You might not realise this but every year 380 million tons of plastic are produced all around the world. It is actually everywhere, from your smartphone in your hand to your food’s packaging. How about, have you ever wondered what makes this omnipresent material come alive?
What is Plastic? Understanding the Basics
Definition
Synthetic or semi synthetic material which can be molded into different shapes and forms. In industries, in everyday life it is known for its versatility, durability and wide range of applications. Polymers form the basis of plastics, which are long chains of molecules that give material its unique properties.
Chemical Composition
Organo polymers are plastics which are made with organic polymers typically derived from petrochemicals. These polymers consist of carbon and hydrogen atoms, often with other elements such as oxygen, nitrogen, or sulfur integrated into their structure. Source of these polymers is crude oil and natural gas, and it is used for monomers that are linked to form polymers.
Different Types
- Thermoplastics: Heat makes these plastics soft and moldable; cooling them hardens them. They are recyclable, they can be reheated and reshaped multiple times. Polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC) are all examples.
- Thermosets: Unlike thermoplastics, thermosetting plastics are heat induced and change chemically to become permanently hard. After the first forming, they cannot be remolded or reheated. Examples are epoxy resins, phenolic resins and melamine.
Manufacturing Historical Development
Plastics go back to the 19th century, in 1862 came the first synthetic plastic called Parkesine (invented by Alexander Parkes). Earlier it was made from cellulose, a naturally occurring polymer found in plants. In 1907 Leo Baekeland developed the first fully synthetic plastic based on no natural polymers because he developed bakelite.
In the second half of the 20th century, successful improvements identifying chemical technologies for production in large volumes of modern plastics, such as polyethylene, brought on the industrial and consumer products revolution. Since then, they have become integral to modern life, as manufacturers eternally strive to improve the recyclability and throughout sustainability of it.
Raw Materials: Plastic Building Blocks
Primary sources of Petroleum and Natural Gas
Most of it, we use comes from petroleum and natural gas. The basis feedstocks for creating polymers are these fossil fuels, the basis for their production.
Crude Oil Extraction, Refining Process
It is extracted from the earth through drilling, and transported to refineries and processed into various fractions via distillation. Crucial key fractions like naphtha are needed to make chemically important monomers, which themselves can be polymerized into plastics.
Petrochemical Derivatives Used in its Production
Plastics are made based on derivates of petrochemicals such as ethylene, propylene, benzene and toluene. These compounds are chemically converted to the polymers such as polyethylene, polypropylene and polystyrene.
Alternative Sources
Bio Based Plastics (Emerging) Becoming more popular are bio based plastics made from renewable resources such as corn, sugarcane, algae. Polylactic acid (PLA) and polyhydroxyalkanoates (PHA) are just such alternatives, which provide the opportunity to curtail dependence on fossil fuels and the environmental impact of its manufacturing.
Manufacturing Processes
Polymerization Techniques
The process of chemically bonding two or more monomers together to form a polymer is known as polymerization. This can be achieved through two main techniques:
- Addition Polymerization: In addition, monomers bind together with no byproducts for making polyethylene and polypropylene.
- Condensation Polymerization: The small molecules so generated by monomers are used for creating polyesters and nylons by the monomers bonding with them.
Injection Molding
Injection molding is the process of melting it granules and injecting the molten material into a mold (under high pressure). Manufacturing complex and detailed parts such as automotive components and consumer goods is widely used for.
Extrusion
This is a continuous process of melting of it and forcing it continuously through a shaped die to create long uniform products such as pipes, tubes and sheets. After the output cools, it is cut to the desired length.
Blow Molding
Plastic hollow products like containers and bottles are made by blow molding. Inflating a heated plastic parison (a plastic tube or sheet) into a mold to get the shape desired.
Rotational Molding
Rotational molding is the process of placing plastic powder into a mold and heating it and rotating it about two perpendicular axes. By doing this the material coats the interior of the mold and produces large, hollowed products such as tanks and playground equipment.
Advanced Manufacturing Methods and 3D Printing
Additive manufacturing, or 3D printing, adds layer by layer from digital design files to build its products. Rapid prototyping is possible and impossible geometries with conventional approaches are able to be developed. However, moving forward, advanced manufacturing methods have been evolving from precision, speed, and on material sustainability.
Environmental Impact and Sustainability
Carbon Footprint
Plastic does consume a lot of energy, most of which is provided by fossils. In doing so it means a lot of carbon footprint, which amounts to greenhouse gas emissions and climate change. To alleviate this, energy efficiency and a shift toward renewable energy while manufacturing the product are being pursued.
Recycling Processes
Recycling it makes referring to its collection, sorting, cleaning, and reprocessing of it into new materials. The most common method is mechanical recycling, where it is shredded and melted for reuse. A new technique is chemical recycling which breaks it down into their monomers for higher quality, recycled products. Yet significantly less of global plastic waste is recycled.
Innovations in Eco Friendly Alternatives
Some innovations in sustainable materials involve the development of bioplastics based on renewable sources like corn starch, sugarcane and algae. The purpose of these alternatives is to find alternatives that are not dependent on fossil fuels and do not have negative environmental impact. Research also focuses on biodegradable plastics which degrade better in natural environments.
Waste Challenges
Because there is so much plastic produced and so little plastic that’s really biodegradable, managing its waste is still quite a challenge. Pollution and damage to ecosystems come from landfills, incineration and improper disposal. There is no easy way out of this but we need unison, tighter norms, improved collection of waste and public awareness for cutting it consumption and developing a culture of responsible disposal.
Manufacturing in Future
Technological Advancements
Technology such as automation, AI driven quality control and precision manufacturing is radically changing the way its manufacturing is done and will shape the future of its manufacturing. The idea behind these is to increase efficiency, decrease waste and increase customized its products.
Production Techniques
Its production is becoming an increasingly important focus on sustainability. To reduce the environmental footprint of plastic manufacturing, strategies include closed loop plastic recycling systems, obsolete plastic recycling and energy and carbon capture technologies.
Emerging Materials and Research
But ongoing research is looking into using alternative feedstocks — plant based or waste derived materials — to create both functional and environmentally friendly. The industry can look forward to much more innovations in material science, like the development of self healing polymers and also of enhanced biodegradable plastics.
Manufacturing Global Trend
There are shifts taking place all around the globe towards more stringent environmental regulations and policies that encourage recycling and cut back on the use of single use plastics. Working to shrink the carbon footprint of the industry, the industry is in the process of adapting to these new realities by investing in eco-friendly practices, collaborating across sectors for sustainable solutions, and investing in research which is scaled green.
Its production is a complicated, intriguing procedure that keeps advancing. With the pressures of global environmental problems, its manufacturing will be propelled forward to future innovation, sustainability and responsible production.