PREFACE

This report has been written to explain my experiences I gained during the 24 weeks
undergraduate industrial training period at D Samson Compounds (Pvt) Limited, Bataduwa,
Galle from 19th October 2015 to 31st March 2016. This report presents a brief presentation of
the skills, knowledge and attitudes that I gained and developed during my industrial training.

This report consists of three chapters; chapter one containing the information about D
Samson Compounds (Pvt) Limited, its main functions, organizational structure and
hierarchical levels with a SWOT analysis of companys current performance.

Chapter two explains about the training experiences during my industrial training period at D
Samson Compounds (Pvt) Limited; duties and functions I carried out as a trainee in Research
and Development section at D Samson Compounds (Pvt) Limited, assignments I was given
and the two projects I undertook, information on production processes, safety procedures,
office practices, operational techniques and financial procedures I was personally exposed.

The third and final chapter of the report is conclusion chapter summarizing all my training
experiences and my weaknesses I identified during the training. This chapter also explains the
ability of D Samson Compounds (Pvt) Limited to provide useful training.

ACKNOWLEDGEMENT
It is a pleasure to acknowledge the enthusiastic support and assistance given to me by many
people for the successful completion of my industrial training. I express my gratitude to
Mrs. Jayangi Wagaarachchige; training coordinator at our department of Chemical and
Processing Engineering for the giving me the opportunity to train at Samson Compounds
(Pvt) Limited.

I also express my gratitude to the Industrial training division at University of Moratuwa and
NAITA for providing this training session.

I express my heart felt gratitude to Mr. Bathiya Samarakoon; the General manager of Samson
Compounds (Pvt) Ltd. and Mr. Jagath Vithanachchi; the manager at Research and
Development Section for excellent supervision and guidance provided to me.

I am also thankful for Eng. Mr. N.S. Porawagamage for providing me with useful projects
and for always helping me whenever possible.

I express my gratitude to the staff members of Research and Development section for their
constant help.

Finally I would like to thank every individual who gave me even the slightest support to
make my industrial training a success.

Contents
PREFACE.................................................................................................................. i
ACKNOWLEDGEMENT............................................................................................. ii
LIST OF FIGURES..................................................................................................... v
LIST OF TABLES...................................................................................................... vi
ABBREVIATIONS.................................................................................................... vii
CHAPTER 1: SAMSON COMPOUNDS (PVT) LIMITED...................................................1
1.1

Introduction to DSI SAMSON Group..................................................................1

1.2 Introduction to Samson Compounds (Pvt) Limited......................................................2

1.3 Hierarchy of the company...................................................................................... 4
1.4 Organizational structure of the company....................................................................5
CHAPTER 2: TRAINING EXPERIENCES.......................................................................7
2.1 Exposure........................................................................................................... 7
2.1.1 Weighing and Mixing Section........................................................................... 7
2.1.1.1 Weighing process........................................................................................ 7
2.1.1.2 Mixing..................................................................................................... 8
2.1.1.3 Weighing and Mixing process.......................................................................10
2.1.1.4 Rubber compound mixing process.................................................................11
2.1.2 Press and Sheeting Section............................................................................. 11
2.1.3 EVA plant.................................................................................................. 12
2.1.3.1 Production process..................................................................................... 13
2.1.3.2 Compounding ingredients in EVA compounding................................................15
2.1.4 PVC Section............................................................................................... 15
2.1.5 Crumb plant............................................................................................... 16
2.1.5.1 Production process of Poly sheets..................................................................17
2.2 Production Systems........................................................................................... 18
2.2.1 Continuous production system.........................................................................18
2.2.2 Job order production system........................................................................... 18
2.3 Coding of raw material....................................................................................... 19
2.4 Safety at Samson Compounds (Pvt) Ltd..................................................................20
2.5 Work carried out as a member of Research and Development team.................................22
2.5.1 Introduction to Research and Development team..................................................22
2.5.2 Assignments carried out................................................................................. 24

2.5.2.1 Finding out the reasons for the discoloration of white PVC V/straps used in BEACH
slippers............................................................................................................ 24
2.5.2.2 Developing NOLEAK compound for Poly sheets...............................................27
2.5.2.3 Developing compound for new cone bush and rubber grommet moulded rubber
products........................................................................................................... 28
2.5.2.4 Observing the mouldability of new prototype cone and bush rubber grommet mould. 29
2.5.2.5 Finding out whether it is suitable to replace ball clay with fly ash...........................30
2.5.2.6 Finding out the heat stability of EVA pigment Red RG10039 M/B........................31
2.5.2.7 Observing the sulphuring temperature of compound for hot water bottle HW-4115. . .32
2.5.2.8 Preparing the samples with Silica as filler for dispersion testing.............................33
2.5.2.9 Checking the deformation of EVA compound sheets WW-1000...........................34
2.5.3 Projects..................................................................................................... 36
2.5.3.1 Environmental Impact Assessment for new PVC shoe related production plant..........36
2.5.3.2

Preparing of project proposal for Solid Waste Management project......................38

CHAPTER 3: CONCLUSION...................................................................................... 39
ANNEX 01............................................................................................................. viii
ANNEX 02................................................................................................................ x

LIST OF FIGURES
Figure2.1: Mixing Line 1.........................................................................................................10
Figure2.2: Mixing Line 2.........................................................................................................10
Figure2. 3: Mixing Line 3........................................................................................................10
Figure 2.4: Sheeting line 1 process..........................................................................................11
Figure 2.5: Sheeting line 2 process..........................................................................................12
Figure 2.6: Cooling drums.......................................................................................................13
Figure 2.7: Production process of EVA micro cellular sheets..................................................14
Figure 2.8: Production process of Poly sheets.........................................................................16
Figure 2.9: EVA off cuts...........................................................................................................17
Figure 2.10: Placement of machinery......................................................................................20
Figure 2.11: Prepared PVC samples for UV testing................................................................25
Figure 2.12: BEACH slipper with the discoloration problem..................................................25
Figure 2.13: Drawings of Cone Bush and Grommet................................................................28
Figure 2.14: Bottom plate filled with compound before pressing...........................................29
Figure 2.15: Middle plate.........................................................................................................30
Figure 2.16: EVA colour samples prepared using RG10039 M/B pigment.............................32
Figure 2.17: Prepared LB pieces from WW-1000....................................................................35

LIST OF TABLES
Table 2.1: EVA Compounding ingredients..............................................................................14
Table 2.2: Preparing of cost sheet............................................................................................23
Table2. 3: Prepared test pieces for various testing...................................................................30
Table 4: Differences in ingredients and their quantities in prepared samples..........................34

ABBREVIATIONS
DSI D Samson Industries
SCOM Samson Compounds
HR Human Resources
R & D Research and Development
MD Managing Director
GM General Manager
QA Quality Assurance
S/C Supply Chain
MT Metric Ton
ISO International Organization for Standardization
EVA Ethylene Vinyl Acetate
PVC Poly Vinyl Chloride
LDPE Low Density Polyethylene
EPDM Ethylene propylene diene monomer
DCP Dicumyl peroxide
UV- Ultra violet
EIA Environmental Impact Assessment

CHAPTER 1: SAMSON COMPOUNDS (PVT) LIMITED

1.1 Introduction to DSI SAMSON Group

The DSI limited was founded by late Mr. D. Samson Rajapaksha who began his career by
selling footwear made out of local rubbers. This was carried out as a contract basis in his
modest outlet in Colombo. After dealing with imported footwear he founded the first
factory of DSI Group to manufacture footwear at Bataduwa in Galle district. The
company was incorporated as a private liability company in 1962. Since then the DSI
Samson Group has developed into one of the leading manufacturer of quality molded and
extruded rubber and EVA (Ethylene Vinyl Acetate) products and compounds in Sri Lanka
while venturing and succeeding in export market over 60 countries such as German,
France, Sweden, Finland, Denmark, Dubai and Fiji island etc.

Today DSI Samson Group shows its strength by extending its manufacturing in 15
sectors, owning 23 companies and approximately 9000 working personnel. The 15 sectors
are as followed.

Footwear

Tyres and tubes

Rubber products

Rubber compounding

Reclaim rubber

Apparel

Retail and trading

Engineering

Brushes

Clay tiles

Information technology

Hydro power

Services

Bikes

Food, beverages and agriculture

The group operates more than 200 showroom chain with over 150 stores island wide
containing 75 brands owning a wide distribution network and warehousing facilities. It
has also become one of the leading manufacturers of not only in footwear but also of
tyres, tubes and bikes exporting to more than 60 countries in 6 continents.

1.2 Introduction to Samson Compounds (Pvt) Limited

Samson Compounds (Pvt) Ltd belongs to the rubber compounding sector within DSI
Samson Group. Company was established thirty years ago in order to manufacture and
supply rubber compounds and sheets to sister companies fulfilling groups internal
requirements. Today Samson Compounds (Pvt) Ltd manufactures and provides
compounds made up of natural rubber, SBR, EPDM, EVA, LDPE and micro cellular
rubber sheets, EVA sheets, PVC soles, PVC V/straps, Poly sheets and other molded and
extruded quality products not only to its sister companies but also for other companies
and has ventured into export market also.

SCOM Vision
Being a fore-runner as trusted customer compounder

SCOM Mission
To be the industrial facilitator for rubber compounding while benefiting the global
customers in conventional and niche markets.

Today Samson Compounds (Pvt) Ltd shows its strength by manufacturing 480,000 EVA
and 430,000 Rubber micro cellular sheets annually and with mixing capacity of

10 MT

Rubber compounds and 3.5 MT of EVA daily. It has become a trusted supplier of polymer
compounds for not only its sister companies but also for other companies even exporting
2

to countries like Dubai, Italy, Japan and Fiji island etc. Company is certified with ISO
9001:2000.

The company has two different mixing plants for natural rubber and EVA which are well
equipped with modern machinery and equipment and a PVC shoe related production plant
for manufacturing PVC V/straps and shoe soles.

Samson compounds (Pvt) Ltd has its own qualified and well-experienced Research and
Development team and houses a well-equipped laboratory for quality testing. Research
and Development team in Samson compounds (Pvt) Ltd provides solutions not only for
the company but for its sister companies as well as for other customers as per request.

Today Samson compounds (Pvt) Ltd is mixing compounds either by customer provide
recipe or formulations designed by its qualified & well-experienced Research and
Development team with the help of well-equipped laboratory.

The PVC shoe related production plant where injection molding is the heart of the
production process in Samson compounds (Pvt) Ltd only V/straps and shoe soles are
manufactured there. Because of this, there is a fluctuation in production rates in PVC
plant. It reaches maximum during New Year and Christmas seasons and the plant is
operated at 24 hours. But sometimes during a year there are times when there are no
orders at all. This can be prevented by venturing into manufacturing new molded PVC
products rather than solely focusing on fulfilling the demand of its sister company D
Samson Industries (Pvt) Ltd.

Colour is one of the most important properties regarding the production of shoe related
products. During my industrial training period as a member of Research and
Development team at Samson compounds (Pvt) Ltd there were numerous occasions
where the EVA and rubber compounds, sheets and PVC V/straps were returned to the
company by the customers due to the colour differences between the returned batches and
the original order or previous batches. This is mainly due to the usage of various colour
pigments in order to get the needed colour rather than using basic colours to get the
3

needed colour. For example to make purple colour compounding they use pigments which
give purple colour rather than mixing red and blue basic colours to a ratio to get purple
colour. So there are more than hundreds of pigments utilized in the production processes.
If a proper colour coding where the secondary colours are made out by mixing basic
colours to a ratio like in CIC paints industries it will be much better since it will reduce
the cost for pigments and changes in colour between same batches.

Samson compounds (Pvt) Ltd is now experimenting in manufacturing roofing materials

also. It is also experimenting using food graded polymers also. PVC plant is
experimenting in using phthalate free PVC master batches for production and EVA plant
is experimenting to manufacture EVA foaming sheets.

Today Samson compounds (Pvt) Ltd has become fore-runner in supplying the demands of
polymer compounding in its sister companies such as D Samson Industries (Pvt) Ltd,
Samson Rubber Products (Pvt) Ltd, Samson Rubber Industries (Pvt) Ltd, Samson
International (Pvt) Ltd and Samson Reclaim Rubber (Pvt) Ltd while providing for other
companies as per request in Sri Lanka and also exporting to other countries.

1.3 Hierarchy of the company

Samson compounds (Pvt) Ltd consists of nine departments; Marketing department,

Research and Development section, Engineering department, Planning department,
Finance department, Human Resources and Administration, Supply chain department,
Quality Assurance department and Production department where each of the department
is managed by the head of the department namely an executive or a manager or a senior
officer. Chairman of the group is at the top of the hierarchical level followed by Joint
Managing Director and then by Director and General Manager.

Chaiman

Joint
MD/MD
Director
/GM
Plannin
g
depart
ment

Research
and
Develop
ment

Senior
officer

Officer

Assistant

Finance
departme
nt

Marketing
departme
nt

Production

Engineerin
g
departme
nt

Quality
Assurance
department

HR and
Administrati
on

Supply
Chain

Accountant

Executive

Executive

Manager

Executive

Executive

Manager

Senior
officer

Senior
officer

Coordinator

Engineer

Senior
Officer

Officer

Officer

Assistant

Assistant

Assistant

Officer

Officer

Employee

Employee

Employee

Assistant

Manager

Senior
officer

Assistant

Officer

Assistant
Employee
Employee

Figure 1.1: Hierarchy of the company

1.4 Organizational structure of the company

Organizational structure of Samson Compounds (Pvt) Ltd can be explained as follows

Human Resources and Administration This department manages the current 243
employees working within the Samson Compounds (Pvt) Ltd

Planning department In this department all the schedules regarding the

production are planned according to the orders and their due dates and ongoing
production orders and given to the relevant department such as Research and
Development, Production department and Supply chain etc.

Supply department All the chemicals and other necessary supplies for
production processes are supplies through supply department unless those were
supplied by the customer.

Research and Development Find solutions for the problems in production

processes and compounding for the company, its sister companies as well as other
customers outside the DSI group if requested. Prepare formulations for rubber,
EVA compounds and provides samples to the production department prior to the
mass batch production. Prepare colour master batch samples for PVC plant.

Production department This consists of various sub sections including Rubber

plant which consists of Weighing and Mixing section and Press and Sheeting
section, PVC shoe related production plant, Crumb plant where the off cuts from
rubber sheets and EVA sheets are recycled into a powder called EVA crumb and
LB crumb and into Poly Sheet which is used as roofing material and EVA plant

Workshop Carries out the maintenance of equipment and machinery within

Samson Compounds (Pvt) Ltd. Designs simple molds and produces them.

Samson Compounds (Pvt)

Ltd

Marketing

Finance

Planning

Research
and
Developmen
t

Crumb plant

Production

PVC section

Workshop

EVA plant

Supply

Human
Resources and
Adm

Rubber plant

Weighing and
Mixing

Press and
Sheeting

Figure 1.2: Organizational structure of the company

6

CHAPTER 2: TRAINING EXPERIENCES

This chapter is a brief presentation of the experiences I gathered during the 24 weeks of my
industrial training as a member of Research and Development team at Samson Compounds
(Pvt) Ltd. It includes the duties and functions I preformed, details of assignments I was given,
details of the two projects I carried out and information on production processes, safety
procedures and operational techniques I was personally exposed during the training.

2.1 Exposure
During my industrial training at Samson Compound (Pvt) Ltd I visited rubber plant, EVA
plant, Crumb plant and PVC section observing their production processes, machinery and
equipment used etc.

2.1.1 Weighing and Mixing Section

Weighing and Mixing section is one of the two sections which together made the rubber
plant of the company. Here in this section mixing of the raw materials are carried out to
produce various rubber compounds after weighing them according to the compound
formulations which are prepared by Research and Development department at Samson
Compounds (Pvt) Ltd or are provided by the customer in need of the compound.

2.1.1.1 Weighing process

Weighing is one of the important processes needed to be carried out carefully in mixing
plant before starting mixing process. This is due to the direct influence of this process
regarding the properties of the compound. An accurate weighing of raw materials in a
compound formula and proper mixing of those raw materials will produce the compound
with its required properties being within specifications while and inaccurate weighing

will results in return batch from the customer to the company thus affecting the profit of
the company.
Weighing process of different classes of materials is carried out under weighing and
mixing section. There are three types of weighing processes. They are
1. Weighing of small materials
2. Weighing of bulk materials
3. Weighing of oils

All the rubbers and chemicals are delivered to this section from Raw Material Stores at
Supply section as per requested by Weighing section. I identified various rubber bases,
raw materials used as pigments, fillers, accelerators, activators, anti-oxidants, processing
agents, vulcanizing agents and observed their physical forms, shapes and colour during
my visits to Weighing and Mixing section. For examples vulcanizing agents like Korean
Sulfur comes in pellets form in yellow colour while petroleum wax which is used as a
processing agent comes in dhal grain shaped pellets. Fillers like silica comes in both
powdered and granules form which are pearl white in colour. All the pigments are in solid
form while processing agents come in both liquid and solid forms.

2.1.1.2 Mixing

Mixing section is the place where the mixing of raw materials is carried out to produce
compounds. This art of mixing of raw materials to produce compounds is call
compounding. For mixing process mainly two types of machinery are used. They are

Banbury mixers also known as Internal mixtures

Two roll mill also known as Open mill

Banbury mixtures

Banbury mixtures are batch type mixers. It is utilized due to the capability of mixing
though, thick and viscous materials using a short span of time. The main parts of a
Banbury mixture are

Rotors rotating in opposite directions

Chamber which encloses rotors

Hopper for receiving feed

Drop door which is hydraulically operated for discharging

Pneumatically controlled flitting weight called ram which is used to generate

mixing pressure

Two roll mill

After the first mixing in Banbury machines then the mixture from Banbury is put into two
roll mill machines. Two roll mill includes two smooth rolls made of chilled cast iron and
plated using hard chrome. These two rolls rotate face to face with slightly different
speeds; back roll is always rotating at higher speed than the front roll. This gives rise to a
friction ratio which is usually kept around 1:1.25 to 1:1.4 for front to back roll. The speed
is adjusted using appropriate gears for drive motors connected to the two rolls.

10

During the mixing rolls are heated due to the heat generated by the friction between rolls
and materials mixing. Because of this they are provided with either corded or sprinkle
system of cooling.

Two roll mills are categorized according to their size and capacity. Capacities vary
between 1 kg to about 75 kg of compound per batch. Samson Compounds (Pvt) Ltd
utilizes 10 kg mills in Research and Development section laboratory and five 75 kg mills
in Mixing section. The size is usually determined by the diameter of the roll to its length.
For example Samson Compounds (Pvt) Ltd utilizes 22" x 60" mills in Mixing section.
This means the diameter of the rolls is 22" while the length of the roll is 60".

Two rolls mills are used in mastication and sulphuring processes since it operates in open
air conditions. It is also used to shape the compound into regular shape compound sheets.
But due to having only one nip the working efficiency of two roll mills are very low.

2.1.1.3 Weighing and Mixing process

In mixing section at Samson Compounds (Pvt) Ltd there are three different mixing lines.
Mixing line will be decided by the officer who is in charge of developing the formulation
for the relevant compound at Research and Development section.

11

Weighin
g

Banbury
Capacity
-75 L

Mill
Size-22" x 60"
Speed - Front-14
rpm
Rear-16 rpm

Mill
Size-22" x 60"
Speed - Front-14
rpm
Rear-16 rpm

Pallets

Figure2.1: Mixing Line 1

Weighing

Banbury
Capacity -75 L

Mill
Size-22" x 60"
Speed - Front-14
rpm
Rear-16 rpm

Soap
Tank

Cooling

Pallets

Cooling

Pallets

Figure2.2: Mixing Line 2

Weighing

Banbury
Capacity -75 L

Mill
Size-22" x 60"
Speed - Front-12
rpm
Rear-15 rpm

Soap
Tank

Figure2. 3: Mixing Line 3

2.1.1.4 Rubber compound mixing process

Mixing process of rubber compounds are carried out under two stages in Mixing section.
In 1st stage mixing all required materials for compounding the relevant compound except
accelerators, inhibitors and cross-linking agents are mixed together in Banbury mixtures.
12

In 2nd stage mixing the mixture from 1st stage mixing is mixed with accelerators, crosslinking agents like sulphur and inhibitors. Two roll mills are usually utilized in second
stage mixing because two roll mills usually operates in temperature below 90 due
to its open air conditions. This temperature is necessary to prevent scorching problems
due to high heat in second stage mixing.

2.1.2 Press and Sheeting Section

Press and Sheeting section is the other section of the rubber plant. Compounds
manufactured in Weighing and Mixing sections are processed into sheets in this section.
In Sheeting section calendar machines are used. Using various type calendar machines
carpets, micro cellular sheets, foot wear parts and other external customer requirements
are manufactured. In this section two Sheeting lines are utilized.

Sheeting line 01 consists of a kneader machine, two two-roll mill machines, a calendaring
machine and a cutter. The main purpose of this line is to manufacture raw rubber sheets
for pressing to produce micro cellular rubber sheets.

In sheeting line one unsulphured compounds are mixed with sulphur in a kneader
machine and further mixing is carried out in two roll mills for proper mixing. After the
compound is well grinded compound is put into the calendar machine shaping the
compound into sheets with proper thickness and width. At the end of the line a cutter is
utilized to cut the raw sheets to the preferred length and weight of the sheets are
measured. After leaving the sheets in racks cooling the raw sheets are pressed in press
section to produce micro cellular rubber sheets.

Sulphurin
g using
kneader
machine

Mixing
using two
roll mil

Mixing
using two
roll mill

Calendari
ng

Raw
sheets
cutting

Coolin
g

Pressing

Figure 2.4: Sheeting line 1 process

13

Sheeting line 2 usually used to manufacture carpets, roofing sheets and insoles of
footwear. This line consists of a two roll mill machine, calendar machine with four rolls, a
conveyor and a cutter.

After the compounds are grinded in the two roll mill machine they are pot into the
calendar machine with four rolls. One roll out of the four rolls in the calendar machine is
a designed roll which gives the pattern to the carpet. After calendaring the cutter at the
end of the conveyor cuts the carpet into the preferred length; usually it is 10 m. Finally
they are put into the chambers for vulcanizing for two hours after bounding them with a
cloth in a roll.

Grinding
in two roll
mill

Calendari
ng

Carpet
cutting

Bounding
with a
cloth in a
roll

Put into
vulcanizin
g
chambers

Figure 2.5: Sheeting line 2 process

2.1.3 EVA plant

In EVA plant the microcellular sheets are manufactured using Ethylene Vinyl Acetate
(EVA) as base material. With EVA fillers, cross linking agents, activators and blowing
agents are mixed together to manufacture EVA compounds. Rather than using rubber as
the polymer for micro cellular sheet production the sheets manufactured using EVA as the
polymers are light weighted and have excellent process ability. And also bright coloured
sheets can be obtained using EVA as the base polymer rather than rubber.

2.1.3.1 Production process

After weighing the raw materials according to the formula of the relevant compounds the
ingredients are mixed using Kneader machines. Kneader machines are also internal
mixers. It consists of two rotors rotating at opposite directions, mixing chamber enclosing
two rotors, steam lines to warm up the rotors, hopper for feeding compound ingredients
and a pneumatically operated floating weight. The Kneader machine differs from
Banbury machine in its ability to warm up the rotors by applying steam. For this there are
steam lines inside the rotors. Another difference between Kneader and Banbury machine
14

is while Banbury machine has two separate doors for feeding raw materials and
discharging mixed compounds Kneader machine has only one door for both task. The
Kneaders utilized within the EVA plant at Samson Compounds (Pvt) Ltd have 55 kg
mixing capacities. During mixing the steam is supplied to the rotors. This is because the
processing temperature of EVA is 125 - 130 . This temperature is necessary
for proper mixing of EVA.

After mixing EVA compound in Kneader machines, the compounds are passed through
four two roll mills for further mixing and to obtain uniform compound. The temperature
of each mill is also maintained at 130 .

Then the sheets are passed through calendar machine where the thickness of the sheet
becomes approximately 0.75 mm. Then the sheets are conveyed along cooling drums for
cooling. The slicing cutter at the end of the cooling drum series cuts the sheets into
required lengths.

After manufacturing raw sheets they are pressed in the hydraulic presses using
compression moulding. The set of raw sheets which are perfectly aligned is put in
between two mould plates and pressed. The mould plates are designed with patterns. In
order to get a quality EVA sheet an appropriate weight of compound should be pressed
between mould for about 12 minutes under 150 kgcm 2 heat pressure and under 7.5 kgcm2
gas pressure.

15

Figure 2.6: Cooling drums

Mixing
in
Kneader
machine
Further
mixing
in
four
two
roll
mills

Calendaring

Cooling

Cutting

Pressing

EVA
micro
cellular
sheets

Figure 2.7: Production process of EVA micro cellular sheets

16

2.1.3.2 Compounding ingredients in EVA compounding

Table 2.1: EVA Compounding ingredients
Category

Polymers

Ingredient

Reason for using

EVA

Main raw material

LDPE

To increase hardness of the

sheets

EPDM
Natural rubber

To improve surface
appearance of the sheets
To obtain required hardness,
reinforcing effect etc.

Fillers

Many types of fillers are

utilized such as Carbon
black, CaCO3

Cross linking agent

DCP

For cross linking

Activators

Zinc Stearate, Stearic acid

To activate blowing agent

during reaction

Blowing agents

Pigments

Many are used

To form the cellular structure

od sheets and to adjust
thickness and hardness of
EVA sheets
To produce requires colour

To produce required steam for the EVA production process Samson Compounds (Pvt) Ltd
uses a boiler at EVA plant. I was able to observe the interior of the boiler when
maintenance of the boiler was carried out during my training period.

2.1.4 PVC Section

In PVC Section PVC V/Straps and PVC soles are manufactured according to the
customer request. Injection moulding is the heart of this section. The production process
17

is simple. First the ingredients needed are weighed according to the formula of relevant
V/Strap. The ingredients are mainly white PVC master batch and the pigments used for
colouring. These are mixed according to a ratio and put into the injection moulding
machine. After the products from moulding machines; V/Straps and soles the flashes are
cut off and finished products are packed.

To clean out the injection moulding machinery purging materials are used. These purging
and offcuts from V/Strap and soles are crushed by crusher machine and make them
recyclable.

One of the most important aspect of PVC section is the colour for the customer orders
come with the requested colour. For colouring PVC section uses PVC colour pigments or
the pigments made by them. The pigments that are made in PVC section are called colour
master batches. They are produced by crushing PVC white or transparent pellet together
with rubber or EVA colour pigments in two roll mills at 170

producing a thin sheet

with needed colour. Then these sheets are cut into small pieces and are used for the
production.

2.1.5 Crumb plant

The rubber sheet and EVA sheet off cuts from D Samson Industries (Pvt) Ltd are recycled
here to produce a powder named crumb to use as filler in rubber and EVA compounding.
Also a product named Poly Sheets is also manufactured at the Crump Plant. Poly sheets is
a product which is used as a roofing material.
Dimensions of the Poly Sheets are

Length 10 m
Width 90 cm
Thickness 1 mm

18

2.1.5.1 Production process of Poly sheets

First the EVA off cuts are crushed together and mixed together. Then the compound is
passed through series of two roll mills into a kneader machine where other ingredients
like rubber, tar, whitening agents and processing oils are added. The mixed compound
then again passes through two roll mill and a calendar machine. Visual inspection using a
light at the end of the production line separates the damaged sheets from quality sheets.

Crushing
the EVA
off cuts

Two
roll
milling

Mixing
with other
ingredient
s in a
kneader
machine

Two
roll
milling

Calendari
ng

Visual
inspection
for
damages

Final
product

Figure 2.8: Production process of Poly sheets

Figure 2.9: EVA off cuts

19

2.2 Production Systems

At Samson Compounds (Pvt) Ltd productions are carried out according to two types.
They are
1. Continuous production systems
2. Job order production systems
2.2.1 Continuous production system
This is also known as mass production system. In this production system large quantities
of products within a limited range is manufactured. This system has high total production
volume and the inspection by a supervisor is not carried out batch to batch. The workers
in production flow are required to maintain product specifications.

2.2.2 Job order production system

In this production system specific customer requirements or orders with small quantities
are manufactured. This system has higher involvement of supervising than continuous
production system since various job instructions have to be given according to the
customer requirement.

20

2.3 Coding of raw material

All the raw materials which are used in production are coded. Since the chemical names
of the materials are difficult to memorize this coding is much needed for the convenience
of the labor force working in production line. The ingredients in every compound formula
are mentioned in the relevant codes for each ingredient. The chemical names of the
materials are hardly used at the company.
A code for a raw material consists of 7 digits.

1st digit this digit indicates whether the raw material is imported or local one. If
the material is local then the digit will be letter L and if imported then
the digit will be letter I.
2 digit this digit indicates whether the material is used in Samson Compounds
(Pvt) Ltd or D Samson Industries (Pvt) Ltd. Number 1 is used when
nd

the material is used at Samson Compounds (Pvt) Ltd and numbers

from 2-9 are used in D Samson Industries (Pvt) Ltd.
3rd digit Usually uses letter C
4th , 5th and 6th digits includes a number between 001-999 which indicates the
category of the raw material in production.
001-099 : Rubber and Polymers
100-199 : Accelerators
200-299 : Antioxidants
300-399 : Activators
400-499 : Vulcanizing agents
500-599 : Fillers
600-699 : Pigments
700-799 : Processing aids
900-910 : Blowing agents
911-999 : Deodorants and others
th
7 digit indicates the quality or the brand of the material. Letters A,B,C,D,E.
are used. For example L1C540A and L1C540B are two codes used for ball

clay differing in the 7th digit due to the two different suppliers of the same
ingredient.
2.4 Safety at Samson Compounds (Pvt) Ltd
Every plant and office and the outdoor premises at Samson Compounds (Pvt) Ltd are well
equipped with fire prevention systems. The workers at Weighing and Mixing section are
21

provided with personal protection equipment like masks, gloves and aprons to provide
protection when handling the chemicals. The containers of the chemicals are labeled
using both the coding and the chemical name of the ingredient and the harmful effects and
the safety procedures in case of such case is clearly mentioned in every and each
container.
Even though these safety methods are carried out there are some weaknesses which can
be clearly seen. One such weakness is the inability to protect the worker at two roll mill
machine when the ingredients are put into two roll mill by Banbury mixers. Usually the
Banbury mixers are placed at the upper floor and two roll mills are placed directly below
the discharging door of Banbury mixers on ground floor.

Figure 2.10: Placement of machinery

When discharging compounds from Banbury to two roll mill due to the speed of
discharging sometimes the compound bumps back from the mill injuring the operators at
two roll mill and properties around two roll mills.
Another weakness is the dust inhalations. Since the most ingredients used in production
process are in powdered form the whole factory is always full of dust specially carbon
black powder. Even though the workers are supplied with masks, the officers working in
offices are not protected from dust.

22

2.5 Work carried out as a member of Research and Development team

During the 24 weeks of industrial training period in Samson Compounds (Pvt) Ltd I
trained as a member of Research and Development section under the guidance of

Mr.

23

Jagath Vithanachchi; the manager of Research and Development department. There I was
given number of assignments and two projects to carry out.

2.5.1 Introduction to Research and Development team

Research and Development section is one of the most important departments at the
Samson Compounds (Pvt) Ltd. There are currently 30 staff working under the
department. Research and Development section consists of Sample mixing area where a
low capacity Banbury machine, two two roll mills and a small laboratory press with
prototype moulds are used to produce rubber and EVA compound samples, PVC colour
master batch samples for testing and laboratory for testing hardness, Rheo data, viscosity,
specific gravity and colour of the samples.

Development of new compounds and redevelopment of compounds after altering their

properties during production process are carried out by Research and Development
department. Also Research and Development department provides solutions to the
problems arise during production processes.

Cost reduction and cost controlling is also another main task which is performed by this
department according to the requirements of the relevant customer. A selling price of a
product cannot increase certain limits in a competitive environment. Therefore cost
controlling and reduction while maintain profitability is much needed. Cost reduction and
control is carried out mainly in developing stage of new compound or when a request is
made by a customer to reduce cost in a developed compound. Research and Development
section prepares cost sheets for master batches, compounds, calendared rubber sheets,
micro cellular rubber and EVA sheets, moulded rubber products considering direct and
indirect material cost, mixing charges, labor costs and profit expected.

24

Table 2.2: Preparing of cost sheet

Type of cost sheet

Type of cost considered

Master batch

Material cost, Mixing charges, Handling

Compounds

charges
Direct and indirect material cost, mixing

Calendared rubber sheets

charges, handling charges

Direct and indirect material cost, mixing

Moulded rubber products

charges, incentives for workers

Direct and indirect material cost, mixing
charges, incentives for workers

If the total cost of the product or compound is higher than the expected amount then the
cost reduction is done by replacing ingredients with low cost materials instead of high
cost materials used in compound or product formulation.
In Research and Development section there is a senior officer appointed for rubber, PVC
and EVA plant within Samson Compounds (Pvt) Ltd and for its sister companies like
Samson Rubber Products (Pvt) Ltd and Samson International (Pvt) Ltd.

2.5.2 Assignments carried out

25

I carried out various assignments given to me by my training supervisor Mr. Jagath

Vithanachchi, the manager at Research and Development section at Samson Compounds
(Pvt) Ltd under the guidance of him with the help of staff members at Research and
Development team. Some of those assignments are mentioned below.

Finding out the reasons for the discoloration of white PVC V/straps used in BEACH

slippers
Developing NOLEAK compound for Poly sheets
Developing compound for new cone bush and rubber grommet moulded rubber

products
Observing the mouldability of new prototype cone and bush rubber grommet mould
Finding out whether it is suitable to replace ball clay with fly ash
Finding out the heat stability of EVA pigment Red RG10039 M/B
Observing the sulphuring temperature of compound for hot water bottle HW-4115
Preparing the samples with Silica as filler for dispersion testing
Checking the deformation of EVA compound sheets WW-1000

2.5.2.1 Finding out the reasons for the discoloration of white PVC V/straps used in
BEACH slippers

I carried out series of laboratory testing to find out the reasons for discoloration of white
PVC V/Straps used in BEACH slippers. This assignment was given to me at the very first
day of my training. First I identified the possible reasons for the discoloration of the
V/Strap. They can be

Migration of chemicals from the sole to the V/strap

External attack like UV, outdoor conditions

26

Then I carried out UV testing in the DSI laboratory for the testing samples prepared using
SPC White PVC master batch which is used to manufacture the discolored PVC V/Straps.
The testing samples which were partly covered using black paper were put in the UV
oven for 1, 2, 3, 4, 5 and 6 hours. One half of the samples were black papered to prevent
the contact with UV rays so that the areas can be compared. 1 hour in UV oven is taken
as approximately equals to the 2 months of outdoor exposure.

Figure 2.11: Prepared PVC samples for UV testing

Since no discoloration was occurred even after 6 hours that is approximately one year at
outdoor exposure it was concluded that the reason for discoloration was not due to UV
attack on PVC V/Starps.

The sole of the slipper in which the discoloration of V/strap has occurred consists of two
layers. Violet coloured top layer is made out of the compound called BE-7120 and black
coloured bottom layer is made out of non-staining LB sheet compound called LB-1059
27

Figure 2.12: BEACH slipper with the discoloration problem

After studying the compound formulations for both top and bottom layers it was decided
with the help of Mr. Sammera Dissanayaka, the senior officer appointed to rubber plant at
Research and Development section that the top layer is completely non-staining. Even
though the compound LB-1059 which is used for the bottom layer of BEACH slipper is
considered non-staining due to the LB crumb 30 mesh ingredient used in compound
formulation there was a possibility for staining. This suspicion was due to the above
ingredient being a recycled product from Crumb plant. Therefore I again carried out UV
testing for SPC white PVC samples after contacting them with LB-1059 sample piece.
After conducting the test the staining was observed.

Since it was concluded that the reason for discoloration of PVC V/Straps in BEACH
slippers was due to the migration of chemicals from bottom layer compound LB-1059 to
the V/Strap it was needed to identify the ingredients in compound formula of LB-1059
which were causing the staining. First the ingredients which had a possibility for staining
were identified. Those were SR-1094 which is the rubber used in LB-1059 compound and
the LB crumb 30 MESH which is used as filler in LB-1059 and the amount of carbon
black N330 used in compound LB-1059.

28

To identify whether the rubber SR-1094 is a staining ingredient a piece of rubber was
contacted with PVC sample and the UV oven test was conducted. Therefore it was
concluded that the SR-1094 rubber was not accounted for the staining of PVC V/strap in
BEACH slipper.

After that to identify whether the LB crumb 30 MESH is a staining ingredient a

compound sample was prepared after altering LB -1059 compound and the LB sheet
sample from the altered compound was contacted with PVC sample and the UV oven test
was conducted.

Alteration made to the LB-1059 compound were as followed

The amount of carbon black used in the LB -1059 compound formula was also
reduced from 6.800 PHR to 5.000 PHR. No staining was given.

SR-1094 rubber was replaced by OFF Grade rubber.

After conducting the UV test the staining was properly observed in the tested PVC
sample. So it was concluded that the discoloration of the PVC white V/Straps used for
BEACH slippers was due to the LB crumb 30 MESH ingredient used in the
LB-1059 compound which is used to produce the bottom layer of the BEACH slipper.

I prepared a report including all the facts I found and gave it to the manager and
Mr. Sammera Dissnayaka.
29

2.5.2.2 Developing NOLEAK compound for Poly sheets

DSI Polysheets is a product which is used as a roofing material. It can be used as a cover
for polished roofs from dew and as a temporary roofing cover.
Dimensions of the polysheets
Length 10 m
Width 90 cm
Thickness 1 mm
Polysheets is a recycled product from EVA offcuts. They are made from EVA offcuts,
rubber, tar, whitening agents and processing oils.
When polysheets are processed after calendaring small holes appear in the sheet. Reasons
for these holes appearing are offcuts from LB sheets sometimes getting mixed with EVA
offcuts and sand crystals getting mixed as the offcuts are deposed on the ground. After the
visual inspection of the polysheets using a light at the end of the production line,
polysheets with large holes are separated for recycling and polysheets having small holes
are sent to cover those holes.
To cover these holes a compound called NOLEAK which is purchased by Samson
Compounds (Pvt) Ltd is used. The task of finding a suitable compound to use instead of
NOLEAK was given to me.
With the guidance of Mr.Jagath Vithanachchi I prepared NL-1000 compound to use as
NOLEAK compound. After preparing the laboratory batch sample, the compound was cut
into small pieces and those were immersed in toluene solution and kept for swelling for
approximately 24 hours. Even after 24 hours the pieces didnt swell therefore a paste from
those pieces could not be made.
Then a laboratory batch sample from the compound MA-1000 which is already being
used as an adhesive for military boots was made and cut into small pieces. Then they
were kept in toluene solution for 24 hours to swell. Unlike in NL-1000 compound, the
30

compound pieces from MA-1000 were swollen after 24 hours. Then a paste was made out
from those pieces and given for trial using to the Crumb plant.

2.5.2.3 Developing compound for new cone bush and rubber grommet moulded rubber
products

The task of developing new compound for Cone Bush and Rubber Grommet moulded
rubber products was given to me. I prepared OC-1001 compound for above products
under the guidance of Mr. Sameera Dissanayaka and Mr.Jagath Vithanachchi and
prepared cost sheets for both Cone bush and Grommet with the help of Mr. Sameera
Dissanayaka and gave samples from both products and cost sheets to the marketing
department.

Figure 2.13: Drawings of Cone Bush and Grommet

31

2.5.2.4 Observing the mouldability of new prototype cone and bush rubber grommet
mould
I was given the task of observing the mouldability of new protptype Cone Bush and
Rubber Grommet mould. The mould consists of three parts.
Bottom plate
Middle plate
Top plate
Mouldability of a mould is the way of filling compound to the mould to get the proper
shape of the product and the way of inserting the mould into the press to get the proper
shape of the product.
First I made the samples as I was instructed under the guidance of Mr. Sameera
Dissanayaka using LS-1100 as the compound from the new mould in the laboratory press
in the Sample Production Area at Research and Development section. Since the cavity in
the Cone bush part is high the bumping was needed to get the proper shape of the product.

Figure 2.14: Bottom plate filled with compound before pressing

32

Figure 2.15: Middle plate

2.5.2.5 Finding out whether it is suitable to replace ball clay with fly ash
I was given the task of finding out whether fly ash can be used as rubber filler compared
to the ball clay filler. In order to do so I prepared four compound samples

Sample A 50 PHR of Ball clay

Sample B 30 PHR of Ball clay and 20 PHR of fly ash
Sample C 20 PHR of Ball clay and 30 PHR of fly ash
Sample D 50 PHR of fly ash

After preparing the compound samples A, B, C, D the reographs were taken of all
samples. From them TS2 and TC90 of the samples were observed. The temperature of the
rheometer is 180 .
Then the test pieces were prepared for testing as follows.
Table2. 3: Prepared test pieces for various testing
Property

Test piece

Time (min)

Temperature (

Hardness
Button
12
150
Specific gravity
Button
12
150
Tensile strength
Tensile piece
12
150
Elongation break
Tensile piece
12
150
300% modulus
Tensile piece
12
150
Tear strength
Tensile piece
12
150
Abrasion
Din
17
150
After checking the properties it is observed that hardness and abrasion of the samples has
increased with the fly ash amount and other properties has decreased without large

33

differences to the A sample. Therefore it was concluded fly ash can be used instead of ball
clay as filler in rubber.
Then I was given the task of modifying the compounds MS-1801 and MS-1501 which use
clay as fillers with fly ash.

MS-1801 : compound for KELSY sole-black. Contents 35.000 PHR of refined clay

MS-1501 : compound for low cost sole compound for all kids/school shoes. Contents

30.000 PHR of ball clay

Four samples were prepared as follows and the properties of modified compound samples
were compared with its original compound samples.

MS- 1801 Rev 02 35.000 PHR of refined clay in compound formula

MS- 1801 Rev 02A - 35.000 PHR of fly ash instead of refined clay in compound

formula

MS-1501 Rev 10 30.000 PHR of ball clay in compound formula

MS- 1801 Rev 02A - 30.000 PHR of fly ash instead of ball clay in compound

formula

34

In order to have high durability the bonding of the compound should be good. In order to
check the bonding of MS-1801 and MS-1501 modified compounds, the soles were made
and given to the DSI laboratory for bonding testing.

2.5.2.6 Finding out the heat stability of EVA pigment Red RG10039 M/B
The assignment of finding out the heat stability of EVA pigment Red RG10039 M/B
was given to me. One of the problem associates with EVA processing is the changes of
colour with the changes of heat. In order to find out the heat stability of the said pigment I
prepared EVA compound sample containing 2.000 PHR of the said pigment under the
guidance of Mr. Jagath Vithanachchi. Then the colour samples were made in the press at
170 temperature for 7, 8, 9, 10, 11 and 12 minutes.
Taking the 7 minutes sample as the control sample

value was measured for each

8, 9, 10, 11, 12 samples against the control sample.

is the measurement of colour

difference between two colours. From colour meter the colour difference that cannot be
observed to naked eye can be measured. If there is a value to

then that means

there is a difference between two colours.

35

Figure 2.16: EVA colour samples prepared using RG10039 M/B

pigment

2.5.2.7 Observing the sulphuring temperature of compound for hot water bottle HW4115
HW- 4115 is a compound for hot water bottles. The sulphuring temperatures of 16
batches of HW-4115 were needed to be measured. The task was given to me. A
thermometer was used for the measuring temperature.
The normal method of measuring the temperature using thermometer is using its probe.
But here it was not possible. The sulphuring temperature of a batch is taken as the
temperature of the batch when the mixture from the Banbury machine is released into two
roll mill. That temperature changes rapidly and also it is dangerous to go near the open
mill when the batch is released onto the two roll mill from Banbury machine since the
batch can bounce off from the roll mill. These reasons are the impossibility to measure
the temperature of the batches using probes of the thermometer.
Therefore laser beam is used to measure the temperature of the batches. A laser beam was
directed at the batches when they were released onto the two roll mill from the Banbury
mixers and the highest temperature observed in the thermometer was taken as sulphuring
temperature for each batch.

2.5.2.8 Preparing the samples with Silica as filler for dispersion testing

36

I was given the task of preparing compound samples silica as filler for dispersion testing.
I prepared compound samples with Silica as an ingredient for mixing cycles 15, 20, 30
minutes with and without coupling agents.
Step 1: Silica powder as an ingredient/ without coupling agents. Three batches
with mixing cycles 15, 20, 30 minutes
Step 2: Silica powder as an ingredient/ with coupling agent. Three batches with
mixing cycles 15, 20, 30 minutes
Step 3: Silica granules as an ingredient/ with coupling agent. Three batches with
mixing cycles 15, 20, 30 minutes
Step 4: Silica powder as an ingredient/ two batches; one with coupling agents and
other without with mixing cycles 45 minutes
After preparing the silica batch samples as above the pieces with dimensions 100 mm x
140 mm x 8 mm were cut from each sample.
Usually when a batch is prepared, zinc stearate is applied on the surface of the batch to
avoid adhesion to surfaces. But in this case the pieces were cleaned with silicon liquid. It
is because zinc stearate can hinder the dispersion test since it is applied as a white powder
on the batch surface
Dispersion test is done in order to identify how well the silica filler is dispersed with
rubber and other compounding ingredients.
Different mixing times were used in order to observe the effect of mixing time on
dispersion of silica with rubber.
Samples were prepared with and without coupling agents to observe the effect of
coupling agents on dispersion of silica.

2.5.2.9 Checking the deformation of EVA compound sheets WW-1000

I was given the task of testing deformation of EVA compound WW-1000 Rev 01. This
compound contains 15 kg of TPI, 10 kg of ENGAGE 8200, 5 kg of 95A master batch in
37

66.730 kg weight of total batch. Two other samples were prepared under the guidance of
Mr. Jagath Vithanachchi. Those samples were named as WW-1000 Rev 01A and

WW-

1000 Rev 01B

Table 4: Differences in ingredients and their quantities in prepared samples

Ingredient

TPI
ENGAGE 8200
95A
EVA Black pigment

WW-1000

WW-1000

WW-1000

Rev 01

Rev 01A

Rev 01B

15 kg
10 kg
5 kg
-

17 kg
10 kg
3.75 kg

15 kg
12 kg
3.75 kg

After preparing the compound sample LB sheets were prepared using each sample at
170oC temperature for 7 minutes. Then those pieces were cut into the dimensions
155 mm x 63 mm x 10 mm

Figure 2.17: Prepared LB pieces from WW-1000

Then those pieces were put in the oven at 60oC temperature for 1 and 2 hours. Another set
were put in oven at 70oC temperature for 1 and 2 hours. Before putting the pieces in oven
the hardness of the each piece was measured and after taking out of the oven pieces were
left to cool and harnesses was measured. Since the pieces made out of compound
38

WW-1000 Rev 01B showed the lowest difference between the hardness before and after
putting in the oven 20 kg batch was made out of that formulation and EVA sheet was
prepared.
But since the specifications for the hardness of WW-1000 sheets is between 40-45 IRDH
and the hardness of the prepared sheet was 35 IRDH another sheet was prepared
increasing the DPC in sample formula. After preparing the sheet from DPC increased
sample batch slipper soles were cut and those soles were put in the oven for 1 hour at
70oC temperature and hardness of each slipper before and after putting in the oven was
measured and those slippers were sent to Export section at D Samson Industries (Pvt) Ltd
for further testing.

2.5.3 Projects
During my training period at Samson Compounds (Pvt) Ltd I undertook two projects
which were given to me by Eng. Mr. N.S. Porawagamage; executive in Production
Engineering Unit at Samson Compound (Pvt) Ltd.
Carrying out Environmental Impact Assessment (EIA) for new PVC shoe related
production plant which is going to be built in Kuruduwatta, Galle by Samson
Compounds (Pvt) Ltd in order to present to Central Environmental Authority
(CEA) in Sri Lanka
Preparing project proposal for Solid Waste Management Project which is intended
to be carried out in Akmeemana, Galle as a CSR project by Samson Compounds
(Pvt) Ltd on behalf of Akmeemana council

2.5.3.1 Environmental Impact Assessment for new PVC shoe related production plant

39

I was given the project of carrying out Environmental Impact Assessment for the new
shoe related production plant which is going to be built in Kuruduwatta, Galle by Samson
Compounds (Pvt) Ltd. First I discussed the relevant details with the relevant engineer Mr.
N.S. Porawagamage, the person in charge of designing the new plant.

In order to do the Environmental Impact Assessment I studied about how to do an

Environmental Impact Assessment according to the rules and regulations of Central
Environmental Authority (CEA) in Sri Lanka. Since the new plant comes under the
category of A5 according to the World Bank Association it is stated in Central
Environmental Authority regulations that Environmental Impact Assessment is needed in
order to request the permission to build the new plant from Central Environmental
Authority.

I discussed the details such as contour plan of the site proposed for plant building, plant
layout, phases of constructions etc. with Mr. N.S. Porawagamage. Them I studied about
the laws and regulations of Sri Lanka regarding the environment such as National
Environmental Act of 1980 and International laws like World Banks project categories
and standards like ISO14000, ISO14001 etc.

After identifying the activities during projects phases; pre-construction phase,

construction phase and operational phase I identified the possible effects from those
activities to the environment; land, air, noise, water, people. For example since the land
40

where the plant is going to be built is a mountainous area in order to build the plant the
land is going to be leveled. This affects the natural contour system of the land.

After identifying the possible effects to the environment I discussed them with

Mr.

N.S.Porawaganage and found out the mitigation methods they have taken or proposed in
order to prevent or minimize the impact of those effects to the environment.

Then I prepared the Environmental Impact Assessment report and Environmental

Management plan under the guidance of Mr.N.S. Porawagamage and submitted it to him.

41

2.5.3.2 Preparing of project proposal for Solid Waste Management project

Another project was given to me by Mr. N.S.Porawagamage. It is to prepare the project
proposal for the Solid Waste Management Project which is intended to be carried out in
Akmeemana, Galle as a CSR project by Samson Compounds (Pvt) Ltd on behalf of
Akmeemana council.
I discussed the layout of then project site, procedures with Mr .N.S.Porawagamage. I also
discussed how to collect waste from houses and decided the best way is to collect them
after separating them under two categories; degrading and non-degrading materials. It
was decided that compost and bio-gas will be generated from degrading waste and nondegrading materials like plastics, polythene, glass, e-waste will be further separated under
polythene, plastics, papers, glass, metals, e-waste etc. and will be sold to relevant places.
After preparing the project proposal I gave it to Mr. N.S.Porawagamage.

42

CHAPTER 3: CONCLUSION

The main purpose of industrial training is to allow undergraduates to apply the theoretical
knowledge they gained at the university into practical usage in industry. In Samson
Compounds (Pvt) Limited I was able to apply the theoretical knowledge regarding the
polymer processing I gain at department of Chemical and Processing Engineering. I was
able to observe the rubber and other polymer processing, injection moulding process and
work with the machinery which I had only seen through slides and books in the
university.

Also during my training period at Samson Compounds (Pvt) Limited, for the first time I
learned how to adjust to the working environment within a company. Blending in with the
cooperated culture within the company following its procedures and practices was a novel
experience to me which I was not exposed in the university.

43

The main weakness I saw in myself during the training period was my hesitance to
present myself in front of an audience. I had to participate in meeting two times during
my training period and at both time I hesitated.

A trainee can experience almost all the things in compounding while training at Samson
Compounds (Pvt) Limited. They also can gather a lot of knowledge and experiences in
injection moulding in the PVC section at Samson Compounds (Pvt) Limited. Working in
Research and Development section at Samson Compounds (Pvt) Limited will give lots of
experiences regarding all the sections within Samson Compounds (Pvt) Limited since
almost every problem arise in the production come to the Research and Development
section.

Trainees are usually directed and supervised by the managers or executives of the section
where the trainee is appointed. They are very helpful and enthusiastic towards training the
trainee. The staff in production lines and offices is also helpful to the trainees and were
always ready to answer the questions from us. There was no probation to use the
chemicals or machinery for us and I must say all the chemicals and equipment in
Research and Development section were free to use for trainees. But finding the right
person at the right time for some advice was somewhat difficult since the Research and
Development section was always busy and the officers were out at inspecting the
problems in production areas assigned to them.

I am really happy about the training I got at Samson Compounds (Pvt) Limited. There I
learned not only technical stuffs but also interpersonal relationships, managing and
resolving conflicts, communication and competition.

44

45

ANNEX 01
Equipment used in production process

Knearder Machine

Two roll mill

Calendar machine

Press machines

ANNEX 02
Environmental Impact Assessment Report

10

11