor ........................................................................................................................ 20
2.8 Major Product defects of the company..................................................................................... 20
2.9 Laboratory instruments of the company ................................................................................... 23
2.9.1 Ash content instrument ...................................................................................................... 23
2.9.2 Digital balance ................................................................................................................... 23

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2.9.3 Differential scanning calory meter..................................................................................... 23
2.9.4 Thermal test........................................................................................................................ 24
2.9.1 Melting flow index instrument........................................................................................... 24
2.9.2 Hydrostatic pressure test .................................................................................................... 24
CHAPTER THREE ............................................................................................................ 25
3. PRODUCTION OF FIBER MAT FROM SISAL(QACHA) PLANT ........................................... 25
3.1 ABSTRACT.............................................................................................................................. 25
3.2 INTRODUCTION .................................................................................................................... 26
3.3 LITERATURE REVIEW ......................................................................................................... 29
3.4 Statement of the problem.......................................................................................................... 32
3.5 Objectives of the study.............................................................................................................. 33
3.5.1 General objective ............................................................................................................... 33
3.5.2 Specific objectives ............................................................................................................. 33
3.6 Scope of the project................................................................................................................... 33
3.7 Significance of the project ........................................................................................................ 33
3.8 Materials and methods .............................................................................................................. 33
3.8.1 Chemicals and Equipments................................................................................................ 33
3.8.1.1 Chemicals.................................................................................................................... 33
3.8.1.2 Equipments.................................................................................................................. 33
3.8.2 Methods.............................................................................................................................. 34
3.8.2.1 Raw material collection and preparation .................................................................... 34
3.8.2.2 Fabrication .................................................................................................................. 34
3.8.3 Experimental process (mechanical testing)........................................................................ 35
3.8.3.1 Tensile test .................................................................................................................. 35

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3.8.3.2 Flexural testing............................................................................................................ 35
3.8.3.3 Hardness test ............................................................................................................... 35
3.9 Results and discussion .............................................................................................................. 37
3.9.1 Tensile test ......................................................................................................................... 37
3.10 Challenges and limitations...................................................................................................... 41
3.11 Conclusion .............................................................................................................................. 42
3.12 Recommendation .................................................................................................................... 42
CHAPTER FOUR............................................................................................................... 43
4. OVERALL INTERNSHIP BENEFITS AND CHALLENGES ..................................................... 43
4.1 Sections of the company we worked ........................................................................................ 43
4.2 Tasks that we had performed .................................................................................................... 43
4.3 Engineering methods, tools and techniques used for performing tasks .................................... 43
4.4 Major challenges and problems we faced ................................................................................. 44
4.5 Benefits that we have gotten during the internship period ....................................................... 44
4.6 What we gained in terms of improving team playing skill....................................................... 44
4.7 Work ethics ............................................................................................................................... 45
4.7.1 Personal Ethics................................................................................................................... 45
4.7.2 Professional Ethics............................................................................................................. 45
4.8 What we gained in terms of entrepreneurship skill .................................................................. 46
4.9 Conclusion and recommendation.............................................................................................. 46
4.9.1 Conclusion ......................................................................................................................... 46
4.9.2 Recommendation ............................................................................................................... 46
Reference ............................................................................................................................ 48

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LIST OF FIGURES
figure1. 1 Main products of the company.............................................................................................3
figure1. 2work flow of the company ....................................................................................................4
figure2. 1raw materials used by the company ......................................................................................7
figure2. 2Extrusion section of AGPFT.......................................................Error! Bookmark not defined.
figure2. 3 Zones of extrusion machine .....................................................Error! Bookmark not defined.
figure2. 4 processflow diagram of injection molding process..............................................................15
figure2. 5 Main injection machine parts.............................................................................................16
figure2. 6 Fiber glass production process ...........................................................................................18
figure2. 7 cooling tower....................................................................................................................19
figure2. 8 water cooled chiller unit ....................................................................................................20
figure2. 9 Burn mark.........................................................................................................................21
figure2. 10 short shot........................................................................................................................22
figure2. 11 surface delamination .......................................................................................................22
figure2. 12 sink mark ........................................................................................................................23
figure 3. 1 shows sisal plant.....................................................................Error! Bookmark not defined.
figure 3. 2 (A) showsextracted sisal fiber strands.(B) shows fiber mat composites...............................34
figure 3. 3 hardness tester.................................................................................................................36
figure 3. 4 The tensile strength of composite material ........................................................................39
figure 3. 5 the flexural strength of composite material........................................................................40
figure 3. 6 shows the hardness number for the sisal fiber composites..................................................41
LIST OF TABLES
Table 1 shows the experimental design of the study .................................................................... 37
Table 2 shows the average results of each test.............................................................................. 39

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ACRONYMS
AGPFT………………………………… Amhara Golden Trust Pipe Fitting Technology
ADWCE……………………………… Amhara Design Works Construction Enterprise
AWWCE……………………………… Amhara Water Works Construction Enterprise
FGRP…………………………………… Fiber Glass Reinforced Polymer
HDPE…………………………………… High Density Polyethylene
PE……………………………………… Polyethylene
PP…………………………………………Polypropylene
PPR……………………………………… Polypropylene Random
PLC……………………………………… Private Limited Company
UPVC……………………………………… Unplasticized Polyvinyl Chloride
E…………………………………………epoxy
4S6E…………………………………….40% sisal fiber and 60% epoxy
FRC…………………………………………fiber reinforced composite
MFI…………………………………………Melt flow index.
DSC………………………………………... differential scanning calory meter
TG…………………………………………glass transition temperature
MAWP…………………………………maximum allowable working pressure.
PVA……………………………………. Polyvinyl alcohol
NFC…………………………………………natural reinforced fiber composites
FAO…………………………………………food and agricultural organization.

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EXECUTIVE SUMMARY
This report contains the internship program performed in AG pipe fitting technology P.L.C from
August 01/2013 E.C to November 20/2014 E.C. It includes the historical background of Amhara
Golden Trust Pipe Fitting Technology (AGPFT), its main services, customers, over all
organization structure and work flow of each section, raw materials, products and the overall unit
processes with their respective operating mechanisms used in AGPFT. This report also explores
the overall internship experience including tasks taken, benefits that can be gained, the challenge
faced and the measures taken to overcome those challenges. During the internship program,
important practical knowledge, experiences in terms of social interaction, team work, punctuality,
leadership which are important in life were considered.
.

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CHAPTER ONE
1. BACKGROUND OF AMHARA GOLDEN TRUST PIPE FITTING
TECHNOLOGY (AGPFT)
1.1 Brief history
Amhara Golden trust pipe fitting technology (AGPFT) was established in 12/05/14G.C by the joint
venture company with the Amhara region development enterprise and part of the golden trust
capital group; its source of capital is from the share holders’ contribution with initial capital of 19
million birr in which the golden trust group accounts 60% and 40% the regional government. It
located at Bahir DAR town. The total land holding is 47,000 square meters.
When the company established, it primarily aims to bring technological transformation in the
region, to develop modern agricultural facilities like irrigation dams and construction. But
unfortunately, the golden trust groups are no eligible to do so and the government took an
immediate action to hold the share contribution of the golden trust group in collaboration with
Amhara water works construction enterprise (AWWCE) and Amhara design works enterprise
(ADWE). Now its capital becomes 244 million birrs in which the government accounts 95.4% and
the rest 4.6% by the golden trust group. At the company there are 78 (male=62 and female=16)
permanent, 9 contracts and totally 87 workers.
Offering the most complete line of manufacturing and locally produced HDPE, PP, PPR, UPVC
pipe fitting and different fiber glass products delivered in the region and anywhere in Ethiopia.
The main aim of the company is to solve regional plastic fitting related problems by manufacturing
locally.
Until the new injection molding machines become installed and commissioning, the company tried
to substitute some of imported fittings by butt welding fabricated manufacturing. Even though the
company is committed to improve its production system by deliver products to customer, and
regarding their feedback to build workers capacity by learning by doing, on job training approach.
But concerned governmental sectors are not keen customer for local regional product. The total
annual demand request and their interest become shift to private sector suppliers.

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The best solution for all these and others is fulfilling budget design, construct, workshop, procure
machines, molds and raw materials at least to start in its opening capacity. This year plan contains
how to solve primary problems to achieve our vision, mission and objectives of annual plan.
1.2 Objectives of the company
 To offer customer information, technical support and customer service that meet and exceed
their requirement.
 To delivery on time and quick reply to consumer inquiries.
 To produce quality and special fittings as per as customer request.
 To provide the best engineered suitable, quality, efficient products and solution for customers.
1.3 Vision of the company
AGPFT is committed to become one of the leading pipe fitting and fiber glass products
manufacturing company in Ethiopia, regarding customer needs and requirements by the year of
2025.
1.4 Missionof the company
To manufacture quality fittings fiber water tanker, transparent Eva sheet sanitary materials and
related fiber glass products to meet customer requirement and expectation, in addition increasing
the company market share all over the region and Ethiopia [13].
1.5 Core values of the company
Meets customer needs and requirements.
1.6 Quality, reliability and socialresponsibility
 Even profit though customer satisfaction.
 Culture of team spirit and intensity.
 Genuine tax payer for national development.
 Save customer expenses by prefight and delivery time.
 Provide quality local products.
1.7 Main products of the company
The main products of AG pipe fitting technology are:
 HDPE fittings like flanges, reducer, normal tee, cross tee and with different ODs
elbows like 90°,45°,22.5°.

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 PPR fittings; elbows, reducers, couples, tees etc. for transportation of hot fluid.
 Stadium chairs, flower containers made from PP.
 PP pipe fittings; cups, couples, straight reducers, tees, elbows etc.
 PP Buckets and fiber glass water tanks.
figure1. 1 Main products of the company
1.8 Main customers/endusers of the company’s products
 Amhara water works construction enterprise (AWWCE)
 Amhara region water office
 Amhara region agricultural and rural development office
 Individual farmers and private construction companies
1.9 Key stake holders of the company
 Amhara region joint venture sector
 Golden trust capital group
 Foreign investors

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1.10 Overall organizationand work flow of the company
A functional organization structure is mainly aiming to organize workers. They are grouped based
on their specific skills and knowledge. It vertically structures each department with their duty from
the general manager to finance and sales departments, to customer service, to employees assigned
to one product or service.
Work flows the company
figure1. 2work flow of the company
General manager
Marketing department Finance and budget Human resource
Purchasing and Property
administration
Maintenance
department
Quality control and
Safety management
Production manager
Maintenance and repair
Team leader
Quality control and
assurance team leader
Production team leader
Tools and utilities
operator
Laboratory
Technician

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1.11 Main tasks of eachdepartment
1.11.1 General Manager
Control, follow up and lead over all the company, apply yearly plan and occupational program.
Generally, control all over working process of the company.
1.11.2 Production Department
Controls all production processes, supplies raw materials, identifies product types, formulate plans
to increase products receiving job order etc.
1.11.3 Quality Control Department
Coordinates, follow up, and controls the quality of product, checks if the raw material full fills the
acceptable quality or not, performance of production machines preservation and production
process and also ensure that non- conforming products are handled.
1.11.4 Maintenance Department
Plan and carry out preventive maintenance parts and major laws; Prepare maintenance schedule
tooth for machinery and vehicles; evaluate machinery performance and suggest equipment that
need mass disposal; advice and assist the deputy general manager on technical matters related to
maintenance.
1.11.5 Marketing Department
Developing and designing price policy promotional strategy distribution mechanisms and
implementing after approval by the general manager; gathers marketing information, searches
market places, purchases raw materials, applies customer attracting activities, and makes product
advertising activities also strategic thinking, planning and implementing of the marketing function
of the company.
1.11.6 Human Resource
Carry out proper man power planning; recruitment and selection of employers; induction and
orientation program for newly recruited staffs also developed policies and procedures for annual
leaves control discipline of community in the company.
1.11.7 Promotion, Finance and Budget Department
Follow up and realize financial planning, perform budget preparation, indicate the direction of
financial sources of the company, and controls the collected finance.

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1.11.8 Purchasing and Property Administration
Basically, purchasing the acquisition of materials and services from suppliers beside on proper
purchasing policy and procedure of the company also support and facilitate the company operation
with uninterrupted flow by supplying materials flow by supplying materials and services at the
right time, right price, and right place from the right source.

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CHAPTER TWO
2. OVERALL PROCESS DESCRIPTION
2.1 Raw materials and their properties
2.1.1 Raw materials
The main raw materials used in the company are:
 PP (polypropylene)
 PPR (polypropylene-Random)
 Master batch
 Waving
 Gel coat
 Risen
 Pigment
 Catalyst
 Wax
 Hardener
 HDPE (high density poly ethylene)
 U-PVC (un-plasticizers polyvinyl chloride)
 Fiber glass
figure2. 1raw materials used by the company

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2.1.2 Properties of raw materials
Polyethylene (PP) and its properties
also known as polypropene, is a thermoplastic polymer used in a wide variety of applications. It is
produced via chain-growth polymerization from the monomer propylene.
Polypropylene belongs to the group of polyolefins and is partially crystalline and non-polar. Its
properties are similar to polyethylene, but it is slightly harder and more heat resistant. It is a white,
mechanically rugged material and has a high chemical resistance. Its properties are:
 Light weight
 High chemical and heat resistance ability
 High tensile strength, corrosion resistance and easily recyclable.
Applications
 Packaging applications; such as buckets.
 Consumer goods; like stadium chairs and house wares.
 Industrial applications; used to produce acid and chemical tanks, sheets, pipes
1. Polypropylene random (PPR) and its properties
Polypropylene random copolymers are thermoplastic resins produced through the polymerization
of polypropylene, with ethylene or butene bonds introduced in the polymer chain. The resins
provide a broad range of characteristics, and are used in a wide range of applications.
Polypropylene random copolymers are thermoplastic resins produced through the polymerization
of propylene, with ethylene or butene bonds introduced in the polymer chain. The resins provide
a broad range of characteristics, and are used in a wide range of applications.
Properties
 It is durable
 High resistance to chemical substances
 Brilliant and smooth inner surface
 Provide heat and sound insulation
 Environmentally friendly

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Application
 High clarity/transparency packaging
 Injection molding
 Blow molding
 Pipe
2. High density polyethylene (HDPE) and its properties
High density poly ethylene (HDPE) is a thermoplastic polymer made from petroleum residues. As
one of the most versatile plastic materials around, HDPE plastic is used in a wide variety of
applications including: plastic bottles milk jugs, shampoo bottles, bleach bottles, cutting boards,
and pipes. HDPE is known for its outstanding tensile strength and large strength-to-density ratio,
high impact resistance and melting point.
Properties of HDPE
 High Density Polyethylene is a chemical resistant,
 Excellent resistance to most solvents
 Very good resistance to alcohols, dilute acids and alkalis
 Moderate resistance to oils and greases
 Poor resistance to hydrocarbons (aliphatic, aromatic, halogenated)
 Higher tensile strength compared to other forms of polyethylene
 Low-cost polymer with good processability
 Good low temperature resistance
 Excellent electrical insulating properties
 Very low water absorption
3. Unplasticized polyvinyl chloride (UPVC) and its properties
UPVC, also known as Unplasticized Polyvinyl Chloride, is a low-maintenance building material
used as a substitute for painted wood, mostly for window frames and sills when installing double
glazing in new buildings, or to replace older single glazed windows. It has many other uses
including fascia, and siding or weatherboarding. The same material has almost entirely replaced

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the use of cast iron for plumbing and drainage, being used for waste pipes, drain pipes, guttering
and downpipes.
Property
 Chemical resistant
 Not flexible
 Fire resistant
 low thermal conductivity
4. Masterbatch (MB)
Masterbatch is a solid additive for plastic used for coloring plastics (color masterbatch) or
imparting other properties to plastics (additive masterbatch). A liquid dosage form is called liquid
color. Masterbatch is a concentrated mixture of pigments and/or additives encapsulated during a
heat process into a carrier resin which is then cooled and cut into a granular shape. Masterbatch
allows the processor to color raw polymer economically during the plastics process.
5. Wax
Wax is used to polish the mold and lubricant it by removing unwanted parts.
6. Gel coat
This is evenly spread on the mold for the purpose of required color and shape.
7. Waving:
Required for strengthen the fiber glass.
8. Harder:
It’s used to for drying purpose. If quick order is coming from end users, then to get the product
fast harder is used.
9. Resins
To transfer stress between reinforcing fibers and to protect them from mechanical and metal
damage and attaches the fiber glass with the gel coat there are two types thermoset resin and
thermoplastic resin

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10. Pigment:
Varnished at the end to prevent the growth bacteria and germs in the stored water.
11. Fiberglas and its properties
It is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly
arranged, flattened into a sheet (called a chopped strand mat), or woven into glass cloth.
The plastic matrix may be a thermoset polymer matrix most often based on thermosetting
polymers such as epoxy, polyester resin, or vinyl ester resin or a thermoplastic.
Properties of fiber glass
 Fiberglass has a specific resistance greater than steel. So, it is used to make high
performance.
 It is good electrical insulator.
 fiberglass is a mineral material; it is naturally incombustible.
 Low thermal conductivity making it highly useful in the building industry.
Application of fiber glass
Materials with high-temperature insulation provide an effective thermal barrier for industrial
gaskets. Since fiberglass is durable, safe and offers high thermal insulation. They not only
provide a better insulation but also help in protecting machinery, conserving the energy and
ensure the safety of the professional workforce. This is the reason why fiberglass is widely
used in industries below:
 Cooling tower
 Storage tank
 Chemical industry
 Car washes
2.2 Overallproduction process ofextrusion molding machine
Extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into
a continuous profile. This process starts by feeding plastic material (pellets, granules, flakes or
powders) from a hopper into the barrel of the extruder. The material is gradually melted by the
mechanical energy generated by turning screws and by heaters arranged along the barrel. The

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molten polymer is then forced into a die, which shapes the polymer into a shape that hardens during
cooling [14].
The die actually gives the shape of the desired plastic like a rod, tube or a profile shape with the
requisite internal or outer diameter. When the material comes out of the die, it moves the length of
the conveyor. The profiles can be manufactured endlessly and cut by the continuous extruding of
each length. Screw extrusion involves a helical feed screw that turns inside a barrel. This is often
called the feed screw or the extruder screw. In most cases the choice of method is based on the
shape of the component and Plastic type (thermoplastic or thermosetting). Screw used for plastic
processing categorized as single screw and multiple screw depending on the raw material used and
product type.
2.2.1 The three different zones of extrusion molding are:
1. Feed zone (solids conveying zone): This zone feeds the raw material in to the extruder, and the
channel depth is usually the same throughout the zone. The function of this zone is to preheat the
plastic and convey it to the subsequent zones. The design of this section is important since the
constant screw depth must supply sufficient material to the metering zone so as not to starve it.
But on the other hand, not supply so much material that the metering zone is overrun. optimum
design is related to nature and shape of the feedstock.
2. Melting zone (transition or compression zone): Most of the polymer is melted in this section and
the channel depth gets progressively smaller so as to compact the plastics. Squeezing any trapped
air pockets back into the feed zone and improving the heat transfer through the reduced thickness
of material.

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3. Metering zone (melt conveying zone): In this section the screw depth is again constant but much
less than the feed zone. The melt is homogenized so as to supply at a constant rate, material of
uniform temperature and pressure to the die. A great advantage of extrusion is rolling sheets of
molten plastics for a desired diameter. Common extrusion processes are the production of pipe,
profile, wire coating and filaments. Extrusion permits multiple-layer extrusion of film, sheet, pipes,
tubing, profiles, and extrusion coating
2.3 Overall production process ofinjection molding machine
Injection molding is a process in which raw materials in the form of granules is feed in to the
hopper and plasticized by reciprocating screw with heat and injected in to a close mold to get the
optimum shape of the required part. It is an ideal process for fabricating a large number of
geometrically complex shapes.
The injection molding process is primarily a sequential operation that results in the transformation
of plastic pellets into a molded part. Identical parts are produced through a cyclic process involving
the melting of a pellet or powder resin followed by the injection of the polymer melt into the hollow
mold cavity under high pressure.
2.3.1 The injection molding machine units
An injection molding machine is a machine which produces components by injection molding. It
is most commonly a hydraulically powered, in-line screw machine although electric machines are
appearing and will be more important in the market in the future. The main units of a typical
injection molding machine are the clamping unit, the injection unit, and the drive unit with their
figure2. 2 Zones of extrusion machine

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respective function illustrated below. Injection molding machines are often classified by the
maximum clamp force that the machine can generate. This is the force that pushes the two mold
halves together to avoid opening of the mold due to internal pressure of the plastic melt in the
mold.
a. injection unit
The injection unit is used to melt the plastic and injects it in to the mold. Injection unit can be described
in four general steps regardless of the type of the machine used.
1) Powder or pelletized polymer is loaded and heated to the molten state.
2) Under pressure, the molten polymer is loaded into a mold through an opening called sprue.
3) The pressurized material is held in the mold until it solidifies.
4) The mold is opened and the part removed by ejector pins.
b. clamping unit
The climbing unit holds the injection mold. It is capable of closing, clamping and opening the
mold. Its main components are the fixed and moving plates, the tie bars, and the mechanism for
opening, closing. and clamping.
c. the driving unit
The drive unit provides power for the plasticizing unit and clamping unit.

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General Block Flow Diagram of Injection Molding
figure2. 3 process flow diagram of injection molding process
2.3.2 Injection molding machine components
 Hopper
In the molding process the plastic materials are supplied in the form of small pellets. The
hopper functions as the holder of these pellets. The pellets are then gravity fed from the
hopper to the barrel.
 The Barrel
Mixer
Raw material
Vacuum
autoloader
Master batch
Feed hopper
Heater barrel
Nozzle
Mold
Product
Packaging and
Distribution

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The main use of the barrel is to give support for the screw. It consists of heater bands which
function as temperature recorder for each section of the barrel so barrels have become available
to facilitate the molding of water sensitive plastics without the need for pre-drying.
figure2. 4 Main injection machine parts
 The screw
It is used for compressing, melting and conveying the plastic material. The screw consists of three
zones; the feeding zone, the transition zone and metering zone.
 The nozzle
The nozzle is screwed into the end of the barrel and provides the means by which the melt can leave
the barrel and enter the mold Contact with the mold causes heat transfer from the nozzle. In cases
where this is excessive it is advisable to withdraw the nozzle from the mold during the screw-back
part of the molding cycle. Otherwise, the plastic may freeze off in the nozzle.
2.4 Overall production process ofblow molding
Blow molding covers several industrial processes used to manufacture the thermoplastic hollow
parts. Their common basic principle is very similar to that of the old art of glass blowing. It starts
from a plastic part which is already hot or has to be heated above its glass transition temperature.

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This is the parson or preform, whose shape is usually a closed cylinder. In this heated state, the
material is easy to strain and able to accept very large deformations without rupture. Then, the
material is blown against the walls of a cooled mold in order to quickly get the material under its
TG, to maintain the molded shape. Mechanical stretching of the part can be done by air only or
can be helped by an internal stretching rod. The part can then be removed for mechanical finishing,
if necessary, and following operations. The three main manufacturing processes are extrusion blow
molding, injection blow molding and stretch blow molding.
2.5 Overall production process offiber technology
Fibers may be subjected to a variety of mechanical deformations; stretching, twisting, shearing,
and abrasion. Consequently, they must have a high tensile strength (over a relatively wide
temperature range) and a high modulus of elasticity, as well as abrasion resistance. These
properties are governed by the chemistry of the polymer chains and also by the fiber drawing
process. The molecular weight of fiber materials should be relatively high or the molten material
will be too weak and will break during the drawing process. Also, because the tensile strength
increases with degree of Crystallinity, the structure and configuration of the chains should allow
the production of a highly crystalline polymer.
2.6 Manufacturing process offiber glass
The most manufacturing process for fiberglass is the hand lay-up or chopper gun spray process
using an open mold. The shape of the part is determined by the shape of the mold, and the mold
surface is typically in contact with the exterior of the part. First clean the mold by water and dry;
then release wax to the mold to prevent the fiberglass part from adhering to the mold and use Gel
coat, harder (catalyst) which is pigmented resin, is applied to the mold to give the part color [3].
Fiber glass and polyester (resin) are then deposited onto the mold and the fiberglass is compressed
by rollers, which evenly distributes the resin and removes air pockets and to attach the fiberglass
with gel coat; and added webbing to improve hardness of the product. Gypsum; silicon; titanium
peroxide also used. Multiple layers of fiberglass are deposited until the desired thickness is
achieved. Once, the resin is cured, the part is removed from the mold. Excess material is trimmed
off, and the part is ready for paint and assembly.

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figure2. 5 Fiber glass production process
2.7 Utility in the company
2.7.1 Cooling tower
A cooling tower is a heat rejection device which extracts waste heat to the atmosphere through
cooling of a water stream to a lower temperature or it is a special type of heat exchanger that allows
water and air to come in contact with each other to lower the temperature of hot water. The type
of heat rejection in a cooling tower is termed as “evaporative” in that it allows a small portion of
the water being cooled to evaporate in to a moving air stream to provide significant cooling to the
rest of that water stream. The heat from the water stream transferred to the air stream raises the
air’s temperature and its relative humidity to 100% and this air is discharged to the atmosphere.
Mold surface
preparation
Coat the mold
Surface with silicon
Spray PVA
On the mold
surface
Gelcoat
preparation
Fiber glass and resin
solution is applied in the
mold layers
Gel coating
the mold surfaces
Curing or drying
Remove the product
from the mold
Trimming and
assembled the
product

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figure2. 6 cooling tower
Most cooling towers work based on the principle of “evaporative cooling”. Evaporative cooling is
the process where warm water from an industrial process is pumped up to the top of the cooling
tower where the water distribution system is. The water then gets distributed by the cooling tower
nozzle to the wet deck. At the same time, air is being drawn through the air-inlet louvers forcing
water to evaporate. Evaporation causes the heat to be removed from the makeup water. The hot air
naturally rises out of the tire.
2.7.2 Chiller
Chiller is a machine which used to reduce the temperature of the medium by vapor compression.
Chillers are used by Amhara golden trust pipe fitting technology when they need to lower process
fluid temperature, when they need to cool the hot plastic that is injected and chilled water is used
in the process of sizing cooling the parts in production. Chillers are used to control the feed throat
temperature and barrel temperature for water- cooled molds it works based on the immutable
principle that the heat will move from the hotter source to the colder source from the process to a

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conditioned fluid it has four major components i.e., condenser, compressor, Expansion valve,
Evaporator.
figure2. 7 water cooled chiller unit
2.7.3 Compressor
Compressor is the major component of the refrigeration unit where Freon gas is used as a
refrigerant. It is used to pump the Freon gas throughout the circuit.
2.8 MajorProduct defects of the company
The main defects that occur in parts are caused by the variation of process parameters.
The major defects observed at AGPFT:
1) Flow lines: They are strikes, patterns, or lines commonly off-toned in color that shows up on
the prototype parts as a consequence of the physical path and cooling profile of the molten
plastic as it flows into the injection molding cavity. These defects are caused by the varying

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speed at which the molten plastic flows as it changes direction through the contours and bends
inside the mold tool.
2) Burn marks: are discolorations usually rust colored that appear on the surface of the injection
molded prototypes. They are caused by degradation of the plastic material due to excessive
heating or by injection speed that are too fast.
figure2. 8 Burn mark
3) Jetting: it refers to a situation where molten plastic fails to stick to the mold surface due the
speed of injection.it occurs mostly when the melt temperature is too low and the viscosity of
the molten plastic becomes too high which results in increasing the resistance of its flow
through the mold.
4) Flash: Flash is a molding defect that occurs when some molten plastic escapes from mold
cavity.it occurs when the mould is not clamped together with enough force which allows the
plastic to seep through.
5) Warping: is the deformation occurs when there is uneven shrinkage in different parts of the
molded component. It is usually caused by non-uniform cooling of the mold material.
6) Vacuum voids: they are packets of air trapped within or close to the surface of an injection
molded prototype. They are caused due to uneven solidification between the surface and the
inner section of the prototype. This is due to holding pressure is insufficient to condense the
molten plastic in the mold.
7) Short shot: as the term implies, short shot can be described as a situation where molding shot
falls short. This means that the molten plastic for some reason doesn’t occupy the mold cavity.
Incorrect calibration of the shot or plasticizing capacities can result in the plastic material

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being inadequate to fill the cavities. If the plastic is too viscous, it may solidify before fully
occupying all the cavities and result in a short shot.
figure2. 9 short shot
8) Surface delamination: this is a condition where thin surface layer layers appear on the part
due to contaminant materials. Addition of foreign materials that find their way into the molten
plastic separate from the finished product because the contaminants and the plastic cannot
bond. This defect in fact has both effects on the appearance and strength of the product.
figure2. 10 surface delamination
9) Sink marks: sink marks are small creators or depressions that develop in thicker area of the
injection molded prototype when shrinkage occurs in the inner portion of the finished product.

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they are formed when the cooling time or cooling mechanisms is insufficient for the plastic to
fully cool and cure while in the mold. They can also cause inadequate pressure in the cavity
or by an excessive temperature at the gate.
figure2. 11 sink mark
2.9 Laboratory instruments of the company
2.9.1 Ash content instrument
The ash content instrument is used to measure the amount of inorganic noncombustible material it
contains.
2.9.2 Digital balance
Used measure the mass of a sample. The digital Balance is a must-have addition for plastic
container laboratories or at-the-line inspection stations. This versatile unit features a digital display
for precise weight measurements and simple operation.
2.9.3 Differential scanning calory meter
Differential scanning calorimetry (DSC) is a thermo-analytical technique in which the difference
in the amount of heat required to increase the temperature of a sample and reference is measured
as a function of temperature. Both the sample and reference are maintained at nearly the same
temperature throughout the experiment. Generally, the temperature program for a DSC analysis is
designed such that the sample holder temperature increases linearly as a function of time. The
reference sample should have a well-defined heat capacity over the range of temperatures to be
scanned. Using this technique it is possible to observe fusion and crystallization events as well

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as glass transition temperatures Tg. DSC can also be used to study oxidation, as well as other
chemical reactions.
2.9.4 Thermal test
Thermal testing is a method of testing a materials ability to operate safely at different temperatures.
Thermal tests are used to measure a materials physical, mechanical, chemical, and thermodynamic
changes. Exact temperatures and loads that cause changes in these properties can also be
ascertained. Thermal testing sheds light on glass transition temperatures, crystalline melt
temperatures, the flammability of materials, as well as their oxidative and thermal stability.
2.9.1 Melting flow index instrument
Melt flow index is an important parameter to determine the property of the polymer to flow at
melting point under the application of the standard weight (3.2 kg). This MFI is an important
parameter, as it provides the necessary data of mass flow rate of the polymer per 10 min. This
obtained data was compared with standard polymer and cross checked. The temperature for the
MFI calculation is taken 230°C and the standard weight is taken as the 3.2 kg. MFI of the material
is calculated as the mass of the material in grams flowing
2.9.2 Hydrostatic pressure test
Hydrostatic testing is the primary method used to test for leaks and assess the structural integrity
of meter skids, compressed gas cylinders, boilers, tubing, pipelines and other pressurized vessels.
It’s performed by filling the system with water, pressurizing it up to a level greater than Maximum
Allowable Working Pressure (MAWP), and monitoring for visible and/or measurable leaks during
a specified amount of time.

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CHAPTER THREE
3. PRODUCTION OF FIBER MAT FROM SISAL(QACHA) PLANT
3.1 ABSTRACT
The main goal of this study is to develop fiber mat composites by using sisal fiber and different
mixing ratios of sisal fiber and resin epoxy. Sisal, very common type of natural fiber, is abundantly
available in Ethiopia. This research also investigates the mechanical properties of sisal reinforced
composites such as tensile, flexural and hardness. Fabrication of samples used the hand lay-up
process with 60, 50 and 40 wt% sisal fiber to epoxy ratio. Tests for the properties indicated were
made using the Instron material testing system. Test results demonstrated, among the samples, that
60 wt% of sisal fiber-reinforced composites have the maximum tensile and flexural strength of
205.6 MPa and 185.34 MPa respectively. The hardness has been found to be maximum for 60wt%
sisal fiber which is 51.5. As the result show, and compared with other researcher findings, the
mechanical properties are acceptable as substitutes for applications demanding low-cost
engineering applications such as automotive internal parts including interior door panel, back seat
and body panels. The average results of the mechanical properties the fiber mat is presented in
graphical form and in table.

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3.2 INTRODUCTION
In relation to the principles of sustainability, natural fibers are a major renewable resource material
throughout the world and specifically in the tropics. According to a Food and Agriculture
Organization (FAO) survey, natural fibers like jute, sisal, coir, and banana are abundantly available
in developing countries such as India, Srilanka, Thailand, Indonesia, Bangladesh, Philippine,
Brazil, and South Africa. Recent reports indicate that plant fibers can be used as reinforcement in
polymer composite to replace more expensive and non-renewable synthetic fibers such as glass
especially in low pressure laminating.[17]
Currently, natural fiber reinforced composites (NFC) have drawn more attention as alternative
building materials, especially as wood substitutes in the developing countries. The concept of using
natural fibre as a building component is actually not a new idea since it has been used centuries
ago for different applications. As the name implies, the NFCs composite is a class of composite
that contains natural fibers mixed with synthetic or bio resins that are inherently environmentally
beneficial. Other advantages of NFC are well explained in many published papers dealing with
this topic, Suddel and Rosemaund (2008) highlighted the advantages of using NFC: low density,
low cost, high toughness, acceptable specific strength properties, good thermal properties, low
embodied energy, reduced tool wear in the molding process and better acoustic properties thereby
reducing the noise, reduced irritation to the skin and respiratory system, and they also have low
energy requirement for processing.[17]
Among the various natural fiber composites, sisal fiber-reinforced composites produce superior
impact strength with moderate tensile and flexural properties making them potential alternatives
for applications that require good impact strength. Currently, sisal fiber has been used as a
reinforcement in variety of thermoset, thermoplastic and bio-degradable polymer composites and
their mechanical properties like stiffness tensile strength, compressional strength, flexural strength
and impact strength have been evaluated. Sisal fiber obtained from the sisal plant (known formally
as Agave sisalana) is one of the most widely used natural fibers in various applications and can be
easily cultivated in many parts of the world. The sisal plant grows about 100–200 leaves during its
lifetime, and each leaf contains long, straight fibers which can be extracted using specialized
processes. For this study, natural fiber composites, produced from sisal and epoxy available in

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Ethiopia, are investigated. Sisal plant is chosen for this research due to its wide abundance in
Ethiopia as well as its lower cost as compared to synthetic fibers. Sisal fibers have additional
benefits of being high strength to weight ratio, more environmentally benign than synthetic fibers
and potentially pose less of a health risk to users. Commercial use of sisal fibers in Ethiopia also
has economic advantage by supporting industries that use sisal fiber composites.[18]
Sisal (Agave Sisalana) is a leaf fiber derived from a plant that most commonly referred to species
of agave family. It is mainly cultivated for its fibre, which is extracted from the leaves. Sisal is
considered to be indigenous to central and south America. Owing to its potential to grow under
diverse ecological and climatic conditions, it has now widespread to Asian and African countries.
The primarily uses of sisal are in ropes and twines industries. Sisal is also converted to yarn, string,
bags, floor mats, wall coverings and handicrafts. The paper industry also uses the plant as a source
of cellulose pulp. Currently, the applications have extended to automotive, furniture and building
industry in the form of sisal-reinforced composites. In building industry, sisal is also seen as a
potential candidate to replace asbestos in roofing material.[18]

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figure 3. 1 shows sisal plant

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3.3 LITERATURE REVIEW
Many scholars have studied the nature, properties and extraction process of fibers from different
plants. Research studies from the past two decades have presented composites as an alternative
over many conventional materials as there is a significant enhancement in the structural,
mechanical, and tribological properties of fiber-reinforced composite (FRC) material.
Kaewkuk etal.[1] investigated the mechanical properties of sisal fiber/polypropylene composite.
They used sisal fiber obtained from Thailand and treated the fiber with 2% NaOH for 2 h and then
dried it in an oven at 60°c over night. Three different fiber contents viz: 10, 20 and 30% sisal fiber
with polypropylene were studied. The 30 wt% fiber contents showed the best property in terms of
tensile strength and Young’s modulus, with values of 26 MPa and 0.99 GPa, respectively.
Boopalan et al. [2] reported the results of comparative study of the tensile and flexural strengths
of jute and sisal fiber treated with 20%NaOH. The treated sisal fiber shown a marginally better
flexural strength of 82.3 MPa, which is ~2.75% more than jute fiber.
Rong et al. [3] experimented with unidirectional sisal-reinforced epoxy composites, which gave
the best tensile strength. They treated the fiber with 2% NaOH alkali with a 58wt% fiber content
and using compression molding method to fabricate the composite. They had better result in terms
of tensile modulus, flexural strength and flexural modulus of 5.55 GPa, 311.5 MPa and 23.75GPa,
respectively.
Khanam et al. [4] also reported, high mechanical properties; however, this was not as high when
compared with Rong etal.” s [3] data. The huge disparity in the results may be due to the fiber
content, chemical treatment, mode of fabrication or the type of matrix used and an admixture of
any of these.
Mechanical properties and morphology of sisal-epoxy composites was investigated by Oksman et
al (2000). Unidirectional sisal fibers were used to reinforce epoxy resin through resin transfer
molding method. The results showed that the stiffness of composite was about 20 GPa compared
to the stiffness of pure epoxy resin of 3.2 GPa. The tensile strength was also higher, 210 MPa
compared to the value obtained by testing pure epoxy resin, 80 MPa.
Alvarez and Vazquez [5] studied the effect of acetylation and alkali-treatment on the properties of
sisal fiber composites. It was demonstrated that both treatments changed the morphology of the

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fibers by removing cellulosic and cementing materials, creating voids and producing fibrillation
of fibers. These effects lead to a better adhesion between fibers and matrix. The authors suggested
that the alkali treatment was more effective than acetylation.
R. Prasanna Venkatesh, K. Ramanathan, V. Srinivasa Raman- In this tensile, flexural, impact
properties and water absorption tests were carried out using sisal/unsaturated polyester composite
material. Initially the optimum fiber length and weight percentage are estimated. To improve the
tensile, flexural and impact properties, sisal fiber was hybridized with bamboo fiber. This work
shows that the addition of bamboo fiber in sisal/ unsaturated polyester composites of up to 50%
by weight results in increasing the mechanical properties and decreasing the moisture absorption
property. In this research work, the effects of fiber treatment and concentration on the mechanical
properties of a short natural fiber reinforced polyester hybrid composite are investigated. The
fibers were subjected to 10% sodium hydroxide solution treatment for 24 h. The mechanical
properties of composites with treated fibers are compared with untreated fiber composites. The
fractured surface of the treated fiber composite specimen was studied using Scanning Electron
Microscopy. The treated hybrid composite was compared with an untreated hybrid composite, with
the former showing a 30% increase in tensile strength, 27.4% - in flexural strength, and 36.9% -
in impact strength, along with an extreme decrease in moisture absorption behavior.
Luju He et al. [6] carried out surface modification of sisal fibers by alkali treatment, heat treatment
and silane treatment respectively in order to enhance the interfacial adhesion of the fiber/polymer
composite for mechanical properties improvement. Sisal fiber/polyethylene (PE) composites were
fabricated at fiber contents of 10, 20, 30 weight% by using twin screw extrude equipment and their
mechanical properties were studied. The test results of tensile and flexural show that mechanical
properties increase after every treatment due to improved interfacial interactions. Silane treated
fiber (with content of 30%) reinforced composites showed 18% increase in tensile strength and
32% in young’s modulus, while the alkali treated fiber (with content of 30%) reinforced
composites performed 37% increase in flexural strength. However, in case of impact strength, the
treatment has been found to cause a reduction. It was also found with increasing fiber content,
tensile strength, flexural strength and modulus of the PP composites increased but impact strength
and elongation at break decreased.

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Mishra and Naik [7] treated sisal fiber with maleic anhydride in order to improve the mechanical
properties. The treated sisal fiber/polystyrene composites also showed better impact strength of
~17 Nm/cm^2; similar result was obtained with the hardness (shore-D) test of ~78.
Kanny and Mohan [8, 9] surface treated the sisal fiber with 40 g of NaOH–clay solution. The
solution was prepared by adding clay to 40 g of NaOH and stirred vigorously until the clay
dissolved completely in the solution. They immersed sisal fiber in the resulting solution for 1 h
and then dried for 4 h at 60°C. They reported that the tensile strength, tensile modulus and strain
of sisal/polypropylene composite increased by 14, 18 and 14%, respectively. NaOH–clay-treated
fiber led to improvement in water uptake from 12.5 to 10.3% when compared with untreated fiber.

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3.4 Statement of the problem
The use of cheap and domestic material is a main factor for the growth and development of the
economy for a country or a particular compony. However, the glass fiber which is imported from
foreign country is very expensive and leads the company to stop producing fiber glass composites
(poly fibers). Amhara golden pipe fitting technology (AGPFT) uses this material for the production
of water tanks, but there is a shortage this material due to its expensiveness to import it. However,
the plants (sisal) used for the production of fiber mat is found in our country. Therefore, to solve
this problem the convenient solution is to prepare fiber mat from fiber strands extracted from the
sisal plant. So, the aim of this study is producing fiber mat from strands of fibers extracted from
the sisal plant and substitute the fiber glass composites by fiber mat.

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3.5 Objectives of the study
3.5.1 General objective
 The general objective of this study is the production of the fiber mat from sisal plant.
3.5.2 Specific objectives
The specific objectives of this studies are investigating mechanical properties such as:
 the tensile strength of the fiber mat
 flexural strength of the fiber mat
 hardness of the fiber mat
3.6 Scope of the project
This project is an experimental study to show the extraction of fiber strands and production of fiber
mat. The scope of this study is analyzing the mechanical properties of the fiber mat such as tensile
strength, flexural strength, and hardness of a material.
3.7 Significance ofthe project
The main significance of this study alleviating the economic problem of the company by reducing
additional costs for buying fiber glass from foreign country. The findings of this study can add to
the existing body of the literature and can serve as a starting point on which future studies can be
built. Most importantly, On the practical side, the approaches and the experiences that is applied
in the research can be disseminated to other studies.
3.8 Materials and methods
3.8.1 Chemicals and Equipments
3.8.1.1 Chemicals
Epoxy is an adhesive used to attach strands of the fiber to each other to produce mat, water used
to wash the strands of the fiber.
3.8.1.2 Equipments
Materials that have been used in this study are; axe used to cut the sisal plant, blunt knife used to
separate/scrap the fiber from the leaves of the sisal plant, table used to support the leaves during
scraping process, scissor used to cut a fiber-epoxy composites to a desired shape, ruler used to
measure the dimension of the fiber-epoxy composites. The process of extracting this stand of fiber
from sisal plant is called decortication.

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3.8.2 Methods
3.8.2.1 Raw material collection and preparation
Raw materials were collected around our study area that Shum Abbo, Bahir Dar. Leaves of sisal
plant were obtained around Shum Abbo and the resins (epoxy) were obtained from market. The
strands of the fiber were dried to remove all the moisture contents of the fiber.
3.8.2.2 Fabrication
Fiber mat was produced by using sequential procedures such as cutting the leaves of the sisal plant,
extracting fibers strands from the leaves of the sisal plant, drying fiber strands and preparing the
mat by cross-linking the strands of fiber. The leaves of the sisal plant were first cut and then the
leaves were scraped to differentiate the fiber from lignin and cellulose. After that the strands of
the fiber were collected and dried. Finally, the strands of the sisal fiber were cross linked each
other using resins such as epoxy as a sticker.
(A) (B)
figure 3. 2 (A) shows extracted sisal fiber strands. (B) shows fiber mat composites

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3.8.3 Experimental process (mechanical testing)
3.8.3.1 Tensile test
In this study the fabricated fiber reinforced polymer composites were shaped with the required
preparation dimension by saw cutter and edge preparation was done by emery sheet for tensile test.
The test specimen was prepared according to ISO13934/1. Specimen was mounted in between the
jaws and it was subjected to under tension. The test sample was loaded in the direction of the fiber
length, until fracture take place. At the same time the reading was noted as a function of increasing
length. The measurement of tensile strength was taken parallel to fiber length to obtain very precise
result on the tension. the same procedure was repeated for three times of the same test. finally, the
average value was taken in account. [15]
3.8.3.2 Flexural testing
The three-point flexural test was commonly conducted on a fiber composite. At present, the flexural
test specimen was carried out under the BS 3356 standards. The test specimen was placed in
between two supports and it was loaded at center until the failure take place on composite
specimen. The results of flexural strength were noted. The same procedure was followed for three
times and finally the mean value was recorded.[15]
3.8.3.3 Hardness test
The hardness test on a fabricated fiber composite were carried by Rockwell hardness number under
the ES ISO 868 standards. The L scale tester was used to measure hardness value of composite
specimen under the applied load. The test was placed on moving jaw and it would be loaded for
10s an ambient condition. Finally, the load was released gradually and corresponding reading was
noted. The same procedure was carried out for four times on test sample. The mean value of the
result was considered as an exact hardness number.[15]

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figure 3. 3 hardness tester
Experimental design
In this project, three factors were selected to conduct our experiment. Those are: tensile strength,
flexural strength and hardness at constant load with three different sisals to epoxy ratio. For each
factor (tension, flexure and hardness) three samples are considered. Therefore, the numbers of
experimental runs that needed to be performed in this study were twenty-seven.
𝑡𝑜𝑡𝑎𝑙 𝑟𝑢𝑛 = 𝑠𝑎𝑚𝑝𝑙𝑒𝑓𝑎𝑐𝑡𝑜𝑟
𝑡𝑜𝑡𝑎𝑙 𝑟𝑢𝑛 = 𝑆𝑓
𝑡𝑜𝑡𝑎𝑙 𝑟𝑢𝑛 = 33
= 27
Where: S is number of samples
f is number of factors

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The factors, number of samples and the selected values of the factors were shown in the table below
Sample type F1 f1 f2 F3 f3
4S6E 3 3 3
5S5E 3 3 3
6S4E 3 3 3
Table 1 shows the experimental design of the study
3.9 Results and discussion
The mechanical properties namely tensile strength, flexural strength and hardness value of
fabricated fiber reinforced polymer composite was experimentally evaluated.
3.9.1 Tensile test
Tensile tests are used to determine the strength of a fiber reinforced polymer composites and tensile
strength at the peak has been investigated. tensile test was carried out according to ISO 13934/1
using an MTS machine with a maximum load capacity of 2467.2KN. three sets of specimens were
prepared for each mechanical property.
The tensile strength of a material is determined by the formula
𝜎 =
𝑓𝑜𝑟𝑐𝑒 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑎𝑡 𝑡ℎ𝑒𝑓𝑎𝑖𝑙𝑢𝑟𝑒
𝑂𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
𝜎 =
𝐹
𝐴0
Where: 𝜎 is the ultimate tensile strength of a material
𝐴0 is the original cross-sectional area of a surface.
𝐹 the load applied at the failure.
A0 = L0xW0
𝐴0 = 0.24 ∗ 0.05 = 0.012𝑚2
F=2467.2KN (Average force for the three sample of 60%S40%UHU)
𝜎𝑎𝑣𝑒 =
𝐹𝑎𝑣𝑒
𝐴0
=
2467 .2𝐾𝑁
0.012𝑚2 = 205.6𝑀𝑃𝑎
For 50%S50%E sample the average tensile strength is

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𝜎𝑎𝑣𝑒 =
𝐹𝑎𝑣𝑒
𝐴0
=
2226𝐾𝑁
0.012𝑚2
= 185.5𝑀𝑃𝑎
For 40%S60%Esample, the average tensile strength is
𝜎𝑎𝑣𝑒 =
𝐹𝑎𝑣𝑒
𝐴0
=
2004𝐾𝑁
0.012𝑚2
= 167𝑀𝑃𝑎
The flexural strength of the fiber composite is determined by the formula;
𝐹𝑙𝑒𝑥𝑢𝑟𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ =
3𝐹𝐿
2𝑏𝑑2
Where; Where F is the ultimate failure load (N); L, the span length (mm); b and d, the width and
thickness of specimen in (mm) respectively [11 12].
L=240mm
B=50mm
D=10mm
𝐹𝑙𝑒𝑥𝑢𝑟𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ =
3𝐹𝐿
2𝑏𝑑
2
𝐹𝑙𝑒𝑥𝑡𝑢𝑟𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ =
3 ∗ 2.5672𝐾𝑁 ∗ 0.24𝑚
2 ∗ 0.05𝑚 ∗ (0.01𝑚)2 = 185.34𝑀𝑃𝑎.
The average results of each test are given in the table below.

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Test samples Tensile strength (MPa) Flexural strength (MPa) Hardness number
40%sisal and 60% E 167 143.67 39.75
50% sisal and 50 %E 185.5 155.47 46.5
60% sisal and 40% E 205.6 185.34 51.5
Table 2 shows the average results of each test
The obtained results from the tensile test of fabricated fiber reinforced polymer composites are
presented in fig below. The result indicated that the sisal fiber composite (60% S and 40 %E)
specimen have better tensile strength relative to other sisal fiber composites. This is due to the
proper mixing of the sisal and epoxy.
figure 3. 4 The tensile strength of composite material
For a comprehensive comparison with literatures, the tensile strength of the fiber mat for this study
is 205.6MPa. The reason for this phenomenon is probably due to each investigator having
employed different types of fibers and material composition, fabricating process or may arise from
different testing standards.
0
50
100
150
200
250
4S6E 5S5E 60S4E
tensile
strength(MPa)
sample test

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INTERNSHIP REPORT
3.9.2 Flexural property
In this work, the flexural test was conducted based upon BS 3356, which is a standard test for the
determination of flexural properties of fibre-reinforced plastic composites. The test was carried
out using an MTS machine with a maximum load capacity of 2.576KN. Three specimens of
recommended dimensions were prepared and tested. A flat rectangular specimen was supported
close to the ends and centrally loaded in three-point bending. The flexural strength of the composite
material is presented in fig below. The sisal fiber composite (60%S and 40 %E) have more flexural
strength as compared to other composite specimens which has a value of 185.5MPa. However, the
flexural strength provided in this study is much less than the result of previous study reported by
Oksman et al (2000), where sisal fiber reinforced polyester composite has the flexural stress of 20
GPa.
figure 3. 5 the flexural strength of composite material
0
50
100
150
200
4S6E 5S5E 6S4E
143.67
155.47
185.34
Flexural
strength(MPa)
Sample test

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INTERNSHIP REPORT
3.9.3 Hardness test
The hardness number for the sisal fiber composite is shown in the fig below. The sisal fiber
composite (60%S and 40 %E) specimen have higher hardness relative to other sisal fiber composite
specimens.
figure 3. 6 shows the hardness number for the sisal fiber composites
3.10 Challenges and limitations
 Permission took a long time to conduct laboratory activity.
 The involuntariness of a laboratory assistant to conduct the lab activity at an appropriate time.
 We could not get the lab result with appropriate time.
 Absence of appropriate instrument to make fiber mat.
 Shortage of hand glove during the extraction of sisal fiber.
0
10
20
30
40
50
60
40%S60%E 50%S50%E 60%S40%
hardness
number
sample test
Hardness number

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INTERNSHIP REPORT
3.11 Conclusion
The mechanical properties of sisal fiber reinforced composites were experimentally investigated.
The tensile strength, flexural and hardness are analyzed as a function of fiber content. Based on
the experimental result the following conclusions are drawn. The tensile strength and flexural
strength of sisal reinforced resin composite are greatly influenced with the ratio of the fiber and
matrix and it exhibited an increase in physical property with the increase of sisal fiber ratio. From
the investigation the fiber composites with high sisal fiber ratio have high tensile strength, have
best flexural strength and has a good hardness. It is possible to use sisal reinforced epoxy
composites as a substitute material for the production of water tanks.
3.12 Recommendation
The fiber mat should be prepared using appropriate molding to keep a uniform alignment of fiber
strands. An instrument is necessary to extract the fiber strand to eliminate the wastage of the fiber
strands. Using different resins such as, epoxy, polyester, glue, have different mechanical properties
such as tensile strength, flexural strength and hardness of the fiber mat. So, the one who is
interested to study this idea can use the best resins to get better mechanical properties.

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CHAPTER FOUR
4. OVERALL INTERNSHIP BENEFITSAND CHALLENGES
4.1 Sections ofthe company we worked
At Amhara golden pipe fitting technology (AGPFT), since the factory mainly focused on
manufacturing of plastic fittings and fiber glass products routine processes widely taking place and
we could have situations to perform in all machines versus steps following that do.
4.2 Tasks thatwe had performed
The tasks we had been performing during our internship period were:
 Identification of product quality
 Carrying raw materials from storage room to production room.
 Carry finished product from main production room to temporary storage
 Carry scrap from main work station to temporary storage
 Help the laboratory assistant while performing experiments.
 Involving in process operations
 Identification of raw materials
4.3 Engineering methods, tools and techniques used for performing tasks
When we were observing these tasks by observation, technical assessment and asking questions to
those agent organs involving and operating activities in the above-mentioned departments and
sometimes by helping them perform different tasks. For the period of internship, we used different

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INTERNSHIP REPORT
tools and laboratory tests which are related to chemical engineering aspects which are ash content
test, melt flow index, DSC and thermal hydrostatic tests and product quality control. Simply the
techniques are general observation about the machine, how to operate each machine and when
defect happen, hazards down times and un error happen to the quality of the product we ask the
operator, the quality assurance manager or shift leader how each problems caused and what is the
cause of the problem then understand it, take data and information on note book.
4.4 Majorchallenges and problems we faced
The major challenges that we had been facing are;
 Shortage of raw materials
 Unable to operate the machine each and every day
 Confusion of work when getting in to the action
 Lack of access to transportation
 Lack of information share through the company
 Noises of production machineries
 There is no internet access
4.5 Benefits that we have gotten during the internship period
 One of the ultimate goals of this internship program is developing the theoretical
knowledge what we have been earlier in to practice and also to encourages the theoretical
concepts that we have learnt so far.
 Applying theoretical concepts and skills to the work situation
 Integrating our theoretical knowledge with practical company work
 Understanding our capacity
 Developing entrepreneurial skill
 Understanding about work ethics
4.6 What we gainedin terms of improving team playing skill
In our internship period we have improved our team playing skills by working together in
cooperation with operators, technicians and other intern students.
Applying team playing skill helps us to get more benefits such as:
 To grasp a good knowledge.

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INTERNSHIP REPORT
 To develop Communication skills.
 To increase an understanding of the task.
 To complete a task effectively.
 To Save time and increase productivity.
 To Listen with each other.
 To improve the habit of idea sharing and confidence.
 To help one another and respect with each other.
4.7 Work ethics
we have identified ethical work conducts which the company workers possess. Appropriate
workplace behaviors are required to develop proper relationships with co-workers and create good
industrial environment.
In the internship period, we got work ethics issue by two types. These are:
4.7.1 Personal Ethics
 Honesty and Integrity
 Fairness
 Compliance to the law
 Respecting the Autonomy of others
 Understanding customers filling according to ethics
 When meeting and discussion in groups listening, and respecting other idea.
 Punctuality
 Not absent (except for special cases)
 Reliability
 Cooperation with colleagues
 Open enough to create smooth relation with partners
4.7.2 Professional Ethics
 Avoiding potential or apparent conflict of interests.
 Accountability.
 Performing service only in an area of competence.
 Being punctual at work and leaved work by the right time.
 Being responsible in analyzing and interpreting gathering of data.

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INTERNSHIP REPORT
 Learning career- related skills such as public speaking, dealing with customers etc.
4.8 What we gainedin terms of entrepreneurship skill
During our stay at the company, we were aware of how to make business, create our own work,
assume the major risks, vision and passion to create incremental wealth for ourselves and the
community from the company owners.
4.9 Conclusionand recommendation
4.9.1 Conclusion
The basic concern of this internship program is to get, hold and accumulate knowledge and
experience in our hosting company through practice. Internship provides many benefits not only
for interns, but also for hosting companies. Since the interns could be parts of the employment,
they could be an additional man power. And accepting interns for internship could able the
company to get short-term support from interns on many tasks.
This internship program did not give us only how we could relate the theoretical knowledge to the
practical world, it also gave us a golden chance to gain different professional skills like, practical
skill, team playing skill, inter personal skill, leadership skills, real working environment,
management system, socio-interaction, work experience in a field of interest, Provides a "real life"
experience with a short-term commitment, Strengthens background in field of choice, Creates the
potential for future work as well as the weakness and good side of the company.
Generally, we conclude that our internship shows what chemical engineering is in real world and
new perspective that we didn’t get yet. Our internship period was very interesting and we are
satisfied in the program because we gain many valuable experiences and it was successful on
achieving its goal.
4.9.2 Recommendation
As an intern student we recommend the company that:
 The company make the profile of the office with full data available.
 The company should give proper attention for intern students.
 The company should provide the detail information about the working parameters of the
machine.

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 The company should give machine manuals for operators to operate very well and to fix
machines, if failure is happened.

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Reference
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11. Ibrahim, Idowu David, Tamba Jamiru, Emmanuel R. Sadiku, Williams Kehinde Kupolati,
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Publishing, 2016.

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