Modern Plastics & Polymers - April 2011 by Infomedia18

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EDITORIAL

A forward looking Budget

oing by the macro pointers in the Union Budget 2011-12, the government seems to be pursuing a three-pronged strategy – to control inflation, achieve fiscal consolidation and maintain growth. Therefore, this balanced Budget neither has many bold moves nor any big surprises. At best, it can be described as a futuristic and reform-oriented one with less short-term impact. The key highlights of this year’s Budget include the Finance Minister’s proposal to contain the deficit at 4.6 per cent of the GDP and attain a growth of 9 per cent for the next year. Besides, the fiscal stimulus package is maintained with the excise duty at 10 per cent. Some of the other positives in this Budget include higher allocation on infrastructure, commitment to make Goods & Service Tax (GST) a reality, no change in excise duty, promoting research, increasing local manufacturing and promoting inclusive growth. In addition, the government targets 25 per cent GDP contribution from manufacturing by 2020 along with the commitment on raising governance standards and reducing surcharge marginally on corporates. Overall, this Budget should have a positive impact on plastics consumption, mainly driven by the growing economy and surging

demand drivers such as rising disposable income in urban and rural areas. Especially, the government’s focus on agriculture will positively impact the polymer demand for packaging, irrigation and water conservation purposes. Going forward, as the emphasis on plasticulture applications such as greenhouse, pond lining, shade net, etc, intensifies, it will expand the consumption base of plastics. On the flip side, the introduction of Minimum Alternate Tax (MAT) on Special Economic Zones (SEZs) and the phasing out of Export-oriented Units (EoUs) will impact their growth. Also, the rise in MAT will affect the corporate sector. As far as the import duty on naphtha feedstock goes, some sections of the industry were expecting an end to it from the prevailing rate of five per cent. This would have enhanced the competitiveness of domestic petrochemical industry vis-à-vis the global peers who enjoy a positive duty differential between polymer products and naphtha feedstock. Although the action plans in this Budget offer ample scope for inclusive growth, a lot will depend on how effective the implementation is in the times to come.

Editorial Advisory Board A E Ladhabhoy Plastics Technologist

Dr Sushil K Verma Former Director General, CIPET

Dr Swapan K Dhara Regional Technical Head, Basell Polyolefins India Pvt Ltd

Mohan K Jain MD, Indoplast & past president, AIPMA

P P Kharas Chairman, Ecoplast

Raman M Patel Chairman, Industrial Products Mfg Co

Vijay Merchant President, Polycraft

Manas R Bastia

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April 2011 | Modern Plastics & Polymers

CONTENTS

Leaders Speak

Dr Melanie Maas-Brunner, Senior Vice President, BASF Polyurethanes Asia Pacific

Konark Plastomech Pvt Ltd: Raising the quality bar

Injection moulding: Technology driver for automotive segment

Medical plastics: Injecting innovations

Welded nylons: Gauging the efficiency quotient Courtesy: BASF SE

Advanced plastics: The next big thing is small Courtesy: Autodesk

Indian plastics: Scaling new heights Anup Patel, Director, Dollplast Machinery Inc

PVC compounding: Infusing strength to polymers Siddhartha Roy, Consultant, RoyPlasTech

Benchmarking for SMEs: Moving from ‘best’ practice to ‘next’ practice M Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd

Engineering Expo, Chennai 2011: Channelising knowledge, building brands

Facility Visit Sector Watch Market Trends Performance Metrics

Case Study

Industry Scope

Technofocus

Management Mantras

Report

REGUL AR SECTIONS Editorial......................... 17

Events Calendar............. 82

National News............... 20

Technology Transfer ......... 90

Asia News ..................... 26

Book Shelf ...................... 94 Product Update............... 96

Details on page no.82

Highlights of Next Issue Sector Watch : IT & Automation for Plastics Industry Market Trends : Rotomoulding

World News................... 34

Product Index............... 106

Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

Tech Updates ................. 40

Advertisers’ List ............ 110

Corrigendum: In the ‘Plastics @ Gujarat’ Supplement of March 2011 issue (Leaders Speak, page no. 29) the designation of Hitesh Shah, was inadvertentently printed as Director in stead of ‘Business Head - IMM’. This is regretted.

Modern Plastics & Polymers | April 2011

NATIONAL NEWS NEW FACILITY

Bayer MaterialScience inaugurates new polyisocyanates unit in India

Dr Tony Van Osselaer

Bayer MaterialScience has inaugurated a manufacturing facility for polyisocyanates at Ankleshwar, Gujarat. Polyisocyanates are used as raw materials for the production of polyurethane coatings and adhesives. With an investment of approximately €20 million, the company wants to expand its business in India and

participate in the strong growth of this local market for coatings and adhesives. The plant will produce Desmodur® N grades based on aliphatic Hexamethylene Di-isocyanate (HDI). These raw materials are used for automotive, industrial and plastics coatings. Furthermore, Desmodur® L grades will be manufactured from aromatic Toluene Di-isocyanate (TDI). These are used as raw materials for wood and furniture coatings as well as for flexible packaging. “This unit is the first of its kind in India and an indication of the confidence that Bayer MaterialScience places in this country and its economic future,” said Dr Tony Van Osselaer, Member of Bayer’s Executive Committee.

GREENFIELD INVESTMENT

Huntsman invests in PU systems facility in India Huntsman Polyurethanes is investing $10 million in new Polyurethane (PU) systems house in Pune to replace its existing facility on a rented site in Thane, Mumbai. The new blending facility will start up in April 2012, with a capacity to handle 36,000 metric tonne of systems per year. This capacity can easily be scaled up, according to Nick Webster, Huntsman’s Polyurethanes Director for Europe, the Middle East and India. At the Pune facility, Huntsman will make the complete range of systems based on Methylene Diphenyl Di-isocyanate (MDI) for footwear, automotive parts, rigid insulation and more. Huntsman bought the land at Pune with the help of a local development agency, and the staff is working to gain the necessary approvals. Anand G, Huntsman’s General Manager for India, informed that the unit will employ 15 people initially, while Huntsman Polyurethanes employs a total of 50 people in India.

Modern Plastics & Polymers | April 2011

APPOINTMENT

Wilder to run polymers business of Reliance

Indian conglomerate Reliance Industries Ltd has hired veteran petrochemicals executive Warren Wilder to run its polymers business, including its massive polypropylene operations. Wilder, 53, most recently was Managing Director at Malaysian petrochemicals maker Titan Chemical Corp. Reliance holds a 70 per cent share of India’s polymers market – producing PP, polyethylene, PVC and PET – and ranks fourth globally in PP production. The appointment of Wilder coincides with longtime Reliance executive Kamal Nanavaty assuming corporate responsibilities in the firm’s petrochemicals business. Nanavaty was previously President of Reliance’s cracker and polymers sector. He joined Reliance in 1989 and helped form its cracker and polymers business. He has also been involved with Reliance’s entry into retail and convenience stores. Mumbai-based Reliance, India’s largest private business, operates oil refineries and is ranked as the world’s largest maker of polyester fibres.

MARKET REVIEW

Unrealised potential within Indian plastics industry

By world standards, India’s consumption of commodity plastics remains low but is rising, according to industry estimates. Mumbai-based Reliance Industries Ltd, the country’s largest Polypropylene (PP) producer by far, expects per capita PP usage to increase from 4.4 pounds to nearly 12 pounds by 2015. Carl Claerbout, President, Rotational Molder Dutchland

Plastics Corp, Oostburg, Wisconsin, at Star Rotomoulding Conference held in Mumbai, compared India’s plastics industry with the US market of 30 years ago. This was the boom period for opportunities in plastics through material conversions and market expansions. “Some of this growth will come from converting existing packaging to PET,” said Ichiro Mizuuchi, Managing Director, Nissei ASB’s India subsidiary. India currently uses PET in only about 20 per cent of the applications. “The market for higher-grade high-density PE pipes, for example, has grown from about £11 million five years ago to £77 million,” said Chanchai Dasgupta, Pipe Applications Marketing Manager, Borouge (India) Pvt Ltd.

NATIONAL NEWS INVESTMENT SCOPE

Rotational moulders seeing opportunities in India Growing domestic demand in India’s rotomoulding market and opportunities to convert traditional products to plastic is prompting the country’s processors to invest in capacity upgrades and seek foreign partnerships. India’s rotomoulding market is growing 15-20 per cent a year, from its current demand of 120,000 metric tonne (264.5 million pounds), as per estimates from the Society of Asian Rotomoulders, a New Delhi-based group that organised the conference. Ravi Mehra, founding Chairman of the group, said that there are opportunities for foreign firms to enter India’s market in partnership with local

firms. “Indian firms do not want to waste 2-3 years in failures,” said Mehra, who is also Managing D i r e c t o r of Norstar a Cedarburg, maker of

The minister announced the measures including incentives under Market Linked Focus Product Scheme (MLFPS), Focus Product Scheme (FPS), Vishesh Krishi and Gram Udyog Yojana (VKGUY) and for improving quality and increasing market access. Under the new measures, the government will provide incentives to 335 products under MLFPS. Products covered by MLFPS are eligible for benefits of 2 per cent of the Free on Board (FOB) value of exports to 15 specified markets. equipment makers and a former JV partner of Sumitomo (SHI) Demag Plastics Machinery GmbH, said that its growth has buoyed by the surging demand in India. It estimates that the overall Indian market for injection presses will increase 20 per cent this year. P Kailas, CEO, L&T Plastics Machinery Ltd, said that the

company is in talks with an Italian press maker about a partnership. “The Italian firm may stop manufacturing lowertonnage machines in Europe because of the high cost of manufacturing.” The expansion at the Chennai factory will double its capacity to 1,500 machines a year. In the current fiscal year ending March, the company expects to make about 800 machines.

International LLC, Wisconsin-based rotomoulding tools. Indian firms appear to be boosting their capital spending. A GermanDutch-Indian joint venture making rotomoulding machines, Reinhardt Roto-Machines said that the country’s processors are buying more expensive equipment, as they search for ways to boost productivity.

Government announces `500 cr incentives for exports

ANNOUNCEMENT

L&T Plastics expanding, in talks with Italian firm

Indian injection press maker L&T Plastics Machinery Ltd has announced that it is investing `100 million ($2.18 million) in its factory to double the capacity. The company is in talks with an Italian machinery maker for jointly manufacturing moulding machines. The Chennai-based company, one of India’s largest plastics

Modern Plastics & Polymers | April 2011

Labotek, Electronica consider joint venture

Indian injection press maker Electronica Plastics Machines Ltd is in talks with Danish auxiliary equipment maker Labotek A/S to form a joint venture for manufacturing some of the Labotek equipment in India. On the potential of local market, Peter Jurgensen, owner, Labotek, said, “There is a huge market, and automation is just starting in India,” He added that the demand for automation will grow as more multinational firms set up manufacturing there. “Indian plastics processing companies are investing more in dryers, conveyors and other auxiliary equipment, and local manufacturing capability for the equipment is crucial,” said PK Ratnaparkhi, Director, Electronica Machine Tools Ltd, Pune, India. Beyond exploring the Labotek partnership, the Indian company has said that it is expanding capacity for making injection presses, from about 400 machines a year to 600. It is also expanding its range of presses, from a maximum of 320 tonne of clamping force up to 650 tonne. The last year has seen changes for Electronica in its international approach, as its partnership with China’s largest injection press maker, Haitian International Holdings Ltd, came to an end.

POLICY PACKAGE

In order to enhance the competitiveness of India’s products in the international market, the government has recently announced a `500 crore package to promote exports, covering more than 600 products such as agriculture, chemicals, carpets, engineering, electronics and plastics. Announcing the scheme, Anand Sharma, Union Minister of Commerce & Industry, said that these measures would help exports to meet the export target of $200 billion and also go beyond that. He said that with the exports growth of 25 per cent per annum, the exports will be doubled by 2014. Also, exports percentage will be doubled by 2020.

PARTNERSHIP

NATIONAL NEWS ALLIANCE

Hong Kong’s Welltec sets up press joint venture in India Hong Kong injection press maker Welltec Machinery Ltd has set up a joint venture manufacturing plant in India with JishuHozen Machines Pvt Ltd (India), a local maker of injection moulding machine accessories. The joint venture company is called JH-Welltec Machines (India) Pvt Ltd. The move by Welltec, which is a subsidiary of one of China’s largest press makers, Cosmos Machinery Ltd, aims to give the company a much larger presence in India. The Ahmedabad operation, with majority owned by Jishu-Hozen, recently received formal approvals, for making Welltec’s Se Greenline series of servodriven energy saving injection moulding machines. “The company anticipates to make about 100 machines this year, with production growing to 300400 presses a year in five years,” said Wilson Wong, General Manager, Welltec.

SEEKING PARTNER

Sabic seeks business expansion in India Sabic Innovative Plastics derives $30-45 million of its total sales $150 million from the country, hoping to reach $75 million in the next five years. The company, formerly known as GE Plastics, one of the world’s largest manufacturers of thermoplastics, is looking to expand its automotive business in India. U Venkatakrishnan, Automotive Director, Sabic Innovative Plastics, said, “We contribute about 3 kg of plastics to India-made vehicles on an average, and are aiming to raise this to 15 kg by 2012.” A plastic component weighs up to 50 per cent less than the same part made from metal. Use of plastic reduces the weight of a vehicle, which helps vehicle manufacturers meet fuel efficiency norms existing in their export markets such as Europe. Internationally, plastics are used extensively in larger vehicles, as these have more scope to replace metal components.

Modern Plastics & Polymers | April 2011

SUSTAINABILITY

Eco Plastics and CCE to jointly set up recycling facility for PET bottles Coca-Cola Enterprises Ltd (CCE) has partnered with the UK-based Eco Plastics to set up a recycling facility to process plastic bottles. The £15-million plant will come up near Gainborough. The plant would allow the UK-based firm to process 75,000 tonne of Polyethylene Terephthalate (PET) per year, up from 35,000 tonne. According to the Department of Environment, Food and Rural Affairs (Defra), the scheme was an innovative blueprint for the future. The project forms part of a 10-year joint venture between the two companies, which would see Eco guarantee an annual supply of recycled plastic to CCE. CCE is contributing £5

million for the project, and the facility would allow the firm to hit its target of 25 per cent recycled PET in all its plastic packaging in Britain by 2012. Simon Baldry, GB Managing Director, CCE, said, “CCE’s investment in this project would address the recycling challenges in India. British PET bottles would be recycled for re-use in packaging and would be sold from the shelves of British retailers. The new plant, projected to be operational next year, would create 15 jobs during the construction phase and up to 30 new jobs once it becomes operational.

COLLABORATION

Kemrock Ind, DSM Composite form JV Reinforced polymer composites manufacturer Kemrock Industries and Exports has announced a joint venture with Netherlands-based DSM Composite Resins. It will invest $25-30 million to set up a plant in Pune. The JV company – DSM Kemrock India – is targeting $50-million revenue from the Indian market by 2015. While DSM will hold a 51 per cent stake in the JV, the balance 49 per cent will be with Kemrock. “India is a growing market with an increasing demand for composite resins. The JV will help us strengthen our expertise in composite manufacturing and providing customised solutions to Indian market as well as Middle East and China,” said Kalpesh Patel, Chairman and MD, Kemrock.

As per the agreement, DSM will focus on the supply of innovative specialised composite resin solutions, and Kemrock will concentrate on production of high-end composite parts at its Pune plant. DSM plans to establish its own local marketing and sales company for composite resins to serve the Indian domestic market. The $10 billion DSM Composite, which commenced operations in India in 2001, currently earns around $250 million from the Indian market.

NATIONAL NEWS NEW RESPONSIBILITY

Vineet Desai to head Marketing & Sales at USF In response to continuous growth opportunities and Vineet Desai increasing market demand for good-quality flexible packaging films, USF has announced expansion of its team by giving the entire responsibilities of Marketing & Sales to Vineet Desai. USF is one of the few units that have been growing with an aim to provide end-users good quality packaging film at affordable prices. A venture of The Unnati Group of Companies, USF is working towards achieving some tie-ups with international markets for supplying PE Stretch Wrap Films. Desai shall be completely responsible for the international collaborations. A graduate in Polymer Engineering from Napier University in Scotland, Desai has had a useful stint with one of the leading extrusion machinery manufactures – Windsor Machines Ltd. At the international sales division of Windsor, he was responsible for the East and South African markets as well as some of the Gulf countries.

ACQUISITION

KET to acquire stake in overseas company Thinking ahead of time as always, Kabra Extrusiontechnik Ltd (KET) has acquired a stake of 15 per cent in Gloucester Engineering Co, (GEC), USA. KET, a part of the $120 million Kolsite Group of Companies, is India’s largest manufacturer and also largest exporter of plastic extrusion equipment. The company is the leader in the production of pipe, profile and blown film machinery. It commands about 40 per cent marketshare in its product range in India and has more than 8,000 installations in 65 countries worldwide. Through its stake, KET can gain exposure to new international customers. It has a strong market presence

in the Indian Subcontinent, Middle East and Africa. The company would be able to reach out to customers in North & South America and European Markets. The investment will strengthen ties with GEC in addition to the JV company – Kabra Gloucester Engineering (KGE). KET will benefit with the ongoing updated technology of GEC. It will be able to offer domestic and international plastic processors, the combined advantage of high output, high-quality blown film lines at globally competitive prices.

April 2011 | Modern Plastics & Polymers

ASIA NEWS EXPANSION

Huntsman announces capacity building at Singapore

The Performance Products division of Huntsman Corporation has announced that it is going ahead with the engineering design for a 40,000-tonne capacity expansion EXHIBITION

Messe Düsseldorf Group expands its trade fair portfolio in Southeast Asia

Following the growing market demands of plastics, packaging and printing industries in Indonesia, the Messe Düsseldorf Group of Companies has recently announced its involvement with INDOPLAS, INDOPACK and INDOPRINT starting in 2012. The collaboration will allow further development, expansion and

ANNOUNCEMENT

ASF continues Asia expansion at Korea plant

Coming on the heels of a similar announcement in China, BASF SE recently released plans for expansion of its engineering plastics plant in Anson, South Korea. The expansion will increase production of the company’s nylon and polybutylene terephthalate compounds by 13,000 metric tonne per year.

Modern Plastics & Polymers | April 2011

programme at its world-scale polyetheramine facility in Singapore. Huntsman plans to invest over $70 million at its Jurong Island plant. This move will more than double the site’s manufacturing capabilities, help satisfy increasing global demand for polyetheramines and strengthen the company’s leadership position in this technology. In the last five years, Huntsman – world’s leading polyetheramine producer – has seen a dramatic increase in interest in its JEFFAMINE® amines. Polyetheramines are typically employed in epoxy coatings or in additives that enhance the performance of fuels, concrete and pesticides. internationalisation of these trade fairs to reflect Indonesia’s evolutionary path driven by a growing economy and increasing consumerism. Messe Düsseldorf Asia and its local partner PT Wahana Kemalaniaga (WAKENI) will organise the three independent exhibitions from April 11-14, 2012, at the Jakarta International Expo. With its expert team, extensive global network and commitment to delivering world-class events, Messe Düsseldorf Asia will play a leading role in organising all three exhibitions and bringing them to a more prominent level. The trade fairs will offer high-quality platforms for international and Indonesian exhibitors and industry partners to present cutting-edge global technologies, machinery, processing solutions, equipment and services in Indonesia. The expansion was announced less than two months after BASF revealed plans to expand its plant in Shanghai by an additional 65,000 metric tonne. “With these two capacity expansions,

INVESTMENT

AXSON technologies investing in China and India

AXSON Technologies, specialising in the formulation and manufacture of epoxy and polyurethane resins, is opening a new production plant in China for the dielectrics and wind turbine market moving closer to PSA, Nissan, Valeo and Schneider. “The new plant will see us triple and even quadruple our production compared to our facilities already in Shanghai. We are also hoping to open a new site in India by

end of 2011,” said Lionel Puget, CEO, AXSON Technologies. This opening is part of the company’s international development strategy launched in 1994 when the company was acquired through an LBO. With six R&D centres across the world, six production units in France, Slovakia, Mexico, the US, Japan, China and soon India, complemented by a network of subsidiaries and exclusive distributors in more than 30 countries, AXSON Technologies has invested in the world’s industries for 15 years and is present on every continent. our total engineering plastics capacity in Asia will be over 220,000 metric tonne per year by 2015,” said Ian DeSouza, Communications Manager, BASF South East Asia Pte. The Korea expansion is scheduled to complete later this year, giving the plant a capacity of 30,000 metric tonne annually. The plan produces the company’s Ultramid and Ultradur compounds. In Korea, the market for engineering plastics is expected to expand 6 per cent.

ASIA NEWS DEMAND SLUMP

Domestic PP, PE prices move lower in China as demand softens

Local PP and PE prices have moved lower in China as the lacklustre demand in the country pushed sellers to reduce prices. Chinese traders are also reported to be actively searching for possible re-export outlets for their excess SHUTDOWN

Over 30 per cent of Japan’s cracker capacity closed Over 30 per cent of Japan’s naphtha cracker capacity has been shutdown after the massive earthquake and tsunami, bringing down Asia’s naphtha cracker to its lowest in just over one week. In Asia’s naphtha market, Japan plays the demand side. If plants in Japan are closed, then demand in the region is expected to fall. JX Nippon Oil & Energy Corp is working to shut all units at 404,000 tpa naphtha cracker at Kawasaki, Mitsubishi Chemical has halted operations of two naphtha crackers, with the capacity to produce 826,000 tpa of ethylene at Kashima, after a

FINANCIAL AID

Kazakhstan seeks finance for $4.4 bn PE plant, in talks with S Korea, Japan

Modern Plastics & Polymers | April 2011

materials, as stock levels within the country are said to be at high levels, putting further pressure on sellers to reduce prices in the hopes of speeding up their sales. Many sellers have directed their re-export offers to Southeast Asia, where demand for both PP and PE has been healthier than China. Most of these re-export offers have been directed to Vietnam, although distributors in the Vietnamese market complain that buying interest within the country is currently not that strong. They added that the large number of re-export offers received from China has further dampened buying interest. Availability in Vietnam is also said to be sufficient since a large number of previously purchased import cargoes arrived at the country’s ports.

CLOSEDOWN

Earthquake damage forces shutdown of Mitsubishi’s ethylene plant in Ibaraki

Mitsubishi Chemical Corp has been forced to halt operations of its plant in Ibaraki Prefecture due to earthquake related damage. This plant, with 830,000 tpa capacity, is Japan’s largest ethylene production capacity. As an aftermath of the earthquake, the piping was warped and jetties used to transfer products were destroyed. Repair work has been hampered by continuing aftershocks and the resumption of operations at the plant is not in sight.

power outage. Maruzen Petrochemical shut a 480,000 tpa unit in Chiba as well as a 690,000 tpa cracker at Keiyo. However, two Indian refiners sold cargoes for March-April loading at strong premiums, in a bid to cover their short positions due to low supply from the Gulf and Europe. Saudi Arabia and Kuwait have scheduled refinery maintenance for the next month, while the US has diverted 300,000-400,000 tonne of European cargoes for late February to early March loading, away from Asia. Another report said that five petrochemical companies under Maruzen Corp, Idemitsu Co, Showa Denko Corp and Mitsubishi Chemical

Corp have stopped operations to conduct inspections. It is estimated that an annual capacity of 1.7 million tonne of ethylene could be affected. Oil & Natural Gas Corp (ONGC) sold 35,000 tonne of naphtha for April loading to Shell at the highest premium in a year, slightly above $25 per tonne.

Kazakhstan is in talks with South Korea’s Hanwha Chemical Corp, Japan’s Marubeni Corp (8002) and the investment arm of the Abu Dhabi government, as it seeks financing for a $4.4 billion polyethylene plant. Discussions are underway with China Petroleum & Chemical Corp (Sinopec), and LG Chem Ltd for partnership on a parity basis. In March 2010, Sinopec was awarded a contract to build a 300 billion

tonne polypropylene plant in Western Kazakhstan. The polypropylene plant will form part of a gas chemicals complex, which will produce 500,000 tpa polypropylene and 800,000 tpa polyethylene once it reaches full capacity in 2015. Sinopec has agreed to buy and export all polypropylene produced at the facility. The Export-Import Bank of China will provide a loan of $1.26 billion for the project.

ASIA NEWS MARKET TRENDS

PRICE RISE

PET TRADE

Naphtha- and gasoline-rich crudes from Middle East may suffer due to impact of Tsunami

Petrochemical prices surge in Asia as buyers in Japan seek front-month cargo

Saudi Arabia sets up technical panel to defend itself in antidumping row

At present, Japan needs only middle distillates for reconstruction, so naphthaand gasoline-rich crudes from the Middle East may suffer. Values of condensates will be particularly affected due to the closure of Japanese petrochemical plants. Barclays Capital estimates that Japan will require the equivalent of 204,000 bpd of oil (about 30,000 tonne), similar to a Very Large Crude Carrier (VLCC) load of low-sulphur cargoes every eight days, to replace the power-generation capacity lost as a result of the nuclear meltdown. For naphtha, with at least a third of Japan’s cracker capacity shut, the Asian market is expected to further weaken after its crackers fell to a week low level. Sellers have approached naphtha buyers in South Korea and Taiwan to take in prompt cargoes, and traders are concerned about the consequence of losing a key demand outlet for a long time. In 2010, Japan used 47.38 million kilolitre (816,468 barrels per day) of crudes. FORECAST

DuPont announces price rise in ethylene copolymers in Europe, Middle East & Africa

DuPont Packaging & Industrial Polymers has announced for Europe, Middle East and Africa, a price increase of up to 15 per cent on all grades of DuPont Ethylene Copolymer resins. This action

Modern Plastics & Polymers | April 2011

Petrochemical prices in Asia has surged as buyers in Japan seek front-month cargoes. The recent earthquake and tsunami have taken a toll on most of the petrochemical infrastructure offline in Japan, reducing prompt supplies. JX Nippon Oil & Energy shut its aromatics units at Sendai, Kashima and Negishi, which have a total benzene capacity of 425,000 tpa. At Chiba, JFE Chemical also shut its 120,000 tpa coal-based aromatics plant. Recently,

benzene assessment climbed $30 to $1212.50/mt FOB Korea. Reduced benzene feedstocks in Japan will hurt domestic styrene monomer production. But, naphtha feedstock prices fell on concerns of demand loss and port closures, resulting from the earthquake in Japan.

is in addition communicated

to the previously increases in

Saudi Arabia has set up a technical panel as part of its drive to defend itself in an anti-dumping row with the 27-member European Commission. The high-level technical panel will coordinate with an

international consulting office to explain the position of the Saudi government and exporters. This announcement follows the European Union’s (EU’s) recent move to launch an investigation against Saudi exporters of Polyethylene Terephthalate (PET). The PET market of the EU, where Saudi PET are allegedly being dumped, exceeds $4.1 billion annually. The complaint claims that the Saudi producers of petrochemicals receive unfair support from the Saudi Government in PET exports that contravenes the provisions of the agreement made by the World Trade Organization. The European Commission had initiated anti-dumping and anti-subsidy investigations following a complaint by the Committee of PET Manufacturers in Europe with respect to imports of PET originating in or exported from Oman and Saudi Arabia. January 1, 2011, and will take effect from April 1, 2011, or as per the contract. This price hike is needed to ensure DuPont’s supply continuity and support the continued reinvestment required for future market demand of high-quality ethylene copolymers. DuPont Packaging & Industrial Polymers is a world-class manufacturer of high-performance resins and films for a variety of packaging and industrial applications.

ASIA NEWS CHANGING TRENDS

PLANT CLOSURE

Sentiment shifting in PE markets in Asia, Mediterranean region

Petrochemicals plant shutdown in Japan

Players in PE Asian and Mediterranean markets have said that sellers have been forced to re-evaluate their initial increase in targets for March in the face of widespread resistance from converters and slower than expected demand. Recent events in upstream markets, which have seen a slump in crude oil and naphtha feedstock prices, have contributed to sellersâ&#x20AC;&#x2122; loss of confidence in their ability to push through the full extent of their original March increase targets. Chinese buyers returned to the market to secure some cargoes after crude oil futures on the Nymex jumped to their highest levels since 2008, eventually reaching a year-to-date high of $105.44 per barrel in March this year. Domestic producers announced increases of Chinese Yuan (CNY)100-300 per tonne ($15-46 per tonne) in accordance with higher upstream costs. However, producers are now losing hope of achieving higher prices as crude oil and naphtha prices have begun to decline from their early month highs.

Wilmington, Delawarebased DuPont has closed its engineering resin plant and research centre in Utsunomiya. The site will remain closed until damage assessments are completed. Shin-Etsu Inc has stopped production at its PVC plant in Kamisu. Some damages have been found at the plant, and the electric power and water supply there are disrupted. Officials informed that it is unclear when the plant will restart production, and that the site has been affected by rolling blackouts enforced by Japanese utility companies. In Ibaraki, a polyester films plant operated by the Teijin DuPont Films Ltd joint venture has also suspended operations. Mitsubishi Chemical has closed a large petrochemicals complex in Kashima, which produces ethylene, styrene, phenol & other plastic feedstocks. Nippon Oil & Energy also has closed a refinery in Sendai, which makes numerous petrochemicals including plastic feedstocks, propylene and benzene. A major petrochemical hub in Chiba has also been affected. A fire at a refinery operated by Cosmo Oil has led to temporary closing of the site. Maruzen Petrochemicals has closed an ethylene cracker in Chiba, and similar crackers operated by Mitsui Chemicals, Sumitomo Chemical, Keiyo Ethylene and Idemitsu Petrochemicals have reduced their operating rates by 60-80 per cent.

April 2011 | Modern Plastics & Polymers

WORLD NEWS

FORECAST

Plastic colours will reflect changing times, predicts Clariant ColorForward™ 2012 In 2012, colours that mirror a sense of movement, evolution and surprise – bright, lively, even quirky hues and special effects – can be expected to find a receptive public. So will soft, muted, earthy and organic tones that convey introspection, stability and personal responsibility. If these two trends seem at odds, that may be because confusion and contradiction are also an important element in some of the major societal trends identified in the latest edition of ColorForward™. This trend analysis and colour design tool from Clariant Masterbatches is released annually to help plastic product designers and marketing professionals make more informed colour choices. “Economic, technological, political and philosophical changes are happening across the globe at an incredibly fast pace,” said Cristina Carrara, Designer, ColorWorks®, Merate, Italy, and a member of the Clariant Masterbatches. GREEN ALTERNATIVES

PolyOne to highlight sustainable solutions portfolio at VDI Automotive Engineering Conference 2011 PolyOne Corporation, a premier global provider of specialised polymer materials, services and solutions, will showcase targeted solutions for the automotive industry at the VDI Plastics in Automotive Engineering conference in Mannheim, Germany. EXPANSION

Eastman expands capacity for its nonphthalate plasticiser

Modern Plastics & Polymers | April 2011

MAKEOVER

Lubrizol relaunches Carbothane® family of TPUs for implantable devices Lubrizol Corporation has specified a new raw material component and relaunched its line of Carbothane® Thermoplastic Polyurethane (TPU) for implantable devices. The specification of the new replacement raw material – a polycarbonate diol – was made necessary due to a supply shutdown. “Our products formulated with the new raw material meet the existing Carbothane

TPU criteria and have passed the biocompatibility test. These provide the same performance as previous grades,” explained Anthony Walder, R&D, Lubrizol. He elaborated, “We worked to quickly validate the new raw material to ensure an uninterrupted supply for our customers.” Carbothane TPUs belong to a family of aliphatic, polycarbonate-based materials available in a wide range of durometers and colours. These offer superior oxidative and hydrolytic stability versus typical TPU polyethers and polyesters and better solvent interaction than polyethers. The relaunched Carbothane TPU line includes a total of 13 clear with 20 per cent barium sulphate-loaded grades in five durometer hardness.

Po l y O n e helps automakers in improving production efficiencies while positioning their products to meet the growing expectations of today’s consumer for eco-conscious alternatives. At the VDI conference, PolyOne will feature solutions to help customers gain a competitive advantage by addressing the latest trends, ranging from weight

reduction for improved fuel efficiency to increased use of raw materials from renewable sources. Marcel Dartée, Global Marketing Director, Biopolymers, PolyOne, said, “Responding to heightened demand within the automotive industry for renewable solutions, PolyOne has developed reSound™ bio-based polymer formulations with up to 50 per cent plant-based content. These durable biopolymers can replace standard ABS and PC-based products.

Eastman Chemical Company has announced successful completion of expansion of its manufacturing capacity for Eastman 168™ nonphthalate plasticiser at its facility in Kingsport, Tennessee, USA. A versatile non-phthalate plasticiser for PVC, Eastman 168™ has been demonstrated to be a ready replacement for some of the most widely used ortho-phthalate plasticisers that

are experiencing regulatory pressure in markets across the world. It finds use in sensitive applications where brand owners are looking for compliance and differentiation, while providing the same highperformance products for their customers. Eastman 168™ non-phthalate plasticiser has a history of safe use by manufacturers of consumer products.

WORLD NEWS RECOVERY

Propylene market recovers

PORTFOLIO EXPANSION

Propylene is one of the most important starting products in the petrochemical industry. A new study from Ceresana Research forecasts a dynamic development of the global demand for propylene, namely, an increase of over 20 million tonne by 2017. “The sales of propylene reached the peak value of over $90 billion in 2008,” reports Oliver Kutsch, President of the Market Research Institute. “This level will be surpassed as soon as in 2012,” he predicted. An important factor to impact the global propylene market is the massive capacity expansions for propylene and downstream products in the Middle East and China. Ceresana Research expects that supply and demand in these countries will have doubled by 2014. However, the Asia-Pacific region will continue dominating the market and generate more than 45 per cent of all demand. MARKET REVIEW

Lanxess reports strong year-end results Lanxess AG has reported strong year-end results. Sales in the last 12 months grew 41 per cent year-onyear to €7.1 billion ($9.95 billion), driven by both vigorous volume growth and price increases. Profit, pre-exceptionals, nearly doubled to €918 million ($1.28 billion). “Our growth story is set to continue after an outstanding 2010 and an excellent start to 2011,” said Dr Axel

SABIC launches PP random copolymer grades at Pharmapack 2011 SABIC, a global plastics industry leader, is extending its polymer portfolio for healthcare applications with the launch of two high-purity Polypropylene (PP) random copolymers. One of the two new grades is for a wide range of blow-moulding applications and the other is for injection-moulded parts. Extrusion-blow moulding grade SABIC® PP PCGR02 exhibits good contact transparency, outstanding impact strength and excellent processability. Key target applications include bottles and ampoules. The other new resin,

Heitmann, Chairman of the Board, LANXESS AG. “Growth will be driven by our focus on emerging markets & premium products serving the global megatrends mobility, urbanisation, agriculture and water.” Performance polymers was the company’s largest segment in 2010, with sales rising 58 per cent year-onyear to €3.8 billion ($5.33 billion). Lanxess expects this part of its business to perform well in 2011. The company is bringing additional capacity on stream this year to meet expected demand.

Looking ahead to 2011, Lanxess expects sales to be higher than the 2010 results, but predicts that higher energy and raw material costs will put pressure on the market. Leverkusen-based Lanxess has also announced that it is building a new compounding plant in Gastonia, NC, USA.

facility is scheduled to go on stream in 2014. Following this, the annual capacity of the existing MDI plant in Brunsbüttel will be more than doubled.

As part of this measure, the TDI plant at the site will be converted to MDI. “The planned world-scale MDI production facility is intended to strengthen the site and provide long-term job security at the plant and in the region,” said Dr Tony Van Osselaer, Member - Bayer MaterialScience Board of Management. “The plastics industry expects continuous rise in global demand for MDI and TDI,” added Peter Vanacker, Member - Executive Committee, Bayer MaterialScience.

EXPANSION PLANS

Bayer unveils isocyanate optimisaton details Bayer MaterialScience plans to invest roughly €100 million to expand its Diphenylmethane Di-isocyanate (MDI) plant at the Bayer Brunsbüttel industrial park in Germany. The move is part of the company’s project to optimise isocyanate production in Europe. The first of the coordinated phases is the construction of a plant for Toluene Di-isocyanate (TDI) in Dormagen. The 36

Modern Plastics & Polymers | April 2011

SABIC® PP PCGR25, features high clarity and good antistatic properties necessary for injection-moulded housings of disposable syringes. The SABIC® PP PCGR25 technology provides exceptional transparency for easy viewing of syringe contents and enhancing aesthetics. It allows the use of lower melt processing temperatures than is normally the case for conventional random copolymers.

WORLD NEWS NEW SOLUTION

REORGANISATION

Self-adjustable and auto-adaptive PETChiller Piovan has offered PETChiller – new solution to obtain the highest energy-efficient performance for chilled water systems. It is developed for PET preform production lines and processes requiring high refrigeration capacity, water flow and pressure. PETChiller is equipped with inverter-controlled compressors for self-tuning of the refrigeration capacity necessary to provide cooling to utilities. Evaporators of the brazed plate-type and condensers of high efficiency shell and tube-type allow exchanging cooling power to refrigerant and chilled water with utmost efficiency. PETChiller modulates its refrigeration capacity, providing outstanding results. It is can give Coefficient of Performance (COP) of 8 and more. COP of 8 corresponds to 0.45 kWh energy utilisation per 1 tonne of refrigeration power. ENVIRONMENT

PE bags have low carbon footprint, reports a British agency The British Environment Agency has released a report saying single-use Polyethylene (PE) grocery bags have a lower carbon footprint than alternative paper or reusable bags. The report concluded that lightweight high-density PE bags have a lower impact on global warming than alternative bags unless the alternatives are reused multiple times. Lightweight single-use carrier bags have

Milacron announces organisational changes Milacron LLC has made a series of organisational changes, including creating a global key accounts team and several new positions, as part of the plastics machinery maker’s customerdriven strategic focus. Glenn Anderson is appointed Senior Vice President of global key accounts. Anderson was earlier Milacron’s Vice President and General Manager of North American injection machinery and global extrusion. Dave Lawrence, President of Milacron’s worldwide plastics machinery, said that the moves are designed to provide Milacron’s expertise anywhere

the lowest carbon footprint per bag based primarily on resource use and production. Paper, heavyweight plastic and cotton bags use more resources and energy in their production. A key issue is that how many times the bags are reused. In order to equal an HDPE bag used just once, the report stated the following: a paper bag would be reused three times; a Low-density PE (LDPE) ‘bagfor-life’ would need to be reused four times; non-woven polypropylene bags would need to be reused 11 times; and

cotton bags would need to be reused 131 times. If the HDPE bag is reused once, as a trash bag, the numbers increase. The paper bag would need to be reused seven times and the LDPE bag nine times.

portfolio management over the last two years, which has de-emphasised its commodity plastics products,” said Andrew Liveris, Chairman and CEO, Dow Chemical Company. He explained, “The Performance Plastics division will have a technology

and market-driven approach to focus on downstream markets such as packaging, health & hygiene and food applications.” The new division will include all previous plastics units of Dow – polyethylene, polypropylene and specialty elastomers. Finished film and wire & cable products are also in the unit, with other known materials such as Saran-brand Polyvinyl Dichloride (PVDC). Howard Ungerleider is President of the new plastics division.

RESHUFFLE

Dow puts plastics units under one division, puts Ungerleider in charge Dow Chemical Company has reorganised its plastics businesses – putting them all under a newly formed Performance Plastics division. Previously, Dow’s plastics businesses – including polyethylene – was scattered among two or more business units at the Midland, Michigan-based firm. “Formation of the new divisions reflects Dow’s active 38

Modern Plastics & Polymers | April 2011

in the world. He commented, “Milacron is in a strong financial position to support these efforts, with resources to move in new and innovative ways. Anderson and team will have no boundaries or borders, just one goal – to support the success of our largest customer base worldwide.” Milacron is also reorganising its sales staff on a regional basis, instead of the past alignment along product lines. The markets in the US and Canada will be grouped into two regions.

TECH UPDATES

Clariant MEVOPUR® helps advanced medical polymers gain control, consistency and compliant colour Manufacturers of medical devices and packaging who choose new plastic materials like Eastman Tritan™ copolyester and TOPAS® Cyclic Olefin Copolymer (COC) now have readily available colour options pretested and compliant with standards governing materials used in medical and pharmaceutical applications. Available under the new Clariant Masterbatches brand name MEVOPUR®, these colour concentrates and pre-colour compounds are produced under controlled conditions in ISO13485 certified plants. Both TOPAS COC and new grades of Tritan resins are being widely considered as substitutes for glass and polycarbonate in medical device and pharmaceutical packaging applications. Both materials offer good resistance to hydrocarboninduced stress cracking, and are free of bisphenol-A, a minor ingredient in polycarbonate and other resins that have recently come under scrutiny by regulatory authorities. Clariant has intoduced the ‘ISO10993/ USPVI standard colour’ range for polymers – Polyether Block Amide (PEBA), polyethylene and polypropylene materials. These come in 17 standard colours, for small-volume applications.

Useful features of plastic soup containers Good quality plastic soup containers are made of top quality polypropylene plastics and have a range of features that contribute to their functionality. These include: safety seal lids to help prevent leakage and spillage even when on the go, microwave safe, freezer safe and dishwasher safe, fitted with tamper-resistant break tabs, durable and shatter-proof, stack well in takeout bags, equipped with insulation technology, easy to clean, can be reused several times before disposal, available in a range of sizes and meet FDA regulations. The market is replete with a variety of attractive plastic soup containers ranging from clear polypropylene plastics to heavy duty plastics. Sizes vary between 16 and 36 ounces. Clear plastic containers are popular as these offer customers a clear view of the contents. Heavy-duty plastic containers are stronger and more durable. Their tamper-resistant structure ensures lasting performance and keeps food safe and fresh. These high-performing containers are effective enough to prevent leakage in any setting – from freezer to microwave.

New PEEK compounds even more tribologically effective Combinations of new additives – even on the nanoscale – have made it possible to increase the wear resistance of LUVOCOM® PEEK compounds. An important factor helping in these developments is reduction in the traditional additive PTFE in LUVOCOM® due to the increasing number of restrictions it faces. PTFE acts as a barrier to increased wear resistance. 40

Modern Plastics & Polymers | April 2011

Materials resulting from the new developments are adapted specifically to counteracting partners. For example, LUVOCOM® 1105-8000 has an extraordinary tribological profile, which significantly surpasses known materials. Knowing the details of the counteracting partner, like is it made of a certain tool steel, aluminium or plastic, with additional parameters, helps to selectively recommend suitable tribocompounds. A range of new innovative

New blender controls from Conair for moulders & extruders Conair offers blender-control options for extruders and injection-moulders. Bringing together control technology developed for its TrueBlend™ family of gravimetric polymer blenders and the TrueBlend EXT extrusion-control system, SmartBlend™ SB-1 and SB-2 offer, respectively, standard and highperformance control for both processes. SB-1 is suited for rapidly changing processing jobs and general-purpose moulding and extrusion. Automatically calibrating itself to material flow rates, it uses direct-to-target dosing and generally hits ingredient targets in one shot. Its control algorithm intelligently analyses dozens of weight readings in milliseconds, filtering out electronic noise and effects of vibration to yield accuracies that are considered the industry standard. SB-2 ensures repeatable, finely tuned precision dosing of multiple ingredients in extrusion or injection moulding. Most of the set-up and operation features are the same as in SB-1, but are based on a different ‘feed forward’ learning algorithm. This platform can be upgraded with a software to help accept inputs from a TrueWeigh™ gravimetric weigh-hopper mounted between the blender and extruder feedthroat.

materials is now available for developers and designers. This opens up new applications in the automotive sector, mechanical and plant engineering as well as other industries.

MPP Apr 2011 Ad Name: Joyti CNC Pg No. 31

MPP Apr 2011 Ad Name: Unimark Pg No. 32

TECH UPDATES

Redefining installation of DN90 to DN315 HDPE pipe Pipe Coil Technology Ltd has developed Low Ovality Technology (LV™). It provides a stable platform for different types of plastic pipes in coil form. It eliminates kinking failures and the need for preinstallation manipulation on site. Due to new ploughing technologies and the need for longer continuous lengths & larger diameters in coil form, a new technology has been introduced to remove the constraints in butt welding, caused by contamination and poor practices. LV can help in this by starting the coils at a smaller ID. Pipe Coil Technology Ltd provides equipment to coil and store unit lengths at the manufacturing point, transport and dispense them at the installation site for various applications. Thus, 4600 m of DN160 or 800 m of DN315 on a reel sounds implausible outside of the offshore oil and gas industry. By combining trenchless ploughingin techniques with the LV reeling technology, huge magnitudes of installation costs can be saved. Ploughs of this type are capable of simultaneously burying 2 × DN315 pipes.

PepsiCo introduces PET made from plant materials, following Coke’s lead PepsiCo has introduced a PET bottle made completely from plant-based materials. “This breakthrough innovation is a transformational development for PepsiCo and the beverage industry, and a direct result of our commitment to R&D,” said Indra Nooyi, Chairman and CEO, PepsiCo. Currently, bottles are made from bio-based raw materials, including switch grass, pine bark and corn husks. PepsiCo is working to expand sources of the raw materials to organic waste from its food businesses, eg, orange peels, potato peels, oat hulls, etc. The Pepsi bottle will first appear on the market in a pilot production in 2012, and then move to commercialisation upon successful completion of the pilot. Dave Cornell, Technical Director, Association of Postconsumer Plastic Recyclers, said, “There are several potential routes to production of terephthalic acid from plants. But, with respect to compatibility, we expect the PET to be identical with the PET commercially made today.”

Xiamen-based Leedarson makes plastic heat sinks for LED bulbs

A Chinese manufacturer of lighting and light-emitting diode bulbs, Leedarson Lighting, is using injection moulding to replace metal components in the heat sinks of some of its LED bulbs, a switch it says will give it more flexibility for design and production. Leedarson, based in Xiamen, Fujian province, said that moving from 42

Modern Plastics & Polymers | April 2011

Alternative for montan wax additives by Struktol Company of America Struktol Company of America has recently introduced STRUKTOL® V-Wax E and STRUKTOL® V-Wax OP additives as a replacements for montan waxbased products. This is in response to global raw material shortages and skyrocketing market prices for montan wax-based additives for use as a lubricant in thermoplastics, including Polyvinyl Chloride (PVC). Traditional montan wax products are extraction of plant wax from lignite, which is refined and processed into products for applications such as polishes, coatings and lubricants for paper & plastics. Struktol’s new refined, organic wax products are designed as drop-in replacements for Montan Wax E and Montan Wax OP. These provide equivalent processing and performance in various applications. “The new products will allow customers to seamlessly replace montan waxes with a natural, organic-based replacement without sacrificing any of the performance benefits they have become accustomed to in their applications,” said Mike Fulmer, Product Manager for Plastic Additives, Struktol. Potential applications of STRUKTOL® V-Wax E and V-Wax OP are lubricants and release agents for PVC, polyolefins, polyamides, thermoplastic polyesters, polyurethanes, thermosets & pigment carriers in coatings for paper, electronics and polishes.

aluminium heat sinks, which require stamping, casting and secondary finishing, to heat sinks using a compound from SABIC Innovative Plastics US LLC, will help improve design and provide heat-stable white colour without the need for secondary painting operations. “The technology will make it easy for us to boost production capacity

because injection moulding is highly scalable compared to metalworking,” said Eder Lee, General Manager, Leedarson. He elaborated, “The material also provides us the freedom to design the next-generation heat sinks for future LED technologies.” Leedarson is using SABIC’s LNP Konduit grade of thermally conductive compounds. It is using the technology in two of its two-watt bulbs sold in major home improvement and chain stores worldwide.

TECH UPDATES

Japanese device converts plastic to crude oil Blest Corporation, Japan, has developed a new machine, which converts plastic to crude oil. This efficient, non-polluting machine can process polyethylene, polystyrene and polypropylene, but not PET bottles. It can convert 2 lb of plastic into a quart of oil by using power of just 1 kW. The machine heats the plastic with electricity, and traps the vapours, which then cools and condenses into crude oil. This crude oil can be used in heat generators and some stoves, and when refined, it can be used as gasoline. By converting plastic into oil, CO2 pollution can be eliminated, as burning of plastics generates large amounts of toxins and CO2. Plastic Technologies, Inc (PTI), Holland, Ohio, has introduced its novel oPTI lightweight foamed PET blow moulding process for beer bottles. The process can be used to produce monolayer PET foam bottles or a combination of a foamed layer and a standard solid PET layer. Dual layers allow customisation of barrier properties. The foaming process reportedly allows up to 5 per cent light-weighting without significant loss of performance, opening the door to new optical and tactile effects.

Lightest 500 ml water bottles by Masafi in UAE Masafi – one of Gulf region’s leading FMCG brands – has introduced in the UAE the lightest 500 ml water bottle manufactured with 23 per cent less plastic. The new eco-friendly bottles weigh 13 g. The reduced amount of plastic in these bottles considerably lowers carbon emissions in the manufacturing and disposal processes. The new bottles is a major step in Masafi’s Carbon Action Plan – a key initiative launched in 2008 aimed at reducing the carbon footprint in the UAE by decreasing carbon emissions from its manufacturing unit, products, systems and services. Mohammad Usman, Factory Manager, Masafi Water and Tissues line, said, “Masafi has always been at the forefront in environmentally sound practices and we are extremely proud to launch the lightest 500 ml water bottles in the UAE. The new bottles with reduced plastic will go a long way in ridding this planet of harmful non-degradable plastic waste.” In 2009, Masafi had launched oxo-biodegradable films in its shrink-wrap packaging for water bottles. These films offer an unparalleled alternative to conventional plastic wraps. While the conventional shrink-wraps can take up to 400 years to break down, the oxo-biodegradable films degrade in just two years.

ElectriPlast conductive plastic clears auto OEM tests The electrically conductive resin ElectriPlast has passed all tests for use in the upcoming 2012 model of an unidentified European OEM, receiving UL approval while also satisfying tensile strength and shielding requirements, according to the Tier One supplier making the parts. ElectriPlast-based components would be introduced after final approval. 44

Modern Plastics & Polymers | April 2011

Integral Technologies Inc (Bellingham, WA), which markets ElectriPlast thermoplastic, said that at some frequencies, its latest compound outperformed the aluminium part it is replacing. This will yield greater weight reductions than the blends used earlier. William Robinson, CEO, Integral, noted, “ElectriPlast’s opportunities within automotive are ‘vast’, given that it is 40-60 per cent lighter than the metals currently used in electrical applications.”

Rubbery muscle motors to make robots more lifelike Artificial Muscle, a company in Sunnyvale, California, has developed EAPbased motors that function like haptic displays, and respond upon touching. “There is huge potential for such an actuator. We will have a different class of robot,” said Chris Melhuish, Director, Bristol Robotics Lab, UK. Robots with artificial muscle would feel soft and flesh-like and be able to mimic the dexterity and mobility of living creatures. These can be used to make instruments for keyhole surgery that are soft enough to be squeezed through tiny incisions but can still perform the job of more rigid mechanical devices. Soft artificial muscles have been used to make a motor with only a few parts, and no gears, bearings or cogs. “This motor signals a new dawn for artificial muscles,” said Iain Anderson, Head Biomimetics Laboratory, Auckland Bioengineering Institute, New Zealand. “Muscles are electroactive structures with two layers of conducting carbon grease separated by an elastic insulating polymer film,” he said. On applying voltage, the configuration acts as a capacitor, with positive and negative charges accumulating on either side of the insulator. As opposite charges attract one another, the insulator in between flattens and stretches.

Integral sees potential application for ElectriPlast in automotive battery covers, connectors, fuses and shielded plugs. It said that making the switch in shielding applications could save 14 lb or more, at a time when stricter fuel economy standards are forcing automakers to reduce the weight of vehicles.

LEADERS SPEAK

â&#x20AC;&#x153;Low per capita PU consumption offers a huge market for us in Indiaâ&#x20AC;? ...says Dr Melanie Maas-Brunner, Senior Vice President, BASF Polyurethanes Asia Pacific. Being associated with BASF for the past 14 years, she intends to bring the globally acknowledged Polyurethane (PU) technology to India, which, from the current way of things, is poised to move forward. Highlighting the present scenario of Indian plastics industry, she expresses her confidence in India moving towards becoming the PU market of the future, in an exclusive interaction with Anwesh Koley.

Modern Plastics & Polymers | April 2011

LEADERS SPEAK

India as a potential market We are working on an Asia regional strategy 2020, where we have identified two major growth-oriented economies â&#x20AC;&#x201C; China and India. The key attraction towards India is its doubledigit Gross Domestic Product (GDP) growth, especially in the Polyurethane (PU) business, which is more or less growing at par with the GDP. However, in India, the usage of PU products is very low compared to other countries. So, we are starting here from a low point in terms of current demand and usage. There is tremendous potential for growth here, for PU as well as the chemical industry as a whole. We have commenced operations in India with products tailor-made for customers here. We are also conducting a feasibility study here to gauge the specific requirements for our products across regions. Efficient industry applications We started off with automotive, footwear, construction and coating solutions. The construction sector is showing a higher growth momentum. Although applications here are not new, these help maintain energy efficiency. In India, energy efficiency is currently not a hot topic but will soon become one, as the government is proactively undertaking green measures. PU can play an important role in this scenario. The insulation materials produced by using PU can help reduce energy consumption in homes. By reducing heat in rooms, air conditioners will need to cool less, which will thus reduce energy consumption. In a region like India, where temperatures vary widely between day and night, insulation is an important concern. PU materials have various applications in the automotive sector, both for the exterior and interior of cars. Small cars dominate the Indian market. As PU materials are light in weight, these help reduce the overall weight of the car, thus

decreasing fuel consumption. The future of energy lies primarily in wind and solar energy, and in both cases, PU materials find extensive use. Investments and product launches in India and Asia We are looking at an investment of approximately $2.3 billion for the Asian region, with a focus on China and India. Our PU spray foam ElastosprayÂŽ fulfils specific roofing requirements, especially in Asia, where durability is a prerequisite along with low maintenance and long life. Another product is ElastoskinÂŽ, which is a PUmoulded skin for used in premium cars. It provides an up-market look to the interior and the exterior of the car, without affecting the mass or thermal qualities of the car. Government support and expectations The government should try to bring down the price of raw materials in India. Higher price of basic raw materials hampers our product pricing, which might make us uncompetitive in the market. In India, traffic is also a problem, as it causes delays in shipping of raw materials. On the positive side, the development of highways across the country is encouraging, as it ensures speedy logistics for materials. With regard to insulation and green energy management, we need various regulations for buildings in order to have in place mandatory measures to ensure energy savings. The government can help the industry by enforcing such regulations. These steps have already been taken in Europe and China. Constraining factors The plastics industry faces several challenges, but in most cases, these are affecting us positively. We find numerous applications of PU in areas where rubber or metal were used earlier. PU offers more customisation avenues to the customer as compared to traditional materials. Another major

challenge in India is inflation. The rising price of oil worldwide has disturbed the entire value chain. India has been witnessing double-digit inflation for quite some time, which needs to be addressed. Maintaining global standards Our products are of high global standards, not only in Asia but also worldwide. However, in growing economies, it is important to have some knowledge of handling products. Safety standards are of key importance. People in India are willing to learn and adopt new technologies. This is a great advantage for products like PU, which is slowly gaining ground. We intend to create a knowledge base here to make people aware of the advantages of using PU products. Evolution of technology Last year, we had started a new technology plant in Europe, which complies with all required environmental norms for the industry. And we hope to replicate the same in India. Customer requirements here are more varied, prompting us to come up with innovative solutions accordingly and also comply with green requirements set by the government. Earlier, the requirements were customer-oriented, but now these are industry-oriented. We hope to become a one-stop solutions provider for all requirements of our customers. India as a PU market of the future India has more interesting possibilities due to the low per capita consumption of PU products. This provides us a big opportunity to expand here. Income levels in the country are also growing steadily, so people are willing to pay that extra bit to have a better product. This holds true mainly in the automotive sector, and also in the housing sector. If the required infrastructure is made available at the earliest, India is set to emerge as a huge market for PU products. April 2011 | Modern Plastics & Polymers

FACILITY VISIT

Konark Plastomech Pvt Ltd

Raising the quality bar As India’s plastics manufacturing market evolves towards becoming more independent and self-sufficient, Konark Plastomech Pvt Ltd, Ahmedabad, is striving to achieve global benchmarks of quality & efficiency in the extrusion machinery segment. Annabel Dsouza unravels Konark’s strategies and solutions as a key player in Gujarat’s plastics industry.

ndia’s booming plastics industry owes a great deal to its engineering and manufacturing division. Today, plastics processing machinery plays a pivotal role in delivering cost-effective and customised technology to the ever-expanding network of polymers application industries. This especially holds true in an industrially dynamic state like Gujarat, where the plastics business is taking giant strides forward. As one of the pioneers in the extrusion machinery segment, Konark Plastomech Pvt Ltd has been providing the latest solutions for myriad applications, particularly in packaging. The company was founded in 1985 by Kantibhai Pithwa, who is currently its Managing Director. Over the years, Konark has gained a stronghold in the regional market and also caters to the exports segment. Specialising in compact extruder

Modern Plastics & Polymers | April 2011

machinery and ancillaries, Konark came to the fore in 1987, when it launched in India a fully automatic synthetic string plant equipped with TDie, instead of the conventional blown type. This was the first of the many successful ventures of the company, and has helped in establishing it in Gujarat’s plastics industry. Jaymin Pithwa, Director, Konark Plastomech Pvt Ltd, says, “Konark has evolved through a challenging phase into a stable solutions provider for the plastics extrusion machinery category. We have been registering an average growth of 15-20 per cent each year. In terms of manufacturing infrastructure, we have kept pace with international standards, while cultivating a strong domestic clientele. Keeping in mind our customers’ business interests, we have constantly upgraded and diversified our machinery for market competitiveness.”

FACILITY VISIT

Infrastructure for excellence Quality and cost-competitiveness being the differentiating factor of Konark machines, the company emphasises on seamless production operations. The 2,900 sq m manufacturing unit at Odhav, Ahmedabad, is wellequipped with Computer Numerical Control (CNC)-enabled assembly lines. An in-house sheetmetal working facility ensures total quality control and efficient process handling. Konark is an ISO 9001:2008 certified company, and follows stringent measures for value-added machinery and services. The presence of the company’s 425 sq m registered office within the premises further facilitates the manufacturing and assembly functions. The facility is designed for effective collaboration between shop-floor and the corporate governance. With an unwavering commitment to market demands and customer satisfaction, Konark has a Research and Development (R&D) division that constantly strives towards innovation and excellence. The research facility focusses on customising solutions on the basis of customer feedback and specifications. With a workforce of about 70 members from both technical and administrative divisions, Konark ensures end-to-end machinery solutions for the burgeoning plastics industry. The company’s engineering expertise has evolved amid intense competition to deliver effective extrusion machines for thermoforming and packaging applications.

Competitive technology The current manufacturing business of Konark includes a wide range of multilayer & monolayer blown film plants, raffia tape stretching lines, extrusion coating lamination plants, cast film lines and air bubble sheet, box strapping, PP TQ film, monofilament, synthetic string, recycling and pipe plants. In 1999, the company had set up a Polyethylene Terephthalate (PET)

Box Strapping Plant for processing of virgin PET material. Since then, Konark has constantly meted out indigenous machines and technologies, with an aim to increasing the overall productivity of its customers. Customisation is the buzzword for Konark’s success. The company is all set to come up with tailor-made machinery and end-to-end solutions for the plastics processing industry. Following are some of the pioneering technologies from the Konark product portfolio: PET recycling plant with a capacity of up to 200 kg/hr Multi-layer (three-layer) raffia tape stretching line with 325 kg/hr output capacity Sixteen-feet wide extrusion coating lamination plant PET box strapping plant processing 100 per cent PET flakes with 125 kg/hr output Twin-lip raffia tape plant Twelve-feet wide extrusion coating lamination plant Air Bubble sheet plant for 600 mm, 1000 mm and 1500 mm width

Distinct innovation In order to interpret the strategic role played by Konark’s extrusion equipment in the plastics industry of Gujarat, it is important to have an understanding of the competitive environment in the region. The market has traditionally been a Small and Medium Enterprises (SME) domain, with the price advantage being a major determining factor. Keeping in view such a scenario, Konark has constantly evolved its machinery solutions to adopt high quality standards at competitive price points. Konark’s customers have played a crucial role in the company’s efforts to deliver market-friendly innovations. From product designs that accurately meet customer specifications to post-delivery feedback for efficient after-sales support, Konark maintains good relations with its customers for product development.

On an average, 30-35 per cent of our business is generated from exports market. We are witnessing tremendous growth in the domestic market and will continue to deliver indigenous technology of worldclass standards. Jaymin Pithwa Director, Konark Plastomech Pvt Ltd

Konark specialises in providing customers with innovative technologies that are consistent in high productivity and low power consumption. It also offers two-layer to five-layer coextrusion blown film plants in screw

Multilayer blown film plant

April 2011 | Modern Plastics & Polymers

FACILITY VISIT

diameters of 40 mm, 50 mm and 65 mm with differrent width options as per the customer’s needs. These plants are ideal for producing Low Density Polyethylene (LDPE), Linear Low Density Polyethylene (LLDPE) and High Density Polyethylene (HDPE) for making milk & ghee pouches, lamination films and stretch clean films. With the focus of global plastics industry shifting to increase sustainability in all stages of processing, India has shown immense enthusiasm in adopting the recycling and reuse of plastic waste. Leveraging on this opportunity, Konark offers reprocess plants to recycle various types of plastic waste and to make recycle granules with the use of ancillary equipment like grinders, mixers and palletisers. In 2007, the company launched a PET recycling plant with a production capacity of 200 kg per hour. Another innovative sustainable solution available in the Konark portfolio is the first ever PET box strapping plant from PET-recycled flakes. This facility with innovative methodology claims to have put behind the era of old-fashioned iron straps, negated the use of expensive PET virgin granules and optimised production capabilities, with output capacities in the range of 50-300 kg per hour.

Solutions-oriented approach The advantage of developing technology in tandem with customer demands is that, not only it enables a firm market presence, but also establishes the company as a complete solutions provider to the industry. Following this, Konark has been manufacturing customised machinery in close association with the processor, resulting in increased availability of process-specific machinery. This solutions-oriented approach has become the cornerstone of the company’s policy. Konark plays a more proactive role in establishing complete integrated production plants 52

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for the specific needs and demands of the customer. This has encouraged start-ups and overall entrepreneurship in Gujarat’s plastics industry. Konark also provides training to customers and their personnel during the testing and trial periods at its factory, and also at customers’ production site during erection and commissioning of the plant. Technical support provided to customers includes maintenance of the plant, and selection & combination of specific polymers for use in specific

With the focus of global plastics industry shifting to increase sustainability in all stages of processing, India has shown immense enthusiasm in adopting the recycling and reuse of plastic waste. processes with the help from their customer care engineers. Customers are briefed about possible operational hindrances, maintenance and processrelated solutions before providing them a process plant. The company also provides ancillaries to its entire range of production plants.

Emerging market potential The packaging and retailing industry is making headway in the region’s plastics segment. This has given a significant boost to plastic films and laminate manufacturers, which, in turn, has increased the demand on machinery manufacturers to provide customised solutions at competitive costs and with higher productivity. Konark has been riding high on this market potential by developing indigenous technologies to keep

pace with the changing demands and needs of the plastics processing industry. The company’s emphasis on quality has propelled it to the global stage, with an expanding network of export customers. “On an average, 30-35 per cent of our business is generated from the exports market. We are currently witnessing tremendous growth in the domestic market and will continue to deliver indigenous technology of world-class standards,” states Pithwa. The company has an efficient marketing network, both in India and across the globe, and has exported machines to the UK; countries in Middle East including UAE, Saudi Arabia and Oman; countries in Africa including South Africa, Kenya, Nigeria, Tanzania and Ghana; as well as a few other countries such as Guatemala, Ecuador and Sri Lanka. Developments on the export front do not impact Konark’s commitment to the domestic turf, which is on a constant growth path. Konark has a strong presence in trade fairs at the global as well as national level. The company had participated at K 2010 held in Dusseldorf, Germany, and also at Plastivision India 2011.

Future scope With an experience spanning more than 25 years, Konark has played an influential role in enhancing the business prospects of its clients while building on its core strengths. As end-user industries like building & construction, pipes and profiles give significant impetus to the extrusion industry in India, manufacturers will have to keep pace through innovation and expansion. Pithwa confirms, “We are currently in the process of expanding our manufacturing facility as well as working towards introducing new products to our existing portfolio. We are aiming at completely automated processes through CNC tooling for higher accuracy and productivity.”

SECTOR WATCH

Courtesy: ENGEL

Injection moulding

Technology driver for automotive segment Injection moulding is a method used to create a variety of products such as automotive plastics, which makes it possible to incorporate exceptional engineering and styling features in todayâ&#x20AC;&#x2122;s cars. It is the most common method of part manufacturing and ideal for producing high volumes of goods. Beverley Lewis takes a closer look at the role played by injection moulding in shaping the automotive sector.

Modern Plastics & Polymers | April 2011

SECTOR WATCH

ith the advancements in technology, the demand for plastics and its products has increased. Evolved over the years, the plastic injection moulding industry has been delivering an array of products for various industries, including medical, aerospace, plumbing and construction as well as smaller components and huge panels. Plastic injection moulding is one among the various injection moulding methods available in the market today. Injection moulding can be best described as a technique in which viscous molten thermoplastic, liquid, etc, are injected under high pressure, held across a force greater than that exerted during injection and allowed to cure to a predetermined temperature. â&#x20AC;&#x153;The automotive injection moulding market is in full swing due to growth and technology drivers, being light-weight in construction,

surfaces and functional integration.â&#x20AC;? says Michael Fischer, Head, Sales Technologies with ENGEL, Schwertberg, Austria. This method moulds components of the same quality as well as for a variety of components, with minimal maintenance. The automotive industry in India is one of the largest and fastest growing segments globally. India manufactures over 11 million vehicles (including two wheeled and four wheeled) and exports about 1.5 million vehicles every year. This sector accounts for about 15-20 per cent of the total injection moulding machine sales. However, plastics in the automotive industry have traditionally been used for large-sized parts such as floor panels, bumpers, dashboard, steering wheel and knobs. Slowly, parts under the hood of the car are also being converted to plastics/ silicone rubber.

Injection moulding technology makes cars and trucks more comfortable, safer, economical and environment-friendly. This integration achievement helps secure future mobility. Jitendra Devlia

Managing Director, ENGEL Machinery India Pvt Ltd

April 2011 | Modern Plastics & Polymers

SECTOR WATCH

Current trends

Changes in the techniques used in moulding, such as using hot runner systems, have added to productivity and brought about a reduction in material wastage losses. Avinash Anand Partner, UNIMARK

The ongoing developments in this technology are headed towards functional integration where we are emphasising on switching elements. Franz Füreder

Head, ENGEL Automotive Business Unit, Schwertberg, Austria

Modern Plastics & Polymers | April 2011

One of the most important developments in automotive injection moulding is the use of technologies, such as gas-assisted injection moulding and multicomponent injection moulding. These technologies help reduce the amount of material used and also the use of downstream assembly processes, respectively. “Changes in techniques used in moulding, such as using hot runner systems, have added to the productivity and brought about a reduction in material wastage losses,” informs Avinash Anand, Partner, UNIMARK. The automobile industry is one of the most important driving force behind the injection moulding technology. For many components in the vehicle shell, such as glazing, interior, power train, safety and control technology, plastics are the only feasible materials, and injection moulding is the only possible approach in such cases. New processes and combinations of processes continually open up new applications and fulfill the continually growing demand from the automotive industry and car drivers. “Injection moulding technology makes cars and trucks more comfortable, safer, economical and environment-friendly. This integration achievement helps secure future mobility,” adds Jitendra Devlia, Managing Director, ENGEL Machinery India Pvt Ltd. Microcellular injection moulding (MuCell) technology has been in use for almost 10 years. So far in India, this technology has not seen wide use. The objective of MuCell technology is to reduce the weight of the parts and, at the same time, keep strength and other physical properties intact. These special technologies can be applied to only select materials and parts. “Another breakthrough technology that has yet to find applications in India is ‘In-Mould Assembly’. It refers to multi-component parts that

are assembled in the machine, eg, louvers for air-conditioners, links and joints. The biggest advantage of this technology is that it eliminates the need for downstream assembly processes and, more importantly, the need to keep inventories of semifinished parts. This enables huge costs savings,” asserts Anand. One of the several striking features about this production cell, with its two injection moulding machines arranged at right angles to each other, is that large metal cores are ‘passed through’ all processing stages. Depending on the fitting size being produced, a pair of cores alone weighs 25-40 kg, while the weight of the fitting itself amounts to only 10 per cent of this (maximum 2 kg per moulding). This production unit was planned to facilitate transfer of preforms containing the resistance wire coil between different moulding machines. Also, the core can be transported in a vertical position by a moving carriage from the first processing stage into the mould of the second injection moulding machine, where the fittings can be completed. “The ongoing developments in this technology are headed towards functional integration where we are emphasising on switching elements. Thanks to functional integration, the clearmelt technology opens up to an enormous variety of applications, and not just in the automotive industry. For example, in future,

Advantages Elimination of moulded-in stresses, due to low cavity pressure exerted by the gas Lower tool cost, and simplification in certain designs Reduced clamp tonnage/lower equipment cost Significant reduction in sink marks over ribs and bosses Improved surface finish Possible elimination of external runners Part design flexibility (eg, mixed thick & thin walls, box sections without movable cores, part consolidation and larger, complex parts)

SECTOR WATCH

Limitations Longer development lead times, due to poor understanding of part/tool design and process optimisation for various materials Difficulty in controlling multi-cavity (more than four) moulds Injection moulding machine should be capable of providing consistent, accurate shot weight Part must have a vent hole on non-visible portions

coffee makers will have a smooth housing because all switching elements will be integrated into the surface. The design of these appliances will be even more attractive than those of today’s models, and these will be easier to clean as well. The integrated production process helps combine aesthetics with functional design,” validates Franz Füreder, Head, ENGEL Automotive Business Unit, Schwertberg, Austria.

Automation and robotics The enhanced use of automation and robotics is evident in all major industrial processes globally, and injection moulding is no exception. Automation and robotics are becoming increasingly commonplace in the injection moulding environment, as moulders are moving towards consistent quality and greater production efficiencies to offset high costs of raw material. Robotic systems and integrated peripherals are becoming a prominent tool for moulders to achieve optimum results even in specialised applications. In India, these utilities are still at a nascent stage. The biggest difference between Indian auto parts suppliers and overseas suppliers is the degree of automation of the moulding process. “The use of robots and automation systems for removal and finishing of moulded parts is common overseas but has not yet been adopted in India. The major reason for this is the availability of cheap labour, but this will change soon,” asserts Anand. Also, Indian companies still tend to focus on purchase price of machines and auxiliaries rather than running costs and faster amortisation. There is a need to focus on qualitative parameters such as reliability and reduction in downtime of machines rather than budgeting money based on the machine price. The desire to enter into niche and specialised applications has led Indian manufacturers to accept the need for integrating automation in their processes. To this, Devlia adds, “Investments in high-quality injection moulding machines are constantly increasing in India. After technical moulding, solutions for the automotive industry are the biggest revenue generators.”

Moving beyond convention Gas injection moulding will see greater use in the future, as it provides a solution for several challenges associated April 2011 | Modern Plastics & Polymers

SECTOR WATCH

with conventional high-pressure injection moulding and structural foam moulding. It significantly reduces volume shrinkage, which causes sink marks on many injection moulded parts. It yields improved surface finish, which is not possible by conventional structural foam moulding. Gas-injection moulding has been developed to save material, shorten cycle times and to improve the surface aspects of thickwalled injection-moulded parts. Various commercial applications exist, but these represent only the tip of the iceberg in terms of the potential of gas injection moulding. Once the process is widely developed and understood, numerous applications will come up that were previously either impossible by conventional injection moulding or never seriously considered.

Plastics for the future The advantage of plastics is that these are moulded – instead of stamped,

as metal is – and thus, are preferred materials for automobiles. The moulding process is longer, though stamp press cycle time for metal is about six seconds, a plastic mould takes about 45 seconds. Moulded parts tend to be on smaller, niche vehicles similar to cars that people prefer to buy today. This trend is beneficial for the plastics and injection moulding industry. Parts manufactured using injection moulding have high precision & productivity, high level of complexity, good surface finish, consistency and relatively low cost, which cannot be achieved using other types of production technology. As the shape of moulds is becoming complex, it is easy to manufacture molten polymer in a mould instead of creating it from stamped steel. Also, a mould can be used to make multiple parts at a time. Among other advantages, plastics can significantly reduce the weight of a vehicle,

improving fuel efficiency by reducing drag, and also cutting down on emissions. Because plastics can be more easily moulded, components can be tailored for more comfortable human-ergonomic features, as well as more streamlined shapes. Less amount of material can be used compared to steel components, and the durability of plastics results in a longer, more reliable vehicle lifetime. Materials, like plastic, are usually tested on high-end vehicles first. Once the materials are proven to be more efficient and cost effective, they filter down to affordable consumer vehicles. By 2020, the automotive industry and society will recognise plastics as a preferred material solution that meets and, in many cases, sets automotive performance and sustainability requirements. . Cars built entirely out of plastic could be the wave of the future, making metal a thing of the past when it comes to autmomobiles.

An invite that rewards as well... Dear Reader, ‘Modern Plastics & Polymers’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the plastics & polymers industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Plastics & Polymers’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Ltd, ‘Modern Plastics & Polymers’ is the leading monthly magazine exclusively meant for producers and user fraternities of the plastics industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,

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Modern Plastics & Polymers | April 2011

MARKET TRENDS

Polymers have a strong presence in the medical segment. Along with standard performance characteristics like chemical and heat resistance, the medical polymers today are seeking enhanced diagnostic applications like optical clarity and UV transmission. Annabel Dsouza elaborates on the processing innovations and precise tooling technology required to manufacture plastic medical devices.

ith the Indian economy soaring to greater heights, the healthcare segment is witnessing a demand for better technology solutions. Also, as the healthcare policy of the nation evolves to reach medical services, there will be increased expenditure on world-class products. The Indian medical device market was estimated at $2,750 million in 2008. Growing at a Compounded Annual Growth Rate (CAGR) of over 20 per cent, the market is likely to reach

Modern Plastics & Polymers | April 2011

$5 billion by 2012. The expenditure on healthcare in India was approximately $26 billion in 2006, constituting 5.5 per cent of the Gross Domestic Product (GDP) as against the 7-10 per cent of GDP spent by established economies of the world. This reveals the tremendous market potential for performance polymers application in the medical devices industry. With growing demand for disposable devices, the use of plastics has increased manifold. Compared to

MARKET TRENDS

conventional material such as metals, ceramics and glass, plastics have unique advantages like design flexibility and processability into a wide range of shapes, sizes, thickness and colours. During compounding of polymers, various additives and fillers are incorporated into plastics to manipulate its basic properties. Hence, in the plastic medical devices portfolio available in the market today, it is not rare to find products with varying characteristics of physical, mechanical, chemical and biocompatibility requirements. Medical application is perhaps the only industry that demands plastics to be flexible or rigid, insulating or conductive, hydrophilic or hydrophobic, transparent or opaque, etc, depending on individual product profiles. The increasing use of combination medical devices, changes in medical packaging market, a shift towards miniature & portable devices and biocompatible features of advanced polymers are expected to promote the development of new products, thereby contributing to the overall market growth. From an industry’s perspective, Rajiv Nath, Joint MD, Hindustan Syringes & Medical Devices Ltd, says, “The major advantages of the use of polymers in the medical devices industry are cost effectiveness achieved from mass production and shorter production life cycles. Also, the dimensional tolerance offered by medical grade plastics is tighter and easily reproducible. Conventional materials like glass, steel and rubber are expensive to produce and may not be biocompatible. For example, dialysers made from polymers perform the function of kidneys. Other equipment made from engineering plastics include syringes, catheters, orthopaedic implants, surgical drapes, sutures, etc.”

Preserving essential properties Plastics that find applications in the medical field can be categorised into different types of resins such as commodity and engineered resins. Major applications of engineering

plastics in medical products can be divided into three key segments: dental & surgical equipment, plastic disposables and implants. All these hold respective marketshares of 40 per cent, 25-30 per cent and 20-25 per cent. Polyvinyl Chloride (PVC) is among the most widely used medical polymers. It is popular due to its properties such as softness, strength, high transparency and facility of sterilisation. PVC-based medical polymers constitute 40 per cent of the market, following which is polypropylene with a significant share of 20 per cent. Polyethylene products constitute 15 per cent of marketshare, while other prominent plastics include polycarbonate, Acrylonitrile Butadiene Styrene (ABS), biopolymers, nylon and polystyrene, accounting for 25 per cent of the medical products in the market. Given the highly sensitive and challenging environment of the medical sector, plastics processors are often faced with limitations of the polymer’s property profile that is unable to meet the complex demands of medical usage. For example, cleaning and sterilisation is an indispensable process for medical equipment. Thus, plastics used in such devices are designed to endure repeated cycles of high-intensity sterilisation without cracking, melting or leaching. Typically, sterilisation techniques include autoclaving in steam or dry heating, ethylene oxide and irradiation with high-energy gamma or electron beam. For this purpose, polycarbonates are reinforced to enable these to withstand mechanical & thermal stress and prevent decomposition. Special stabilisers are added to polymers used in devices such as syringes and catheters that undergo sterilisation with high-energy radiation in order to prevent them from changing colour. Biocompatibility is a deciding factor for polymers used in implants and other products that function in close contact to the patient. These have to meet stringent directives of cytotoxicity and genotoxicity.

Major advantages of the use of polymers in the medical devices industry are cost effectiveness achieved from mass production and shorter production life cycles. Rajiv Nath

Joint MD, Hindustan Syringes & Medical Devices Ltd

One of the biggest innovations in medical applications of performance polymers is the radiolucent carbon fibre composite material. But some of these materials are not readily available in India and need to be imported. Sanjay Agarwal

Managing Director, Magna-Tek Enterprises

April 2011 | Modern Plastics & Polymers

MARKET TRENDS

Advances in polymer science have unleashed an unlimited potential for application of highperformance plastics in tissue engineering and drug delivery. Dr Rasika Bhat

Medical Geneticist & Lecturer – Medical Genetics, Institute of Nursing Education, J J Hospital and Bombay Hospital College of Nursing, Mumbai

Tooling technology Accuracy is integral to manufacture of medical devices; hence, production cost is significantly high to ensure zero-defect moulding. As plastics are increasingly employed in drug dosage and delivery, there is increased emphasis on innovative design and

manufacture of plastics. End-users are searching for the latest technologies at the most competitive prices without compromising on product safety. Processors have to balance operations while building economies of scale with respect to capabilities. Plastic is a process-friendly material that can be injection moulded, extruded, blow moulded, rotomoulded, thermoformed or machined to form moulded parts, films and fibres. These have excellent balance of strength, stiffness, toughness, ductility and impact resistance. A number of applications now use plastics to replace metal or glass to reduce costs, leverage design flexibility and maintain performance. Manufacturers of plastic medical devices must create a differentiating business model for a material niche market. Although medical manufacturing standards do not require high levels of cleanliness in mould-making areas, manufacturers are building cleanrooms within their facilities to give their brands an edge. Besides, two-shot moulding on multi-axis automated machines are the norm for medical devices to ensure higher standards of precision and quality delivery. Sanjay Agarwal, Managing Director, Magna-Tek Enterprises, says, “In recent times, one of the biggest innovations in medical applications of performance polymers is the radiolucent carbon fibre composite material. This material is used in the manufacture of operation table tops, which helps in sharp and crisp imaging when used with a C-arm. As some radiolucent materials are not readily available in India, these need to be imported. This impacts the overall production costs.”

Ensuring quality standards One aspect of supplier controls is to ensure that components and parts are manufactured in a controlled manner to provide consistency and precision. The Food and Drug Administration (USFDA) Medical Device Regulation and ISO certifications prescribe production 62

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controls, which include specific requirements for process validation. This is conducted during the design and development stage for producing moulds and components that adhere to process specifications in real time. As demand soars and volumes of processed components have to be delivered, a 100 per cent quality control is a considerable challenge. In such cases, toolroom validation is integrated only in certain processes, eg, injection moulding, extrusion, compounding, sterilisation, welding, plastic bonding, wave/hand soldering, heat treatment, plating, dipping, sealing, cleaning, filling and sterile packaging. Despite the high costs involved, the complexity and criticality of medical devices usage demand rigorous quality checks and zero-fault manufacturing. Benefits of validating the toolroom include increased control & minimal testing, better productivity & quality, increased profitability, easy troubleshooting and analysis.

Unlimited future potential Various new technologies are yet to be taken up by the medical devices industry. For instance, the benefits of Rapid Temperature Cycling (RTC) and infrared tool face reheating render flawless plastic component surfaces that deliver considerable benefits in sterilisation and reduction in bioburden. Dr Rasika Bhat, Medical Geneticist & Lecturer – Medical Genetics, Institute of Nursing Education, J J Hospital and Bombay Hospital College of Nursing, Mumbai, states, “Advances in polymer science have unleashed an unlimited potential for application of high-performance plastics in tissue engineering & drug delivery, with the most prominent use in cardiology, dentistry, neurology, dermatology, oncology and genetic engineering. The benefits of these polymers as gene carriers in gene therapy are easy controllability, biocompatibility, biodegradability, besides non-toxicity and non-immunogenicity.”

PERFORMANCE METRICS

Welded nylons

Gauging the efficiency quotient As a continuation of the two-part series on welded nylons and various welding methods, namely, Linear Vibration Welding (LVW), Orbital Vibration Welding (OVW), Hot-Plate (H-P) welding, this part takes a look at the efficiency of these technologies. It also offers insights into memory effects in nylons and weld interface as well as local reinforcement effects on weld interface.

ith the demand for welded nylons witnessing a rise over the years, manufacturers have been focussing on the welding technologies, especially those that will suit one’s requirements in the best possible way. In this backdrop, researchers have conducted a study, emphasising on OVW, LVW and H-P welding methods to assess their feasibility on different types of nylons, such as nylon 6, nylon 66, nylon 46 and nylon High Temperature Resistance Nylon (HTRN).

Memory effects in nylons A factor affecting the crystallisation process of slowly or moderately slowly crystallising polymers is called the ‘crystalline memory’. Its results are usually lumped together under the umbrella of ‘memory effects’. It is manifested by the formation of a defined degree of macromolecular order in the welded interface, as well as a rise in the melting temperature (Tm) of semi-crystalline systems (Table 1). Memory effects reflect the thermal history of the moulded part and, in addition, are affected by the melt temperature and welding time spent in the molten state. The highest

temperature at which the polymer crystal may survive is the equilibrium melting point (Tmo). For nylon 6, Tmo may be about 270°C. Other Tmo values obtained for nylon 6 by various extrapolations range from as low as 215°C to as high as 306°C. Anneal temperature (Ta) – the temperature at which the melt is kept in order to remove the nuclei – must be higher than Tmo. For nylon 6, Ta as low as 260°C were sufficient to eliminate memory effects, but 270°C and 280°C are now being recommended at temperatures at which memory effects are completely erased. In these instances, it is assumed that Ta = Tmo. Similar results were observed in pellets of several other nylon types. Variations in the applied pressure of the amorphous phase of semi-crystalline polymers may affect changes in glass transition (Tg), melt Tm and Ta. Mould temperatures for various nylon compositions recommended by manufacturers include cavity surface temperatures, which are often the same as temperature of the circulating water or other fluid used to control mould temperature. Higher mould temperatures delay freezing to facilitate filling long, thin sections (similar to

Table 1: Memory effects of various nylons (at same heat/cooling rate)

Type of PA Nylon Nylon Nylon Nylon Nylon Nylon

Modern Plastics & Polymers | April 2011

6 6 6 6 6 6

Sample preparation Pellets Ground 3 times Pellets Ground 3 times Pellets Ground 3 times

Anneal temperature (Ta), °C 270 270 290 290 305 305

Melting point (Tmp), °C 221.6 218.9 262 260.1 287 262

Glass transition temperature (Tg), °C 54.8 51.1 63.3 58.7 76.7 74.7

PERFORMANCE METRICS

remelting processes in weld bead areas). These also encourage greater crystallisation of semi-crystalline resins, which affects mechanical properties as well as dimensions. The more common nylons for injection moulding, such as nylon 6, nylon 66, nylon 610 and nylon 612, often use mould temperatures of 40°C-70°C. Optimised mechanical performance of welded joint was achieved at weldmelt temperature of crystalline melting point (range, 35°C-60°C). Observed values of the maximum temperatures of melt in weld interface (Tmw) are slightly higher (range, 15°C-30°C) than the Ta for evaluated nylons. These results and evidences conform to the Criterion of the Minimum Flow Rate Hypothesis. During the frictional welding processes (LVW and OVW), the Tmw and crystallisation kinetics can be influenced by weld time-temperature parameters and the flow rate of the melt.

Efficiency of LVW and OVW The results of the tensile strength of glass fibre reinforced (GF), and mineral-filled (MF) nylon 6-based plastics and welded-butt joints (at optimised LVW processing conditions for longitudinal vibration directions) are mentioned in Table 2. These results can be compared to tensile strength of the base matrix m/polymer (or to tensile strength of the welded plastic pl), using welding factor fwm (or fwpl), respectively. Welding factors fwm and fwpl are equal to the following ratios (1 and 2): fwm = tensile strength of weld/ tensile strength of base polymer (1) fwm = tensile strength of weld/ tensile strength of reinforced or filled plastics) (2) For OVW technology, it is possible to select among circular (orbital), straight (linear) or elliptical weld paths. The tensile strength of OVW is slightly higher than that in LVW technology. By the nature of heat generation, an orbital/circular and elliptical path is more efficient (at the optimised welding

Table 2: Influence of fibre-glass reinforcement on tensile strength (at 23°C, dry as moulded) of H-P and LVW butt joints (optimised processing conditions)

Wt% GF

Tensile strength of plastics (MPa)

6 – nylon 6 14 – nylon 6 25 – nylon 6 33 – nylon 6 33 – nylon 66 45 – nylon 6 50 – nylon 6

85 125 160 185 185 208 220

parameters) in glass fibres reorientation and polymer blending.

Weldability of similar and dissimilar nylon through LVW For automotive application, joining of dissimilar (by type of used resins, reinforcements & fillers, levels of loading, etc) plastics, copolymers and blends is needed by design requirements (aesthetics, structural, noise, vibration, etc). But limited literature is available in this area. Currently, there is no published data available on mechanical performance of dissimilar (by type of nylon, level of fibre-glass reinforcement and mineral fillers) welded nylon-based plastics. For the automotive powertrain parts design with nylon, it is important to obtain data for the weld strength between the following dissimilar materials: Nylon 6 welded with nylon 66 Nylon 6 or nylon 66 welded with 66/6 copolymer Nylon 6 or nylon 66 welded with nylon 46 Nylon 6 or nylon 66 welded with HTRN It was pointed out that limited interdiffusion is expected at the joint of dissimilar polymers. Because of their difference in thermal properties, one material may melt faster than the other. Sometimes, one of the materials may not even reach its melting point at the interface. In all welds between two plagues or specimens, greater flash was seen at the nylon 6 side. This phenomenon is consistent with the lower melting temperature in these nylon materials. Due to the temperature

LVW technology tensile strength of weld (MPa) 83.1 90.7 90.2 85.6 83.6 80.5

H-P technology tensile strength of weld (MPa) 78.2 89.8 84.5 88.8 80.3 -

gradient in the width of the joint and the length of the weld, the lateral flow of the joined plastics is not uniform. Additional experimental data is needed for optimising the similar and dissimilar nylon butt joint. The low tensile strength in the joints between nylon 66/nylon 6 with HTRN has been related to polymer mixing and weld interface thickness. At the steady state welding process, the band thickness of nylon 66 or nylon 6 becomes constant, but the band thickness of HTRN continues to rise. For dissimilar welds, the final thickness of the interface is smaller than that of the similar welds (at optimised conditions). To increase the mechanical performance of the dissimilar joints, it is necessary to achieve asymmetric heating conditions for the two halves of the joined parts. This, however, is not possible in the LVW or OVW methods due to the nature of internal heating (self-adjustable process). For the H-P technology, it is essential to design special heating equipment adjustable according to thermal properties of materials in the joint.

Effectiveness of H-P welding technology H-P is not a dynamic process in terms of heat generation. It is an attractive welding method for the evaluation Table 3: Efficiency of welding technologies

Technology (Method) LVW OVW H-P U/SW

Weld factor fwm 1.08 1.1 1.12 0.34

Weld factor fwpl 0.46 0.47 0.48 0.15

April 2011 | Modern Plastics & Polymers

PERFORMANCE METRICS

Fibres do not cross interface

Figure 1: Fibre-glass orientation at non-optimised (standard set-up) LVW conditions

of reinforcement effects in the weld interface area. In experimenting with H-P procedures, researchers have used the same plastics. These experiments were conducted using nylon 6 products with glass-fibre reinforcement in the range of 0-45 weight per cent and nylon 66 with 0-33 weight per cent GF.

Evaluating welding technologies Tensile strength of welded nylon 6 (weight per cent 33 per cent GF) butt joints were conducted at room temperature conditions. LVW, OVW and H-P welding methods are efficient as per the mechanical performance criterion. For the three above mentioned welding technologies, it is possible to achieve tensile strength of butt joint equal to or slightly higher than tensile strength of the base polymer (matrix). For H-P technology, the researchers repeatedly received localised reinforcement effects in nylon 6 and nylon 66 plastics. The

best tensile strength was achieved for nylon 66 with weight 33 per cent GF. Performance of welded polyamides using ultrasonic welding technology was three times less than the similar parameters for other frictional and H-P methods.

Local reinforcement effects on weld interface Optical microscopy was used to study the morphology of samples (fibreglass orientation, local reinforcement effects, presence of microporosity, small inclusions, etc), while image analysis was used to quantitatively characterise the fibre-glass state including diameter, length & breakage as well as positioning of the welded components (penetration, meltdown, etc). A study of the weld zone fracture surfaces on both technologies by scanning electron microscopy suggested that there is no excessive breakage of fibre-glass at the weld interface. This Fibres do cross interface

technique allows one to determine quantitatively the effects of local reinforcement on weld fracture surfaces. For glass fibre-reinforced thermoplastics, the maximum weld strength for the butt joints is equal to or less than the strength of the matrix or base materials. The reduction in tensile strength was attributed to changes in the fibre-glass orientation at the welded joint, where the glass fibres align on the weld plane, perpendicular to the applied stresses. The orientations of glass fibres are as follows: In the weld interface, local area fibres were oriented mostly along the weld-melt flow direction In the bulk of material, fibre orientation was random, based on part design, moulding conditions, etc. The minor chain repetition model explained the effects of non-reinforced plastics healing and strengthening during the welding process time. In this study, the effects of strength and performance improvement for welded joints were explained from the dynamic mode of fibre-glass reorientation in joining process time. With the optimised welding parameters in LVW and OVW, some of the glass fibres were found to orient perpendicular or at an angle to the weld plane across the interface. This local reinforcement effect for LVW and OVW methods was observed for both nylon 6 and nylon 66 plastics. For nylon 66 plastics, the performance of weld similar to that in nylon 6 for LVW and OVW techniques was achieved.

Conclusion

Figure 2: Fibre-glass orientation at optimised LVW conditions (local reinforcement effects in weld interface)

Modern Plastics & Polymers | April 2011

Comparing studies of LVW and OVW joining technologies demonstrated that the OVW process is efficient for nylons and may be used as an alternative to LVW and Ultrasonic (U/ SW) technologies for welding of small components. For both frictional (LVW, OVW) and H-P joining technologies, the maximum tensile strength at the weld was achieved in materials with 14-24 weight per cent GF. Studies on

PERFORMANCE METRICS

heat generation and melt propagation in weld area (time-temperature profile) in LVW processing using infrared technology have demonstrated the dynamics of temperature distribution in overall and interface areas. For joining of similar nylons, a difference of 15-20°C at the interface was found during the steady state in LVW technology, and as a result, the hot-plate/tool temperature (H-P technology) is recommended. The difference may be due to the accuracy of the previously applied measurement methods, the calibration procedures, etc. The utilisation of standard IR method and Thermovision 900® Series System (FSI/AGEMA) allows monitoring of temperature distribution in overall and local (interface) areas. Increase in melt temperature (at the interface) at welding time correlated well with the ‘memory effects’ of semicrystalline systems. Morphology studies using microscopy have revealed the fibre-glass distribution and orientation in the bulk of material & at the interface. Under optimised LVW, OVW and H-P welding conditions, some parts of glass fibres oriented perpendicular to or at an angle to the weld plane, and they were also seen crossing the interface. These local reinforcement effects were found to be repeatable for the butt joint welded from similar (both halves are nylon 6 or nylon 66, and nylon 66/6 copolymer) and dissimilar (nylon 66 with nylon 6) plastics. At present, the optimised weld performance for nylon 46 and HTRN, dissimilar butt joints are not yet achieved due to the large difference in the melt temperature and solubility of the base materials. The presented optimised weld performance data for commercially available polyamides (nylons) will allow designers to recommend LVW, OVW or H-P technology in plastic product development for welding applications and welded components manufacturing.

Acknowledgements Support

provided

Branson

Fibres do cross interface

Figure 3: Fibre-glass orientation at optimised hot-plate welding conditions (local reinforcement effects in weld interface)

Ultrasonics Corporation, Bielomatik, Inc. and FSI/AGEMA Infrared Systems is gratefully acknowledged. Special thanks to Shaul Aharoni for knowledge, and to Chris Roth and Nanying Jia for offering help in preparing this study for publishing. Their contributions are greatly appreciated.

References 1. Shaul M Aharoni, ‘n-Nylons: Their Synthesis, Structure, and Properties’, John Wiley & Sons, New York, 1997, 598 p. 2. V Kagan, ‘Joining of Nylon Based Plastic Components: Vibration and Hot Plate Welding Technologies’, ANTEC’99, SPE Conference Proceedings, Vol. 1, pp. 1349-1359. 3. H Potente, M Uebbing and E Lewandowski, ‘The Vibration Welding of Polyamide 66’, Journal of Thermoplastic Composite Materials, Vol. 6, January 1993, pp. 2-17. 4. V K Stokes and S Y Hobbs, ‘Strength and Bonding Mechanisms in Vibration-Polycarbonate to Polyetherimide Joints’, Polymer Engineering and Science, MidDecember, 1989, Vol. 29, No. 23. 5. Shaul M Aharoni, ‘Increased Glass Transition Temperature in Motionally Constrained Semicrystalline Polymers’, Polymers for Advanced Technologies, Vol. 9, 1998, pp. 169-201. 6. V Kagan, Siu-Ching Lui, etc, ‘The Optimized Performance of

Linear Vibration Welded Nylon 6 and Nylon 66 Butt Joints’, ANTEC’96, SPE Conference Proceedings, Vol. 1, pp. 1266-1274. 7. Richard P Wool, Polymers Interfaces – Structure and Strength. Hanser Publishers, New York, 1995, 494 p. 8. D A Grewel, ‘Amplitude and Force Profiling: Studies in Ultrasonic Welding of Thermoplastics’, ANTEC’96, SPE Conference Proceedings, Vol. 1, pp. 1051-1058. 9. K W Nelson, ‘Vibration Welding: A Low Cost Assembly Process for Thermoplastic Intake Manifolds’, SAE’95 Technical Paper Series Plastics: Components, Processes, and Technology (SP-950230), 10 p. 10. US Patent # 5,874,146 , V Kagan, etc, ‘Performance of Vibration Welded Thermoplastic Joints’, 1999. Note: The information submitted in this publication is based on BASF’s current knowledge and experience. In view of the many factors that may affect processing and application, these data do not relieve processors of the responsibility of carrying out their own tests and experiments; neither do they imply any legally binding assurance of certain properties or of suitability for a specific purpose. It is the responsibility of those to whom BASF supplies their products to ensure that all proprietary rights and existing laws & legislations are observed. Courtesy: BASF SE

April 2011 | Modern Plastics & Polymers

CASE STUDY

Advanced plastics

The next big thing is small The untoward consequences of indiscriminate use of plastics on the environment are quite obvious. For reducing the burden of plastics wastes on the environment, researchers worldwide have come up with various techniques, some of which also utilise microbes. An example of such efforts is Micromidas, a company that has developed a bioreactor in which microbes convert polluting, biosolids sludge to biodegradable plastics.

icromidas is a venture by three graduates from the University of California at Davis – John Bissell, Ryan Smith and Casey McGrath. In 2008, they had participated in a clean technology national competition sponsored by the Environmental Protection Agency (EPA) in Washington, DC, competing against some 400 universities. At the competition, their technology was judged to be sufficiently unique and ambitious, which brought to them the laurels of victory. Not long after their triumph, Micromidas was born.

Developing unique solutions While researching on microbe-based

Micromidas mobile refinery, rear view Courtesy: Autodesk

Modern Plastics & Polymers | April 2011

wastewater treatment methods at their alma mater, the Micromidas team developed unique processes for transforming the carbon in organic wastewater to fully biodegradable plastics. Disposal of biosolids – also known as ‘sludge’ – is an expensive and complex problem. Carbon and other nutrients present in wastewater biosolids are not incinerated, as it releases greenhouse gases, or deposited in landfills. Instead, these material are engulfed by microbes, which the Micromidas team has harnessed from soil and water. During the Micromidas biorefinery process, flake-like particles of Polyhydroxyalkanoates (PHA) are produced from sequestered carbon. As much as 65 per cent of the sludge is refined in this process, with the remainder immediately recycled through the system. Micromidas then sanitises the PHA flakes and converts these into pellet form. These pellets can be used to produce PHA plastics. And customers can use PHA plastics to create a range of products. The PHA plastics manufactured from Micromidas pellets are expected to be safe for use with food items. These can also be used to make products such as biodegradable medical sutures. Since PHA plastics are produced from organic materials, these degrade in landfills or other composting environment in a matter of months, as opposed to petroleum-based plastics that can take even centuries to degrade completely. And there is

CASE STUDY

Micromidas mobile refinery, top view Courtesy: Autodesk

more to this; as PHA bioplastics are situationally recyclable, these are an earth-friendly packaging alternative.

Introducing the new technology Micromidas is developing a unique way to introduce its technology to municipal wastewater treatment plant authority customers. The Mobile Biorefinery from Micromidas is a pilot plant built on a flat-bed truck capable of travelling to and plugging into wastewater treatment plants across the US. It will demonstrate how to convert wastewater streams to PHA flakes for producing bioplastics. This rolling show will enable Micromidas to demonstrate the compelling benefits of biosolids disposal technology to potential customers at their own sites. “Autodesk® Inventor® and Autodesk® Algor® Simulation software are playing key roles in the evolution of Micromidas technology and processes,” says John Bissell, Chief Executive Officer and Co-Founder, Micromidas. He continues, “Autodesk software has helped the Micromidas team to speed up and evolve its chemical and process engineering in record time.” Micromidas has used Autodesk® Inventor® software and a Digital Prototyping workflow to design, visualise and simulate its bioreactor and Mobile Biorefinery systems. Showing a

Micromidas mobile refinery, side view Courtesy: Autodesk

validated digital prototype of its system to customers on-site indicates that Micromidas can communicate more effectively the efficiency of biosolids disposal processes in a real-world wastewater treatment plant. Micromidas is currently using Autodesk® Algor® Simulation software to precisely visualise and analyse a wide range of design scenarios for its refinery reactor in the real-world context of a wastewater treatment plant. “Measuring fluid dynamics interactions across the Micromidas technology platform is critical to achieving optimal results,” explains Ryan Smith, Chief Technology Officer and Co-Founder, Micromidas. He elaborates, “Algor Simulation software has yielded more detailed, trustworthy designs and has also reduced the timeto-market for Micromidas.”

Small is the next big thing Time will only tell if biodegradable plastics can fully replace petroleumbased plastics. For its part, however, the Micromidas team is aware that the benefits of using earth-friendly microbes to solve environmental problems are undeniable. Make no mistake: tiny microbes are the next big thing. Courtesy: Autodesk The Autodesk Clean Tech Partner Program supports early-stage clean technology companies with design and engineering software that they can use to accelerate their development of solutions to the world’s most pressing environmental challenges. For more information, visit autodesk.com/cleantech

Autodesk Inventor and Autodesk Algor Simulation software are playing key roles in the evolution of Micromidas technology and processes. Autodesk software has helped the Micromidas team to speed up and evolve its chemical and process engineering in record time. John Bissell

Chief Executive Officer and Co-Founder, Micromidas

Measuring fluid dynamics interactions across the Micromidas technology platform is critical to achieving optimal results. Algor Simulation software has yielded more detailed, trustworthy designs and has also reduced the time-to-market for Micromidas. Ryan Smith

Chief Technology Officer and Co-Founder, Micromidas

April 2011 | Modern Plastics & Polymers

INDUSTRY SCOPE

Indian plastics

Scaling new heights The Indian plastics industry has been growing at the rate of 15 per cent and holds tremendous potential for growth. The industry is all set to double the plastics processing capacity and consumption, which will make India the third-largest consumer of polymers in the world in the coming years. The world today recognises the capacity of the Indian plastics industry and the inherent talent capital. Anup Patel

he plastics industry in India has taken significant strides forward, ever since it made a modest but promising beginning by commencing production of polystyrene in 1957. This potential of the Indian market has motivated entrepreneurs in the country to acquire technical expertise, achieve high quality standards and build capacities in various segments of the booming plastics industry. Phenomenal developments in the plastics machinery sector coupled with matching developments in the petrochemical sectors, both of which support the plastic processing sector, have facilitated the plastic processors to build capacities for servicing the domestic as well as overseas markets.

The growth curve Courtesy: BASF

Modern Plastics & Polymers | April 2011

The onset of liberalisation policies in the 1990s gave a boost to the plastics industry. Despite global competition generated through low customs duty, the Indian industryâ&#x20AC;&#x2122;s growth rate of 3-4 per cent, along with a substantial number of major raw material manufacturers and 22,000 processing units, have enabled the turnover of the plastics industry to touch more than `25,000 crore in 2010. Moreover, capital investment is worth around `35,000 crore. Raw material production

has reached the mark of about 3.7 million tonne and consumption is nearly 3.4 million tonne. The Indian plastics industry has enormous opportunities in meeting consumer needs in virtually all sectors. India ranks eighth in the world in total plastics consumption. But the per capita plastics consumption in India of about 4.3 kg is well below the world average of 26 kg. India is likely to be the third-largest consumer of plastics after the US and China in the near future. All these make it obvious that the plastics industry holds a promising future in India. The fundamentals in terms of low per capita plastics consumption base, coupled with lower prices, will accelerate the growth rate of the plastics sector in India.

Diverse capacities The Indian petrochemical sector mainly comprises polymers, synthetic fibres, fibre intermediates and plastics processing, and offers bright prospects. The industry is growing at the rate of 14-15 per cent annually, almost double the growth rate of GDP in India. The liberalisation process in the 90s had helped the petrochemical industry open up to the private sector. In fact, in the 1980s and 1990s, production of hydrocarbons had increased, resulting in excess availability of naphtha. Also, plastics

INDUSTRY SCOPE

Indian plastics industry: Vital stats Per capita plastics consumption set to double by 2012 Exports growth at 21 per cent All leading companies import from India Offers consistent quality Capable management by young and savvy entrepreneurs were perceived as cost-effective and superior alternatives to conventional materials. Synthetic fibres, generally considered as a luxury material, became critical in supplementing cotton. Lower prices of crude oil helped reduce the prices of imported petrochemicals. Thus, the demand for petrochemicals increased significantly and new facilities were set up to meet the growing domestic demand. The demand potential for commodity polymers rose from 5.3 million tonne in 2006-07 to 12.5 million tonne at a Compounded Annual Growth Rate (CAGR) of 18 per cent during the 11th FiveYear Plan period. This suggested certain changes in the policy environment towards removing structural constraints. In the synthetic fibres segment, the demand potential rose from 2.4 million tonne in 2006-07 to 5.8 million tonne by end of the 11th Five-Year Plan, with a CAGR of 8.5 per cent. These developments are likely to result in an investment potential of $8 billion (`40,000 crore) in upstream cracker complexes and polymer plants and about $6 billion (`30,000 crore) in downstream plastics processing sector. Investment potential in synthetic fibres and fibre intermediates is estimated at $4 billion (`20,000 crore) in the near future.

Gaining a competitive edge India caters to a diverse range of consumer demands by producing quality products at competitive prices. Today, the industry has the capability to compete with the best in the world. In the present global economic scenario, the Indian plastics industry attracts business entrepreneurs from across the world for meeting diverse requirements as well as setting up base in the country. The growth story along with progressive and entrepreneurfriendly government initiatives in this sector indicate Indiaâ&#x20AC;&#x2122;s stride towards becoming a developed country by 2020. The impetus from the economic growth in the last five years has provided tremendous opportunities for the future growth of the plastics industry and the Indian economy as a whole. Anup Patel is Director of Dollplast Machinery, Inc. Email: dollplast@dollplast.com

April 2011 | Modern Plastics & Polymers

TECHNOFOCUS

PVC compounding

Infusing strength to polymers Plastics manufacturers add a number of compounding ingredients to Polyvinylchloride (PVC) resins for imparting attributes such as strength and durability to plastics, and also keep them light in weight. This article, the first of a two-part series, highlights the role of two essential components - plasticisers and stabilisers - that are used in PVC formulation. Siddhartha Roy

olyvinylchloride (PVC) - a unique and widely used plastic worldwide - has diverse properties and finds use in various applications, eg, electric cables, upholstery, floor coverings, etc. PVC is produced by polymerisation of vinyl chloride monomer (VCM). As it has low thermal stability and high melt viscosity, PVC is combined with several additives having varied properties to suit different applications. Formulation of PVC requires proper compounding and good lubricant balance for obtaining desirable end product properties. This requires several essential ingredients â&#x20AC;&#x201C; plasticisers, stabilisers, lubricants, fillers, pigments, special additives, etc.

PVC resin PVC resin is categorised into four types on the basis of polymerisation method used. Suspension grade PVC: The most widely prevalent type, suspension grade PVC, is made by polymerising droplets of VCM suspended in water. When polymerisation is complete, the 74

Modern Plastics & Polymers | April 2011

slurry is centrifuged and the resulting PVC cake is gently dried by special heating systems so as not to subject the unstabilised resin to heat degradation. Resin particles have porous popcorn-like structures, which readily absorb plasticisers, and their size is in the range of 50-250 Âľm. The structure of PVC particles can be modified by selecting suitable suspending agents and polymerisation catalyst. Less porous types are extensively used for high-volume Rigid or Unplasticised PVC (UPVC) applications such as PVC pipes, windows, sidings and ductings. Suspension grade PVC of a coarser particle size and porous structures absorb large quantities of plasticiser, forming a dry blend at temperatures as low as 80Â°C. The more porous types are used in plasticised applications like cables, footwear, soft calendered sheeting and films. Emulsion grade PVC: This is similar to paste grade resin. It is used almost exclusively for plastisols. Paste grade resin is fine particle-sized PVC produced by spray-drying an emulsion of PVC in water. It requires more energy for production and is costlier than suspension resin.

TECHNOFOCUS

Paste grade resin contains emulsifying chemicals and catalysts. It is less pure than suspension polymerised or bulk polymerised PVC. The electrical properties of paste grade resin plastisols are poorer than suspension resin compounds. Its clarity is also poorer than that of suspension or bulk PVC. Paste grade resin is compact in structure, and does not absorb much plasticiser at room temperatures. But at temperatures in excess of 160-180oC during the curing process, it can absorb the plasticiser. Paste grade resin is extensively used for wide cushion vinyl floorings. Different layers of specially formulated pastes are coated either on a suitable substrate (direct coating) or on a release paper (transfer coating). The layers are fused continuously in long ovens and rolled up after stripping off the release paper. The rolled up good flooring has a tough semitransparent wear layer on top of printed and foamed layers over the filled base coats to build up thickness. Addition of these layers gives various attractive and rich effects, representing the higher end of vinyl flooring. Bulk polymerised PVC: Bulk polymerisation yields the purest form of PVC resin, as it does not require emulsifying or suspending agents. It is mainly used for transparent applications. It is available in lower K value (an indicator of the molecular weight and degree of polymerisation of resins) groups, as unplasticised PVC foils for blister packaging and other calendered/extruded transparent films are best processed from PVC of lower K value. Recent refinements in suspension resin technology have edged out bulk PVC. Copolymer PVC: Vinyl chloride is copolymerised with co-monomers like vinyl acetate, yielding a range of resins with unique properties. Most important of these is a copolymer of vinyl chloride and Vinyl Acetate (PVAc). The good solubility of PVAc in solvents makes it a prime choice for making vinyl printing inks and solvent cements. PVAc has

Compatibility of PVC with secondary plasticisers Compatibility limits, % of DOP

Secondary plasticiser

Chlorination level

CPWax

40%

0.40-0.50

CPWax

56% (near solid)

0.50-0.55

40%

35%

CPOil

42%

0.75

50-80%

40-70%

CPOil

56%

0.8

60-100%

50-60%

Plasticising efficiency

special applications in floor tiling and is the resin of choice for vinyl asbestos tiles. It actually functions as a binder rather than the main ingredient. In case of copolymer resin, it is possible to manufacture floor tiles with fillers like asbestos and calcium carbonate. These fillers account for as much as 84 per cent with the copolymer and as low as 16 per cent with other compounding additives. This is not possible with suspension resin, as its melt viscosity is higher and cannot coat and encapsulate such high levels of inert fillers. Special calendering trains are required for vinyl asbestos tiles. However, with asbestos falling out of favour, the use of these products has slowly died out. PVC has 56 per cent chlorine, and this gives it the selfextinguishing feature, as chlorine is a strong flame inhibitor.

Plasticisers Plasticisers are additives used to soften hard PVC resins. These increase the flexibility and durability of the end product. These are of two main types â&#x20AC;&#x201C; primary and secondary. Primary plasticisers: These have good compatibility with PVC resin and can be absorbed in large

Shore A (75-90)

Shore A (60-70)

35%

30%

quantities. In special cases, as much as 140-150 Parts Per Hundred Resin (PHR) of primary plasticiser can be gelated into PVC for obtaining super-soft products. Nearly all plasticisers are in liquid form and have to be absorbed in suspension resin in heated mixers. Highspeed mixers (that generate frictional heat while mixing) are the most popular type of dry blending equipment. Heated ribbon blenders and sigma mixers are used only when very high plasticiser levels are required. A vast array of primary plasticisers exists for PVC, the most popular being phthalate esters. Phthalic acid is reacted with various alcohols to manufacture a family of phthalate plasticisers, of which Dioctyl Pthalate (DOP) is the most popular one. Other important primary plasticisers include Dioctyl Adipatem (DOA) and Dioctyl Sebacate (DOS) (for low-temperature applications), trimellitates (for high-temperature applications) and polymeric plasticisers (high permanence). Purity is an extremely important requirement in plasticisers. Presence of even minute quantities of unreacted acid or alcohol reduces the efficiency of the plasticiser. Impure plasticisers have an unpleasant odour. Impurities

Number of carbon atoms in the alcohol decides the gradation of properties Alcohol

Carbon atoms

Plasticiser name

Gelation rate

Major usage

Butyl Octyl Iso-octyl

4 8 8

Dibutyl phthalate (DBP) Dioctyl phthalate (DOP) Di-iso-octyl phthalate (DIOP)

Fastest Standard Standard

Nonyl

Dinonyl phthalate (DNP)

Slower

Isodecyl

Di-isodecyl phthalate (DIDP)

Slowest

Fast fusing, cheaper Most popular Slightly cheaper than DOP Non-toxic applications; costlier Best heat ageing; costliest

April 2011 | Modern Plastics & Polymers

TECHNOFOCUS

Plasticising efficiencies of phthalates Plasticising Plasticiser name efficiency Dibutyl phthalate (DBP) 1.05 Dioctyl phthalate (DOP) 1.0 Di-iso-octyl phthalate (DIOP) 1.0 Dinonyl phthalate (DNP) 0.98 Di-isodecyl phthalate (DIDP) 0.95

also have an adverse effect on electrical properties of plasticisers. For a totally smell-free DOP, double distillation is used, though it increases costs. Blends of such plasticisers can also be used, but this can complicate the manufacturing process. In some cases, small amounts of Dibutyl Phthalate (DBP) have been used to promote processing. DBP tends to evaporate slowly with use, thereby stiffening the product and making it hard and brittle. This indicates that it has low permanency. The higher carbon atoms phthalates have better permanence. These do not volatilise easily at high temperatures. Also, fusing and gelation take longer with Dinonyl Phthalate (DNP) and Di-Isodecyl Phthalate (DIDP). Phthalate plasticisers are not fire resistant, causing flexible PVC products to be more flammable than unplasticised (rigid) ones. Flameresistant plasticisers are available, mainly phosphates, but these have to be imported. Other families of plasticisers impart special properties to resins, eg, low temperature, high permanence, non-migrating, continuous high temperature, smoke resistance, etc. Plasticising efficiency is an important concept in PVC formulation. Plasticising efficiency of DOP is set as 1. The plasticising efficiency of any other plasticiser is expressed as a ratio with DOP for producing a moulding of same softness (that of DOP). For example, if 50 PHR of DOP yields a shore hardness of 77, and 55 PHR of another plasticiser gives the same hardness, the plasticising efficiency of the plasticiser is calculated as: 50/55 Ă&#x2014; 100 or 0.91 (91 per cent). 76

Modern Plastics & Polymers | April 2011

Secondary plasticisers: Secondary plasticisers and extenders have limited compatibility. Their main purpose is to decrease costs. Some of the properties of these plasticisers have been improved, eg, fire retardance. The most common secondary plasticisers are chlorinated paraffins, eg, waxes or paraffin oils, and contain 40-60 per cent of chlorine level. Chlorinated Paraffin Waxes (CPW) are viscous and rarely used today. Chlorinated Paraffin Oil (CPO) is more popular, as its viscosity and plasticising efficiency are superior to those of CPW. The higher the chlorine content, the better the plasticising efficiency, though the viscosity also increases. Addition of CPO adversely affects gelation rates of resins. Also, their cost increases with rising chlorine levels. Special paraffin oil cuts are used as extenders, but are overshadowed by their chlorinated derivatives. Another important parameter is compatibility, which indicates the amount of secondary plasticisers that PVC can hold. If the amount added exceeds the compatibility limit, the secondary plasticiser will ooze out on the surface of the product during use. Secondary plasticisers are rarely used as sole plasticiser, except in semi-rigid applications. These are combined with primary plasticisers to achieve desired properties.

Stabilsers The PVC molecule is unstable to heat and light. Heating PVC causes breakage of polymer chains, liberating Hydrochloric Acid (HCl) gas in the process. HCl further catalyses degradation, which can make the degradation explosive, and thus release large quantities of corrosive HCl and other toxic gases. Exposure to Ultraviolet (UV) radiation also breaks up polymer chains, but this process is slower than heat degradation. Some of the stabilisers used widely in PVC formulation are heat and light stabilisers.

Heat stabilisers: For processing PVC, it has to be stabilised against heat at processing temperatures. A majority of stabilisers contain metal elements that react with HCl and inhibit further degradation of polymers, eg, metal salts, soaps or complexes. Heat stabilisers are an important ingredient second to plasticisers in a flexible PVC formulation. Light stabilisers: A number of mixed metal stabilisers also protect PVC from adverse effects of UV radiation. Among lead stabilisers, DBL phosphite has some UV resistance properties. However, the light stabilisation effect may need to be boosted in applications that are subject to outdoor exposure to harsh conditions. These light stabilisers are complex chemicals, eg, Hindered Amine Light Stabilisers (HALS), and are expensive (Rs 3,000-5,000/kg). These are effective at very low dosages (0.10.3 PHR), and so used only when absolutely necessary, due to the high cost factor. Epoxidised vegetable oils â&#x20AC;&#x201C; groundnut oil and soyabean oil â&#x20AC;&#x201C; are an important group under secondary plasticisers. Addition of these oils boosts the heat and light stability of a number of plastics. These oils are frequently used in combination with mixed metals for best results, and the process is commonly referred to as the synergistic effect. However, these plasticisers are more expensive than DOP. Strengthening the resins Addition of plasticisers and stabilisers to PVC resin infuses qualities such as durability and strength, thus making it one of the most versatile polymers in use today. Siddhartha Roy is well-versed in the processing of polyolefins, styrenics, polyamides and PC. A Chemical Engineer from IIT Kharagpur, he is a consultant at RoyPlasTech. Email: royplastech@rediffmail.com

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MANAGEMENT MANTRAS

Benchmarking for SMEs

Moving from ‘best’ practice to ‘next’ practice Benchmarking in an organisation identifies best practices for products and processes as well as areas that need improvement. Proper implementation of benchmarking exercise can help improve the performance of companies. This article explores the genesis, appropriateness and approach that companies, particularly small and medium enterprises, can incorporate for benchmarking processes and look beyond best practices. M Hariharan

n an intriguing instance related to benchmarking processes, a company expressed its perspective on water consumption habits in offices, on a message board displayed in its washroom. The message said: ‘The world best practice in water consumption is 3 litres per person per day. In our company we consume 8 litres per day per person.’ And the explanation given was: ‘This is a way to sensitise and motivate our people to reach the global standard.’ This is a classic case of misplaced benchmarking. A firm grasp of the genesis, the appropriateness and approach for benchmarking products and processes is a must for companies, especially Small and Medium Enterprises (SMEs).

Genesis of benchmarking The word benchmarking was first used by cobblers to mark foot dimensions on a bench. They grouped the footwear as a family of sizes. This practice led to standardisation of foot sizes. The groups of foot size are marked on a bench. When a customer walks in, his foot size can be compared to the benchmark and accordingly be served off the shelf. As a management process, the term ‘benchmarking’ was first used by the company Rank Xerox. In the early 1980s, competition in the copier industry had intensified. Players like Ricoh, Canon and Sevin were eating into the marketshare of Xerox. With a legacy of high costs (bad practices developed when the going was good) 78

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and comparatively poor products (bad practices developed in the absence of worthwhile competition) Xerox’s profitability and marketshare suffered a huge blow. In 1982, David Kearns took over as Chief Executive Officer (CEO) of Xerox. He brought into the company an external perspective, that the extremely low manufacturing cost for Japanese competitors (almost half of the costs at Xerox) was enabling them to set their prices so low. He embarked on a programme called ‘Leadership Through Quality’, in which benchmarking was one of the keystones. This programme helped Xerox move ahead with a positive result. In this example, Xerox did not compare with instances outside its market and product level, nor did it opt for a world standard. The company actually benchmarked the processes and not the output.

Instances of appropriateness of benchmarking Benchmarking does not mean comparing the results, but comparing the processes that yield the results. The purpose of benchmarking is to understand the best practices followed by the competitors and non-competitors as well as to modify and adapt one’s own practices to those best practices. Xerox follows the mantra: ‘The emphasis of benchmarking is on improving a given business operation or process by exploiting best practices, and not on best performance’. Benchmarking is appropriate when there is a clear understanding of the conditions for achieving a

MANAGEMENT MANTRAS

specific standard. It need not be from the same industry or a competitor. For example, Xerox benchmarked multiple areas of its businesses – Amex for billing and collection, Cummins for plant layout, Toyota for Quality Management, HP for New Product Development, DuPont for Safety and Fuji Xerox for manufacturing practices.

What can be benchmarked? At the strategic level, the understanding of how a company succeeded by following some core values and competencies can be benchmarked. At the product level, comparing with competitors’ products using Teardown Analysis can give an idea of the best practices. It can include benchmarking of specific processes for the organisations incorporating best practices. As a first step, comparisons among units within the company can help develop standardised work practice across the company.

Approach for SMEs Benchmarking need not be applicable only to large organisations. SMEs can also embark on benchmarking. This can work best for SMEs through four formats. Industrial area-specific benchmarking: Usually, SMEs focus on a specific industrial area [eg, Maharashtra Industrial Development Corporation (MIDC), Industrial & Technical Consultancy Organisation of Tamil Nadu Limited (ITCOT), etc]. Following approaches can be tried out in an industrial area. Industrial area elders: At the strategic level, one can approach a peer group best-performing company in order to understand how they run their business. Usually, ‘Industrial Elders’ are found in every industrial area. Approaching them for guidance and taking a cue from their experiences for one’s business is a plausible step. Interacting with an aim of sharing and improving one’s practices can be a sensible (though sensitive) first step. This is a sensitive issue, because there is always reluctance in sharing one’s problems and successes with other members of the association. Industrial area associations: At the functional level, benchmarking for best practices can be evolved through the association. For example, benchmarking is possible in the following areas: • HR functions: Because industries in the same area recruit people from the same locality peer group best practices for recruitment, employee growth, training, labour productivity, working conditions, labour welfare, labour law compliance and exit. • Accounting function: Best practices for book keeping, finalisation of accounts, bank compliance, audit compliance, etc. April 2011 | Modern Plastics & Polymers

MANAGEMENT MANTRAS

• Manufacturing operations- The next level is benchmarking with competitors in the same area. But benchmarking with those in other areas using similar processes can also be attempted. • Health, safety and environment practicesWith a common sewage system, water treatment and pollution control issues being in the same area, best practices here are viable as well. • Logistics- Engagement, tariff, turnaround time and reverse logistics practices can also be benchmarked. • Quality processes- Initiatives undertaken, Kaizen, Total Quality Management (TQM), Total Productive Maintenance (TPM) and Six Sigma Practices can also be benchmarked. The biggest gain from this exercise can be consolidation of these functions across companies, which can lower costs and improve the competitive edge versus other areas. Industry-specific associations: Industry-specific associations [(eg, Indian Machine Tool Manufacturers’ Association (IMTMA), Organization of Pharmaceutical Producers of India (OPPI), Automotive Component Manufacturers Association of India (ACMA)] and some others can play a big role in creating benchmarks across members. Database for best practices: Industry associations can create databases beyond the normal consolidation of sales, production and other financial numbers. Without 80

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mentioning the member companies’ names, it is possible to develop industry standards and actual performances. For example: • Cycle times- Manufacturing (process wise), order processing, loading and unloading, set-up & changeover times, product development as well as accounts and audit finalisation are some possible areas. • Operational parametersEnergy consumption, yield, rework, Mean Time To Repair (MTTR), Mean Time Between Failures (MTBF), downtime, labour turnover, inventory turns, debtor and creditor velocity. • Quality parameters- OEE for key operations, Six Sigma levels

Benchmarking does not mean comparing the results, but comparing the processes that yield the results. (PPM), number of customer complaints and input quality measures. Value chain cluster approach: Peer group visits for benchmarking is difficult, due to mutual mistrust prevailing in most industries. For overcoming this, one approach is to select companies in the value chain (one company represents each link). For example, a forging company, a casting company, a machining company, an assembler, a packer in the same industry can be clustered to develop internal benchmarks. • Cluster approach: Industry bodies such as Confederation of Indian Industry (CII), Federation of Indian Chambers of Commerce & Industry (FICCI) and Associated Chambers of Commerce and Industry of India (ASSOCHAM) have created clusters that

include companies from different industries. These industry bodies undertake quality initiatives and best practices in the management across various companies within an industry. The Government of India encourages cluster formation to promote initiatives like lean manufacturing. These clusters can develop benchmarks within themselves, and share across various clusters. • Developing next practices: This seems to be the best approach an SME can undertake without depending on industrial area peers, industry peers and industry bodies. Best practice need not be appropriate for an individual unit, given its own hurdles and limitations. One should try developing one’s own ‘Next Practices’ that are appropriate and implementable. For this, one should believe that there is always scope for improvement in all processes. One should thus look for incremental improvement initiatives as well as breakthrough ideas to be implemented.

A matter of common sense Benchmarking is a process that requires common sense, but it is always uncommon. As in any other initiative, if one fails to articulate the objective of the exercise, the processes will be rudderless. Searching for data across the globe for benchmarking will not lead anywhere. And people will end up only looking towards achieving inappropriate benchmarking goals. Thus, one can follow the famous quote: Find the purpose, the means will follow. M Hariharan practises consultancy in the field of cost management, lean thinking, constraint management, management control system and business excellence as Founder Director at Savoir Faire Management Services. Email: sfgroup@vsnl.com

EVENTS CALENDAR

National Ahmedabad Gujarat Oct 14-17, 2011 Gujarat University Exhibition Hall

Pune

Maharashtra Nov 18-21, 2011 Auto Cluster Exhibition Centre, Pimpri-Chinchwad

Chennai

Tamil Nadu Dec 2011 Chennai Trade Centre, Nandambakkam

Indore

Madhya Pradesh Jan 6-9, 2012 Poddar Plaza, Nr Gandhi Hall

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details contact: Infomedia 18 Ltd, Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in

Petrochemical Conference on Engineering Plastics

With India becoming an automotive hub, demand for engineering plastics is expected to rise globally, driven by the ongoing replacement of metal parts with ABS, polycarbonate and nylon. This conference will highlight trends and opportunities in motor vehicles, medical products and construction through largest volume types and leading gains from polycarbonate; April 14, 2011; Hyatt Regency, Mumbai For details contact: Heital Yaagnik Polymerupdate.com 344, A–Z Industrial Estate, G K Marg, Lower Parel, Mumbai – 400013 Tel: +91-22-30408821/25 Fax: +91-22-30408826 Email: conferences@polymerupdate.com Website: www.pgpc.co.in

Automotive Plastics India 2011

This conference will be an exclusive chance to learn about new materials, novel processing techniques and manufacturing techniques, unique & latest emerging technologies, market dynamics and new business guidelines for automotive plastics. It will enhance networking opportunities with several professionals, key decision-makers, industry experts, business executives and leading professionals from the OEMs; April 29, 2011; The Lalit, Mumbai For details contact: Cerebral Business Research Pvt Ltd G-80, Lower Ground Floor Lajpat Nagar-1, New Delhi – 110024 Tel: 011 3190 9988/3190 9977

Modern Plastics & Polymers | April 2011

Fax: 011 2982 0180 E-mail: info@cerebralbusiness.com Website:www.cerebralbusiness.com/ autoplast2011

Plastex Caspian

This is an international trade exhibition for raw materials, equipment, plastics & rubber production and processing technologies. This is the first edition of the show; May 25-27, 2011; at the International Exhibition Centre, Pune For details contact: GiMA International Exhibition Group GmbH Mathias Lauk, CEO Lübeck Str 128, D-22087 Hamburg Tel: +49 (0)40 2 35 24-0 Fax: +49 (0)40 2 35 24-400 E-mail: info@gima.de Website: www.gima.de

Eastern Plastic & Rubber Expo

This exhibition is expected to be a platform for modern machinery, materials and accessories segments, and to understand their need and demands. The four-day international exhibition will showcase the entire spectrum of products, latest trends, technology, equipment and services in its chosen sector; June 16-19, 2011; at TBA, Kolkata For details contact: Nayan Dhayani, Director D-43 Clover Centre, 7- Moledina Road Camp, Pune Tel: 020 40068318/32911450 Mob: 09371025233, Fax: 020 26054870 E-mail: info@vnbindia.com Website: www.vnbindia.com

PET+Drink TECH ASIA 2011

The fifth edition of this international exhibition and seminar will showcase the entire spectrum of products, latest trends, technology, equipment and services in PET, drinks and liquid processing, filling & packaging related sector; August 27-29, 2011; at Milan Mela Exhibition Centre, Kolkata For details contact: SK Bhardwaj Scf 172-A, First Floor Grain Market Sector-26, Chandigarh Tel: 0172 2795067 Mob: 09216129027 E-mail: kesarimedia@yahoo.co.in/ kesarimedia@gmail.com Website: www.kesarimedia.com

CONVEXPO

This exhibition is dedicated to the converting and printing industry, with applications of paper and plastics in packaging. Leading exhibits at this event will be plastic films, packaging & printing machinery, tapes/ plastic pallets, warehousing equipment, bag making machinery; material handling equipment, November 23-27, 2011; at University Grounds, Ahmedabad For details contact: B Swaminathan Smart Expos T-6, Agarwal Court - K G Plaza 41-44, General Patters Road, Chennai Tel: 044-28603086, Fax: 044-28604261 Mob: 09789095247 Email: info@smartexpos.in Website: www.smartexpos.in

EVENTS CALENDAR

International Polymers in Photovoltaics 2011 This conference will bring together top materials experts and module component manufacturers to discuss the best materials and manufacturing technologies for the solar industry. It is an opportunity to network with professionals who work with and produce photovoltaic systems worldwide; April 12-14, 2011; at Maritim Hotel, Cologne, Germany

For details contact: Lillian Tse Adsale Exhibition Services Limited 6th Floor, 321 Java Road, North Point, Hong Kong Tel: (852) 2516 3374, Fax: (852) 2516 5024 Email: publicity@adsale.com.hk Website: www.chinaplasonline.com

PLASTPOL 2011

For details contact: Dr Sally Humphreys Business Development Manager Applied Market Information Ltd AMI House, 45-47 Stokes Croft Bristol, United Kingdom Tel: +44 117 924 9442 Fax: +44 (0) 117 311 1534 Email: sh@amiplastics.com Website: www2.amiplastics.com

Dedicated to the plastics industry in Poland, this exhibition features almost all products used in and related to the plastics processing industry – from production to disposal and recycling. Among the exhibits will be plastics processing machines, moulds and tools, components, recycling technologies and IT systems applied in plastics processing; May 24-27, 2011; at Kielce fairground, Kielce, Poland

Bangla Plast 2011

For details contact: Kamil Perz Targi Kielce, Zakladowa 1 25-672 Kielce, Poland Tel: +48 41 365 12 30, Fax: +48 41 345 62 61 E-mail: perz.k@targikielce.pl/ plastpol@targikielce.pl Website: www.targikielce.pl

This international fair seeks to explore the latest inventions & research for the plastics industry. It will enable entrepreneurs in the Indian subcontinent to consolidate and strengthen their business opportunities globally; April 20-23, 2011; at Bangabandhu International Conference Centre, Dhaka, Bangladesh For details contact: KMG Business Technology Ahmedabad Gujarat, India Tel: 079 26851511/079 3241 0602 Fax: +91 79 2685 1716 Email: info@kmgindia.com Website: www.kmgindia.com

CHINAPLAS 2011 The largest plastics and rubber trade fair in Asia, CHINAPLAS has evolved as an ideal business partner of the region’s surging speciality polymers industry. CHINAPLAS will serve as a platform to network with all the application sectors like automotives, construction, electrical & electronics, etc, May 17-20, 2011; at the China Import & Export Fair Pazhou Complex, Guangzhou, PR China

PLASTEC East This conference will witness the latest developments, technologies, products and services affecting the industry, including primary processing machinery, computer-aided design and manufacturing, production machinery, materials, moulds & mould components, automation technology, materials handling and logistics; June 6-9, 2011; at Jacob Javits Convention Centre, New York For details contact: UBM Canon 11444 W Olympic Boulevard Los Angeles, California 90064-1549 Tel: 310/445-4200 Fax: 310/996-9499 Email: pleinfo@ubm.com Website: www.plastecheast.com

InterPlas Thailand 2011 This will be the 20th edition of Thailand’s leading plastics & rubber manufacturing machinery and technologies conference. Apart from showcasing the ASEAN region’s key plastics processing technologies, the show will feature business activities and industrial conferences focussed on latest trends and know-how. This will help all visitors to further expand their horizons and synergise with industrial networks; June 23-26, 2011; at Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand For details contact: Reed Tradex Company 32nd floor, Sathorn Nakorn Tower 100/68-69 North Sathon Road, Silom Bangkok-10500 Thailand Tel: +66 2686-7299 Fax: +66 2686-7288 E-mail: rtdx@reedtradex.co.th Website: www.reedtradex.com

Interplas 2011 This international event is aimed at showcasing the European polymer industry. It will feature the latest machinery & equipment for processing and converting polymers; September 27-29, 2011; at NEC, Birmingham, United Kingdom For details contact: Jenna Reid Plastics Multimedia Communications Ltd Unit 2, Chowley Oak Lane Tattenhall Cheshire United Kingdom Tel: +44 (0) 1829 770037 Fax: +44 (0) 1829 770047 Email: jenna@rapidnews.com Website: www.britishplasticsshow.com The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Business Insights •Technologies•Opportunities

April 2011 | Modern Plastics & Polymers

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Engineering Expo Chennai 2011

Channelising knowledge, building brands Keeping pace with the giant strides of the manufacturing sector in Tamil Nadu, the third edition of Engineering Expo Chennai created an aura for promoting interaction between various stakeholders in the industry. With technology and innovations as its core strengths, the Expo offered better commercial prospects for exhibitors and visitors alike. Annabel Dsouza

here is no denying that entrepreneurship and initiatives are integral to industrial success of companies as well as the entire trade ecosystem of a region. Facilitating this culture of business expansion through technological advancements, the third edition of Engineering Expo Chennai was held from March 11-13, 2011, at the Chennai Trade Centre, Nandambakkam. During the three days of intense networking, the city’s burgeoning engineering industry received a further impetus in terms of information upgradation as well as profitable partnerships. The event was marked by the presence of V Arumugam, Zonal GM-South I & III, National Small Industries Corporation Ltd (NSICL); R

Selvaraj, President, Ambattur Industrial Estate Manufacturers’ Association (AIEMA); and Sunil Kaul, Senior GM, Power Transmission Division, Fenner India Ltd; as Guests of Honour. The esteemed guests highlighted Chennai’s emergence as a manufacturing hub and sourcing base for India’s auto industry. Further, they emphasised on the pivotal role played by trade shows and exhibitions in supporting entrepreneurship in the region. Awareness and expertise go a long way in constructing the right environment for competitive businesses. As the global economic scenario converges to become more inclusive, local players have to compete with products and services in the international market for harnessing export demand. Selvaraj said, “Chennai is bestowed with abundant technical knowledge and skill sets.

The educational initiatives of the State have yielded good results in tapping the vast human capital in the region. However, industry collaboration is the need of the hour at student and professional level.” He further added, “Besides commercial gains, trade fairs offer entrepreneurs an opportunity to grasp technical developments and convert them into profitable business ventures.”

The knowledge factor

This year’s edition of Expo performed exceptionally well in terms of business generation and networking prospects. Around 80,000 kg of machinery was displayed at the event while business leads worth ` 39.34 crore were generated. However, the key highlights were the knowledge and technology sharing offered by the 200 plus exhibitors at the event.

Chennai charms…

Engrossed

serving visitors ob

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y at its be

technolog

The city is emerging as a major player in the auto components and ancillaries industry. Its strategic location as a seaport city is reinforcing its status as a leading sourcing hub for most brands in the engineering industry. An abundance of skilled workforce and thriving economic culture attract industries to this city. With many large and small players from all spheres of the engineering world competing for market space, innovative technology and value-added services are going to be the key determining factors for success. Sunil Kaul, Senior GM, Power Transmission Division, Fenner India Ltd, asserted, “The Indian engineering industry is poised to grow immensely. As markets expand and demand increases, we look at competitors as partners in progress. There is plenty of scope for upgrading existing product portfolios, and companies should benchmark their products against international standards and not restrict themselves to local competition.”

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(L-R): Guests of Honour Sunil Kaul, Senior GM, Power Transmission Division, Fenner India Ltd; R Selvaraj, President, Ambattur Industrial Estate Manufacturers’ Association; and V Arumugam, Zonal GM-South I & III, National Small Industries Corporation Ltd at the inaugural function

As the famous adage goes, one cannot deliver today’s solutions with yesterday’s technology and expect to be in business tomorrow. Similarly, adopting the latest available technology in the market fosters a large number of start-ups and Small and Medium Enterprise (SME) initiatives. This is the most critical aspect of a self-sustaining economy. As Chennai emerges into mainstream auto components manufacturing, every effort is being made by the State Government to promote and support entrepreneurship. Arumugam said, “SMEs generate over 40 per cent of employment. Their share in the export market is more than 9 per cent. To further encourage SMEs’ excellence, there is a credit rating based on faster delivery with value-added services. Benefits are also extended towards sponsoring and promoting participation at international trade fairs.”

Business latitude

All successful businesses understand the crucial role played by exhibitions

and conferences in fostering opportunities. Engineering Expo has always been a platform for branding and interacting with suppliers, OEMs, auxiliary service providers and endusers. Competitive acumen is another advantage offered by this Expo, which not only facilitates sales and marketing, but also supports decision makers in formulating future strategies. Kaul stated, “Engineering Expo offers a good opportunity for companies to share knowledge and expertise on processes & innovations. It promotes partnerships between industries and their ancillaries, which in turn plays a crucial role in technology transfer and R&D. Exhibitions and trade shows enable companies to collaborate with each other in seeking new opportunities and providing a learning curve on cost compression, quality circle, service improvement, energyefficiency, etc. The Expo assures tremendous benefits for the parties involved and the industry at large.” Besides strengthening brands, this edition of Engineering Expo Chennai also witnessed companies building

strong networks and collaborations. Suresh C K, General Manager Marketing, Surya Automotive & Plastics, said, “From a business perspective, this exhibition has enabled us to tap the enormous potential within the industry. Our products and services have evinced interests among our target audience. Moreover, at this exhibition, we received valuable feedback that helped us identify areas in and around Chennai where there is demand for our products.”

On an optimistic note

Like its previous editions, this Expo redefined its benchmark of success. Reiterating the importance of the event to give a boost to the industrial scenario of Chennai, Kaul added, “The worth of a trade show in the league of Engineering Expo cannot be estimated only from a profit-gaining perspective. Although immediate business gains are important, one should look at the larger perspective in terms of industry awareness, key strengths and overall brand building.” The Chennai Expo seemed to be a perfect culmination of the enterprising spirit of Engineering Expo as it brings down the curtains on this season. India’s engineering industry earnestly awaits the next season, with renewed vigour and enhanced prospects as the Expo returns to Chennai in December 2011.

Mission SME

V Arumugam, Zonal GM-South I & III, National Small Industries Corporation Ltd (NSICL), said, “The technologies and solutions offered by local ancillaries in Tamil Nadu certainly meet international standards of quality and efficiency. Exhibitions like Engineering Expo allow companies to showcase their products effectively, while also garnering sales and revenues.” He further added, “We at NSICL do our best to encourage participation at trade shows, both at the national as well as international level. These expos also serve as a platform for awareness and exposure of innovative technology in the market.” India’s automobile industry consists of some of the A panoram ic view of world’s leading brands like Ford, Royal Enfield, Mitsubishi, pulsating business a Volkswagen, among others. In this context, Arumugam stated, “In terms of t the Expo outsourcing, Multinational Companies (MNCs) cannot manufacture all components, and outsourcing is integral to their operations. Here, SMEs play an important role in MNC establishment in the State. SMEs help the region to become a major sourcing destination.” Modern Plastics & Polymers | April 2011

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Total number of visitors: 15,550+

First-time exhibitors

Exhibitorsâ&#x20AC;&#x2122; insights

Rajul Gandhi, Director, Seion Watertech Pvt Ltd Chennai is a crucial market for our industry. However, there is a dearth of high-end solutions, and this exhibition has helped us reach out to local clients. We experianced considerable demand for our state-of-the-art products. This was evident from the impressive visitor turnout at the Engineering Expo and we have generated enquiries worth ` 1.5 crore.

Falgun Pandya, MD, Saimona Air-Mech Pvt Ltd We sold five machines during the first two days. This alone speaks for the market demand and the role of this exhibition in facilitating business. Besides, we look at trade shows like this as opportunities for interacting with our vendors, suppliers, distributors, etc. Such events enable us to boost our brand image and promote our products significantly.

Anand Kannan, VP- Marketing, Powerica Ltd I am quite satisfied with the quality and visitor turnout. Given that our technology has a unique edge in efficiency and pricing, we hope to leverage the enquiries and generate business. In terms of brand building as well, I would rate this Expo on the higher side.

Vipin Shah, Director, Electroweld Automations India Pvt Ltd Automation is critical to any engineering industry and we see tremendous potential for our products and services in Chennai. This edition of Engineering Expo has been successful in attracting the best companies from the industry, which in turn helped us in networking and building collaborations.

Bony Paul, MD - India & GCC Region, Trelleborg Sealing Solutions This exhibition has been a good experience in strengthening our business in Chennai. The visitor turnout and their interests in our solutions were quite encouraging. We were able to achieve our aim of brand building. C Kumarakrishnan, Assistant Manager Sales, Pepperl+Fuchs (India) Pvt Ltd The response that we received at this expo was heartening. Among the visitors, many were students, who were keen on exploring our world-class solutions. However, in terms of business prospects we will be utilising the key contacts generated at this Expo for future sales and revenue.

4,532

Total business leads generated

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Ganesh Parthasarthy, CEO, Tussor Machine Tools India Pvt Ltd Our CNC solutions were well-received in the market for its high precision delivery as well as rough handling capacity. At this exhibition, we were able to leverage on our strong pricing advantage and also promote our brand among target visitors. Pavandeep Singh, Managing Partner, Engineering Hindustan The scale of this exhibition has grown manifold over the years, and we are glad to have participated this time as well. The quality of visitors has been quite satisfactory and we have received good feedback from potential clients. We hope to convert these into profitable partnerships in future.

80,000 kg

Total machin ery movement a t the venue

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Total number of exhibitors: 200+

Total business generated: ` 39.34 crore

Innovative edge

Visionary visitors

Rajul Gandhi, Director, Seion Watertech Pvt Ltd Our industrial reverse osmosis solutions bring down the TDS count to 2,000 ppm. This portable water technology is ideally suitable for industries in Chennai. The saline water available in this region is not feasible for processing purposes. This technology has wide-scale applications in the pharmaceuticals, tanneries, electronics sectors, etc.

Vinod Kumar, Branch Manager, Wilson Sandhu Logistics India Ltd An exhibition with large participation from the SME sector is important for my company. Being from the logistics industry, I was glad to interact with several companies having large-scale import-export operations. This has also been a great knowledge gaining experience and I hope to follow-up with the leads generated here.

R J Subramanian, Deputy GM, Power Transmission Division, Fenner India Ltd The PowerTran belts are designed for heavy-duty applications in agriculture, mining, construction, etc. It offers power savings up to 40 per cent and also reduces drive cost. It is almost maintenance-free, with optimum tension throughout service life. Ameer Munaff, CEO, Fein Power Tools The powerful belt sander has been developed for machining welded seams on pipes and can be used to precisely smooth corners, edges, profiles and deburr sheetmetal. The tool features a header, which can be swivelled 1800, allowing for flexible and comfortable use even in complex applications. Sriram Subramonian, Country Manager, Boge Compressors (India) Pvt Ltd The C Series compressor has been launched recently in the Asian market. It is unique because 70 per cent of its components like pipes and connections have been reduced into a manifold block, making it compact and user-friendly.

78%

appy Exhibitors h of with quality visitors

P Samba Murthy, Partner, Vimal Industries The construction and infrastructure market in Chennai is on the upswing, and such exhibitions bring to the fore the latest materials and machinery of world-class standards. I was able to source some ventilators for my construction business. Besides, I have also observed that products and services available here have a major price advantage, due to the intensely competitive environment, which promotes excellence. Mark Wei, Senior Business Manager, System Integration Outsourcing CEG, Huawei Technologies Company Ltd I am often on the look-out for electronic component suppliers for the telecom industry. I observed a large number of machine manufacturers and few from the electrical segment at the Expo. I met some potential suppliers and look forward to more exhibitions like this with international participation.

83%

Exhibito rs found Enginee ring Exp o better th an other trade ev ents in Chenna i

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TECHNOLOGY TRANSFER

Technology Offered As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Conversion of batch-poly plant to C P plant A company from China is interested in providing consultancy for the modification of batch-poly plant to C P plant like polyester plant, polyester chip or direct spinning. Areas of application Chemical fibre and plastics Forms of transfer Turnkey

Plastic recycling technologies using organic and inorganic compounds An Iranian company offers plastic recycling technologies using organic and inorganic compounds. This idea is based on the principle of water electrolysis in which sodium chloride is kept in proximity of turpentine/pine oil and plastics. Areas of application Plastic recycling Forms of transfer Others

Plastic recycling technologies An Iranian company is willing to provide plastic recycling technologies using urea and ammonium carbonate and synthetic ammonia. Areas of application Plastic recycling

Forms of transfer Technology licensing

Polyester chip plant A company from China offers polyester production plant, polycondensation plant, polymerisation line, hot-melt adhesive plant (500-5,000 tpa), polyester chip plant (2,000-1,50,000 tpa) and film grade polyester plant (2,000-1,50,000 tpa). Areas of application Polymerisation and fibre lines Forms of transfer Technology licensing and turnkey

Pilot plants for small-scale production An Indian company offers pilot plants for laboratory or small-scale production purpose. The plant consists of a spinneret, metering pump, spinning beam, candle filter, extruder unit, godet unit, PP multifilament plant manufacturer, singlescrew extruder machine or melt flow index tester machine for masterbatch industries. Areas of application Plastics, textiles, etc Forms of transfer Sub-contracting, turnkey, etc

Rotational moulding of plastics A manufacturer of rotational moulding

machines from India offers plant and machinery for constructing water storage tanks and other hollow plastic parts. Areas of application Chemical storage tanks, water storage tanks, material handling trolleys, pallets, containers, etc Forms of transfer Others

Recycling of PET wastes into polyester polyols A Czech Republican company is offering the technology for recycling of PET wastes (plastic PET bottles, X-ray films, etc) to produce polyester polyols. The process consists of the following steps: Collection of PET wastes, sorting out & shredding of collected PET wastes, simple chemical process of glycolysis & esterification and production of polyester polyols. Areas of application Chemicals industry: Polyester polyol is a base material for the chemistry of polyurethanes, especially production of polyurethane foams, which are primarily transferred into energy saving and insulating materials Forms of transfer Technology licensing, others

Share Your Technology Propositions The mission of Modern Plastics and Polymers is to spread the technology culture. We offer you an opportunity to participate in this endeavour by publishing the best technology ideas. Technology developers/sellers are invited to furnish the techno-commercial details (with environmental benefits, if any) for publication in the Technology Transfer column of Modern Plastics and Polymers. R&D organisations, technical consultancy organisations and individuals assisting small and medium enterprises send the relevant literature, indicating the scope & services and the areas of specification. Contact: Modern Plastics and Polymers Infomedia 18 Ltd, â&#x20AC;&#x2DC;Aâ&#x20AC;&#x2122; Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022-3024 5000 l Fax: 022-3003 4499 l Email: spedit@infomedia18.in

Modern Plastics & Polymers | April 2011

TECHNOLOGY TRANSFER

Technology Requested Disposal and recycling of plastics waste A Polish firm seeks the technology for dry processing of all kinds of plastic waste or a magnetic processing method in the electrostatic field. The technology should allow sorting of all kinds of plastic materials, hay-silage foils, PET, HDPE, PVC, etc, by excluding dangerous waste. Specific technical requirements include initial cleaning without the use of water, sorting of all kinds of plastic materials after cleaning in a closed system, and a maximum processing capacity of 10,000 tonne of waste per annum. Areas of application Plastics industry, waste recycling, waste management Forms of transfer Others

Lab-scale non-woven and monofilament plant An Indian company is looking for a labscale, non-woven and monofilament plant in a single station. Areas of application Plastics Forms of transfer Others

Plastics recycling technologies A Sri Lankan company is seeking the latest plastics recycling technologies, especially for automatic sorting, washing, metal detection, granulation process system, washing plants, crushers, extruders, etc. Areas of application Plastics recycling Forms of transfer Others

Polyacetal resins A Gulf-based organisation wants to promote projects in the chemicals and petrochemicals sectors in GCC countries. It is looking for technology suppliers for the manufacture of polyacetal resins. Areas of application Chemicals/petrochemicals industry Forms of transfer Feasibility study, know-how, equipment, turnkey plant, joint venture

PP/PET strap processing An Indian company is seeking the technology for PP and PET strap processing. Areas of application Packaging industry Forms of transfer Others

Recycled PET polyester polyols plant A Poland-based company specialising in recycled PET polyester polyols manufacturing, is looking for an alternative proposal of design and engineering of bigger (approximately 25 ktpa) production plant. It plans to start with proper quality recycled PET flakes being delivered in big bags. Hence, the company needs a complete package offer for this service. Areas of application Plastics and polymers industry Forms of transfer Others

Recycled plastic-making technology A company based in Vietnam is seeking the technology to recycle plastics.

The diameters of recycled plastic granules should range from 120 to 200 mm, while the capacity of the production should range from 150 to 300 kg/hr. Areas of application Raw materials for making plastic products Forms of transfer Others

Road filling materials for road maintenance An Indian company requires the technology to make materials by transforming waste plastics that gels uniformly with road materials. This is for filling potholes in roads. It also needs the know-how regarding products that are made from waste plastics like jumble strips, speed breakers, etc. Areas of application Road transport Forms of transfer Others

Utilisation of natural rubber in asphalt A Pakistan-based company needs knowhow regarding utilisation of natural rubber in modified asphalt covering. It needs the following information: Standards and specifications guiding the use of natural rubber in modified asphalt; appropriate proportion of natural rubber in mixture & handling of the operation; additives needed; and details of improvement in the asphalt properties by using natural rubber. Areas of application Rubber industry Forms of transfer Others

Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations Asian and Pacific Centre for Transfer of Technology (APCTT), APCTT Building , C-2, Qutab Institutional Area, New Delhi 110 016 Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: krishnan@apctt.org, Website: www.apctt.org

For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.

Modern Plastics & Polymers | April 2011

BOOK SHELF

Designing with Plastics Author Price

: Gunter Erhard : `8,315

Injection Molding Handbook Authors : Tim A Osswald, Lin-Sheng Turng and Paul Gramann Price : `10,235

This book is an indispensable reference material for every engineer and designer working with plastic materials. It will assist in developing plastic parts that are not only functional and aesthetically pleasing, but also manufacturable, while also meeting the ever-increasing end-use requirements. The short but concise introduction into specific properties of this class of material focusses on the practical needs of the designer and lays the foundation for the following in-depth discussion of part design suitable for production and intended end-use application. Also, numerous detailed examples highlight practical tips and rules of thumb for successful part design. Although component design is complex, following a few fundamental principles will help minimise problems during injection moulding and in part performance. In some instances it may not be possible to incorporate or follow all the suggested advice but the guidelines should increase one’s understanding of designing with thermoplastics. This book reveals basic information required by personnel in the plastics field while designing various plastic components. It has many examples and illustrations of real-life applications instead of endless derivations of equations. It is a very useful, well structured, easy-to-follow guide that will help the user improve the design and knowledge of polymer-related products.

The handbook serves as an introductory textbook for students to get acquainted with the injection moulding process. It presents a thorough, up-to-date view of injection moulding processing equipment and techniques, with related fundamental information on chemistry, physics, material science and process engineering. This handbook was written to serve engineers, professionals and others involved with this important industry sector. It not only covers the injection moulding machine and process, but also includes the topics that directly affect the injection moulding process, such as materials, process control, simulation, design and troubleshooting. The handbook presents a well-rounded overview of the underlying theory and physics that control the various injection moulding processes without losing the practical flavour that governs the manuscript between its covers. The carefully chosen set of authors includes experts in the field, practitioners and researchers in both industry and academia. The Injection Molding Handbook provides essential information in chapters that are organised to present a methodology for injection moulding. It examines considerable technological advancements, especially those in computer methods, which have been made since the classic second edition was published. Anyone involved in injection moulding – directly or indirectly, technical or non-technical – will find the Injection Molding Handbook an indispensable resource.

Avaliable at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958 • Telefax: 022-2203 4058 • Email: thadam@vsnl.com

Modern Plastics & Polymers | April 2011

MPP Apr _2011_Tab 3_Alok PG_67 MPP Apr _2011_Tab 3_Alok PG_67

MPP Apr _2011_Tab 3_Plovan PG_68 MPP Apr _2011_Tab 3_Plovan PG_68

PRODUCT UPDATE

PVC pipe extrusion unit

Oven Dryer

Malik Engineers offer rigid Polyvinyl chloride (PVC) pipe extrusion units for producing pipes for water supply, irrigation and electrical conduits. The unit includes a single screw extruder fitted with die for PVC pipe, vacuum tank fitted with sizer, water tank, caterpiller take-off, motorised cutting device and seperate control panel for complete machine. The extruder is fitted with nitrided and hard chrome-plated screw & barrel set, DC main drive, gear box, pulleys, heaters, die, etc. In operation, the PVC dry blend compound is fed into the extruder, where it is heated, melted and forced out of the annular die in the form of hot hollow pipe. This passes through vacuum sizing chamber for proper size as per the OD of pipe desired, and then through the water tank where the pipe is cooled. The pipe thus produced is passed through caterpiller unit, which maintains the pipe straight as it passes through the line, and finally through the cutter where desired lengths are cut. The control panel is fitted with controls for the DC motors of extruder, caterpiller and precision electronic solid state controllers for accurate control of the process temperature and safety devices.These machines are manufactured in screw sizes of 40 mm, 45 mm, 50 mm, 65 mm, 75 mm and 90 mm.

Yann Bang Electrical Machinery offers oven dryer. It is mainly used for drying of plastic resin, and also in various testing usage. It avoids the trouble of changing and cleaning materials, and saves time. Its powerful, heated air flow system and unique air circuit are designed for even temperature control and the best baking quality. The stainless trays can be used to dry different types of resins. Also the hot air recycling system is durable and energy saving. The oven dryer can dry electric motor and part, pharmaceutical products, paint, printing, agricultural and food material (grain, garlic, tea, etc).

Malik Engineers Thane - Maharashtra Tel: 0250-239 0839, Fax: 022-2883 0751 Email: info@malikengg.com

Proximity switch Katlax Enterprises’ Sensors and Field Devices Group (SFDG) offers magnetic proximity & capacitive proximity, optical sensors and switches, special sensors for textile and other applications, with different shapes to suite applications. If one wants to improve automatic control system, then one should make improvements in sensing technology. All progress observed are mainly due to improvements made in sensors or such devices, which provide inputs for control. Final control in all cases depends on the quality of vital inputs that are provided by first-level sensors and such devices. Katlax Enterprises Pvt Ltd Gandhinagar - Gujarat Tel: 02764-286784, Fax: 02764–28679 Mob: 09724506614 Email: info@katlax.com 96

Modern Plastics & Polymers | April 2011

Yann Bang Electrical Machinery Co Ltd Taichung - Taiwan Tel: +886-4-2271 6999, Fax: +886-4-2271 1988 Email: yb@yannbang.com

Lab extruder Neoplast Engineering offers fully instrumented single-screw & twin-screw laboratory extruders with integrated data acquisition PLC. This machine can be attached to various downstream equipment for carrying out a variety of tests like extrudability of polymers, studying the problems occurring in R&D as well as in practical applications. It is provided with manifold screws, die heads and downstream equipment to fulfil all kinds of extrusion tasks. The sample material is plastified under practice-oriented conditions and extruded through die-head. All measuring values such as torque, melt pressure, and melt temperature are recorded continuously and represented in the form of tables and graphs parallel to the running test. The extruder frame is mounted on four caster wheels with level screw arrangement for fixing it rigidly on the floor. The main motor with AC variable frequency drive and detachable keyboard are fitted with this extruder. For attaching various tools, the barrel flange is provided with hinge-type arrangement for its quick opening, dismantling and screw cleaning. Since the maximum output is just 5 kg/hr, it prevents wastage of expensive material under testing. The maximum processing temperature is up to 40°C, which can be controlled by auto tune type and dual display PID temperature controllers. Neoplast Engineering Pvt Ltd Ahmedabad - Gujarat Tel: 079-2583 0602/1185, Fax: 079-2583 5298 Email: info@neoplastindia.com

PRODUCT UPDATE

Co-extrusion blow moulding machine

Single screw extruder

Full Shine offers co-extrusion blow moulding machinery for combining different material in one parison for saving cost, energy and protecting the environment. The machine has specially designed co-extrusion die head to combine up to six different materials, incorporating highly efficient melting screws, linear function for swift and steady production, auto lubrication system, auto conveyer system and parison control. The die head for multi-layer co-extrusion ensures quality melting material of non-scorch and best combination. Full Shine is capable of making up to six-layer co-extrusion technology. The blow pin unit and deflashing unit have innovative designs for perfect neck and bottom deflashing. Adjustable extruder is for easy mould changing and alignment. All equipment are made in accordance with CE standards and ISO 9001 quality control. Co-extrusion bottles and products are used in agricultural containers, chemical containers, auto parts, long-storage food packages, cosmetic containers, recycled material re-use, etc. Co-extrusion blow moulding technology is the new trend worldwide for moulding various products.

Malik Engineers offers single screw extruder with equipment & dies for producing high-density foam sheet from Low-Density Polyethylene (LDPE) with typical density of 0.25-0.4 gm/ cc. This is manufactured with Physical Blowing Agent (PBA) injection into molten polyethylene, in the specially designed extruder by means of highpressure metering pumps. The LDPE granules are cold fed to the extruder, premixed with required additives, except the foaming gas. The screw rotating inside a heated barrel transports the compound towards the die. The compound melts, and at the appropriate stage in the barrel, PBA viz. CO2 is continually injected at high pressure through metering pumps. The gas-laden melt is continuously transported forward and it exits through a rectangular slit die at the exit end of the extruder. Due to the release of pressure as the product emerges from the die, the entrapped gas from the gas-laden mass expands the product, and the foamed sheet passes over the chill roller set with chilled water circulation to cool the product. The latter then continues to pass over the idlers to cool down to a safe temperature before being wound on the winder as rolls. The machine is available in standard screw size of 65 mm with hourly throughput capacity of 50 kg/hr.

Full Shine Plastic Machinery Co Ltd Taiping - Taiwan Tel: +886-4-22765071, Fax: +886-4-22765070 Email: fulshine@ms7.hinet.net

Feeding system ACS Auxiliaries India offers ‘AccuMeterTM series’ continuous loss-in-weight feeding system manufactured by AEC Inc, USA. Pellets, regrind, powders and liquids can be metered into the process, even at very low levels (>50 gm/hr). Its refill system is designed for up to 40 refills per hour, which can significantly reduce system size and cost, especially when used with integral conveying systems. The vacuum receiver can also be used as the refill hopper, to further reduce the height of the system. Smaller components allow quick changeover, since less material needs to be drained and fewer components need cleaning. It can feed from 50 gm/hr to 16,500 lb/hr (7,500 kg/hr) and accommodate up to eight precision feeders per extruder. The system has a cumulative dosing accuracy of ±0.5 per cent and is driven by variable speed DC drive motors. The control system includes an Allen-Bradley CompactLogix™ programmable controller with a PanelView CE 1000™ colour touchscreen. ACS Auxiliaries India Pvt Ltd Pune - Maharashtra Tel: 020-4014 7575, Mob: 09371 154045 Email: acsindia@corpemail.com 98

Modern Plastics & Polymers | April 2011

Malik Engineers Thane - Maharashtra Tel: 0250-239 0839, Fax: 022-2883 0751 Email: info@malikengg.com

Screen changer Rajhans Plastics Machinery offers platen-type screen changer for the processing of thermoplastic extruder. This screen changer filters the plastic material and removes impurities, thereby preventing damage to the die & barrel. It is available with accessories, which include die side and barrel side adapters, fabricated wheel-mounted trolley for mounting, spare screen packs and heaters, strain/dori die, special die for die face cutter. It is used in re-process granules plant, lamination plant, masterbatch plant, special design for PVC plant, gulla/lumba plant, pipe plant, sheet plant, filler plant, blow moulding plant, etc. Rajhans Plastic Machinery Pvt Ltd Ahmedabad - Gujarat Tel: 079-2583 0003, 2589 5852 Fax: 079-2589 1838 Email: exports@rajhansindia.com

PRODUCT UPDATE

Gravure proofing machine Graphic (India) offers JM Heafordâ&#x20AC;&#x2122;s SCOF gravure proofing machine. The open fronted design ensures fast cylinder loading for greater productivity, with additional space around the cylinder for ease of operation. The moving rail and fixed drum design helps consistently print high quality, in register, proofs. The low open fronted rail with load platform and easy lift system ensures that smaller cylinders can be loaded by hand and the design of the load platform and register camera position allows for larger cylinder loading by crane. Processing times vary by user but it can handle up to 10 cylinders per hour including one substrate change. It incorporates a larger drum, which gives longer proof length and the higher proofing speed improves ink transfer from fine cells. A range of smaller detailed modifications such as addition of a quick change doctor blade, have also been made. The machines are used by both printing companies and cylinder engraving service houses for checking cylinder quality, separations, text and register, producing production quality proofs for customer approval, in-house development work and staff training purposes. Graphic (India) Mumbai - Maharashtra Tel: 022-2261 3151/ 6147 Fax: 022-2262 5300 Email: trs.sanon@vsnl.com

Cartridge heater Pratik Heat Products offers cartridge heaters. The heating conductor grade NiCr 80:20 is uniformly wound over the supporting core that is located centrally in a SS-304 tube and the inner space is packed with particularly chosen high-purity magnesium oxide. The unit is compressed, thereby converting the core, powder and conductor into a homogenous mass. The base of the heater is welded with a disc washer to avoid contamination. These products are used in marking & sealing machinery, medical & laboratory apparatus, hot runner bushings, packaging industry and shoe making industry. These cartridge heaters are CE certified. Pratik Heat Products Pvt Ltd Mumbai - Maharashtra Tel: 022-2920 0183 Fax: 022-2925 4309 Mob: 09004388444 Email: sales@phpheat.com April 2011 | Modern Plastics & Polymers

PRODUCT UPDATE

Colour marking machine Aeromec Marketing Co offers rotary automatic hot colour (hot embossing) sequential colour marking machine. This machine is designed to mark colour on all types of polyethylene pipes, rigid PVC pipes and sections during extrusion process. It requires power only for heating. The model 'AMC-210' machine can mark 10-315 mm outside diameter of pipes. The marking is done at every one metre on the pipes/sections by using pantographed brass/SS stereos fixed on the heater body. The stereos are heated by using electronic percentage differential circuit which adjusts the temperature. It is designed to colour mark by using a coloured polyester tape placed between the stereos and the pipes/sections to be marked. The option of periodical marking can be given with special electronic equipment and an apparatus with pneumatic working. Periodical marking can be set up to three digits. Other models available with the company include automatic sequential counter with three or four digits and up to seven digits coder (hand-operated) colour marking machine. Aeromec Marketing Co Pvt Ltd Thane - Maharashtra Tel: 0250 245 4915 / 3896, Fax: 0250-245 5579 Email: mail@aeromec.in

Coder

Mr L. R. Katrat Managing Director - CEO Katlax Enterprises Pvt. Ltd. “We have been a regular advertiser of our products in leading publications such as SEARCH, Modern Machine Tools and Modern Plastics & Polymers of Infomedia 18 Ltd. We are associated with the publication house for more than 12 years and are utilising these magazines to promote our products aggressively and receiving good response.”

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Process Instrumentation and Controls offers 'Sparsh' coder. It is used to print various statutory information like batch number, date of manufacturing, expiry date, prices and any other information on various packing like tins, container, cartons, lids, stickers, laminated flexible pouches & films, metal containers, etc. It is a small compact intermittent motion reciprocating contact coder with an ink cartridge enclosed in a sealed container to give a constant amount of PIC fast drying coding ink. It is specially used for high-speed coding application viz self-sticker labelling and multitracking line, FFS, blister pack and strip pack machine. Its compact design makes it easy to install where space is limited. It can be mounted in any angle vertical, horizontal or side mounting. Due to separate ink cartridge, it avoids film contamination and keeps the printing area clean. It is a versatile controller, which consist of in-built cyclic timer and five different input modules to achieve or optimise printing speeds up to 180-200 impressions per minute with easy operation. It also runs through external inputs. Process Instrumentation & Controls Vadodara - Gujarat Tel: 0265-235 7228, 232 0756, Fax: 0265-235 5429 Email: batchprinting@yahoo.com

PRODUCT UPDATE

Desiccant dryer Atlas Copco Compressor Sales offers energy efficient 'CDX 120-1050' desiccant dryers. Features include low pressure drop and almost negligible power consumption. Reliable performance of the dryers is achieved by massive desiccant overfill, wide desiccant chambers, low air speed design and proper selection of the desiccant. Wide desiccant vessels and optimised flow have reduced the pressure drop to as little as 0.25 bar for smaller dryers. Routine maintenance has been made fast, clean and as simple as possible. Changing the desiccant takes just a few minutes, as the desiccant can be removed and replaced without disconnecting the dryer from the compressor. Standard pressure dew point performance is -40ยบC (with activated alumina as desiccant), for more demanding applications 70ยบC pressure dew point is available as an option (with molecular sieves). Each dryer of the 'CDX 120-1050' range can operate in 4-16 bar working pressure. Each dryer is also suitable for both G and NPT connection. Atlas Copco Compressor Sales Pune - Maharashtra Tel: 020-3985 2316, 3985 2318, Fax: 020-2714 5948 Email: littlemaster@in.atlascopco.com

Laser displacement sensor Banner Engineering offers triangulation laser displacement sensors for non-contact height or thickness measurement of a wide variety of materials such as sheetmetal, wood, ceramic, paper, plastic, rubber, foam and baking dough. These sensors provide precise measurement of distance, web thickness and alignment. Applications include hot parts, machined parts, semiconductors & PCBs, shiny or reflective parts and soft or sticky parts. There are three models in the series, with measurement ranges of 25-35 mm, 60-100 mm and 100-200 mm. Thickness is measured by two sensors mounted at either side of the target that automatically synchronise with one another. Up to 32 sensors can be easily combined in a mixed measurement network of multi-track displacement or thickness sensors. The dedicated software application included with each sensor allows easy set up, configuration and software accommodates data logging and monitoring for statistical process control. Output communication is via simultaneous 4-20 mA (16 bit D/A) and RS-485 serial connection. Banner Engineering India Pvt Ltd Pune - Maharashtra Tel: 020-6640 5624, Fax: 020-6640 5623, Mob: 9322339208 Email: salesindia@bannerengineering.com April 2011 | Modern Plastics & Polymers

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PRODUCT UPDATE

EPS cup making machine Neejtech India offers EPS cup making machine from THERMOWARE BV. This machine ensures high volume production since it comprises a highly efficient pneumatic control. Equipped with 16-cavity moulds, it is designed to run at an optimised cycle time and comparatively offers a 60 per cent higher production rate. Its user-friendly electronics and the company’s good after-sales services enhance the popularity of the product. This machine is used for making drinking cups for hot & cold drinks and icecream cups. Besides, even disposable trays, plates, containers, etc, can easily be made by changing the mould. Neejtech India Ahmedabad - Gujarat Tel: 079-2656 1312 Mob: 09825040231 Email: sales@neejtech.com

Dispensing system AM Spa offers ‘Servo-Flo® 801-HV’ positive-displacement, two-component meter-mix dispensing system manufactured by Sealant Equipment & Engineering. It is designed to apply small precision beads and small metered shots of precisely mixed resins and provides longer bead lengths and/or an increased quantity of metered shots. The servo-motor design provides consistent and repeatable bead profiles and a change of flow rate during the dispense cycle. The fixed-ratio design improves production rates, product quality and reduces manufacturing costs in micro-dispensing applications. This dispensing system is designed to provide a variety of preset material-dispensing profiles and dispense results ranging from 0.2 cc to 18 cc at 1:1 ratio. It can dispense precisely mixed materials for different part configurations in batch or random processes. It can be preset to vary the flow rate during dispensing in automated, indexing, XYZ-motion and robotic processes. The control accepts operator preset material profiles or electronic commands from the automation. AM Spa Mumbai - Maharashtra Tel: 022-2648 9074, Mob: 98339 32265 Email: anjanitewari@amspa.org The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of Business Insights •Technologies•Opportunities

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PRODUCT INDEX

To know more about the products in this magazine, refer to our ‘Product Index’ or write to us at spedit@infomedia18.in or call us at +91-22-3003 4685 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Sl No Product

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Pg No

Additive masterbatch...................... 16 Air bubble film plant .......................... 99 Air chiller........................................... 23 Air cooled chiller ............................... 11 Air cooled sealer................................ 25 Air treatment...................................... 45 Air-conditioner ................................... 97 Air-conditioner part .......................... FGF Ammonia liquid chiller ....................... 43 APFC panel ....................................... 97 Automation controller......................... 41 Automation system ............................. 59 Automotive Dealership Excellence Awards 2010................... 109 Auxiliary equipment ............................ 53 Banking services............................. 73 Barrel screw....................................... 99 Biodegradable masterbatch ................ 16 Black masterbatch.............................. 16 Blender ...................................... 32, FIC Blending unit ................................... FGF Blower series ..................................... 59 Blowing agents .................................. 29 Boiler ................................................ 77 Brine chiller ....................................... 11 Bulk milk cooler................................. 43 Butterfly valve .................................... 43 Calorifer......................................... 77 Cartridge heater ................................ 99 Chemical........................................... 49 Chiller ......................................... 11, 57 Clean room application ....................... 8 Cluster facia .................................... FGF CNC................................................ BIC CNC machine ................................... 31 CNC vertical machining centre ........... 50 Coder ............................................. 100 Co-extrusion blow moulding machine . 98 Colour marking machine.................. 100 Colour masterbatch ..................... 16, 67 Colouring of plastics .......................... 29 Compact chiller ................................. 23 Complex multi part assembly ................ 9

Sl No Product

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83

Pg No

Compressed air dryer......................... 68 Connector ....................................... FGF Conveying & handling system ............. 53 Cooling pad ...................................... 77 Cooling tower.............................. 45, 77 Counters & power supplies ................... 5 Credit guarantee to micro enterprises.. 21 Credit guarantee to SME .................... 21 Crystalliser......................................... 68 Dairy machinery............................. 43 Dehumidified air dryer................23, FGF Dehumidified dryer............................ FIC Desiccant dryer ................................ 101 Digital temperature controller ............. 39 Dispensing system ............................ 102 Distribution transformer ...................... 97 Door trim ........................................ FGF Dosing & mixing system...................... 59 Double column vertical machining centre.................... 31 Drip irrigation system ......................... 77 Drives.......................................... 39, 41 Drying & dehumidifying system ........... 59 Drymax dryer .................................... FIC Drymax pet-dehumidified dryer .......... FIC Dual channel with modbus ................. 39 Dyestuff ............................................... 6 Dynamic controller ............................. 39 Elastomer ....................................... 55 Electric injection moulding machine garbox .................... 7 Electro magnet................................... 14 Electro permanent magnet.................. 14 Email marketing................................. 95 Encoder............................................... 5 Engineering product ........................... 49 EPS cup making machine ................. 102 Extruder machine ............................... 13 Extrusion die .............................. 99, 112 Extrusion line ..................................... BC Extrusion machinery............................ 19 Extrusion system ................................. BC Fast mould clamping...................... 14

Sl No Product

84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124

Pg No

Feeder............................................... 53 Feeding & conveying system ......... 59, 68 Feeding system .................................. 98 Financial services ............................... 73 Flame retardant masterbatch .............. 16 Flame retardants ................................ 29 Gases............................................. 49 Gearbox.............................................. 7 Geared box....................................... 37 Geared motor ................................... 37 Granulating & recycling system ........... 59 Granulator ...........................23, 68, FIC Gravure proofing machine ................. 99 Grinder ............................................. 23 Head lamp & tail lamp................. FGF Heating & cooling system ................... 59 High cavitation .................................... 8 High speed heater/cooler ................... 99 High speed mixer............................... 13 HMI .................................................. 41 Hopper dryer ..................................... 23 Hopper loader ................................... 23 Hopper magnet ................................. 14 Horizontal machining centre .............. BIC Hot air dryer.................................... FGF Hot runner system .............................. 59 IML technique .................................. 8 Induction motor ................................. 41 Induction sealing................................ 25 Industrial control & sensing device ........ 5 Industrial cooler ................................. 45 Injection moulding machine..................... 15, 33, 35, 77, 79, 81, 93, 105, FGF Injection mouldingmulti-component system ..................... 33 Ink adhesion...................................... 25 Invertor/variable frequency drive ........... 5 Isolation transformer........................... 97 Knobs & switches ......................... FGF Lab extruder................................... 96 Lab mixer .......................................... 99 Label adhesion .................................. 25 Large-flow water heater ...................... 59

COC - Cover On Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover

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PRODUCT INDEX Sl No Product

125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170

Pg No

Laser displacement sensor ................ 101 Lathe machine .................................. BIC Level controller .................................... 5 LIM ................................................... 55 Liquefier ............................................ 11 Loader.............................................. FIC Magnet modules ............................ 14 Magnetic base ................................... 14 Magnetic chuck ................................. 14 Magnetic lifter.................................... 14 Magnetic platter................................. 14 Magnetic separator ............................ 14 Manufacturing of plastic ..................... 29 Masterbatch....................................... 16 Material dryer .................................... 32 Measuring & monitoring relay for 1ph/3ph ................................ 5 Medical mould .................................... 8 Metal ................................................ 49 Milling centre.................................... BIC Moulding automation system ................ 9 Monolayer blown film line .................. BC Motion control system .......................... 5 Mould ............................................... 13 Mould clamping magnet .................... 14 Mould temperature controller.............. 23 Moulding machine ............................... 8 MTC ................................................ FIC Multi component mould ....................... 8 Multilayer blown film line.................... BC Multilayer co-extrusion sheet line .. 10, 91 Multi-station ...................................... 33 Neat resin........................................ 6 Oil chiller....................................... 11 Oil cooler ......................................... 57 Online B2B marketplace ............ 27, 111 Optic sheet extrusion line ............. 10, 91 Oven dryer ........................................ 96 Panel cooler ................................... 57 Paper & allied chemical...................... 49 Paper chemical .................................... 6 Permanent magnet ............................. 14 PET masterbatch ................................ 16 PET sheet extrusion ..................... 10, 91 Photoelectric sensor.............................. 5 Pipe extrusion line .............................. 81 Pipe line ............................................ 77

Sl No Product

Pg No

171 Pipe making ...................................... 33 172 Plastic conveyor belt........................... 13 173 Plastic processing machinery/ancillaries/spare ................ 99 174 Plastic sheet extrusion line ............ 10, 91 175 Plasticizers for polymer ....................... 29 176 Plate heat exchanger.......................... 43 177 PLC................................................... 39 178 Plug valve.......................................... 43 179 Pneumatic valve ................................. 43 180 Polymer ............................................. 29 181 Polymer allies product ........................ 49 182 Polymer auxiliaries.............................. 29 183 Polymer conveyer belt......................... 23 184 Power saver ....................................... 97 185 PP glass filled compound.................... 16 186 PP mineral filled compound................ 16 187 Precision moulding........................... FGF 188 Process tank ...................................... 43 189 Procurement & auditing servicing ........ 49 190 Profile controller................................. 39 191 Programmable logic controller .............. 5 192 Programmable terminal ........................ 5 193 Proximity sensor ................................... 5 194 Proximity switch .................................. 96 195 Pulveriser ........................................... 13 196 PVC pipe........................................... 77 197 PVC pipe extrusion unit ...................... 96 198 Quick connector............................. 63 199 Quick mould change system............... 63 200 Rail tanker ..................................... 43 201 Refrigerant pump ............................... 43 202 Refrigeration ...................................... 43 203 Resin dehumidifier.............................. 68 204 RFID.................................................... 5 205 Robot ............................................... FIC 206 Robot system ............................... 15, 23 207 Rock n roll machine ........................... 13 208 Rotary .............................................. BIC 209 Rotary automatic hot colour marking machine............... 12 210 Rotomoulding machine....................... 13 211 Round table carrousel ........................ 13 212 Rubber injection machine ................... 55 213 Safety light curtain ........................... 5 214 Screen changer.................................. 98 215 Screw ................................................ 99

Sl No Product

216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262

Pg No

Screw compressor .............................. 43 Sealer ............................................... 25 Segmented barrel............................... 99 Servo motor....................................... 41 Servo stabiliser................................... 97 Single mill pulveriser .......................... 13 Single screw and barrel ...................... 99 Single screw extruder.......................... 98 Single screw extruder gearbox............... 7 SME finance .............................. 73, 107 Software for central monitoring ........... 68 Sprinkler system ................................. 77 Stack mould ........................................ 8 Surface treatment............................... 25 Switching relay..................................... 5 System solution .................................. 59 Tanks & silos .................................. 43 Tea.................................................... 49 Technical mould................................... 8 Temperature controller.................... 5, 39 Thermoforming & PS foam ................. BC Thermoplastic alloy .............................. 6 Thermoplastic compound ..................... 6 Timer .................................................. 5 TPE ................................................... 55 TPE/TPU compound ........................... 16 TPU masterbatch................................ 67 Transformer ....................................... 97 Turnkey projects ................................ 97 Twin mill pulveriser............................. 13 Twin screw extruder gearbox ................. 7 Universal controller ........................ 39 Universal masterbatch ........................ 16 UPS................................................... 97 UV & PU masterbatch ........................ 16 Vacuum forming machine ..............BC Vacuum loader ................................ FGF Vertical machining centre.............31, BIC Vibro screen ...................................... 13 Vision sensor ....................................... 5 Volumetric dosing unit ........................ 68 Water chiller................................... 68 Water cooled chiller ........................... 11 Welding gun...................................... 77 WFR................................................. FIC White masterbatch ............................. 16 Wire-EDM ......................................... 50

COC - Cover On Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover

�� www.engg-expo.com

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Modern Plastics & Polymers | April 2011

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ADVERTISERS’ LIST Advertiser’s Name & Contact Details

Pg No

AB Diachem Systems Pvt Ltd

T: +91-11-25155456 E: sales@scalewatcher.in W: www.scalewatcher.in ADEA

109

T: +91-22-30034650 E: prachi.mutha@infomedia18.in Aeromec Marketing Co Pvt Ltd

Advertiser’s Name & Contact Details Enercon Asia Pacific Iss Pvt Ltd

Pg No 25

Advertiser’s Name & Contact Details Jyoti Cnc Automation Pvt. Ltd.

T: +09600344430 / 91-4344 244303

T: +91-2827-287081

E: info@enerconasiapacific.com

E: info@jyoti.co.in

W: www.enerconaciapacific.com

W: www.jyoti.co.in

Ferromatik Milacron India Ltd

T: +91-11-43606200

E: salesfmi@milacron.com

E: rohit@kplintl.com

W: www.milacronindia.com

W: www.kplintl.com

T: +91-250-2454915

Freeze Tech Equipments Pvt Ltd

E: hvt@aeromec.in

T: +91-44-42152387

T: +91-22-26734822

E: info@freezetechequip.com

E: nishant@kolsitegroup.com

W: www.freezetechequip.com

W: www.kolsite.com

W: www.aeromec.in Alok Masterbatches Ltd

T: +91-11-41612244

Gem Equipments Ltd

E: sales@alokindustries.com W: www.alokmasterbatches.com Bharat Bijlee Ltd

Kabra Extrusion Technik Ltd

T: +41-62-885-7171

E: sales@gemindia.com

E: ifischer@ktron.com

W: www.gemindia.com

W: www.ktroncan.com

T: +91-22-24306237

Haas Automation India Pvt Ltd

E: vishwajyoti.vengurlekar@bharatbijlee.com

T: +91-20-32935433

T: +91-44-26812000

E: sales@haasindia.com

E: handigolg@larsentoubro.com

W: www.HaasCNC.com

W: www.larsentoubro.com

W: www.bharatbijlee.com Blend Colours Pvt Ltd

T: +91-40-2436 1499 / 2436 0887

IDMC Limited

E: info@blendcolours.com W: www.blendcolours.com Credit Guarantee Fund Trust For Mic

W: www.cgtmse.in Disha Technologies

L & T Plastics Machinery Ltd

T: +91-22-21729200

E: idmc@idmc.coop

E: rekha.kumar@lanxess.com

W: www.idmc.coop

W: www.lanxess.in 27, 111

FGF

Livewire18 T: +91-22-30245000

T: +91-11-45635747

E: pr@indiamart.com

E: b2b@infomedia18.in

E: dishatech@gmail.com

W: www.indiamart.com

Loxim Industries Limited

W: www.dishatech.co.in

Jing Cheng Mold Machinery Co., Ltd

E: info@loxim.com

E: jingcheng_times@vip.163.com

W: www.loxim.com

E: info@sardamagnets.com

W: www.jc-times.com

Maplan Mashchinen Und Techn. Anlagen

W: www.sardamagnets.com

Jon Wai Machinery Works Co., Ltd.

T: +91-40-23098262

Planungs-Und Fertigungs-Ges.M.B.H.

T: +886-2-2595-4867

T: +43-2630-35706-0

T: +91-22-32531959

E: jonwai.mc@msa.hinet.net

E: Sabine.poetz@maplan.at

E: vkt@electronicapmd.com

W: www.jonwai.com.tw

W: www.maplan.at

Electronica Plastic Machiners Ltd

T: +91-2717-308000

T: +86-576-8461-0001

East Coast Magnets (P) Ltd.

T: +1800-200-4444 / 91-120-3911000

112

Lanxess India Pvt.Ltd.

T: +91-2692-225399

India Mart Intermesh Ltd 105

K-Tron Process Group

T: +91-422-3267800

BIC

K P L International Ltd

T: +91-79-25890081

Pg No

Our consistent advertisers

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Modern Plastics & Polymers | April 2011

ADVERTISERS’ LIST Advertiser’s Name & Contact Details Mifa Systems

Pg No 39

Advertiser’s Name & Contact Details Rajoo Engineers Ltd

Pg No BC

Advertiser’s Name & Contact Details Standard Chartered Bank

T: +91-79-26870825

T: +91-2827-252701

T: +91-22-39401616

E: info@mifasystems.com

E: kcdoshi@rajoo.com

E: sme.customercare@sc.com

W: www.rajoo.com

W: www.standardchartered.co.in

W: www.mifasystems.com Neejtech India (Braunform)

Reynold India Pvt Ltd

T: +91-79-26561312 T: +91-120-4664000

E: info@neejtech.com

Neejtech India (Hekuma)

T: +91-79-26561312

Sacmi Engineering India Pvt Ltd

E: contact@niigataindia.com

T: +91-7600003968

Omron Automation Pvt. Ltd.

W: www.negribossi.com

E: in_enquiry@ap.omron.com

Sanity International

W: www.omron-ap.com

T: +91-79-65227458

Piovan India Pvt Ltd

T: +91-22-28560450

E: infomum@unimark.in 99

E: infomum@unimark.in 97

Shini Plastics Technologies I Pvt Ltd

W: www.prasadgroup.com Premium Transmission Ltd

E: sales.imm@windsormachines.com 59

W: www.windsormachines.com Wittmann Battenfeld India Pvt Ltd

T: +91-250-3021166

T: +91-20-27488886

E: jnbhat@shiniindia.com

T: +91-44-42077009

W: www.premiumtransmission.com

W: www.shini.com

E: info@wittman-group.in

R R Plast Extrusions Pvt Ltd

10, 91

Shree Radhekrishna Extrusions Pvt Ltd

T: +91-79-25841591

W: www.servomax.net

E: plastics@prasadgroup.com

W: www.unimark.in Windsor Machines Limited

T: +91-40-44436666 / 44436600 E: dharmesh@servomax.net

T: +91-79-25830112

T: +91-22-25506712

W: www.piovan.com Prasad Koch Technik Pvt. Ltd.

W: www.unimark.in Unimark (Staubli Faverges Sca)

E: info@sanityindia.com

Servomax India Ltd.

T: +91-22-25506712

W: www.sanityindia.com

E: amit.bajaj@piovnindia.com

W: www.unimark.in Unimark (Maguire)

E: sales@negribossi.in

T: +91-80-40726400

E: infomum@unimark.in

W: www.stengineers.com

T: +91-09909974224

Unimark (Arburg Gmbh) T: +91-22-25506712

E: stycm@stengineers.com

W: www.neejtech.com Neejtech India (Niigata)

W: www.sbi.co.in 50

T: +91-422-2590810

E: info@neejtech.com

107

E: contactcentre@sbi.co.in

W: www.reynoldindia.com S&T Engineers

State Bank Of India

T: +1800 11 22 11/ 18004253800

E: v.bali@reynoldindia.com

W: www.neejtech.com

Pg No

FIC

W: www.wittmann-group.com

T: +91-22-42461500

T: +91-79-25842509

Zambello Riduttori Group

E: info@rrplast.com

E: mail@radhekrishnaexports.com

T: +39-0331-307-616

W: www.rrplast.com

W: www.radhekrishnaexports.com

W: www.zambello.it

Our consistent advertisers

April 2011 | Modern Plastics & Polymers

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