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INTRODUCTION

A plant visit by a group of student Bachelor of Chemical Engineering was to Polyplastics Asia
Pacific Sdn Bhd which is located at Gebeng, Kuantan, Pahang. The objectives of this visit are to
give information on the plant design based on the company production which on polymer, to
give understanding on overall process involve, locating of the system in the plant and operation
system in the plant until producing of the products.
Polyplastics is the company which is produce, provide and seller engineering plastics.
Their business operation is manufacturing and selling various types of engineering plastics. The
company starts operating since 1962 and well develops until now. The company starts operating
in Malaysia in 1997 which is at two business location, Kuala Lumpur as headquarters office and
Kuantan as manufacturing plant. The main production of Polyplastics are Acetal
copolymer(POM), Polybutylene terephthalate(PBT), Fiberglass Reinforced Polyethylene
terephthalate(GF-PET), Liquid crystal polymer(LCP), Polyphenylene sulfide(PPS) and Cyclic
olefin copolymer(COC). All this engineering plastics are used to develop and to install to any
component such as cars, digital and electronic equipment, and gadget.
ORGANIZATION AND HUMAN RESOURCES

Figure 1 : The organization of Polyplastic Sdn Bhd

The plant manager in Kuantan Plant is Sim Ah Siang. Based on figure 4, there are 5 departments
in Kuantan Plant which are production, mechanical engineering, electrical equipment, quality
assurance and safety, health & environment.

All the equipment is located in the plant. The flow of production is from the feed which
row material (methanol) on the unloading bay, formaldehyde unit, monomer units which are
dioxolane (OD) and trioxane (TOX) and polymer unit. All four units are located in sequence
which is place in separate for safety and all units are under controlling by control centre building.
The company has safety measures and operations in any works in the plant. With 303 000
m3 of area which is include development and research site, the company attaining many
certificates such as ISO. As example on safety measures such as interlock as well as release
valve installed in the plant system.
Before the engineering plastics produce in resins formed, three stages of formation will
occur which is formaldehyde, DO and TOX. The polymerization process encloses in gases,
liquid and solid reaction which is about 55% of product in water is desired. After all the process,
the product will continue extruder machine to extrude the product in resins size. The resins form
will pack on variations packaging based on customer demands. The production of engineering
plastics, POM is about 123 000 tons/year and compounding is 26 000 tons/year.
As a chemical plant, Polyplastic have to do their waste management process efficiently to
make sure not effect to environment and human. The waste from the production of POM, it
contained with formaldehyde which need to treat with equivalent Chemical Oxygen Demand
(COD) before discharge to the river. The techniques used in wastewater management are aeration
and clarification of solution which contaminated. The formaldehyde waste is divide into three
tanks which aeration technique is used to treat the solution that contains formaldehyde to
circulate with air that occur bubbles. Then, it will promote bacteria for cleansing material in the
solutions. After that, the solution will send to settling tank for sedimentation process and filter.
The solution will discharge to the river after COD is desired and safe to discharge.

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