Modern Plastics & Polymers - June 2011 by Infomedia18

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EDITORIAL

Six stimuli of success

elcome to the 6th Anniversary Edition of ‘Modern Plastics & Polymers’! As we celebrate this special occasion, it is heartening to see the growing array of specialty and commodity polymers in various applications, and the creative use of plastics on an upswing. This trend also reflects a plethora of new opportunities to replace conventional materials across the contemporary product portfolio. The question is what are the enabling elements and how best one can leverage these opportunities and excel in delivering the goods? As devices get thinner, smaller and lighter, the right mechanical performance of plastics is the need of the hour. With miniaturisation of parts and complete systems fast becoming the global norm, manufacturing systems need to be upgraded to meet the requirements of new components. The point to note here is that processors who are in sync with the latest technological advancements and applications will get a headstart in the race to be the ‘suppliers of choice’. That said, demand for bioplastics is rising at a faster pace than expected, with growing awareness to reduce the carbon Editor Manas R Bastia Senior Features Writer Beverley Lewis Features Writer Annabel Dsouza Correspondent Anwesh Koley (Delhi) Copy Editor Swati Sharma Edit Associate - Products Abha Mishra Chief Photographer Mexy Xavier Photographer Neha Mithbawkar, Joshua Navalkar Design Sharad Bharekar Production Pravin Koyande, Dnyaneshwar Goythale, Vikas Bobhate, Ravikumar Potdar, Ravi Salian, Sanjay Shelar, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Abhay Borkar, Akshata Rane

footprint, although development costs continue to be high and the few players in this space are yet to achieve economyof-scale. In this regard, collaboration, planning & forecasting with suppliers for right outsourcing along with technology integration and continuous improvements in process offer promising prospects. This unique edition reflects all these and more. Turn to the ‘Anniversary Special’ section (with six distinct growth avenues such as automotive, electrical/electronics, medical plastics, packaging, construction and bioplastics) to discern what several experts across the global plastics and polymers industry have to opine, not just on the latest trends but also on the future prospects. Believe, you will benefit from exploring this focussed mix of latest news, views and analyses as much as we at ‘Modern Plastics & Polymers’ enjoyed putting it together. Have a good read and looking forward to your valuable feedback!

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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June 2011 | Modern Plastics & Polymers

CONTENTS

100

45 46

102

106

Anniversary Special: Six growth avenues for plastics Automotive

• Industry Insights: Plastics in automotive • Viewpoint: Sanjay Jain, Business Director, DSM Engineering Plastics India • Trend Analysis: Polyamide 6 and 66

Electrical/Electronics • Industry Insights: Plastics in electronics • Viewpoint: Georg Steinbichler, Senior Vice President, Development Technologies; Rudolf Ehrenweber, Area Sales Manager, Teletronics Business Unit, ENGEL • Trend Analysis: Plastics in electricals

Medical Plastics • Industry Insights: Plastics in medical devices • Viewpoint: Dr Vinny Sastri, President, Winovia LLC • Trend Analysis: Plastics in healthcare

Packaging • Industry Insights: Polymers for packaging • Viewpoint: S V Kabra, CMD, Kabra Extrusiontechnik Ltd Vimal Kedia, Managing Director, Manjushree Technopack Ltd • Trend Analysis: Plastics in packaging

110

Construction • Industry Insights: Plastics in construction • Viewpoint: CRG Prasad, Commercial Manager – Construction (India and South Asia), Dow Corning India Pvt Ltd • Trend Analysis: Buildings and construction

Bioplastics • Industry Insights: Bioplastics • Viewpoint: Perses Bilimoria, Founder and CEO, Earthsoul India Pvt Ltd • Trend Analysis: Biocompostable products

Leaders Speak 100

Amandeep Singh Cheema, Country Head, DuPont Performance Polymers

102

Zylog Plastalloys Pvt Ltd: A promise for unparalleled quality

106

Blow moulding: Ensuring quality, durability and versatility

110

Plastics in road construction: Recycling wastes for commercial viability

114

Vibration welding of thermoplastics: Reinforcing the strength of polymers Courtesy: BASF SE

122

Post recession: Turning the tides in one’s favour

Facility Visit Sector Watch

122

Market Trends Performance Metrics

Management Mantras M Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd

REGUL AR SECTIONS Editorial......................... National News............... Asia News ..................... World News................... Tech Updates ................. 22

21 24 30 36 40

Events Calendar........... 126 Product Update............. 130 Product Index............... 139 Advertisers’ List ............ 142

Modern Plastics & Polymers | June 2011

Details on page no.129

Cover photo courtesy: Car Advice, Timbercon, European Bioplastics, Global Package Gallery, PolyOne

Highlights of Next Edition Sector Watch : Thermoforming Market Trends : Plastics in Home Applications Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

NATIONAL NEWS APPOINTMENT

IPI announces new board members

G K Srinivasan (R) handing over Presidential Medallion to Prof E Narayanan (L)

Prof E Narayanan succeeds G K Srinivasan as President of Indian Plastics Institute (IPI). He is a Life Member of IPI and has served IPI in various capacities, including several educational programmes over the years. He was Past Chairman of IPI Mumbai Chapter and Vice President of IPI for the last three years. He is a professional academician associated with various educational

institutes including Institute of Materials, London. Also, Dr Prakash Trivedi succeeds Francis Pinto as Chairman of IPI. He is a Founding Life Member of IPI and has the distinction of serving IPI for several years in different capacities, including Chairman of Mumbai Chapter and Vice Chairman of the Governing Council. Dr Trivedi has several innovative plans & programmes to take IPI to the next level of progress. He has

Francis Pinto (L) handing over IPI charge to Dr Prakash Trivedi (R)

played a vital role in the education committee to introduce online e-learning courses.

NEW FACILITY

CPP commissions continuous filament winding plant in Vadodara Chemical Process Piping Pvt Ltd (CPP) has recently announced the commissioning of its new Continuous Filament Winding (CFW) plant in Vadodara. The CFW plant will produce Glass Reinforced Plastic (GRP) pipes and sleeves of diameter in the range of 300-2,600 mm. The plant is fully computer controlled, based on the CFW process, fully in compliance with ASTM code D 2996 (Standard Specification for Filament Wound Reinforced, Thermosetting Resin Pipes). Vijay Rajpurohit, MD, CPP, commented, “CPP is looking forward to its foray into the water industry. With rapid increase in population, there is a scarcity of water on one hand and an increased need for electricity on the other. Both these problems can be solved by implementing desalination projects and setting up power plants. In both cases, large amounts of GRP piping would be required.” With the commissioning of these plants, CPP foresees a huge demand for GRP pipes, which are low on maintenance, highly resistant to soil corrosion & sea water, need no special linings on the exterior and also come at a competitive price.

Modern Plastics & Polymers | June 2011

SEEKING BUSINESS

Plastic Omnium Varroc to expand Plastic Omnium Varroc Pvt Ltd, a supplier of plastic auto exterior components, is looking forward to set up more manufacturing plants in India and plans to add just-in-time facilities in adjacent supplier parks. The company is a Joint Venture (JV) between Plastic Omnium Auto Exterior in France and Varroc Polymers in India. Plastic Omnium owns 60 per cent of the venture. It produces thermoplastic and thermoset exterior parts such as bumpers, fenders, tailgates and front-end modules at its plant in Chakan, Pune. It has established sequencing and assembly operations plants near Original Equipment Manufacturers (OEMs) in North India and Maharashtra. “We already supply plastic exterior components to Indian automaker Mahindra & Mahindra for its existing models Gio & Maximmo and plastic exterior painted components to General Motors India,” said B P Shiv, Chief Marketing Officer, Plastic Omnium Varroc Pvt Ltd. The companies set up their first JV plant in Chakan in 2009 to serve automakers that had set up base in India.

INDIA CALLING

SPE announces ANTEC conference in India

Ken Braney

The Society of Plastics Engineers (SPE) has announced hosting the first ever Annual Technical Conference (ANTEC) conference in Mumbai in 2012. Ken Braney, President of SPE, said that coordinating a major Indian conference continues the globalisation moves for the Newtown, Connecticut-based SPE. India has long been a strong destination for the society, and the India emphasis has almost doubled its membership in previous years. The India

section has earlier hosted topical conferences on specific technical subjects, but never the entire ANTEC, with a series of technical papers on a wide range of topics. Braney also said that the Mumbai conference should draw attendees from the Middle East, where SPE has a new section. ANTEC, sponsored by the SPE is among the largest conferences on plastics in the US. It is a leading technical forum for providing cuttingedge technological issues and information pertinent to the needs of the plastics industry. In the process, ANTEC has developed a 20,000-member network of leading engineers, scientists and other plastics professionals, including technicians, sales personnel, marketers, retailers and representatives from tertiary industries.

NATIONAL NEWS CAPACITY ADDITION

NEW PLANT

Xmould to double compounding capacity The Chennai-based custom compounder, Xmould Polymers Pvt Ltd, is planning to set up two plants in the automobile hubs of Pune and Delhi. On this, S Srinivasan, MD & CTO, Xmould Polymers, said, “We have a plant in Chennai with annual production capacity of 10,000 metric tonne and plan to set up two more plants in Pune and Delhi in the next five years to tap the growing demand from the automobile industry.” He further informed, “The Chennai plant was recently expanded in 2008, with a Berstorff and Steer twin-screw extruders. About 70 per cent of the company’s sales are from automotive ACTIVITY INTEGRATION

Motherson Sumi Systems plans group merger The supplier of plastic components and modules to the automotive industry, Motherson Sumi Systems (MSS) will merge with three group firms Sumi Motherson Innovative Engineering (SMIE), MSSL Global Wiring (MGW) and India Nails Manufacturing (INM), following approval from its board of directors. The company aims to become a $ 5-billion entity by 2015. The board has also approved the appointment of an independent valuer, Deloitte, to determine a fair exchange ratio for the merger of SMIE, presently a subsidiary of Sumitomo Wiring Systems CONTRACT

Samsung Engineering wins $ 230-million order from India Samsung Engineering, South Korea’s largest industrial plant builder, has won a $ 230-million order to build a High-Density Polyethylene (HDPE) plant

Modern Plastics & Polymers | June 2011

S Srinivasan

customers, with the remainder Xmould Polymers appliance, telecommunications, defence and railway applications.” The company’s products include nylon, polypropylene and Acrylonitrile Butadiene Styrene (ABS) compounds & alloys. The proposed Pune and Delhi plants would each have annual production capacity of 5,000 metric tonne. Xmould also plans to pursue the export market in Japan and Europe. (SWS). The assessment will be complete in 3-4 weeks, and the merger of group firms is expected to be complete in 6-9 months. MSS is the flagship company of the Samvardhana Motherson Group, a joint venture between Samvardhana Motherson Group and SWS. SMIE manufactures components for wiring harnesses and other plastic components, while MGW makes wiring harnesses and INM is an importer of nail machinery. Other products comprise rubber components for automotive and industrial applications, high-precision machined metal pads and injection moulding tools. in western India. Under the deal with ONGC Petro-additions Ltd (OPaL), a unit of India’s state-run Oil & Natural Gas Corporation Ltd (ONGC), Samsung Engineering will build the plant with an annual production capacity of 340,000 tonne HDPE. HDPE is a raw material used for industrial film, pipes and paints. The company will handle the engineering, procurement, construction, commissioning on a lump-sum turnkey basis, with the completion date set for August 2013. The plant will be built at the special economic zone in Dahej,

Dorf Ketal begins production at organic titanate plant Dorf Ketal specialty catalysts has announced full production at its new, state-of-the-art organic titanate plant in Mundra, Gujarat. Sudhir Menon, Chairman, Dorf Ketal, commented, “The plant will annually produce up to 10,000 metric tonne of the industry’s broadest portfolio of titanates, making it the largest facility of its kind in the world. The Mundra plant joins the company’s recently expanded Dadra plant in shipping TYZOR® and VERTEC™ organic titanates worldwide.” Dorf Ketal, the largest manufacturer of organic titanates, has grown rapidly through acquisition, beginning with the INTEC® and TYZOR® titanate brands. In April 2011, the company acquired the patents, trademarks and related intellectual property for VERTEC™ polyester catalysts and SNAPCURE™ polyurethane catalysts. Dorf Ketal is a global manufacturer of process chemicals & additives for the oil field industry, refineries, petrochemical plants and fuels & plastics. In less than 15 years, Dorf Ketal has emerged as India’s largest manufacturer of these products. Gujarat. Kwangyong Chun, Executive Vice President-Hydrocarbon Business, Samsung Engineering, said, “This is the eighth project in India to be awarded to Samsung Engineering. Currently, in the construction phase, the project has earned praise from both ONGC and OPaL.” In February 2009, Samsung Engineering had signed another agreement with OPaL for constructing an ethylene plant with an annual production capacity of 1.1 million tonne in Dahej. The deal is targeted to be complete by December 2012.

NATIONAL NEWS COMPETENCE CENTRE

NEW APPLICATIONS

Mahle opens filter factory in Chennai

Sabic’s plans for Indian auto market

Mahle Group (Stuttgart, Germany) has opened a purpose-built 3,300-sq m new filter production plant in Chennai to serve as a competence centre for its injection moulding technology in India. It will supply air filter modules to Indian vehicle manufacturers. First orders of customers are already at hand. Mahle had organised a ground-breaking ceremony for the new plant in June 2010, with the construction completed by December. Installation of production equipment and basic facilities were finalised in January 2011. The new facility will start production of air-filter systems, intake modules and cylinder head covers with integrated oil mist separation. The company has already received large-scale orders for these product groups to supply automobile manufacturers in the Chennai area. The first intake modules and air filters will be dispatched in August 2011. “The new plant in Chennai will be established as a competence centre for injection moulding. It will be a model for other Mahle filter factories in India, which currently do not have in-house injection moulding, besides over-moulded air filter elements in the Gurgaon location,” said Heinz K Junker, Chairman, Mahle Group.

INAUGURATION

Nu-Vu Conair Plc establishes new facility in Ahmedabad Nu-Vu Conair Pvt Ltd, manufacturer & exporter of plastic auxiliary equipment, has inaugurated its new manufacturing/office facility at Piplaj, Ahmedabad. Through this, the company with its global headquarters and Global Technology Centre in Cranberry, USA, aims at increasing global production capacity. The new facility is spread over a 100,000 sq ft area, with a stateof-the-art assembly and paint shop. Along with its technological prowess, the plant boasts of eco-friendliness. The new facility also incorporates a flexible and agile approach to manufacturing, which will ensure that it is future ready and able to respond rapidly to changing customer needs. Key focus areas include people, environment, connected manufacturing and operational excellence. The plant has been envisioned as the hub of innovation and technology for Nu-Vu Conair, which plans to roll out several new products this year. The firm has made considerable investments in the project and believes that it will set new standards for Nu-Vu Conair Plc and the plastics auxiliary industry.

Modern Plastics & Polymers | June 2011

Sabic Innovative Plastics plans to launch a series of products targeting the Indian automobile market. The company is gearing up to launch Lexan GLX polycarbonate in India to replace glass for automotive glazing application. Manish Chaturvedi, Segment Manager, Automotive Product Marketing Unit, Sabic, Bengaluru, said, “It is less than half in weight as compared to glass, scratch-resistant and relatively harder.” He added that an Indian automaker is commercialising Lexan EXL polycarbonate by the end of 2011. Sabic is targeting the material for use in steering wheel and air bag covers. Sabic currently supplies Lexan for automobile lighting, door handles and interior components. The company is also lining up the launch of Xenoy – APC PBT for bumpers for new vehicles in 2014, which would help meet new pedestrian safety laws. Sabic has a facility in Vadodara and a technical centre in Bengaluru, with 250 employees. Chaturvedi added, “With the increasing size of the Indian automobile market, Sabic is planning for expansion at its Vadodara centre in the next few years.”

SUPPLY ORDER

Rajoo Engineers supplies film line to Polypack Rajoo Engineers Ltd is one of the first Indian companies to supply a three-layer blown film line to a customer in Pakistan. Rajkot-based Rajoo customised the extruder for the Lahore-based Polypack Pvt Ltd, a major flexible packaging supplier in Pakistan, with products including shrink film, milk pouches and lamination-grade film. Sunil Jain, President, Rajoo Engineers, said, “For Rajoo, this sale provides a significant entry into the Pakistan market by being the supplier of a multilayer blown-film line to Polypack, one of the largest manufacturers of polypropylene woven sacks in Lahore as the first reference.” The line installed is equipped with 2 x 50 mm and 1 x 60 mm grooved feed barrier extruders.

The machine is made with fully automatic load cell-based tension-controlled surface winder. To compensate lasting thickness irregularities, which cannot be prevented, the take-off unit is furnished with an oscillating hauloff unit. In addition to other film products, the machine is designed to produce 37.5-micron film with 1,500-mm lay-flat width and output of 250 kg/hr.

ASIA NEWS MARKET TRENDS

Dampening auto sales in China not to hit plastics consumption

While China’s automobile industry is slowing from the breakneck growth of the previous two years, this is unlikely to dent the plastics consumption in its automotive industry, as the country’s auto makers are gearing up to expand their use of polymers. BASF, based in Ludwigschafen, Germany, has recently made heavy NEW TECHNOLOGY

Chang’an claims first allplastic front end for China car

Chang’an Automobile Co has manufactured the first all-plastic front end for a Chinese developed car. The long glassfibre polypropylene part is 40 per cent lighter than the steel parts it replaces, thus reducing vehicle weight by about 4 kg and lowering emissions. It also allows for modular assembly on the company’s production lines, reducing its overall system costs, according to company officials. ALLIANCE

JCI forms joint venture in China Johnson Controls Inc (JCI), a global automotive interior manufacturer, is forming a Joint Venture (JV) in the southern Chinese city of Changsha to supply interiors for an assembly plant being built there by Guangzhou Automobile Group Co Ltd (GAC) and Turin, the Italybased Fiat Group Automobiles SpA. The large JCI facility will include injection moulding machines with clamping forces of 800-3,200 metric tonne. The 30

Modern Plastics & Polymers | June 2011

investments in automotives in China, and announced doubling the capacity of its Shanghai engineering plastics compounding factory by 2015. The firm recently broke ground on an 8 billion yuan ($ 1.23 billion) methylene diphenyl di-isocyanate production facility in Chongqing. The country’s car makers are on a steady path to boost their use of plastics from the current levels, and which will not change, stated Albert Heuser, President - Market and Business Development, BASF in Asia Pacific. China’s car makers, for example, use only about 50 per cent of the amount of commodity plastics used by Western European car firms, and even less so for engineering grades of plastics made by BASF, informed Andy Postlethwaite, Senior Vice President-Engineering Plastics, BASF in Asia Pacific. Chang’an, based in Chongqing, China, uses Stamax LGFPP material from Sabic Innovative Plastics. “We have achieved significant improvements in quality and productivity,” said Wang Xiao, R&D Director-Interiors and Exteriors, Chang’an. He further stated, “Integration of 22 metal components into one injectionmoulded part has greatly simplified the front-end structure of the CX30 model for lighter weight, easier assembling and overall cost reduction.” new site will manufacture the interiors for vehicles produced by the new GACFiat JV. John Moulton, Group Vice President and General Manager, JCI, China, ‘Automotive Experience’ unit, said, “We make the entire interior,

BRAND INTEGRATION

Teknor Apex Asia Pacific Pte Ltd replaces Singapore Polymer Corp Teknor Apex Co has established a new corporate name for its operations that serve Asia, the Middle East and Oceania – the region that stretches from Saudi Arabia to New Zealand. Teknor Apex Asia Pacific Pte Ltd replaces Singapore Polymer Corp, a business that was bought by Pawtucket, RI-based Teknor Apex, in 2001. A sister company in China, Teknor Apex Suzhou Advanced Polymer Compounds Co Ltd, has a similar name. Stanly LK Tan was appointed Managing Director of both enterprises. “Combining all our operations under the Teknor Apex brand represents the culmination of a decade long process of integration that has created one company in fact, and not just in name,” said Tan. He added, “Whether our customers are based in Saudi Arabia, India, China or Australia, they now have the assurance of dealing with a single organisation having uniform standards, product designations, business practices and regulatory approvals.” instrument panel, door panels, floor console, overhead console and key interior components.” Moulton informed that the investment will be ‘sizable’, not only for the facility but also for training a workforce in Changsha. “There are not many people with experience in automotive in that area. We need to hire people and train them to build up the workforce there.” The JCI plant will employ 700 people. The GAC-Fiat auto assembly plant in Changsha is expected to start operation in mid-2012.

ASIA NEWS DEMAND PROSPECT

Sabic optimistic about engineering resins

The engineering resins market is facing volatile feedstock prices, increased regulation and a margin squeeze. “But the glass half full feels much better,” SAFETY POLICY

Thailand to ask Indonesia to halt safety measures against Thai polypropylene The Indonesian government has started an investigation against polypropylene exported by Siam Cement Group of Thailand. Meanwhile, Thailand plans to request Indonesia not to put in place safeguard measures against imports of Thai polypropylene. INTEGRATED INFRASTRUCTURE

Petronas to construct refinery and petrochemicals complex Petronas plans to construct a $ 20-billion integrated refinery and petrochemicals complex in Southern Johor to be commissioned by the end of 2016. The project, known as the Refinery and Petrochemicals Integrated Development (RAPID), is in the detailed feasibility study stage and would comprise a crude AGREEMENT

Ma’aden, Sahara in new caustic soda and EDC joint venture The Saudi Arabian Mining Company (Ma’aden) and Sahara Petrochemical Company (Sahara) have established a new joint venture for manufacturing

Modern Plastics & Polymers | June 2011

said Nitin Apte, General Manager, Global Marketing and Technology, Sabic Innovative Plastics. Apte cited big future markets such as solar power, electric vehicles, home healthcare and Light Emitting Diode (LED) lighting, in a keynote speech during the Society of Plastics Engineers’ ANTEC 2011. Citing numbers from Chemical Market Associates Inc, Apte stated that global engineering resin demand should grow by 3-8 per cent per year. “We are optimistic about engineering thermoplastics. Many of the megatrends are opportunities and will need innovation,” said Apte. In 2010, Thailand exported almost three times its polypropylene exports in 2009, ie, about 250,000 tonne. This increased amount was because of the shutdown of a 260,000-tonne plant by Indonesia’s second-largest producer, which reduced the domestic production to levels that could serve only 60 per cent of total demand. Thailand believes that the increased exports did not affect the Indonesian domestic industry due to lack of sufficient domestic availability. oil refinery, a naphtha cracker that would produce about 3 million tpa of ethylene, propylene, C4 and C5 olefins as well as a petrochemicals and polymer complex that would produce differentiated and highly specialised chemicals. This project would enhance Malaysia’s refining capacity in products such as gasoline, jet fuel and diesel to meet the nation’s growing fuel requirements indigenously and boost fuel exports. caustic soda and Ethylene Dichloride (EDC). The $ 750-million (SR2.81 billion) project, located within the Sahara complex in Jubail Industrial City, will produce 250,000 tpa of caustic soda and 300,000 tpa of EDC. This joint venture arrangement follows the announcement made

MARKET UPDATE

Indonesia’s Chandra Asri skips spot naphtha purchases in June Indonesia’s Chandra Asri will not buy any spot naphtha cargoes for June as it advances a medium range-sized term cargo scheduled for delivery into Anyer in July to meet its June requirements. This decision comes amid firm premiums being reported from India and the Middle East, which have translated to strong Code of Federal Regulations (CFR) premiums for Asian markets. Chandra Asri usually seeks 1-2 medium range-sized parcels of either light or full-range naphtha every month, which it feeds into its sole naphtha-fed steam cracker at Anyer. The cracker can produce 600,000 tpa of ethylene and 306,000 tpa of propylene. For May and June, the company is keeping its cracker run rate stable at 90 per cent.

Medium range-sized cargoes of light naphtha for delivery into Anyer is estimated to command a premium of $ 20/Million Tonne (MT) to MOPJ naphtha assessments, which could have contributed to Chandra Asri’s decision to not buy a spot cargo for June. This is the second consecutive month that the petrochemical producer has decided to skip spot purchases. The company had previously bought two spot naphtha parcels totaling 60,000 MT for delivery into Anyer for April. However, the company may have to seek more spot cargoes for July. last year by both companies with regard to the approval received from the Saudi Industrial Development Fund to provide $ 240 million (SR900 million) in project financing. Sahara is 90 per cent owned by Zamil Group Holding.

MPP June 2011 Ad Name: Alok Pg No. 33

MPP June 2011 Ad Name: Boge Pg No. 34

WORLD NEWS

PORTFOLIO EXTENSION

DSM expands functional materials business unit DSM has announced expansion of its innovation activities in the area of formulated coatings and composites with the formation of DSM Functional Materials Business Unit. This announcement was made following an extensive strategic study for its resins businesses – part of DSM’s performance materials cluster. The activities of its current DSM Desotech Business Unit will be integrated into this new structure. DSM Desotech is the world leader in the development of high-performance UV-curable materials including the topselling brands of DeSolite® optical fibre coatings and Cablelite® inks for the telecommunication industry and Somos® stereolithography additive fabrication materials. In 2008, this UV-curable portfolio was expanded to include UVolve® Instant Floor Coatings and UVaCorr® anticorrosion coatings for tubes and pipes. FDA APPROVAL

Eastman 168™ gets additional US FDA food contact clearance Eastman Chemical Company has recently announced US Food and Drug Administration (USFDA) expanded food contact clearance for its Eastman 168™ non-phthalate plasticiser. Food Contact Notification (FCN) 1056 permits the use of Eastman 168 in contact with all food types at levels up to 55 per cent FUTURE PLASTICS

Automobile experts debate the future of CFRP At the VDI conference on Plastics in Automotive held recently in Mannheim, Germany, experts focussed on using Carbon-Fibre Reinforced Plastic (CFRP) for lightweight design of vehicle. Huber Jäger, Head-Technology and Innovation, SGL Group, said that the future lies in hybrid CFRP and aluminium design. Günter Deinzer, ManagerTechnology and Fibre-Reinforced Plastic Composites, Audi, stated that 36

Modern Plastics & Polymers | June 2011

CAPACITY EXPANSION

LANXESS expands capacities for Therban

Specialty chemicals company LANXESS is expanding its production capacities by 40 per cent for Hydrogenated Nitrile Butadiene Rubber (HNBR) at its facilities in Leverkusen, Germany, and Orange, Texas, USA. This synthetic highperformance rubber is marketed under the brand name Therban. LANXESS will invest a small amount in this expansion. “We are responding to the significant increase in global demand for this high-performance rubber and are rigorously continuing our growth strategy,” informed Günther Weymans, Head-Technical Rubber Products (TRP) Business Unit, LANXESS. Expansion work has begun in the German and US production facilities. The expansion in Leverkusen is scheduled for completion in April 2012, while the

facilities in Orange will be ready by December 2012. These measures will create 15 new jobs. The global HNBR market is currently growing at a double-digit annual rate. This growth is particularly driven by a strong global demand from automotive manufacturers, especially in China and India.

by weight of the finished plasticised Polyvinyl Chloride (PVC) formulations for repeated-use articles. “The new FCN 1056 for Eastman 168™ non-phthalate plasticiser further solidifies the safe use of this novel plasticiser,” commented Brian Yobst, Manager-Plasticizers Business Unit, Eastman. He elaborated, “This expanded clearance by the FDA will allow more brand owners to realise the benefits and efficiencies of Eastman 168.”

Eastman 168™ non-phthalate plasticiser has over 30 years of experience of safe use in sensitive applications like food contact, toys & childcare articles and medical devices. It has a long and growing track record of regulatory clearances and is supported by a clean and comprehensive toxicological profile. Eastman 168 offers customers regulatory compliance and differentiation without sacrificing performance or the need for major changes to manufacturing processes.

CFRP is a logical development in Audi multi-material lightweight design strategy in terms of economy and ecology potential.

metric tonne per year by 2015. The automotive CFRP use could account for 4,000-6,000 metric tonne annually by then. Jäger explained, “It takes a while to get into the car development process. So even 10 per cent use in automotive by 2015 would be a lot.” He added, “How do we get away from an oil base for carbon fibres in future, as 2 kg of plastic precursor is needed for 1 kg of carbon fibre?” On this, Deinzer said, “We are not yet ready for large series production, as further development is needed.”

Carbon fibre producers worldwide are striving towards achieving a production capacity of 60,000-65,000

WORLD NEWS PRODUCT LAUNCH

Dow, PolyOne introduce PLA masterbatches

INVESTMENT

Dow Plastics Additives, a division of Dow Chemical Co, has teamed up with PolyOne Corp to introduce OnCap BIO L masterbatches, a range of additives aimed at users of bioplastics in packaging markets. OnCap BIO L is based on Paraloid BPM-520, an impact modifier manufactured by Dow that helps improve the impact resistance of opaque, injection moulded Polylactic Acid (PLA) products, with minimal effect on heat distortion temperature and stiffness. Dow has selected PolyOne as its exclusive European formulator for converters seeking ready-to-use formulations with Paraloid BPM-520. According to the company, OnCap BIO L additive masterbatch broadens the choices available to brand owners looking to use sustainable polymers in applications like opaque ice cream & food packaging as well as semi-durable applications such as cosmetic packaging and housing for laptops or mobile phones. “We have worked closely with PolyOne to offer an effective impact modifier to help extend the use of bio-based PLA resins into injection moulded packaging,” said Robin Madgwick, Marketing Manager, Dow Plastic Additives. NEW FACILITY

BASF SE successfully commissions Ecoflex® plant in Ludwigshafen In early 2011, Uhde Inventa-Fischer and BASF SE have successfully commissioned a plant for production of Ecoflex®, a biodegradable co-polyester polymer developed by BASF. The production capacity at the Ludwigshafen (Germany) plant can be increased from the current DEMAND SUPPLY

Europe boosts infrastructure for thriving petrochemical demand

Modern Plastics & Polymers | June 2011

DuPont Packaging & Industrial Polymers expand capacity in the Netherlands DuPont Packaging & Industrial Polymers has announced that it will increase capacity at its site at Dordrecht, the Netherlands. This expansion aims to meet strong demand for specialty copolymers such as DuPont Bynel adhesive resins, DuPont Fusabond modifier resins and DuPont Appeel lidding sealants, which are used in packaging, construction and industrial markets. This expansion will enhance the company’s global network of manufacturing capabilities at its sites in North America, Europe and Asia Pacific. These specialty copolymers will be available from Dordrecht starting July 2011. According to DuPont, the investment helps

improve supply reliability to all regions and provides another platform for new products & technology development. “Investing to increase capacity accelerates DuPont’s ability to respond to rapidly growing demand worldwide, particularly in Central Europe and Asia,” said Carolann Haznedar, Global Business Director, DuPont Ethylene Copolymers. Fusabond enables reuse of mixed plastic waste streams. Bynel plays a critical role in reducing the amount of material in multilayer packaging structures and Appeel adds sustainability benefits for package convenience features.

14,000 tpa to 74,000 tpa. The plant uses the patented proprietary 2R technology of Uhde InventaFischer. The proven and particularly energy-efficient Uhde Inventa-Fischer 2R process has been geared to the needs of the customer BASF and is ideal for producing the sustainable plastic Ecoflex®. The 2R process was invented by Uhde Inventa-Fischer and is based on the patented Espree®

and Discage® reactors. In the two reactors, the process-relevant chemical reactions as well as formation of polymer chains occur. The finishing process steps for the end-product are part of the BASF know-how. The Uhde Inventa-Fischer scope of supplies and services includes basic and detail engineering, supply of essential plant equipment and supervision of erection and commissioning activities.

Increased cargoes of refrigerated propane are flowing into Northwest Europe as a result of thriving petrochemicals sector demand. Onset of warm weather, which has reduced demand from the traditional heating market, has been replaced by emerging healthy demand from the petrochemicals sector where propane is used as an alternative feedstock to naphtha. Substitution of propane for naphtha is viable as long as the delivered price of propane is at a discount to that of

naphtha. More than 100,000 Metric Tonne (MT) of propane from Algeria and the US Gulf arrived in Northwest Europe with Dow, Borealis and Sabic, all of which are reported to have received refrigerated imports for use as feedstock. More imports, totaling about 120,000 MT, are expected to arrive, with suggestions of even more cargoes. The propane/naphtha price ratio was reported to be just over 90 per cent, which showed slight increase and is currently at 92.1 per cent.

TECH UPDATES

‘Green Pipe’ an alternative for stormwater and drainage systems

Developed and manufactured in regional Australia, the ‘Green Pipe’ is an environment-friendly and costeffective answer to low-pressure fluid applications. Manufactured from 100 per cent recycled High-Density Polyethylene (HDPE) by Recycled Plastic Technology Pty Ltd (RPT), the ‘Green Pipe’ has rapidly become the first choice for farmers, engineers, councils, National Parks and Forests, developers and a host of other users. Dam work, drainage, stormwater and culverts are typical applications for the ‘Green Pipe’. It is made in 6-m lengths and creates fewer joints during installation, improves laying rates and minimises potential leakage points. Even the highest level of acidic soils have no effect on these, and once installed, will last indefinitely. These can easily be cut with a chainsaw, circular saw or angle grinder. The ‘Green Pipe’ is extensively used across Australia as a crossing or culvert by primary producers, contractors, foresters and government bodies. Combined with RPT’s 100 per cent recycled plastic headwall to provide the total package, the ‘Green Pipe’ correctly installed with recommended minimum coverage and side compaction can carry the heaviest legally loaded traffic and provide years of trouble-free service under the roads.

University of Warwick devises new technique to process 100 per cent of household plastics

Researchers at University of Warwick have devised a new technique that could process 100 per cent of household plastics instead of the small fraction that is currently processed. At present, only 12 per cent of plastic waste is recycled, with the remainder often dumped in landfills or simply burnt as fuel. The researchers, with support from AWM’s Science City funding, have devised a unit that uses pyrolysis (using heat in the absence of oxygen to decompose materials) in a ‘fluidised bed’ reactor. They put large amounts of mixed plastics in a reactor so that these can be broken down to useful products. Most of these can be retrieved by simple distillation. This finding could have a significant impact on the budgets of local authorities and produce considerable environmental benefits. The laboratoryscale tests have successfully produced distilled liquids and solids that can be used for processing into new products.

New design helps Plastic Technologies get grip on PET bottles

Plastic Technologies Inc (PTI) and Procter & Gamble have jointly developed a breakthrough grip handle technology for containers – Deep Grip technology. It creates a grip that is deep enough for the average-sized hand to completely close around and still not have the fingers of the individual holding the bottle touch the container wall. This will give consumer product goods companies an opportunity to reduce packaging weight by as much as 25 per cent and explore new design

Modern Plastics & Polymers | June 2011

Ford’s MuCell plastic technology uses air bubbles to reduce weight Car makers are working to make the greenest car possible, where one easy way to decrease emissions is reducing weight. Ford, with the help of researchers at Massachusetts Institute of Technology (MIT), has developed a new plastic technology called MuCell. In this technology, small bubbles of nitrogen or carbon are injected during the manufacturing process to reduce weight of the plastic components by 10-20 per cent, while maintaining nearly the same strength. The technology is slowly being implemented and the first cars equipped with MuCell plastics will roll out of Ford’s lines in the next few years. So what components will be made with this so-called MuCell plastic? Ford plans to begin with engine covers and slowly spread the technology to fan shrouds, radiator end tanks, wing mirror housings, airbag covers, etc. Mazda also plans to use MuCellproduced parts for its instrument panel retainers and door panel liners. This specific technology has existed since 1995 but has become viable only at present. Ford will start using this new plastic material extensively by 2020.

aesthetics, particularly where high clarity is desired. “The Deep Grip technology is an ideal option for brand owners looking to reduce weight & cost of their containers, improve their environmental profile and create ways to differentiate their product,” said Vincent Le Guen, Managing Director, PTI-Europe, Yverdon-les-Bains, Switzerland. PTI-Europe, a subsidiary of PTI, will initially market the new deep grip containers in partnership with Sidel Group in Le Havre, France, an industry division of privately owned Tetra Laval International S.A. in Pully, Switzerland. The initial target markets for the new containers are detergent bottles,

household cleaner containers, milk, edible & motor oil containers, baby bottles and non-carbonated beverages, eg, juices, ready-to-drink tea & water.

TECH UPDATES

New technology for plastic composite lumber

Recycled plastic composite lumber has been manufactured for 20 years, most commonly from relatively pure post-consumer plastics such as High-Density Polyethylene (HDPE). Until now, there was no way to produce a consistently high-quality product from mixed feedstock. However, Cierra Industries Inc has developed a new technology that enables processing of mixed environmental wastes and plastic material into extruded composite lumber, which can be used for building materials such as windows and door trims, outdoor flooring materials, complete panels for structural buildings, outdoor furniture, marine application and a number of other structures. Years of research and trial & error developments have finally resulted in a reliable system that yields a quality assured product from low-end materials. Thirdgeneration Cierra lines are now producing up to 65 per cent recycled cellulosic materials and 30 per cent recycled plastic materials.

Phones made from recycled plastics Cell phones have been classified as hazardous material because of electromagnetic radiation they emit and their electronic composition. These contain substances such as antimony, arsenic, beryllium, cadmium, copper, lead, nickel and zinc, which belong to a class of chemicals known as persistent toxins. These toxins remain in the environment for prolonged periods. Safe disposal of cell phones is necessary to protect the environment and health from a build-up of these toxins. Considering these facts, a cell phone has been made using biodegradable or recycled materials, which helps reduce the problems of disposal due to toxic waste that piles up every year as cell phones are discarded. Recently, Samsung Replenish – an Android touch QWERTY smartphone – partially built with recycled plastics & packaging materials – manufactured by Sprint, has been introduced to the market. The smartphone is encased in partially recycled plastics, is energy efficient and built with fewer number of environmentally sensitive materials. This smartphone offers eco-credentials such as using less environmentally sensitive materials, energy efficiency and nearly 82 per cent of the device is made from recyclable materials. Also, an optional solar charging battery cover made from Naturacell will be available for Samsung Replenish.

Modern Plastics & Polymers | June 2011

Innovative technology that utilises waste plastics to construct roads

A new technology developed by a team of entrepreneurs to use waste plastic materials for construction of roads has caught the government’s attention. The government is now contemplating to use this innovative method on a large scale. K K Polyflex, a Bengaluru-based firm manufacturing plastic goods, has come up with the new technology, which also addresses the problem associated with disposal of plastic wastes in an environment-friendly manner. The Centre for Transportation Engineering and Civil department of Bangalore University carried out the tests to assess its strength and durability. Waste plastics are a good material for construction of roads, as these increase the life of roads threefold. Also, these would reduce the frequency of road repairs, as the chances of seepage of rain water is minimised due to the presence of plastics. Although the cost of road construction using this technology will be slightly higher than the conventional method, it should not deter the government from adopting it, as the benefits that it provides are higher than the cost.

Polymer that self-heals in one minute on exposure to UV light

A self-healing material has been developed that can repair in about one minute under Ultraviolet (UV) light. This polymeric material relies on localised heating and metalligand interactions. A team of researchers from the Case Western Reserve University, the Army Research Laboratory at Aberdeen Proving Ground and the Adolphe Merkle Institute of the University of Fribourg have developed a polymer-derived substance that can heal on its own when exposed to UV light for not more than one minute. This polymer-based substance is not yet ready for commercial use. In future, these substances could find use in varnishes for furniture & floors, motor vehicle paints, etc. The polymers include a Napoleon Complex and the distinct weak molecular interactions offer innovative behaviour to these small polymers. The molecular layout of the polymers enables them to alter their characteristics when exposed to intense UV light. These substances are made of tiny molecules grouped in long, polymer-resembling chains by using metal ions as ‘molecular glue.’

ANNIVERSARY SPECIAL

SIX GROWTH AVENUES FOR PLASTICS Automotive .............................................................. 46 Electrical/Electronics ................................................. 60 Medical Plastics ....................................................... 72 Packaging................................................................ 80 Construction ............................................................ 86 Bioplastics ............................................................... 94

June 2011 | Modern Plastics & Polymers

INDUSTRY INSIGHTS AUTOMOTIVE

Plastics in automotive

Engineering new-generation vehicles With automotive being one of the most dynamic manufacturing sectors in India, cost and efficiency of fuel are fast emerging as pivotal market drivers. Annabel Dsouza traces the route of this industry, as it continues to evolve and show huge potential for plastics in the future.

Courtesy: 2010 Ford Motor Company Courtesy: LotusCars

n a burgeoning Indian economy, automotive is a sunrise sector. Following its delicensing in 1991 by the New Industrial Policy, there has been no looking back ever since. The automobile industry in India has developed rapidly, with a Compounded Annual Growth Rate (CAGR) of nearly 20 per cent and domestic sales growth at 13 per cent. India currently stands as the worldâ&#x20AC;&#x2122;s ninth largest market for this industry and the fourth largest exporter of automobile and auto components.

Modern Plastics & Polymers | June 2011

Apart from leading Indian manufacturers, the industry is witnessing intensive investments by Multinational Companies (MNCs). Indiaâ&#x20AC;&#x2122;s growing middle class population is expected to further drive the demand for passenger cars as well as commercial vehicles. As it is predicted that most Indians will own cars by 2015, the concerns of the industry have shifted towards making automotives more affordable while also reducing their environmental impact. Thus, performance plastics play

INDUSTRY INSIGHTS AUTOMOTIVE

a significant role in today’s automotive manufacturing space. The focus on the use of plastics in the automotive industry has particularly increased since the mid2008, when the credit crunch began to drastically influence automotive sales and production. Govind Ramakrishnan, Research Analyst-South Asia & Middle East, Chemicals, Materials & Food, Frost & Sullivan, says, “Globally, the long-term trends for plastics usage are still strong, driven primarily by the urgent need to reduce the carbon footprint of travel. This is best enabled by increasing the amount of lightweight plastics used in automotives, as lighter vehicles allow lower fuel consumption, and hence lower emissions.”

Current market trends On an average, the use of polyamide per car in Europe is 20 kg, while Korea is not far behind with 15 kg. However, in India, an average of less than 5 kg polyamide is used per car. The increased use of plastics

for weight reduction is currently a global trend. A 10 per cent weight reduction will decrease 25 kg of CO2 emission in the lifetime of a car. Global automotive plastics market is projected to cross 12.7 million tonne by 2015, as per global industry analysts. Although, Europe represents the largest market for automotive plastics, Asia-Pacific represents the fastest growing automotive plastics market, with a CAGR of 8.5 per cent. This reveals the infinite opportunities within India’s automotive plastics applications. P Balendran, Vice President, Corporate Affairs, General Motors-India, states, “The use of plastics as structural components in closures, roofs, hoods and front end systems is an emerging trend. Adhesives are being used to reduce Body In White (BIW) spotwelds, while foams are used for acoustic and structural appearance. A general practice today is to use bumper fascias, which are painted through moulded-in film application. Carbon and glass fibre composite matrix in plastics

Globally, the longterm trends for plastics usage are still strong, driven primarily by the urgent need to reduce the carbon footprint of travel. Govind Ramakrishnan

Research Analyst-South Asia & Middle East, Chemicals, Materials & Food, Frost & Sullivan

June 2011 | Modern Plastics & Polymers

INDUSTRY INSIGHTS AUTOMOTIVE

As material science evolves in future, the balance of commercial success will drift towards the material that meets all part functions at a lower cost and weight penalty. P Balendran

Vice President, Corporate Affairs, General Motors-India also provide an option for adequate structural strength.”

Innovation index The growing array of specialty and commodity plastics developed for automotive applications like interiors, lighting, glazing, structural components, etc, have driven the market growth. The creative use of plastics is rising, as Original Equipment Manufacturers (OEMs) and suppliers find opportunities to replace conventional materials across their existing product lines. Global automotive OEMs clearly stipulate the essential requirements expected from automotive materials. The primary specifications are mechanical, physical and thermal properties. The second is part performance standards, including functional characteristics, aesthetics, environmental safety and statutory compliance. These factors play a crucial role during the compounding process and formulation design, thereby impacting the selection of base resin, type & level of impact modifier, proportion 48

Modern Plastics & Polymers | June 2011

of reinforcing agent and additive/ pigment package. Over the years, Polypropylene (PP) has gained technical and commercial importance in low-cost vehicles as well as luxury cars. It is a preferred material in the compounded form for automotive interiors, exteriors and under-the-hood & chassis applications. However, today all types of plastics like Polyurethane (PU), Polyamide (PA), Acrylonitrile-ButadieneStyrene (ABS), Polycarbonate (PC), etc, are applied to high-end automotive demands. With increasing usage of plastics in automotives, innovations towards reducing total part count as against steel components are also gaining great significance. Efforts are directed towards large-scale process integration of injection moulding and thermoforming of plastic components. The automotive industry is the largest user of Reaction Injection Moulded (RIM) PU parts. Without adding weight or bulk, RIM maximises the shock absorption capacity of car fenders, bumpers and spoilers. Lightweight RIM PUs provide cars with better gas mileage and allow for affordable, innovative designs. Metal alloys that were earlier used for automobile exterior parts are now being replaced by RIM PU, as these were susceptible to dents, dings, stone chips and corrosion. Today, several interior components are made with RIM PU, such as steering wheels, air ducts, floor mats and seat bottoms. Another advantage of performance polymers is that they suit higher automation levels to control engine performance. As cars change from mechanical to more ‘electronic’ machines, they need to be engineered with plastic components that provide electronic shielding as well as increased heat and chemical resistance. This results in greater demand for engineering thermoplastics. Ramakrishanan asserts, “Driving these innovations are government initiatives in the form of incentives or punitive fines, in order to reduce per vehicle environmental

footprint as well as enhance driver and pedestrian safety.”

Countering challenges In optimising material economy, plastic components are more durable than those produced from conventional materials. Also, plastic coatings on the underbody of a car provide protection against corrosion and contribute significantly to extending the car’s life. In almost all areas of plastics use, a mechanical recycling infrastructure continues to develop. Larger car parts such as bumpers are most suited to mechanical recycling because these can be easily dismantled and offer a single type of plastic, with good recyclable quality. But, as several plastic car components are small in size or encase other materials like electronic devices, the disassembly to create large quantities of single-type plastics waste can be challenging and expensive. Alternative recovery routes are therefore required to balance the environmental gains from lightweight components, with the challenge of increasing recyclability. Automotive manufacturers continue to face unrelenting pressure in the areas of regulatory compliance, global competition and cost control while striving to meet industry demands. Converting from glass, metal and other conventional materials to plastics or creating entirely new components from plastics can help OEMs and suppliers find answers to most of the challenges.

Future scope Greater use of plastics in vehicles to substitute metals and glass is vital to reduce the manufacturing costs and, subsequently, cost of the vehicle. The market drivers allow for easy entry with low capital costs. Manufacturers who are in tune with the latest technological advancements and applications will be the suppliers of choice. Balendran concludes, “As material science evolves in future, the balance of commercial success will drift towards the material that meets all part functions at a lower cost and weight penalty.”

MPP June_2011 Ad Name: KPL Tab-2, Pg No. 51

D&M Enterprises

MPP June_2011 Ad Name: D&M Tab-2, Pg No. 52

VIEWPOINT

“All major global automotive moulders have established a manufacturing footprint in India” Sanjay Jain, Business Director, DSM Engineering Plastics India Opportunities for automotive plastics in India With India’s booming automotive industry, the engineering plastics segment is expected to be greatly benefitted. There is significant awareness and demand for energy savings and emission reducing solutions, especially with soaring oil prices. Weight reduction is a key factor to solve these issues, which provides enormous opportunities to engineering plastics suppliers.

Current market dynamics In the Indian market, the use of metal still dominates, so penetration of engineering plastics is in line with global usage. Also, the production numbers are increasing due to overall economic progress of the country. Key demand drivers are weight reduction and sustainability, which promote use of engineering plastics. We are observing an increased usage of recycled plastics, followed by introduction of bio-based materials. An example is EcoPaXXTM Polyamide (PA) 410, a bio-based, high-performance resin that is carbon neutral from ‘cradle to grave’. About 70 per cent of this innovative polymer’s building blocks are derived from castor oil. It also delivers exceptional performance, including mechanical properties, chemical resistance and a high melting point, and is therefore 50

Modern Plastics & Polymers | June 2011

suitable for a number of demanding automotive applications.

Emerging innovations Engineering plastics are used in a temperature range restricted by their melting temperature, which is lower than that of regular metals. Also, for large production volumes, the productivity of engineering thermoplastics via injection moulding outperforms that of regular metals. Plastic materials have major benefits over metal in areas with a huge potential for integration of multiple functionality without the need for secondary operations. DSM is known for the quality of its engineering plastics products and technological solutions.

India’s growth index in the global industry As compared to global standards, the Indian automotive plastics industry is still in a nascent stage but showing a rapid growth. All major global automotive moulders have established a manufacturing footprint in India. This creates competition for the local Indian players and indicates that the overall standard of the industry will dramatically improve in the coming years.

Sustainability functions As a market leader, DSM ensures the effecient use of energy and raw materials

in order to reduce the environmental impact of our activities. However, at the same time, we must work towards improving the eco-efficiency of our products and processes on a continuous basis. As OEMs and end-users are looking to reduce their environmental impact, we aim at engineering plastic products that meet the industry’s specific sustainability needs. These include the quest for lower emissions and reduced fuel consumption as well as further weight reduction. In the Dow Jones sustainability index, we are listed as one of the leaders in the chemical industry sector. In 2010, five of our performance materials were awarded Cradle to Cradle® certification by the internationally renowned sustainable design firm, McDonough Braungart Design Chemistry (MBDC).

Export market scenario There is huge export potential for Indian suppliers. India has proved itself capable for the export of metal auto components and the same can be done for plastic components. The first opportunities will be more in the exterior and interior components of the car, which will later move on to critical components for engine parts. Therefore, Indian suppliers need to first prove to OEMs locally that their supplies are competitive, quality conscious and reliable.

TREND ANALYSIS AUTOMOTIVE

Polyamide 6 and 66

Proving their mettle over metals The excellent strength and toughness during exposure to hot, aggressive automotive fluids or hot air make polyamides useful for manufacturing durable and functional components for automobiles. The rigidity of polyamides reinforced by glass fibres can be equivalent to that of metals, and thus can be considered in metal replacement projects. The remarkable properties of these materials make them indispensable in nearly all fields of engineering for various machine components and specific applications.

he use of engineering thermoplastics in automotive components has grown significantly over the last several years, with a number of new applications emerging in electrical and other vehicle areas. Typical modern vehicles have a majority of components made from plastics. Some of the main forces driving demand growth include weight reduction, production gains and more design flexibility, eg, air intake manifolds, fuel supply, etc. Properties such as excellent heat resistance, mechanical strength and rigidity have made polyamides (PAs) successful in these areas. Polyamide (PA6) and PA66 are among the most important polymers by volume on the world market for engineering plastics. The automotive

Front end

Coolant pipes

Short-handled connector Courtesy: LANXESS AG

industry continues to be one of the largest consumers of compounded PA6 and PA66. The largest producers of PA66 compounds are DuPont, Rhodia and BASF, while LANXESS, BASF and DSM lead in PA6 production. In automotive engineering, PA6 and PA66 find major applications in the production of components for the engine compartment and structural body parts. In under-thehood applications, these materials are faced with new challenges because intensive work is done to improve the efficiency of the â&#x20AC;&#x2DC;classicâ&#x20AC;&#x2122; internal combustion engine while also reducing the engine capacity (downsizing) in order to cut down CO2 emissions and, subsequently, fuel consumption. Therefore, the current trend is of turbocharged engines with selective air and cooling management and, more recently, for petrol engines. This means that PA6 and PA66, from which the pipe systems for air management and oil & coolant circuits are produced, must be capable of withstanding higher temperatures and pressures as well as exposure to chemicals. Below mentioned are some automotive components and functions, which utilise PA6 and PA66.

Air management

Fuel filter 54

Modern Plastics & Polymers | June 2011

In air intake systems, the temperatures in diesel engines, eg, in the area of turbocharger and intercooler, can

TREND ANALYSIS AUTOMOTIVE

reach over 200°C. Efforts are being made to develop PA6 and, particularly PA66 materials, with significantly improved resistance to heat ageing. The first promising materials with reduced heat ageing due to addition of new stabilisers and/or modification of the polymer architecture are now being introduced to the market. The aim here is to offer an alternative material to high-performance plastics, eg, Polyphthalamide (PPA), Polyphenylene Sulphide (PPS) and PA46. Some examples of such materials include the new PA Zytel® Plus from DuPont or Ultramid® Endure from BASF. Air ducts as well as charge and clean air lines are frequently manufactured as combinations of rigid and soft PA blow moulding compounds. Moreover, cost-effective ‘monomaterial’ alternatives are available with special pseudoplastic PA6 variants from the Durethan® product range. Due to High-Temperature Stabilisation (HTS), these materials meet the demands in the upper temperature range and can be conventionally blow moulded or processed by three-dimensional methods with robot parison handling or suction blow moulding. These materials exhibit excellent melt rigidity with good resistance to heat ageing and chemicals, eg, to blow-by gases. With a tensile modulus of 400 MPa (conditioned) the PA6 is so soft that the bellows can compensate relative movements of the engine and assembly tolerances. An even softer material variant with a tensile modulus of 200 MPa (conditioned) was developed for special demands, and this is currently being launched on the market. As far as process and material are concerned, inexpensive alternatives to sequential co-extrusion of the two polyamides with different levels of hardness are therefore available.

Oil circuit An important application for PA6 and PA66 is in oil sumps. Transmission sumps made from PA have been widely

used earlier; therefore, large engine oil sumps are now being manufactured more frequently from PA, including those for trucks. In comparison with sheet steel or aluminium variants, PA offers greater freedom for design in the implementation in case of complex component geometries (eg, limited installation space). Furthermore, it helps in integrating functions such as magnetic metal separators or mountings, eg, for oil filters. This often results in a significant reduction in weight, apart from cost savings. Here, the use of PA66 is not essential, as PA6 exhibits a similar behaviour in hot engine oil. Moreover, oil modules are increasingly being made with PA66 rather than sheet steel or aluminium. The demands for rigidity and strength of the thermoplastic are enormous here. PA6 can also be used here as long as it does not come in contact with the coolant circuit.

Coolant circuit PA66 grades are predominantly used for manufacturing moulded parts for the coolant circuit. In view of the trend towards turbocharged engines, these need to be more heat resistant in the future. The demand is thus moving towards highly reinforced materials that are rigid and have a high modulus of elasticity in tension. An example of this is Durethan® DP AKV 50 HR H2.0, which is reinforced with 50 per cent glass fibres and used for injection moulding of coolant manifolds. Due to its high rigidity, this material enables the component to attach the ignition coil to the coolant manifold by means of an integrated bracket. Some vehicle manufacturers are currently investigating new coolant mixtures containing bio-based components. This will place new demands on the chemical resistance of the PA66 materials used in the coolant circuit. A proven method for manufacturing coolant pipes from PA – apart from

the conventional injection moulding process – is Gas Injection Technology (GIT). Another fast establishing method is the Water Injection Technology (WIT). The most important advantage of WIT over GIT is that water provides better cooling than gases, eg, nitrogen. Therefore, the cycle times can be up to 70 per cent shorter as compared with that in GIT, depending on the geometry of the moulding. Furthermore, larger blow moulding diameters can be achieved with smaller and more uniform residual wall thicknesses.

Fuel supply Another major application of the PA is in manufacturing components for the fuel supply system in the engine compartment. The trend towards alternative fuels is making new demands on the media resistance of PA. This, together with an international testing company, a system supplier for engine compartment components and a fuel producer, Lanxess has tested the long-term resistance of the most important variants of Durethan®. These are employed in the engine compartment for different types of biodiesel and gasoline with various ethanol contents under realistic operating conditions. Moreover, a number of facts and figures are available that describe the mechanical behaviour of PA6 and PA66 grades after up to 5,000 hr exposure to ethanol-based gasoline at 60°C. These figures show that the materials are able to withstand extreme demands. In case of biodiesel, tests were continued at 90°C with up to 20,000 hr exposure in order to obtain the necessary long-term data, for PA components in trucks. In trucks and cars, a technology is gaining importance in which nitrous oxides that are harmful to the environment are removed from diesel exhaust fumes by using AdBlue® urea solutions. Leading PA producers have developed and optimised compounds for applications in contact with AdBlue® that meet the special purity demands June 2011 | Modern Plastics & Polymers

TREND ANALYSIS AUTOMOTIVE

involved, as well as offer adequate resistance to the urea solution. The mechanical behaviour of the PA66 Durethan® AKV 35 H3.0 optimised for applications with AdBlue® remains unchanged after storage for 28 days at 60°C. The composition of the AdBlue® solution is barely influenced by contact with the PA. PA6 is becoming a frequent alternative to die cast aluminium for production of fuel filter housings because it produces components requiring no finishing, offers greater design freedom and saves more weight. In order to ensure that the fuel does not create a static charge in the filter housing as it flows through, the PA6 must be electrically conductive (eg, Durethan® BCF 30X H2.0). This material reinforced with 30 per cent glass and carbon fibres is still ductile, despite the conductivity additive, and can be easily processed and welded. A number of plastic components with continuous fuel contact have been made to date from a multilayer thermoplastic system, ie, based on High-Density Polyethylene (HDPE). Parts such as filler necks can now be produced as mono-material solutions more easily and efficiently in shorter cycle times by blow moulding from the new PA6 and PA66 Fuel’In by Technyl® from Rhodia. Further, PA blow moulding materials designed as single-layer solutions are currently being tested for use in smaller fuel tanks, eg, in motorcycles.

PA car body components Today, PA6 is playing an ever more important role in the lightweight concept for high-strength car body structural components. This applies for the plastic-metal composite technology, also known as hybrid technology. This technique is established worldwide for the production of automobile front ends. And PA6 is being used to make car roof frames and pedal bearing blocks as well as brake pedals for light transporters. The importance of 56

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this material in lightweight construction potential is growing in view of the trend towards the use of electric automobile and problem of climate change. Manufacturing doors, tailgates and hoods or cross car beams and longitudinal members as well as rocker panel for the floor group using the hybrid technology are now also being contemplated. Currently, the performance potential of the hybrid technology is bringing in profits due to new material developments. The leading PA producers have introduced easy-flowing PA variants to the market (eg, Durethan® EF and XF). These are used in the hybrid technology for front ends to reduce wall thickness, and hence further reduce weight. The high flowability of PA allows

Film 7% Textile filament 25% Engineering plastics 32%

Staple fibre 4%

Technical filament 19% Carpet filament 13%

Leading applications of PA6 and PA66 in 2009 Source: PCI Yellow Book 2010

it to be reinforced with far higher glass fibre content. Corresponding products that some PA producers currently have in their product range exhibit exceptionally high strength and rigidity, thereby opening up new areas of design freedom. The hybrid technology allows components to be designed stronger, thinner and lighter. In some applications, the highly reinforced PA grades are already proving to be an alternative to thermoset plastics and metals. A current example of the substitution of sheetmetal is the spare wheel well with integrated reinforcement channels in the new car Audi A8. This wheel is made of one of the PA variants

(Durethan® BKV 60 EF H2.0), which renders significant overall rigidity to the component. The PA reinforced with 60 per cent glass fibres precisely images the complex geometry of the spare wheel well in the injection moulding process, which helps in eliminating time-consuming finishing steps. It is also possible to integrate a total of upto 70 kg of attachments into the spare wheel well. The hybrid technology is now facing a leap forward with the development of organic sheets (glass fibre-reinforced thermoplastic semi-finished goods). These are sheet intermediates made from a glass fibre fabric that is embedded into a PA matrix. These are significantly lighter than steel or aluminium sheets. The organic sheets are thermoformed and processed with PA in the injection moulding process to produce lightweight hybrid structural components with high strength. The first application of this series production is in manufacturing the hybrid front end of the Audi A8. The organic sheet is used in the lower beam of the front end. The highly integrated front end satisfies all demands with respect to torsional and bending strength. It is thus anticipated that, in future, hybrid front ends will be increasingly produced using inserts of organic sheet as all-plastic components in series production. The use of these new hybrid systems offers further savings potential in the component weight of 10 per cent. However, the applications, materials and technologies must be examined for possible pending industrial property rights before use.

Bright and light prospects Therefore, plastics are now making inroads in areas where metals once had a monopoly. Light weight is the mantra for future vehicles; hence, plastics, particularly polyamides, are all set to take the automotive industry to the next level. Courtesy: LANXESS AG

INDUSTRY INSIGHTS ELECTRICAL/ELECTRONICS

Plastics in electronics

On an infinite evolutionary path Almost all electronic & electrical appliances today depend on the use of plastics, including electric cables that are insulated with plastics. In some cases, the dependence on plastics provides safety to the operator, while in others it optimises efficiency of the appliance. Beverley Lewis unravels the wonders of this miracle material.

Courtesy: HellermannTyton

Courtesy: Daetwyler

lastics play a variety of roles in Electrical and Electronic (E&E) gadgets, thus making our lives easier, safer, less expensive and more fun. Today, plastics with premium thermal & insulating properties are used to insulate wirings around the house as well as in electric switches, connectors and receptacles in the home. The use of polymers in these devices has made the manufacturing easier, thus making these a common sight today. Properties such 60

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as lighter weight, flexibility in design, ease of processing and overall durability make plastics a better option, and hence these are fast replacing metals. After the automotive sector, the E&E industry is the second largest consumer of engineering plastics. Lightweight plastics are used to manufacture everything from cell phones to computers, and thus play a significant role in the E&E industry.

INDUSTRY INSIGHTS ELECTRICAL/ELECTRONICS

Role of polymers

OLED technology

Polymers have evolved from just being insulating materials to being used as conductors and semiconductors. These materials have helped in the trend towards miniaturisation and weight reduction. A well known development with respect to materials of plastics for use in electronics is the availability of plastic grades with improved flowability, which help reduce cycle times by up to 30 per cent. These also assist in thin-walled part designs, leading to compact components. In line with improved flow grades, formulations with higher filler content (up to 60 per cent) have been recently introduced in the market. Processing of these materials is comparable with normal-filled grades, but provides better surface finish. The high modulus of these materials opens up new possibilities to substitute die-casting applications with higher service temperatures. Also, advanced grades show good ageing behaviour, which is crucial for E&E applications. Miniaturisation of parts and complete systems is a worldwide trend today. To keep up with this ever-growing trend, manufacturing systems need to have upgradations for manufacturing new components. Y R Anand, Partner, Unimark, states, “Parts are becoming smaller and smaller, so the challenge for machinery manufacturers would be to ensure that machines produce even smaller parts. Dimension and tolerance, both play an important role in this aspect. Developments carried out in this arena would focus on improving the speed of obtaining the material out of the cylinder, and on accurate control of the dosage shot-by-shot to obtain the same amount of dosing every time.” He continues, “This needs special screw designs to reduce dwell time. Other directions of research are the screw and piston-type arrangement for use in micromoulding.” Few suppliers today offer specially designed machines or attachments for such applications.

Polymers are also used for innovations in organic photovoltaics, Organic Light Emitting Diode (OLED) displays and lightings, data memories, etc. As devices become thinner, smaller and lighter in weight, excellent mechanical performance of the plastic used becomes important to electronics manufacturers. The OLED technology is one field in which polymer usage is significant. It has replaced Liquid Crystal Display (LCD) and Light-Emitting Diode (LED) technology in cell phones. OLED offers advantages like low-cost raw materials & processing techniques and higher performance in brightness and colour accuracy. OLED is a flexible plastic display technology that utilises organic light-emitting diodes to produce an emission electroluminescent layer in a film of organic compounds, which emits light in response to electric current. It is used in television screens, computer monitors, mobile phones, watches, advertising billboards, light sources for space illumination, etc. Ths technology has introduced the global polymer market to unconventional materials like polyaniline, poly phenylene, vinylene and polyfluorene. Anil Duggal, Advanced Technology Leader, Electronic Material Systems & Chief Scientist, GE Global Research, says, “Polymer-based OLEDs have two key advantages. First, these are mechanically flexible, allowing longer scope for application. Second, roll-to-roll processing of polymer-based OLEDs makes devices available at lower costs than batch-processed glass-based OLED devices.”

Evolving with the environment With increasing focus of the electronics industry on the environment, the industry will increase efforts to use biopolymers that are not based on mineral oil. Also, the ongoing growth in integration of functionality into electronics will lead to developments across other industries to address the complexity of such products by developing a total solution rather than only a product.

Parts are becoming smaller and smaller, so the challenge for machinery manufacturers would be to ensure that machines produce even smaller parts. Y R Anand

Partner, Unimark

Roll-to-roll processing of polymer-based OLEDs makes devices available at lower costs than batch-processed glass-based OLED devices. Anil Duggal

Advanced Technology Leader, Electronic Material Systems & Chief Scientist, GE Global Research

June 2011 | Modern Plastics & Polymers

VIEWPOINT

“Multiplecomponent technologies are becoming increasingly significant” Georg Steinbichler

Rudolf Ehrenweber

Senior Vice President, Development Technologies, ENGEL Breakthrough micromoulding techniques that require tremendous precision and attention to detail Ehrenweber: Micro-moulded parts are typically required in large quantities in the electronics industry, which is reflected in the trend towards highcavity moulds. An example of this is the production of Light Emitting Diode (LED) lead frames. This shows that classical micro-injection moulding machines are not the only option for microinjection moulding. This is because there is a lower limit to plasticising. The problems caused by plasticising minimal shot volumes can be avoided by using moulds with a larger number of cavities.

Latest developments in the field of plastic moulding machines for use in electronics Steinbichler: As the trend towards thin-walled applications in combination with film decoration continues to grow in laptop production, a new process technology is imperative. Keeping the resulting shear stress and thermal loads as low as possible helps avoid damage to the decorative foil caused by the melt flowing in during 62

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Area Sales Manager, Teletronics Business Unit, ENGEL filling. This has prompted ENGEL to offer Injection Compression Moulding (ICM) machines for this application. In ICM, the mould is filled at a low pressure, and the mould’s clamping force gives the part its final shape. ENGEL recently presented this technology at our special ‘Think thin’ symposium in Shanghai. In future, manufacturers will be able to produce film decorated body housings with low distortion and wall thicknesses of just one millimetre, whereas typical thicknesses today are in the range of 1.7-2.3 mm.

Machinery requirements of electronic product manufacturers using plastic parts Ehrenweber: In the display and case segment, where parts are visible, it is the design that drives requirements. There is a clear trend away from painting; in other words, the injection moulding process is required to produce optically perfect parts. This is achieved by means of Inmould Labelling (IML), or vario-thermal mould temperature control. At the same time, two-

component applications are becoming more important, eg, two-component television frames. In the electronic components sector, with components such as plugs or sensors, the emphasis is mainly on maximum precision, which must be reproducibly guaranteed.

Challenges and future outlook Ehrenweber: The teletronics sector is extremely dynamic. No other industry has a wider range of models and shorter production lifecycles. This adds urgency to the requirement of a faster time to market and minimal lead times. At the same time, production systems are becoming more complex because – as is the case in the mobile phone segment – multiplecomponent technologies are becoming increasingly significant.

Global trends are replacing metal parts with plastics Ehrenweber: Processing of electrically conductive plastics is an extremely interesting topic, and one which has a huge potential for growth. Moreover, the ability to mould circuits directly introduces a new degree of freedom in product design.

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TREND ANALYSIS ELECTRICAL/ELECTRONICS

Plastics in electricals

Delivering reliable performance Some time back, the Tamil Nadu Electricity Board (TNEB) needed to establish an extra high voltage main distribution link in metropolitan Chennai, where a huge population, high costs and lack of space were some of the challenges faced. TNEB thus selected the leading Cable Corporation of India (CCI) to take up this task. Read on to find how CCI undertook this challenge, and emerged a winner. Suresh Daga

able Corporation of India (CCI) was established in 1957 as a joint venture between Siemens AG and Felten & Guillaume AG of Germany, and Thackersey and Khatau of India. The first manufacturer of its kind in India, CCI was originally set up to produce Polyvinyl Chloride (PVC)-insulated wires and cables. By 1997, its portfolio had been extended to include Cross-Linked Polyethylene (XLPE)-insulated cables up to 33 kV. In 1992, it became the first company in Asia, outside Japan, to be licensed by Mitsubishi Cable Industries to use its patented Mitsubishi Dainichi Continuous Vulcanising (MDCV) process technology for manufacturing Extra High Voltage (EHV) cables. Today, CCI is Indiaâ&#x20AC;&#x2122;s leading EHV cable manufacturer. It has two state-ofthe-art manufacturing centres at Nashik,

Courtesy: Borouge

Modern Plastics & Polymers | June 2011

Maharashtra, producing the full range of wires & cables for both domestic and international markets. These centres meet industry standards that include British Standards (BS), Verein Deutscher Ingenieure (VDI), International Electrotechnical Commission (IEC), Gosudarstvennyy Standart (GOST in Russian; which means state standard) and Bureau of Indian Standards (BIS). CCI has the distinction of being the first cable maker in India to have been awarded ISO 9001 Quality Management System certification by Bureau Veritas Quality International. It is also the first company in India to manufacture and supply EHV cables up to 230 kV.

Overcoming scale and complexity CCI received a project order from Tamil Nadu Electricity Board (TNEB) for turnkey supply of 230-kV cable 1,200 sq mm Milliken conductor & accessories and supervision of laying the cable in the heart of Chennai. Here, CCI faced two key challenges. First, the manufacture of 135 km of EHV cable, which is a significant production volume. Second was installation of power line across the middle of a busy city. With a population of over 8.5 million people, Chennai has limited availability of free space. Availability of land is low and costs are high; hence, installing an overhead power line was not feasible. Thus, CCI focussed on planning the route for an underground power transmission line. Simultaneously,

TREND ANALYSIS ELECTRICAL/ELECTRONICS

Table 1: Project summary: Extra high voltage mains distribution cable for Chennai city Customer name Tamil Nadu Electricity Board, Chennai, India Contractor and cable producer Cable Corporation of India Application Cable materials for EHV power supply Voltage – 230 kV Cable length – 135 km Conductor size – (Al) 1,200 mm – Milliken construction Insulation thickness – 27 mm Cable weight – 15,000 kg/km PE materials used

Classification – A2XLy2Y 1x1200 RM/VS Superclean™ LE4244EHV XLPE insulation compound Superclean™ LE4244S XLPE insulation compound Supersmooth™ LE0592S XLPE semi-conductive screen compound

Functional requirements Benefits

LE7710 semi-conductive screen compound Consistent extra high voltage performance and long-term reliability Reliable high performance working life, as Superclean™ compound excludes contaminants above 100 micron and controls those below 70 micron Minimised electrical stresses, and hence consistently stable power flow due to the smooth interface of Supersmooth™ with the insulation

it began designing a cable construction that would meet the key criterion of delivering clean power, with the security of its supply unaffected by environmental conditions over a long service lifetime.

Performance reliability While the actual length of the cable route is 29.8 km, in two stretches, from Elephant Gate to the substation at Mylapore and from Mylapore to the Tharamani substation, the total cable length needed for the distribution circuit was 135 km. The length of the route also necessitated a 230 kV cable with straight through joints. The primary functional requirement was the construction of a watertight Milliken Al 1,200-mm conductor. CCI considered that the MDCV technology provided the most reliable production process for High Voltage (HV) and EHV cables. For this, CCI selected two products from Borealis and Borouge – Superclean™ XLPE for conductor insulation and Supersmooth™ XLPE for the semi-conductive screen. “This was our first prestigious cable project in India with a conductor of this size, type, voltage grade and overall 68

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length to be laid in a crowded city. It has provided us with a valuable learning curve. While processing, we stabilised the line after several trials and then conducted various tests on the cable core to standardise the production parameters for continuous running,” avers Nalge Gajanan, Senior Executive Vice President - Marketing, CCI. He elaborates, “After some initial trials, it was clear that with Superclean LE4244EHV we could achieve the reliability, stability and consistent quality essential for this type of cable.” In order to comply with global norms, CCI production team headed by Anjan Banerjee, further evaluated Superclean LE4244S. The grade was successfully run on the company’s MDCV line.

Aiming for lasting performance Superclean cable materials are produced using advanced procedures to eliminate all contaminants, and maintain cleanliness till the point of delivery to the customer. The performance of this insulation material is complemented by its use in conjunction with Supersmooth for the semi-conductive layers of XLPE cables. At high electrical stresses,

the Supersmooth interface with the insulation reduces the potential of stress transfer from the conductor, thereby increasing the reliability of uninterrupted power flow and a long trouble-free cable service life.

Continuing to pioneer Successful completion of the first 135-km, 230-kV EHV cable project won the confidence of TNEB, and resulted in CCI being awarded another similar contract for 139 km of 230-kV EHV cable. The company has again chosen Borealis and Borouge as its preferred supplier for advanced insulation & semi-conductive XLPE materials. In view of the growing demand for HV cables, CCI has invested in a Maillefer Catenary Continuous Vulcanisation (CCV) line for production of cables up to 132 kV. Trial production runs are planned to be conducted in late 2011. CCI has identified Borealis and Borouge’s Superclean™ LE4201S and Supercure LS4201S grades, specifically designed for HV applications, as its first choice materials. This new line is scheduled to come on-stream in the later half of 2011. Keeping up its tradition of being a pioneer of India’s cable industry, CCI has undertaken production trials of 400-kV cables using Superclean LE4244EHV XLPE insulation compound and Supersmooth LE0500 XLPE semi-conductive screen compound. This cable has passed all in-house tests of the company. CCI will be ready to undertake commercial production of 400-kV cables by 2012. Finally, CCI stresses that its partnership with Borealis and Borouge in the development of HV and EHV cable solutions is a clear example that ‘Working together works’.

Suresh Daga is Senior Sales Manager Wire & Cable at Borouge India Pvt Ltd. Email: Suresh.Daga@Borouge.com

INDUSTRY INSIGHTS MEDICAL PLASTICS

Plastics in medical devices

Expanding the realm of healthcare Advances in high-performance polymers have enhanced the opportunities for plastics in the medical devices industry, making diagnosis and treatment more easy & efficient. Annabel Dsouza highlights the innovations in plastics application for medical devices manufacturing.

Courtesy: Tekni Plex

Courtesy: Bayer MaterialScience AG

ndia’s growing population is playing a pivotal role in the nation’s economic success. The pulsating demographics are in turn greatly impacting the Indian healthcare sector. This sector is likely to reach $ 77 billion by 2013, sustaining a Compounded Annual Growth Rate (CAGR) of 15 per cent. Contributing about 6 per cent to India’s Gross Domestic Product (GDP), the demands on this sector are huge. This has resulted in considerable demands on the industry’s manufacturing segment.

Modern Plastics & Polymers | June 2011

Medical infrastructure in India is far from adequate, which implies the huge opportunities awaiting Indian medical equipment manufacturers. The market is growing at a rate of 20 per cent and the demand is expected to reach $ 5 billion by 2012. Thus, to achieve global standards of medical services, the government and the private sector have embarked on an accelerated growth plan to facilitate the medical devices market, in terms of volumes as well as value-added technology.

INDUSTRY INSIGHTS MEDICAL PLASTICS

Myriad solutions Plastics have made inroads into perhaps all leading verticals of the manufacturing segment. However, medical application has its own challenges pertaining to high heat & Ultraviolet (UV) endurance and biostability. Plastics cover large application areas in healthcare due to their light weight, biocompatibility, noncorrosive nature, chemical inertness, low cost and comparable densities with that of human organs. In some cases, they may contain additives or reinforcing agents to modify and/or enhance properties. But, plastics used in medical applications must adhere to stringent national and international standards and be non-toxic, non-carcinogenic, biocompatible and in no way injurious to the biological environment. On the global front, the total demand of medical grade polymers is about 1.87 million tonne per annum, of which the contribution of commodity plastics such as Polypropylene (PP), Polyvinyl Chloride (PVC) and Polyethylene (PE) is 74 per cent. Plastics not only help in facilitating diagnosis and treatment by way of natural data access, safer surgery through plastic robots, targeting treatment but also in making effective and life-like prostheses for joints, muscles, organs and blood. Tim Uhrmeister, Head-Polycarbonates, Bayer MaterialScience India, says, “Advances in healthcare are vital, considering the issues of population rise. Polymers enhance manufacturing and end-use performance for various medical devices.”

Beyond convention PVC-based medical polymers constitute 40 per cent of the market, followed by PP, with a significant share of 20 per cent. PE products constitute 15 per cent, while other prominent plastics including polycarbonate, Acrylonitrile Butadiene Styrene (ABS), biopolymers, nylon and polystyrene, account for 25 per cent of medical products available on market. As the medical devices industry gears up to increased application of engineered polymers, features like

clarity, durability and ability to withstand large temperature gradients (from 40°C to 121°C) will be the primary differentiating factor. Plastic medical equipment have to endure extreme sterilisation conditions like steam, ethylene oxide and gamma radiation. Dr S C Shit, Deputy Director, CIPET -Ahmedabad, says, “In clinical practice, increasing demands for environmental degradation of plastics have led to the popularity of biodegradable Thermoplastic Elastomer (TPE). These have a broad range of applications in the biomedical field, eg, surgical sutures, matrices for drug delivery and scaffold in tissue engineering.” However, in healthcare operations, safety cannot be compromised for sustainability. Dr Shit explains, “Biodegradable materials such as Polyactic Acid (PLA), Polyglycolic Acid (PGA), Polycaprolactone (PCL) and Poly(1,4-dioxan-2-one) (PPDO) are used in temporary therapeutic applications such as sustained drug delivery, surgery and tissue engineering. Due to high Young’s modulus & elongation at breakvalues, these are inappropriate for clinical uses that require strong, flexible, biodegradable polymeric materials in applications like ureters, artificial skin and veins.”

Polymers enhance manufacturing and end-use performance for various medical devices. Tim Uhrmeister

Head-Polycarbonates, Bayer MaterialScience India

Cost advantages Plastics offer significant design edge that makes expensive healthcare equipment like Magnetic Resonance Imaging (MRI) and Computed Tomography (CT) scanners more affordable to emerging economies like India. But, cutting costs is not always advisable in the highly regulated healthcare sector.

Going forward The long-term prospects for medical applications of plastics are good, with a greater demand from an ageing population and growing levels of lifestyle-related chronic diseases. Indian processors also need to adapt to fundamental changes in global industry dynamics.

In clinical practice, increasing demands for environmental degradation of plastics have led to the popularity of biodegradable Thermoplastic Elastomer (TPE). Dr S C Shit

Deputy Director, CIPET - Ahmedabad

June 2011 | Modern Plastics & Polymers

VIEWPOINT

“The medical device industry is one sector where innovation continues to thrive and succeed” Dr Vinny Sastri, President, Winovia LLC Opportunities for plastics application in medical devices The opportunities for performance plastics in the medical device industry are continuously growing. The global medical plastics market is estimated at nearly £ 10 billion (4.5 x 106 metric tonne) by 2015. Most of this growth will come from Asia and the Pacific region. Engineering performance plastics will have a higher growth rate compared to the commodity plastics used in medical device applications. The need for materials with properties like superior dimensional stability, high energy and high heat sterilisation capability, long-term durability, high strength, biocompatibility and bioresorbability will bring significant growth.

Emerging trends for processing medical plastics Some of the major new technologies such as micro-moulding, thin-wall extrusion & moulding and production of precision parts & components with economies of scale will continue to expand. The joining & welding of plastics and innovative packaging processes also continue to push the boundaries of processing innovation. Coating technologies that add significant value & property enhancement are also increasing and technologies that provide durability, 74

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consistency & performance along with affordability will find success in future.

India’s growth index in the global medical plastics industry The Indian medical plastics industry is still in a nascent stage. Export to North America and Europe is marginal and has significant growth potential. Improving production standards in terms of quality, cleanliness and economies of scale is the need of the hour. In addition, the education of engineers and workforce in terms of understanding and implementing effective quality systems that meet global medical device standards is also an area of concern. The pharmaceutical industry in India already meets these high standards. Thus, the Indian medical plastics industry can adopt the best manufacturing practices from the pharmaceutical sector.

Need for high performance plastics Drivers of healthcare costs are complex and inter-related. An ageing population coupled with a shortage of healthcare workers is likely to increase healthcare costs. However, innovative medical technologies will continue to alleviate healthcare expenses. Increased home healthcare technologies in terms of remote diagnostics, home monitoring, wireless technologies and user-friendly

devices will increase the demand for affordable therapies and treatments. The surging demand for disposables and devices that are light weight & portable, user-friendly, well-designed and durable will increase the use of plastics, including high-performance plastics. In addition, increased emphasis on disposal of waste will force manufacturers to consider sustainability, recyclability and biodegradability of the plastics used in such devices.

Overcoming challenges faced by the industry Over the last 3-4 years, regulatory bodies in the US and Europe have increased their emphasis on supplier controls during inspections of medical device manufacturers. As a result, medical device manufacturers have started to exert more control over their suppliers, including plastic component & part suppliers and sometimes even resin suppliers. Part of the regulatory requirements includes stringent change notification of raw materials and processes. Plastics suppliers must be prepared to work along with their medical device customers to meet these needs when they change any materials in their formulations. This will result in effective production controls for safe, high-quality products that meet customers’ requirements.

TREND ANALYSIS MEDICAL PLASTICS

Plastics in healthcare

Setting new benchmarks Advanced technology, novel materials and new concerns are transforming the global healthcare landscape, inspiring new standards in plastics for healthcare applications. Increasing use of plastics in medical devices have prompted manufacturers to continually develop breakthrough materials and product designs. Advancements made in plastics for the medical devices industry promise to transform the healthcare delivery systems over the next decade.

he medical devices market in India has been experiencing double-digit growth. Increased affordability by patients, greater awareness of healthcare, improving hospital infrastructure and increased disease patterns are some of the key factors that will drive the medical industry in India. With a steadily increasing Gross Domestic Product (GDP), population and standard of living, India is one of the high growth markets for the medical devices industry. In 2010, the Indian market for medical equipment and supplies was around $ 3.1 billion. Advancements in polymer technology have enabled plastics to be used in healthcare applications that demand high consistency, performance, precision and compliance with regulations. Over the years, polymer resin manufacturers,

Courtesy: Bayer MaterialScience AG

Modern Plastics & Polymers | June 2011

compounders, device processors and medical device Original Equipment Manufacturers (OEMs) have together risen to the challenge to provide application-specific polymer solutions.

Polymers in healthcare High purchasing power of the Indian population will help make advanced medical treatment more affordable. This will facilitate the healthcare segment to provide further growth opportunities for plastics, especially high-performance plastics, eg, Polytetrafluoroethylene (PTFE), Polyether Block-Amide (PEBA), Polymethylmethacrylate (PMMA), Polyetheretherketone (PEEK) and Ultra High Molecular Weight Polyethylene (UHMWPE). These materials are chosen for their high-performance properties such as clarity, impact & chemical resistance, sterilisability, lubricity and kink resistance. However, these polymers are not versatile, their high production costs make these materials expensive, and thus are not used on a large scale in high-volume applications. PEBA is the ideal material for making catheter tubing due to its enhanced flexibility. PEEK is also used to make catheter tubing. Fluoropolymers (PTFE) are used mainly in high-lubricity, heat-shrink medical tubing. These are also used to some extent in medical implants. DuPont is the leading manufacturer of fluoropolymers for the medical devices segment, with its Teflon

TREND ANALYSIS MEDICAL PLASTICS

range. SABIC-IP is a major producer of PEI for the medical device segment. Its product Ultem* is widely used in medical device applications like pipettes & vials in labware, syringes for drug delivery and leurs and valves in the IV fluid delivery segment. Acrylic compounds (PMMA) have various applications in the medical device segment. Typical applications include diagnostic devices, IV filter housings, IV spikes and luer connectors due to properties such as high Ultraviolet (UV) transmittance capabilities, good resistance to gamma and to lipids found in fluid treatment & body fluids. Traditionally, PMMA was used mainly for cuvettes and cassettes. The advent of modified acrylics has broadened its scope in the medical device industry. As it has greater impact and chemical resistance than the traditional ones, it is used in disposable IV sets. Currently, on a global scale, acrylics account for almost 40 per cent of the IV set segment, and polycarbonates account for almost an equal share. Up to 90 per cent of acrylic applications in the medical device industry are for the disposable segment. Polyurethane, UHMWPE, PEEK and fluoropolymers are some of the major polymers used for orthopaedic implant applications. This is one of the segments showing high growth among other medical devices. PEEK is mainly used in hip, knee and spine replacements, due to its non-elastomeric nature. UHMWPE is mainly applied in spine implant systems, eg, spacers.

Advantages of polymer application Polymers in healthcare applications include medical device applications (disposable and non-disposable) & packaging, wound care management and hospital environment. Performance polymers such as PEEK and PMMA are typically used in non-disposable device applications, as these have minimal impact on body tissues. Commodity polymers such as Polyvinyl Chloride 78

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(PVC), Polystyrene (PS) and Polyethylene (PE) are used primarily in disposable applications and form the largest portion of plastics used in the medical device sector. PVC is used in medical tubing due its low cost and high flexibility, while PE is used in medical device packaging. Polypropylene (PP) is mainly used in medical device housing, containers and trays. PS is preferred for syringes, although polycarbonates are increasing in popularity. Globally, around 750,000 tonne of plastics are used in healthcare applications. Of this, around 75,000 tonne comprise engineering plastics (eg, polycarbonates) and highperformance plastics (eg, PEEK). Thus, high-performance plastics constitute a small volume of all polymers used in the medical device sector. However, advancements in medical technology will propel the consumption of engineering plastics and high-performance plastics in the healthcare sector.

Safety matters A mega-trend affecting the performance materials industry is safety associated with the material. Safety is a key issue during polymer material selection for a medical device. High-performance materials such as PEEK are often rendered safe as compared to commodity thermoplastics, as they have minimum impact on body tissues. Also, the high cost of PEEK has prompted medical device manufacturers to use a cheaper material, which demonstrates good biocompatibility and regulatory compliance. Thus, PVC manufacturers are now developing innovative forms of plasticiser-free PVC. An example is PVC involving the use of the Tri-(2-ethylhexyl) trimellitate (TEHTM) plasticiser, which has low cytotoxicity and migration as compared to the Bis(2ethylhexyl)phthalate (DEHP) version.

Changing lifestyle trends Rising medical treatment costs have led to an increase in demand for medical treatment at home, often referred to as homecare. This has been

possible due to developments in the fields of IV access systems and patient self-monitoring systems. In order to facilitate growth in the homecare and patient monitoring markets, companies must adapt to the changes in material requirements. Medical devices used in homecare are prone to rough handling, and hence require higher impact resistance. Also, the design of the medical device would play a key role in penetrating the homecare market. All these factors will affect patient self-monitoring devices as well. Thus, engineering polymer manufacturers need to develop solutions for unique requirements of the homecare medical device market.

Product quality and differentiation Polymers in the medical devices market is relationship oriented. It is challenging for a new player to enter this market, mainly due to the dominance of market leaders. By assisting customers in areas such as material selection & development as well as regulatory certifications, market leaders can maintain good relationships with their customers; therefore, customers would be reluctant to change the material supplier. But, product differentiation must be accompanied by product quality and sustainability.

Need to analyse key trends Quality plays a major role in adding value to a product in the medical device sector. Differentiating medical grade polymers from the standard grades would help enhance customer satisfaction. This is facilitated by introducing a dedicated medical grade product line. Thus, for polymer material manufacturers, compounders, formulators and medical device processors need to analyse the key trends in the performance material industry on the market for polymers in medical devices. Courtesy: Frost & Sullivan, Materials Practice, South Asia and Middle East.

INDUSTRY INSIGHTS PACKAGING

Polymers for packaging

Keeping innovation and sustainability in tune Plastics has exhibited a trend of surpassing other packaging materials. New technologies and new materials related to plastic packaging have been constantly developed, further pushing the growth of plastics in packaging. Beverley Lewis looks at the role played by plastics in the packaging industry.

he packaging industry is facing a challenge in terms of reducing material consumption while increasing package strength, improving product performance for filling as well as conveying and accelerating design cycles while reducing cost. Besides, the industry has a responsibility towards improving environmental sustainability for everything it manufactures. Virtual prototyping is a key strategic initiative within successful packaging companies 80

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to meet these challenges and improve competitiveness. The aim of packaging is to protect the content inside. But most companies today consider packaging as a means to portray their products. Also, packaging has now become an expression with the finest shapes and colours. In fact, some industry experts would even argue that packaging is a form of art. Currently, the packaging industry is concentrating on reducing costs while focussing on sustainability.

INDUSTRY INSIGHTS PACKAGING

Current trends At present, the packaging industry is adopting cutting-edge technologies for cutting down costs. New and better technologies are also gaining foothold in this industry. Jatin Khanna, CEO, M&C Packaging, says, “This can be achieved by contacting the best vendors who provide leading-edge technologies at the most competitive prices and by designing systems that maximise output, while minimising labour & material costs. This can also be achieved if companies optimise the efficiency of existing packaging lines that maximise uptime and eliminate rewraps & repackaging. Also, companies should invest in high-quality equipment and employ experienced and well-trained service technicians, which will help bring down costs.”

Hurdles before the industry Increasing awareness among companies about the dangers related to disposal and recycling of packaging wastes, coupled with government initiatives to minimise greenhouse gas emissions, and stringent regulations are driving the growth of sustainable packaging. “With environmental concerns gaining precedence the world over, demand is increasing for recyclable and safe packaging. Environmental issues such as global warming, dearth of natural resources and high-energy consumption are driving the need for sustainability in packaging. All these may be challenging for some companies,” asserts Manmohan Chahal, Market Unit Manager, Nefab India Pvt Ltd. Sustainability has become a key trend for packaging companies across the world. Sustainable packaging such as sustainable raw materials like recycled materials and renewable resources. Companies are offering novel packaging designs, with improvements in several key performance areas, such as environment-friendliness, simplicity, material saving and cost reduction without compromising on ease of use. Chahal adds, “Sustainability helps

companies to cut costs and reduce packaging waste by using recycled and reusable materials.” With sustainable packaging becoming a mainstream global trend, several companies are adopting ‘green packaging’ as a marketing tool. Environmental concerns are putting manufacturers under pressure to use environment-friendly materials and adopt methods that require low-energy consumption and reduce the environmental impact of packaging. Khanna states, “A sustainable packaging is required to meet the needs of the product it holds. Besides being environment-friendly, it should ensure that the product is protected from contamination and leakage.” In terms of market segmentation, recycled material accounts for the largest category in packaging. However, biodegradables represent the fastest growing segment in the packaging industry. “Biodegradable materials are easily decomposed by microorganisms, and hence reduce packaging waste. Among biodegradables, bioplastics are garnering the greatest attention in the green packaging market,” oberves Chahal. Despite questions looming about limitations of bioplastics, demand continues to swell, presenting an expanding market as bioplastics evolve. Markets using sustainable packaging include cosmetics and personal care, food & beverage, food service & shipping markets and healthcare.

A sustainable packaging is required to meet the needs of the product it holds. Besides being environment-friendly, it should ensure that the product is protected from contamination and leakage. Jatin Khanna

CEO, M&C Packaging

Future outlook The future of the packaging industry will be defined by how efficiently it faces issues that could hamper its growth. “Packaging will become more sustainable. Companies will look towards developing the highest quality packaging using minimum of material and, if possible, from recycled materials,” claims Chahal. Investing in research and development will be crucial for the industry, enabling companies to bring out more sophisticated and sustainable packaging solutions.

Sustainability helps companies to cut costs and reduce packaging waste by using recycled and reusable materials. Manmohan Chahal Market Unit Manager, Nefab India Pvt Ltd

June 2011 | Modern Plastics & Polymers

VIEWPOINT

“The major drivers of packaging market are continued substitution of conventional materials with plastics.” S V Kabra, Chairman and Managing Director, Kabra Extrusiontechnik Ltd Current market scenario The packaging industry is currently showing rapid growth, and new applications are entering the market at a fast pace. Thus, technology has also been developed and enhanced to suffice these demands. Moreover, the consumption patterns have shown an upward trend, indicating a positive growth for the industry.

Recent growth drivers The major growth in the packaging sector is driven by the growing middle class. This has given the existing demand a major boost; the retail sector comes next, as it supplies the demand created by people. Also, tapping opportunities on the basic level is important. Although it is mandated that oil must be sold in packaged form, almost half of the total edible oil produced is sold loose. Thus, tapping these opportunities while also concentrating on major sectors will drive demand in the packaging industry.

Sectors contributing to demand for packaging Packaging mainly serves two purposes – aesthetics and asepticism. Our standards for hygiene have improved drastically in the last few years, raising the demand for packaging material. The major drivers of packaging 82

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market are continued substitution of conventional materials with plastics. Sectors such as Fast Moving Consumer Goods (FMCG), pharma, food & beverage will continuously contribute to growing demand for packaging.

Latest developments Packaging is a vast subject and undergoing numerous developments. In India, we are advancing towards implementing modern technology, some of which may not be recent developments in this sector, but have now become popular. Shrink packaging, stretch cling and, the latest, penetrating barrier films have entered the market, and are thus here to stay.

Indian packaging market in the global arena As per a report by CRISIL titled Vision 2012, per capita consumption in the packaging industry is about 2.2 kg, which is one-tenth of the consumption in a developed country. This can be markedly increased in three ways: first, tap opportunities in existing products and reduce quantity of products sold loose; second, pack items that have never been packed before; and, third, develop novel applications in packaging. These actions, if put into practice, will certainly help us reach the level where global market stands today.

Research & development initiatives and product pipeline Constant developments are being made in our R&D centre. Also, factors such as power efficiency, automation and consistency in end-product quality are constantly worked on for further improvement. We continuously share technology with Gloucester Engineering Company for upgrading our plant. In the current era, customers have become more aware and demanding. Various production factors demand the machine to require minimal maintenance, be power efficient and yield quality output without breakdown.

Vision for packaging sector The expectations of improving the standard of living in India’s fastest growing middle class with a population of over 350 million present enormous opportunities for improving packaging of products, their shelf life, assurance of genuine quality, etc. Thus, like the west, we need to use specialty multilayer films, to meet the expectations and demands. Raising the standard of living is directly related to raising standards of packaging, for hygiene, healthcare, quality, etc. We are thus heading towards a revolutionary change in the field of packaging, which will provide immense opportunities for growth in this sector year after year.

VIEWPOINT

“Plastics is perhaps the most easily recycleable product” Vimal Kedia, Managing Director, Manjushree Technopack Ltd Current market scenario of Indian packaging industry The packaging industry is currently estimated at ` 75,000 crore and is expected to continue growing at doubledigit rates. There is a huge upsurge in demand for packaging across most industry verticals and all packaging materials such as paper, glass, tin and plastic. While all have different growth percentages, plastics have the highest percentage growth.

Growth drivers The huge demand from Fast Moving Consumer Goods (FMCG) and Food and Beverage (F&B) sectors plays a crucial role in growth of the packaging industry, and also contributes the highest share. The changing lifestyle of customers has a significant contribution, besides the willingness to spend a little more for high-quality packaging, eg, packaged and ready-to-eat foods, which are either frozen or preserved. The availability of specialty materials and technology, which aid in longer shelf-life and better preservation are also helping the packaging industry; moreover, multilayer packaging is a huge attraction today, eg, Kissan Squeezo, Del Monte containers, etc. We are increasingly becoming aware of the latest packaging trends across the world and are quickly adopting them in India.

Sectors contributing to continued demand for rigid packaging Continued demand for rigid packaging comes primarily from the packaged foods businesses and the carbonated beverages industry. Recently, we have noted interests from new sectors like alcohol beverages industry, home and personal care, dairy, agrichemical and motor oil industry.

Indian packaging market on the global front The Indian packaging industry is still a small dot on the global packaging map. The per capita consumption of packaging in India is at a merely 8 kg per year, while an average European uses about 230 kg of packaging and an American about 360 kg of packaging in a year. This indicates the huge opportunity for use of packaging within India.

Key challenges One of the key challenges faced by the industry is the continuous cost reduction expected by clients, particularly in the FMCG segment. This is quite an irony because input costs for the packaging industry are rising. Some innovations like use of alternative material, lightweighting of existing packages and better processing can help drive down

costs to some extent, but this comes at a sizeable capital cost, which neither parties are willing to bear, nor do they want to pass it to the customer. Thus, a large number of new and innovative options remain without hitting the market.

Environmentally sustainable solutions As opposed to the common perception, plastic rigid package is environmentfriendly and more sustainable than other packaging materials such as paper, glass and tin. Irrespective of the material used, it is our responsibility to ensure that the container or package is disposed in the right way and not randomly thrown away. Most packages, except paper, can be re-used. In terms of recycling, plastics is perhaps the most easily recycleable product and with the current upgradation of technology, it is possible for a bottle to become a bottle again after recycling.

R&D and product pipeline In line with our vision and goals for the coming years, we at Manjushree have made ‘light weighting’ and ‘long shelflife’ our mantra to work on. We have invested a lot of effort to develop an innovative neck design, which will save weight and, in some cases, are also working on a neck-less design. June 2011 | Modern Plastics & Polymers

TREND ANALYSIS PACKAGING

Plastics in packaging

Giving a boost to brand appeal As the understanding of proper packaging by manufacturers is shifting from simply delivering the goods to making packaging a tool to win customers, the Indian packaging industry stands a good chance for further growth. An overview of how the current developments are fuelling the growth of this fragmented industry. Didier Lacroix

ndiaâ&#x20AC;&#x2122;s highly fragmented packaging industry today is pegged at ` 8,000 crore and is growing at the rate of 22-25 per cent per annum. In the next five years, the sector is expected to triple to about $ 60 billion. The current wave of economic development across all major economic sectors in India is creating huge demand for packaging solutions. With several international consumer brands across different sectors entering India, the packaging industry is becoming trendy and innovative in its offerings.

Growth factors Packaging in India is no longer only about delivering the product. Companies are using this medium to attract buyers. Also, the use of different grades of plastics in packaging consumer goods and industrial products has increased. Several socio-economic factors are responsible for this growth in innovative packaging.

These include rising brand awareness for imported products, which are now easily available in India; increase in consumer spending patterns; adaptation to western culture (eg, ready-to-eat meals); and a robust economic growth across various industrial sectors in India.

Innovation in action Growth in the processed food sector, growing demand for products from consumers in the middle class, liberalisation of various Indian industrial sectors and development of the organised retail sector are factors that will further push demand of the packaging sector. Traditionally, food packages were designed to keep products safe and protect them from the impacts of the environment. But, today, product packaging plays an active role in food preservation and allows monitoring & communicating information on food quality.

Future: Full of challenges

Courtesy: Cognex

To compete with global counterparts, packaging companies in India will have to counter various challenges like lesser food processing as compared to that in the West, high import duties on packaging machinery and low per capita packaging consumption of less than $ 15 against world average of $ 100. Didier Lacroix is Senior Vice President, Worldwide Sales & Marketing at Cognex Inc. Email: sales.in@cognex.com

Courtesy: Cognex

Modern Plastics & Polymers | June 2011

INDUSTRY INSIGHTS CONSTRUCTION

Plastics in construction

Scoring high on ‘green’ index Engineering plastics are introducing India’s construction industry to innovative and functional designs for aesthetic appeal as well as commercial viability. Annabel Dsouza highlights the performance plastics industry’s initiatives to collaborate further with this growing market.

Courtesy: Menainfra

n India’s tryst to emerge as a global economic power, it is important to understand and appreciate the link between infrastructure & fiscal development. Liberalisation of government regulations and a deliberate strategy on the part of government to promote infrastructure has played a countercyclical role to encourage intensive public private partnerships in the building & construction industry. Besides being an economy growing at about 9 per cent,

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India’s infrastructure domain offers fewer restrictions on Foreign Direct Investment (FDI) and significant tax holidays for developers of most infrastructure projects. PricewaterhouseCoopers estimates India’s projected spending during 2007-2012 as: Electricity: $ 167 billion Railways: $ 65 billion Roads and highways: $ 92 billion Ports: $ 22 billion Airports: $ 8 billion

INDUSTRY INSIGHTS CONSTRUCTION

The potential of plastics As construction applications become increasingly high-tech, builders & developers in India are fast realising the potential of customised polymer solutions that address conventional challenges in a cost-effective manner. Polyvinyl Chloride (PVC) piping, siding, window frames, roofing, etc, have been the conventional forte of commodity plastics. However, functions like insulation, moulding trim, wall coverings, flooring, beams, columns, doors, etc, have introduced designers and architects to the benefits of performance polymers. There is a growing practice towards the use of polymers in blended products for concrete chemicals, wood board and paint. While this list of products clearly demonstrates that plastics are prominent in today’s building market, the industry is yet to recognise the material as an answer for sustainable building designs.

Current market landscape The current demand for plastics in India’s infrastructure sector is about 20 per cent. This is below the average standard of about 25 per cent of total capacity. This indicates the opportunities available for processors of construction grade plastics. Ashok Goel, President, Plastindia Foundation, says, “India holds tremendous potential for use of polymers in infrastructure. Policy enablers in this sector can drive demand from 13 per cent to about 20 per cent in the next 3 years. Plastics are fast replacing conventional materials like steel, casts iron and wood, enabling the industry to witness enhanced performance through energy efficiency and reduced labour costs. With regard to these advantages, we anticipate greater demand from applications like telecommunications, power generation, (both conventional & renewable) and construction.” In order to analyse the potential of plastics in building applications, the most important characteristics of conventional construction materials

must be considered, eg, safety, durability, low processability, costcompetitiveness and zero pollutant content. Plastics score high in each of these parameters and offer a commercially viable solution for the infrastructure industry. Engineered polymers, in fact, have the added advantages of water resistance, easy maintenance, aesthetic appearance and versatility. In addition, the plastics industry offers energy-efficient and environmentally conscious products, and is likely to play a proactive role in the development of green building materials and green practices.

The forte of plastics Builders are realising the sustainability features and total product life cost of PVC pipes, which has resulted in accelerated growth in sales volumes. Timothy Madden, Managing Director – South Asia, Lubrizol, comments, “Plastics are certainly a more sustainable alternative for construction. There is a lower requirement for power when plastics are being used on site. As plastics do not corrode or break down easily, there is less chance of having to partially destroy facilities for replacement of damaged pipes. The industry is showing greater interest and understanding of quality & willingness to consider total cost over time as against initial purchase price. This allows more scope for performance polymers versus lower performing commodity-based plastics.”

A sustainable design Engineering plastics score significantly high on the ‘green’ index; however, the industry is facing a lack of knowledge & awareness in understanding its application in construction. Madden concludes, “One of the biggest challenges is introducing the consumer to the benefits of plastics as against conventional materials. However, we are witnessing a keen interest in the building design community towards performance plastics solutions.”

Plastics are fast replacing conventional materials like steel, casts iron and wood, enabling the industry to witness enhanced performance through energy efficiency and reduced labour costs. Ashok Goel

President, Plastindia Foundation

The industry is showing greater interest and understanding of quality & willingness to consider total cost over time as against initial purchase price. Timothy Madden

Managing Director – South Asia, Lubrizol

June 2011 | Modern Plastics & Polymers

VIEWPOINT

“We want to continue contributing to India’s economic growth and sustainable development goals” C R G Prasad, Commercial Manager - Construction (India and South Asia),

Dow Corning India Pvt Ltd Innovations introduced in the construction polymers market Silicones not only outperform and outlast organic weather-proofing materials, but also enable innovative applications that would otherwise be impossible. Siliconebased adhesives and sealants are helping Indian architects design distinctive, modern structures and, at the same time, enabling them to meet the growing demand for environmentally sustainable designs and construction techniques. Dow Corning’s window sealant technology saves energy by allowing window manufacturers to create larger, more efficient windows that provide better thermal insulation and allow more daylight to enter the building, which reduces the need for artificial lighting. Silicone sealant technology thus enables the absorption of stress, prevents air & water intrusion and provides excellent insulation between window layers. A properly insulated building envelope keeps the interiors warm in winter and cool in summer. In addition, silicone products last longer than organic products and need to be replaced less often. This reduces the waste and solvent usage that results from sealing (and resealing) the building with an organic sealant.

Current market dynamics At Dow Corning, we believe that the Indian market provides us a huge 88

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opportunity to expand the usage of silicones in the field of construction. The per capita usage of silicones in developed countries is 40 times more than that in India. As India progresses and technology advances, the need for world-class products and highquality materials will also increase. This is where we see silicones as a contributor to India’s growth. We are looking at offering local presence backed by the company’s global expertise and innovative practices to create solutions that meet the exact needs of Indian customers.

Efforts towards sustainable construction Dow Corning is a responsible corporate citizen company with a strong commitment towards safety, sustainability, environmental protection as well as welfare of the community. Increasing demand for products, processes and technologies that meet environmental and societal needs will play a key role in the company’s innovation activities. Dow Corning provides a total solutions package aimed at improving productivity and reducing overall costs. We endeavour to ensure that our projects are centred on the principles of sustainability and innovation. We also anticipate more than 50 per cent of our innovation

portfolio to be on projects linked to sustainability. This focus has helped us enjoy a strong performance for seven consecutive years.

Engineering polymers for safer and disaster-proof buildings Architects often specify silicone sealants for their projects because these accommodate the integration of a wide range of materials into their designs and allow for greater overall design flexibility. Silicone sealants perform well under the stress of Ultraviolet (UV) radiation, extreme heat & cold and acid rain, as well as natural disasters or even security threats. Dow Corning construction experts work with architects and engineers from the early planning phase through the completion of the building to select products tailored for the type of building and its environment. Dow Corning’s technical support for major building projects includes the ability to test aspects of engineering and design, eg, how the building will be able to withstand extreme conditions such as gale force winds or drastic temperature fluctuations. Silicone sealants in impactresistant window systems help keep broken glass within its frame, thus reducing injuries caused by flying glass during a natural disaster.

TREND ANALYSIS CONSTRUCTION

Buildings and construction

Green design for a sustainable future Owing to their extreme versatility, plastics have forayed in nearly all industries, including the construction sector. From residential buildings to skyscrapers, and from hospitals to schools, architects & designers today are using plastic materials to achieve architectural feats and meet construction challenges like never before. Besides decreasing the weight of a structure, plastic products can help use energy efficiently and reduce maintenance costs considerably in the long term.

he demand for sustainable construction, including reduced energy consumption of buildings, is continuously increasing. This is particularly because buildings account for about 40 per cent of global energy use. This figure can be reduced significantly, by designing buildings that are more energy-efficient. Already several countries in Asia are promoting sustainability in the building and construction industry by introducing credit rating systems or insulation regulations that will provide energy savings, among other benefits. Throughout Asia, energy efficiency guidelines have become a feature of construction design. Singapore introduced its BCA Green Mark Scheme in 2005, while Mumbai introduced the Energy Conservation Building Code in 2007. Recently, Malaysia

introduced the Green Building Index in early 2009. Other countries in moderate climate zones such as China, Korea and Japan are also focussing on insulation in their energy-efficient construction guidelines.

Effective thermal insulation Insulation is one of the requirements of energy-efficient construction. This is essential in cities like Singapore and Mumbai that have a hot and humid climate practically throughout the year. Accordingly, greater attention is being placed on the conservation of cooling energy and lowering of CO2 emissions through effective thermal insulation of both old and new buildings. Research has resulted in advances in reinforcing construction polymers with finely dispersed infrared absorbing particles, which reflect thermal radiation like tiny mirrors, thus dramatically increasing insulation performance.

Innovative insulation solutions

Hefei Grand Theatre, Anhui, China

Microscopic cross-section of melamine foam Courtesy: BASF

EPS in the construction process

Modern Plastics & Polymers | June 2011

As the global performance polymers industry strives to provide a wide range of energy-efficient materials for use in the construction sector, it is necessary to understand the key strengths and advantages of polymers in building applications. Expandable Polystyrene (EPS) contains infrared absorbers, and is an exceptionally versatile polymer that offers builders outstanding insulation performance. It substantially decreases

TREND ANALYSIS CONSTRUCTION

the energy required for cooling in warm climates and for heating in cold climates in order to maintain room temperatures within a comfortable range. Thus, polymers help reduce cooling and heating costs in buildings. According to a study by the Passive House Institute, Darmstadt, Germany, energy consumption for cooling buildings can be reduced by up to 40 per cent in Singapore and by up to 48 per cent in Mumbai, depending on the thickness of the insulation panels used. This study was based on the dynamic hygro-thermal building simulation program DYNBIL, which assesses the heating, cooling and dehumidification energy requirement of a double-story corner terrace house with a basement & living area of approximately 120 m2. The study was carried out using BASF’s Neopor® EPS in insulation panels of walls & roofs in the cities of Singapore, Mumbai, Dubai, Los Angeles and Buenos Aires. Besides environmental benefits, energy-efficient construction also directly translates to real cost-savings for consumers. For building owners, insulation could even translate to an increase in the value of buildings due to Neopor’s improved environmental compatibility. Insulation polymers play a valueadded role when building components are subject to pressure and moisture. Here, the insulating polymer should absorb as little water as possible since water absorption has a significant detrimental effect on thermal insulation. The water-resistant properties make these polymers suitable for use in tropical climates, typically, for roof insulation and roof greening systems. An example of this is BASF’s Peripor®, developed specifically for such applications. Polymers have special functional characteristics for use as lightweight filling material in buildings and other infrastructure projects. Apart from its lightweight nature, EPS is engineered to meet the required compressive strength, while also being durable and resistant to moisture. These properties 92

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make it an inert and predictable material in long-term burial conditions, enabling engineer assurance in the design process. At 25 kg/m3, the density of BASF’s specially designed EPS, Geofoam®, is approximately 100 times lighter than most conventional earth fills. On the other hand, conventional earth fills, being heavy, can cause settlement, instability and lateral pressures, which in turn lead to soil erosion. The lightweight property of EPS makes it easy to handle, transport, apply and arrive at the job site prefabricated and ready to place, thus maximising onsite installation efficiency. Also, its installation is independent of weather conditions. So, as opposed to other fills, EPS application reduces total construction cost by providing the greatest possible control over design, timeliness, materials and results. Recent projects include Marina Bay Sands in Singapore and the Indira Gandhi Airport in New Delhi, India.

Thermal and acoustic solutions Continuous research from the polymer design fraternity has yielded a type of flexible foam that is being increasingly used in numerous construction applications. These include thermally insulating solar systems from panels to hot water boilers or combining effective sound insulation with enhanced fire safety regulations. Basotect®, an open-celled foam based on melamine resin has a unique set of properties. It is a flame-retardant and can be used at temperatures up to 240°C, while retaining its properties across a wide temperature range. The open-celled foam structure makes it lightweight (9 g/L), sound-absorbing, flexible and thermally insulating. This combination of properties allows this foam to be used as a versatile, high-quality solution in energy-efficient applications, with advantages in all stages, from processing to final use. The construction sector benefits particularly from melamine foam’s

low thermal conductivity of less than 0.035 Watt per metre and Kelvin [W/(m*K)], which renders it good insulation performance. Combined with its high temperature resistance, melamine foam increases the efficiency level of solar thermal energy systems. These systems have to be well-insulated to ensure that the heat of the sun can be used optimally. The foam insulates the collectors on rooftops, pipes transporting heat and the heat reservoir. Also, melamine foam can be used to reduce energy losses in computing centres. Computing rooms with network cabinets are often equipped with false floors to accommodate cabling. Through the openings in the floors, the cables are routed upwards. However, the cold air, intended to cool the servers, escapes through these openings. In order to eliminate this thermal bridge, this melamine polymer acts as an energy-saving foam closure. With application of this foam, up to 99.9 per cent of air losses in false floors can be reduced, and the temperature & air pressure remain stable. It also decreases the cost of air conditioning by up to 10 per cent. The advantages of Basotect® for the insulation of the collectors on the roof are twofold. In contrast with other insulation materials, Basotect® can be cut into different shapes. This foam releases practically no volatile substances that could obstruct solar radiation, eg, fogging on glass panels of collectors, which could reduce the efficiency of the solar energy system.

Dual comfort with plastics Insulation and cooling are important factors in energy-efficient construction, particularly in regions with hot and humid climate. Therefore, plastics are now finding applications in the construction of energy-efficient buildings, which will help reduce energy use, and subsequently, cost-savings, in the coming years. Courtesy: BASF

INDUSTRY INSIGHTS BIOPLASTICS

Bioplastics

A commitment to green initiatives The increasing attention towards environment consciousness has prompted the bioplastics industry to continuously grow and thrive. Beverly Lewis finds out how these eco-friendly alternatives to plastics are slowly gaining foothold in the consumer products category.

Courtesy: Greediamz

ioplastics or biopolymers are polymers made from natural/ renewable or synthetic raw materials, which are always completely biodegradable/compostable. Demand for bioplastics has increased significantly, with growing awareness among companies to reduce the carbon footprint. Ravi Srinivassan, Consultant, Bioplastics Technologies India, adds, â&#x20AC;&#x153;The use of biodegradable plastics leads to reduced recycling, less incineration of plastics and less scrap, which in turn reduces costs.â&#x20AC;?

Modern Plastics & Polymers | June 2011

Often referred to by their chemical component, Polylactic Acid (PLA), bioplastics are formulated from 100 per cent natural materials, eg, corn, potato, sugarcane. Derived from renewable sources, manufacturing of bioplastics consumes 65 per cent less energy than the that of conventional plastics. Bioplastics are disposable through a method called composting. These produce 70 per cent less Greenhouse Gas (GHG) than standard plastics, and degrade naturally in landfills in a few months.

INDUSTRY INSIGHTS BIOPLASTICS

Current demand Plastics derived from plant materials currently make up only 0.2 per cent of the roughly 350 Million Metric Tonne (MT) of plastics consumed annually worldwide. But this volume is expected to jump 30 per cent a year over the next decade. This volume hike is said to be due to the growing demand for ecofriendly packaging and other products that will use biomass as a feedstock. Also, the demand for biodegradable plastics in India is growing at a steady pace and is estimated to reach 5 MT by 2015. When biomass is used in making plastics, it replaces petroleum products as an ingredient, thus reducing the demand for carbon-laden fossil fuels. Dr Ramani Narayan, Professor, Chemical & Bio Chemical Engineering, Michigan State University, explains, “Carbon is the major basic element and the building block of polymeric materials – bio-based, petroleum-based and biotechnology products as well as fuels, even life. Therefore, discussions on sustainability, sustainable development, environmental responsibility, etc revolve around the issue of managing carbon (carbonbased materials) in a sustainable and environmentally responsible manner.” The natural ecosystem manages carbon through its biological carbon cycle, and so it must be reviewed how carbonbased polymeric materials fit in nature’s carbon cycle and address any issues that may arise. Designing plastics that can be completely consumed by microorganisms present in the disposal environment in a short span of time is a safe and environmentally responsible approach for the end-of-life management of single use, disposable packaging. Thus, when considering a bio-based resin, certain environmental considerations must be taken into account, eg, end-of-life management, complete biodegradation, its agriculture-based feedstock and the energy required and GHGs emitted during production. Dr Narayan asserts, “The rationale for using bio-based

products is that one can manage carbon emissions in a sustainable manner (the rate of carbon fixation by photosynthesis equals the rate of use and liberation to the atmosphere – carbon neutral). Therefore, it makes sense to use carbon as the basis for the measure of bio-based content and not oxygen or hydrogen, or weight or mole.” But, this industry is still in a nascent stage in India, compared to the global scenario.

Popularity of bioplastics The interest in bioplastics fluctuates with the price of oil. PLA is a transparent bioplastic and costs manufacturers about 20 per cent more as compared to petroleum-based plastics. Polyhydroxyalkanoate (PHA) biodegrades more easily but costs more than double the regular plastics. The base ingredient for both these is fermented corn sugar that allows them to degrade fast when buried. PLA is more popular and used to manufacture bags and water bottles. Companies are trying to make PLA from potato, algae and some varieties of grass. While PHA, despite being more expensive, has several advantages. It can withstand higher temperatures and decompose in water or soil.

The need of the hour is the willingness among manufacturers to produce and consume bio poly bags. Ravi Srinivassan

Consultant, Bioplastics Technologies India

Future trends The eco-friendly alternatives to plastics are gaining foothold in the consumer products category, but are yet to prove their durability and pliability as the good old plastics. Bioplastics currently lack the heat resistance and impact absorbing powers of ordinary plastics. And, as with all new environmentcompatible technologies, development costs can be high and companies in the bioplastics industry have yet to achieve economies of scale and a benefit of mass production. But, is the society green enough to use bioplastics? “Thus, the need of the hour is the willingness among manufacturers to produce and consume bio poly bags,” concludes Srinivassan.

The rationale for using bio-based products is that one can manage carbon emissions in a sustainable manner. Dr Ramani Narayan

Professor, Chemical & Bio Chemical Engineering, Michigan State University

June 2011 | Modern Plastics & Polymers

VIEWPOINT

“The key to success in the bioplastics industry is raw material availability” Perses Bilimoria, Founder and CEO, Earthsoul India Pvt Ltd Current trends and demand in India The current demand for bioplastics in India is approximately 5,000 Million Tonne (MT) per year, and this is expected to further go up to 15,000 MT by the next year. Bioplastics are plastics that degrade without any processing/ facilities and re-enter the carbon cycle in the form of basic elements. Although the Indian market does not have a clear understanding of the definition of bioplastics, most people agree that bioplastics must be derived from a renewable source. Thus, biodegradable plastics basically are blends of petroleum-based polymer resins and resins obtained from a renewable source. Some additives are added to these resins in order to enhance the degradation process, and usually degrade in 10-15 years. These plastics require composting and waste management facilities. The effect of these plastics on alteration of soil composition and compost sites is not yet known.

Bioplastics as plant derivatives All bioplastics are not plant derivatives; some are fossil-based or synthetic-based as well. However, most bioplastics today are produced from materials such as starch, waste stream starch, non-edible vegetable oils and other sources. These 96

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complete the lifecycle analysis or what is commonly called as the ‘Cradle to Grave’ cycle.

to synthetic plastics such as single-use shopping bags, which damage the environment.

Bioplastic material after use

Key strategies for success

It is important to understand what needs to be done with bioplastic products after they are used. Bioplastics once used cannot be recycled. However, three months after being used, these begin to degrade and assimilate into the soil or convert into carbon and water.

The key to success in the bioplastics industry is raw material availability. Another factor is to create a sustainable market demand, which should be met by a sustainable supply of raw materials.

Reducing emission

greenhouse

gas

Bioplastic materials, in the course of their way to grave, emit a small amount of carbon, which is easily assimilated into the soil as a nutrient. These materials are often considered as an instrument for carbon sequestration.

Need of the hour The need of the hour for this industry is implementation of the Certification Standards adopted by the Bureau of Indian Standards (BIS), that is the ISO 17088 for compostability. Already, there are several unauthenticated compostable bag manufacturers in India.

Threats to the environment Currently, the major concerns of the global Bioplastics industry are to present a sustainable, viable alternative

Future of bioplastics in India Choice of market segment, geographic regions and target markets: Development of new catalysts and improved biopolymer processing technologies are enabling better control of macromolecular structures. These allow new generations of ‘commodity’ polymers to challenge more expensive ‘specialty’ polymers for both functional and structural purposes, thereby creating new markets. Examples of these include biomedical applications for implants, dentistry and surgery. Moreover, implementation of the Kyoto Protocol is likely to increase the demand for certain bio-based materials. Finally, development of supply chain in the fragmented biopolymers industry as well as business implications of economies of scale versus a focus on products with superior attributes that can be sold at premium prices, are some of the areas needing more attention.

TREND ANALYSIS BIOPLASTICS

Biocompostable products

Taking responsibility towards the environment The alarmingly increasing burden of plastics has prompted researchers worldwide to look for an alternative to plastic products, which is also environment-friendly. Biocompostable or biodegradable plastics provide a solution to this problem, as these have already been proven effective and practical in packaging. Thus, it is time to take steps to address the problem of alternative packaging solutions.

Dipack Sangghvi

onsider this scenario: an individual walks into a grocery store, buys a week’s groceries and walks out with the purchases neatly packed in four or five plastic bags, which he later throws away. In another scenario, one buys his favourite brand of chips packed in shiny plastic packs. After finishing the snack, he throws away the packets. End of story, except that each plastic bag or packet will take as much as 400-1000 years to biodegrade or break down naturally. This means that not even a single plastic bag has yet been naturally degraded since the time they were first introduced to the world. They will remain in the environment for centuries, creating an ecological hazard like never before. Recycling is the buzzword of

Courtesy: Greediamz

Modern Plastics & Polymers | June 2011

the day, as is the suggestion to use alternatives such as paper or cloth. However, the problem with paper or cloth is that these materials are hardly as durable, strong or even as waterproof as plastics. What then is the solution? Is our planet doomed to suffocate under an ever-increasing pile of plastics?

Looking for biodegradable solutions For the nature’s welfare, small but extremely significant steps are being taken to address the problem of offering alternative packaging solutions. Experts believe that biodegradable and biocompostable plastics are the key to a greener future. According to Wikipedia, “Biodegradable plastics are plastics that will decompose in natural aerobic (composting) and anaerobic (landfill) environments. Biodegradation of plastics can be achieved by enabling microorganisms in the environment to metabolise the molecular structure of plastic films to produce an inert humuslike material that is less harmful to the environment.” Researchers across the world are studying the possibilities of creating plastics and polymer films with materials that will allow natural elements to break down the packets and assimilate the same in the environment. India is not far behind in this quest for a greener future. Although there are initial hurdles of raw material import costs and the cost of new technology, these products

TREND ANALYSIS BIOPLASTICS

will help ramp up manufacturing operations and provide an effective, eco-friendly alternative towards packaging needs. In the near future, bioplastics will have the potential to provide an alternative to plastics to a large cross-section of industries such as retail, manufacturing units, food storage, hospitality and Food & Beverage (F&B), and local municipalities (eg, Truegreen from Greendiamz), with respect to effective garbage disposal solutions. As the Indian Government is showing increased sensitivity and concern for ecological hazards faced by the country, it is hoped that progressive government policies and laws will encourage organisations from other countries to set up operations in India. The industry is creating global awareness for use of bioplastics, which is the perfect acceptable substitute of plastics.

Environmental awareness There is still a long way to go for this industry, as most sectors in India are not using compostable products. While, revolution and reforms have started against the use of plastics, government interference is a must to support this industry, as this is the nearest and a better available option against encountering pollution. Food packaging and religious trusts have started using bioplastics with perfect acceptability from their end-users. The future of bioplastics is bright, since awareness in market is picking up in all major sectors of the country, including agriculture, food packaging, waste disposal, hospitality, religious institutions and retail trade. More number of companies producing biocompostable plastics will mean a greater number of alternatives to plastic packaging, and therefore a better chance at a greener future.

Gearing up for a greener future Is the country really ready to consider alternative environmentfriendly solutions? The answer is a resounding yes! In a short span of time, biocompostable film will find application as the inner lining for packing milk and other dry foods. With rapid growth of the Indian economy, sectors such as manufacturing, retail and hospitality will also expand and contribute to the economic development. This growth will be parallel to the increase in plastic packaging, thereby adding to an existing environmental problem. The technology and products are at a nascent stage, but have already been proven to be an effective and practical alternative to plastic packaging. In the years to come, biocompostable packaging solutions will be the key to saving the country from choking under layers of suffocating plastic material. Dipack Sangghvi is Director of Greendiamz. The company manufactures TrueGreen brand of packaging solution through biocompostable films. Email: dipack@truegreen.in

June 2011 | Modern Plastics & Polymers

LEADERS SPEAK

â&#x20AC;&#x153;High-performance polymers have excellent long-term prospectsâ&#x20AC;?

...believes Amandeep Singh Cheema, Country Head, DuPont Performance Polymers. As a company willing to invest in countries having high growth potential, India offers just the right mix of challenges and opportunities for DuPont to chart a long-term growth plan in the country. He elaborates on research initiatives, technological advancements and increasing applications of polymers with respect to the Indian market, in this interaction with Anwesh Koley.

Current trends in the polymer industry Conventional polymers have lower mechanical, thermal and impact properties and cannot be used in demanding applications; hence, engineering polymers are preferred in such cases. Highperformance polymer products from DuPont have a higher strength to weight ratio and better durability at various temperature ranges. Therefore, these present opportunities to replace metal and rubber where the incumbent materials do not function satisfactorily. A large proportion of DuPont Indiaâ&#x20AC;&#x2122;s work on applications with high-performance polymers is targeting to replace metal and rubber parts to provide cost-effective solutions to customers. These applications are in automotive, two-wheelers, railways, industrial consumer industries and infrastructure. 100

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India as a market for DuPont DuPont India is of strategic importance to DuPont global, and we are investing for a sustained long-term growth. Along with the growth in Indian market, we are positioning ourselves to fully leverage the India advantage for DuPont global. We are witnessing growth opportunities for our different businesses in all three horizons. In the immediate and short term, our growth opportunities lie in our businesses of agriculture & nutrition (Pioneer seeds, Solae nutrition & crop protection products), building & construction, infrastructure and automotive (white pigments, high-performance engineering & industrial polymers for roads, railways, automotive, building & construction). In the medium to long term, we are looking at opportunities in sectors such as defence, renewable energy and materials (photovoltaics, bioethanol & biobutanol) and renewably sourced materials for different applications. We are and will continue to invest heavily in human talent as well. India provides tremendous growth opportunities for us. As a dynamic science company, DuPont wishes to partner with India in its march towards becoming an economic superpower.

LEADERS SPEAK

Growth prospects High-performance polymers have excellent long-term prospects. Modern polymers are being preferred to substitute applications in metal & rubber parts in industries such as automotive, energy, electrical and electronics, consumer & industry durables, food packaging, healthcare, highways and railways. Also, DuPont specialty ethylene co-polymers and/or Thermoplastic Elastomer Ether Ester (TEEE) contribute to performance enhancement in wire and cables. DuPont is witnessing some of the fastest growths in emerging markets like India. As the fourth largest and one of the fastest growing economies in the world, India provides tremendous opportunities for DuPont in a trillion-dollar economy, with a focus on infrastructure, construction and automotive. Market for engineering and industrial polymers Engineering polymers have bright growth prospects in the years to come. DuPont has several offerings in the category of high-performance polymer products, which can replace metal and offer weight & cost reductions to customers, while also meeting the functional needs of the application. The socio-economic trend of increasing younger-age working population (including more women) has created new avenues for packaging and industrial polymers as well. Today, the hectic lifestyle and dual income of people are encouraging the emergence of organised retail, and thus creating new application avenues in the area of packaging. Moreover, demand for safe and hygienic packaging for food, beverages and medicines is growing. DuPont is approaching these opportunities with its unique and high-performance offerings through its new-generation polymers. Technology advancements witnessed through the years Based on our expertise and experience in polymer technology, every year

DuPont has several offerings in the category of high-performance polymer products, which can replace metal and offer weight & cost reductions to customers, while also meeting the functional needs of the application. DuPont develops various innovations to commercialise a number of new product grades. Thus, our innovation pipeline is solid and full. DuPont has introduced Bio-based Polymer globally, DuPont™ and high-performance Sorona®, polymers that can withstand high temperature while maintaining high strength and stiffness. We have also introduced products that can be used in structural applications. DuPont’s ‘Superstructural’ resins offer a possible way to reduce wall thickness while maintaining the load-carrying capacity. Research and development initiatives undertaken In November 2008, DuPont had set up the DuPont Knowledge Center in Hyderabad. The company invested approximately ` 130 crore in the facilities of its first R&D centre in India. The 15-acre DuPont Knowledge Center has been made to accommodate more than 300 scientists and other employees. This number is expected to double in the next 3-5 years. The people here work closely with nearly 5,000 scientists of DuPont located around the world. This is the sixth major DuPont R&D facility outside the US and includes biotechnology laboratories, materials research laboratories, engineering design centre and high-end information technology capabilities. We are investing heavily in human resources as well.

The DuPont Knowledge Center works on application development in order to create local customised solutions to meet India-specific needs of customers. For example, DuPont™ Hytrel® RS, a thermoplastic elastomer, which is less than 20 per cent renewably sourced, is the latest offering in renewable polymers. It is attractive for automotive components, electrical & electronic parts and consumer and industrial products. In India, DuPont has production facilities in Savli, Gujarat (for DuPont Engineering Polymers, DuPont Crop Protection products and DuPont Refinish Paints); in Medchal, Andhra Pradesh (for Pioneer® seeds); and in Madurai, Tamil Nadu (for DuPont Filaments & DuPont non-stick coatings). All these facilities have witnessed further infusion of capital and capacity expansion in the last 12-18 months. Opportunities for domestic and international markets The global trend today is to replace metal with high-performance polymer products, thereby offering multiple benefits to the customers, such as weight reduction and cost-effectiveness without compromising on functional needs of the polymer application. DuPont excels in this category. In the current scenario, engineering polymers have an excellent future, where customers are awakening to the multiple advantages enjoyed by such polymers. One of the areas in which DuPont is witnessing fast growth is in emerging markets, where the company’s high-performance polymers are replacing rubber, metal or not-inkind plastic materials in a multitude of applications. DuPont has begun focussing on ‘sustainable growth’ that is more relevant to its business performance. As part of this strategy, we have strengthened our focus of ‘Go where the Growth is’; this implies high-growth geographies like India as well as high-growth market segments. June 2011 | Modern Plastics & Polymers

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FACILITY VISIT

Zylog Plastalloys Pvt Ltd

A promise for unparalleled quality As India’s automotive industry seeks greater horizons, Zylog Plastalloys is working to strengthen its role as the industry’s ideal solutions partner through constant innovation and value-added services. Annabel Dsouza decodes the driving forces behind the company’s phenomenal success in the automotive plastics space.

he automotive industry is a sunrise sector of India’s surging economy, and performance plastics make an integral part of it. And, who better than Zylog Plastalloys could understand this. The comapny has been a pioneer of performance plastics processing for automotive applications in India as well as on the global front. With replacement of metal by plastics being a profitable and sustainable move, the demands by automotive Original Equipment Manufacturers (OEMs) for plastics have increased, both in

Photo: Joshua Navalkar

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properties and volumes. Competing and collaborating in this highly technical arena requires immense knowledge and experience gained over decades. This is exactly what Zylog Plastalloys has come to be known as – a reliable and reputed brand in the automotive plastics domain. Today, the company takes pride in having all major domestic and multinational OEMs and Tier 1 suppliers as its customers. With Tata, Mahindra and Bajaj on the home turf, Zylog has built a long & stable relationship with global giants such as Toyota, Fiat and Volkswagen. As India is emerging as an attractive destination for automobile engineering, Zylog Plastalloys is poised to continue its vision as an end-to-end solutions provider for the automotive industry.

FACILITY VISIT

Tracing the growth path In 1984, Zylog’s foray into the Indian compounding industry seems to have strategically coincided with the commencement of plastics application in the Indian automobile industry. The company’s main compounding base operated from Maharashtra Industrial Development Corporation (MIDC), Ambad, Nashik. With the breakthrough initiative of launching India’s first singlepiece Instrument Panel (IP) for the Tata 207 model, the company has grown over the years with a large number of formulations for various applications, which meet the specifications of OEMs across the world. Thus, another forte of Zylog is development of products that meet international quality standards & safety, thereby catering to export demands from Indian automotives. By 1989, Zylog began providing services to leading automakers like General Motors, Ford and Hindustan Motors. A noteworthy achievement came with Zylog striking a strategic partnership with the Tata Indica programme, for which it continues to supply the entire interiors. This considerable increase in production volume called for a greenfield expansion of the facility at Sinnar, near Nashik. Currently, this is the largest in Zylog’s portfolio of four manufacturing facilities across India. Started in 1989-90, the Sinnar compounding unit spans an area of 3-3.5 acre, with an annual production capacity of 25,000 tonne. With its corporate functions based out of Pune, West India remains the conventional thrust zone of Zylog Plastalloys. It is worth mentioning that during 1998-99, Zylog had worked closely with the now defunct Joint Venture (JV) between Mitsubishi and Exxon Mobil called Mytex Polymers. Mytex catered to the material requirements of Toyota Innova and Corolla. Subsequently, Zylog’s commitment to stringent performance deliverables from its products earned it direct approval from Toyota. This approval was a landmark

achievement that propelled Zylog towards becoming the first Indian automotive compounder to meet the challenging technical specifications by the Japanese OEM. Mirisch Damani, Chairman & Managing Director, Zylog Plastalloys Pvt Ltd, says, “We began with the vision of becoming a complete solutions partner to the global automotive industry. Over the years, we have achieved this goal by sheer quality and technological competence. This is the core strength and value of Zylog.”

Pan India presence As it began incorporating all major OEMs and Tier 1 suppliers to its customer portfolio, there has been no looking back for Zylog. This resulted in a wide sales and support network across all major auto manufacturing hubs in India. Zylog also has its manufacturing base at Sriperumbudur, near Chennai. This has enabled it to collaborate better with companies like Nissan and Renault. Currently, Micra is Nissan’s flagship model for the export market, and it uses 25 kg of Polypropylene (PP) per car, supplied by Zylog and moulded in-house by Nissan and its Tier 1 vendors. In Chennai, Zylog also works with Diamler for truck manufacturing, while in Bengaluru, it caters to Toyota and its vendor base. In North India, Zylog collaborates with leading Indian auto brands like Maruti Suzuki and Hero Honda. Overall, the company has a 65 per cent capacity demand from domestic OEMs, while 35 per cent is accounted by multinationals. This ratio is likely to reverse, as India moves further to become the world’s auto manufacturing hub.

Technology edge In the successful growth curve at Zylog, technological merit has played a crucial role in deciding the company’s stake in India’s automotive plastics industry. At Zylog, PP and Ethylene Propylene Diene Monomer (EPDM) are the base resins

We began with the vision of becoming a complete solutions partner to the global automotive industry. We have achieved this goal by sheer quality and technological competence. Mirisch Damani

Chairman & Managing Director, Zylog Plastalloys Pvt Ltd

used to manufacture a range of PP compounds, Thermoplastic Polyolefins (TPOs) and Thermoplastic Vulcanisates (TPVs). Branded as Hipolyene and Neoplast, these are highly engineered performance plastics that meet rigorous OEM specifications for exterior, interior and under-the-bonnet applications. Damani highlights, “The role of a compounder is to understand the application and technically develop the formulation by involving various impact & reinforcing agents and additives such as heat and Ultraviolet (UV) stabilisers, antioxidants and pigments. These additives modify the base resin, converting it into a mouldable form that meets the application criteria. This is then supplied to the injection moulder.” At its Sinnar facility, Zylog runs four high-speed compounding lines, each with a capacity of 1,000 kg per hour. The resins and additives are mixed in a twin-screw extruder, in a continuous compounding process. The entire compounding unit is designed June 2011 | Modern Plastics & Polymers

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Technology competence

Superior compounding process

High-temperature polymer entering coolant bath

Entire processing line

Photo: Joshua Navalkar

as a closed-loop, contaminant-free system that increases material and energy efficiency.

Legacy of quality Quality is an integral aspect of all products and processes at Zylog. A typical formulation passess the stages of testing, validation and OEM approval, before starting commercial production. The stringent quality checks involve appropriate methods for analysing physical, mechanical, thermal and rheological properties of polymer resins. For analysing the performance of automotive plastics in extreme climatic conditions, Zylog has installed a Xenonarc weatherometer, which simulates the weathering effect to test the stability of plastics in conditions varying from the Siberian to the Saharan climate. Zylog’s culture of quality extends not only to its products, but also ensures complete quality control over the compounding process. This involves quality filters at the raw material stage to half-hourly validation tests per consignment. The entire process inspection is controlled online and automatically corrected. Considering all these, it is no surprise that Zylog was the first company in Maharashtra to obtain ISO TS 16949 certification for the 2009 version. Zylog has also received ISO 14001 and OSHAS 104

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18001 certification for following proper environmental management and health & safety practices. As the automotive industry is highly competitive, Zylog ensures minimum set-up & grade changeover time, thus ensuring effective utilisation of material and equipment. For a compounding industry, this is a significant achievement considering that over a period of 26 years, Zylog has developed a database of more than 500 formulations. “For 90 per cent of the enquiries at Zylog, we have a readymade solution in our database. Thus, it is a question of efficient fine-tuning and processing to reach the optimum specification,” informs Damani.

Empowering employees With an employee strength of over 130, Zylog emphasises on employee welfare and growth in order to improve the overall performance of the company. It has devised a single-window decisionmaking process, which will enable delivering quality services to customers on time. The company has thus empowered the staff to play a more proactive role in its growth. Damani states, “We believe that people are our strength, and hence we ensure regular medical check-ups for managerial staff as well as shopfloor operators. We also work towards refreshing our staff’s knowledge and

skills through regular training and workshops.” He further adds, “It is important to understand our core values followed in day-to-day functions. We also incorporate a spiritual side to the business for stress management among our staff. Our people should be able to enjoy the work environment and have time for their family life as well.”

Towards brighter prospects India’s automotive industry continues to surge at a Compounded Annual Growth Rate (CAGR) of 30 per cent, with 4.5 million cars expected to hit the market by 2015 from the current production of 2.5 million cars. On the plastics front, the industry is anticipating the annual automotive PP consumption to rise from the current 80,000 tonne to 200,000 tonne. In such a scenario, Zylog Plastalloys will be a bigger stakeholder, with large volume supplies to all leading OEMs. The company is on an accelerated capacity expansion drive adjacent to its current facility. Damani concludes, “With excellent response from our customers and the entire automotive industry, we will continue expanding our operations through JVs, technical & service collaborations, mergers & acquisitions, business alliances and strategic forward integration. We are also planning intensive investments in all major automotive verticals.”

SECTOR WATCH

Blow moulding

Ensuring quality, durability and versatility Product durability and design versatility are key requirements of the packaging industry today and blow moulding technology offers exactly these features and much more to customers for whom, the external packaging is as important as the product inside. Anwesh Koley tracks the emerging trends and customer preference that are driving the use of plastic bottles, thus increasing the demand for blow moulding products.

he Indian market for blow moulded products is on the rise. The global trend towards plastics and Polyethylene Terephthalate (PET) products indicate the preference of consumers for packaging products that are lightweight, portable and, most importantly, recyclable. To begin with, the cost of polyethylene is lower than most other materials available in the market, such as aluminium and tin. This makes plastic material a cheaper alternative to its metal counterparts. Blow moulding is a process of manufacturing hollow cylinders by using a plastic moulding technique.

The technique had originated during the industrial revolution in the 19 th century and proved to be a potent technology for producing bottles with desired shapes and sizes. â&#x20AC;&#x153;Among the plastic conversion technologies, blow moulding dominates, as the resulting materials/forms have a cross-section of applications,â&#x20AC;? avers P V Narayanan, Chairman, Cognizance Packaging. There is a consensus among industry players that blow moulded products, especially PET, serve industrial purposes better as compared to other similar techniques because of attributes such as light weight, recyclability, shatter resistance and higher clarity.

Rising demand

Courtesy: BASF

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The advantages of blow moulding technology can be seen from its rapid adoption by the plastics and packaging industry. Due to the low manufacturing costs of this material, the Indian packaging industry is fast becoming a preferred destination for global players and the most common technology used is blow moulding. The flexible packaging industry relies heavily on this technology, as the end-product meets most of the customer expectations. â&#x20AC;&#x153;The demand for blow moulding machines has increased in the Indian market in the last two years, as more and more department stores are opening across big cities like Mumbai, Ahmedabad

SECTOR WATCH

and Delhi. Also, the emergence of new housing societies is fuelling the demand in a big way,” says Vijay Vora, Director, Roshma Pet Plast Pvt Ltd. Another major advantage of these products is the ease of transportation. Due to the convenient shape and size of these products, these can be easily compartmentalised for shipments and the delivery process becomes easier. “From the time blow moulded products, primarily PET bottles, have come in vogue, our delivery time has shortened and a consignment takes lesser time to reach our customers. The light weight of these products is a major reason for this improvement,” adds Vora. Blow moulded products have a higher capacity to withstand hot and cold temperatures as compared to similar materials such as glass.

Key techniques These are of various types: extrusion blow moulding, injection blow moulding and stretch blow moulding. The extrusion blow moulding process uses conventional extrusion of a parison or tube using a die similar to that used for making plastic pipes. In the injection blow moulding process, the material flows through an injection barrel into the mould. This allows the end product to have more precise details in the neck and threaded area than extrusion blow moulding. However, this process is limited to the production of relatively small bottles. “A major difference between the two processes is that extrusion blow moulding utilises unsupported parison, while injection blow moulding utilises supported parison on a metal core,” explains Narayanan. He adds, “Blow moulded containers have forayed into packaging as well, with their major application areas including vanaspathi, edible oils, dairy products, paints, chemicals, etc. The extended version of stretch

blow moulded bottles or containers finds applications in squashes, syrups, colas, malted foods, grains, pickles, etc.” Elaborating on currently available high-productivity blow moulding machines, Dinesh Bharati, Manager (Sales Engineering), Toshiba Machine (India) Pvt Ltd, says, “With regard to types of blow moulding machines available in India, the current trend is towards prestretch blow moulding machines. The pharmaceutical industry is one of the largest industries in India and consumes huge numbers of small bottles; hence, pre-stretch blow moulding machines are witnessing high demand.”

Fulfilling requirements of packaging industry “Developments in packaging technology have not only contributed to improving the aesthetic appeal of the products but also increased their shelf-life. This is where blow moulded articles score, as not only these provide better containing options, but can also be customised according to customer needs,” opines Rajesh Panchal, Director, Om Chamunda Enterprises. The varying needs of the packaging sector warrant the use of technologies that can be suitably adopted according to the market. While discussing blow moulded products, the first thing that comes to mind is PET bottle. Perhaps the best known technique for producing PET bottles is stretch blow moulding. PET containers are ideal for storing water, juices and a number of other products that are used for regular consumption. PET bottles are manufactured by injection stretch blow moulding method. This method requires a large floor area for the injection moulds to create the preform and then for the blow moulds to create the final finished product after blowing the container.

Plastics score over metals Earlier, metal products were frequently used for packing liquid,

Among the plastic conversion technologies, blow moulding dominates, as the resulting materials/forms have a cross-section of applications. P V Narayanan

Chairman, Cognizance Packaging

The demand for blow moulding machines has increased in the Indian market in the last two years, as more and more department stores are opening across big cities like Mumbai, Ahmedabad and Delhi. Vijay Vora

Director, Roshma Pet Plast Pvt Ltd

June 2011 | Modern Plastics & Polymers

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SECTOR WATCH

Pharmaceutical industry is one of the largest industries in India and consumes huge numbers of small bottles; hence, pre-stretch blow moulding machines are witnessing high demand. Dinesh Bharati

Manager (Sales Engineering), Toshiba Machine (India) Pvt Ltd

semi-liquid and solid products. However, the consistent rise in metal prices has witnessed a steady decline in the use of metal products, and this has resulted in plastics becoming the preferred material for packaging. “The packaging industry is of the opinion that packaging materials made of tin should be replaced with blow-moulded plastics. This is because tin, aluminium and other similar metals used in packaging are not only more expensive, but also in short supply,” says Amit Kumar Singh, Manager - Business Development, Alok Masterbatches. Today, blow moulded plastic products are being heavily used by the endconsumer. However, certain items such as beverages are still sold in tin cans, as the quantity supplied in these cans do not have a similar blow moulded counterpart. “If the blow moulding technology is extended to making containers with dimensions similar to those of tin containers, the customer will readily accept it,” believes Panchal. Moreover, the food grade material used in blow moulded plastics is better in terms of retaining the quality of the product inside than a metal container.

Market trends

The Indian blow moulding machinery market is maturing due to constant growth in competition and quality increases, with the endcustomer being the final winner. Rajesh Panchal

Director, Om Chamunda Enterprises

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In any supermarket today, almost every plastic container that holds a liquid has undergone some variety of blow moulding. This indicates the ubiquity of the process and the versatility that can be attempted with the shape, size and design of the final product. Industries like automobiles use blow moulded products for their fuel tanks and alloys and the result can be seen in their final applications. “According to an Internet survey, automobile companies are expecting a growth of about 20-25 per cent every year, and thus the demand for white goods is also likely to grow over the next few years. This growth is the result of increasing per capita income and availability of various financing schemes in the market,” says Bharati.

The blow moulding technique cuts down on labour and the potential for breaking parts, as the moulded component is essentially a single piece. “Modifications in the processes and availability of resin varieties enable blow moulded containers to have extended applications, thus rendering the technology with an excellent growth potential,” adds Narayanan. A practical advantage of blow moulding is the easy availability of machinery for processing. “The Indian blow moulding machinery market is maturing due to constant growth in competition and quality increases, with the end-customer being the final winner,” says Panchal. The cost of preparing a blow moulded parison is comparatively less than that of other techniques. It has a high Environmental Stress Crack Resistance (ESCR), which is a boon in the current scenario where recyclability and environmental concerns are top priorities for manufacturers. The current market for blow moulded products is vast and is steadily increasing as a result of heavy demand from customers and also the global trend towards such materials. While a quick shift was witnessed from the use of glass bottles towards

Courtesy: Uniloy Milacron

SECTOR WATCH

The packaging industry is of the opinion that packaging materials made of tin should be replaced with blow-moulded plastics. Amit Kumar Singh

Manager - Business Development, Alok Masterbatches polyethylene products, the shift from metal products towards plastics is rather gradual. The use of glass for packaging has several disadvantages, the most common being the breakability of such products, which makes it hazardous. Second, the weight of a blow moulded glass article is higher than a similar plastic product, which makes its transportation difficult.

Future outlook The future of blow moulded products shows a lot of promise in terms of scope and acceptability. “The standards of the people and their requirements run parallel. Due to this, small, medium and even large companies in the blow moulding industry are booming today. The future may be more extractive and innovative, as products such as HighDensity Polyethylene (HDPE) bottles, jars and PET bottles may enter a new field of packaging,” says Vora. Adding to this, Panchal opines, “Packaging machinery manufacturers are increasingly focussing on developing rapid output and low-cost packaging equipment. Blow moulding offers an easy solution for all these. Thus, in future, equipment will become smaller in size, more flexible, multi-functional and highly efficient, and will aid in saving time as well as cost.”

Blow moulding is here to stay With mobility being of primary importance for the endconsumer today, blow moulded products will continue growing in the current environment. Eye-catching packages, better durability of the product inside and ability to provide the desired quantity of products are some of the features enjoyed by blow moulded products, which proves that this technology is here to stay. June 2011 | Modern Plastics & Polymers

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Plastics in road construction

Recycling wastes for commercial viability With rampant urbanisation resulting from Indiaâ&#x20AC;&#x2122;s booming economy, the plastics industry is aiming towards development of novel applications for recycled plastics. Beverley Lewis and Annabel Dsouza shed light on the innovative technology used in recycling of plastics for road construction.

uch has been said about recycling of plastics; however, integration of conventional waste management methods with commercial viability requires skills beyond simply entrepreneurship. In 1996, Rasool Khan, Director, K K Plastic Waste Management Pvt Ltd, based at Bengaluru, came up with the idea of recycling plastics and using in construction of roads. Along with his brother Ahmed Khan, he realised that plastics could be mixed

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with bitumen for use in building roads. With the concern about the condition of roads in Bengaluru, they thought of constructing more durable roads in the city. Rasool Khan made the first trial use of plastics with bitumen. He successfully used the bitumen-plastic mixture to fill about 100-200 potholes on Rajalakshmi Nursing Home Road in Jayanagar, Bengaluru. Following this success, he encouraged his son Amjad Khan, a student of chemical engineering at RV College of Engineering, Bengaluru,

MARKET TRENDS

to take up this topic as a research project and also funded it. After two years of research work, Amjad Khan concluded that it was feasible to use bitumen-plastic in laying roads. Subsequently, they received approval from highway engineers at the Central Road Research Institute (CRRI), New Delhi, for using the bitumen-plastic mixture to lay roads. Thus, in 2002, the Khans constructed India’s first bitumen-reinforced road in Bengaluru. This is just one story in India’s fast-paced economic growth. It is symbolic of the industry’s efforts to reduce its carbon footprint and material consumption. Plastics being integral to India’s manufacturing sector, manufacturers are realising the potential of using recycled materials for commercial gains. Rasool Khan states, “As we are a manufacturer of plastic bags, the demand for a ban on plastics began threatening our livelihood. We also have 100 odd employees working with our company. Thus, this prompted us to think of researching on alternative usage of plastics.”

The process: Innovation There is no denying that plastics have immense applications in nearly all verticals of the manufacturing industry – from automotives to packaging. However, the industry is realising the vast opportunities offered by recycled plastics as well. Vijay Merchant, Director, Polycraft Group, highlights, “The potential for use of plastics for road construction in India is huge, as the country has one of the largest road networks in the world.” The use of plastics in road construction goes a long way. Traditionally, plastics have been used as Polyvinyl Chloride (PVC) or HighDensity Polyethylene (HDPE) pipe mat crossings built by cabling together PVC or HDPE pipes to form plastic mats. Road constructed with plastics include transition mats that ensure smooth flow of traffic. Besides, it

improves the durability and lifespan of Indian roads that are subjected to large volumes of heavy vehicles and irregular maintenance procedures. In the waste plastic and bitumen mixture, plastics increase the melting point of bitumen and enable the road to retain its flexibility during high friction with traffic volume. Shredded plastic waste acts as a strong binding agent for tar, thus augmenting the longevity of the asphalt. The mixing of plastics with bitumen enhances the ability of bitumen to withstand high temperature. The plastic waste is melted and mixed with bitumen in a specific ratio. Blending generally takes place when temperature reaches 45.5°C, but after mixing the plastic, the mixture remains stable even at 55°C. Rigorous laboratory tests have proved that the bituminous concrete mix prepared with the treated bitumen binder meets all specified safety and regulatory criteria. Another important observation is that the bituminous mix prepared using the treated binder could withstand adverse soaking conditions under water for a longer duration. The durability of the roads laid out with shredded plastic waste is higher as compared to roads laid with asphalt in the ordinary mix. Roads laid with plastic waste mix are found to be better than the conventional ones. The binding property of plastics makes the road last longer, besides providing additional strength to withstand greater loads.

Every day India produces 123,000 tonne of waste, of which about 2,000 tonne is plastic. If we can use all that plastic, the plastic waste problem can be solved. Rasool Khan

Director, K K Plastic Waste Management Pvt Ltd

The sustainability index Apart from channelising waste material towards building the nation’s infrastructure, plastic-bitumen roads enhance road longevity and overall performance. While a normal ‘highway quality’ road lasts 4-5 years, it is claimed that roads built with the plastic-bitumen mix can last up to 10 years. Rainwater will not seep through because of the plastic mixed in the tar. Therefore, this technology will result in lesser need for road repairs. Each June 2011 | Modern Plastics & Polymers

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The potential for use of plastics for road construction in India is huge, as the country has one of the largest road networks in the world. Vijay Merchant

Director, Polycraft Group

kilometre of road with an average width requires over two tonne of the bitumen-plastic mixture. This will reduce the amount of non-biodegradable waste in the environment. Merchant avers, “The advantage of using plastic waste in road construction is noteworthy. For example, there is no need for employing new costly high-tech machinery. It improves the performance of the road and helps it last much longer, and thus solves

the problem of disposal of harmful plastic waste.” Several other laboratory studies conducted by CRRI for the utilisation of waste plastic bags in bituminous concrete mixes have proved that these enhance the properties of mix in addition to solving disposal problems. The results of the studies indicated an improvement in strength properties in comparison with the conventional mix. Therefore, the life of pavement surfacing using waste plastics is expected to increase substantially in comparison with the use of conventional bituminous mix. There are two different processes, namely, dry and wet process, to incorporate waste plastic bags into the bituminous mixes. The performance test proved that the plastics doubled the fatigue life of roads while also building resistance to rutting and water damages. Field trials have been carried out using the dry process, ie, by mixing the appropriate quantity of dry shredded plastic bags with hot aggregate prior to production of bituminous mixes at hot mix plant. Wet process includes blending of shredded plastic bags and bitumen prior to the production of modified bituminous mixes, and is at the commercialisation stage. The wet process for modification

Porous side walks: PET waste and soil mixed to avoid flooding Courtesy: Polycraft Group

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of bitumen using waste plastics has been patented by CRRI. Field trials have also been carried out using the dry process in Delhi. Under these trials, a 3.5-km road stretch in the city has recently been constructed with 40-mm bituminous concrete overlay. This section of road will be monitored for the next three years for its performance.

The road to better future The cost of plastic road construction may be slightly higher as compared to the conventional method. However, this should not be a deterrent to adoption of the technology, as the benefits are significantly higher than the cost. The recycling or reuse of materials for road construction can have direct as well as indirect economic benefits. Furthermore, it reduces transportation and production costs since materials are reused. The use of this innovative technology will not only strengthen the road construction but also increase the lifespan of roads and help improve the environment while also generating employment. Plastic roads would be a boon for India’s hot and extremely humid climate, where temperatures frequently cross 50°C and torrential rains create havoc, leaving most of the roads with big potholes. Due to rapid urbanisation taking place in India, plastic-bitumen roads are likely to address challenges of solid waste management. Rasool Khan signs off, “Everyday India produces 123,000 tonne of waste, of which about 2,000 tonne is plastic. If we can use all that plastic, the plastic waste problem can be solved.” It is hoped that in the near future, India will have strong, durable and eco-friendly roads, which will solve the problems associated with plastic wastes. The use of this innovative technology will not only strengthen the road construction, but also increase the road life. Going further, it will help improve the environment while also creating a source of income.

PERFORMANCE METRICS

Vibration welding of thermoplastics

Reinforcing the strength of polymers Advancements in welding methods have resulted in thermoplastics being increasingly used to replace metals and thermosets in new components for automotive parts. Orbital vibration welding has been found to be efficient in strengthening welded joints in reinforced nylons, and is considered as an alternative to linear vibration and ultrasonic welding. This is the first of a two-part series on a comprehensive study on types of nylon and welding technologies for various applications.

esigning a one-piece hollow plastic part is ideal because it eliminates the need for assembly. However, design, processing technology, product performance, reliability and other considerations often necessitate joining of thermoplastic parts and components. Nylons – Polyamides (PAs) – are high-performance, semi-crystalline thermoplastics that possess a number of attractive chemical, physical and mechanical properties. Moulded

Figure 1: Manifold for six-cylinder engine

Figure 2: Air-intake manifold for three-cylinder engine

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nylon parts are more resistant to creep, fatigue, repeated impact and challenging chemical environments than parts made of less durable thermoplastics. Various classes of nylon resins exist, eg, nylon 6, nylon 66, nylon 46, nylon 12, nylon 66/6, etc.

Thermoplastics in automotives Welded nylons are used in several industrial products, the largest being the automotive. In recent years, there has been a sharp rise in demand for non-filled, fibreglass-reinforced and filled nylon products to replace metals and thermosets in the lawn & garden equipment, power tools and automotive industries. In the automotive industry, on an average, each passenger car built uses 15-20 kg of nylon-based plastics. With annual passenger vehicle production at nearly 15 million, the automotive industry demand for nylon is over 200 MM kg, where more than 45 MM kg are consumed in under-the-hood applications and another 11 MM kg in welded Air-Intake Manifolds (AIMs) and resonators. The design of these critically stressed welded components requires advanced analysis of the structure; Noise, Vibration, and Harshness (NVH); and welded joints by using short-term and long-term strength and life criteria. The AIMs, resonators, valves, fluid reservoirs and several other components are hollow parts that can be produced by ‘lost-core’

PERFORMANCE METRICS

injection moulding, plastic welding or welding plus fastening/over-moulding technologies. Nearly 80 per cent of all plastic AIMs across the world are produced by the lost-core process or injection moulding followed by Linear Vibration Welding (LVW). The lostcore process is more capital-intensive than plastic welding processes, as it involves additional forming, melting and metallic core removal. The LVW and Orbital Vibration Welding (OVW) equipment, welding tools and nests are inexpensive, and the welding process takes less time. The LVW and OVW processes are PC-controlled, with sensors scanning the positions and automatically reporting key process parameters critical for both welding technologies.

Figure 3: Fluid reservoir

Figure 4: Linear vibration welding machine

Importance of vibration welding technology Automotive manufacturers are increasingly converting complicated under-the-hood components such as AIMs, air-filter housings and resonators, to thermoplastics. In 1979, Franceâ&#x20AC;&#x2122;s Peugeot Citroen became the worldâ&#x20AC;&#x2122;s first automaker to apply the vibration welding process to AIMs. Since then, Europe has remained the biggest proponent of this technology. In 1997, plastics held a 45 per cent share of the European AIMs market, compared with only 25 per cent in North America and four per cent in Asia. Welded nylons typically provide weight savings of up to 55 per cent as well as reduction in production costs. Various thermal and mechanical joining processes are available for thermoplastics, including LVW & OVW, spin welding (SW), hot-plate, electromagnetic, ultrasonic, infrared (IR), laser, etc. Choosing the best joining method for thermoplastics requires a thorough understanding of the design, purpose of the joint/ assembly and characteristics of the joining processes under consideration. Also, engineers should know the geometry of the component, nature of plastic materials, internal & external load, time/temperature requirements and other environmental conditions, as well as specific criteria required in the final assembly (aesthetics, noise, vibration, dimensional stability, etc). The LVW, OVW and SW require an internal heating process by using friction. For all frictional welding methods, the temperature in the weld interface is a function of processing parameters such as time, clamp-pressure, amplitude, frequency and meltdown, and also depends on physical characteristics of the polymers. Welding temperature in the joining interface during the welding process is not a directly controlled and guided parameter in standard LVW and OVW equipment available today. In order to determine temperatures over the total area and weld interface as well

Typical welding phases in frictional joining technologies Placement of plastic parts to be joined in nest with gripping provided by specially designed tools Materials heated in areas where the joints are to be formed Local melting in joint surface areas Contact/pressing together of surfaces to be joined Cooling in the joint interface and other areas Removal of joined/welded part from welding tool/nest and machine as optimise LVW processing conditions (including temperature at the interface), the advanced, IR, thermal-imaging method and computerised system are used.

How vibration welding works? The process of LVW entails rubbing two thermoplastic components together at a frequency, typically in the range of 120-240 Hz, at which the material produces frictional (Coulomb) heat. This results in a melt at their interface and subsequent melding/joining of the parts. The displacement may be linear, orbital or angular. The OVW method is also based on friction, which uses an electromagnetic drive to create a relative motion between two plastic components. This technology allows motion to be programmed in different ways, and gives more freedom for designing the weld areas. The orbital motion ensures that each point surface of the driven plastic part orbits a different point on the butt joint surface of the stationary part. This orbit of motion is continuous and identical for all points on the joint surface. OVW operates at low-vibration amplitudes. OVW avoids some of the hindrances of LVW, which faces problem with unsupported walls perpendicular to the direction of oscillation/vibration. Even sensitive electronic components on preassembled parts are not damaged mechanically or thermally, in contrast with other plastic joining methods. Typically, LVW machines combine all advantages of vertical or horizontal and vertical design for June 2011 | Modern Plastics & Polymers

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Figure 5: Orbital vibration welding machine

joining components made from similar or dissimilar plastics. The sizes of parts that can be joined vary from small (eg, valves, fluid reservoirs, etc) to very large (eg, car crossbeams, etc). When applying LVW and OVW technologies, one must consider the following: Weight and design limitations in the sizes of the part in upper nest/ fixture Limitations on weld-plane configuration and maximum value of out-of-welded plane angle Difficulties (to achieve optimised mechanical strength/life performance of joint) in using dissimilar plastics with different melt temperatures (>50°C or 122°F) Dimensional limitations (in nonisometric melt distribution in local areas of possible gaps) in reinforced plastics and for nonoptimised moulding conditions LVW is a reliable joining method for injection moulded, blow moulded and extruded thermoplastics, as well as hollow components. Here, it is critical to maintain the required wall stiffness – via angle and thickness – in the direction perpendicular to the direction of oscillation. The growing popularity of vibration welding in the auto industry can be 116

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attributed to its flexibility and low cost. Linear vibration welders are complete plastic assembly systems designed to join large or irregularly shaped thermoplastic parts up to 48 x 20 inch (1,220 x 508 mm) wide. Additionally, LVW is a fast joining process, with cycle times in the order of 0.5-12 sec. Typical cycle times are 30 sec – including both welding and cooling time – which is approximately 1/50 the cycle time of other methods and requires substantially less energy. This makes vibration welding considerably more cost-effective than the hot-plate or electromagnetic methods.

Technical parameters and phases In a typical LVW machine, surfaces of two components are mechanically clamped together. The first component is held stationary without oscillation, while the second component is vibrated (oscillated) against the first. This vibration is in the form of high-amplitude, low-frequency, reciprocating linear or orbital motion. Typical nominal frequencies are 120 Hz (for some European-made machines) and 240 Hz, with an amplitude range of 0.02-0.20 inch (0.5-5.0 mm). After the vibration stops, the melt cools and the parts become permanently welded in the clamped alignment. Vibration welding of thermoplastics takes place in four phases: Heating of the interface by Coulomb friction Unsteady melting and flow of material in lateral directions Melt-zone establishment at steadystate conditions Unsteady flow and solidification of the materials at the weld zone upon cessation of vibration The new vibration welding machines on market provide significant improvements in controlling welding process parameters, including amplitude, pressure, meltdown, welding & cooling time and improved automatic cycling.

Welded-joint performance requirements In order to optimise vibration-welded joint performance for highly stressed structural components, the material properties and part-production techniques must be carefully evaluated. The most important parameters for plastic joints are: Joining and production (moulding & welding) flexibility for multi-piece parts Specific performance requirements (strength, life/durability, chemical resistance, mechanical test conditions, etc) to vibration-weld plastic components and assembled parts Desirable level of welded-joint hermetic seal (burst & backfire pressure) Specific requirements of weldedjoint geometry (eg, shape, size, stiffness), joined parts’ dimensional

Critical processing and weld interface parameters for high-performance LVW and OVW joints Welding amplitude (variable in process) (in inch/mm): pre-melt (heating) melting Clamp pressure (variable in process) (in psi/MPa): pre-melt hold/sealing (cooling) Thickness of interface of pre-heated layer(s) (in micron): melt collapse/meltdown final thickness of interface (in local areas) Temperature in °F (or °C): in local and weld interface areas during the melt formation phase at start and final temperatures at hold/sealing (local cooling) phase Time (in second): pre-melt (heating) melting hold/sealing (cooling) Direction of oscillation/linear vibrations (longitudinal, perpendicular to thickness of wall/bead, by angle) Vibration frequency (in Hz) (range, 120-240 Hz)

PERFORMANCE METRICS

stability and tolerance Type of welded joint design (eg, butt, shear/overlap) Short-term mechanical properties of joints by tensile, flexural or combined-load conditions and impact-strength criteria Long-term mechanical properties of joints by creep and fatigue strength & life criteria NVH performance Desirable level of quality in weld areas (internal & external surface smoothness; aesthetics aspects; no defects, cracks, voids, inclusions, etc)

Material requirements for welded-joint performance In vibration welding, important requirements for the welded materials are: Type of joining materials (similar, dissimilar) Thermoplastic compositions (type of matrix, fillers & reinforcement) Optimised content of reinforcement elements, fillers and additives, pigments, etc Short-term and long-term mechanical properties of joined materials and mechanical properties

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of matrix with influence of loading, welding, time/temperature and environment conditions Dimensional stability of joined materials In general, manufacturers of plastic air-intake components and AIMs look for tensile strength values of 7,2508,750 psi (50-60 MPa) at ambient conditions of 73Â°F (23Â°C) to match the mechanical performance of aluminium. Performance of the welded joint has a major impact on the ability of manufacturers to meet these requirements. As a base material, 30-35 weight-per cent fibreglassreinforced nylon 6 and 66 products meet the above-mentioned tensile strength requirements. Another important design and material requirement for vibrationwelded air-intake components/AIMs is dimensional stability. Post-mould warpage will impact the tolerance of joined surfaces, clamp & welding pressure conditions, thus creating residual stress. For optimising vibrationwelding process parameters and enhance welding joint performance, the part for possible warpage and its effects on the geometry of joined parts/surfaces must be analysed. The

effects of tooling design and moulding conditions on warpage should also be examined.

Optimising vibration welding of joints The tensile strength of welded butt joints is one of the most important mechanical performance parameters for critically stressed under-the-hood components. For non-reinforced thermoplastics (polypropylene, polyester, etc), 30-90 per cent of tensile strength is retained with different welding techniques. For non-reinforced nylon 6 and nylon 66, the strength of a butt weld joint is nearly equivalent to that of the base material. But, for fibreglass-reinforced thermoplastics, the maximum achievable weld strength is usually 70-80 per cent of the strength of the base material.

Conclusion The different types of mould joints and welding methods facilitate production of high-strength & highquality products parts and components in automotive and power-tools industries, thus expanding profit margins of companies, besides gaining customersâ&#x20AC;&#x2122; trust.

PERFORMANCE METRICS

Acknowledgements Support provided by Branson Ultrasonics Corporation and FSI/ AGEMA Infrared Systems, Inc is gratefully acknowledged. The author thanks Nanying Jia, Chris Roth and Frank Hume for their help in preparing this study for publishing. Their contributions are greatly appreciated.

References 1.

6. 7.

“Suppliers Adopt Module Approach to Airfuel Systems,” Modern Plastics, February 1998, pp. 64-66 “Plastics Continue to Penetrate Automotive Air Induction Systems,” Injection Molding, SME, September 1998, pp. 37-38 Michel Costes, Jean-Bruno Monteil, “Trends in Plastics Used for the Construction of European Cars – An Analysis Based on PLASTICAR, A Specialised Benchmarking Tool,” SAE’99 Technical Paper Series Plastics: Components, Processes, and Technology (SP- 1410), p. 5 “Cut in Chain Saw Parts Due to Vibration Welding,” Appliance Manufacturing, August 1997, p. 93 Kevin Edwards, Paul D. Daly, “Plastic Intake Manifolds – Geometric Growth for 7 Years,” SAE’98 Technical Paper Series - Plastics: Components, Processes, and Technology (SP- 1315), p. 8 “Seek But Don’t Destroy,” Machine Design, March 1996, pp. 60-63 V. Kagan, “Joining of Nylon Based Plastic Components: Vibration and Hot Plate Welding Technologies,” ANTEC’99, SPE Conference Proceedings, Vol. 1, pp. 12621271 V. Kagan, “Vibration Welding of Glass-Fibre-Reinforced Polyamide Plastics,” Kunststoffe plastic europe, Vol 87, December 1997, pp. 1804-1807 Chul S. Lee, Val Kagan, Norman Knowlden, etc., “Optimization of Vibration Weld Joint Strength for Plastic Air Intake Manifold,”

10.

11.

12.

13.

14.

15.

SAE’98 Technical Paper Series Plastics: Components, Processes, and Technology (SP-1340), pp. 111-115 Ian D. Froment, “Vibration Welding Nylon 6 and Nylon 66 – A Comparative Study,” ANTEC’95, SPE Conference Proceedings, Vol. 1, pp. 1285-1289 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 Melvin I. Kohan, Nylon Plastics Handbook, Hanser Publishing, New York, 1995, p. 631 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 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), p. 10 Ian D. Froment, “Central Composite Design – An Aid to Weld Optimization,” ANTEC’98, SPE Conference Proceedings, Vol. 1, pp. 1055-1059

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

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Post recession

Turning the tides in one’s favour The recent financial crisis has shown that in this age of globalisation, no country can remain isolated from the fluctuations of world economy. India too faced the heat, but managed to escape the worst consequences of the global financial turmoil. This article presents a model for how India can work towards progress and still remain immune to such economic instabilities in the future.

M Hariharan

morbid concern has always been ‘If US sneezes, the world catches cold’. However, the global meltdown that impacted the US, Europe and the rest of the world seemed not to affect India as much as was feared. Although Information Technology (IT) and IT-Enabled Services (ITES) were affected to some extent, most other industries and agriculture seemingly remained less affected. There are various reasons for this so-called ‘immunity’ from the global meltdown.

Prudent financial sector Indian banks have always been accused of being way too conservative and stringent when it comes to helping the industry. This conservatism in a way has helped them not to commit to a ‘subprime’ kind of lending. The loans are generally backed by tangible securities rather than derivatives. However, the current situation is not as optimistic as it was earlier. Until few years ago, most Indian banks had less than one per cent of net Non-Performing Assets (NPAs) and few of them even had 122

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zero-net NPAs. They could manage this because of the often complained conservative lending and by aggressively making provisions. But currently, there is no zero-net NPA bank in India. Of the 39 banks in the country, 18 have at least one per cent net NPAs, with Development Credit Bank topping the list (3.11 per cent), followed by Indian Overseas Bank (2.52 per cent). When it comes to gross NPAs as a percentage of loans, the Development Credit Bank is the worst performer (8.69 per cent). Other prominent names in this list are ICICI Bank Ltd (5.06 per cent), Indian Overseas Bank (4.47 per cent), Kotak Mahindra Bank Ltd (3.62 per cent), United Bank of India (3.21 per cent) and State Bank of India (3.05 per cent). (Source: http://www.livemint.com/2010/ 05/30221921/The-biggest-worry-forindian-b.html)

Inclined towards saving People in India have a tendency towards savings, but this has both advantages and disadvantages. The advantage is that the country is rarely short of cash in the system, while the disadvantage is that it stifles growth. This cultural bend

MANAGEMENT MANTRAS

to save leads to stability, which helps tide over events such as recession. In contrast, in the US, the savings is negative, ie, an average American spends tomorrowâ&#x20AC;&#x2122;s income today. The private capital formation continues to surge. The pattern of household savings is shifting towards financial assets, thereby raising the available loanable funds in the economy. Culturally, India is a more tolerant society than several others. The basic contented attitude, which is still prevalent in the semi-urban and rural India has played an important role in the global meltdown, which did not affect them as much as it affected the developed economies. The neo-rich IT/ ITES professionals were indeed affected more than others within India.

Domestic consumption Manufacturers and service providers in India have sufficient market potential to survive on their own. Although exports are increasing, a major proportion of

the output is consumed within India. The ever-increasing middle-income group, which is about one-fourth of the Indian populace, spends and saves predominantly within India. This minimises the dependence of Indians on the recession-hit economies (besides IT/ ITES) â&#x20AC;&#x201C; another major reason why India could pass through the recession with minimal damage.

Foreign aid for local and export needs Indiaâ&#x20AC;&#x2122;s Foreign Direct Investment (FDI) flows over the last few years have increased to over $ 25 billion. The greatest opportunity considered by multinational firms is the market potential within India. In the World Competitiveness Index, India ranks third in terms of market size (World Competitiveness Report 2007-08: World Economic Forum). A significant shift has been noted in the attitude of the Indian firms, which have also been investing globally in the last decade. There is

a huge negative aspect to this story. World Competitiveness Report 2007-08 has ranked India as low as 48 among 131 countries. Due to the sheer market size, India has managed to attract foreign investments, though fared poorly on other fronts. On a positive note, there is a huge potential for India to attract more FDI, if it manages to perform well on the other parameters.

Immunity from recession India has still not fully recovered from the recession, but has taken this event in its stride, which is a positive attitude. Adapting to recession does not mean becoming recession proof. Systemic immunity from recession and the capability to overcome recession is critical to ensure that people do not get impacted by recessions in future. However, the country still has a long way to go. Lack of infrastructure, less public spending on education and a corrupt bureaucracy & polity are a huge

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MANAGEMENT MANTRAS Table: India’s ranking according to World Competitiveness Report 2007-08 Rank Global Competitiveness Index 2007-08 (131 countries)

Global Competitiveness Index 2006-07 (122 countries)

Sub-index A: Basic requirements 1st Pillar: Institutions

2nd Pillar: Infrastructure 3rd Pillar: Macroeconomic stability

67 108

4th Pillar: Health and primary education

101

Sub-index B: Efficiency enhancers 5th Pillar: Higher education and training

6th Pillar: Goods market efficiency 7th Pillar: Labour market efficiency

55 96

8th Pillar: Financial market sophistication 9th Pillar: Technological readiness

37 62

10th Pillar: Market size

Sub-index C: Innovation and sophistication factors 11th Pillar: Business sophistication

12th Pillar: Innovation

Source: World Competitiveness Report 2007-08: World Economic Forum

hurdle in the country’s journey towards real stability. The country’s cultural base, especially Urban India, is getting impacted by the ‘spend tomorrow’s income today’ mindset of the West. Urban India is bordering out of a contented mindset, while rural India is getting further steeped in poverty. To explain a probable solution in this context, worth mentioning is the case of a remote village of Kuthambakkam near Chennai.

Kuthambakkam: A model village Kuthambakkam was like any other village of India. An educated local R Elango, a Chemical Engineer by qualification, quit his job with the government sector and decided to change completely the face of his village. His attempts, with the help of his friends, started off by forming youth clubs, wall posters with reformist messages, organising study groups, providing special tuitions and various other reforms. But, these proved inadequate and yielded little result. He realised that reforms can be effective and sustainable only if they are carried out through the formal governmental process, and by harmonising the local passion. To make this happen, he then became President of the Kuthambakkam Village Panchayat. People the world over talk about ‘inclusive growth’. Under the stewardship 124

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of Elango, Kuthambakkam has become a model village for inclusive growth. He urged the local populace to get involved in building roads, culverts, drains and housing colonies by using locally available material. Therefore, a major portion of the government funds for village development was actually used for that purpose. Officials supported his approach of cutting out contractors and employing locals instead. As he created jobs, the liquor menace also receded. He paid the people wages that were above the market average and, most revolutionarily, paid the same to women. He mastered the governmental promulgations for village development and availed of every scheme for the village. In the words of Elango, “There are enough well-meaning schemes announced by the government. So it is up to the local leadership to go and get them.” He has been an efficient conduit between the people in his village and available opportunities. The concept of Kuthambakkam model village has been replicated in several other villages in the last few years, thanks to the evangelical enthusiasm of Elango and his motivated team. He has developed an economic theory for village clusters. In simple terms, about 7-8 villages form a free trade zone. They identify and produce goods and

services without overlap. They consume each other’s produce, and the money is retained within the villages and invested for the development of people. Elango has optimistic views for India. According to him, “This system will face definitely some resistance. But, there are successful, honest Panchayat Presidents also. For now, we have begun to network and stay connected, and this number will only increase in the future. Similar will be the situation in other states.” He adds, “We are starting a Panchayat Academy to teach the Presidents their powers and villages’ entitlement, which will rouse people’s expectations. A force emerging, though it is not visible to the media and most people. It is working and changing India from the basic level, and one that cannot be stemmed.” This is the way forward for India to replicate more models through grassroots democracy. This will help create a model that is inclusive, generates self-sufficient village clusters, provides housing for all, water management, hygiene and a perfect environment for harmonising the passion of the local populace. (Source: http://www.modelvillageindia.org.in and http://www.goodnewsindia.com/ index.php/Magazine/story/elangokuthambakkam)

Braving the recession It is possible for India to remain largely unaffected from the consequences of economic meltdowns that may occur in the future, if not prevent it. And this model created by Elango may well guide us in achieving this goal. 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. Savoir Faire develops cost information systems to support pricing, outsourcing and control decisions using the cost excellence (CE©) model. Email: sfgroup@vsnl.com

EVENTS CALENDAR

National Rudrapur

Uttarakhand Sep 23-26, 2011 Gandhi Park

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 8-11, 2011 Chennai Trade Centre, Nandambakkam

Indore

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

Aurangabad Maharashtra Feb 17-20, 2012 Garware Stadium, Chikkalthana

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 • Web: www.engg-expo.com

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 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

PackPlus South 2011

Packaging is among the leading enduser segments of the commodity plastics industry. This is among the Indian packaging industry’s leading exhibitions that will bring together highly competitive and new-age solutions from major suppliers and buyers under one roof; July 1-4, 2011; at HITEX Exhibition Centre, Hyderabad For details contact: Neetu Arora Print-Packaging.com Pvt Ltd F 101, Tower No 7 1st Floor, International Infotech Park, Vashi Navi Mumbai - 400 705 Tel: 022 2781 2093, 2619 Fax: 022 2781 2578 Email: info@packplus.in Website: www.packplussouth.in

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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

Indian Petrochem 2011

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

This will be an ideal platform for cutting-edge technologies and products for petrochemicals industry. It will constitute an exciting blend of buyers and distributors, investors and decision-makers, suppliers, agents from the petrochemicals markets, feedstock, downstream sectors and manufacturers & end-users, consulting firms, financial analysts; November 8-9, 2011; at Hotel Renaissance, Mumbai

Plastindia 2012

For details contact: 606, Bhagyalaxmi Kennedy Bridge Mumbai - 400004 Tel: 022 23851430 Fax: 022 23851431 Email: info@eliteconferences.com Website: www.eliteconferences.com

For details contact: Plastindia Foundation 401, Landmark B, Suren Road Off Andheri Kurla Road, Andheri (East), Mumbai - 400093 Tel: 022 26832911, Fax: 022 26845861 Email: info@plastindia.org Website: www.plastindia.org

This is the premier exhibition of the Indian plastics industry. It will once again prove to be a strategic meeting point for all large and small players from the global arena. It will showcase cutting-edge technology and applications of high-end polymer solutions; February 1-6, 2012; at Pragati Maidan, New Delhi

EVENTS CALENDAR

International PLASTEC East This conference will witness the latest developments, technologies, products and services affecting the industry, including primary processing machinery, computeraided design and manufacturing, production machinery, materials, moulds & mould components, automation technology, material 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

sectors of plastics, rubber and packaging industry; July 13-15, 2011; at Kenyatta International Conference Centre (KICC), Nairobi, Kenya

Tel: +44(0)117 924 9442 Fax: +44(0)117 989 2128 Website: www.amiplastics.com Email: info@amiplastics.com

For details contact: Jeen Joshua Al Fajer Information & Services PO Box 11183, Dubai, United Arab Emirates Tel: + 971 4 3407743, Fax: +971 4 340 3608 Email: jeen@alfajer.net Website: www.plastpackafrica.net

Interplas 2011

PLASTEC Midwest

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

This will be a chance to explore first-hand the latest developments, technologies, products and services affecting the plastics processing industry. Among the exhibits at this show will be computer-aided design and manufacturing, production machinery, materials, moulds and mould components, automation technology, material handling/logistics, etc; September 20-22, 2011; at McCormick Place, North Chicago, Illinois For details contact: UBM Canon 11444 W, Olympic Blvd, Los Angeles CA 90064-1549 Tel: +310 445-4200, Fax: +310 996-9499 Website: www.canontradeshows.com Email: pleinfo@ubm.com

Plastic Pipes Fittings and Joints 2011

Plast Pack East Africa 2011

This exhibition cum conference offers an international forum for designers, pipe fitting manufacturers, construction specialists, pipe laying companies, adhesives & welding equipment suppliers and the industry supply chain. The aim is to bring together plastics, adhesives and welding experts to network with the end-users of their products; September 27-29, 2011; at Hotel Nikko Düsseldorf, Düsseldorf, Germany

This specialised trade show will be an ideal platform to form business alliances, showcase products & services and interact with the East African plastics industry. It will provide an opportunity to meet potential buyers, traders and decision-makers from all levels and

For details contact: Applied Market Information Ltd AMI House 45-47 Stokes Croft Bristol, BS1 3QP, United Kingdom

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

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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

JEC Composite Asia 2011 The composite market in Asia accounts for 50 per cent of the global industry. This conference will address this booming market’s requirements in terms of raw materials, technology and automation solutions. It will be a meeting ground for the scientific community, R&D professionals across Australia, China, India, Japan, Malaysia, Taiwan, Thailand, etc; October 18-20, 2011; at SUNTEC International Convention & Exhibition Centre, Singapore For details contact: Journals and Exhibitions (JEC) 25 boulevard de l’Amiral Bruix Paris-75116, France Tel: +33 (0)1 58 36 15 00 Fax: +33 (0)1 58 36 15 13 Website: www.jeccomposites.com Email: wang@jeccomposites.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

PRODUCT UPDATE

Air-cooled compressor

Quick mould change system

Elgi Equipments Ltd offers a unique range of air-cooled compressors for industries that demand oil-free air at their application point. These nonlubricated compressors offer customers the advantages of low energy consumption and low running costs. The air-cooled design eliminates the need for water cooling systems, thereby saving industrial water costs. The two-stage air-cooled aftercooler has a 0.25-kW single-phase motor driving a cooling fan. It eliminates the need for cooling towers, water circulation pumps and the associated piping, thus reducing the initial investment. It also reduces the installed power. The two-stage design increases the efficiency of compression, as it facilitates inter cooling. It also reduces the load on moving parts by reducing the compression ratio of any stage. These features enhance the life of the compressor. The compressor motor fits within a space of 1.74 sq m and rests on anti-vibration pads. A typical Elgi package consists of a motor, air end, air-cooled aftercooler, 500-litre air receiver with associated piping and control panel.

Madhu Machines & Systems offers electromagnetic Quick Mould Change (QMC) system from EMT, Hong Kong. This innovative solution is meant for the plastic processing industry for injection moulding machines. The QMC system can also be supplied for machines up to 3,000 tonne capacity. Its features include: most efficient QMC system to replace conventional hydraulic clamp; compatibility with any machine & considerable mould; easy installation & setup for minimum machine downtime; permanent magnetic force: powerful, reliable & safe; uniform & flexible; and clean & power saving. The QMC system can be easily interfaced with main machine control. It can also be supplied for various special applications like side loading & oversize mould, rotating system, large moulds for automotive, etc. Major areas of applications are: for end use in sectors like automotive, motorcycles, home appliances, electrical & electronics, packaging, consumer products, etc.

Elgi Equipments Ltd Coimbatore - Tamil Nadu Tel: 0422-258 9326 Fax: 0422-257 3697 Mob: 097900 39326 Email: enquiry@elgi.com

Digital colour mark sensor Lubi Electronics offers â&#x20AC;&#x2DC;Sunxâ&#x20AC;&#x2122; LX-100 series digital colour mark sensor. It can detect any marking because the sensor is equipped with red, green and blue Light Emitting Diode (LED) element. Furthermore, to expand the functionality, the sensor comes with a dual mode, ie, mark mode (ultra high-speed response) & colour mode (high-precision mark colour discrimination) to suit all applications. This sensor comes with Mode Navi technology for enhancing features and is easy to use. This is provided with four-digit digital display, 12-bit A/D converter, D-code, key lock, timer, NPN or PNP outputs, IP67 protection, etc. This sensor is used in many applications/industries, especially in packaging, food, pharmaceuticals, textile, plastics, among others. Lubi Electronics Ahmedabad - Gujarat Tel: 079-2220 5471, Fax: 079-2220 0660 Mob: 093274 97006 Email: info@lubielectronics.com 130

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Madhu Machines & Systems Pvt Ltd Vadodara - Gujarat Tel: 0265-235 3886/232 1104, Fax: 0265-233 4278 Email: machinery@madhu-group.com

Plastic brightner/shiner Plast Fine Polymers offers plastic brightners/shiners/ whitener for natural transparent colours and milky white end-products. It is used for adding clarity and gloss finish to natural transparent polymers. It gives shine and bright finish colours to end-products. The brightner/whitener removes yellowness and dullness from the end-products and makes them super milky white. This product is used in virgin, second, dull natural or milky white sutli; ropes; twine; reprocess granules; HighDensity Polyethylene, Low-Density Polyethylene, Polyvinyl Chloride (HDPE-LDPE-PVC) pipes & profiles; box strap; Polyethylene Terephthalate (PET) jars; spoon; container; carry bags; liners; sheet; yarns and many more. A major advantage of this product is that it saves excess usage of white pigments and titanium dioxide for opaque end-products. Plast Fine Polymers Ahmedabad - Gujarat Tel: 079-6524 2332, Mob: 098255 87152 Email: plastfine@indiatimes.com

PRODUCT UPDATE

Vented screw and barrel

Temperature controller

Malik Engineers offers vented screw and barrels. These are used for processing highly hygroscopic polymers viz nylon, delrin, Acrylonitrile Butadiene Styrene (ABS), polycarbonate, etc. The design has single or multiple vent ports on the extrusion screw & barrel to expel hot gases and other volatiles from the melt, before extrusion through the die. This not only results in safety of operator & processing equipment, but also standardises the quality of extruded product and ensures a void-free, technically and commerically acceptable product. Computer Aided Design (CAD) techniques are used for designing, which involve accurate calculations and determinations of chamber volumes & pitches for most efficient operation, with no material blockages at the vents. The construction material for screw and barrel is usually special grade of nitro alloy-steel (EN 41-B) pretreated and gas nitrided after complete machining, grinding & polishing operations. The extrusion screw is safeguarded against corrosion by a layer of hard chrome plating, which aids in smooth flow of material and easier cleaning while material and colour changes.

Microprocessor-based temperature controllers manufactured by Wavetronics are available in single or double display. These temperature controllers have supply voltage of 220 V AC with input Resistance Temperature Detector (RTD). Salient features include: output: relay contact or Solid State Relay (SSR), alarm contact or buzzer; cooling application; range of -99.09-100.0; temperature setting lock as per range adjustable in set mode; alarm high 0.3-10.0 adjustable; alarm low 0.3-10.0 adjustable; alarm mute by decrement key; hysteresis 0.2 or 2-25Â°C adjustable; defrost cycle start temperature adjustable; defrost on time 0-250 minute; defrost off time 0-9999 minute; defrost on indication by DP blinking; defrost on time countdown indication (double display); defrost on time countdown indication by enter key (single display); manual defrost by pressing increment key for 5 second; delay 0-10 minute adjustable; open display if sensor breaks; relay trip if sensor breaks or connection opens; and calibration error correction by front key switch.

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

Connector Katlax Enterprisesâ&#x20AC;&#x2122; Interface Products Group (IPG) offers connectors, connectors with cables and interface products, which help in connecting various types of sensors to different types of cable trees or amplifier & controller units to make automation systems. The test facilities include micro ohm meter, insulation and high-voltage tester as well as routine automatic tester for mass production needs. The group also supplied Enterprise Resource Planning (ERP) system and programmable length cable cutting machine-customised cable lengths, which help in reducing waste. These are time saving, and do not require skilled electrician to change a device since these becomes as versatile as a PCB & can be replaced by anyone. These are environment-friendly and reduce carbon footprint by preventing scrapping in cables. These are also automation-friendly and can be better used for higher levels of control. After replacement, the wiring does not become worse as it is not affected. In the old system, due to lack of proper dressing components, the wiring after such replacement becomes shabby and unreliable. Katlax Enterprises Pvt Ltd Gandhinagar - Gujarat Tel: 02764-286 784/85, Fax: 02764-286 793 Email: info@katlax.com 132

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Wavetronics Ahmedabad - Gujarat Tel: 079-2281 1329 Fax: 079-2281 1519 Mob: 093270 03425 Email: info@wavetronics.co.in

Compress moulding press machine Amrut Brothers offers Bakelite or rubber fully automatic compress moulding press machine. The machine is manufactured using high-quality raw material. It is equipped with a buzzer system to save time. It is a fully hydraulic and electronic controlled machine and also consumes less power. This is a two-in-one machine since its motor automatically turns on-off while heating processing time. Amrut Brothers Ahmedabad - Gujarat Tel: 079-2292 8163 Fax: 079-2292 8163 Mob: 98240 93682 Email: exports@amrutbrothers.com

PRODUCT UPDATE

Automatic extrusion blow moulding machine Full Shine Plastic Machinery offers automatic extrusion blow moulding machine for making view stripe/window line for lubricant field. This machine is fitted with a view stripe extruder to produce various bottles & containers with the window line. The carriage movement is linear, and its Germany-made parts provide swift performance. It has a special brake system that ensures swift and stable movement of the mould carriage. Mould clamping is improved by designing with column bars for strong and equal clamping performance. The extruder drive has an energy-saving design that offers efficient and cost-saving production. The company specialises in making automatic blow moulding machine, multilayer co-extrusion blow moulding machine (2-6 layer bottles), accumulatorhead blow moulding machine, one-stage injection blow moulding machine, Polyethylene Terephthalate (PET) stretch blow moulding machine, moulds, die heads and auxiliary equipment. The machinery is used for processing plastic bottles, cans, tanks and auto parts. Full Shine Plastic Machinery Co Ltd Taiping - Taiwan Tel: +886-4-2276 5071 Fax: +886-4-2276 5070 Email: fulshine@ms7.hinet.net

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PRODUCT UPDATE

Finishing flap wheel Valgro Engineers offers Fynex abrasive finishing flap wheels. These are used for finishing curved and irregularly shaped parts, especially the hard to reach areas. These offer a great degree of conformance, and provide even pressure for uniform surface finishing with long scratch pattern on softer materials such as aluminium, plastic, wood and non-ferrous metals. These remove debris and contamination from surfaces, creating a clean surface for coating operations. These also provide a consistent satin scratch pattern and other cosmetic finishes, to improve the surface appearance. Valgro Engineers Pvt Ltd Ahmedabad - Gujarat Tel: 079-2297 2603 Fax: 079-2297 2606 Mob: 093740 83443 Email: sales@valgroabrasives.com

Feeding system Pass controller Priamus-Uniplast Technoogy (Kunshan) offers pass controller. The machine set data do not represent part quality at all. Even two moulding machines of the same type and identical settings will not necessarily produce the same part quality. With different calibration, the machine controls will yield different results. The only possibility for a quality-related mould setup is through cavity pressure and cavity temperature. If these signals are identical, same part quality can be guaranteed independent of the set parameters of the machine. A fill simulation serves to optimise a mould during its design phase, while machine settings can be calculated. This helps in optimising the process to a certain extent. However, during the actual production, the measured process data in the mould cannot be replaced. Real-time graph displays the actual process condition. If the process conditions change, and hence part quality, there are alarms signals to indicate the need for separating undesired parts in order to calculate process capabilities and save measuring data with easy connection to a computer. Priamus-Uniplast Technology Kunshan Co Ltd Jiangsu - China Tel: +86-512-5791 1258, Fax: +86-512-5791 1238 Email: info@priamus-uniplast.com 134

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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 overall 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 can 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

PRODUCT UPDATE

Quick die changing system Forwell Precision Machinery offers quick die changing system punching machine. Punching automation improves productivity and reduces the operating cost and intensity of industrial safety. The quick die changing system punching machine can save more than 90 per cent of time, thus greatly improving the rate of utilisation of machine and ensuring staff safety. For dies with largescale use, it can further help achieve labour conservation, fast speed, safety and reduce chances of damage to machine or die. It also helps meet various requirements such as small amount and different types, reducing stock, improving quality, extending die life, reducing personnel expenses and occupational damage and other benefits. These features improve the productivity of the company and reform operation and management, thereby enhancing the comprehensive productivity of the enterprise competitiveness, which creates more profits. Forwell Precision Machinery Co Ltd Changhua - Taiwan Tel: +886-4-8345196 Fax: +886-4-8345195 Email: forwell@forwell.com

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PRODUCT UPDATE

Injection moulding machine Jon Wai Machinery Works offers Thin Wall container injection moulding machine (TW series). The TW series is equipped with further improved functions for achieving high-speed performance, ease of use and field-proven reliability. This series has injection moulding machines capable of processing thin-walled moulding of multicavities. Clamping forces are in the range of 60-500 tonne, with three different injection units clamping the force level. The company also offers plastic injection moulding machines, system and complete turnkey production lines. These enable plastics processors meet escalating market pressure in the future. Jon Wai Machinery Works Co Ltd Taipei - Taiwan Tel: +886-2-2595 4867, Fax: +886-2-2593 2358 Email: jonwai.mc@msa.hinet.net

Water chiller Yann Bang Electrical Machinery offers a series of water chillers. After moulding the plastic raw materials, to shorten the moulding cycle, it is necessary to use the chiller for reducing product temperature. This series uses the latest European, American and Japanese compressors, available in single and double compressors. The compressors of the double-compressor model can be used individually or jointly. High-efficiency shell-pipe condenser, which has a heat-transmission function, can save up to 25 per cent of energy. The chiller has a well-designed safety protection function. It is equipped with a digital temperature display and indicator to warn about any abnormality, which guarantees a long life of the chiller. The series can directly control the moulding temperature and shorten the moulding cycle to accelerate shaping products. This chiller can be applied to any plastic moulding machine. Yann Bang Electrical Machinery Co Ltd Taichung - Taiwan Tel: +886-4-2271 6999 Fax: +886-4-2271 1988 Email: yb@yannbang.com 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 â&#x20AC;˘Technologiesâ&#x20AC;˘Opportunities

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PRODUCT INDEX

To know more about the products in this magazine, refer to our â&#x20AC;&#x2DC;Product Indexâ&#x20AC;&#x2122; 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

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Accumulator................................. 133 AD & DC power pack system ........... 133 Additive ........................................... 131 Additive masterbatch ................ 20, COC Air chiller........................................... 27 Air cooled chiller ............................. 135 Air cooled die face pelletiser ............ 117 Air-conditioner parts......................... FGF Air-cooled compressor...................... 130 Aluminium extrusion system .............. 135 Ammonia liquid chiller ....................... 10 Analytical instrument ........................ 127 Auto dosing and mixing system......... 121 Auto vacuum loader......................... 121 Automatic extrusion blow moulding machine ................... 133 Automatic material handling system .. 117 Automation system ............................. 57 Auxiliary equipment ...................... 41, 52 Bakelite compression machine ..... 141 Banking services .............................. 109 Battery charger .................................. 44 Bi-axial plant ................................... 143 Biodegradable masterbatch ...... 20, COC Black masterbatch............20, 131, COC Blender ...................................... 53, FIC Blending unit ................................... FGF Blow moulding machine ..................... 52 Blower series ..................................... 57 Blown film extrusion system................. BC Boiler ................................................ 67 Bulk milk cooler................................. 10 Butterfly valve .................................... 10 Calorifer......................................... 67 Cam follower................................... 136 Central material conveying system .... 121 Chemicals ......................................... 51 Chiller ............................................... 75 CIPET placement/recruitment ............ 118 Circular weaving machine .................. 16 Clean room application ..................... 11 Cluster facia .................................... FGF CNC................................................ BIC CNC machine ................................... 69 CNC vertical machining centre ........... 29 Colour additive................................ 131 Colour masterbatch ...20, 33, 131, COC Colouring extrusion plant ................. 143 Compact chiller ............................. 8, 27 Compounding extrusion plant ........... 143 Compounding mixer ........................ 143 Compress moulding press machine... 132 Compressed air dryer......................... 97 Compressed air system....................... 34 Compressor ....................................... 34 Compressor air chiller ................ 14, 145 Compressor spares .......................... 133 Conductive compound ................... COC Conical twin-screw extruder ........ 39, 117 Connector ............................... FGF, 132

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Control panel .................................. 135 Convertor ........................................ 135 Conveying & handling system ............. 41 Cooling pad ...................................... 67 Cooling tower............................ 67, 135 Counters & power supplies ................... 7 CPVC pipe ................................... 23 25 Crusher ........................................... 121 Crystalliser......................................... 97 Cutting and stitching machine............. 16 Dairy machinery............................. 10 Data logging software ...................... 135 Dehumidified air dryer........... 8, 27, FGF Dehumidifying dryer ............13, 121, FIC Digital colour sensor ........................ 130 Digital panel meter ............................ 12 Digital temperature controller ............. 31 Door trim ........................................ FGF Dosing & mixing ................................ 57 Double column vertical machining centre ............................... 69 Double shaft gearbox....................... 105 Drip irrigation system ......................... 67 Drives................................................ 31 Drives & automation .......................... 44 Dry vacuum pump ........................... 136 Drying & dehumidifying system ........... 57 Drymax air-hot air dryer .................... FIC Drymax dryer .................................... FIC Drymax pet-dehumidified dryer .......... FIC Dual channel with modbus ................. 31 Dyestuff ............................................. 70 Dynamic controller ............................. 31 Electric injection moulding machine . 9 Electric injection moulding machine gearbox ................................. 9 Element shrink disc .......................... 136 Embedded system .............................. 44 Encoder............................................... 7 Engineering products.......................... 51 Exhibition - Engineering Expo............ 129 Extruder machine ......................... 15, 37 Extrusion coating line ......................... 16 Extrusion dies................................... 146 Extrusion machinery......................91, BC Extrusion plant ................................. 143 Extrusion pump .................................. 89 Extrusion system ................................. BC Feeder ........................................... 41 Feeding & conveying system ......... 57, 97 Feeding system ................................ 134 Ferrous casting ............................... 135 Filler compound............................... 131 Financial services ............................. 109 Finishing flag wheel.......................... 134 Flame retardant ............................... 131 Flame retardant masterbatch .............. 20 Florescent.......................................... 70 Fluid system....................................... 18 Forged component........................... 135

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118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175

Pg No

Freewheel oneway clutch .................. 136 FRP-induced draft cooling tower........ 135 Gases............................................. 51 Gear motor ....................................... 18 Gear pump ....................................... 89 Gearbox................................9, 18, 105 Geared & flexible coupling................. 18 Gear ......................................... 18, 105 Granulating & recycling...................... 57 Granulator ...................... 8, 27, 97, FIC Gravimetric blender ............................. 8 Grinder ............................................. 27 Head & tail lamp ......................... FGF Heart valve frame .............................. 58 Heater controller................................ 44 Heater cooler mixer ......................... 117 Heating & cooling system ................... 57 Heavy toggle clamp ......................... 141 Helical speed reducer ...................... 105 High cavitation .................................. 11 High-precision hydraulic clamping .... 134 High-speed mixer......................... 15, 37 Hold back ....................................... 136 Hopper dryer ............................. 27, 121 Hopper loader ............................... 8, 27 Horizontal machining centre .............. BIC Hot air dryer......................... 8, 13, FGF Hot runner system .............................. 57 Hydraulic clamping moulding machine ........................... 141 Hydraulic gear pump ....................... 133 Hydraulic press ........................ 117, 141 Hydraulic sealing solution................. 133 IML technique ................................ 11 Industrial control & sensing device ........ 7 Industrial electronic plastic parts ....... 127 Injection and blow moulding ...... 14, 145 Injection mould.................................. 47 Injection moulding ....................... 47, 67 Injection moulding machine..........17, 35, 49, 79, 99, 113, 134, 136, 141, FGF, BGF Inline drip tubing plant ................. 23, 25 Inverter.............................................. 44 Inverter/variable frequency drives .......... 7 Jumbo bag dumping station......... 117 Keyless transmission element ....... 136 Knobs & switches ............................. FGF Lab extruder................................. 117 Lab mixer ........................................ 117 Largeflow water heater ....................... 57 Lathe................................................ BIC Level controller .................................... 7 Loader.............................................. FIC Machined component................... 135 Masterbatch............................... 20, 131 Masterbatch feeder .......................... 121 Masterbatch mixer............................ 117 Material dryer .................................... 53 Material storage system ........................ 8 Measuring & monitoring relay ............. 7

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

June 2011 | Modern Plastics & Polymers

139

PRODUCT INDEX Sl No Product

176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240

Pg No

Medical mould .................................. 11 Metal ................................................ 51 Micro fine pulverising system ............ 143 Milling centre.................................... BIC Mono and multilayer sheet line........... 16 Monoblock high vacuum pump ........ 136 Monofilament line .............................. 16 Monolayer blown film line .................. BC Monolayer blown film plant .......... 23, 25 Motion control system .......................... 7 Mould ......................................... 15, 37 Mould sweat protector................ 14, 145 Mould temperature controller....8, 13, 27 Moulding system ................................ 11 MTC ................................................ FIC Multi component mould ..................... 11 Multilayer blown film line..............16, BC Multilayer blown film plant ........... 23, 25 Multilayer cast film line....................... 16 Multilayer co-extrusion sheet line .. 19, 71 Multi-station ...................................... 47 Neat resin...................................... 70 Non-ferrous casting.......................... 135 Oil cooler....................................... 75 Oil seal high vacuum pump ............. 136 On-line B2B marketplace ........... 43, 139 Optic sheet extrusion line ............. 19, 71 Optical brightner ........................... COC Panel cooler ................................... 75 Paper & allied chemical...................... 51 Paper chemical .................................. 70 Paperless recorder.............................. 12 Pass controller ................................. 134 PET masterbatch ................................ 20 PET sheet extrusion line ................ 19, 71 PET/PE washing line ........................... 16 Photoelectric sensor.............................. 7 PID controller................................... 135 Pipe extrusion line ........................... 113 Pipe line ............................................ 67 Pipe making system............................ 47 Planetary gearbox ............................ 105 Plastic compound............................. 131 Plastic articles .................................. 127 Plastic brightner/shiner ..................... 130 Plastic compound............................. 131 Plastic conveyor belt........................... 15 Plastic industrial part ........................ 127 Plastic injection moulding machine ................... 123, 141 Plastic making machine .................... 141 Plastic processing machine ................. 16 Plastic sheet extrusion line ............ 19, 71 Plate heat exchanger.......................... 10 PLC................................................... 31 Plug valve.......................................... 10 Pneumatic valve ................................. 10 Polyethylene ................................. 63, 93 Polymer allies product ........................ 51 Polymer conveyer belt......................... 27 Polyolefin pipes ............................ 23, 25 Portable air cooled chiller................. 135 PP glass-filled compound ................... 20 PP mineral-filled compound ................ 20 PPR pipes .................................... 23, 25 Precision mould ............................... 127

Sl No Product

241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304

Pg No

Precision moulding system ................. FIC Precision temperature control............ 135 Printing and cutting/rewinding machine16 Process controller ....................... 12, 135 Process cooling chiller ...................... 135 Process tank ...................................... 10 Procurement & auditing servicing ........ 51 Product assemblies........................... 135 Profile controller................................. 31 Programmable logic controller .............. 7 Programmable terminal ........................ 7 Proximity sensor ................................... 7 PTFE & filled product........................ 133 PU parts .......................................... 127 Pulveriser ..................................... 15, 37 Pulverising system............................. 143 Pump .............................................. 136 PVC foam core pipe .................... 23, 25 PVC mixer cooler ......................... 23, 25 PVC palletising line ...................... 23, 25 PVC pipe...............................23, 25, 67 PVC profile line............................ 23, 25 Quick connector............................. 77 Quick die changing system............... 135 Quick mould change system....... 77, 130 Rail tanker ..................................... 10 Railway product ................................. 44 Recycling line..................................... 16 Refrigerant pump ............................... 10 Refrigeration ...................................... 10 Resin dehumidifier.............................. 97 RFID.................................................... 7 Robot system ............................... 17, 27 Robots.............................................. FIC Rock n roll machine ..................... 15, 17 Roots vacuum pump ........................ 136 Rotary automatic hot colour marking machine..................... 65 Rotary machine ................................. BIC Rotary pump .................................... 136 Rotational mould ............................. 143 Rotational moulding machine ........... 143 Rotomoulding machine.........15, 37, 143 Round table carrousel ........................ 15 RTD................................................. 135 Rubber bakelite compression machine141 Safety light curtain ........................... 7 Screw compressor .............................. 10 Screw-type moulding machine .......... 141 Semi-auto vertical plunger ................ 141 Servo-type injection moulding machine 52 Shaft-mounted speed reducer ........... 105 Shuttle rotomoulding machine .......... 143 Shuttle series plant ........................... 143 Single bag feeding system ................ 117 Single mill pulveriser .................... 15, 37 Single screw extruder........................ 117 Single screw extruder gearbox............... 9 Single screw extruder plant ................. 39 Single shaft extruder gearbox............ 105 Single stage monoblock vacuum pump.................................. 136 Single stage vacuum pump............... 136 SME finance .................................... 109 Software for central monitoring ........... 97 Solar power system ............................ 44

Sl No Product

305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372

Pg No

Solid granulator ............................... 143 Solid state relay ............................... 135 Spiral cum helical gearbox ................. 18 Sprinkler system ................................. 67 Sprocket .......................................... 105 Stack mould ...................................... 11 Strand pelletiser ............................... 117 Switching relay..................................... 7 System solution .................................. 57 Tanks & silos .................................. 10 Tape stretching line ........................... 16 Tea.................................................... 51 Technical mould................................. 11 Teflon part ....................................... 127 Temperature controller............................ 7, 12, 31, 132, 135 Temperature sensor .......................... 135 Tempting solution............................... 52 Tensioner nut ................................... 136 Thermocouple.................................. 135 Thermoformer .................................... BC Thermoforming & PS foam ................. BC Thermoplastic alloy ............................ 70 Thermoplastic compound ................... 70 Thyristorised power controller............ 135 Timer .................................................. 7 Toggle clamping moulding machine.. 141 TPE/TPU compound ........................... 20 TPU masterbatch................................ 33 Track roller ...................................... 136 Turned component ........................... 135 Twin-mill pulveriser ....................... 15, 37 Twin-roll mill .................................... 117 Twin-screw co-rotating extruder ........... 58 Twin-screw element ............................ 58 Twin-screw extruder ............................ 58 Twin-screw extruder gearbox ................. 9 Twin-screw extrusion line..................... 39 Two-layer blown film .................... 23, 25 Two-stage vacuum pump.................. 136 Ultrasonic flowmeter ...................... 12 Underwater pelletiser........................ 117 Universal controller ............................ 31 Universal input temperature scanner.. 135 Universal masterbatch ........................ 20 UPS................................................... 44 Utility support equipment .................... 44 UV & PU masterbatch ........................ 20 UV stabiliser .................................. COC Vacuum dryer................................. 13 Vacuum forming machine................... BC Vacuum loader ................................ FGF Vacuum pump ................................. 136 Vented screw and barrel ................... 132 Ventilator ........................................... 85 Vertical machining centre.............69, BIC Vertical plunger................................ 141 Vibratory screening system ................ 143 Vibro screen ............................7, 15, 37 Volometric dosing unit........................ 97 Water chiller...........................97, 136 Water cooled chiller ......................... 135 Welding guns..................................... 67 WFR................................................. FIC White masterbatch ...........20, 131, COC Wire-EDM ......................................... 29 Worm gear ........................................ 18 Worm reducer.................................. 105 Worm reducer gearbox..................... 105

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

140

Modern Plastics & Polymers | June 2011

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 Adinath Controls Pvt Ltd

135

T: +91-40-2726166 E: info@articaircon.com W: www.articaircon.com Ash Win Engineers

143

131

T: +91-40-23550551 E: info@aviadditives.com W: www.aviadditives.com Battenfeld-Cincinnati Austria Gmbh T: +91-098207 01960 E: shah.d@battenfeld-cincinnati.com W: www.battenfeld-cincinnati.com Blend Colours Pvt Ltd T: +91-40-2436 1499 E: info@blendcolours.com W: www.blendcolours.com Boge Compressed Air System

T: +91-44-43009610 E: S.Sriram@boge.de W: www.boge.in CIPET Haldia

118

T: +91-3224-255534 E: cipet.haldia@gmail.com D & M Enterprises T: +91-44-42184295 E: dmeindia@gmail.com W: www.dmeindia.net

T: +91-79-23827180 E: v_jaikumar@hirel.net W: www.hirel.com

E: idmc@idmc.coop

T: +1800-200-4444

Ingeco Gears Pvt Ltd

Modern Plastics & Polymers | June 2011

105

E: info@ingecogears.com 133

W: www.ingecogears.com J.P. Extrusiontech Limited

T: +91-2646-222163 75

E: Iinfo@jpextrusiontech.com W: www.jpextrusiontech.com Jing Cheng Mold Machinery Co., Ltd

BIC

146

T: +86-576-8461-0001 E: jingcheng_times@vip.163.com W: www.jc-times.com Jon Wai Machinery Works Co., Ltd

135

T: +886-2-2595-4867 E: jonwai.mc@msa.hinet.net W: www.jonwai.com.tw

133

Joyam Engineering & Consultants Pvt Ltd

136

T: +91-79-26569533 123

E: joyam@joyamvactech.com W: www.joyamvactech.com Jyoti Cnc Automation Pvt Ltd

T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in Kabra Extrusion Technik Ltd

23,25

T: +91-22-2673 4822 E: sunil@kolsitegroup.com W: www.kolsite.com

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

142

43,139

T: +91-2717-651551

T: +91-11-25724865 E: poonam@hindustanplastics.com W: www.hindustanplastics.com Hi-Rel Electronics Pvt Ltd

T: +91-2692-225399

W: www.indiamart.com

T: +91-124-28124921 E: hinds@rediffmail.com Hindustan Plastic And Machine Corporation

E: pr@indiamart.com

T: +91-79-25857182 E: sales@fluoroplastind.com W: www.fluoroplastind.com Hinds Machineries

W: www.husky.ca

IndiaMART InterMESH Limited 63,93

T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com Hiflon Polymers Industries

BGF

W: www.idmc.coop

T: +91-20-32935433 E: sales@haasindia.com W: www.HaasCNC.com Heattrans Equipments Pvt Ltd

129

T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com Haas Automation India Pvt Ltd

Husky Injection Molding Systems P Ltd

IDMC Limited

T: +91-44-42083536 E: sales@fecindia.com W: www.fecindia.com Freeze Tech Equipments Pvt Ltd

T: +91-79-22811879 E: info@ashwinengineersindia.com W: www,ashwinengineersindia.com Avi Additives Pvt Ltd

T: +91-79-25890081 E: salesfmi@milacron.com W: www.milacronindia.com Fluid Energy Controls Inc

Pg No

E: snair@husky.ca

T: +86-10-5965-7385 E: bo.ding@exxonmobil.com W: www.exxonmobilchemical.com Ferromatik Milacron India Ltd

141

Advertiser’s Name & Contact Details

T: +91-22-25706316

T: +91-09920401226 E: engexpo@infomedia18.in W: www.engg-expo.com Exxonmobil Chemical Asia Pacific

T: +91-79-22928163 E: exports@amrutbrothers.com W: www.amrutbrothers.com Artic Aircon Pvt Ltd

Electronica Plastic Machiners Ltd

Engineering Expo

T: +91-11-41612244 E: sales@alokindustries.com W: www.alokmasterbatches.com Amrut Brothers

T: +91-22-32531959 E: vkt@electronicapmd.com

T: +91-250-2454915 E: hvt@aeromec.in W: www.aeromec.in Alok Masterbatches Ltd

Elecon Engineering Co Ltd

Pg No

T: +91-2692-236469 E: infogear@elecon.com W: www.elecon.com

T: +91-2764-286573 E: info@adinathcontrols.com W: www.adinathcontrols.com Aeromec Marketing Co Pvt Ltd

Advertiser’s Name & Contact Details

Our consistent advertisers

ADVERTISERS’ LIST Advertiser’s Name & Contact Details

Pg No

KPL International Ltd

T: +91-11-43606200 E: rohit@kplintl.com W: www.kplintl.com K-Tron Process Group

T: +41-62-885-7171 E: ifischer@ktron.com W: www.ktroncan.com L & T Plastics Machinery Ltd

FGF

Omron Automation Pvt Ltd

Loxim Industries Limited

T: +91-2717-308000 E: info@loxim.com W: www.loxim.com

Perkinelmer India Ltd

T: +91-265-2353886 E: info@madhu-group.com W: www.madhu-group.com Matsui Technologies India Ltd T: +91-120-4243862 E: rahuldeep@mass.motherson.com Mifa Systems

T: +91-79-25840374 E: info@naroto.com W: www.naroto.com Neejtech India (Braunform)

T: +91-79-26561312 E: info@neejtech.com W: www.neejtech.com Neejtech India (Niigata)

T: +91-09909974224 E: contact@niigataindia.com Neoplast Engg Pvt Ltd

117

127

136

T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com Nu-Vu Conair Pvt. Ltd T: +91-79-32985993 E: nuvu@conairgroup.com W: www.conairgroup.com

COC

19,71

T: +91-250-3021166 E: jnbhat@shiniindia.com W: www.shini.com T: +91-44-24343343 E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com

Supermac Machinery

Modern Plastics & Polymers | June 2011

134

Toshiba Machine (India) Pvt Ltd

Unimark (Arburg Gmbh)

Unimark (Maguire)

Unimark (Staubli Faverges Sca)

T: +91-22-25506712 E: infomum@unimark.in W: www.unimark.in Windsor Machines Limited

113

T: +91-79-25841591 E: sales.imm@windsormachines.com W: www.windsormachines.com Witte Pumps & Technologies

T: +’91-11-41613643 E: witte@goodiesons.com W: www.witte-pumps.de , www.goodie.in Wittmann Battenfeld India Pvt Ltd

FIC

T: +91-44-42077009 E: info@wittman-group.in W: www.wittmann-group.com Yann Bang Electrical Machinery Co.,Ltd 121 T: +886-4-2271-6999 E: yb@yannbang.com; judy.w@yannbang.com W: www.yannbang.com Zambello Riduttori Group

T: +39-0331-307-616 E: info@zambello.it W: www.zambello.it

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

144

T: +91-22-25506712 E: infomum@unimark.in W: www.unimark.in

T: +91-7600003968 E: sales@negribossi.in W: www.negribossi.com

Sreelakshmi Traders

Steer Engineering Pvt Ltd

T: +91-22-25506712 E: infomum@unimark.in W: www.unimark.in

T: +91-422-2590810 E: stycm@stengineers.com W: www.stengineers.com

Shini Plastics Technologies I Pvt Ltd

109

T: +91-11-43291111 E: dineshelija@toshiba-machine.co.in W: www.toshiba-machine.co.jp

T: +91-2827-252701 E: kcdoshi@rajoo.com W: www.rajoo.com

Sacmi Engineering (I) Pvt Ltd

T: +91-79-25630319 E: nidhiplast@gmail.com W: www.nidhiplastindia.com NMTG Mechtrans Techniques Pvt Ltd.

Rajoo Engineers Limited

Standard Chartered Bank

T: +91-09998040433 E: info@supermachinery.com W: www.supermacmachinery.com

T: +91-22-42461500 E: info@rrplast.com W: www.rrplast.com

S&T Engineers

T: +91-79-25830602 E: info@neoplastindia.com W: www.neoplastindia.com Nidhi Polylast

T: +91-79-25830112 E: plastics@prasadgroup.com W: www.prasadgroup.com

R R Plast Extrusions Pvt Ltd

Pg No

T: +91-80-23723309 E: info@steerworld.com W: www.steerworld.com

T: +91-79-27492566 E: info@procon.co.in W: www.procon.co.in

T: +91-79-26870825 E: info@mifasystems.com W: www.mifasystems.com N.A. Corporation

125

T: +91-22-67205200 E: rsd@kolsitegroup.com W: www.plastiblendsindia.com

Procon Technologies Pvt Ltd

Advertiser’s Name & Contact Details

T: +91-22-39401616 E: sme.customercare@sc.com W: www.standardchartered.co.in

T: +91-22-28560450 E: amit.bajaj@piovnindia.com W: www.piovan.com

Prasad Koch Technik Pvt. Ltd. 13

T: +91-22-67601786 E: jayant.dharma@perkinelmer.in W: www.perkinelmer.in

Plastiblends India Ltd 14,145

Pg No

T: +91-80-40726400 E: in_enquiry@ap.omron.com W: www.omron-ap.com

Piovan India Pvt Ltd

T: +91-44-26812000 E: handigolg@larsentoubro.com W: www.larsentoubro.com

Madhu Machines & Systems Pvt Ltd

Advertiser’s Name & Contact Details

Our consistent advertisers

Modern Plastics & Polymers

June 2011

Modern Plastics & Polymers

June 2011

Reg No: MH / MR / WEST / 234 // 2009 – 2011 RNI No: MAHENG / 2008 / 25265 WPP Licence No: MR / Tech / WPP – 357 / West / 2009- 2011 Licence to Post Without Pre-Payment at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001. Date Of Posting 1st & 2nd Of Every Month / English & Monthly. Date Of Publication: 28th Of Every Month.

150