การปรับปรุงสูตรการผลิตแผ่นโฟมโพลีเอทิลลีนเพื่อลดต้นทุนการผลิต

Recipe Improvements in the Production of Polyethylene Based-Foam Sheets

Name: ศิริชัย บุญศรีอุดมสุข

Organization : มหาวิทยาลัยเทคโนโลยีพระจอมเกล้าธนบุรี

keyword: Residence Time

; Scrap

; Set Point Temperature of IntroducedCooling Water

; Polyethylene Foam

Abstract: Polyethylene based-foam enjoys a big market, both domestic and overseas,primarily in the footwear, toy, and packaging industries. This research is aimed atfinding a cheaper alternate recipe in the production of polyethylene-based foamsheets. The motivation comes as a result of increasing prices in crude oil andpetrochemicals in recent years. Thai Sui Heng Industry Co., Ltd. is used as the casestudy and provides the facilities for conducting this research.In trying to lower the production cost, this research focuses on 2 key areasin the process, namely adjusting the ratio of LDPE to foam scrap ratio in the recipeand finding an optimum operating condition of the internal mixer. The constraint isthat the resulting product must still satisfy customer specifications, which aredimension, hardness, and uniformity of appearance and color.The investigation is carried out in two stages: experimentation of recipes atthe factory and the study of morphology in laboratories. Three key parameters werestudied which were thought to affect the quality of the final product most. Theparameters are: the ratio of LDPE to foam scrap, the residence time (or mixing time),and the set point temperature of introduced cooling water. It was found that a goodratio that could lower the production cost of foam was 1.15 kg of scrap per 1 kg ofLDPE. The optimum conditions were found to be 15 minutes residence time and110 degree centigrade set point temperature. In addition, the foam sheets producedfrom this improved recipe yielded higher thickness, as much as 3 millimeters for a27 mm thick foam, than those of the present recipe. Because of less LDPE pellets ina batch, a shorter batch cycle time, and more thickness in the products, it wasestimated that Thai Sui Heng would be able to make as much as 17M Baht per yearin additional profits.The study of morphology was carried out to study the effect of foam cellsizes on the hardness and tensile strength. The use of scrap has a big impact uponthe cell sizes. Using an image analyzer, the mean cell size was found to increasewith decreasing scrap composition and decreasing residence time, whereas adecrease in set point temperature decreased the mean cell size. Moreover, thehardness of foam increased with increasing mean cell size. Tests on the tensilestrength of the foam were also carried out using Tensile Strength Tester. Insummary, the foam sheets made from the new recipe were found to be non-uniformthroughout the whole sheet in terms of hardness and tensile strength. However, thisnon-uniformity is of secondary concerns to customers and is acceptable to allcustomers.

มหาวิทยาลัยเทคโนโลยีพระจอมเกล้าธนบุรี

Address: กรุงเทพมหานคร (Bangkok)

Email: info.lib@mail.kmutt.ac.th

Name: Dr.Hong-Ming Ku

Role: Supervisor

Created: 2543

Issued: 2005-10-28

Modified: 2006-05-30

วิทยานิพนธ์/Thesis

ISBN: 9746282743

CallNumber: CHE1102

tha

DegreeName: วิศวกรรมศาสตรมหาบัณฑิต

Level: ปริญญาโท

Descipline: วิศวกรรมเคมี

Grantor: มหาวิทยาลัยเทคโนโลยีพระจอมเกล้าธนบุรี

©copyrights มหาวิทยาลัยเทคโนโลยีพระจอมเกล้าธนบุรี

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