Beruflich Dokumente
Kultur Dokumente
Submitted By
Umer Khalid
Submitted to
Production Appliance Division
Internship Duration
July 23, 2010 to August 19, 2010
Internship Department
Development - AD
Program
BE Materials Engineering
Institution
School of Chemical and Materials Engineering (SCME)
Acknowledgement
The whole praise is to almighty Allah, creator of this universe. Who made us the super
creature with great knowledge and who able me to accomplish this work, I feel great pleasure in
expressing my deepest appreciation and heartiest gratitude to the staff of Pakistan Elecktron
Limited (PEL) their guidance and great help during the internship period.
I would like to express my deepest affection for my parents and my friends who prayed
for my success and encouraged me during this internship period. I appreciate and acknowledge
the patience, understanding and love provided by employees of PEL.
A token of special thanks to the people who had been very friendly, co-operated with me
throughout my internship and made it possible for me to learn and gather information. These are
the people who in spite of their busy scheduling took time out to explain to me the procedures
and mechanics of work in the organization.
Umer Khalid
Table of contents
Background of PEL……………………………………………………………………….....4
1. Thermoforming……………………………………………………………………....6
2. Extrusion………………………………………………………………………………8
3. Harness Assembly…………………………………………………………………...9
4. Foaming………………………………………………………………………………..9
5. Pre-Assembly and Assembly line…………………………………………………11
6. Condensor and anti-condensate………………………………………………….12
7. Deep Freezer………………………………………………………………………….14
8. Split AC………………………………………………………………………………...15
9. Press Shop……………………………………………………………………………16
10. Plastic Injection Moulding………………………………………………………….17
11. Dies and Moulds……………………………………………………………………...19
12. Power Division………………………………………………………………………..21
13. Development………………………………………………………………………….21
Refrences ……………………………………………………………………………………..22
Pak Elektron Limited (PEL) is the flag bearer of the Saigol Group of Companies.
Pak electron ltd is the pioneer manufacture of electrical goods. It was establish in 1956 in
technical collaboration with M/S AEG of Germany. In October 1978 the group was bought by
saigol group of industries. Since its inception, the company has always been contribution
towards the advancements and development of the engineering sector in Pakistan by producing
hundreds of engineer’s, skilled workers and technicians through its apprenticeship schemes and
training program.
The products manufactured by PEL have always been of high standard and the name 'PEL' is
synonymous with QUALITY all over Pakistan. Since its inception, the company has been
working for the advancement and development of engineering know-how in Pakistan. The
company has produced hundreds of engineers, skilled workers and technicians through its
apprenticeship schemes & training programs.
PEL has been continuously adding new products to its range. As a result, PEL has
registered a significant increase in its sales volume, during the last ten years.
Background of PEL
Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in Pakistan. It was
established in 1956 in technical collaboration with M/s AEG of Germany. In October 1978, the
company was taken over by Saigol Group of Companies. Since its inception, the company has
always been contributing towards the advancement and development of the engineering sector in
Pakistan by introducing a range of quality electrical equipments and home appliances and by
• Appliances Division
• Power Division
APPLIANCES DIVISION
This Division of PEL consists of appliances manufacturing.
PEL REFRIGERATORS
The manufacturing of refrigerators started in 1986-87 in technical collaboration with M/s IAR-
SILTAL of Italy. Like the air conditioner, PEL's refrigerators are also in great demand. Today,
PEL Crystal has 30% market share. Its cooling performance is tested and approved by Danfoss,
Germany and its manufacturing facility is ISO 9002 certified by SGS Switzerland.
PEL is one of the major electrical equipment suppliers to Water and Power Development
Authority (WAPDA) and Karachi Electrical Supply Corporation (KESC), which are the largest
power utilities in Pakistan.
Over the years, PEL electrical equipment has been used in numerous power projects of national
importance within Pakistan. PEL has the privilege of getting its equipment approved and
certified by well-reputed international consultants such as:
• Ensa, France
1. Thermoforming
The Air slip thermoforming machine with sheet feed system are
being used in thermoforming section. HIPS sheet is placed in the machine and heaters
move forward and sheet is heated to softening point. Then compressed air is blown
from down side of sheet to form a balloon for the purpose of even wall thickness
distribution. The preheated mold moves up to level of sheet and the Stretched plastic is
then forced against the mold by application of vacuum. Air is blown on mold from upper
side for cooling purpose and water circulate in the mold to keep it temperature within
limited range. After cabinet or door forming the extra sides (which is used for clamping
the sheet) are trimmed by operator or helper with handheld knives.
1. Sheet transportation
2. Heating
3. Forming/cooling
4. Trimming.
Commercial Forms
Standard HIPS grades are widely used in packaging and in durable goods. In recent
years, many specialty grades that have been developed to satisfy new applications
compete with more costly engineering thermoplastics. Grades are now available that
2. Extrusion
Gasket:
The gasket profile is extruded using soft PVC. While extrusion compressed air is
blown from inside the die so that Gasket should keep its profile uniform and keep it
inflated. The gasket is immediately cooled with water spray which solidifies the material
The gasket is cut into required length with 45° angle at corners. Now Flexible Ferrite
Magnetic Strip is entered in and then foam. The gaskets are joined by hot welding
process to form rectangular profile for refrigerator and freezer door.
1. Harness Assembly
Harness:
A gathering of electrical wires terminating in a central plug that usually operates the turn
signals, brake lights, and electrical brakes for a mobile office. Wiring Harness created
here is used to convey signal from thermostat to compressor, from door to light bulb and
contact the system to the power.
2. Foaming
In this section the bodies and doors are foamed with polyurethane
Cabinet are kept pre-oven at 40-45°C for some time. The amount of material to be
injected in the body is controlled by maintaining 31 Kg/m3 density. Density is kept
constant and volume is measured hence mass can be calculated.
If the ratio starts increasing than it start becoming harder and its insulation property start
decreasing. And if it start decreasing then it becomes soft, providing poor structural
strength.
POLYURETHANES (PUR)
The aromatic isocyanates are important members of this family. They are most reactive
than the aliphatic type and less expensive and therefore claim the largest share of
production volume. In spite of their inherits toxicity, isocyanates can be safety
precautions are used. Toluene diisocyanate (TDI) is the largest product (in volume) of
RIGID FOAM
The primary application for rigid PUR foam is the thermal insulation. These foams are of
major importance to the transportation industry, especially with respect to frozen food,
and for containers for trucks, aircraft, trains and ships. They are used in warehouses,
walk-in coolers, displays cases, refrigerators, and deep freezers.
In many cases, using PUR rigid foam could reduce wall thickness by up to 45%
compared to other insulation materials. This is a consequence of the low thermal
conductivity of the foam and its use as a structural elements in the most of these frozen
storage applications. Additional applications are found in the insulation for the storage
vessels, pipelines, doors, roofs, and tank; as lightweight concrete aggregate for wall
panels and windows sills; and as integrated insulation for building blocks
3. Pre assembly
This area consumes different parts of refrigerator produced by different sections which
are press shop, injection molding, paint plant, thermoforming and some parts from
BASE
Base + Foaming Plug + Cabinet + Cabinet Pipe (on back) + Sealing with shine +
Freezer Cabinet + Sides + Back + Back Box + Foaming Plug
DOOR ASSEMBLY
Door Front Sheet (from Press) + Plastic Ends (Injection Molding FOAMING
SECTION after foaming Removing Tapes
4. Assembly Line
• CR 0.4mm x 80 mm
• Bundy Tube (MS Tube with Cu Coating) Ø = 4.76 mm
• Cu Tube Ø =3/16 inch
• Condenser Side Strip (Press Shop)
Process :
Condenser
Spot welding --- Electric Spot at 440V, and daily tips are changed
Anti Condensate
1. DEEP FREEZER
Inner & Outer joining Pre-heating oven Foaming process. Components (Fr-11 +
polyon+ iso-cyner)
Eutectic Bottles
2. SPLIT AIR-CONDITIONRS
Split Air conditioners consists of two units
• Indoor unit
• Outdoor unit
Outdoor Unit:
Vacuuming is done.
Leak checking.
INDOOR UNIT:
These parts are assembled to form the indoor unit. It is checked by connecting
with outdoor unit and then is packed.
1. Press Shop
Press Shop uses metal sheets to make sheet metal part of refrigerator (doors, side
panels, top, base, freezer side plates, different supports, etc)
Process include cutting of sheets of required length and width on shearing machines.
Then according to design of product other process are completed steps include are
notching, bending, pressing, pressing, drawing, etc. on presses
The raw materials used in the press shop are cold rolled sheets, galvanized iron, VCM
and stainless steel sheets.
• Shearing Machines 8
• Vertical presses 10
• OBI Presses 40
• Side forming machines 1
• Hydraulic presses 18
• Spot Welding Machines 7
• Tapping Machines 02
Injection molding is perhaps the most common and versatile method of forming plastic
into products. In essence, the injection molding process converts raw material plastic, in
the form of solid pellets, into a highly viscous fluid; the material is then pushed or
“injected” into a mold. Once the product is formed, and the mold is opened and the part
extracted: at this point, it is essentially ready for use. This process allows for part
designs with a great deal of intricacy, including fine small parts, thin webs decorative
designs and surface finishes, extremely high gloss surface finishes, and highly complex
contours and shapes
COMPONENTS
• Injection system
• Mold system
• Hydraulic system
• Clamping system
• Control system
Material Product
ABS – Color Top Frame, Kick Plate, Drain Tray, Handle Base
ABS crush Handle Upper Strip, Kick Cavity, Bike Side Cover
ABS – DC Chill Box, Freezer Plate (left + right), Center Railing Plate,
Freezer Frame
MOLDS
TWO-PLATE MOLD:
The vast majority of molds consist essentially of two halves, as shown below.
This kind of mold is used for parts that are typically gated on or around their edge, with
the runner in the same mold plate as the cavity.
THREE-PLATE MOLD:
The three-plate mold is typically used for parts that are gated away from their
edge. The runner is in two plates, separate from the cavity and core, as shown in Figure
below.
1. Dies are used for metals and molds are for plastics.
2. Materials cannot be filled in die, & vice versa.
3. Different operations such as shearing, blanking, piercing etc can be done by die
only.
4. The whole is through the die whereas there is a partial hole in the molds.
1. Power Division
2. Development
We get a feedback from the management department. They give their requirement.
Then it is sent to the design section.
Trial run
If it is OK then
Production.
This section works with the aim to bring new development. This department starts from
scratch to new designs, which can attract the new market and will give new concepts of
refrigeration. For the designing they also consider the refrigerator by other local &
international firms.
From virtual to reality the modeling is brought by prototyping. The drawings are
then converted into prototype models made of wood, ABS, Acrylic Sheets.
The prototypes are shown to marketing department and to executives from for
the final selection. The new options are included in the design and final drawing and
prototype
REFERENCES:
• Wikipedia
• How stuff works
• Self observation & workers in the shop.