Plastic is a substance that is used in the everyday lifestyle of every person. It is a material that has been taken for granted that people do not even realise how many different forms and functions plastic can have. From Tupperware to spectacles, plastic is clearly a versatile product that can be used almost anywhere.

There is, however, a significant difference in some plastics and the reason for this lies in the fact plastics aren’t produced through the same manufacturing processes. Each process lends different qualities to the plastic and it influences the uses of these materials as well. Understanding these processes will be advantageous to those buying plastics so that it can suit the purpose.

What material is used when making plastic?

In general, plastics are made up of different elements such as carbon, hydrogen, oxygen, nitrogen, chloride, and sulphur. All plastics, except for silicones, can be based on the carbon atom which connects to the abovementioned elements. Plastics, also called polymers, generally have a high molecular weight which will explain its durability and strength. When they emerge from the reactor, several additives can be added to the product in order to determine its final form, such as antioxidants, colorants, foaming agents, lubricants, and flame retardants.

How many different types of plastic are there?

There are two types of plastic namely thermoset and thermoplastic. Thermosets are more durable due to the irreversible setting that they overtake when heat is applied. From thermosets one can produce polyurethanes, unsaturated polyesters, epoxies, and phenol formaldehyde. Thermoplastics are a bit weaker due to the secondary bonding that takes place in its molecular structure. These are easily reshaped when heat is applied. From thermoplastics one can produce polyethylene, polypropylene, and polyvinyl chloride used in everyday household items.

How is plastic made?

There are many processes that can be applied in order to produce plastic:

• Extrusion: this is done by feeding raw plastic materials (pellets or powder) into the extrusion machine by using a hopper. The plastic is then heated and melted, and ejected through the die where it is formed to the desired shape. It is fed onto a conveyor belt where it is then cooled by water immersion.

• Calendering: this is an advanced version of extrusion, where the still warm plastic is chilled on cold, polished rolls to create plastic sheets. Rollers then smooth this sheet out until it is very thin. High volume PVC films are usually made by calendering.

• Film blowing: during this process the semi-molten polymer is continuously extruded by a vertical motion, upwards. A bubble of air is maintained which then stretches the plastic into a tube. This tube is then cooled by air while being nipped and flattened.

• Rotational molding: during this process a mold is mounted onto a machine that can rotate on two axes at the same time. Solid or liquid resin is then placed into the mold, and is heated. The rotation of the machine distributes the plastic into a uniform coating on the inside of the mold. After this process, the mold is cooled.

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