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Secondary 2 · Technology
Materials and manufacturing · Plastics and their manufacturing

Plastics

Before you start, make sure you know: The properties of materials (Secondary Year 1)
Before you start, make sure you know: Waste, recycling, and the circular economy (Secondary Year 1)

A water bottle, the handle of a pot, and a rubber band are all made of plastic, but they behave very differently when heated. That difference is the key to understanding where each type is used, how it is recycled, and what harm it can cause if we throw it away carelessly.

What a plastic is and where it comes from

Plastics are everywhere because they are lightweight, cheap, insulating, rust-proof, and easy to mold. But they are not a single material: they are a huge family.

Diagram of a polymer: a chain of eight identical units (monomers) linked one after another, repeating along the whole chain. unit (monomer) the chain continues polymer: repeating units in a chain

The path from petroleum to an object has several stages, and it almost always ends with waste. This is the life cycle of the material.

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Explain in your own words what a plastic is, where the raw material for most of them comes from (crude oil), and what polymers are: long chains of repeating molecules…

Explain in your own words what a plastic is, where the raw material for most of them comes from (crude oil), and what polymers are: long chains of repeating molecules that give the material its properties.

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List three common properties of plastics that explain their huge success (lightweight, insulating, cheap, do not corrode, easy to mould) and name an everyday object that…

List three common properties of plastics that explain their huge success (lightweight, insulating, cheap, do not corrode, easy to mould) and name an everyday object that takes advantage of each of the three you choose.

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Put in order the journey of crude oil to a plastic bottle and explain what happens at each stage: factory converting plastic pellets into containers, oil extraction,…

Put in order the journey of crude oil to a plastic bottle and explain what happens at each stage: factory converting plastic pellets into containers, oil extraction, refinery producing chemical raw materials, polymer production in pellet form, shop.

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Three families according to their behavior with heat

Not all plastics react the same way when heated: that difference determines how they are manufactured and what they are used for.

Three families of plastics: loose chains that slide past each other with heat (thermoplastic), a network of chains with fixed cross-links (thermoset), and chains with few bonds that stretch and recover their shape (elastomer). Thermoplastic softens and can be remolded Thermoset does not soften: burns first Elastomer stretches and recovers its shape at rest stretched
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The figure classifies plastics into three families according to their behavior with heat, but one of them is unlabelled. Observe the behavior and examples of the covered…

The figure classifies plastics into three families according to their behavior with heat, but one of them is unlabelled.

Plastics Thermoplastics soften with heat and can be remoulded PET, PVC, polystyrene Thermosetting plastics do not soften with heat: they char before melting Bakelite, melamine ? stretch a lot and recover their shape neoprene, silicone, rubber

Observe the behavior and examples of the covered family: name it, explain what distinguishes it from the other two, and add two everyday objects that belong to it.

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Define each type of plastic in one sentence — thermoplastic, thermosetting plastic and elastomer —, give an example of an object for each one, and explain which of the…

Define each type of plastic in one sentence — thermoplastic, thermosetting plastic and elastomer —, give an example of an object for each one, and explain which of the three can be remelted and remoulded.

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Topic challenge. Classify plastics according to their behavior when heated and their elasticity: thermoplastic (softens with heat and can be molded again), thermoset…

Topic challenge. Classify plastics according to their behavior when heated and their elasticity: thermoplastic (softens with heat and can be molded again), thermoset (does not soften when heated; once molded it stays rigid) and elastomer (very elastic, recovers its shape after being stretched).

Match each object with the type of plastic that fits best:

  1. a) Water bottle.
  1. b) Frying pan handle, which does not soften when close to fire.
  1. c) Rubber band.
  1. d) Flexible insulation covering an electric cable.

Then, justify one of your choices and answer: what would happen if the frying pan handle were made of a thermoplastic?

You will be assessed on: correctly assigning the type of plastic to each object, justifying one choice using the properties of the material, and explaining well what would happen with the thermoplastic handle.

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Choose the appropriate plastic for each application and justify the choice using a property: (a) a window that imitates glass; (b) a saucepan handle; (c) a flexible…

Choose the appropriate plastic for each application and justify the choice using a property: (a) a window that imitates glass; (b) a saucepan handle; (c) a flexible garden hose; (d) cling film for wrapping food.

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A frying pan handle is made of Bakelite, a thermosetting plastic. Reason why a thermoplastic cannot be used for this purpose, what would happen to polyethylene near…

A frying pan handle is made of Bakelite, a thermosetting plastic. Reason why a thermoplastic cannot be used for this purpose, what would happen to polyethylene near heat, and what other kitchen item you think uses the same material for the same reason.

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Identifying and recycling each plastic

The triangle with a number on almost any container does not say "this will be recycled": it tells you what material it is made of.

Plastic identification symbols: triangle of three arrows with the number 1 (PET, bottles), 3 (PVC, pipes and profiles), and 5 (PP, containers); the number indicates the material, not whether it recycles easily. 1 PET 3 PVC 5 PP bottles pipes and profiles containers The number indicates the material, not whether it recycles easily

In Mexico, recycling depends heavily on collection centers and on the work of waste pickers (pepenadores), who sort by hand what has value. PET is the most collected plastic and is reused to make fibers, trays, and new bottles.

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The figure shows several plastic identification symbols with their number, their abbreviation and their common uses, but one is incomplete: its number and abbreviation…

The figure shows several plastic identification symbols with their number, their abbreviation and their common uses, but one is incomplete: its number and abbreviation are missing.

Four triangular recycling symbols: 1 PET, 2 HDPE, one covered with question marks for pipes and profiles, and 5 PP 1 PET water bottles 2 HDPE milk and shampoo containers ? ? pipes and profiles 5 PP food containers and lids

The covered symbol corresponds to the plastic used for pipes and window profiles, a rigid material that is resistant to weathering and contains chlorine in its composition. State its number and its abbreviation, and explain what this identification code is used for when recycling.

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The triangle with a number that appears on many packaging items does not mean 'this object will be recycled', but 'this is the material it is made of'. Explain the…

The triangle with a number that appears on many packaging items does not mean 'this object will be recycled', but 'this is the material it is made of'. Explain the difference between both ideas and why confusing them leads to incorrect waste disposal.

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State whether these statements are true or false and justify each answer: (a) all plastics can be melted and remoulded; (b) plastic is a naturally occurring material;…

State whether these statements are true or false and justify each answer: (a) all plastics can be melted and remoulded; (b) plastic is a naturally occurring material; (c) elastomers recover their shape after being stretched; (d) the number inside the recycling triangle ranges from 1 to 7.

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The figure shows the lifecycle of a bottle from raw material to waste, with three possible final destinations, one of which is covered. Of the three possible…

The figure shows the lifecycle of a bottle from raw material to waste, with three possible final destinations, one of which is covered.

Crude oil Pellets Bottle Use Waste ? Landfill The sea

Of the three possible destinations for the used bottle, the covered one is the only one that turns waste back into raw material. Name it, explain which bin starts that process in Mexico, and what difference exists between that destination and the other two.

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Find three plastic containers at home with the triangle symbol and write down their numbers. Research which material each number indicates and order the three from…

Find three plastic containers at home with the triangle symbol and write down their numbers. Research which material each number indicates and order the three from easiest to hardest to recycle in a recycling bin, justifying the order.

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The impact of plastic on nature and society

Plastic lasts hundreds of years, and yet it is used mostly for objects meant to be used for minutes: straws, bags, wrappers. What happens to all of that afterward?

A plastic container breaks into fragments in the water. The fragments and synthetic fibers are microplastics that enter the food chain: zooplankton ingest them, a small fish eats the zooplankton, and a large fish eats the small fish, so the microplastics pass from prey to predator. water container breaking apart food chain zooplankton small fish large fish Microplastics in the water pass from prey to predator.

The damage is not only environmental. Discarded plastics clog storm drains and ravines and contribute to flooding, and burning them in the open releases toxic smoke that affects nearby communities. To prevent this harm there are local alternatives: clay containers, baskets and bags made of natural fibers such as ixtle or palm, and reuse of PET bottles.

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Explain what microplastics are, cite two everyday sources that generate them (synthetic clothing in the washing machine, tyre wear or cosmetics with microbeads), and…

Explain what microplastics are, cite two everyday sources that generate them (synthetic clothing in the washing machine, tyre wear or cosmetics with microbeads), and reason how they can end up in the food chain.

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Explain what a bioplastic is (plastic obtained from plants such as maize or potatoes), what difference exists between 'plant-based' and 'biodegradable', and why a…

Explain what a bioplastic is (plastic obtained from plants such as maize or potatoes), what difference exists between 'plant-based' and 'biodegradable', and why a bioplastic cannot always be thrown into the organic waste bin.

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Analyse the plastic paradox: a material that lasts for hundreds of years is used mainly for single-use items lasting minutes (straws, bags, food wrappers). Explain how…

Analyse the plastic paradox: a material that lasts for hundreds of years is used mainly for single-use items lasting minutes (straws, bags, food wrappers). Explain how this situation came about and propose three changes — in design, habits and regulations — to correct it.

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A packaging item is advertised as 'green' because it is biodegradable, but the small print clarifies that it only degrades in industrial composting plants. Formulate…

A packaging item is advertised as 'green' because it is biodegradable, but the small print clarifies that it only degrades in industrial composting plants. Formulate three questions you should ask yourself before believing the label, and explain what greenwashing is using this example.

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A family consumes $12\ \text{L}$ of water per week in $1.5\ \text{L}$ PET bottles (each empty bottle weighs $30\ \text{g}$) and $6\ \text{L}$ of milk in $1\ \text{L}$…

A family consumes $12\ \text{L}$ of water per week in $1.5\ \text{L}$ PET bottles (each empty bottle weighs $30\ \text{g}$) and $6\ \text{L}$ of milk in $1\ \text{L}$ PE-HD bottles ($28\ \text{g}$ per bottle). To reduce their environmental impact, they are considering replacing the water bottles with $6\ \text{L}$ PET jugs ($95\ \text{g}$ each) and the milk with $1\ \text{L}$ carton bricks (each carton contains $11\ \text{g}$ of polyethylene, $15\ \text{g}$ of paperboard, and $2\ \text{g}$ of aluminum).

  1. a) Calculate the total mass of plastic (in $\text{kg}$) discarded by the family per year ($52\ \text{weeks}$) under their original consumption.
  2. b) Calculate how many kilograms of plastic waste they would save per year if they adopt the proposed change.
  3. c) Even though the carton brick uses less plastic than the PE-HD bottle, explain why, from the perspective of mechanical recycling and the circular economy, it poses a much greater technological challenge than a monomaterial container.
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Deciding with good judgment

Choosing a material or a container almost never has a single answer: you have to compare cost, safety, durability, and final destination.

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For the end-of-year party, two options for cups are being considered: disposable PET cups or reusable hard plastic cups. Analyze the cost per use, safety (breakage),…

For the end-of-year party, two options for cups are being considered: disposable PET cups or reusable hard plastic cups. Analyze the cost per use, safety (breakage), waste generated over fifty parties, and washing effort, and recommend an option with supporting arguments.

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Design the recycling system for a school festival: which bins you would set up, what types of plastic you expect to find based on what is sold, what problem…

Design the recycling system for a school festival: which bins you would set up, what types of plastic you expect to find based on what is sold, what problem 'compostable' cups pose if they end up in the plastics recycling bin, and how you would explain this on a poster.

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When recycling plastic, the material loses quality with each cycle and ends up in lower-grade products, whereas glass or aluminum can be recycled almost infinitely.…

When recycling plastic, the material loses quality with each cycle and ends up in lower-grade products, whereas glass or aluminum can be recycled almost infinitely. Explain what this difference means for the circular economy and what practical consequence it has when choosing packaging.

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A cloth bag needs to be used many times to offset its manufacturing environmental impact compared to a plastic bag. Reason which factors determine this 'break-even…

A cloth bag needs to be used many times to offset its manufacturing environmental impact compared to a plastic bag. Reason which factors determine this 'break-even point' (material, washing, manufacturing distance) and which habit is more important than the choice of bag itself.

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You need to choose the material for an outdoor toy casing: compare a rigid thermoplastic such as ABS, flexible polypropylene, and treated wood, assessing resistance to…

You need to choose the material for an outdoor toy casing: compare a rigid thermoplastic such as ABS, flexible polypropylene, and treated wood, assessing resistance to sun and water, impact safety, cost, and end-of-life disposal. Decide on and defend your choice.

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Write four rules for the 'responsible use of plastic' in your school technology workshop (purchasing, reusing offcuts, recycling by type, and alternatives) and justify…

Write four rules for the 'responsible use of plastic' in your school technology workshop (purchasing, reusing offcuts, recycling by type, and alternatives) and justify each one by explaining the problem it avoids.

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Back to the beginning: the water bottle is a thermoplastic (it melts with heat so it can be reshaped), the pot handle is a thermoset (it withstands the flame without warping), and the rubber band is an elastomer (its chains return on their own to their original length).

Summary

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